Exhaust manifold cracked where the exhaust runners of cylinders 2 &3 converge and the output flange connects to the catalytic converter. The crack made the cabin smell like exhaust whenever the HVAC was set to pull in outside air. Recirculate had to be used to keep the exhaust out. I replaced the exhaust manifold myself, which was a real pain in the ass. The dealer wanted $600 to do the job. I bought an aftermarket manifold and gasket set for about $70.

An exhaust leak that close to the cabin fresh air intake in the wiper tray is a carbon monoxide hazard. Not to mention that there is no excuse for an exhaust manifold to crack. Ever. The only reason that happens is because the part was cast poorly.

This is a well documented problem that affects many 2.0, 2.2, and 2.4 eco tec engines, and something GM should address.

After paying $400.00 to have the exhaust manifold replaced, the exhaust is still loud and exhaust fumes are entering the passenger compartment. When I took it in, I did not diagnose the issue, I just told the mechanic that the exhaust was coming in the car and it was noisy. He did the diagnostic and said it was the exhaust manifold. He said he had just finished another Malibu with the same issue. Maybe, he should have looked a little more. I’ll be taking it back, when they open. This ain’t over!

Update from Feb 2, 2019: I ended up taking it to the dealership, hoping it would be covered by emissions or service bulletins. It wasn’t, It cost me $675 to fix the stripped out and missing bolts the first mechanic caused. My exhaust has never been worked on prior to his repair. I had been feeling really bad since a little before Christmas, and was taken to the ER twice in a two week period with chest pains. I later learned this is one of the symptoms of carbon monoxide poisoning. I also had the flu like symptoms, nausea, fatigue dull headache. I’ve since started researching the number of complaints that are on the internet about GM’s cracked exhaust manifolds and I’m surprised that a recall, or at least a service bulletin hasn’t been issued. This defect could have cost me my life. I’m thankful it didn’t, but I’m still out over $1000 dollars for a repair that shouldn’t have happened.

Update from Feb 17, 2019: The exhaust has been fixed. My health has not. Blood tests that I requested from my primary care physician revealed elevated levels of carboxyhemoglobin in my blood a full week after I had the exhaust fixed. My follow up care a week after that still showed elevated levels but they were dropping. My symptoms were quite obvious, but completely missed by medical staff at the hospital ER.