Engine Mechanical - 2.2l (l61) Chevrolet Malibu VI

Fastener Tightening Specifications

Fastener Tightening Specifications

Engine Mechanical Specifications

Engine Mechanical Specifications

Sealers, Adhesives, and Lubricants

Sealers, Adhesives, and Lubricants

Scheme 1

Engine Block - Front View

Scheme 2

Engine Block - Back View

Scheme 3

Engine Block - Left Side View

Scheme 4

Engine Block - Bottom View

Scheme 5

Engine Block - Right Side View

Scheme 6

Engine Block - Top View

Scheme 7

Lower Crankcase - Front View

Scheme 8

Lower Crankcase - Back View

Scheme 9

Lower Crankcase - Bottom View

Scheme 10

Lower Crankcase - Left View

Scheme 11

Lower Crankcase - Right View

Scheme 12

Cylinder Head - Top View

Scheme 13

Cylinder Head - Intake Manifold Deck View

Scheme 14

Cylinder Head - Exhaust Manifold Deck View

Scheme 15

Cylinder Head - Front View

Scheme 16

Cylinder Head - Back View

Note: 1, 2, 5, 6 holes are oil passages.

Scheme 17

Cylinder Head - Bottom View

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Identification can be made through the use of the Broadcast Code label on the engine front cover (1) and the use of the partial VIN etched on the oil filter bowl (2).

1. Barcode (1)
2. Sequence Number (2)
3. Day (3)
4. Month (4)
5. Year (5)
6. Engine Assembly Plant (6)
7. Broadcast Code (7)
8. Part Designation (8)
9. Engine Assembly Number (9)
10. Broadcast Code (10)

The partial VIN identifies the specific vehicle by sequence number.

Diagnostic Starting Point - Engine Mechanical

Begin the system diagnosis by reviewing the Disassembled Views , Engine Component Description , Lubrication Description , and the Drive Belt System Description . Reviewing the description and operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Engine Mechanical in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Strategy Based Diagnostics

1. Perform the «Diagnostic System Check - Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/oem-general-information/#vehicle-dtc-information) in Vehicle DTC Information before using the symptom tables, if applicable.
2. Review the system operations in order to familiarize yourself with the system functions. Refer to «Disassembled Views»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) , «Engine Component Description»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) and «Lubrication Description»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system condition. The diagnostic flow is the place to start when repairs are necessary.

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the engine.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
3. Check for the correct oil level, proper oil viscosity, and correct filter application.
4. Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM, ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
5. Compare the engine sounds, if applicable, to a known good engine and make sure you are not trying to correct a normal condition.

Intermittent

Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Base Engine Misfire without Internal Engine Noises»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__base-engine-misfire-without-internal-engine)
2. «Base Engine Misfire with Abnormal Internal Lower Engine Noises»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__base-engine-misfire-with-abnormal-internal)
3. «Base Engine Misfire with Abnormal Valve Train Noise»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__base-engine-misfire-with-abnormal-valve)
4. «Base Engine Misfire with Coolant Consumption»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__base-engine-misfire-with-coolant-consumption)
5. «Base Engine Misfire with Excessive Oil Consumption»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__base-engine-misfire-with-excessive-oil)
6. «Engine Compression Test»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-compression-test)
7. «Engine Noise on Start-Up, but Only Lasting a Few Seconds»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-noise-on-start-up-but-only)
8. «Upper Engine Noise, Regardless of Engine Speed»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__upper-engine-noise-regardless-of-engine)
9. «Lower Engine Noise, Regardless of Engine Speed»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__lower-engine-noise-regardless-of-engine)
10. «Engine Noise Under Load»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-noise-under-load)
11. «Engine Will Not Crank - Crankshaft Will Not Rotate»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-will-not-crank-crankshaft)
12. «Oil Consumption Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__oil-consumption-diagnosis)
13. «Oil Pressure Diagnosis and Testing»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__oil-pressure-diagnosis-and-testing)
14. «Oil Leak Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__oil-leak-diagnosis)

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises

Base Engine Misfire with Abnormal Valve Train Noise

Base Engine Misfire with Abnormal Valve Train Noise

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Coolant Consumption

Base Engine Misfire with Excessive Oil Consumption

Base Engine Misfire with Excessive Oil Consumption

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Engine Noise on Start-Up, but Only Lasting a Few Seconds

Upper Engine Noise, Regardless of Engine Speed

Upper Engine Noise, Regardless of Engine Speed

Lower Engine Noise, Regardless of Engine Speed

Lower Engine Noise, Regardless of Engine Speed

Engine Noise Under Load

Engine Noise Under Load

Engine Will Not Crank - Crankshaft Will Not Rotate

Engine Will Not Crank - Crankshaft Will Not Rotate

Coolant in Combustion Chamber

Coolant in Combustion Chamber

Coolant in Engine Oil

Coolant in Engine Oil

Engine Compression Test

Perform the following steps to conduct a compression test.

1. Conduct the following steps to check cylinder compression. Engine should be at room temperature. Disconnect wiring from the ignition module. Remove the spark plugs. Throttle body valve should be wide open. Battery should be at or near full charge.
2. For each cylinder, crank engine through 4 compression strokes.
3. The lowest reading cylinder should not be less than 70 percent of the highest.
4. No cylinder reading should be less than 689 kPa (100 psi).

Cylinder Leakage Test

Tools Required

J 35667-A Cylinder Head Leakdown Tester or equivalent. See Special Tools and Equipment .

Test

1. Worn or burnt valves
2. Broken valve springs
3. Stuck valve lifters
4. Incorrect valve lash/adjustment
5. Damaged piston
6. Worn piston rings
7. Worn or scored cylinder bore
8. Damaged cylinder head gasket
9. Cracked or damaged cylinder head
10. Cracked or damaged engine block

1. Disconnect the battery ground negative cable.
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L.
3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center (TDC) of the compression stroke.
4. Install the J 35667-A or equivalent. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturers instructions. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent in considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: Air leakage sounds at the throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring. Air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring. Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket.
7. Perform the leakage test on the remaining cylinders and record the values.

Oil Consumption Diagnosis

Excessive oil consumption, not due to leaks, is the use of 0.9 L (1 qt) or more of engine oil within 3 200 kilometers (2,000 miles). The causes of excessive oil consumption include the following conditions

1. External oil leaks Tighten bolts and/or replace gaskets and oil seals as necessary.
2. Incorrect oil level or improper reading of oil level indicator With the vehicle on a level surface, allow adequate drain down time and check for the correct oil level.
3. Improper oil viscosity Use recommended SAE viscosity for the prevailing temperatures.
4. Continuous high speed driving and/or severe usage
5. Crankcase ventilation system restrictions or malfunctioning components
6. Valve guides and/or valve stem oil seals worn, or the seal omitted Ream guides and install oversize service valves and/or new valve stem oil seals.
7. Piston rings broken, improperly installed, worn, or not seated properly Allow adequate time for rings to seat. Replace broken or worn rings as necessary.
8. Piston improperly installed or mis-fitted

Oil Pressure Diagnosis and Testing

Tools Required

J-21867-850 Oil Pressure Gage Adapter. See Special Tools and Equipment .

Diagnosis and Testing

1. With the vehicle on a level surface, allow adequate drain down time of 2-3 minutes and measure for a low oil level. Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator.
2. Run the engine, and verify low, or no oil pressure on the vehicle gage or light. Listen for a noisy valve train or a knocking noise.
3. Inspect for the following: Oil diluted by moisture or unburned fuel mixtures Improper oil viscosity for the expected temperature Incorrect or malfunctioning oil pressure sender Incorrect or malfunctioning oil pressure gage Plugged oil filter Malfunctioning oil bypass valve
4. Remove the oil pressure sender or another engine block oil gallery plug.
5. Install J-21867-850 and an oil pressure gage and measure the engine oil pressure. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
6. Compare the readings to specifications. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) .
7. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: Oil pump worn or dirty Refer to «Oil Pump Disassemble»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__oil-pump-disassemble) . Oil pump-to-engine front cover bolts loose Refer to «Engine Front Cover and Oil Pump Installation»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-front-cover-and-oil-pump) . Oil pump screen loose, plugged, or damaged Oil pump screen O-ring seal missing or damaged Malfunctioning oil pump pressure regulator valve Excessive bearing clearance Refer to «Crankshaft and Bearings Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__crankshaft-and-bearings-cleaning-and-inspection) . Cracked, porous or restricted oil galleries Oil gallery plugs missing or incorrectly installed Refer to «Engine Block Assemble»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-block-assemble) . Broken lash adjusters

Oil Leak Diagnosis

Oil Leak Diagnosis

Crankcase Ventilation System Inspection/Diagnosis

1. Disconnect the PCV hose.
2. Start the engine.
3. Check for vacuum at the hose. If there is no vacuum, check for a plugged hose or manifold port. Check for a hose that collapses when blocked (vacuum applied). Replace the plugged or the deteriorated hoses.
4. Allow the engine to idle at normal operating temperature.
5. Remove the engine oil dipstick and install a vacuum gage on the dipstick tube.
6. Block off the PCV system fresh air intake passage.
7. Run the engine at 1500 RPM for 30 seconds, then read vacuum gage while engine is running at 1500 RPM. If vacuum is present, this indicates that the crankcase ventilation system is functioning properly. If no vacuum is indicated, the engine may not be sealed and is drawing in outside air. Check the valve covers, the oil pan gasket or other sealing areas for leaks. If the vacuum gage registers a pressure, or if a vacuum gage is pushed out of dipstick tube, check for a plugged PCV port, a plugged hose or an excessive engine blow-by.

Diagnostic Aids

The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution.

A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise.

Test Description

The numbers below refer to the step number on the diagnostic table.

1. 2: The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table.
2. 3: The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed.
3. 4: Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust.
4. 6: Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley.
5. 10: Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed.
6. 12: Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley.
7. 14: Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair.

Drive Belt Chirping Diagnosis

A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise.

If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.

The numbers below refer to the step numbers on the diagnostic table.

1. 2: The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table
2. 3: The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed.
3. 4: This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly.
4. 5: This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise.
5. 6: This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction.
6. 7: Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley.
7. 8: This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes.

Drive Belt Squeal Diagnosis

The drive belt will not cause the whine noise.

If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing.

The numbers below refer to the step numbers on the diagnostic table.

1. 3: This test is to verify that the noise is being caused by the drive belt or the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed.
2. 4: The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure.

Drive Belt Whine Diagnosis

Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise.

The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom.

If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise.

The numbers below refer to the step numbers on the diagnostic table.

1. 2: This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom.
2. 3: This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed.
3. 4: Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt.
4. 5: Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation.

Drive Belt Rumbling Diagnosis

The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components.

The numbers below refer to the step numbers on the diagnostic table.

1. 2: This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain.
2. 3: This test is to verify that the drive belt or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed.
3. 4: The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the condition of the belt.
4. 6: Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed.
5. 8: This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange.
6. 9: This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump.
7. 10: Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate.

Drive Belt Vibration Diagnosis

If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.

An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly.

If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt.

The numbers below refer to the step numbers on the diagnostic table.

1. 2: This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys.
2. 4: Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley.
3. 5: Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley.
4. 6: Accessory drive component brackets that are bent or cracked will let the drive belt fall off.
5. 7: Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.

Drive Belt Falls Off Diagnosis

Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application.

Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off.

Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off.

The numbers below refer to the step numbers on the diagnostic table.

1. 2: The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mis-positioning the drive belt by one groove on a pulley.
2. 3: The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys.
3. 4: This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle.

Drive Belt Excessive Wear Diagnosis

Drive Belt Tensioner Diagnosis

Drive Belt Tensioner Diagnosis

Drive Belt Replacement

Tools Required

J 44811 Accessory Belt Tensioner Unloader. See Special Tools .

Removal Procedure

1. Remove the front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .
2. Use the J 44811 in order to rotate the drive belt tensioner counter-clockwise to release the spring tension.
3. Remove the drive belt.

Installation Procedure

1. Use the J 44811 in order to rotate the drive belt tensioner counter-clockwise to release the spring tension.
2. Install the drive belt.
3. Install the front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .

Drive Belt Tensioner Replacement

Tools Required

J 45025 . See Special Tools and Equipment .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Use a J 45025 to tighten the drive belt tensioner bolt. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Tighten: Tighten the drive belt tensioner bolt to 45 N.m (33 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) .

Engine Mount Inspection

1. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-support-fixture) .
2. Observe the engine mount while raising the engine. Raising the engine removes the weight from the engine mount and creates slight tension on the rubber.
3. Replace the engine mount if the engine mount exhibits any of the following conditions: The hard rubber is covered with heat check cracks. The rubber is separated from the metal plate of the engine mount. The rubber is split through the center of the engine mount. The engine mount itself is leaking fluid.
4. For engine mount replacement. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Disconnect the engine oil pressure sensor electrical connector.
4. Remove the engine oil pressure sensor.

1. Install the engine oil pressure sensor. Tighten: Tighten the oil pressure switch to 22 N.m (16 lb ft).
2. Connect the engine oil pressure sensor electrical connector.
3. Lower the vehicle.
4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.

Powertrain Mount Balance Procedure - Total Mount

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Loosen the front transmission mount through bolt. Do not remove.
3. Loosen the rear transmission mount through bolt. Do not remove.
4. Position two floor jacks with wood blocks under the engine and transmission to support the powertrain assembly.
5. From the engine compartment, loosen the transmission mount to transmission bolts.
6. Loosen the engine mount to intermediate bracket bolts.
7. Reposition the floor jacks to allow a 1/8 inch gap between the mount and mount bracket.
8. Tighten the transmission mount to transmission bolts using the following sequence: Rear bolt Middle bolt Front bolt Tighten: Tighten the bolts to 50 N.m (37 lb ft).
9. Tighten the engine mount to intermediate bracket bolts starting with the center bolt. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
10. Remove the floor jacks.
11. Shake the powertrain vigorously from front to rear and allow the powertrain to settle.
12. Tighten the rear transmission mount through bolt. Tighten: Tighten the bolts to 90 N.m (66 lb ft).
13. Tighten the front transmission mount through bolt. Tighten: Tighten the bolts to 90 N.m (66 lb ft).
14. Lower the vehicle.

