Malibu V6-3.5L VIN 8 (2004)
Exhaust Resonator: All Technical Service Bulletins
Exhaust System - Loud Pinging Noise On Cool Down
Bulletin No.: 06-06-05-002
Date: April 05, 2006
TECHNICAL
Subject:
Exhaust System Noise/Leak or Pinging Type Noise While Vehicle Cools Down (Replace Exhaust Resonator Assembly)
Models:
2004-2005 Chevrolet Malibu, Malibu Maxx
with 3.5L V6 Engine (VIN 8 - RPO LX9)
Condition
Some customers may comment on a loud exhaust noise or a pinging type noise that can be heard after the vehicle is shut off and cooling down.
Cause
This condition may be caused by premature failure of the resonator due to thermal cycling. The resonator end caps may split open. The internal resonator
design has a solid pipe through it that would expand quicker than the external shell and eventually crack out the ends.
Correction
Replace only the resonator assembly following the procedure listed below. DO NOT replace the complete exhaust system for this condition. This new
resonator has incorporated a slip joint internal pipe design to reduce thermal stresses.
1.
Raise and suitably support the vehicle.
2.
Cut the resonator outlet pipe as close to the weld as possible. The best way to do this is with a hacksaw.
3.
Remove the catalytic converter down pipe to the resonator nuts.
4.
Remove the resonator from the hanger.
5.
Remove the exhaust flange gasket.
6.
File down the cut exhaust pipe to remove any burrs.
7.
Install the new exhaust flange gasket.
8.
Install the new resonator assembly to the hanger.
9.
Connect the resonator outlet pipe and install the clamp.
10.
Install the catalytic converter down pipe to the resonator nuts.
Tighten
Tighten the nuts to 30 Nm (22 lb ft).
11.
Lower the vehicle.
