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Home › Saturn › 2005 › L300 › Repair and Diagnosis › Engine Mechanical › Engine Exhaust System › Repair Instructions › Exhaust Manifold Pipe Replacement › Installation Procedure

Installation Procedure

    Fig 1: Removing/Installing Exhaust Manifold Pipe-To-Exhaust Manifold Nuts
    GM892169Courtesy of GENERAL MOTORS CORP.
  1. Position the gasket on the manifold pipe.
  2. Position the manifold pipe into the vehicle.
    3. IMPORTANT: Do not tighten the fasteners.
  3. Install the exhaust manifold pipe to exhaust manifold nuts.
    4. Fig 2: Removing/Installing Exhaust Manifold Pipe-To-Exhaust/Resonator Fasteners
    GM892067Courtesy of GENERAL MOTORS CORP.
  4. Position the gasket between the manifold pipe and resonator.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the exhaust manifold pipe to resonator bolts and tighten.

    Tighten:  Tighten the exhaust manifold pipe-to-resonator bolts to 20 N.m (15 lb ft).

  6. Tighten the exhaust manifold pipe to exhaust manifold nuts.

    Tighten:  Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N.m (22 lb ft).

    7. Fig 3: Installing Frame Alignment Fixture (J 43628)
    GM891923Courtesy of GENERAL MOTORS CORP.
  7. Install the J 43628  , or equivalent, and raise the frame to the vehicle.
    8. Fig 4: Identifying Remaining Frame Attachment Fasteners
    GM891622Courtesy of GENERAL MOTORS CORP.
  8. Remove the remaining frame bolts and replace with new bolts and tighten.

    Tighten:  Tighten the frame-to-body bolts to 100 N.m (74 lb ft) plus 45 degrees plus 60 degrees.

    9. Fig 5: Removing/Installing Suspension Support Assemblies
    GM891611Courtesy of GENERAL MOTORS CORP.
  9. Install the new cage nuts into the body for the suspension supports, as torque retention of old nuts may not be sufficient.
  10. Install the suspension supports using new bolts and tighten.

    Tighten:  Tighten the suspension support-to-body bolts to 90 N.m (60 lb ft) plus 45 degrees plus 60 degrees.

    11. NOTE: Always use a nickle-based anti-seize compound Saturn P/N 21485279 (or equivalent) on the threads of the heated oxygen sensor (H02S-2). If the H02S-2 is replaced, do not apply anti-seize to the new sensor. New sensors have anti-seize pre-applied. Never use silicone products. Silicone products will damage the sensor.
  11. Install the HO2S.

    Tighten:  Tighten the HO2S 2 sensor-to-exhaust pipe to 45 N.m (33 lb ft).

  12. Connect the HO2S harness connector.
  13. Connect the HO2S harness to heat shield.

    Tighten:  Tighten the HO2S 2 harness clip-to-heat shield bolt to 4 N.m (35 lb in).

  14. Lower the vehicle from the hoist.
  15. Start the engine and check for exhaust leaks.
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