Chevrolet Cobalt Service & Repair Manual: Exhaust System Complete, Replace

Chevrolet Cobalt Service & Repair Manual / Exhaust / Exhaust System Complete, Replace

Removal

Warning: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.
Caution: Do not over flex or damage the flex joint when moving the flex joint from the normal mounting position.
A service muffler will be needed when replacing the exhaust resonator pipe on a factory equipped exhaust system.
1. Raise and support vehicle using suitable lift.
2. Support exhaust resonator pipe using a suitable jack stand.
3. Remove insulators (1) from resonator pipe (2), Fig. 1.
4. Remove insulators (1) from muffler (3), Fig. 2.
5. Cut resonator pipe (4) forward of weld at muffler inlet pipe using a suitable tool, Fig. 2.
6. Remove muffler (3) from vehicle, Fig. 2.
7. Remove resonator pipe nuts (3) from catalytic converter (4), Fig. 3.
8. Remove resonator pipe (1) and gasket (2) from catalytic converter (4), Fig. 3.
9. Deburr resonator pipe and muffler inlet pipe ends, as required.

Installation

1. Install new gasket (2) to resonator pipe (1), Fig. 3.
2. Install resonator pipe (1) to catalytic converter (4), Fig. 3.
3. Install resonator pipe nuts (3) and torque to 22 ft. lbs., Fig. 3.
4. Install resonator pipe (2) to insulators (1), Fig. 1.
5. Install muffler (3) to resonator pipe (4), Fig. 2.
6. Install muffler (3) to insulators (1), Fig. 2.
7. Install service clamp (1) on exhaust muffler (2), Fig. 4.
8. Install service clamp nuts (3) and torque to 33 ft. lbs., Fig. 4.
9. Remove support jack from exhaust system.
10. Inspect for exhaust leaks and underbody clearance.

Fig. 1 Exhaust resonator pipe insulator removal

Fig. 2 Exhaust muffler removal

Fig. 3 Exhaust resonator pipe removal

Fig. 4 Exhaust muffler service clamp installation

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    See also:

    Chevrolet Cobalt Owners Manual. Engine Oil Life System
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