LEMON Manuals: Even more car manuals for everyone
Home >> Saturn >> 2009 >> Astra XR, 4D Hatchback, Standard >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust >> Repair Instructions >> Exhaust System Replacement >> Removal Procedure

Removal Procedure

  1. Open the hood.
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  3. Fig 1: View Of Rear Muffler Fastening Clamp
    GM1937690Courtesy of GENERAL MOTORS CORP.
  4. Remove the rear muffler.
    1. When removing and installing the exhaust system, remove the electrical plug connection.
    2. Release the rear muffler fastening clamp (1).
  5. Fig 2: Identifying Muffler Brackets
    GM1937689Courtesy of GENERAL MOTORS CORP.
  6. Remove the rear muffler from bracket (1) in 2 places.
  7. Fig 3: Identifying Oxygen Sensor And Wire Harness Plug
    GM1998458Courtesy of GENERAL MOTORS CORP.
  8. Disconnect the wiring harness from the oxygen sensor (1).

    Disconnect the wire harness plug (2).

  9. Fig 4: Identifying Shipping Protector Installation Instructions
    GM1936302Courtesy of GENERAL MOTORS CORP.
    CAUTION: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.
    NOTE: The fastening clips of the exhaust system should be replaced every time that they are loosened. When replacing the exhaust system, the shipping fastening should only be removed after installation and before starting the engine. The shipping fastening should be removed for other operations in which the exhaust system has to be removed, stored and used to secure the flex pipe.
  10. See assembly instruction (1) on the shipping fastening.
  11. Fig 5: Identifying Exhaust Pipe Nuts
    GM1937693Courtesy of GENERAL MOTORS CORP.
  12. Remove the front exhaust pipe from the catalytic converter.

    Remove the 3 nuts (1).

  13. With the aid of an assistant, remove the exhaust system.

    Remove the center muffler from the bracket in 4 places.

  14. NOTE: When replacing the center or front exhaust pipe.
  15. Secure the front exhaust pipe with a vice.
  16. NOTE: When replacing the center or front exhaust pipe.
  17. Remove the center muffler from the front exhaust pipe.

    Release clamp fitting.

  18. Remove the oxygen sensor of the catalytic converter monitoring device.