Engine Mechanical - 2.2l (l61) Chevrolet Malibu VI рестайлинг

Fastener Tightening Specifications

Fastener Tightening Specifications

Engine Mechanical Specifications

Engine Mechanical Specifications

Sealers, Adhesives, and Lubricants

Sealers, Adhesives, and Lubricants

Scheme 1

Engine Block - Front View

Scheme 2

Engine Block - Back View

Scheme 3

Engine Block - Left Side View

Scheme 4

Engine Block - Bottom View

Scheme 5

Engine Block - Right Side View

Scheme 6

Engine Block - Top View

Scheme 7

Lower Crankcase - Front View

Scheme 8

Lower Crankcase - Back View

Scheme 9

Lower Crankcase - Bottom View

Scheme 10

Lower Crankcase - Left View

Scheme 11

Lower Crankcase - Right View

Scheme 12

Cylinder Head - Top View

Scheme 13

Cylinder Head - Intake Manifold Deck View

Scheme 14

Cylinder Head - Exhaust Manifold Deck View

Scheme 15

Cylinder Head - Front View

Scheme 16

Cylinder Head - Back View

Scheme 17

Cylinder Head - Bottom View

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

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

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

The partial VIN identifies the specific vehicle by sequence number.

Diagnostic Starting Point - Engine Mechanical

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

Strategy Based Diagnostics

1. Perform the «Diagnostic System Check - Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-system-check-vehicle) 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-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) , «Engine Component Description»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) , and «Lubrication Description»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .

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

Visual/Physical Inspection

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

Intermittent

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

Symptom List

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

1. «Base Engine Misfire without Internal Engine Noises»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__base-engine-misfire-without-internal-engine)
2. «Base Engine Misfire with Abnormal Internal Lower Engine Noises»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__base-engine-misfire-with-abnormal-internal)
3. «Base Engine Misfire with Abnormal Valve Train Noise»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__base-engine-misfire-with-abnormal-valve)
4. «Base Engine Misfire with Coolant Consumption»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__base-engine-misfire-with-coolant-consumption)
5. «Base Engine Misfire with Excessive Oil Consumption»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__base-engine-misfire-with-excessive-oil)
6. «Engine Noise on Start-Up, but Only Lasting a Few Seconds»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-noise-on-start-up-but-only)
7. «Upper Engine Noise, Regardless of Engine Speed»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__upper-engine-noise-regardless-of-engine)
8. «Lower Engine Noise, Regardless of Engine Speed»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__lower-engine-noise-regardless-of-engine)
9. «Engine Noise Under Load»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-noise-under-load)
10. «Engine Will Not Crank - Crankshaft Will Not Rotate»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-will-not-crank-crankshaft)
11. «Engine Compression Test»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-compression-test)
12. «Oil Consumption Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__oil-consumption-diagnosis)
13. «Oil Pressure Diagnosis and Testing»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61)
14. «Oil Leak Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__oil-leak-diagnosis)
15. «Drive Belt Chirping, Squeal, and Whine Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61)
16. «Drive Belt Rumbling and Vibration Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61)
17. «Drive Belt Falls Off and Excessive Wear Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61)
18. «Drive Belt Tensioner Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__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

Perform the following steps to conduct a compression test.

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

Cylinder Leakage Test

Tools Required

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

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

1. Disconnect the battery ground negative cable.
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) in Engine Controls - 2.2L.
3. Rotate the crankshaft to place the piston in the cylinder being tested at Top Dead Center (TDC) of the compression stroke.
4. Install the J 35667-A or equivalent. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
5. Apply shop air pressure to the J 35667-A and adjust according to the manufacturers instructions. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
6. Record the cylinder leakage value. Cylinder leakage that exceeds 25 percent is considered excessive and may require component service. In excessive leakage situations, inspect for the following conditions: Air leakage sounds at the throttle body or air inlet hose that may indicate a worn or burnt intake valve or a broken valve spring. Air leakage sounds at the exhaust system tailpipe that may indicate a worn or burnt exhaust valve or a broken valve spring. Air leakage sounds from the crankcase, oil level indicator tube, or oil fill tube that may indicate worn piston rings, a damaged piston, a worn or scored cylinder bore, a damaged engine block or a damaged cylinder head. Air bubbles in the cooling system may indicate a damaged cylinder head or a damaged cylinder head gasket.
7. Perform the leakage test on the remaining cylinders and record the values.

Oil Consumption Diagnosis

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

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

Tools Required

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

1. With the vehicle on a level surface, allow adequate drain down time of 2-3 minutes and measure for a low oil level. Add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator.
2. Run the engine, and verify low, or no oil pressure on the vehicle gage or light. Listen for a noisy valve train or a knocking noise.
3. Inspect for the following: Oil diluted by moisture or unburned fuel mixtures Improper oil viscosity for the expected temperature Incorrect or malfunctioning oil pressure sender Incorrect or malfunctioning oil pressure gage Plugged oil filter Malfunctioning oil bypass valve
4. Remove the oil pressure sender or another engine block oil gallery plug.
5. Install J-21867-850 and an oil pressure gage and measure the engine oil pressure. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
6. Compare the readings to specifications. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) .
7. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: Oil pump worn or dirty Refer to «Oil Pump Disassemble»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__oil-pump-disassemble) . Oil pump-to-engine front cover bolts loose Refer to «Engine Front Cover and Oil Pump Installation»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-front-cover-and-oil-pump) . Oil pump screen loose, plugged, or damaged Oil pump screen O-ring seal missing or damaged Malfunctioning oil pump pressure regulator valve Excessive bearing clearance Refer to «Crankshaft and Bearings Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) . Cracked, porous or restricted oil galleries Oil gallery plugs missing or incorrectly installed Refer to «Engine Block Assemble»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-block-assemble) . Broken lash adjusters

Oil Leak Diagnosis

Oil Leak Diagnosis

Crankcase Ventilation System Inspection/Diagnosis

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

Diagnostic Aids

1. A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution.
2. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
3. A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise.
4. The drive belts will not cause a whine noise.

Test Description

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

1. 2: The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table.
2. 3: The noise may be an internal engine noise. Removing the drive belts one at a time and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed.
3. 4: Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust.
4. 6: Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley.
5. 10: Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed.
6. 12: Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley.
7. 14: This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise.
8. 15: This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction.
9. 16: 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 two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure for that pulley.
10. 17: This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes.
11. 19: Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair.

Drive Belt Chirping, Squeal, and Whine Diagnosis

The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components.

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

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

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

1. 2: This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom.
2. 3: This test is to verify that one of the drive belts is causing the rumbling noise or vibration. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belts the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belts removed.
3. 4: Inspecting the drive belts is to ensure that they are not causing the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt.
4. 5: Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation.
5. 9: Inspecting of the fasteners can eliminate the possibility that the wrong bolt, nut, spacer, or washer was installed.
6. 11: 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 smooth operation and excessive play. Compare the water pump with a known good water pump.
7. 12: Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate.

Drive Belt Rumbling and Vibration Diagnosis

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

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

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

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: This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys.
2. 4: Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the proper installation procedure of that pulley.
3. 5: Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley.
4. 6: Accessory drive component brackets that are bent or cracked will let the drive belt fall off.
5. 7: Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.
6. 13: 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.
7. 14: The installation of a drive belt that is too wide or too narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys.
8. 15: 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 Falls Off and Excessive Wear Diagnosis

Drive Belt Tensioner Diagnosis

Drive Belt Tensioner Diagnosis

J 44811 Accessory Belt Tensioner Unloader

Removal Procedure

1. Remove the front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
2. Use the J 44811 in order to rotate the drive belt tensioner counter-clockwise to release the spring tension.
3. Remove the drive belt.

Installation Procedure

1. Use the J 44811 in order to rotate the drive belt tensioner counter-clockwise to release the spring tension.
2. Install the drive belt.
3. Install the front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .

J 45025 Torque Wrench Adapter. See Special Tools .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner.

1. Install the drive belt tensioner.
2. Install the drive belt tensioner bolt. Use a J 45025 to tighten the drive belt tensioner bolt. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Tighten: Tighten the drive belt tensioner bolt to 45 N.m (33 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
3. Disconnect the engine wiring harness electrical connector (1) from the oil pressure sensor.
4. Remove the oil pressure sensor.

1. Install the oil pressure sensor. Tighten: Tighten the sensor to 22 N.m (16 lb ft).
2. Connect the engine wiring harness electrical connector (1) to the oil pressure sensor.
3. Lower the vehicle.
4. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .

Engine Mount Inspection

1. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-support-fixture) .
2. Observe the engine mount while raising the engine. Raising the engine removes the weight from the engine mount and creates slight tension on the rubber.
3. Replace the engine mount if the engine mount exhibits any of the following conditions: The hard rubber is covered with heat check cracks. The rubber is separated from the metal plate of the engine mount. The rubber is split through the center of the engine mount. The engine mount itself is leaking fluid.
4. For engine mount replacement. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .

1. Use a floor jack and a block of wood to support the powertrain from the oil pan.
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
3. Remove the engine mount to bracket bolts.
4. Remove the engine mount to body bolts.
5. Remove the engine mount from the vehicle.

1. Install the engine mount to the vehicle. Hand tighten the bolts at this time.
2. Install the engine mount to engine bracket bolts. Tighten: Tighten the engine mount to bracket bolts to 50 N.m (37 lb ft). Tighten the engine mount to vehicle bolts to 50 N.m (37 lb ft).
3. Remove the floor jack and block of wood.
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .

Powertrain Mount Balance - Total Mounts

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Loosen, but DO NOT REMOVE the front transmission mount through bolt.
3. Loosen, but DO NOT REMOVE the rear transmission mount through bolt.
4. Position 2 floor jacks with wood blocks under the engine and transmission to support the powertrain.
5. From inside the engine compartment, loosen the transmission mount bracket to transmission bolts.
6. Loosen the engine mount bracket nuts.
7. Reposition the floor jacks to allow a 1/8 inch gap between the engine mount and engine mount bracket.
8. Tighten the transmission mount bracket to transmission bolts using the following sequence: Rear bolt Middle bolt Front bolt Tighten: Tighten the bolts to 50 N.m (37 lb ft).
9. Tighten the engine mount bracket nuts. Tighten: Tighten the nuts to 50 N.m (37 lb ft).
10. Remove the floor jacks.
11. Rock the powertrain vigorously from front to rear and allow the powertrain to settle.
12. Tighten the rear transmission mount through bolt. Tighten: Tighten the bolt to 90 N.m (66 lb ft).
13. Tighten the front transmission mount through bolt. Tighten: Tighten the bolt to 90 N.m (66 lb ft).
14. Lower the vehicle.

Powertrain Mount Balance - Lower Mount

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Loosen, but DO NOT REMOVE the front transmission mount through bolt.
3. Loosen, but DO NOT REMOVE the rear transmission mount through bolt.
4. Rock the powertrain vigorously from front to rear and allow the powertrain to settle.
5. Tighten the rear transmission mount through bolt. Tighten: Tighten the bolt to 90 N.m (66 lb ft).
6. Tighten the front transmission mount through bolt. Tighten: Tighten the bolt to 90 N.m (66 lb ft).
7. Lower the vehicle.

Engine Mount Position Adjustment

Tools Required

J 23498-A Driveshaft Inclinometer

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Loosen, but DO NOT REMOVE the front transaxle mount through bolt.
3. Loosen, but DO NOT REMOVE the rear transaxle mount through bolt.
4. Install the J 23498-A on the bottom of the flex coupling of the exhaust pipe.
5. Rock the engine by hand until the J 23498-A reading is as close to "0" degrees as possible.
6. While still holding the powertrain in position, tighten the front through bolt.
7. Tighten the rear through bolt.
8. After the through bolts have been tightened, re-check the angle.
9. There should be no more then "5" degrees of angle in the flex coupling with the powertrain in the static position.
10. If there is no more then "5" degrees of angle, tighten the through bolts to specifications. Tighten: Tighten the bolts to 90 N.m (66 lb ft).
11. If there is more then "5" degrees of angle, loosen the through bolts and return to step 5.

Engine Support Fixture

Tools Required

1. J 28467-B Universal Engine Support Fixture. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 36462 Engine Support Adapter Leg

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

1. Remove the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the intermediate bracket to engine bolts.
3. Remove the intermediate bracket from the engine.

1. Install the intermediate bracket to the engine.
2. Hand tighten the engine mount intermediate bracket bolts in the following locations: The long bolts in the forward and front lower holes The short bolt in the rear upper hole
3. Tighten the intermediate bracket bolts. Tighten: Tighten the bolts to 100 N.m (74 lb ft).
4. Install the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
2. Remove the knock sensor electrical connector clip (3) from the oil level indicator tube.
3. Remove the oil level indicator.
4. Remove the oil level indicator tube bolt.
5. Remove the oil level indicator tube.
6. Remove the oil level indicator tube seal, if required.

1. Install the oil level indicator tube seal, if required.
2. Install the oil level indicator tube.
3. Install the oil level indicator tube bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
4. Install the oil level indicator.
5. Install the knock sensor electrical connector clip (3) to the oil level indicator tube.
6. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .

1. Reposition the positive crankcase ventilation (PCV) hose clamp (1) at the air cleaner outlet duct.
2. Remove the PCV hose from the air cleaner outlet duct.
3. Reposition the PCV hose clamp (1) at the camshaft cover.
4. Remove the PCV hose from the camshaft cover.

1. Install the PCV hose to the camshaft cover.
2. Position the PCV hose clamp (1) at the camshaft cover.
3. Install the PCV hose to the air cleaner outlet duct.
4. Position the PCV hose clamp (1) at the air cleaner outlet duct.

1. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
2. Remove the fuel rail. Refer to «Fuel Rail Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
3. Remove the evaporative emission (EVAP) canister purge solenoid valve tube. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
4. Reposition the brake booster vacuum hose clamp at the intake manifold.
5. Remove the brake booster hose from the intake manifold.
6. Disconnect the engine wiring harness electrical connector from the fuel injector inline electrical connector (2).
7. Remove the fuel injector inline connector clip (1) from the intake manifold.
8. Remove the oil level indicator tube bolt.
9. Remove the knock sensor electrical connector clip (3) from the oil level indicator tube.
10. Reposition the oil level indicator tube as needed.
11. Remove the engine wiring harness clips (1) from the intake manifold.
12. Remove the intake manifold lower bolts.
13. Remove the intake manifold upper bolt and nuts.
14. Remove the intake manifold.
15. If replacing the intake manifold proceed to the Installation Procedure.
16. If reusing the intake manifold perform the following, Inspect the intake manifold gasket for damaged, replace the gasket if necessary.

1. Install the NEW gasket to the intake manifold, if necessary.
2. Install the intake manifold onto the studs.
3. Install the intake manifold upper bolt and nuts.
4. Install the intake manifold lower bolts. Tighten: Tighten the bolts/nuts to 10 N.m (89 lb in).
5. Install the engine wiring harness clips (1) to the intake manifold.
6. Position the oil level indicator tube as needed.
7. Install the knock sensor electrical connector clip (3) to the oil level indicator tube.
8. Install the oil level indicator tube bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
9. Connect the engine wiring harness electrical connector to the fuel injector inline electrical connector (2).
10. Install the fuel injector inline connector clip (1) to the intake manifold.
11. Install the brake booster hose to the intake manifold.
12. Position the brake booster vacuum hose clamp at the intake manifold.
13. Install the EVAP canister purge solenoid valve tube. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
14. Install the fuel rail. Refer to «Fuel Rail Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
15. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .

Crankshaft Balancer Replacement

Tools Required

1. J 38122-A Crankshaft Balancer Holder. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 45059 Angle Meter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
2. Install the J 38122-A to the balancer in order to keep the balancer from rotating when removing the balancer bolt. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. Remove and discard the crankshaft balancer bolt.
4. Remove the J 38122-A . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
5. Remove the crankshaft balancer.

1. Install the crankshaft balancer.
2. Install the J 38122-A to the balancer in order to keep the balancer from rotating while tightening the balancer bolt. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. Install a NEW crankshaft balancer bolt.
4. Tighten the crankshaft balancer bolt. Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus an additional 75 degrees using the J 45059 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
5. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .

J 35268-A Camshaft/Front Main Seal Installer

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__crankshaft-balancer-replacement) .
2. Use a flat bladed tool to remove the seal from the front cover.

1. Use the J 35268-A in order to install the crankshaft front oil seal to the engine front cover.
2. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__crankshaft-balancer-replacement) .

1. Remove the crankcase balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__crankshaft-balancer-replacement) .
2. Remove the drive belt tensioner.
3. Remove the engine front cover to water pump bolt.
4. Remove the remaining engine front cover bolts.
5. Remove the engine front cover. If the engine front cover gasket is damaged. Remove the front engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) . Remove the engine front cover gasket if it is damaged.

1. If removed install a new engine front cover gasket.
2. Install the front engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
3. Install the engine front cover.
4. Install the engine front cover bolts. Tighten: Tighten the engine front cover bolts to 25 N.m (18 lb ft).
5. Install the water pump bolt. Tighten: Tighten the water pump bolt to 25 N.m (18 lb ft).
6. Install the drive belt tensioner.
7. Install the drive belt tensioner bolt. Tighten: Tighten the drive belt tensioner bolt to 45 N.m (33 lb ft).
8. Install the crankcase balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__crankshaft-balancer-replacement) .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
3. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
4. Lower the vehicle. IMPORTANT: To rotate the camshaft, use a 24 mm open-end wrench on the camshaft flats. Camshaft should be rotated in a clockwise direction only, facing camshaft sprockets from the passenger side of the vehicle.
5. Locate the No. 1 piston to approximately 60 degrees before top dead center (diamond shaped hole on intake camshaft sprocket at 12 o'clock position). Remove the spark plugs. This will ease the rotation effort.
6. Remove the timing chain tensioner.
7. Remove the fixed timing chain guide access plug.
8. Remove the fixed timing chain guide.
9. Remove the upper timing chain guide.
10. Use a 24 mm wrench to hold the camshafts from turning.
11. Remove the exhaust camshaft sprocket bolt and discard.
12. Remove the exhaust camshaft sprocket.
13. Remove the timing chain tensioner guide.
14. Remove the intake camshaft sprocket bolt and discard.
15. Remove the intake camshaft sprocket.
16. Remove the timing chain through the top of the cylinder head.
17. Remove the crankshaft sprocket.
18. Remove the oil nozzle and bolt.
19. Remove the balance shaft drive chain tensioner.
20. Remove the adjustable balance shaft chain guide.
21. Remove the small balance shaft drive chain guide.
22. Remove the upper balance shaft drive chain guide.
23. Remove the balance shaft drive chain.

