Chevrolet Sonic Repair Manual: Catalytic Converter Replacement (LUV)

Removal Procedure

Warning:

Refer to Exhaust Service Warning.

Warning:

Refer to Protective Goggles and Glove Warning.

1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement.
2. Remove the catalytic converter heated oxygen sensor - 1. Refer to Heated Oxygen Sensor Replacement - Sensor 1.



3. Remove the catalytic converter to the turbocharger clamp fastener (1) and discard the clamp (2).
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
5. Remove the drivetrain and front suspension frame skid plate. Refer to Drivetrain and Front Suspension Frame Skid Plate Replacement.



6. Remove the exhaust front pipe fasteners (1) and discard the exhaust gasket (2).


7. Remove the catalytic converter brace fasteners (1) from the catalytic converter brace (2).
8. Remove the catalytic converter.

Installation Procedure

1. Install the catalytic converter into the catalytic converter brace (2) and loosely tighten the fasteners (1).


2. Install a NEW clamp into the position shown and loosely tighten the clamp fastener (1).



Caution:

Refer to Fastener Caution.

3. Install the exhaust front pipe (3) to the catalytic converter with a NEW gasket (2) and tighten the fasteners (1) to 22 Y (16 lb ft)

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4. Tighten the catalytic converter brace fasteners (1) to 22 Y (16 lb ft)

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5. Install the drivetrain and front suspension frame skid plate. Refer to Drivetrain and Front Suspension Frame Skid Plate Replacement.
6. Lower the vehicle.


7. Tighten the turbocharge clamp fastener (1) to 13 Y (115 lb in)

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8. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement.
9. Install the catalytic converter heated oxygen sensor - 1. Refer to Heated Oxygen Sensor Replacement - Sensor 1.
10. Start the engine and check for exhaust leaks.

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