9-734 EigLne Exhaust

Engine Exhaust

Specifications

Fastener Tightening Specifications

Specification
Application Metric English
ExhaustPipe
Converter—to-Front 20N-m 15lbft
3—WayCatalytic
3—WayCatalyticConverter-to-ExhaustMuffler 17N-m 13lbft
CatalyticConverterBrace Fastener(LUV) 22N-m 16lbft
CatalyticConverterBraceFastener(LUW) 20Nm 15lbft
Head
WithCatalyticConverter—to-Cylinder
EggtaeunsetrthaBWId 15Nm 11lbft

ExhaustManifoldBrace Fastener(LUW) 20Nm 15lbft

ExhaustManifoldHeatShield (LUV) 9 N-m 80lbin
ExhaustMufflerClamp(Service) 50N-m 37lbft
ExhaustMufflerHeatShield 4 N-m 35lbin
Converter(LUW)
FrontExhaustPipe-to—Catalytic 20N-m 15lbft
TurbochargerClampFastener (LUV) 13N-m 115lb in

Symptom List
Diagnostic Information and Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
Procedures
- Loss of power—Refer to Restricted Exhaust on
page 9-734.
Symptoms - Engine Exhaust - Poor acceleration—Refer to Restricted Exhaust
Description and on page 9-734.
- Review the Exhaust System
Operation in order to familiarize yourself with the - Poor fuel economy—Refer to Restricted Exhaust
system functions. Refer to Exhaust System on page 9-734.
Description on page 9—753. - Exhaust hissing noise—Refer to Exhaust Leakage
- All diagnostics on a vehicle should follow a logical on page 9736.
process. Strategy Based Diagnostics is a uniform ‘ Exhaust popping noise—Refer to Exhaust
approach for repairing all systems. The diagnostic Leakage on page 9—736.
flow is the place to start when repairs are 0 Exhaust rattle noise—Refer to Exhaust Noise on
necessary and may always be used in order to page 9-736.
resolve a system problem. For a detailed
explanation, refer to Strategy Based Diagnosis on - Loud exhaust noise—Refer to Exhaust Noise on
page 9-736.
page 6—58.
- Exhaust buzz, groan, hum noise—Refer to
VisuallPhysical Inspection Exhaust Noise on page 9-736.
- Inspect for aftermarket or non-OEM devices such
as, but not including, tailpipe extensions, mufflers, Restricted Exhaust
and exhaust hangers. This could affect the
operation and proper performance of the exhaust Special Tools
system. EN—35314-A Exhaust Back Pressure Gauge
- Verify the exact operating conditions under which For equivalent regional tools. Refer to Special Tools on
the concern exists. Note factors such as engine page 9-754.
RPM, engine temperature, engine load, and
frequency of concern. Diagnostic Aids
- Inspect the easily accessible or visible system A quick check of exhaust flow will help determine for
components for obvious damage or conditions gasoline engines.
which could cause any symptom.
Intermittent
Test the vehicle under the same conditions that the
customer reported in order to verify the system is
operating as designed.
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 Engine Exhaust 9-735

Test Description This step will isolate the catalytic converter from
the remainder of the exhaust system.
The numbers below refer to the step numbers on the
diagnostic table. Confirming that the condition has been fixed is
essential. Ifthe symptom still exists and the vehicle
3. The exhaust system has very low back pressure has a dual exhaust system, proceed to Step 2 and
under normal conditions. Ifthe exhaust system is repeat diagnostic procedure on the opposite
restricted, a significant increase in the exhaust exhaust pipe.
pressure is noticed on the EN-35314-Agauge.
Removing the heated oxygen sensor may set a
DTC. When finishing this diagnostic table, be sure
to clear all codes.

