GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Crossover Pipe Replacement

Removal Procedure
  1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
  2. Remove thermostat by-pass pipe assembly. Refer to Thermostat Bypass Pipes Replacement in Engine-Engine Cooling.

    3. Object Number: 63508 Size: SH
  3. Remove the exhaust crossover pip heat shield bolts.
  4. Remove the crossover pipe heat shield.

    5. Object Number: 54282 Size: SH
  5. Remove the exhaust crossover pipe bolts.
  6. Remove the exhaust crossover pipe.

Installation Procedure

    Object Number: 54282 Size: SH
  1. Install the exhaust crossover pipe.

    2. 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.

  2. Install the exhaust crossover pipe bolts.

    3. Tighten
    Tighten the exhaust crossover pipe bolts to 25 N·m (18 lb ft).


    Object Number: 63508 Size: SH
  3. Install the exhaust crossover pipe heat shield.
  4. Install the exhaust crossover pipe heat shield bolts.

    5. Tighten
    Tighten the exhaust crossover pipe heat shield bolts to 10 N·m (89 lb in).

  5. Install thermostat by-pass pipe assembly. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
  6. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
  7. Inspect for exhaust leaks.