SECTION 8C - ENGINE EXHAUST (C22NE MODELS)

GENERAL DESCRIPTION

SERVICE PRECAUTION

EXHAUST PIPE

EXHAUST PIPE AND ASSOCIATED PARTS

REMOVAL

INSTALLATION

INSPECTION

FRONT EXHAUST PIPE

FRONT EXHAUST PIPE AND ASSOCIATED PARTS

REMOVAL

INSTALLATION

MID PIPE

MID PIPE AND ASSOCIATED PARTS

REMOVAL

INSTALLATION

CATALYTIC CONVERTER (IF APPLICABLE)

CATALYTIC CONVERTER AND ASSOCIATED PARTS

REMOVAL

INSTALLATION

3 WAY CATALYTIC CONVERTER S YST EM

INSPECTION

EXHAUST PIPE ASSEMBLY

CATALYTIC CONVERTER

REMOVAL

INSTALLATION

EXHAUST SILENCER

EXHAUST SILENCER AND ASSOCIATED PARTS

REMOVAL

INSTALLATION

REAR EXHAUST PIPE

REAR EXHAUST PIPE AND ASSOCIATED PARTS

REMOVAL

INSTALLATION

MAIN DATA AND SPECIFICATIONS

TORQUE SPECIFICATION

GENERAL DESCRIPTION

This illustration is based on the 4×4 with TWC model.

When inspecting or replacing exhaust system components,

make sure there is adequate clearance from all points on the

underbody to prevent overheating the floor pan and possible

damage to the passenger compartment insulation and trim

materials.

Check complete exhaust system and nearby body areas and

rear compartment lid for broken, damaged, missing or

misaligned parts, open seams, holes, loose connections or

other deterioration which could permit exhaust fumes to seep

into the rear compartment or passenger compartment. Dust or

water in the rear compartment may be an indication of a

problem in one of these areas. Any faulty areas should be

corrected immediately.

HANGERS

Various types of hangers are used to support exhaust

system(s). These include conventional rubber straps, rubber

rings, and rubber blocks.

The installation of exhaust system supports is very important,

as improperly installed supports can cause annoying

vibrations, which can be difficult to diagnose.

THREE WAY CATALYTIC CONVERTER (I F

APPLICABLE)

The three-way catalytic converter is an emission control device

added to the exhaust system to reduce pollutants from the

exhaust gas stream.

CAUTION: The catalytic converter requires the use of

unleaded fuel only.

Periodic maintenance of the exhaust system is not required. If

the vehicle is raised for other service, it is advisable to check

the condition of the complete exhaust system.

A dual bed monolith catalytic converter is used in combination

with three-w ay catalytic converter.

Catalytic Types:

Three way (Reduction/Oxidation) catalyst

The catalyst coating on the three way (reduction) converter

contains platinum and rhodium which lowers the levels of

nitrous oxide (NOx) as well as hydrocarbons (HC) and carbon

monoxide (Co).

GASKET

The gasket must be replaced whenever a new exhaust pipe,

muffler or catalytic converter is installed.

SERVICE PRECAUTION

CAUTION:

Always use the correct fastener in the proper location.

When you replace a fastener, use ONLY the exact part

number for that application. HOLDEN will call out those

fasteners that require a replacement after removal.

HOLDEN will also call out the fasteners that require thread

lockers or thread sealant. UNLESS OTHERWISE

SPECIFIED, do not use supplemental coatings (Paints,

greases, or other corrosion inhibitors) on threaded

fasteners or fastener joint interfaces. Generally, such

coatings adversely affect the fastener torque and the joint

clamping force, and may damage the fastener. When you

install fasteners, use the correct tightening sequence and

specifications. Following these instructions can help you

avoid damage to parts and sys tems.

EXHAUST PIPE

EXHAUST PIPE AND ASSOCIATED PARTS

REMOVAL

1. Front exhaust pipe flange nut and gasket

2. Front exhaust pipe

3. Center exhaust pipe damper rubber

4. Catalytic converter

5. Center exhaust pipe

6. Rear exhaust pipe damper rubber

7. Exhaust silencer with rear exhaust pipe

8. Rear exhaust pipe

9. Mid pipe (for 4×4)

9’. Mid pipe (for 4×2)

INSTALLATION

To install, follow the removal steps in the reverse order.

IMPORTANT - INSTALLATION

1. Front Exhaust Pipe Flange Nut

Connect the exhaust pipe to the exhaust manifold.

Front exhaust pipe to manifold nut.

Torque

N⋅m (kgf⋅m)

28 (2.9)

INSPECTION

Make the necessary adjustments, and part replacements if

excessive wear or damage is discover during inspection.

1. Front E xhaust Pipe

2. Center Exhaust Pipe and Catalytic Converter Flange

Nut

3. Exha ust Pipe Damper Rubber

4. Exhaust Silencer with Rear Exhaust P ipe

Check the pipes for corrosion, cracking, damage or

misalignment and repair if required.

Check the damper rubber for deterioration or damage and

repair if required.

FRONT EXHAUST PIPE

FRONT EXHAUST PIPE AND ASSOCIATED PARTS

Legend

1 Front Exhaust Pipe Fixing Nuts

2 O2 Sensor (If applicable) 3 Front Exhaust Pipe

4 Front Exhaust Pipe Fixing Bolts and Nuts

REMOVAL

1. Disconnect battery ground cable.

2. Raise the vehicle and support with suitable safety stands.

3. Disconnect O2 sensor harness connector and remove front

side O2 sensor (2). (If applicable)

4. Remove front exhaust pipe fixing bolts and nuts (4).

5. Remove front exhaust pipe fixing four stud nuts from

exhaust manifold (1).

