Malibu, Malibu MAXX 2006-2008

Exhaust Manifold

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shield
     
    Block heater, if equipped
     
    Oxygen sensor
     
    Exhaust manifold retaining nuts
     
    Exhaust manifold and catalytic converter assembly
     

  6.  

To install:

  1. Install or connect the following:

    New manifold studs if necessary. Tighten to 89 inch lbs. (10 Nm).
     
    Exhaust manifold gasket
     
    Exhaust manifold and catalytic converter assembly. Tighten new nuts to 124 inch lbs. (14 Nm)
     
    Oxygen sensor. Tighten to 22 ft. lbs. (30 Nm)
     
    Block heater, if equipped
     
    Exhaust manifold heat shield
     
    Negative battery cable
     

  2.  
  3. Refill the cooling system to the correct level.
  4.  
  5. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Exhaust manifold bolt torque sequence-2.2L engine

  6.  

3.5L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heated oxygen (HO2S) sensor
     
    Spark plugs
     
    Exhaust manifold heat shield
     
    Exhaust manifold

    Click image to see an enlarged view

    Fig. Exploded view of the left-hand exhaust manifold-3.5L engine

     

  4.  

To install:

  1. Install new exhaust manifold if necessary. Tighten to 13 ft. lbs. (18 Nm).
  2.  
  3. Install or connect the following:

    Exhaust manifold gasket
     
    Exhaust manifold. Tighten nuts in sequence to 12 ft. lbs. (16 Nm).
     
    Exhaust manifold heat shield
     
    Spark plugs
     
    HO2S sensor
     
    Negative battery cable
     

  4.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Heated oxygen (HO2S) sensor
     
    Spark plugs
     
    Exhaust gas circulation (EGR) pipe
     
    Exhaust manifold heat shield
     
    Exhaust manifold and gasket
     

  4.  

To install:

  1. Install or connect the following:

    New exhaust manifold studs, if necessary. Tighten to 13 ft. lbs. (18 Nm).
     
    Exhaust manifold and gasket. Tighten nuts in sequence to 12 ft. lbs. (16 Nm).
     
    Exhaust manifold heat shield. Tighten bolts to 89 inch lbs. (10 Nm).
     
    EGR pipe
     
    Spark plugs
     
    HO2S sensor
     
    Negative battery cable
     

  2.  

3.9L Engine
Left Side
  1. Remove the air cleaner outlet duct.
  2.  
  3. Remove the Connector Position Assurance (CPA) retainer.
  4.  
  5. Disconnect the heated oxygen sensor (HO2S) electrical connector.
  6.  
  7. Remove the HO2S clip from the oil level indicator tube bracket.
    WARNING
    The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

  8.  
  9. Remove the HO2S using approved tool.
  10.  
  11. Remove the exhaust manifold heat shield bolts.
  12.  
  13. Remove the exhaust manifold heat shield.
  14.  
  15. Remove the upper exhaust manifold bolts.
  16.  
  17. Raise and support the vehicle.
  18.  
  19. Remove the left catalytic converter.
  20.  
  21. Remove the lower exhaust manifold bolts.
  22.  
  23. Remove the exhaust manifold.
  24.  
  25. Remove and discard the exhaust manifold gasket.
  26.  

To install:

  1. Install a NEW exhaust manifold gasket onto the cylinder head studs.
  2.  
  3. Install the exhaust manifold.
  4.  
  5. Install the exhaust manifold bolts and tighten to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the left catalytic converter.
  8.  
  9. Lower the vehicle.
  10.  
  11. Install the exhaust manifold heat shield and mounting bolts, tighten to 89 inch. lbs. (10 Nm).
    NOTE
    Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound.

  12.  
  13. Install the HO2S using approved tool and tighten to 31 ft. lbs. (42 Nm).
  14.  
  15. Connect the HO2S electrical connector.
  16.  
  17. Install the CPA retainer.
  18.  
  19. Install the HO2S clip to the oil level indicator tube bracket.
  20.  
  21. Install the air cleaner outlet duct.
  22.  

Right Side
  1. Remove the generator.
  2.  
  3. Remove the connector position assurance (CPA) retainer.
  4.  
  5. Disconnect the engine harness electrical connector heated oxygen sensor (HO2S) electrical connector (4).
  6.  
  7. Remove the HO2S clip from the oil level indicator tube bracket.
    WARNING
    The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

  8.  
  9. Remove the HO2S using approved tool.
  10.  
  11. Remove the exhaust manifold shield bolts.
  12.  
  13. Remove the exhaust manifold shield.
  14.  
  15. Remove the upper exhaust manifold bolts.
  16.  
  17. Remove the right catalytic converter.
  18.  
  19. Remove the lower exhaust manifold bolt.
  20.  
  21. Remove the exhaust manifold.
  22.  
  23. Remove and discard the exhaust manifold gasket.
  24.  

To install:

  1. Install a new exhaust manifold gasket onto the cylinder head studs.
  2.  
  3. Install the exhaust manifold.
  4.  
  5. Install the exhaust manifold bolts and tighten to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the right catalytic converter.
  8.  
  9. Install the exhaust manifold shield.
  10.  
  11. Install the exhaust manifold shield bolts and tighten to 89 inch. lbs. (10 Nm).
    NOTE
    Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound.

  12.  
  13. Install the HO2S using approved tool and tighten to 31 ft. lbs. (42 Nm).
  14.  
  15. Connect the engine harness electrical connector to the HO2S electrical connector.
  16.  
  17. Install the CPA retainer.
  18.  
  19. Install the HO2S clip to the oil level indicator tube bracket.
  20.  
  21. Install the generator.
  22.  

 
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