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Hyundai Getz>> Engine>> System of production of the fulfilled gases
Features of the device 
The system of production of the fulfilled gases consists of a final collector, catalytic converter, a reception pipe of exhaust silencers, exhaust silencers. Necessary for work with adjustable catalytic converter the sensor of concentration of oxygen (lambda probe) is established in the case of catalytic converter.
The reception pipe of exhaust silencers fastens to the catalytic converter established on a flange of a final collector. All details are connected with each other by means of carving connections and can be replaced separately. After removal it is necessary to replace being self-stopped nuts and laying new. Rubber rings of fastening of elements of system of release and rubber buffers should be checked on lack of cracks and damages, and if necessary – to replace. At installation of new system of production of the fulfilled gases it is recommended to replace and all elements of fastening.

Removal and installation of system of release 
Cars with engines in working volume of 1,1 and 1,3 l 

Fig. 2.267. Elements of system of the release, located in a motor compartment of the engine in working volume of 1,3 l: 1–laying of a final collector; 2–final collector; 3–heat-shielding casing of a final collector


Elements of system of the release, located in a motor compartment of the engine in working volume of 1,3 l, are shown on fig. 2.267 .

Fig. 2.268. Elements of system of the release, located in a motor compartment of the engine in working volume of 1,1 l: 1–laying of a final collector; 2–final collector; 3–heat-shielding casing of a final collector; 4–sensor of concentration of oxygen


Elements of system of the release, located in a motor compartment of the engine in working volume of 1,1 l, are shown on fig. 2.268 .
Check of a technical condition

Fig. 2.269. Final collector


Check a final collector (fig. 2.269) on absence of damages or cracks.

Fig. 2.270. Laying of a final collector


Check laying of a final collector (fig. 2.270) on lack of an otslaivaniye or damage.

Fig. 2.271. Reception pipe and exhaust silencers of system of release: 1–laying of a reception pipe of exhaust silencers; 2–pillow of a suspension bracket of a reception pipe of exhaust silencers; 3–additional exhaust silencer; 4–main exhaust silencer


The reception pipe and exhaust silencers of system of release are shown on fig. 2.271 .

PREVENTION
Removal and check of details of system of release carry out only on cold system.

Removal

Fig. 2.272. A flange of fastening of the main exhaust silencer to the additional exhaust silencer


Disconnect the main exhaust silencer from additional (fig. 2.272) .
Remove  the main  exhaust silencer,  having disconnected  suspension bracket pillows.
Disconnect the additional exhaust silencer from the main exhaust silencer.
Remove the additional exhaust silencer, having disconnected a suspension bracket pillow.
Disconnect catalytic converter from a reception pipe of exhaust silencers.
Disconnect a reception pipe of exhaust silencers from catalytic converter (on the engine working at unleaded gasoline) or from a final collector (on the engine working at etilirovanny gasoline).
Unscrew a bolt of a collar of fastening of a reception pipe of exhaust silencers and a nut of its fastening.
Check of a technical condition
Check exhaust silencers and pipes on absence of corrosion and damages.
Check pillows of a suspension bracket and tape collars on lack of cracks and aging signs.
Installation
Establish catalytic converter, a reception pipe of exhaust silencers, the additional exhaust silencer and the main exhaust silencer as transfer and temporarily fix them.
Tighten fastenings of elements of system of release, watching that they did not concern a body.

Cars with engines in working volume of 1,5 and 1,6 l

Fig. 2.273. Elements of system of the release, located in a motor compartment: 1–laying of a final collector; 2–final collector; 3–sensor of concentration of oxygen; 4–catalytic converter; 5–heat-shielding casing of a final collector


Elements of system of the release, located in a motor compartment, are shown on fig. 2.273 .

Fig. 2.274. Reception pipe and exhaust silencers of system of release: 1–laying of a reception pipe of exhaust silencers; 2–pillows of a suspension bracket of a reception pipe of exhaust silencers; 3–additional exhaust silencer; 4–main exhaust silencer


The reception pipe and exhaust silencers of system of release are shown on fig. 2.274 .
Removal

Fig. 2.275. A flange of fastening of the main exhaust silencer to the additional exhaust silencer


Disconnect the main exhaust silencer from additional (fig. 2.275) , having unscrewed nuts of fastening and having taken out bolts.
Remove  the main  exhaust silencer,  having disconnected  suspension bracket pillows.

