Exhaust systems

What kind of noise? Inside an engine there are pretty heavy explosions taking place and they tend to be very noisy, which is why an exhaust system is fitted. The task of this system is to cool down the exploded gases and allow them to lessen their pressure before bringing them in contact with the cooler air outside. If any part of the exhaust system malfunctions, the engine will be noisy.

This system consists of the exhaust manifold, which is bolted directly to the cylinder head and sealed with a manifold gasket, The first exhaust section is usually bolted to this with a flange, which has a gasket or ball and socket seal.

Check the gaskets and check for cracks. After the first exhaust section you will usually find either the second section or the muffler, which allows the gas to expand. Check for cracks or breaks in this unit. From there a further pipe goes to the rear of the car, or in some cases to a resonator box which looks like a second muffler. This has to do with tuning the frequency of the exhaust gases to allow a free flow of exhaust gas at cruising speed to enhance fuel consumption. Check here also for cracks, breaks.

Another kind of noise from the engine could be knocking, which could mean serious engine trouble. If this is the noise you hear, take it to a repair shop immediately.

direct bolt on. 304 stainless. not sure what more you'd need to know.

You will find it in the exhaust pipe somewhere before you get to the catalytic converter. It may be in the exhaust manifold that bolts to the engine head, or anywhere between there and the middle of the exhaust system

usually if there is a hole in an exhaust component the component is replaced. you can check any online parts store for exhaust parts and find the part that you need.

Exhaust systems can be a real bear to work on. Rusted bolts and pipes can make the job really difficult. It may not be a bad idea to have a shop take a look and give you an estimate for repairs. Exhaust is pretty competitive so the prices may not be as bad as you may think.

I’m happy to assist further over the phone at https://www.6ya.com/expert/jeremy_d728a59f986299fa

Hello vocalviixen,

The pipe that you referred to is the exhaust crossover pipe. Below I've included removal and installation instructions.

Also, the procedure for bleeding the coolant system is critical; if you need those instructions please post the question.

REMOVAL PROCEDURE
1. Disconnect the battery ground (negative) cable.
2. Remove the throttle body air inlet duct.
3. Drain the coolant from the cooling system.
4. Remove the inlet radiator hose from the engine.
5. Remove the thermostat bypass pipe.
6. Remove the exhaust crossover heat shield bolts.
7. Remove the exhaust crossover heat shield.
8. Remove the exhaust crossover pipe studs/nuts.
9. Remove the exhaust crossover pipe.
INSTALLATION PROCEDURE
1. Install the exhaust crossover pipe.
2. Install the exhaust crossover pipe studs/nuts.
3. Tighten the exhaust crossover pipe studs/nuts to 18 lb ft.
4. Install the exhaust crossover heat shield.
5. Install the exhaust crossover heat shield bolts.
6. Tighten the exhaust crossover heat shield bolts to 89 lb in.
7. Install the thermostat bypass pipe.
8. Install the inlet radiator hose to the engine.
9. Fill the cooling system with engine coolant.
10. Install the throttle body air inlet duct.
11. Connect the battery ground (negative) cable.


Regards,
netvan

Thermostat Removal & Installation 2.2L Engine To Remove:

1. Remove the exhaust manifold. If equipped with an automatic transmission.
2. Drain the cooling system.
3. Remove or disconnect the following:
   
   
   • Thermostat housing to water pump feed pipe bolts.
     
     
   • Thermostat housing to water pump feed pipe.
   • Thermostat.

To Install:

1. Install or connect the following:
   • Thermostat.
   • Thermostat housing to water pump feed pipe.
   • Thermostat housing to water pump feed pipe bolt.
     1. Tighten bolt to 89 in lbs (10 Nm).
   • Exhaust manifold if equipped with an automatic transmission.
2. Fill the cooling system.

2.4L Engine To Remove:
Thermostat assembly 2.4L

1. Drain the cooling system.
2. Remove the exhaust manifold heat shield.
3. Remove the coolant inlet housing mounting bolts through the exhaust manifold.
4. Raise and safely support the vehicle.
5. Remove the coolant inlet housing stud from the oil pan.
6. Remove wheel and tire assembly.
7. Remove the engine splash shield.
8. Remove the mounting bolts from the transaxle-to-engine block support. Remove the support.
9. Remove the coolant housing pipe.
10. Remove the thermostat.
11. Clean the mating surfaces.

To Install:

1. Install the thermostat.
2. Install the coolant housing pipe.
3. Install and secure the transaxle support-to-engine block mounting bolts.
4. Install the engine splash shield.
5. Install the wheel and tire assembly.
6. Install the coolant inlet housing stud to the oil pan.
   • Tighten to 19 ft lb (26 Nm).
7. Lower the vehicle.
8. Install the coolant inlet housing bolts through the exhaust manifold.
   • Tighten the coolant inlet housing bolts to 10 ft lb (14 Nm).
9. Install the exhaust manifold heat shield.
10. Fill the cooling system.
11. Inspect the system for leaks.

3.4L Engine To Remove:

1. Drain the cooling system.
2. Remove the air cleaner.
3. Remove exhaust crossover pipe.
4. Disconnect the surge tank line fitting from the coolant outlet.
5. Remove the thermostat housing to intake manifold bolts.
6. Remove the thermostat housing outlet and thermostat.

To Install:

1. Install the thermostat and housing outlet.
2. Install the thermostat housing bolts.
   • Tighten the thermostat housing bolts to 18 ft lb (25 Nm).
3. Install exhaust crossover pipe.
4. Connect the surge tank line fitting to the coolant outlet.
   • Tighten the fittings to 15 ft lb (21 Nm).
5. Install the air cleaner.
6. Fill the cooling system.
7. Inspect the system for leaks

Removal & Installation 2.2L VIN 4 To Remove:

1. Drain the cooling system.
2. Remove the lower radiator hose from thermostat housing.
3. Remove the thermostat housing bolts and outlet.
4. Remove the thermostat.
5. Clean the mating surfaces.

