Exhaust rattle on cold engine start. Mystery Solved!

Nicholsk · 07-14-2008, 10:08 AM

So I had this problem for a while now and I finally figured it out. Basically the problem was when the engine was cold on my 2003 Grand Vitara I would hear an exhaust rattle, almost sounded like a heat shield rattling. You would hear it at 1500-2000 rpm range while in drive (never in neutral) for about the first 1 or 2 mins of driving. Drove my crazy for awhile trying to figure out what was rattling. I was under the GV looking at all the heat shields trying to figure out which one was loose, all were fine. I saw I few posting on this site from different GV and XL7 owners with the same type problem but no posting of a solution. Well this is what it turned out to be my problem.

It turned out to be the donut gasket seal which was gone. This gasket seals the joints between the end of the Y pipe and the front of the catalytic converter pipe where they meet, its location is basically under the drivers feet.

If you are hearing this noise like I described above here is a simple test to determine if your gasket seal is what is gone. Insure you have a cold engine start and a cold exhaust. Start the engine and while in park with the e-brake applied get out of the vehicle and down on the ground. Behind the drivers side front tire look under and you will see the joint where the end of the Y pipe meets the front of the catalytic converter pipe. There are 2 large bolts and 2 large springs which attach the two pipes. Take your hand and feel around the two joining pipes. If you feel puffs of air/exhaust then your gasket seal is gone and needs to be replaced.

I replace the gasket donut seal and the 2 large bolts and 2 large springs because they were rusty and couldn’t be reused. When I got the joint apart I had one tiny little piece of gasket left (basically nothing left) and the two metal pipes were rattling on each other until they heated up and expanded. So hopefully if you hear this noise this will be your simple fix.

Kev

XL7Limited · 07-14-2008, 05:44 PM

thanks Kev. I will look at mine. Mine started on day 3 years ago and it never got worst and I never found it.. Mine does it in neutral tho too..

did you get it from a dealer? If so how much ?? Thanks

Nicholsk · 07-15-2008, 08:52 AM

Hi XL7Limited,

Yes I got this part from the Suzuki dealer. It was $22 CDN. If you need the part number let me know and I can get it for you. I believe we have the same size exhaust pipe 2.5 L Grand Vitara (mine) and 2.7 XL7 (yours). When I contacted the dealer to ask about the part they made it sound like it was a pretty common part which fails behind the Y pipe and they always carry it in stock. It looks like a little hockey puck with a hole in the middle and made out of metal almost like the SOS pad material.

I saw your comment from a post awhile back asking about the same type of problem, hopefully this is all it is for you. Let me know me know how you make out?

Kev

XL7Limited · 07-15-2008, 06:43 PM

yea kev, get me the part number.. Did you also replace the bolts? hey Im just thinking.. Thiis a warranty issue. 8 years/80k miles for exhaust systems before the cat converter.Which this is..

Nicholsk · 07-16-2008, 08:39 AM

Hi XL7Limited,
Part number for the exhaust seal: 14183-65D10.

Yes I replace the 2 bolts because the were very rusty and the springs also, one bolt is larger then the other, 2 springs are the same size.
Large bolt part number is: 14193-77E00
Smaller bolt part number is: 09119-10041
Spring part number is: 14492-67D00 (times 2)

Torque setting on the bolts is 36.5 ft/lbs.

I didn't ask Suzuki if it was covered under warranty but if you can get them to cover it then I say go for it.

Did you check to see if you could feel the exhaust around the joint on the cold engine startup yet?

Kev

XL7Limited · 07-17-2008, 09:24 PM

thanks!! that helped a lot

murcod · 07-31-2008, 04:46 AM

I think mine might be doing it too- I get a "rythmic" rattling noise from the engine bay area at idle when cold but I've never bothered to try and work out where it's from. I can't hear it inside the cabin though.

ewetho · 08-01-2008, 11:03 PM

One to be aware of though is the stiffener brackets between the cats and the block that sometimes cracks and sometimes the Y-pipe sometimes cracks too.

ferry · 08-03-2008, 02:43 PM

Hi

this is and interesting post as I have a metallic rattle coming from my 2001Grand Vitara. It happens at 2400 rpm hot or cold. I read your post and went outside to have a closer look and found the exact same corroded gasket as you describe.

Here is a picture of the offending region. The plate on the right vibrates so can I assume I need to replace that gasket?

Thanks very much

Max · 08-03-2008, 07:31 PM

I think you've found the problem area. Be forewarned though. Those bolts are going to need machining surgery in order to remove / replace them. That and drill / re-tapping of any internal threaded holes, as you are sure to snap off the mechanical connections. Don't attempt it unless you have the tools / talent or plan on getting help.