Malibu 2001-2005

Rocker Arms & Shafts

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Removal & Installation



3.5L Engine

NOTE
Place the valve train components in a rack in order to ensure that the components are installed in the same location from which they were removed.

  1. Remove the valve covers.
  2.  
  3. Remove the valve rocker arm bolts.
  4.  
  5. Remove the rocker arms.
  6.  
  7. Remove the pushrods.
  8.  
  9. Take note of the following:

    The intake push rods measure 5.81 inch. (147.51 mm).
     
    The exhaust push rods measure 6.1 inch. (154.87 mm).

    Click image to see an enlarged view

    Fig. Rocker arm, pushrod and bolt shown

     

  10.  

To install:

  1. Coat the ends of the pushrods using prelube.
  2.  
  3. Install the pushrods.

    The intake pushrods are identified with blue stripes.
     
    The exhaust pushrods are identified with yellow stripes.
     

  4.  
  5. Ensure that the pushrods seat in the lifter bore.
  6.  
  7. Coat the rocker arm friction surfaces using prelube.
    NOTE
    Shims (88894006) may be required under the valve rocker arm pedestals if reconditioning has been performed on the cylinder head or its components.

  8.  
  9. Install the rocker arms.
  10.  
  11. Install the rocker arm bolts and tighten to 25 ft. lbs. (34 Nm).
  12.  
  13. Install the valve rocker arm covers.
  14.  

Left Side (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Partially drain the cooling system to a level below the coolant pipe.
  6.  
  7. Remove or disconnect the following:

    Rear ignition wire harness at the upper intake manifold and at the spark plugs
     
    Coolant bypass hose clamp at the coolant tube
     
    Coolant tube from the cylinder head and move it aside
     
    Positive Crankcase Ventilation (PCV) valve from the rocker arm cover
     
    Rocker arm cover
     
    Rocker arms and pushrods
     

  8.  

To install:


NOTE
The intake pushrods are identified with yellow stripes and are 5 ¾ inches long. The exhaust pushrods are identified with green stripes and are 6 inches long.

  1. Coat all valve train components with engine oil.
  2.  
  3. Install the pushrods and rocker arms. Tighten to 24 ft. lbs. (32 Nm)
  4.  
  5. Install or connect the following:

    Rocker arm cover with a new gasket. Torque the bolts to 89 inch lbs. (10 Nm).
     
    PCV valve
     
    Coolant tube and thermostat bypass hose. Torque the screw at the water pump to 106 inch lbs. (12 Nm) and the nut/bolt at the cylinder head to 18 ft. lbs. (24 Nm).
     
    Rear ignition wire harness to the upper intake manifold and the spark plugs
     
    Negative battery cable
     

  6.  
  7. Refill the cooling system.
  8.  
  9. Start the vehicle and verify no leaks.
  10.  

Right Side (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Spark plug wires
     
    Power brake booster vacuum pipe from the intake plenum
     
    Accessory drive belt
     
    Alternator
     
    Ignition coil assembly
     
    Evaporative Emission (EVAP) canister purge solenoid
     
    Rocker arm cover
     
    Rocker arms and pushrods
     

  4.  

To install:


NOTE
The intake pushrods are identified with yellow stripes and are 5 ¾ inches long. The exhaust pushrods are identified with green stripes and are 6 inches long.

  1. Coat all valve train components with engine oil.
  2.  
  3. Install the pushrods and rocker arms. Tighten to 24 ft. lbs. (32 Nm)
  4.  
  5. Install or connect the following:

    Rocker arm cover with a new gasket. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Ignition coil assembly
     
    EVAP canister purge solenoid
     
    Alternator. Torque the bolts to 18 ft. lbs. (24 Nm).
     
    Accessory drive belt
     
    Power brake booster vacuum pipe to the plenum
     
    Spark plug wires
     
    Negative battery cable

    Click image to see an enlarged view

    Fig. Rocker arm components

     

  6.  

 
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