GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 3.1L 🢒 Exhaust Manifold Replacement - Right Side

Removal Procedure

    Object Number: 54282 Size: SH
  1. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement .
  2. Remove EGR pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.
  3. Disconnect oxygen sensor.
  4. Raise vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  5. Remove catalytic converter. Refer to Catalytic Converter Replacement .

    6. Object Number: 54707 Size: SH
  6. Remove the exhaust manifold heat shield bolts.
  7. Remove the exhaust manifold heat shield.

    8. Object Number: 187052 Size: SH
  8. Remove the exhaust manifold nuts.
  9. Remove the exhaust manifold and gaskets.
  10. Clean the mating surfaces at the cylinder head and at the exhaust manifold.

Installation Procedure

    Object Number: 187052 Size: SH
  1. Install the exhaust manifold gasket.
  2. Install the exhaust manifold.

    3. 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.

    4. Tighten
    Tighten the exhaust manifold nuts to 16 N·m (12 lb ft).


    Object Number: 54707 Size: SH
  4. Install the exhaust manifold heat shield.
  5. Install the exhaust manifold heat shield bolts.

    6. Tighten
    Tighten the exhaust manifold heat shield bolts to 10 N·m (89 lb in).

  6. Install catalytic converter. Refer to Catalytic Converter Replacement .
  7. Lower vehicle.
  8. Connect oxygen sensor.
  9. Install EGR pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls.

    10. Object Number: 54282 Size: SH
  10. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement .