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Home › Chevrolet › 2003 › Tracker 2D Utility, RWD, Automatic › Repair and Diagnosis › Engine Mechanical › Engine Exhaust System › Repair Instructions › Front Pipe Replacement (2.0L) › Installation Procedure

Installation Procedure

IMPORTANT: When installing a new exhaust system component, always use new gaskets and seals.
  1. On all, install the front pipe/TWC assembly to the vehicle.
  2. Support the TWC with a hanger.
  3. Attach the front pipe/TWC assembly with a new gasket to the resonator/muffler/tail pipe assembly.
  4. Secure the resonator/muffler/tail pipe assembly with 2 nuts. Do not fully tighten the nuts.
  5. On non-California 2.0L engine, attach the electrical connector to the heated oxygen sensor (HO2S2) (6).
  6. On all, connect the front pipe/TWC assembly, with a new seal, to the exhaust manifold and secure with 2 bolts. Do not fully tighten the bolts.
    Fig 1: Attaching Electrical Connector To Heated Oxygen Sensor (HO2S2)
    G01471738Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  7. On California 2.0L engine, install 1 bolt and 1 nut to the exhaust manifold pipe bracket.

    Tighten 

    Tighten the front exhaust pipe bracket nut and bolt to 50 N.m (37 lb ft).

    Fig 2: Installing Bolt & Nut To Exhaust Manifold Pipe Bracket
    G01471739Courtesy of GENERAL MOTORS CORP.
  8. Install the heated oxygen sensor (HO2S) 2. Refer to HEATED OXYGEN SENSOR (HO2S) 2 REPLACEMENT (W/ PUP-TWC) or HEATED OXYGEN SENSOR (HO2S) 2 REPLACEMENT (W/O PUP-TWC) in Engine Controls-2.0L.
  9. On non-California engines, align all system components before tightening the fasteners, in order to prevent noise or vibrations.

    Tighten 

    • Tighten the front pipe/TWC assembly-to-exhaust manifold bolts to 50 N.m (37 lb ft).
    • Tighten the front pipe/TWC assembly-to-resonator/muffler/tail pipe assembly nuts to 35 N.m (26 lb ft).
    Fig 3: Heated Oxygen Sensor (HO2S)
    G01471740Courtesy of GENERAL MOTORS CORP.
  10. On California 2.0L engine, align all system components before tightening the fasteners, in order to prevent noise or vibrations.

    Tighten 

    Tighten the front pipe/TWC assembly-to-resonator/muffler/tail pipe assembly nuts to 35 N.m (26 lb ft).

  11. On all, lower the vehicle.
  12. On California 2.0L engine, install 3 exhaust manifold to front pipe nuts (1).

    Tighten 

    Tighten the front pipe assembly-to-exhaust manifold bolts to 50 N.m (37 lb ft).

  13. Position exhaust manifold upper heat shield to the exhaust manifold.
  14. Install 5 exhaust manifold upper heat shield bolts.
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