Restricted Exhaust
Step Action Value(s) Yes No
1 Didyouverifythecustomerscomplaint? —— Go to Step2 -
Didyoureviewtheexhaustsymptomsdiagnosticinformation Go to Symptoms
2 and performthenecessaryinspections? — - EngineExhaust
Go to Step3 onpage 9-734
1. Removetheheatedoxygensensor1.Referto Heated
OxygenSensorReplacement- Sensor 1onpage9-249
forthe 1.4Lor HeatedOxygenSensorReplacement-
Sensor 1 onpage 9-538forthe1.6L.
2. InstalltheEN-35314-Agaugein placeoftheheated
3 oxygensensor1. 14kPa (2psi)
3. Starttheengine.
4. Increaseandmonitortheenginespeedat 2,000RPM.
5. Observetheexhaustsystembackpressurereadingon
thegauge.
Doesthereadingexceedthespecifiedvalue? Go to Step4 Go to Step 7
1. TurntheengineoffandplacetheIgnitionInthelock
position.
2. RemovetheEN-35314-A gauge.
3. Installtheheatedoxygensensor1.Referto Heated
OxygenSensorReplacement—Sensor1 onpage9-249
forthe 1.4Lor HeatedOxygenSensorReplacement-
Sensor 1 onpage 9538forthe1.6L.
4. Removetheheatedoxygensensor2. Referto Heated
OxygenSensorReplacement- Sensor2 onpage9-250
4 forthe 1.4Lor HeatedOxygenSensorReplacement- -
Sensor2 onpage 9-539 forthe1.6L.
5. InstalltheEN—35314-A gaugein placeoftheheated
oxygensensor2.
6. Starttheengine.
7. increaseandmonitortheenginespeedat 2,000RPM.
8. Observetheexhaustsystembackpressurereadingon
thegauge.
Doesthereadingexceedthespecifiedvalue? Go to Step5 Go to Step6
Inspecttheexhaustsystemforthefollowingconditions:
- Damagein theexhaustpipe.
5 - Debrisin theexhaustpipe. fl __
- Muffleror resonatorinternalfailure.
' Two-iayerexhaustpipeseparation.
Didyoufindandcorrectthecondition? Go to Step 7
Replacethecatalyticconverter.Referto WarmUp
Three—Wa y CatalyticConverterReplacement(LUV,LUW) on
6 page 9-745. , _ -
Didyoufindandcorrectthecondition? Go to Step 7

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9-736 Engine Exhaust

Restricted Exhaust (cont'd)

Step . Action Value(s) Yes No
1. RemovetheEN~35314-A gauge.
2. installtheheatedoxygensensor2. Referto Heated
OxygenSensorReplacement- Sensor2 onpage9-250
forthe 1.4Lor HeatedOxygenSensorReplacement-
7 Sensor2 onpage9-539 forthe 1.6L. -
3. Clear any DTCs.
4. Roadtestthevehiclein ordertoverifytherepair.
Didyoucorrectthecondition? SystemOK Go to Step2

Exhaust Leakage
Problem Action
Warning: While engineis operating,the exhaust system will become extremelyhot. Toprevent burns avoid contacting
a hot exhaust system.
DEFlNlTlON:An exhaustleakmayshowstainsat theareaoftheleak.The leakmaybefeltby holdinga handcloseto the
suspectedareasor usinga smokepencil.The leak maymakea poppingor hissingnoise.
Referto Symptoms-EngineExhaustonpage 9-734priorto beginningthistable.
Misalignedor improperlyinstalled Alignandtightenthecomponentstothespecifications.Referto FastenerTightening
exhaustsystemcomponents Specificationsonpage 9-734.
Exhaustleaksat thefollowing Tightenthecomponentstothespecifications.Referto FastenerTightening
connections: Specificationsonpage 9-734.
- Exhaustmanifoldto pipe
- Flanges
' Pipe clamps
Seals or gasketsleaking. Replacetheleakingseal or gasket.Refertotheaffectedcomponentsprocedurefor
- Exhaustmanifoldto cylinderhead service.
- Exhaustpipesto exhaustmanifold
- Catalyticconverterconnection
- AIR connectionstotheexhaust
manifoldor cylinderhead
irregularitiesat thematingsurfaceson Repairas requiredor replacetheaffectedcomponent.Refertotheaffected
theflangeconnections componentsprocedureforservice.
Exhaustmanifoldcrackedor broken Replacetheexhaustmanifoldwithcatalyticconverter.Referto ExhaustManifoldwith
CatalyticConverterReplacement(LUW)onpage 9-737.
Exhaustsystemcomponent Replacetheleakingcomponent.Refertotheaffectedcomponent‘sprocedurefor
connectionweldsleaking serVice.
Ductdamagedor leakingat theseams Replacetheaffectedduct.RefertoAir CleanerInletDuctReplacementonpage9-579
forthe1.6LorAir CleanerlnletDuctReplacementonpage 9-287 forthe1.4L.