1. Install the upper balance shaft chain guide. Tighten: Tighten the upper balance shaft chain guide bolts to 15 N.m (133 lb in).
2. Install the balance shaft drive chain with the colored links lined up on with the marks on the balance shaft drive sprockets and the crankshaft sprocket. Use the following procedure to line up the links with the sprockets: Orient the chain so that the copper colored and chrome links are visible.
3. Place the copper colored link (1) so that it lines up with the timing mark on the intake side balance shaft sprocket.
4. Working clockwise around the chain, place the first chrome link (2) in line with the timing mark on the crankshaft drive sprocket. (approximately 6 o'clock position on the crank sprocket)
5. Place the chain (3) on the water pump drive sprocket (alignment is not critical).
6. Align the last chrome link (4) with the timing mark on the exhaust side balance shaft drive sprocket.
7. Install the small balance shaft chain guide.
8. Tighten the balance shaft chain guide bolts. Tighten: Tighten the chain guide bolts to 10 N.m (89 lb in).
9. Install the adjustable balance shaft drive chain guide. Tighten: Tighten the chain guide bolts to 10 N.m (89 lb in).
10. Turn the tensioner plunger 90 degrees in its bore and compress the plunger until a paper clip can be inserted through the hole in the plunger body and into hole in the tensioner plunger.
11. Install the timing chain tensioner.
12. Tighten the chain tensioner bolts. Tighten: Tighten the chain tensioner bolts to 10 N.m (89 lb in).
13. Remove the paper clip from the balance shaft drive chain tensioner.
14. Install the oil nozzle and bolt. Tighten: Tighten the oil nozzle bolt to 10 N.m (89 lb in).
15. Install the crankshaft sprocket with timing mark at the 5 o'clock position.
16. Lower the timing chain through the opening in the top of the cylinder head. Carefully ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
17. Install the intake camshaft sprocket with the INT diamond at the 2 o'clock position.
18. Hand tighten a NEW intake camshaft sprocket bolt.
19. Route the timing chain around the crankshaft sprocket with the matching colored link aligning with the timing mark.
20. Route the timing chain around the intake camshaft sprocket with the uniquely colored link (1) aligning with the INT diamond.
21. Install the timing chain tensioner guide through the opening in the top of the cylinder head. Tighten: Tighten the timing chain tensioner guide bolt to 10 N.m (89 lb in).
22. Install the exhaust camshaft sprocket with the timing chain matching colored link (3) at EXH triangle aligned at the 10 o'clock position.
23. Use a 24 mm wrench to rotate the camshaft slightly, until exhaust sprocket aligns with the camshaft.
24. Hand tighten the NEW exhaust camshaft sprocket bolt.
25. Install the fixed timing chain guide. Tighten: Tighten the fixed timing chain bolts to 15 N.m (133 lb in).
26. Apply sealant compound to thread and install the timing chain guide bolt access hole plug. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__sealers-adhesives-and-lubricants) for the correct part number. Tighten: Tighten the chain guide plug to 90 N.m (66 lb ft).
27. Install the timing chain upper guide. Tighten: Tighten the timing chain upper guide bolts to 10 N.m (89 lb in).
28. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner.
29. Measure the timing chain tensioner assembly from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
30. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
31. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint free cloth.
32. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
33. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end repeat steps 30.1 and 30.4.
34. Install the timing chain tensioner. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
35. Use a suitable tool with a rubber tip on the end. Feed the tool down through the camshaft drive chant to rest on the timing chain. Then give a sharp jolt diagonally downwards to release the tensioner.
36. Use a 24 mm wrench to hold the camshaft. Tighten: Tighten the NEW camshaft bolts to 85 N.m (63 lb ft) plus 30 degrees.
37. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
38. Raise the vehicle.
39. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
40. Lower the vehicle.
41. Connect negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Remove the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
2. Reposition the positive crankcase ventilation (PCV) hose clamp (1) at the camshaft cover.
3. Remove the PCV hose from the camshaft cover.
4. Disconnect the engine compartment fuel feed line quick connect fitting (4) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
5. Remove the engine compartment fuel line clips (2) from the fuel line bracket.
6. Reposition the engine compartment fuel feed line out of the way.
7. Remove the fuel line bracket bolt and bracket.
8. Remove the ignition coils. Refer to «Ignition Coil Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
9. Remove the engine wiring harness clips (1) from the camshaft cover.
10. Remove the camshaft cover bolts.
11. Remove the camshaft cover.

1. Transfer the oil fill cap to the NEW camshaft cover, if necessary.
2. Install the camshaft cover.
3. Install the camshaft cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Install the engine wiring harness clips (1) to the camshaft cover.
5. Install the ignition coils. Refer to «Ignition Coil Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
6. Install the fuel line bracket and bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
7. Position the engine compartment fuel feed line.
8. Connect the engine compartment fuel feed line quick connect fitting (4) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
9. Install the engine compartment fuel line clips (2) to the fuel line bracket.
10. Install the PCV hose to the camshaft cover.
11. Position the PCV hose clamp (1) at the camshaft cover.
12. Install the air cleaner outlet resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .

J 43655 Sprocket Holding Tool. See Special Tools .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the upper timing chain guide.
3. Install the J 43655 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
4. Remove both the intake and exhaust camshaft sprocket bolts and discard.
5. Slide the camshaft sprockets forward.
6. Mark the caps to ensure they are installed in the original position.
7. Remove the caps.
8. Remove the intake camshaft.
9. Remove the camshaft roller followers.
10. Remove the hydraulic lash adjusters.

1. Lubricate the valve tips.
2. Install the hydraulic lash adjusters.
3. Install the camshaft roller followers.
4. Ensure that the alignment notches are aligned with the camshaft sprocket.
5. Install the intake camshaft.
6. Install the camshaft caps.
7. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the camshaft cap bolts to 10 N.m (89 lb in).
8. Apply a 3.5 mm (0.138 in) bead of sealant to the rear intake camshaft bearing cap. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__sealers-adhesives-and-lubricants) for the correct part number.
9. Install the rear intake camshaft cap bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
10. Install camshaft sprockets onto the camshafts.
11. Hand tighten NEW camshaft sprocket bolts.
12. Remove the J 43655 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
13. Tighten the camshaft sprocket bolts. Tighten: Tighten the bolts to 85 N.m (63 lb ft) plus 30 degrees.
14. Install the upper timing chain guide. Tighten: Tighten the upper timing chain guide to 10 N.m (89 lb in).
15. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .

J 43655 Sprocket Holding Tool. See Special Tools .

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the upper timing chain guide.
3. Install the J 43655 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
4. Remove both the intake and the exhaust camshaft sprocket bolts and discard.
5. Slide the camshaft sprockets forward.
6. Mark the caps to ensure that the caps are installed in the original position.
7. Remove the caps.
8. Remove the exhaust camshaft.
9. Remove the camshaft roller followers.
10. Remove the hydraulic lash adjusters.

1. Lubricate the valve tips.
2. Install the hydraulic lash adjusters.
3. Install the camshaft roller followers.
4. Ensure that the alignment notches are aligned with the camshaft sprocket.
5. Install the exhaust camshaft.
6. Install the camshaft caps.
7. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the camshaft cap bolts to 10 N.m (89 lb in).
8. Install camshaft sprockets onto the camshafts.
9. Hand tighten NEW camshaft sprocket bolts.
10. Remove the J 43655 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
11. Tighten the camshaft sprocket bolts. Tighten: Tighten the bolts to 85 N.m (63 lb ft) plus 30 degrees.
12. Install the upper timing chain guide. Tighten: Tighten the upper timing chain guide to 10 N.m (89 lb in).
13. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. J 43649 Valve Spring Compressor. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 36017 Valve Guide Seal Remover. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. J 43653 Flywheel Holding Tool. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

1. If equipped with a manual transmission, leave the transmission in first gear with the vehicle on the ground and the parking brake set.
2. If equipped with an automatic transmission, remove the starter. Refer to «Starter Motor Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Install the J 43653 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
4. Remove the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) or «Exhaust Camshaft and Lifter Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
5. Remove the camshaft roller followers.
6. Install the J 43649 to the cylinder head. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
7. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
8. Install an air hose adaptor into the spark plug hole.
9. Pressurize the cylinder to 690 kPa (100 psi).
10. Compress the valve spring.
11. Remove the valve spring keepers.
12. Remove the valve spring.
13. Using the J 36017 remove the valve seal. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

1. Using the J 36017 install the valve seal. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. Install the valve spring.
3. Compress the valve spring.
4. Install the valve spring keepers.
5. Remove the air hose adaptor into the spark plug hole.
6. Remove the J 43649 from the cylinder head. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
7. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
8. Install the camshaft roller followers.
9. Install the camshaft. Refer to «Intake Camshaft and Lifter Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) or «Exhaust Camshaft and Lifter Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
10. If removed, install the starter. Refer to «Starter Motor Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
11. If used, remove the J 43653 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

J 45059 Angle Meter. See Special Tools .

1. Remove the intake manifold. Refer to «Intake Manifold Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system) .
3. Remove the timing chain. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
4. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Remove the cylinder head bolts in sequence and discard.
6. Remove the cylinder head and gasket.
7. Clean all gasket surfaces.

1. Install the cylinder head and gasket.
2. Install NEW cylinder head bolts.
3. Tighten the cylinder head bolts in sequence. Tighten: Using a J 45059 tighten the cylinder head bolts to 30 N. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .m (22 lb ft) plus 155 degrees.
4. Install the NEW front cylinder head bolts. Tighten: Tighten the front cylinder head bolts to 35 N.m (26 lb ft).
5. Install the timing chain. Refer to «Timing Chain, Sprockets, and/or Tensioner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
6. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system) .
7. Lower the vehicle.
8. Install the intake manifold. Refer to «Intake Manifold Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
9. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Place a drain pan under the oil pan drain plug.
3. Remove the oil pan drain plug.
4. Drain the engine oil.
5. Remove the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
6. Remove the lower AC compressor bolt.
7. Remove the oil pan bolts (1).
8. Remove the oil pan.
9. Remove any old oil pan sealant (1).

1. Ensure that the oil pan and the sealing surface on the lower crankcase are free of all oil and debris.
2. Apply a 2 mm (0.079 in) bead of sealant (1) around the perimeter of the oil pan and the oil suction port opening. DO NOT over apply the sealant. More than a 2 mm (0.079 in) bead is not required. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__sealers-adhesives-and-lubricants) .
3. Install the oil pan.
4. Install the oil pan bolts.
5. Tighten the oil pan bolts in the sequence shown. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Install the lower AC compressor bolt. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
7. Ensure that the oil pan drain plug is tightened. Tighten: Tighten the drain plug to 25 N.m (18 lb ft).
8. Install the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
9. Lower the vehicle.
10. Fill the crankcase with oil.

Crankshaft Rear Oil Seal Replacement

Tools Required

1. J 38122-A Crankshaft Balancer Holder. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 42067 Rear Main Seal Installer. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. J 45059 Angle Meter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

1. Remove the automatic transmission. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
2. Install the J 38122-A to the crankshaft balancer in order to keep the flexplate from rotating when removing the flexplate bolts. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. Have an assistant hold the J 38122-A with a breaker bar. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
4. Remove the flexplate bolts. If reusing the old flexplate discard the flexplate bolts, NEW bolts will need to be installed.
5. Remove the flexplate.
6. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft
7. Pry the crankshaft rear oil seal with a flat-bladed tool.

1. Lubricate the outside diameter of the NEW crankshaft seal with clean engine oil.
2. Using the J 42067 , press the NEW crankshaft seal into the housing. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . The J 42067 will establish the depth of the seal. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. Install the J 38122-A to the crankshaft balancer in order to keep the flexplate from rotating when tightening the flexplate bolts. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
4. Install the flexplate.
5. Have an assistant hold the J 38122-A with a breaker bar. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
6. Install the NEW flexplate bolts. Tighten: Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using J 45059 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
7. Install the automatic transmission. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .

Engine Flywheel Replacement

Tools Required

1. J 38122-A Crankshaft Balancer Holder. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 45059 Angle Meter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

1. Remove the automatic transmission. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
2. Install the J 38122-A to the crankshaft balancer in order to keep the flexplate from rotating when removing the flexplate bolts. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. Have an assistant hold the J 38122-A with a breaker bar. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
4. Remove the flexplate bolts. If reusing the old flexplate discard the flexplate bolts, NEW bolts will need to be installed.
5. Remove the flexplate.
6. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

1. Install the J 38122-A to the crankshaft balancer in order to keep the flexplate from rotating when tightening the flexplate bolts. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. Install the flexplate.
3. Have an assistant hold the J 38122-A with a breaker bar. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
4. Install the NEW flexplate bolts. Tighten: Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using J 45059 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
5. Install the automatic transmission. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .

EN 45680-850 Cylinder Liner Removal and Installation Kit. See Special Tools .

1. Remove the cylinder head. Refer to «Cylinder Head Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
2. Remove the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
3. Remove the piston and connecting rod. Refer to «Piston, Connecting Rod, and Bearing Removal»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__piston-connecting-rod-and-bearing-removal) .
4. Inspect the condition of the piston. Refer to «Piston, Connecting Rod, and Bearings Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
5. Rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
6. Install the cylinder bore sleeve puller EN 45680-852 (1) through the cylinder bore.
7. Align the shoe (1) of the cylinder bore sleeve puller EN 45680-852 to the bottom of the cylinder bore sleeve (2).
8. Hold the threaded shaft of the cylinder bore sleeve puller EN 45680-852 upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
9. Install the fixture EN 456850-851 (4) onto the threaded shaft of the cylinder bore sleeve puller EN 456850-852 and the engine block.
10. Install the bearing (3) and the nut (1).
11. Tighten the nut (1) to the bearing (3).
12. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
13. Rotate the nut clockwise in order to remove the cylinder bore liner.
14. Remove fixture EN 45680-851, cylinder bore sleeve puller EN 45680-852, and the cylinder bore sleeve from the engine block.
15. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.

1. Place the NEW cylinder bore sleeve onto the cylinder block.
2. Install fixture EN 45680-851/cylinder bore sleeve installer EN 45680-853 assembly over the cylinder bore sleeve and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve.
3. Insert the 4 attachment bolts into the legs of the fixture EN 45680-851 (1). Do not apply downward pressure to the cylinder bore sleeve (2). Tighten: Tighten the 4 attachment bolts to 15 N.m (11 lb ft).
4. Align the bottom of the cylinder bore sleeve (1) with the cylinder bore of the block (2).
5. Align the installation arbor (1) onto the top of the cylinder bore sleeve (2).
6. Align the pusher block (2) of cylinder bore sleeve installer EN 45680-853 into the groove of fixture EN 45680-851 (1).
7. Using a ratchet, rotate the threaded shaft of fixture EN 45680-851/cylinder bore sleeve installer EN 45680-853 assembly in order to install the cylinder bore sleeve into the engine block.
8. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1/16 inch of the cylinder bore sleeve above the surface of the cylinder block.
9. Using a torque wrench, torque the threaded shaft of the fixture EN 45680-851/cylinder bore sleeve installer EN 45680-853 assembly to 102 N.m (75 lb ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore liner flange will protrude above the block deck surface.
10. Remove the fixture EN 45680-851/cylinder bore sleeve installer EN 45680-853 assembly (1) from the cylinder block (2).

Scheme 24

1. EN 45680-865 Debris Collector (3)
2. EN 45680-861 Trim Tool Assembly (2)
3. Air Control Valve (1)
4. Drill Motor with 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction

Scheme 25

1. Trim Tool Preloader (1)
2. EN 45680-862 Set Gage Ring (2)
3. EN 45680-863 Metal Shavings Catch Plug (3)
4. EN 45680-866 Drive Adapter (4)
5. EN 45680-864 Bolts (5)

1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.
2. Place metal shaving catch plug EN 45680-863 into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-863 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place additional metal shaving catch plugs EN 45680-863 into all remaining cylinder bore sleeves.
4. Ensure that the metal shaving catch plug EN 45680-863 is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. The groove side of the set gage ring EN 45680-862 (1) should be positioned upward on a flat surface.
6. Carefully position trim tool assembly EN 45680-861 onto the set gage ring EN 45680-862.
7. Loosen the shaft collar screw (2).
8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3).
9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten: Tighten the shaft collar screw to 19 N.m (14 lb ft).
10. Place trim tool assembly EN 45680-861 onto the cylinder to be trimmed with the directional arrow pointing in line with the crankshaft centerline and the front of the block.
11. Install the 4 bolts EN 45680-864 into the cylinder head bolt holes in the block. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
12. Fasten drive adapter EN 45680-866 into the drill chuck.
13. Connect a compressed air supply (75-125 psi) to the male quick connect located on trim tool assembly EN 45680-861. Turn the compressed air valve to the open position. This starts the venturi vacuum system that will catch the metal shavings.
14. Place drive adapter EN 45680-866 and drill assembly vertically onto the drive adapter end of trim tool assembly EN 45680-861. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds.
15. Remove drive adapter EN 45680-866 (1) and drill assembly from the trim tool assembly EN 45680-861.
16. Turn OFF the compressed air valve.
17. Remove trim tool assembly EN 45680-861 from the engine block.
18. Wipe the cylinder bore sleeve and surrounding areas for of any powder residue and then remove the metal shaving catch plug EN 45680-863.
19. Install a straight edge on the cylinder block perpendicular to the crankshaft centerline.
20. Using a light, illuminate the backside of the straight edge.
21. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side of both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
22. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly.
23. Proceed to the next bore sleeve to be trimmed repeating steps 10-19 if necessary.
24. Install the piston and connecting rod. Refer to «Piston, Connecting Rod, and Bearing Installation»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__piston-connecting-rod-and-bearing-installation) .
25. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
26. Install the cylinder head. Refer to «Cylinder Head Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .

1. With the tires in the straight forward position, remove the key from the ignition.
2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Remove the air inlet duct and resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
4. Secure the cooling module to the upper body structure.
5. Disconnect the engine compartment fuel feed line quick connect fitting (4) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
6. Drain the cooling system. Refer to «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Remove the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Remove the surge tank to cylinder head hose. Refer to «Surge Tank Hose/Pipe Replacement - Inlet (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) and «Surge Tank Hose/Pipe Replacement - Outlet (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
9. Remove the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
10. Remove the inlet (1) and outlet (2) heater hoses. Refer to «Heater Inlet Hose Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) and to «Heater Hose Replacement - Outlet (L61)»(/chevrolet/malibu/vi-2006-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Disconnect the following harness connectors: The electronic throttle control The map sensor The crankshaft sensor The oil pressure sensor The purge solenoid The ignition coil and module assembly The O2 sensor The vehicle speed sensor The engine temperature sensor The back-up lamp switch
12. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
13. Remove the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
14. Remove the AC compressor bolts and set the compressor aside.
15. Disconnect the starter harness connectors (3, 4, 5).
16. Disconnect the generator harness connectors.
17. Drain the engine oil.
18. Disconnect the front exhaust pipe from the exhaust manifold. Refer to «Exhaust Manifold Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system) .
19. Disconnect the transmission harness connectors.
20. Disconnect the transmission shift cable from the transmission.
21. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
22. Remove the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
23. Remove the side transmission mount. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
24. Disconnect the stabilizer links from the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/malibu/vi-2006-2008/remont/suspension-front/#front-suspension-system) .
25. Disconnect the outer tie rod ends from the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/malibu/vi-2006-2008/remont/manual-power-steering/#rack-pinion-power-steering-system) .
26. Disconnect the intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/chevrolet/malibu/vi-2006-2008/remont/steering-column-switches/#steering-wheel-steering-column) .
27. Disconnect the lower control arms from the steering knuckles. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2006-2008/remont/suspension-front/#front-suspension-system) .
28. Disconnect the drive axles from the steering knuckle. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2006-2008/remont/axle-shafts/#wheel-drive-shafts__wheel-drive-shaft-replacement) .
29. Use a paint pen or magic marker in order to mark the frame to body position.
30. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
31. Use wood blocks as necessary between the lift table and the frame to support the assembly.
32. Slowly remove the frame bolts using the following sequence: Remove the front frame bolts. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
33. Slowly lower the table to the floor.
34. Attach the engine lift hoist to the engine lift hooks.
35. Remove the starter.
36. Remove the transaxle brace to engine bolts.
37. Remove the transaxle brace to transaxle bolts and brace.
38. Remove the torque converter to flywheel bolts, if applicable.
39. Remove the transaxle to engine bolts.
40. Separate the engine from the transaxle.
41. Remove the clutch pressure plate and disc. if applicable.
42. Remove the following components: The exhaust manifold and catalytic converter assembly The exhaust manifold studs The engine mount bracket The engine block heater The thermostat housing and feed pipe The generator
43. Install the engine to a suitable engine stand.

