Engine Mechanical - 3.5l 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 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

The Vehicle Identification Number - VIN derivative (1) for 3400 LZ4 is stamped or laser etched on the front and left side of the engine block. The Vehicle Identification Number - VIN derivative is nine digits long and can be used to determine if a vehicle contains the original engine.

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

Diagnostic Starting Point - Engine Mechanical

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

Strategy Based Diagnostics

1. Perform A Diagnostic System Check in Engine Controls before using the symptom tables - if applicable.
2. Review the system operations in order to familiarize yourself with the system functions. Refer to «Disassembled Views»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) , «Engine Component Description»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-component-description) , «Drive Belt System Description»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__drive-belt-system-description) and «Lubrication Description»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) in Engine Mechanical.

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system problem. The diagnostic flow is the place to start when repairs are necessary. For a detailed explanation, refer to Strategy Based Diagnosis in General Information.

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the Engine. Refer to «Checking Aftermarket Accessories»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__checking-aftermarket-accessories) in Wiring Systems.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
3. Check for the correct oil level, proper oil viscosity, and correct filter application.
4. Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM, ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
5. Compare the engine sounds - if applicable to a known good engine and make sure you are not trying to correct a normal condition.

Intermittent

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

Symptom List

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

1. «Base Engine Misfire without Internal Engine Noises»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__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-35l__base-engine-misfire-with-abnormal-internal)
3. «Base Engine Misfire with Abnormal Valve Train Noise»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__base-engine-misfire-with-abnormal-valve)
4. «Base Engine Misfire with Coolant Consumption»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__base-engine-misfire-with-coolant-consumption)
5. «Base Engine Misfire with Excessive Oil Consumption»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__base-engine-misfire-with-excessive-oil)
6. «Engine Compression Test»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-compression-test)
7. «Engine Noise on Start-Up, but Only Lasting a Few Seconds»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-noise-on-start-up-but-only)
8. «Upper Engine Noise, Regardless of Engine Speed»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__upper-engine-noise-regardless-of-engine)
9. «Lower Engine Noise, Regardless of Engine Speed»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__lower-engine-noise-regardless-of-engine)
10. «Engine Noise Under Load»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-noise-under-load)
11. «Engine Will Not Crank - Crankshaft Will Not Rotate»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-will-not-crank-crankshaft)
12. «Oil Consumption Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__oil-consumption-diagnosis)
13. «Oil Pressure Diagnosis and Testing»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l)
14. «Oil Leak Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l)
15. «Drive Belt Chirping, Squeal, and Whine Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l)
16. «Drive Belt Rumbling and Vibration Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l)
17. «Drive Belt Falls Off and Excessive Wear Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l)
18. «Valve Rocker Arm Cover Replacement - Right Side»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l)
19. «Drive Belt Tensioner Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__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

Tools Required

J 38722 Compression Tester. See Special Tools .

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

1. Disable the ignition.
2. Disable the fuel systems.
3. Remove the spark plugs from all the cylinders.
4. Remove the air duct from the throttle body.
5. Block the throttle plate in the open position.
6. Measure the engine compression, using the following procedure: Firmly install the compression gage to the spark plug hole. Have an assistant crank the engine through at least 4 compression strokes in the testing cylinder. Record the readings on the gage at each stroke. Disconnect the gage. Repeat the compression test for each cylinder.
7. Using the J 38722 record the compression readings from all of the cylinders. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) . The lowest reading should not be less than 70 percent of the highest reading. No cylinder reading should be less than 689 kPa (100 psi).
8. The following list contains examples of the possible measurements: When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, the piston rings may be the cause. If the compression improves considerably with the addition of 3 squirts of oil, the piston rings may be the cause. When the compression is low on the first stroke and does not build up in the following strokes, the valves may be the cause. The addition of oil does not affect the compression, the valves may be the cause. When the compression is low on 2 adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause.
9. Remove the block from the throttle plate.
10. Install the air duct to the throttle body.
11. Install the spark plugs.
12. Install the powertrain control module (PCM) fuse.
13. Install the ignition fuse to the I/P fuse block.

Cylinder Leakage Test

Tools Required

J 35667-A Cylinder Head Leakdown Tester

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

1. Disconnect the negative battery cable.
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
3. Install the J 35667-A .
4. Measure each cylinder on the compression stroke, with both valves closed.
5. Apply air pressure, using the J 35667-A . Refer to the manufacturer's instructions.
6. Record the cylinder leakage readings for each cylinder.
7. Inspect the 4 primary areas in order to properly diagnose a leaking cylinder.
8. If air is heard from the intake or exhaust system, perform the following procedure: Remove the valve rocker arm cover of the suspect cylinder head. Ensure that both valves are closed. Inspect the cylinder head for a broken valve spring. Remove and inspect the suspect cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__cylinder-head-cleaning-and-inspection) .
9. If air is heard from the crankcase system at the crankcase - oil filler tube, perform the following procedure: Remove the piston from the suspect cylinder. Inspect the piston and connecting rod assembly. Refer to «Piston, Connecting Rod, and Bearings Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__piston-connecting-rod-and-bearings-cleaning) . Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-block-cleaning-and-inspection) .
10. If bubbles are found in the radiator, perform the following procedure: Remove and inspect both cylinder heads. Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__cylinder-head-cleaning-and-inspection) . Inspect the engine block. Refer to «Engine Block Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-block-cleaning-and-inspection) .
11. Remove the J 35667-A .
12. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
13. 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) .

Oil Consumption Diagnosis

An engine that has excessive oil consumption uses 0. 9 L (1 qt) of oil, or more, within 3 200 km (2,000 mi). The following list indicates the conditions and corrections of excessive oil consumption

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

Low or No Oil Pressure

The following conditions may cause low or no oil pressure

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

Oil Pressure Testing

Tools Required

1. J-21867-6 Oil Pressure Adapter Fitting. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. J 25087-C Oil Pressure Tester and Pump Primer. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

If the vehicle has low oil pressure complete the following steps

1. Inspect the oil level.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
3. Remove the oil filter.
4. Assemble the plunger valve in the large hole of the J 25087-C base. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) . Insert the hose in the small hole of the J 25087-C base. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) . Connect the gage to the end of the hose.
5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve.
6. Install the J 25087-C and J-21867-6 on the filter mounting pad. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
7. Start the engine.
8. Inspect the overall oil pressure, the oil pressure switch, and for noisy lifters. Ensure that the engine is at operating temperature before inspecting the oil pressure. The oil pressure should be approximately 414 kPa (60 psi) at 1,850 RPM using 5W-30 engine oil.
9. If adequate oil pressure is indicated, test the oil pressure switch.
10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the valve indicates a faulty pump.

Tools Required

J 28428-E High Intensity Black Light Kit

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

Locating and Identifying the Leak

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

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

Visual Inspection Method

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

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

Powder Method

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

Black Light and Dye Method

A dye and light kit is available for finding leaks.

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

Possible Causes for Leaks

Inspect the vehicle for the following conditions

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

Description

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

Crankcase Ventilation System Inspection/Diagnosis

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 2 or 3 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 2 or 3 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 two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys.
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

Removal Procedure

1. Remove the engine oil fill cap and tube.
2. If equipped with electric power steering, grasp the cover by the sides and pull up, disengaging the cover from grommets from the ball studs.
3. If equipped with hydraulic power steering, grasp the cover by the sides and pull up, disengaging the cover from grommets from the ball studs.

