Saturn 12615497 Engine Exhaust Manifold Rear

First and foremost before proceeding to the removal of the exhaust manifold, it is important to unscrew the cable connection which is from the negative terminal of the battery. Lift the car and use jack stands to hold it; then unbolt the exhaust pipe connecting to the rear exhaust manifold and suspend the weight of the exhaust system with wire. Discharge the spark plug connectors of the rear cylinder bank and also remove the dipstick tube. Subsequently, take out the spark plugs and uncouple the exhaust crossover pipe kindly and from the manifold that will be discarded but carefully noting the exhaust crossover pipe nuts and manifold mounting bolts. If required, the exhaust manifold heat shield should be unbolted to provide working space, then the exhaust manifold mounting bolts should be removed to release the exhaust manifold from the cylinder head. During installation, the manifold must be inspected whether it has cracks and the internal threads for the bolt must be clear and unharmed; besides, the surfaces of the manifold and cylinder head must be clean. Sit the manifold in position and fit the heat shields, bolts and gaskets, the retaining tabs help to keep the assembly together as it is tightened up. Put in a strip of the medium strength contemporary threadlocking compound ¼ inch wide from the fourth thread of the bolts, excluding the first three. Insert the manifold onto the cylinder head and, using the mounting bolts, just tightly screw them by hand, then using the torque wrench, tighten the bolts in two stages, starting from the center and ending with the ends. As an option, if the exhaust manifold gasket exposes some portion, it is to be bent backwards against the cylinder head. The rest of the steps are taken in reverse order as the removal and fit them and finally crank the engine to check for any exhaust leak.

Begin by removing the alternator and the rear manifold oxygen sensor, followed by the manifold heat shield and the heat shield from the crossover pipe.