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

Installation Procedure

    Fig 1: Installing Muffler (L61)
    GM890536Courtesy of GENERAL MOTORS CORP.
  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. Fig 2: Installing Service Muffler Clamp
    GM890538Courtesy of GENERAL MOTORS CORP.
  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. NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  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.
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