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Home › Saturn › 2005 › Relay AWD › Repair and Diagnosis › Engine Mechanical › Engine Exhaust System › Repair Instructions › Exhaust Manifold Replacement - Right › Installation Procedure

Installation Procedure

  1. If removed, install the HO2S. Refer to Heated Oxygen Sensor Replacement - Position 1 in Engine Controls - 3.5L.
  2. If removed, install the EGR valve pipe. Refer to Exhaust Gas Recirculation (EGR) Pipe Replacement in Engine Controls - 3.5L.
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
    4. Fig 1: Right Exhaust Manifold (3.4L)
    GM187052Courtesy of GENERAL MOTORS CORP.
  4. Install the exhaust manifold gasket.
  5. Install the exhaust manifold.
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the exhaust manifold nuts.

    Tighten:  Tighten the exhaust manifold nuts to 16 N.m (12 lb ft).

    7. Fig 2: View Of Right Exhaust Manifold Heat Shields & Bolts
    GM187050Courtesy of GENERAL MOTORS CORP.
  7. Install the exhaust manifold lower heat shield.
  8. Install the exhaust manifold upper heat shield.
  9. Install the exhaust manifold heat shield bolts.

    Tighten:  Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).

  10. Install the catalytic converter. Refer to Catalytic Converter Replacement .
  11. Lower the vehicle.
  12. Install the exhaust crossover pipe nuts/studs to the engine right side exhaust manifold. Refer to.
  13. Install the exhaust crossover pipe heat shield. Refer to Exhaust Crossover Pipe Replacement .
  14. Lower the vehicle.
  15. Connect the HO2S electrical connector.
  16. Install the spark plug wires to the engine right bank spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls - 3.5L.
  17. Install the ignition module and the ignition coils with the bracket. Refer to Ignition Control Module Replacement in Engine Controls - 3.5L.
  18. Install the EGR valve to the intake manifold. Refer to Exhaust Gas Recirculation (EGR) Valve Replacement in Engine Controls - 3.5L.
  19. Install the MAP sensor. Refer to Manifold Absolute Pressure (MAP) Sensor Replacement in Engine Controls - 3.5L.
  20. Rotate the engine back to the original position. Refer to Rotating the Engine for Service Access in Engine Mechanical - 3.5L.
  21. Install the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.5L.
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