GM Service Manual Online
For 1990-2009 cars only

Step

Action

Value(s)

Yes

No

1

Inspect for improperly installed or misaligned components.

Are there any improperly installed or misaligned components?

--

Go to Step 2

Go to Step 3

2

Reinstall and/or align the components and tighten the connections to specifications. Refer to Fastener Tightening Specifications .

Is there still exhaust leakage and/or excessive noise?

--

Go to Step 3

System OK

3

Inspect 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 Fastener Tightening Specifications .

Is there still exhaust leakage and/or excessive noise?

--

Go to Step 5

System OK

5

Inspect for a cracked or broken exhaust manifold.

Are there cracked or broken exhaust manifolds?

--

Go to Step 6

Go to Step 7

6

Replace the manifold.

Refer to one of the following:

    •  Exhaust Manifold Replacement in Engine Mechanical - 3.1L
    •  Exhaust Manifold Replacement in Engine Mechanical - 3.1L
    •  Exhaust Manifold Replacement in Engine Mechanical - 3.8L
    •  Exhaust Manifold Replacement in Engine Mechanical - 3.8L

Is there still exhaust noise?

--

Go to Step 7

System OK

7

Inspect 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 fasteners to specifications. Refer to Fastener Tightening Specifications .

Is there still exhaust leakage and/or excessive noise?

--

Go to Step 9

System OK

9

Inspect for any damaged or worn seals.

Are there any damaged or worn seals?

--

Go to Step 10

Go to Step 11

10

Replace the damaged or worn seals.

Is there still exhaust leakage and/or excessive noise?

--

Go to Step 11

System OK

11

Inspect 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 excessive noise?

--

Go to Step 13

System OK

13

Inspect for a burned or rusted exhaust 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 Replacement or Muffler Replacement .

Is there still exhaust leakage and/or excessive noise?

--

Go to Step 15

System OK

15

Inspect for leakage at the exhaust component joints and coupling.

Is there leakage at the exhaust component joints or couplings?

--

Go to Step 16

--

16

Replace the seals and tighten the flange bolts to specifications. Refer to Fastener Tightening Specifications .

Is there still exhaust leakage or excessive noise?

--

--

System OK