GM Service Manual Online
For 1990-2009 cars only

Exhaust Leakage - Not OBD II Pontiac/Buick

Step

Action

Values

Yes

No

1

Check for improperly installed or misaligned components.

Are there any improperly installed or misaligned components?

--

Go to Step 2

Go to Step 3

2

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

Is there still exhaust leakage and/or excess noise?

--

Go to Step 3

System OK

3

Check for loose connections at the exhaust manifold or the three way catalytic converter.

Are there any loose connections at the exhaust manifold or the three way catalytic converter?

--

Go to Step 4

Go to Step 5

4

Tighten all fasteners to specifications. Refer to Engine Mechanical.

Is there still exhaust leakage and/or excess noise?

--

Go to Step 5

System OK

5

Check for a cracked or broken exhaust manifold.

Is the exhaust manifold cracked or broken?

--

Go to Step 6

Go to Step 7

6

Replace any cracked or broken exhaust manifolds. Refer to Engine Mechanical.

Is there still exhaust leakage and/or excess noise?

--

Go to Step 7

System OK

7

Check for any leakage at the crossover pipe connection.

Is there any leakage at the crossover pipe connection?

--

Go to Step 8

Go to Step 9

8

Tighten the nuts and bolts to specifications. Refer to Fastener Tightening Specifications .

Is there still exhaust leakage and/or excess noise?

--

Go to Step 9

System OK

9

Check for any damaged or worn seals.

Are there any damaged or worn seals?

--

Go to Step 10

Go to Step 11

10

Replace any damaged or worn seals.

Is there still exhaust leakage and/or excess noise?

--

Go to Step 11

System OK

11

Check for a burned or rusted extension pipe.

Is there a burned or rusted extension pipe?

--

Go to Step 12

Go to Step 13

12

Replace the extension pipe (and muffler assembly if not previously serviced).

Is there still exhaust leakage and/or excess noise?

--

Go to Step 13

System OK

13

Check for a burned or rusted muffler.

Is there a burned or rusted muffler?

--

Go to Step 14

Go to Step 15

14

Replace the muffler/tail pipe assembly. Refer to Muffler or to Tail Pipe .

Is there still exhaust leakage and/or excess noise?

--

Go to Step 15

System OK

15

Check for leakage at the exhaust component joints or couplings, if previously serviced. Is there any leakage at the exhaust component joints or couplings?

--

Go to Step 16

--

16

Replace the seals and tighten the flange bolts to specifications. If necessary, weld the joint where leakage is present. Refer to Fastener Tightening Specifications .

Is there still exhaust leakage and/or excess noise.

--

--

System OK

Exhaust Leakage - Not OBD II Chevrolet/Oldsmobile

Step

Action

Values

Yes

No

1

Check for improperly installed or misaligned components.

Are there any improperly installed or misaligned components?

--

Go to Step 2

Go to Step 3

2

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

Is there still exhaust leakage and/or excess noise?

--

Go to Step 3

System OK

3

Check for loose connections at the exhaust manifold or the three way catalytic converter.

Are there any loose connections at the exhaust manifold or the three way catalytic converter?

--

Go to Step 4

Go to Step 5

4

Tighten all fasteners to specifications. Refer to Engine Mechanical.

Is there still exhaust leakage and/or excess noise?

--

Go to Step 5

System OK

5

Check for a cracked or broken exhaust manifold.

Is the exhaust manifold cracked or broken?

--

Go to Step 6

Go to Step 7

6

Replace any cracked or broken exhaust manifolds. For the 3.1 L engine, refer to Engine Mechanical. For the 3.4 L engine, refer to Engine Mechanical.

Is there still exhaust leakage and/or excess noise?

--

Go to Step 7

System OK

7

Check for any leakage at the crossover pipe connection.

Is there any leakage at the crossover pipe connection?

--

Go to Step 8

Go to Step 9

8

Tighten the nuts and bolts to specifications. Refer to Fastener Tightening Specifications .

Is there still exhaust leakage and/or excess noise?

--

Go to Step 9

System OK

9

Check for any damaged or worn seals.

Are there any damaged or worn seals?

--

Go to Step 10

Go to Step 11

10

Replace any damaged or worn seals.

Is there still exhaust leakage and/or excess noise?

--

Go to Step 11

System OK

11

Check for a burned or rusted extension pipe.

Is there a burned or rusted extension pipe?

--

Go to Step 12

Go to Step 13

12

Replace the extension pipe, and muffler assembly if not previously serviced.

Is there still exhaust leakage and/or excess noise?

--

Go to Step 13

System OK

13

Check for a burned or rusted muffler.

Is there a burned or rusted muffler?

--

Go to Step 14

Go to Step 15

14

Replace the muffler/tail pipe assembly. Refer to Muffler .

Is there still exhaust leakage and/or excess noise?

--

Go to Step 15

System OK

15

Check for leakage at the exhaust component joints or couplings, if previously serviced. Is there any leakage at the exhaust component joints or couplings?

--

Go to Step 16

--

16

Replace the seals and tighten the flange bolts to specifications. If necessary, weld the joint where leakage is present. Refer to Fastener Tightening Specifications .

Is there still exhaust leakage and/or excess noise.

--

--

System OK