Engine Mechanical - 3.5l (lx9) Chevrolet Malibu VI

Fastener Tightening Specifications

Fastener Tightening Specifications

Engine Mechanical Specifications

Engine Mechanical Specifications

Sealers, Adhesives, and Lubricants

Sealers, Adhesives, and Lubricants

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

The Vehicle Identification Number - VIN derivative (1) for 3500 LX9 is stamped or laser etched on the left side rear of the engine block. The Vehicle Identification Number - VIN derivative is nine digits long and can be used to determine if a vehicle contains the original engine.

1. The first digit identifies the division.
2. The second digit identifies the model year.
3. The third digit identifies the assembly plant.
4. The fourth through ninth digits are the last six digits of the Vehicle Identification Number - VIN.

Diagnostic Starting Point - Engine Mechanical

Begin the system diagnosis by reviewing the Disassembled Views , Engine Component Description , Drive Belt System Description and Lubrication Description in Engine Mechanical. 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 A Diagnostic System Check in Engine Controls 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-35l-lx9) , «Engine Component Description»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-component-description) , «Drive Belt System Description»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__drive-belt-system-description) and «Lubrication Description»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) in Engine Mechanical.

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 problem. The diagnostic flow is the place to start when repairs are necessary. For a detailed explanation, refer to Strategy Based Diagnosis in General Information.

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the Engine. Refer to «Checking Aftermarket Accessories»(/chevrolet/malibu/vi-2003-2006/remont/body-electrical/#wiring-systems-specifications-component-views-and-connector-end-views__checking-aftermarket-accessories) in Wiring Systems.
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-35l-lx9__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-35l-lx9__base-engine-misfire-with-abnormal-internal)
3. «Base Engine Misfire with Abnormal Valve Train Noise»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__base-engine-misfire-with-abnormal-valve)
4. «Base Engine Misfire with Coolant Consumption»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__base-engine-misfire-with-coolant-consumption)
5. «Base Engine Misfire with Excessive Oil Consumption»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__base-engine-misfire-with-excessive-oil)
6. «Engine Compression Test»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-compression-test)
7. «Engine Noise on Start-Up, but Only Lasting a Few Seconds»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-noise-on-start-up-but-only)
8. «Upper Engine Noise, Regardless of Engine Speed»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__upper-engine-noise-regardless-of-engine)
9. «Lower Engine Noise, Regardless of Engine Speed»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__lower-engine-noise-regardless-of-engine)
10. «Engine Noise Under Load»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-noise-under-load)
11. «Engine Will Not Crank - Crankshaft Will Not Rotate»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-will-not-crank-crankshaft)
12. «Oil Consumption Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__oil-consumption-diagnosis)
13. «Oil Pressure Diagnosis and Testing»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9)
14. «Oil Leak Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9)
15. «Drive Belt Chirping Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__drive-belt-chirping-diagnosis)
16. «Drive Belt Squeal Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__drive-belt-squeal-diagnosis)
17. «Drive Belt Whine Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__drive-belt-whine-diagnosis)
18. «Drive Belt Rumbling Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__drive-belt-rumbling-diagnosis)
19. «Drive Belt Vibration Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9)
20. «Drive Belt Falls Off Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9)
21. «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9)
22. «Drive Belt Tensioner Diagnosis»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__drive-belt-tensioner-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

A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket.

1. Disable the ignition.
2. Disable the fuel systems.
3. Remove the spark plugs from all the cylinders.
4. Remove the air duct from the throttle body.
5. Block the throttle plate in the open position.
6. Measure the engine compression, using the following procedure: Firmly install the compression gauge to the spark plug hole. Have an assistant crank the engine through at least 4 compression strokes in the testing cylinder. Record the readings on the gauge at each stroke. Disconnect the gauge. Repeat the compression test for each cylinder.
7. Record the compression readings from all of the cylinders. The lowest reading should not be less than 70 percent of the highest reading. No cylinder reading should be less than 689 kPa (100 psi).
8. The following list contains examples of the possible measurements: When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, the piston rings may be the cause. If the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. When the compression is low on the first stroke and does not build up in the following strokes, the valves may be the cause. The addition of oil does not affect the compression, the valves may be the cause. When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause.
9. Remove the block from the throttle plate.
10. Install the air duct to the throttle body.
11. Install the spark plugs.
12. Install the Powertrain Control Module (PCM) fuse.
13. Install the ignition fuse to the I/P fuse block.

Cylinder Leakage Test

Tools Required

J 35667-A Cylinder Leakdown Tester

With the use of air pressure, a cylinder leakage test will aid in the diagnosis. Use the cylinder leakage test in conjunction with the engine compression test in order to isolate the cause of leaking cylinders.

1. Disconnect the negative battery cable.
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls.
3. Install the J 35667-A .
4. Measure each cylinder on the compression stroke, with both valves closed.
5. Apply air pressure, using the J 35667-A . Refer to the manufacturer's instructions.
6. Record the cylinder leakage readings for each cylinder.
7. Inspect the 4 primary areas in order to properly diagnose a leaking cylinder.
8. If air is heard from the intake or exhaust system, perform the following procedure: Remove the valve rocker arm cover of the suspect cylinder head. Ensure that both valves are closed. Inspect the cylinder head for a broken valve spring. Remove and inspect the suspect cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__cylinder-head-cleaning-and-inspection) .
9. If air is heard from the crankcase system at the crankcase - oil filler tube, perform the following procedure: Remove the piston from the suspect cylinder. Inspect the piston and connecting rod assembly. Refer to «Piston, Connecting Rod, and Bearings Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__piston-connecting-rod-and-bearings-cleaning) . Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-block-cleaning-and-inspection) .
10. If bubbles are found in the radiator, perform the following procedure: Remove and inspect both cylinder heads. Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__cylinder-head-cleaning-and-inspection) . Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-block-cleaning-and-inspection) .
11. Remove the J 35667-A .
12. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls.
13. 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.

Oil Consumption Diagnosis

An engine that has excessive oil consumption uses 0.9 L (1 qt) of oil, or more, within 3 200 km (2,000 mi). The following list indicates the conditions and corrections of excessive oil consumption

1. An improperly read oil level indicator dipstick Inspect the oil level while the vehicle is parked on a level surface. Allow adequate drain-down time.
2. Improper oil viscosity Use the recommended SAE viscosity for prevailing temperatures.
3. Continuous high-speed driving
4. Severe hauling, such as a trailer. This causes decreased oil mileage.
5. A malfunctioning crankcase ventilation system
6. External oil leaks Tighten the bolts, as needed. Replace the gaskets and seals, as needed.
7. Worn or omitted valve guides and/or valve stem seals Ream the guides. Install oversized service valves and/or new valve stem seals.
8. Broken or worn piston rings
9. Improperly installed or unseated piston rings
10. Improperly installed or improperly fitted piston
11. Plugged cylinder head gasket oil drain holes
12. Damaged intake gaskets

Low or No Oil Pressure

The following conditions may cause low or no oil pressure

1. Low oil level Fill to the full mark on the oil level indicator.
2. Incorrect or malfunctioning oil pressure switch Replace the oil pressure switch.
3. Incorrect or malfunctioning oil pressure gauge Replace the oil pressure gauge.
4. Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. Install new oil if the oil is diluted.
5. A worn or dirty oil pump Clean or replace the oil pump.
6. A plugged oil filter Replace the oil filter.
7. A loose or plugged oil pickup screen Replace the oil pickup screen.
8. A hole in the oil pickup tube Replace the oil pickup tube.
9. Excessive rod, main, or cam bearing clearance Replace the bearings.
10. Cracked, porous, or plugged oil gallery Repair or replace the engine block.
11. Missing or improperly installed gallery plugs Install or repair the plugs as needed.
12. A stuck pressure regulator valve Inspect the pressure regulator valve for sticking in the bore. Inspect the bore for scoring and burrs.
13. A worn or poorly machined camshaft Replace the camshaft.
14. Worn valve guides Repair the valve guides as needed.

Oil Pressure Testing

Tools Required

J 25087-C Oil Pressure Tester. See Special Tools and Equipment .

If the vehicle has low oil pressure complete the following steps

1. Inspect the oil level.
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 oil filter.
4. Assemble the plunger valve in the large hole of the J 25087-C base. Insert the hose in the small hole of the J 25087-C base. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) . Connect the gauge to the end of the hose.
5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve.
6. Install the J 25087-C on the filter mounting pad. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
7. Start the engine.
8. Inspect the overall oil pressure, the oil pressure switch, and for noisy lifters. Ensure that the engine is at operating temperature before inspecting the oil pressure. The oil pressure should be approximately 207-310 kPa (30-45 psi) at 1,850 RPM using 5W-30 engine oil.
9. If adequate oil pressure is indicated, test the oil pressure switch.
10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the valve indicates a faulty pump.

Tools Required

J 28428-E High Intensity Black Light Kit

You may repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the leak and the cause of leak.

Locating and Identifying the Leak

Use the visual inspection method in order to determine if the leaking fluid is one of the following items

1. Engine oil
2. Transmission fluid
3. Power steering fluid
4. Brake fluid
5. Some other fluid

Visual Inspection Method

Complete the following steps in order to perform the visual inspection method

1. Bring the vehicle to normal operating temperature.
2. Park the vehicle over a large sheet of paper, or other clean surface.
3. Wait several minutes, then inspect for dripping fluids.
4. Identify the type of fluid, and the approximate location of the leak.
5. Visually inspect the suspected area. Use a small mirror if necessary.
6. Inspect for leaks at sealing surfaces, fittings, or from cracked or damaged components.
7. If you cannot locate the leak, perform the following steps: Completely clean the entire engine and surrounding components. Operate the vehicle for several miles at normal operation temperature and at varying speeds. Park the vehicle over a large sheet of paper, or other clean surface. Wait several minutes, then inspect for dripping fluids. Identify the type of fluid, and the approximate location of the leak. Visually inspect the suspected area. Use a small mirror if necessary.
8. If you still cannot locate the leak, use the powder method or the black light and dye method.

Powder Method

1. Completely clean the entire engine and surrounding components.
2. Apply an aerosol-type powder, baby powder, foot powder, etc., to the suspected area.
3. Operate the vehicle for several miles at normal operation temperature and at varying speeds.
4. Identify the type of fluid, and the approximate location of the leak, from the discolorations in the powder surface.
5. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas. Refer to Possible Causes for Leaks if necessary.

Black Light and Dye Method

A dye and light kit is available for finding leaks.

1. Use the J 28428-E or the equivalent. Refer to the manufacturer's instructions when using the tool.
2. Visually inspect the suspected area. Use a small mirror if necessary Refer to Possible Causes for Leaks if necessary.

Possible Causes for Leaks

Inspect the vehicle for the following conditions

1. Higher than recommended fluid levels
2. Higher than recommended fluid pressures
3. Plugged or malfunctioning fluid filters or pressure bypass valves
4. Plugged or malfunctioning engine ventilation system
5. Improperly tightened or damaged fasteners
6. Cracked or porous components
7. Improper sealants or gaskets where required
8. Improper sealant or gasket installation
9. Damaged or worn gaskets or seals
10. Damaged or worn sealing surfaces

Scheme 62

1. A plugged valve (3 ) or hose (2 & 4 ) may cause the following conditions: Rough idle Stalling or a low idle speed Oil leaks Oil in the air cleaner Sludge in the engine
2. A leaking crankcase ventilation valve (3 ) or hose (2 & 4 ) may cause the following conditions: Rough idle Stalling High idle speed

Functional Test

With these systems, any blow-by in excess of the system capacity, from a badly worn engine, sustained heavy load, etc., is exhausted into the air intake passages and is drawn into the engine.

Proper operation of the crankcase ventilation system depends upon a sealed engine. If oil sludging or dilution is noted and the crankcase ventilation system is functioning properly, inspect the engine for a possible cause. Correct any problems.

If an engine is idling rough, inspect for a clogged crankcase ventilation valve, a dirty vent filter or air cleaner element, or a plugged hose. Replace any components as required. Refer to the following procedure

1. Remove the crankcase ventilation valve from the rocker arm cover.
2. Operate the engine at idle.
3. Place your thumb over the end of the valve in order to check for a vacuum. If there is no vacuum at the valve, check for the following items: Any plugged hoses The manifold port The crankcase ventilation valve
4. Turn OFF the engine. Remove the crankcase ventilation valve. Shake the valve. Listen for the rattle of the check needle inside of the valve. If valve does not rattle, replace the valve.

Drive Belt Chirping Diagnosis

Drive Belt Chirping Diagnosis

Drive Belt Squeal Diagnosis

Drive Belt Squeal Diagnosis

Drive Belt Whine Diagnosis

Drive Belt Whine Diagnosis

Drive Belt Rumbling Diagnosis

Drive Belt Rumbling Diagnosis

Diagnostic Aids

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

Test Description

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 belts 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 belts may cause a vibration. While the drive belts are 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

1. If the drive belts repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
2. 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.
3. 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 to the belt may have occurred when it came off of the pulleys. The drive belt may have 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 misaligned pulley using a straight edge in the pulley grooves across 2 or 3 pulleys. If a misaligned pulley is found, refer to that accessory drive component for the proper installation procedure for 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

Removal Procedure

1. 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. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Rotate the drive belt tensioner counterclockwise to release the spring tension.
4. Remove the drive belt.

Installation Procedure

1. Rotate the drive belt tensioner counterclockwise to release the spring tension.
2. Install the drive belt.
3. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
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.

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Removal»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__drive-belt-tensioner-removal) .

1. Install the drive belt tensioner. «Drive Belt Tensioner Installation»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__drive-belt-tensioner-installation) .
2. Install the drive belt tensioner bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

Engine Mount Inspection

1. Install the engine support fixture. Refer to «Engine Mount Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-mount-inspection) .
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-35l-lx9) .

Engine Support Fixture

Tools Required

1. J 28467-B Engine Support Fixture
2. J 36462 Engine Support Adapter Leg. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

1. Raise the hood.
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. Install the thread support nuts J 28467-33A onto the strut attaching studs.
4. Install the strut tower support assemblies J 28467-5A over the thread support nuts J 28467-33A.
5. Install the T-bolts J 28467-5 with 5/16 inch washers through the strut tower support assemblies J 28467-5A into the thread support nuts J 28467-33A. Hand tighten the bolts.
6. Install the 2 cross bracket assemblies J 28467-1A over the strut tower tube J 28467-3.
7. Install the strut tower tube J 28467-3 into the strut tower support assemblies J 28467-5A.
8. 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.
9. 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.
10. 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.
11. 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.
12. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
13. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
14. Install the assembled lift hook bracket J 28467-6A over the radiator shelf tube J 28467-2A.
15. 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.
16. Hand tighten the driver side cross bracket assembly J 28467-1A wing nuts.
17. 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.
18. 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.
19. 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.
20. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
21. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
22. Install the assemblage lift hook bracket J 28467-6A over the radiator shelf tube J 28467-2A.
23. 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.
24. Hand tighten the passenger side cross bracket assembly J 28467-1A wing nuts.
25. Hand tighten the lift hook wing nuts J 28467-34 securely in order to remove all slack from the engine support fixture assembly.

