Exhaust System Uniform Inspection Guidelines Article Text

* EXHAUST SYSTEM UNIFORM INSPECTION GUIDELINES *
Article Text
1989 Volkswagen Golf
For Volkswagen Technical Site
Copyright 1998 Mitchell Repair Information Company, LLC
Monday, August 23, 1999 11:25PM
ARTICLE BEGINNING
GENERAL INFORMATION
Exhaust Systems
All Makes & Models
Updated:
September, 1996
MAP UNIFORM INSPECTION GENERAL GUIDELINES

OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program (MAP) is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
The Motorist Assurance Program was established as an
industry-wide effort to address concerns raised by regulators, the
media and consumers questioning our ethics and methods of doing
business. The automotive repair industry had been bombarded by months
of negative stories in the media and scrutiny from state and federal
regulators who focused on how the need for repairs is determined. MAP
was formed as an industry response to this issue.
Our mission is to strengthen the relationship between the
consumer and the auto repair industry. We produce materials that give
motorists the information and encouragement to take responsibility for
their vehicles - through proper, manufacturer-recommended,
maintenance. We encourage participatinf service and repair shops
(including franchisees and dealers) to adopt a Pledge to their
Customers and the Motorist Assurance Program developed Standards of
Service. All participating service providers have agreed to subscribe
to this Pledge and to adhere to the promulgated Standards of Service
which demonstrates to their customers that they are serious about
customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made according to industry guidelines.
After learning that neither the car manufacturers nor any other source
had complete guidelines, leading industry organizations, along with
other industry participants banded together to address this
challenging task. During the past two and a half years, they
successfully developed industry inspection guidelines for the
following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical systems.
Guidelines for Drive Train and Transmision are currently being
promulgated. Revisions to the inspection guidelines for Exhaust,
Brakes/ABS and Steering and Suspension Systems, which were issued two
years ago, are now being published for implementation beginning spring
1997. Participating shops utilize these Uniform Inspection Guidelines
as part of the inspection process and for communicating their findings

Article Text (p. 2)
to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
concerned with auto repair and/or consumer protection are conducted.
Feedback from these representatives are brought back to members, and
the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers arbitration through MAP/BBB-CARE in cooperation with the
Council of Better Business Bureaus and individual participating
Bureaus. MAP "piloted" in Indianapolis and Pittsburgh during spring,
1996 - and publicized "roll-outs" in New Jersey, Detroit (MI), Chicago
(IL) and Richmond (VA) were conducted. To put some "teeth" in the
program, and accreditation requirement for shops was initiated. The
requirements are stringent and a self-policing method has been
incorporated which includes the "mystery shopping" of outlets. In
addition, a committee of service providers had been working diligently
developing standards for newspaper, television and Internet
advertising.
We welcome you to join us as we continue our outreach ...
with your support, both the automotive repair industry and your
customers will reap the benefits. Please visit MAP at our Internet
site: www.hunter.com/map.htm or contact us at:
808 17th Street, NW Suite 200
Washington, D.C. 20006
Ph. (202) 466-7050 Fax (202) 223-9569
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS

It is MAP policy that all exhaust, brake, ABS, steering and
suspension, wheel alignment, tires and wheels, driveline, engine
performance and maintenance and heating, ventilation and air
conditioning services be offered and performed under the guidelines
and procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be required or suggested.
In addition, suggestions may be made to satisfy the needs expressed by
the customer.
This section lists the various parts and conditions that
indicate required or suggested service or part replacement. Although
this list is extensive, it is not inclusive. In addition to this list,
a technician may make a suggestion. This suggestion must be based on
substantial and informed experience or the vehicle manufacturer's

Article Text (p. 3)
recommended service interval.

Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
*
Example: An exhaust pipe has corroded severely and has a hole

in it through which exhaust gases are leaking. Replacement of
the exhaust pipe in this case is required due to functional
failure.
Example: A brake rotor has been worn to the point where it

measures less than the vehicle manufacturer's specifications.
Replacement of the rotor is required because it does not meet
design specifications.
Some conditions indicate that a service or part replacement

is suggested because the part is close to the end of its useful life
or to address a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may
only be to suggest service.
*
Example: An exhaust pipe is rusted, corroded or weak, but no

leaks are present. In this case, the exhaust pipe has not
failed. However, there is evidence that the pipe may need
replacement in the near future. Replacement of the pipe may
be suggested for the customer's convenience in avoiding a
future problem.
Example: The customer desires improved ride and/or handling,

but the vehicle's shocks or struts have not failed. In this
case, replacement may be suggested to satisfy the customer's
wishes. In this case, replacement of the shocks or struts may
not be sold as a requirement.
A customer, of course, has the choice of whether or not a

shop will service his or her vehicle. He or she may decide not to
follow some of your suggestions. When a customer declines to authorize
a service or repair indicated in the MAP Uniform Inspection Guidelines
as "required," a MAP shop may refuse service on that system, if
proceeding with the work could create or continue an unsafe or
unsatisfactory condition.
The following reasons may be used for required and suggested
services. These codes are shown in the "Code" column of the Uniform
Inspection Guidelines that follow.
PART REPLACEMENT CODE IDENTIFICATION

NOTE:
Refer to the following tables for definitions of the codes

listed in the condition/procedure tables for the specific
components that may need to be replaced.

Article Text (p. 4)
A - PART NO LONGER PERFORMS INTENDED PURPOSE
Reasons to Require Repair
Reasons to Suggest Repair
or Replacement
or Replacement
A - Part no longer performs

1 - Part is close to the end of
intended purpose
its useful life (just above
discard specifications, or
weak; failure likely to
occur soon, etc.)
B - PART DOES NOT MEET DESIGN SPEC., REGARDLESS OF PERFORMANCE
or Replacement
or Replacement
B - Part does not meet a design 2 - To address a customer need,
specification (regardless
convenience, or request (to
of performance)
stiffen ride, enhance
performance, eliminate noise
etc.)
C - PART IS MISSING
or Replacement
or Replacement
C - Part is missing
3 - To comply with maintenance
recommended by the vehicle's
Original Equipment
Manufacturer (OEM)
4 - Technician's recommendation
based on substantial and
informed experience
EXHAUST
SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER
VEHICLE OPERATION
WARNING: Federal EPA rules prohibit altering an exhaust system in
any way that defeats the emission reduction components of
a vehicle. Be sure to review and adhere to EPA policy on
removing and replacing catalytic converters. Where state or
local laws are stricter, they take precedence over these
guidelines.
Some exhaust systems are of a welded design. It is not
required that the entire system be replaced. Determine the need to

Article Text (p. 5)
replace individual components based on conditions of component.
CATALYTIC CONVERTERS
CAUTION: Before working on an exhaust system, review EPA regulations
on removing and replacing catalytic converters.
NOTE:
Any time a converter has failed, further diagnosis is

required to determine the reason(s) for converter failure.
Advise customer of cause(s).
CATALYTIC CONVERTERS
Condition
Code
Procedure
Air injection tube broken

A
Air injection tube burnt

A
Air injection tube damaged B
Air injection tube leaking A
Air injection tube loose

A
Require repair or replacement of
injection tube or replacement of
Air injection tube
A
catalytic converter.
restricted
Air injection tube threads B
damaged
Air injection tube threads A
stripped (threads missing)
Body cracked
B
Converter empty
A
Require repair or replacement.
Converter fill plug missing C
Converter missing
C
Require replacement.
Exhaust gases leaking

A
Flanges leaking
A
Require repair or replacement of
flanges.
Inlet pipes cracked

B
Internal rattle (except

B,2 Further inspection required.
pellet-type)
See note (1) below.

Article Text (p. 6)
Mounting brackets that are A

part of converter broken
Obvious overheating
Further inspection required.
See note (2) below.
Outlet pipes cracked

B
Pieces of catalyst material A,1 Suggest replacement.

found downstream
Plugged
A
Require replacement. See note (3)
Testing has determined that A

existing converter has been
lead-poisoned, contaminated
or failed testing
NOTE: (1) If the converter is breaking up, suggest converter

replacement. If an object has fallen into the converter,
remove the object.
(2) Further diagnosis is required to determine the cause of
the overheating. Replacement of the converter may not be
necessary.
(3) Determine cause and correct to ensure that new converter
will not become plugged.
EXHAUST & TAIL PIPES

NOTE:
For pipes with resonators, also refer to the section on

Mufflers and Resonators.
EXHAUST & TAIL PIPES
Condition
Code
Procedure
Bracket broken
A
Pipe bent out of position B

Pipe broken
A
Pipe cracked
B
Pipe leaking
A
Pipe missing
C
Pipe plugged
A
Pipe weak due to corrosion, A,1 Suggest replacement.

