Engine Exhaust: Removal & Installation Saab 9-7X I

Installation Procedure

1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493, (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the exhaust manifold NEW gasket and bolts. Tighten: Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the bolts a final pass to 25 N.m (18 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
3. Install the heat shield, and bolts to the exhaust manifold. Tighten: Tighten the bolts to 9 N.m (80 lb in).
4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the left cylinder head.
5. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-268122-S04202183032007101800000) .
6. Raise the vehicle.
7. Install the nuts that secure the catalytic converter to the left exhaust manifold. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
8. Lower the vehicle.

Scheme 1

Scheme 2

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Remove the nuts securing the catalytic converter to the right exhaust manifold.
3. Lower the vehicle.
4. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-268122-S04202183032007101800000) .
5. Remove the heat shield bolts, and shield from the exhaust manifold.
6. Remove the exhaust manifold bolts, manifold, and gasket.
7. Discard the gasket.
8. Clean and inspect the exhaust manifold. Refer to «Exhaust Manifold Cleaning and Inspection»(ref-268156-S40807375832007101800000) .

Scheme 3

1. Apply a 5 mm (0.2 in) wide band of threadlock GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the exhaust manifold bolts. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the exhaust manifold NEW gasket and bolts. Tighten: Tighten the bolts a first pass to 15 N.m (11 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. Tighten the bolts a final pass to 25 N.m (18 lb ft). Tighten the bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts.
3. Install the heat shield, and bolts to the exhaust manifold. Tighten: Tighten the bolts to 9 N.m (80 lb in).
4. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the front of the right cylinder head.
5. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-268122-S04202183032007101800000) .
6. Raise the vehicle.
7. Install the nuts that secure the catalytic converter to the left exhaust manifold. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
8. Lower the vehicle.

Scheme 4

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) in General Information.
2. Remove the frame brace. Refer to «Frame Brace Replacement»(ref-268103-S29507564282007101800000) in Frame and Underbody.
3. Remove the spare tire assembly.
4. Remove the rear axle tie rod. Refer to «Rear Axle Tie Rod Replacement»(ref-268160-S09198420392007101800000) in Rear Suspension.
5. Remove the rear axle brace. Refer to «Rear Axle Brace Replacement»(ref-268160-S27851049132007101800000) in Rear Suspension.
6. Remove the nuts that secure the muffler to the catalytic converter.
7. Separate the exhaust system from the exhaust hanger insulators.
8. Remove the exhaust system.

Scheme 5

1. Install the exhaust system to the vehicle and secure with the exhaust system hanger insulators.
2. Install the muffler to the catalytic converter and secure with the nuts. Tighten: Tighten the nuts to 45 N.m (33 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
3. Inspect the exhaust system for leaks and underbody contact.
4. Install the rear axle brace. Refer to «Rear Axle Brace Replacement»(ref-268160-S27851049132007101800000) in Rear Suspension.
5. Install the rear axle tie rod. Refer to «Rear Axle Tie Rod Replacement»(ref-268160-S09198420392007101800000) in Rear Suspension.
6. Install the spare tire assembly.
7. Install the frame brace. Refer to «Frame Brace Replacement»(ref-268103-S29507564282007101800000) in Frame and Underbody.
8. Lower the vehicle.

Scheme 6

Scheme 7

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Remove the heated oxygen sensor (H2OS). Refer to «Heated Oxygen Sensor 2 Replacement»(ref-268121-S40202039302007101800000) .
3. Remove the nuts that secure the catalytic converter pipe to the exhaust manifold.
4. Discard the old exhaust seal. Do NOT reuse the seal.
5. Remove the nuts that secure the catalytic converter pipe to the muffler.
6. Remove the transmission mount. Refer to «Transmission Mount Replacement (4.2L)»(ref-268097-S23784203382007101800000) or «Transmission Mount Replacement (5.3L)»(ref-268097-S10914700932007101800000) .
7. Remove the catalytic converter pipe from the vehicle.
8. Remove the exhaust hanger from the catalytic converter pipe.

1. Install the exhaust hanger to the catalytic converter pipe.
2. Install the catalytic converter pipe to the vehicle.
3. Install the transmission mount. Refer to «Transmission Mount Replacement (4.2L)»(ref-268097-S23784203382007101800000) or «Transmission Mount Replacement (5.3L)»(ref-268097-S10914700932007101800000) .
4. Install the converter pipe to the muffler. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) . IMPORTANT: The exhaust flange nuts must be tightened evenly to align the joint and prevent exhaust leaks.
5. Hand thread both nuts evenly until they contact the exhaust flange. Tighten: Tighten the nuts to 45 N.m (33 lb ft). IMPORTANT: Do NOT reuse the old exhaust seal. ALWAYS replace the exhaust seal to prevent exhaust leaks.
6. Install the converter pipe to the exhaust manifold with a NEW exhaust seal.
7. Hand thread the nuts evenly against the exhaust flange until the pipe is secure. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
8. Install the H2OS. Refer to «Heated Oxygen Sensor 2 Replacement»(ref-268121-S40202039302007101800000) .
9. Lower the vehicle.

