Malibu 2001-2005

Cylinder Head

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:

    Intake manifold
     
    Exhaust manifold
     
    Timing chain
     
    Cylinder head bolts in sequence
     
    Cylinder head

    Click image to see an enlarged view

    Fig. 2.2L engine cylinder head bolt removal sequence.

     

  8.  

To install:

  1. Install the cylinder head using new gaskets. Tighten the bolts in sequence to 22 ft. lbs. (30 Nm) plus 155 degrees.
  2.  
  3. Using new bolts, install the front cylinder head bolts. Tighten to 26 ft. lbs. (35 Nm).
  4.  
  5. Install or connect the following:

    Timing chain
     
    Exhaust manifold
     
    Intake manifold
     

  6.  
  7. Fill the cooling system to the correct level.
  8.  
  9. Start the engine and check for leaks.

    Click image to see an enlarged view

    Fig. Location of the front four cylinder head bolts-2.2L engine



    Click image to see an enlarged view

    Fig. 2.2L engine cylinder bolt sequence installation.

  10.  

3.1L Engine
Left (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    When removing the valve train components, keep them in order for installation in the same locations they were removed from.



    Upper half of the air cleaner assembly
     
    Air inlet duct
     
    Exhaust crossover pipe heat shield and the crossover pipe
     
    Spark plug wires
     
    Rocker arm covers
     
    Intake plenum and lower intake manifold
     
    Left side exhaust manifold
     
    Oil level indicator tube
     



    Rocker arm nuts, rocker arms, balls and pushrods
     
    Cylinder head bolts, evenly, by reversing the torque sequence
     
    Cylinder head
     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence

  1. Install the cylinder head with a new gasket. Torque the bolts to 33 ft. lbs. (45 Nm) plus an additional 90 degree turn.
  2.  
  3. Install or connect the following:

    Pushrods, rocker arms and balls. Torque the rocker arm nuts to 18 ft. lbs. (24 Nm).
     
    Lower intake manifold. Torque the bolts to 115 inch lbs. (13 Nm).
     
    Upper intake plenum. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    Rocker arm covers. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Oil level indicator tube
     
    Spark plug wires
     
    Left side exhaust manifold. Torque the bolts to 12 ft. lbs. (16 Nm).
     
    Exhaust crossover pipe. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    Crossover pipe heat shield. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Upper half of the air cleaner assembly
     
    Air inlet duct
     
    Negative battery cable
     

  4.  
  5. Refill the cooling system.
    NOTE
    An oil change is recommended.

  6.  
  7. Start the vehicle and check for leaks.
  8.  

Right (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    When removing the valve train components, keep them in order for installation in the same locations they were removed from.



    Upper half of the air cleaner assembly
     
    Throttle body air inlet duct
     
    Exhaust crossover pipe heat shield and the crossover pipe
     
    Oxygen (O 2 S) sensor
     
    Exhaust pipe from the exhaust manifold
     
    Right side exhaust manifold
     
    Spark plug wires
     
    Rocker arm cover
     
    Upper intake plenum
     
    Lower intake manifold
     



    Rocker arms nut, rocker arms, balls and pushrods
     
    Cylinder head bolts, evenly, by reversing the torque sequence
     
    Cylinder head
     

  8.  

To install:

  1. Install or connect the following:

    Cylinder head with a new gasket. Torque the bolts to 37 ft. lbs. (50 Nm) plus an additional 90 degree turn.
     
    Pushrods, rocker arms and balls. Torque the rocker arm nuts to 18 ft. lbs. (24 Nm).
     
    Lower intake manifold. Torque the bolts to 115 inch lbs. (13 Nm).
     
    Upper intake plenum. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    Rocker arm covers. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Spark plug wires
     
    Exhaust manifold. Torque the bolts to 12 ft. lbs. (16 Nm).
     
    Exhaust pipe to the exhaust manifold. Torque the bolts to 26 ft. lbs. (35 Nm).
     
    O 2 S sensor
     
    Exhaust crossover pipe. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    Heat shield. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Upper half of the air cleaner assembly
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  2.  
  3. Refill the cooling system.
  4.  
  5. An oil and filter change is recommended.
  6.  
  7. Start the vehicle and check for leaks.
  8.  

