Chevrolet Sonic Repair Manual: Exhaust Front Pipe Replacement (LUV,LUW)

Removal Procedure

Warning:

Refer to Exhaust Service Warning.

1. Remove the drivetrain and front suspension frame skid plate. Refer to Drivetrain and Front Suspension Frame Skid Plate Replacement.
2. Disconnect the heated oxygen sensor-2. Refer to Heated Oxygen Sensor Replacement - Sensor 2.



3. Remove the 3–way catalytic converter fasteners (1) and disconnect the 3-way catalytic converter (4) from the front pipe.
4. Discard the exhaust gasket (2).


5. Remove the exhaust front pipe (3) to the catalytic converter fasteners (1).
6. Remove the front pipe (3) from the catalytic converter and discard the exhaust gasket (2).

Installation Procedure

1. Install a NEW gasket (2) to the exhaust front pipe.

Caution:

Refer to Fastener Caution.

2. Install the 3-way catalytic converter (4) to the exhaust isolators (3) and tighten the fasteners (1) to 17 Y (13 lb ft)

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3. Position the exhaust front pipe (3) to the catalytic converter with a NEW gasket (2).
4. Install the exhaust front pipe fasteners (1) to the catalytic converter and tighten to 20 Y (15 lb ft)

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5. Connect the heated oxygen sensor-2. Refer to Heated Oxygen Sensor Replacement - Sensor 2.
6. Install the drivetrain and front suspension frame skid plate. Refer to Drivetrain and Front Suspension Frame Skid Plate Replacement.
7. Start the engine and check for exhaust leaks.