Engine Exhaust System Chevrolet Aveo I рестайлинг

Fastener Tightening Specifications

Diagnostic Starting Point - Engine Exhaust

Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the information will help you determine the correct symptom diagnostic procedure when a malfunction exists. It will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Engine Exhaust in order to identify the correct procedure for diagnosing the system.

Symptoms - Engine Exhaust

1. Review the Exhaust System Description and Operation in order to familiarize yourself with the system functions. Refer to «Exhaust System Description»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system__exhaust-system-description) .
2. All diagnostics on a vehicle should follow a logical process. Strategy Based Diagnostics is a uniform approach for repairing all systems. The diagnostic flow is the place to start when repairs are necessary and may always be used in order to resolve a system problem.

Visual/Physical Inspection

1. Inspect for aftermarket or non-OEM devices such as, but not including; tailpipe extensions, headers, and exhaust cutouts. This could affect the operation and proper performance of the exhaust system.
2. Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM, engine temperature, engine load, and frequency of concern.
3. Inspect the easily accessible or visible system components for obvious damage or conditions, which could cause any symptom.

Intermittents

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating as designed.

Symptom List

1. Loss of power-Refer to «Restricted Exhaust»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system) .
2. Poor acceleration-Refer to «Restricted Exhaust»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system) .
3. Poor fuel economy-Refer to «Restricted Exhaust»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system) .
4. Excessive smoke-diesel-Refer to «Restricted Exhaust»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system) .
5. Exhaust hissing noise-Refer to «Exhaust Leakage»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system__exhaust-leakage) .
6. Exhaust popping noise-Refer to «Exhaust Leakage»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system__exhaust-leakage) .
7. Exhaust rattle noise-Refer to «Exhaust Noise»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system__exhaust-noise) .
8. Loud Exhaust noise-Refer to «Exhaust Noise»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system__exhaust-noise) .
9. Exhaust buzz, groan, hum noise-Refer to «Exhaust Noise»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system__exhaust-noise) .

Special Tools

J 35314-A Exhaust Back Pressure Gage. See Special Tools .

Diagnostic Aids

Test Description

The numbers below refer to the step numbers on the diagnostic table.

Note. Removing the O2S sensor may set a DTC. When finishing this diagnostic table, be sure to clear all codes.

1. 4: The exhaust system has very low backpressure under normal conditions. If the exhaust system is restricted, a significant increase in exhaust pressure is noticed on the J 35314-A . See «Special Tools»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system) .
2. 5: This step will isolate the catalytic converter from the remainder of the exhaust system.
3. 7: Confirming that the condition has been fixed is essential. If the symptom still exists and the vehicle has a dual exhaust system, proceed to Step 2 and repeat diagnostic procedure on the opposite exhaust pipe.

Exhaust Noise

Exhaust Leakage

DEFINITION: An exhaust leak may show stains at the area of the leak. The leak may be felt by holding a hand close to the suspected areas or using a smoke pencil. The leak may make a popping or hissing noise. Refer to Symptoms - Engine Exhaust prior to beginning this testing.

Check the following

Misaligned or improperly installed exhaust system components.

Exhaust leaks at the following connections

1. Exhaust manifold-to-pipe
2. Flanges
3. Pipe clamps

Seals or gaskets leaking

1. Exhaust manifold-to-cylinder head
2. Exhaust pipes-to-exhaust manifold
3. Catalytic converter connections
4. Exhaust gas recirculation (EGR) connections, if equipped

Irregularities at the mating surfaces on the flange connections

Exhaust manifold cracked or broken. Replace exhaust manifold

Muffler or resonator, if equipped, damaged or leaking at the seams. Replace affected muffler.

Removal Procedure

1. Remove the fuel pump fuse.
2. Start the engine. After it stalls, crank the engine after it stalls for 10 seconds to rid the fuel system of fuel pressure.
3. Disconnect the oxygen sensor connector.
4. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (1.4L LDT/1.6L LXV)»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (1.2L)»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system)
5. Remove the exhaust manifold.