3.5L Engine
Left (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Lower intake manifold
     
    Rocker arms and pushrods
     
    Exhaust crossover pipe
     
    Oil level indicator tube
     
    Spark plug wires and spark plugs
     
    Exhaust manifold
     
    Cylinder head bolts
     
    Cylinder head

    Click image to see an enlarged view

    Fig. 3.5L engine cylinder head bolt torque sequence

     

  10.  

To install:

  1. Install or connect the following:

    Cylinder head using new gasket. Tighten the bolts in sequence to 44 ft. lbs. (60 Nm) plus 95 degrees.
     
    Exhaust manifold
     
    Spark plugs and spark plug wires
     
    Oil level indicator tube
     
    Exhaust crossover pipe
     
    Rocker arms and pushrods
     
    Lower intake manifold
     

  2.  
  3. Fill the engine with oil to the correct level.
  4.  
  5. Fill the cooling system to the correct level.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Lower intake manifold
     
    Rocker arms and pushrods
     
    Exhaust crossover pipe
     
    Oil level indicator tube
     
    Spark plug wires and spark plugs
     
    Exhaust manifold
     
    Cylinder head bolts
     
    Cylinder head

    Click image to see an enlarged view

    Fig. 3.5L engine cylinder head bolt torque sequence

     

  10.  

To install:

  1. Install or connect the following:

    Cylinder head using new gasket. Tighten the bolts in sequence to 44 ft. lbs. (60 Nm) plus 95 degrees.
     
    Exhaust manifold
     
    Spark plugs and spark plug wires
     
    Oil level indicator tube
     
    Exhaust crossover pipe
     
    Rocker arms and pushrods
     
    Lower intake manifold
     

  2.  
  3. Fill the engine with oil to the correct level.
  4.  
  5. Fill the cooling system to the correct level.
  6.  
  7. Start the engine and check for leaks.
  8.  

Right (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Lower intake manifold
     
    Rocker arms and pushrods
     
    Exhaust crossover pipe
     
    Right side spark plug wires and spark plugs
     
    Fuel line bracket
     
    Alternator
     
    Right exhaust manifold
     
    Cylinder head bolts, in reverse order of the torque sequence
     
    Cylinder head
     

  10.  

To install:

  1. Install or connect the following:

    Cylinder head with new gasket. Torque the bolts to 44 ft. lbs. (60 Nm) plus and additional 95 degrees.
     
    Right exhaust manifold
     
    Alternator
     
    Fuel line bracket. Tighten bolt to 37 ft. lbs. (50 Nm).
     
    Right side spark plugs and spark plug wires
     
    Exhaust crossover pipe
     
    Pushrods and rocker arms
     
    Lower intake manifold
     
    Negative battery cable
     

  2.  
  3. Fill engine with oil to the correct level.
  4.  
  5. Fill the cooling system to the correct level.
  6.  
  7. Start the engine and check for leaks.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Lower intake manifold
     
    Rocker arms and pushrods
     
    Exhaust crossover pipe
     
    Right side spark plug wires and spark plugs
     
    Fuel line bracket
     
    Alternator
     
    Right exhaust manifold
     
    Cylinder head bolts, in reverse order of the torque sequence
     
    Cylinder head
     

  10.  

To install:

  1. Install or connect the following:

    Cylinder head with new gasket. Torque the bolts to 44 ft. lbs. (60 Nm) plus and additional 95 degrees.
     
    Right exhaust manifold
     
    Alternator
     
    Fuel line bracket. Tighten bolt to 37 ft. lbs. (50 Nm).
     
    Right side spark plugs and spark plug wires
     
    Exhaust crossover pipe
     
    Pushrods and rocker arms
     
    Lower intake manifold
     
    Negative battery cable
     

  2.  
  3. Fill engine with oil to the correct level.
  4.  
  5. Fill the cooling system to the correct level.
  6.  
  7. Start the engine and check for leaks.
  8.  