Exhaust Noise
Conditions Action
DEFINITION:An audibleor physicalnoiseduetoa faultycomponentor damagedcomponentscausinga looseor misaligned
exhaustsystemresultingin a rattleor vibrationnoise,i.e.buzz,groan,hum.Referto Symptoms—EngineExhaustonpage9-734
priorto beginningthistable.
Poppingor hissingnoise Exhaustleak.Referto ExhaustLeakageonpage 9-736.
1. Comparetoa knowngoodvehicle.
Loudexhaust Inspectfora damagedorfailedmuffler.
Replacethefaultymuffler.Referto ExhaustSystemReplacementonpage9-739.
Inspectfora bentor loosehanger,looseheatshield,or looseclamp.
Externalrattleor vibration Inspectforan exhaustpipecausinginterference.
noise WNT‘
9’!”Repairor replacetheaffectedcomponent.Referto theaffectedcomponent'sservice
procedure.

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 Engine Exhaust 9-737

Exhaust Noise (cont'd)

Conditions Action
1. Testthecomponentsbytappingwitha rubbermalletto confirma rattle.
2. Replacethefaultycatalyticconverter,or muffler.Referto one of thefollowingprocedures:
internalrattle
- CatalyticConverterReplacement(LUV)onpage 9-742
° ExhaustSystemReplacementonpage 9-739

Repair Instructions

Exhaust Manifold Replacement (LUV)

Refer to TurbochargerReplacement on page 9-843.

Exhaust Manifold with Catalytic Converter Replacement (LUW)

2509158

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9-738 Engine Exhaust

Exhaust Manifold with Catalytic Converter Replacement (LUW)

Callout I Component Name
Warning: Refer to Protective Goggles and Glove Warningon page 0-5.
Warning: Refer to Exhaust Service Warningon page 0-4.
Preliminary Procedure
1. Removethecatalyticconverterheatshield.Referto CatalyticConverterHeatShieldReplacement(LUV)onpage9-746.
2. Removetheexhaustfrontpipe.Referto ExhaustFrontPipe Replacement(LUV,LUW) onpage 9-738.
ExhaustManifoldto CylinderHeadNut(Qty:9)
Caution: RefertoFastenerCautiononpage 0-8.
Tighten
15N-m(11|bft)
2 ExhaustManifoldGasket
ExhaustManifoldBraceBolt(Qty:4)
3 Tighten
20N-m(15lbft)
4 ExhaustManifoldBrace
ExhaustManifoldwithCatalyticConverter
Procedure
1. Disconnectthetemperaturesensorandtransferpartsif replacingtheexhaustmanifoldwithcatalytic
5 convenen
2. Cleanthesealingsurfaces. ,
3. Replacetheexhaustgasketwitha NEW gasket.
4. ReplacetheexhaustmanifoldnutswithNEW nuts.I

Exhaust Front Pipe Replacement

(LUV,LUW)

Removal Procedure
Warning: Refer to Exhaust Service Warning on
page 0-4.
1. Remove the drivetrain and front suspension frame
skid plate. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement on
page 3-143.
2. Disconnect the heated oxygen sensor-2. Refer to
Heated Oxygen Sensor Replacement - Sensor 2
on page 9—539.

