SECTION 6F - ENGINE EXHAUST
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 System
Exhaust Silencer
Exhaust Silencer and Associated Parts
Removal & Installation
Main Data and Specifications
Torque Specification
General Description
(2.4L 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
mispositioned 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 (If 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 way 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
systems.
Exhaust Pipe
Exhaust Pipe and Associated parts
(2.4L Model)
Removal
(2.2L & 2.0L)
1.Front exhaust pipe fixing nut
2.Front exhaust pipe
3.Center exhaust pipe damper rubber
4.Catalytic converter (If applicable)
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)
(2.4L)
CAUTION:
When you remove or install the front exhaust pipe, make
sure not to damage the fuel evaporative pipe.
1.Damper rubber
2.Exhaust silencer
3.Mid pipe
4.Propeller shaft assy
5.Damper rubber
6.Front exhaust pipe fixing nut
7.Catalytic converter (If applicable)
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 Exhaust Pipe
2. Center Exhaust Pipe and Catalytic Converter Flange Nut
3. Exhaust Pipe Damper Rubber
4. Exhaust Silencer with Rear Exhaust Pipe
Check the pipes for 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
(2.4L Models)
Legend
1 Front Exhaust Pipe Fixing Nuts
2 O
2
Sensor (If applicable)
3 Front Exhaust Pipe
Removal (2.4L)
1.Disconnect battery ground cable.
2.Raise the vehicle and support with suitable safety stands.
3.Remove the exhaust silencer.
4.Remove mid pipe.
5.Remove the propeller shaft assy.
6.Remove the O2 sensor.
7.Remove front exhaust pipe.
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 O2 sensor
harness connector. (If applicable)
Torque:55 N⋅
⋅⋅⋅m (5.6 kgf⋅
⋅⋅⋅m)
Mid Pipe
Mid Pipe and Associated Parts
(2.4L Model)
Legend
1. Front Exhaust Pipe Fixing Nuts
2. O
2
Sensor
3. Front Exhaust Pipe
Removal (2.4L)
1.Disconnect battery ground cable.
2.Raise the vehicle and support with suitable safety stands.
3.Remove exhaust silencer.
4.Remove mid pipe.
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
(2.4L Model)
Legend
1. Catalytic Converter
Removal (2.4L)
1.Disconnect battery ground cable.
2. Raise the vehicle and support with suitable safety stands.
3. Remove exhaust silencer.
4. Remove mid pipe.
5. Remove the propeller shaft assy.
6. Remove the O2 sensor.
7. Remove the front exhaust pipe with catalytic converter.
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)
N2
Inspection
Make the necessary adjustments, and part replacements if
excessive or damage is discovered during inspection.
Exhaust Pipe Assembly
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.
(2.4L model)
Exhaust Silencer
Exhaust Silencer and Associated Parts
Legend
1. Exhaust Silencer
Removal & Installation (2.4L)
Remove the two nuts and bolts securing the silencer.
For installation reverse the removal procedure.
Torque
Bolts: 43 N m (4.4 kgf m)
.
.
Main Data and Specifications
Exhaust system
Pipe outside diameter ✕ thickness
Front pipe mm(in)
44.5 ✕ 1.5 (1.75✕0.059)
<Flange>
50.8 ✕ 1.5 (2.00 ✕ 0.059)
Middle pipe mm(in)
Rear pipe mm(in)50.8 ✕ 1.5 (2.0 ✕ 0.059)
Silencer
Type Circular section-shell construction
of triple (for 2.4L & 2.0L); double (for 2.4L) skin and
end plates, internal construction of baffles
and perforated tubes.
Inside diameter mm (in) Approximately 180 (7.09)
Length mm (in) Approximately 525 (20.67)
Mounting
Number of suspension points
Type
Catalytic converter type
4
Rubber
Three way Catalytic Converter
Main Data and Specifications
Torque Specification
N!m (kgf!m)