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Exhaust Leakage

Exhaust Leakage


Problem Action
Warning

While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.


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

Misaligned or improperly installed exhaust system components

Align and tighten the components to the specifications. Refer to Fastener Tightening Specifications

Exhaust leaks at the following connections:


• Exhaust manifold to pipe

• Flanges

• Pipe clamps


Tighten 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 connections

• AIR connections to the exhaust manifold or cylinder head


Replace the leaking seal or gasket. Refer to the affected components procedure for service.

Irregularities at the mating surfaces on the flange connections

Repair as required or replace the affected component. Refer to the affected components procedure for service.

Exhaust manifold cracked or broken

Replace the exhaust manifold. Refer to Exhaust Manifold Replacement (Diesel) Exhaust Manifold Replacement (LHU/A20NFT) or Exhaust Manifold Replacement - Left Side (LAU/A28NER) or Exhaust Manifold Replacement - Right Side (LAU/A28NER) .

Exhaust system component connection welds leaking

Replace the leaking component. Refer to the affected components procedure for service.

Muffler or resonator, if equipped, damaged or leaking at the seams

Replace the affected muffler. Refer to Exhaust System Replacement (LAU/A28NER) Exhaust System Replacement (LLU/A16LET) Exhaust System Replacement (LHU/A20NFT) Exhaust System Replacement (LHU/A20NFT - AWD, LAU/A28NER - AWD) .