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Home >> Chevrolet >> 2004 >> Malibu Base >> Repair and Diagnosis >> Engine Mechanical >> Engine Exhaust System >> Repair Instructions >> Intermediate Pipe Replacement >> Installation Procedure

Installation Procedure

    Fig 1: Installing Catalytic Converter Downpipe Gasket
    GM1238991Courtesy of GENERAL MOTORS CORP.
  1. Install catalytic converter downpipe gasket.
  2. Fig 2: Installing Intermediate Pipe To Hangers
    GM1238995Courtesy of GENERAL MOTORS CORP.
  3. Install the intermediate pipe to the hangers.

    Lubricate the exhaust system hangers with Dielectric Silicone Grease GM P/N 12345579 (Canadian P/N 1974984) to ease installation.

  4. Fig 3: Installing Intermediate Pipe Bolts To Catalytic Converter
    GM1238991Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the intermediate pipe bolts to catalytic converter.

    Tighten:  Tighten the intermediate pipe bolts to 30 N.m (22 lb ft).

  6. Fig 4: Identifying Cutline On Intermediate Pipe
    GM25822Courtesy of GENERAL MOTORS CORP.
  7. Clamp the muffler (2) to the intermediate pipe (1).
  8. Align the two halves of the exhaust system to prevent contact with underbody components and torque the exhaust system clamp.

    Tighten:  Tighten the exhaust clamp nuts to 50 N.m (37 lb ft).

  9. Lower the vehicle.