Scheme 8

Scheme 9

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Unscrew both front heated oxygen sensor (HO2S) sensors (1) from the catalytic converter. NOTE: Refer to «Heated Oxygen and Oxygen Sensor Notice»(ref-268087-S07811484262007101800000) . NOTE: Refer to «Excessive Force and Oxygen Sensor Notice»(ref-268087-S29858955022007101800000) .
3. Unscrew both rear HO2S sensors (2) from the catalytic converter.
4. Remove the rear propeller shaft. Refer to «Rear Propeller Shaft Replacement»(ref-268134-S25048335612007101800000) .
5. If equipped with 4-wheel drive (4WD), remove the front propeller shaft. Refer to «Front Propeller Shaft Replacement»(ref-268134-S01108098002007101800000) .
6. Support the transmission with a transmission jack.
7. Remove the transmission support. Refer to «Transmission Support Replacement»(ref-268103-S27156480052007101800000) .
8. Remove the exhaust muffler nuts.
9. Separate the exhaust hanger insulators from the exhaust system and position the exhaust system rearward for additional clearance.
10. Remove the left exhaust manifold pipe nuts.
11. Remove the right exhaust manifold pipe nuts.
12. Raise the transmission with the transmission jack for additional catalytic converter pipe clearance.
13. Tilt the catalytic converter (1) in order to lower the left side catalytic converter pipe below the vehicle frame. Rotate the catalytic converter outlet pipe toward the left side of the vehicle to gain the necessary clearance for the right side catalytic converter pipe to clear the vehicle frame. Remove the catalytic converter (1) from the vehicle.

1. Install the catalytic converter (1) in reverse order of removal by starting with the catalytic converter outlet pipe angled toward the left side of the vehicle and positioning the right side catalytic converter pipe above the frame. Rotate the catalytic converter outlet pipe toward the rear of the vehicle and lift the left side catalytic converter pipe up above the frame. Then position the catalytic converter (1) to the exhaust manifolds.
2. Install the exhaust hanger insulators to the exhaust system. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the exhaust muffler nuts. Ensure the catalytic converter is held in the installed position before tightening the nuts. Tighten: Tighten the nuts to 45 N.m (33 lb ft).
4. Install the right exhaust manifold pipe nuts. Ensure the catalytic converter is held in the installed position before tightening the nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
5. Install the left exhaust manifold pipe nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
6. Install the transmission support. Refer to «Transmission Support Replacement»(ref-268103-S27156480052007101800000) .
7. Remove the transmission jack.
8. If equipped with 4WD, install the front propeller shaft. Refer to «Front Propeller Shaft Replacement»(ref-268134-S01108098002007101800000) .
9. Install the rear propeller shaft. Refer to «Rear Propeller Shaft Replacement»(ref-268134-S25048335612007101800000) . IMPORTANT: A special anti-seize compound is used on the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before the reinstallation.
10. If reinstalling the old sensors, coat the threads with anti-seize compound GM P/N 12377953, or equivalent.
11. Install both front HO2S sensors (1) to the catalytic converter. Tighten: Tighten the sensor to 42 N.m (31 lb ft). NOTE: Refer to «Component Fastener Tightening Notice»(ref-268087-S05601325242007101800000) . IMPORTANT: If the HO2S sensor is connected to the main wiring harness during installation. Rotate the HO2S sensor several turns counterclockwise before threading the HO2S sensor into the catalytic converter. This action of initially reverse winding of the pigtail wires will prevent a condition where the HO2S sensor pigtail wires become severely twisted or binding once the HO2S sensor is installed into the catalytic converter.
12. Install both rear HO2S (2) to the catalytic converter. Tighten: Tighten the sensor to 42 N.m (31 lb ft).
13. Lower the vehicle.

Scheme 10

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Disconnect the heated oxygen sensor (H2OS) electrical connector.
3. Remove the nuts that secure the catalytic converter pipe to the exhaust manifold.
4. Discard the old exhaust seal. Do NOT reuse the seal.
5. Remove the nuts that secure the catalytic converter pipe to the muffler.
6. Remove the bolt securing the exhaust hanger to the transmission mount.
7. Remove the transmission mount.
8. Remove the catalytic converter and exhaust hanger assembly from the vehicle.
9. Remove the exhaust hanger from the catalytic converter.

1. Install the exhaust hanger to the catalytic converter.
2. Install the catalytic converter and exhaust hanger assembly to the vehicle.
3. Install the bolt securing the catalytic converter pipe hanger to the transmission mount. Tighten: Tighten the bolt to 30 N.m (22 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Install the transmission mount.
5. Install the catalytic converter pipe to the exhaust manifold with a NEW exhaust seal.
6. Hand thread the nuts evenly against the exhaust flange until the pipe is secure. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
7. Connect the H2OS electrical connector.
8. Lower the vehicle.

