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Engine Exhaust System Pontiac Solstice I final

Exhaust 1 illustration ~2170 words

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
Catalytic Converter Bracket Bolt/Nut (LNF)58 N.m43 lb ft
Catalytic Converter to Catalytic Converter Brace Bracket Bolt (LE5)50 N.m37 lb ft
Catalytic Converter to Catalytic Converter Brace Bracket Bolt (LNF)22 N.m16 lb ft
Catalytic Converter to Exhaust Manifold Nut (LE5)50 N.m37 lb ft
Catalytic Converter to Muffler Nut17 N.m13 lb ft
Catalytic Converter to Turbocharger Nut (LNF)58 N.m43 lb ft
Engine Mount to Frame Lower Nut (LNF)55 N.m41 lb ft
Exhaust Manifold Heat Shield Bolt (LNF)25 N.m18 lb ft
Exhaust Manifold Heat Shield Bolt (LE5)10 N.m89 lb in
Exhaust Manifold Nut14 N.m10 lb ft
Turbocharger Heat Shield (LNF)10 N.m89 lb in

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»(/pontiac/solstice/i-final-2010-2010/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. For a detailed explanation, refer to «Strategy Based Diagnosis»(/pontiac/solstice/i-final-2010-2010/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) .

Visual/Physical Inspection

  1. Inspect for aftermarket or non-OEM devices such as, but not including; tailpipe extensions, mufflers, and exhaust hangers. 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.

Intermittent

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

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

  1. Loss of power - Refer to «Restricted Exhaust»(/pontiac/solstice/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) .
  2. Poor acceleration - Refer to «Restricted Exhaust»(/pontiac/solstice/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) .
  3. Poor fuel economy - Refer to «Restricted Exhaust»(/pontiac/solstice/i-final-2010-2010/remont/exhaust/#engine-exhaust-system) .
  4. Exhaust hissing noise - Refer to «Exhaust Leakage»(/pontiac/solstice/i-final-2010-2010/remont/exhaust/#engine-exhaust-system__exhaust-leakage) .
  5. Exhaust popping noise - Refer to «Exhaust Leakage»(/pontiac/solstice/i-final-2010-2010/remont/exhaust/#engine-exhaust-system__exhaust-leakage) .
  6. Exhaust rattle noise - Refer to «Exhaust Noise»(/pontiac/solstice/i-final-2010-2010/remont/exhaust/#engine-exhaust-system__exhaust-noise) .
  7. Loud exhaust noise - Refer to «Exhaust Noise»(/pontiac/solstice/i-final-2010-2010/remont/exhaust/#engine-exhaust-system__exhaust-noise) .
  8. Exhaust buzz, groan, hum noise - Refer to «Exhaust Noise»(/pontiac/solstice/i-final-2010-2010/remont/exhaust/#engine-exhaust-system__exhaust-noise) .

Test Description

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

  1. 3: 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 Exhaust Back Pressure Gauge. See «Special Tools»(/pontiac/solstice/i-final-2010-2010/remont/exhaust/#engine-exhaust-system__special-tools) . Removing the heated oxygen sensor (HO2S) may set a DTC. When finishing this diagnostic table, be sure to clear all codes.
  2. 4: This step will isolate the catalytic converter from the remainder of the exhaust system.
StepActionValuesYesNo
1Did you verify the customer complaint?Go to Step 2
2Did you review the exhaust symptoms diagnostic information and perform the necessary inspections?Go to Step 3Go to Symptoms - Engine Exhaust
3Remove the pre-catalyst heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Sensor 1 . Install the J 35314-A Exhaust Back Pressure Gauge in place of the HO2S sensor. See Special Tools . Start and run the vehicle. Increase and monitor the engine speed at 2,500 RPM. Observe the exhaust system back pressure reading on the gauge. Does the reading exceed the specified value?9 kPa (1.25 psi)Go to Step 4Go to Step 7
4Turn the engine OFF and place the ignition in the LOCK position. Remove the J 35314-A . See Special Tools . Install the pre-catalyst HO2S sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 1 . Remove the post-catalyst HO2S sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 2 . Install the J 35314-A in place of the post HO2S sensor. See Special Tools . Start the engine. Increase and monitor the engine speed at 2,500 RPM. Observe the exhaust system back pressure reading on the gauge. Does the reading exceed the specified value?9 kPa (1.25 psi)Go to Step 5Go to Step 6
5Inspect the exhaust system for the following conditions: Damage in the exhaust pipe Debris in the exhaust pipe Muffler or resonator internal failure Two-layer exhaust pipe separation Did you find and correct the condition?Go to Step 7
6Replace the catalytic converter. Refer to Catalytic Converter Replacement (LE5) or Catalytic Converter Replacement (LNF) . Did you find and correct the condition?Go to Step 7
7Remove the J 35314-A . See Special Tools . Install the post-catalyst HO2S sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 2 . Clear any codes. Road test the vehicle in order to verify the repair. Did you correct the condition?System OKGo to Step 2

