Malibu, Malibu MAXX 2006-2008

Engine

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the engine coolant.
  8.  
  9. With the tires in the straight forward position, remove the key from the ignition.
  10.  
  11. Secure the cooling module to the upper body structure.
  12.  
  13. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Fuel lines from the fuel rail
     
    Coolant hoses
     
    Heater hoses
     
    Throttle control electrical connector
     
    MAP sensor electrical connector
     
    Crankshaft sensor electrical connector
     
    Oil pressure electrical connector
     
    Purge solenoid electrical connector
     
    Ignition coil electrical connector
     
    O 2 sensor electrical connector
     
    Vehicle speed sensor (VSS) electrical connector
     
    Coolant temperature sensor electrical connector
     
    Back-up lamp switch electrical connector
     

  14.  
  15. Raise and support the vehicle.
  16.  
  17. Remove or disconnect the following:

    Accessory drive belt
     
    A/C compressor mounting bolts and set compress aside
     
    Starter electrical connectors
     
    Alternator electrical connector
     
    Front exhaust down pipe from the exhaust manifold
     
    Transmission harness connectors
     
    Transmission shift cable from the transmission
     

  18.  
  19. Support the powertrain assembly between the frame and the powertain using a block of wood or suitable equivalent.
  20.  
  21. Remove or disconnect the following:
    WARNING
    In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.



    Engine mount
     
    Side transmission mount, if equipped with automatic transmission
     
    Stabilizer links
     
    Outer tie rods from steering knuckles
     
    Intermediate shaft from the steering gear
     



    Lower control arms from the steering knuckles
     
    Halfshafts from the steering knuckles
     

  22.  
  23. Matchmark the frame to body position.
  24.  
  25. Position a lift table under the frame to support the frame assembly.
  26.  
  27. Slowly remove the front frame bolts.
  28.  
  29. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
  30.  
  31. Slowly lower the lift table.
  32.  
  33. Attach an engine lift hoist to the engine.
  34.  
  35. Remove the starter.
  36.  
  37. Remove the torque converter to flywheel bolts, if equipped.
  38.  
  39. Remove the transmission to engine bolts.
  40.  
  41. Separate the engine from the transmission.
  42.  
  43. Remove the clutch pressure plate and disc, if equipped.
  44.  
  45. Remove or disconnect the following:

    Exhaust manifold and studs
     
    Catalytic converter assembly
     
    Engine mount bracket
     
    Engine block heater, if equipped
     
    Thermostat housing and feed pipe
     
    Alternator
     

  46.  

To install:

  1. If removed, install or connect the following:

    Exhaust manifold
     
    Engine mount bracket
     
    Fuel rail
     
    Engine block heater, if equipped
     
    Thermostat housing and feed pipe
     
    Alternator
     
    Flywheel
     
    Clutch pressure plate and disc, if equipped
     

  2.  
  3. Align the engine to the transmission. Tighten to the engine-to-transmission bolts to 55 ft. lbs. (75 Nm).
  4.  
  5. Install the torque converter bolts, if equipped. Tighten bolts to 46 ft. lbs. (62 Nm).
  6.  
  7. Install the starter.
  8.  
  9. Reinstall the powertrain assembly to the frame assembly. Raise and position the frame/powertrain assembly to the vehicle.
  10.  
  11. Hand start all the frame bolts while aligning the frame to the body matchmarks. Tighten the frame bolts to 74 ft. lbs. (100 Nm) plus 180 degrees.
  12.  
  13. Remove the lift table.
  14.  
  15. Install or connect the following:

    Halfshafts to the steering knuckles
     
    Lower control arms to the steering knuckles
     
    Intermediate steering shaft to the steering gear
     
    Outer tie rods to the steering knuckles
     
    Stabilizer links
     
    Side transmission mount, if equipped with automatic transmission
     
    Engine mount
     
    Transmission shift cable to the transmission
     
    Transmission wiring harness connector
     
    Front exhaust down pipe to the exhaust manifold. Tighten nuts to 22 ft. lbs. (30 Nm).
     
