Saturn 90537679 Engine Exhaust Manifold Assembly

Before going further to remove the exhaust manifolds, anyone should first unplug the cable of the negative terminal of the battery then lift the car and put on car stands securely. Take off the splash shield from under the engine hood and use the penetrating oil on the studs and nuts of the exhaust pipe to manifold. For the front exhaust manifold, it is necessary, respectively, to remove the connection of upper wire to the oxygen sensor, to unlock the bolt fixed to the bracket of engine hoist, take out the dipstick tube, and to unscrew four bolts of the manifold basic junctions, which are available. Take off the right front wheel and inner fender splash shield, then, loosen the right front wheel lug nuts, lift the vehicle one more time. Then, the front exhaust pipe should be disconnected, followed by the drivebelt which is attached to the tensioner; the air conditioning compressor wiring should also be disconnected Next, the three compressor mounting bolts should be removed and then the compressor should be hung out of the way but not dropped out of the unit and the AC refrigerant lines should not be removed. Last of all unscrew the lower mounting nuts of the exhaust manifold and unbolt it from the cylinder head. Again, to get good access to the rear exhaust manifold, it is necessary to delete the air intake duct assembly and the EVAP purge solenoid. Lift the car, provide it with sufficient support, then loosen the middle exhaust manifold bolt, and then disconnect the wiring of the top oxygen sensor and then take off the front aspect of the exhaust pipe. Partial disconnection of the stabilizer bar, detachment of the heat shield of the exhaust manifold and then, the nuts that connect the manifold to the cylinder head must be unscrewed. During the installation process check the exhaust manifolds for crack and also clean the bolt threads so as to had no deformation. Scrub the contact area of mating surfaces on the exhaust manifold and cylinder head and put a new gasket in place and then slide the exhaust manifold over the studs and tighten the nuts on the studs. When tightening the nuts, do it starting from the middle going round the top row then round the bottom row and when reconnecting the EGR tube use anti seize compound on the threads. Lastly, join the battery back, switch on the engine, and inspect drips the engine is cold then conducted the test when the engine is hot.

Disconnect the cable from the negative battery terminal. On turbocharged models, remove the turbocharger. If not already done, remove the exhaust manifold heat shield. Raise the vehicle and support it on jackstands. If equipped, remove the engine block heater. Detach the exhaust pipe from the manifold. Soak the exhaust pipe retaining nuts with penetrating oil, then remove them. Follow the lead from the oxygen sensor up to its electrical connector, then unplug the connector. Also detach the lead from its retaining clip. Remove the exhaust manifold mounting nuts and detach the manifold from the cylinder head. Using a scraper, thoroughly clean the mating surfaces on the cylinder head, manifold and exhaust pipe. Remove the residue with a solvent such as acetone or lacquer thinner. Check that the mating surfaces are perfectly flat and not damaged in any way. A warped or damaged manifold may require machining or, if severe enough, replacement. Install the new gasket to the cylinder head studs and place the manifold on the cylinder head. Tighten the nuts evenly, working from the center outwards, to the torque. Connect the exhaust pipe to the manifold and tighten the nuts evenly to the torque. The remainder of installation is the reverse of the removal steps. Reconnect the battery. Run the engine and check for exhaust leaks.

Before you can even think of disposing the exhaust manifold, unbend the cable that connects the negative battery terminal, then get rid of the air intake duct assembly and the heat shield that was earlier fixed on the exhaust manifold. Remove both the LSB and the HFM plug connections, lift the car and safely install it on jackstands. The front part of the exhaust pipe can now be cut off; the nuts that hold the exhaust pipe to the mounting bracket are best soaked with penetrating oil first, and the wiring of the oxygen sensor on the heat shield should be disconnected. Then, cut off the exhaust manifold mounting nuts, and disconnect the exhaust pipe from the manifold: For installation clean the mating surfaces on the cylinder head, manifold and exhaust pipe by scraping off any debris then using a rag and brake system cleaner to clean the surface further. Inspection to ensure that the mating surface is flat and that there is no sign of chipping, if there is evidence of warping or chipping then probably the two would require to be machined or changed respectively. New gasket needs to be set on the cylinder head studs and then manifold needs to be placed on the cylinder head studs, nuts needs to be tight from center to outer circle with the recommended torque value. Join the exhaust pipe with the manifold then torque the nuts that are tighten an even manner to the standard torque. Perform exhaust leaks check and then reconnect the battery and start the engine once again but before doing so reverse the above steps of removal.

Disconnect the cable from the negative battery terminal. Raise the vehicle and support it securely on jackstands. Remove the splash shield from below the engine compartment. Working under the vehicle, apply penetrating oil to the exhaust pipe-to-manifold studs and nuts. Drain the coolant. Remove the oxygen sensor from the exhaust manifold. Install an engine support fixture and remove the transaxle mount through-bolt. Raise the engine slightly to access the coolant extension housing. Remove the oil dipstick and dipstick tube. Remove the coolant extension housing. Remove the power steering pipe bracket. Remove the front exhaust pipe assembly. Remove the oil filter housing assembly. Remove the mounting nuts from the exhaust manifold, then detach the manifold from the cylinder head. Disconnect the EGR pipe from the exhaust manifold. Remove the oxygen sensor from the exhaust manifold. Remove the rear exhaust pipe assembly from the vehicle. Remove the mounting nuts from the exhaust manifold, then detach the manifold from the cylinder head. Check the exhaust manifolds for cracks. Make sure the bolt threads are clean and undamaged. The exhaust manifold and cylinder head mating surfaces must be clean before the exhaust manifolds are reinstalled-use a gasket scraper to remove all carbon deposits. Position a new gasket in place and slip the exhaust manifold over the studs on the cylinder head. Install the mounting nuts. When tightening the mounting nuts, work from the center outwards, alternating between top and bottom rows. Tighten the bolts to the specific torque. The remaining installation steps are the reverse of removal. When reconnecting the EGR tube to the exhaust manifold, use a slight amount of anti-seize compound on the threads. If the front exhaust manifold was removed, refill the cooling system. Reconnect the battery. Start the engine and check for leaks.

The first step is to disconnect the cable from the negative battery terminal.

Detach the exhaust pipe from the manifold by soaking the exhaust pipe retaining nuts with penetrating oil and then removing them. Follow the lead from the oxygen sensor up to its electrical connector, unplug the connector, and detach the lead from its retaining clip.

The remainder of the installation is the reverse of the removal steps.