1. Attach the engine lift hoist to the engine lift hooks.
2. Install the following components: The exhaust manifold - Refer to «Exhaust Manifold Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system) . The engine mount bracket - Refer to «Engine Mount Bracket Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) . The fuel rail - Refer to «Fuel Rail Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) . The engine block heater, if equipped - Refer to «Coolant Heater Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) . The drive belt tensioner - Refer to «Drive Belt Tensioner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) . The thermostat housing and feed pipe - Refer to «Thermostat Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) . The generator - Refer to «Generator Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) . The flywheel - Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-flywheel-replacement) .
3. If applicable, install the clutch pressure plate and disk.
4. Align the engine to the transmission.
5. Secure the engine to the transaxle. Tighten: Tighten the bolts to 75 N.m (55 lb ft).
6. If applicable, install the torque converter bolts. Tighten: Tighten the bolts to 62 N.m (46 lb ft).
7. Position the transaxle brace to the engine and transaxle and install the brace to transaxle bolts.
8. Install the transaxle brace to engine block bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
9. Install the starter. Refer to «Starter Motor Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
10. Remove the engine lift from the engine.
11. Raise and position the frame and powertrain assembly to the vehicle.
12. Hand start all the frame bolts while aligning the frame to the paint marks.
13. Tighten the frame bolts. Tighten: Tighten the frame bolts to 100 N.m (74 lb ft) plus 180 degrees.
14. Remove the lift table.
15. Connect the drive axles to the steering knuckles. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vi-2006-2008/remont/axle-shafts/#wheel-drive-shafts__wheel-drive-shaft-replacement) .
16. Connect the lower control arm to the steering knuckle. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vi-2006-2008/remont/suspension-front/#front-suspension-system) .
17. Connect the intermediate steering shaft to the steering gear. Refer to «Power Steering Gear Replacement (Electronic Power Steering (EPS))»(/chevrolet/malibu/vi-2006-2008/remont/manual-power-steering/#rack-pinion-power-steering-system) or «Power Steering Gear Replacement (Hydraulic Power Steering (HPS))»(/chevrolet/malibu/vi-2006-2008/remont/manual-power-steering/#rack-pinion-power-steering-system) .
18. Connect the outer tie rod ends to the steering knuckles. Refer to «Rack and Pinion Outer Tie Rod End Replacement»(/chevrolet/malibu/vi-2006-2008/remont/manual-power-steering/#rack-pinion-power-steering-system) .
19. Connect the stabilizer links to the stabilizer bar. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/malibu/vi-2006-2008/remont/suspension-front/#front-suspension-system) .
20. Install the side transmission mount. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
21. Install the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
22. Remove the wood blocks between the powertrain and frame.
23. Connect the transmission shift cable to the transmission.
24. Connect the transmission harness connector.
25. Connect the exhaust takedown pipe to the exhaust manifold. Tighten: Tighten the nuts to 30 N.m (22 lb ft).
26. Connect the generator harness connectors. Tighten: Tighten the nut to 20 N.m (15 lb ft).
27. Connect the starter harness connectors (3, 4, 5). Tighten: Tighten the battery terminal nut to 17 N.m (13 lb ft). Tighten the S-terminal nut to 3 N.m (27 lb in).
28. Install the AC compressor to the engine. Refer to «Compressor Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
29. Install the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
30. Connect the following harness connectors: The electronic throttle control The map sensor The crankshaft sensor The oil pressure sensor The purge solenoid The ignition coil and module assembly The O2 sensor The vehicle speed sensor The engine temperature sensor
31. Install the inlet heater hose (1) and outlet heater hose (2). Refer to «Heater Inlet Hose Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) and «Heater Hose Replacement - Outlet (L61)»(/chevrolet/malibu/vi-2006-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
32. Install the radiator outlet hose. Refer to «Radiator Inlet Hose Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
33. Connect the engine compartment fuel feed line quick connect fitting (4) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
34. Connect the brake booster hose at the brake booster.
35. Release the cooling module from the upper body structure.
36. Install the air inlet duct and resonator. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
37. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
38. Fill the engine with engine oil to the proper level. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/malibu/vi-2006-2008/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
39. Fill the cooling system. Refer to «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
40. Road test the vehicle.

J 44887 Oil Filter Wrench. See Special Tools .

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Place a drain pan under the oil drain plug.
3. Remove the oil pan drain plug.
4. Use a J 44887 to remove the oil filter cap. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
5. Remove the oil filter cap with filter.
6. Remove the filter from the cap.

1. Install the filter to the cap.
2. Install the oil filter cap with filter.
3. Use a J 44887 on the oil filter cap. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Tighten: Tighten the oil filter cap until fully seated. DO NOT exceed 25 N.m (18 lb ft).
4. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
5. Lower the vehicle.
6. Fill the engine with oil. Refer to «Fluid and Lubricant Recommendations»(/chevrolet/malibu/vi-2006-2008/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .

Draining Fluids and Oil Filter Removal

Tools Required

J 44887 Oil Filter Wrench. See Special Tools .

1. Use J 44887 to remove the oil filter cap. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Remove the oil pan drain plug and allow the oil to drain out.
2. Remove the oil filter from the cap and discard.
3. Clean the oil filter housing in the engine block.
4. Install the oil pan drain plug. Tighten: Tighten the oil pan drain plug to 25 N.m (18 lb ft).
5. Remove the water pump drain plug from the water pump and allow the coolant to drain from the water jacket.
6. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the water pump drain plug.
7. Install the water pump drain plug. Tighten: Tighten the water pump drain plug to 20 N.m (15 lb ft).
8. If cleaning or repairing the engine block, it is not necessary to reinstall the plugs.

Crankshaft Balancer Removal

Tools Required

J 38122-A Crankshaft Balancer Holder. See Special Tools .

1. Install the J 38122-A . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. Remove the balancer retaining bolt and washer. Use the J 38122-A and a breaker bar to prevent the crankshaft from rotating when loosening the bolt. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Discard the bolt.
3. Remove the crankshaft balancer assembly.

Engine Flywheel Removal

Tools Required

J 38122-A Crankshaft Balancer Holder. See Special Tools .

1. Remove the flywheel attaching bolt. Use the J 38122-A to prevent crankshaft rotation. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. Remove the flywheel retainer.
3. Remove the flywheel.
4. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

Oil Level Indicator and Tube Removal

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

Exhaust Manifold Removal

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

Intake Manifold Removal

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

Camshaft Cover Removal

1. Remove the power steering blockout plate.
2. Remove the camshaft cover grounding strap.
3. Remove the front lift bracket.
4. Remove the rear lift bracket.
5. Remove the ignition coil bolts.
6. Remove the ignition coils.
7. Remove the camshaft cover assembly.

Engine Front Cover and Oil Pump Removal

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

Timing Chain and Tensioner Removal

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

Intake Camshaft, Follower, and Adjuster Removal

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

Exhaust Camshaft, Follower, and Adjuster Removal

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

Balance Shaft Drive Chain and Tensioner Removal

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

Balance Shaft Removal

Tools Required

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

1. Remove the balance shaft bearing carrier bolts.
2. Remove the balance shaft assemblies.
3. Install the J 43650 into the balance shaft hole. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Insert the tool with the foot parallel to the shaft.
4. When the J 43650 is inserted in the block turn the J 43650 so that the foot becomes perpendicular to the shaft. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
5. Center the foot of the J 43650 on the balance shaft bushing. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
6. Once the J 43650 is centered on the balance shaft bushing, then insert the centering guide into the front balance shaft bore and tighten the nut with an appropriate wrench. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . When the J 43650 is properly installed, before removing the bushing, the end of the tool should be 116 mm (4. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .6 in) (a) from the block face. If the J 43650 is less than approximately 114 mm (4. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .5 in) (a), recheck the tool alignment.
7. Tighten the nut on the J 43650 until the tension releases. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . When the tension releases, remove the J 43650 and the balance shaft bushing. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

Water Pump Removal

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

Cylinder Head Removal

Tools Required

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

1. Remove the exhaust gas recirculation (EGR) cover, bolts, and the EGR cover gasket.
2. Remove the cylinder head to the block bolts in sequence. Discard the bolts.
3. Remove the cylinder head.
4. Remove the cylinder head gasket.
5. Clean all of the gasket surfaces.
6. Use the following procedures when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge any surface. IMPORTANT: Do not use any other method or technique to clean these gasket surfaces. Use a new razor blade for each cylinder head and cylinder block. IMPORTANT: Be careful not to gouge or scratch the gasket surfaces. Do not gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the new gasket. Hold the razor blade as parallel to the gasket surface as possible.
7. Clean the old sealer/lube and dirt from the bolt holes.
8. Clean the bolt holes with a nylon bristle brush.
9. When cleaning the cylinder head bolt holes use a suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun to reach the bottom of the holes.
10. Remove any broken long cylinder head bolts using the J 38188 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

Oil Pan Removal

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

Piston, Connecting Rod, and Bearing Removal

Tools Required

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

1. Rotate the crankshaft to a position where the connecting rod bolts are the most accessible.
2. Mark the connecting rod and cap with the cylinder position. Also mark their orientation. This will ensure the caps and connecting rods are re-assembled properly.
3. Remove any ridge at the top of the cylinder bore to avoid damage to the piston ring lands.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap.
6. Install J-43966-1 on the connecting rod bolts before removing the piston and connecting rod assembly. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
7. Remove the piston and connecting rod assembly.

Lower Crankcase Removal

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

Crankshaft and Bearings Removal

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

Engine Block Disassemble

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

Engine Block Cleaning and Inspection

Tools Required

1. J 7872 Magnetic Base Dial Indicator. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 8087 Cylinder Bore Gage. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

1. Clean the sealing material from the gasket mating surfaces.
2. Clean the engine block and lower crankcase in a cleaning tank with solvent appropriate for aluminum.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and install thread inserts. Refer to «Thread Repair»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
8. Use a straight edge and a feeler gage to check the deck surface for flatness. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) . If the deck surface is out of specification, replace the block. Do not machine the block.
9. Inspect the oil pan rail for nicks. Inspect the front cover attaching area for nicks. Use a flat mill file to remove any nicks.
10. Clean the sealing material from the gasket mating surfaces on the lower crankcase engine block side.
11. Clean the sealing material from the gasket mating surfaces on the lower crankcase oil pan side.
12. Inspect the mating surfaces of the transmission face.
13. Use the following procedure in order to measure the engine block flange runout at the mounting bolt hole bosses: Temporarily install the upper bearings, crankshaft and bedplate. Measure the crankshaft flange runout using the J 7872 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Hold the gage plate flat against the crankshaft flange. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.203 mm (0.008 in). Recheck the crankshaft flange runout if the readings vary more than 0.203 mm (0.008 in).
14. Remove the bedplate.
15. Remove the crankshaft and bearings.
16. Install the bedplate.
17. Inspect the crankshaft main bearing bores. Use the J 8087 to measure the bearing bore concentricity and alignment. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
18. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.
19. Inspect the cylinder bores using the J 8087 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Inspect for the following items: Wear Taper Runout Ridging
20. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) .
21. If the cylinder bores are out of specification, install a NEW cylinder bore sleeve. Refer to «Cylinder Sleeve Removal»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__cylinder-sleeve-removal) and «Cylinder Sleeve Installation»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__cylinder-sleeve-installation) .

Cylinder Honing

Tools Required

J 8087 Cylinder Bore Gage. See Special Tools .

1. Measure the cylinder bore for out-of-round and taper.
2. Measure dimension (1) at 13 mm (1/2 in) below the head gasket surface. Measure dimension (2) at 100 mm (4 in) below the head gasket surface.
3. Measure the cylinder bores by setting the J 8087 dial at zero in the cylinder at the point of the desired measurement. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Lock the dial indicator at zero before removing the dial from the cylinder. Measure across the gage contact points with an outside micrometer, with the gage at the same zero setting as when the gage was removed from the cylinder.
4. Fine vertical scratches made by the ring ends do not, by themselves, cause excessive oil consumption. Do not hone the cylinder in order to remove these scratches.
5. If the bore is glazed but otherwise serviceable, lightly break the glaze with a hone. Replace the piston rings. Refer to «Piston, Connecting Rod, and Bearing Installation»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__piston-connecting-rod-and-bearing-installation) . The honing stones must be clean, sharp, and straight. Move the hone slowly up and down to produce a 45 degree cross-hatch pattern. Clean the bore thoroughly with soap and water. Dry the bore. Rub clean engine oil in the bore. Remeasure the bore.
6. If the cylinder bore is out of specification, replace the block.
7. If honing is not required, clean the cylinder bores with hot water and detergent. Apply clean engine oil to the bore after washing and drying the bore.