2678269
3. Remove the 3—waycatalytic converter
fasteners (1) and disconnect the 3—waycatalytic
converter (4)from the front pipe.
4. Discard the exhaust gasket (2).

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 Engine Exhaust 9-739

2509518 2509518
5. Remove the exhaust front pipe (3) to the catalytic 3. Position the exhaust front pipe (3) to the catalytic
converter fasteners (1). converter with a NEW gasket (2).
6. Remove the front pipe (3) from the catalytic 4. install the exhaust front pipe fasteners (1) to the
converter and discard the exhaust gasket (2). catalytic converter and tighten to 20 Nm (15 lb ft).
5. Connect the heated oxygen sensor—2.Refer to
Installation Procedure Heated Oxygen Sensor Replacement - Sensor 2
on page 9-539.
6. install the drivetrain and front suspension frame
skid plate. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement on
page 3-143.
7. Start the engine and check for exhaust leaks.

Exhaust System Replacement

Removal Procedure
Special Tools
CH-6614Chain Pipe Cutter
For equivalent regional tools, refer to Special Tools on
page 9754.
Warning: Refer to Protective Goggles and Glove
Warning on page 0-5
Warning: Refer to Exhaust Service Warning on
page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
2678269 Jacking the Vehicle on page 1-31
1. Install a NEW gasket (2) to the exhaust front pipe.
Caution: Refer to Fastener Caution on page 0-8.
2. Install the 3—waycatalytic converter (4) to the
exhaust isolators (3) and tighten the fasteners (1)
to 17 N'm (13 lb ft).

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9-740 Efingine Exhaust

2510137 2678269
with the CH—6614
2. Cut the exhaust rear muffler(2) 6. Remove the exhaust front pipe fasteners (1) and
pipe cutter at position (1). discard the gasket (2).
7. Remove the 3—waycatalytic converter(4) from the
exhaust isolators (3).

4 3 5 2 1 2
2494571
3. Remove the rear exhaust muffler (2) from the
exhaust isolators (1). 2525772
4. Sand smooth the front exhaust pipe for ease of 8. Lower the intermediate exhaust front muffler
installation. pipe (5).
5. Remove the exhaust rear muffler. 9. Remove and transfer the catalytic converter,
if necessary.

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 Engine Exhaust 9-741

Installation Procedure

2678269
Caution: Refer to Fastener Caution on page 0-8.
2494571 3. Install the 3-way catalytic converter (4) into the
exhaust Isolators (3)with a NEW gasket (2) and
1. Installthe exhaust rear muffler (2) into the exhaust tighten the fasteners (1)to 17 N-m(13 lb ft).
isolators (1).

2494571
2525772
4. Install the new rear exhaust muffler (2) into the
2. Installthe intermediate exhaust front muffler(5)
to exhaust isolators.
the front exhaust hanger isolators (2).
5. Lower the vehicle.
6. Start the engine and check for exhaust leaks.

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9-742 Engine Exhaust

2494560
7. Position the exhaust front pipe (3) into the exhaust
muffler clamp.
Note: There are 3 different exhaust mufflerclamps
depending on the diameter of the exhaust pipe.
8. Install the rear exhaust muffler (2) into the exhaust
muffler clamp and tighten the bolt (1) to 50 N-m
(37 lb ft).
9. Lower the vehicle.
10. Start the engine and check for exhaust leaks.
2609439
. Remove the catalytic converter to the turbocharger
clamp fastener(1) and discard the clamp (2).
. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.
. Remove the drivetrain and front suspension frame
skid plate. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement on
page 3—143.

