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HOMESERVICE MANUALSPONTIAC2006G6 GTP, 2D COUPE, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1028 (ENGINE EXHAUST SYSTEM)REPAIR INSTRUCTIONSCATALYTIC CONVERTER REPLACEMENTINSTALLATION PROCEDURE
2006 Pontiac G6 GTP, 2D Coupe, Standard

Installation Procedure

2006 Pontiac G6 GTP, 2D Coupe, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2007 Pontiac Montana SV6, 2007 Chevrolet Uplander, and 2007 Buick Terraza. However, it is still accessible from the selected car via links, so may be relevant.
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.
    Fig 1: Identifying Catalytic Converter (FWD)
    GM1681406Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW gasket onto the muffler studs.
  2. Install a NEW gasket onto the exhaust manifold studs.
  3. Position and install the catalytic converter.
  4. Install the converter to the hanger.
    5. Fig 2: Removing/Installing Catalytic Converter To Muffler Nuts
    GM1681430Courtesy of GENERAL MOTORS CORP.
  5. Install the catalytic converter onto the muffler studs.
    6. Fig 3: Exhaust Manifold Pipe Stud
    GM260064Courtesy of GENERAL MOTORS CORP.
  6. Gently pull back the catalytic converter and muffler assembly until the converter can be installed onto the exhaust manifold studs.
  7. Install the catalytic converter onto the exhaust manifold studs.
  8. Install the catalytic converter to muffler nuts until snug.
    9. NOTE: Refer to Fastener Notice .
  9. Install the catalytic converter to exhaust manifold nuts until snug.

    Tighten: 

    • Tighten the catalytic converter to exhaust manifold nuts to 35 N.m (26 lb ft).
    • Tighten the catalytic converter to muffler nuts to 34 N.m (25 lb ft).

  10. Remove the jackstand from under the muffler.
    11. Fig 4: Disconnecting/Connecting HO2S Electrical Connector
    GM1681413Courtesy of GENERAL MOTORS CORP.
  11. Connect the H02S electrical connector.
  12. 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.