Installation Procedure

1. Install the exhaust manifold retaining bolts/nuts and tighten. The exhaust manifold retaining bolts to 25 N.m (18.4 lb ft). The exhaust manifold retaining nuts to 20 N.m (14.7 lb ft).
2. Install the catalytic converter. Refer to «Catalytic Converter Replacement (1.4L LDT/1.6L LXV)»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system) or «Catalytic Converter Replacement (1.2L)»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system)
3. Connect the heater outlet hose from the coolant pipe.
4. Install the exhaust manifold heat shield and tighten to 15 N.m (11 lb ft).
5. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/aveo/i-2006-2012/remont/charging-system/#battery-charging-system-and-starting-system)

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/aveo/i-2006-2012/remont/charging-system/#battery-charging-system-and-starting-system)
2. Disconnect the upper oxygen sensor connector.
3. Remove the exhaust manifold heat shield with engine oil indicator tube.
4. Remove the exhaust front pipe. Refer to «Front Pipe Replacement»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system) .
5. Remove the exhaust manifold with the gasket.

1. Install the exhaust manifold with the gasket and tighten. The exhaust manifold nuts to 20 N.m (14.7 lb ft). The exhaust manifold lower bracket bolts to 20 N.m (14.7 lb ft).
2. Install the exhaust front pipe. Refer to «Front Pipe Replacement»(/chevrolet/aveo/i-2006-2012/remont/exhaust/#engine-exhaust-system) .
3. Install the exhaust manifold heat shield with the engine oil indicator tube and tighten to 8 N.m (70.8 lb in).
4. Connect the upper oxygen sensor connector.
5. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/aveo/i-2006-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Remove the rear heated oxygen sensor.
2. Remove the connecting pipe mounting bracket bolt.
3. Remove the connecting pipe nuts and the gasket from the catalytic converter.
4. Remove the nuts from the front muffler pipe to the connecting pipe.
5. Clean the sealing surfaces on the front muffler pipe flange and the connecting pipe.
6. Check the connecting pipe for holes, damage, open seams, or other deterioration which could permit exhaust fumes to seep into the passenger compartment.

1. Install the catalytic converter and the connecting pipe and the gasket to the front muffler pipe flange. Use the nuts to secure the converter and the connecting pipe and tighten to 30 N.m (22 lb ft).
2. Using the nuts and the gasket secure the connecting pipe to the catalytic converter and tighten to 40 N.m (30 lb ft).
3. Install the front exhaust pipe mounting bracket bolt and tighten to 40 N.m (30 lb ft).
4. Install the rear heated oxygen sensor and tighten to 41 N.m (30 lb ft).

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/aveo/i-2006-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Disconnect the front heated oxygen sensor connector.
3. Remove the oil level gage tube.
4. Remove the exhaust manifold heat shield.
5. Remove the catalytic converter upper flange nuts.
6. Remove the exhaust front pipe mounting bracket bolt.
7. Remove the catalytic converter lower flange nuts.
8. Remove the catalytic converter and the gasket.

1. Install the catalytic converter and the gasket.
2. Install the catalytic converter lower flange nuts and the exhaust front pipe mounting bracket and tighten. The exhaust front pipe to catalytic converter nuts to 40 N.m (30 lb ft). The exhaust front pipe mounting bracket bolt to 40 N.m (30 lb ft).
3. Install the catalytic converter upper flange nuts to exhaust manifold nuts to 40 N.m (30 lb ft).
4. Install the exhaust manifold heat shield and tighten to 8 N.m (5.9 lb ft).
5. Install the oil level gage tube.
6. Connect the front heated oxygen sensor connector.
7. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/aveo/i-2006-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Remove the exhaust manifold cover with the bolts.
2. Remove the catalytic converter upper flange nut.
3. Remove the connecting pipe mounting bracket bolt.
4. Remove the catalytic converter lower flange nuts.
5. Remove the catalytic converter and the gasket.

