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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 707 (Engine Exhaust System) >> Repair Instructions >> Exhaust Manifold Replacement (RPO L61) >> Removal Procedure

Removal 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 AIR Outlet Hose/Pipe
    GM1650779Courtesy of GENERAL MOTORS CORP.
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  2. If equipped with regular production option (RPO) NU3, remove the secondary air injection (AIR) outlet hose/pipe bracket nut.
  3. Disconnect the AIR outlet hose/pipe quick connect fitting from AIR check valve. Refer to Plastic Collar Quick Connect Fitting Service .
    4. Fig 2: Identifying Air Outlet Hose/Pipe Bracket To/From Heat Shield Stud
    GM1650781Courtesy of GENERAL MOTORS CORP.
  4. If equipped with RPO NU3, remove the AIR outlet hose/pipe bracket bolt.
  5. Remove the AIR outlet hose/pipe bracket from the heat shield stud and reposition the hose/pipe out of the way.
    6. Fig 3: Identifying Exhaust Manifold Heat Shield
    GM1631387Courtesy of GENERAL MOTORS CORP.
  6. Remove the exhaust manifold heat shield studs (2).
  7. Remove the exhaust manifold heat shield (1).
    8. Fig 4: Identifying Engine Harness Electrical Connectors - Top Of Engine
    GM1647986Courtesy of GENERAL MOTORS CORP.
  8. If equipped with regular production option (RPO) MN5, remove the heated oxygen sensor (HO2S) connector position assurance (CPA) retainer.
  9. Disconnect the engine harness electrical connector (2) from the HO2S.
  10. Remove the HO2S clip from the thermostat housing.
    11. Fig 5: Identifying Engine Harness Electrical Connectors
    GM1648166Courtesy of GENERAL MOTORS CORP.
  11. If equipped with RPO M86, remove the HO2S CPA retainer.
  12. Disconnect the engine harness electrical connector (1) from the HO2S.
  13. Remove the HO2S clip from the thermostat housing.
    14. Fig 6: Identifying HO2S
    GM1631780Courtesy of GENERAL MOTORS CORP.
  14. Remove the HO2S.
  15. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    16. Fig 7: Identifying Catalytic Converter
    GM1650780Courtesy of GENERAL MOTORS CORP.
    NOTE: Do not bend the exhaust flex decoupler more than 3 degrees in any direction. Movement of more than 3 degrees will damage the exhaust flex decoupler.
  16. Remove the catalytic converter to exhaust manifold nuts.
  17. Pull down and back on the exhaust pipe in order to separate the catalytic converter from the exhaust manifold.
  18. Remove and discard the catalytic converter gasket.
  19. Lower the vehicle.
    20. Fig 8: Identifying Exhaust Manifold
    GM1631764Courtesy of GENERAL MOTORS CORP.
  20. Remove the exhaust manifold nuts.
  21. Remove the exhaust manifold.
  22. Remove and discard the exhaust manifold gasket.
  23. Clean and inspect all gasket mating surfaces.
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