Tools You'll Need:
* Jack and jack stands: To safely lift the car. Never work under a car supported only by a jack.
* Wheel chocks: Essential for safety.
* Wrench(es): Likely 13mm and 15mm, but check your exhaust system for the correct sizes. A ratchet wrench will be much easier than a regular open-end or box-end wrench.
* Socket set: Makes it easier to get to the bolts.
* Extension(s): Might be needed to reach certain bolts.
* Exhaust gasket(s): New gaskets are crucial to prevent leaks. Get the correct size from an auto parts store. If you reuse old gaskets, you'll likely experience leaks.
* Penetrating oil (like PB Blaster): Helps loosen rusted bolts. Apply liberally and let it sit for a while before attempting to remove the bolts.
* Gloves: To protect your hands.
* Safety glasses: Protect your eyes from flying debris.
* New muffler: Make sure it's the correct one for your 1999 Chevy Malibu.
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and use wheel chocks. Raise the vehicle using a jack and securely support it with jack stands. Never work under a car supported only by a jack.
2. Locate the Muffler: Identify the old muffler and the connection points to the pipes.
3. Remove the Old Muffler:
* Spray penetrating oil: Apply penetrating oil to all the bolts connecting the muffler to the pipes. Let it sit for at least 15-20 minutes.
* Remove the bolts: Carefully remove the bolts connecting the muffler to the pipes. You may need to use a wrench and socket to access and remove them. Some bolts might be stubborn due to rust. Use caution to avoid stripping the bolt heads.
* Lower the muffler: Once the bolts are out, carefully lower the old muffler. It might be heavy and hot, so wear gloves.
4. Prepare for the New Muffler:
* Install new gaskets: Install the new exhaust gaskets onto the pipes at the connection points where the new muffler will attach.
5. Install the New Muffler:
* Align the muffler: Carefully align the new muffler with the exhaust pipes.
* Install the bolts: Hand-tighten the bolts to secure the muffler. Then, tighten them securely using a wrench, but don't overtighten. Refer to your vehicle's repair manual or the muffler's instructions for the correct torque specifications.
6. Lower the Vehicle: Carefully lower the vehicle to the ground.
7. Check for Leaks: After lowering the vehicle, start the engine and let it run for a few minutes. Check carefully for any exhaust leaks around the muffler connections. You should not hear any hissing or see any exhaust escaping. If you hear a leak, you may need to tighten the bolts or replace the gaskets.
8. Disposal of old muffler: Dispose of the old muffler responsibly, according to local regulations.
Important Considerations:
* Exhaust System Design: The 1999 Chevy Malibu's exhaust system might have hangers or clamps in addition to bolts. Pay close attention to how the old muffler was connected.
* Torque Specifications: Over-tightening can damage the exhaust system. Under-tightening can lead to leaks. Always refer to your repair manual or the muffler manufacturer's instructions for the correct torque specifications.
* Professional Help: If you're not comfortable working on your car, it's always best to take it to a qualified mechanic. Exhaust work can be dangerous if not done properly.
This is a general guide, and the specific steps may vary slightly depending on your car's exact model and the type of muffler you are installing. Always prioritize safety and consult your vehicle's repair manual for the most accurate and detailed instructions.
