Engine Exhaust System: Removal & Installation Chevrolet Sonic I

Exhaust Manifold Replacement (LUV)

Refer to Turbocharger Replacement .

Scheme 1

Exhaust Manifold with Catalytic Converter Replacement (LUW)

Removal Procedure

1. Remove the drivetrain and front suspension frame skid plate. Refer to «Drivetrain and Front Suspension Frame Skid Plate Replacement»(ref-542501-S42788884472013041600000) .
2. Disconnect the heated oxygen sensor-2. Refer to «Heated Oxygen Sensor Replacement - Sensor 2»(ref-542510-S11424779042013041600000) .
3. Remove the 3-way catalytic converter fasteners (1) and disconnect the 3-way catalytic converter (4) from the front pipe.
4. Discard the exhaust gasket (2).
5. Remove the exhaust front pipe (3) to the catalytic converter fasteners (1).
6. Remove the front pipe (3) from the catalytic converter and discard the exhaust gasket (2).

Installation Procedure

1. Install a NEW gasket (2) to the exhaust front pipe.
2. Install the 3-way catalytic converter (4) to the exhaust isolators (3) and tighten the fasteners (1) to 17 N.m (13 lb ft).
3. Position the exhaust front pipe (3) to the catalytic converter with a NEW gasket (2).
4. Install the exhaust front pipe fasteners (1) to the catalytic converter and tighten to 20 N.m (15 lb ft).
5. Connect the heated oxygen sensor-2. Refer to «Heated Oxygen Sensor Replacement - Sensor 2»(ref-542510-S11424779042013041600000) .
6. Install the drivetrain and front suspension frame skid plate. Refer to «Drivetrain and Front Suspension Frame Skid Plate Replacement»(ref-542501-S42788884472013041600000) .
7. Start the engine and check for exhaust leaks.

Special Tools

CH-6614 Chain Pipe Cutter

For equivalent regional tools, refer to Special Tools .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000)
2. Cut the exhaust rear muffler (2) with the CH-6614 pipe cutter at 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.

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. Install the 3-way catalytic converter (4) into the exhaust Isolators (3) with a NEW gasket (2) and tighten the fasteners (1) to 17 N.m (13 lb ft).
4. Install the new rear exhaust muffler (2) into the exhaust isolators.
5. Lower the vehicle.
6. Start the engine and check for exhaust leaks.
7. Position the exhaust front pipe (3) into the exhaust muffler clamp.
8. Install the rear exhaust muffler (2) into the exhaust muffler clamp and tighten the bolt (1) to 50 N.m (37 lb ft).
9. Lower the vehicle.
10. Start the engine and check for exhaust leaks.

1. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LUV)»(ref-542543-S09598436702013041600000) , «Exhaust Manifold Heat Shield Replacement (LUW)»(ref-542543-S02756170052013041600000) .
2. Remove the catalytic converter heated oxygen sensor - 1. Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(ref-542528-S27806594812013041600000) .
3. Remove the catalytic converter to the turbocharger clamp fastener (1) and discard the clamp (2).
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
5. Remove the drivetrain and front suspension frame skid plate. Refer to «Drivetrain and Front Suspension Frame Skid Plate Replacement»(ref-542501-S42788884472013041600000) .
6. Remove the exhaust front pipe fasteners (1) and discard the exhaust gasket (2).
7. Remove the catalytic converter brace fasteners (1) from the catalytic converter brace (2).
8. Remove the catalytic converter.

1. Install the catalytic converter into the catalytic converter brace (2) and loosely tighten the fasteners (1).
2. Install a NEW clamp into the position shown and loosely tighten the clamp fastener (1).
3. Install the exhaust front pipe (3) to the catalytic converter with a NEW gasket (2) and tighten the fasteners (1) to 22 N.m (16 lb ft).
4. Tighten the catalytic converter brace fasteners (1) to 22 N.m (16 lb ft).
5. Install the drivetrain and front suspension frame skid plate. Refer to «Drivetrain and Front Suspension Frame Skid Plate Replacement»(ref-542501-S42788884472013041600000) .
6. Lower the vehicle.
7. Tighten the turbocharge clamp fastener (1) to 13 N.m (115 lb in).
8. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LUV)»(ref-542543-S09598436702013041600000) , «Exhaust Manifold Heat Shield Replacement (LUW)»(ref-542543-S02756170052013041600000) .
9. Install the catalytic converter heated oxygen sensor - 1. Refer to «Heated Oxygen Sensor Replacement - Sensor 1»(ref-542528-S27806594812013041600000) .
10. Start the engine and check for exhaust leaks.

Scheme 2

Warm Up Three-Way Catalytic Converter Replacement (LUV, LUW)

Scheme 3

Catalytic Converter Heat Shield Replacement (LUV)

Scheme 4

Exhaust Heat Shield Replacement

1. Support the fuel tank with a suitable jack.
2. Remove the fuel tank strap fasteners (1) and lower the fuel tank straps (2).
3. Remove the fuel tank heat shield fasteners (1) and remove the fuel tank heat shield (2).

1. Install the fuel tank heat shield (2) and tighten the fasteners (1) to 10 N.m (89 lb in).
2. Install the fuel tank straps (2) and tighten the fasteners (1) to 22 N.m (16 lb ft).

Scheme 5

Exhaust Manifold Heat Shield Replacement (LUV)

Scheme 6

Exhaust Manifold Heat Shield Replacement (LUW)

Scheme 7

Exhaust Rear Muffler Heat Shield Replacement

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-542467-S12591948612013041600000) .
2. Cut the exhaust rear muffler (2) with the CH-6614 pipe cutter at 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.

1. Install the new rear exhaust muffler (2) into the exhaust isolators.
2. Position the exhaust front pipe (3) into the exhaust muffler clamp.
3. Install the rear exhaust muffler (2) into the exhaust muffler clamp and tighten the bolt (1) to 50 N.m (37 lb ft).
4. Lower the vehicle.
5. Start the engine and check for exhaust leaks.