Saturn 12606805 Engine Exhaust Manifold

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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.

On turbocharged models, you should remove the turbocharger. If not already done, remove the exhaust manifold heat shield.