Malibu 2001-2005

Removal & Installation

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2.2L (L61) Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Partially drain the cooling system.
  4.  
  5. Disconnect the engine wiring harness electrical connector from the Engine Coolant Temperature (ECT) sensor.
  6.  
  7. Remove the ECT sensor.

    Click image to see an enlarged view

    Fig. Engine Coolant Temperature (ECT) sensor removal

  8.  

To install:

  1. Apply sealant to the threads of the ECT sensor.
  2.  
  3. Install the ECT sensor.
  4.  
  5. Tighten the ECT sensor to 15 ft. lbs. (20 Nm).
  6.  
  7. Connect the engine wiring harness electrical connector to the ECT sensor.
  8.  
  9. Fill and bleed the cooling system as needed.
  10.  

2.2L Engine



  1. Turn the ignition OFF .
    NOTE
    Engine coolant must be drained below the level of the Engine Coolant Temperature (ECT) sensor.

  2.  
  3. Disconnect the ECT sensor harness connector.
  4.  
  5. Remove the ECT.

    Click image to see an enlarged view

    Fig. The removal and installation of the coolant temperature sensor

  6.  

To install:


NOTE
Tap out the sensor mounting hole in the engine head to remove any thread sealant residue. Clean any sealant residue from the old sensor and apply the RTV sealant to threads if old the sensor is going to be reused.

  1. Apply the thread sealant GM P/N 21485227, LOCTITE 242® Threadlocker or equivalent to the sensor threads.
  2.  
  3. Install the ECT sensor, and tighten the ECT sensor to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect the ECT sensor harness connector. Push in the connector until a click is heard, then pull back to confirm a positive engagement.
  6.  
  7. Fill the engine coolant to the proper level.
  8.  

3.1L Engine




NOTE
Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

  1. Turn OFF the ignition.
  2.  
  3. Drain the coolant below the level of the ECT sensor.
  4.  
  5. Disconnect the sensor electrical connector.
  6.  
  7. Carefully remove the ECT sensor.

    Click image to see an enlarged view

    Fig. The removal and installation of the coolant temperature sensor

  8.  

To install:


NOTE
Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.


NOTE
Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

  1. Coat the threads with sealer GM P/N 9985253 or equivalent.
    NOTE
    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.  
  3. Carefully install the ECT sensor, and tighten the ECT sensor to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect the ECT electrical connector to the sensor.
  6.  
  7. Refill the cooling system.
  8.  

3.5L (LZ4) & 3.9L (LZ9) Engine



  1. Drain the cooling system.
  2.  
  3. Remove the intake manifold cover, if necessary.
  4.  
  5. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
  6.  
  7. Remove the ECT sensor.
    NOTE
    Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

  8.  

To Install:

  1. Coat the threads of the ECT sensor with sealer.
  2.  
  3. Install the ECT sensor and tighten to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect the ECT electrical connector.
  6.  
  7. Install the intake manifold cover, if necessary.
  8.  
  9. Fill and bleed the cooling system as needed.
  10.  

3.5L Engine




NOTE
Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.

  1. Partially drain the cooling system.
  2.  
  3. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
  4.  
  5. Remove the ECT sensor.

    Click image to see an enlarged view

    Fig. The removal and installation of the coolant temperature sensor

  6.  

To install:


NOTE
Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

  1. Coat the threads with sealer GM P/N 13246004 (Canadian P/N 10953480) or equivalent.
  2.  
  3. Install the ECT sensor, and tighten the ECT sensor to 15 ft. lbs. (20 Nm).
  4.  
  5. Connect the ECT electrical connector.
  6.  
  7. Fill the cooling system.
  8.  

 
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