Powertrain Mount Balance Procedure - Lower Mount

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Loosen the front transmission mount through bolt. Do not remove.
3. Loosen the rear transmission mount through bolt. Do not remove.
4. Shake the powertrain vigorously from front to rear and allow powertrain to settle.
5. Tighten the rear transmission mount through bolt. Tighten: Tighten the bolt to 90 N.m (66 lb ft).
6. Tighten the front transmission mount through bolt. Tighten: Tighten the bolt to 90 N.m (66 lb ft).
7. Lower the vehicle.

1. Remove the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the intermediate bracket to engine bolts.
3. Remove the intermediate bracket from the engine.

1. Install the intermediate bracket to the engine.
2. Hand tighten the engine mount intermediate bracket bolts in the following locations: The long bolts in the forward and front lower holes The short bolt in the rear upper hole
3. Tighten the intermediate bracket bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
4. Install the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

1. Use a floor jack and a block of wood to support the powertrain from the oil pan.
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls 2.2L (L61).
3. Remove the engine mount to bracket bolts.
4. Remove the engine mount to body bolts.
5. Remove the engine mount from the vehicle.

1. Install the engine mount to the vehicle. Hand tighten the bolts at this time.
2. Install the engine mount to engine bracket bolts. Tighten: Tighten the engine mount to bracket bolts to 50 N.m (37 lb ft). Tighten the engine mount to vehicle bolts to 50 N.m (37 lb ft).
3. Remove the floor jack and block of wood.
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls 2.2L (L61).

Engine Support Fixture

Tools Required

1. J 28467-B Universal Engine Support Fixture. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. J 36462 Engine Support Adapter Leg

1. Raise the hood.
2. Install the thread support nuts (J 28467-33A) onto the strut attaching studs.
3. Install the strut tower support assemblies (J 28467-5A) over the thread support nuts (J 28467-33A).
4. Install the T-bolts (J 28467-53) with 5/16 inch washers through the strut tower support assemblies (J 28467-5A) into the thread support nuts (J 28467-33A) and hand tighten.
5. Install the two cross bracket assemblies (J 28467-1A) over the strut tower tube (J 28467-3).
6. Install the strut tower tube (J 28467-3) into the strut tower support assemblies (J 28467-5A).
7. Install the 1/2 inch x 2.5 inch quick release pin (J 28467-10) through the strut tower support assemblies (J 28467-5A) and the strut tower tube (J 28467-3) on one side only.
8. Install the radiator shelf tube (J 28467-2A) through the driver side cross bracket assembly (J 28467-1A) on the top of the strut tower tube (J 28467-3).
9. Place the rubber padded foot of the front support assembly (J 28467-4A) on the vehicle radiator shelf. The foot position used in the front support assembly (J 28467-4A) depends on the vehicle application.
10. Install the 7/16 inch x 2.0 inch quick release pin (J 28467-9) through the hole in the front support assembly (J 28467-4A) in order to level the radiator shelf tube (J 28467-2A). The hole used in the front support assembly (J 28467-4A) depends on the vehicle application.
11. Install the lift hook (J 28467-7A) through the lift hook bracket (J 28467-6A).
12. Install the 1/2 inch lift hook washer and lift hook wing nut (J 28467-34) onto the lift hook (J 28467-7A).
13. Install the assembled lift hook bracket (J 28467-6A) over the radiator shelf tube (J 28467-2A).
14. Adjust the radiator shelf tube (J 28467-2A) and the assemblage lift hook bracket (J 28467-6A) in order to align the hook with the left (front), rear of engine, lift hook bracket part of the left engine mount strut bracket.
15. Hand tighten the driver side cross bracket assembly (J 28467-1A) wing nuts.
16. Install the second radiator shelf tube (J 28467-2A) through the passenger side cross bracket assembly (J 28467-1A) on the top of the strut tower tube (J 28467-3).
17. Place the rubber padded foot of the front support assembly (J 28467-4A) on the vehicle radiator shelf. The foot position used in the front support assembly (J 28467-4A) depends on the vehicle application.
18. Install the 7/16 inch x 2.0 inch quick release pin (J 28467-9) through the hole in the front support assembly (J 28467-4A) in order to level the radiator shelf tube (J 28467-2A). The hole used in the front support assembly (J 28467-4A) depends on the vehicle application.
19. Install the lift hook (J 28467-7A) through the lift hook bracket (J 28467-6A).
20. Install the 1/2 inch lift hook washer and lift hook wing nut (J 28467-34) onto the lift hook (J 28467-7A).
21. Install the assemblage lift hook bracket (J 28467-6A) over the radiator shelf tube (J 28467-2A).
22. Adjust the radiator shelf tube (J 28467-2A) and the assemblage lift hook bracket (J 28467-6A) in order to align the hook with the right (rear), front of engine, lift hook bracket located next to the generator.
23. Hand tighten the passenger side cross bracket assembly (J 28467-1A) wing nuts.
24. Hand tighten the lift hook wing nuts (J 28467-34) securely to remove all slack from the engine support fixture assembly.

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls-2.2L (L61).
2. Unclip the electrical wiring harness from the oil level indicator tube.
3. Remove the oil level indicator tube bolt.
4. Remove the oil level indicator tube.
5. Remove the oil level indicator tube seal.

1. Install the oil level indicator tube seal.
2. Install the oil level indicator tube.
3. Clip the electrical wiring harness to the oil level indicator tube.
4. Install the oil level indicator tube bolt. Tighten: Tighten the oil level indicator tube bolt to 10 N.m (89 lb in).
5. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls-2.2L (L61).

1. Disconnect the crankcase ventilation hose from the camshaft cover.
2. Disconnect the crankcase ventilation hose from the intake manifold.

1. Connect the crankcase ventilation hose to the camshaft cover.
2. Connect the crankcase ventilation hose to the intake manifold.

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61).
2. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61).
3. Disconnect the PCV hose.
4. Disconnect the purge solenoid tube.
5. Disconnect the brake booster hose.
6. Remove the oil level indicator tube bolt.
7. Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61).
8. Disconnect the knock sensor electrical connector.
9. Remove the knock sensor harness connector from the intake manifold.
10. Remove the intake manifold nuts and bolts.
11. Remove the intake manifold.
12. If applicable, remove the intake manifold gasket.

1. If applicable, install the intake manifold gasket.
2. Install the intake manifold.
3. Install the intake manifold nuts and bolts. Tighten: Tighten the intake manifold nuts and bolts to 10 N.m (89 lb in).
4. Install the knock sensor harness connector to the intake manifold.
5. Connect the knock sensor electrical connector.
6. Install the fuel rail. Refer to «Fuel Rail Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls -2.2L (L61).
7. Install the throttle body.
8. Install the oil level indicator tube bolt. Tighten: Tighten the oil level indicator tube bolt to 10 N.m (89 lb in).
9. Connect the brake booster hose.
10. Connect the purge solenoid tube.
11. Connect the PCV hose.
12. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61).
13. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61).

Crankshaft Balancer Replacement

Tools Required

J 38122-A Harmonic Balancer Holder. See Special Tools and Equipment .

1. Remove the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) .
2. Use J 38122-A to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
3. Remove the crankshaft balancer bolt. Discard the bolt.
4. Remove the crankshaft balancer.

1. Install the crankshaft balancer.
2. Install a NEW crankshaft balancer bolt.
3. Use J 38122-A to prevent the crankshaft from rotating while tightening the crankshaft balancer bolt. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus 75 degrees.
4. Install the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) .

Tools Required

J 35268-A Camshaft/Front Main Seal Installer. See Special Tools and Equipment .

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__crankshaft-balancer-replacement) .
2. Use a flat bladed tool to remove the seal from the front cover.

1. Use the J 35268-A in order to install the crankshaft front oil seal to the engine front cover. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__crankshaft-balancer-replacement) .

1. Remove the crankcase balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__crankshaft-balancer-replacement) .
2. Remove the drive belt tensioner.
3. Remove the engine front cover to water pump bolt.
4. Remove the remaining engine front cover bolts.
5. Remove the engine front cover. If the engine front cover gasket is damaged. Remove the front engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Remove the engine front cover gasket if it is damaged.

1. If removed install a new engine front cover gasket.
2. Install the front engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
3. Install the engine front cover.
4. Install the engine front cover bolts. Tighten: Tighten the engine front cover bolts to 25 N.m (18 lb ft).
5. Install the water pump bolt. Tighten: Tighten the water pump bolt to 25 N.m (18 lb ft).
6. Install the drive belt tensioner.
7. Install the drive belt tensioner bolt. Tighten: Tighten the drive belt tensioner bolt to 45 N.m (33 lb ft).
8. Install the crankcase balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__crankshaft-balancer-replacement) .

Timing Chain, Sprockets, and/or Tensioner Replacement

Tools Required

J 45027 Tensioner Tool. See Special Tools and Equipment .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
4. Rotate the engine until the crankshaft sprocket mark aligns with the matching colored link (2) at the 5 o'clock position.
5. Lower the vehicle.
6. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
7. Ensure that the INT diamond on the intake camshaft sprocket is aligned with the uniquely colored link at (1) at the 2 o'clock position.
8. Ensure that the EXH triangle on the exhaust camshaft sprocket is aligned with the matching colored link (3).
9. Remove the timing chain tensioner.
10. Remove the fixed timing chain guide access plug.
11. Remove the fixed timing chain guide.
12. Remove the upper timing chain guide.
13. Use a 24 mm wrench to hold the camshafts from turning.
14. Remove the exhaust camshaft sprocket bolt and discard.
15. Remove the exhaust camshaft sprocket.
16. Remove the timing chain tensioner guide.
17. Remove the intake camshaft sprocket bolt and discard.
18. Remove the intake camshaft sprocket.
19. Remove the timing chain through the top of the cylinder head.
20. Remove the crankshaft sprocket.
21. Remove the balance shaft drive chain tensioner.
22. Remove the adjustable balance shaft chain guide.
23. Remove the small balance shaft drive chain guide.
24. Remove the upper balance shaft drive chain guide.
25. Remove the balance shaft drive chain.

1. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position.
2. Assemble the intake camshaft sprocket to the timing chain with the timing mark lined up with the uniquely colored link (1). Hand tighten a new intake camshaft sprocket bolt.
3. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
4. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
5. Install the adjustable timing chain guide through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten: Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
6. Install the exhaust camshaft sprocket and a new bolt loosely onto the exhaust camshaft.
7. Align the timing mark on the sprocket with the last matching colored link (3). Install the bolt finger tight.
8. Using a 24 mm wrench, first turn the intake camshaft until the alignment feature on the back of the camshaft sprocket seats in the notch in the front of the intake camshaft. Turn the crankshaft 45 degrees in either direction. Turn the intake cam to the appropriate location. Turn the crankshaft back to top dead center.
9. When the sprocket seats on the cam, tighten the sprocket bolt hand tight.
10. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not, repeat the portion of the procedure necessary to align the timing marks.
11. Install the fixed timing chain guide. Tighten: Tighten the fixed timing chain guide bolts to 10 N.m (89 lb in).
12. Install the upper timing chain guide. Tighten: Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
13. Using a 24 mm wrench, engage the hex on the intake camshaft and using a torque wrench, tighten the camshaft sprocket bolt. Tighten: Tighten the intake camshaft sprocket bolt to 85 N.m (63 lb ft), plus 30 degrees.
14. Using a 24 mm wrench, engage the hex on the exhaust camshaft and using a torque wrench, tighten the camshaft sprocket bolt. Tighten: Tighten the exhaust camshaft sprocket bolt to 85 N.m (63 lb ft), plus 30 degrees.
15. Remove the old oil from the timing chain tensioner.
16. Inspect the timing chain tensioner for scoring or free movement.
17. Inspect the timing chain washer and O-ring for damage. If damaged, replace the timing chain tensioner.
18. Measure the timing chain tensioner assembly from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
19. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
20. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint free cloth.
21. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
22. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end repeat steps 16.1 and 16.4.
23. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
24. Install the timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (66 lb ft).
25. The timing chain tensioner is released by compressing it 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
26. Inspect to ensure that all dirt and debris is removed from the timing chain oiling nozzle hole in the engine block.
27. Install the timing chain oiling nozzle. Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
28. Apply sealant P/N 21485277 compound to the thread, and install the timing chain guide bolt access hole plug. Tighten: Tighten the access hole plug to 90 N.m (59 lb ft).
29. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
30. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
31. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
32. Lower the vehicle.
33. Connect negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls -2.2L (L61).
2. Remove the PCV hose.
3. Remove the fuel line bracket.
4. Remove the ignition coil and module assembly. Refer to «Ignition Coil Housing Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls -2.2L (L61).
5. Remove the ground strap retaining stud from the camshaft cover and disconnect the ground strap.
6. Remove the camshaft cover bolts.
7. Remove the camshaft cover.

1. Install the camshaft cover and bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
2. Install the ground strap to the camshaft cover. Tighten: Tighten the ground strap stud to 10 N.m (89 lb in).
3. Install the ignition coil and module assembly. Refer to «Ignition Coil Housing Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls -2.2L (L61).
4. Install the fuel pipe bracket. Tighten: Tighten the fuel pipe bracket bolt to 10 N.m (89 lb in).
5. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls -2.2L (L61).

