Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSSATURN1996SC2 L4-1.9L DOHC VIN 7REPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTEMISSION CONTROL SYSTEMSCATALYTIC CONVERTERSERVICE AND REPAIRINTERMEDIATE PIPE (SERVICE REPLACEMENT)INSTALLATION
1996 Saturn SC2 L4-1.9L DOHC VIN 7
Installation
1996 Saturn SC2 L4-1.9L DOHC VIN 7SECTION Installation
INSTALLATION
1. Position the service intermediate pipe under the vehicle.
2. Install the sleeve, if required, on the intermediate pipe outlet and the clamp on the muffler inlet.
NOTE: The sleeve furnished with each muffler is required when both a service muffler and service intermediate pipe are installed.
Sleeve Dimensions:
^ Inside Diameter: 41.28 mm (1 5/8 in.)
^ Length: 46 mm (113/16 in.)
Muffler Clamps:
^ Service muffler to OE pipe and service muffler to service intermediate pipe Saturn P/N 25517280
^ Service intermediate pipe to O.E. muffler Saturn P/N 21010754
3. Insert the intermediate pipe outlet into the muffler inlet.
NOTE: The intermediate pipe must extend a minimum of 31.75 mm (11/4 in.) into the muffler inlet pipe.
4. Clean the intermediate pipe-to-three way catalytic converter outlet pipe.
5. Install a new gasket on the three way catalytic converter outlet pipe.
6. Make sure the three way catalytic converter gasket is properly located and install the three intermediate pipe-to-three way catalytic converter fasteners.
- Torque: 31 N.m (23 ft-lbs.)
7. Check the entire exhaust system for alignment and leaks.
Service Sleeve:
1. Position the service intermediate pipe under the vehicle.
2. Install the sleeve, if required, on the intermediate pipe outlet and the clamp on the muffler inlet.
NOTE: The sleeve furnished with each muffler is required when both a service muffler and service intermediate pipe are installed.
Sleeve Dimensions:
^ Inside Diameter: 41.28 mm (1 5/8 in.)
^ Length: 46 mm (113/16 in.)
Muffler Clamps:
^ Service muffler to OE pipe and service muffler to service intermediate pipe Saturn P/N 25517280
^ Service intermediate pipe to O.E. muffler Saturn P/N 21010754
3. Insert the intermediate pipe outlet into the muffler inlet.
NOTE: The intermediate pipe must extend a minimum of 31.75 mm (11/4 in.) into the muffler inlet pipe.
4. Clean the intermediate pipe-to-three way catalytic converter outlet pipe.
Converter Installation:
5. Install a new gasket on the three way catalytic converter outlet pipe.
6. Make sure the three way catalytic converter gasket is properly located and install the three intermediate pipe-to-three way catalytic converter fasteners.
- Torque: 31 N.m (23 ft-lbs.)
7. Check the entire exhaust system for alignment and leaks.
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.