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HOMESERVICE MANUALSSATURN2000SL1 AUTOMATICREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE MECHANICALENGINE EXHAUST SYSTEMREMOVAL AND INSTALLATIONRESONATOR (2ND DESIGN 1998-2000 MODEL YEAR - DOHC ONLY)INSTALLATION
2000 Saturn SL1 Automatic

RESONATOR (2nd DESIGN 1998-2000 MODEL YEAR - DOHC ONLY): Installation

2000 Saturn SL1 AutomaticSECTION Installation
  1. Install pipe clamp over outlet end of resonator.
  2. Slide outlet end of replacement resonator over remaining section of intermediate pipe.
  3. Install new gasket at outlet end of catalytic converter.
  4. Install resonator to catalytic converter outlet flange and install nuts. Flat portion of resonator flange should face downward.

    Torque: 

    Converter Flange Nuts: 25 N.m (19 ft-lbs) 

    Fig 1: Installing Converter To Outlet Flange
    G01068152Courtesy of GENERAL MOTORS CORP.
  5. Refer to illustration and position pipe clamp 25 mm (1 in.) from the end of resonator pipe and facing downward.
    Fig 2: Positioning Pipe Clamp
    G01068153Courtesy of GENERAL MOTORS CORP.
  6. Align resonator and muffler to achieve proper clearances shown in step  7 . Then, tighten clamp.
  7. Check exhaust system alignment and clearance to heat shields. Rattle noises will occur if any of the following clearances are not sufficient.
    • Resonator should have at least 15 mm (9/16 in.) clearance from heat shields. If necessary, bend heat shields away in any areas with insufficient clearance.
    • Position muffler to ensure 19 mm (3/4 in.) of clearance between rear of muffler and muffler ramp (2). If proper clearance cannot be obtained, intermediate pipe must be shortened at resonator joint.
    • Muffler hanger block should not contact hanger screw (1). If necessary, loosen muffler mounting strap, shift muffler mounting strap forward to eliminate contact, and retighten.
      Fig 3: Positioning Muffler And Components
      G01068154Courtesy of GENERAL MOTORS CORP.

    Torque: 

    Muffler Mounting Strap Fasteners: 22 N.m (16 ft-lbs) 

  8. Start engine and check for exhaust system leaks.

    Torque: 

    Exhaust Pipe Clamp Nuts: 41 N.m (30 ft-lbs) 

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.