GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Malibu 🢒 Engine 🢒 Engine Cooling 🢒 Exhaust Manifold Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.

    2. Object Number: 33611 Size: SH
  2. Remove the upper heat shield.

    3. Object Number: 388157 Size: SH
  3. Disconnect the Oxygen (O2S) sensor connector. Refer to Oxygen Sensor Replacement in Engine Controls - 2.4L.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    5. Object Number: 387917 Size: SH
  5. Remove fasteners which connect the exhaust manifold brace to the manifold.

    6. Object Number: 388033 Size: SH

    Notice: Do not bend the exhaust flex decoupler more than 3 degrees in any direction. Movement of more than 3 degrees will damage the exhaust flex decoupler.

  6. Remove the fasteners which secure the manifold to the exhaust flex decoupler.

    7. Object Number: 33612 Size: SH
  7. Pull down and back on the exhaust pipe in order to disengage the pipe from the exhaust manifold.
  8. Lower the vehicle.
  9. Remove the retaining nuts which secure the exhaust manifold to the cylinder head.
  10. Remove the following components:
    11. • The exhaust manifold
    • The seals
    • The gaskets
  11. Clean all sealing surfaces.

Installation Procedure

    Object Number: 33612 Size: SH
  1. Install a new exhaust manifold gasket.
  2. Install the exhaust manifold.

    3. Object Number: 60046 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  3. Install the exhaust manifold nuts in the sequence shown.

    4. Tighten
    Tighten the nuts to 13 N·m (110 lb in).

  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    5. Object Number: 33609 Size: SH
  5. Install the fasteners which secure the exhaust manifold brace to the exhaust manifold.

    6. Tighten

        • Tighten the bolt to 56 N·m (41 lb ft).
        • Tighten the nuts to 26 N·m (19 lb ft).

    Object Number: 60045 Size: SH
  6. Install the fasteners which secure the manifold to the flex decoupler.

    7. Tighten
    Tighten the fasteners to 35 N·m (26 lb ft).

  7. Lower the vehicle.

    8. Object Number: 33611 Size: SH
  8. Install the heat shield.

    9. Tighten
    Tighten the bolts to 14 N·m (124 lb in).

  9. Coat the threads of the oxygen sensor (O2S) connector with anti-seize compound GM P/N 5613695 or equivalent.

    10. Object Number: 388157 Size: SH
  10. Install the oxygen sensor. Refer to Oxygen Sensor Replacement in Engine Controls - 2.4L.
  11. Connect the oxygen sensor (O2S) connector.
  12. Connect the negative battery cable.