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Home › Saturn › 2004 › Ion Red Line › Repair and Diagnosis › Engine Mechanical › Engine Exhaust System › Repair Instructions › Catalytic Converter Replacement (LSJ) › Installation Procedure

Installation Procedure

  1. Install NEW exhaust gaskets to the exhaust manifold and to the exhaust extension pipe. The gaskets are designed to be retained to the flange by the flange studs.
  2. Position the catalytic converter pipe assembly to the vehicle.
  3. Move the extension pipe rearward and down in order to connect the converter pipe to the extension pipe.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the catalytic converter pipe-to-exhaust extension pipe nuts.

    Tighten:  Tighten the nuts to 30 N.m (22 lb ft).

    5. Fig 1: View Of Catalytic Converter Pipe-To-Exhaust Extension Pipe Nuts (LSJ)
    GM1388612Courtesy of GENERAL MOTORS CORP.
  5. Carefully install the converter pipe to the exhaust manifold.
  6. Install the catalytic converter pipe-to-exhaust manifold nuts.

    Tighten:  Tighten the nuts to 50 N.m (37 lb ft).

    7. Fig 2: View Of Catalytic Converter Pipe
    GM1382207Courtesy of GENERAL MOTORS CORP.
  7. Install the post catalytic converter HO2S. Refer to Heated Oxygen Sensor Replacement - Position 2 in Engine Controls - 2.0L (LSJ).
  8. Lower the vehicle.
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