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

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Install a NEW exhaust manifold gasket onto the studs.
Install the exhaust manifold.

Fig 2: Exhaust Manifold Bolt Tightening Sequence

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NOTE: Refer to Fastener Notice .

Install NEW exhaust manifold nuts.
Tighten: Tighten the nuts in the sequence shown to 14 N.m (10 lb ft).
Raise and support the vehicle.

Fig 3: Identifying Catalytic Converter

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Install a NEW catalytic converter gasket.
Install the catalytic converter to the exhaust manifold studs.
Install the catalytic converter to exhaust manifold nuts.
Tighten: Tighten the nuts to 50 N.m (37 lb ft).
Lower the vehicle.

Fig 4: Identifying HO2S

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If reinstalling the old HO2S, coat the threads with anti-seize compound, Saturn P/N 21485279 or equivalent.
Install the HO2S.
Tighten: Tighten the sensor to 42 N.m (31 lb ft).

Fig 5: Identifying Engine Harness Electrical Connectors

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If equipped with RPO M86, connect the engine harness electrical connector (1) to the HO2S.
Install the HO2S clip to the thermostat housing.
Install the HO2S CPA retainer.

Fig 6: Identifying Engine Harness Electrical Connectors - Top Of Engine

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If equipped with RPO MN5, connect the engine harness electrical connector (2) to the HO2S.
Install the HO2S clip from the thermostat housing.
Install the HO2S CPA retainer.

Fig 7: Identifying Exhaust Manifold Heat Shield

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Install the exhaust manifold heat shield (1).
Install the exhaust manifold heat shield studs (2).
Tighten: Tighten the studs to 22 N.m (16 lb ft).
Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .