GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Engine 🢒 Engine Exhaust 🢒 Exhaust Manifold Replacement

Removal Procedure

    Object Number: 892169 Size: SH
  1. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Remove the exhaust manifold pipe-to-exhaust manifold nuts.

    3. Notice: Do not over-flex or damage the flex joint when moving the flex joint from the normal mounting position.

  3. Pull down on the exhaust manifold pipe just enough to free from the manifold studs and secure to the frame.
  4. Lower the vehicle.

    5. Object Number: 1238972 Size: SH
  5. Remove the exhaust manifold heat shield bolts.
  6. Remove the heat shield.

    7. Object Number: 895176 Size: SH
  7. Disconnect the exhaust manifold heated oxygen sensor (HO2S) electrical connection.
  8. Remove the HO2S from the manifold.

    9. Object Number: 1238974 Size: SH
  9. Remove the exhaust manifold nuts.
  10. Remove the exhaust manifold and discard the gasket.

Installation Procedure

    Object Number: 1238974 Size: SH
  1. Install the new exhaust manifold gasket on the cylinder head.
  2. Install the exhaust manifold. Refer to Exhaust Manifold Replacement .

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the exhaust manifold nuts.

    4. Tighten
    Tighten the exhaust manifold-to-cylinder head nuts to 14 N·m (124 lb in).


    Object Number: 895176 Size: SH
  4. Install the HO2S.

    5. Tighten
    Tighten the oxygen sensor-to-exhaust manifold pipe to 45 N·m (33 lb ft).

  5. Connect the exhaust manifold HO2S electrical connection.

    6. Object Number: 1238972 Size: SH
  6. Install the exhaust manifold heat shield.

    7. Tighten
    Tighten the exhaust manifold heat shield bolts to 25 N·m (18 lb ft).


    Object Number: 892169 Size: SH
  7. Install the new exhaust manifold flange gasket onto the exhaust manifold flange studs.
  8. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information.
  9. Position the exhaust manifold pipe flange onto the exhaust manifold studs.

    10. Tighten
    Tighten the exhaust manifold pipe-to-exhaust manifold nuts to 30 N·m (22 lb ft).

  10. Lower the vehicle.
  11. Start the vehicle and inspect for leaks.