Catalytic Converter
Replacement (LUV)

Removal Procedure
Warning: Refer to Exhaust Service Warning on
page 0-4.
Warning: Refer to Protective Goggles and Glove
Warning on page 0-5.
1. Remove the exhaust manifold heat shield. Refer to
Exhaust Manifold Heat Shield Replacement (LUV)
on page 9-749or Exhaust Manifold Heat Shield
Replacement (LUW)on page 9—750.
Remove the catalytic converter heated oxygen
sensor - 1. Refer to Heated Oxygen Sensor
Replacement - Sensor1 on page 9-249.

2609448
6. Remove the exhaust front pipe fasteners (1) and
discard the exhaust gasket (2).

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 Engine Exhaust 9-743

2609441 2191860
7. Remove the catalytic converter brace fasteners (1) 2. install a NEW clamp into the position shown and
from the catalytic converter brace (2). loosely tighten the clamp fastener (1).
8. Remove the catalytic converter.
Installation Procedure

2609448
Caution: Refer to Fastener Caution on page 0-8.
3. Install the exhaust front pipe (3) to the catalytic
2609441 converter with a NEW gasket (2) and tighten the
1. install the catalytic converter into the catalytic fasteners (1)to 22 NW (16 lb ft).
converter brace (2) and loosely tighten the
fasteners (1).

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9-744 Ewine Exhaust

2609441
4. Tighten the catalytic converter brace fasteners (1)
to 22N'm(16lbft).
5. install the drivetrain and front suspension frame
skid plate. Refer to Drivetrain and Front
Suspension Frame Skid Plate Replacement on
page 3—143.
6. Lower the vehicle.
10. Start the engine and check for exhaust leaks.
2609439
7. Tighten the turbocharge clamp fastener (1) to
13 Nm (115lbin).
8. Install the exhaust manifold heat shield. Refer to
Exhaust Manifold Heat Shield Replacement (LUV)
on page 9749 or Exhaust Manifold Heat Shield
Replacement (LUW)on page 9-750.
9. Install the catalytic converter heated oxygen
sensor —1. Refer to Heated Oxygen Sensor
Replacement - Sensor 1 on page 9-249.

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 Engine Exhaust 9-745

Warm Up Three-Way Catalytic Converter Replacement (LUV,LUW)

2668341
Warm Up Three-Way Catalytic Converter Replacement (LUV,LUW)
Callout I Component Name
Warning: Refer to Exhaust Service Warningon page 0-4.
Warning: Refer to Safety Glasses Warningon page 0-5.
Preliminary Procedure
Raise andsupportthevehicle.Referto LiftingandJackingthe Vehicleonpage 1-31.
ExhaustMufflerFasteners(Qty:2)
Caution: RefertoFastenerCautiononpage 0-8.
Tighten
17N'm(13lbft).
ExhaustGasket
Note: ReplacewithNEW gaskets
ExhaustFrontPipe Fasteners(Qty:2)
3 Tighten
17N'm (13lbft).
4 ExhaustIsolators
5 CatalyticConverter

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9-746 Eflgine Exhaust

Catalytic Converter Heat Shield Replacement (LUV)

2668491

Catalytic Converter Heat Shield Replacement (LUV)

Callout Component Name
Warning: Refer to Exhaust Service Warningon page 0-4.
CatalyticConverterHeatShield Fasteners(Qty:4)
Caution: Referto FastenerCautiononpage0-8.
Tighten
9N-m(80lb in).
2 CatalyticConverterHeatShield

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 Engine Exhaust 9-747

4V

2494821
Exhaust Heat Shield Replacement
Callout I Component Name
Preliminary Procedure
Disconnecttheexhaustsystemhangersandallowtheexhaustsystemto reston therearaxle.
1 ExhaustHeatShieldFastener(Qty:6)
2 ExhaustHeatShield

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9-748 Engfiie Exhaust

Fuel Tank Heat Shield Replacement Installation Procedure

Removal Procedure
1. Support the fuel tank with a suitable jack.

