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SECTION 1G

ENGINE EXHAUST

SPECIFICATIONS

Fastener Tightening Specifications

Application
N•m
Lb-Ft
Lb-In
Catalytic Converter-to-Exhaust Manifold Nuts
40
30
-
Exhaust Front Pipe-to-Catalytic Converter Nuts
40
30
-
Exhaust Manifold Heat Shield Bolts (B12D)
15
11
-
Exhaust Manifold Heat Shield Bolts (G14D)
8
5.9
-
Front Muffler-to-Exhaust Front Pipe Nuts
40
30
-
Front Muffler-to-Rear Muffler Nuts
40
30
-
Heated Oxygen Sensor
40
30
-

COMPONENT LOCATOR

Exhaust System


T3D11G01
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  1. Exhaust Rear Muffler
  2. Muffler Gasket
  3. Exhaust Front Muffler
  4. Muffler Gasket
  5. Exhaust Front Pipe (1.4D)
  6. Exhaust Front Pipe (1.2D)
  7. Pop Converter
  8. Exhaust Front Resonator
  9. Exhaust Pipe Front Gasket
  10. Exhaust Front Pipe Gasket
  11. Pop Converter Gasket
  12. Pop Converter Gasket
  13. Exhaust Manifold
  14. Exhaust Manifold Shield
  15. Underbody Protective Shield
  16. Underbody Protective Shield

MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE


T8B52G01
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Catalytic Converter - 1.2 DOHC - B12D -

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the front heated oxygen sensor connector.
  3. Remove the exhaust manifold heat shield.

    4. T8B52G02
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  4. Remove the catalytic converter upper flange nuts.

    5. T8B52G03
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  5. Remove the exhaust front pipe mounting bracket bolt.
  6. Remove the catalytic converter lower flange nuts.
  7. Remove the catalytic converter and the gasket.

T8B52G03
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Installation Procedure

  1. Install the catalytic converter and the gasket.

    2. Important : Position the catalytic converter onto the exhaust manifold flange with one upper flange nut .

  2. Install the catalytic converter lower flange nuts and the exhaust front pipe mounting bracket.

    3. Tighten


    T8B52G02
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  3. Install the catalytic converter upper flange nuts.

    4. Tighten
    Tighten the catalytic converter to exhaust manifold nuts to 40 N•m (30 lb-ft).


    T8B52G01
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  4. Install the exhaust manifold heat shield.

    5. Tighten
    Tighten the exhaust manifold heat shield bolts to 15N•m (11 lb-ft).

  5. Connect the front heated oxygen sensor connector.
  6. Connect the negative battery cable.

T8B11C13
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Catalytic Converter - 1.4 DOHC - G14D -

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the front heated oxygen sensor connector.
  3. Remove the oil level gage tube.
  4. Remove the exhaust manifold heat shield.

    5. T8B11C14
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  5. Remove the catalytic converter upper flange nuts.

    6. T8B11G01
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  6. Remove the exhaust front pipe mounting bracket bolt.
  7. Remove the catalytic converter lower flange nuts.
  8. Remove the catalytic converter and the gasket.

T8B11G01
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Installation Procedure

  1. Install the catalytic converter and the gasket.

    2. Important : Position the catalytic converter onto the exhaust manifold flange with one upper flange nut .

  2. Install the catalytic converter lower flange nuts and the exhaust front pipe mounting bracket.

    3. Tighten


    T8B11C14
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  3. Install the catalytic converter upper flange nuts.

    4. Tighten
    Tighten the catalytic converter to exhaust manifold nuts to 40 N•m (30 lb-ft).


    T8B11C13
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  4. Install the exhaust manifold heat shield.

    5. Tighten
    Tighten the exhaust manifold heat shield bolts to 8 N•m (5.9 lb-ft).

  5. Install the oil level gage tube.

    6. Caution : Check the oil. If the oil dropped when removing the oil level gage tube, check and refill it.

  6. Connect the front heated oxygen sensor connector.
  7. Connect the negative battery cable.

T3B11G05
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Exhaust Front Pipe

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the rear heated oxygen sensor connector.

