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SECTION 1G1

ENGINE EXHAUST - 2.0 DIESEL

SPECIFICATIONS

Fastener Tightening Specifications

Application
N•m
Lb-Ft
Lb-In
DPF Heat Sheild Retaining Nut
2.5
-
22.1
Exhaust Front Pipe Nuts
40
29.5
-
Exhaust Manifold Heat Sheild Nut and Bolt
20
14.8
-
Front Muffler Heat Sheild Retaining Nut
2.5
-
22.1
Front Muffler–to–Rear Muffler Nut
40
29.5
-
Pre-Catalyst Bracket Bolt
40
29.5
-
Rear Muffler Heat Sheild Retaining Nut
2.5
-
22.1
Rear Muffler–to–Front Muffler Nut
40
29.5
-

COMPONENT LOCATOR

Exhaust System


C7A52G04
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  1. Exhaust Manifold Heat Shield
  2. Pre-Catalyst
  3. Seal Ring
  4. Clamp
  5. DPF Pressure Sensor
  6. DPF Pressure Sensor Hose
  7. Exhaust Gas Temperature Sensor 2
  8. Gasket
  9. Rubber Hanger
  10. Exhaust Gas Temperature Sensor 1
  11. Exhaust Front Pipe Assembly
  12. DPF(Diesel Particulate Filter) Assembly
  13. DPF Heat Shield
  14. Front Muffler Heat Shield
  15. Front Muffler Assembly
  16. Rear Muffler Assembly(Right-Side)
  17. Rear Muffler Assembly(Left-Side)

DIAGNOSIS

Condition
Probable Cause
Correction
Leaking exhaust gases
Leaks at pipe joints.
Tighten nuts and bolts to the specified torques.
Damaged or improperly installed converter sealing ring/gaskets.
Replace sealing ring/gasket as necessary.
Burned or rusted out exhaust pipe or muffler/s.
Replace component as necessary.
Exhaust noises
Leaks at manifold or pipe connections.
Tighten bolts/nuts at leaking connections to specified torques. Replace gasket as required.
Burned or blown out pipe or muffler/s.
Replace pipe/muffler assembly as necessary.
Exhaust manifold/s cracked or broken.
Replace manifold.
Leak between manifold/s and cylinder head/s.
Tighten manifold to cylinder head studs to specified torque.
Loss of engine power, hesitation, surging, poor fuel economy, stalling or hard starting
Clogged pre-catalyst (may result from serious engine malfunction).
Replace pre-catalyst.
Crushed pipe work.
Replace pipe work.
Internal rattling in muffler
Dislodged tubes and/or baffles in muffler.
Replace muffler.
Pre-catalyst has crumbled and pieces blown into muffler.
Replace pre-catalyst assembly and affected muffler.
Rattling or knocking exhaust system
Damaged, worn, missing or improperly installed support rubber hangers.
Check and replace as necessary.
Damaged mounting hangers or pegs.
Service / replace hangers or pegs as necessary.
Improper alignment.
Tighten all fasteners according to tightening sequence and the specified torques.
Damaged or incorrect exhaust system components.
Replace damaged or incorrect components as necessary.

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE


C7A52B46
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Pup Converter

Removal Procedure

    Caution : Make sure to confirm that the components are cool. And do work.

  1. Disconnect the negative battery cable.
  2. Remove the exhaust manifold heat shield.

    3. C7A52G05
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  3. Remove the exhaust front pipe. Refer to “Exhaust Front Pipe” in this Section.
  4. Remove the pre-catalyst clamp.
  5. Remove the pre-catalyst bracket bolt from the engine block.
  6. Remove the pre-catalyst with the seal ring.

C7A52G05
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Installation Procedure

  1. Install the pre-catalyst with the seal ring. If damaged, replace the new seal ring.
  2. Install the pre-catalyst clamp and the bracket bolt.

    3. Tighten
    Tighten the pre-catalyst bracket bolt to 40 N•m (29.5 lb-ft).


    C7A52B46
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  3. Install the exhaust manifold heat shield.

    4. Tighten
    Tighten the exhaust manifold heat shield bolt and nut to 20 N•m (14.8 lb-ft).


C7A52FE0
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Exhaust Front Pipe

Removal/Installation Procedure

    Caution : Make sure to confirm that the components are cool. And do work.

  1. Disconnect the negative battery cable.
  2. Disconnect the exhaust gas temperature sensor 1 connector.

    3. C7A52G06
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  3. Remove the rubber hanger.
  4. Remove the exhaust front pipe with the gasket. If damaged, replace the new gasket.

    5. Tighten
    Tighten the exhaust front pipe nuts to 40 N•m (29.5 lb-ft).


C7A11G55
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Front Muffler

Removal Procedure

    Caution : Make sure to confirm that the components are cool. And do work.

  1. Remove the nuts and the gasket from the front muffler pipe-to-DPF.

    2. C7A11G56
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  2. Remove the nuts and the gaskets from the both rear muffler pipe flange.

    3. C7A11G57
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  3. Remove the rubber hangers.
  4. Remove the front muffler.

C7A11G57
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Installation Procedure

  1. Secure the front muffler to the rubber hangers.

    2. C7A11G56
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  2. Install the nuts and the gaskets to the both rear muffler pipe flange. If damaged, replace the new gasket.

    3. Tighten
    Tighten the front muffler-to-rear muffler nuts to 40 N•m (30 lb-ft).


    C7A11G55
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  3. Install the nuts and gasket to the front muffler pipe-to-DPF. If damaged, replace the new gasket.

    4. Tighten
    Tighten the front muffler-to-DPF nuts to 30 N•m (22 lb-ft).


C7A11G56
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Rear Muffler

Removal Procedure

  1. Remove the nuts and the gaskets from the both rear muffler pipe flange-to-front muffler pipe flange.

    2. C7A11G58
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  2. Detach the both rear muffler assembly from the rubber hangers.
  3. Remove the both rear muffler.
  4. Check the rear muffler and the pipe for holes, damage, open seams and other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk.

C7A11G58
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Installation Procedure

  1. Secure the both rear muffler assembly to the rubber hangers.

    2. C7A11G56
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  2. Install the nuts and the gaskets to the both rear muffler pipe flange-to-front muffler pipe flange.

    3. Tighten
    Tighten the front muffler-to-rear muffler nuts to 40 N•m (30 lb-ft).

GENERAL DESCRIPTION AND SYSTEM OPERATION

Pre-Catalyst

The catalyst converters are emission control devices added to the exhaust system to reduce pollutions from the exhaust pipes.
It has coating only platinum, which simultaneously lower the level of HC and CO. But NOx is able to be reduced from engine control system (example: cooled EGR system, etc).

C7A52G01
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Front Muffler

The function of the muffler is to reduce engine noise. It is made up of a series of perforated tubes and baffles to break up the sound waves and reflect them.
It is made of Stainless Steel to protect the front muffler from corrosion.
It is mounted on the middle of underbody.

C7A52G02
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Rear Muffler

The rear muffler is to reduce broad band engine exhaust noise. It is comprised of a series of perforated tubes and baffles to break up the sound waves and reflect them. The adopted dual muffler for this vehicle improves the efficiency to reduce flow noise.
It is made of Stainless Steel to protect the front muffler from corrosion.
It is mounted behind the rear wheel.

C7A52G03
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