Page 1650 of 2490
Exha
ust System - Catalytic Conv
erter RH4.0L SC V8 - AJ26
Remo
val and Installation
Remov
a
l
1.
Op
en the engine compartment and fit paintwork protection
sheets.
2. CAUT
ION: Note the position of the upstream and
downstream (where fitted) o xygen sensor multiplugs for
reassembly.
Disconnect the oxygen sensor multiplugs.
Di spl
ace the multiplugs from the engine mounting bracket.
Dis
connect the plug(s) from the oxygen sensor(s).
3.
Re
move the four nuts which se
cure the downpipe catalytic
converter to the exhaust manifold.
4. Raise the vehicle on a ramp.
5. Re
move the bolts which secure
the rear of the front muffler
assembly to the transmission rear mounting.
6. Remove the bolts which secure the front flange of the front
muffler to the downpipe flange.
R e
peat for the flange bolt
s on the opposite side.
Page 1651 of 2490
I
nstallation
7.
R
emove the gasket from the front
muffler flange at each side.
R
eposition the front silencer rearwards.
R
emove the gasket from each flange.
8. R
emove the downpipe catalytic converter.
R
emove the bolts which se
cure the downpipe lower
mounting bracket.
Remove the
downpipe assembly.
9. R
emove the oxygen sensor(s).
The downstream sensor i
s fitt
ed only for North American
markets.
10. Remove gasket from the manifold flange.
Clean and inspect th
e manifold joint faces.
Clean and inspect th
e threads
on the downpipe studs.
Page 1652 of 2490
1. Fit
the oxygen sensor(s).
The downstream sensor is
fitt
ed only for North American
markets.
2. Fit a new gasket to the mani fold mating flange on the
downpipe.
3. Fit
the downpipe catalytic converter.
1. Fit the downpipe assembly to the manifold.
Fit,
but do not fully tighten, the mounting bracket securing
bolts. (Leave loose until the nu ts securing the downpipe to
the exhaust manifold are fitted.)
4. Lower the ramp.
5. Tigh te
n the nuts securing the downpipe flange to the manifold
flange..
6. Connec t
the oxygen sensor multiplugs.
Con
n
ect the plug(s) to the respective (previously noted)
sensor(s).
Cor r
ectly position the multiplu
gs on the mounting bracket.
7. Raise the vehicle on the ramp.
8. Tighten the mounting brac ket securing bolts.
Page 1654 of 2490
Exha
ust System - Catalyti
c Converter Gasket LH4. 0L NA V8 - AJ27/3.2L
NA V8 - AJ26
Re mo
val and Installation
Remova
l
1.
Op
en the engine compartment and fit paintwork protection
sheets.
2. Remove the front muffler; refer to Operation 30.10.18 in this
section.
3. Re
move the centre trim panel
from the engine compartment.
1. Remove the left hand side enclosure panel.
2. Remove the centre trim panel.
4. Repo
sition the expansion tank from the mounting.
1. Disconnect the coolant level sensor connector.
2. Remove the nuts which secures the tank.
5. CAUT
ION: Note the position of the upstream and
downstream (where fitted) o xygen sensor multiplugs for
reassembly.
Disconnect the oxygen sensor multiplugs.
Re
lease the multiplugs from th
e engine mounting bracket.
Dis
connect the plug(s) from the oxygen sensor(s)
6.
Re
move the four nuts which se
cure the downpipe catalytic
converter to the exhaust manifold.
Page 1656 of 2490
5. Connec t
the oxygen sensor multiplugs.
Con
n
ect the plug(s) to the respective (previously noted)
sensor(s).
Cor r
ectly position the multiplu
gs on the mounting bracket.
6. Fi
t the coolant header tank.
1. Reposition the tank and fit the securing nuts.
2. Connect the harness connector
7. Re
fit the centre trim panel and th
e left hand enclosure panel to
the engine compartment.
1. Refit the centre trim panel.
2. Refit the left hand enclosure panel.
8. Raise the ramp.
9. Tighten the mounting brac ket securing bolts.
Page 1658 of 2490
Exha
ust System - Cataly
tic Converter Gasket LH 4.0L SC V8 - AJ26
Remo
val and Installation
Remov
a
l
1.
Op
en the engine compartment and fit paintwork protection
sheets.
2. Re
move the centre trim panel
from the engine compartment.
1. Remove the left hand side enclosure panel.
2. Remove the centre trim panel.
3. Repo
sition the expansion tank from the mounting.
1. Disconnect the coolant level sensor connector.
2. Remove the nuts which secures the tank.
4. CAUT
ION: Note the position of the upstream and
downstream (where fitted) o xygen sensor multiplugs for
reassembly.
Disconnect the oxygen sensor multiplugs.
Di spl
ace the multiplugs from the engine mounting bracket.
Dis
connect the plug(s) from the oxygen sensor(s).
5.
Re
move the four nuts which se
cure the downpipe catalytic
converter to the exhaust manifold.
Page 1660 of 2490
In
stallation
1.
Fit a ne
w gasket to the mani
fold mating flange on the
downpipe.
2. Fit
the downpipe catalytic converter.
1. Fit the downpipe assembly to the manifold.
Fit,
but do not fully tighten, the mounting bracket securing
bolts. (Leave loose until the nu ts securing the downpipe to
the exhaust manifold are fitted.)
3. Lower the ramp.
4. Tigh te
n the nuts securing the downpipe flange to the manifold
flange.
5. Connec t
the oxygen sensor multiplugs.
Con
n
ect the plug(s) to the respective (previously noted)
sensor(s).
Cor r
ectly position the multiplu
gs on the mounting bracket.
6. Fi
t the coolant header tank.
1. Reposition the tank and fit the securing nuts.
2. Connect the harness connector
7. Refit the centre trim panel and th e left hand enclosure panel to
the engine compartment.
Page 1662 of 2490

Exha
ust System - Catalyti
c Converter Gasket RH4. 0L NA V8 - AJ27/3.2L
NA V8 - AJ26
Re mo
val and Installation
Remova
l
Installation
1. Op
en the engine compartment and fit paintwork protection
sheets.
2. Remove the front muffler; refer to Operation 30.10.18 in this
section.
3. CAUT
ION: Note the position of the upstream and
downstream (where fitted) o xygen sensor multiplugs for
reassembly.
Disconnect the oxygen sensor multiplugs.
Di spl
ace the multiplugs from the engine mounting bracket.
Dis
connect the plug(s) from the oxygen sensor(s).
4.
Re
move the four nuts which se
cure the downpipe catalytic
converter to the exhaust manifold.
5. Raise the vehicle on a ramp.
6. Re
move the downpipe catalytic converter.
R
e
move the bolts which se
cure the downpipe lower
mounting bracket.
Remove the down
pipe assembly.
7. Remove gasket from the manifold flange.
Clean and inspect th e manif
old joint faces.
Clean and inspect th
e threads on th
e downpipe studs.
1. Fit a new gasket to the mani fold mating flange on the