Home ReviewsRefund Car not listed?
Home/Pontiac/Aztek/Pontiac Aztek I (2001-2005)/Repair manual/Exhaust/Engine Exhaust System: Overview
Contents Wiring diagrams Section: Exhaust All sections

Engine Exhaust System: Overview Pontiac Aztek I

Exhaust 20 illustrations ~1346 words

Test Description

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

  1. 4. The exhaust system has very low back pressure under normal conditions. If the exhaust system is restricted, a significant increase in the exhaust pressure is noticed on the J 35314-A. Removing the AIR check valve or HO2S sensor may set a DTC. When finishing this diagnostic table, be sure to clear all codes.
  2. 5. This step will isolate the catalytic converter from the remainder of the exhaust system.
  3. 8. 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.

Scheme 1

Scheme 1
Scheme 1

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3: Exhaust Leakage
Scheme 3: Exhaust Leakage

Scheme 4

Scheme 4: Exhaust Noise
Scheme 4: Exhaust Noise

Scheme 5

Scheme 5: Removal Procedure
Scheme 5: Removal Procedure

Scheme 6

Scheme 6
Scheme 6
  1. Remove the throttle body air inlet duct.
  2. Drain the engine coolant from the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .
  3. Remove the right engine mount strut bracket. Refer to «ENGINE MOUNT STRUT BRACKET REPLACEMENT - RIGHT»(ref-180865-S15558019272005073000000) .
  4. Disconnect the inlet radiator hose from the engine. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-203946-S31176646802005072900000) .
  5. Remove the thermostat bypass pipe. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT»(ref-203946-S16493366932005072900000) .
  6. Remove the exhaust crossover pipe. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT»(ref-180882-S15890259552005073000000) .
  7. Remove the exhaust manifold heat shield bolts.
  8. Remove the exhaust manifold heat shield.
  9. Remove the exhaust manifold nuts.
  10. Remove the exhaust manifold.
  11. Remove the exhaust manifold gasket.
  12. Clean the engine left side exhaust manifold to the engine left side cylinder head sealing surfaces. Refer to «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-180865-S34482979022005073000000) .

Scheme 7

Scheme 7: Installation Procedure
Scheme 7: Installation Procedure

Scheme 8

Scheme 8
Scheme 8
  1. Install the exhaust manifold gasket.
  2. Install the exhaust manifold.
  3. Install the exhaust manifold nuts. Tighten Tighten the exhaust manifold nuts to 16 N.m (12 lb ft).
  4. Install the exhaust manifold heat shield.
  5. Install the exhaust manifold heat shield bolts. Tighten Tighten the exhaust manifold heat shield bolts to 10 N.m (89 Ib. in).
  6. Install the exhaust crossover pipe. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT»(ref-180882-S15890259552005073000000) .
  7. Install the thermostat bypass pipe. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT»(ref-203946-S16493366932005072900000) .
  8. Connect the inlet radiator hose to the engine. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-203946-S31176646802005072900000) .
  9. Install the right engine mount strut bracket. Refer to «ENGINE MOUNT STRUT BRACKET REPLACEMENT - RIGHT»(ref-180865-S15558019272005073000000) .
  10. Fill the cooling system with engine coolant. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .
  11. Install the throttle body air inlet duct.

Scheme 9

Scheme 9: Removal Procedure
Scheme 9: Removal Procedure

Scheme 10

Scheme 10
Scheme 10
  1. Disconnect negative battery cable.
  2. Remove the throttle body air inlet duct.
  3. Remove the accelerator cable bracket from the throttle body.
  4. Remove the manifold air pressure (MAP) sensor.
  5. Remove the exhaust gas recirculation (EGR) valve.
  6. Rotate the engine for service access. Refer to «ROTATING THE ENGINE FOR SERVICE ACCESS»(ref-180865-S26514588882005073000000) .
  7. Remove the ignition module and the ignition coils with the bracket.
  8. Remove the spark plug wires from the engine right bank spark plugs.
  9. Disconnect the oxygen sensor electrical connector.
  10. Remove the evaporative emissions (EVAP) solenoid bracket.
  11. Remove the exhaust crossover pipe. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT»(ref-180882-S15890259552005073000000) .
  12. Raise and support the vehicle.
  13. Remove the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-180882-S02540016632005073000000) .
  14. Remove the exhaust manifold heat shield bolts.
  15. Remove the exhaust manifold heat shields.
  16. Remove the exhaust manifold nuts.
  17. Remove the exhaust manifold.
  18. Remove the exhaust manifold gasket.
  19. Lower the vehicle.
  20. Clean the engine right side exhaust manifold sealing surfaces and the cylinder head sealing surfaces. Refer to «EXHAUST MANIFOLD CLEANING AND INSPECTION»(ref-180865-S34482979022005073000000) .
  21. If you are REPLACING the engine right side exhaust manifold, remove the exhaust gas recirculation (EGR) valve pipe.
  22. If you are REPLACING the engine right side exhaust manifold, remove the Heated Oxygen Sensor (HO2S).