1. Install the catalytic converter and the gasket.
2. Install the catalytic converter lower flange nuts and the connecting pipe mounting bracket and tighten. The connecting pipe to catalytic converter nuts to 40 N.m (30 lb ft). The connecting pipe mounting bracket bolt to 40 N.m (30 lb ft).
3. Install the catalytic converter upper flange nuts and tighten to 50 N.m (37 lb ft).
4. Install the exhaust manifold cover bolts and tighten to 15 N.m (11 lb ft).

1. Remove the nuts and the gasket from the front muffler pipe to the connecting pipe flange.
2. Remove the nuts and the gasket from the rear muffler pipe flange.
3. Disconnect the front muffler from the rubber hanger.
4. Remove the front muffler.
5. Check the exhaust pipe and the front muffler for holes, damage, open seams, or other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk.

1. Connect the front muffler to the rubber hanger.
2. Attach the front muffler and the gasket to the rear muffler using the nuts. Secure the front muffler to the rubber hanger and tighten to 30 N.m (22 lb ft).
3. Loosely secure the front muffler assembly to the connecting pipe flange.
4. Secure the front muffler assembly to the connecting pipe flange with the nuts and tighten to 30 N.m (22 lb ft).

1. Remove the nuts and the gasket from the rear muffler pipe flange-to-front muffler pipe flange.
2. Detach the rear muffler assembly from the rubber hangers on the tail pipe end.
3. Remove the rear muffler assembly.
4. Check the rear muffler and the pipe for holes, damage, open seams, and other deterioration which could permit exhaust fumes to seep into the passenger compartment or the trunk.

1. Secure the rear muffler assembly to the rubber hangers on the tail pipe end.
2. Secure the nuts and the gasket from the rear muffler pipe flange-to-front muffler pipe flange and tighten to 30 N.m (22 lb ft).

Exhaust System Description

Muffler

Note. Use of non-OEM parts may cause driveability concerns.

The exhaust system carries exhaust gases, treated by the catalytic converter, through a resonator, if applicable and into the exhaust muffler where exhaust noise is lessened.

In order to secure the exhaust pipe to the exhaust manifold, a flange and seal joint coupling is utilized. The exhaust system may utilize a slip-joint coupling design with a clamp and a U-bolt or a flange connection with a gasket.

Exhaust hangers and rubber insulators help to support the weight of the exhaust pipe along with insulating any exhaust system vibration, rattle, or noise.

Exhaust hangers also space the exhaust system away from the underbody of the vehicle and allows the exhaust system to expand as the exhaust system warms up.

Exhaust heat shields are used to protect the body and other components from damage due to the heat from the exhaust system.

The exhaust system may be comprised of the following components

1. Exhaust manifold
2. Exhaust pipes
3. Catalytic converters
4. Exhaust muffler
5. Exhaust resonator, if equipped
6. Exhaust tail pipe, if equipped
7. Exhaust hangers
8. Exhaust heat shields

If holes, open seams or any deterioration is discovered upon inspection of the front muffler and pipe assembly, the complete assembly should be replaced. The same procedure is applicable to the rear muffler assembly.

Catalytic Converters

The catalytic converters are emission control devices added to the exhaust system to reduce pollutants from the exhaust pipes.

The 3-way catalyst has coatings which contain palladium, platinum and rhodium, which simultaneously lower the levels of HC, CO and NOx.

Illustration Tool Number/ Description J 35314-A Exhaust Back Pressure Gage

Scheme 1

See also:
• Fastener Caution
• Battery Negative Cable Disconnection and Connection
• Battery Disconnect Warning
• Exhaust Service Warning
• Flex Decoupler Caution
• Catalytic Converter Movement Caution
• Symptoms - Engine Exhaust
• Exhaust System Description
• Restricted Exhaust
• Exhaust Leakage
• Exhaust Noise