Engine Exhaust System: Removal & Installation Saturn ION I

Removal Procedure

1. Remove the exhaust manifold heat shield.
2. Remove the oxygen sensor. Refer to «Heated Oxygen Sensor Replacement - Position 1»(ref-196953-S12323004222005101000000) in Engine Controls - 2.0L (LSJ).
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
4. Remove the pipe to manifold nuts.
5. Pull down and back on the exhaust pipe in order to disengage the pipe from the exhaust manifold.
6. Lower the vehicle.
7. Remove the exhaust manifold to cylinder head nuts.
8. Remove the exhaust manifold.
9. Clean all the sealing surfaces.

Installation Procedure

1. Install a new exhaust manifold gasket.
2. Install the exhaust manifold to the cylinder head.
3. Install the new exhaust manifold to cylinder head retaining nuts. Follow the tightening sequence. Tighten: Tighten the nuts to 13 N.m (115 lb in).
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
5. Install a new exhaust manifold to flex coupler gasket.
6. Push the flex coupler into position on the exhaust manifold.
7. Install the retaining nuts which secure the manifold to the flex decoupler. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
8. Lower the vehicle.
9. Install the oxygen sensor. Refer to «Heated Oxygen Sensor Replacement - Position 1»(ref-196953-S12323004222005101000000) in Engine Controls - 2.0L (LSJ).
10. Install the exhaust manifold heat shield. Tighten: Tighten the bolts to 25 N.m (18 lb ft).

1. Remove the exhaust manifold heat shield.
2. Remove the oxygen sensor. Refer to «Heated Oxygen Sensor Replacement - Position 1»(ref-196955-S14464016402005101000000) in Engine Controls - 2.2L (L61).
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
4. Remove the pipe to manifold nuts.
5. Pull down and back on the exhaust pipe in order to disengage the pipe from the exhaust manifold.
6. Lower the vehicle.
7. Remove the exhaust manifold to cylinder head nuts.
8. Remove the exhaust manifold.
9. Clean all the sealing surfaces.

1. Install a new exhaust manifold gasket.
2. Install the exhaust manifold to the cylinder head.
3. Install the new exhaust manifold to cylinder head retaining nuts. Follow the tightening sequence. Tighten: Tighten the nuts to 13 N.m (115 lb in).
4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
5. Install a new exhaust manifold to flex coupler gasket.
6. Push the flex coupler into position on the exhaust manifold.
7. Install the retaining nuts which secure the manifold to the flex decoupler. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
8. Lower the vehicle.
9. Install the oxygen sensor. Refer to «Heated Oxygen Sensor Replacement - Position 1»(ref-196955-S14464016402005101000000) in Engine Controls - 2.2L (L61).
10. Install the exhaust manifold heat shield. Tighten: Tighten the bolts to 25 N.m (18 lb ft).

1. Remove the wheel drive shaft heat shield. Refer to «Wheel Drive Shaft Heat Shield Replacement»(ref-197010-S15114761432005101000000) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
3. Remove the post catalytic converter heated oxygen sensor (HO2S). Refer to «Heated Oxygen Sensor Replacement - Position 2»(ref-196955-S27389451202005101000000) in Engine Controls - 2.2L.
4. Remove the catalytic converter pipe-to-exhaust manifold nuts.
5. Carefully separate the converter pipe from the exhaust manifold.
6. Lower the converter pipe to rest on the rear crossmember of the front suspension frame.
7. Remove the catalytic converter pipe-to-exhaust extension pipe nuts.
8. Position the converter pipe forward and support the pipe.
9. Move the extension pipe rearward and down in order to separate the pipes.
10. Remove the catalytic converter pipe assembly from the vehicle.
11. If the exhaust gaskets have remained on the vehicle, remove the gaskets from the exhaust manifold and from the exhaust extension pipe, and discard the gaskets.
12. Clean the flange surfaces of any remaining gasket material.

1. Install NEW exhaust gaskets to the exhaust manifold and to the exhaust extension pipe. The gaskets are designed to be retained to the flange by the flange studs.
2. Position the catalytic converter pipe assembly to the vehicle.
3. Move the extension pipe rearward and down in order to connect the converter pipe to the extension pipe.
4. Install the catalytic converter pipe-to-exhaust extension pipe nuts. Tighten: Tighten the nuts to 30 N.m (22 lb ft).
5. Carefully install the converter pipe to the exhaust manifold.
6. Install the catalytic converter pipe-to-exhaust manifold nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
7. Install the post catalytic converter HO2S. Refer to «Heated Oxygen Sensor Replacement - Position 2»(ref-196955-S27389451202005101000000) in Engine Controls - 2.2L.
8. Install the wheel drive shaft heat shield. Refer to «Wheel Drive Shaft Heat Shield Replacement»(ref-197010-S15114761432005101000000) .
9. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Remove the post catalytic converter heated oxygen sensor (HO2S). Refer to «Heated Oxygen Sensor Replacement - Position 2»(ref-196953-S10397640492005101000000) in Engine Controls - 2.0L (LSJ).
3. Remove the catalytic converter pipe-to-exhaust manifold nuts.
4. Carefully separate the converter pipe from the exhaust manifold.
5. Lower the converter pipe to rest on the rear crossmember of the front suspension frame.
6. Remove the catalytic converter pipe-to-exhaust extension pipe nuts.
7. Position the converter pipe forward and support the pipe.
8. Move the extension pipe rearward and down in order to separate the pipes.
9. Remove the catalytic converter pipe assembly from the vehicle.
10. If the exhaust gaskets have remained on the vehicle, remove the gaskets from the exhaust manifold and from the exhaust extension pipe, and discard the gaskets.
11. Clean the flange surfaces of any remaining gasket material.

1. Install NEW exhaust gaskets to the exhaust manifold and to the exhaust extension pipe. The gaskets are designed to be retained to the flange by the flange studs.
2. Position the catalytic converter pipe assembly to the vehicle.
3. Move the extension pipe rearward and down in order to connect the converter pipe to the extension pipe.
4. Install the catalytic converter pipe-to-exhaust extension pipe nuts. Tighten: Tighten the nuts to 30 N.m (22 lb ft).
5. Carefully install the converter pipe to the exhaust manifold.
6. Install the catalytic converter pipe-to-exhaust manifold nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
7. Install the post catalytic converter HO2S. Refer to «Heated Oxygen Sensor Replacement - Position 2»(ref-196953-S10397640492005101000000) in Engine Controls - 2.0L (LSJ).
8. Lower the vehicle.

Note. Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Support the exhaust muffler.
3. Cut the exhaust extension pipe just forward of the weld at the front of the exhaust muffler using the SA9168NE . See «Special Tools»(ref-197010-S37313881612005101000000) .
4. Release the muffler insulator from the underbody hanger and remove the exhaust muffler.
5. Support the catalytic converter pipe.
6. Remove the catalytic converter pipe-to-exhaust extension pipe nuts.
7. Release the exhaust extension pipe insulators from the underbody hangers, and support the extension pipe.
8. Separate the extension pipe from the converter pipe and remove the extension pipe from the vehicle.
9. Clean the converter pipe flange surface of any remaining gasket material.

1. Install a NEW exhaust gasket to the service exhaust extension pipe. The gasket is designed to be retained to the flange by the flange studs.
2. Install the catalytic converter pipe-to-exhaust extension pipe nuts. Tighten: Tighten the nuts to 30 N.m (22 lb ft).
3. Position the extension pipe to the vehicle.
4. Connect the extension pipe to the converter pipe, and support the extension pipe.
5. Install the exhaust extension pipe insulators to the underbody hangers.
6. Install the service muffler to the vehicle.
7. Slide the muffler inlet pipe over the extension pipe, then install the muffler insulator to the underbody hanger.
8. Install a service muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (3/4 in), from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister.
9. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia.
10. While maintaining muffler positioning, tighten the exhaust clamp nuts. Tighten: Tighten the nuts to 45 N.m (33 lb ft).
11. Lower the vehicle.

Note. Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Support the exhaust muffler.
3. Cut the exhaust extension pipe just forward of the weld at the front of the exhaust muffler using the SA9168NE . See «Special Tools»(ref-197010-S37313881612005101000000) .
4. Release the muffler insulator from the underbody hanger and remove the exhaust muffler.
5. Support the catalytic converter pipe.
6. Remove the catalytic converter pipe-to-exhaust extension pipe nuts.
7. Release the exhaust extension pipe insulators from the underbody hangers, and support the extension pipe.
8. Separate the extension pipe from the converter pipe and remove the extension pipe from the vehicle.
9. Clean the converter pipe flange surface of any remaining gasket material.

1. Install a NEW exhaust gasket to the service exhaust extension pipe. The gasket is designed to be retained to the flange by the flange studs.
2. Position the extension pipe to the vehicle.
3. Connect the extension pipe to the converter pipe, and support the extension pipe.
4. Install the exhaust extension pipe insulators to the underbody hangers.
5. Install the catalytic converter pipe-to-exhaust extension pipe nuts. Tighten: Tighten the nuts to 30 N.m (22 lb ft).
6. Install the service muffler to the vehicle.
7. Slide the muffler inlet pipe over the extension pipe, then install the muffler insulator to the underbody hanger.
8. Install a service muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (3/4 in), from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister.
9. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia.
10. While maintaining muffler positioning, tighten the exhaust clamp nuts. Tighten: Tighten the nuts to 45 N.m (33 lb ft).
11. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Support the exhaust muffler.
3. Cut the exhaust extension pipe just forward of the weld at the front of the exhaust muffler.
4. Release the muffler insulator from the underbody hanger and remove the exhaust muffler.
5. Deburr the extension pipe end as necessary.

