Malibu, Malibu MAXX 2006-2008

Camshaft, Bearings & Lifters

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Bearing Replacement



3.5L & 3.9L Engines
  1. Select the expander assembly and driving washer.
  2.  
  3. Assemble the J 33049.

    Click image to see an enlarged view

    Fig. Camshaft bearing service set J 33049

  4.  
  5. Drive out the camshaft bearings. Use the J 33049.
  6.  

To install:

  1. Assemble the J 33049 service set according to the manufacturer's instructions.
    WARNING
    Severe engine damage may result if the oil holes are not correctly aligned.



    Click image to see an enlarged view

    Fig. Camshaft bearing service set J 33049 installed for bearing installation

  2.  
  3. Install the camshaft bearings in the following order:

    Index the camshaft bearing oil holes with the engine block oil passages.
     
    Place the bearing on the J 33049.
     
    Install the third camshaft bearing.
     
    Install the second camshaft bearing.
     
    Install the outer camshaft bearings.
     

  4.  
  5. Apply sealer GM P/N 12377901 (Canadian P/N 10953504) or the equivalent to the camshaft rear bearing hole plug.

    Click image to see an enlarged view

    Fig. Rear bearing hole plug installed to 0.10 inch. (2.5 mm).

  6.  
  7. Install the camshaft rear bearing hole plug.
  8.  

Inspection



2.2L Engine
  1. Inspect the camshaft journals and lobes for wear or scoring.
  2.  
  3. Inspect the camshaft sprocket alignment notch for damage.
  4.  
  5. Inspect the camshaft cover for damage or loose oil control baffles.
  6.  
  7. Clean the camshaft cover.
  8.  
  9. Wash the camshaft in solvent.
  10.  
  11. Oil the camshaft.
  12.  
  13. Inspect the camshaft cover for cracks or other signs of damage.
  14.  
  15. Check for valve tappet face wear.
  16.  
  17. Check for excessive valve tappet clearance.
  18.  

3.5L & 3.9L Engines
  1. Remove and discard the camshaft position actuator filter.
  2.  
  3. Clean the camshaft with cleaning solvent.
  4.  
  5. Inspect the camshaft for scored bearing journals, damaged lobes or damaged position sensor reluctor areas.
  6.  
  7. Measure the camshaft journals using a micrometer. If the camshaft journals are not within 1.868-1.869 in (47.443-47.468mm) on 3.5L or 2.024-2.025 in (51.415-51.440mm) on 3.9L, replace the camshaft.
  8.  
  9. Measure the camshaft run out. If run out exceeds 0.001 in (0.025mm), replace the camshaft.
  10.  
  11. Measure the camshaft lobe lift using a dial indicator. Lubricate the camshaft and set the camshaft on V-blocks. If lobe lift exceeds 0.2727 in (6.9263mm), replace the camshaft.
  12.  
  13. Install a new camshaft position actuator filter. 
  14.  
  15. Check for valve tappet face wear.
  16.  
  17. Check for excessive valve tappet clearance.
  18.  

Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    PCV hose
     
    Fuel line bracket
     
    Ignition coil and module assembly
     
    Ground strap and ground strap retaining stud from camshaft cover
     
    Camshaft cover
     
    Upper timing chain guide
     

  4.  
  5. Install Camshaft Sprocket Holding Tool J-43655 and remove both the intake and exhaust camshaft sprocket bolts.
  6.  
  7. Slide the camshaft sprockets forward.
  8.  
  9. Matchmark the caps and remove.
  10.  
  11. Remove the camshaft.
  12.  

To install:

  1. Install the camshaft.
  2.  
  3. Install the camshaft caps as follows:
    1. Apply a 0.13 inch (3.5mm) bead of GM P/N 12378521 sealant to the rear intake camshaft cap.
    2.  
    3. Install camshaft caps and tighten bolts in increments of 3 turns until they are seated.
    4.  
    5. Tighten cap bolts to 89 inch lbs. (10 Nm).
    6.  
    7. Tighten intake camshaft rear cap bolts to 18 ft. lbs. (25 Nm).
    8.  

  4.  
  5. Install the camshaft sprockets onto the camshafts and hand tighten new camshaft sprocket bolts.
  6.  
  7. Remove Camshaft Sprocket Holding Tool J-43655.
  8.  
  9. Tighten the camshaft sprocket bolts to 63 ft. lbs. (85 Nm) plus 30 degrees.
  10.  
  11. Install or connect the following:

    Upper timing chain guide. Tighten bolts to 89 inch lbs. (10 Nm).
     
