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Installation 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.
    Fig 1: Identifying Exhaust Manifold
    GM1631764Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW exhaust manifold gasket onto the studs.
  2. Install the exhaust manifold.
    3. Fig 2: Exhaust Manifold Bolt Tightening Sequence
    GM1340643Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice .
  3. Install NEW exhaust manifold nuts.

    Tighten:  Tighten the nuts in the sequence shown to 14 N.m (10 lb ft).

  4. Raise and support the vehicle.
    5. Fig 3: Identifying Catalytic Converter
    GM1650780Courtesy of GENERAL MOTORS CORP.
  5. Install a NEW catalytic converter gasket.
  6. Install the catalytic converter to the exhaust manifold studs.
  7. Install the catalytic converter to exhaust manifold nuts.

    Tighten:  Tighten the nuts to 50 N.m (37 lb ft).

  8. Lower the vehicle.
    9. Fig 4: Identifying HO2S
    GM1631780Courtesy of GENERAL MOTORS CORP.
  9. If reinstalling the old HO2S, coat the threads with anti-seize compound, Saturn P/N 21485279 or equivalent.
  10. Install the HO2S.

    Tighten:  Tighten the sensor to 42 N.m (31 lb ft).

    11. Fig 5: Identifying Engine Harness Electrical Connectors
    GM1648166Courtesy of GENERAL MOTORS CORP.
  11. If equipped with RPO M86, connect the engine harness electrical connector (1) to the HO2S.
  12. Install the HO2S clip to the thermostat housing.
  13. Install the HO2S CPA retainer.
    14. Fig 6: Identifying Engine Harness Electrical Connectors - Top Of Engine
    GM1647986Courtesy of GENERAL MOTORS CORP.
  14. If equipped with RPO MN5, connect the engine harness electrical connector (2) to the HO2S.
  15. Install the HO2S clip from the thermostat housing.
  16. Install the HO2S CPA retainer.
    17. Fig 7: Identifying Exhaust Manifold Heat Shield
    GM1631387Courtesy of GENERAL MOTORS CORP.
  17. Install the exhaust manifold heat shield (1).
  18. Install the exhaust manifold heat shield studs (2).

    Tighten:  Tighten the studs to 22 N.m (16 lb ft).

    19. Fig 8: Identifying Air Outlet Hose/Pipe Bracket To/From Heat Shield Stud
    GM1650781Courtesy of GENERAL MOTORS CORP.
  19. If equipped with RPO NU3, position the AIR hose/pipe and install the bracket onto the heat shield stud.
  20. Position the AIR outlet hose/pipe bracket to the cylinder head.
  21. Install the AIR outlet hose/pipe bracket bolt.

    Tighten:  Tighten the bolt to 20 N.m (15 lb ft).

    22. Fig 9: Identifying AIR Outlet Hose/Pipe
    GM1650779Courtesy of GENERAL MOTORS CORP.
  22. Connect the AIR outlet hose/pipe quick connect fitting to AIR check valve. Refer to Plastic Collar Quick Connect Fitting Service .
  23. Install the AIR outlet hose/pipe bracket nut.

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

  24. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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