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. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
3. Remove the engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
4. Remove the engine mount to engine mount bracket nuts.
5. Remove the motor mount to frame nuts.
6. Using a suitable jackstand, raise the engine.
7. Remove the motor mount from the vehicle.

Scheme 63

1. Position the motor mount on the frame
2. Use the jackstand to lower the engine mount bracket on to the engine mount.
3. Install the engine mount to frame bolts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
4. Install the motor mount to motor mount bracket nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
5. Install the engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Lower»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
6. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
7. Lower the vehicle.

1. Remove the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. Remove the engine mount bracket bolts from the engine.
3. Remove the engine mount bracket from the vehicle.

1. Position the engine mount bracket to the engine.
2. Install the front mount bracket bolts to the engine. Hand tighten the bolts at this time. Tighten: Tighten the upper engine mount bracket bolts to 90 N.m (66 lb ft). Tighten the lower engine mount bracket bolts to 50 N.m (37 lb ft).
3. Install the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

1. 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 - 3.5L (LX9).
2. Remove the engine mount strut to engine mount bolts.
3. Rotate the engine mount strut to the vertical position.
4. Remove the engine mount strut to body bolts.
5. Remove the engine mount strut from the vehicle.

1. Install the engine mount strut in to the vehicle. Tighten: Tighten the engine mount strut to body bolts to 50 N.m (37 lb ft).
2. Rotate the engine mount strut to the horizontal position.
3. Install the engine mount strut to bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
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 - 3.5L (LX9).

1. Remove the engine mount strut. Refer to «Engine Mount Strut Bracket Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. Remove the engine mount strut bracket to engine bolts.
3. Remove the engine mount strut bracket from the vehicle.

1. Install the engine mount strut bracket to the engine. Tighten: Tighten the engine mount strut bracket to engine bolts to 25 N.m (18 lb ft).
2. Install the engine mount strut. Refer to «Engine Mount Strut Bracket Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

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. Remove the oil filter.
3. Remove the oil filter adapter and gasket.
4. Remove the oil filter bypass hole plug.
5. Insert a flat bladed tool into the oil filter bypass hole and remove the bypass valve.

1. Install the oil filter bypass valve (1) to the proper depth.
2. Install the oil filter bypass hole plug. Tighten: Tighten the plug to 19 N.m (14 lb ft).
3. Install the oil filter and gasket. Tighten: Tighten to 25 N.m (18 lb ft).
4. Install the oil filter.
5. Lower the vehicle.
6. Check and fill the crankcase as necessary.

1. Remove the spark plug wire from the number 6 cylinder spark plug.
2. Remove the oil level indicator.
3. Remove the oil level indicator tube bracket bolt.
4. Remove the oil level indicator tube.

1. Clean the oil level indicator tube.
2. Apply sealant around the oil level indicator tube 12.7 mm (0.50 in) below the bead. Use sealant GM P/N 12346286 (Canadian P/N 10953472) or the equivalent.
3. Install the oil level indicator tube into the engine block.
4. Install the oil level indicator tube bracket bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
5. Install the oil level indicator.
6. Install the spark plug wire to the number 6 cylinder spark plug.

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. Remove the vacuum hoses from the following: Evaporative emissions (EVAP) canister purge valve Manifold vacuum source Brake booster Heater and air conditioning source
3. Disconnect the electrical connectors from the following: Exhaust gas recirculation (EGR) valve Mass air flow (MAF) sensor Intake air temperature (IAT) sensor Electronic throttle control EVAP canister purge valve
4. Remove the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
5. Drain the cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
6. Remove the left side spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
7. Remove the following wiring harnesses from the retainers: Camshaft position (CMP) sensor wiring harness Left side spark plug wire harness Engine wiring harness
8. Remove the ignition coil bracket with the coils. Refer to «Ignition Control Module Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
9. Remove the EVAP canister purge valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
10. Remove the manifold absolute pressure (MAP) sensor and the bracket. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
11. Remove the EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
12. Remove the upper intake manifold bolts and the stud.
13. Remove the upper intake manifold.
14. Remove the upper intake manifold gaskets.
15. If replacing the upper intake manifold, remove the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
16. Clean the upper intake gasket mating surfaces.

1. If removed, install the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
2. Install the upper intake manifold gaskets.
3. Install the upper intake manifold.
4. Install the right upper intake manifold bolts and the stud. Tighten: Tighten the bolts and the stud to 25 N.m (18 lb ft).
5. Install the EGR valve. Refer to «Exhaust Gas Recirculation (EGR) Valve Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
6. Install the MAP sensor bracket and the sensor. Refer to «Manifold Absolute Pressure (MAP) Sensor Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
7. Install the EVAP canister purge valve. Refer to «Evaporative Emission (EVAP) Canister Purge Solenoid Valve Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
8. Install the ignition coil bracket with the coils. Refer to «Ignition Control Module Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
9. Install the following wiring harnesses to the retainers: The engine wiring harness The left side spark plug wire harness The CMP sensor wiring harness
10. Install the left side spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
11. Install the air cleaner intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
12. Connect the electrical connectors to the following: The EVAP canister purge valve The electronic throttle control The IAT sensor The MAF sensor The EGR valve
13. Install the vacuum hoses to the following: The heater and air conditioning source The brake booster The manifold vacuum source The EVAP canister purge valve
14. 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.
15. Fill the cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.

1. Disconnect the battery ground negative 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. Remove the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Remove the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. Remove the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
5. Disconnect the engine coolant temperature (ECT) wiring harness.
6. Disconnect and remove the fuel injector and manifold air pressure (MAP) wiring harness.
7. Remove the fuel injector rail. Refer to «Fuel Rail Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
8. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition.
9. Disconnect the radiator inlet hose from the engine. Refer to «Radiator Hose Replacement - Inlet (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
10. Remove the water outlet.
11. Remove the thermostat.
12. Remove the lower intake manifold bolts.
13. Remove the lower intake manifold.
14. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
15. Remove the lower intake manifold gaskets and seals.
16. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
17. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
18. Remove all the loose room temperature vulcanizing sealer (RTV) (1).

1. Install the lower intake manifold gaskets.
2. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. With gaskets and seals in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12378521 (Canadian P/N 88901148), or equivalent, to the 4 corners of the intake manifold to block joints (1).
4. Install the lower intake manifold.
5. Apply sealer GM P/N 12345382 (Canadian P/N 10953489), or equivalent, to the lower intake manifold bolt threads.
6. Install the new lower intake manifold bolts, if applicable, in sequence. Tighten: Tighten the lower intake manifold bolts in sequence to 13 N.m (115 lb in) on the first pass. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 20 N.m (15 lb ft) on the final pass. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on the final pass.
7. Install the heater inlet pipe.
8. Install the heater inlet pipe nut. Tighten: Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).
9. Install the thermostat.
10. Install the water outlet bolts. Refer to «Thermostat Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
11. Install the ECT sensor. Tighten: Tighten the ECT sensor to 20 N.m (15 lb ft).
12. Connect the thermostat bypass hose to the thermostat bypass pipe and lower intake manifold pipe.
13. Connect the radiator inlet hose to the engine. Refer to «Radiator Hose Replacement - Inlet (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
14. Connect the heater inlet pipe and heater hose to the lower intake manifold.
15. Install the power steering pump to the front engine cover.
16. Install the fuel injector rail. Refer to «Fuel Rail Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
17. Connect the fuel feed pipe to the fuel injector rail.
18. Connect the fuel injector and MAP wiring harness.
19. Connect the ECT wiring harness.
20. Install the right valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
21. Install the left valve rocker arm cover. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
22. Install the upper intake manifold. Refer to «Intake Manifold Replacement - Upper»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
23. Connect the battery ground negative 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. Disconnect the vacuum hose from positive crankcase ventilation (PCV) valve.
2. Remove the PCV valve retainer.
3. Remove the PCV valve.

1. Install the PCV valve.
2. Install the PCV valve retainer.
3. Connect the vacuum hose to PCV valve.

1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
2. Remove the front ignition wire harness at the upper intake manifold and at the spark plugs.
3. Remove the thermostat bypass pipe. Refer to «Thermostat Bypass Pipes Replacement»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
4. Disconnect the positive crankcase ventilation (PCV) vacuum hose.
5. Remove the valve rocker arm cover bolts.
6. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
7. Trim the valve cover and sealant away from the lower intake manifold gasket at the cylinder head to the lower intake manifold joints (1).
8. Remove the valve cover gasket.
9. Clean the sealing surface on the cylinder head with degreaser.
10. Clean the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__valve-rocker-arm-cover-cleaning-and) .

1. Apply sealant at the cylinder head to the lower intake manifold joints (1).
2. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
3. Install the valve rocker cover.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Connect the PCV valve vacuum line.
6. Install the thermostat bypass pipe. Refer to «Thermostat Bypass Pipes Replacement»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
7. Install the front ignition wire harness.
8. Refill the cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.

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. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Remove the generator. Refer to «Generator Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system__generator-replacement-lx9) in Engine Electrical.
4. Remove the generator bracket. Refer to «Generator Bracket Replacement»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
5. Remove the right spark plug wires. Refer to «Spark Plug Wire Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
6. Disconnect the vacuum hoses from the evaporative emission (EVAP) purge valve.
7. Remove the EVAP purge valve.
8. Remove the ignition coil bracket with the coils. Refer to «Ignition Coil(s) Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
9. Remove the ignition coil bracket studs.
10. Remove the vacuum hose from the grommet in the right valve rocker arm cover.
11. Remove the right valve rocker arm cover bolts.
12. Remove the valve rocker arm cover. Bump the end of the valve rocker cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
13. Trim the valve gasket and sealant away from the lower intake manifold gasket at the cylinder head to lower intake manifold joints (1).
14. Remove the valve cover gasket.
15. Clean the sealing surface on the cylinder head with degreaser.
16. Clean the valve rocker arm cover. Refer to «Valve Rocker Arm Cover Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__valve-rocker-arm-cover-cleaning-and) .

1. Apply sealant at the cylinder head to lower intake manifold joints (1).
2. Install a new gasket to the valve rocker arm cover. Ensure that the gasket is properly seated in the groove of the valve rocker arm cover.
3. Install the right valve rocker arm cover.
4. Install the valve rocker arm cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the vacuum hose to the grommet in the right valve rocker arm cover.
6. Install the ignition coil bracket studs.
7. Install the ignition coil bracket with coils. Refer to «Ignition Coil(s) Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
8. Install the EVAP purge valve.
9. Connect the vacuum hoses to the EVAP purge valve.
10. Install the right spark plug wires. Refer to «Spark Plug Wire Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
11. Install the generator bracket. Refer to «Generator Bracket Replacement»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
12. Install the generator. Refer to «Generator Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system__generator-replacement-lx9) in Engine Electrical.
13. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
14. 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.

1. Remove the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) or «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. Remove the rocker arm bolts.
3. Remove the rocker arms.
4. Remove the pushrods.

1. Install the pushrods in the original location. Coat the ends of the pushrods with GM P/N 1052356 or the equivalent. The intake pushrods are identified with yellow stripes and are 5 3/4 inches long. Exhaust pushrods are identified with green stripes and are 6 inches long. Ensure that the pushrods seat in the lifter.
2. Install the rocker arms.
3. Install the rocker arm bolts. Tighten: Tighten the rocker arm bolts to 32 N.m (24 lb ft).
4. Install the valve rocker covers. Refer to «Valve Rocker Arm Cover Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) or «Valve Rocker Arm Cover Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 22794 Spark Plug Port Adapter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. J 38606 Valve Spring Compressor. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

1. Remove the spark plug. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
2. Remove the rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Install the J 22794 into the spark plug port. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) . Apply compressed air in order to hold the valves in place.
4. Install the J 38606 on the valve spring. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
5. Compress the valve spring with the J 38606 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
6. Remove the valve locks.
7. Remove the valve cap.
8. Remove the valve spring.
9. Inspect the valve spring for damage. Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__cylinder-head-cleaning-and-inspection) .
10. Remove the valve stem oil seal.

1. Install the valve stem oil seal.
2. Install the valve spring.
3. Install the valve cap.
4. Compress the valve spring with the J 38606 .
5. Install the valve locks. If necessary, hold the valve locks in place with grease.
6. Release the valve spring using the J 38606 .
7. Ensure the valve locks are seated.
8. Release the air pressure and remove the J 22794 from the spark plug port. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
9. Install the valve rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
10. Install the spark plug. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.

1. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Remove the intake manifold oil splash shield.
4. Remove the lifter guide bolts.
5. Remove the valve lifter guides.
6. Remove the valve lifters.
7. Clean all gasket surfaces with degreaser.
8. Clean the valve train parts.
9. Inspect the valve lifters and the cam lobes for wear. Refer to «Valve Lifters Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__valve-lifters-cleaning-and-inspection) .

1. Coat the valve lifters with prelube GM P/N 1052367 (Canadian P/N 992869) or equivalent.
2. Install the valve lifters to the same location from which they were removed.
3. Install the valve lifter guides.
4. Install the valve lifter guide bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
5. Install the intake manifold oil splash shield
6. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
7. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

Crankshaft Balancer Replacement

Tools Required

1. J 29113 Balancer and Crank Sprocket Installer. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. J 37096 Flywheel Holder. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. J 41816 Harmonic Balancer Remover. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. J 45059 Angle Meter

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
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 right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
4. Remove the right engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Side (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
5. Install the jack stands to the frame.
6. Loosen the left frame bolts and remove the right side frame bolts. Refer to «Frame Replacement (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
7. Using the jack stands, lower the right side of the frame to access the crankshaft balancer.
8. Remove the torque converter covers.
9. Install the J 37096 to the flywheel to prevent flywheel rotation. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
10. Remove the crankshaft balancer bolt and the washer.
11. Remove the crankshaft balancer. Use the J 41816 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

1. Apply sealant GM P/N 12346286 (Canadian P/N 10953472) or the equivalent to the keyway of the balancer.
2. Install the crankshaft balancer. Use the J 29113 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Remove the J 29113 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. Install the J 37096 to the flywheel to prevent flywheel rotation. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
5. Install the crankshaft balancer washer and the bolt. Tighten: Tighten the bolt to 70 N.m (52 lb ft). Use the J 45059 to rotate the crankshaft balancer bolt an additional 70 degrees.
6. Remove the J 45059 from the flywheel.
7. Install the torque converter covers.
8. Raise the frame to the original position.
9. Install and tighten the frame bolts. Refer to «Frame Replacement (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
10. Install the right engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Side (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
11. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
12. Lower the vehicle.
13. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
14. Perform a crankshaft position (CKP) system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9__ckp-system-variation-learn-procedure) in Engine Controls - 3.5L.