Installation Procedure

1. If equipped with hydraulic power steering, place the cover over the ball studs, aligning the cover openings with the power steering reservoir cap and oil fill tube opening.
2. Push down on the cover above the studs in order to engage the cover grommets to the studs.
3. If equipped with electric power steering, place the cover over the ball studs, aligning the cover opening with the oil fill tube opening.
4. Push down on the cover above the studs in order to engage the cover grommets to the studs.
5. Install the engine oil fill tube and cap.

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
2. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
3. Install a breaker bar to the drive belt tensioner.
4. Rotate the drive belt tensioner counterclockwise to release the spring tension.
5. Remove the drive belt, if equipped with hydraulic power steering.
6. Remove the drive belt, if equipped with hydraulic power steering.

1. Install a breaker bar to the drive belt tensioner.
2. Rotate the drive belt tensioner counterclockwise to release the spring tension.
3. Route and install the drive belt, if equipped with hydraulic power steering.
4. Route and install the drive belt, if equipped with electric power steering.
5. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-39l) .
2. Loosen the appropriate drive belt idler pulley bolt (1, 2).
3. Remove the appropriate drive belt idler pulley.

1. Install the appropriate drive belt idler pulley.
2. Tighten the appropriate drive belt idler pulley bolt (1,2). Tighten: Tighten the bolt (1) to 50 N. m (37 lb ft). Tighten the bolt (2) to 30 N. m (22 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-39l) .

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
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. Tighten: Tighten the bolt to 50 N. m (37 lb ft).
3. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

Engine Support Fixture

Tools Required

1. J 28467-B Engine Support Fixture
2. J 36462 Engine Support Adapter Leg. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

1. Raise the hood.
2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
3. 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) .
4. Install the thread support nuts J 28467-33A onto the strut attaching studs.
5. Install the strut tower support assemblies J 28467-5A over the thread support nuts J 28467-33A.
6. Install the T-bolts J 28467-5 with 5/16 inch washers through the strut tower support assemblies J 28467-5A into the thread support nuts J 28467-33A. Hand tighten the bolts.
7. Install the 2 cross bracket assemblies J 28467-1A over the strut tower tube J 28467-3.
8. Install the strut tower tube J 28467-3 into the strut tower support assemblies J 28467-5A.
9. 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.
10. 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.
11. 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.
12. 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.
13. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
14. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
15. Install the assembled lift hook bracket J 28467-6A over the radiator shelf tube J 28467-2A.
16. 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.
17. Hand tighten the driver side cross bracket assembly J 28467-1A wing nuts.
18. 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.
19. 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.
20. 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.
21. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A.
22. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A.
23. Install the assemblage lift hook bracket J 28467-6A over the radiator shelf tube J 28467-2A.
24. 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.
25. Hand tighten the passenger side cross bracket assembly J 28467-1A wing nuts.
26. Hand tighten the lift hook wing nuts J 28467-34 securely in order to remove all slack from the engine support fixture assembly.

Engine Mount Inspection

1. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__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-35l) .

1. Remove the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2006-2008/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
2. Remove the engine splash shield. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the engine mount to fame nuts.
4. Remove the engine mount to engine mount bracket nuts.
5. Using a suitable jackstand, raise the engine.
6. Remove the engine mount.

1. Position the motor mount onto the frame.
2. Use the jackstand to lower the engine mount bracket on to the engine mount.
3. Install the engine mount to engine mount bracket nuts. Tighten: Tighten the nuts to 50 N. m (37 lb ft).
4. Install the engine mount to frame nuts. Tighten: Tighten the nuts to 50 N. m (37 lb ft).
5. Install the engine splash shield. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Install the tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2006-2008/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .

1. Remove the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the engine mount bracket bolts (1, 3) from the engine.
3. Remove the engine mount bracket (2).

1. Position the engine mount bracket to the engine.
2. Loosely install the engine mount bracket bolts.
3. Hold the engine mount bracket firmly to the front of the engine and snug the oil pan bolts (3) so that the bracket is just seated to the oil pan.
4. Tighten the engine mount bracket to engine bolt. Tighten: Tighten the bolt to 90 N. m (66 lb ft).
5. Tighten the engine mount bracket to oil pan bolts. Tighten: Tighten the bolts to 50 N. m (37 lb ft).
6. Install the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
2. Remove the engine mount strut to engine mount strut bracket bolts (1).
3. Rotate the engine mount strut (2) to the vertical position in order to access the lower bolt.
4. Remove the engine mount strut bolt (1).
5. Remove the engine mount strut.

1. Install the engine mount strut (2) in to the engine compartment side rail. Ensure that the tab on the strut is inserted into the hole in the side rail.
2. Install the engine mount strut bolt (1). Tighten: Tighten the bolt to 50 N. m (37 lb ft).
3. Rotate the engine mount strut to the horizontal position.
4. Install the engine mount strut to engine mount strut bracket bolts (1). Tighten: Tighten the bolts to 50 N. m (37 lb ft).
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .

1. Remove the engine mount strut. Refer to «Engine Mount Strut Bracket Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the engine mount strut bracket to engine bolts.
3. Remove the engine mount strut bracket.

1. Position the engine mount strut bracket to the engine. Tighten: Tighten the bolts to 25 N. m (18 lb ft).
2. Install the engine mount strut. Refer to «Engine Mount Strut Bracket Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

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 strut to engine mount strut bracket bolts (1).
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 strut to engine mount strut bracket bolts (1). Tighten: Tighten the bolts 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.

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.

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. Remove the oil filter adapter heat shield nuts.
3. Remove the oil filter adapter heat shield (2).
4. Disconnect the engine wiring harness electrical connector (1) from the oil pressure sensor.
5. Remove the oil filter.
6. Remove the oil filter adapter bolts and stud.
7. Remove the oil filter adapter and gasket.
8. Insert a flat bladed tool into the oil filter bypass hole and remove the oil filter bypass valve.

Note. Maximum gasket performance is achieved when using new fasteners, which contain a thread-locking patch. If the fasteners are not replaced, a thread locking chemical must be applied to the fastener threads. Failure to replace the fasteners or apply a thread-locking chemical MAY reduce gasket sealing capability.

1. Install the oil filter bypass valve. Seat the valve fully below the bypass valve hole chamfer.
2. Position the oil filter adapter and gasket to the engine.
3. Apply threadlock to the bolt/stud threads, if required. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
4. Install the oil filter adapter bolts and stud. Tighten: Tighten the bolts/stud to 25 N. m (18 lb ft).
5. Install the oil filter.
6. Connect the engine wiring harness electrical connector (1) to the oil pressure sensor.
7. Install the oil filter adapter heat shield (2).
8. Install the oil filter adapter heat shield nuts. Tighten: Tighten the nuts to 25 N. m (18 lb ft).
9. Lower the vehicle.
10. Check and fill the crankcase, if necessary.

1. Remove the spark plug wire from the number 6 cylinder spark plug.
2. Remove the heated oxygen sensor electrical connector (HO2S) (3) clip from the indicator tube tab.
3. Remove the oil level indicator.
4. Remove the oil level indicator tube bracket bolt.
5. Remove the oil level indicator tube.
6. Inspect the oil level indicator tube O-ring seal for damage, replace as necessary.

1. Lubricate the oil level indicator tube O-ring seal with clean engine oil.
2. Install the oil level indicator tube into the engine block.
3. Install the oil level indicator tube bracket bolt. Tighten: Tighten the bolt to 25 N. m (18 lb ft).
4. Install the oil level indicator.
5. Install the HO2S electrical connector (3) to from the indicator tube tab.
6. Install the spark plug wire to the number 6 cylinder spark plug.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Disconnect the fuel feed pipe quick connect fitting from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
3. Disconnect the evaporative emission (EVAP) pipe quick connect fitting from the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
4. Remove the fuel line clip from the manifold absolute pressure (MAP) sensor bracket.
5. Reposition the fuel/EVAP lines out of the way.
6. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «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) .
7. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
8. Remove the positive crankcase ventilation (PCV) fresh air tube from the rocker cover.
9. Remove the PCV foul air tube quick connect fitting from the rocker cover. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
10. Remove the PCV foul air tube from the intake manifold.
11. Reposition the brake booster vacuum hose clamp (2) at the intake manifold.
12. Remove the brake booster vacuum hose (1) from the intake manifold.
13. Reposition the radiator surge tank inlet hose clamp (1).
14. Remove the radiator surge tank inlet hose from the inlet pipe.
15. Remove the radiator surge tank inlet pipe bolts (2).
16. Remove the radiator surge tank inlet pipe.
17. Remove and discard the O-ring seal (1).
18. Disconnect the engine wiring harness electrical connector (1) from the MAP sensor.
19. Disconnect the engine wiring harness electrical connector (1) from the EVAP canister purge solenoid.
20. Disconnect the engine wiring harness electrical connector (2) from the electronic throttle control (ETC).
21. Disconnect the left side spark plug wires from the spark plugs.
22. Disconnect the left side spark plug wires from the ignition coil.
23. Disengage the spark plug wire retainer clips from the heater inlet and outlet pipe bracket and the MAP sensor bracket.
24. Remove the left side spark plug wires.
25. Remove the heater inlet and outlet pipe nuts (1) from the throttle body studs.
26. Reposition the heater inlet and outlet hose clamps (2) from the pipes.
27. Remove the heater inlet and outlet hoses from the heater inlet and outlet pipes.
28. Remove the heater inlet and outlet pipe bracket from the throttle body studs. Reposition the inlet and outlet pipe out of the way.
29. Remove the ignition coil bracket bolts (1).
30. Remove the generator rear brace upper nut (1).
31. Remove the generator through bolt (3).
32. Remove the generator rear brace (2).
33. Remove the upper intake manifold bolts (1, 2) and stud (3).
34. Separate and remove the upper intake manifold from the lower intake manifold.
35. Remove the upper to lower intake manifold gaskets.
36. If replacing the upper intake manifold, perform the following steps otherwise proceed to step 8 in the Installation Procedure.
37. Remove the EVAP canister purge solenoid valve bolt (1), valve (2).
38. Remove and discard the EVAP canister purge solenoid O-ring seal (3).
39. Remove the intake manifold cover ball stud (4).
40. Remove the MAP sensor bracket (5) and MAP sensor (6).
41. Remove the throttle body bolts (9) and nuts (10).
42. Remove the throttle body (8) and throttle body O-ring seal (7).

1. If replacing the upper intake manifold, perform the following steps otherwise proceed to step 8.
2. Install a NEW throttle body O-ring seal (7) into the groove on the throttle body and install the throttle body (8).
3. Install the throttle body bolts (9) and nuts (10). Tighten: Tighten the bolts/nuts to 10 N. m (89 lb in).
4. Lubricate the MAP sensor seal and install the MAP sensor (6), place the bracket (5) into position.
5. Install the intake manifold cover ball stud (4). Tighten: Tighten the ball stud to 10 N. m (89 lb in).
6. Lubricate and install a NEW EVAP canister purge solenoid O-ring seal (3) onto the solenoid.
7. Install the EVAP canister purge solenoid valve (2) and bolt (1). Tighten: Tighten the bolt to 12 N. m (106 lb in).
8. Install the NEW upper to lower intake manifold gaskets.
9. Set the upper intake manifold onto the lower intake manifold.
10. Apply threadlock to the upper intake manifold bolts/stud threads. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
11. Install the upper intake manifold bolts (1, 2) and stud (3). Tighten: Tighten the bolts/stud to 25 N. m (18 lb ft).
12. Place the generator rear brace (2) onto the stud.
13. Install the generator through bolt (3) until snug.
14. Install the generator rear brace upper nut (1) until snug. Tighten: Tighten the generator through bolt to 50 N. m (37 lb ft). Tighten the generator rear brace upper nut to 25 N. m (18 lb ft).
15. Install the ignition coil bracket bolts (1). Tighten: Tighten the bolts to 25 N. m (18 lb ft).
16. Position the inlet and outlet pipe and install the heater inlet and outlet pipe bracket to the throttle body studs.
17. Install the heater inlet and outlet hoses to the heater inlet and outlet pipes.
18. Position the heater inlet and outlet hose clamps (2) to the pipes.
19. Install the heater inlet and outlet pipe nuts (1) to the throttle body studs. Tighten: Tighten the nuts to 10 N. m (89 lb in).
20. Install the left side spark plug wires.
21. Connect the left side spark plug wires to the spark plugs.
22. Connect the left side spark plug wires to the ignition coil.
23. Engage the spark plug wire retainer clips to the heater inlet and outlet pipe bracket and the MAP sensor bracket.
24. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.
25. Connect the engine wiring harness electrical connector (2) to the ETC.
26. Connect the engine wiring harness electrical connector (1) to the MAP sensor.
27. Install a NEW O-ring seal (1) to the inlet pipe.
28. Install the radiator surge tank inlet pipe.
29. Install the radiator surge tank inlet pipe bolts (2). Tighten: Tighten the bolts to 10 N. m (89 lb in).
30. Install the radiator surge tank inlet hose to the inlet pipe.
31. Position the radiator surge tank inlet hose clamp (1).
32. Install the brake booster vacuum hose (1) to the intake manifold.
33. Position the brake booster vacuum hose clamp (2) at the intake manifold.
34. Install the PCV foul air tube to the intake manifold.
35. Install the PCV foul air tube quick connect fitting to the rocker cover. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
36. Install the PCV fresh air tube to the rocker cover.
37. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
38. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «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) .
39. Position the fuel/EVAP lines.
40. Install the fuel line clip to the MAP sensor bracket.
41. Connect the fuel feed pipe quick connect fitting to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
42. Connect the EVAP pipe quick connect fitting to the purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
43. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
44. 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) .

1. Remove the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) and «Valve Rocker Arm Cover Replacement - Right Side»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
3. Remove the coolant crossover pipe. Refer to «Engine Coolant Crossover Pipe Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Disconnect the fuel injector wiring harness electrical connector from the engine coolant temperature (ECT) sensor.
5. Disconnect the engine wiring harness electrical connector (2) from the fuel injector inline electrical connector.
6. Disconnect the fuel injector wiring harness electrical connector from the camshaft position (CMP) sensor.
7. Remove the fuel injector wiring harness connector bracket bolt from the intake manifold.
8. Remove the fuel rail bolts and rail.
9. Remove the lower intake manifold bolts.
10. Remove the lower intake manifold.
11. Loosen the rocker arm bolts.
12. Remove the rocker arms.
13. Remove the push rods. The intake push rods measure 147. 51 mm (5. 81 in). The exhaust push rods measure 154. 87 mm (6. 1 in).
14. Remove the lower intake manifold gaskets and seals.
15. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
16. Clean the gasket and seal surfaces on the lower intake manifold with degreaser.
17. Remove all the loose room temperature vulcanizing (RTV) sealer.

