How to Replace the Exhaust Manifold in a Saturn VUE

Saturn introduced the Vue in 2002 as its entry into the small SUV segment of the market. Saturn realized the stiff competition and carved out a spot with its low price and noted "no hassle" experience at the dealer. The following steps guide you through the removal and installation of the exhaust manifold on the 3.5L V6 engine.

Instructions

Remove the Intake Manifold

1

Disconnect the sensor connector for the Intake Air Temperature (IAT). Release the clasp to the air cleaner assembly and remove the push-pin from the outlet resonator assembly on the support bracket. Loosen the throttle body assembly clamp.

2

Pull the Positive Crankcase Vent (PCV) hose from the cam cover. Take off the outlet resonator assembly.

3

Loosen the bolts of the exhaust manifold heat shield and remove it. Disconnect the connectors (front and rear) for the Oxygen sensor. Pull the rear Oxygen sensor wire from the heat shield.

4

Pull the exhaust manifold pipe and the resonator pipe apart and take out the gasket. Discard the gasket.

5

Remove the exhaust manifold nuts and then lift the exhaust manifold from the engine. Remove the gasket and discard it.

Install the Intake Manifold

6

Clean the manifold mating surfaces. Install the new gasket on the cylinder head.

7

Set the manifold in position. Torque the nuts in sequence working out from the center to 13 foot pounds. Transfer the Oxygen sensor to the new manifold after coating the threads with a nickel-based anti-seize material.

8

Install the Oxygen sensor into the manifold and torque the nut to 33 foot pounds. Put the gasket and exhaust pipe in place and torque the nuts to 22 foot pounds. Connect the rear oxygen sensor to the heat shield.

9

Position the new exhaust manifold on the flange studs. Set the nuts in place and finger-tighten them, then torque to 31 foot pounds. Set the exhaust manifold heat shield in place and torque the bolts to 17 foot pounds.

10

Put the outlet resonator assembly in place and connect the PVC fresh air hose. Tighten the clamp for the throttle body assembly. Position the outlet resonator assembly to the support bracket and set the push-pin in place.

11

Secure the air cleaner assembly and connect the IAT sensor. Start the engine. Check for exhaust leaks.