GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Aveo 🢒 Preface 🢒 Cautions and Notices 🢒 Front Pipe Replacement

Removal Procedure

    Caution: Refer to Exhaust Service Caution in the Preface section.


    Object Number: 1241945 Size: SH
  1. Remove the rear heated oxygen sensor.

    2. Object Number: 1241944 Size: SH
  2. Remove the connecting pipe mounting bracket bolt.
  3. Remove the connecting pipe nuts and the gasket from the catalytic converter.

    4. Object Number: 1241655 Size: SH
  4. Remove the nuts from the front muffler pipe to the connecting pipe.
  5. Clean the sealing surfaces on the front muffler pipe flange and the connecting pipe.
  6. Check the connecting pipe for holes, damage, open seams, or other deterioration which could permit exhaust fumes to seep into the passenger compartment.

Installation Procedure

    Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1241655 Size: SH
  1. Install the catalytic converter and the connecting pipe and the gasket to the front muffler pipe flange. Use the nuts to secure the converter and the connecting pipe.

    2. Tighten
    Tighten the front muffler to connecting pipe nuts to 30 N·m (22 lb ft).


    Object Number: 1241944 Size: SH
  2. Using the nuts and the gasket secure the connecting pipe to the catalytic converter.

    3. Tighten
    Tighten the connecting pipe to catalytic converter nuts to 40 N·m (30 lb ft).

  3. Install the front exhaust pipe mounting bracket bolt.

    4. Tighten
    Tighten the bracket bolt to 40 N·m (30 lb ft).


    Object Number: 1241945 Size: SH
  4. Install the rear heated oxygen sensor.

    5. Tighten
    Tighten the rear heated oxygen sensor to 41 N·m (30 lb ft).