    Camshaft cover. Tighten bolts to 89 inch lbs. (10 Nm).
     
    Ground strap
     
    Ignition coil and module assembly
     
    Fuel line bracket
     
    PCV hose
     
    Air intake assembly
     
    Negative battery cable
     

  12.  
  13. Start the engine and check for leaks.
  14.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
    NOTE
    When removing valve train components, marked them for installation in the same location they are removed from.

  4.  
  5. Remove or disconnect the following:

    Rocker arm covers
     
    Intake manifold
     
    Rocker arms and push rods
     
    Lifter guide bolts and the guide
     
    Valve lifter(s) from the lifter bores
     
    Crankshaft balancer
     
    Front cover
     
    Timing chain and sprockets
     
    Oil pump driven gear bolt and gear
     
    Camshaft thrust plate
     
    Camshaft
     

  6.  

To install:

  1. Install or connect the following:

    Camshaft, lubricated with camshaft lubricant
     
    Camshaft thrust plate. Torque bolts to 89 inch lbs. (10 Nm).
     
    Oil pump driven gear. Torque the bolt to 27 ft. lbs. (36 Nm).
     
    Timing chain and sprocket. Torque the bolt to 103 ft. lbs. (140 Nm).
     
    Front cover. Torque the bolts to 35 ft. lbs. (47 Nm).
     
    Crankshaft balancer. Torque the bolt to 76 ft. lbs. (103 Nm).
     
    Valve lifters in their original locations
     
    Lifter guide. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Pushrods, rocker arms, rocker balls and rocker arm nuts. Torque the rocker arm nuts to 89 inch lbs. (10 Nm) plus an additional 30 degrees.
     
    Intake manifold. Torque the upper and lower intake bolts to 115 inch lbs. (13 Nm).
     
    Rocker arm covers. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Negative battery cable
     

  2.  
  3. Start the engine and verify no oil leaks.
  4.  

3.9L Engine
  1. Drain the engine oil and cooling system.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. To remove the valve lifters, remove the valve covers.
  6.  
  7. Remove the intake manifolds.
  8.  
  9. Remove the rocker arm bolts.
  10.  
  11. Remove the rocker arms.
  12.  
  13. Remove the pushrods.
  14.  
  15. Remove the intake manifold oil splash shield.
  16.  
  17. Remove the lifter guide bolts.
  18.  
  19. Remove the valve lifter guides.
  20.  
  21. Remove the valve lifters.
  22.  
  23. Clean all gasket surfaces with degreaser.
  24.  
  25. Clean the valve train parts.
  26.  
  27. Inspect the valve lifters and the cam lobes for wear.
  28.  
  29. To remove the camshaft, remove the engine front cover, timing chain and sprockets.
  30.  
  31. Remove the camshaft position sensor.
  32.  
  33. Remove the camshaft thrust plate.
  34.  
  35. Install the camshaft sprocket bolt into the camshaft. Tighten finger tight only.
  36.  
  37. Carefully rotate and remove the camshaft from the engine block.
  38.  

To install:

  1. Coat the camshaft journals with clean engine oil.
  2.  
  3. Coat the camshaft lobes with prelube.
  4.  
  5. Install the camshaft sprocket bolt into the camshaft. Tighten finger tight only.
  6.  
  7. Carefully rotate and install the camshaft to the engine block.
  8.  
  9. Install the camshaft thrust plate and tighten to 89 inch lbs. (10 Nm).
  10.  
  11. Install the camshaft position sensor and tighten to 89 inch lbs. (10 Nm).
  12.  
  13. Install the timing chain, sprockets and front cover.
  14.  
  15. Coat the valve lifters with prelube and install them.
  16.  
  17. Install the valve lifter guides and tighten to 89 inch lbs. (10 Nm).
  18.  
  19. Install the intake manifold oil splash shield.
  20.  
  21. Install the pushrods in their original locations.
    NOTE
    The intake pushrods are identified with yellow stripes and are 5-3/4 inches long. Exhaust pushrods are identified with green stripes and are 6 inches long.

  22.  
  23. Install the rocker arms and tighten to 24 ft. lbs. (32 Nm).
  24.  
  25. Install the intake manifolds.
  26.  
  27. Install the valve covers.
  28.  
  29. Connect the negative battery cable.
  30.  
  31. Fill the cooling system.
  32.  
  33. Start the vehicle, check for leaks and repair if necessary.
  34.  

 
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