Exhaust System Inspection Checklist

This exhaust system inspection checklist ensures complete evaluation of all exhaust components for leaks, damage, emissions compliance, and carbon monoxide risk. Aligned with EPA Clean Air Act emission standards, CARB (California Air Resources Board) regulations, and OSHA 29 CFR 1910.94 carbon monoxide exposure limits. Exhaust leaks are a serious safety hazard - complete this inspection at every service lift or whenever exhaust noise or fume complaints are reported.

Industry: Automotive Service
Frequency: Every 12 months / Per Customer Complaint
Estimated Time: 20-30 minutes
Role: Service Technician / Emissions Inspector
Total Items: 30
Compliance: EPA Clean Air Act - Mobile Source Emissions, CARB OBD-II and Emissions Standards, OSHA 29 CFR 1910.94 (Carbon Monoxide Limits), EPA CAA Section 203 (Emissions Tampering Prohibition), SAE J1874 Catalytic Converter Standards

Exhaust Manifold & Header Inspection

Inspect exhaust manifolds and headers for cracks, leaks, and broken studs. Manifold leaks create carbon monoxide risk and affect engine performance.

Exhaust manifold(s) free of visible cracks, especially between ports?
All exhaust manifold studs and bolts intact (no broken/missing fasteners)?
No evidence of exhaust leak at manifold-to-head gasket (no soot/carbon streaks)?
Flex pipe section (if equipped) intact - no cracks or separation?
Oxygen sensor bungs and sensors installed securely with no leaks?

Catalytic Converter Inspection & Compliance

Inspect catalytic converter for physical damage, theft, and efficiency. EPA prohibits removing or replacing functional catalytic converters with non-compliant parts.

Catalytic converter(s) present and not removed or replaced with test pipe?
No rattling noise from catalytic converter indicating internal substrate damage?
No evidence of excessive heat damage, discoloration, or melting on cat exterior?
No evidence of attempted catalytic converter theft (fresh cuts, new clamps)?
OBD-II monitor shows catalyst efficiency ready and no P0420/P0430 codes?

Mid-Pipe, Resonator & Muffler Condition

Inspect all exhaust pipe sections, resonators, and muffler for corrosion, holes, and physical damage.

All exhaust pipes free of through-rust holes or severe external corrosion?
Muffler free of holes, separation, or internal noise (rattling)?
All exhaust rubber hangers intact and supporting system properly?
Adequate clearance maintained between exhaust and fuel lines, brake lines, and floor pan?
All exhaust pipe clamps and flanges tight - no exhaust leaks at joints?

Emissions System Components

Verify all emissions-related exhaust components are present, functional, and unmodified.

EGR system (if equipped) functional with no P0400 series codes?
Diesel Particulate Filter (DPF) regeneration status normal - not forced regen needed?
DEF (diesel exhaust fluid) system level adequate and no SCR fault codes?
Tailpipe emissions visual check - no blue (oil), white (coolant), or black (rich) smoke at operating temp?
OBD-II readiness monitors set for emissions inspection (no pending monitors)?

Carbon Monoxide Safety Assessment

Assess carbon monoxide risk from exhaust leaks, particularly for enclosed vehicle inspection or customer safety.

No exhaust fume odor detected in vehicle cabin during inspection?
Floor pan, firewall, and body seals intact - no exhaust entry points into cabin?
Shop exhaust ventilation system operating - vehicle not run in enclosed space?
Any exhaust leaks found communicated to customer as safety-critical item?
Exhaust repair urgency documented (Monitor / Repair Soon / Immediate Safety Stop)?
Photos taken of all exhaust defects for customer documentation?
Written repair estimate provided for all exhaust deficiencies?

Emissions Test Readiness

Verify vehicle is ready for state emissions testing.

All required OBD-II readiness monitors set for state emissions test?
Malfunction Indicator Lamp (MIL) off - vehicle will pass visual inspection portion?
Customer advised if vehicle is ready or not ready for scheduled emissions test?

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Why Use This Exhaust System Inspection Checklist?

This exhaust system inspection checklist helps automotive service teams maintain compliance and operational excellence. Designed for service technician / emissions inspector professionals, this checklist covers 30 critical inspection points across 6 sections. Recommended frequency: every 12 months / per customer complaint.

Ensures compliance with EPA Clean Air Act - Mobile Source Emissions, CARB OBD-II and Emissions Standards, OSHA 29 CFR 1910.94 (Carbon Monoxide Limits), EPA CAA Section 203 (Emissions Tampering Prohibition), SAE J1874 Catalytic Converter Standards, UK MOT Exhaust & Emissions Standards, India BS VI Emission Standards. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Exhaust System Inspection Checklist cover?

This checklist covers 30 inspection items across 6 sections: Exhaust Manifold & Header Inspection, Catalytic Converter Inspection & Compliance, Mid-Pipe, Resonator & Muffler Condition, Emissions System Components, Carbon Monoxide Safety Assessment, Emissions Test Readiness. It is designed for automotive service operations and compliance.

How often should this checklist be completed?

This checklist should be completed every 12 months / per customer complaint. Each completion takes approximately 20-30 minutes.

Who should use this Exhaust System Inspection Checklist?

This checklist is designed for Service Technician / Emissions Inspector professionals in the automotive service industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.