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Home >> Saturn >> 2007 >> Ion Red Line >> Repair and Diagnosis >> External Pages >> Different car >> Section 66 (Engine Exhaust System) >> Repair Instructions >> Muffler Replacement (L61) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Saturn Ion Red Line, 2004 Saturn Ion 3, 2004 Saturn Ion 2, and 2004 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.
  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 1: Installing Muffler (L61)
    GM890536Courtesy 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. Fig 2: Installing Service Muffler Clamp
    GM890538Courtesy of GENERAL MOTORS CORP.
  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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