J 28467-B Universal Engine Support Fixture

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. Drain the crankcase.
4. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
5. Remove the right front splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Side (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
6. Remove the wheel speed sensor harness from the right suspension support.
7. Remove the right front ball joint, bolt, and nut. Separate the ball joint from the steering knuckle. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) in Front Suspension.
8. Remove lower closeout panel.
9. Remove the air conditioning (A/C) compressor bolts and position the compressor aside.
10. Remove the braces that support the engine to the transmission.
11. Disconnect the oil level sensor.
12. Remove the retainers that secure the brake line to the frame.
13. Support the engine using the J 28467-B or a tall jackstand and a block of wood.
14. Remove the right side engine mount nuts and bolts. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
15. Loosen the left side cradle bolts. Refer to «Frame Replacement (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
16. Remove the cradle bolts from the right front and the right rear.
17. Remove the starter. Refer to «Starter Motor Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
18. Remove the oil pan side bolts.
19. Remove the oil pan bolts.
20. Remove the oil pan.
21. Remove the oil pan gasket.
22. Clean the following items: The oil pan flanges The oil pan rail The front cover The rear main bearing cap The threaded holes

1. Install a new gasket. If you are installing the rear main bearing cap, place sealant on the oil pan gasket tabs. Place the sealer on the tabs that insert into the gasket groove on the outer surface of the main bearing cap. Use GM P/N 1052080 (Canadian P/N 10953480) or the equivalent.
2. Install the oil pan.
3. Install the oil pan bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
4. Install the oil pan side bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
5. Install the starter. Refer to «Starter Motor Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
6. Install the flywheel inspection cover.
7. Install the A/C compressor to the engine. Refer to «Compressor Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation, and Air Conditioning.
8. Install the frame bolts on the right side. Refer to «Frame Replacement (W/LX9)»(/chevrolet/malibu/vi-2003-2006/remont/frames-subframes-crossmembers/#frame-and-underbody) in Frame and Underbody.
9. Install engine mount bolts and nuts. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
10. Install the right side ball joint to the steering knuckle. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2003-2006/remont/suspension-front/#front-suspension-system) in Front Suspension.
11. Connect the right front antilock brake system (ABS) wheel speed sensor harness.
12. Install the retainers that support the brake line to the frame.
13. Install the braces that support the engine to the transmission.
14. Install the right front splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Side (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
15. Install the right front tire and wheel assembly. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2003-2006/remont/wheel-tire-system/#tires-wheels) in Tires and Wheels.
16. Install the lower closeout panel.
17. Lower the vehicle.
18. Fill the crankcase.
19. 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.

1. Disconnect the battery negative cable from the battery. 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. Remove the electrical connector from the engine oil pressure sensor.
3. Remove the engine oil pressure switch.

1. Install the engine oil pressure switch. Tighten: Tighten the switch to 16 N.m (12 lb ft).
2. Install the electrical connector to the engine oil pressure switch.
3. Connect the battery negative cable to the battery. 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 oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. Remove the oil pump bolt.
3. Remove the oil pump and the oil pump drive shaft.
4. Inspect the oil pump drive shaft and the oil pump. Refer to «Oil Pump Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__oil-pump-cleaning-and-inspection) .

1. Install the oil pump drive shaft and the oil pump.
2. Install the oil pump bolt. Tighten: Tighten the bolt to 41 N.m (30 lb ft).
3. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

Scheme 64

1. Remove the air intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L. Remove the oil pump drive bolt.
2. Remove the oil pump drive clamp.
3. Remove the oil pump drive.
4. Remove the oil pump drive seal.

1. Install the oil pump drive seal. Coat the seal or bore in the engine block with engine oil.
2. Coat the drive gear on the oil pump drive with prelube GM P/N 1052367 (Canadian P/N 992869) or the equivalent.
3. Install the oil pump drive.
4. Install the oil pump drive clamp.
5. Install the oil pump drive bolt. Tighten: Tighten the bolt to 36 N.m (27 lb ft).
6. Install the air intake duct. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.

J 35468 Cover Aligner and 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-35l-lx9__crankshaft-balancer-replacement) .
2. Remove the crankshaft key from the keyway.
3. Pry out the oil seal using a large screwdriver or the equivalent.
4. Inspect the following items for scratches: The front cover The crankshaft

1. Lubricate the oil seal using clean engine oil.
2. Insert the oil seal into the front cover with the lip facing the engine. Use the J 35468 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Install the crankshaft key into the keyway.
4. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__crankshaft-balancer-replacement) .

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. Drain the cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
3. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
5. Remove the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
6. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__crankshaft-balancer-replacement) .
7. Remove the thermostat bypass pipe from the engine front cover. Refer to «Thermostat Bypass Pipes Replacement»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
8. Remove the radiator outlet hose from the engine front cover. Refer to «Radiator Hose Replacement - Outlet (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
9. Remove the water pump from the engine front cover. Refer to «Water Pump Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
10. Remove the crankshaft position (CKP) sensor wiring harness bracket bolt.
11. Remove the CKP sensor wiring harness bracket.
12. Remove the engine front cover bolts.
13. Remove the engine front cover.
14. Remove the engine front cover gasket.
15. Clean and inspect the engine front cover. Refer to «Engine Front Cover Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-front-cover-cleaning-and-inspection) .
16. If replacing the engine front cover, remove the drive belt shield bolt and the drive belt shield.
17. If replacing the engine front cover remove the water pump. Refer to «Water Pump Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
18. If replacing the engine front cover, remove the 24X CKP sensor. Refer to «Crankshaft Position (CKP) Sensor Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.

1. If removed, install the 24X CKP sensor. Refer to «Crankshaft Position (CKP) Sensor Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
2. If removed install the water pump. Refer to «Water Pump Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
3. If removed, install the drive belt shield. Install the drive belt shield bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Apply sealant to both sides of the engine front cover gasket with GM P/N 12346004 (Canadian P/N 10953480) or equivalent.
5. Install the engine front cover gasket.
6. Install the engine front cover.
7. Install the engine front cover bolts (1, 2, and 3). Tighten: Tighten the small engine front cover bolts (1) to 27 N.m (20 lb ft). Tighten the large engine front cover bolts (2, 3) to 55 N.m (41 lb ft).
8. Install the CKP sensor wiring harness bracket.
9. Install the CKP sensor wiring harness bracket bolt. Tighten: Tighten the bolt to 27 N.m (20 lb ft).
10. Install the radiator outlet hose to the engine front cover. Refer to «Radiator Hose Replacement - Outlet (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
11. Install the thermostat bypass pipe to the engine front cover. Refer to «Thermostat Bypass Pipes Replacement»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
12. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__crankshaft-balancer-replacement) .
13. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
14. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
15. Fill the crankcase with new engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
16. Fill the cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
17. 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.
18. Perform the CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9__ckp-system-variation-learn-procedure) in Engine Controls - 3.5L.

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. Rotate the crankshaft until the timing marks in the following locations are aligned: The camshaft alignment pin (4). The timing chain dampener (1) to the crankshaft sprocket (2).
3. Remove the camshaft sprocket bolt.
4. Remove the camshaft sprocket with the timing chain.
5. Remove the crankshaft sprocket.
6. Remove the timing chain dampener bolts.
7. Remove the timing chain dampener.
8. If necessary, remove the camshaft thrust plate bolts.
9. Remove the camshaft thrust plate.
10. Clean and inspect the timing chain and the gears. Refer to «Timing Chain and Sprockets Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__timing-chain-and-sprockets-cleaning-and) .

1. If removed, install the camshaft thrust plate.
2. Install the camshaft thrust plate bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the crankshaft sprocket.
4. Apply engine oil supplement (EOS) GM P/N 1052367 (Canadian P/N 992869), or equivalent, to the sprocket thrust surface.
5. Install the timing chain dampener.
6. Install the timing chain dampener bolts. Tighten: Tighten the bolts to 21 N.m (15 lb ft).
7. Install the timing chain onto the camshaft gear.
8. Hold the camshaft sprocket with the chain hanging down, and install the chain to the crankshaft gear.
9. Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain dampener (1).
10. Align the timing mark on the camshaft gear, center line of the locator hole (4), with the timing mark on the top of the chain dampener (3).
11. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket (1).
12. Install the camshaft sprocket bolt. Tighten: Tighten the bolt to 140 N.m (103 lb ft).
13. Coat the crankshaft and camshaft sprocket with engine oil.
14. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

J 45059 Angle Meter

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 cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
3. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. Lower the vehicle.
5. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
6. Remove the valve rocker arms and the pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
7. Remove the exhaust crossover pipe. Refer to «Exhaust Crossover Pipe Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
8. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
9. Remove the left spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
10. Remove the left spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
11. Remove the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
12. Remove the left cylinder head bolts and discard.
13. Remove the left cylinder head.
14. Remove the left cylinder head gasket.
15. Clean and inspect the cylinder head and the gasket mating surfaces. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-block-cleaning-and-inspection) and «Cylinder Head Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__cylinder-head-cleaning-and-inspection) .

1. Install a new left cylinder head gasket.
2. Install the left cylinder head over the locator pins and the gasket.
3. Install the new cylinder head bolts. Tighten: Tighten the bolts in sequence to 60 N.m (44 lb ft). Use the J 45059 to rotate the bolts in sequence an additional 95 degrees.
4. Install the left exhaust manifold. Refer to «Exhaust Manifold Replacement - Left»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
5. Install the left spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
6. Install the left spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
7. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
8. Install the exhaust crossover pipe. Refer to «Exhaust Crossover Pipe Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
9. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
10. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
11. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
12. Fill the cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
13. Inspect for leaks.

J 36660-A Torque Angle Meter

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 cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
3. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. Lower the vehicle.
5. Remove the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
6. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
7. Remove the exhaust crossover pipe. Refer to «Exhaust Crossover Pipe Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) .
8. Remove the right spark plug wires from the spark plugs. Refer to «Spark Plug Wire Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
9. Remove the right spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
10. Remove the fuel line bracket bolt and the stud.
11. Remove the fuel line bracket.
12. Remove the generator. Refer to «Generator Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system__generator-replacement-lx9) in Engine Electrical.
13. Remove the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
14. Remove the right cylinder head bolts and discard.
15. Remove the right cylinder head.
16. Remove the right cylinder head gasket.
17. Clean and inspect the cylinder head and the gasket mating surfaces. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-block-cleaning-and-inspection) and «Cylinder Head Cleaning and Inspection»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__cylinder-head-cleaning-and-inspection) .

1. Install a new right cylinder head gasket.
2. Install the right cylinder head over the locator pins and the gasket.
3. Install the new cylinder head bolts Tighten: Tighten the bolts in sequence to 60 N.m (44 lb ft). Use the J 36660-A to rotate the bolts in sequence an additional 95 degrees.
4. Install the right exhaust manifold. Refer to «Exhaust Manifold Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) .
5. Install the generator. Refer to «Generator Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system__generator-replacement-lx9) in Engine Electrical.
6. Install the fuel line bracket.
7. Install the fuel line bracket bolt and the stud. Tighten: Tighten the bolt and the stud to 50 N.m (37 lb ft).
8. Install the right spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
9. Install the right spark plug wires to the spark plugs. Refer to «Spark Plug Wire Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
10. Install the exhaust crossover pipe. Refer to «Exhaust Crossover Pipe Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) .
11. Install the pushrods and valve rocker arms. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
12. Install the lower intake manifold. Refer to «Intake Manifold Replacement - Lower»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
13. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
14. Fill the cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
15. Inspect for leaks.

J 37096 Flywheel Holder. See Special Tools and Equipment .

1. Remove the automatic transaxle. 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. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Loosen the 6 flywheel bolts.
4. Remove 5 of the 6 flywheel bolts leaving one bolt at the top of the crankshaft rotation.
5. Grip the flywheel and remove the remaining bolt. Do not drop the flywheel when removing the final bolt.
6. Remove the engine flywheel retainer and the flywheel.
7. Clean the engine flywheel bolt threads and bolt holes.

1. Install the flywheel and the flywheel retainer.
2. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Install the engine flywheel bolts. Tighten: Tighten the bolts to 71 N.m (52 lb ft).
4. Measure the flywheel runout: Install a dial indicator on the engine block and inspect the engine flywheel runout at 3 attaching bosses. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9__engine-mechanical-specifications) . If the condition cannot be corrected, replace the engine flywheel.
5. Install the automatic transaxle. 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.

J 34686 Rear Main Seal Installer. See Special Tools and Equipment .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. Remove the crankshaft rear oil seal. Insert a flat-bladed tool or similar tool through the dust lip at an angle. Pry the crankshaft rear oil seal out by moving the handle of the tool towards the end of the crankshaft. Repeat, as necessary, around the crankshaft rear oil seal.

1. Carefully remove the protection sleeve from the new crankshaft rear oil seal.
2. Install the crankshaft rear oil seal into the J 34686 by sliding the crankshaft rear oil seal over the mandrel using a twisting motion until the back of the crankshaft rear oil seal bottoms squarely against the collar of the tool. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Install the J 34686 onto the rear of the crankshaft. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) . Hand tighten the screws in order to ensure the seal will be installed squarely over the crankshaft.
4. Install the crankshaft rear oil seal to the crankshaft.
5. Tighten the wing nut on the J 34686 until it bottoms. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
6. Remove the J 34686 from the crankshaft. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
7. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. Remove the camshaft rear bearing hole plug.

1. Coat the camshaft rear bearing hole plug with sealer GM P/N 12377901 (Canadian P/N 10953504) or equivalent.
2. Install the camshaft rear bearing hole plug.
3. Ensure that the camshaft rear bearing plug is installed to specifications.
4. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

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. Drain the cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
3. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. 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 - 3.5L.
5. Remove the hood. Refer to «Hood Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
6. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
7. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
8. Disconnect the following electrical connectors: The knock sensor (KS) The camshaft position (CMP) sensor The crankshaft position (CKP) sensor The heated oxygen sensor (HO2S) The manifold absolute pressure (MAP) sensor The exhaust gas recirculation (EGR) valve The evaporative emission (EVAP) canister purge solenoid The electronic throttle control The ignition coil The body wiring harness-to-engine harness
9. 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.
10. Remove the catalytic converters. Refer to «Catalytic Converter Replacement (Bank 1)»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) and «Catalytic Converter Replacement (Bank 2)»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
11. Remove the engine wiring harness grounds from the transaxle.
12. Remove the engine mount lower nuts.
13. Remove the torque converter covers. Refer to «Torque Converter, Turbine Shaft Seal Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
14. Remove the starter motor. Refer to «Starter Motor Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
15. Remove the air conditioning (A/C) compressor. DO NOT discharge the A/C system. Support the compressor. Refer to «Compressor Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation, and Air Conditioning.
16. Remove the torque converter bolts. Refer to «Torque Converter, Turbine Shaft Seal Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
17. Remove the transaxle brace.
18. Remove the lower transaxle-to-engine bolt (6) and the stud (1).
19. Remove the radiator outlet hose from the engine. Refer to «Radiator Hose Replacement - Outlet (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
20. Lower the vehicle and support the transaxle.
21. Remove the heater outlet and inlet hoses from the engine.
22. Remove the vacuum hoses from the upper intake manifold.
23. Remove the brake booster vacuum hose from the upper intake manifold.
24. Remove the fuel lines from the fuel rail. Refer to «Fuel Rail Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
25. Remove the radiator inlet hose from the engine. Refer to «Radiator Hose Replacement - Inlet (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
26. Install the engine lifting device to the engine.
27. Remove the upper transaxle-to-engine bolts (3, 4, 5) and the stud (2).
28. Remove the engine from the vehicle.
29. Remove the flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
30. Install the engine to the engine stand.

1. Remove the engine from the engine stand.
2. Install the flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Install the engine to the vehicle.
4. Install the upper transaxle-to-engine bolts (3, 4, 5) and the stud (2). Tighten: Tighten the bolts (3, 4, 5) and the stud (2) to 75 N.m (55 lb ft).
5. Remove the engine lifting device.
6. Install the radiator inlet hose to the engine. Refer to «Radiator Hose Replacement - Inlet (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
7. Install the fuel lines to the fuel rail. Refer to «Fuel Rail Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L.
8. Install the brake booster vacuum hose to the upper intake manifold.
9. Install the vacuum hoses to the upper intake manifold.
10. Install the heater inlet and outlet hoses to the engine.
11. Raise the vehicle and remove the transaxle support.
12. Install the radiator outlet hose to the engine. Refer to «Radiator Hose Replacement - Outlet (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
13. Install the lower transaxle-to-engine bolt (6) and the stud (1). Tighten: Tighten the bolt (6) and the stud (1) to 75 N.m (55 lb ft).
14. Install the transaxle brace. Tighten: Tighten the transmission-to-engine brace bolts to 72 N.m (53 lb ft).
15. Install the torque converter bolts. Refer to «Torque Converter, Turbine Shaft Seal Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-trans/#automatic-transaxle-4t40-e4t45-e-introduction-service-replacement) in Automatic Transaxle - 4T40-E/4T45-E.
16. Install the A/C compressor. Refer to «Compressor Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) in Heating, Ventilation, and Air Conditioning.
17. Install the starter motor. Refer to «Starter Motor Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
18. Install the torque converter covers. Refer to «Torque Converter, Turbine Shaft Seal 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 lower nuts. Tighten: Tighten the nuts to 43 N.m (32 lb ft).
20. Install the engine wiring harness grounds to the transaxle.
21. Install the engine wiring harness ground nut to the transaxle stud. Tighten: Tighten the nut to 35 N.m (26 lb ft).
22. Install the catalytic converters. Refer to «Catalytic Converter Replacement (Bank 1)»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) and «Catalytic Converter Replacement (Bank 2)»(/chevrolet/malibu/vi-2003-2006/remont/exhaust/#engine-exhaust-system) in Engine Exhaust.
23. Lower the vehicle.
24. Connect the following electrical connectors: The body wiring harness-to-engine harness The ignition coil The electronic throttle control The EVAP canister purge solenoid The EGR valve The MAP sensor The HO2S The CKP sensor The CMP sensor The KS
25. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
26. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
27. Install the hood. Refer to «Hood Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
28. 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 - 3.5L.
29. 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.
30. Fill the crankcase with engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
31. Fill cooling system. Refer to «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
32. Perform a CKP system variation learn procedure. Refer to «CKP System Variation Learn Procedure»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9__ckp-system-variation-learn-procedure) in Engine Controls - 3.5L.
33. Inspect for leaks.

1. Remove the negative battery cable.
2. 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.
3. Remove the oil pan bolt.
4. Remove the oil filter.

1. Install the oil filter.
2. Install the oil pan drain bolt. Tighten: Tighten the oil pan drain bolt to 26 N.m (19 lb ft). Lower the vehicle.
3. Fill the engine with oil to the appropriate mark.
4. Install negative battery cable.
5. Start engine and inspect for leaks.

Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain plug.
2. Drain the engine oil.
3. Remove the oil filter.
4. Remove the coolant drain plug from the left side.
5. Remove the coolant drain plug from the right side.
6. Drain the coolant.

Crankshaft Balancer Removal

Tools Required

1. J 41816-A Crankshaft Balancer Remover.
2. EN 46359 Puller End Protector. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

1. Remove the crankshaft balancer bolt and washer.
2. Remove the crankshaft balancer using the J 41816-A along with EN 46359 or equivalent. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

Engine Flywheel Removal

1. Remove the flywheel bolts.
2. Remove the flywheel.

Drive Belt Tensioner Removal

1. Remove the drive belt tensioner bolt.
2. Remove the drive belt tensioner.

Engine Lift Bracket and Generator Bracket Removal

1. Remove the generator bracket assembly bolts (230, 231, 232).
2. Remove the generator assembly bracket.
3. Remove the front engine lift hook.

Engine Mount Support and Strut Bracket Removal

1. Remove the engine mount support and strut bracket bolts.
2. Remove the engine mount support and strut bracket.

Engine Lift Bracket Removal - Rear

1. Remove the rear engine lift bracket bolts.
2. Remove the rear engine lift bracket.

Oil Level Indicator and Tube Removal

1. Remove the thermostat bypass pipe hose from the thermostat bypass pipe.
2. Remove the 16 pin connector.
3. Remove the spark plug wires from the spark plugs and set aside.
4. Remove the spark plug wire clip from the pipe.
5. Remove the heated oxygen sensor connector from pipe.
6. Remove the thermostat bypass pipe to throttle body nuts.
7. Remove the thermostat bypass pipe to throttle body bolt.
8. Remove the thermostat bypass pipe to engine front cover bolt.
9. Remove the thermostat bypass pipe.
10. Remove the oil level indicator tube bolt.
11. Remove the oil level indicator and oil level indicator tube.

Oil Filter Adapter Removal

1. Remove the oil filter adapter bolts.
2. Remove the oil filter adapter and gasket.
3. Remove the oil filter bypass hole plug.
4. Remove the oil filter bypass valve by prying out with a suitable tool.

Exhaust Manifold Removal - Left

1. Remove the heated oxygen sensor.
2. Remove the spark plugs.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
5. Remove the exhaust manifold nuts (1, 2, 3, 4, 5, 6).
6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.
8. Remove the exhaust studs, if required.

Exhaust Manifold Removal - Right

1. Remove the heated oxygen sensor.
2. Remove the spark plug wires.
3. Remove the spark plugs.
4. Remove the exhaust gas recirculation (EGR) pipe bolts from the exhaust manifold.
5. Remove the EGR pipe bolt at the EGR valve.
6. Remove the EGR pipe.
7. Remove the exhaust manifold heat shield bolts.
8. Remove the exhaust manifold heat shields.
9. Remove the exhaust manifold nuts (1, 2, 3, 4, 5, 6).
10. Remove the exhaust manifold.
11. Remove the exhaust manifold gasket.
12. Remove the exhaust studs, if required.

Water Outlet and Thermostat Removal

1. Remove the water outlet bolts.
2. Remove the water outlet.
3. Remove the thermostat.

Valve Rocker Arm Cover Removal - Left

1. Remove the positive crankcase ventilation (PCV) tube bolt and clip.
2. Remove the PCV tube.
3. Remove the valve rocker arm cover bolts.
4. Remove the valve rocker arm cover.
5. Trim valve cover gasket and sealant away from lower intake manifold gasket at the cylinder head to lower intake manifold joints (1).
6. Remove the valve rocker arm cover gasket.

Valve Rocker Arm Cover Removal - Right

Tools Required

J 37088-A Fuel Line Disconnect Tool Set. See Special Tools and Equipment .

Removal

1. Remove the fuel feed pipe bolts.
2. Remove the fuel feed pipe secondary latch.
3. Using J 37088-A remove the fuel feed pipe. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. Remove any remaining spark plug wires from their retainers.
5. Remove the ignition coil assembly bolts and nuts.
6. Remove the ignition coil assembly.
7. Remove the ignition coil assembly studs, if necessary.
8. Remove the positive crankcase ventilation tube from the valve rocker arm cover.
9. Remove the valve rocker arm cover bolts.
10. Remove the valve rocker arm cover.
11. Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
12. Remove the valve rocker arm cover gasket.

Intake Manifold Removal - Upper

1. Remove the connector from manifold absolute pressure (MAP) sensor.
2. Remove the exhaust gas recirculation (EGR) bolts.
3. Remove the EGR.
4. Remove the upper intake manifold bolts or studs.
5. Remove the upper intake manifold and gaskets.

Intake Manifold Removal - Lower

1. Remove the heater inlet pipe nut.
2. Remove the heater inlet pipe.
3. Remove the heater inlet pipe stud, if necessary.
4. Remove the fuel injector rail bolts.
5. Remove the fuel rail assembly.
6. Remove the lower intake manifold bolts.
7. Remove the lower intake manifold.

Valve Rocker Arm and Push Rod Removal

1. Loosen the valve rocker arm bolts.
2. Remove the valve rocker arms.
3. Remove the push rods. The intake push rods measure 144.18 mm (5.68 in). The exhaust push rods measure 152.51 mm (6.0 in).
4. Remove the intake manifold gaskets.

Valve Lifter Removal

1. Remove the valve lifter guide bolts.
2. Remove the valve lifter guides.
3. Remove the valve lifters.

Water Pump Removal

1. Remove the water pump pulley bolts.
2. Remove the water pump pulley.
3. Remove the water pump bolts.
4. Remove the water pump.
5. Remove the water pump gasket.

Scheme 65

1. Remove the cylinder head bolt and discards.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Remove the cylinder head locator dowel pins, if required.

Cylinder Head Removal - Right

1. Remove the cylinder head bolts and discard.
2. Remove the cylinder head.
3. Remove the cylinder head gasket.
4. Remove the cylinder head locator dowel pins, if required.

Oil Pan Removal

1. Remove the oil pan support bracket bolts and brackets as needed
2. Remove the oil pan side bolts.
3. Remove the oil pan bolts.
4. Remove the oil pan.
5. Remove the oil pan gasket.

Oil Pump Removal

1. Remove the oil pump bolt.
2. Remove the oil pump and oil pump drive shaft.
3. Remove the crankshaft oil deflector nuts.
4. Remove the crankshaft oil deflector.

Oil Pump Drive Removal

1. Remove the oil pump drive clamp bolt.
2. Remove the oil pump drive clamp.
3. Remove the oil pump drive.

Scheme 66

Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or the crankshaft.

Engine Front Cover Removal

1. Remove the engine front cover bolts (540, 541, 545).
2. Remove the engine front cover.
3. Remove the engine front cover gasket.

Timing Chain and Sprockets Removal

1. Remove the camshaft sprocket bolt.
2. Remove the camshaft sprocket and timing chain.
3. Remove the crankshaft sprocket.
4. Remove the timing chain dampener bolts.
5. Remove the timing chain dampener.

Camshaft Removal

1. Remove the camshaft position sensor bolt.
2. Remove the camshaft position sensor.
3. Remove the camshaft thrust plate screws.
4. Remove the camshaft thrust plate.
5. Complete the following steps in order to remove the camshaft. Install the camshaft sprocket bolt into the camshaft. Tighten finger tight only. Carefully rotate and remove the camshaft from the engine block.

Tools Required

1. J 24270 Cylinder Bore Ridge Reamer. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. J 41556 Connecting Rod Guide. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

1. Mark the piston with the number of the cylinder from which the piston is being removed.
2. Mark the connecting rod and the connecting rod cap in order to ensure correct assembly.
3. Use the J 24270 in order to remove the cylinder bore ring ridge. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) . Complete the following steps: Turn the crankshaft until the piston is at the bottom of the stroke. Cover the piston with a cloth. Remove the cylinder ring ridge. Turn the crankshaft until the piston is at the top of the stroke. Remove the cloth. Remove the metal shavings from the cylinder and piston.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap.
6. Remove the connecting rod bearing half.
7. Install J 41556 into the connecting rod. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
8. Remove the connecting rod and piston assembly from the engine with a suitable tool.

Crankshaft Rear Oil Seal Removal

1. Remove the crankshaft rear oil seal.
2. Pry out the crankshaft rear oil seal out using a suitable tool.

Crankshaft and Bearings Removal

1. Remove the crankshaft position sensor heat shield nut and heat shield.
2. Remove the crankshaft position sensor stud.
3. Remove the crankshaft position sensor from the side of the block.
4. Remove the crankshaft main bearing cap bolt and studs.
5. Remove the crankshaft main bearing caps and lower crankshaft main bearing halves.
6. Remove the crankshaft.
7. Remove the upper crankshaft main bearing halves.

Camshaft Bearing Removal

Tools Required

J 33049 Camshaft Bearing Remover/Installer. See Special Tools and Equipment .

1. Select the expander assembly and driving washer.
2. Assemble the J 33049 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Drive out the camshaft bearings. Use the J 33049 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

Engine Block Disassemble

1. Remove the camshaft rear bearing hole plug.
2. Remove the rear oil gallery plugs (102, 103).
3. Remove the front oil gallery plugs (107, 110, 137).
4. Remove the engine front cover locating pins (546).
5. Remove the piston oil nozzle bolt (424) and nozzle (423).
6. Remove the engine block plug, if applicable.
7. Remove the engine block heater, if applicable.
8. Remove the transmission locating pins.
9. Remove the knock sensors.
10. Remove the engine oil pressure indicator switch.

Engine Block Cleaning and Inspection

Tools Required

1. J 8001 Dial Indicator Set. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. J 8087 Cylinder Bore Gage

Scheme 67

1. Clean the sealing material from the gasket mating surfaces.
2. Boil the engine block in caustic solution.
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.
8. Clean the holes with a tap. Drill out the holes and install thread inserts, as needed.
9. Use a straight edge and a feeler gauge in order to test the deck surface for flatness. Replace the block if it is outside of the specification limit.
10. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file in order to remove any nicks.
11. Inspect the mating surfaces of the transmission case.
12. Use the following procedure in order to measure the engine block flange runout at the 6 mounting bolt hole bosses: Temporarily install the crankshaft. Measure the crankshaft flange runout. Hold the J 8001 gage plate flat against the crankshaft flange. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) . 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 0.25 mm (0.010 in). Retest the crankshaft flange runout if the readings vary more than 0.25 mm (0.010 in). If the crankshaft flange runout is not within the specification, replace the engine block.
13. Inspect the crankshaft main bearing bores. Use the J 8087 in order to measure the bearing bore concentricity and alignment at the following locations: The camshaft The crankshaft
14. Replace the engine block if the bores are out of specification.
15. Use the J 8087 in order to inspect the cylinder bores. Inspect the bores for the following conditions: Wear Taper Runout Ridging
16. Leave sufficient material in order to allow honing when fitting the piston.

