GM Malibu/Cutlass 1997-2000

Exhaust Manifold

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REMOVAL & INSTALLATION



2.4L Engine
  1. Disconnect the negative battery cable
  2.  
  3. Detach the Oxygen (O2) sensor electrical connector.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Unfasten the exhaust manifold brace-to-manifold bolt and the oil pan nuts, if necessary.
  8.  



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Fig. On the 2.4L engine, remove the bolt and nuts, then remove the exhaust manifold brace

  1. Remove the upper heat shield.
  2.  



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Fig. Unfasten the retaining bolts, then remove the heat shield-2.4L engine


NOTE
Do NOT bend the exhaust flex decoupler more than necessary to remove it. Excessive movement will damage the flex decoupler.

  1. Remove the manifold-to-exhaust flex decoupler fasteners.
  2.  
  3. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
  4.  
  5. Carefully lower the vehicle.
  6.  
  7. Unfasten the exhaust manifold-to-cylinder head retaining nuts/bolts, then remove the manifold. Remove and discard the gaskets and/or seals. Clean the mating surfaces.
  8.  

To install:

  1. Use new gaskets, then position the exhaust manifold. Following the sequence in the accompanying figure, tighten fasteners to the specifications listed in the chart found in this section.
  2.  



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Fig. Exhaust manifold installation and fastener tightening sequence-2.4L engine

  1. Raise and safely support the vehicle.
  2.  
  3. Install the heat shield. Tighten the bolts to 10 ft. lbs. (14 Nm).
  4.  
  5. Fasten the exhaust manifold brace-to-manifold bolt and the oil pan nuts. Tighten the bolts to 41 ft. lbs. (56 Nm) and the nuts to 18 ft. lbs. (24 Nm).
  6.  
  7. Install the manifold-to-flex decoupler fasteners. Tighten the bolts to 26 ft. lbs. (35 Nm).
  8.  



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Fig. Installing the exhaust flex decoupler found on the 2.4L engine

  1. Carefully lower the vehicle.
  2.  
  3. Attach the O2 sensor electrical connector. Coat the threads of the sensor with a suitable anti-seize compound.
  4.  
  5. Connect the battery and check for leaks.
  6.  

3.1L Engine
FRONT (LEFT)
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the top half of the air cleaner assembly and throttle cable duct.
  4.  
  5. Partially drain the cooling system.
  6.  
  7. Disconnect the radiator hose from the thermostat housing.
  8.  
  9. Detach the coolant bypass hose at the coolant pump and from the exhaust manifold.
  10.  
  11. Remove the exhaust crossover heat shield.
  12.  
  13. Detach the exhaust crossover pipe from the manifold.
  14.  
  15. Tag and disconnect the ignition wires from the spark plugs.
  16.  
  17. Remove the exhaust manifold heat shield.
  18.  
  19. Unfasten the exhaust manifold retaining nuts, then lift the manifold and gasket from the engine.
  20.  
  21. Clean mating surfaces at the cylinder head and manifold.
  22.  

To install:

  1. Install the exhaust manifold gasket and the exhaust manifold. Tighten the manifold mounting nuts to 12 ft. lbs. (16 Nm).
  2.  
  3. Install the exhaust manifold heat shield and tighten the bolts to 89 inch lbs. (10 Nm).
  4.  
  5. Connect the exhaust crossover pipe to the manifold.
  6.  
  7. Install the exhaust crossover pipe heat shield.
  8.  
  9. Attach the ignition wires to the appropriate spark plugs.
  10.  
  11. Connect the coolant bypass pipe to the coolant pump and exhaust manifold.
  12.  
  13. Attach the radiator hose to the coolant outlet housing.
  14.  
  15. Install the top half of the air cleaner and the throttle body duct.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Start the engine and check for leaks.
  20.  



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Fig. Left and right side exhaust manifold mounting-3.1L engine

REAR (RIGHT)
  1. Disconnect the negative battery cable.
  2.  
  3. Remove the top half of the air cleaner assembly and throttle cable duct.
  4.  
  5. Remove the exhaust crossover heat shield.
  6.  
  7. Detach the exhaust crossover pipe from the manifold.
  8.  
  9. Remove the Heated Oxygen (HO2) sensor.
  10.  
  11. Disconnect the EGR pipe from the exhaust manifold.
  12.  
  13. Raise and safely support the front of the vehicle.
  14.  
  15. Remove the transaxle oil fill tube and lever indicator assembly.
  16.  
  17. Disconnect the front exhaust pipe from the exhaust manifold.
  18.  
  19. Disconnect the exhaust pipe from the converter flange, then support the converter.
  20.  
  21. Remove the converter heat shield from the body.
  22.  
  23. Remove the exhaust manifold heat shield.
  24.  
  25. Unfasten the exhaust manifold nuts, then remove the manifold and gasket from the bottom of vehicle.
  26.  
  27. Clean the mating surfaces at the cylinder head and manifold.
  28.  

To install:

  1. Position the exhaust manifold gasket, then install the manifold loosely and install the heat shield at this time.
  2.  
  3. Install the manifold nuts and tighten to 12 ft. lbs. (16 Nm).
  4.  
  5. Install the exhaust manifold heat shield nuts and tighten them to 12 ft. lbs. (16 Nm).
  6.  
  7. Install the converter heat shield to the body.
  8.  
  9. Attach the exhaust pipe to the converter flange.
  10.  
  11. Connect the exhaust pipe to the exhaust manifold.
  12.  
  13. Install the transaxle oil level indicator and fill tube assembly.
  14.  
  15. Carefully lower the vehicle.
  16.  
  17. Install the Heated Oxygen (HO2) sensor.
  18.  
  19. Attach the crossover pipe to the exhaust manifolds and the crossover heat shield.
  20.  
  21. Connect the EGR pipe to exhaust manifold.
  22.  
  23. Install the top half of the air cleaner assembly and the throttle body duct.
  24.  
  25. Connect the negative battery cable.
  26.  
  27. Start the engine and check for leaks.
  28.  

 
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