Scheme 11

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) . IMPORTANT: Do not reuse any component of the exhaust system that is corroded or damaged. IMPORTANT: When replacing the muffler in a vehicle with the LL8 engine, the resonator and tailpipe must also be ordered. The 2 pieces may be attached with a clamp.
2. Inspect the exhaust system components to determine if they can be reused.
3. Remove the frame brace. Refer to «Frame Brace Replacement»(ref-268103-S29507564282007101800000) .
4. Remove the nuts that secure the muffler to the catalytic converter pipe.
5. Separate the muffler and the tail pipe assembly from the hanger insulators.
6. Lower the muffler and tail pipe assembly.
7. Suitably support the exhaust system.
8. Cut the exhaust pipe at the dashed line (1).
9. Remove the muffler from the tail pipe.

1. Install the new muffler to the tail pipe.
2. Attach the muffler and tail pipe to the hanger insulators.
3. Install the muffler to the catalytic converter and secure with the nuts. Tighten: Tighten the nuts to 45 N.m (33 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Loosely install the clamp to secure the muffler to the tail pipe.
5. Align the tail pipe in the proper position. Tighten: Tighten the clamp nuts to 50 N.m (37 lb ft).
6. Inspect the exhaust system for leaks and underbody contact.
7. Install the frame brace. Refer to «Frame Brace Replacement»(ref-268103-S29507564282007101800000) .
8. Lower the vehicle.

Scheme 12

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) . IMPORTANT: Do not reuse any component of the exhaust system that is corroded or damaged.
2. Inspect the exhaust system components to determine if they can be reused.
3. Cut (1) the resonator pipe as close to the exhaust hanger as possible.
4. Separate the resonator and tailpipe assembly from the hanger insulators.
5. Remove the resonator and tailpipe assembly.

1. Install the new resonator and tailpipe assembly to the muffler.
2. Attach the resonator and tailpipe to the hanger insulators.
3. Loosely install the clamp to secure the resonator to the muffler. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
4. Align the tailpipe in the proper position. Tighten: Tighten the clamp nuts to 50 N.m (37 lb ft).
5. Inspect the exhaust system for leaks and underbody contact.
6. Lower the vehicle.

Scheme 13

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Remove the 5 bolts securing the heat shield to the floor panel studs.
3. Remove the heat shield from the vehicle.

1. Place the catalytic converter heat shield onto the floor panel studs. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Secure the heat shield with the 5 bolts. Tighten: Tighten the catalytic converter heat shield bolts to 7 N.m (62 lb in).
3. Lower the vehicle.

Scheme 14

1. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-268121-S03746815782007101800000) .
2. Remove the secondary air injection (AIR) solenoid valve. Refer to «Secondary Air Injection Solenoid Valve Replacement»(ref-268121-S34923269412007101800000) .
3. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(ref-268132-S29487714212007101800000) .
4. Remove the oxygen sensor from the exhaust manifold. Refer to «Heated Oxygen Sensor 1 Replacement»(ref-268121-S09490877122007101800000) .
5. Remove the 4 manifold heat shield nuts and remove the heat shield.

1. Install the exhaust manifold heat shield with the 4 nuts. Tighten: Tighten the exhaust manifold heat shield nuts to 10 N.m (89 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the oxygen sensor. Refer to «Heated Oxygen Sensor 1 Replacement»(ref-268121-S09490877122007101800000) .
3. Install the oil level indicator. Refer to «Oil Level Indicator and Tube Replacement»(ref-268132-S29487714212007101800000) .
4. Install the AIR solenoid valve. Refer to «Secondary Air Injection Solenoid Valve Replacement»(ref-268121-S34923269412007101800000) .
5. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(ref-268121-S03746815782007101800000) .

Scheme 15

1. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-268122-S04202183032007101800000) .
2. Remove the heat shield bolts and the shield from the exhaust manifold.

1. Install the heat shield and the bolts to the exhaust manifold. Tighten: Tighten the bolts to 9 N.m (80 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-268122-S04202183032007101800000) .

Scheme 16

1. Remove the spark plugs. Refer to «Spark Plug Replacement»(ref-268122-S04202183032007101800000) .
2. Remove the heat shield bolts and the shield from the exhaust manifold.

1. Install the heat shield and the bolts to the exhaust manifold. Tighten: Tighten the bolts to 9 N.m (80 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the spark plugs. Refer to «Spark Plug Replacement»(ref-268122-S04202183032007101800000) .

Scheme 17

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
2. Remove the catalytic converter heat shield rear 2 bolts where the catalytic converter heat shield connects to the muffler heat shield.
3. Remove the remaining exhaust muffler heat shield bolts and remove the heat shield from the floor panel studs.

1. Install the muffler heat shield to the floor panel studs placing the muffler heat shield under the rear part of the converter heat shield. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Secure the muffler heat shield with 5 bolts. Tighten: Tighten the exhaust muffler heat shield bolts to 7 N.m (62 lb in).
3. Lower the vehicle.