Boring Procedure

1. Before honing or boring, measure all of the new pistons. Select the smallest piston for the piston fitting. Slightly varied pistons in a set may provide correction, if the first piston is too loosely fitted.
2. Before using any type of boring bar, file the top of the engine block to remove any dirt or burrs. If the cylinder block is not straight, the boring bar may be tilted, causing the bored cylinder wall to have incorrect right angles to the crankshaft.
3. Carefully follow the instructions furnished by the manufacturer regarding use of equipment.
4. Install all crankshaft main bearing caps to specification when boring cylinders. Cover or tape the crankshaft bearings and other internal parts to protect these parts during the boring or honing operation.
5. Leave 0.03 mm (0.001 in) on the diameter for finish honing when performing the final cut with a boring bar. Carefully perform the honing and boring operation to maintain the specified clearances between pistons, rings, and cylinder bores.

Honing Procedure

1. Follow the manufacturer's recommendations for use, cleaning, and lubrication when honing the cylinders. Use only clean, sharp stones of the proper grade for the amount of material to be removed. Dull, dirty stones cut unevenly and generate excessive heat. When using coarse or medium-grade stones, leave sufficient metal so all stone marks may be removed with the fine stones used for finishing to provide the proper clearance.
2. During the honing operation, thoroughly clean the cylinder bore. Check for the correct piston fit.
3. Make full strokes in the cylinder to eliminate taper. Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder bore.
4. When finish honing a cylinder bore to fit a piston, move the hone up and down at a sufficient speed to obtain a fine and uniform surface finish in a cross hatch pattern.
5. The finish marks should be clean but not sharp. The finish marks should be free from imbedded particles and torn or folded metal.
6. Determine the finish hone cylinder measurement by measuring the piston to be installed, and by adding the average of the clearance specification. Measure the block and the piston at normal room temperature.
7. True up the refinished cylinder bores. Final hone each cylinder bore to remove all stone or cutter marks.
8. After final honing and before the piston is checked for fit, clean the bores with hot water and detergent. Scrub the bores with a stiff bristle brush and rinse the bores thoroughly with hot water. Do not allow any abrasive material to remain in the cylinder bores. This abrasive material will wear the new rings, the cylinder bores, and the bearings lubricated by the contaminated oil. After washing dry the bore.
9. Permanently mark the piston for the cylinder to which the piston has been fitted.
10. Apply clean engine oil to each bore to prevent rusting.

Scheme 68

1. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil pressure switch threads.
2. Install the engine oil pressure switch. Tighten: Tighten the engine oil pressure switch to 16 N.m (12 lb ft).
3. Install the knock sensors. Tighten: Tighten the knock sensors to 25 N.m (18 lb ft).
4. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the engine block plug or engine block heater, if applicable.
5. Install the engine block plug or engine block heater, if applicable. Tighten: Tighten the engine block plug or engine block heater to 60 N.m (44 lb ft).
6. Install the transmission locating pins. The installation height should be 8.3-9.3 mm (0.327-0.366 in) (A).
7. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the front oil gallery plug threads (110, 137).
8. Install the front oil gallery plug (110). Tighten: Tighten the front oil gallery plug to 19 N.m (14 lb ft).
9. Install the front oil gallery plug (137). Tighten: Tighten the front oil gallery plug to 33 N.m (24 lb ft).
10. Apply sealer GM P/N 12377901 (Canadian P/N 10953504), or equivalent to the front oil gallery plug (107).
11. Install the front oil gallery plug (107) so that it is 2.3 mm (0.10 in) below flush of the engine block.
12. Install the engine front cover locating pins (546). The installation height should be 5.8-8.2 mm (0.228-0.323 in) (A).
13. Install the piston oil nozzle and bolt. Tighten: Tighten the piston oil nozzle bolt to 10 N.m (89 lb in).
14. Apply Sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the rear oil gallery plugs.
15. Install the rear oil gallery plugs (103). Tighten: Tighten the rear oil gallery plugs to 19 N.m (14 lb ft).
16. Install the rear oil gallery plugs (102). Tighten: Tighten the rear oil gallery plugs to 33 N.m (24 lb ft).
17. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the left and right coolant drain plug threads.
18. Install the left coolant drain plug. Tighten: Tighten the left coolant drain plug to 19 N.m (14 lb ft).
19. Install the right coolant drain plug. Tighten: Tighten the right coolant drain plug to 19 N.m (14 lb ft).

Crankshaft and Bearings Cleaning and Inspection

Tools Required

1. J 8087 Cylinder Bore Gage
2. J 45059 Angle Meter

1. Clean the crankshaft of the following elements: Oil Sludge Carbon
2. Inspect the crankshaft oil passages for obstructions.
3. Inspect the crankshaft keyway for the following conditions: A worn crankshaft key (1) A worn crankshaft keyway (2)
4. Inspect the crankshaft threads (3) for damage.
5. Inspect the crankshaft bearing journals and the crankshaft thrust surfaces for the following conditions: Wear without any grooves or scratches (1) Grooves or scoring (2) Scratches or excessive wear (3) Pitting or embedded bearing material (4)-Inspect the corresponding crankshaft bearing inserts for embedded material and determine the source of the material. Overheating or discoloration
6. The crankshaft bearings are the precision insert type.
7. Inspect the outer surfaces of the crankshaft bearings for the following conditions: Wear-surface wear indicates either movement of the insert, or high spots in the surrounding material - spot wear. Overheating or discoloration Looseness or rotation indicated by flattened tangs and wear grooves
8. Inspect the crankshaft main bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue.
9. Inspect the thrust surfaces of the main thrust bearing for the following conditions: Wear Grooving-Grooves are caused by irregularities of the crankshaft thrust surface.
10. Inspect the crankshaft bearings for excessive scoring or discoloration.
11. Inspect the crankshaft main bearings for dirt or imbedded debris.
12. Inspect the crankshaft main bearings for improper seating indicated by bright, polished sections.
13. Inspect the crankshaft bearings for uneven side-to-side wear. This may indicate a bent crankshaft or a tapered bearing journal.
14. Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure: Tighten the bearing cap to specification. Use the J 8087 in order to measure the bearing bore for taper and out-of-round. Record the readings for bearing selection. No taper or out-of-round should exist.

Bearing Selection

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.

1. Method A yields measurement from which the bearing clearance can be computed.
2. Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-out.

Method A

1. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements.
2. Measure the crankshaft bearing journal taper and runout.
3. Install the crankshaft bearing inserts. Tighten the bearing cap bolts to specification using J 45059 .
4. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.
5. Measure the crankshaft main bearing inside diameter with an inside micrometer.
6. Select a set of bearing inserts that will produce the desired clearance.
7. If the specified clearances cannot be met, the crankshaft journals must be reconditioned and undersized bearing inserts installed.

Method B

1. Clean the used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width.
4. 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.
5. Install the bearing cap bolts to specification using J 45059 .
6. 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.
7. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
9. Select a set of bearing inserts that will produce the desired clearance.

Crankshaft Balancer Cleaning and Inspection

1. Clean the crankshaft balancer in solvent.
2. Clean the belt grooves of all dirt or debris with a wire brush.
3. Inspect the crankshaft balancer for the following: IMPORTANT: A crankshaft balancer hub seal surface with excessive scoring, grooves, rust or other damage must be replaced. Minor imperfections on the hub seal surface may be removed with polishing compound or fine grade emery cloth. Worn, grooved, or damaged hub seal surface IMPORTANT: In order for the belt to track properly, the belt grooves should be free of all dirt, debris, nicks, gouges or other damage. Minor imperfections may be removed with a fine file. Dirty or damaged belt grooves. Worn, chunking or deteriorated rubber between the hub and pulley

Engine Flywheel Cleaning and Inspection

1. Clean the engine flywheel with solvent.
2. Dry the engine flywheel with compressed air.
3. Inspect the engine flywheel for the following: Damaged ring gear teeth Stress cracks around the flywheel-to-crankshaft bolt hole locations IMPORTANT: Do not attempt to repair the welded areas that retain the ring gear to the flywheel plate. Install a new flywheel. Welded areas that retain the ring gear onto the flywheel for cracking

Piston and Connecting Rod Disassemble

Tools Required

J 24086-C Piston Pin Remover/Installer Set. See Special Tools and Equipment .

Disassembly

1. Using piston ring pliers, remove the piston rings from the piston.
2. Install fork insert J 24086-310 into fixture J 24086-10 piston pin remover/installer base, which are part of J 24086-C . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Install the piston and connecting rod assembly onto J 24086-10.
4. Install the J 24086-107 onto the piston pin and J 24086-88A through the fixture and onto J 24086-107, which are part of J 24086-C . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
5. Press the piston pin from the piston and connecting rod assembly.
6. The piston and pin are a matched set and are not to be serviced separately. Mark, sort organize the piston and the matching piston pin.

Piston, Connecting Rod, and Bearings Cleaning and Inspection

Tools Required

J 8087 Cylinder Bore Gage

1. Clean the piston and connecting rod in solvent.
2. Dry off the piston and connecting rod with compressed air.
3. Clean the piston ring grooves with a suitable ring groove cleaning tool.
4. Clean the piston oil lubrication holes and slots.
5. Inspect the piston for the following: Eroded areas (1) on the top of the piston Scuffed or damaged skirt (2) Damage to the pin bore (3) Cracks in the piston ring lands, the piston skirt, or the pin bosses Piston ring grooves for nicks, burrs, or other warpage which may cause the piston ring to bind
6. Inspect the piston pin for scoring, wear or other damage.
7. Measure the piston ring-to-piston ring groove side clearance. Insert the edge of the piston ring into the piston ring groove. Roll the piston ring completely around the piston ring groove. If binding is caused by distorted piston ring groove, replace the piston. If binding is caused by a distorted piston ring, replace the piston ring.
8. Measure the piston ring side clearance with a feeler gage.
9. If the side clearance is too small try another ring set.
10. If the proper piston ring-to-piston ring groove clearance cannot be achieved, replace the piston and pin assembly. Proper ring-to-piston ring groove clearance for the top ring is 0.03-0.076 mm (0.001-0.003 in). Proper ring-to-piston ring groove clearance for the second ring is 0.04-0.078 mm (0.002-0.003 in).
11. Measure the piston pin diameter using and ouside micrometer.
12. Measure the piston pin bore using an inside micrometer.
13. Subtract the piston pin diameter from the piston pin bore diameter in order to determine the piston pin-to-piston pin bore clearance.
14. Piston-to-piston pin bore clearance must measure 0.008-0.016 mm (0.0003-0.0006 in). Replace the piston and the piston pin if the piston and the piston pin are not within specifications.
15. Measure the piston diameter with a micrometer at a right angle to the piston bore with the piston pin removed, and record the measurement. Measure the piston at 43 mm (1.692 in) from dome of piston. Piston diameter must measure no less than 93.960 mm (3.699 in). Replace the piston and the pin as an assembly if the piston is not within specifications.
16. Measure the cylinder bore, using J 8087 .
17. Measure the J 8087 . Record this reading.
18. Subtract the diameter of the piston from the diameter of the cylinder bore to determine the piston-to-bore clearance. The cylinder bore clearance must be no more than 0.080 mm (0.003 in).
19. If a used piston is not acceptable, inspect the service piston size and determine if a new piston may be selected. Service pistons are available in standard and 0.5 mm (0.012 in) oversize.
20. When a piston has been selected, mark the piston in order to identify the cylinder for which the piston was fitted.
21. Inspect the connecting rod for an out-of-round bearing bore. If the out-of-round measurement exceeds 0.005 mm (0.0002 in) the connecting rod must be replaced.
22. Inspect the connecting rod for twisting. Install the connecting rod cap. Place the connecting rod assembly on a checking fixture. Inspect the assembly for bending or twisting. Do not attempt to straighten the connecting rod. Ensure that the connecting rod meets the following conditions: The connecting rods are not bent more than 0.18 mm (0.007 in). The connecting rods are not twisted more than 0.38 mm (0.0015 in). Replace any bent or twisted connecting rods. Inspect the new connecting rods before using the new rods.
23. Inspect the connecting rod for damage to the bearing cap and bolt threads.
24. Measure the piston compression ring end gap. IMPORTANT: Fit each compression ring to the cylinder in which it will be used. Place the compression ring into the cylinder bore. Push the compression ring into the bottom of the cylinder bore to approximately 6.5 mm (0.25 in) above ring travel. The ring must be square to the cylinder wall. Use a feeler gage in order to measure the end gap. The first compression ring end gap must measure 0.18-0.39 mm (0.007-0.015 in), the second compression ring must measure 0.48-0.74 mm (0.019-0.029 in). Select another size ring set if the end gap exceeds specifications. If ring gap clearance is below specifications, increase the gap by carefully filing off excess material.
25. Inspect the connecting rod bearings for craters or pockets. Flattened sections on the connecting rod bearing halves may indicate fatique.
26. Inspect the connecting rod bearings for excess scoring or discoloration.
27. Inspect the connecting rod bearings for dirt or debris imbedded into the connecting rod bearing halves.
28. Inspect the connecting rod bearings for improper seating indicated by bright, polished sections of the bearings.
29. Inspect the inside of the connecting rod bearing and the outside diameter of the connecting rod bearing journal for wear. This indicates high spots.

Piston and Connecting Rod Assemble

Tools Required

J 24086-C Piston Pin Remover/Installer Set. See Special Tools and Equipment .

Assembly

1. Install fork insert J 24086-310 into fixture J 24086-10, which are part of J 24086-C . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. Lubricate the piston pin with clean engine oil.
3. Assemble the piston, connecting rod and adapter J 24086-6A and install onto fixture J 24086-10, which are part of J 24086-C . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. Adjust installation pin J 24086-9 to G-4.
5. Insert pin J 24086-9 through fixture J 24086-10, which are part of J 24086-C and to the piston pin. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
6. Press pin J 24086-9 until it bottoms on fixture J 24086-10.
7. Using piston ring pliers, install the piston rings onto the piston. Install the oil control ring spacer into the bottom groove of the piston. Install the lower oil control ring. The oil control rings do not have a dimple or orientation mark and may be installed in either direction. Install the upper oil control ring. Install the middle compression ring with the dot facing up. Install the top compression ring in either direction. The ring has no orientation markings.

