How to Repair a Car's Exhaust System

A car's exhaust system removes harmful carcinogens from the engine and helps keep the motor running at peak efficiency. If it is malfunctioning, it affects the car's performance and can even pose a health hazard as harmful toxins are released. Usually only a trained mechanic should repair a car's exhaust system, but if you are sufficiently knowledgeable about cars, you can conduct the repair yourself.

Difficulty: Moderately Challenging

Instructions

Things You'll Need:

• Jack or hydraulic lift
• Soldering iron, solder
• Pipe patches
• Replacement bolts
• Welding torch
• Bolt cutters
• Socket wrenches
• Replacement parts

1. Raise the car on a jack or hydraulic lift so that you can examine the exhaust system safely, without the threat of the car collapsing on you.

2. Determine the spot on the exhaust system that needs repair. The exhaust system consists of a number of different parts: the exhaust manifold, the oxygen gauge, the catalytic converter, the muffler and the exhaust pipe, as well as different pipes connecting these various parts (usually, only one part of the system is damaged, either through rust and corrosion, bumps on the road or product malfunction). The causes of the damage are myriad, but the solution is invariably either to repair a leaky hole or to replace the malfunctioning part.

3. Patch any leaky holes with a soldering iron, using a metal patch to seal the hole if necessary. This should be done only if the damaged area consists of one leak and the remainder of the car's exhaust system is intact. Otherwise, the entire part will need to be replaced.

4. Remove the exhaust system part by part, starting with the tailpipe and moving backwards to the damaged component. Sometimes, you will be able to remove each part simply by cutting the bolts that hold it to the frame. Usually, however, you will need to use a welding torch to uncouple it and remove any support hangers, in which case take care not to damage any of the car's surrounding components.

5. Replace the faulty component (or components) with a new one, making sure that it matches the parameters of your car and the remainder of your exhaust system.

6. Reconnect the remainder of the exhaust system, starting with the new part and working backwards along the system until you reach the tailpipe.

7. Double-check the fittings and welds for leaks. You can do this with a visual inspection, but you might also want to turn the engine on and run it to see if any exhaust is escaping.

8. Weld the support hangers back on, securing the exhaust system in place.

Tips & Warnings

• It may be necessary to run the car's engine to determine the place in the exhaust system that needs repair. Make sure you have proper ventilationand that the exhaust fumes do not build up in the area.