Warning: Exhaust system components should only be inspected and repaired after sufficient time has passed since the vehicle was driven, so that the components have cooled completely. This is especially true for the catalytic converter, which operates at very high temperatures. Before working under the vehicle, make sure that it is securely supported.
General information
1. On models with 4-cylinder engines manufactured before 01/1998, the exhaust system consists of an exhaust manifold, downpipe and catalytic converter, and a rear section that contains two (or three on some models) mufflers and an exhaust pipe assembly. The replacement exhaust system consists of three or four sections: a downpipe/catalytic converter, a midpipe and a front muffler, and an exhaust pipe and a rear muffler. Alternatively, the exhaust pipe may consist of two parts with two mufflers. The entire exhaust system is suspended from the body on rubber mounts.
2. On models with 4-cylinder engines produced from 01.1998, the exhaust system consists of an exhaust manifold, a downpipe and a catalytic converter, as well as a rear section that contains two mufflers and an exhaust pipe assembly (see Fig. 15.2).
3. On models with V-shaped 6-cylinder engines, the exhaust system contains two exhaust manifolds connected by a fork section, a catalytic converter, and a rear section with three mufflers (see Fig. 15.3, a-c).
4. On all midships, the exhaust system is installed in rubber supports located along its entire length (see Fig. 15.4).
Replacement of components
5. If any of the above components is damaged or destroyed, this will be manifested by excessive noise and vibration.
6. Regularly inspect the exhaust system to maintain low noise levels and system reliability. Check for damaged or bent parts, cracked welds, holes, loose connections and joints, excessive corrosion, and other defects that could allow exhaust gases to enter the vehicle. Failed system components cannot be repaired and must be replaced with new ones.
7. If the exhaust system components are significantly corroded or rusted together, they should be cut off from the exhaust system. And this should be entrusted to specialists. If you want to do it yourself, cut off the defective components with a hacksaw (if you do not have gas cutting equipment). You can also use a pneumatic tool with a cutting attachment for this work. In this case, protect your eyes from metal shavings and work with gloves. To repair a system installed during the manufacture of the car, it must be cut off in the specified places (see Fig. 15.7, a, b) in order to install sections from the exhaust system repair kit.
8. When repairing the exhaust system, follow these simple rules:
Warning: The catalytic converter gets very hot and takes a long time to cool. Allow it to cool completely before removing it. Failure to follow these instructions may result in serious burns.
- a) Remove the exhaust system components starting from the rear end and working your way toward the front of the exhaust system.
- b) Use kerosene or another liquid that penetrates well into the joints as an aid when removing components and disconnecting its fasteners.
- c) When installing exhaust system components, install new gaskets, rubber mounts and clamps.
- d) When assembling, apply anti-seize compound to all threads of fasteners of the exhaust system.
- d) Note that on some models the downpipe is secured to the manifold with two bolts, each with a coil spring, spring seat and self-locking nut. When installing, tighten the nuts until they touch the shoulder of the bolt. This creates sufficient tension in the spring to ensure a tight seal (see Fig. 15.8). Do not overtighten the nuts when trying to fix a leak, or the bolts will shear. Replace the gasket and spring if leaks are detected
- e) Ensure that there is sufficient clearance between newly installed components and the body. This prevents overheating of the floor panel and possible damage to the carpet and insulation material. Pay particular attention to the catalytic converter and its heat-insulating casing.
