GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 VUE - AWD 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Manifold Replacement - Right Side

Removal Procedure

    Object Number: 963963 Size: SH
  1. Loosen the clamp at the air cleaner assembly and throttle body assembly.
  2. Remove the attachment bolts from the outlet resonator/duct assembly to support bracket.
  3. Remove the outlet resonator/duct assembly.

    4. Object Number: 958550 Size: SH
  4. Disconnect the purge solenoid from the manifold to allow sufficient clearance when removing the upper exhaust manifold nut.

    5. Object Number: 933620 Size: SH

    Important: Access to the middle exhaust manifold nut to limited from under vehicle.

  5. Remove the middle exhaust manifold nut using a boxed end wrench.
  6. Disconnect the bank #1 02 sensor #1 connector at the rear of the engine.

    7. Object Number: 927888 Size: SH
  7. Raise the vehicle.
  8. Remove the rear exhaust down pipe assembly. Refer to Exhaust Manifold Pipe Replacement

    9. Object Number: 929945 Size: SH

    Important: Due to a clearance issue, when removing rear exhaust manifold (with 02 sensor), the right hand side of stabilizer bar must be rotated and positioned away from exhaust manifold.

  9. Remove the right hand stabilizer bar to frame mounting bolts.

    10. Object Number: 927949 Size: SH

    Notice: Do not allow the stud to rotate when removing or installing the right hand stabilizer nut. Secure the stud with a wrench while removing or installing the nut to prevent damage to the link.

  10. Remove the left and right hand stabilizer bar to lower link nut and discard the nut.

    11. Object Number: 964386 Size: SH
  11. Remove the exhaust heat shield bolts.
  12. Remove the exhaust heat shield.

    13. Object Number: 946726 Size: SH
  13. Remove the exhaust manifold nuts to the cylinder head.
  14. Remove the rear exhaust manifold and gasket.

Installation Procedure

    Object Number: 946726 Size: SH

    Important: Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound such as SA P/N 21485279 (or equivalent). Never use silicon products, silicon products will cause damage to oxygen sensor.

  1. Transfer the 02 sensor to the manifold if the manifold is being replaced.

    2. Tighten
    Tighten the oxygen sensor-to-exhaust manifold pipe - L81 to 45 N·m (33 lb ft).

  2. Install the new manifold gasket on the cylinder head.
  3. Install the exhaust manifold.
  4. Install the exhaust manifold nuts except for the outer nuts that will hold the heat shield to the manifold.

    5. Tighten
    Tighten the exhaust manifold nuts - L81 to 20 N·m (15 lb ft).


    Object Number: 964386 Size: SH
  5. Install the exhaust heat shield.
  6. Install the exhaust manifold heat shield nuts and bolt.

    7. Tighten
    Tighten the exhaust manifold nuts - L81 to 20 N·m (15 lb ft).

    Tighten
    Tighten the exhaust manifold heat shield bolt - L81 to 25 N·m (15 lb ft)

  7. Connect the 02 sensor connector near the rear of the engine.

    8. Object Number: 929945 Size: SH
  8. Install the right hand stabilizer bar to frame bolts.

    9. Tighten
    Tighten the stabilizer bar-to-frame bolts -- L81 to 50 N·m (37 lb ft).


    Object Number: 927949 Size: SH

    Notice: Do not allow the stud to rotate when removing or installing the right hand stabilizer nut. Secure the stud with a wrench while removing or installing the nut to prevent damage to the link.

  9. Install the new nuts, left and right hand stabilizer bar to stabilizer link and tighten.

    10. Tighten
    Tighten the stabilizer link nuts - L81 to 65 N·m (48 lb ft).


    Object Number: 927888 Size: SH
  10. Install the rear exhaust manifold down pipe assembly. Exhaust Manifold Pipe Replacement .

    11. Object Number: 933620 Size: SH
  11. Lower the vehicle.
  12. Attach the 02 electrical connector to bracket.
  13. Install the middle exhaust manifold nut.

    14. Tighten
    Tighten the exhaust manifold nuts - L81 to 20 N·m(15 lb ft).

  14. Re-position the purge valve to the intake manifold.
  15. Install the outlet resonator/duct assembly into position.
  16. Tighten the clamp at the throttle body assembly into position.
  17. Position the outlet resonator/duct assembly to support bracket and install the bolts.

    18. Tighten
    Tighten outlet resonator/duct assembly-to-support bracket bolts - L81 10 N·m (89 lb in).

  18. Tighten the clamp at the air cleaner assembly.