2008 Chevrolet Malibu Service Repair Manual PDF

Document ID: 1840741 Page 1 of 1
2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Engine | Engine Exhaust | Specifications |
Document ID: 1840741
Fastener Tightening Specifications

Specification
Application Metric English
Catalytic Converter to Exhaust Manifold Nut (LZ4/LY7) 45 N·m 33 lb ft
Exhaust Manifold Bolt (LZ4/LY7) 20 N·m 15 lb ft
Exhaust Manifold Brace Bolt (LAT) 58 N·m 43 lb ft
Exhaust Manifold/Catalytic Converter to Exhaust Manifold Pipe Nut (LAT) 30 N·m 20 lb ft
Exhaust Manifold Heat Shield Bolt (LAT) 23 N·m 17 lb ft
Exhaust Manifold Heat Shield Bolt (LZ4/LY7) 10 N·m 89 lb in
Exhaust Manifold Lower Heat Shield Bolt (LY7) 10 N·m 89 lb in
Exhaust Manifold Lower Heat Shield Bolt (LY7) 50 N·m 37 lb ft
Exhaust Manifold Nut (LAT) 14 N·m 10 lb ft
Exhaust Manifold Pipe to Muffler Nut (LAT) 25 N·m 18 lb ft
Exhaust Pipe Heat Shield Nut 10 N·m 89 lb in
Exhaust Pipe to Muffler Nut (LZ4/LY7) 25 N·m 18 lb ft
Exhaust Pipe to Right Catalytic Converter Nut (LZ4/LY7) 25 N·m 18 lb ft
Frame Bolt - First Pass 100 N·m 74 lb ft
Frame Bolt - Final Pass 90 Degrees
Heater Oxygen Sensor (HO2S) (LZ4) 42 N·m 31 lb ft
Heat Shield Nut 10 N·m 89 lb in
Left Catalytic Converter-to-Right Catalytic Converter Nut (LZ4/LY7) 25 N·m 18 lb ft
© 2010 General Motors Corporation. All rights reserved.
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2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Engine | Engine Exhaust | Repair Instructions |
Exhaust Manifold Replacement (LE5 With MH8)
Callout Component Name

Preliminary procedures
1. Remove the exhaust manifold heat shield. Refer to Exhaust Heat Shield Replacement
2. Remove the exhaust extension pipe. Refer to Exhaust Pipe Replacement
Nut (Qty 10)
Caution: Refer to Fastener Caution in the Preface section.

1
Tighten
14 N·m (124 lb in)
Exhaust Manifold
Procedure
2
1. Remove and discard the Exhaust manifold gasket.
2. Clean any exhaust manifold gasket debris from the cylinder head and exhaust
manifold.
3. Tighten the Manifold nuts working from the center out.
Exhaust Manifold Replacement (LAT and LE5)

Removal Procedure
Warning: Refer to Exhaust Service Warning in the Preface section.
Warning: Refer to Protective Goggles and Glove Warning in the Preface section.
1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield
Replacement.
2. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement -
Sensor 1.
3. If equipped with a LE5, remove the exhaust manifold pipe. Refer to Exhaust Manifold Pipe
Replacement.
4. If equipped with a LAT, remove the catalytic converter. Refer to Catalytic Converter
Replacement.
5. Lower the vehicle.
6. Remove the upper exhaust manifold brace bolt (1).
7. Remove and discard the exhaust manifold nuts (1).

8. Remove the exhaust manifold/catalytic converter assembly (2).
9. Remove and discard the exhaust manifold gasket.
Installation Procedure
1. Install a NEW exhaust manifold gasket onto the manifold studs.

2. Install the exhaust manifold/catalytic converter assembly (2).
3. Install the NEW exhaust manifold nuts (1) finger tight.
4. Install the upper exhaust manifold brace bolt (1) and tighten to 58 N·m (43 lb ft).
5. Tighten the exhaust manifold nuts in the sequence shown to 14 N·m (10 lb ft).
6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
7. If equipped with a LE5, install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe
Replacement
8. If equipped with a LAT, install the catalytic converter. Refer to Catalytic Converter
Replacement.
9. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Sensor 1.
10. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement.
Exhaust Manifold Replacement - Left Side (LY7)

Removal Procedure
1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield
Replacement - Left Side.
2. Remove the oil level indicator. Refer to Oil Level Indicator Tube Replacement.
3. Remove the catalytic converter to exhaust manifold nuts (1).
4. Remove the exhaust manifold bolts (1).

5. Remove the exhaust manifold and gasket. Discard the gasket.
1. Install one exhaust manifold bolt to the exhaust manifold.

2. Install the NEW exhaust manifold gasket onto the cylinder head and bolt.
3. Install the exhaust manifold (with gasket) to the catalytic converter and the cylinder head.
4. Install the remaining exhaust manifold bolts (1) and tighten to 20 N·m (15 lb ft).
5. Install the catalytic converter to exhaust manifold nuts (1) and tighten to 45 N·m (33 lb ft).
6. Install the oil level indicator. Refer to Oil Level Indicator Tube Replacement.
7. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement -
Left Side.
8. Inspect for exhaust leaks.
Exhaust Manifold Replacement - Left Side (LZ4)
Special Tools
J 39194-B Heated Oxygen Sensor Wrench
Removal Procedure
Caution: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove
the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect
proper operation of the oxygen sensor.
Caution: The use of excessive force may damage the threads in the exhaust manifold/pipe.
Note: The in-line connector and louvered end must be kept clear of grease, dirt or other
contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the
heated oxygen sensor (HO2S).
Note: The HO2S may be difficult to remove when the engine temperature is less than 48°C (120°
F)
1. Remove the air intake duct. Refer to Air Cleaner Inlet Duct Replacement.
2. Remove the connector position assurance (CPA) retainer (5).
3. Disconnect the engine wiring harness electrical connector (4) from the HO2S electrical
connector (3).
4. Remove the HO2S electrical connector rosebud clip from the oil level indicator tube tab.
5. Remove the HO2S using the J 39194-B .
6. Remove the exhaust manifold heat shield bolts and shield.
7. Remove the upper exhaust manifold bolts.

8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
9. Remove the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side.
10. Remove the lower exhaust manifold bolts.
11. Remove the exhaust manifold.
1. Install a NEW exhaust manifold gasket onto the cylinder head studs.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts.
Tighten
Tighten the bolts to 20 N·m (15 lb ft).
4. Install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side.
5. Lower the vehicle.
6. Install the exhaust manifold heat shield and bolts.
Tighten
Tighten the bolts to 10 N·m (89 lb in).
Note: A special anti-seize compound is used on the HO2S threads. The compound consists of
graphite suspended in fluid and glass beads. The graphite will burn away, but the glass beads
will remain, making the sensor easier to remove. New or service sensors will already have
the compound applied to the threads. If a sensor is removed from an engine and is to be
reinstalled, the threads must have anti-seize compound applied before the reinstallation.
7. Coat the threads of the HO2S with anti-seize compound GM P/N 12377953 or equivalent, if
necessary.
8. Install the HO2S using J 39194-B .
Tighten
Tighten the sensor to 42 N·m (31 lb ft).
9. Connect the engine wiring harness electrical connector (4) to the HO2S electrical
connector (3).
10. Install the HO2S electrical connector rosebud clip to the oil level indicator tube tab.
11. Install the CPA retainer (5).
12. Install the air intake duct. Refer to Air Cleaner Inlet Duct Replacement.
Exhaust Manifold Replacement - Right Side (LY7)
Removal Procedure
1. Remove the catalytic converter. Refer to Catalytic Converter Replacement - Right Side.
2. Remove the exhaust manifold lower bolts.
3. Lower the vehicle half way.
4. Remove the exhaust manifold upper bolts.
5. Remove the exhaust manifold.
1. Install one upper exhaust manifold bolt (1) to the exhaust manifold.
2. Place the NEW exhaust manifold gasket onto the bolt.
3. Position and install the exhaust manifold (with gasket) to the cylinder head.
4. Loosely install the remaining upper exhaust manifold bolts.