    3. T8B52G03
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  3. Remove the exhaust front pipe mounting bracket bolt.
  4. Remove the catalytic converter lower flange nuts.

    5. T3B11G06
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  5. Remove the nuts from the front muttler pipe to the exhaust front pipe.
  6. Remove the exhaust front pipe from the rubber hanger.
  7. Clean the sealing surtaces on the front muttler pipe flange and the exhaust front pipe.
  8. Check the exhaust front pipe for holes, damage, open seams, or other deterioration which could permit exhaust fumes to seep into the passenger compartment.

T3B11G06
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Installation Procedure

  1. Secure the exhaust front pipe to the rubber hanger.
  2. Install the nuts and gasket to the exhaust front pipe-to-front muffler.

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


    T8B52G03
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  3. Install the catalytic converter lower flange nuts and the exhaust front pipe mounting bracket.

    4. Tighten

    Tighten the exhaust front pipe to catalytic converter nuts to 40 N•m (30 lb-ft).
    Tighten the exhaust front pipe mounting bracket bolt to 40 N•m (30 lb-ft).

    T3B11G05
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  4. Connect the rear heated oxygen sensor connector.
  5. Connect the negative battery cable.

T3B11G06
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Muffler - Front

Removal Procedure

  1. Remove the nuts and the gasket from the front muffler pipe to the exhaust front pipe flange.

    2. T3B11G07
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  2. Remove the nuts and the gasket from the rear muffler pipe flange.

    3. T3B11G08
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  3. Disconnect the front muffler from the rubber hanger.
  4. Remove the front muffler.
  5. Check the exhaust pipe and the front muffler for holes, damage, open seams, or other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk.

T3B11G07
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Installation Procedure

  1. Connect the front muffler to the rubber hanger.
  2. Attach the front muffler and the gasket to the rear muffler using the nuts. Secure the front muffler to the rubber hanger.

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


    T3B11G08
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  3. Loosely secure the front muffler assembly to the connecting pipe flange.

    4. T3B11G06
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  4. Secure the front muffler assembly to the connecting pipe flange with the nuts.

    5. Tighten
    Tighten the front muffler-to-exhaust front pipe nuts to 40 N•m (30 lb-ft).


T3B11G07
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Muffler - Rear

Removal Procedure

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

    2. T3B11G09
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  2. Detach the rear muffler assembly from the rubber hangers on the tail pipe end.
  3. Remove the rear muffler assembly.
  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.

T3B11G09
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Installation Procedure

  1. Secure the rear muffler assembly to the rubber hangers on the tail pipe end.

    2. T3B11G07
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  2. Secure the nuts and the gasket from the 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

Exhaust System

Notice : When you are inspecting or replacing the exhaust system components, make sure there is adequate clearance from all points on the underbody to avoid possible overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.

Caution : Check the complete exhaust system and the nearby body areas and the trunk lid for broken, damaged, missing, or mispositioned parts, open seams, holes, loose connections, or other deterioration which could permit hazardous exhaust fumes to seep into the trunk or the passenger compartment. Dust or water in the trunk may be an indication of a problem in one of these areas. Any defects should be corrected immediately.

Muffler

If holes, open seams or any deterioration is discovered upon inspection of the front muffler and pipe assembly, the complete assembly should be replaced. The same procedure is applicable to the rear muffler assembly.
Heat shields in the front and the rear muffler assembly positions, as well as for the catalytic converter and the connecting pipe, protect the vehicle and the environment from high temperatures the exhaust system develops.

Catalytic Converters

Notice : The catalytic converter requires the use of unleaded fuel only, or damage to the catalyst will result.

The catalytic converters are emission control devices added to the exhaust system to reduce pollutants from the exhaust pipes.
The three-way catalyst has coatings which contain palladium, platinum and rhodium, which simultaneouly lower the levels of HC, CO and NOx.


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