Malibu, Malibu MAXX 2006-2008

Removal & Installation

Print

2.2L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the left headlamp.
  4.  
  5. Remove the right headlamp.
  6.  
  7. Unclip the upper transmission oil cooler pipe from the fan shroud. Do not disconnect transmission oil cooler pipe from transmission or radiator.
  8.  
  9. Loop a rope around each of the upper 2 tabs on the condenser and tie a rope around the upper tie bar.
  10.  
  11. Remove the upper radiator support bracket bolts.
  12.  
  13. Remove the upper radiator support brackets.
  14.  
  15. Pry upward on the fan shroud tabs at the radiator clips.
  16.  
  17. Raise the vehicle.
  18.  
  19. Remove the lower radiator air deflector retainers.
  20.  
  21. Remove the lower radiator air deflector.
  22.  
  23. Remove the right front fender liner.
  24.  
  25. Remove the right radiator air deflector retainers.
  26.  
  27. Remove the right radiator air deflector.
  28.  
  29. Remove the left radiator air deflector retainers.
  30.  
  31. Remove the left radiator air deflector.
  32.  
  33. Remove the lower radiator support bracket bolts.
  34.  
  35. Remove the lower radiator support brackets.
  36.  
  37. Remove the fan wire harness connectors.
  38.  
  39. Remove the fan shroud assembly.

    Click image to see an enlarged view

    Fig. Removal and installation of the fan

  40.  

To install:

  1. Install the fan shroud assembly.

    Click image to see an enlarged view

    Fig. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields

  2.  
  3. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
  4.  
  5. The radiator air side seals must be in the proper position for proper air flow.
  6.  
  7. Install the lower radiator support brackets.
  8.  
  9. Install the lower radiator support bracket bolts, and tighten the bolts to 44 ft. lbs. (60 Nm).
  10.  
  11. Install the fan wire harness connectors.
    NOTE
    Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

  12.  
  13. Install the left radiator air deflector.
  14.  
  15. Install the left radiator air deflector retainers.
  16.  
  17. Install the right radiator air deflector.
  18.  
  19. Install the right radiator air deflector retainers.
  20.  
  21. Install the right front fender liner.
  22.  
  23. Install the lower radiator air deflector.
  24.  
  25. Install the lower radiator air deflector retainers.
  26.  
  27. Lower the vehicle.
  28.  
  29. Snap the fan shroud tabs into the radiator clips.
  30.  
  31. Remove the rope attached to the condenser and upper tie bar.
  32.  
  33. Install the upper radiator support brackets.
    NOTE
    Do not allow the upper bracket to twist when tightening the screw or vibration may result.

  34.  
  35. Install the upper radiator support bracket bolts, and tighten the bolts to 7 ft. lbs. (10 Nm).
  36.  
  37. Clip the upper transmission oil cooler pipe to the shroud.
  38.  
  39. Install the right headlamp.
  40.  
  41. Install the left headlamp.
  42.  

3.5L & 3.9L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the coolant.
  4.  
  5. Remove the left headlamp.
  6.  
  7. Remove the right headlamp.
  8.  
  9. Remove the upper transmission oil cooler pipe from the radiator.
  10.  
  11. Loop a rope around each of the upper 2 tabs of the condenser and tie a rope around the upper tie bar.
  12.  
  13. Remove the upper radiator support bracket bolts.
  14.  
  15. Remove the upper radiator support brackets.
  16.  
  17. Pry upward on the fan shroud tabs at the radiator clips.
  18.  
  19. Raise the vehicle.
  20.  
  21. Remove the lower radiator air deflector retainers.
  22.  
  23. Remove the lower radiator air deflector.
  24.  
  25. Remove the right front fender liner.
  26.  
  27. Remove the right radiator air deflector retainers.
  28.  
  29. Remove the right radiator air deflector.
  30.  
  31. Remove the left radiator air deflector retainers.
  32.  
  33. Remove the left radiator air deflector.
  34.  
  35. Reposition the radiator outlet hose clamp at the radiator using the special tool J38185.
  36.  
  37. Remove the radiator outlet hose from the radiator.
  38.  
  39. Remove the fan wire harness connectors.
  40.  
  41. Remove the lower radiator support bracket bolts.
  42.  
  43. Remove the lower radiator support brackets.
  44.  
  45. Place a drain pan under the transmission oil cooler pipes.
  46.  
  47. Remove the transmission oil cooler pipes attachment nut from the transmission.

    Click image to see an enlarged view

    Fig. Transmission oil cooler pipe and attachment nut

  48.  
  49. Remove both transmission oil cooler pipes from the transmission.
  50.  
  51. Remove the transmission oil cooler pipe clip from the fan shroud.
  52.  
  53. Remove the lower transmission oil cooler pipe from the radiator.
  54.  
  55. Remove the transmission oil cooler pipes.
  56.  
  57. Remove the fan wire harness connectors.
  58.  
  59. Remove the fan shroud assembly.

    Click image to see an enlarged view

    Fig. Fan shroud assembly removal

  60.  

To install:

  1. Install the fan shroud assembly.
  2.  
  3. Install the transmission oil cooler pipes.
  4.  
  5. Install the lower transmission oil cooler pipe to the radiator.
  6.  
  7. Install the transmission oil cooler pipe clip to the fan shroud.
  8.  
  9. Install both transmission oil cooler pipes to the transmission.
  10.  
  11. Install the transmission oil cooler pipe attachment nut to the transmission, and tighten the nut to 62 lb inches (7 Nm).
  12.  
  13. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
  14.  
  15. The radiator air side seals must be in the proper position for proper air flow.
  16.  
  17. Install the lower radiator support brackets.
  18.  
  19. Install the lower radiator support bracket bolts, and tighten the bolts to 44 ft. lbs. (60 Nm).
  20.  
  21. Install the fan wire harness connectors.
  22.  
  23. Install the radiator outlet hose to the radiator.
  24.  
  25. Reposition the radiator outlet hose clamp at the radiator using the special tool J38185.
    NOTE
    Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

  26.  
  27. Install the left radiator air deflector.
  28.  
  29. Install the left radiator air deflector retainers.
  30.  
  31. Install the right radiator air deflector.
  32.  
  33. Install the right radiator air deflector retainers.
  34.  
  35. Install the right front fender liner.
  36.  
  37. Install the lower radiator air deflector.
  38.  
  39. Install the lower radiator air deflector retainers.
  40.  
  41. Lower the vehicle.
  42.  
  43. Snap fan shroud tabs into the radiator clips.
  44.  
  45. Remove the rope attached to the condenser and upper tie bar.
  46.  
  47. Install the upper radiator support brackets.
    NOTE
    Do not allow the upper bracket to twist when tightening the screw or vibration may result.

  48.  
  49. Install the upper radiator support bracket bolts, and tighten the bolts to 89 lb inches (10 Nm).
  50.  
  51. Install the upper transmission oil cooler pipe to the radiator.
  52.  
  53. Install the right headlamp.
  54.  
  55. Install the left headlamp.
  56.  
  57. Fill the coolant.
  58.  
  59. Inspect the transmission fluid level.
  60.  

 
label.common.footer.alt.autozoneLogo