Page 881 of 2643
SECTION : 1G
ENGINE EXHAUST
TABLE OF CONTENTS
SPECIFICATIONS1G–1 . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications 1G–1. . . . . . . . . .
COMPONENT LOCATOR1G–2 . . . . . . . . . . . . . . . . . . . .
Exhaust System 1G–2. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE AND REPAIR1G–3 . . . . . . . . . . . . . . .
ON–VEHICLE SERVICE 1G–3. . . . . . . . . . . . . . . . . . . . .
Catalytic Converter 1G–3. . . . . . . . . . . . . . . . . . . . . . . . Exhaust Front Pipe 1G–4. . . . . . . . . . . . . . . . . . . . . . . .
Muffler – Front 1G–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler – Rear 1G–7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION AND SYSTEM
OPERATION1G–9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 1G–9. . . . . . . . . . . . . . . . . . . . . . . . . .
Muffler 1G–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Catalytic Converters 1G–9. . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
ApplicationNSmLb–FtLb–In
Catalytic Converter–to–Exhaust Manifold Nuts4037–
Exhaust Front Pipe–to–Catalytic Converter Nuts4030–
Exhaust Manifold Cover Bolts1511–
Exhaust Front Pip–to–Front Muffler3022–
Front Muffler–to–Rear Muffler Nuts3022–
Front Bracket–to–Cylinder Block Bolt5037–
Catalytic Converter–to–Underbody Shield2.5–22
Front Muffler–to–Underbody Shield2.5–22
Rear Muffler–to–Underbody Shield2.5–22
Page 882 of 2643
1G – 2IENGINE EXHAUST
DAEWOO V–121 BL4
COMPONENT LOCATOR
EXHAUST SYSTEM
1. Exhaust Rear Muffler
2. Muffler Gasket
3. Exhaust Front Muffler
4. Muffler Gasket
5. Exhaust Front Pipe (1.8D)
6. Exhaust Front Pipe (1.6D)
7. Catalytic Converter8. Exhaust Pipe Front Gasket
9. Exhaust Front Pipe Gasket
10. Exhaust Manifold
11. Catalytic Converter Protective Shield
12. Front Muffler Protective Shield
13. Rear Muffler Protective Shield
Page 883 of 2643
ENGINE EXHAUST 1G – 3
DAEWOO V–121 BL4
MAINTENANCE AND REPAIR
ON–VEHICLE SERVICE
CATALYTIC CONVERTER
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the oxygen sensor electrical connector.
3. Remove the exhaust manifold cover with the bolts.
4. Remove the catalytic converter upper flange nuts.
Important : The nuts and the stud may unscrew as a unit
because of the high temperature associated with the ex-
hast manifold, but they can be re–used as such
5. Remove the exhaust front pipe mounting bracket
bolt.
6. Remove the nuts from the exhaust front pipe–to–
catalytic converter flange.
7. Remove the catalytic converter and the gasket.
8. Clean the sealing surfaces on the exhaust front
pipe flange and the exhaust manifold.
9. Check the exhaust front pipe and the exhaust man-
ifold for holes, damage, open seams or other dete-
rioration which could permit exhaust fumes to seep
into the passenger compartment.
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1G – 4IENGINE EXHAUST
DAEWOO V–121 BL4
Installation Procedure
1. Install the catalytic converter and the gasket to the
exhaust front pipe flange.
Tighten
Tighten the exhaust front pipe–to–catalytic converter
nuts to 40 NSm (30 lb–ft).
Tighten the exhaust front pipe–to–cylinder block bolt
to 50 NSm (37 lb–ft).
2. Install the catalytic converter to exhaust manifold
nuts and the gasket.
Tighten
Tighten the catalytic converter to exhaust manifold
nuts to 40 NSm (30 lb–ft).
3. Install the exhaust manifold conver bolts.
Tighten
Tighten the exhaust manifold cover bolts to 15 NSm
(11 lb–ft).
4. Connect the oxygen sensor electrical connector.
5. Connect the negative battery cable.
EXHAUST FRONT PIPE
Removal Procedure
1. Remove the crossmember lower bracket with the
bolts.
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ENGINE EXHAUST 1G – 5
DAEWOO V–121 BL4
2. Disconnect the oxygen sensor connector.
3. Remove the exhaust front pipe mounting bracket
bolt.
4. Remove the nuts from the exhaust front pipe–to–
catalytic converter flange.
5. Remove the nuts from the exhaust front pipe–to–
exhaust front muffler.
6. Remove the exhaust front pipe and the gasket.
7. Clean the sealing surfaces on the exhaust front
muffler pipe flange and the exhaust front pipe.
8. Check the exhaust front pipe for holes, damage,
open seams or other deterioration which could per-
mit exhaust fumes to seep into the passenger
compartment.
Installation Procedure
1. Install the exhaust front pipe and the gasket.
2. Install the nuts from the exhaust front pipe–to–ex-
hasut front muffler.
Tighten
Tighten the exhaust front pipe–to–exhaust front muf-
fler nets to 30 NSm (22 lb–ft).
3. Install the nuts from the exhaust front pipe–to–cata-
lytic converter flange.
4. Install the exhaust front pipe mounting bracket bolt.
Tighten
Tighten the exhaust front pipe–to–catalytic converter
nuts to 40 NSm (30 lb–ft).
Tighten the exhaust front pipe–to–cylinder block bolt
to 50 NSm (37 lb–ft).
5. Connect the oxygen sensor connector.
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1G – 6IENGINE EXHAUST
DAEWOO V–121 BL4
6. Install the crossmember lower bracket bolts to 35
NSm (26 lb–ft).
MUFFLER – FRONT
Removal Procedure
1. Remove the nuts and the gasket from the front
muffler pipe to the exhaust front pipe flange.
2. Disconnect the front muffler from the rubber hang-
er.
3. Remove the nuts and the gasket from the rear muf-
fler pipe flange.
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.
Installation Procedure
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.
Tighten
Tighten the front muffler–to–rear muffler nuts to 30
NSm (22 lb–ft).
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ENGINE EXHAUST 1G – 7
DAEWOO V–121 BL4
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.
Tighten
Tighten the front muffler–to–exhaust front pipe nuts to
30 NSm (22 lb–ft).
MUFFLER – REAR
Removal Procedure
1. Remove the nuts and the gasket from the rear muf-
fler 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, dam-
age, open seams, and other deterioration which
could permit exhaust fumes to seep into the pas-
senger compartment or the trunk.
Installation Procedure
1. Secure the rear muffler assembly to the rubber
hangers on the tail pipe end.
Page 888 of 2643
1G – 8IENGINE EXHAUST
DAEWOO V–121 BL4
2. Secure the nuts and the gasket from the rear muf-
fler pipe flange–to–front muffler pipe flange.
Tighten
Tighten the front muffler–to–rear muffler nuts to 30
NSm (22 lb–ft).