6. Remove front exhaust pipe (3)

INSTALLATION

1. Install front exhaust pipe (3) and tighten four stud nuts.

Torque:

Stud Nuts: 28 N⋅

⋅⋅⋅m (2.9 kgf⋅

⋅⋅⋅m)

Nuts: 43 N⋅

⋅⋅⋅m (4.4 kgf⋅

⋅⋅⋅m)

2. Tighten front side O2 sensor and reconnect O2senso

harness connector. (If applicable)

Torque:55 N⋅

⋅⋅⋅m (5.6 kgf⋅

⋅⋅⋅m)

MI D PIPE

MID PI PE AND ASSOCIATED PARTS

Legend

1. Front Exhaust Pipe Fixing Bolts and Nuts

2. Mid Pipe Fixing Bolts

3. Mid Exhaust Pipe Mounting Rubber

4. Mid Pipe

REMOVAL

1. Disconnect battery ground cable.

2. Raise the vehicle and support with suitable safety stands.

3. Remove front exhaust pipe fixing bolts and nuts (1).

4. Remove mid pipe fixing four stud nuts from Catalytic

Converter.

5. Remove mid pipe (4)

INSTALLATION

1. Install center exhaust pipe (4) and tighten four fixing bolts

(2) and two bolts and nuts (1) to the specified torque:

Torque:

Fixing bolts: 43 N⋅

⋅⋅⋅m (4.4 kgf⋅

⋅⋅⋅m)

Bolts: 43 N⋅

⋅⋅⋅m

CATALYTIC CONVERTER (IF APPLICABLE)

CATALYTIC CONVERTER AND ASSOCIATED PARTS

Legend

1. Catalytic Converter

2. Grakets

REMOVAL

1. Disconnect battery ground cable.

2. Raise the vehicle and support with suitable safety stands.

3. Remove center exhaust pipe fixing bolts.

4. Remove exhaust silencer fixing bolts.

5. Remove catalytic converter (1).

INSTALLATION

1. Install Catalytic Converter (1) and tighten four exhaust

silencer fixing bolts and center exhaust pipe fixing bolts to

the specified torque:

Torque:

Fixing bolts: 43 N⋅

⋅⋅⋅m (4.4 kgf⋅

⋅⋅⋅m)

3 WAY CATALYTIC CONVERTER SYSTEM (IF APPLICABLE)

INSPECTION

Make the necessary adjustments and part replacements if

excessive or damage is discovered during inspection.

EXHAUST PIPE ASSEM BLY

1. Check connections for looseness or damage.

2. Check clamps for weakness, crack, or damage.

CATALYTIC CONVERTER

Check for dents or damage.

If any part of the converter is damaged or dented, repair or

replace it.

REMOVAL

1. Jack up the vehicle.

2. Check that the converter is cool.

3. Remove the bolts at the front and rear of the converter.

4. Remove the converter and gaskets.

INSTALLATION

1. Place new gaskets on the converter front and rear pipes,

and connect the converter to the exhaust pipes.

Note:

When placing new gaskets, check that “U” mark on the

gasket is upside.

2. Tighten the bolts with the specified torque.

3. Reinstall the bracket bolts and tighten them.

EXHAUST SILENCER

EXHAUST SILENCER AND ASSOCIATED PARTS

Legend

1. Exhaust Silencer Fixing Bolts

2. Exhaust Silencer

REMOVAL

1. Disconnect battery ground cable.

2. Raise the vehicle and support with suitable safety stands.

3. Remove four exhaust silencer fixing bolts (1) and two rea

exhaust pipe fixing bolts and nuts (2) then disconnect rea

exhaust silencer from rear exhaust pipe

4. Remove exhaust silencer mounting rubbers from chassis

side then remove exhaust silencer.

INSTALLATION

1. Install the exhaust silencer and tighten two bolts and nuts

(2) on rear exhaust pipe to specified torque then tighten

four bolts (1) on Catalytic Converter to specified torque.

Torque:

Bolts: 43 N⋅

⋅⋅⋅m (4.4 kgf⋅

⋅⋅⋅m)

REAR EXHAUST PIPE

REAR EXHAUST PIPE AND ASSOCI ATED PARTS

Legend

1 Gasket

2 Mounting Rubber

3 Rear Exhaust Pipe

REMOVAL

1. Disconnect battery ground cable

2. Raise the vehicle and support with suitable safety stands.

3. Remove rear exhaust pipe fixing bolts and nuts, then

disconnect rear exhaust pipe (3) from exhaust silencer.

4. Remove mounting rubber (2).

5. Remove rear exhaust pipe (3).

INSTALLATION

1. Install the mounting rubber (2).

2. Install the exhaust pipe (3) and tighten two bolts and nuts

on exhaust silencer to specified torque.

Torque:

Nuts: 43 Nm (4.4 kgf.m)

MAIN DATA AND SPECIFICATIONS

Exhaust system

Pipe outside diameter ✕ thickness

Front pipe mm(in)

Middle pipe mm(in)

Rear pipe mm(in)

42.7 ✕ 1.5 (1.8✕0.059)<Flange>

54.0 ✕ 1.5 (2.0 ✕ 0.059)

50.8 ✕ 1.5 (2.0 ✕ 0.059)

Silencer

Type Circular section-shell construction

of triple skin and end plates,

internal construction of baffles

and perforated tubes.

Inside diameter mm (in)

Length mm (in) Approximately 180 (7.09)

Approximately 525 (20.67)

Mounting

Number of suspension points

Type

Catalytic converter type

Rubber

Three way Catalytic Converter

TORQUE SPECIFICATION

Nm (kgfm)