Removal

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITION. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED. MAKE SURE HOIST DOES NOT CONTACT FUEL OR BRAKE LINES.

NOTE: There will neither be a service converter nor a service front pipe for 1996 Saturns. When service is needed to either the front exhaust pipe or the catalytic converter on 1996 Saturns, both pieces must be replaced as a unit.



FRONT EXHAUST PIPE TO THREE WAY CATALYTIC CONVERTER REMOVAL

Vehicle Lifting:

1. Raise vehicle squarely on a lift.

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




2. Remove rear heated oxygen sensor wiring harness from cradle by pushing up on retaining clip tab.




3. Remove connector position assurance (CPA) device and unplug rear heated oxygen sensor wiring harness from engine harness.




4. Remove rear heated oxygen sensor wiring harness from trough in converter heat shield by gently pulling wiring harness from its retaining clips.

5. Remove rear heated oxygen sensor using Saturn tool SA9603E. If necessary, use a liquid penetrate before removing sensor.

NOTE: The rear heated oxygen sensor uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

6. Remove the front exhaust pipe fasteners at manifold and discard gasket.

Rear Oxygen Sensor:

7. Remove the front exhaust pipe fasteners at rear of three way catalytic converter.

NOTE: Do not bend the front exhaust pipe hanger attached to the engine stiffening bracket when servicing the front exhaust pipe and/or three way catalytic convertor. Bending the bracket may cause premature failure.

8. Remove the exhaust pipe support bracket to exhaust pipe fasteners and remove the pipe.

Converter Installation:

9. Remove three way catalytic converter gasket and discard.

10. Inspect the front exhaust pipe-to-exhaust manifold flange.
Front Exhaust Pipe to Manifold Flange Warpage:
^ Standard: 0.7 mm (0.028 in.) max.
^ Service Limit: 0.7 mm (0.028 in.) max.