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Home >> Saturn >> 2003 >> Ion 1 Standard >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust >> Repair Instructions >> Catalytic Converter Replacement >> Installation Procedure

Installation Procedure

    Fig 1: View Of Catalytic Converter Pipe-To-Exhaust Extension Pipe Nuts (L61)
    GM889724Courtesy of GENERAL MOTORS CORP.
  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. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  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. Fig 2: View Of Exhaust Takedown Pipe
    GM878834Courtesy of GENERAL MOTORS CORP.
  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 - POSITION 2 in Removal and Installation in Engine Performance.
  8. Install the wheel drive shaft heat shield. Refer to Wheel Drive Shaft Heat Shield Replacement .
  9. Lower the vehicle.
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