Scheme 11

Scheme 11: Installation Procedure
Scheme 11: Installation Procedure

Scheme 12

Scheme 12
Scheme 12
  1. If removed, install the Heated Oxygen Sensor (HO2S).
  2. If removed, install the exhaust gas recirculation (EGR) valve pipe.
  3. Raise and support the vehicle.
  4. Install the exhaust manifold gasket.
  5. Install the exhaust manifold.
  6. Install the exhaust manifold nuts. Tighten Tighten the exhaust manifold nuts to 16 N.m (12 lb ft).
  7. Install the exhaust manifold lower heat shield.
  8. Install the exhaust manifold upper heat shield.
  9. Install the exhaust manifold heat shield bolts. Tighten Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
  10. Install the catalytic converter. Refer to «CATALYTIC CONVERTER REPLACEMENT»(ref-180882-S02540016632005073000000) .
  11. Lower the vehicle.
  12. Install the exhaust crossover pipe. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT»(ref-180882-S15890259552005073000000) .
  13. Install the exhaust crossover pipe heat shield. Refer to «EXHAUST CROSSOVER PIPE REPLACEMENT»(ref-180882-S15890259552005073000000) .
  14. Connect the Heated Oxygen Sensor (HO2S) electrical connector.
  15. Install the EVAP solenoid bracket.
  16. Install the spark plug wires to the engine right bank spark plugs.
  17. Install the ignition module and the ignition coils with the bracket.
  18. Rotate the engine back to the original position. Refer to «ROTATING THE ENGINE FOR SERVICE ACCESS»(ref-180865-S26514588882005073000000) .
  19. Install the EGR valve to the intake manifold.
  20. Install the MAP sensor.
  21. Install the accelerator cable bracket to the throttle body.
  22. Install the throttle body air inlet duct.
  23. Connect negative battery cable.

Scheme 13

Scheme 13: Removal Procedure
Scheme 13: Removal Procedure

Scheme 14

Scheme 14
Scheme 14
  1. Disconnect the battery ground (negative) cable.
  2. Remove the throttle body air inlet duct.
  3. Drain the coolant from the cooling system. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .
  4. Remove the inlet radiator hose from the engine. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-203946-S31176646802005072900000) .
  5. Remove the thermostat bypass pipe. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT»(ref-203946-S16493366932005072900000) .
  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.

Scheme 15

Scheme 15: Installation Procedure
Scheme 15: Installation Procedure

Scheme 16

Scheme 16
Scheme 16
  1. Install the exhaust crossover pipe.
  2. Install the exhaust crossover pipe studs/nuts. Tighten Tighten the exhaust crossover pipe studs/nuts to 25 N.m (18 lb ft).
  3. Install the exhaust crossover heat shield.
  4. Install the exhaust crossover heat shield bolts. Tighten Tighten the exhaust crossover heat shield bolts to 10 N.m (89 lb in).
  5. Install the thermostat bypass pipe. Refer to «THERMOSTAT BYPASS PIPES REPLACEMENT»(ref-203946-S16493366932005072900000) .
  6. Install the inlet radiator hose to the engine. Refer to «RADIATOR HOSE REPLACEMENT - INLET»(ref-203946-S31176646802005072900000) .
  7. Fill the cooling system with engine coolant. Refer to «DRAINING AND FILLING COOLING SYSTEM»(ref-203946-S00496132822005072900000) .
  8. Install the throttle body air inlet duct.
  9. Connect the battery ground (negative) cable.

Scheme 17

Scheme 17: Removal Procedure
Scheme 17: Removal Procedure

Scheme 18

Scheme 18
Scheme 18
  1. Raise and support the vehicle.
  2. Use a utility stand to support the catalytic converter.
  3. Disconnect the oxygen sensor electrical connector. NOTE: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.
  4. Remove the catalytic converter nuts from the exhaust manifold.
  5. Disconnect the catalytic converter from the catalytic converter hangers.
  6. Reposition the exhaust system in order to access the exhaust seal.
  7. Remove the catalytic converter seal.

Scheme 19

Scheme 19: Installation Procedure
Scheme 19: Installation Procedure

Scheme 20

Scheme 20
Scheme 20
  1. Install the catalytic converter seal.
  2. Install the catalytic converter to the exhaust manifold.
  3. Connect the catalytic converter to the catalytic converter hangers.
  4. Remove the utility stand.
  5. Install the catalytic converter nuts. Tighten Tighten the nuts to 35 N.m (26 lb ft).
  6. Install the oxygen sensor electrical connector.
  7. Lower the vehicle.

Exhaust System Description

Important: 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

More articles — Engine Exhaust System