How to Replace Exhaust Manifold on Chevrolet Malibu?

The Exhaust Manifold replacing procedure for 2.2L, 3.5L and 3.9L engine models.

In this chapter details are provided for Chevrolet Malibu exhaust manifold.

The procedure is as follows:----

Removal & Installation

2.2L Engine

1. Drain the cooling system.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Exhaust manifold heat shield

   Block heater, if equipped

   Oxygen sensor

   Exhaust manifold retaining nuts

   Exhaust manifold and catalytic converter assembly

To install:

1. Install or connect the following:
   
   
   New manifold studs if necessary. Tighten to 89 inch lbs. (10 Nm).

   Exhaust manifold gasket

   Exhaust manifold and catalytic converter assembly. Tighten new nuts to 124 inch lbs. (14 Nm)

   Oxygen sensor. Tighten to 22 ft. lbs. (30 Nm)

   Block heater, if equipped

   Exhaust manifold heat shield

   Negative battery cable
2. Refill the cooling system to the correct level.
3. Start the engine and check for leaks. 
   
   
   
   Fig. Exhaust manifold bolt torque sequence-2.2L engine

3.5L Engine
Left Side

1. Remove or disconnect the following: 
   
   
   Negative battery cable

   Heated oxygen (HO2S) sensor

   Spark plugs

   Exhaust manifold heat shield

   Exhaust manifold 
   
   
   

   Fig. Exploded view of the left-hand exhaust manifold-3.5L engine

To install:

1. Install new exhaust manifold if necessary. Tighten to 13 ft. lbs. (18 Nm).
2. Install or connect the following:
   
   
   Exhaust manifold gasket

   Exhaust manifold. Tighten nuts in sequence to 12 ft. lbs. (16 Nm).

   Exhaust manifold heat shield

   Spark plugs

   HO2S sensor

   Negative battery cable

Right Side

1. Remove or disconnect the following:
   
   
   Negative battery cable

   Heated oxygen (HO2S) sensor

   Spark plugs

   Exhaust gas circulation (EGR) pipe

   Exhaust manifold heat shield

   Exhaust manifold and gasket

To install:

1. Install or connect the following:
   
   
   New exhaust manifold studs, if necessary. Tighten to 13 ft. lbs. (18 Nm).

   Exhaust manifold and gasket. Tighten nuts in sequence to 12 ft. lbs. (16 Nm).

   Exhaust manifold heat shield. Tighten bolts to 89 inch lbs. (10 Nm).

   EGR pipe

   Spark plugs

   HO2S sensor

   Negative battery cable

3.9L Engine
Left Side

1. Remove the air cleaner outlet duct.
2. Remove the Connector Position Assurance (CPA) retainer.
3. Disconnect the heated oxygen sensor (HO2S) electrical connector.
4. Remove the HO2S clip from the oil level indicator tube bracket.
   
   WARNING

   The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.
5. Remove the HO2S using approved tool.
6. Remove the exhaust manifold heat shield bolts.
7. Remove the exhaust manifold heat shield.
8. Remove the upper exhaust manifold bolts.
9. Raise and support the vehicle.
10. Remove the left catalytic converter.
11. Remove the lower exhaust manifold bolts.
12. Remove the exhaust manifold.
13. Remove and discard the exhaust manifold gasket.

To install:

1. Install a NEW exhaust manifold gasket onto the cylinder head studs.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts and tighten to 15 ft. lbs. (20 Nm).
4. Install the left catalytic converter.
5. Lower the vehicle.
6. Install the exhaust manifold heat shield and mounting bolts, tighten to 89 inch. lbs. (10 Nm).
   
   NOTE

   Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound.
7. Install the HO2S using approved tool and tighten to 31 ft. lbs. (42 Nm).
8. Connect the HO2S electrical connector.
9. Install the CPA retainer.
10. Install the HO2S clip to the oil level indicator tube bracket.
11. Install the air cleaner outlet duct.

Right Side

1. Remove the generator.
2. Remove the connector position assurance (CPA) retainer.
3. Disconnect the engine harness electrical connector heated oxygen sensor (HO2S) electrical connector (4).
4. Remove the HO2S clip from the oil level indicator tube bracket.
   
   WARNING

   The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.
5. Remove the HO2S using approved tool.
6. Remove the exhaust manifold shield bolts.
7. Remove the exhaust manifold shield.
8. Remove the upper exhaust manifold bolts.
9. Remove the right catalytic converter.
10. Remove the lower exhaust manifold bolt.
11. Remove the exhaust manifold.
12. Remove and discard the exhaust manifold gasket.

To install:

1. Install a new exhaust manifold gasket onto the cylinder head studs.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts and tighten to 15 ft. lbs. (20 Nm).
4. Install the right catalytic converter.
5. Install the exhaust manifold shield.
6. Install the exhaust manifold shield bolts and tighten to 89 inch. lbs. (10 Nm).
   
   NOTE

   Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound.
7. Install the HO2S using approved tool and tighten to 31 ft. lbs. (42 Nm).
8. Connect the engine harness electrical connector to the HO2S electrical connector.
9. Install the CPA retainer.
10. Install the HO2S clip to the oil level indicator tube bracket.
11. Install the generator.

These details will help.

Thanks.           

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Car repair guide?

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