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

Removal Procedure
  1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    2. Object Number: 372621 Size: SH

    Important: Use caution handling the pipe that contains an oxygen sensor. Do not cut the wire. For removal or repositioning disconnect the connector.

  2. Remove the exhaust front pipe nuts from the exhaust manifold studs.

    3. Important: Suitably support the exhaust system where hangers are removed.

  3. In order to remove the exhaust seal disconnect any hangers necessary to reposition the exhaust system.
  4. Reposition the exhaust system.

    5. Object Number: 107855 Size: SH
  5. Remove the exhaust manifold pipe gasket.

Installation Procedure

    Object Number: 107855 Size: SH
  1. Install the exhaust manifold pipe gasket.

    2. Object Number: 372621 Size: SH
  2. Return the exhaust system to the proper position.
  3. Connect any hangers.
  4. Remove the exhaust system support.

    5. 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.

  5. Install the exhaust front pipe nuts to the exhaust manifold pipe studs.

    6. Tighten
    Tighten the exhaust nuts to 35 N·m (26 lb ft).

  6. Inspect the exhaust system for leaks and underbody contact.
  7. Lower the vehicle.