Intake Camshaft and Lifter Replacement

Tools Required

J 43655 Camshaft Sprocket Holding Tool. See Special Tools and Equipment .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the upper timing chain guide.
3. Install the J 43655 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
4. Remove both the intake and exhaust camshaft sprocket bolts and discard.
5. Slide the camshaft sprockets forward.
6. Mark bearing caps to ensure they are installed in the original position.
7. Remove the bearing caps.
8. Remove the intake camshaft.
9. Remove the camshaft roller followers.
10. Remove the hydraulic element lash adjusters.

1. Lubricate the valve tips.
2. Install the hydraulic element lash adjusters.
3. Install the camshaft roller followers.
4. Ensure that the alignment notches are aligned with the camshaft sprocket.
5. Install the intake camshaft.
6. Install the camshaft bearing caps.
7. Tighten the camshaft bearing cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the camshaft bearing cap bolts to 10 N.m (89 lb in).
8. Apply a 5 mm (0.197 in) bead of Permatex Anaerobic Gasket Maker® 51813 (or equivalent), to the rear intake camshaft bearing cap.
9. Install the rear intake camshaft bearing cap bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
10. Install camshaft sprockets onto the camshafts.
11. Hand tighten NEW camshaft sprocket bolts.
12. Remove the J 43655 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
13. Tighten the camshaft sprocket bolts. Tighten: Tighten the bolts to 85 N.m (63 lb ft) plus 30 degrees.
14. Install the upper timing chain guide. Tighten: Tighten the upper timing chain guide to 10 N.m (89 lb in).
15. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

J 43655 Camshaft Sprocket Holding Tool. See Special Tools and Equipment .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the upper timing chain guide.
3. Install the J 43655 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
4. Remove both the intake and the exhaust camshaft sprocket bolts and discard.
5. Slide the camshaft sprockets forward.
6. Mark the bearing caps to ensure that the bearing caps are installed in the original position.
7. Remove the bearing caps.
8. Remove the exhaust camshaft.
9. Remove the camshaft roller followers.
10. Remove the hydraulic element lash adjusters.

1. Lubricate the valve tips.
2. Install the hydraulic element lash adjusters.
3. Install the camshaft roller followers.
4. Ensure that the alignment notches are aligned with the camshaft sprocket.
5. Install the exhaust camshaft.
6. Install the camshaft bearing caps.
7. Tighten the camshaft bearing cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the camshaft bearing cap bolts to 10 N.m (89 lb in).
8. Install camshaft sprockets onto the camshafts.
9. Hand tighten NEW camshaft sprocket bolts.
10. Remove the J 43655 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
11. Tighten the camshaft sprocket bolts. Tighten: Tighten the bolts to 85 N.m (63 lb ft) plus 30 degrees.
12. Install the upper timing chain guide. Tighten: Tighten the upper timing chain guide to 10 N.m (89 lb in).
13. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

J 36660-A Torque Angle Meter. See Special Tools and Equipment .

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
3. Remove the timing chain. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__timing-chain-sprockets-andor-tensioner-replacement) .
4. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
5. Remove the cylinder head bolts in sequence and discard.
6. Remove the cylinder head and gasket.
7. Clean all gasket surfaces.

1. Install the cylinder head and gasket.
2. Install NEW cylinder head bolts.
3. Tighten the cylinder head bolts in sequence. Tighten: Tighten the cylinder head bolts to 30 N.m (22 lb ft) plus 155 degrees.
4. Install the NEW front cylinder head bolts. Tighten: Tighten the front cylinder head bolts to 35 N.m (26 lb ft).
5. Install the timing chain. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__timing-chain-sprockets-andor-tensioner-replacement) .
6. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
7. Lower the vehicle.
8. Install the intake manifold. Refer to «Intake Manifold Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
9. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Drain the engine oil.
3. Remove the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) .
4. Remove the lower AC compressor bolt.
5. Remove the oil pan bolts.
6. Remove the oil pan

1. Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris.
2. Apply a 2 mm bead of GM P/N 12346286 (Canadian P/N 10953472) around the perimeter of the oil pan and the oil suction port opening. Do not over apply the RTV. More than a 2 mm bead is not required.
3. Install the oil pan.
4. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft).
5. Install the AC compressor bolts. Refer to «Compressor Replacement (L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation and Air Conditioning.
6. Install the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) .
7. Lower the vehicle.
8. Fill the engine oil to the proper level.

J 42067 Rear Main Seal Installer. See Special Tools and Equipment .

1. Remove the transmission. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
2. Remove the flywheel.
3. Pry the crankshaft rear oil seal with a flat-bladed tool.

1. Use the J 42067 and install the seal. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Install the flywheel. Tighten: Tighten the flywheel bolts to 53 N.m (39 lb ft) plus 25 degrees.
3. Install the transmission. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.

1. Remove the transmission. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
2. Remove the flywheel bolts, and note the position of the flywheel to the crankshaft.
3. Remove the flywheel.

1. Position the flywheel on the crankshaft as previously noted.
2. Install the flywheel bolts. Tighten: Tighten the flywheel bolts to 53 N.m (39 lb ft) plus 25 degrees.
3. Install the transmission. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.

1. With the tires in the straight forward position, remove the key from the ignition.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Remove the air inlet duct and resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61).
4. Secure the cooling module to the upper body structure.
5. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief Procedure»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61__fuel-pressure-relief-procedure) in Engine Controls - 2.2L (L61).
6. Disconnect the fuel lines from the fuel rail.
7. Drain the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
8. Remove the radiator inlet hose. Refer to «Radiator Hose Replacement - Inlet (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
9. Remove the surge tank to cylinder head hose. Refer to «Surge Tank Hose/Pipe Replacement - Inlet (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) , «Surge Tank Hose/Pipe Replacement - Outlet (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
10. Remove the radiator outlet hose. Refer to «Radiator Hose Replacement - Outlet (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
11. Remove the inlet (1) and outlet (2) heater hoses. Refer to «Heater Hose Replacement - Inlet (L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) and «Heater Hose Replacement - Outlet (L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation and Air Conditioning.
12. Disconnect the following harness connectors: The electronic throttle control The map sensor The crankshaft sensor The oil pressure sensor The purge solenoid The ignition coil and module assembly The O2 sensor The vehicle speed sensor The engine temperature sensor The back-up lamp switch
13. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
14. Remove the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) .
15. Remove the AC compressor bolts and set the compressor aside.
16. Disconnect the starter harness connectors (3, 4, 5).
17. Disconnect the generator harness connectors.
18. Drain the engine oil.
19. Disconnect the front exhaust pipe from the exhaust manifold. Refer to «Exhaust Manifold Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
20. Disconnect the transmission harness connectors.
21. Disconnect the transmission shift cable from the transmission.
22. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
23. Remove the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
24. Remove the side transmission mount. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
25. Disconnect the stabilizer links from the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) in Front Suspension.
26. Disconnect the outer tie rod ends from the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/malibu/vi-2003-2006/remont/manual-power-steering/#power-rack-pinion-steering-system) in Power Steering System.
27. Disconnect the intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/steering-column-switches/#steering-wheel-steering-column) in Steering Wheel and Column.
28. Disconnect the lower control arms from the steering knuckles. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) in Front Suspension.
29. Disconnect the drive axles from the steering knuckle. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
30. Use a paint pen or magic marker in order to mark the frame to body position.
31. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
32. Use wood blocks as necessary between the lift table and the frame to support the assembly.
33. Slowly remove the frame bolts using the following sequence: Remove the front frame bolts. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
34. Slowly lower the table to the floor.
35. Attach the engine lift hoist to the engine lift hooks.
36. Remove the starter.
37. If applicable, remove the torque converter to flywheel bolts.
38. Remove the transmission to engine bolts.
39. Separate the engine from the transmission.
40. If applicable, remove the clutch pressure plate and disk.
41. Remove the following components: The exhaust manifold and catalytic converter assembly The exhaust manifold studs The engine mount bracket The engine block heater The thermostat housing and feed pipe The generator
42. Remove the engine from the engine lift.

1. Attach the engine lift hoist to the engine lift hooks.
2. Install the following components: The exhaust manifold - Refer to «Exhaust Manifold Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) in Engine Exhaust. The engine mount bracket - Refer to «Engine Mount Bracket Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . The fuel rail-Refer to «Fuel Rail Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61). The engine block heater, if equipped-Refer to «Coolant Heater Replacement (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling. The drive belt tensioner - Refer to «Drive Belt Tensioner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-tensioner-replacement) . The thermostat housing and feed pipe - Refer to «Thermostat Replacement (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling. The generator - Refer to «Generator Replacement (L61)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) . The flywheel - Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
3. If applicable, install the clutch pressure plate and disk.
4. Align the engine to the transmission.
5. Secure the engine to the transmission. Tighten: Tighten the transmission to engine bolts to 75 N.m (55 lb ft).
6. If applicable, install the torque converter bolts. Tighten: Tighten the bolts to 62 N.m (46 lb ft).
7. Install the starter. Refer to «Starter Motor Replacement (L61)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
8. Remove the engine lift from the engine.
9. Raise and position the frame and powertrain assembly to the vehicle.
10. Hand start all the frame bolts while aligning the frame to the paint marks.
11. Tighten the frame bolts. Tighten: Tighten the frame bolts to 100 N.m plus 180 degrees (74 lb ft plus 180 degrees).
12. Remove the lift table.
13. Connect the drive axles to the steering knuckles. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2003-2006/remont/axle-shafts/#wheel-drive-shafts) in Wheel Drive Shafts.
14. Connect the lower control arm to the steering knuckle. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) in Front Suspension.
15. Connect the intermediate steering shaft to the steering gear. Refer to «Power Steering Gear Replacement»(/chevrolet/malibu/vi-2003-2006/remont/manual-power-steering/#power-rack-pinion-steering-system) in Power Steering System.
16. Connect the outer tie rod ends to the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/malibu/vi-2003-2006/remont/manual-power-steering/#power-rack-pinion-steering-system) in Power Steering System.
17. Connect the stabilizer links to the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) in Front Suspension.
18. Install the side transmission mount. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
19. Install the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
20. Remove the wood blocks between the powertrain and frame.
21. Connect the transmission shift cable to the transmission.
22. Connect the transmission harness connector.
23. Connect the exhaust takedown pipe to the exhaust manifold. Tighten: Tighten the nuts to 30 N.m (22 lb ft).
24. Connect the generator harness connectors. Tighten: Tighten the generator terminal nut to 20 N.m (15 lb ft).
25. Connect the starter harness connectors (3,4,5). Tighten: Tighten the battery terminal nut to 17 N.m (13 lb ft). Tighten the S-terminal nut to 3 N.m (27 lb in).
26. Install the AC compressor to the engine. Refer to «Compressor Replacement (L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation and Air Conditioning.
27. Install the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) .
28. Connect the following harness connectors: The electronic throttle control The map sensor The crankshaft sensor The oil pressure sensor The purge solenoid The ignition coil and module assembly The O2 sensor The vehicle speed sensor The engine temperature sensor
29. Install the inlet heater hose (1) and outlet heater hose (2). Refer to «Heater Hose Replacement - Inlet (L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Heater Hose Replacement - Outlet (L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation and Air Conditioning.
30. Install the radiator outlet hose. Refer to «Radiator Hose Replacement - Inlet (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
31. Connect the fuel line to the fuel rail.
32. Connect the brake booster hose at the brake booster.
33. Release the cooling module from the upper body structure.
34. Install the air inlet duct and resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61).
35. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
36. Fill the engine with engine oil to the proper level. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/malibu/vi-2003-2006/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) in Maintenance and Lubrication.
37. Fill the cooling system. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
38. Road test the vehicle.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Place a drain pan under the oil drain plug.
3. Remove the oil pan drain plug.
4. Use a 32 mm (1 1/4 in) socket on the hex on the top of the oil filter cap, or an oil filter wrench on the outside diameter of the oil filter cap.
5. Remove the oil filter cap with filter.
6. Remove the filter from the cap.

1. Install the filter to the cap.
2. Install the oil filter cap with filter.
3. Use a 32 mm (1 1/4 in) socket on the hex on the top of the oil filter cap, or an oil filter wrench on the outside diameter of the oil filter cap. Tighten: Tighten the oil filter cap until fully seated, DO NOT exceed 25 N.m (18 lb ft).
4. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
5. Lower the vehicle.
6. Fill the engine with oil. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/malibu/vi-2003-2006/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) in Maintenance and Lubrication.

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 43649 Valve Spring Compressor. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. J 36017 Valve Guide Seal Remover. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

1. Remove the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__intake-camshaft-and-lifter-replacement) or «Exhaust Camshaft and Lifter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the camshaft roller followers.
3. Install the J 43649 to the cylinder head. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
4. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61).
5. Install an air hose adaptor into the spark plug hole.
6. Pressurize the cylinder to 690 kPa (100 psi).
7. Compress the valve spring.
8. Remove the valve spring keepers.
9. Remove the valve spring.
10. Using the J 36017 remove the valve seal. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

1. Using the J 36017 install the valve seal. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Install the valve spring.
3. Compress the valve spring.
4. Install the valve spring keepers.
5. Remove the air hose adaptor into the spark plug hole.
6. Remove the J 43649 from the cylinder head. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
7. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61).
8. Install the camshaft roller followers.
9. Install the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__intake-camshaft-and-lifter-replacement) or «Exhaust Camshaft and Lifter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

Draining Fluids and Oil Filter Removal

Tools Required

J 44887 Oil Filter Wrench. See Special Tools and Equipment .

1. Use J 44887 to remove the oil filter cap. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Remove the oil pan drain plug and allow the oil to drain out.
2. Remove the oil filter from the cap and discard.
3. Clean the oil filter housing in the engine block.
4. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
5. Remove the water pump drain plug from the water pump and allow the coolant to drain from the water jacket.
6. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the water pump drain plug.
7. Install the water pump drain plug. Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
8. If cleaning or repairing the engine block, it is not necessary to reinstall the plugs.

