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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 707 (Engine Exhaust System) >> Repair Instructions >> Exhaust Extension Pipe Replacement (RPO L61) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Pontiac G5 Pursuit, 2007 Pontiac G5, and 2007 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Extension Pipe
    GM890535Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW exhaust gasket to the service muffler pipe studs.
  2. With the aid of an assistant, install the muffler pipe to the catalytic converter and support the muffler pipe.
  3. Install the muffler pipe insulators (1) to the underbody hangers.
    4. Fig 2: Identifying Catalytic Converter and Muffler Pipe
    GM1650810Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  4. Install the catalytic converter to muffler pipe nuts.

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

    5. Fig 3: Installing Muffler (L61)
    GM890536Courtesy of GENERAL MOTORS CORP.
  5. Slide the muffler inlet pipe over the muffler pipe, then install the muffler insulator to the underbody hanger.
    6. Fig 4: Installing Service Muffler Clamp
    GM890538Courtesy of GENERAL MOTORS CORP.
  6. Install a service 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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