Fig. 2.276. Connecting collar of a reception pipe of exhaust silencers and additional exhaust silencer


Disconnect the additional exhaust silencer from the main exhaust silencer and a reception pipe of exhaust silencers (fig. 2.276) .
Remove the additional exhaust silencer, having disconnected a suspension bracket pillow.

Fig. 2.277. Elements of fastening of a reception pipe of exhaust silencers to catalytic converter


Unscrew bolts of collars of fastening of a reception pipe of exhaust silencers and a nut of its fastening to catalytic converter (fig. 2.277) .
Unscrew a bolt of fastening of a reception pipe to the additional exhaust silencer.
Installation
Establish a reception pipe of exhaust silencers, additional and main exhaust silencers in the listed order, temporarily fix them.
Tighten fastenings of elements of system of release, watching that they did not concern a body.

PREVENTION
Removal and check of details of system of release carry out only on cold system.

Check of tightness of system of production  of the fulfilled gases 
On cars with adjustable catalytic converter lack of tightness of connections of system of release in front of the sensor of concentration of oxygen can lead to the following malfunctions:
– difficulties at engine start-up;
– the engine stops;
– non-uniform operation of the engine idling;
– breakthroughs at acceleration.

PREVENTION
 Check condition – the engine cold or hand temperatures. The source of the compressed air is necessary for check.

Start up the engine and hear on the working engine to system of production of the fulfilled gases on absence of leakages of the fulfilled gases.
Stop the engine.
Insert the gun of a source of the compressed air (compressor) into an exhaust pipe and condense with a rag.
Establish pressure of the compressed air 6 a bar. Turn on the gun.
Cover with means for definition of places of leakages of a junction of a head of the block of cylinders and a final collector, a final collector and a reception pipe of the exhaust silencer, a reception pipe of the exhaust silencer and catalytic converter and check on formation of vials.
Eliminate violations of a leakage of system of release.

Cars with catalytic converter in system of production of the fulfilled gases 
Hyundai cars serially equip with catalytic converter. At its existence use of unleaded gasoline is obligatory. Cars with operated catalytic converter, besides, should be equipped with the device of an adjustable smeseobrazovaniye.
The device of an adjustable smeseobrazovaniye is understood as system of injection of fuel in which a ratio fuel/air can constantly change depending on service conditions and the content of oxygen in the fulfilled gases.
Management teams the device of a smeseobrazovaniye are received from the sensor of concentration of oxygen by (lambda probe) which is established before catalytic converter or in a final collector and is blown by a stream of the fulfilled gases. The lambda probe is the electric sensor which is registering the residual content of oxygen in fulfilled gases and giving out the corresponding electric signal. The size of a signal allows to draw a conclusion on structure of a toplivovozdushny mix. In fractions of a second the lambda probe can give out the corresponding signal on the electronic control unit, at the expense of it the structure of a mix can constantly be corrected. It, on the one hand, is necessary, as service conditions (for example, full gas, idling), on the other hand, because constantly change
optimum reburning occurs in catalytic converter only in that
case if in the fulfilled gases there is enough of particles of carbon (not burned down gasoline).
So that at temperature of 300-800 °C in catalytic converter in general there could be a reburning, the fulfilled gases should contain bigger amount of fuel, than it is required for complete combustion in engine cylinders. In this regard at operation of the car equipped with the engine with catalytic converter, fuel consumption increases approximately by 5 %. Catalytic converter is in a motor compartment of the car on a place of the forward exhaust silencer. Converter consists of the ceramic cellular block covered with noble metal catalyst – platinum or rhodium. For fastening of the ceramic block sensitive to blows the elastic heat resisting wire grid is used.
Used catalytic converter represents so-called three-componental catalytic converter. It means that in it at the same time there is an oxidation of an oxide of carbon (WITH) both hydrocarbons (SN) and decrease in the content of oxides of nitrogen (NOx).

