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Home >> Pontiac >> 2005 >> G6 Base >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Catalytic Converter Replacement (Front) >> Installation Procedure
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Installation Procedure

    Fig 1: Front Catalytic Converter To Rear Catalytic Converter
    GM1492085Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW gasket to the front catalytic converter studs.
  2. Install the front catalytic converter (1).
  3. Install a NEW gasket (2) to the rear catalytic converter studs.
  4. Install the rear catalytic converter (3).
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the rear catalytic converter bolt (4) and nuts (1) at the exhaust manifold.

    Tighten:  Tighten the bolt and nuts to 31 N.m (23 lb ft).

    6. Fig 2: Front Catalytic Converter To Rear Catalytic Converter View
    GM1492086Courtesy of GENERAL MOTORS CORP.
  6. Install the front catalytic converter to rear catalytic converter nuts (3). (Powertrain shown removed for clarity).

    Tighten:  Tighten the nuts to 31 N.m (23 lb ft).

    7. Fig 3: Identifying HO2S
    GM1492088Courtesy of GENERAL MOTORS CORP.
  7. Install the front and rear HO2S's (1, 2) using the J 39194-B  .

    Tighten:  Tighten the sensor to 42 N.m (31 lb ft).

    8. Fig 4: Front HO2S CPA Retainer
    GM1492090Courtesy of GENERAL MOTORS CORP.
  8. Connect the front HO2S electrical connector (1).
  9. Install the front HO2S CPA retainer (2).
    10. Fig 5: Rear Heated Oxygen Sensor
    GM1492091Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the rear HO2S electrical connector (2).
  11. Install the rear HO2S CPA retainer (1).
  12. Install the muffler assembly. Refer to Muffler Replacement .
    13. Fig 6: Front Catalytic Converter
    GM1492084Courtesy of GENERAL MOTORS CORP.
  13. Install the front catalytic converter nuts (1) at the exhaust manifold.

    Tighten:  Tighten the nuts to 31 N.m (23 lb ft).

  14. Start the engine, and check for exhaust leaks.
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