1. Install the lower intake manifold gaskets and seals.
2. Coat the ends of the push rods using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
3. Install push rods in their original location. The intake pushrods are identified with yellow stripes. The exhaust pushrods are identified with green stripes.
4. Coat the rocker arm friction surfaces using prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
5. Install the rocker arms in their original locations.
6. Install the rocker arm bolts. Tighten: Tighten the bolts to 34 N. m (25 lb ft).
7. With the NEW gaskets and seals in place, apply a small drop, 8-10 mm (0. 31-0. 39 in) of RTV sealer to the 4 corners of the intake manifold to block joints (1). Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
8. Install the lower intake manifold.
9. Apply sealer to the lower intake manifold bolt threads. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
10. Install the lower intake manifold bolts.
11. Tighten the lower intake manifold bolts in the sequence shown. Tighten: Tighten the bolts (1, 2, 3, 4) in sequence to 16 N. m (12 lb ft). Tighten the bolts (5, 6, 7, 8) in sequence to 25 N. m (18 lb ft).
12. Inspect the fuel rail, fuel injectors for damage and replace as necessary.
13. Lubricate and install NEW injector lower O-rings seals onto the injectors. Lubricate the NEW O-rings seals with GM P/N 12345616 (Canadian P/N 993182).
14. Install the injector nozzles into the lower intake manifold injector bores.
15. Press on the injector rail using the palms of both hands until the injectors are fully seated.
16. Install the fuel injector rail bolts. Tighten: Tighten the bolts to 14 N. m (10 lb ft).
17. Position the fuel injector wiring harness electrical connector bracket to the intake manifold and install the bolt. Tighten: Tighten the bolt to 14 N. m (10 lb ft).
18. Connect the fuel injector wiring harness electrical connector to the CMP sensor.
19. Connect the engine wiring harness electrical connector (2) to the fuel injector inline electrical connector.
20. Connect the fuel injector wiring harness electrical connector to the ECT sensor.
21. Install the coolant crossover pipe. Refer to «Engine Coolant Crossover Pipe Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
22. Install the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) and «Valve Rocker Arm Cover Replacement - Right Side»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
23. Install the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

1. Partially drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
3. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
4. Disconnect the left side spark plug wires from the spark plugs.
5. Disengage the spark plug wire retainer clips from the heater inlet and outlet pipe bracket and the MAP sensor bracket.
6. Remove the heater inlet and outlet pipe. Refer to «Heater Hose/Pipe Replacement - Inlet/Outlet (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Disconnect the positive crankcase ventilation (PCV) foul air tube quick connect fitting from the PCV fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
8. Loosen the rocker arm cover bolts.
9. Remove the rocker arm cover (2). If necessary, bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
10. Cut the room temperature vulcanizing (RTV) sealer in the channel where the intake, cylinder head, and rocker cover meet with a suitable tool.
11. Remove the rocker arm cover gasket.

1. All gasket mating surfaces need to be free of oil and foreign material. Use GM P/N 12346139 (Canadian 10953463) or equivalent to clean the surfaces.
2. Install the rocker arm cover gasket into the rocker arm cover.
3. Apply sealer to the surfaces where the cylinder head and the intake manifold meet (1). Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
4. Place the rocker arm cover (2) onto the cylinder head.
5. Tighten the rocker arm cover bolts. Tighten: Tighten the bolts to 10 N. m (89 lb in).
6. Connect the PCV foul air tube quick connect fitting to the PCV fitting. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
7. Install the heater inlet and outlet pipe. Refer to «Heater Hose/Pipe Replacement - Inlet/Outlet (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Engage the spark plug wire retainer clips to the heater inlet and outlet pipe bracket and the MAP sensor bracket.
9. Connect the left side spark plug wires to the spark plugs.
10. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
11. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
12. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «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) .

1. Remove the generator. Refer to «Generator Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Disconnect the positive crankcase ventilation (PCV) fresh air tube from the air cleaner outlet duct. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
3. Remove the PCV fresh air tube from the right rocker arm cover.
4. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
5. Disconnect the engine wiring harness electrical connector (2) from the fuel injector wiring harness electrical connector.
6. Remove the ignition coil assembly. Refer to «Ignition Coil Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2)
7. Loosen the rocker arm cover bolts.
8. Remove the rocker arm cover (2). If necessary, bump the end of the cover with the palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
9. Cut the room temperature vulcanizing (RTV) sealer in the channel where the intake, cylinder head, and rocker cover meet with a suitable tool.
10. Remove the rocker arm cover gasket.

1. All gasket mating surfaces need to be free of oil and foreign material. Use GM P/N 12346139 (Canadian 10953463) or equivalent to clean the surfaces.
2. Install the rocker arm cover gasket into the rocker arm cover.
3. Apply sealer to the surfaces where the cylinder head and the intake manifold meet (1). Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
4. Place the rocker arm cover (2) onto the cylinder head.
5. Tighten the rocker arm cover bolts. Tighten: Tighten the bolts to 10 N. m (89 lb in).
6. Install the ignition coil assembly. Refer to «Ignition Coil Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
7. Connect the engine wiring harness electrical connector (2) to the fuel injector wiring harness electrical connector.
8. Connect the engine wiring harness electrical connector (1) to the MAP sensor.
9. Install the PCV fresh air tube to the right rocker arm cover.
10. Connect the PCV fresh air tube to the air cleaner outlet duct. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
11. Install the generator. Refer to «Generator Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Remove the valve rocker arm covers. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) or «Valve Rocker Arm Cover Replacement - Right Side»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the rocker arm bolts.
3. Remove the rocker arms.
4. Remove the pushrods. The intake push rods measure 147. 51 mm (5. 81 in). The exhaust push rods measure 154. 87 mm (6. 1 in).

1. Coat the ends of the pushrods using prelube. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
2. Install the pushrods. The intake pushrods are identified with yellow stripes. The exhaust pushrods are identified with green stripes.
3. Ensure that the pushrods seat in the lifter bore.
4. Coat the rocker arm friction surfaces using prelube. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
5. Install the rocker arms.
6. Install the rocker arm bolts. Tighten: Tighten the bolts to 32 N. m (24 lb ft).
7. Install the valve rocker covers. Refer to «Valve Rocker Arm Cover Replacement - Left Side»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) or «Valve Rocker Arm Cover Replacement - Right Side»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

Valve Stem Oil Seal and Valve Spring Replacement

Tools Required

1. EN-47823 Valve Spring Compressor Adapter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. J 22794 Spark Plug Port Adapter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
3. J 5892-D Valve Spring Compressor. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

1. Remove the spark plug. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
2. Remove the rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
3. Install the J 22794 into the spark plug port. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) . Apply compressed air in order to hold the valve in place.
4. Using caution so as not to damage the valve spring or valve spring dampener, compress the valve spring using the J 5892-D (1) and the EN-47823 (2). See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
5. Remove the valve spring cap keys.
6. Remove the valve cap.
7. Remove the valve spring.
8. Remove the valve stem oil seal.

