GM Service Manual Online
For 1990-2009 cars only

Complaint/Condition

Possible Cause(s)

Correction(s)

Leaking Exhaust Gases

Leaks at pipe joints.

Weld joint.

Damaged or improperly installed gaskets.

Replace gaskets as necessary.

Loose exhaust pipe connections.

Tighten stud nuts or bolts to specification.

Burned or rusted out exhaust pipes.

Replace as required.

Exhaust Noises (includes noises at various road speeds and idle).

Leaks at manifold or pipe connections.

Tighten leaking connection fasteners to specified torque. Replace gasket as required.

Damaged flex pipe.

Replace front exhaust pipe.

Burned or blown out muffler.

Replace muffler assembly.

Burned or rusted out exhaust pipe/ resonator.

Replace exhaust pipe assembly.

Exhaust pipe leaking at manifold flange.

Torque attachment nuts.

Exhaust pipe/muffler hangers.

Damaged, missing or binding.

Replace or adjust hanger(s).

Update intermediate pipe isolator, if required.

Exhaust manifold cracked or broken.

Replace manifold.

Leak between manifold and cylinder head.

Replace gaskets, tighten manifold to cylinder head stud nuts or bolts to specifications.

Loss of Engine Power and/or Internal Rattles in Muffler.

Dislodged tuning tubes and/or baffles in muffler.

Replace muffler.

Poor acceleration and/or hesitation.

Damaged exhaust pipe.

Replace exhaust pipe.

Plugged three way catalytic converter (may result from serious engine malfunction).

Check exhaust back pressure and replace three way catalytic converter, exhaust pipe, or muffler as required.

Important: The muffler should move in the isolator block a minimum of 1.60 mm (1/16 in.) vertically and 3 mm (1/18 in.) horizontally to prevent vibrations from being transmitted into the vehicle's body.

Important: When a catalytic converter's catalyts fails, pieces of the converter can become lodged in the muffler causing poor acceleration/hesitation. A plugged catalytic converter can also cause the engine not to start when exhaust flow is completely blocked.