Exhaust Leakage

ProblemAction
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 table.
Misaligned or improperly installed exhaust system componentsAlign and tighten the components to the specifications. Refer to Fastener Tightening Specifications .
Exhaust leaks at the following connections: Exhaust manifold to pipe Flanges Pipe clampsTighten the components to the specifications. Refer to Fastener Tightening Specifications .
Seals or gaskets leaking. Exhaust manifold to cylinder head Exhaust pipes to exhaust manifold Catalytic converter connection EGR connectionsReplace the leaking seal or gasket. Refer to the affected components procedure for service.
Irregularities at the mating surfaces on the flange connectionsRepair as required or replace the affected component. Refer to the affected components procedure for service.
Exhaust manifold cracked or brokenReplace the exhaust manifold. Refer to Exhaust Manifold Replacement (LNF) or Exhaust Manifold Replacement (LE5) .
Exhaust system component connection welds leakingReplace the leaking component. Refer to the affected component's procedure for service.
Muffler or resonator, if equipped, damaged or leaking at the seamsReplace the muffler. Refer to Exhaust Muffler Replacement (LE5) or Exhaust Muffler Replacement (LNF) .

Exhaust Noise

ConditionAction
DEFINITION: An audible or physical noise due to a faulty component or damaged components causing a loose or misaligned exhaust system resulting in a rattle or vibration noise, i.e. buzz, groan, hum. Refer to Symptoms - Engine Exhaust prior to beginning this table.
Popping or hissing noiseExhaust leak - Refer to Exhaust Leakage .
Loud exhaustCompare to a known good vehicle. Inspect for a damaged or failed muffle. Replace the faulty muffler. Refer to Exhaust Muffler Replacement (LE5) or Exhaust Muffler Replacement (LNF) .
External rattle or vibration noiseInspect for a bent or loose hanger, loose heat shield, or loose clamp. Inspect for a exhaust pipe causing interference. Repair or replace the affected component. Refer to the affected component's service procedure.
Internal rattleTest the components by tapping with a rubber mallet to confirm a rattle. Replace the faulty catalytic converter, or muffler. Refer to one of the following procedures: Catalytic Converter Replacement (LE5) Catalytic Converter Replacement (LNF) Exhaust Muffler Replacement (LE5) Exhaust Muffler Replacement (LNF)

Removal Procedure

  1. Remove the turbocharger. Refer to «Turbocharger Replacement»(/pontiac/solstice/i-final-2010-2010/remont/mechanical/#engine-mechanical-20l-repair-instructions-on-vehicle) .
  2. Remove the exhaust manifold heat shield bolts.
  3. Remove the heat shield.
  4. Remove and discard the exhaust manifold nuts.
  5. Remove the exhaust manifold.
  6. Remove and discard the exhaust manifold gasket.