1. Lubricate the valve stem with clean engine oil.
2. Install the valve stem oil seal, ensuring the proper seals (intake - black seal and exhaust - brown seal), are installed.
3. Install the valve spring.
4. Install the valve cap.
5. Using caution so as not to damage the valve spring or valve spring dampener, compress the valve spring using the J 5892-D (1) and the EN-47823 (2). See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
6. Install the valve cap keys. If necessary, use grease in order to hold the valve cap keys in place.
7. Ensure the valve cap keys are seated.
8. Remove the compressed air and remove the J 22794 from the spark plug port. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
9. Install the rocker arm. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
10. Install the spark plug. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .

1. Remove the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
3. Remove the valve lifter guide bolts.
4. Remove the valve lifter guides.
5. Remove the valve lifters.

1. Coat the valve lifters with prelube. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
2. Install the valve lifters.
3. Apply threadlock to the valve lifter guide bolt threads. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
4. Install the valve lifter guides and bolts. Tighten: Tighten the bolts to 10 N. m (89 lb in).
5. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
6. Install the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

Crankshaft Balancer Replacement

Tools Required

1. EN 46359 Puller End Protector. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. J 29113 Balancer and Crank Sprocket Installer. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
3. J 37096 Flywheel Holder. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
4. J 41816 Harmonic Balancer Remover. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
5. J 45059 Angle Meter

Note. The inertial weight section of the crankshaft balancer is assembled to the hub with a rubber type material. The correct installation procedures (with the proper tool) must be followed or movement of the inertial weight section of the hub will destroy the tuning of the crankshaft balancer.

1. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2006-2008/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
3. Remove the right engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Side»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Install adjustable jack stands under the frame.
5. Loosen the left frame bolts and remove the right side frame bolts.
6. Using the jack stands, lower the right side of the frame to access the crankshaft balancer.
7. Remove the torque converter covers.
8. Install the J 37096 to the flywheel to prevent flywheel rotation. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
9. Remove the crankshaft balancer bolt and the washer.
10. Remove the crankshaft balancer using the J 41816 and EN 46359 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

1. Apply sealant to the keyway of the crankshaft balancer. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Thread the J 29113 into the crankshaft. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
4. Rotate the hex nut on the J 29113 in order to install the crankshaft balancer onto the crankshaft. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
5. Remove the J 29113 from the crankshaft. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
6. Install the crankshaft balancer washer and the bolt.
7. Tighten the crankshaft balancer bolt. Tighten: Tighten the bolt to 70 N. m (52 lb ft) plus an additional 70 degrees using the J 45059 .
8. Remove the J 37096 from the flywheel. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
9. Install the torque converter covers.
10. Raise the frame to the original position.
11. Install and tighten the right and left side frame bolts. Tighten: Tighten the bolts to 100 N. m (74 lb ft) plus an additional 90 degrees using the J 45059 .
12. Install the right engine splash shield. Refer to «Radiator Air Baffle and Deflector Replacement - Side»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
13. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vi-2006-2008/remont/wheel-tire-system/#tires-wheels__tire-and-wheel-removal-and-installation) .
14. Lower the vehicle.
15. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

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. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-support-fixture) .
3. 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) .
4. Place a suitable drain pan under the oil pan drain plug.
5. Remove the oil pan drain plug and drain the engine oil from the crankcase.
6. Reinstall the oil pan drain plug until snug.
7. Remove the starter. Refer to «Starter Motor Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
8. Remove the oil filter adapter. Refer to «Oil Filter Adapter and Bypass Valve Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
9. Remove the air conditioning (A/C) compressor bolts/nut and position the compressor aside.
10. Remove the engine mount bracket bolts and bracket.
11. Remove the transaxle brace bolts (5 and 6) and remove the brace (7).
12. Remove the transaxle to oil pan brace bolts and brace.
13. Remove the flexplate to torque converter bolts.
14. Lower the vehicle.
15. Remove the engine harness ground nut (3) from the transaxle stud.
16. Remove the engine wiring harness ground (2) and the negative battery cable ground (1) from the transaxle stud.
17. Remove the engine wiring harness clip nut (5) from the transaxle stud.
18. Remove the engine wiring harness clip (6) from the transaxle stud.
19. Remove the engine wiring harness clips (2, 3) from the oil pan.
20. Loosen, DO NOT REMOVE the transaxle studs and bolts.
21. Using the engine support fixture, raise the engine and transaxle slightly.
22. Raise and support the vehicle.
23. Remove the oil pan bolts (1 and 2).
24. Separate the engine and transaxle approximately 13 mm (1/2 inch).
25. Ensure that when removing the oil pan, the pan clears the boss (1) on the transaxle.
26. Remove the oil pan, if the oil pan cannot be removed, lower the vehicle and perform steps 21 and 23 again until the pan can be removed.
27. Remove and discard the oil pan gasket.
28. Clean the oil pan sealing surfaces.

1. Apply sealer to both sides of the front cover/block mating area. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
2. Apply sealer to both sides of the crankcase rear main bearing cap. Press the sealer into the gap using a putty knife. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
3. Install a NEW oil pan gasket.
4. Install the oil pan.
5. Install the oil pan bolts (1 and 2). Tighten: Tighten the bolts (1) to 50 N. m (37 lb ft). Tighten the bolts (2) to 25 N. m (18 lb ft).
6. Lower the vehicle.
7. Using the engine support fixture, lower the engine and transaxle.
8. Tighten the transaxle studs and bolts. Tighten: Tighten the bolts/studs to 75 N. m (55 lb ft).
9. Install the engine wiring harness clips (2, 3) to the oil pan.
10. Install the engine wiring harness clip (6) to the transaxle stud.
11. Install the engine wiring harness clip nut (5) to the transaxle stud. Tighten: Tighten the nut to 25 N. m (18 lb ft).
12. Install the negative battery cable ground (1) and the engine wiring harness ground (2) to the transaxle stud.
13. Install the engine harness ground nut (3) to the transaxle stud. Tighten: Tighten the nut to 25 N. m (18 lb ft).
14. Raise and support the vehicle.
15. Install the flexplate to torque converter bolts. Tighten: Tighten the bolts to 62 N. m (46 lb ft).
16. Position the transaxle to oil pan brace and install the bolts. Tighten: Tighten the bolts to 50 N. m (37 lb ft).
17. Position the transaxle brace (7) to the transaxle and install the bolts (5 and 6) until snug.
18. Install the engine wiring harness clip to the rear of the transaxle brace.
19. Position the engine mount bracket to the engine and install the bolts until snug.
20. Tighten the engine mount bracket bolts and transaxle brace bolts. Tighten: Tighten the engine mount bracket upper bolt to 90 N. m (66 lb ft). Tighten the engine mount bracket lower bolts to 50 N. m (37 lb ft). Tighten the transaxle brace bolts to 72 N. m (53 lb ft).
21. Position the A/C compressor and install the bolts. Tighten: Tighten the bolts to 50 N. m (37 lb ft).
22. Install the oil filter adapter. Refer to «Oil Filter Adapter and Bypass Valve Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
23. Install the starter. Refer to «Starter Motor Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
24. Ensure that the oil pan drain plug is tighten. Tighten: Tighten the drain plug to 26 N. m (19 lb ft).
25. Lower the vehicle.
26. Remove the engine support fixture.
27. Fill the crankcase with oil.
28. 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) .
29. Start the vehicle and inspect for leaks.

