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SECTION 1G
ENGINE EXHAUST
TABLE OF CONTENTS
Description and Operation . . . . . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . . . 1G-2 1G-2 1G-2 1G-2 Repair Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Pipe/Catalytic Converter . . . . . . . . . . . . Pup-up Catalitic Converter . . . . . . . . . . . . . . . . . . Front Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications . . . . . . . . . . . 1G-4 1G-4 1G-4 1G-5 1G-7 1G-8 1G-9 1G-9
Component Locator . . . . . . . . . . . . . . . . . . . . . . . . 1G-3 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-3
DAEWOO M-150 BL2
1G 2 ENGINE EXHAUST
DESCRIPTION AND OPERATION
EXHAUST SYSTEM
Notice: When you are inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to avoid possible overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials. Check the complete exhaust system and the nearby body areas and tailgate for broken, damaged, missing or mispositioned parts, open seams, holes, loose connections or other deterioration which could permit exhaust fumes to seep into the luggage or passenger compartment. Dust or water in the luggage may be an indication of a problem in one of these areas. Any defects should be corrected immediately. complete assembly should be replaced. The same procedure is applicable to the rear muffler assembly. Heat shields in the front and rear muffler assembly positions, as well as for the catalytic converter and front exhaust pipe, protect the vehicle and the environment from high temperatures the exhaust system develops.
CATALYTIC CONVERTER
Notice: When jacking or lifting the vehicle from the body side rails, be certain that the lift pads do not contact the catalytic converter as this could damage the catalytic converter. Notice: The catalytic converter requires the use of unleaded fuel only, or damage to the catalyst will result. The catalytic converter is an emission control device added to the exhaust system to reduce pollutants from the exhaust pipes. The oxidation catalyst is coated with a catalytic material containing platinum and palladium, which reduces levels of hydrocarbon (HC) and carbon monoxide (CO) from the exhaust gas. The three-way catalyst has coatings which contain platinum and rhodium, which additionally lower the levels of oxides of nitrogen (NOx).
MUFFLER
The muffler reduces the temperature, pressure, and noise of the exhaust gas. Aside from the exhaust manifold connection, the exhaust system uses a flange and seal joint design opposed to a slip joint coupling design with clamp. If holes, open seams or any deterioration is discovered upon inspection of the front muffler and pipe assembly, the
DAEWOO M-150 BL2
ENGINE EXHAUST 1G 3
COMPONENT LOCATOR
EXHAUST SYSTEM
D12G4011
1 Pup-up Catalytic Converter 2 Front Exhaust Pipe/Catalytic Converter Assembly
3 Front Muffler Pipe 4 Rear Muffler Pipe
DAEWOO M-150 BL2
1G 4 ENGINE EXHAUST
REPAIR INSTRUCTIONS ONVEHICLE SERVICE
EXHAUST PIPE/CATALYTIC CONVERTER
Caution : Make sure to confirm that the components is cool. And do work.
Removal Procedure
1. Remove the floor console. Refer to Section 9G, Interior Trim, if equipped Heated Oxygen Sensor (HO2S). 2. Disconnect HO2S connector.
MAA1G010
3. Remove the front exhaust pipe from the exhaust manifold or pup-up catalytic converter. D Remove the nuts (1). D Remove the gasket (2). 4. Check the gasket for damage or crack.
D102G501
5. Remove the front exhaust pipe from the front muffler pipe. D Remove the nuts (1).
D102G502
DAEWOO M-150 BL2
ENGINE EXHAUST 1G 5
6. Remove the front exhaust pipe and the catalytic converter assembly. a. Front exhaust pipe. b. Catalytic converter. 7. Clean the sealing surfaces on the front exhaust pipe flange and the exhaust manifold. 8. Check the exhaust pipe and the catalytic coverter for holes, damage, open seams, or other deterioration which could permit exhaust fumes to seep into the passenger compartment.
D102G503
Installation Procedure
2535 NSm 1. Using the nuts and the gasket, secure the front exhaust pipe and the catalytic converter assembly to the exhaust manifold.
