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)REMOVAL
1996 Saturn SC2 L4-1.9L DOHC VIN 7
Removal
1996 Saturn SC2 L4-1.9L DOHC VIN 7SECTION Removal
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED PRIOR TO LIFTING. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED. MAKE SURE HOIST DOES NOT CONTACT FUEL OR BRAKE LINES.
REMOVAL
1. Raise vehicle squarely on a lift.
NOTE: When replacing the intermediate pipe, it will be necessary to remove or cut off the muffler at the dimension provided. Removing the muffler and disconnecting the three way catalytic converter allows for intermediate pipe replacement without lowering the rear suspension. It will be necessary to complete an alignment check if the rear suspension is lowered.
2. Remove the fasteners at rear of three way catalytic converter.
NOTE: Do not bend the front exhaust pipe or hanger attached to the engine stiffening bracket when servicing the front exhaust pipe and/or three way catalytic convertor. Bending the bracket or pipe may cause premature failure.
3. Remove three way catalytic converter gasket and discard.
NOTE: Always use a chain cutter to cut the stainless steel exhaust system pipes. A torch leaves rough edge and warps the pipe end, preventing good exhaust system sealing.
4. Using chain cutter SA9168 NE (or equivalent), cut the muffler inlet pipe off 61.91 mm (27/16 in.) forward of the weld. If a service muffler has been installed, separate the joint.
5. Remove the intermediate pipe support bracket isolator and the intermediate pipe.
REMOVAL
Vehicle Lifting:
1. Raise vehicle squarely on a lift.
NOTE: When replacing the intermediate pipe, it will be necessary to remove or cut off the muffler at the dimension provided. Removing the muffler and disconnecting the three way catalytic converter allows for intermediate pipe replacement without lowering the rear suspension. It will be necessary to complete an alignment check if the rear suspension is lowered.
Converter Installation:
2. Remove the fasteners at rear of three way catalytic converter.
NOTE: Do not bend the front exhaust pipe or hanger attached to the engine stiffening bracket when servicing the front exhaust pipe and/or three way catalytic convertor. Bending the bracket or pipe may cause premature failure.
3. Remove three way catalytic converter gasket and discard.
NOTE: Always use a chain cutter to cut the stainless steel exhaust system pipes. A torch leaves rough edge and warps the pipe end, preventing good exhaust system sealing.
Cutting The Muffler Inlet Pipe:
4. Using chain cutter SA9168 NE (or equivalent), cut the muffler inlet pipe off 61.91 mm (27/16 in.) forward of the weld. If a service muffler has been installed, separate the joint.
5. Remove the intermediate pipe support bracket isolator and the intermediate pipe.
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.