5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
6. Loosely install the lower exhaust manifold bolts.
7. Tighten the exhaust manifold bolts to 20 N·m (15 lb ft).

8. Install the catalytic converter. Refer to Catalytic Converter Replacement - Right Side.
Exhaust Manifold Replacement - Right Side (LZ4)
Special Tools
J 39194-B Heated Oxygen Sensor Socket
Removal Procedure
Caution: The oxygen sensor uses a permanently attached pigtail and connector. Do not remove
the pigtail from the oxygen sensor. Damage to or removal of the pigtail connector could affect
proper operation of the oxygen sensor.
Caution: The use of excessive force may damage the threads in the exhaust manifold/pipe.
Note: The in-line connector and louvered end must be kept clear of grease, dirt or other
contaminants. Avoid using cleaning solvents of any type. DO NOT drop or roughly handle the
heated oxygen sensor (HO2S).
Note: The HO2S may be difficult to remove when the engine temperature is less than 48°C (120°
F)
1. Remove the generator. Refer to Generator Replacement.

2. Remove the connector position assurance (CPA) retainer (3).
3. Disconnect the engine wiring harness electrical connector (2) from the HO2S electrical
connector.
4. Remove the HO2S electrical connector rosebud clip (1) from the ignition coil bracket.
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Document ID: 1840741 Page 1 of 1

Fastener Tightening Specifications

© 2010 General Motors Corporation. All rights reserved.

Exhaust Manifold Replacement (LE5 With MH8)

Callout Component Name

Caution: Refer to Fastener Caution in the Preface section.

© 2010 General Motors Corporation. All rights reserved.

Exhaust Manifold Replacement (LAT and LE5)

Warning: Refer to Exhaust Service Warning in the Preface section.

© 2010 General Motors Corporation. All rights reserved.

7. Remove and discard the exhaust manifold nuts (1).

1. Install a NEW exhaust manifold gasket onto the manifold studs.

Caution: Refer to Fastener Caution in the Preface section.

Exhaust Manifold Replacement - Left Side (LY7)

Warning: Refer to Exhaust Service Warning in the Preface section.

© 2010 General Motors Corporation. All rights reserved.

4. Remove the exhaust manifold bolts (1).

1. Install one exhaust manifold bolt to the exhaust manifold.

Caution: Refer to Fastener Caution in the Preface section.

Exhaust Manifold Replacement - Left Side (LZ4)

J 39194-B Heated Oxygen Sensor Wrench

© 2010 General Motors Corporation. All rights reserved.

5. Remove the HO2S using the J 39194-B .

6. Remove the exhaust manifold heat shield bolts and shield.

7. Remove the upper exhaust manifold bolts.

Caution: Refer to Fastener Caution in the Preface section.

3. Install the exhaust manifold bolts.

6. Install the exhaust manifold heat shield and bolts.

Exhaust Manifold Replacement - Right Side (LY7)

Warning: Refer to Exhaust Service Warning in the Preface section.

© 2010 General Motors Corporation. All rights reserved.

4. Remove the exhaust manifold upper bolts.

5. Remove the exhaust manifold.

6. Remove and discard the exhaust manifold gasket.

4. Loosely install the remaining upper exhaust manifold bolts.

6. Loosely install the lower exhaust manifold bolts.

Caution: Refer to Fastener Caution in the Preface section.

7. Tighten the exhaust manifold bolts to 20 N·m (15 lb ft).

Exhaust Manifold Replacement - Right Side (LZ4)

J 39194-B Heated Oxygen Sensor Socket

1. Remove the generator. Refer to Generator Replacement.

© 2010 General Motors Corporation. All rights reserved.

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