2678482
Caution: Refer to Fastener Caution on page 0—8.
1. Install the fuel tank heat shield (2) and tighten the
2678481 fasteners (1)to 10 Nm (89 lb in).
2. Remove the fuel tank strap fasteners (1) and lower
the fuel tank straps (2).

2678481
2. install the fuel tank straps (2) and tighten the
2673432 fasteners (1)to 22 N-m(16 lb ft).
3. Remove the fuel tank heat shield fasteners (1) and
remove the fuel tank heat shield (2).

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 Engine Exhaust 9349

Exhaust Manifold Heat Shield Replacement (LUV)

2668495
Exhaust Manifold Heat Shield Replacement (LUV)
Callout Component Name
Warning: Refer to Exhaust Service Warningon page 0-4.
ExhaustManifoldHeatShieldFasteners(Qty:3)
Caution: Referto FastenerCautiononpage 0-8.
1 Tighten
9 NW(80lb in).
2 ExhaustManifoldHeatShield

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9=750 Engine Exhaust

Exhaust Manifold Heat Shield Replacement (LUW)

2509123

Exhaust Manifold Heat Shield Replacement (LUW)

Callout Component Name
Warning: Refer to Exhaust Service Warningon page 0-4.
Preliminary Procedures
1. Disconnectthenegativebatterycable.Referto BatteryNegativeCable Disconnectionand Connectiononpage9-713.
2. Removetheoil levelindicatortube.Referto Oil LevelIndicatorTubeReplacementonpage 9-1026.
3. Disconnecttheheatedoxygensensorconnector.
CatalyticConverterHeatShield Bolt
Caution: Referto FastenerCautiononpage 0-8.
Tighten
15N~m(11|bft)
2 HeatedOxygenSensorHarnessBracket
CatalyticConverterHeatShieldBolt(Qty:2)
3 Tighten
8 N-m(71|bin)
4 CatalyticConverterHeatShield

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 Engine Exhaust 9-751
Exhaust Rear Muffler Heat Shield Replacement

2494819
Exhaust Rear Muffler Heat Shield Replacement
Callout Component Name
Preliminary Procedure
Disconnecttheexhaustsystemhangersin therearandallowtheexhaustsystemto reston therearaxle.
1 ExhaustHeatShield Rear MufflerFastener(Qty:3)
2 ExhaustHeatShield Rear Muffler

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9-752 Engine Exhaust

Exhaust Rear Muffler Replacement 4. Sand smooth the front exhaust pipe for ease of
installation.
(LUV,LUW)
Installation Procedure
Special Tools
CH-6614Chain Pipe Cutter
For equivalent regional tools, refer to Special Tools on
page 9-754.
Removal Procedure
Warning: Refer to Exhaust Service Warning on
page 0-4.
1. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle on page 1-31.

2494571
into the
1. Install the new rear exhaust muffler(2)
exhaust isolators.

_2510137
with the CH-6614
2. Cut the exhaust rear muffler(2)
pipe cutter at position (1).

2494560
Caution: Refer to Fastener Caution on page 0-8.
Note: There are 3 differentexhaust muffler clamps
depending on the diameter of the exhaust pipe.
2. Position the exhaust front pipe (3) into the exhaust
muffler clamp.
3. Install the rear exhaust muffler(2) into the exhaust
muffler clamp and tighten the bolt (1) to 50 Nm
(37 lb ft).
2494571 4. Lowerthe vehicle.
5. Start the engine and check for exhaust leaks.
3. Remove the rear exhaust muffler(2)from the
exhaust isolators (1).

