Exhaust Manifold Replacement - Rear

REMOVAL





1. Disconnect exhaust manifold oxygen sensor electrical connection.
2. Remove exhaust manifold oxygen sensor using J-39194-C, oxygen sensor socket.
3. Remove EGR pipe.

NOTICE: Do not apply grease or silicon products to the heated oxygen sensor. Do not alter the wiring in any way. The wires carry air reference to the sensor.

4. Disconnect rear exhaust manifold pipe oxygen sensor electrical connection.





5. Remove rear exhaust manifold pipe heat shield.





6. Remove rear exhaust manifold pipe oxygen sensor.

CAUTION: MAKE SURE THAT VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST.

7. Raise vehicle on hoist.





8. Remove rear exhaust manifold pipe to front exhaust manifold pipe attachment bolts.





9. Remove rear exhaust manifold pipe to resonator bolts.
10. Remove rear exhaust manifold pipe assembly from vehicle.
11. Remove exhaust manifold nuts.
12. Remove exhaust manifold and gasket.

INSTALLATION





1. Install exhaust manifold and new gasket.
2. Install exhaust manifold nuts.
^ Torque: 20 Nm (15 ft. lbs.)





3. Install rear exhaust manifold pipe assembly and gaskets.

NOTICE: Do not tighten fasteners.

4. Install exhaust manifold to rear exhaust manifold pipe nuts.





5. Install front exhaust manifold pipe to rear exhaust manifold pipe attachment bolts.
^ Torque: 20 Nm (15 ft. lbs.)





6. Install rear exhaust manifold pipe to resonator bolts.
^ Torque: 20 Nm (15 ft. lbs.)





7. Tighten rear exhaust manifold pipe to exhaust manifold nuts
^ Torque: 30 Nm (25 ft. lbs.)
8. Lower vehicle
9. Install EGR pipe to exhaust manifold and EGR flange
^ Torque: 25 Nm (19 ft. lbs.)

NOTICE: Always use a nickel-based anti-seized compound (Saturn P/N 21485279 or equivalent) on the threads of the oxygen sensor If the oxygen sensor is replaced, do not apply anti-seize to the new sensor New sensors have anti-seize pre-applied. Never use silicon product; silicon products will cause damage to oxygen sensor.





10. Install oxygen sensor using J-39194C oxygen sensor socket.
^ Torque: 50 Nm (37 ft. lbs.)
11. Connect rear exhaust manifold pipe oxygen sensor electrical connections.





12. Install exhaust manifold pipe heat shield.
^ Torque: 8 Nm (71 inch lbs.)
13. Start vehicle and inspect for exhaust leaks.