Inspection Of The Pre-EPA07 Exhaust System

4700 mm 49.01.007
  1. On all vehicles, check the condition of the muffler body and the top stack. Check the inlet/outlet tubes for leakage, dents, and corrosion, and check for holes in the muffler. Replace parts as required. Use new parts, equivalent to parts originally installed on the vehicle.
  2. Inspect the exhaust flex hose (see Fig.) for leakage, wear, or damage. Replace with new parts if replacement is needed.

    1. Flex Hose

    2. V-Band Coupling

    3. Exhaust Pipe

    4. Turbocharger Exhaust Outlet

    Fig. 1, V-Band Coupling and Flex Hose

  3. Check for leakage at the V-band coupling, which attaches the exhaust pipe to the turbocharger exhaust outlet. See Fig..
  4. If leakage exists, tighten the nut on the V-band coupling 85 lbf·in (940 N·cm). If leakage persists, install a new V-band coupling.
  5. Inspect the turbocharger outlet pipe, and replace it as needed.
  6. Check the U-bolt clamps for tightness, and tighten as needed.
  7. Check the isolator at the base and the top of the exhaust stack (see Fig.) for cracking, damage, and dry rot. Replace as needed.

    1. Exhaust Elbow

    2. Exhaust Isolator

    Fig. 2, Exhaust Isolator

  8. Check for leakage at all wide-band exhaust clamps. See Fig.. If leakage exists, tighten the nuts 40 to 60 lbf·ft (54 to 81 N·m). If leakage persists, inspect the wide-band exhaust clamps. Install a new Donaldson SealClamp™ if necessary.

    Fig. 3,  Donaldson SealClamp Wide-Band Exhaust Clamp

Note:
Parent topic: EPA07 Exhaust System
Document Number: 0000121091
Manual Publication Date: 2024-05-23
Topic Publication Date: 2024-10-31