Engine Flywheel Removal

Tools Required

J 38122-A Harmonic Balancer Holder. See Special Tools and Equipment .

Removal

1. Remove the flywheel attaching bolt. Use the J 38122-A to prevent crankshaft rotation. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the flywheel retainer.
3. Remove the flywheel.
4. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

Oil Level Indicator and Tube Removal

1. Remove knock sensor connector from the oil level indicator tube.
2. Remove the tube bracket to the intake manifold bolt.
3. Remove the tube from the oil pan.

Exhaust Manifold Removal

1. Remove the exhaust manifold heat shield.
2. Remove the block heater if equipped.
3. Remove the oxygen sensor.
4. Remove and discard the exhaust manifold to cylinder head retaining nuts.
5. Remove the exhaust manifold and catalytic converter assembly.
6. Clean all of the sealing surfaces.
7. If the exhaust manifold and catalytic converter assembly is being replaced, transfer the following parts: The exhaust manifold heat shield The oxygen sensor

Intake Manifold Removal

1. Remove the EVAP emission canister valve tube (1).
2. Remove the EVAP emission canister valve (2).
3. Remove the throttle body.
4. Remove fuel pipes and clip. Remove the fuel rail assembly.
5. Remove the fuel injector tip insulators and discard.
6. Remove the intake manifold retaining nuts and bolts.
7. Remove the intake manifold.
8. Remove the intake manifold gasket, if necessary. The gasket is reusable if it is not damaged.
9. If the intake manifold needs to be replaced, transfer the following parts: The throttle body The throttle body gasket The manifold-to-throttle body gasket is reusable if it is not damaged.

Crankshaft Damper Removal

Tools Required

J 38122-A Harmonic Balancer Holder. See Special Tools and Equipment .

1. Install the J 38122-A . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the damper retaining bolt and washer. Use the J 38122-A and a breaker bar in order to prevent the crankshaft from rotating when loosening the bolt. Discard the bolt.
3. Remove the damper assembly.

Camshaft Cover Removal

1. Remove the power steering blockout plate, if equipped.
2. Remove the camshaft cover grounding strap.
3. Remove the front lift bracket.
4. Remove the rear lift bracket.
5. Remove the ignition module and coil assembly.
6. Remove the camshaft cover assembly.

Engine Front Cover and Oil Pump Removal

1. Remove the accessory drive belt tensioner bolt.
2. Remove the accessory drive belt tensioner.
3. Remove the engine front cover bolts.
4. Remove the long water pump bolt.
5. Remove the engine front cover and gaskets.
6. Remove the crankshaft front cover oil seal with an appropriate tool.

Timing Chain and Tensioner Removal

1. Remove the upper timing chain guide bolts.
2. Remove the upper timing chain guide.
3. Remove the timing chain tensioner plunger.
4. Locate hex on the exhaust camshaft and hold with a wrench.
5. Remove the exhaust cam bolt and the exhaust cam sprocket. Discard the bolt.
6. Remove the adjustable timing chain guide bolt.
7. Remove the adjustable timing chain guide.
8. Remove the plug to gain access to the fixed timing chain guide bolt.
9. Remove the fixed timing chain guide bolts.
10. Remove the fixed timing chain guide.
11. Locate hex on the intake camshaft and hold with a wrench.
12. Remove the intake cam sprocket bolt, the intake cam sprocket and the timing chain through the top of the cylinder head. Discard the bolt.
13. Remove the crankshaft sprocket.
14. Remove the oil nozzle and bolt.

Intake Camshaft, Follower, and Adjuster Removal

1. Mark bearing caps to ensure they are installed in the same position.
2. Remove the intake camshaft bearing cap bolts.
3. Remove the camshaft bearing caps.
4. Remove the intake camshaft.
5. Remove the intake camshaft roller finger followers.
6. Remove the hydraulic element adjusters.

Exhaust Camshaft, Follower, and Adjuster Removal

1. Mark bearing caps to ensure they are installed in the same position.
2. Remove the exhaust camshaft bearing cap bolts.
3. Remove the camshaft bearing caps ensuring they are marked and refitted in same position on assembly.
4. Remove the exhaust camshaft.
5. Remove the exhaust camshaft roller finger followers.
6. Remove the hydraulic element adjusters.

Balance Shaft Drive Chain and Tensioner Removal

1. Remove the balance shaft drive chain tensioner bolts.
2. Remove the balance shaft drive chain tensioner.
3. Remove the adjustable balance shaft chain guide bolt.
4. Remove the adjustable balance shaft chain guide.
5. Remove the small balance shaft drive chain guide bolts.
6. Remove the small balance shaft drive chain guide.
7. Remove the upper balance shaft drive chain guide bolts.
8. Remove the upper balance shaft drive chain guide.
9. Remove the balance shaft drive chain.
10. Remove the balance shaft drive sprocket.

Balance Shaft Removal

Tools Required

J 43650 Balancer Shaft Bearing Remover and Installer. See Special Tools and Equipment .

1. Remove the balance shaft bearing carrier bolts.
2. Remove the balance shaft assemblies.
3. Install the J 43650 into the balance shaft hole. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Insert the tool with the foot parallel to the shaft.
4. When the J 43650 is inserted in the block turn the J 43650 so that the foot becomes perpendicular to the shaft. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
5. Center the foot of the J 43650 on the balance shaft bushing. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
6. Once the J 43650 is centered on the balance shaft bushing, then insert the centering guide into the front balance shaft bore and tighten the nut with an appropriate wrench. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . When the J 43650 is properly installed, before removing the bushing, the end of the tool should be 116 mm (4.6 in). See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) (a) from the block face. If the J 43650 is less than approximately 114 mm (4.5 in) (a), recheck the tool alignment. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
7. Tighten the nut on the J 43650 until the tension releases. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . When the tension releases, remove the J 43650 and the balance shaft bushing. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

Water Pump Removal

1. Remove the engine coolant temperature sensor.
2. Remove the water pipe support bracket and bolts.
3. Remove the thermostat and water feed pipe retaining bolts.
4. Remove the thermostat housing and water feed pipe from the water pump cover.
5. Remove the water pump retaining bolts. Be sure to remove the bolt that goes through the front of the engine block.
6. Remove the water pump assembly.

Cylinder Head Removal

Tools Required

J 38188 Cylinder Head Broken Bolt Extractor Kit. See Special Tools and Equipment .

1. Remove the EGR cover (607), the bolts (608), and the EGR cover gasket (606).
2. Remove the cylinder head to the block bolts in sequence. Discard the bolts.
3. Remove the cylinder head.
4. Remove the cylinder head gasket.
5. Clean all of the gasket surfaces.
6. Use the following procedures when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge any surface. IMPORTANT: Do not use any other method or technique to clean these gasket surfaces. Use a new razor blade for each cylinder head and cylinder block. IMPORTANT: Be careful not to gouge or scratch the gasket surfaces. Do not gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket. Hold the razor blade as parallel to the gasket surface as possible.
7. Clean the old sealer/lube and dirt from the bolt holes.
8. Clean the bolt holes with a nylon bristle brush.
9. When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes.
10. Remove any broken long cylinder head bolts using the J 38188 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

Oil Pan Removal

1. Remove the oil pan bolts.
2. Remove the oil pan at pry points.

Piston, Connecting Rod, and Bearing Removal

Tools Required

J-43966-1 Connecting Rod Guides. See Special Tools and Equipment .

1. Rotate the crankshaft to a position where the connecting rod bolts are the most accessible.
2. Mark the connecting rod and cap with the cylinder position. Also mark their orientation. This will ensure the caps and connecting rods are re-assembled properly.
3. Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap.
6. Install J-43966-1 on the connecting rod bolts before removing the piston and connecting rod assembly. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
7. Remove the piston and connecting rod assembly.

Lower Crankcase Removal

1. Remove the crankshaft position sensor. Inspect the position sensor for damage. Replace if necessary.
2. Remove the bedplate perimeter bolts.
3. Remove and discard the crankshaft bearing bolts.
4. Using the pry-points and an appropriate prying tool, gently separate the upper and lower crankcase.

Crankshaft and Bearings Removal

1. Remove the crankshaft from the block.
2. Remove the crankshaft rear oil seal from the block.
3. Remove the bearing inserts from the block.
4. Remove the bearing inserts from the bed plate.
5. Clean the oil, sludge, and carbon.
6. Inspect the oil passages for obstructions.
7. Inspect the threads.
8. Inspect the bearing journals and the thrust surfaces for the following conditions: Cracks Chips Gouges Roughness Grooves Overheating (discoloration)
9. Inspect the corresponding bearing inserts for imbedded foreign material. If foreign material exists find the cause and repair it.
10. Measure the crankshaft journals. Use a micrometer or dial indicator to measure the taper and runout. Note the result for the later selection of bearing inserts. If not within limits the crankshaft must be replaced. Note the location of the main bearing high spots. If they are not in line, the crankshaft is bent and must be replaced.

Engine Block Disassemble

1. Remove the water jacket drain plug.
2. Remove the oil flow check valve.
3. Remove the rear oil passage plug.
4. Remove the six oil passage plugs on the sides of the block.
5. Remove the two water passage plugs on the top of the block.
6. Remove the two front oil passage plugs.
7. Remove the knock sensor and bolt.
8. Remove the oil pressure switch.
9. Remove the crankshaft position sensor and bolt.

Engine Block Cleaning and Inspection

Tools Required

1. J 7872 Magnetic Base Dial Indicator. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. J 8087 Cylinder Bore Gage. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

1. Clean the sealing material from the gasket mating surfaces.
2. Clean the engine block and lower crankcase in a cleaning tank with solvent appropriate for aluminum.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and install thread inserts. Refer to «Thread Repair»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
8. Use a straight edge and a feeler gage to check the deck surface for flatness. Carefully machine minor irregularities. Replace the block if more than 0.254 mm (0.010 in) must be removed.
9. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.
10. Clean the sealing material from the gasket mating surfaces on the lower crankcase engine block side.
11. Clean the sealing material from the gasket mating surfaces on the lower crankcase oil pan side.
12. Inspect the mating surfaces of the transmission face.
13. Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole bosses: Temporarily install the crankshaft. Measure the crankshaft flange runout using the J 7872 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Hold the gage plate flat against the crankshaft flange. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.203 mm (0.008 in). Recheck the crankshaft flange runout if the readings vary more than 0.203 mm (0.008 in).
14. Inspect the crankshaft main bearing bores. Use the J 8087 to measure the bearing bore concentricity and alignment. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
15. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.
16. Inspect the cylinder bores using the J 8087 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Inspect for the following items: Wear Taper Runout Ridging
17. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) .
18. If the cylinder bores are out of specification, install a NEW cylinder bore liner. Refer to «Cylinder Sleeve Removal»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__cylinder-sleeve-removal) and «Cylinder Sleeve Installation»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__cylinder-sleeve-installation) .

Cylinder Honing

Tools Required

J 8087 Cylinder Bore Gage. See Special Tools and Equipment .

1. Measure the cylinder bore for out-of-round and taper.
2. Measure dimension (1) at 13 mm (1/2 in) below the head gasket surface. Measure dimension (2) at 100 mm (4 in) below the head gasket surface.
3. Measure the cylinder bores by setting the J 8087 dial at zero in the cylinder at the point of the desired measurement. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Lock the dial indicator at zero before removing the dial from the cylinder. Measure across the gage contact points with an outside micrometer, with the gage at the same zero setting as when the gage was removed from the cylinder.
4. Fine vertical scratches made by the ring ends do not, by themselves, cause excessive oil consumption. Do not hone the cylinder in order to remove these scratches.
5. If the bore is glazed but otherwise serviceable, lightly break the glaze with a hone. Replace the piston rings. Refer to «Piston, Connecting Rod, and Bearing Installation»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__piston-connecting-rod-and-bearing-installation) . The honing stones must be clean, sharp, and straight. Move the hone slowly up and down to produce a 45 degree cross-hatch pattern. Clean the bore thoroughly with soap and water. Dry the bore. Rub clean engine oil in the bore. Remeasure the bore.
6. If the cylinder bore is out of specification, install a new cylinder bore sleeve. Refer to «Cylinder Sleeve Removal»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__cylinder-sleeve-removal) and «Cylinder Sleeve Installation»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__cylinder-sleeve-installation) .
7. If honing is not required, clean the cylinder bores with hot water and detergent. Apply clean engine oil to the bore after washing and drying the bore.

Cylinder Sleeve Removal

Tools Required

EN-45680-400 Cylinder Sleeve Removal and Installation Kit. See Special Tools and Equipment .

1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
2. Install the cylinder bore sleeve puller (1) through the cylinder bore.
3. Align the shoe (1) of the cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (117).
4. Hold the threaded shaft of the cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
5. Install the fixture (4) onto the threaded shaft of the cylinder bore sleeve puller and the engine block.
6. Install the bearing (3) and the nut (1).
7. Tighten the nut (1) to the bearing (3).
8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
9. Rotate the nut clockwise in order to remove the cylinder bore sleeve.
10. Remove the fixture, cylinder bore sleeve puller, and the cylinder bore sleeve (117) from the engine block.
11. Loosen the nut (1) to remove the cylinder bore sleeve (117).
12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.
13. Inspect the piston, piston rings, and connecting rod for damage. Refer to «Piston, Connecting Rod, and Bearings Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

Cylinder Sleeve Installation

Tools Required

EN-45680-400 Cylinder Sleeve Removal and Installation Kit. See Special Tools and Equipment .