Cylinder Sleeve Removal

Tools Required

EN 45680-850 Cylinder Sleeve Removal and Installation Kit. See Special Tools .

1. If the crankshaft is still installed, rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
2. Install the cylinder bore sleeve puller (1) through the cylinder bore.
3. Align the shoe (1) of the cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (117).
4. Hold the threaded shaft of the cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
5. Install the fixture (4) onto the threaded shaft of the cylinder bore sleeve puller and the engine block.
6. Install the bearing (3) and the nut (1).
7. Tighten the nut (1) to the bearing (3).
8. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten: Tighten the bolts to 15 N.m (11 lb ft).
9. Rotate the nut clockwise in order to remove the cylinder bore sleeve.
10. Remove the fixture, cylinder bore sleeve puller, and the cylinder bore sleeve (117) from the engine block.
11. Loosen the nut (1) to remove the cylinder bore sleeve (117).
12. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.
13. Inspect the piston, piston rings, and connecting rod for damage. Refer to «Piston, Connecting Rod, and Bearings Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .

Cylinder Sleeve Installation

Tools Required

EN 45680-850 Cylinder Sleeve Removal and Installation Kit. See Special Tools .

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

Cylinder Sleeve Trimming

1. EN 45680-865 Debris Collector (3)
2. EN 45680-861 Trim Tool Assembly (2)
3. Air Control Valve (1)
4. Drill Motor with 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction
5. EN 45680-881 Bore Chamfer Bit
6. EN 45680-899 Bore Trimmer Pilot, white in color

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

1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.
2. Place the metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place additional metal shaving catch plugs into all remaining cylinder bore sleeves.
4. Ensure that the metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. Change the bore chamfer bit to EN 45680-881.
6. Change the bore trimmer pilot to EN 45680-885.
7. The groove side of the set gage ring (1) should be positioned upward on a flat surface.
8. Carefully position the trim tool assembly onto the set gage ring.
9. Loosen the shaft collar screw (2).
10. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3).
11. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw. Tighten: Tighten the shaft collar screw to 19 N.m (14 lb ft).
12. Place the trim tool assembly onto the cylinder to be trimmed with the directional arrow (1) pointing in line with the crankshaft centerline and the front of the block.
13. Install the 4 bolts (2) into the cylinder head bolt holes in the block. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
14. Fasten drive adapter (1) into the drill chuck.
15. Connect a compressed air supply 517.10-861.84 kPa (75-125 psi) to the male quick connect (3) located on trim tool assembly. Turn the compressed air valve (2) to the open position. This starts the venturi vacuum system that will catch the metal shavings.
16. Place the drive adapter and drill assembly (1) vertically onto the drive adapter end of trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, apply firm downward force until the cutting action is complete.
17. Remove the drive adapter (1) and drill assembly from the trim tool assembly.
18. Turn off the compressed air valve (2).
19. Remove the trim tool assembly from the engine block.
20. Remove any material shavings that may be found on the metal shaving catch plug.
21. Wipe the cylinder bore sleeve and surrounding areas free of any powder residue and then remove the metal shaving catch plug.
22. Install a straight edge on the cylinder block perpendicular to the crankshaft center line.
23. Using a light, illuminate the backside of the straight edge.
24. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side or both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
25. Looking at the front of the straight edge, check to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly.
26. Proceed to the next bore sleeve to be trimmed repeating steps 10-23 if necessary.

Crankshaft Balancer Cleaning and Inspection

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

Engine Flywheel Cleaning and Inspection

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

Piston and Connecting Rod Disassemble

Tools Required

EN-46745 Piston Pin Retainer Remover and Installer

1. Disassemble the piston rings. Use a suitable tool to expand the rings. The piston rings must not be reused.
2. Remove the piston pin retainers using the EN-46745 .
3. Remove the piston pin.

Connecting Rod Measurement

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

Piston Measurement

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

Piston Selection

1. Inspect the engine block cylinder bore. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-block-cleaning-and-inspection) .
2. Inspect the piston and the piston pin. Refer to «Piston, Connecting Rod, and Bearings Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
3. Use a bore gauge and measure the cylinder bore diameter. Measure at a point 64 mm (2.5 in) from the top of the cylinder bore.
4. Measure the bore gauge with a micrometer and record the reading.
5. With a micrometer or caliper at a right angle to the piston, measure the piston 14 mm (0.570 in) from the bottom of the skirt.
6. Subtract the piston diameter from the cylinder bore diameter in order to determine piston-to-bore clearance.
7. For proper piston-to-bore clearance. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) .
8. If the proper clearance cannot be obtained, select another piston and measure for the clearances.
9. If the proper fit cannot be obtained, hone the cylinder bore or replace the cylinder block.
10. When the piston-to-cylinder bore clearance is within specifications, mark the top of the piston using a permanent marker for installation to the proper cylinder. Refer to «Separating Parts»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__separating-parts) .

Piston and Connecting Rod Assemble

Tools Required

EN-46745 Piston Pin Retainer Remover and Installer

1. The cast boss (1), on the underside of the piston, must go to the rear of the block.
2. The cast mark (1), on the connecting rod, must go to the front of the block.
3. Assemble the connecting rod and the piston.
4. Use the following procedure to assemble the piston pin and the retainer: Coat the piston pin with oil. Install one side of one piston pin retainer into the retaining groove using EN-46745 . Rotate the retainer until it is fully seated in the groove. Install the connecting rod and the piston pin. Push the piston pin until it bottoms in the previously installed retainer. Install the second piston pin retainer, using EN-46745 . Ensure that the piston moves freely.
5. Install the following components of the oil control ring assembly (bottom ring): The expander The lower oil control ring The upper control ring
6. Install the lower compression ring (second ring). Place the manufacturer's mark facing up.
7. Install the upper compression ring (top ring).

Camshaft Cleaning and Inspection

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

Timing Chain and Sprockets Cleaning and Inspection

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

Balance Shaft Cleaning and Inspection

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

Balance Shaft Drive Chain and Sprockets Cleaning and Inspection

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

Cylinder Head Disassemble

Tools Required

1. J 8062 Valve Spring Compressor. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 36017 Valve Seal Remover. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. J 43963 Valve Spring Compressor (off car). See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

1. Remove the coolant air bleed hose fitting.
2. Using the J 8062 and the J 43963 , compress the valve spring. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. Remove the valve keys.
4. Slowly release the J 8062 and the J 43963 from the valve spring assembly. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
5. Remove the retainer.
6. Remove the spring.
7. Remove the valve seal. Use the J 36017 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Do not reuse.
8. Remove the valve.
9. Remove the remaining valves.
10. Remove the cylinder head plugs.

Valve Cleaning and Inspection

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

Cylinder Head and Gasket Surface Cleaning and Inspection

1. Remove the spark plugs.
2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has failed, use the following faults to determine the cause: Improper installation Loose or warped cylinder head Missing, off location or not fully seated dowel pins Corrosion in the seal area around the coolant passages Chips or debris in the cylinder head bolt holes Bolt holes in the cylinder block not drilled or tapped deep enough
3. Inspect the cylinder head gasket surface. Cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in) band around each combustion chamber (1). Replace the cylinder head if the area between the valve seats is cracked (2). Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each combustion chamber (3).
4. Clean the cylinder head bolts.
5. Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.
6. Clean the valve guides.
7. Clean the threaded holes. Use a nylon bristle brush.
8. Clean the remains of the sealer from the plug holes.
9. Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools.
10. Replace all suspect bolts.
11. Inspect the cylinder head for cracks. Check between the valve seats and in the exhaust ports.
12. Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
13. Inspect the cylinder head deck surface for flatness. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) . If the cylinder head is out of specification, replace it. Do not machine the cylinder head.
14. Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
15. Inspect the sealing surfaces.
16. Inspect the cylinder head plugs.

Cylinder Head Assemble

Tools Required

1. J 8062 Valve Spring Compressor. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 9666 Valve Spring Tester
3. J 43963 Valve Spring Compressor (off car). See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

1. Install NEW cylinder head plugs. Coat the plugs with sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent.
2. Inspect the valve springs for the following conditions: Expanded height Unparallel spring ends Spring tension using J 9666 Any distorted springs should be replaced
3. Assemble the valves.
4. Use the following steps to measure valve runout: Apply a dab of Prussian blue on the entire valve face. Seat the valve but do not rotate it. The Prussian blue traces transferred to the valve seat are an indication of concentricity of the valve seat. Clean all traces of Prussian blue. Apply a dab of Prussian blue on the valve seat and repeat the check. The traces of Prussian blue transferred to the valve face indicates valve face concentricity.
5. Replace the valves, if required.
6. Install the new valve seals. Fully seat the seals on the valve guides.
7. Install the spring.
8. Install the retainer.
9. Using the J 8062 and the J 43963 , compress the valve spring. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
10. Install the valve keys.
11. Slowly release the J 8062 and the J 43963 from the valve/spring assembly. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
12. Inspect for proper valve key seating.
13. Install the remaining valves, springs, and other components.
14. Install the cylinder head air bleed tube. Tighten: Tighten the tube to 15 N.m (133 lb in).

Oil Pump Disassemble

1. Disassemble the pressure relief valve.
2. Remove the oil pump gerotor cover and bolts.
3. Clean all of the parts in cleaning solvent. Remove varnish, sludge and dirt.
4. Inspect the oil pump for wear and scoring. Insure that all components are within specifications. Refer to «Engine Mechanical Specifications»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-mechanical-specifications) . Replace the front cover and oil pump assembly if it is out of specification or damaged.

Oil Pump Assemble

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

Intake Manifold Cleaning and Inspection

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

Exhaust Manifold Cleaning and Inspection

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

Oil Pan Cleaning and Inspection

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

General Thread Repair

Tools Required

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

Scheme 26

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

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

Cylinder Head Bolt Hole Thread Repair

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

Main Cap Bolt Hole Thread Repair

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

Service Prior to Assembly

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

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

Engine Block Assemble

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

Crankshaft and Bearings Installation

Tools Required

1. J 8087 Cylinder Bore Checking Gage. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 45059 Angle Meter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

Scheme 27

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

1. Tighten the bedplate to specification using the J 45059 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. Measure the bearing bore for taper and out-of-round using the J 8087 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. No taper or out-of-round should exist.

