Removal (Right): Removal & Installation Chevrolet Malibu V facelift

Installation

1. Clean cylinder block holes. Install gasket on cylinder block with THIS SIDE UP mark up (if equipped). Ensure all holes align with cylinder block. Install cylinder head. Apply Sealant (1052080) to head bolt threads.
2. Tighten NEW cylinder head bolts to specification in sequence. See «TORQUE SPECIFICATIONS»(ref-97546-S09466128262001050900000). (Scheme 3) To complete installation, reverse removal procedure. Fill and bleed cooling system. See «COOLING SYSTEM BLEEDING»(ref-97546-S37242749072001050900000).

Scheme 3

Disconnect negative battery cable. Raise and support vehicle. Remove right front wheel and inner fender splash shield. Prevent crankshaft from turning, and remove crankshaft balancer bolt. Remove crankshaft balancer with a puller. Remove crankshaft balancer key. Pry seal out of front cover with a large screwdriver.

Lubricate seal with engine oil. Using Seal Installer (J-35468), install seal with open end toward engine. To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS .

1. Disconnect negative battery cable. Using approved refrigerant recovery/recycling equipment, recover A/C refrigerant. Drain cooling system. Support engine from above with Engine Support Fixture (J-28467-360). Remove engine mount assembly. Remove engine mount bracket support. Remove serpentine drive belt. Remove air cleaner assembly and throttle body tube.
2. Remove power steering pump (leave hoses connected). Loosen top 2 A/C compressor bolts. Remove generator and bracket. Raise and support vehicle. Remove right front wheel and inner splash shield. Remove flexplate/flywheel cover. Remove bolt and washer securing crankshaft balancer. Use a puller to remove crankshaft balancer.
3. Remove serpentine drive belt tensioner. Remove engine mount strut between top of radiator panel and left side of engine. Disconnect electrical connectors from ABS front wheel speed sensors (if equipped) and suspension supports. Separate right ball joint stud from steering knuckle. Disconnect stabilizer shaft from right control arm and right suspension support. Remove bolts, then remove right suspension support and control arm as an assembly.
4. Remove bolts securing A/C compressor to oil pan. Remove oil filter and adapter. Remove engine mount strut bracket. Remove brace between engine and transaxle. Drain crankcase. Remove starter. Remove oil pan. See «OIL PAN»(ref-97546-S21938113482001050900000) . Remove crankshaft sensor. Remove lower bolts from front cover. Lower vehicle. Remove coolant by-pass pipe. Disconnect radiator hose from coolant thermostat housing. Remove upper bolts and front cover. Remove oil seal from front cover.

1. Throughly clean mating surface. Apply RTV sealant to sealing surface of front cover. Install NEW front cover oil seal. See «FRONT COVER OIL SEAL»(ref-97546-S41349860852001050900000) . Apply RTV sealant to keyway in crankshaft and crankshaft balancer.
2. Install crankshaft balancer using Balancer Installer (J-29113). Ensure balancer installer threads are inserted at least .20" (5.1 mm) into crankshaft. To complete installation, reverse removal procedure. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-97546-S09466128262001050900000) .

Note. If camshaft sprocket does not come off easily, lightly strike lower edge of sprocket with a plastic mallet.

Rotate crankshaft until cylinder No. 1 is at TDC of compression stroke (align timing mark on crankshaft balancer with mark on front cover). Disconnect negative battery cable. Remove front cover. See FRONT COVER . Drain coolant. Remove camshaft sprocket bolt. Remove camshaft sprocket and timing chain. Remove crankshaft sprocket with Crankshaft Sprocket Remover (J-5825-A).

1. Install crankshaft sprocket (if removed) using Installer (J-38612). If camshaft or crankshaft was rotated during removal of chain or sprockets, rotate camshaft and/or crankshaft as necessary to align timing marks. (Scheme 4)
2. Install timing chain onto camshaft sprocket. Hold camshaft sprocket vertically with chain hanging down. Install timing chain onto crankshaft sprocket, then camshaft sprocket onto camshaft. Install and tighten camshaft sprocket bolt to specification. See «TORQUE SPECIFICATIONS»(ref-97546-S09466128262001050900000). Lubricate timing chain with engine oil. To complete installation, reverse removal procedure.

Scheme 4

Note. During disassembly, keep valve train components together and identified in order to install parts in original locations. Perform a compression test and record results before removing cylinder heads and valve mechanism.

Disconnect negative battery cable. Drain coolant. Remove lower intake manifold. See INTAKE MANIFOLD . Remove rocker arm nuts, rocker arms and push rods. Remove bolts and lifter guide. Remove lifters.

If installing old lifters, lubricate lifters and bores with engine oil. If replacing lifters, lubricate lifters and bores with Prelube (1052365). Install lifters. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS .

Note. During disassembly, keep valve train components together and identified in order to install parts in original locations. Perform a compression test and record results before removing cylinder heads and valve mechanism.

1. Disconnect negative battery cable. Remove engine. See «ENGINE»(ref-97546-S21252941942001050900000) . Remove lower intake manifold. See «INTAKE MANIFOLD»(ref-97546-S39395320042001050900000) . Remove rocker arm nuts, rocker arms and push rods. Remove bolts and lifter guide. Remove lifters. Remove front cover. See «FRONT COVER»(ref-97546-S41605228002001050900000) .
2. Remove timing chain and camshaft sprocket. See «TIMING CHAIN»(ref-97546-S33719861432001050900000) . Remove oil pump drive assembly from top rear of cylinder block (held in place with a bolt and clamp like a distributor). Remove camshaft thrust plate. Remove camshaft. If necessary, remove camshaft bearings using Remover/Installer (J-33049).

If reusing camshaft, lubricate bearings and lobes with engine oil. Install camshaft. To complete installation, reverse removal procedure. Ensure timing marks are aligned. (Scheme 4) Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS.

1. Disconnect negative battery cable. Remove transaxle. See appropriate TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING.
2. On M/T remove pressure plate, clutch disc and flywheel. On A/T models, remove flexplate and retainer.
3. On all models, careful pry seal from housing (DO NOT damage sealing surfaces). Note direction of seal installation.

1. Coat inner and outer seal surfaces with engine oil. Install seal on mandrel of Seal Installer (J-34686) until dust lip bottoms against seal installer collar. (Scheme 5)
2. Install seal installer onto crankshaft, aligning dowel pin on seal installer with alignment hole in crankshaft flange. To install seal in seal bore, tighten seal installer handle until collar on seal installer is even with cylinder block.
3. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-97546-S09466128262001050900000).

Scheme 5

Disconnect negative battery cable. Drain cooling system. Loosen water pump pulley bolts. Remove serpentine drive belt. Remove water pump pulley bolts and pulley. Note position of locator tab on top of water pump for installation reference. Remove bolts, water pump and gasket.

Apply thread sealant to water pump bolts. Install water pump and NEW gasket. Ensure locator tab on top of water pump housing is positioned vertically. Tighten bolts to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure. Fill and bleed cooling system. See COOLING SYSTEM BLEEDING .