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
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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:
Questions and Answers About Safety Belts
Q: Will I be trapped in the vehicle after a crash if I am wearing a safety belt?
A: You could be— whether you are wearing a safety belt or not. Your chance of being
conscious during and after a crash, so you can unbuckle and get out, is much greater
if you are belted.
Q: If my vehicle has ai ...
Front Bumper Impact Bar Lower Bracket Replacement
Front Bumper Impact Bar Lower Bracket Replacement
Callout
Component Name
Preliminary Procedure
Remove the front bumper opening cover. Refer to Front Bumper Fascia Opening
Lower Cover Replacement.
1
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Rail Dust Damage Repair
Warning: Refer to Eye Protection Warning.
Note: If rail dust has penetrated into the basecoat, the panel requires
refinishing. Ensure all the rail dust has been removed prior to refinishing
or the rust spots will return.
Rail dust damage comes from the tiny iron particles produce ...
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