Exhaust System: Service and Repair

Exhaust System Replacement (2.0L LHU)

Removal Procedure

Warning: Refer to Exhaust Service Warning Exhaust Service Warning.


Warning: Refer to Protective Goggles and Glove Warning Protective Goggles and Glove Warning.


Caution: Refer to Exhaust Flexible Pipe Bending Caution Exhaust Flexible Pipe Bending Caution.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

2. Remove the rear axle. Refer to Rear Axle Replacement Rear Axle Replacement.

3. Remove the equalizer beam support in conjunction with the center links. Refer to Equalizer Beam Support Replacement Service and Repair.

4. Support the exhaust system with a suitable tool.




5. Remove the 2 exhaust hanger bolts (1).

6. Remove the 2 exhaust hanger brackets (2) from the exhaust system (4).

7. Remove the 2 exhaust hanger insulators (3) from the exhaust system (4).




8. Remove the 2 exhaust system to catalytic converter nuts (1).

9. Remove the exhaust system (4) from the catalytic converter (2).

10. Remove and DISCARD the gasket (3).

Note: A second technician is required.

11. Unsupport and remove the exhaust system.




12. Remove the 3 catalytic converter to the three way catalytic converter nuts (4).

13. Remove the catalytic converter (1) from the three way catalytic converter (3).

14. Remove and DISCARD the gasket (2).




15. Remove the 2 bolts (5).

16. Remove the 2 bolts (6).

17. Remove the 2 catalytic converter hanger bracket (3) along with the catalytic converter (2).

18. Remove the 2 catalytic converter insulator nuts (4).

19. Remove the 2 catalytic converter insulators (1) from the catalytic converter (2).

Installation Procedure




1. Install the 2 catalytic converter insulators (1) to the catalytic converter (2).

2. Install the catalytic converter hanger bracket (3) to the catalytic converter (2).

Caution: Refer to Fastener Caution Fastener Caution.

3. Install the 2 catalytic converter insulator nuts (4) and tighten to 22 Nm (16 lb ft).

4. Install the 2 exhaust front pipe hanger bracket bolts M8 (5) and tighten to 22 Nm (16 lb ft).

Caution: Refer to Torque-to-Yield Fastener Caution Torque-to-Yield Fastener Caution.

5. Install the 2 drive frame bolts M10 (6) and tighten a first pass to 60 Nm (44 lb ft).

6. Tighten the 2 drive frame bolts M10 (6) a final pass to an additional 30 - 45 degrees, using the EN-45059 - meter.




7. Install a NEW gasket (2).

8. Install the catalytic converter (1) to the three way catalytic converter (3).

9. Install the 3 catalytic converter to the three way catalytic converter nuts (4) and tighten the nuts to 22 Nm (16 lb ft).





Note: A second technician is required.

10. Install and support the exhaust system.

11. Install a NEW gasket (3).

12. Install the exhaust system (4) to the catalytic converter (2).

13. Install 2 exhaust system to catalytic converter nuts (1) and tighten to 22 Nm (16 lb ft).




14. Raise the exhaust system and install the install the 2 exhaust hanger insulators (3) to the exhaust system (4) and the hanger brackets.

15. Install the 2 exhaust hanger brackets (2) to the exhaust system (4).

16. Install the 2 exhaust hanger bolts (1) and tighten to 22 Nm (16 lb ft).

17. Unsupport the exhaust system.

18. Install the equalizer beam support in conjunction with the center links. Refer to Equalizer Beam Support Replacement Service and Repair.

19. Install the rear axle. Refer to Rear Axle Replacement Rear Axle Replacement.

20. Lower and unsupport the vehicle.