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

Other materials:

Leaving the Vehicle with the Engine Running (Automatic Transmission)
Warning It can be dangerous to leave the vehicle with the engine running. It could overheat and catch fire. It is dangerous to get out of the vehicle if the shift lever is not fully in P (Park) with the parking brake firmly set. The vehicle can roll. Do not leave the vehicle when the engine i ...

Driver Information Center (DIC)
The DIC displays information about your vehicle. It also displays warning messages if a system problem is detected. See Vehicle Messages. All messages appear in the DIC display in the instrument cluster. DIC Operation and Displays The DIC has different displays which can be accessed b ...

Rear Compartment Lid Inner Panel Trim Replacement (Sedan)
Rear Compartment Lid Inner Panel Trim Replacement Callout Component Name Preliminary Procedures Remove the rear compartment lid outer bumpers. Remove the latch cover. 1 Rear Compartment Lid Inner ...

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