A. Exhaust System Inspection and Repair (11 questions)

1. Inspection (6 questions)

1. Inspect all exhaust system components for noises, rattles, missing parts, configuration, and routing by visual, audible, and thump testing; determine needed repair.

2. Inspect exhaust system for leaks, restrictions, and overheating by visual, audible, back pressure, vacuum, and temperature testing; determine needed repair.

3. Inspect exhaust subsystems [air injection reactor (AIR), exhaust gas recirculation (EGR), oxygen sensor(s) (O2S/HO2S), heat riser/early fuel evaporation (EFE), turbochargers] and mounting hardware; determine needed repair.

4. Visually inspect exhaust system for evidence of tampering (missing/modified and/or improperly installed components); determine needed repair.

5. Inspect exhaust system electrical components; determine needed repair.

6. Inspect engine/transmission mount condition and alignment; determine needed repair.

2. Repair (5 questions)

1. Repair or replace failed or damaged mufflers, pipes, and related components.

2. Repair or replace damaged catalytic converters.

3. Repair or replace exhaust manifolds.

4. Repair or replace exhaust system mounting hardware and related installation components.

5. Repair or replace exhaust subsystems [air injection reactor (AIR), exhaust gas recirculation (EGR), oxygen sensor (O2S/HO2S), heat riser/early fuel evaporation (EFE), turbochargers] and mounting hardware.

B. Emissions Systems Diagnosis (8 questions)

1. Identify failed catalytic converter(s); determine cause of failure; determine needed repair.

2. Identify failed air injection reactor (AIR) system; determine root cause of failure; determine needed repair.

3. Identify failed exhaust gas recirculation (EGR) system; determine root cause of failure; determine needed repair.

4. Identify failed early fuel evaporation (EFE) system [heat riser]; determine root cause of failure; determine needed repair.

5. Identify failed oxygen sensor(s) (O2S/HO2S) component(s) and circuitry; determine cause of failure; determine needed repair.

6. Inspect emission systems for evidence of tampering (missing/modified and/or improperly installed components); determine needed repair.

C. Exhaust System Fabrication (6 questions)

1. Pipe Bending (3 questions)

1. Determine bending method (program card, pattern/copy, or custom).

2. Determine center of bends, rotation of pipe, depth of bends, and pipe diameter(s); perform bending operation.

3. Perform end-forming and hardware installation operations.

4. Determine the cause of pipe material failures that occur during bending operations.

2. Welding and Cutting (3 questions)

1. Select appropriate welding method (gas or MIG); perform welding operation; verify integrity of weld.

2. Set up and adjust welding equipment to repair application; observe applicable personnel, vehicle, and equipment safety procedures.

3. Select appropriate cutting method (gas or mechanical); perform cutting operation.

4. Set up and adjust cutting equipment to repair application; observe applicable personnel, vehicle, and equipment safety procedures.

D. Exhaust System Installation (8 questions)

1. Identify exhaust system configuration and options according to manufacturer’s specifications (routing, single/dual, etc).

2. Select components according to accepted standards regarding material, type, design, and size.

3. Install appropriate exhaust system components (mufflers, resonators, catalytic converters, pipes, and manifolds).

4. Install appropriate exhaust system hardware (clamps, hangers, gaskets, flanges, fasteners, and heat shields).

5. Inspect system for proper exhaust component clearance and routing.

6. Inspect system for proper exhaust component-to-component connection sealing.

7. Install exhaust subsystem components [air injection reactor (AIR), exhaust gas recirculation (EGR) valve, oxygen sensor(s) (O2S/HO2S), early fuel evaporation (EFE) system (heat riser)].

E. Exhaust System Repair Regulations (7 questions)

1. Comply with warranty and diagnostic requirements regarding permissible catalytic converter installations.

2. Comply with requirements regarding prohibited catalytic converter installations.

3. Comply with requirements regarding record keeping.

4. Comply with requirements regarding catalytic converter replacement, location, and type.

5. Comply with requirements regarding replacement of air injection reactor (AIR), exhaust gas recirculations (EGR), oxygen sensor (O2S/HO2S), heat riser [early fuel evaporation (EFE)], and turbocharger systems.

6. Comply with requirements regarding exhaust system configuration.