Bearing Selection

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

Lower Crankcase Installation

Tools Required

J 45059 Angle Meter. See Special Tools .

1. Install the upper crankshaft bearings and lubricate bearing surfaces with engine oil.
2. Install the crankshaft on the journals.
3. Install the lower bearing halves, without grooves, into the lower crankcase. Apply oil to bearing surfaces.
4. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) to the surfaces of the engine block to bedplate mating surfaces.
5. Install the lower crankcase. Tap gently into place with a suitable tool if necessary. Ensure it is aligned properly on the dowels.
6. Install the NEW crankshaft bearing bolts in sequence finger tight. Tighten the crankshaft bearing bolts in sequence. Tighten: Tighten the crankshaft bearing bolts to 20 N.m (15 lb ft). Tighten the crankshaft bearing bolts in sequence using the J 45059 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Tighten: Tighten the crankshaft bearing bolts 70 degrees using the torque angle meter.
7. Tighten the lower crankcase perimeter bolts in sequence. Tighten: Tighten the lower crankcase perimeter bolts to 25 N.m (18 lb ft).

Crankshaft Rear Oil Seal Installation

Tools Required

J 42067 Rear Crankshaft Seal Installer. See Special Tools .

1. Remove excess sealer from seal recess.
2. Lubricate the outside diameter of the new crankshaft seal with clean engine oil.
3. Using the J 42067 , press the new crankshaft seal into the housing. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . The J 42067 also establishes the depth of the seal in the crankshaft seal bore. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 43953 Piston Ring Compressor. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 45059 Angle Meter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. J-43966-1 / J 41742 Connecting Rod Guides. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

1. Install the connecting rod bearings. Use the proper size bearings. Install the bearing inserts into the connecting rod and the connecting rod cap. Lubricate the connecting rod bearings with engine oil.
2. Install the J-43966-1 / J 41742 into the connecting rod bolt holes. This protects the crankshaft journal during piston and connecting rod installation. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. Install the piston and the connecting rod to the correct bore. Stagger each piston ring end gap equally around the piston. Lubricate the piston and the piston rings with engine oil. Install J 43953 over the piston. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Do not disturb the piston ring end gap location. The piston must be installed so that the mark on the top of the piston faces the front of the engine. Place the piston in its matching bore. Tap the piston into its bore with a hammer handle. Guide the connecting rod to the connecting rod journal while tapping the piston into place. Hold the J 43953 against the engine block until all the rings have entered the cylinder bore. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Remove the connecting rod guides from the connecting rod bolt holes.
4. Install the connecting rod cap.
5. Install the connecting rod bolts. Always use new bolts. Tighten: Tighten the connecting rod bolt nuts to 25 N.m (18 lb ft), plus 100 degrees using J 45059 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
6. Install the remaining connecting rods and piston assemblies.
7. Measure the connecting rod side clearance with a feeler gage. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in).

Cylinder Head Installation

Tools Required

J 45059 Angle Meter. See Special Tools .

1. Install the cylinder head gasket to the block.
2. Install the cylinder head.
3. Install and tighten the cylinder head bolts in sequence. Tighten: Tighten the bolts to 30 N.m (22 lb ft). Then turn all the bolts 155 degrees in sequence. Use the J 45059 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
4. Install the front cylinder head bolts. Tighten: Tighten the cylinder head bolts to 35 N.m (26 lb ft).
5. Install the exhaust gas recirculation (EGR) cover, bolts, and the EGR cover gasket. Tighten: Tighten the EGR cover bolts to 25 N.m (18 lb ft).

Intake Camshaft, Follower, and Adjuster Install

1. Install the hydraulic lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
3. Lubricate the valve tips.
4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Lubricate roller followers with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Set the intake camshaft on top of the roller followers in the camshaft journals. Lubricate with GM P/N 12345501 (Canadian P/N 992704) or equivalent.
6. Install the camshaft caps and hand start the camshaft cap bolts.
7. The timing chain sprocket alignment notch should be oriented to the 11 o'clock position.
8. Tighten the camshaft cap bolts in increments of 3 turns until they are seated. Tighten: Tighten the camshaft caps to 10 N.m (89 lb in).
9. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to rear intake camshaft cap.
10. Install the rear intake camshaft cap bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).

Exhaust Camshaft, Follower, and Adjuster Install

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

Balance Shaft Installation

Tools Required

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

1. Install the balance shaft bushing using the J 43650 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. Seat the balance shaft bushing into the bore using the J 43650 and a wrench. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. When the J 43650 is fully seated in the engine block, remove it with a wrench. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
4. Place the number one piston at top dead center (TDC).
5. Lubricate the balance shaft lobes with engine oil.
6. Install the balance shafts into their bores.
7. Install the balance shaft retaining bolts. Tighten: Tighten the balance shaft retaining bolts to 10 N.m (89 lb in).

Water Pump Installation

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

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

Balance Shaft to Engine Timing

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

Balance Shaft Drive Chain and Tensioner Install

1. Install the upper balance shaft chain guide and bolts. Tighten: Tighten the upper balance shaft chain guide bolts to 15 N.m (11 lb ft).
2. Install the small balance shaft chain guide.
3. Install the balance shaft chain guide bolts. Tighten: Tighten the chain guide bolts to 15 N.m (11 lb ft).
4. Install the adjustable balance shaft drive chain guide.
5. Install the adjustable balance shaft drive chain guide bolts. Tighten: Tighten the chain guide bolts to 10 N.m (89 lb in).
6. Reset the timing chain tensioner by performing the following steps: Turn the tensioner plunger 90 degrees in its bore and compress the plunger. Turn the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hole in the tensioner plunger.
7. Install the timing chain tensioner.
8. Install the chain tensioner bolts. Tighten: Tighten the chain tensioner bolts to 10 N.m (89 lb in).
9. Remove the paper clip from the balance shaft drive chain tensioner.

Timing Chain, Sprockets, Tensioner Installation

Tools Required

J 45059 Angle Meter. See Special Tools .

1. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position.
2. Assemble the intake camshaft sprocket to the timing chain with the timing mark lined up with the uniquely colored link (1). Hand tighten a new intake camshaft sprocket bolt.
3. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
4. Route the timing chain around the crankshaft sprocket and line up the first matching colored link (2) with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
5. Install the adjustable timing chain guide through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten: Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
6. Install the exhaust camshaft sprocket and a new bolt loosely onto the exhaust camshaft.
7. Align the timing mark on the sprocket with the last matching colored link (3). Install the bolt finger tight.
8. If the camshaft is 180 degrees out of time, use the following procedure to re-align the cam. Using a 24 mm wrench, first turn the intake camshaft until the alignment feature on the back of the camshaft sprocket seats in the notch in the front of the intake camshaft. Turn the crankshaft 45 degrees in either direction. Turn the intake cam to the appropriate location. Turn the crankshaft back to top dead center.
9. When the sprocket seats on the cam, tighten the sprocket bolt hand tight.
10. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not, repeat the portion of the procedure necessary to align the timing marks.
11. Install the fixed timing chain guide. Tighten: Tighten the fixed timing chain guide bolts to 15 N.m (11 lb ft).
12. Install the upper timing chain guide. Tighten: Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
13. Using a 24 mm wrench, engage the hex on the intake camshaft and using a torque wrench, tighten the camshaft sprocket bolt. Tighten: Tighten the intake camshaft sprocket bolt to 85 N.m (63 lb ft), plus 30 degrees using the J 45059 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
14. Using a 24 mm wrench, engage the hex on the exhaust camshaft and using a torque wrench, tighten the camshaft sprocket bolt. Tighten: Tighten the exhaust camshaft sprocket bolt to 85 N.m (63 lb ft), plus 30 degrees using the J 45059 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
15. Inspect the timing chain tensioner seal. If the timing chain tensioner seal is damaged, replace the timing chain tensioner seal.
16. Measure the timing chain tensioner assembly from end to end. A new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
17. If the timing chain tensioner is not in the compressed state, simply push in, twist, and lock by hand.
18. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
19. Install the new timing chain tensioner assembly. Tighten: Tighten the timing chain tensioner to 75 N.m (55 lb ft).
20. The timing chain tensioner is released by compressing it 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
21. Install the timing chain oiling nozzle. Tighten: Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
22. Apply sealant GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the thread, and install the timing chain guide bolt access hole plug. Tighten: Tighten the access hole plug to 90 N.m (66 lb ft).

Crankshaft Front Oil Seal Installation

Tools Required

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

1. Install the seal into the front cover using the J 35268-A . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. Ensure that the engine front cover is properly supported when installing the seal.

Engine Front Cover and Oil Pump Installation

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

Camshaft Cover Installation

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

Oil Pan Installation

1. Make sure that the oil pan and mounting surface on the lower crankcase are free of all oil and debris.
2. Apply a 3.5 mm bead of GM P/N 12378521 (Canadian P/N 88901148) or equivalent around the perimeter of the oil pan and the oil suction port opening.
3. Install the oil pan.
4. Install the oil pan bolts. Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft) in sequence.

Crankshaft Balancer Installation

Tools Required

1. J 38122-A Crankshaft Balancer Holder. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 45059 Angle Meter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

1. Install the balancer onto the crankshaft indexing keyway. Use care to properly align the keyway and flats on the balancer with the oil pump drive.
2. Install the J 38122-A . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
3. Install a new retaining bolt and washer. Use the J 38122-A and a breaker bar to prevent the crankshaft from rotating when tightening the bolt. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Tighten: Tighten the bolt to 100 N.m (74 lb ft) plus 125 degrees using the J 45059 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

Oil Filter Adapter Installation

Tools Required

J 44887 Oil Filter Wrench. See Special Tools .

1. Install a new oil filter on the oil filter cap.
2. Lubricate the O-ring on the oil filter cap with 5W30 engine oil.
3. Use J 44887 to install the oil filter adapter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Tighten: Tighten the oil filter adapter to 22 N.m (16 lb ft).