To Install:

1. Install the thermostat.
2. Install the thermostat housing and bolts.
3. Install the coolant housing bolts. Tighten bolts to 14 Nm (10 ft. lbs.).
4. Install the lower radiator hose to thermostat housing.
5. Fill the cooling system.
6. Inspect for leaks.

2.2L VIN F To Remove:

1. Remove the exhaust manifold. If equipped with an automatic transmission.
2. Drain the cooling system.
3. Remove or disconnect the following:
   
   
   • Thermostat housing to water pump feed pipe bolts.
     
     
   • Thermostat housing to water pump feed pipe.
   • Thermostat.

To Install:

1. Install or connect the following:
   • Thermostat.
   • Thermostat housing to water pump feed pipe.
   • Thermostat housing to water pump feed pipe bolt. Tighten bolt to 10 Nm (18 in. lbs.).
   • Exhaust manifold. If equipped with an automatic transmission.
2. Fill the cooling system.

2.4L VIN T To Remove:

1. Drain the cooling system.
2. Remove the exhaust manifold heat shield bolts and shield.
   
   
   
   
3. Remove the coolant inlet housing bolts.
4. Lift vehicle.
5. Remove the coolant inlet housing stud from the oil pan.
6. Remove the wheel.
7. Remove the right engine splash shield.
8. Remove the transaxle-to-engine block brace bolts and brace.
9. Remove the radiator outlet pipe.
10. Remove the thermostat.
11. Clean the mating surfaces.

To Install:

1. Clean the mating surfaces.
2. Install the thermostat.
3. Install the radiator outlet pipe.
4. Install the transaxle-to-engine block brace and install bolts.
5. Install the right engine splash shield.
6. Install the wheel.
7. Lower the vehicle.
8. Install the exhaust manifold heat shield and bolt.
9. Tighten the exhaust manifold heat shield bolts to 14 Nm (10 ft. lbs.).
10. Fill the cooling system.
11. Inspect the system for leaks.

it is on your exhaust pipe-most vehicle have at least 2 o2 sensors so you need to find out which one is bad
ex-o2s1/o2s2/ho2s1/ho2s2
these are all descriptions for your o2 sensors when you pull the dtc code(check engine light)

Hi, I have done this and it is not too bad, but will take you about 4 hours if you are good, and longer if you have not done much mechanics.

The trick is to find a reasonably priced turbo, check ebay. There is a dude on there that just does rebuilt turbos. Very good, got mine for $

I have been reading up on turbo replacement procedure and I have found this list: First, there are a couple of questions that I have about the list:

2 air openings, pretty easy to figure out
2 exhaust openings, pretty easy to figure out
3 round openings in the center, all banjo bolts?
1 round / two bolt opening in the center.
1 Hose fitting off of the waste-gate
1 Hose fitting off of the air side of the turbo.

STEP 1 Open the expansion tank cap to release the system pressure.
STEP 2 Raise the car & Remove the lower front cover under the car
STEP 3 Drain off the coolant & Remove the turbo brackets
STEP 4 Loosen the return fitting and the pipe from the turbo to the block
STEP 5 Loosen the oil pipe between the filter adapter and the turbo
STEP 6 Lower the car to the floor & Remove the bypass valve & Unplug the connector from the control valve
STEP 7 Disconnect the mass air flow sensor connector & Loosen the hoses to the turbo
STEP 8 Remove the crankcase banjo bolt from the intake manifold and unscrew the bolt from the cam cover
STEP 9 Move the pipe and wiring aside & Remove the engine lifting eye
STEP 10 Remove the mass air flow sensor and air hose
STEP 11 Remove the exhaust manifold heat shield by removing the nut and two clips from underneath
STEP 12 Undo the intake manifold clamp at the turbo & remove the intake
STEP 13 Disconnect the hose clip on the hose between the intercooler & turbo & plug it to keep something from falling in it
STEP 14 Loosen the front exhaust system from the turbo & lower the front exhaust system away from the turbo (DO NOT BEND -THE FLEX HOSE)
STEP 15 Remove the oil pipe from the oil filter adapter & grab the copper washers
STEP 16 Loosen the coolant pipe by the turbo & grab the copper washers & loosen the coolant pipe bolt
STEP 17 Remove the coolant return pipe from the cylinder head & pressure sensor bracket. Once again, Grab the copper washers
STEP 18 Undo the coolant return pipe bolt by the turbo
STEP 19 Undo the nuts securing the turbo to the exhaust manifold. (spray the nuts with WD40)
STEP 20 Install in Reverse


Just did this for the first time. Here are a few hints that may help others.

1) PB BLASTER is your friend. Remove the exhaust top front heat shield and hit exhaust nuts with PB Blaster as soon as you start the job, or night before.

2) Make sure that you have 12mm closed end wrench with AND without ratchet. Also a 1/2 size 12mm socket if you can find / make. These will help.

3) You don't have to remove the oil filter, but there one bolt that it would be nice for. I did not and did manage to get the job done.

4) Take you time. More of finding the right tool combination for each bolt.

5) Two banjo bolts on the turbo were really on there. Needed to use a mini-acetylene torch to eat up.

6) Have extracting sockets and bits ready just in case there are issues getting bolts / nuts off.

Turbo had quite a bit of end-play, but spun fine. Classic symptoms, blue smoke at start up and from time to time when driving. It was also making a bit of noise at idle.

jeffo2 ort11


Also, should get new copper washers. I did not have I have some micro leaks from time to time but nothing bad.