Exhaust Manifold Pipe Replacement - Automatic Transmission

^ TOOLS REQUIRED
- J-43628 Frame Alignment Fixture
- SA9140E Torque Angle Gauge

REMOVAL

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





1. Raise vehicle on hoist.

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

2. Remove heated oxygen sensor harness from heat shield.
3. Disconnect oxygen sensor electrical connector.
4. Remove heated oxygen sensor.





5. Remove exhaust manifold pipe to exhaust manifold fasteners.





6. Remove suspension support assemblies and discard bolts.





7. Loosen remaining frame attachment fasteners to allow clearance for exhaust manifold pipe flange to pass by the frame.





8. Remove exhaust manifold pipe to exhaust/resonator fasteners.
9. Remove exhaust manifold pipe.

INSTALLATION





1. Position gasket on manifold pipe.
2. Position manifold pipe into vehicle.

IMPORTANT: Do not tighten fasteners.

3. Install exhaust manifold pipe to exhaust manifold nuts.





4. Position gasket between manifold pipe and resonator.
5. Install exhaust manifold pipe to resonator bolts and tighten.
^ Torque: 20 Nm (15 ft. lbs.)
6. Tighten exhaust manifold pipe to exhaust manifold nuts.
^ Torque: 30 Nm (25 ft. lbs.)





7. Install Frame Alignment Tool J-43628 (or equivalent) and raise frame to vehicle.

NOTICE: New bolts must be used. Torque retention of old bolts may not be sufficient.





8. Remove remaining frame bolts and replace with new bolts and tighten.
^ Torque: 100 Nm (74 ft. lbs.) + 45 to 60 degrees

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.





9. Install oxygen sensor.
^ Torque: 45 Nm (33 ft. lbs.)
10. Connect oxygen sensor harness connector.
11. Connect oxygen sensor harness to heat shield.
^ Torque: 4 Nm (35 inch lbs.)
12. Lower vehicle from hoist
13. Start engine and check for exhaust leaks.