Installation

1. Place the NEW cylinder bore sleeve (117) onto the cylinder block.
2. Install the fixture (1) over the cylinder bore sleeve (117) and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve (117).
3. Insert the 4 attachment bolts into the legs of the fixture (1).
4. Tighten the 4 attachment bolts. Do not apply downward pressure to the cylinder bore sleeve (117). Tighten: Tighten the 4 attachment bolts to 15 N.m (11 lb ft).
5. Align the bottom of the cylinder bore sleeve (117) with the cylinder bore of the block (100).
6. Align the installation arbor (1) onto the top of the cylinder bore sleeve (117).
7. Align the pusher block (2) into the groove of fixture (1).
8. Using a ratchet, rotate the threaded shaft of fixture (1) in order to install the cylinder bore sleeve (117) into the engine block (100).
9. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block.
10. Using a torque wrench, torque the threaded shaft to 102 N.m (75 lb ft) to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore sleeve flange will protrude above the block deck surface.
11. Remove the fixture (1) from the cylinder block (100).

Scheme 24

1. EN 45680-865 Debris Collector (3)
2. EN 45680-411 Trim Tool Assembly (2)
3. Air Control Valve (1)
4. Drill Motor with 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction

Scheme 25

1. Trim Tool Preloader (1)
2. EN 45680-412 Set Gage Ring (2)
3. EN 45680-413 Metal Shavings Catch Plug (3)
4. EN 45680-866 Drive Adapter (4)
5. EN 45680-414 Bolts (5)

1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.
2. Place the metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place additional metal shaving catch plugs into all remaining cylinder bore sleeves.
4. Ensure that the metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. The groove side of the set gage ring (1) should be positioned upward on a flat surface.
6. Carefully position the trim tool assembly onto the set gage ring.
7. Loosen the shaft collar screw (2).
8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3).
9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten: Tighten the shaft collar screw to 19 N.m (14 lb ft).
10. Place the trim tool assembly onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block.
11. Install the 4 bolts (2) into the cylinder head bolt holes in the block. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
12. Fasten drive adapter (1) into the drill chuck.
13. Connect a compressed air supply (75-125 psi) to the male quick connect (3) located on trim tool assembly. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings.
14. Place the drive adapter and drill assembly (1) vertically onto the drive adapter end of trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds.
15. Remove the drive adapter (1) and drill assembly from the trim tool assembly.
16. Turn off the compressed air valve (2).
17. Remove the trim tool assembly from the engine block.
18. Remove any material shavings that may be found on the metal shaving catch plug.
19. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the metal shaving catch plug.
20. Install a straight edge on the cylinder block perpendicular to the crankshaft center line.
21. Using a light, illuminate the backside of the straight edge.
22. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side or both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
23. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly.
24. Proceed to the next bore sleeve to be trimmed repeating steps 10-23 if necessary.

Crankshaft Balancer Cleaning and Inspection

1. Clean the crankshaft balancer.
2. Clean the belt grooves of all dirt or debris with a wire brush.
3. Dry the crankshaft balancer with compressed air.
4. Inspect the crankshaft balancer for the following: Worn, grooved, or damaged hub seal surface A crankshaft balancer hub seal surface with excessive scoring, grooves, rust or other damage must be replaced. IMPORTANT: In order for the belt to track properly, the belt grooves should be free of all dirt or debris. Dirty or damaged belt grooves The balancer belt grooves should be free of any nicks, gouges, or other damage that may not allow the belt to track properly. Minor imperfections may be removed with a fine file. Worn, chunking or deteriorated rubber between the hub and pulley

Engine Flywheel Cleaning and Inspection

1. Clean the flywheel in solvent.
2. Dry the flywheel with compressed air.
3. Inspect the automatic transmission flywheel for the following: Damaged ring gear teeth Stress cracks around the flywheel-to-crankshaft bolt hole locations Weight saving holes

Crankshaft and Bearings Cleaning and Inspection

Tools Required

J 7872 Magnetic Base Dial Indicator Set. See Special Tools and Equipment .

Cleaning and Inspection

1. Clean the crankshaft with solvent.
2. Thoroughly clean all oil passages and inspect for restrictions or burrs.
3. Dry the crankshaft with compressed air.
4. Perform a visual inspection of the crankshaft for damage.
5. Inspect the crankshaft journals for wear (1). Journals should be smooth with no signs of scoring, wear, or damage.
6. Inspect the crankshaft journals for grooves or scoring (2).
7. Inspect the crankshaft journals for scratches or wear (3).
8. Inspect the crankshaft journals for pitting or imbedded bearing material (4).
9. Measure the crankshaft journals for out-of-round.
10. Measure the crankshaft journals for taper.
11. Measure the crankshaft runout. Using wooden V blocks, support the crankshaft on the front and rear journals.
12. Use the J 7872 in order to measure the crankshaft runout at the front and rear intermediate journals. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
13. Use the J 7872 in order to measure the runout of the crankshaft rear flange. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
14. Replace the crankshaft if the measurements are not within specifications.
15. Inspect crankshaft bearings for craters or pockets. Flattened sections on the bearing halves also indicate fatigue.
16. Inspect the crankshaft bearings for excessive scoring or discoloration.
17. Inspect the crankshaft bearings for dirt or debris imbedded into the bearing material.
18. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections of the bearing. If the lower half of the bearing is worn or damaged, both upper and lower halves should be replaced. Generally, if the lower half is suitable for use, the upper half should also be suitable for use.

Piston and Connecting Rod Disassemble

Tools Required

J 43654 Piston Pin Clip Remover and Installer. See Special Tools and Equipment .

Disassembly

1. Disassemble the piston rings. Use a suitable tool in order to expand the rings. The piston rings must not be reused.
2. Remove the piston pin retaining clips using the J 43654 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
3. Remove the piston pin.

Connecting Rod Measurement

1. Clean the connecting rods in solvent and dry with compressed air.
2. Inspect the connecting rods for the following: Signs of being twisted, bent, nicked, or cracked Scratches or abrasion on the rod bearing seating surface
3. If the connecting rod bores contain minor scratches or abrasions, clean the bores in a circular direction with a light emery paper. DO NOT scrape the rod or rod cap.
4. If the beam of the rod is scratched or has other damage replace the connecting rod.
5. Measure the piston pin to connecting rod bore using the following procedure: Using an outside micrometer, take two measurements of the piston pin in the area of the connecting rod contact. Using an inside micrometer, measure the connecting rod piston pin bore. Subtract the piston pin diameter from the piston pin bore diameter. The clearance should not be more than 0.021 mm (0.0008 in).
6. If there is excessive clearance, replace the piston pin.
7. If there is still excessive clearance, replace the connecting rod.

Piston Measurement

1. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
2. Clean the piston ring grooves with a groove cleaner. Make sure oil ring holes and slots are clean.
3. Inspect the pistons for the following conditions: Cracked ring lands, skirts, or pin bosses Ring grooves for nicks, burrs that may cause binding Warped or worn ring lands Eroded areas at the top of the piston (1) Scuffed or damaged skirts (2) Worn piston pin bores (3)
4. Replace pistons that show any signs or damage or excessive wear.
5. Measure the piston pin bore to piston pin clearances using the following procedure: Piston pin bores and pins must be free of varnish or scuffing. Use an outside micrometer to measure the piston pin in the piston contact areas. Using an inside micrometer, measure the piston pin bore. Subtract the measurement of the piston pin bore from the piston pin. The clearance should be within 0.002-0.012 mm (0.00007-0.00047 in). If the clearance is excessive, determine which component is out of specification.
6. Measure the piston ring end gap using the following procedure: Place the piston ring in the area of the bore where the piston ring will travel (approximately 25 mm or 1 inch down from the deck surface). Be sure the ring is square with the cylinder bore by positioning the ring with the piston head. Measure the end gap of the piston ring with feeler gages. Compare the measurements with those provided below: The top compression ring end gap should be 0.20-0.40 mm (0.0060-0.015 in). The second compression ring end gap should be 0.35-0.55 mm (0.0137-0.0216 in). The oil ring end gap should be 0.25-0.76 mm (0.0098-0.029 in). If the clearance exceeds the provided specifications, the piston rings must be replaced. Repeat the procedure for all the piston rings.
7. Measure the piston ring side clearance using the following procedure: Roll the piston ring entirely around the piston ring groove. If any binding is caused by a distorted piston ring, replace the ring. With the piston ring on the piston, use feeler gages to check clearance at multiple locations. The clearance between the surface of the top piston ring and the ring land should be no greater than 0.075 mm (0.0030 in). If the clearance is greater than specifications, replace the piston ring. If the new ring does not reduce the top ring side clearance to 0.075 mm (0.0030 in) or less, install a new piston.
8. The top compression ring may be installed with either side up. There is a locating dimple on the 2nd compression ring near the end for identification of the top side. Install the 2nd compression ring with the dimple facing up.
9. The clearance between the surface of the second piston ring and the ring land should be no greater than 0.069 mm (0.0026 in).
10. If the new ring does not reduce the clearance to 0.069 mm (0.0026 in) or less, install a new piston.
11. Measure piston width using the following procedure: Using an outside micrometer, measure the width of the piston 14.5 mm (0.570 in) above the bottom of the piston skirt at the thrust surface perpendicular to the centerline of the piston pin. Compare the measurement of the piston to its original cylinder by subtracting the piston width from the cylinder diameter. The proper clearance specification for the piston is 0.010-0.041 mm (0.0006-0.0016 in).
12. If the clearance obtained through measurement is greater than these specifications and the cylinder bores are within specification, replace the piston.

Piston Selection

1. Inspect the engine block cylinder bore. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-block-cleaning-and-inspection) .
2. Inspect the piston and the piston pin. Refer to «Piston, Connecting Rod, and Bearings Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
3. Use a bore gauge and measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore.
4. Measure the bore gauge with a micrometer and record the reading.
5. With a micrometer or caliper at a right angle to the piston, measure the piston 14 mm (0.570 in) from the bottom of the skirt.
6. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance.
7. For proper piston-to-bore clearance. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) .
8. If the proper clearance cannot be obtained, select another piston and measure for the clearances.
9. If the proper fit cannot be obtained, hone the cylinder bore or replace the cylinder block.
10. When the piston-to-cylinder bore clearance is within specifications, mark the top of the piston using a permanent marker for installation to the proper cylinder. Refer to «Separating Parts»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__separating-parts) .

Piston and Connecting Rod Assemble

1. Assemble the connecting rod and the piston.
2. Use the following procedure in order to assemble the piston pin and the retainer: Coat the piston pin with oil. Install one side of one piston pin retainer into the retaining groove using the J 43654 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Rotate the retainer until it is fully seated in the groove, use insertion tool. Install the connecting rod and the piston pin. Push the piston pin until it bottoms in the previously installed retainer. Install the second piston pin retainer, using the J 43654 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Ensure that the piston moves freely.
3. Install the following components of the oil control ring assembly (bottom ring): The expander The lower oil control ring The upper control ring
4. Install the lower compression ring (second ring). Place the manufacturer's mark facing up.
5. Install the upper compression ring (top ring).

Camshaft Cleaning and Inspection

1. Inspect the camshaft journals and lobes for wear or scoring.
2. Inspect the camshaft sprocket alignment notch for damage.
3. Inspect the camshaft cover for damage or loose oil control baffles.
4. Clean the camshaft cover.
5. Wash the camshaft in solvent.
6. Oil the camshaft.
7. Inspect the camshaft cover for cracks or other signs of damage.

Timing Chain and Sprockets Cleaning and Inspection

1. Inspect the timing chain guides for cracking or wear.
2. Replace the timing chain guides if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
3. Inspect the timing chain tensioner shoe for wear.
4. Replace the timing chain tensioner shoe if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
5. Inspect the timing chain and sprockets for wear.
6. Inspect the camshaft sprocket faces for signs of movement.
7. Inspect the camshaft sprocket teeth and chain for signs of excessive wear, chipping, or seizure of the timing chain links.
8. Inspect the oil nozzle body for collapse or cracks at the bolt boss. Discard and replace the oil nozzle body if it is damaged.
9. Remove the old oil from the timing chain tensioner.
10. Inspect the timing chain tensioner for the scoring or free movement.
11. Inspect the timing chain washer and O-ring for damage. If damaged, replace the timing chain tensioner.

Balance Shaft Cleaning and Inspection

1. Clean the balance shafts in solvent.
2. Remove the balance shaft front bearing carriers from the balance shafts.
3. Inspect the bearing surfaces on the balance shafts for scoring or unusual wear.
4. Inspect the balance shaft drive sprockets for wear, damage, or missing teeth. When installing new balance shaft drive sprockets tighten to 55 N.m (41 lb ft).
5. Measure the rear bearing journals on the balance shafts, the journals should be 36.723-36.743 mm (1.4458-1.4466 in) in diameter.
6. Measure the front bearing journals on the balance shafts, the front bearing journals should be 20.020-20.000 mm (0.7881-0.7874 in) in diameter.
7. When the balance shafts have been installed in the engine block, check for smooth rotation, sticking, binding, or roughness.

Balance Shaft Drive Chain and Sprockets Cleaning and Inspection

1. Inspect the balance shaft drive chain guides for cracking or wear.
2. Replace the balance shaft drive chain guides if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
3. Inspect the balance shaft drive chain tensioner guide shoe for wear. Replace the balance shaft drive chain tensioner guide shoe if wear exceeds 1.12 mm (0.045 in) depth on the chain guide surface.
4. Inspect the balance shaft drive chain and sprockets for wear.
5. Inspect the crankshaft sprocket faces for signs of movement.
6. Inspect the alignment notch in the balance shaft for cracking or damage.
7. Inspect the water pump, crankshaft, and balance shaft sprocket teeth and chain for signs of excessive wear, chipping, or seizure of the balance shaft drive chain links.
8. Inspect the timing chain tensioner for damage or wear.

