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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
50
37
-
Exhaust Front Pipe-to-Catalytic Converter Nuts
40
30
-
Exhaust Manifold Cover Bolts
15
11
-
Front Muffler-to-Exhaust Front Pipe Nuts
30
22
-
Front Muffler-to-Rear Muffler Nuts
30
22
-
Heated Oxygen Sensor
41
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 (1.2S)
  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


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Catalytic Converter

Removal Procedure

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

    4. T3D11C24
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  4. Remove the catalytic converter upper flange nuts.

    5. T3B11G04
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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.

T3B11G04
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Installation Procedure

  1. Install the catalytic converter and the gasket.

    2. Important : Position the catalytic converteronto the exhaust manifold flange with one upper flangenut .

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

    3. Tighten


    T3D11C24
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  3. Install the catalytic converter upper flange nuts.

    4. Tighten
    Tighten the catalytic converter to exhaust manifold nuts to50 N•m (37 lb-ft).


    T3D11C19
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  4. Install the exhaust manifold heat shield.

    5. Tighten
    Tighten the exhaust manifold heat shield bolts to15N•m (11 lb-ft).

  5. Connect the front heated oxygen sensor connector.
  6. 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. T3B11G04
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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.

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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 30 N•m (22 lb-ft).


    T3B11G04
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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 mufflerpipe flange.

    3. T3B11G08
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  3. Disconnect the front muffler fromthe rubber hanger.
  4. Remove the front muffler.
  5. Check the exhaust pipe and the front muffler forholes, damage, open seams, or other deteriorationwhich could permit exhaust fumes to seep into thepassenger 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 rearmuffler using the nuts. Secure the front muffler to therubber hanger.

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


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Muffler - Rear

Removal Procedure

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

    2. T3B11G09
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  2. Detach the rear muffler assembly from the rubberhangers on the tail pipe end.
  3. Remove the rear muffler assembly.
  4. Check the rear muffler and the pipe forholes, damage, open seams, and other deteriorationwhich could permit exhaust fumes to seep into thepassenger 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 mufflerpipe flange-to-front muffler pipe flange.

    3. Tighten
    Tighten the front muffler-to-rear muffler nuts to30 N•m (22 lb-ft).

GENERAL DESCRIPTION AND SYSTEM OPERATION

Exhaust System

Notice : When you are inspecting or replacing the exhaustsystem components, make sure there is adequateclearance from all points on the underbody to avoid possibleoverheating of the floor pan and possible damageto the passenger compartment insulation and trim materials.

Caution : Check the complete exhaust system andthe nearby body areas and the trunk lid for broken,damaged, missing, or mispositioned parts, openseams, holes, loose connections, or other deteriorationwhich could permit hazardous exhaustfumes to seep into the trunk or the passengercompartment. Dust or water in the trunk may be anindication of a problem in one of these areas. Anydefects should be corrected immediately.

Muffler

If holes, open seams or any deterioration is discoveredupon inspection of the front muffler and pipe assembly,the complete assembly should be replaced. Thesame procedure is applicable to the rear muffler assembly.
Heat shields in the front and the rear muffler assemblypositions, as well as for the catalytic converter andthe connecting pipe, protect the vehicle and the environmentfrom high temperatures the exhaust system develops.

Catalytic Converters

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

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


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