GM Chevy Mid-Size Cars 1964-1988 Repair Guide



See Figures 1 and 2

Safety glasses should be worn at all times when working on or near the exhaust system. Older exhaust systems will almost always be covered with loose rust particles which will shower you when disturbed. These particles are more than a nuisance and could injure your eye.

Whenever working on the exhaust system always keep the following in mind:

  1. Check the complete exhaust system for open seams, holes loose connections, or other deterioration which could permit exhaust fumes to seep into the passenger compartment.
  3. The exhaust system is supported by free-hanging rubber mountings which permits some movement of the exhaust system, but does not permit transfer of noise and vibration into the passenger compartment. Do not replace the rubber mounts with solid ones.
  5. Before removing any component of the exhaust system, ALWAYS squirt a liquid rust dissolving agent onto the fasteners for ease of removal. A lot of knuckle skin will be saved by following this rule.
  7. Annoying rattles and noise vibrations in the exhaust system are usually caused by misalignment of the parts. When aligning the system, leave all bolts and nuts loose until all parts are properly aligned, then tighten, working from front to rear.
  9. When replacing a muffler and/or resonator, the tailpipe(s) should be checked. Often, the same wear or damage which caused a vehicle's muffler or resonator to fail will have taken the same toll on the tailpipe.
  11. When installing exhaust system parts, make sure there is enough clearance between the hot exhaust parts and pipes and hoses that would be adversely affected by excessive heat. Also make sure there is adequate clearance from the floor pan to avoid possible overheating of the floor.
  13. Exhaust pipe sealers should be used at all slip joint connections except at the catalytic convertor. Do not use any sealers at the convertor as the sealer will not withstand convertor temperatures.

Click image to see an enlarged view

Fig. Fig. 1: Exploded view of an exhaust system-Monte Carlo SS

Click image to see an enlarged view

Fig. Fig. 2: Replacing the manifold catalytic converter on the inline 6-cylinder engine