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.
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
- Cut the exhaust rear muffler (2) with the CH-6614 pipe cutterat position (1).
- Remove the rear exhaust muffler (2) from the exhaust isolators (1).
- Sand smooth the front exhaust pipe for ease of installation.
- Remove the exhaust rear muffler.
- Remove the exhaust front pipe fasteners (1) and discard the gasket (2).
- Remove the 3-way catalytic converter (4) from the exhaust isolators (3).
- Lower the intermediate exhaust front muffler pipe (5).
- Remove and transfer the catalytic converter, if necessary.
- Installation Procedure
-
- Install the exhaust rear muffler (2) into the exhaust isolators (1).
- Install the intermediate exhaust front muffler (5) to the front exhaust hanger isolators (2).
- 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)
.
- Install the new rear exhaust muffler (2) into the exhaust isolators.
- Lower the vehicle.
- Start the engine and check for exhaust leaks.
- 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.
- Install the rear exhaust muffler (2) into the exhaust muffler clamp
and tighten the bolt (1) to 50 Y (37 lb ft)
.
- Lower the vehicle.
- Start the engine and check for exhaust leaks.
Caution:
Refer to Fastener Caution.
Exhaust2
...
Catalytic Converter Heat Shield Replacement (LUV)
Catalytic Converter Heat Shield Replacement
Callout
Component Name
Warning: Refer to Exhaust Service Warning.
...
Other materials:
Dome Lamps
The dome lamp controls are in the headliner above the rear seats.
(Dome Lamp Override): Press to turn
the lamps off, even when a door is open.
(Door): When the button is returned
to the middle position, the lamps turn on automatically when a door is opened.
| (On): Press to turn on the dom ...
Brake Pedal Pushrod Inspection
Disconnect the brake pedal pushrod (2) from the brake pedal.
Reposition the pedal pushrod boot (1) toward the front of the vehicle to
expose as much of the pedal pushrod (2) as possible.
Inspect the brake pedal pushrod (2) for straightness.
If the brake p ...
Tire Terminology and Definitions
Air Pressure
The amount of air inside the tire pressing outward on each square inch
of the tire. Air pressure is expressed in kPa (kilopascal) or psi (pounds per
square inch).
Accessory Weight
The combined weight of optional accessories. Some examples of optional
access ...
0.006