    Alternator electrical connectors
     
    Starter harness connectors
     
    A/C compressor
     
    Accessory drive belt
     
    Throttle control electrical connector
     
    MAP sensor electrical connector
     
    Oil pressure electrical connector
     
    Purge solenoid electrical connector
     
    Ignition coil electrical connector
     
    O 2 sensor electrical connector
     
    VSS electrical connector
     
    Coolant temperature sensor electrical connector
     
    Heater hoses
     
    Coolant hoses
     
    Fuel line to fuel rail
     
    Air intake assembly
     
    Negative battery cable
     

  16.  
  17. Release the cooling module from the upper body structure.
  18.  
  19. Fill with engine oil to the correct level.
  20.  
  21. Fill the cooling system to the correct level.
  22.  
  23. Start the engine and check for leaks.
  24.  

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

    Negative battery cable
     
    Air intake assembly
     
    Hood
     
    Engine mount strut
     
    Accessory drive belt
     
    Knock sensor (KS) electrical connector
     
    Camshaft position (CMP) sensor electrical connector
     
    Crankshaft position (CKP) sensor electrical connector
     
    Heated oxygen sensor (HO2S) electrical connector
     
    Manifold absolute pressure (MAP) sensor electrical connector
     
    Exhaust gas recirculation (EGR) valve electrical connector
     
    Evaporative emission (EVAP) canister purge solenoid electrical connector
     
    Throttle control electrical connector
     
    Ignition coil electrical connector
     
    Body wiring harness
     

  10.  
  11. Raise and support the vehicle.
  12.  
  13. Remove or disconnect the following:

    Catalytic converters
     
    Engine wiring harness grounds
     
    Engine mount lower nuts
     
    Torque converter covers
     
    Starter
     
    A/C compressor mounting bolts and support the compress aside
     
    Torque converter bolts
     
    Transmission support brace
     
    Lower transmission-to-engine bolt
     
    Radiator hoses
     

  14.  
  15. Lower the vehicle and support the transmission.
  16.  
  17. Remove or disconnect the following:

    Heater hoses
     
    Vacuum hoses from upper intake manifold
     
    Fuel lines from the fuel rail
     

  18.  
  19. Install a suitable engine lifting device to the engine.
  20.  
  21. Remove the remaining transmission-to-engine bolts.
  22.  
  23. Remove the engine from the vehicle.
  24.  

To install:

  1. Install the engine to the transmission. Tighten the upper bolts to 55 ft. lbs. (75 Nm).
  2.  
  3. Remove the engine lifting device.
  4.  
  5. Install or connect the following:

    Radiator hoses
     
    Fuel lines to the fuel rail
     
    Brake booster vacuum hose to the upper intake manifold
     
    Heater hoses
     
    Lower transmission bolt and tighten to 55 ft. lbs. (75 Nm)
     
    Transmission support brace. Tighten bolts to 53 ft. lbs. (72 Nm)
     
    Torque converter bolts
     
    A/C compressor mounting bolts
     
    Starter
     
    Torque converter covers
     
    Engine mount lower nuts. Tighten nuts to 32 ft. lbs. (43 Nm).
     
    Engine wiring grounds. Tighten nut to 26 ft. lbs. (35 Nm).
     
    Catalytic converters
     
    Body wiring harness
     
    Ignition coil electrical connector
     
    Throttle control electrical connector
     
    EVAP canister purge solenoid electrical connector
     
    EGR valve electrical connector
     
    MAP sensor electrical connector
     
    HO2S electrical connector
     
    CKP sensor electrical connector
     
    CMP sensor electrical connector
     
    KS electrical connector
     
    Accessory drive belt
     
    Engine mount strut
     
    Hood
     
    Air intake assembly
     
    Negative battery cable
     

  6.  
  7. Fill the engine with oil to the correct level.
  8.  
  9. Fill the cooling system to the correct level.
  10.  
  11. Start the engine and check for leaks.
  12.  

