SsangYong Stavic / SsangYong Rodius (2005 year). Service manual - part 110

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AFFECTED VIN

EXHAUST SYSTEM

DI ENG SM - 2004.9

EGR Valve and Pipe
- Removal and Installation

1. Remove the vacuum hose from the EGR valve.

2. Unscrew the bolts and remove the EGR valve (2), EGR

valve #1 pipe (1) and gasket.

Installation Notice

3. Remove the EGR valve #1 pipe, #2 pipe, #3 pipe and

gaskets from the engine.

Installation Notice

4. Install in the reverse order of removal.

Notice

• Make sure to observe the specified tightening

torques.

• Never reuse the EGR #1 pipe (intake) and #3 pipe

(exhaust) once removed.

• Replace the gaskets with new ones.

Tightening torque

25 

± 2.5 Nm

Tightening torque

25 

± 2.5 Nm

EGR #3 pipe (LH)

EGR center pipe

EGR #1 pipe (RH)

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EXHAUST SYSTEM

DI ENG SM - 2004.9

Vacuum Modulator
- Removal and Installation

1. Remove the vacuum hose from the vacuum modulator.

2. Remove the vacuum modulator from the bracket.

Installation Notice

3. Install in the reverse order of removal.

Tightening torque

10 

± 1.0 Nm

Notice

Make sure that the vacuum hoses are connected to
correct locations.

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EXHAUST SYSTEM

DI ENG SM - 2004.9

EXHAUST SYSTEM AND MUFFLER

MUFFLER

The muffler is located at the middle of the exhaust pipe and reduces the pulse noise and the tail pipe noise by eliminating
the flowing resistance from the exhaust gas.

The important elements of the muffler are volume, construction and location.

Heat shield

Muffler

#3 Hanger

DOC (Diesel Oxidation Catalyst)

Muffler

#1 Hanger

Heat shield

#2 Hanger

#1 Pipe

DOC (Diesel Oxidation Catalyst)

Tail pipe

Muffler

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EXHAUST SYSTEM

DI ENG SM - 2004.9

SYSTEM OVERVIEW

Exhaust System

Check the complete exhaust system and the nearby body
areas and trunk lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose
connections, or other deterioration which could permit
exhaust fumes to seep into the trunk may be an indication
of a problem in one of these areas. Any defects should be
corrected immediately.

Muffler

Aside from the exhaust manifold connection, the exhaust
system uses a flange and seal joint design rather than a
slip joint coupling design with clamp and U-bolts. If hole,
open seams, or any deterioration is discovered upon in-
spection of the front muffler and pipe assembly, the com-
plete assembly should be replaced. The same procedure
is applicable to the rear muffler assembly. Heat shields for
the front and rear muffler assembly and catalytic converter
protect the vehicle and the environment from the high tem-
peratures that the exhaust system develops.

Heat Shield

The heat shield protects the vehicle and components from
the high heat generated from the exhaust system.

In this vehicle, the heat shield to block the heat from DOC
is installed to the underbody, and the heat shield to block
the heat from the rear muffler is installed to the underbody
between the fuel tank and the rear muffler.

Hanger

The hanger is to support the components.

If the ganger is not properly installed, it may cause the
vibration that is very difficult to diagnose. Therefore, install
the hanger to the correct location so that the exhaust sys-
tem cannot contact to the underbody and other
components.

Notice

When you are inspecting or replacing exhaust system
components, make sure there is adequate clearance
from all points on the underbody to avoid possible
overheating of the floor panel and possible damage to
the passenger compartment insulation and trim
materials.

DOC (Diesel Oxidation Catalyst)

DOC (Diesel Oxidation Catalyst) is the purification device
to reduce the toxic emissions from the exhaust gas from
the engine. By using the chemical reaction, the amount of
toxic gas such as NOx can be reduced.

Notice

To prevent damage of DOC, never contact the lift pad
when lifting up the vehicle.