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Home >> Chevrolet >> 2005 >> Cobalt SS >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Intermediate Pipe Replacement >> Installation Procedure

Installation Procedure

    Fig 1: View Of Catalytic Converter Pipe-To-Exhaust Extension Pipe Nuts (LSJ)
    GM1388612Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW exhaust gasket to the service exhaust extension pipe. The gasket is designed to be retained to the flange by the flange studs.

    Connect the extension pipe to the converter pipe, and support the extension pipe.

    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the catalytic converter pipe-to-exhaust extension pipe nuts.

    Tighten:  Tighten the nuts to 30 N.m (22 lb ft).

    3. Fig 2: Exhaust Extension Pipe
    GM1546675Courtesy of GENERAL MOTORS CORP.
  3. Install the exhaust extension pipe to the underbody hangers insulators.
  4. Install the muffler to the vehicle.
  5. Slide the muffler inlet pipe over the extension pipe, then install the muffler insulator to the underbody hanger.
  6. Install a muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (3/4 in) from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister.
  7. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia.
  8. While maintaining muffler positioning, tighten the exhaust clamp nuts.

    Tighten:  Tighten the nuts to 45 N.m (33 lb ft).

  9. Lower the vehicle.
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