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Home >> Saturn >> 2007 >> Ion Red Line >> Repair and Diagnosis >> External Pages >> Different car >> Section 149 (Engine Exhaust System) >> Repair Instructions >> Exhaust Extension Pipe Replacement (LSJ) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2005 Saturn Ion Red Line, 2005 Saturn Ion 3, 2005 Saturn Ion 2, and 2005 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
  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. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the catalytic converter pipe-to-exhaust extension pipe nuts.

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

    3. Fig 1: View Of Catalytic Converter Pipe-To-Exhaust Extension Pipe Nuts (LSJ)
    GM1388612Courtesy of GENERAL MOTORS CORP.
  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. Fig 2: View Of Exhaust Muffler (LSJ)
    GM1382254Courtesy 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. While maintaining muffler positioning, tighten the exhaust clamp nuts.

    Tighten:  Tighten the nuts to 45 N.m (33 lb ft).

    11. Fig 3: View Of Catalytic Converter Pipe-To-Exhaust Extension Pipe Nuts (LSJ)
    GM1388612Courtesy of GENERAL MOTORS CORP.
  11. Lower the vehicle.
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