Exhaust Pipe: Service and Repair
Exhaust Crossover Pipe Replacement
Removal Procedure
Danger:
To avoid any vehicle damage, serious personal injury or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed and strap the vehicle to the hoist.
Warning:
Refer to Exhaust Service Warning Exhaust Service Warning.
Warning:
Refer to Protective Goggles and Glove Warning Protective Goggles and Glove Warning.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
2. Support the exhaust system using a suitable jack.
3. Remove the rear exhaust muffler assemblies. Refer to Exhaust Muffler Replacement - Left Side Exhaust Muffler Replacement - Left Side and Exhaust Muffler Replacement - Right Side Exhaust Muffler Replacement - Right Side.
Caution:
Refer to Heated Oxygen and Oxygen Sensor Caution Heated Oxygen and Oxygen Sensor Caution.
4. Disconnect the left post-catalytic converter heated oxygen sensor (HO2S) electrical connector (1).
5. Disconnect the right post-catalytic converter HO2S electrical connector (1).
Note:
The intermediate exhaust assembly to left catalytic converter retaining nuts (3) are single use parts. They must be discarded after removal.
6. Remove the intermediate exhaust assembly to left catalytic converter retaining nuts (3).
Discard the nuts.
7. Disconnect the intermediate exhaust assembly (2) from the left catalytic converter (1).
Note:
The intermediate exhaust assembly to right catalytic converter retaining nuts (3) are single use parts. They must be discarded after removal.
8. Remove the intermediate exhaust assembly to right catalytic converter retaining nuts (3).
Discard the nuts.
9. Disconnect the intermediate exhaust assembly (2) from the right catalytic converter (1).
10. Remove the intermediate exhaust assembly to rear muffler retaining bolts (1).
11. Detach the intermediate exhaust assembly (2) by removing the front insulator hangers (1) if fitted.
12. Detach the intermediate exhaust assembly by removing the center insulator hanger bracket retaining nut (1) to the differential stud (1).
13. Carefully lower the intermediate exhaust assembly from the vehicle.
14. Remove the left post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.
15. Remove the right post-catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2.
Installation Procedure
1. Clean all threads and flange faces of the intermediate exhaust system.
2. Always check the condition of the catalytic converter to intermediate pipe flange gaskets and replace as necessary.
3. Install the left post-catalytic converter HO2S to the intermediate exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 2 Heated Oxygen Sensor Replacement - Bank 1 Sensor 2.
4. Install the right post-catalytic converter HO2S to the intermediate exhaust system. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 2 Heated Oxygen Sensor Replacement - Bank 2 Sensor 2.
Warning:
Refer to Exhaust Service Warning Exhaust Service Warning.
Caution:
Refer to Exhaust System Inspection Caution Exhaust System Inspection Caution.
5. Position the intermediate exhaust assembly to the vehicle using a suitable jack.
6. Attach the intermediate exhaust assembly by installing the center insulator hanger bracket to differential stud (1).
Caution:
Refer to Fastener Caution Fastener Caution.
7. Install the insulator hanger bracket to differential retaining nut (1) and tighten to
Tighten the nuts to 40 Nm (30 lb ft).
8. Attach the intermediate exhaust assembly (2) by installing the front insulator hangers (1) if fitted.
9. Tighten the intermediate exhaust assembly to rear muffler retaining bolts.
10. Align the intermediate exhaust assembly (2) to the right catalytic converter (1).
11. Tighten the intermediate exhaust assembly to right catalytic converter retaining nuts (3).
Tighten the nuts to 40 Nm (30 lb ft).
12. Align the intermediate exhaust assembly (2) to the left catalytic converter (1).
13. Tighten the intermediate exhaust assembly to left catalytic converter retaining nuts (3).
Tighten the nuts to 40 Nm (30 lb ft).
14. Connect the right post-catalytic converter HO2S electrical connector (1).
15. Connect the left post-catalytic converter HO2S electrical connector (1).
16. Connect the left rear muffler (3) to the intermediate exhaust assembly (2).
Tighten the bolts (1) to 45 Nm (33 lb ft).
17. Make sure that the exhaust system is clear of all other components and chassis. If the exhaust system is not clear of all the other components loosen all retaining nuts and re-align.
18. Lower the vehicle to the ground.
19. If re-programming is required. Refer to Control Module References Control Module References.
20. Perform diagnostic system check using diagnostic scan tool, clear all relative DTCs and inspect the system for correct operation.