Cylinder Head Disassemble

Tools Required

1. J 8062 Valve Spring Compressor. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. J 36017 Valve Guide Seal Remover. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
3. J 43963 Valve Spring Compressor (off car). See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

1. Remove the coolant air bleed hose fitting.
2. Using the J 8062 and the J 43963 to compress the valve spring. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
3. Remove the valve keys.
4. Slowly release the J 8062 and the. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Remove J 43963 from the valve spring assembly. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
5. Remove the retainer.
6. Remove the spring.
7. Remove the valve seal. Use the J 36017 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Do not reuse.
8. Remove the valve.
9. Remove the remaining valves.
10. Remove the cylinder head plugs.

Valve Cleaning and Inspection

1. Clean the valves of carbon, oil and varnish. Carbon can be removed with a wire brush. Varnish can be removed by soaking in Parts Immersion Solvent GM P/N 12345368 (Canadian P/N 10953514) or equivalent.
2. Clean the valve guides.
3. Inspect the valve stem for wear (4).
4. Inspect the valve keeper groove for chipping or wear (5). Replace the valve if chipped or worn.
5. Inspect the valve face for burning or cracking (1). If pieces are broken off, inspect the corresponding piston and cylinder head area for damage.
6. Inspect the valve stem for burrs and scratches. Burrs and minor scratches may be removed with an oil stone.
7. Inspect the valve stem for straightness and the valve head for bending or distortion (3) using V blocks. Bent or distorted valves must be replaced.
8. Clean the deposits from the valve face. Inspect the valve face for grooving.
9. Replace the valve if the face is grooved. Valve faces cannot be machined. If worn, or damaged, the valves must be replaced.
10. The valves may be lightly lapped to the valve seats.

Cylinder Head and Gasket Surface Cleaning and Inspection

1. Remove the spark plugs.
2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has failed, use the following faults to determine the cause: Improper installation Loose or warped cylinder head Missing, off location or not fully seated dowel pins Corrosion in the seal area around the coolant passages Chips or debris in the cylinder head bolt holes Bolt holes in the cylinder block not drilled or tapped deep enough Other
3. Inspect the cylinder head gasket surface. Cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in) band around each combustion chamber (1). Replace the cylinder head if the area between the valve seats is cracked (2). Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each combustion chamber (3).
4. Clean the cylinder head bolts.
5. Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.
6. Clean the valve guides.
7. Clean the threaded holes. Use a nylon bristle brush.
8. Clean the remains of the sealer from the plug holes.
9. Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools.
10. Replace all suspect bolts.
11. Inspect the cylinder head for cracks. Check between the valve seats and in the exhaust ports.
12. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
13. Inspect the cylinder head deck surface for flatness. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) .
14. Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
15. Inspect the sealing surfaces.
16. Inspect the cylinder head plugs.

Cylinder Head Assemble

Tools Required

1. J 8062 Valve Spring Compressor. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. J 9666 Valve Spring Tester
3. J 43963 Valve Spring Compressor (off car). See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

1. Install NEW cylinder head plugs. Coat the plugs with sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent.
2. Inspect the valve springs. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) for the tolerances.
3. Look for the following conditions when inspecting the valve springs: Expanded height Unparallel spring ends Spring tension using J 9666 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Any distorted springs should be replaced
4. Assemble the valves.
5. Use the following steps to measure valve runout: Apply a dab of Prussian blue on the entire valve face. Seat the valve but do not rotate it. The Prussian blue traces transferred to the valve seat are an indication of concentricity of the valve seat. Clean all traces of Prussian blue. Apply a dab of Prussian blue on the valve seat and repeat the check. The traces of Prussian blue transferred to the valve face indicates valve face concentricity.
6. Replace the valves, if required.
7. Install the new valve seals. Fully seat the seals on the valve guides.
8. Install the spring.
9. Install the retainer.
10. Using the J 8062 and the J 43963 , compress the valve spring. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
11. Install the valve keys.
12. Slowly release the J 8062 and the J 43963 from the valve/spring assembly. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
13. Inspect for proper valve key seating.
14. Measure the valve installed height using a ruler. Measure from the base of the valve spring to the top of the valve. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) for the correct specification.
15. Install the remaining valves, springs, and other components.
16. Install the cylinder head air bleed tube. Tighten: Tighten the bolts to 15 N.m (133 lb in).

Oil Pump Disassemble

1. Disassemble the pressure relief valve.
2. Remove the oil pump gerotor cover and bolts.
3. Clean all of the parts in cleaning solvent. Remove varnish, sludge and dirt.
4. Inspect the oil pump for wear and scoring. Insure that all components are within specifications. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) . Replace the front cover and oil pump assembly if it is out of specification or damaged.

Oil Pump Assemble

1. Lubricate all oil pump parts with engine oil.
2. Install the inner gear into the outer gear.
3. Install the gears together into the front cover with the hub of the center gear facing the front cover.
4. Install the oil pump gerotor cover and bolts. Tighten: Tighten the oil pump gerotor bolts to 6 N.m (53 lb in).
5. Install the pressure relief valve piston.
6. Install the pressure relief valve spring. Tighten: Tighten the pressure relief valve plug to 40 N.m (30 lb ft).

Intake Manifold Cleaning and Inspection

1. Clean the intake manifold mating surfaces.
2. Inspect the intake manifold for damage.
3. Inspect the intake manifold for cracks near metallic inserts.
4. Inspect the crankcase ventilation passages in the intake manifold face for blockage.
5. Clean the crankcase ventilation passages with compressed air if necessary. Use a maximum of 172 kPa (25 psi) of air pressure.
6. Replace the intake manifold as necessary.

Exhaust Manifold Cleaning and Inspection

1. Remove the oxygen sensor from the manifold.
2. Clean the exhaust manifold in solvent.
3. Dry the exhaust manifold with compressed air.
4. Inspect the heat shield for damage.
5. Use a straight edge and a feeler gage and measure the exhaust manifold mounting face for warpage. An exhaust manifold face with warpage in excess of 0.25 mm (0.010 in) may cause an exhaust leak and may effect OBD II system performance. Exhaust manifolds not within specifications must be replaced.

Oil Pan Cleaning and Inspection

1. Clean the oil pan mating surface.
2. Clean the oil pan. Remove all the sludge and the oil deposits.
3. Inspect the threads for the engine oil drain plug.
4. Inspect the oil pan for cracking near the pan rail and the transmission mounting points.
5. Inspect the oil pan for cracking resulting from impact or flying road debris.
6. Inspect the oil pan baffle and pickup screen.
7. Repair or replace the oil pan as necessary.

General Thread Repair

Tools Required

J 42385-850 Thread Repair Kit. See Special Tools and Equipment .

Scheme 26

The thread repair process involves a solid, thin walled, self-locking, carbon steel, bushing type insert (1). During the bushing installation process, the driver tool expands the bottom external threads of the insert into the base material (2). This action mechanically locks the insert in place. Also, when installed to the proper depth, the flange of the insert will be seated against the counterbore of the repaired hole.

1. Drill out the threads of the damaged hole (1). M6 inserts require a minimum drill depth of 15 mm (0.59 in). M8 inserts require a minimum drill depth of 20 mm (0.79 in). M10 inserts require a minimum drill depth of 23.5 mm (0.93 in).
2. Using compressed air, clean out any chips.
3. Counterbore the hole to the full depth permitted by the tool (1).
4. Using compressed air, clean out any chips.
5. Using a tap wrench (2), tap the threads of the drilled hole. M6 inserts require a minimum tap depth of 15 mm (0.59 in). M8 inserts require a minimum tap depth of 20 mm (0.79 in). M10 inserts require a minimum tap depth of 23.5 mm (0.93 in).
6. Using compressed air, clean out any chips.
7. Spray cleaner GM P/N 12346139, GM P/N 12377981 (Canadian P/N 10953463) or equivalent, into the hole.
8. Using compressed air, clean any cutting oil and chips out of the hole.
9. Lubricate the threads of the installer tool (2) with the driver oil (1).
10. Install the insert (2) onto the driver tool (1).
11. Apply threadlock LOCTITE™ 277, J 42385-109 (1), or equivalent to the insert OD threads (2).
12. Install the insert (2) into the hole. Install the insert until the flange of the insert contacts the counterbored surface. Continue to rotate the installer tool (1) through the insert. The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.
13. Inspect the insert for proper installation into the hole. A properly installed insert (1) will be either flush or slightly below flush with the surface of the base material (2).

Cylinder Head Bolt Hole Thread Repair

1. The cylinder head bolt hole thread repair kit consists of the following items: Drill (1) Tap (2) Installer (3) Sleeve (4) Alignment Pin (5) Bushing (6) Bolts (7) Fixture Plate (8)
2. Install the fixture plate (3), bolts (1), and bushing (2) onto the engine block deck. Position the fixture plate and bushing over the hole that is to be repaired (4).
3. Position the alignment pin (1) through the bushing and into the hole.
4. With the alignment pin in the desired hole, tighten the fixture retaining bolts (2).
5. Remove the alignment pin from the hole.
6. Install the sleeve (2) onto the drill (1), if required.
7. Drill out the threads of the damaged hole. Drill the hole until the stop collar of the drill bit or the sleeve contacts the bushing.
8. Using compressed air, clean out any chips.
9. Using a tap wrench, tap the threads of the drilled hole.
10. Using a TAP wrench, tap the threads of the drilled hole. In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark (3) on the tap align with the top of the drill bushing (2).
11. Remove the fixture plate (1), bushing (2), and bolts.
12. Using compressed air, clean out any chips.
13. Spray cleaner GM P/N 12346139 or GM P/N 1237798 (Canadian P/N 10953463), or equivalent, into the hole.
14. Using compressed air, clean any cutting oil and chips out of the hole.
15. Lubricate the threads of the installer tool (2) with the driver oil (1).
16. Install the insert (2) onto the driver tool (1).
17. Apply threadlock LOCTITE™ 277, J 42385-109 (1), or equivalent to the insert OD threads (2).
18. Install the insert and driver (1) into the hole. Rotate the driver tool until the mark on the tool aligns with the deck surface of the engine block. The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.

Main Cap Bolt Hole Thread Repair

1. The main cap bolt hole thread repair kit consists of the following items: Drill (1) Tap (2) Installer (3) Fixture Plate (4) Long Bolts (5) Short Bolts (6) Alignment Pin (7) Bushing (8)
2. Remove the alignment dowel pins from the holes (1-4), if necessary.
3. Install the fixture plate, bolt, and bushing, onto the engine block. Position the fixture plate and bushing over the hole that is to be repaired.
4. Position the alignment pin in the desired hole and tighten the fixture retaining bolts.
5. Drill out the damaged hole.
6. Using compressed air, clean out any chips.
7. Using a tap wrench, tap the threads of the drilled hole. In order to tap the new threads to the proper depth, rotate the tap into the hole until the mark (3) on the tap aligns with the top of the bushing (2).
8. Using compressed air, clean out any chips.
9. Spray cleaner GM P/N 12346139 (Canadian P/N 10953463) or equivalent, into the hole.
10. Using compressed air, clean any cutting oil and chips out of the hole.
11. Lubricate the threads of the installer tool (2) with the driver oil (1).
12. Install the insert (2) onto the driver tool (1).
13. Apply threadlock LOCTITE™ 277, J 42385-109 (1), or equivalent to the insert OD threads (2).
14. Install the insert and driver through the bushing (2), fixture plate (1) and into the hole. Rotate the driver tool until the mark on the tool (3) aligns with the top of the bushing (2). The installer tool will tighten up before screwing completely through the insert. This is acceptable. You are forming the bottom threads of the insert and mechanically locking the insert to the base material threads.
15. Remove the driver, bushing (2), fixture plate (1), and bolts.
16. Install the alignment dowel pins in holes (1-4), if necessary.

Service Prior to Assembly

The importance of cleanliness during assembly cannot be overstated. Dirt or debris will cause engine damage. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.

Lubricate all moving parts with engine oil or a specified assembly lubricant. This will provide lubrication for initial start up.

Engine Prelubing

Tools Required

J 45299 Engine Preluber. See Special Tools and Equipment .

1. Locate the oil pressure switch and remove.
2. Install the M12 x 1.75 adapter P/N 509376.
3. Install the flexible hose to the adapter and open the valve.
4. Pump the handle on the J 45299 in order to flow a minimum of 1-1. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .9 liters (1-2 quarts) of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
5. Close the valve and remove the flexible hose and adapter from the engine.
6. Install the oil pressure switch to the engine. Tighten: Tighten the oil pressure switch to 22 N.m (16 lb ft).
7. Top-off the engine oil to the proper level.

Engine Block Assemble

1. Install the drain plug in the water pump.
2. Apply GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the plug before installation.
3. Install the coolant jacket plugs. Tighten: Tighten the coolant jacket plug to 35 N.m (26 lb ft).
4. Install the rear oil passage plugs.
5. Apply GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the plugs before installation. Tighten: Tighten the oil passage plug to 60 N.m (44 lb ft).
6. Install the other oil passage plugs.
7. Apply GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the plug before installation. Tighten: Tighten the oil passage plugs to 35 N.m (26 lb ft).
8. Lubricate the crankshaft position sensor O-ring with engine oil.
9. Install the crankshaft position sensor and bolt. Tighten: Tighten the crankshaft position sensor bolt to 10 N.m (89 lb in).
10. Install the oil pressure switch. Tighten: Tighten the oil pressure switch to 10 N.m (89 lb in).
11. Install the knock sensor and bolt. Tighten: Tighten the knock sensor bolt to 25 N.m (18 lb ft).

Crankshaft and Bearings Installation

Tools Required

1. J 8087 Cylinder Bore Checking Gauge. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. J 45059 Angle Meter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

Scheme 27

Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure

1. Tighten the bearing cap to specification using the J 45059 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Measure the bearing bore for taper and out-of-round using the J 8087 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
3. No taper or out-of-round should exist.