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 Engine Exhaust 9753

Description and Operation The catalytic converter is similar to a muffler in

appearance however, within the outer stainless steel
shell (4),there is a ceramic monolith (1)which is
honeycombed in the direction of the exhaust, as
Exhaust System Description shown. The ceramic monolith is surrounded by a
Note: Use of Non—OEMparts may cause driveability mat (2),which has the primary function of holding the
concerns. monolith firmly in place to prevent any contact with the
The exhaust system carries exhaust gases, treated by inner shell (3).A mesh (5 and 6) at each end of the
the catalytic converter, through a resonator, converter prevents exhaust gases from fouling and
if applicable and into the exhaust muffler where exhaust eroding the mat.
noise is lessened. Surfaces of the ceramic monolith that are exposed to
In order to secure the exhaust pipe to the exhaust exhaust gases are coated with a catalytic material. This
manifold, a flange and seaI-joint coupling is utilized. material contains rhodium and platinum, which act to
facilitate the chemical reactions necessary to oxidize
Exhaust hangers and rubber insulators help to support carbon monoxide and hydrocarbons into harmless
the weight of the exhaust pipe along with insulating any carbon dioxide.
exhaust system vibration, rattle,or noise.
The catalytic converter is a substance that accelerates
Exhaust hangers also space the exhaust system away a chemical reaction without itself being changed.
from the underbody of the vehicle and allows the Engine exhaust gases contain carbon monoxide (CO),
exhaust system to expand as the exhaust system hydrocarbons (HC)and oxides of nitrogen (NOx).When
warms up. the exhaust gases flow through the monolith, reactions
Exhaust heat shields are used to protect the body and with the catalytic converter occur.CO and HC are
other components from damage due to the heat from converted by oxidation with oxygen (02)in the exhaust
the exhaust system. gases to produce carbon dioxide (CO2)and water
The exhaust system may be comprised of the following vapour (H20).NOx is converted by reduction with CO
components: to produce nitrogen (N2).The catalytic converter is
called a three—waytype because it simultaneously
- Exhaust manifold
converts three components of exhaust gas (CO, HC
. Exhaust pipes and NOx)to harmless natural gases.
° Catalytic converters
Service Notes
' Exhaust muffler
. Vehicles fitted with a catalytic converter should not
' Exhaust resonator, if equipped be operated with leaded petrol. Lead will
. Exhaust hangers contaminate the catalytic converter.
' Exhaust heat shields o Do not drop the catalytic converter as it will
damage the ceramic monolith.
Catalytic Converter ' Do not allow water, oil or fuel to enter the
Through developments in various emissions reduction converter as the ceramic monolith will be
system, significant reductions in emissions have been contaminated.
achieved. The developments have been primarily ' Do not drive the vehicle with the engine misfiring
concerned with refinements in engine calibration and or with any of the spark plug leads disconnected.
the optimization of exhaust system catalytic converter
configurations. Note: Catalytic converter can be damaged or rendered
infective, if:
. Operated outside the limits of the closed loop
i\>c><:)c>c mixture control system.
FSOOC - The engine burns excessive amount of oil.
DOOOC - The exhaust temperature at the converter is too
)OOOC high (exceeds 840°C).
2999s Resonator
Some exhaust systems are equipped with a resonator.
The resonator, located either before or after the muffler,
allows the use of mufflers with less back pressure.
Resonators are used when vehicle characteristics
require specific exhaust tuning.

_/ Muffler
The exhaust muffler reduces the noise levels of the
engine exhaust by the use of tuning tubes. The tuning
tubes create channels inside the exhaust muffler that
lower the sound levels created by the combustion of the
engine.

1949732
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9-754 Engine Exhaust
The center mufflers on vehicles fitted with the LFW Special Tools and Equipment
engine option contains a variable exhaust valve. The
purpose of the valve is to reduce exhaust noise for
minimal impact on performance and back pressure. Illustration Tool Number/Description
The valve consists of a spring loaded flap which is
closed at lower gas flow (lower engine speed/load)
forcing the exhaust gasses through a more restrictive
path therefore providing improved noise performance.
As gas flow increases with higher engine load/speed, EN 35314-A
the valve opens providing a less restrictive path for the J 35314-A
exhaust gases and therefore providing good wide open ExhaustBackPressure
throttle performance. Gauge

13544

CH—6614
MKM—6614

2028026

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