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. Remove the oil pressure sensor heat shield bolts and shield.
3. Disconnect the engine wiring harness electrical connector (1) from the oil pressure sensor.
4. Remove the engine oil pressure sensor.

1. Install the engine oil pressure sensor. Tighten: Tighten the sensor to 16 N. m (12 lb ft).
2. Connect the engine wiring harness electrical connector (1) to the oil pressure sensor.
3. Install the oil pressure sensor heat shield and bolts. Tighten: Tighten the bolts to 10 N. m (89 lb in).
4. Lower the vehicle.

1. Remove the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the oil pump bolt.
3. Remove the oil pump and the oil pump drive shaft.

1. Install the oil pump drive shaft and the oil pump.
2. Install the oil pump bolt. Tighten: Tighten the bolt to 41 N. m (30 lb ft).
3. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2)
3. Remove the oil pump drive bolt.
4. Remove the oil pump drive.

1. Coat the drive gear on the oil pump drive with prelube. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
2. Install the oil pump drive.
3. Install the oil pump drive bolt. Tighten: Tighten the bolt to 50 N. m (37 lb ft).
4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
5. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

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

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__crankshaft-balancer-replacement) .
2. Remove the crankshaft key from the keyway.
3. Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or the crankshaft.

1. Lubricate the NEW oil seal with clean engine oil.
2. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
3. Install the crankshaft front oil seal using the J 35468 and a suitable tool. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
4. Install the crankshaft key into the keyway.
5. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__crankshaft-balancer-replacement) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
3. Disconnect the engine wiring harness electrical connector (2) from the camshaft position actuator magnet.
4. Remove the camshaft position actuator magnet bolts.
5. Remove the camshaft position actuator magnet and O-ring seal.

1. Install the camshaft position actuator magnet O-ring seal and magnet.
2. Install the camshaft position actuator magnet bolts. Tighten: Tighten the bolts to 10 N. m (89 lb in).
3. Connect the engine wiring harness electrical connector (2) to the camshaft position actuator magnet.
4. Install the engine mount strut bracket. Refer to «Engine Mount Strut Bracket Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
5. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «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) .
2. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
3. Remove the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
4. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__crankshaft-balancer-replacement) .
5. Remove the crankshaft position actuator magnet. Refer to «Camshaft Position Actuator Magnet Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
6. Remove the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Remove the water pump. Refer to «Water Pump Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Remove the engine front cover bolts (1).
9. Remove the engine front cover.
10. Remove the engine front cover gasket.

1. Install the engine front cover gasket.
2. Install the engine front cover.
3. Apply sealant to the bolts in the locations pointed out (1) in the graphic. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
4. Install the engine front cover bolts. Tighten: Tighten the bolts to 25 N. m (18 lb ft).
5. Install the water pump. Refer to «Water Pump Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Install the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Install the crankshaft position actuator magnet. Refer to «Camshaft Position Actuator Magnet Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
8. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__crankshaft-balancer-replacement) .
9. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
10. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
11. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «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)

EN-47719 Tensioner Compressor. See Special Tools .

1. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
3. Align the timing mark on the camshaft position actuator gear (4) with the timing mark on top of the timing chain tensioner (3).
4. Remove the camshaft position actuator bolts.
5. Remove the timing chain, camshaft position actuator, and crankshaft sprockets.
6. Remove the timing chain tensioner bolts.
7. Remove the timing chain tensioner.
8. Remove the crankshaft sprocket.
9. Remove the timing chain dampener bolts.
10. Remove the timing chain dampener.
11. Remove and discard the camshaft position actuator filter (1) from the end of the camshaft.

1. Install a NEW the camshaft position actuator filter (1) to the end of the camshaft.
2. Install the crankshaft sprocket.
3. Apply prelube to the crankshaft sprocket thrust surface. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
4. Install the timing chain tensioner.
5. Install the timing chain tensioner bolts. Tighten: Tighten the bolts to 21 N. m (15 lb ft).
6. Using the EN-47719 , fully collapse the tensioner, and place he tensioner retaining pin into the retaining hole (1). See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
7. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
8. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
9. Align the timing mark on the camshaft position actuator gear (4) with the timing mark on top of the timing chain tensioner (3).
10. Align the dowel in the camshaft position actuator with the dowel hole in the camshaft.
11. Install the camshaft position actuator bolts.
12. Draw the camshaft actuator onto the camshaft using the bolts. Tighten: Tighten the bolts to 16 N. m (12 lb ft).
13. Remove the retaining pin from the timing chain tensioner in order to make the tensioner active.
14. Coat the crankshaft and camshaft sprockets with clean engine oil.
15. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

J 45059 Angle Meter

1. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Lower the vehicle.
3. Remove the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
4. Remove the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
5. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system)
6. Remove the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
7. Remove the left spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
8. Remove and discard the cylinder head bolts.
9. Remove the cylinder head.
10. Remove and discard the cylinder head gasket.
11. Remove the cylinder head locator dowel pins, if necessary.
12. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__cylinder-head-cleaning-and-inspection) .

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head and bolts.
5. Tighten the NEW cylinder head bolts. Tighten: Tighten the bolts a first pass in sequence to 60 N. m (44 lb ft). Tighten the bolts a final pass in sequence to 95 degrees using the J 45059 .
6. Install the left spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
7. Install the oil level indicator tube. Refer to «Oil Level Indicator and Tube Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
8. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Left Side (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system) .
9. Install the valve rocker arms and pushrods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
10. Install the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
11. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
12. Inspect for leaks.

J 45059 Angle Meter

1. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Lower the vehicle.
3. Remove the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
4. Remove the valve rocker arms and push rods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
5. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system) .
6. Remove the right spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
7. Remove the generator. Refer to «Generator Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
8. Remove and discard the cylinder head bolts.
9. Remove the cylinder head.
10. Remove and discard the cylinder head gasket.
11. Remove the cylinder locator dowel pins, if necessary.
12. Clean and inspect the cylinder head. Refer to «Cylinder Head Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__cylinder-head-cleaning-and-inspection) .

1. Install the cylinder head locator dowel pins, if necessary.
2. Inspect the cylinder head locator dowel pins for proper installation.
3. Install the cylinder head gasket.
4. Install the cylinder head and bolts.
5. Tighten the NEW cylinder head bolts. Tighten: Tighten the bolts a first pass in sequence to 60 N. m (44 lb ft). Tighten the bolts a final pass in sequence to 95 degrees using the J 45059 .
6. Install the generator. Refer to «Generator Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
7. Install the right spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
8. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement - Right Side (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system) .
9. Install the valve rocker arms and push rods. Refer to «Valve Rocker Arm and Push Rod Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
10. Install the lower intake manifold. Refer to «Lower Intake Manifold Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
11. Fill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
12. Inspect for leaks.

J 37096 Flywheel Holder. See Special Tools .

