GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2007 🢒 Spark 🢒 Preface 🢒 Cautions and Notices 🢒 Exhaust Pipe Replacement

Removal Procedure

    Caution: Refer to Hot Exhaust System Caution in the Preface section.


    Object Number: 1225437 Size: SH

    Important: Ensure that the components are cool.

  1. Remove the floor console. Refer to Front Floor Console Replacement .
  2. Disconnect the heated oxygen sensor (HO2S) connector.

    3. Object Number: 1230395 Size: SH

    Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

  3. Remove the nuts (1).
  4. Remove the gasket (2).
  5. Remove the front exhaust pipe from the exhaust manifold or from the pup-up catalytic converter.
  6. Inspect the gasket for damage or cracks.

    7. Object Number: 1225436 Size: SH
  7. Remove the front exhaust pipe from the front muffler pipe (1).

    8. Object Number: 1225439 Size: SH
  8. Remove the front exhaust pipe (1) and the catalytic converter assembly (2).
  9. Clean the sealing surfaces on the front exhaust pipe flange and on the exhaust manifold.
  10. Inspect the exhaust pipe and the catalytic converter 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: 1225438 Size: SH
  1. Using the nuts and the gasket, secure the front exhaust pipe (1) and the catalytic converter assembly to the exhaust manifold.

    2. Tighten
    Tighten the nuts to 25-35 N·m (18-25 lb ft).

    Important: Do NOT contact the components with the underbody.

  2. Install the front exhaust pipe and the catalytic converter assembly to the front muffler pipe flange. Use the nuts (2) to secure the front exhaust pipe and the catalytic converter assembly.

    3. Tighten
    Tighten the nuts to 25-35 N·m (18-25 lb ft).

  3. Connect the HO2S connector.
  4. Install the floor console. Refer to Front Floor Console Replacement .