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

Installation Procedure

    Fig 1: View Of Extension Pipe
    GM890535Courtesy of GENERAL MOTORS CORP.
  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 (1) to the underbody hangers.
    5. Fig 2: View Of Catalytic Converter Pipe-To-Exhaust Extension Pipe Nuts (L61)
    GM889724Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  5. Install the catalytic converter pipe-to-exhaust extension pipe nuts.

    Tighten:  Tighten the nuts to 30 N.m (22 lb ft).

    6. Fig 3: Installing Muffler (L61)
    GM890536Courtesy of GENERAL MOTORS CORP.
  6. Install the service muffler to the vehicle.
    7. Fig 4: Installing Service Muffler Clamp
    GM890538Courtesy of GENERAL MOTORS CORP.
  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. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  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.
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