How do you change exhaust headers on Saturn sl2?

Answer 1

It would probably be best to remove the radiator fan and radiator, to give you a little more working room.

Then remove the bolts that hold the exhaust manifold to the headpipe.

There are several bolts and/or studs with nuts that hold the exhaust manifold to the engine head, remove them, saving one of the center bolts/nuts for last.

You may need to remove the AC compressor, but don't disconnect the refrigerant lines if you do; just set the compressor somewhere out of the way.

Once all of the bolts and nuts have been removed, just gently work the exhaust manifold loose and pull it off.

Clean all surfaces. The gasket between the head and the exhaust manifold will stick in places, causing some inconvenience as you remove it. Don't nick the head as you clean it, that can result in a place for hot exhaust to leak out and will result in eroding away part of the head and you'll end up with an even larger exhaust leak.

Find a good technical reference book to get the proper torque settings for the exhaust manifold bolts/nuts. If you over tighten, they will pull out of the head. If you do not tighten enough, they will work loose.

Use a NEW doughnut gasket between the header and the head pipe.