Chevrolet Sonic Repair Manual: Exhaust System Replacement

Removal Procedure

Special Tools

CH-6614 Chain Pipe Cutter

For equivalent regional tools, refer to Special Tools.

Warning:

Refer to Protective Goggles and Glove Warning

Warning:

Refer to Exhaust Service Warning.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle



2. Cut the exhaust rear muffler (2) with the CH-6614 pipe cutterat position (1).



3. Remove the rear exhaust muffler (2) from the exhaust isolators (1).
4. Sand smooth the front exhaust pipe for ease of installation.
5. Remove the exhaust rear muffler.


6. Remove the exhaust front pipe fasteners (1) and discard the gasket (2).
7. Remove the 3-way catalytic converter (4) from the exhaust isolators (3).


8. Lower the intermediate exhaust front muffler pipe (5).
9. Remove and transfer the catalytic converter, if necessary.

Installation Procedure

1. Install the exhaust rear muffler (2) into the exhaust isolators (1).


2. Install the intermediate exhaust front muffler (5) to the front exhaust hanger isolators (2).



Caution:

Refer to Fastener Caution.

3. Install the 3-way catalytic converter (4) into the exhaust Isolators (3) with a NEW gasket (2) and tighten the fasteners (1) to 17 Y (13 lb ft)

   .




4. Install the new rear exhaust muffler (2) into the exhaust isolators.
5. Lower the vehicle.
6. Start the engine and check for exhaust leaks.


7. Position the exhaust front pipe (3) into the exhaust muffler clamp.

   Note:

   There are 3 different exhaust muffler clamps depending on the diameter of the exhaust pipe.

8. Install the rear exhaust muffler (2) into the exhaust muffler clamp and tighten the bolt (1) to 50 Y (37 lb ft)

   .

9. Lower the vehicle.
10. Start the engine and check for exhaust leaks.

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