GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 3.5L (LX9) 🢒 Exhaust Crossover Pipe Replacement

Removal Procedure

    Object Number: 1238994 Size: SH
  1. Remove the exhaust crossover pipe nuts.
  2. Remove the exhaust crossover pipe.

    3. Object Number: 1238991 Size: SH
  3. If any of the studs on the exhaust system break, they can be replaced in a manner similar to a wheel lug.
  4. Using a hammer and drift, drive out the broken portion of the stud.
  5. Install a new stud by driving the replacement stud flange using a ball pein hammer.

Installation Procedure

    Object Number: 1238994 Size: SH
  1. Using new gaskets, install the exhaust crossover pipe.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the exhaust crossover pipe nuts.

    3. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).