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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 863 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSCATALYTIC CONVERTER REPLACEMENT (LAP)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 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Catalytic Converter
    GM1650780Courtesy of GENERAL MOTORS CORP.
  1. Remove the catalytic converter to exhaust manifold nuts.
  2. Remove the catalytic converter.
  3. Discard the exhaust gaskets.
  4. Clean the flange mating surfaces of any remaining gasket material.
    5. Fig 2: Identifying Catalytic Converter & Muffler Pipe
    GM1650810Courtesy of GENERAL MOTORS CORP.
  5. Install a NEW gasket onto the resonator pipe studs.
    6. CAUTION: Refer to Fastener Caution .
  6. Install the catalytic converter to the resonator pipe nuts and tighten to 30 N.m (22 lb ft).
  7. Install the (HO2S). Refer to Heated Oxygen Sensor Replacement - Sensor 2 .
  8. Install the wheel drive shaft heat shield. Refer to Front Wheel Drive Shaft Joint Boot Shield Replacement .
  9. Inspect the exhaust system for leaks.
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.