Service regulations of cars with catalytic converter in system of production of the fulfilled gases 
To avoid damage of the sensor of concentration of oxygen (lambda probe) and catalytic converter, it is necessary to follow the following instructions.
It is obligatory to refuel unleaded gasoline.
If etilirovanny fuel was by mistake filled in, it is necessary to replace a final collector and catalytic converter. Before installation of new elements of system of release not less than two times it is necessary to fill a fuel tank with unleaded gasoline completely.
Start-up of the heated-up engine by pushing or towage is inadmissible. It is necessary to use an electric cable for engine start-up. Not burned down fuel at ignition can lead to an overheat of catalytic converter and its subsequent destruction.
It is necessary to avoid the frequent cold start-up following one by one. Otherwise in catalytic converter not burned down fuel which is burning down at heating with explosion gathers, converter is thus damaged.
At difficulties at start-up of the engine let's to a starter work long as during start-up there is a fuel injection. It is necessary to find and eliminate malfunction, and then to start up the engine.
At interruptions in work of system of ignition before definition of a cause of defect do not allow fuel injection at engine start-up.
Do not check spark existence at the removed tip of a spark plug.
It is impossible to carry out balance test shutdown of a high-voltage wire of ignition of one of cylinders. At a detachment of a high-voltage wire of ignition of the separate cylinder, even by means of the special tester, not burned down fuel will get to catalytic converter.
At interruptions in work of system of ignition avoid operation of the engine with high frequency of rotation of a cranked shaft. Eliminate malfunction as soon as possible.
Do not park the car on the dried foliage or a grass. The temperature of system of production of the fulfilled gases in an installation site of catalytic converter very high, radiation of heat occurs even after engine switching off.
When filling engine oil it is necessary to watch that the maximum level of oil on щупу was not exceeded. Otherwise its surplus can get to catalytic converter and damage a covering or completely destroy it.