Intake Manifold Installation

1. Install the intake manifold studs in the manifold face. Tighten: Tighten the intake manifold studs to 6 N.m (60 lb in).
2. Install a NEW intake manifold gasket on the intake manifold, if necessary.
3. Install the intake manifold.
4. Install the intake manifold bolts and nuts. Follow the tightening sequence. Tighten: Tighten the bolts and nuts to 10 N.m (89 lb in).
5. Lubricate NEW fuel injector tip insulators with engine oil.
6. Install the NEW fuel injector tip insulators.
7. Install the fuel rail assembly.
8. Install the fuel rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Install a NEW throttle body stud, if necessary. Tighten: Tighten the bolts and nuts to 6 N.m (60 lb in).
10. Install the throttle body, bolts and nut. Tighten: Tighten the bolt and nuts to 10 N.m (89 lb in).
11. Install the EVAP canister valve (2). Tighten: Tighten the EVAP canister valve nut to 18 N.m (13 lb ft).
12. Install the EVAP canister valve tube (1).

Exhaust Manifold Installation

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

Oil Level Indicator and Tube Installation

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

Engine Flywheel Installation

Tools Required

1. J 38122-A Crankshaft Balancer Holder. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .
2. J 45059 Angle Meter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

1. Install the flywheel.
2. Install the NEW bolts.
3. Holding the crankshaft balancer with the J 38122-A , tighten the bolts evenly. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) . Tighten: Tighten the bolts to 53 N.m (39 lb ft), plus 25 degrees using the J 45059 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .

Engine Prelubing

Tools Required

J 45299 Engine Preluber. See Special Tools .

1. Remove the oil pressure switch.
2. Install the M12 x 1.75 adapter P/N 509376.
3. Install the flexible hose to the adapter and open the valve.
4. Pump the handle on the J 45299 in order to flow a minimum of 1-1. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__special-tools) .9 liters (1-2 quarts) of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
5. Close the valve and remove the flexible hose and adapter from the engine.
6. Install the oil pressure switch to the engine. Tighten: Tighten the oil pressure switch to 22 N.m (16 lb ft).
7. Top-off the engine oil to the proper level.

General Description

A crankcase ventilation system is used to consume crankcase vapors in the combustion process instead of venting them to atmosphere. Fresh air from the intake system is supplied to the crankcase, mixed with blow by gases and then passed through a calibrated orifice into the intake manifold.

Scheme 28

The primary control is through the positive crankcase ventilation (PCV) orifice which meters the flow at a rate depending on inlet vacuum. The PCV orifice is an integral part of the camshaft cover. If abnormal operating conditions occur, the system is designed to allow excessive amounts of blow by gases to back flow through the crankcase vent into the intake system to be consumed by normal combustion.

Results of Incorrect Operation

A plugged orifice may cause the following conditions

1. Rough idle
2. Stalling or slow idle speed
3. Oil leaks
4. Sludge in engine

A leaking orifice may cause the following conditions

1. Rough idle
2. Stalling
3. High idle speed

Drive Belt System Description

The drive belt system consists of the following components

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

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

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

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

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

Engine Description

Cylinder Block

The cylinder block is lost foam cast aluminum with 4 cylinders arranged in-line. The cylinders have pressed in place iron liners. The block has 5 crankshaft bearings with the thrust bearing located on the second bearing from the front of the engine. The cylinder block incorporates a bedplate design that forms an upper and lower crankcase. This design promotes cylinder block rigidity and reduced noise and vibration.

Crankshaft

The crankshaft is cast nodular iron with 8 counterweights. The number 8 counterweight is also the ignition system reluctor wheel. The main bearing journals are cross-drilled, and the upper bearings are grooved. The crankshaft has a slip fit balance shaft drove sprocket. Number 2 main bearing is the thrust bearing. A harmonic damper is used to control torsional vibration.

Connecting Rod and Piston

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

Oil Pan

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

Balance Shaft Assembly

There are 2 block mounted balance shafts located on each side of the crankcase at the bottom of the cylinder bores. The balance shafts are driven by a single roller chain that also drives the water pump. The chain is tensioned by a hydraulic tensioner that is supplied pressure by the engine oil pump. This design promotes the maximum effectiveness of the balance shaft system and reduces noise and vibration.

Cylinder Head

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

Valves

There are 2 intake and 2 exhaust valves per cylinder. Rotators are used on all of the intake valves. The rotators are located at the bottom of the valve spring to reduce valve train reciprocating mass. Positive valve stem seals are used on all valves.

Camshaft

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

Valve Lifters

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

Camshaft Cover

The camshaft cover has a steel crankcase ventilation baffling incorporated. The camshaft cover has mounting locations for the ignition system.

Camshaft Drive

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

Intake and Exhaust Manifold

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

Scheme 29

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

Cleanliness and Care

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

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

Separating Parts

Separate, mark, or organize the following components

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

J 28410 Gasket Remover

Gasket Reuse and Applying Sealants

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

Separating Components

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

Cleaning Gasket Surfaces

1. Remove all gasket and sealing material from the part using the J 28410 or equivalent.
2. Care must be used to avoid gouging or scraping the sealing surfaces.
3. Do not use any other method or technique to remove sealant or gasket material from a part.
4. Do not use abrasive pads, sand paper, or power tools to clean the gasket surfaces. These methods of cleaning can cause damage to the component sealing surfaces. Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and has been known to cause internal engine damage.

Assembling Components

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

Pipe Joint Compound

1. Pipe joint compound is a pliable sealer that does not completely harden. This type sealer is used where two non-rigid parts (such as the oil pan and the engine block) are assembled together.
2. Do not use pipe joint compound in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where gasket eliminator is specified.
3. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
4. Apply the pipe joint compound to a clean surface. Use a bead size or quantity as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause component damage when the bolt is tightened.
5. Apply a continuous bead of pipe joint compound to one sealing surface. Sealing surfaces to be resealed must be clean and dry.
6. Tighten the bolts to specifications. Do not overtighten.

RTV Sealer

1. Room Temperature Vulcanizing (RTV) sealant hardens when exposed to air. This type sealer is used where two rigid parts (such as the lower crankcase and the engine block) are assembled together.
2. Do not use Room Temperature Vulcanizing (RTV) sealant in areas where extreme temperatures are expected. These areas include: exhaust manifold, head gasket, or other surfaces where a gasket eliminator is specified.
3. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
4. Apply RTV to a clean surface. Use a bead size as specified in the procedure. Run the bead to the inside of any bolt holes. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause damage when the bolt is tightened.
5. Assemble components while RTV is still wet (within 3 minutes). Do not wait for RTV to skin over.
6. Tighten bolts to specifications. Do not overtighten.

Anaerobic Sealer

1. Anaerobic gasket eliminator hardens in the absence of air. This type sealer is used where two rigid parts (such as castings) are assembled together. When two rigid parts are disassembled and no sealer or gasket is readily noticeable, the parts were probably assembled using a gasket eliminator.
2. Follow all safety recommendations and directions that are on the container. To remove the sealant or the gasket material, refer to «Replacing Engine Gaskets»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61) .
3. Apply a continuous bead of gasket eliminator to one flange. Surfaces to be resealed must be clean and dry.
4. Spread the sealer evenly with your finger to get a uniform coating on the sealing surface.
5. Do not allow the sealer to enter any blind threaded holes, as it may prevent the bolt from clamping properly or cause damage when tightened.
6. Tighten bolts to specifications. Do not overtighten.
7. After properly tightening the fasteners, remove the excess sealer from the outside of the joint.

Tools and Equipment

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

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

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

Special Tools

Special Tools Illustration Tool Number/Description EN 45680-850 Cylinder Sleeve Removal and Installation Kit EN 46745 Piston Pin Retainer Remover and Installer J 7872 Magnetic Base Dial Indicator Set J 8062 Valve Spring Compressor - Head Off J 8087 Cylinder Bore Gage J 9666 Valve Spring Tester J 21867-850 Oil Pressure Gage Adapter J 23600-B Belt Tension Gage J 28410 Gasket Remover J 28428-E High-Intensity Black Light Kit J 28467-B Universal Engine Support Fixture J 28467-501 Engine Support Fixture Adapters J 35268-A Camshaft/Front Main Seal Installer J 35667-A Cylinder Head Leakdown Tester J 35749 Oil Sensor Socket 1 1/16 in J 36017 Valve Guide Seal Remover J 38122-A Crankshaft Balancer Holder J 38188 Cylinder Head Broken Bolt Extractor Kit J 42067 Rear Crankshaft Seal Installer J 42385-850 Thread Repair Kit J 42451 Engine Support Adapter Set J 43649 Valve Spring Compressor J 43650 Balance Shaft Bearing Remover and Installer J 43653 Flywheel Holding Tool J 43655 Sprocket Holding Tool J 43953 Ring Compressor J 43963 Valve Spring Compressor (off car) J 43966-1 Connecting Rod Guides J 44887 Oil Filter Wrench J 45025 Torque Wrench Adapter J 45027 Tensioner Tool J 45059 Angle Meter J 45299 Engine Pre-Luber

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See also:
• Diagnostic System Check - Vehicle
• Symptoms - Engine Controls
• Spark Plug Replacement
• Belt Dressing Notice
• Fastener Notice
• Vibration Analysis - Engine
• Water Pump Replacement (L61)
• Water Pump Replacement (LZ4)
• Front Fender Liner Replacement
• Battery Negative Cable Disconnection and Connection
• Lifting and Jacking the Vehicle
• Exhaust Manifold Replacement (L61)
• Draining and Filling Cooling System (GE 47716)
• Transmission Replacement
• Heater Inlet Hose Replacement (L61)
• Stabilizer Shaft Link Replacement
• Rack and Pinion Outer Tie Rod End Replacement
• Intermediate Steering Shaft Replacement
• Wheel Drive Shaft Replacement
• Fluid and Lubricant Recommendations
• SAFETY GLASSES CAUTION
• Disassembled Views
• 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 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
• Engine Compression Test
• Oil Consumption Diagnosis
• Oil Leak Diagnosis
• Drive Belt Tensioner Diagnosis
• Special Tools
• Engine Mechanical Specifications
• Oil Pump Disassemble
• Engine Front Cover and Oil Pump Installation
• Engine Block Assemble
• Fastener Tightening Specifications
• Engine Support Fixture
• Crankshaft Balancer Replacement
• Sealers, Adhesives, and Lubricants
• Piston, Connecting Rod, and Bearing Removal
• Piston, Connecting Rod, and Bearing Installation
• Engine Flywheel Replacement
• Cylinder Sleeve Removal
• Cylinder Sleeve Installation
• Engine Block Cleaning and Inspection
• Separating Parts