1. Install the service muffler to the vehicle.
2. Slide the muffler inlet pipe over the extension pipe, then install the muffler insulator to the underbody hanger.
3. Install a service muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (3/4 in), from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister.
4. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia.
5. While maintaining muffler positioning, tighten the exhaust clamp nuts. Tighten: Tighten the nuts to 45 N.m (33 lb ft).
6. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Support the exhaust muffler.
3. Cut the exhaust extension pipe just forward of the weld at the front of the exhaust muffler.
4. Release the muffler insulator from the underbody hanger and remove the exhaust muffler.
5. Deburr the extension pipe end as necessary.

1. Install the service muffler to the vehicle.
2. Slide the muffler inlet pipe over the extension pipe, then install the muffler insulator to the underbody hanger.
3. Install a service muffler clamp to the muffler inlet pipe. Position the clamp approximately 19 mm (3/4 in), from the edge of the muffler inlet, with the clamp nuts oriented away from the evaporative emission (EVAP) canister.
4. Align the muffler and tailpipe to the vehicle underbody and rear bumper fascia.
5. While maintaining muffler positioning, tighten the exhaust clamp nuts. Tighten: Tighten the nuts to 45 N.m (33 lb ft).
6. Lower the vehicle.

Note. Do not over-flex or damage the flex decoupler joint when moving the flex decoupler joint from the normal mounting position. The flex decoupler joint will flex a maximum of six degrees which is equivalent to the pipes connected at the joint which move 1 inch for each foot length of pipe. A three foot pipe would move a maximum of three inches.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Separate the post catalytic converter HO2S wiring (1) from the exhaust heat shield.
3. Remove the catalytic converter pipe from the vehicle, to access the center rivet on the exhaust heat shield. Refer to «Catalytic Converter Replacement (L61)»(ref-197010-S20629904922005101000000) or «Catalytic Converter Replacement (LSJ)»(ref-197010-S35951311282005101000000) .
4. Release the exhaust extension pipe forward insulators from the underbody hangers, and support the extension pipe.
5. Remove the exhaust heat shield retaining nut.
6. Drill out and remove the heat shield retaining rivets.
7. Remove the heat shield from the vehicle.

1. Install the exhaust heat shield into position on the vehicle.
2. Install new heat shield retaining rivets.
3. Install the exhaust heat shield retaining nut. Tighten: Tighten the nut to 10 N.m (89 lb in).
4. Remove the support from the exhaust extension pipe.
5. Install the exhaust extension pipe forward insulators to the underbody hangers.
6. Install the catalytic converter pipe to the vehicle. Refer to «Catalytic Converter Replacement (L61)»(ref-197010-S20629904922005101000000) or «Catalytic Converter Replacement (LSJ)»(ref-197010-S35951311282005101000000) .
7. Install the post catalytic converter HO2S wiring (1).
8. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Remove the wheel drive shaft heat shield-to-transmission mount bracket bolt.
3. Remove the drive shaft heat shield-to-engine block bolt.
4. Remove the wheel drive shaft heat shield.

1. Install the wheel drive shaft heat shield into position on the vehicle.
2. Install the wheel drive shaft heat shield-to-engine block bolt. Tighten: Tighten the bolt to 30 N.m (22 lb ft).
3. Install the wheel drive shaft heat shield-to-transmission mount bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Lower the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-196965-S31699626272005101000000) in General Information.
2. Release the exhaust extension pipe insulators (1, 2) from the underbody hangers.
3. Release the muffler insulator (3) from the underbody hanger and slowly lower the exhaust to rest on the rear axle beam.
4. Support the LH side of the fuel tank, just clear of the fuel tank heat shield.
5. Remove the LH fuel tank strap bolts and the strap.
6. Using a flat-bladed screwdriver, release the heat shield push-rivet style retainers (1).
7. Remove the fuel tank heat shield from the vehicle.

1. Carefully install the fuel tank heat shield into position on the fuel tank.
2. Install the heat shield retainers into position, then press to secure the retainers. Ensure that each of the retainers is fully seated.
3. Install the LH fuel tank strap and strap bolts.
4. Tighten the fuel tank strap bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
5. Remove the support from the fuel tank.
6. Raise the exhaust into position and install the muffler insulator (3) to the underbody hanger.
7. Install the exhaust extension pipe insulators (1, 2) to the underbody hangers.
8. Lower the vehicle.