Camshaft and Bearings Cleaning and Inspection

Tools Required

J 7872 Magnetic Base Dial Indicator Set

1. Clean the camshaft with cleaning solvent.
2. Inspect the camshaft for the following conditions: Scored camshaft bearing journals (1) Damaged camshaft lobes (2) Damaged camshaft sprocket locator pins (3) Damaged threads (4) Damage to the camshaft reluctor tooth (5)
3. Measure the camshaft journals using a micrometer. If the camshaft journals are not within specifications, replace the camshaft.
4. Measure the camshaft runout using the J 7872 . Mount the camshaft in V-blocks between the centers. Use the J 7872 in order to measure the intermediate camshaft journal.
5. Measure the camshaft lobe lift using the J 7872 . Lubricate the camshaft using GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent. Set the camshaft on V-blocks. Use the J 7872 in order to measure the lobe lift.
6. If the runout or lobe lift is not within specifications, replace the camshaft.

Timing Chain and Sprockets Cleaning and Inspection

1. Clean all components with cleaning solvent.
2. Dry the components with compressed air.
3. Inspect the timing chain for binding or wear.
4. Inspect the camshaft and crankshaft sprockets for: Worn teeth (1) Broken teeth (2) Chipped teeth (3)
5. Inspect the timing chain dampener for excessive wear or cracks.

Valve Lifters Cleaning and Inspection

1. Clean the valve lifters in cleaning solvent.
2. Dry the valve lifters with compressed air.
3. Inspect the valve lifters for the following: Bent or broken clip (1) Worn push rod socket (2) Scuffed or worn sides (3) If the valve lifter shows wear, inspect the engine block lifter bores for wear or damage. Flat spots on the roller (4) Loose or damaged pin (5) Plugged oil hole (6) Worn or damaged roller bearing The roller should rotate freely with no binding or roughness.
4. Inspect the valve lifter guides for the following: For cracks or damage Excessive wear in the lifter mounting bores

Valve Rocker Arm and Push Rods Cleaning and Inspection

1. Clean the valve rocker arms and push rods in cleaning solvent.
2. Dry the valve rocker arms and push rods with compressed air.
3. Inspect the valve rocker arms for the following conditions: Excessive wear at the valve contact or push rod socket area (1) A loose or damaged pin (2) A worn or damaged roller bearing (2) The roller should rotate freely with no binding or roughness. The bolt threads for damage
4. Inspect the push rods for the following conditions: Straightness using a straight edge (1) Excessive wear on the push rod ends (3) Clogging of the oil passage (2)

Cylinder Head Disassemble

Tools Required

J 38606 Valve Spring Compressor. See Special Tools and Equipment .

1. Remove the heater inlet pipe stud from the right cylinder head, if required.
2. Remove the coolant temperature sensor from the right cylinder head, if required.
3. Compress the valve springs using the J 38606 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. Remove the valve spring cap keys.
5. Remove the valve spring caps.
6. Remove the valve springs.
7. Remove the valves.
8. Remove the valve stem oil seals and spring seats as an assembly.

Cylinder Head Cleaning and Inspection

Tools Required

1. J 8089 Carbon Removing Brush. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. J 9666 Valve Spring Tester

1. Inspect the cylinder head gasket and the mating surfaces. Inspect for leaks, corrosion, and blowby.
2. If the gasket failed, determine the cause. The following conditions may cause gasket failure: Improper installation A loose or warped cylinder head Missing, off location, or not fully seated dowel pins Low torque on the cylinder head bolts Cylinder head bolts with the incorrect length A warped engine block surface Scratched surfaces Excessive intake manifold torque Cracked engine block threaded holes
3. Use the J 8089 in order to remove the carbon from the combustion chambers. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. Clean the following components: The gasket surfaces Do not use a motorized brush on any gasket sealing surface. Valve stems and heads on a buffing wheel The bolt hole threads Remove all dirt, debris, or threadlocking material from the bolt holes.
5. Inspect the cylinder head mating surfaces for flatness. Replace the cylinder head if it is outside of the specification limit.
6. Inspect the cylinder head for cracks.
7. Inspect the cylinder head deck for corrosion. Do not attempt to weld the cylinder head. If the cylinder head is damaged, replace the cylinder head.
8. Inspect the valve springs for squareness.
9. Use the J 9666 in order to measure the valve spring tension. Replace the spring if the spring tension is not within specification.

Valve Guide Reaming/Valve and Seat Grinding

Tools Required

J 8520 Camshaft Lobe Lift Indicator Set. See Special Tools and Equipment .

1. Inspect the valves for the following conditions: Burnt or eroded areas (1) A worn margin (2) A bent stem (3) A worn or scored stem (4) A worn key groove (5) A worn stem tip (6)
2. Inspect the valve face for the following conditions: Worn margin (4) No margin (1) Pitted surfaces (2) Burnt or eroded areas (3)
3. Inspect the valve seats for a loose fit in the cylinder head.
4. Inspect for excessive valve stem (1) to guide (2) clearance.
5. Use a dial indicator in order to measure the valve stem-to-guide clearance. Complete the following steps: Install the valve into the guide. Install the J 8520 onto the cylinder head. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) . Locate the dial indicator so that the movement of the valve stem from side to side, crosswise to the cylinder head, will cause a direct movement on the indicator stem. Ensure that the indicator stem contacts the side of the valve stem just above the valve guide. Drop the valve head about 2 mm (1/8 in) off the valve seat. Use light pressure and move the valve stem side to side in order to obtain a clearance reading. If the valve stem to guide clearance is not within specification, replace the valve and/or repair the guide in order to obtain the proper clearances.
6. Ream the valve guides for oversize valves if the clearance exceeds the specifications.
7. Ream the valve guide in order to obtain the proper specification.
8. Inspect the valves for excessive scoring.
9. Inspect the valve face. Replace the valve if the valve margin is not within specifications after grinding.
10. Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the head and the stem.
11. Recondition the valve seats after reaming the valve guide bores or installing the new valve guides.
12. The valve seats should be concentric to within 0.05 mm (0.031 in) total indicator reading.

J 38606 Valve Spring Compressor. See Special Tools and Equipment .

1. Lubricate the valve stem with clean engine oil.
2. Install the valves.
3. Lightly tap the new or reconditioned valves into the valve seat.
4. Install the valve stem oil seals.
5. Install the valve springs.
6. Install the valve spring caps.
7. Compress the valve springs using the J 38606 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
8. Install the valve spring cap keys. Hold the valves in place with grease, if necessary.
9. Release the valve springs.
10. Ensure that the valve locks are seated.
11. Measure valve spring installed height.
12. If the valve spring installed height is not within specifications install 0.25 mm (0.010 in) rocker arm shims P/N 88894006 as needed. If more than 2 shims are needed replace the cylinder head or valve.
13. Apply sealer P/N 21485278 to the coolant temperature sensor.
14. Install the coolant temperature sensor, if required. Tighten: Tighten the coolant temperature sensor to 23 N.m (17 lb ft).
15. Install the heater inlet pipe stud, if required. Tighten: Tighten the heater inlet pipe stud to 35 N.m (26 lb ft).

Oil Pump Disassemble

1. Remove the oil pump driveshaft and oil pump driveshaft retainer.
2. Remove the oil pump screen, if necessary. The oil pump screen has a press fit into the oil pump cover.
3. Remove the oil pump cover bolts.
4. Remove the oil pump cover.
5. Remove the oil pump drive gear and the oil pump driven gear.
6. Matchmark the gear teeth for assembly.
7. Remove the following items: The oil pump pressure relief valve spring straight pin. The oil pump pressure relief spring. CAUTION: Refer to Cleaning Solvent Caution in Cautions and Notices. The oil pump pressure relief valve. If the valve is stuck, soak the pump housing in cleaning solvent.

Oil Pump Cleaning and Inspection

1. Clean all parts of sludge, oil, and varnish by soaking in cleaning solvent.
2. Inspect for foreign material and determine the source of the foreign material.
3. Inspect the pump housing and cover for the following conditions: Cracks or casting imperfections Scoring (3) Damaged threads
4. Do not attempt to repair the pump housing. Replace the pump housing.
5. Inspect the oil pump gears for the following conditions: Scoring (1) Excessive wear (2)
6. Inspect the idler shaft for looseness or scoring (4). If loose or damaged, replace the oil pump.
7. Inspect the drive gear shaft for looseness or scoring (5).
8. Inspect the pressure regulator valve for the following conditions: Scoring Sticking Burrs may be removed using a fine oil stone.
9. Inspect the pressure regulator valve spring for the following conditions: Loss of tension Bending
10. Inspect the suction pipe and screen assembly for the following conditions: Looseness If the suction pipe is loose, bent or has been removed, replace the pump body cover and suction pipe. Broken wire mesh or screen
11. Measure the oil pump gear lash. Install the gears, and measure in several places.
12. Measure the oil pump housing gear pocket (1, 2).
13. Measure the oil pump gears (1, 2).
14. Measure the oil pump gear side clearance.

Oil Pump Assemble

Tools Required

1. J 21882 Oil Suction Pipe Installer. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. J 22144 Oil Suction Pipe Installer. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

1. Lubricate all the internal oil pump parts using engine oil during assembly.
2. Install the oil pump gears.
3. Install the oil pump cover.
4. Install the oil pump cover bolts. Tighten: Tighten the oil pump cover bolts to 10 N.m (89 lb in).
5. Install the pressure regulator valve.
6. Install the pressure regulator spring.
7. Install the cotter pin.
8. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the new suction pipe.
9. Tap the new suction pipe into place using a plastic hammer. Use the J 21882 for 5/8 inch pipe or J 22144 for 3/4 inch pipe. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

Engine Front Cover Cleaning and Inspection

1. Clean the engine front cover with solvent.
2. Dry the engine front cover with compressed air.
3. Inspect the engine front cover sealing surfaces for damage.
4. Inspect the engine front cover threaded holes.
5. Repair or replace the engine front cover as needed.

Valve Rocker Arm Cover Cleaning and Inspection

1. Remove all rubber grommets from the valve rocker arm covers.
2. Inspect the rubber grommets, if cracked or torn replace.
3. Clean the valve rocker arm covers with solvent.
4. Dry the valve rocker arm covers with compressed air.
5. Inspect the valve rocker arm covers for damage and replace if necessary.
6. Install all rubber grommets into the valve rocker arm covers.

Oil Pan Cleaning and Inspection

1. Clean the oil pan with solvent. Remove all sludge and debris from the oil pan.
2. Dry the oil pan with compressed air.
3. Inspect the oil pan sealing surface for damage and replace if necessary.

Intake Manifold Cleaning and Inspection - Lower

Tools Required

J 21882 Oil Suction Pipe Installer. See Special Tools and Equipment .

1. Remove the intake manifold coolant pipe bolt, if required.
2. Remove the intake manifold coolant pipe, if required.
3. Clean the intake manifold gasket mating surfaces using GM P/N 12346139 (Canadian P/N 10953463) or equivalent.
4. Clean the fuel injector bores.
5. Inspect the intake manifold for damage.
6. Repair or replace the intake manifold as necessary.
7. Apply sealant GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the end of the intake manifold coolant pipe, if required.
8. Install the intake manifold coolant pipe using J 21882 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
9. Install the intake manifold coolant pipe bolt. Tighten: Tighten the intake manifold coolant pipe bolt to 10 N.m (89 lb in).

Intake Manifold Cleaning and Inspection - Upper

1. Remove the throttle body bolts.
2. Remove the throttle body.
3. Remove the throttle body studs, if required.
4. Remove the manifold absolute pressure (MAP) sensor bolt and clip.
5. Remove the MAP sensor.
6. Remove the evaporative emissions (EVAP) purge valve bolt.
7. Remove the EVAP purge valve.
8. Clean the intake manifold with solvent.
9. Dry the intake manifold with compressed air.
10. Inspect all gasket mating surfaces for nicks or cracks and replace if necessary.
11. Inspect the EVAP purge valve seal for damage and replace if necessary.
12. Install the EVAP purge valve.
13. Install the EVAP purge valve bolt. Tighten: Tighten the EVAP purge valve bolt to 16 N.m (12 lb ft).
14. Inspect the MAP sensor seal for damage and replace if necessary.
15. Install the MAP sensor.
16. Install the MAP sensor clip and bolt. Tighten: Tighten the MAP sensor bolt to 10 N.m (89 lb in).
17. Install the throttle body studs, if required. Tighten: Tighten the throttle body studs to 6 N.m (53 lb in).
18. Inspect the throttle body seal for damage and replace if necessary.
19. Install the throttle body.
20. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) to the throttle body bolt threads.
21. Install the throttle body bolts. Tighten: Tighten the throttle body bolts to 10 N.m (89 lb in).

Exhaust Manifold Cleaning and Inspection

1. Clean the exhaust manifold and heat shield in solvent.
2. Dry the exhaust manifold and heat shield with compressed air.
3. Inspect the exhaust manifold for cracks or damage.

Water Pump Cleaning and Inspection

1. Remove all gasket material from the sealing surface.
2. Inspect the water pump impeller for damage.
3. Inspect the water pump shaft for looseness.
4. Replace the water pump if necessary.

Thread Repair

General purpose thread repair kits are available commercially.

1. Determine the size, the pitch, and the depth of the damaged thread.
2. Adjust the stop collars on the cutting tool as needed. Tap the stop collars to the required depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread.
6. Use the tap in order to cut new thread.
7. Clean the thread.
8. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the thread insert onto the end of the mandrel.
9. Lubricate the thread insert with clean engine oil - except when installing in aluminum - and install the thread insert.
10. If the tang of the thread insert does not break off when backing out the thread insert installer, break off the tang using a drift punch.

Service Prior to Assembly

Dirt will cause premature wear of the rebuilt engine. Clean all of the components. Use the proper tools in order to measure components when inspecting for excessive wear. Repair or replace the components that are not within the manufacturers specification. When components are reinstalled into an engine, return the components to their original location, position, and direction. During assembly, lubricate all of the moving parts with clean engine oil or engine assembly lubricant unless otherwise specified. This will provide initial lubrication when the engine is first started.

Engine Prelubing

Tools Required

J 45299 Engine Preluber

1. Remove the engine oil filter, fill with clean engine oil, and reinstall. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
2. Locate the engine oil pressure indicator switch on the left side of the engine and remove.
3. Install the 1/4 inch adapter P/N 509373.
4. Install the flexible hose to the adapter and open the valve.
5. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
6. Close the valve and remove the flexible hose and adapter from the engine.
7. Install the engine oil pressure indictor switch. Tighten: Tighten the engine oil pressure indictor switch to 16 N.m (12 lb ft).
8. Top off the engine oil to the proper level.

