Product Overview

Summary: This Exhaust System Repair Safe Operating Procedure sets out a clear, safe and compliant method for inspecting, repairing and replacing vehicle exhaust components. It helps Australian workshops control hazards such as hot surfaces, fumes, working under raised vehicles and power tool use, while improving quality and consistency of repair work.

Exhaust system repair work exposes mechanics and apprentices to a combination of risks – from hot exhaust components and toxic gases, to working under hoisted vehicles and handling rusted, seized fittings. This Exhaust System Repair Safe Operating Procedure provides a structured, step‑by‑step process for planning, conducting and finalising exhaust repairs in a way that prioritises safety, compliance and workmanship. It guides workers from initial vehicle intake and fault diagnosis through to safe lifting, system isolation, component removal, installation, leak testing and final sign‑off.

Designed for Australian automotive workshops, dealerships and fleet maintenance operations, this SOP helps businesses demonstrate due diligence under WHS legislation while lifting the standard of everyday repair work. It clarifies required PPE, safe use of hoists and stands, control of fumes in enclosed workshops, and correct handling and disposal of damaged exhaust components, including catalytic converters and diesel particulate filters. By embedding this SOP into your training and daily operations, you reduce the likelihood of crush injuries, burns, fume exposure and rework, while presenting a professional, consistent service to your customers.

Key Benefits

• Reduce the risk of crush injuries, burns and fume exposure during exhaust system repairs.
• Ensure consistent, high‑quality diagnostic, removal and installation practices across all technicians.
• Demonstrate compliance with Australian WHS duties for plant, hazardous atmospheres and workshop safety.
• Streamline training and onboarding for new and apprentice mechanics with a clear, documented procedure.
• Minimise rework, comebacks and customer complaints through standardised leak testing and quality checks.

Who is this for?

• Automotive Technicians
• Light Vehicle Mechanics
• Heavy Vehicle Mechanics
• Workshop Supervisors
• Service Managers
• WHS Officers in Automotive Workshops
• Fleet Maintenance Managers
• Apprentice Mechanics and Trainers

Hazards Addressed

• Crush injuries from vehicle hoists, jacks and stands failing or being used incorrectly
• Burns from hot exhaust components, catalytic converters and turbochargers
• Inhalation of exhaust gases (carbon monoxide, nitrogen oxides and particulates) in poorly ventilated workshops
• Exposure to metal fumes, rust, dust and debris during cutting, grinding or welding of exhaust components
• Noise exposure from impact tools, grinders and cutting equipment
• Eye injuries from flying particles during cutting, grinding or chiselling seized fasteners
• Musculoskeletal injuries from awkward postures and manual handling of exhaust components under vehicles
• Fire and explosion risks when cutting or welding near fuel lines, underbody coatings or flammable residues
• Electrical hazards when working around oxygen sensors, wiring looms and electronic exhaust components

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities (Mechanics, Supervisors, WHS Representatives)
• 4.0 Required Competencies and Training
• 5.0 Tools, Equipment and Materials
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre‑Job Planning and Risk Assessment (Including Pre‑Start Checks)
• 8.0 Vehicle Intake, Identification and Verification
• 9.0 Safe Vehicle Lifting, Supporting and Isolation Procedures
• 10.0 Exhaust System Inspection and Fault Diagnosis
• 11.0 Safe Removal of Exhaust Components (Including O2 Sensors and DPFs)
• 12.0 Installation of Replacement Components and Fasteners
• 13.0 Use of Cutting, Grinding and Welding Equipment on Exhaust Systems
• 14.0 Ventilation and Control of Exhaust Fumes in the Workshop
• 15.0 Leak Testing, Noise Checks and Final Quality Inspection
• 16.0 Housekeeping, Waste Management and Disposal of Removed Components
• 17.0 Emergency Procedures (Fire, Fume Exposure, Crush Injury, Burns)
• 18.0 Environmental Considerations (Emissions‑related Components)
• 19.0 Record Keeping, Sign‑off and Continuous Improvement
• 20.0 Review, Audit and Document Control

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Part 4.1 Hazardous work and Part 5.1 Plant and structures
• Safe Work Australia – Code of Practice: Managing Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing the Work Environment and Facilities
• Safe Work Australia – Code of Practice: Hazardous Manual Tasks
• AS/NZS 4024 series: Safety of machinery (relevant to hoists and workshop plant)
• AS/NZS 2550.9: Cranes, hoists and winches – Vehicle hoists
• AS/NZS 1715: Selection, use and maintenance of respiratory protective equipment
• AS/NZS 2161 series: Occupational protective gloves
• AS/NZS 1337.1: Personal eye protection
• AS/NZS 1270: Acoustics – Hearing protectors