Exhaust - Noise During Hard Acceleration

04-018

June 18, 2004

Applies To:
2002-03 RSX - ALL
2004 RSX - From VIN JH4DC5...4S000001 thru JH4DC5...4S017610

Exhaust Noise During Hard Acceleration

SYMPTOM

During hard acceleration, exhaust noise or rattle comes from the engine compartment.

PROBABLE CAUSE

Compression of the exhaust gasket allows movement at the catalytic-converter-to-exhaust-manifold connection.

CORRECTIVE ACTION

Replace the flexible exhaust gasket.





PARTS INFORMATION

WARRANTY CLAIM INFORMATION

In warranty:
The normal warranty applies.

Operation Number: 311115

Flat Rate Time: 0.6 hour

Failed Part: P/N 18229-S6M-003 (RSX)
P/N 18229-S6M-A51 (Type-S)

Defect Code: 05401

Symptom Code: 04206

Skill Level: Repair Technician

Out of warranty:
Any repair performed after warranty expiration may be eligible for goodwill consideration by the District Parts and Service Manager or your Zone Office. You must request consideration, and get a decision, before starting work.

REPAIR PROCEDURE

1. Disconnect the secondary oxygen sensor and the air-fuel (A/F) sensor connectors from their sockets. (Refer to Section 9 of the 2002-04 RSX Service Manual).

2. Remove the catalytic converter from the exhaust system.

3. Remove and discard these parts:

^ The flex joint gasket. For Type-S, also discard the two bolts used on the flex joint.

^ The compression gasket on the outlet of the catalytic converter.

^ The three self-locking nuts on the outlet of the catalytic converter.





4. Use a piece of scrap wood and a plastic mallet to drive a new gasket onto the manifold outlet. Pound around the gasket several times.

5. Install the catalytic converter:

^ Assemble the flex joint. Use the new bolts included in the kit for the Type-S. Use the original bolts on the RSX. Torque the bolts, in steps from side to side, to 22 N.m (16 lb-ft).

^ Assemble the catalytic converter outlet joint using a new pre-chamber gasket and three new self-locking nuts. Torque the self-locking nuts to 33 N.m (25 lb-ft).

6. Connect the secondary oxygen sensor and the A/F sensor connectors.

7. Test-drive the vehicle to confirm that the noise is gone.





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