Exhaust & Emission System Repair Cost Guide
Below are estimated costs for common exhaust and emission system repairs. Labor rate: $125/hour. Parts costs may vary based on vehicle make and model.
Catalytic Converter ReplacementLabor: 1-2 hours ($125-250)
Parts: $300-1,200
Total Estimated Cost: $425-1,450
Labor: 0.5-1 hour ($62-125)
Parts: $50-300
Total Estimated Cost: $112-425
Labor: 2-4 hours ($250-500)
Parts: $200-600
Total Estimated Cost: $450-1,100
Labor: 1-2 hours ($125-250)
Parts: $100-400
Total Estimated Cost: $225-650
Labor: 3-5 hours ($375-625)
Parts: $300-1,500
Total Estimated Cost: $675-2,125
Labor: 1-2 hours ($125-250)
Parts: $150-500
Total Estimated Cost: $275-750
Labor: 1-2 hours ($125-250)
Parts: $75-300
Total Estimated Cost: $200-550
Note: These are estimated costs and may vary depending on vehicle make, model, and condition. Additional repairs may be necessary based on inspection findings. Please contact us for a detailed quote specific to your vehicle.
Common Exhaust & Emission System Repair Procedures
Catalytic Converter Replacement
Steps:
- Perform diagnostic testing to confirm catalytic converter failure
- Raise vehicle on lift and inspect mounting points
- Allow exhaust system to completely cool
- Remove oxygen sensors if present
- Cut or unbolt the old catalytic converter
- Clean mounting surfaces
- Install new catalytic converter with new gaskets
- Reinstall oxygen sensors
- Test for leaks and proper operation
Muffler Replacement
Steps:
- Inspect muffler for damage and confirm replacement need
- Raise vehicle on lift
- Remove hangers and support exhaust system
- Cut or unbolt old muffler
- Clean pipe surfaces
- Install new muffler with proper gaskets or clamps
- Reattach hangers
- Check alignment and clearance
- Test for leaks and noise
Oxygen Sensor Replacement
Steps:
- Connect diagnostic tool to verify sensor failure
- Locate faulty oxygen sensor
- Allow exhaust system to cool completely
- Disconnect sensor electrical connector
- Remove old sensor using special socket
- Apply anti-seize compound to new sensor threads
- Install new sensor and torque to specifications
- Reconnect electrical connector
- Clear diagnostic codes and verify proper operation
Exhaust Manifold Replacement
Steps:
- Allow engine to cool completely
- Remove necessary components for access
- Remove heat shields
- Disconnect oxygen sensors if present
- Remove manifold bolts and manifold
- Clean mounting surface thoroughly
- Install new gasket
- Install new manifold and torque bolts to specification
- Reconnect all components
- Start engine and check for leaks
EGR Valve Replacement
Steps:
- Perform diagnostic testing to confirm EGR valve failure
- Locate EGR valve on engine
- Disconnect electrical connector and vacuum lines
- Remove mounting bolts
- Clean mounting surface
- Install new gasket
- Mount new EGR valve
- Reconnect electrical connector and vacuum lines
- Clear diagnostic codes
- Test for proper operation
Exhaust Pipe Replacement
Steps:
- Raise vehicle on lift
- Support exhaust system
- Remove hangers near repair area
- Cut or unbolt damaged section
- Clean mounting surfaces
- Install new pipe section with proper gaskets or clamps
- Reattach hangers
- Check alignment and clearance
- Start engine and check for leaks
Note:All repairs should be performed by qualified technicians using proper safety equipment and following manufacturer specifications. Repair procedures may vary by vehicle make and model.
Understanding Exhaust and Emission Systems

Catalytic Converter
A catalytic converter is a critical emissions control device that converts harmful pollutants in exhaust gases into less harmful substances before they exit the tailpipe. It transforms carbon monoxide, hydrocarbons, and nitrogen oxides into carbon dioxide, water, and nitrogen through chemical reactions.
Muffler
The muffler is designed to reduce engine noise by controlling how exhaust gases exit your vehicle. It contains a series of chambers and baffles that create opposing sound waves to cancel out loud engine noises while allowing exhaust gases to flow through.
Exhaust Manifold
The exhaust manifold collects exhaust gases from multiple cylinders of the engine and channels them into a single pipe. It's typically the first component in the exhaust system and must withstand extremely high temperatures while maintaining efficient gas flow.
