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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 125 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSCATALYTIC CONVERTER REPLACEMENT (LY7)INSTALLATION PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Installation Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2005 Buick LaCrosse and 2005 Buick Allure. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Catalytic Converter Mounting Nuts
    GM212193Courtesy of GENERAL MOTORS CORP.
  1. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Position 2 in Engine Controls - 3.6L.
    2. NOTE: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.
  2. Install a new gasket to the exhaust pipe studs.
  3. Install and support the catalytic converter.
    4. NOTE: Refer to Fastener Notice .
  4. Install the catalytic converter nuts.

    Tighten:  Tighten the nuts to 60 N.m (44 lb ft).

    5. Fig 2: Catalytic Converter
    GM1577368Courtesy of GENERAL MOTORS CORP.
  5. Install a new exhaust manifold pipe gasket (1).
  6. Install the exhaust manifold pipe stud nuts (2).

    Tighten:  Tighten the nuts to 35 N.m (26 lb ft).

    7. Fig 3: View Of Catalytic Converter Hangers
    GM289493Courtesy of GENERAL MOTORS CORP.
  7. Install the catalytic converter hangers.
  8. Remove the support from the exhaust system.
  9. Inspect the exhaust system for leaks and underbody contact.
  10. Lower the vehicle.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.