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Home >> Saturn >> 2008 >> Astra XR, 4D Hatchback, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Exhaust Manifold Replacement >> Installation Procedure

Installation Procedure

  1. Clean the sealing surface.
    2. NOTE: Refer to Fastener Notice .
  2. Install the exhaust manifold.

    Use new gasket and nuts.

    Tighten:  Tighten the 9 nuts to 20 N.m (15 lb ft).

  3. Replace the heat shield.

    Install the wiring harness bracket of the oxygen sensor mixture regulator.

    Tighten:  Tighten the bolt to 15 N.m (11 lb ft).

  4. Raise the vehicle by its full height.
  5. If equipped with air conditioning, install the compressor. Refer to Air Conditioning Compressor Replacement .

    Tighten:  Tighten the 3 bolts to 22 N.m (16 lb ft).

  6. In vehicles with air conditioning, install the drive belt. Refer to Drive Belt Replacement .
  7. Install the catalytic converter bracket.

    Install to the cylinder block.

    Tighten:  Tighten the 2 bolts to 20 N.m (15 lb ft).

  8. Install the catalytic converter to the bracket.

    Tighten:  Tighten the 2 bolts to 20 N.m (15 lb ft).

  9. Install the heat shield to the catalytic converter.

    Tighten:  Tighten the 2 bolts to 8 N.m (70 lb in).

  10. Install the exhaust system.

    Install the 6 damper rings.

  11. Install the front exhaust pipe to the catalytic converter.

    Use a new gasket.

    Tighten:  Tighten the 3 new nuts to 20 N.m (15 lb ft).

  12. Install the catalytic converter control oxygen sensor wiring harness.
    • Connect the wiring harness plug.
    • Install the wiring harness into the bracket.
  13. Install the oil dipstick guide tube. Refer to Oil Level Indicator and Tube Replacement .
  14. Clean the 2 threads.
  15. Install the 2 engine transport shackles.

    Tighten:  Tighten the 2 bolts to 25 N.m (18 lb ft).

  16. Install the bracket, wiring harness for the mixture regulator oxygen sensor to the cylinder head together with the exhaust manifold heat shield.

    Tighten:  Tighten the bolt to 25 N.m (18 lb ft).

  17. Install the mixture regulator oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement .
  18. Install the resonator. Refer to Air Cleaner Inlet Duct Replacement .
  19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  20. Connect the battery.

    Install the negative connection to the ground terminal.

    Tighten:  Tighten the nut to 5 N.m (44 lb in).

  21. Inspect and correct the engine oil level.
  22. For programming procedures, refer to Control Module References .
  23. Close the hood.
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