GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 RELAY 🢒 Preface 🢒 Cautions and Notices 🢒 Exhaust Manifold Replacement - Left Side

Removal Procedure
  1. Remove the throttle body air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.
  2. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Remove the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Right Side in Engine Mechanical - 3.5L.
  4. Disconnect the inlet radiator hose from the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  5. Remove the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
  6. Remove the exhaust crossover pipe bolts from the engine left side exhaust manifold. Refer to Exhaust Crossover Pipe Replacement .

    7. Object Number: 60831 Size: SH
  7. Remove the exhaust manifold heat shield bolts.
  8. Remove the exhaust manifold heat shield.

    9. Object Number: 54301 Size: SH
  9. Remove the exhaust manifold nuts.
  10. Remove the exhaust manifold.
  11. Remove the exhaust manifold gasket.
  12. Clean the engine left side exhaust manifold to the engine left side cylinder head sealing surfaces.

Installation Procedure

    Object Number: 54301 Size: SH
  1. Install the exhaust manifold gasket.
  2. Install the exhaust manifold.

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the exhaust manifold nuts.

    4. Tighten
    Tighten the exhaust manifold nuts to 16 N·m (12 lb ft).


    Object Number: 60831 Size: SH
  4. Install the exhaust manifold heat shield.
  5. Install the exhaust manifold heat shield bolts.

    6. Tighten
    Tighten the exhaust manifold heat shield bolts to 10 N·m (89 lb in).

  6. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement .
  7. Install the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
  8. Connect the inlet radiator hose to the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
  9. Install the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement - Right Side in Engine Mechanical - 3.5L.
  10. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  11. Install the throttle body air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.