3.9L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the hood.
  10.  
  11. Remove the intake manifold cover.
  12.  
  13. Remove the engine mount strut.
  14.  
  15. Remove the drive belt.
  16.  
  17. Drain the cooling system.
  18.  
  19. Drain the engine oil.
  20.  
  21. Remove the starter motor.
  22.  
  23. Remove the oil pressure sensor heat shield nuts and shield.
  24.  
  25. Disconnect the engine wiring harness electrical connector from the oil pressure sensor.
  26.  
  27. Disconnect the engine wiring harness electrical connector from the knock sensor.
  28.  
  29. Remove the engine wiring harness clip from the Air Conditioning (A/C) compressor bracket.
  30.  
  31. Remove the engine wiring harness clip bolt.
  32.  
  33. Separate the engine wiring harness clip from the engine boss
  34.  
  35. Disconnect the engine wiring harness electrical connector from the A/C compressor.
  36.  
  37. Disconnect the engine wiring harness electrical connector from the oil level sensor.
  38.  
  39. Remove the engine wiring harness clips from the transaxle bracket.
  40.  
  41. Remove the engine wiring harness clip from the transaxle bracket.
  42.  
  43. Remove the Connector Position Assurance (CPA) retainer.
  44.  
  45. Disconnect the lower front Heated Oxygen Sensor (HO2S) electrical connector from the engine wiring harness electrical connector.
  46.  
  47. Remove the engine wiring harness electrical connector from the thermostat housing stud.
  48.  
  49. Disconnect the lower rear HO2S electrical connector.
  50.  
  51. Remove the engine wiring harness electrical connector rosebud from the transaxle mount.
  52.  
  53. Disconnect the Knock Sensor (KS) and Crankshaft Position (CKP) sensor.
  54.  
  55. Lower the vehicle.
  56.  
  57. Remove all wiring harness clips.
  58.  
  59. Using the J 25034-C, remove power steering pump pulley.
  60.  
  61. Remove power steering pump.
  62.  
  63. Disconnect the Evaporative Emission (EVAP) canister purge solenoid.
  64.  
  65. Disconnect the Electronic Throttle Control (ETC).
  66.  
  67. Disconnect the Heated Oxygen Sensor (HO2S).
  68.  
  69. Disconnect the Manifold Absolute Pressure (MAP) sensor and the ignition control module.
  70.  
  71. Disconnect the alternator electrical connectors.
  72.  
  73. Disconnect the inlet manifold valve and the fuel injector inline electrical connector.
  74.  
  75. Disconnect the electrical connector from the camshaft phasor.
  76.  
  77. Disconnect the engine wiring harness electrical connectors from the body wiring harness electrical connector.
  78.  
  79. Disconnect the engine wiring harness electrical connectors from the Powertrain Control Module (PCM).
  80.  
  81. Disconnect the engine harness electrical connector from the Transmission Control Module (TCM).
  82.  
  83. Disconnect the vehicle speed sensor and transaxle wiring harness.
  84.  
  85. Remove engine wiring harness bolts and ground connections.
  86.  
  87. Remove battery cable ground terminal.
  88.  
  89. Reposition all of the harnesses out of the way.
  90.  
  91. Remove the catalytic converters.
  92.  
  93. Remove the engine mount.
  94.  
  95. Remove the torque converter cover.
  96.  
  97. Remove the flexplate to torque converter bolts.
  98.  
  99. Unbolt and reposition the A/C compressor to the side. DO NOT discharge the A/C system.
  100.  
  101. Remove the transaxle brace to oil pan bolts.
  102.  
  103. Remove the transaxle brace to transaxle bolts and remove the brace.
  104.  
  105. Remove the radiator outlet hose from the thermostat housing.
  106.  
  107. Lower the vehicle and support the transaxle.
  108.  
  109. Reposition the radiator surge tank hose clamp at the surge tank pipe.
  110.  
  111. Remove the radiator surge tank hose from the surge tank pipe.
  112.  
  113. Remove the brake booster vacuum hose from the intake manifold.
  114.  
  115. Remove the heater outlet and inlet hoses from the engine.
  116.  
  117. Disconnect the fuel feed line from the fuel rail.
  118.  
  119. Disconnect the EVAP purge line from the canister purge solenoid.
  120.  
  121. Remove the radiator inlet hose from the engine.
  122.  
  123. Install an engine lifting device to the engine.
  124.  
  125. Remove all the transaxle-to-engine bolts and studs.
  126.  
  127. Separate the engine from the transaxle and remove the engine from the vehicle.
  128.  

