Page 1521 of 3229
Publi s hed: 11-May-2011
Exhaust System - I6 3.2L Petrol - Catalytic Converter
Removal and Inst all ati on
Special T ool(s) 310-121
W rench, H02S
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
1. W ARNING: Make sure t o s upport the vehicle wit h axle
s tands .
Rais e t he vehicle on a li ft .
1.
Remove t he front spl as h s hiel d.
Refer t o: Engi ne Unders hi eld (501-02 Front End Body Panel s ,
Removal and Ins tall ati on).
2. 3.
T orque:
25 Nm 4.
Page 1522 of 3229
5. CAUTION: Di scard the bolt s .
T orque: 27 Nm 5.
Speci al Tool (s ):
310-121 T orque:
M18 45 Nm M5
6 Nm 6.
Installation To i nst all , revers e t he removal procedure.
1.
2. NOTE: For NAS vehicl es onl y.
If required, carry out a l ong drive cycl e.
Refer t o: Powertrain Cont rol Modul e (PCM) Long Drive Cycle Sel f-Tes t
(303-14 Electroni c Engine Controls - 3.2L, General Procedures).
2.
Page 1523 of 3229
Publi s hed: 11-May-2011
Exhaust System - I6 3.2L Petrol - Exhaust System
Removal and Inst all ati on
Removal W ARNING: Observe due care when worki ng near a hot exhaust s ys tem.
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
All vehicles
1. W ARNING: Do not work on or under a vehi cle s upported onl y
by a jack. Al ways support t he vehi cl e on s afet y s tands .
Rais e and s upport t he vehi cl e.
1.
Vehicles with petrol engine T orque:
25 Nm 2.
Vehicles with diesel engine T orque:
40 Nm 3.
All vehicles
Page 1524 of 3229
4. W ARNING: Thi s s tep requi res t he aid ofanother technician.4.
Vehicles with petrol engine
Remove and dis card t he gas ket .5.
All vehicles
6. NOTE: Do not dis ass embl e further if t he component i s removedfor acces s onl y.
Remove t he rubber mount s .
6.
Installation
To i nst all , revers e t he removal procedure.1.
Page 1525 of 3229

Publi s hed: 11-May-2011
Exhaust System - TD4 2.2L Diesel -
Lubricants, Fluids, Sealers and AdhesivesItemSpecification
Heated oxygen s ens or (H02S) removal*W D40 or s uit able al ternat ive
Heated oxygen s ens or (H02S) t hreadsApply s uit able hi gh temperat ure ant i-s ei ze compound t o t hreads of s ens or* Apply to area around sensor threads prior to attempting to remove sensor
General Specification
ItemSpecificationCatal yt ic convert ers -t ype/locat ionAn oxidizi ng cat alyti c convert er is fit t ed in t he front s ect ion of t he exhaus t s ys t em
Exhaus t manifold -Locat ionA mani fold ass embly is fit ted to t he cylinder head.
Exhaus t s yst emStai nl ess st eel exhaust s ys tem s uppl ied as t wo s eparate ass embli es. Front s ecti on incorporat inga catal yt ic converter and a rear s ect ion i ncorporat ing a rear s il encer
Torque Specifications
DescriptionNmlb-ft
Catal yt ic convert er t o center s ect ion retai ning clamp4030Catal yt ic convert er t o t urbocharger hous ing retaini ng clamp107
Exhaus t manifold el bow t o EGR cool er2518
Exhaus t manifold heat s hield bol ts107Exhaus t manifold heat s hield nut s107
Exhaus t manifold retai ni ng nuts2418
Exhaus t manifold retai ni ng s tuds75Exhaus t s upport bracket s t o s ubframe / fl oor2518
Heated oxygen s ens or (H02S)++4533
+ Apply anti-seize lubricant to threads of sensor - See Lubricants
Page 1526 of 3229
Publi s hed: 11-May-2011
Exhaust System - TD4 2.2L Diesel - Exhaust System
Des cript ion and Operat ion
COMPONENT LOCATION - WITH DIESEL PARTICULATE FILTER
ItemPart NumberDescription1-Exhaus t mani fold (ref onl y)
2-Pres s ure di fferenti al sens or
3-Heat ed Oxygen Sens or (HO2S) (ref onl y)4-Cat al yti c convert er
Page 1527 of 3229
5-Gas ket
6-'Torca' clamp
7-Connect ing pi pe8-Mounti ng rubber (6 off)
9-Rear muffler
10-Di esel Part iculat e Filt er (DPF)11-Flange
12-Body hanger
13-Decoupl er14-Out let elbow
15-'V' clamp and gasket
16-Turbocharger (ref onl y)
COMPONENT LOCATION - WITHOUT DIESEL PARTICULATE FILTER
Page 1528 of 3229
ItemPart NumberDescription
1-Exhaust mani fol d (ref only)2-HO2S (ref onl y)
3-Cat alyt ic converter
4-'Torca' joint5-Rear connecti ng pipe
6-Mount ing rubber (5 off)
7-Rear muffl er8-Front connect ing pi pe
9-Body hanger
10-Decoupler11-Outl et el bow