Tighten
Tighten the nuts to 2535 NSm (1825 lb-ft). a. Front exhaust pipe nut. 2. Install the front exhaust pipe and the catalytic converter assembly to the front muffler pipe flange. Use the nuts to secure the front exhaust pipe and the catalytic converter assembly.
D12G504A
2535 NSm
Tighten
Tighten the nuts to 2535 NSm (1825 lb-ft). b. Front muffler pipe nut. Notice : Make sure not to contact the components with the underbody. 3. Connect the Heated Oxygen Sensor (HO2S) connector. 4. Install the floor console. Refer to Section 9G, Interior Trim.
PUP-UP CATALITIC CONVERTER
Removal Procedure
1. Remove the front exhaust pipe from the pup-up catalitic converter. D Remove the nuts (1). D Remove the gasket (2). 2. Check the gasket for damage or leak.
D102G501
DAEWOO M-150 BL2
1G 6 ENGINE EXHAUST
3. Remove the air cleaner assembly. Refer to Section 1B, SOHC Engine Mechanical. 4. Disconnect Oxygen Sensor (O2S) connector. 5. Remove the exhaust manifold heat shield. 6. Remove the exhaust manifold. Refer to Section 1B, SOHC Engine Mechanical.
MAA1B010
7. Remove pup-up catalytic convertor. D Remove the bolts.
MAA1B040
Installation Procedure
1. Install pup-up catalytic convertor to exhaust pipe.
Tighten
Tighten the bolts to 2535 NSm (1825 lb-ft).
MAA1B041
2. Install exhaust manifold. Refer to Section 1B, SOHC Engine Mechanical.
Tighten
Tighten the bolts and nuts to 1727 NSm (1320 lb-ft). Tighten the exhaust manifold heat shield bolts to 812 NSm (71106 lb-in).
MAA1B011
DAEWOO M-150 BL2
ENGINE EXHAUST 1G 7
3. Install the front exhaust pipe to pup-up catalytic convertor.
Tighten
Tighten the bolts to 2535 NSm (1825 lb-ft).
D12G504B
FRONT MUFFLER
Removal Procedure
1. Remove the front exhaust pipe-to-front muffler nuts. D Remove the nuts (1).
D102G502
2. Remove the front muffler-to-rear muffler nuts. 3. Detach the front muffler from rubber hanger and remove the front muffler.
MAA1G030
Installation Procedure
1. Hang the front muffler to rubber hanger. 2. Install the front muffler-to-rear muffler nuts.
Tighten
Tighten the nuts to 2535 NSm (1825 lb-ft). 3. Install the exhaust pipe-to-front muffler nuts.
Tighten
Tighten the nuts to 2535 NSm (1825 lb-ft) (a).
MAA1G031
DAEWOO M-150 BL2
1G 8 ENGINE EXHAUST
REAR MFFLER
Removal Procedure
1. Remove the front muffler-to rear muffler nuts.
Tighten
Tighten the nuts to 2535 NSm (1825 lb-ft). 2. Detach the rear muffler from the rubber hangers.
MAA1G030
3. Remove the rear muffler. 4. Installation should flow the removal procedure in reverse order.
MAA1G040
DAEWOO M-150 BL2
ENGINE EXHAUST 1G 9
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Application Front Exhaust Pipe-to-Front Muffler Pipe Nuts Front Exhaust Pipe-to-Exhaust Manifold Nuts Front Exhaust Pipe-to-Pup-up Catalytic Converter Front Muffler-to-Rear Muffler nuts Pup-up Catalytic Convertor-to-Exhaust Manifold Bolt Muffler Clamp Nut Catalytic Converter Heat Shield Rear Muffler Heat Shield NSm 25 35 25 35 25 35 25 35 25 35 24 28 8 12 8 12 Lb-Ft 18 25 18 25 18 25 18 25 18 25 18 21 Lb-In 71 106 71 106
DAEWOO M-150 BL2