Bearing Selection

1. Measure the bearing clearance to determine the correct replacement bearing insert size. There are two methods to measure bearing clearance. Method A gives more reliable results and is preferred. Method A yields measurement from which the bearing clearance can be computed. Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.
2. To measure bearing clearance using Method A, use the following procedure: Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements. Measure the crankshaft bearing journal taper and runout. Install the lower crankcase and tighten the bearing cap bolts to specification. Measure bearing I.D. in several places 90 degrees apart, average measurements. Subtract journal measurement from bearing I.D. measurement to determine clearance. Determine whether clearance is within specification. If out of spec choose different inserts. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer. Measure the crankshaft main bearing inside diameter with an inside micrometer.
3. To measure bearing clearance using Method B, use the following procedure: Clean the used bearing inserts. Install the used bearing inserts. Place a piece of gaging plastic across the entire bearing width. Install the bearing caps. NOTE: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap. Install the bearing cap bolts to specification. IMPORTANT: Do not rotate the crankshaft. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the bearing cap. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package. Remove the gaging plastic.

Lower Crankcase Installation

Tools Required

J 45059 Angle Meter. See Special Tools and Equipment .

1. Install the upper crankshaft bearings and lubricate bearing surfaces with engine oil.
2. Install the crankshaft on the journals.
3. Install the lower bearing halves, without grooves, into the lower crankcase. Apply oil to bearing surfaces.
4. Apply sealer GM P/N 12346286 (Canadian P/N 10953472) to the surfaces of the engine block to bedplate mating surfaces.
5. Install the lower crankcase. Tap gently into place with a suitable tool if necessary. Ensure it is aligned properly on the dowels.
6. Install the NEW crankshaft bearing bolts in sequence finger tight. Tighten the crankshaft bearing bolts in sequence. Tighten: Tighten the crankshaft bearing bolts to 20 N.m (15 lb ft). Tighten the crankshaft bearing bolts in sequence using the J 45059 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Tighten: Tighten the crankshaft bearing bolts 70 degrees using the angle meter.
7. Tighten the lower crankcase perimeter bolts in sequence. Tighten: Tighten the lower crankcase perimeter bolts to 25 N.m (18 lb ft).

Crankshaft Rear Oil Seal Installation

Tools Required

J 42067 Rear Main Seal Installer. See Special Tools and Equipment .

1. Remove excess sealer from seal recess.
2. Lubricate the outside diameter of the new crankshaft seal with clean engine oil.
3. Using the J 42067 , press the new crankshaft seal into the housing. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . The J 42067 also establishes the depth of the seal in the crankshaft seal bore. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 Piston Ring Compressor. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. J-43966-1 Connecting Rod Guides. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
3. J 45059 Angle Meter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

1. Install the connecting rod bearings. Use new bearings. Install the bearing inserts into the connecting rod and the connecting rod cap. Lubricate the connecting rod bearings with engine oil.
2. Install the J-43966-1 into the connecting rod bolt holes. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . This protects the crankshaft journal during piston and connecting rod installation.
3. Install the piston and the connecting rod to the correct bore. Stagger each piston ring end gap equally around the piston. Lubricate the piston and the piston rings with engine oil. Install J 8037 over the piston. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Do not disturb the piston ring end gap location. The piston must be installed so that the mark on the top of the piston faces the front of the engine. Place the piston in its matching bore. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place. Hold the J 8037 against the engine block until all the rings have entered the cylinder bore. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Remove the connecting rod guides from the connecting rod bolt holes.
4. Install the connecting rod cap.
5. Install the connecting rod bolts. Always use new bolts. Tighten: Tighten the connecting rod bolts to 25 N.m (18 lb ft), then rotate 100 degrees using the J 45059 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
6. Install the remaining connecting rods and piston assemblies.
7. Measure the connecting rod side clearance with a feeler gauge. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in).

Cylinder Head Installation

Tools Required

J 45059 Angle Meter. See Special Tools and Equipment .

1. Install the cylinder head gasket to the block.
2. Install the cylinder head.
3. Lightly apply clean engine oil to the threads and the bottom side of the flange of the head bolt and allow the oil to drain before installing.
4. Install and tighten the cylinder head bolts in sequence. Tighten: Tighten bolts 30 N.m (22 lb ft). Then turn all the bolts 155 degrees in sequence. Use the J 45059 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
5. Install the front cylinder head bolts. Tighten: Tighten the cylinder head bolts to 35 N.m (26 lb ft).
6. Install the EGR cover (607), the bolts (608), and the EGR cover gasket (606). Tighten: Tighten the EGR cover bolts to 25 N.m (18 lb ft).

Intake Camshaft, Follower, and Adjuster Install

1. Install the hydraulic element lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM P/N 1234550 (Canadian P/N 992704) or equivalent.
3. Lubricate the valve tips.
4. Position the roller followers on the tip of the valve stem and on the lash adjustor. Lubricate roller followers with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Set the intake camshaft on top of the roller followers in the camshaft bearing journals. Lubricate with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
6. Install the camshaft bearing caps and hand start the camshaft cap bolts.
7. The timing chain sprocket alignment notch should be oriented to the 11 o'clock position.
8. Tighten the camshaft bearing cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the camshaft bearing caps to 10 N.m (89 lb in).
9. Apply anaerobic sealer, 3.5 mm (0.138 in) bead, GM P/N 1052942 (Canadian P/N 10953466) or equivalent to rear intake camshaft bearing cap.
10. Install the rear intake camshaft bearing cap bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).

Exhaust Camshaft, Follower, and Adjuster Install

1. Install the hydraulic element lash adjusters into their bores in the cylinder head. Apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent to hydraulic element lash adjuster.
2. Lubricate the valve tips with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
3. Position the roller followers on the tip of the valve stem and on the lash adjustor, apply lubricant GM P/N 12345501 (Canadian P/N 992704) or equivalent.
4. Set the exhaust camshaft on top of the roller followers in the camshaft bearing journals. Lubricate with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Install the camshaft bearing caps and hand start the camshaft cap bolts.
6. The timing chain sprocket alignment notch should be oriented to the 2 o' clock position.
7. Tighten the camshaft bearing cap bolts in increments of 3 turns until they are seated, lubricate. Tighten: Tighten the camshaft bearing caps to 10 N.m (89 lb in).

Balance Shaft Installation

Tools Required

J 43650 Balance Shaft Bushing Remover/Installer. See Special Tools and Equipment .

1. Install the balance shaft bushing using the J 43650 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Seat the balance shaft bushing into the bore using the J 43650 and a wrench. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
3. When the J 43650 is fully seated in the engine block remove it with a wrench. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
4. Place the number one piston at TDC.
5. Install the balance shaft drive chain sprocket on the crankshaft.
6. Lubricate the balance shaft lobes with engine oil.
7. Install the balance shafts into their bores.
8. Install the balance shaft retaining bolts. Tighten: Tighten the balance shaft retaining bolts to 10 N.m (89 lb in).

Water Pump Installation

Prior to installing the water pump, read the entire procedure. Pay special attention to avoid part damage and to ensure proper sealing.

1. Install the water pump assembly.
2. Install the water pump bolts. Finger tighten the bolts.
3. Tighten the water pump bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the water pump drain plug.
5. Install the water pump drain plug, if necessary. Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
6. Install the water feed tube.
7. Lubricate the feed tube O-ring with antifreeze.
8. Install the water feed tube by twisting and pushing toward the water pump. Take care not to tear or damage the O-ring.
9. Install the thermostat housing to block bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Install the water pipe support bracket and bolts. Tighten: Tighten the water pipe support bracket bolts to 10 N.m (89 lb in).
11. Install the engine coolant temperature sensor by hand.
12. Tighten the engine coolant temperature sensor. Tighten: Tighten the engine coolant temperature sensor to 20 N.m (15 lb ft).

Timing Balance Shafts to Engine

1. Install the balance shaft drive sprocket.
2. Install the balance shaft drive chain with the colored links lined up on with the marks on the balance shaft drive sprockets and the crankshaft sprocket. There are three colored links on the chain. Two links are of matching colors, and one link is of a unique color. Use the following procedure to line up the links with the sprockets: Orient the chain so that the colored links are visible.
3. Place the uniquely colored link (1) so that it lines up with the timing mark on the intake side balance shaft sprocket.
4. Working clockwise around the chain, place the first matching colored link (2) in line with the timing mark on the crankshaft drive sprocket. (approximately 6 o'clock position on the crank sprocket)
5. Place the chain (3) on the water pump drive sprocket. The alignment is not critical.
6. Align the last matching colored link (4) with the timing mark on the exhaust side balance shaft drive sprocket.

Balance Shaft Drive Chain and Tensioner Install

1. Install the upper balance shaft chain guide and bolts. Tighten: Tighten the upper balance shaft chain guide bolts to 10 N.m (89 lb in).
2. Install the small balance shaft chain guide.
3. Install the balance shaft chain guide bolts. Tighten: Tighten the chain guide bolts to 10 N.m (89 lb in).
4. Install the adjustable balance shaft drive chain guide.
5. Install the adjustable balance shaft drive chain guide bolts. Tighten: Tighten the chain guide bolts to 10 N.m (89 lb in).
6. Reset the timing chain tensioner by performing the following steps: Turn the tensioner plunger 90 degrees in its bore and compress the plunger. Turn the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hole in the tensioner plunger.
7. Install the timing chain tensioner.
8. Install the chain tensioner bolts. Tighten: Tighten the chain tensioner bolts to 10 N.m (89 lb in).
9. Remove the paper clip from the balance shaft drive chain tensioner.

Timing Chain, Sprockets, Tensioner Installation

Tools Required

1. J 45027 Tensioner Tool. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. J 45059 Angle Meter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

1. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position.
2. Assemble the intake camshaft sprocket to the timing chain with the timing mark lined up with the uniquely colored link (1). Hand tighten a new intake camshaft sprocket bolt.
3. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1,2).
4. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
5. Install the adjustable timing chain guide through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten: Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
6. Install the exhaust camshaft sprocket and a new bolt loosely onto the exhaust camshaft.
7. Align the timing mark on the sprocket with the last matching colored link (3). Install the bolt finger tight.
8. If the camshaft is 180 degrees out of time, use the following procedure to re-align the cam. Using a 24 mm wrench, first turn the intake camshaft until the alignment feature on the back of the camshaft sprocket seats in the notch in the front of the intake camshaft. Turn the crankshaft 45 degrees in either direction. Turn the intake cam to the appropriate location. Turn the crankshaft back to top dead center.
9. When the sprocket seats on the cam, tighten the sprocket bolt hand tight.
10. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not, repeat the portion of the procedure necessary to align the timing marks.
11. Install the fixed timing chain guide. Tighten: Tighten the fixed timing chain guide bolts to 10 N.m (89 lb in).
12. Install the upper timing chain guide. Tighten: Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
13. Using a 24 mm wrench, engage the hex on the intake camshaft and using a torque wrench, tighten the camshaft sprocket bolt. Tighten: Tighten the intake camshaft sprocket bolt to 85 N.m (63 lb ft), plus 30 degrees using the J 45059 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
14. Using a 24 mm wrench, engage the hex on the exhaust camshaft and using a torque wrench, tighten the camshaft sprocket bolt. Tighten: Tighten the exhaust camshaft sprocket bolt to 85 N.m (63 lb ft), plus 30 degrees using the J 45059 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
15. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner.
16. Measure the timing chain tensioner assembly from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
17. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
18. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint free cloth.
19. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
20. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end repeat steps 17.1 and 17.4.
21. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
22. Install the new timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
23. The timing chain tensioner is released by compressing it 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
24. Install the timing chain oiling nozzle. Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
25. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the thread, and install the timing chain guide bolt access hole plug. Tighten: Tighten the access hole plug to 90 N.m (66 lb ft).

J 35268-A Camshaft/Front Main Seal Installer. See Special Tools and Equipment .

1. Install the seal into the front cover by driving it in from the timing chain side using J 35268-A . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Ensure that the engine front cover is properly supported when installing the seal.

Engine Front Cover and Oil Pump Installation

1. Install the engine front cover with a new gasket.
2. Install the long water pump bolt. Tighten: Tighten the water pump bolt to 25 N.m (18 lb ft).
3. Install the engine front cover bolts. Tighten: Tighten the engine front cover bolts to 25 N.m (18 lb ft).
4. Install the accessory drive belt tensioner.
5. Install the accessory drive belt tensioner bolt. Tighten: Tighten the bolt to 45 N.m (33 lb ft).

Camshaft Cover Installation

1. Assemble the camshaft cover and gasket. Ensure that the gasket is located in the retaining groove in the camshaft cover.
2. Install the cover on the cylinder head and hand start the bolts. Tighten: Tighten the camshaft cover bolts to 10 N.m (89 lb in).
3. Install the front lift bracket. Tighten: Tighten the front lift bracket bolt to 25 N.m (18 lb ft).
4. Install the rear lift bracket. Tighten: Tighten the rear lift bracket bolts to 25 N.m (18 lb ft).
5. Install the ground strap. Tighten: Tighten the camshaft cover ground strap bolts to 10 N.m (89 lb in).
6. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft).
7. Install the ignition coil and module assembly to the cam cover. Tighten: Tighten the ignition coil and module assembly bolts to 10 N.m (89 lb in).
8. Install the power steering blockout plate, if equipped. Tighten: Tighten the power steering pump bolts to 25 N.m (18 lb ft).

Oil Pan Installation

1. Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris.
2. Apply a 2 mm bead of GM P/N 12346286 (Canadian P/N 10953472) or equivalent around the perimeter of the oil pan and the oil suction port opening.
3. Install the oil pan.
4. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft) in sequence.

J 44887 Oil Filter Wrench. See Special Tools and Equipment .

