GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2001 🢒 SL1/SC1/SW1 🢒 Engine 🢒 Engine Exhaust 🢒 Catalytic Converter and Intermediate Pipe Heat Shields Replacement

Removal Procedure

    Object Number: 872284 Size: SH

    Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

  1. Raise the vehicle squarely on a lift.

    2. Object Number: 865465 Size: SH
  2. Loosen the front exhaust pipe clamp at the engine block bracket and slide the clamp out of engagement with the bracket.
  3. Remove the front exhaust pipe nuts at the exhaust manifold.

    4. Object Number: 862045 Size: SH
  4. Remove the nuts at the outlet of the catalytic converter to intermediate pipe.
  5. Disengage the 2 rubber isolators from the hanger rod on the front exhaust pipe and remove the pipe from the vehicle.

Installation Procedure
  1. Clean the intermediate pipe-to-catalytic converter flange surface.

    2. Object Number: 862045 Size: SH
  2. Install a new gasket on the catalytic converter outlet.
  3. Install the catalytic converter to intermediate pipe with 3 nuts.

    4. Tighten
    Tighten the catalytic converter-to-isolator to 25 N·m (19 lb ft)

  4. Install the 2 rubber isolators supporting the front exhaust pipe to the hanger rod on the pipe.
  5. Install the new exhaust pipe to manifold gasket on the studs.
  6. Install the exhaust pipe to the manifold with 3 nuts.

    7. Tighten
    Tighten the exhaust pipe-to-manifold to 31 N·m (23 lb ft)

  7. Slide the front exhaust pipe clamp over the engine block bracket and tighten the clamp.

    8. Tighten
    Tighten the exhaust pipe clamp-to-support bracket to 60 N·m (44 lb ft)

  8. Check the exhaust system for leaks.