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Exhaust Leakage

Problem

Action

Warning: While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.

DEFINITION: An exhaust leak may show stains at the area of the leak. The leak may be felt by holding a hand close to the suspected areas or using a smoke pencil. The leak may make a popping or hissing noise.

Refer to Symptoms - Engine Exhaust prior to beginning this table.

Misaligned or improperly installed exhaust system components

Align and tighten the components to the specifications. Refer to Fastener Tightening Specifications : 2.4L LAF → 2.0L Diesel LNP → LDE, LXV, 2H0, LUW and LFH .

Exhaust leaks at the following connections:

    • Exhaust manifold to pipe
    • Flanges
    • Pipe clamps

Tighten the components to the specifications. Refer to Fastener Tightening Specifications : 2.4L LAF → 2.0L Diesel LNP → LDE, LXV, 2H0, LUW and LFH .

Seals or gaskets leaking.

    • Exhaust manifold to cylinder head
    • Exhaust pipes to exhaust manifold
    • Catalytic converter connection
    • AIR connections to the exhaust manifold or cylinder head

Replace the leaking seal or gasket. Refer to the affected components procedure for service.

Irregularities at the mating surfaces on the flange connections

Repair as required or replace the affected component. Refer to the affected components procedure for service.

Exhaust manifold cracked or broken

Replace the exhaust manifold. Refer to Exhaust Manifold Replacement : 2.4L LAF → 2.0L Diesel LNP → 1.6L LDE, LXV, 1.8L 2H0, LUW and LFH .

Exhaust system component connection welds leaking

Replace the leaking component. Refer to the affected component procedure for service.

Duct damaged or leaking at the seams

Replace the affected duct. Refer to.

    • Air Cleaner Inlet Duct Replacement for 1.8L 2H0.
    • Air Cleaner Outlet Duct Replacement for 1.8L 2H0.
    • Inlet Air Duct Replacement for 2.0L LNP.
    • Rear Inlet Air Duct Replacement for 2.0L LNP.
    • Air Cleaner Outlet Duct Replacement for 2.0L LNP.
   


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