Installation Procedure

  1. Install a NEW exhaust manifold gasket onto the studs.
  2. Install the exhaust manifold.
  3. Install the NEW exhaust manifold nuts.
  4. Tighten the exhaust manifold nuts in the sequence shown. Tighten: Tighten the nuts to 14 N.m (10 lb ft).
  5. Install the heat shield.
  6. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
  7. Install the turbocharger. Refer to «Turbocharger Replacement»(/pontiac/solstice/i-final-2010-2010/remont/mechanical/#engine-mechanical-20l-repair-instructions-on-vehicle) .
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/solstice/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
  2. Remove the connector position assurance (CPA) retainer.
  3. Disconnect the heated oxygen sensor (HO2S) electrical connector (2).
  4. Remove the HO2S (1). Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(/pontiac/solstice/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
  5. Remove the exhaust manifold heat shield bolts.
  6. Remove the heat shield.
  7. Remove the catalytic converter to exhaust manifold nuts (1).
  8. Remove and discard the exhaust manifold nuts.
  9. Remove the exhaust manifold.
  10. Remove and discard the exhaust manifold gasket.
  1. Install a NEW exhaust manifold gasket onto the studs.
  2. Install the exhaust manifold.
  3. Install the NEW exhaust manifold nuts finger tight.
  4. Install the catalytic converter to exhaust manifold nuts (1). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
  5. Tighten the exhaust manifold nuts in the sequence shown. Tighten: Tighten the nuts to 14 N.m (10 lb ft).
  6. Install the heat shield.
  7. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  8. Install the HO2S (1). Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(/pontiac/solstice/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
  9. Connect the HO2S electrical connector (2).
  10. Install the CPA retainer.
  11. Start the vehicle and inspect for leaks.
  12. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/solstice/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
  1. Open the hood.
  2. Remove the exhaust manifold heat shield bolts and shield.
  3. Remove the catalytic converter to exhaust manifold nuts (1).
  4. Remove the connector position assurance (CPA) retainer.
  5. Disconnect the engine wiring harness electrical connector (3) from the position 2 heated oxygen sensor (HO2S).
  6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/solstice/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
  7. Remove the catalytic converter to catalytic converter brace bracket bolt.
  8. Remove the catalytic converter to muffler nuts.
  9. Separate the exhaust pipe from the catalytic converter studs.
  10. Position and support the exhaust pipe out of the way.
  11. Remove the catalytic converter and gasket (2).
  1. Install the catalytic converter along with a NEW gasket (2) to the exhaust manifold.
  2. Position and join the exhaust pipe to the catalytic converter studs.
  3. Loosely install the catalytic converter to muffler nuts.
  4. Install the catalytic converter to catalytic converter brace bracket bolt. Tighten: Tighten the catalytic converter to muffler nuts to 17 N.m (13 lb ft). Tighten the catalytic converter to catalytic converter brace bracket bolt to 50 N.m (37 lb ft).
  5. Lower the vehicle
  6. Connect the engine wiring harness electrical connector (3) to the position 2 HO2S.
  7. Install the CPA retainer.
  8. Install the catalytic converter to exhaust manifold nuts (1). Tighten: Tighten the nuts to 50 N.m (37 lb ft).
  9. Install the exhaust manifold heat shield and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  10. Close the hood.
  1. Open the hood.
  2. Remove the turbocharger heat shield bolts (1) and shield.
  3. Remove the position 1 heated oxygen sensor (HO2S). Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(/pontiac/solstice/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  4. Remove the catalytic converter to turbocharger nuts (2).
  5. Remove the connector position assurance (CPA) retainer.
  6. Disconnect the position 2 HO2S electrical connector (4) from the engine wiring harness electrical connector (2).
  7. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/solstice/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
  8. Remove the catalytic converter to muffler nuts.
  9. Separate the exhaust pipe from the catalytic converter studs.
  10. Position and support the exhaust pipe out of the way.
  11. Loosen, DO NOT REMOVE the driver side engine mount to frame lower nut.
  12. Remove the passenger side engine mount to frame lower nut.
  13. Place an adjustable jack and a block of wood under the oil pan. Using the adjustable jack, raise the oil pan slightly.
  14. Remove the catalytic converter to catalytic converter bracket bolts.
  15. Reposition the catalytic converter out of the way.
  16. Remove the catalytic converter bracket bolt and nut.
  17. Remove the catalytic converter bracket.
  18. Rotate and remove the catalytic converter (3).
  19. Remove and discard the catalytic converter gasket (2).
  1. Install a NEW catalytic converter gasket (2) onto the turbocharger studs.
  2. Install, rotate, and position the catalytic converter (3).
  3. Position the catalytic converter bracket to the engine block.
  4. Install the catalytic converter bracket bolt and nut. Tighten: Tighten the bolt/nut to 58 N.m (43 lb ft).
  5. Install the catalytic converter onto the turbocharger studs.
  6. Install the catalytic converter to catalytic converter bracket bolts. Tighten: Tighten the bolts to 22 N.m (16 lb ft).
  7. Using the adjustable jack, lower the oil pan.
  8. Install the passenger side engine mount to frame lower nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
