Chevrolet Sonic manuals

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

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

  3. Caution:

    Refer to Fastener Caution.

  4. 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)

    .



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

  8. 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.

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

    .

  10. Lower the vehicle.
  11. Start the engine and check for exhaust leaks.
Exhaust2
...

Catalytic Converter Heat Shield Replacement (LUV)
Catalytic Converter Heat Shield Replacement Callout Component Name Warning: Refer to Exhaust Service Warning. ...

Other materials:

Antilock Brake System (ABS) Warning Light
This light comes on briefly when the engine is started. If the light stays on, turn the ignition to LOCK/OFF or if the light comes on, stop as soon as possible and turn the ignition off. Then start the engine again to reset the system. If the light still stays on, or comes on again while driv ...

Drivetrain and Front Suspension Frame Skid Plate Replacement
Removal Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. Remove the mounting bolts?€‰(1) for the front suspension frame skid plate. Remove the front suspension frame skid plate?€‰(2). Installation Procedur ...

Front Wheelhouse Liner Replacement (Front)
Front Wheelhouse Liner Replacement Callout Component Name Preliminary Procedure Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation. 1 Front Wheelhouse Liner Scr ...

© 2014-2019 Copyright www.csmans.com
   
0.085