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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 LSJ) >> 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 PCV Vent Tube
    GM1649566Courtesy of GENERAL MOTORS CORP.
  1. Reposition the positive crankcase ventilation (PCV) vent hose clamps (1, 3) at the air cleaner outlet duct and the camshaft cover.
  2. Remove the PCV vent hose ends from the outlet duct and cover.
  3. Remove the PCV vent tube bolt (4) and nut (5).
  4. Remove the PCV vent hose/tube.
    5. Fig 2: Identifying Exhaust Manifold Heat Shield
    GM1631387Courtesy of GENERAL MOTORS CORP.
  5. Remove the exhaust manifold heat shield studs (2).
  6. Remove the exhaust manifold heat shield (1).
    7. Fig 3: View Of HO2S & Electrical Connector
    GM1389438Courtesy of GENERAL MOTORS CORP.
  7. Remove the heated oxygen sensor (HO2S) connector position assurance (CPA) retainer.
  8. Disconnect the engine harness electrical connector (1) from the HO2S.
  9. Remove the HO2S clip from the bracket on the thermostat housing.
    10. Fig 4: Identifying HO2S
    GM1631780Courtesy of GENERAL MOTORS CORP.
  10. Remove the HO2S.
  11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    12. Fig 5: Identifying Catalytic Converter
    GM1650775Courtesy 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.
  12. Remove the catalytic converter to exhaust manifold nuts.
  13. Pull down and back on the exhaust pipe in order to separate the catalytic converter from the exhaust manifold.
  14. Remove and discard the catalytic converter gasket.
  15. Lower the vehicle.
    16. Fig 6: Identifying Exhaust Manifold
    GM1631764Courtesy of GENERAL MOTORS CORP.
  16. Remove the exhaust manifold nuts.
  17. Remove the exhaust manifold.
  18. Remove and discard the exhaust manifold gasket.
  19. Clean and inspect all gasket mating surfaces.
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