Oxygen Sensor
Also known as an O2 sensor, this device monitors the amount of oxygen in your exhaust gases. It helps the engine's computer adjust the fuel-to-air ratio for optimal engine performance and minimal emissions.
EGR Valve
The Exhaust Gas Recirculation (EGR) valve helps reduce nitrogen oxide emissions by recirculating a portion of exhaust gases back into the engine's combustion chambers. This lowers combustion temperatures and reduces harmful emissions.
Resonator
Working in conjunction with the muffler, the resonator helps fine-tune the exhaust note and further reduces noise. It's designed to cancel out specific sound frequencies that the muffler might not completely address.
DPF (Diesel Particulate Filter)
Found in diesel vehicles, the DPF captures and stores soot and ash particles from the exhaust gas. When full, it undergoes a regeneration process to burn off accumulated particles, helping reduce diesel emissions.
Exhaust Pipes
These pipes connect all components of the exhaust system, carrying gases from the engine to the tailpipe. They're designed to withstand high temperatures and corrosive conditions while maintaining proper flow characteristics.
SCR (Selective Catalytic Reduction)
Common in modern diesel vehicles, SCR systems use a liquid-reductant agent (usually DEF - Diesel Exhaust Fluid) to convert nitrogen oxides into nitrogen and water, significantly reducing emissions.
EVAP System
The Evaporative Emission Control System prevents fuel vapors from escaping into the atmosphere. It captures and stores fuel vapors from the fuel tank and later returns them to the engine to be burned during combustion.
Common Failure Symptoms of Exhaust and Emission Systems
Exhaust and Emission System Components - Warning Signs & Maintenance Guide
Catalytic Converter
Signs of Failure:
- Check Engine Light illumination
- Decreased engine performance
- Rotten egg smell from exhaust
- Rattling noise from under vehicle
- Failed emissions test
Service Schedule: Usually lasts 10+ years or 100,000 miles under normal conditions. No regular maintenance required, but should be inspected during routine service.
Oxygen (O2) Sensors
Signs of Failure:
- Check Engine Light activation
- Poor fuel economy
- Rough idling
- Failed emissions test
Service Schedule: Replacement typically needed every 60,000-100,000 miles.
Exhaust Manifold
Signs of Failure:
- Loud ticking noise, especially when cold
- Exhaust leaks
- Decreased engine performance
- Burning smell
Service Schedule: No regular maintenance required, but should be inspected annually for cracks or leaks.
Muffler
Signs of Failure:
- Louder than normal exhaust noise
- Visible rust or holes
- Dragging on the ground
- Excessive condensation dripping
Service Schedule: Typically lasts 5-7 years. Annual inspection recommended.
EGR Valve
Signs of Failure:
- Rough idle
- Poor acceleration
- Check Engine Light illumination
- Failed emissions test
- Fuel smell
Service Schedule: Clean every 50,000 miles. Replace if malfunctioning.
Exhaust Pipes
Signs of Failure:
- Hissing or popping sounds
- Visible rust or holes
- Exhaust fumes in cabin
- Loose connections
Service Schedule: Annual inspection recommended. Typically last 8-10 years depending on climate and driving conditions.
PCV Valve
Signs of Failure:
- Oil leaks
- Increased oil consumption
- Check Engine Light illumination
- Rough idle
Service Schedule: Replace every 20,000-50,000 miles, depending on vehicle manufacturer recommendations.
Note: All service intervals are general guidelines. Consult your vehicle's owner's manual for specific maintenance schedules and recommendations.
How It Works
- Get a quote online or set-up a time to have your vehicle looked at.
- Pick time slots that work for you, easily, online.
- We will confirm appointments and send reminders.
- Our mechanics bring everything that is needed to you.
- All you have to do is provided a safe area for the work to be performed.
What we need from you
- A safe place to work on your vehicle
- No working on the side of busy roads
- No working on unstable or steep surfaces.
- We do not perform repairs during severe weather.
- Authorization from a property owner or management.
- Repair work done in a parking lot or at your requires permission.
- We do not do repairs in areas restricted by law.
Common Questions
Service Area
Our primary service area is greater Grand Rapids and includes Comstock Park, East Grand Rapids, Grandville, Kentwood, Walker, and Wyoming
Our secondary service area is provided by our Belding location and includes: Belding, Greenville, Ionia and the sorrounding areas.
Contact us if you have any questions about where we provide services.