The design of the vehicle exhaust system consists of a catalytic converter, a bellows, a downpipe combined with a catalytic converter and a main muffler

Hyundai Solaris Exhaust System Repair

Gases are vented from the engine through a catalytic converter combined with an exhaust gas catalytic converter

Hyundai Solaris Exhaust System Repair

To reduce the transmission of vibrations from the power plant, a bellows is used, into which gases are supplied from the collector

Hyundai Solaris Exhaust System Repair

Further, the gases enter the exhaust pipe, combined with an additional catalytic converter and an additional silencer

Hyundai Solaris Exhaust System Repair

After that, the gases enter the main silencer

Hyundai Solaris Exhaust System Repair

A control oxygen concentration sensor is installed at the inlet of the catalytic converter

Hyundai Solaris Exhaust System Repair

Diagnostic oxygen sensor mounted on bellows

Hyundai Solaris Exhaust System Repair

All connections of the gas exhaust system are sealed with metal-reinforced gaskets

Hyundai Solaris Exhaust System Repair

The parts of the system are suspended from the body using rubber cushions

Replacing silencer suspension pads

We install the car on a lift or a viewing ditch

Hyundai Solaris Exhaust System Repair

Pry off with a screwdriver and remove the pillow first from the bellows bracket

Hyundai Solaris Exhaust System Repair

Then we remove the front cross member of the vehicle from the bracket

A damaged pillow can be cut with a knife

Hyundai Solaris Exhaust System Repair

In the same way, we replace the remaining pillows of the exhaust system

Install pillows in reverse order

To facilitate installation, we lubricate the bellows and body brackets with soapy water

Removing and installing the collector

The system has an exhaust gas catalytic converter combined with a catalytic converter.

A possible reason for the failure of the collector may be the use of leaded gasoline and non-recommended types of motor oils with a high content of sulfur and phosphorus.

Hyundai Solaris Exhaust System Repair

A metal-reinforced gasket is installed between the cylinder head and the collector

Disconnect the negative battery terminal

We clean the threaded ends of the studs and nuts with a metal brush and treat them with a penetrating lubricant like WD-40

Hyundai Solaris Exhaust System Repair

We unscrew the two nuts securing the collector to the bellows

Hyundai Solaris Exhaust System Repair

And disconnect the bellows from the collector

Hyundai Solaris Exhaust System Repair

We unscrew the three bolts securing the upper thermal screen of the collector

Hyundai Solaris Exhaust System Repair

And remove the thermal screen

Hyundai Solaris Exhaust System Repair

Unscrew the bolt securing the collector to the bracket on the engine

Hyundai Solaris Exhaust System Repair

We unscrew the nine nuts securing the collector to the cylinder head

Hyundai Solaris Exhaust System Repair

Remove the collector from the studs of the head of the block and take it out of the engine compartment up

Hyundai Solaris Exhaust System Repair

Remove the manifold gasket

Hyundai Solaris Exhaust System Repair

If necessary, unscrew the four bolts securing the middle thermal screen of the collector

Hyundai Solaris Exhaust System Repair

Remove the thermal screen

Hyundai Solaris Exhaust System Repair

We unscrew the three bolts securing the lower thermal screen of the collector

Hyundai Solaris Exhaust System Repair

And remove the lower thermal screen

Install the collector in reverse order.

Removing and installing the bellows

Before unscrewing the nuts securing the bellows flange to the collector flange, we clean the nuts and fastening studs with a metal brush and treat them with easily penetrating grease

Hyundai Solaris Exhaust System Repair

We unscrew the two nuts securing the manifold to the bellows

Hyundai Solaris Exhaust System Repair

Disconnect the bellows from the collector and remove the gasket

Hyundai Solaris Exhaust System Repair

We unscrew the two nuts securing the bellows flange to the exhaust pipe flange

Hyundai Solaris Exhaust System Repair

Pry off with a screwdriver and disconnect the pillow from the bellows bracket

Hyundai Solaris Exhaust System Repair

Remove the bellows from the front pipe

Hyundai Solaris Exhaust System Repair

Remove the gasket from the studs

Hyundai Solaris Exhaust System Repair

Remove the bellows from the engine compartment

Install the bellows in reverse order and replace the gaskets

Removing and installing additional catalytic converter and additional muffler

Hyundai Solaris Exhaust System Repair

We unscrew the two nuts securing the bellows flange to the exhaust pipe flange

Hyundai Solaris Exhaust System Repair

Remove the bellows from the front pipe

Hyundai Solaris Exhaust System Repair

Remove the gasket from the studs

Hyundai Solaris Exhaust System Repair

We unscrew the two nuts securing the additional converter and the additional silencer to the main silencer

Hyundai Solaris Exhaust System Repair

Disconnect the main muffler from the additional converter and additional muffler

Hyundai Solaris Exhaust System Repair

Remove the gasket from the studs

Hyundai Solaris Exhaust System Repair

We pry off with a screwdriver and, holding the pipe, disconnect the bracket of the additional muffler from the suspension cushions

Hyundai Solaris Exhaust System Repair

Remove the additional catalytic converter and additional muffler assembly

Setting all the details in arr order

Replacing the main muffler

Hyundai Solaris Exhaust System Repair

We unscrew the two nuts securing the additional converter and silencer to the main silencer

Hyundai Solaris Exhaust System Repair

Remove the main muffler

Hyundai Solaris Exhaust System Repair

Remove the gasket from the studs

Hyundai Solaris Exhaust System Repair

Pry off with a screwdriver

Hyundai Solaris Exhaust System Repair

And detach the front cushion from the main muffler bracket

Hyundai Solaris Exhaust System Repair

Also detach the rear cushion from the main muffler bracket

Hyundai Solaris Exhaust System Repair

Remove the main muffler from the car

Removing and installing thermal screens

Hyundai Solaris Exhaust System Repair

Remove the bellows as described above

Hyundai Solaris Exhaust System Repair

We unscrew the four nuts securing the thermal screen of the additional catalytic converter

Hyundai Solaris Exhaust System Repair

Remove the thermal screen

Hyundai Solaris Exhaust System Repair

To remove the thermal screen of the main muffler, unscrew the three nuts securing the thermal screen on the right

Hyundai Solaris Exhaust System Repair

Unscrew the two nuts on the left

Hyundai Solaris Exhaust System Repair

Turn the thermal screen around the muffler and remove it