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Home › Chevrolet › 2004 › Malibu Base › Repair and Diagnosis › Engine Mechanical › Engine Exhaust System › Repair Instructions › Exhaust Manifold Replacement › Installation Procedure

Installation Procedure

    Fig 1: Installing New Exhaust Manifold Gasket On Cylinder Head
    GM1238974Courtesy of GENERAL MOTORS CORP.
  1. Install the new exhaust manifold gasket on the cylinder head.
  2. Install the exhaust manifold. Refer to Exhaust Manifold Replacement  .
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the exhaust manifold nuts.

    Tighten:  Tighten the exhaust manifold-to-cylinder head nuts to 18 N.m (13 lb ft).

    4. Fig 2: Connecting Exhaust Manifold HO2S Electrical Connection
    GM895176Courtesy of GENERAL MOTORS CORP.
  4. Install the HO2S.

    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. Fig 3: Installing Exhaust Manifold Heat Shield
    GM1238972Courtesy of GENERAL MOTORS CORP.
  6. Install the exhaust manifold heat shield.

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

    7. Fig 4: Installing New Exhaust Manifold Flange Gasket Onto Exhaust Manifold Flange Studs
    GM892169Courtesy of GENERAL MOTORS CORP.
  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.

    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.
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