3.9L Engine
Left (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the cooling system.
  6.  
  7. Lower the vehicle.
  8.  
  9. Remove the upper and lower intake manifolds.
  10.  
  11. Remove the valve rocker arms and the pushrods.
  12.  
  13. Remove the exhaust manifold.
  14.  
  15. Remove the oil level indicator tube.
  16.  
  17. Remove the left spark plugs.
  18.  
  19. Remove and discard the cylinder head bolts.
  20.  
  21. Remove the cylinder head.
  22.  
  23. Remove and discard the cylinder head gasket.
  24.  
  25. Remove the cylinder head locator dowel pins, if necessary.
  26.  
  27. Clean and inspect the cylinder head.
    WARNING
    Head gaskets are specific for right hand and left hand applications, and also must be installed with the correct side facing up. Note the markings on the head gaskets for proper installation. Failure to do so may lead to engine damage.



    Click image to see an enlarged view

    Fig. Cylinder head gasket markings shown

  28.  
  29. Install the cylinder head locator dowel pins, if previously removed
  30.  
  31. Inspect the cylinder head locator dowel pins for proper installation.
  32.  
  33. Install a new cylinder head gasket.
  34.  
  35. Install the cylinder head onto the locator pins and the engine.
    WARNING
    This component uses torque-to-yield bolts. When servicing this component do not reuse the bolts, New torque-to-yield bolts must be installed. Reusing used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield bolts may lead to engine damage.

  36.  
  37. Install new cylinder head bolts finger tight.
  38.  
  39. Tighten the cylinder head bolts in sequence to 44 ft. lbs. (60 Nm). plus an additional 140 degrees using the J 45059 angle meter.

    Click image to see an enlarged view

    Fig. 3.9L Left cylinder head tightening sequence

  40.  
  41. Install the left spark plugs.
  42.  
  43. Install the oil level indicator tube.
  44.  
  45. Install the exhaust manifold.
  46.  
  47. Install the valve rocker arms and the pushrods.
  48.  
  49. Install the lower intake manifold.
  50.  
  51. Fill the engine with oil.
  52.  
  53. Fill and bleed the cooling system.
  54.  
  55. Start the engine and check for leaks.
  56.  

Right (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise the vehicle.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Lower the vehicle.
  10.  
  11. Remove the upper and lower intake manifold.
  12.  
  13. Remove the valve rocker arms and pushrods.
  14.  
  15. Remove the exhaust manifold.
  16.  
  17. Remove the right spark plugs.
  18.  
  19. Remove the fuel line bracket bolt and stud.
  20.  
  21. Remove the fuel line bracket.
  22.  
  23. Remove the alternator.
  24.  
  25. Remove and discard the cylinder head bolts.
  26.  
  27. Remove the cylinder head.
  28.  
  29. Remove and discard the cylinder head gasket.
  30.  
  31. Remove the cylinder head locator dowel pins, if necessary.
    WARNING
    Head gaskets are specific for right hand and left hand applications, and also must be installed with the correct side facing up. Note the markings on the head gaskets for proper installation. Failure to do so may lead to engine damage.

  32.  
  33. Clean and inspect the cylinder head.
  34.  

To install:

  1. Install the cylinder head locator dowel pins, if previously removed
  2.  
  3. Install a new cylinder head gasket.
  4.  
  5. Install the cylinder head onto the locator pins and the engine.
    WARNING
    This component uses torque-to-yield bolts. When servicing this component do not reuse the bolts, New torque-to-yield bolts must be installed. Reusing used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield bolts may lead to engine damage.

  6.  
  7. Install new cylinder head bolts finger tight.
  8.  
  9. Tighten the cylinder head bolts in sequence to 44 ft. lbs. (60 Nm). plus an additional 140 degrees using the J 45059 angle meter.

    Click image to see an enlarged view

    Fig. 3.9L Right cylinder head tightening sequence

  10.  
  11. Install the alternator.
  12.  
  13. Position the fuel line bracket to the cylinder head and tighten to 37 ft. lbs. (50 Nm).
  14.  
  15. Install the right spark plugs.
  16.  
  17. Install the exhaust manifold.
  18.  
  19. Install the valve rocker arms and pushrods.
  20.  
  21. Install the lower intake manifold.
  22.  
  23. Fill the engine with oil.
  24.  
  25. Fill and bleed the cooling system.
  26.  
  27. Start the engine and check for leaks.
  28.  

 
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