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2005-2008 Chevy Cobalt Exhaust System Installation

October 3rd, 2009 · No Comments

Prior to installation, be sure your vehicle is parked on a level surface, and the exhaust system is cool. For safety purposes and ease of installation, we urge you to take your vehicle to a qualified service center or muffler installer that employs the use of a lift.

Exhaust System Removal:
1. Measure the exhaust pipe 7-1/2 inches forward of the rear axle and mark a line.
2. Using a saw or chain style pipe cutter, cut the stock system.
3. Using a 15 mm socket remove the two flange nuts.
4. Remove the front hanger from the rubber isolator and remove the front section of the stock exhaust system.
5. Remove the rubber isolator after the axle from both the vehicle and the exhaust system (See Fig. D).
NOTE: Be sure to save all rubber isolators removed from the vehicle. They will be used to install the CORSA Performance exhaust system in later steps.
6. Support the exhaust system, and remove the rubber isolators after
the rear muffler from both the vehicle and the exhaust system.
7. Remove the remaining section of the exhaust system.
8. Install all rubber isolators back onto the vehicle.

CORSA Performance Exhaust System Installation:
1. Remove all exhaust system components from the shipping cartons, including clamps. NOTE: There are three 2-1/2 inch clamps supplied. NOTE: Apply the anti-seize lubricant (supplied) to the threads ONLY of all the TORCA band clamps and flange bolts. Failure to follow this procedure can cause nuts to seize on clamps and potentially damage threads.
After applying anti-seize lubricant, be sure to thoroughly clean hands as lubricant will tarnish stainless steel.
2. Locate the front muffler assembly, flange gasket, nuts and bolts
3. Place the flange gasket over the flange after the catalytic converter, and using a 15mm socket and a 5/16” allen wrench install the front muffler assembly. Tighten the flange bolts to 40 ft-lbs (See Fig. G).
4. Locate the intermediate pipe assembly and place a TORCA clamp on the inlet.

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