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:

License Plate Lamp
Lamp Assembly Bulb Assembly Bulb Socket Bulb Lamp Assembly To replace one of these bulbs: Push the left end of the lamp assembly toward the right. Turn the lamp assembly down to remove it. Turn the bulb socket (1) counterc ...

Water Outlet Replacement (LUV)
Removal Procedure Drain the engine coolant system. Refer to Cooling System Draining and Filling. Remove the following: Engine coolant air bleed hose (1) Engine coolant temperature sensor (2) and connector clip (3) Heated oxygen senso ...

Manual Transmission Shift Lever Cable Adjustment
Special Tools DT-527-A Adjuster or 5mm drill bit For equivalent regional tools, refer to Special Tools. Note: Not using the specified tools may lead to shift system mis-adjustment. Remove the floor console. Refer to Front Floor Console Replacement. Lift upward an ...

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