Home ReviewsRefund
Home/Chevrolet/Spark/Chevrolet Spark M300 (2009-2016)/Repair manual/Exhaust/Engine Exhaust System: Removal & Installation
Contents Wiring diagrams Section: Exhaust All sections

Engine Exhaust System: Removal & Installation Chevrolet Spark M300

Exhaust 5 illustrations ~494 words

Removal Procedure

  1. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement»(ref-544484-S19110600102013042400000) .
  2. Raise the vehicle by its full height. Refer to «Lifting and Jacking the Vehicle»(ref-544446-S16578637502013042400000) .
  3. Remove the exhaust manifold pipe nut (1).
  4. Remove the exhaust manifold bracket bolts (2).
  5. Remove the exhaust manifold pipe gasket.
  6. Remove the 10 exhaust manifold bolt (1).
  7. Remove the exhaust manifold (2) and gasket.
  8. Transfer parts as necessary.

Installation Procedure

  1. Install the exhaust manifold (2) and gasket.
  2. Install the 10 exhaust manifold bolt (1) and tighten to 20 (15 lb ft).
  3. Raise the vehicle by its full height. Refer to «Lifting and Jacking the Vehicle»(ref-544446-S16578637502013042400000) .
  4. Install the exhaust manifold pipe gasket.
  5. Install the exhaust manifold pipe nut (1) and tighten to 46 (34 lb ft).
  6. Install the exhaust manifold bracket bolts (2) and tighten to 46 (34 lb ft).
  7. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement»(ref-544484-S19110600102013042400000) .

Scheme 1

Scheme 1: Exhaust Front Pipe Replacement
Scheme 1: Exhaust Front Pipe Replacement
CalloutComponent Name
Preliminary Procedures Raise the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the heated oxygen sensor 2. Refer to Heated Oxygen Sensor Replacement - Sensor 2 .
1Exhaust Front Pipe to Exhaust Muffler Nut (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 46 (34 lb ft)
2Exhaust Front Pipe Hanger (Qty: 1)
3Exhaust Front Pipe to Exhaust Manifold Nut (Qty: 3) Tighten 46 (34 lb ft)
4Exhaust Front Pipe
CAUTION
Refer to Fastener Caution .

Exhaust Front Pipe Replacement

Scheme 2

Scheme 2: Exhaust Muffler Replacement - Front
Scheme 2: Exhaust Muffler Replacement - Front
CalloutComponent Name
Preliminary Procedure Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
1Exhaust Front Muffler to Exhaust Muffler Nut (Qty: 2) CAUTION: Refer to Component Fastener Tightening Caution . Tighten 46 (34 lb ft)
2Exhaust Front Pipe to Exhaust Muffler Nut (Qty: 2) CAUTION: Refer to Component Fastener Tightening Caution . Tighten 46 (34 lb ft)
3Exhaust Muffler Hanger (Qty: 2)
4Exhaust Muffler (Front)
CAUTION
Refer to Component Fastener Tightening Caution .
CAUTION
Refer to Component Fastener Tightening Caution .

Exhaust Muffler Replacement - Front

  1. Remove the exhaust pipe - rear muffler nut.
  2. Disconnect the exhaust rear muffler assembly from the rubber hanger and remove it.
  1. Connect the exhaust rear muffler assembly to the rubber hanger and install.
  2. Install the exhaust pipe - rear muffler nut and tighten to 46 (34 lb ft).
  1. Remove the front exhaust muffler assembly. Refer to «Exhaust Muffler Replacement - Front»(ref-544484-S15656020482013042400000) .
  2. Remove the fuel tank strap retaining bolt and band (1) left side only.
  3. Remove the 3 fuel tank heat shield retaining screw bolt (2).
  4. Remove the fuel tank heat shield (3).
  1. Install the fuel tank heat shield (3).
  2. Install the 3 fuel tank heat shield retaining screw bolt (2) and tighten to 6 (53 lb in).
  3. Install the fuel tank strap (1) retaining bolt and tighten to 20 (15 lb ft).
  4. Install the front exhaust muffler assembly. Refer to «Exhaust Muffler Replacement - Front»(ref-544484-S15656020482013042400000) .

Scheme 3

Scheme 3: Exhaust Manifold Heat Shield Replacement
Scheme 3: Exhaust Manifold Heat Shield Replacement
CalloutComponent Name
Preliminary Procedures Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . Remove the front headed oxygen sensor. Refer to Heated Oxygen Sensor Replacement - Sensor 1 .
1Exhaust Manifold Heat Shield Retaining Bolt (Qty: 4) CAUTION: Refer to Fastener Caution . Tighten 10 (89 lb in)
2Exhaust Manifold Heat Shield
CAUTION
Refer to Fastener Caution .

Exhaust Manifold Heat Shield Replacement

  1. Remove the exhaust rear muffler. Refer to «Exhaust Muffler Replacement»(ref-544484-S14093199902013042400000) .
  2. Remove the 4 exhaust rear muffler heat shield retaining nuts.
  1. Install the 4 exhaust rear muffler heat shield retaining nuts and tighten to 1.2 (11 lb in).
  2. Install the exhaust rear muffler. Refer to «Exhaust Muffler Replacement»(ref-544484-S14093199902013042400000) .

Scheme 4

Scheme 4: Catalytic Converter
Scheme 4: Catalytic Converter

The catalytic converter is an emission control device added to the engine exhaust system in order to reduce hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx) pollutants from the exhaust gas. The catalytic converter is comprised of a ceramic monolith substrate, supported in insulation and housed within a sheet metal shell. The substrate may be washcoated with 3 noble metals, Platium (Pt), Palladium (Pd) and Rhodium (Rh).

Scheme 5

Scheme 5: Exhaust Rear Muffler
Scheme 5: Exhaust Rear Muffler

The rear muffler is to reduce broad band engine exhaust noise. It is comprised of a series of perforated tubes and baffles to break up the sound waves and reflect them. It is made of stainless steel to protect the front muffler from corrosion.

More articles — Engine Exhaust System