Useful data and councils
How to save converter
Replacement of the refused converter will run into money, therefore it is good in advance the nobility as business with converters in the market of automobile spare parts is and what problems arise at their operation.
Until recently we knew about converter only the following: it is such piece which unclear why is necessary, it is unclear as works, our gasoline "kills" her, generally one troubles. To cut out – and any problems! But gradually we started to get used to that converter – a thing after all reasonably useful, at least thoughts on «surgical intervention» in system of production of the fulfilled gases visit everything more rare and the lesser quantity of the heads.
In the spring when the staff of traffic police begins «fight for purity of air», one more problem falls down us – it is necessary to adjust WITH. Owners of the cars equipped with converters, do not reflect on it at all, and check posts WITH pass without a shiver in knees and fear for the purse. However, the same purse can decently "grow thin" for other reason. Penalties for level excess WITH will seem cheap in comparison with expenses on purchase and converter replacement if it fails. That is why it is necessary to know, how with it to address, and for this purpose at first it is necessary to understand, as it is arranged and as works.
As converter works
At combustion of a toplivovozdushny mix a row unhealthy the person of products – carbon oxide (WITH), various hydrocarbons (SN) and nitrogen (NO) oxides and so forth is formed. In spite of the fact that these substances also make only 1 % of total amount of an exhaust (the rest is a nitrogen, dioxide of carbon and water vapor), they are very harmful and neutralization demand. There are some ways of fight against harmful components of an exhaust, for example mix pauperization at which the engine works, or the retsirkulyatsiya of the fulfilled gases, but any of them will not be compared by efficiency to result of work of catalytic converter.
As experts speak, catalytic converter is a simple device in which there is a difficult chemical process. In the case from stainless steel there is ceramic or metal "brick" with cellular structure. At this monolith the huge area of a surface, and all it is covered with the thinnest layer of a special alloy – actually the catalyst containing platinum, rhodium and a palladium. These rare metals are responsible for wonderful properties of converter, they define its high cost.
The fulfilled gases "wash" a monolith surface, and when the temperature reaches "critical" value of +270 °C, catalytic reaction begins. Oxide of carbon turns into dioxide (carbon dioxide), hydrocarbons – in water and besides in carbon dioxide, and nitrogen oxides – in water and nitrogen. All this for environment less harmfully.
Catalytic converters are capable to reduce quite effectively toxicity of an exhaust, thus they practically do not influence consumption of fuel and engine capacity. In the presence of converter return pressure of an exhaust from what the engine loses 2–3 h.p., but it practically all "payment" for purification of the fulfilled gases slightly increases. However installation of catalytic converter – not the ideal decision. Theoretically it should serve infinitely as aforementioned metals serve only as the catalyst which at chemical reaction, as we know, is not spent. In practice life expectancy of converter has a limit...
Converter causes of failure
Refusal of catalytic converter can occur for several reasons though usually it is process gradual, to catch which without the special equipment it is impossible.
"Core" of the majority of converters is made of ceramics – a material known for the fragility. The car can get for the speed to a hollow, hit about something or even it is simple to "strike" the converter case on a stone from what catalytic "brick" can burst. After that loss by "core" of the working qualities – time business.
The converters of new generation containing a metal monolith, are not so vulnerable in this respect. To break them, of course, it is possible, but in any case it is not so simple.
Except physical destruction, there is one more frequent reason of an exit of converter out of operation – fuel. It is extremely sensitive to composition of fuel. If gasoline etilirovanny, a tetraetilsvinets containing in it, is postponed on an active surface of catalytic "brick" and quickly "pollutes" it from what any reactions stop., Apparently, on fillings and tips of hoses put the different size, and distributing columns paint in different colors, and write about it at every turn, and all the same consumers sometimes confuse and fill in not that gasoline. And after all it is enough to "burn" half-tank of such gasoline to "kill" converter.
But not only etilirovanny gasoline – the enemy of converter. It can be ruined and unleaded if the control system of the engine is faulty, the toplivovozdushny mix or the engine not completely burns down is strongly worn-out.
Threefold catalytic converters ("threefold" because as the catalyst set of three metals serves) establish only on those cars which engines are equipped with the closed monitoring system of an exhaust. Before converter the sensor of concentration of oxygen which estimates composition of the fulfilled gases is established and transfers these data in the central block of an electronic control system of the engine. Depending on the content of oxygen in gases the central block regulates composition of gas mixture and ignition so that their optimum values were supported. It serves as the main protection of converter and provides economy of fuel, high profitability of the engine. Converter does not transfer big deviations to this or that party as a part of a mix. Badly adjusted engine with the raised content of hydrocarbons in an exhaust simply ruins converter. Too poor mix can cause a sharp overheat of converter from what the monolith, only already "physically" again will suffer. Thus, "life" of converter depends on serviceability of a control system of the engine.
A lot of things depends and on serviceability of the most oxygen sensor. With "age" it becomes "lazy" or absolutely fails that affects structure of a working mix and according to serviceability of converter.
Spoil converter the exhaust of strongly worn-out engine burning oil can also. The last, getting together with an exhaust to converter, "is baked" on a monolith surface, like a varnish, and let's to converter work.
There are also other harmful factors. For example, candles. Improper candles will not give complete combustion that can cause pernicious reaction of fusion in converter.
Be careful when using additives to gasoline or engine oil. The majority of drivers on it do not reflect, and after all additives too can harmfully influence converter. If on a product it is not written «it is compatible to catalytic converter», do not risk better.
One more dangerous case – engine start-up by towage. Thus there can be a hit in converter of pure gasoline. It poisons converter, and also can cause instant reaction and even explosion.
Still watch where go, try not to get to deep pools. The working temperature of converter makes about +900 °C. Its sudden hit in water can be fatal.
As a whole it is noticed that service life of converter is influenced also by service conditions. Converters by the cars maintained in a city mode when the engine often start up more suffer and stop. Nevertheless at long driving with high speed in the country converter also suffers, but already from an overheat.
At last, you arrive reasonably if will begin to examine release system regularly. If arms are broken or rubber pillows of a suspension bracket of exhaust silencers fell off, the exhaust pipe will vibrate, transferring to converter unnecessary loadings.