Removal 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.

NOTE: Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

IMPORTANT: A service exhaust muffler will be needed when replacing the exhaust muffler pipe on an factory equipped system.

Fig 1: Removing Exhaust Muffler (L61)

Courtesy of GENERAL MOTORS CORP.

Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
Support the exhaust muffler.
Cut the exhaust muffler pipe just forward of the weld at the front of the exhaust muffler using a suitable exhaust pipe cutter.
Remove the muffler insulator from the underbody hanger and remove the exhaust muffler.
Deburr the muffler inlet pipe end as necessary.

Fig 2: Identifying Catalytic Converter and Muffler Pipe

Courtesy of GENERAL MOTORS CORP.

Place a suitable jack stand under the catalytic converter for support.
Remove the catalytic converter to exhaust muffler pipe nuts.

Fig 3: View Of Extension Pipe

Courtesy of GENERAL MOTORS CORP.

With the aid of an assistant, separate the exhaust muffler pipe insulators (1) from the underbody hangers.
Remove the muffler pipe from the catalytic converter and remove the muffler pipe from the vehicle.
Remove and discard the muffler pipe gasket.
Clean the catalytic converter flange mating surfaces of any remaining gasket material.