Inspect and replace light vehicle exhaust components

This standard is about inspecting exhaust components for replacement or continued serviceability and removing and replacing components identified as being faulty, damaged, deteriorated or where the customer has requested replacement.

P1 select and wear suitable personal protective equipment throughout all exhaust system component inspection and replacement activities
P2 seek confirmation that all equipment is safe prior to use
P3 carry out inspections on exhaust system components relevant to the faults reported
P4 conduct all inspection and replacement activities following:
P4.1 vehicle, equipment and component manufacturers’ recommendations
P4.2 your workplace procedures
P4.3 health and safety requirements
P5 ensure your inspection clearly identifies the serviceability of the exhaust system component and the cause of any faults identified
P6 make clear and suitable recommendations for further action based upon the results of your inspection to the relevant person(s)
P7 carry out removal and replacement activities using:
P7.1 suitable tools and equipment
P7.2 the correct techniques
P7.3 suitable exhaust components and fixings
P8 ensure that the replacement exhaust system components are correctly fitted and aligned prior to releasing the vehicle to the customer
P9 advise customers of any running in procedures for new exhausts
P10 dispose of removed exhaust system components safely to comply with legal requirements and your workplace procedures
P11 complete all inspection and replacement activities within the agreed timescale
P12 promptly report any anticipated delays in completion to the relevant person(s)

Legislative and organisational requirements and procedures
K1 the current health and safety legislation and workplace procedures relevant to workshop practices and personal and vehicle protection
K2 the current legal requirements relating to vehicle exhaust systems
K3 your workplace procedures for:
K3.1 the referral of problems
K3.2 reporting of delays to the completion of work
K3.3 personal protection
K4 how to dispose of removed components in line with health and safety and legal requirements
K5 the importance of working to agreed timescales and keeping others informed of progress
K6 the importance of promptly reporting anticipated delays to the relevant person(s)
K7 the relationship between time and costs
Tools and equipment
K8 the tools and equipment used for the removal and replacement of exhausts, for testing and resetting and how to select and use them
K9 how to perform safety and operational checks on tools and equipment
K10 how to use cutting equipment to make straight through section cuts
Exhaust inspection, removal and replacement operations
K11 the purpose, function and layout of vehicle exhaust systems and their associated components
K12 the common faults associated with vehicle exhaust system components
K13 the fault identification methods and procedures associated with vehicle exhaust system components
K14 the removal and replacement procedures associated with vehicle exhaust systems, including health and safety requirements
K15 the construction of vehicle exhaust system components
K16 when and how to use heat to remove seized components if applicable
K17 how to check that replacement components are of the correct type and quality for the vehicle and conform to legal requirements where relevant i.e type approved
K18 how to make adjustments to exhaust system components
K19 how to check exhaust system components are functioning correctly after refitting and or replacement and the importance of doing so before release to the customer
K20 the importance of ensuring customers are advised of the running in procedures for new exhausts prior to leaving your premises
K21 how to work safely avoiding injury to yourself, to others and damage to vehicles
K22 exhaust related emissions control systems
K23 how to remove, replace and clean or rethread broken, damaged or seized exhaust fixings

​1. Exhaust system components include:
1.1. complete exhaust system (separately or as complete unit)
1.2. individual component, e.g. silencer, link pipe, tail pipe etc.
1.3. catalytic converters/particulate filters and associated components and fluids
1.4. lambda sensors
1.5. Selective catalytic reduction (SCR) system and associated components and fluids
1.6. NOx reduction system
2. Tools and equipment include:
2.1. hand tools
2.2. special purpose tools
2.3. lifting and supporting equipment
2.4. heating and cutting equipment
2.5. electronic equipment
2.6. diagnostic equipment

​This section contains examples and explanations of some of the terms used but does not form part of the standard.
Agreed timescales
Examples include job times set by your company or agreed with a specific customer.
Catalytic converter associated components and fluids
To include fuel treatments, for example Eolys
Complete exhaust system
This is a system from the engine to exit of the vehicle - to include additional exhaust components (e.g. gaskets, hangers, mounting rubbers, clamps, sleeves) and consumables (e.g. exhaust sealing compound)
Heating and cutting equipment
To include oxy-acetylene, plasma cutters, induction heating equipment etc.
Lambda sensors
To include pre and post catalytic converter, wide band, zirconia, titania/titanium.
Manufacturers
This term can include product and vehicle manufacturers
Selective catalytic reduction (SCR) system components and fluids
To include exhaust gas treatment, for example Ad-blue
Special purpose tools
Examples include exhaust chain cutter, exhaust flaring dolly, thread cutting taps and dies, stud removal tools