GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Manifold Front Pipe Replacement

Exhaust Manifold Front Pipe Replacement Gasket - L81

Removal Procedure

    Caution: Refer to Vehicle Lifting Caution in the Preface section.


    Object Number: 892169 Size: SH
  1. Raise the vehicle on a hoist.
  2. Remove the exhaust manifold to front exhaust manifold pipe fasteners.

    3. Notice: Avoid excessive movement of the pipe.

  3. Pull down the front exhaust manifold pipe just enough to remove the gasket.
  4. Remove the old gasket and discard.

Installation Procedure

    Object Number: 892169 Size: SH
  1. Install the new gasket onto the exhaust manifold studs.
  2. Install the front exhaust manifold pipe to exhaust manifold nuts and tighten.

    3. Tighten
    Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N·m (25 lb ft).

  3. Lower the vehicle from the hoist.
  4. Check the entire exhaust system for leaks.

Exhaust Manifold Front Pipe Replacement L81

Removal Procedure

    Object Number: 892062 Size: SH

    Important: Do not apply grease or silicon products to the heated oxygen sensor (H02S-2). Do not alter the wiring in any way. The wires carry air reference to the sensor.

  1. Remove the heated oxygen sensor electrical connector.

    2. Caution: Refer to Vehicle Lifting Caution in the Preface section.

  2. Raise the vehicle on a hoist.
  3. Remove the heated oxygen sensor.

    4. Object Number: 892049 Size: SH
  4. Remove the exhaust manifold pipe to exhaust manifold nuts.

    5. Object Number: 892044 Size: SH
  5. Remove the front exhaust manifold pipe to the rear exhaust manifold pipe attachment bolts.

Installation Procedure

    Object Number: 892049 Size: SH
  1. Position the gasket on the exhaust manifold pipe.
  2. Position the front exhaust manifold pipe in to the vehicle.

    3. Important: Do not tighten the fasteners.

  3. Install the exhaust manifold pipe to exhaust manifold units.

    4. Object Number: 892044 Size: SH
  4. Position the gasket between the front and rear exhaust manifold pipes.
  5. Install the front exhaust manifold pipe to rear exhaust manifold pipe bolts and tighten.

    6. Tighten
    Tighten the exhaust manifold pipe bolts to 20 N·m (15 lb ft).

  6. Tighten the exhaust manifold pipe to exhaust manifold nuts.

    7. Tighten
    Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N·m (25 lb ft).

    Notice: Refer to Heated Oxygen Sensor Damage Notice in the Preface section.


    Object Number: 892062 Size: SH
  7. Install the heated oxygen sensor.

    8. Tighten
    Tighten the oxygen sensors (lower exhaust pipe) to 45 N·m (33 lb ft).

  8. Connect the heated oxygen sensor harness connector.
  9. Lower the vehicle from the hoist.
  10. Start the engine and check for exhaust leaks.