Article Text (p. 7)
but no leaks present
Weld(s) broken
A
EXHAUST CONNECTIONS
EXHAUST CONNECTIONS
Condition
Code
Procedure
Attaching hardware incorrect B

Require replacement of hardware.
Corroded, affecting
A,1 Suggest replacement.
structural integrity
Incorrect type (i.e. flange, B

ball & socket etc.)
Leaking
A
Require repair.
Loose
A
Require repair.
HANGERS
HANGERS
Condition
Code
Procedure
Broken
A
Corroded, affecting structural integrity A,1 Suggest replacement.
Incorrect type
B
Loose
A
Require repair or
replacement.
Missing
C
Out of position
B
Require repair or
replacement.
Rubber deteriorated
HEAT RISERS
HEAT RISERS
Condition
Code
Procedure

Article Text (p. 8)
Broken
A
Require replacement of affected
parts.
Diaphragm inoperative
A
Further inspection required.
See note (1) below.
Leaking
A
Rattles
B,2 Suggest replacement of affected
parts.
Seized
A
Require replacement of affected
parts.
Spring(s) broken
B
Require replacement of spring(s).
Spring(s) inoperative
A
Require replacement of spring(s).
NOTE: (1) If the inoperative diaphragm is separate from the heat

riser, then require replacement of the inoperative
diaphragm. If the inoperative diaphragm is part of the heat
riser, then replace the heat riser.
HEAT SHIELDS
HEAT SHIELDS
Condition
Code
Procedure
Bent
B
Broken
A
Corroded, affecting
structural integrity
Loose
A
Require repair.
Missing
C
MANIFOLDS: CAST & TUBE TYPE

MANIFOLDS: CAST & TUBE TYPE
Condition
Code
Procedure
Air injection tube in

A
Require repair of injection tube
manifold broken
or replacement of manifold.

Article Text (p. 9)

A,1 Suggest replacement of injection
manifold corroded,
tube or manifold.
affecting structural
integrity

A
manifold leaking
or replacement of manifold.

A
Require repair.
manifold loose

A
Require replacement of injection
manifold restricted
tube or manifold.

A
manifold threads damaged
manifold.

A
Require replacement of injection
manifold threads stripped
tube or manifold.
(threads missing)
Bolt(s) broken
A
Bolt(s) loose
A
Require tightening or replacement
of bolts.
Bolt(s) missing
C
Gasket leaking
A
Require tightening or replacement
of gasket.
Heat stove bent

B
Require repair or replacement
of stove. See note (1) below.
Heat stove broken

A
Require replacement of stove.
See note (1) below.
Heat stove corroded,

A,1 Suggest replacement of stove.
affecting structural
See note (1) below.

integrity
Heat stove missing

C
Require replacement of stove.
See note (1) below.
Manifold broken
A
Manifold cracked
B
Manifold warped
A
Stud(s) broken
A
Require replacement of stud.

Article Text (p. 10)
Stud(s) missing
C
Stud(s) threads damaged

A
Require repair/replacement of stud
Stud(s) threads stripped

A
(threads missing)
NOTE: (1) Stove may not be available separately; this may require
replacement of manifold.
MUFFLERS & RESONATORS

MUFFLERS & RESONATORS
Condition
Code
Procedure
Body shell distorted, affecting

A
performance or structural integrity
Corrosion hole
A
Missing
C
Mounting bracket(s) broken

A
Mounting bracket(s) cracked

B
Require repair or
replacement.
Nipple cracked
A
Nipple loose
B
Outer wrap peeling (exhaust not leaking) A,1 Suggest replacement.
Plugged
A
Puncture (other than a drain hole)

A
Rattling or knocking noise from muffler B
Seam(s) open (exhaust leaking)

A
Sound quality unsatisfactory

B,2 Suggest replacement
to address customer
need and/or request.
Split (exhaust leaking)

A
Weak due to corrosion, but no leaks

present

Article Text (p. 11)
END OF ARTICLE

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* EXHAUST SYSTEM UNIFORM INSPECTION GUIDELINES *

MAP UNIFORM INSPECTION GENERAL GUIDELINES