GM Service Manual Online
For 1990-2009 cars only

Step

Action

Value(s)

Yes

No

1

Check for improperly installed or misaligned components.

Are there improperly installed or misaligned components?

--

Go to Step 2

Go to Step 3

2

Align the components and tighten the connections to specifications.

Is there exhaust leakage and/or excessive noise?

--

Go to Step 3

System OK

3

Check for loose connections at the exhaust manifold or the Three Way Catalytic Converter.

Are there loose connections?

--

Go to Step 4

Go to Step 5

4

Tighten all fasteners to specifications. Refer to Fastener Tightening Specifications .

Is there exhaust leakage and/or excessive noise?

--

Go to Step 5

System OK

5

Inspect the exhaust manifold.

Is the exhaust manifold cracked or broken?

--

Go to Step 6

Go to Step 7

6

Replace the exhaust manifold.

Refer to Exhaust Manifold Replacement In Engine Mechanical - 2.4L or Intake Manifold Replacement in Engine Mechanical - 3.4L.

Is there exhaust leakage and /or excessive noise?

--

Go to Step 7

System OK

7

Inspect the crossover pipe connections.

Is there leakage at the crossover pipe connections?

--

Go to Step 8

Go to Step 9

8

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

Is there exhaust leakage and /or excessive noise?

--

Go to Step 9

System OK

9

Inspect all seals.

Are the seals damaged or worn?

--

Go to Step 10

Go to Step 11

10

Replace the damaged or worn seals.

Is there exhaust leakage and /or excessive noise?

--

Go to Step 11

System OK

11

Inspect the extension pipe.

Is the extension pipe burned or rusted?

--

Go to Step 12

Go to Step 13

12

Replace the extension pipe.

Is there exhaust leakage and /or excessive noise?

--

Go to Step 13

System OK

13

Inspect the muffler.

Is the muffler burned or rusted?

--

Go to Step 14

Go to Step 15

14

Replace the muffler/tailpipe assembly. Refer to Tail Pipe Replacement .

Is there exhaust leakage and /or excessive noise?

--

Go to Step 15

System OK

15

Inspect for leakage at the exhaust component joints or couplings (if not previously serviced).

Is there leakage?

--

Go to Step 16

System OK

16

Replace the seals and tighten flange bolts to specifications or weld the joints where leakage is present.

Is there leakage?

--

Go to Step 1

System OK