SPS

Performance Exhaust Header Preparation (DT3301)

1. Make sure that you have all the parts listed below before you attempt this installation! Contact SPS immediately if you have questions or concerns regarding part quantities or part descriptions.

Air Conditioning Compressor Removal

1. Disconnect the vehicle negative battery terminal
2. Remove the engine accessory drive belt (serpentine belt) and lay aside for reuse.
3. Remove the upper and lower rear AC compressor-to-bracket fasteners. Loosen the center rear bolt, but do NOT remove it at this time.
4. Remove the three front AC compressor-to-bracket fasteners, leaving the bracket attached to the engine.
5. Place the AC compressor "out of the way" of the engine exhaust manifold. Use caution not to bend, kink, or otherwise damage the refrigerant lines running from the AC compressor through the dash panel (it may be helpful to use a piece of rope or wire to tie the compressor to the upper radiator support bar). Note: you will NOT need to further disconnect any part of the AC system.
6. Remove the four fasteners holding the rear support bracket to the engine. Remove the bracket from the engine and place the bracket and fasteners aside for later reuse.

Vehicle Preparation and Support

1. At this point, raise the front end of the vehicle and place on jackstands supporting the vehicle by either the front cradle or spaceframe. Be sure that the car is firmly supported before going ANY further with this installation! Note that the car should be in gear (or ‘park’) and the emergency brake set to keep the car from moving while being supported.

Exhaust Manifold and Downpipe Removal (93+)

1. From under the car, loosen and remove the three 13mm downpipe-to-manifold nuts.
2. Loosen and remove the clamp that holds the downpipe to the bracket on the underside of the transmission. This clamp if often severely corroded. If necessary, you may remove the fasteners that attach the bracket to the transmission. However, once you have removed the downpipe (see step 6 below,) then you must reinstall the bracket to the underside of the transmission!
3. Loosen the downpipe clamp nut and slide the clamp forward, disengaging it from the bracket.
4. Pull down the downpipe, remove the downpipe-to-manifold gasket, and discard the gasket. (Your new header uses gasketless aerospace flanges.)
5. Cut the downpipe from the catalytic converter approximately 3 inches forward of the welded mounting posts. Do not remove the catalytic converter from the vehicle. Be sure to leave enough pipe forward of the converter to install the header's catalytic converter adapter pipe.
6. Remove the downpipe from the vehicle. (If you removed the transmission bracket in step 2 above, you must reinstall the bracket at this time.)
7. From above, disconnect the electrical connector for the oxygen sensor.
8. Loosen and remove the oxygen sensor from the manifold using a 19mm crows foot tool. A 19mm open-ended wrench will probably work just fine, too. Lay the sensor aside for reuse. Do NOT touch the sensing element when removed from the exhaust manifold.
9. Loosen and remove the five 13mm manifold-to-head nuts. If you have received new nuts with the purchase of the header installation kit, then you may discard the nuts upon removal.
10. Remove the manifold from the head. Discard the manifold-to-head gasket upon removal. (We strongly recommend the use of a new gasket.)
11. If you purchased the header installation kit with new studs, then remove the five manifold studs from the cylinder head using a torx tool. You may discard the old studs upon removal.

SPS DT3301 Installation

1. If you purchased the header installation kit and removed the manifold studs during step 11 above, then install the five new manifold studs into the cylinder head using a torx tool. Snug the studs in their bores by hand.
2. Install the new exhaust manifold gasket (part number SAT21008327,) facing the smooth side toward the manifold. Install the manifold to the head. (If you purchased the header installation kit, use the five new nuts provided with the kit.) Torque the nuts to 31 Nm (23 ft-lb). Note: a dab of anti-seize on the threads will make future disassembly much easier. Be sure to tighten from the center stud outward, repeating the sequence twice to ensure an even tightening of the manifold to the head. (Note: an improper torque procedure can cause damage to the cylinder head.)
3. Install the oxygen sensor to the manifold using a 19mm crows foot tool. Torque the sensor to 25 Nm (18 ft-lb). If anti-seize is used on these threads, be sure to use a NON-silicone based product, as silicone will damage the sensor element, requiring its replacement.
4. Reconnect the electrical connector for the oxygen sensor.
5. From beneath the vehicle, slide the catalytic converter adapter onto the front of the catalytic converter pipe. This can be clamped into place, however, we recommend welding for the best permanent results.
6. Install the downpipe by aligning the gasketless aerospace flanges and slipping the gasketless flange clamps into place around the outside edge of the flange. Hand-tighten the clamps to firmly snug.
7. If previously removed, insert and tighten the two downpipe-to-transmission support bracket fasteners. Torque these fasteners to 31 Nm (23 ft-lb).
8. Install one of the 2-inch stainless exhaust clamps around the downpipe forward of the flexible section. Slide the clamp over the support bracket on the underside of the transmission and tighten the downpipe clamp nut to 60 Nm (44 ft-lb). Important: the downpipe MUST be clamped to the transmission support bracket per these instructions. Failure to perform and properly document this step may void your DT3301 warranty! See warranty card for details.

Air Conditioning Compressor Installation

1. Raise the front end of the vehicle and remove jackstands. Lower the vehicle leaving the hand brake on.
2. Place the rear AC compressor bracket against the engine.
3. Install and FINGER START ONLY the four fasteners holding the rear support bracket to the engine.
4. Place the AC compressor front bracket against the engine and FINGER START ONLY the three fasteners.
5. Place the AC compressor in the rear bracket using the rear center fastener to locate the compressor in the bracket. FINGER START ONLY the rear upper and lower fasteners.

The steps 6, 7, and 8 must be performed in order to prevent damage to the engine block or cylinder head!!

6. Torque the three front bracket-to-compressor fasteners to 54 Nm (40 ft lb).
7. Torque the three rear bracket-to-compressor fasteners to 30 Nm (22 ft lb).
8. Torque the four rear bracket-to-engine fasteners to 30 Nm (22 ft lb). Be sure to tighten in a cross pattern, and not in a circular pattern, similar to wheel lug nuts.
9. Install the engine accessory drive belt (serpentine belt).
10. Reconnect the vehicle negative battery terminal.

Vehicle Wrap-up and Road Test

1. Release the hand brake lever.
2. Road test the vehicle to confirm proper function of your new exhaust system components. USE CAUTION THE FIRST TIME YOU DRIVE YOUR CAR AFTER MODIFICATION TO ENSURE THE PROPER FUNCTION OF ALL VEHICLE SYSTEMS!
3. Enjoy your modified Saturn!