Exhaust Manifold Pipe Replacement - Manual Transmission

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 the heated oxygen sensor. Do not alter the wiring in any way. The wires carry air reference to the sensor.

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





5. Remove nuts that hold exhaust manifold pipe to exhaust manifold.





6. Remove bolts that hold exhaust manifold pipe to exhaust resonator.
7. Remove exhaust manifold pipe from vehicle.

INSTALLATION





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

IMPORTANT: Do not tighten fasteners.

3. Install nuts that hold exhaust manifold pipe to exhaust manifold.





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





7. Install oxygen sensor.
8. Connect oxygen sensor harness connector.
9. Connect oxygen sensor harness to heat shield.
10. Lower vehicle from hoist.
11. Start engine and check for exhaust leaks.