1. Install a new oil filter on the oil filter cap.
2. Lubricate the O-ring on the oil filter cap with 5 W 30 engine oil.
3. Use J 44887 to install the oil filter adapter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) . Tighten: Tighten the oil filter adapter to 22 N.m (16 lb ft).

Intake Manifold Installation

1. Install the intake manifold studs in the manifold face. Tighten: Tighten the intake manifold studs to 6 N.m (60 lb in).
2. Install a new intake manifold gasket on the intake manifold, if necessary.
3. Install the intake manifold.
4. Install the intake manifold bolts and nuts. Follow the tightening sequence. Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
5. Lubricate NEW fuel injector tip insulators with engine oil.
6. Install the NEW fuel injector tip insulators.
7. Install the fuel rail assembly.
8. Install the fuel rail stud. Tighten: Tighten the stud to 10 N.m (89 lb in).
9. Install a NEW throttle body stud, if necessary. Tighten: Tighten the bolts and nuts to 6 N.m (60 lb in).
10. Install the throttle body. Tighten: Tighten the bolt and nuts to 10 N.m (89 lb in).
11. Install the EVAP emission canister valve (2). Tighten: Tighten the EVAP emission canister valve to 22 N.m (16 lb ft).
12. Install the EVAP emission canister valve tube (1).

Crankshaft Damper Installation

1. J 38122-A Harmonic Balancer Holder
2. J 45059 Angle Meter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

1. Install the damper onto the crankshaft indexing keyway. Use care to properly align the keyway and flats on the damper with the oil pump drive.
2. Install the J 38122-A .
3. Install a new retaining bolt and washer. Use the J 38122-A and a breaker bar in order to prevent the crankshaft from rotating when tightening the bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus 125 degrees using the J 45059 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

Exhaust Manifold Installation

1. Install NEW exhaust manifold studs, if necessary. Tighten: Tighten the studs to 10 N.m (89 lb in).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold and catalytic converter assembly to the cylinder head.
4. Install NEW exhaust manifold to cylinder head retaining nuts finger tight.
5. Tighten the NEW exhaust manifold cylinder head retaining nuts in sequence. Tighten: Tighten the nuts to 14 N.m (124 lb in).
6. Coat the threads of the oxygen sensor with anti-seize compound GM P/N 12397953.
7. Install the oxygen sensor. Tighten: Tighten the oxygen sensor to 30 N.m (22 lb ft).
8. Install the block heater and bolt, if equipped. Tighten: Tighten the bolt to 10 N.m (89 lb in).
9. Install the exhaust manifold heat shield.
10. Install the exhaust manifold heat shield bolts. Tighten: Tighten the bolts to 23 N.m (17 lb ft).

Oil Level Indicator and Tube Installation

1. Lubricate the oil level indicator tube O-ring with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
2. Install the oil level indicator and the oil level indicator tube into the oil pan.
3. Install the oil level indicator tube bracket to the intake manifold bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the electrical wiring harness to the oil level indicator tube.
5. Install the knock sensor wiring clip into the oil level indicator tube.

Engine Flywheel Installation

Tools Required

1. J 38122-A Harmonic Balancer Holder
2. J 45059 Angle Meter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

1. Install the flywheel.
2. Install the NEW bolts.
3. Holding the crankshaft damper with the J 38122-A , tighten the bolts evenly. Tighten: Tighten the bolts to 53 N.m (39 lb ft), plus 25 degrees using the J 45059 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .

Drive Belt System Description

The drive belt system consists of the following components

1. The drive belt
2. The drive belt tensioner
3. The drive belt idler pulley
4. The crankshaft balancer pulley
5. The accessory drive component mounting brackets
6. The accessory drive components The power steering pump, if belt driven The generator The A/C compressor, if equipped The engine cooling fan, if belt driven The water pump, if belt driven The vacuum pump, if equipped The air compressor, if equipped

The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are made of different types of rubbers (chloroprene or EPDM) and have different layers or plys containing either fiber cloth or cords for reinforcement.

Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth.

The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft.

The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory.

Cylinder Block

The cylinder block is lost foam cast aluminum with four cylinders arranged in-line. The cylinders have pressed in place iron liners. The block has five crankshaft bearings with the thrust bearing located on the second bearing from the front of the engine. The cylinder block incorporates a bedplate design that forms an upper and lower crankcase. This design promotes cylinder block rigidity and reduced noise and vibration.

Crankshaft

The crankshaft is cast nodular iron with eight counterweights. The number eight counterweight is also the ignition system reluctor wheel. The main bearing journals are cross-drilled, and the upper bearings are grooved. The crankshaft has a slip fit balance shaft drove sprocket. Number two main bearing is the thrust bearing. A harmonic damper is used to control torsional vibration.

Connecting Rod and Piston

The connecting rods are powdered metal. The connecting rod incorporates the floating piston pin. The pistons are cast aluminum. The piston rings are of a low tension type to reduce friction. The top compression ring is ductile iron with a molybdenum facing and phosphate coated sides. The second compression ring is gray iron. The oil ring is a 3-piece spring construction with chromium plating.

Oil Pan

The oil pan is die cast aluminum. The oil pan includes an attachment to the transmission to provide additional structural support.

Balance Shaft Assembly

There are two block mounted balance shafts located on each side of the crankcase at the bottom of the cylinder bores. The balance shafts are driven by a single roller chain that also drives the water pump. The chain is tensioned by a hydraulic tensioner that is supplied pressure by the engine oil pump. This design promotes the maximum effectiveness of the balance shaft system and reduces noise and vibration.

Cylinder Head

The cylinder head is a lost foam aluminum casting. Pressed-in powdered metal valve guides and valve seat insets are used. The fuel injection nozzle is located in the intake port. The cylinder head incorporates camshaft bearing journals and camshaft bearing caps.

Valves

There are two intake and two exhaust valves per cylinder. Rotators are used on all of the intake valves. The rotators are located at the bottom of the valve spring to reduce valve train reciprocating mass. Positive valve stem seals are used on all valves.

Camshaft

Two camshafts are used, one for all intake valves, the other for all exhaust valves. The camshafts are cast iron. The intake camshaft had a pressed-in hex insert. The hex inset is used to drive the direct drive power steering pump.

Valve Lifters

The valve train uses a roller finger follower acted on by a hydraulic element adjuster. The roller finger follower reduces friction and noise.

Camshaft Cover

The camshaft cover is cast aluminum with steel crankcase ventilation baffling incorporated. The camshaft cover has mounting locations for the ignition system.

Camshaft Drive

A single row roller chain is used for camshaft drive. There is a tensioner and active guide used on the slack side of the chain to control chain motion and noise. The chain drive promotes long valve train life and low maintenance.

Intake and Exhaust Manifold

The intake manifold is made of composite plastic. The exhaust manifold is cast iron. The intake manifold incorporates a distribution and control system for PCV gases. The exhaust manifold is a dual plane design that promotes good low end torque and performance.

Scheme 28

Oil is applied under pressure to the crankshaft, connecting rods, balance shaft assembly, camshaft bearing surfaces, valve lifters and timing chain hydraulic tensioner. All other moving parts are lubricated by gravity flow or splash. Oil enters the gerotor type oil pump thorough a fixed inlet screen. The oil pump is driven by the crankshaft. The oil pump body is within the engine front cover. The pressurized oil from the pump passes through the oil filter. The oil filter is located on the right (front) side of the engine block. The oil filter is housed in a casting that is integrated with the engine block. The oil filter is a disposable cartridge type. A by-pass valve in the filter cap allows continuous oil flow in case the oil filter should become restricted. Oil then enters the gallery where it is distributed to the balance shafts, crankshaft, camshafts and camshaft timing chain oiler nozzle. The connecting rod bearings are oiled by constant oil flow passages through the crankshaft connecting the main journals to the rod journals. A groove around each upper main bearing furnishes oil to the drilled crankshaft passages. The pressurized oil passes through the cylinder head restrictor orifice into the cylinder head and then into each camshaft feed gallery. Cast passages feed each hydraulic element adjuster and drilled passages feed each camshaft bearing surface. An engine oil pressure switch or sensor is installed at the end. Oil returns to the oil pan through passages cast into the cylinder head. The timing chain lubrication drains directly into the oil pan.

Cleanliness and Care

An automobile engine is a combination of many machined, honed, polished, and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate the surfaces during initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.

When valve train components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed.

Separating Parts

Separate, mark, or organize the following components

1. Piston and the piston pin
2. Piston to the specific cylinder bore
3. Piston rings to the piston
4. Connecting rod to the crankshaft journal
5. Connecting rod to the bearing cap A paint stick or etching/engraving type tool are recommended. Stamping the connecting rod or cap near the bearing bore may affect component geometry.
6. Crankshaft main and connecting rod bearings
7. Camshaft and valve lifters
8. Valve lifters, lifter guides, pushrods and rocker arm assemblies
9. Valve to the valve guide
10. Valve spring and shim to the cylinder head location
11. Engine block main bearing cap location and direction
12. Oil pump drive and driven gears

J 28410 Gasket Remover

Gasket Reuse and Applying Sealants

1. Do not reuse any gasket unless specified.
2. Gaskets that can be reused will be identified in the service procedure.
3. Do not apply sealant to any gasket or sealing surface unless called out in the service information.

Separating Components

1. Use a rubber mallet to separate components.
2. Bump the part sideways to loosen the components.
3. Bumping should be done at bends or reinforced areas to prevent distortion of parts.

Cleaning Gasket Surfaces

1. Remove all gasket and sealing material from the part using the J 28410 or equivalent. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
2. Care must be used to avoid gouging or scraping the sealing surfaces.
3. Do not use any other method or technique to remove sealant or gasket material from a part.
4. Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces. These methods of cleaning can cause damage to the component sealing surfaces. Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and has been known to cause internal engine damage.

Assembling Components

1. When assembling components, use only the sealant specified or equivalent in the service procedure.
2. Sealing surfaces should be clean and free of debris or oil.
3. Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly.
4. Components requiring lubrication will be identified in the service procedure.
5. When applying sealant to a component, apply the amount specified in the service procedure.
6. Do not allow the sealant to enter into any blind threaded holes, as it may prevent the bolt from clamping properly or cause component damage when tightened.
7. Tighten bolts to specifications. Do not overtighten.

Pipe Joint Compound

1. Pipe joint compound is a pliable sealer that does not completely harden. This type sealer is used where two non-rigid parts (such as the oil pan and the engine block) are assembled together.
2. Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.
3. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
4. Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause component damage when the bolt is tightened.
5. Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed must be clean and dry.
6. Tighten the bolts to specifications. Do not overtighten.

RTV Sealer

1. Room Temperature Vulcanizing (RTV) sealant hardens when exposed to air. This type sealer is used where two rigid parts (such as the lower crankcase and the engine block) are assembled together.
2. Do not use Room Temperature Vulcanizing (RTV) sealant in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where a gasket eliminator is specified.
3. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
4. Apply RTV to a clean surface. Use a bead size as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause damage when the bolt is tightened.
5. Assemble components while RTV is still wet (within 3 minutes). Do not wait for RTV to skin over.
6. Tighten bolts to specifications. Do not overtighten.

Anaerobic Sealer

1. Anaerobic gasket eliminator hardens in the absence of air. This type sealer is used where two rigid parts (such as castings) are assembled together. When two rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator.
2. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61) .
3. Apply a continuous bead of gasket eliminator to one flange. Surfaces to be resealed must be clean and dry.
4. Spread the sealer evenly with your finger to get a uniform coating on the sealing surface.
5. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause damage when tightened.
6. Tighten bolts to specifications. Do not overtighten.
7. After properly tightening the fasteners, remove the excess sealer from the outside of the joint.

Tools and Equipment

Special tools are listed and illustrated throughout this section with a complete listing at the end of the section. These tools, or their equivalents, are specially designed to quickly and safely accomplish the operations for which they are intended. The use of these special tools will also minimize possible damage to engine components. Some precision measuring tools are required for inspection of certain critical components. Torque wrenches and a torque angle meter are necessary for the proper tightening of various fasteners.

To properly service the engine assembly, the following items should be readily available

1. Approved eye protection and safety gloves
2. A clean, well lit, work area
3. A suitable parts cleaning tank
4. A compressed air supply
5. Trays or storage containers to keep parts and fasteners organized
6. An adequate set of hand tools
7. Approved engine repair stand
8. An approved engine lifting device that will adequately support the weight of the components

Special Tools

Special Tools Illustration Tool Number/Description EN 45680-400 Cylinder Sleeve Removal and Installation Kit EN 46745 Piston Pin Retainer Remover and Installer J 7872 Magnetic Base Dial Indicator Set J 8037 Ring Compressor J 8062 Valve Spring Compressor - Head Off J 8087 Cylinder Bore Gage J 9666 Valve Spring Tester J 21867-850 Oil Pressure Gage Adapter J 23600-B Belt Tension Gage J 28410 Gasket Remover J 28428-E High-Intensity Black Light Kit J 28467-B Universal Engine Support Fixture J 28467-501 Engine Support Fixture Adapters J 35268-A Camshaft/Front Main Seal Installer J 35667-A Cylinder Head Leakdown Tester J 36017 Valve Guide Seal Remover J 38188 Cylinder Head Broken Bolt Extractor Kit J 42067 Rear Main Seal Installer J 42385-850 Thread Repair Kit J 42451 Engine Support Adapter Set J 43649 Valve Spring Compressor J 43650 Balance Shaft Bearing Remover and Installer J 43654 Piston Pin Retainer Remover and Installer J 43963 Valve Spring Compressor (off car) J 43966-1 Connecting Rod Guides J 44887 Oil Filter Wrench J 45025 Torque Wrench Adapter J 45027 Tensioner Tool J 45059 Angle Meter J 45299 Engine Pre-Luber

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