  9. Tighten the driver side engine mount to frame lower nut. Tighten: Tighten the nut to 55 N.m (41 lb ft).
  10. Position and install the exhaust pipe to the catalytic converter studs.
  11. Install the catalytic converter to muffler nuts. Tighten: Tighten the nuts to 17 N.m (13 lb ft).
  12. Lower the vehicle.
  13. Connect the position 2 HO2S electrical connector (4) to the engine wiring harness electrical connector (2).
  14. Install the CPA retainer.
  15. Install the catalytic converter to turbocharger nuts (2). Tighten: Tighten the nuts to 58 N.m (43 lb ft).
  16. Install the position 1 HO2S. Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(/pontiac/solstice/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  17. Install the turbocharger heat shield and bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  18. Close the hood.
  1. Open the hood.
  2. Remove the connector position assurance (CPA) retainer.
  3. Disconnect the heated oxygen sensor (HO2S) electrical connector (3).
  4. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/solstice/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
  5. Remove the HO2S (2). Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(/pontiac/solstice/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
  6. Remove the catalytic converter to muffler nuts.
  7. Have an assistant support the muffler assembly.
  8. Separate the muffler insulators from the hangers.
  9. With the aid of an assistant, remove the muffler assembly.
  1. With the aid of an assistant, position the muffler assembly.
  2. Install the muffler insulators onto the hangers.
  3. Install the catalytic converter to muffler nuts. Tighten: Tighten the nuts to 17 N.m (13 lb ft).
  4. Install the HO2S (2). Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(/pontiac/solstice/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
  5. Lower the vehicle.
  6. Connect the HO2S electrical connector (3).
  7. Install the CPA retainer.
  8. Close the hood.
  1. Open the hood.
  2. Remove the heat shielding from the heated oxygen sensor (HO2S) electrical connector, if necessary.
  3. Remove the connector position assurance (CPA) retainer.
  4. Disconnect the position 2 HO2S electrical connector (4) from the engine wiring harness electrical connector (2).
  5. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/pontiac/solstice/i-final-2010-2010/remont/ignition-switchsteering-lock/#general-information) .
  6. Remove the HO2S. Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(/pontiac/solstice/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  7. Remove the catalytic converter to muffler nuts.
  8. Have an assistant support the muffler assembly.
  9. Separate the muffler insulators (2) from the hangers (1).
  10. With the aid of an assistant, remove the muffler assembly.
  1. With the aid of an assistant, position the muffler assembly.
  2. Install the muffler insulators (2) onto the hangers (1).
  3. Install the catalytic converter to muffler nuts. Tighten: Tighten the nuts to 17 N.m (13 lb ft).
  4. Install the HO2S. Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(/pontiac/solstice/i-final-2010-2010/remont/testing-diagnostics/#engine-controls-and-fuel-20l-repair-instructions) .
  5. Lower the vehicle.
  6. Connect the position 2 HO2S electrical connector (4) to the engine wiring harness electrical connector (2).
  7. Install the CPA retainer.
  8. Install the heat shielding to the HO2S electrical connector, if necessary.
  9. Close the hood.
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/solstice/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
  2. Remove the exhaust manifold heat shield bolts.
  3. Remove the exhaust manifold heat shield.
  1. Install the exhaust manifold heat shield.
  2. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/pontiac/solstice/i-final-2010-2010/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
  1. Remove the turbocharger. Refer to «Turbocharger Replacement»(/pontiac/solstice/i-final-2010-2010/remont/mechanical/#engine-mechanical-20l-repair-instructions-on-vehicle) .
  2. Remove the exhaust manifold heat shield bolts.
  3. Remove the exhaust manifold heat shield.
  1. Install the exhaust manifold heat shield.
  2. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Install the turbocharger. Refer to «Turbocharger Replacement»(/pontiac/solstice/i-final-2010-2010/remont/mechanical/#engine-mechanical-20l-repair-instructions-on-vehicle) .

Exhaust System Description

IMPORTANTUse 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

Resonator

Some exhaust systems are equipped with a resonator. The resonator, located either before or after the muffler, allows the use of mufflers with less back pressure. Resonators are used when vehicle characteristics require specific exhaust tuning.

Catalytic Converter

The catalytic converter is an emission control device added to the engine exhaust system in order to reduce hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) pollutants from the exhaust gas.

The catalytic converter is comprised of a ceramic monolith substrate, supported in insulation and housed within a sheet metal shell. The substrate may be washcoated with 3 noble metals

  1. Platinum (Pt)
  2. Palladium (Pd)
  3. Rhodium (Rh)

The catalyst in the converter is not serviceable.

Muffler

The exhaust muffler reduces the noise levels of the engine exhaust by the use of tuning tubes. The tuning tubes create channels inside the exhaust muffler that lower the sound levels created by the combustion of the engine.

Special Tools

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

Scheme 1

Scheme 1: Special Tools
Scheme 1: Special Tools