For 1990-2009 cars

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.