Camshaft Bearing Installation

Tools Required

J 33049 Camshaft Bearing Remover/Installer

Installation

1. Assemble the J 33049 according to the manufacturer's instructions.
2. Install the camshaft bearings in the following order: Index the camshaft bearing oil holes with the engine block oil passages. Place the bearing on the J 33049 . Install the third camshaft bearing. Install the second camshaft bearing. Install the outer camshaft bearings.
3. Apply sealer GM P/N United States 12377901, GM P/N Canada 10953504 or the equivalent to the camshaft rear bearing hole plug.
4. Install the camshaft rear bearing hole plug.

Crankshaft and Bearings Installation

Tools Required

J 45059 Angle Meter

1. Dip the crankshaft bearing cap bolts in clean engine oil.
2. Place the crankshaft bearing inserts into the crankshaft bearing cap and into the engine block.
3. Lubricate the crankshaft main bearing surface with clean engine oil.
4. Install the crankshaft.
5. Install the crankshaft main bearing caps. Apply a small amount of sealer GM P/N 1052942 (Canadian P/N 10953466) to the rear of the #4 crankshaft main bearing cap sealing surface.
6. Install the crankshaft main bearing cap bolts. Tighten: Use the J 45059 in order to tighten the crankshaft main bearing cap bolts to 50 N.m (37 lb ft) plus 77 degrees.
7. Measure the crankshaft end play. Thrust the crankshaft forward or rearward. Insert a feeler gage between the number 3 crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance. The proper crankshaft end play clearance is 0.06-0.21 mm (0.002-0.008 in). If the bearing clearance is not within specifications, inspect the thrust surfaces for nicks, gouges or raised metal. Minor inperfections may be removed with a fine stone.
8. Install the crankshaft position sensor into the side of the engine block.
9. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the crankshaft position sensor stud threads.
10. Install the crankshaft position sensor stud. Tighten: Tighten the crankshaft position sensor stud to 11 N.m (98 lb in).
11. Install the crankshaft position sensor shield and nut. Tighten: Tighten the crankshaft position sensor shield nut to 11 N.m (98 lb in).

Crankshaft Rear Oil Seal Installation

Tools Required

J 34686 Rear Main Seal Installer. See Special Tools and Equipment .

1. Carefully remove the protection sleeve from the new crankshaft rear oil seal.
2. Install the crankshaft rear oil seal onto the J 34686 by sliding the crankshaft rear oil seal over the mandrel using a twisting motion until the back of the crankshaft rear oil seal bottoms squarely against the collar of the tool. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
3. Perform the following steps in order to install the crankshaft rear oil seal: Align the dowel pin of the J 34686 with the dowel pin in the crankshaft. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) . Attach the J 34686 to the crankshaft by hand, or tighten attaching screws to 5 N.m (45 lb in). See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) . Turn the T-handle of the J 34686 in order to engage allow the collar to push the seal into the bore. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) . Turn the handle until the collar is tight against the engine block. Ensure that the seal is seated properly. Loosen the T-handle until the T-handle comes to a stop. Remove the attaching screws.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 Ring Compressor
2. J 45059 Angle Meter
3. J 41556 Connecting Rod Guide. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

1. Lightly lubricate the following components with clean engine oil: The piston The piston rings The cylinder bore The bearing surfaces
2. Stagger the oil control ring end gaps a minimum of 90 degrees.
3. Stagger the compression ring end gaps a minimum of 25 mm (1.0 in).
4. Install the J 8037 onto the piston and compress the piston rings.
5. Install the J 41556 into the connecting rod. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
6. Install the piston and connecting rod assembly into the proper cylinder bore.
7. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore.
8. Using J 41556 , guide the connecting rod end onto the crankshaft journal. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
9. Install the bearing, bearing cap and bolts. Tighten: Tighten the connecting rod bearing cap bolts a first pass to 25 N.m (18 lb ft). Tighten the connecting rod bearing cap bolts a final pass to 110 degrees using the J 45059 .
10. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankpin to make sure that the rods have side clearance.
11. Measure the connecting rod side clearance using a feeler gage or dial indicator. Connecting rod side clearance should be within 0.18-0.44 mm (0.007-0.017 in).

Camshaft Installation

1. Coat the camshaft journals with clean engine oil.
2. Coat the camshaft lobes with prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
3. Install the camshaft using the following procedure: Install the camshaft sprocket bolt into the camshaft. Tighten finger tight only. Carefully rotate the camshaft while installing the camshaft into the camshaft bearings.
4. Install the camshaft thrust plate.
5. Install the camshaft thrust plate screws. Tighten: Tighten the camshaft thrust plate screws to 10 N.m (89 lb in).
6. Install the camshaft position sensor.
7. Install the camshaft position sensor bolt. Tighten: Tighten the camshaft position sensor bolt to 10 N.m (89 lb in).

Timing Chain and Sprockets Installation

1. Install the crankshaft sprocket.
2. Apply prelube GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent to the crankshaft sprocket thrust surface.
3. Install the timing chain dampener.
4. Install the timing chain dampener bolts. Tighten: Tighten the timing chain dampener bolt to 21 N.m (15 lb ft).
5. Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain dampener (1).
6. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
7. Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain dampener (3).
8. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket.
9. Draw the camshaft sprocket onto the camshaft using the mounting bolt.
10. Coat the crankshaft and camshaft sprocket with engine oil. Tighten: Tighten the bolt to 140 N.m (103 lb ft).

Engine Front Cover Installation

1. Install the engine front cover gasket.
2. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to both sides of the lower tabs of the engine front cover gasket. Apply the sealer no less than 5.0 mm (0.20 in) wide.
3. Install the engine front cover.
4. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the bolts in the locations pointed out in the graphic.
5. Install the engine front cover bolts (545). Tighten: Tighten the engine front cover bolts to 27 N.m (20 lb ft).
6. Install the engine front cover bolts (540, 541). Tighten: Tighten the engine front cover bolts to 55 N.m (41 lb ft).

Crankshaft Front Oil Seal Installation

Tools Required

J 35468 Cover Aligner and Seal Installer. See Special Tools and Equipment .

1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .

Oil Pump Drive Installation

1. Apply prelube GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent to the oil pump drive gear.
2. Apply engine oil to the oil pump drive gear assembly for ease of assembly.
3. Install the oil pump drive gear assembly.
4. Install the oil pump drive gear clamp.
5. Install the oil pump drive gear clamp bolt. Tighten: Tighten the oil pump drive gear clamp bolt to 36 N.m (27 lb ft).

Oil Pump Installation

1. Install the crankshaft oil deflector.
2. Install the crankshaft oil deflector nuts. Tighten: Tighten the crankshaft oil deflector nuts to 25 N.m (18 lb ft).
3. Install the oil pump.
4. Position the oil pump onto the pins.
5. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap. Tighten: Tighten the oil pump bolt to 41 N.m (30 lb ft).

Oil Pan Installation

1. Apply sealer GM P/N 12378521, (Canadian P/N 88901148) or the equivalent to both sides of the crankshaft rear main bearing cap (1). Press sealer into gap using a putty knife.
2. Install the oil pan gasket.
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 oil pan side bolts. Tighten: Tighten the oil pan side bolts to 50 N.m (37 lb ft).
6. Install the oil pan drain plug. Tighten: Tighten the oil pan drain to 25 N.m (18 lb ft).

Cylinder Head Installation - Left

Tools Required

J 45059 Angle Meter

Installation - Left

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head.
5. Install the new cylinder head bolts. Tighten: Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft). Tighten the cylinder head bolts a final pass in sequence to 95 degrees using the J 45059 .

Cylinder Head Installation - Right

Tools Required

J 45059 Angle Meter

Installation - Right

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head.
5. Install the new cylinder head bolts. Tighten: Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft). Tighten the cylinder head bolts a final pass in sequence to 95 degrees using the J 45059 .

Scheme 69

1. Install the water pump gasket.
2. Install the water pump.
3. Install the water pump bolts. Tighten: Tighten the water pump bolts to 10 N.m (89 lb in).
4. Install the water pump pulley.
5. Install the water pump pulley bolts. Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb ft).

Scheme 70

1. Coat the valve lifters using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
2. Install the valve lifters in their original locations.
3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the threads.
4. Install the valve lifter guides and guide bolts. Tighten: Tighten the valve lifter guide bolts to 10 N.m (89 lb in).

Valve Rocker Arm and Push Rod Installation

1. Install the lower intake manifold gaskets.
2. Coat the ends of the push rods using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
3. Install the push rods in their original location.
4. Coat the rocker arm friction surfaces using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
5. Install the valve rocker arms in their original positions.
6. Install the valve rocker arm bolts. Tighten: Tighten the valve rocker arm bolts to 32 N.m (24 lb ft).

Scheme 71

1. With gaskets and seals in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the 4 corners of the intake manifold to block joints (1).
2. Install the lower intake manifold.
3. Apply sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the lower intake manifold bolt threads.
4. Install the lower intake manifold bolts. Tighten: Tighten the center lower intake manifold bolts (1, 2, 3, 4) in sequence to 20 N.m (15 lb ft). Tighten the visible corner lower intake manifold bolts (5, 8,) to 25 N.m (18 lb ft). Tighten the hidden corner lower intake manifold bolts (6, 7) to 25 N.m (18 lb ft).
5. Inspect the heater inlet pipe and seal for damage and replace if necessary.
6. Install the heater inlet pipe stud, if necessary. Tighten: Tighten the heater inlet pipe stud to 35 N.m (26 lb ft).
7. Install the heater inlet pipe.
8. Install the heater inlet pipe nut. Tighten: Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).
9. Inspect the fuel rail, fuel injectors, and fuel injector O-rings for damage and replace if necessary.
10. Lubricate the fuel injector O-ring using GM P/N 12345616 (Canadian P/N 993182) or equivalent.
11. Install the injector nozzles into the lower intake manifold injector bores.
12. Press on the injector rail using the palms of both hands until the injectors are fully seated.
13. Install the fuel injector rail bolts. Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).

Intake Manifold Installation - Upper

1. Install the upper intake manifold gaskets and manifold.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the upper intake manifold bolt threads.
3. Install the upper intake manifold bolts and stud. Tighten: Tighten the upper intake manifold bolts and stud to 25 N.m (18 lb ft).
4. Install the exhaust gas recirculation (EGR) gasket and EGR.
5. Install the EGR bolts. Tighten: Tighten the EGR bolts to 30 N.m (22 lb ft).
6. Reconnect the manifold absolute pressure (MAP) sensor.

Valve Rocker Arm Cover Installation - Left

1. Install the valve rocker arm cover gasket into the valve rocker arm cover.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the surfaces where the cylinder head and intake manifold meet (1).
3. Install the valve rocker arm cover.
4. Install the valve rocker arm cover bolts, if necessary. Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
5. Install the PCV tube.
6. Install the PCV clip and tube bolt. Tighten: Tighten the PCV tube bolt to 10 N.m (89 lb in).

Valve Rocker Arm Cover Installation - Right

1. Install the valve rocker arm cover gasket into the valve rocker arm cover.
2. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the surfaces where the cylinder head and intake manifold meet (1).
3. Install the valve rocker arm cover.
4. Install the valve rocker arm cover bolts, if necessary. Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
5. Install the Positive Crankcase Ventilation (PCV) tube into the valve rocker arm cover.
6. Install the ignition coil assembly studs, if necessary. Tighten: Tighten the ignition coil assembly studs to 25 N.m (18 lb ft).
7. Install the ignition coil assembly.
8. Install the ignition coil assembly bolts and nuts. Tighten: Tighten the ignition coil assembly bolts and nuts to 25 N.m (18 lb ft).
9. Install the fuel feed pipe.
10. Install the fuel feed pipe secondary latch.
11. Install the fuel feed pipe bolts. Tighten: Tighten the fuel feed pipe bolts to 10 N.m (89 lb in).

Water Outlet and Thermostat Installation

1. Install the thermostat.
2. Install the water outlet.
3. Install the water outlet bolts. Tighten: Tighten the water outlet bolts to 25 N.m (18 lb ft).

Exhaust Manifold Installation - Left

1. Install the exhaust manifold studs, if required. Tighten: Tighten the exhaust manifold studs to 18 N.m (13 lb ft).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold.
4. Install the exhaust manifold nuts. Tighten: Tighten the exhaust manifold nuts in sequence to 16 N.m (12 lb ft).
5. Install the exhaust manifold heat shield.
6. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
7. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft) when installing spark plugs into a new cylinder head. Tighten the spark plugs to 15 N.m (13 lb ft) when installing spark plugs after initial installation.
8. Install the spark plug wires.
9. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).

Exhaust Manifold Installation - Right

1. Install the exhaust manifold studs, if required. Tighten: Tighten the exhaust manifold studs to 18 N.m (13 lb ft).
2. Install the exhaust manifold gasket.
3. Install the exhaust manifold.
4. Install the exhaust manifold nuts. Tighten: Tighten the exhaust manifold nuts in sequence to 16 N.m (12 lb ft).
5. Install the exhaust manifold heat shield.
6. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
7. Install the Exhaust Gas Recirculation (EGR) pipe.
8. Install the EGR pipe bolt to the EGR Valve. Tighten: Tighten the EGR pipe bolt to 25 N.m (18 lb ft).
9. Install the EGR pipe bolts to the exhaust manifold. Tighten: Tighten the EGR pipe bolts to 30 N.m (22 lb ft).
10. Install the spark plugs. Tighten: Tighten the spark plugs to 20 N.m (15 lb ft) when installing spark plugs into a new cylinder head. Tighten the spark plugs to 15 N.m (13 lb ft) when installing spark plugs after initial installation.
11. Install the spark plug wires.
12. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).

Oil Filter Adapter Installation

1. Install the oil filter bypass valve.
2. Install the oil filter bypass hold plug. Tighten: Tighten the oil filter bypass hole plug to 19 N.m (14 lb ft).
3. Install the oil filter adapter.
4. Apply threadlocker P/N 21485277 to the bolt threads if required.
5. Install the oil filter adapter bolts. Tighten: Tighten the oil filter adapter bolts to 25 N.m (18 lb ft).
6. Install the oil filter. Tighten: Tighten the oil filter to 30 N.m (22 lb ft).

Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube and oil level indicator.
2. Install the oil level indicator tube bolt. Tighten: Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft).
3. Install the thermostat bypass pipe.
4. Install the thermostat bypass pipe to engine front cover bolt. Tighten: Tighten the thermostat bypass pipe to engine front cover bolt to 10 N.m (89 lb in).
5. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) to the throttle body studs.
6. Install the thermostat bypass pipe to throttle body bolt and nuts. Tighten: Tighten the thermostat bypass pipe to throttle body bolt and nuts to 10 N.m (89 lb in).
7. Install the heated oxygen sensor connector to the thermostat bypass pipe.
8. Install the spark plug wire clip to the thermostat bypass pipe.
9. Install the spark plug wires onto the spark plugs.
10. Position the 16 pin connector harness as shown in the graphic and secure the connector in its respective location.
11. Install the thermostat bypass pipe hose to pipe.

