Exhaust Leakage - Suzuki XL7 2007 Service Manual

1K-7 Exhaust System:

Exhaust Leakage

Condition
WARNING
!
Refer to "Hot Exhaust System Caution".
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 components
Exhaust leaks at the following
connections:
• Exhaust manifold to pipe
• Flanges
• Pipe clamps
Seals or gaskets leaking;
• Exhaust manifold to cylinder
head
• Exhaust pipes to exhaust
manifold
• Catalytic converter connection
Irregularities at the mating surfaces
on the flange connections
Exhaust manifold cracked or broken Replace the exhaust manifold. Refer to "Exhaust Manifold Replacement - Left
Exhaust system component
connection welds leaking
Muffler or resonator, if equipped,
damaged or leaking at the seams
Exhaust Noise
Condition
WARNING
!
Refer to "Hot Exhaust System Caution".
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 noise
Loud exhaust
External rattle or vibration noise
Internal rattle
• Align and tighten the exhaust system components to the specifications. Refer
to "Fastener Tightening Specifications - Engine Exhaust".
• Ensure the exhaust hangers are in the proper locations and not loose.
Tighten the components to the specifications. Refer to "Fastener Tightening
Specifications - Engine Exhaust".
Replace the leaking seal or gasket. Refer to the affected components procedure
for service.
Repair as required or replace the affected component. Refer to the affected
components procedure for service.
Side" or "Exhaust Manifold Replacement - Right Side".
Replace the leaking component. Refer to the affected component's procedure
for service.
Replace the affected muffler or resonator, if equipped. Refer to "Muffler
Replacement".
Exhaust leak - Refer to "Exhaust Leakage".
1. Compare to a known good vehicle.
2. Inspect for a damaged or failed muffler or resonator, if equipped.
3. Replace the faulty muffler or resonator (if equipped). Refer to "Muffler
Replacement".
1. Inspect for a bent or loose hanger, loose heat shield, or loose clamp.
2. Inspect for a exhaust pipe causing interference.
3. Repair or replace the affected component. Refer to the affected
component's service procedure.
1. Test the components by tapping with a rubber mallet to confirm a rattle.
2. Replace the faulty catalytic converter, resonator, if equipped, or muffler.
Refer to "Muffler Replacement".
Action
Action