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 30 N.m (22 lb ft).

Fig 5: View Of HO2S & Electrical Connector

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Connect the engine harness electrical connector (1) to the HO2S.
Install the HO2S clip to the bracket on the thermostat housing.
Install the HO2S CPA retainer.

Fig 6: 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).

Fig 7: Identifying PCV Vent Tube

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Install the PCV vent hose/tube.
Install the PCV vent tube bolt (4) and nut (5).
Tighten: Tighten the bolt/nut to 10 N.m (89 lb in).
Install the PCV vent hose ends to the outlet duct and cover.
position the PCV vent hose clamps (1, 3) at the air cleaner outlet duct and the camshaft cover.