Malibu 2001-2005

Rocker Arms

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Removal & Installation



3.1L & 3.5L Engines
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. Torque the rocker arm as follows:
    1. 3.1L Engines: Tighten to 89 inch lbs. (10 Nm) plus an additional 30 degree turn.
    2.  
    3. 3.5L Engines: Tighten to 24 ft. lbs. (32 Nm)
    4.  

  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. Torque the rocker arm as follows:
    1. 3.1L Engines: Tighten to 89 inch lbs. (10 Nm) plus an additional 30 degree turn.
    2.  
    3. 3.5L Engines: Tighten to 24 ft. lbs. (32 Nm)
    4.  

  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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