Exhaust Manifold Pipe Replacement - Automatic Transmission

EXHAUST MANIFOLD PIPE AUTOMATIC TRANSAXLE

TOOLS REQUIRED
- J43628 Frame Alignment Fixture

REMOVAL

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





1. Raise vehicle on hoist.

NOTICE: Do not apply grease or silicone 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 heated 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:
Exhaust Manifold Pipe-to-Resonator Bolts: 20 Nm (15 ft. lbs.)
6. Tighten exhaust manifold pipe to exhaust manifold nuts.
Torque:
Exhaust Manifold Pipe-to-Exhaust Manifold Nuts: 30 Nm (22 ft. lbs.)





7. Install Frame Alignment Fixture J43628 (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:
Frame-to-Body Bolts: 100 Nm (74 ft. lbs.) + 45 degrees to 60 degrees





9. Install new cage nuts into the body for the suspension supports, as torque retention of old nuts may not be sufficient.
10. Install suspension supports using new bolts and tighten.
Torque:
Suspension Support-to-Body Bolts: 90 Nm (60 ft. lbs.) + 45 degrees to 60 degrees





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

11. Install heated oxygen sensor.
Torque:
HO2S-2 Sensor-to-Exhaust Pipe: 45 Nm (33 ft. lbs.)
12. Connect heated oxygen sensor harness connector
13. Connect heated oxygen sensor harness to heat shield.
Torque:
HO2S-2 Harness Clip-to-Heat Shield Bolt: 4 Nm (35 inch lbs.)
14. Lower vehicle from hoist.
15. Start engine and check for exhaust leaks.