To install:

  1. Install the engine to the vehicle and install the engine to the transaxle.
  2.  
  3. Install the transaxle-to-engine bolts and studs.
  4.  
  5. Install the remaining transaxle-to-engine bolts and studs and tighten to 55 ft. lbs. (75 Nm).
  6.  
  7. Install the radiator inlet hose and tighten clamp.
  8.  
  9. Connect the EVAP purge line to the canister purge solenoid.
  10.  
  11. Connect the fuel feed line from the fuel rail.
  12.  
  13. Install the heater outlet and inlet hoses and tighten clamps.
  14.  
  15. Install the brake booster vacuum hose to the intake manifold.
  16.  
  17. Install the radiator surge tank hose to the surge tank pipe and tighten clamp.
  18.  
  19. Remove the support from the transaxle and raise the vehicle.
  20.  
  21. Install the radiator outlet hose to the thermostat housing.
  22.  
  23. Snug all the transaxle brace to engine block bolts and oil pan lower bolts.
  24.  
  25. Tighten the bolts to 37 ft. lbs. (50 Nm).
  26.  
  27. Install A/C compressor and tighten to 37 ft. lbs. (50 Nm).
  28.  
  29. Install the flexplate to torque converter bolts and tighten to 46 ft. lbs. (62 Nm).
  30.  
  31. Install the torque converter cover.
  32.  
  33. Install the engine mount and tighten the frame nuts to 37 ft. lbs. (50 Nm).
  34.  
  35. Install the catalytic converters and tighten to 23 ft. lbs. (31 Nm).
  36.  
  37. Position the branches of the engine wiring harness over the engine.
  38.  
  39. Install the battery cable ground terminal and the engine harness ground terminal to the transaxle stud.
  40.  
  41. Tighten the harness retaining nut to 18 ft. lbs. (25 Nm).
  42.  
  43. Install the engine wiring harness ground bolt and tighten to 18 ft. lbs. (25 Nm).
  44.  
  45. Install and tighten all additional harness mounting bolts and tighten to 18 ft. lbs. (25 Nm).
  46.  
  47. Connect the engine wiring harness electrical connector to the transaxle and the vehicle speed sensor.
  48.  
  49. Reconnect the PCM and TCM electrical connectors.
  50.  
  51. Connect all the engine wiring harness electrical connectors to the body wiring harness electrical connectors.
  52.  
  53. Install all wiring harness clips and any remaining wiring harness bolts.
  54.  
  55. Reconnect the camshaft phasor, fuel injector inline electrical connector and the inlet manifold valve.
  56.  
  57. Reconnect the alternator electrical connectors and tighten stud nut to 15 ft. (20 Nm).
  58.  
  59. Reconnect the rear upper HO2S electrical connector, ignition control module and the MAP sensor.
  60.  
  61. Reconnect the front HO2S electrical connector, the ETC and the EVAP canister purge solenoid.
  62.  
  63. Install the power steering pump and tighten mounting bolts to 18 ft. lbs. (25 Nm).
  64.  
  65. Using the J 25033-C, install power steering pump pulley.
  66.  
  67. Install the engine wiring harness clip to the power steer pump bracket.
  68.  
  69. Raise the vehicle.
  70.  
  71. Reconnect the CKP sensor and the KS sensor.
  72.  
  73. Install the engine wiring harness electrical connector rosebud to the transaxle mount.
  74.  
  75. Connect the lower rear HO2S electrical connector. 
  76.  
  77. Install the engine wiring harness electrical connector to the thermostat housing stud.
  78.  
  79. Connect the lower front HO2S electrical connector. 
  80.  
  81. Install the entire remaining engine wiring harness clips to the transaxle.
  82.  
  83. Reconnect the oil level sensor and the A/C compressor electrical connectors.
  84.  
  85. Install the engine wiring harness clip to the engine boss.
  86.  
  87. Reconnect to the knock sensor and oil pressure sensor electrical connectors.
  88.  
  89. Install the oil pressure sensor heat shield tighten the mounting nuts to 89 inch. lbs. (10 Nm).
  90.  
  91. Install the starter motor and tighten mounting bolts to 32 ft. lbs. (43 Nm).
  92.  
  93. Tighten the solenoid mounting nut to 89 inch. lbs. (10 Nm).
  94.  
  95. Install the drive belt.
  96.  
  97. Install the engine mount strut and tighten bots to 37 ft. lbs. (50 Nm).
  98.  
  99. Install the intake manifold cover.
  100.  
  101. Install the air cleaner assembly.
  102.  
  103. Install the hood and tighten bolts to 89 inch. lbs. (10 Nm).
  104.  
  105. Fill the cooling system.
  106.  
  107. Refill crankcase with engine oil.
  108.  
  109. Connect the negative battery cable.
  110.  
  111. Perform the CKP system variation learn procedure.
  112.  
  113. Check for leaks and recheck all fluid levels.
  114.  

 
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