Engine Lift Bracket Installation - Rear

1. Install the rear engine lift bracket.
2. Install the rear engine lift bracket bolts. Tighten: Tighten the rear engine lift bracket bolts to 50 N.m (37 lb ft).

Engine Mount Support and Strut Bracket Installation

1. Install the engine mount support and strut bracket.
2. Install the engine mount support and strut bracket bolts. Tighten: Tighten the engine mount support and strut bracket bolts to 25 N.m (18 lb ft).

Engine Lift Bracket and Generator Bracket Installation

1. Install the front engine lift hook.
2. Install the generator bracket assembly.
3. Install the generator bracket assembly bolts (230, 231, 232). Tighten: Tighten the generator bracket assembly bolts to 50 N.m (37 lb ft).

Drive Belt Tensioner Installation

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).

Engine Flywheel Installation

1. Install the flywheel.
2. Install the flywheel bolts. Tighten: Tighten the flywheel bolts to 70 N.m (52 lb ft).

Crankshaft Balancer Installation

Tools Required

1. J 29113 Balancer and Crank Sprocket Puller. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
2. J 45059 Angle Meter

1. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or the equivalent to the keyway of the crankshaft balancer.
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Install the J 29113 onto the crankshaft. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
4. Rotate the hex nut on the J 29113 to install the crankshaft balancer onto the crankshaft. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
5. Remove the J 29113 from the crankshaft. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) .
6. Install the crankshaft balancer washer and bolt. Tighten: Tighten the crankshaft balancer bolt a first pass to 70 N.m (52 lb ft). Tighten the crankshaft balancer bolt a final pass to 70 degrees using the J 45059 .

General Description

A crankcase ventilation system is used to consume crankcase vapors (1) in the combustion process instead of venting them to atmosphere. Fresh air from the throttle body is supplied to the crankcase, mixed with blow by gases, and then passed through a positive crankcase ventilation (PCV) valve (3) into the intake manifold.

Scheme 72

The primary control is through the positive crankcase ventilation (PCV) valve which meters the flow at a rate depending on inlet vacuum. To maintain idle quality, the PCV valve restricts the flow when inlet vacuum is high. If abnormal operating conditions arise, the system is designed to allow excessive amounts of blow by gases to back flow through the crankcase vent into the throttle body to be consumed by normal combustion.

Drive Belt System Description

The drive belt system consists of the following components

1. The drive belt
2. The drive belt tensioner
3. The crankshaft balancer pulley
4. The accessory drive components The generator The A/C compressor The water pump

The drive belt system uses one belt. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belt is 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.

Engine Component Description

The cylinder block is made of cast alloy iron. The cylinder block has 6 cylinders that are arranged in a V shape. There are 3 cylinders in each bank. The cylinder banks are set at a 60 degree angle from each other.

Starting from the front of the engine - accessory belt end, the right bank cylinders are 2, 4, 6. The left bank cylinders are 1, 3, 5.

Four main bearings support the crankshaft. The crankshaft is retained by the bearing caps. The bearing caps are machined with the block for proper alignment and clearances. The main bearing caps are drilled and tapped for the structural oil pan side bolts.

The aluminum cylinder heads have individual intake and exhaust ports for each cylinder. The valve guides are pressed in. The roller rocker arms are located on a pedestal in a slot in the cylinder head. The roller rocker arms are retained on individual threaded bolts.

The crankshaft is forged steel - some applications use cast iron, with deep rolled fillets on all 6 crankpins and all 4 main journals. Four steel-backed aluminum bearings are used. The #3 bearing is the end-thrust bearing.

The camshaft is made from a new metal composite design. The camshaft profile is a hydraulic roller design. The camshaft is supported by 4 journals. The camshaft includes an oil pump drive gear.

The pistons are cast aluminum using 2 compression rings and 1 oil control ring. The pistons also have 2 polymer coated patches on the skirt for noise reduction. The piston pin is offset 0.8 mm (0.031 in) towards the major thrust side. This placement allows for a gradual change in thrust pressure against the cylinder wall as the piston travels its path. The pins are made of chromium steel and have a foating fit in the pistons. The pins are retained in the connecting rods by a press fit.

The connecting rods are made of forged steel. Full pressure lubrication is directed to the connecting rods by drilled oil passages from the adjacent main bearing journal.

A roller rocker type valve train is used. Motion is transmitted from the camshaft through the hydraulic roller lifter and from the pushrod to the roller rocker arm. The rocker arm pivots on the needle roller bearings. The rocker arm transmits the camshaft motion to the valve. The rocker arm pedestal is located in a slot in the cylinder head. The rocker arm is retained in the cylinder head by a bolt. The pushrod is located by the rocker arm.

The intake manifold is a 2-piece cast aluminum unit. The intake manifold centrally supports a fuel rail with 6 fuel injectors.

The exhaust manifolds are cast nodular iron.

Scheme 73

Full pressure lubrication, through a full flow oil filter, is furnished by a gear type oil pump. The oil is drawn up through the pickup screen and the tube. The oil passes through the pump to the oil filter.

The oil filter is a full flow paper element unit. An oil filter bypass is used in order to ensure oil supply during the following conditions

1. On a cold start
2. If the filter is plugged
3. If the filter develops excessive pressure drop

The bypass is designed to open at 69-83 kPa (10-12 psi).

A priority oil delivery system supplies oil first to the crankshaft journals. The oil from the crankshaft main bearings is supplied to the connecting rod bearings by intersecting the passages drilled in the crankshaft. The passages supply the oil to the crankshaft main bearings and the camshaft bearings through the intersecting vertical drilled holes. The oil passages from the camshaft journals supply oil to the hydraulic lifters.

The piston oil nozzle lubricates the pistons and cylinder walls in cylinders 5 and 6. A nonserviceable check valve integrated into the nozzle prevents oil bleed down from the nozzle when the engine is not running.

The hydraulic lifters pump oil up through the pushrods to the rocker arms. The cast dams in the crankcase casting direct the oil that drains back from the rocker arms in order to supply the camshaft lobes. The camshaft chain drive is lubricated by indirect oil splash.

Scheme 74

Scheme 75

Cleanliness and Care

An automobile engine is a combination of many of the following surfaces

1. Machined
2. Honed
3. Polished
4. Lapped

The tolerances of these surfaces are measured in the ten-thousandths of an inch. When you service any internal engine part, cleanliness and care are important. Apply a liberal coating of engine oil to the friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, practice proper cleaning and protection procedures to the machined surfaces and to the friction areas.

Note. Engine damage may result if an abrasive paper, pad, or motorized wire brush is used to clean any engine gasket surfaces.

Whenever you remove the valve train components, keep the components in order. Follow this procedure in order to install the components in the same locations and with the same mating surfaces as when removed.

Disconnect the negative battery cables before you perform any major work on the engine. For more information on the disconnection of the battery, refer to Engine Electrical.

Separating Parts

In addition to the room temperature vulcanizing (RTV) sealant's sealing capabilities, the RTV sealants may form an adhesive bond between the components. This may make the components difficult to remove or to separate. If possible, bump the components sideways rather than using prying tools in order to remove the components. This technique prevents damage when the bonding strength of the RTV sealant is stronger than the component itself. Perform bumping at the bends or at the reinforced areas in order to prevent part distortion.

Replacing Engine Gaskets

1. Do not reuse any gasket unless otherwise specified. Reusable gaskets will be identified in the service procedure. Do not apply sealant to any gasket or sealing surface unless called out in the service procedure.
2. Use a rubber mallet in order to separate components. Bump the part sideways in order to loosen the components. Perform the bumping at the bends or at the reinforced areas in order to prevent the distortion of components.
3. Remove all of the gasket and the sealing material from the component using a plastic or a wood scraper. Do not gouge or scrape the sealing surfaces.
4. When assembling components, use only the sealant specified in the service procedure. Ensure that the sealing surfaces are clean and free of debris or oil. When applying sealant to a component, apply a bead size as specified in the service procedure.
5. Tighten the bolts to the specifications.

Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealer

The following 2 types of sealer are commonly used in engines

1. The RTV sealer
2. The anaerobic gasket eliminator sealer

Follow the service procedure instructions. Use the correct sealer in the proper place in order to prevent oil leaks. Do not interchange the 2 types of sealers. Use the sealer recommended in the service procedure.

Applying RTV Sealer

1. Do not use the room temperature vulcanizing (RTV) sealant in areas where extreme temperatures are expected. These areas include the following locations: The exhaust manifold The head gasket The other surfaces where gasket eliminator is specified
2. Use a rubber mallet in order to separate the components sealed with RTV sealant. Bump the part sideways in order to shear the RTV sealer. Perform the bumping at the bends or the reinforced areas in order to prevent distortion of the components. The RTV sealant is weaker in shear (lateral) strength than in tensile (vertical) strength.
3. Do not use the following items in order to clean the gasket surfaces: Abrasive pads Sand Paper Power tools

These methods of cleaning may damage the part.

Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.

1. Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite® brand gasket remover P/N 4MA or the equivalent. Follow all of the safety recommendations and the directions that are on the container. IMPORTANT: Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following conditions: Prevent you from properly seating the bolt Cause damage when you tighten the bolt
2. Apply the RTV sealant to a clean surface. Use a bead size as specified in the procedure. Apply the bead to the inside of any bolt holes.
3. Assemble the components while the RTV sealant is still wet (within 3 minutes). Do not wait for the RTV sealant to skin over.
4. Tighten the bolts to specifications.

Applying Anaerobic Sealer

The anaerobic gasket eliminator hardens in the absence of air. This type of sealer is used where 2 rigid parts (such as castings) are assembled together. When 2 rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator.

Do not use the following items in order to clean the gasket surfaces

1. Abrasive pads
2. Sand paper
3. Power tools

These methods of cleaning may damage the part.

Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and may cause internal engine damage.

1. Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite® brand gasket remover P/N 4MA or the equivalent. Follow all of the safety recommendations and the directions that are on the container.
2. Apply a continuous bead of the gasket eliminator to 1 flange. Clean and dry any surfaces that you will reseal.
3. Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following conditions: Prevent you from properly seating the bolt Cause damage when you tighten the bolt
4. Spread the sealer evenly in order to get a uniform coating on the sealing surface.
5. Tighten the bolts to the specifications.
6. Remove the excess sealer from the outside of the joint.

Tools and Equipment

Work in a clean and well-lit area. Have the following components available before you begin to work

1. A suitable parts cleaning tank
2. A compressed air supply
3. Trays, in order to keep the parts and the fasteners organized
4. An adequate set of hand tools

An approved engine repair stand will prevent personal injury or damage to the engine components. The special tools are designed in order to quickly and safely accomplish the operations for which the tools are intended. Using the tools will minimize possible damage to the engine components. Precision measuring tools are required for the inspection of certain critical components. Torque wrenches are needed for the correct assembly of various parts.

Special Tools

Special Tools Illustration Tool Number/Description J 7872 Magnetic Base Dial Indicator J 8001 Dial Indicator Set J 8037 Ring Compressor J 8087 Cylinder Bore Gage J 8089 Carbon Removal Brush J 8520 Cam Lobe Lift Indicator J 9666 Valve Spring Tester J 21882 Oil Suction Pipe Installer J 22144 Oil Suction Pipe Installer J 22794 Spark Plug Port Adapter J 24086-C Piston Pin Remover/Installer Set J 24270 Cylinder Bore Ridge Reamer J 25087-C Oil Pressure Tester J 28428-E High Intensity Black Light Kit J 28467-B Universal Engine Support Fixture J 29113 Balancer and Crank Sprocket Installer J 33049 Camshaft Bearing Service Set J 34686 Rear Main Seal Installer J 35468 Cover Aligner and Seal Installer J 35667-A Cylinder Leakdown Tester J 36462 Engine Support Adapter Leg J 37088-A Fuel Line Disconnect Tool Set J 37096 Flywheel Holder J 38606 Valve Spring Compressor J 41556 Connecting Rod Guide J 41816 Crankshaft Balancer Remover J 45059 Angle Meter J 45299 Engine Preluber EN 46359 Puller End Protector

Scheme 76

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Scheme 95

See also:
• Strategy Based Diagnosis
• Checking Aftermarket Accessories
• Spark Plug Inspection
• Diagnostic Starting Point - Engine Cooling
• Electronic Ignition (EI) System Description
• Electrical Center Identification Views
• Battery Negative Cable Disconnect/Connect Procedure
• Lifting and Jacking the Vehicle
• Vibration Analysis - Engine
• Diagnostic Starting Point - Vibration Diagnosis and Correction
• Fasteners
• Symptoms - Engine Mechanical
• Drive Belt Replacement
• Air Cleaner Assembly Replacement
• Fastener Notice
• Tire and Wheel Removal and Installation
• Radiator Air Baffle and Deflector Replacement - Lower
• Generator Replacement (LX9)
• Frame Replacement (W/LX9)
• CKP System Variation Learn Procedure
• Lower Control Arm Replacement
• Compressor Replacement (LX9)
• Exhaust Crossover Pipe Replacement
• Transmission Replacement
• Hood Replacement
• Disassembled Views
• Engine Component Description
• Drive Belt System Description
• Base Engine Misfire without Internal Engine Noises
• Base Engine Misfire with Abnormal Internal Lower Engine Noises
• Base Engine Misfire with Abnormal Valve Train Noise
• Base Engine Misfire with Coolant Consumption
• Base Engine Misfire with Excessive Oil Consumption
• Engine Compression Test
• Engine Noise on Start-Up, but Only Lasting a Few Seconds
• Upper Engine Noise, Regardless of Engine Speed
• Lower Engine Noise, Regardless of Engine Speed
• Engine Noise Under Load
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Oil Consumption Diagnosis
• Drive Belt Chirping Diagnosis
• Drive Belt Squeal Diagnosis
• Drive Belt Whine Diagnosis
• Drive Belt Rumbling Diagnosis
• Drive Belt Tensioner Diagnosis
• Crankshaft Balancer Replacement
• Cylinder Leakage Test
• Cylinder Head Cleaning and Inspection
• Piston, Connecting Rod, and Bearings Cleaning and Inspection
• Engine Block Cleaning and Inspection
• Fastener Tightening Specifications
• Drive Belt Tensioner Removal
• Drive Belt Tensioner Installation
• Engine Mount Inspection
• Valve Rocker Arm Cover Cleaning and Inspection
• Valve Lifters Cleaning and Inspection
• Oil Pump Cleaning and Inspection
• Engine Front Cover Cleaning and Inspection
• Timing Chain and Sprockets Cleaning and Inspection
• Engine Mechanical Specifications