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
Page 1663 of 2490
do
wnpipe.
2. F
it the downpipe catalytic converter.
Fit the down
pipe assemb
ly to the manifold
Fi
t, 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
ten the nuts securing the downpipe flange to the manifold
flange..
5. Connec
t the oxygen sensor multiplugs.
Con
nect the plug(s) to the respective (previously noted)
sensor(s).
Cor
rectly position the multiplu
gs on the mounting bracket.
6. Raise the ramp.
7. Tigh
ten the mounting brac
ket securing bolts.
8. Fit the front muffler; refer to Operation 30.10.18.
9. Lower the ramp.
10
.
Remove the paintwork protection sheets and close the engine
cover.
Page 1664 of 2490
Exha
ust System - Cataly
tic Converter Gasket RH 4.0L 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 engine rear mounting.
6. Remove the nuts which secure the front flanges of the front
muffler to the downpipe flanges.
Page 1666 of 2490
3. Lower the ramp.
4. Tighte
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. Raise the vehicle on the ramp.
7. Tigh ten th
e mounting brac
ket securing bolts.
8. Connect the downpipe catalytic converter to the front muffler.
1. Position a new gasket to the flange studs at each side.