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 Exhaust Manifold Heat Shield

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Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
Remove the exhaust manifold heat shield studs (2).
Remove the exhaust manifold heat shield (1).

Fig 2: Identifying Engine Harness Electrical Connectors - Top Of Engine

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If equipped with regular production option (RPO) MN5, remove the heated oxygen sensor (HO2S) connector position assurance (CPA) retainer.
Disconnect the engine harness electrical connector (2) from the HO2S.
Remove the HO2S clip from the thermostat housing.

Fig 3: Identifying Engine Harness Electrical Connectors

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If equipped with RPO M86, remove the HO2S CPA retainer.
Disconnect the engine harness electrical connector (1) from the HO2S.
Remove the HO2S clip from the thermostat housing.

Fig 4: Identifying HO2S

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Remove the HO2S.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig 5: Identifying Catalytic Converter

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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.

Remove the catalytic converter to exhaust manifold nuts.
Pull down and back on the exhaust pipe in order to separate the catalytic converter from the exhaust manifold.
Remove and discard the catalytic converter gasket.
Lower the vehicle.

Fig 6: Identifying Exhaust Manifold

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Remove the exhaust manifold nuts.
Remove the exhaust manifold.
Remove and discard the exhaust manifold gasket.
Clean and inspect all gasket mating surfaces.