1. Remove the automatic transaxle. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
2. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
3. Loosen the flywheel bolts.
4. Remove 5 of the 6 flywheel bolts leaving one bolt at the top of the crankshaft.
5. Grip the flywheel and remove the remaining bolt. Do not drop the flywheel when removing the final bolt.
6. Remove the engine flywheel.
7. Clean the engine flywheel bolt threads and bolt holes.

1. Position the flywheel to the crankshaft.
2. Install the flywheel bolts finger tight.
3. Use the J 37096 to secure the flywheel in order to prevent the crankshaft from rotating. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
4. Install the engine flywheel bolts. Tighten: Tighten the bolts to 70 N. m (52 lb ft).
5. Install the automatic transaxle. Refer to «Transmission Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .

EN-48108 Rear Main Oil Seal Installer. See Special Tools .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the crankshaft rear main oil seal using one of the following techniques
3. If removing the new style seal - seal lip facing outward, insert a flat bladed or similar tool between the sealing lip and the outer casting of the seal at an angle, and gently pry the seal out by moving the tool towards the center of the crankshaft.
4. If removing an old style seal - seal lip faces inward, insert a flat bladed or similar tool between the outer seal casing and the engine block casting and gently pry the seal out.
5. Repeat the above steps as necessary around the crankshaft rear oil seal, until the seal is removed.

1. The EN-48108 tool has a unique design to allow the technician to easily install the rear main seal squarely to the correct depth and direction. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) . Before proceeding with the installation, review the above illustration to become familiar with the following components: Mandrel (1) Drive drum (2) Drive Nut (3) Washer (4) Bearing (5)
2. Align the mandrel dowel pin to the dowel pin hole in the crankshaft.
3. Using a flat-bladed screwdriver, tighten the 2 mandrel screws to the crankshaft, ensuring the mandrel is snug to the crankshaft hub.
4. Install the rear main seal, with protective nylon sleeve attached, onto the mandrel.
5. Install the outer drive drum onto the mandrel.
6. Install the bearing, washer, and the drive nut onto the threaded shaft.
7. Using a wrench, turn the drive nut on the mandrel, which will push the seal into the engine block bore.
8. Turn the wrench until the drive drum is snug and flush against the engine block.
9. Loosen and remove the drive nut, washer, bearing and drive drum. Discard the nylon plastic seal protector.
10. Use the flat-bladed screwdriver and remove the 2 attachment screw from the mandrel and remove the mandrel from the crankshaft hub.
11. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

1. Remove the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the camshaft rear bearing hole plug.

1. Coat the camshaft rear bearing hole plug with sealer. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__sealers-adhesives-and-lubricants) .
2. Install the camshaft rear bearing hole plug.
3. Ensure that the camshaft rear bearing plug is installed to specifications.
4. Install the engine flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

Engine Replacement

Tools Required

1. J 37096 Flywheel Holder. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. J 25033-C Pulley Installer
3. J 25034-C Pulley Remover

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. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
3. Remove the hood. Refer to «Hood Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-body-panels/#bolted-exterior-body-panels-and-closures) .
4. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
5. Remove the engine mount strut. Refer to «Engine Mount Strut Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
6. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
7. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «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) .
8. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
9. Remove the starter motor. Refer to «Starter Motor Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
10. Remove the oil pressure sensor heat shield nuts and shield.
11. Disconnect the engine wiring harness electrical connector (1) from the oil pressure sensor.
12. Disconnect the engine wiring harness electrical connector (2) from the knock sensor.
13. Remove the engine wiring harness ground bolt (1).
14. Separate the engine wiring harness ground terminal (2) from the engine boss.
15. Remove the engine wiring harness clip (1) from the air conditioning (A/C) compressor bracket.
16. Remove the engine wiring harness clip bolt (3).
17. Separate the engine wiring harness clip (2) from the engine boss.
18. Disconnect the engine wiring harness electrical connector from the A/C compressor.
19. Remove the connector position assurance (CPA) retainer (3).
20. Disconnect the lower front heated oxygen sensor (HO2S) electrical connector from the engine wiring harness electrical connector (1).
21. Remove the engine wiring harness electrical connector clip (2) from the thermostat housing stud.
22. Remove the lower rear CPA retainer (1).
23. Disconnect the lower rear HO2S electrical connector from the engine wiring harness electrical connector (2).
24. Remove the engine wiring harness electrical connector (2) rosebud from the transaxle mount.
25. Disconnect the engine wiring harness electrical connector (1) from the knock sensor.
26. Disconnect the engine wiring harness electrical connector (2) from the crankshaft position (CKP) sensor.
27. Remove the engine wiring harness clip (1) from the engine stud.
28. Lower the vehicle.
29. Using the J 25034-C , remove the power steering pump pulley.
30. Remove the power steering pump bolts (3).
31. Remove the power steering line clip bolt (1) from the generator stud.
32. Remover the power steering line clip (2) from the stud.
33. Reposition and secure the power steering pump assembly out of the way.
34. Disconnect the engine wiring harness electrical connector (1) from the evaporative emission (EVAP) canister purge solenoid.
35. Disconnect the engine wiring harness electrical connector (2) from the electronic throttle control (ETC).
36. Remove the CPA retainer (5).
37. Disconnect the engine wiring harness electrical connector (4) from the HO2S.
38. Disconnect the engine wiring harness clips (1, 2) from the heater inlet and outlet pipe brackets.
39. Disconnect the engine wiring harness clip (3) from the engine lift bracket.
40. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
41. Disconnect the engine wiring harness electrical connector (2) from the ignition control module.
42. Remove the CPA retainer (3).
43. Disconnect the engine wiring harness electrical connector (2) from the rear upper HO2S.
44. Remove the engine wiring harness clips (1, 2) from the ignition control module bracket.
45. Reposition the engine wiring harness terminal boot (4).
46. Remove the engine wiring harness to generator stud nut (1).
47. Remove the engine wiring harness terminal (2) from the generator.
48. Disconnect the engine wiring harness electrical connector (3) from the generator.
49. Disconnect the engine wiring harness electrical connector (2) from the fuel injector inline electrical connector.
50. Remove the engine wiring harness bolt (1).
51. Disconnect the engine wiring harness electrical connector (2) from the camshaft phasor.
52. Remove the engine wiring harness clip (3) from the engine.
53. Disconnect the engine wiring harness electrical connector (1) from the body wiring harness electrical connector (2).
54. Disconnect the engine wiring harness electrical connector (3) from the body wiring harness electrical connector (2).
55. Disconnect the body harness electrical connector from the powertrain control module (PCM).
56. Disconnect the engine wiring harness electrical connector (1) from the PCM.
57. Disconnect the engine wiring harness electrical connector from the transmission control module (TCM).
58. Disconnect the engine wiring harness electrical connector from the vehicle speed sensor.
59. Remove the engine wiring harness clip from the vehicle speed sensor bracket.
60. Disconnect the engine wiring harness electrical connector (1) from the neutral safety backup switch.
61. Disconnect the engine wiring harness electrical connector (1) from the transaxle.
62. Remove the engine wiring harness clip bolt (4).
63. Remove the engine wiring harness clip nut (5).
64. Remove the engine wiring harness clip (6) from the transaxle stud.
65. Remove the engine wiring harness ground nut (3).
66. Remove the engine wiring harness ground terminal (2) and the battery cable ground terminal (1) from the transaxle stud.
67. Gather all branches of the engine wiring harness and reposition the harness out of the way.
68. Remove the catalytic converter. Refer to «Catalytic Converter Replacement - Left Side (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system) and/or «Catalytic Converter Replacement - Right Side (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system) .
69. Remove the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
70. Remove the torque converter cover bolts and cover.
71. Remove the flexplate to torque converter bolts.
72. Unbolt and reposition the A/C compressor off to the side. DO NOT discharge the A/C system.
73. Remove the transaxle brace bolts and brace.
74. Reposition the radiator outlet hose clamp at the thermostat housing.
75. Remove the radiator outlet hose from the thermostat housing.
76. Lower the vehicle and support the transaxle.
77. Reposition the radiator surge tank hose clamp at the surge tank pipe.
78. Remove the radiator surge tank hose from the surge tank pipe.
79. Reposition the brake booster vacuum hose clamp (2) at the intake manifold.
80. Remove the brake booster vacuum hose (1) from the intake manifold.
81. Reposition the heater inlet (1) and outlet (2) hose clamps at the engine.
82. Remove the heater outlet and inlet hoses from the engine.
83. Disengage the fuel/EVAP line clip (1) from the MAP sensor bracket.
84. Disconnect the fuel feed line quick connect fitting (3) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
85. Disconnect the EVAP purge line quick connect fitting (2) from the canister purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
86. Reposition the radiator inlet hose clamp at the engine.
87. Remove the radiator inlet hose from the engine.
88. Install a engine lifting device to the engine.
89. Remove the transaxle-to-engine bolts/studs.
90. Separate the engine from the transaxle and remove the engine from the vehicle.
91. Using the J 37096 , secure the flexplate in order to prevent the flexplate from rotating. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
92. Loosen the flexplate bolts.
93. Remove 5 of the 6 flexplate bolts leaving one bolt at the top of the crankshaft.
94. Grip the flexplate and remove the remaining bolt. Do not drop the flexplate when removing the final bolt.
95. Remove the flexplate.
96. Install the engine to the engine stand.

1. Install a engine lifting device to the engine.
2. Remove the engine from the engine stand.
3. Position the flexplate to the crankshaft.
4. Install the flywheel bolts finger tight.
5. Install the J 37096 to the flexplate in order to prevent the flexplate from rotating. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
6. Tighten the flexplate bolts. Tighten: Tighten the bolts to 70 N. m (52 lb ft).
7. Remove the J 37096 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
8. Install the engine to the vehicle and install the engine to the transaxle.
9. Install the transaxle-to-engine bolts/studs. Tighten: Tighten the bolts to 75 N. m (55 lb ft).
10. Install the radiator inlet hose to the engine.
11. Position the radiator inlet hose clamp at the engine.
12. Connect the EVAP purge line quick connect fitting (2) to the canister purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
13. Connect the fuel feed line quick connect fitting (3) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
14. Engage the fuel/EVAP line clip (1) to the MAP sensor bracket.
15. Install the heater outlet and inlet hoses to the engine.
16. Position the heater inlet (1) and outlet (2) hose clamps at the engine.
17. Install the brake booster vacuum hose (1) to the intake manifold.
18. Position the brake booster vacuum hose clamp (2) at the intake manifold.
19. Install the radiator surge tank hose to the surge tank pipe.
20. Position the radiator surge tank hose clamp at the surge tank pipe.
21. Remove the support from the transaxle and raise the vehicle.
22. Install the radiator outlet hose to the thermostat housing.
23. Position the radiator outlet hose clamp at the thermostat housing.
24. Install the transaxle brace and bolts. Tighten: Tighten the bolts to 50 N. m (37 lb ft).
25. Position and install the A/C compressor onto the stud.
26. Tighten the A/C compressor nut first, then the rear bolt, then the front bolt. Tighten: Tighten the bolts/nut to 50 N. m (37 lb ft).
27. Install the flexplate to torque converter bolts. Tighten: Tighten the bolts to 62 N. m (46 lb ft).
28. Install the torque converter cover and bolts. Tighten: Tighten the bolts to 10 N. m (89 lb in).
29. Install the catalytic converter. Refer to «Catalytic Converter Replacement - Left Side (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system) and/or «Catalytic Converter Replacement - Right Side (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/exhaust/#engine-exhaust-system) .
30. Install the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
31. Position the branches of the engine wiring harness over the engine.
32. Install the battery cable ground terminal (1) and the engine wiring harness ground terminal (2) to the transaxle stud.
33. Install the engine wiring harness ground nut (3). Tighten: Tighten the nut to 25 N. m (18 lb ft).
34. Install the engine wiring harness clip (6) to the transaxle stud.
35. Install the engine wiring harness clip nut (5). Tighten: Tighten the nut to 25 N. m (18 lb ft).
36. Install the engine wiring harness clip bolt (4). Tighten: Tighten the bolt to 25 N. m (18 lb ft).
37. Connect the engine wiring harness electrical connector (1) to the transaxle.
38. Connect the engine wiring harness electrical connector (1) to the neutral safety backup switch.
39. Install the engine wiring harness clip to the vehicle speed sensor bracket.
40. Connect the engine wiring harness electrical connector to the vehicle speed sensor.
41. Connect the engine wiring harness electrical connector to the TCM.
42. Connect the engine wiring harness electrical connector (1) to the PCM.
43. Connect the body harness electrical connector to the PCM.
44. Connect the engine wiring harness electrical connector (3) to the body wiring harness electrical connector (2).
45. Connect the engine wiring harness electrical connector (1) to the body wiring harness electrical connector (2).
46. Install the engine wiring harness clip (3) to the engine.
47. Connect the engine wiring harness electrical connector (2) to the camshaft phasor.
48. Install the engine wiring harness bolt (1). Tighten: Tighten the bolt to 10 N. m (89 lb in).
49. Connect the engine wiring harness electrical connector (2) to the fuel injector inline electrical connector.
50. Connect the engine wiring harness electrical connector (3) to the generator.
51. Install the engine wiring harness terminal (2) to the generator.
52. Install the engine wiring harness to generator stud nut (1). Tighten: Tighten the nut to 20 N. m (15 lb ft).
53. Position the engine wiring harness terminal boot (4).
54. Install the engine wiring harness clips (1, 2) to the ignition control module bracket.
55. Connect the engine wiring harness electrical connector (2) to the rear upper HO2S.
56. Install the CPA retainer (3).
57. Connect the engine wiring harness electrical connector (2) to the ignition control module.
58. Connect the engine wiring harness electrical connector (1) to the MAP sensor.
59. Connect the engine wiring harness clip (3) to the engine lift bracket.
60. Connect the engine wiring harness clips (1, 2) to the heater inlet and outlet pipe brackets.
61. Connect the engine wiring harness electrical connector (4) to the HO2S.
62. Install the CPA retainer (5).
63. Connect the engine wiring harness electrical connector (2) to the ETC.
64. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.
65. Unsecure and position the power steering pump.
66. Install the power steering line clip (2) to the stud.
67. Install the power steering line clip nut (1) to the generator stud. Tighten: Tighten the nut to 5 N. m (44 lb in).
68. Install the power steering pump bolts (3). Tighten: Tighten the bolts to 25 N. m (18 lb ft).
69. Using the J 25033-C , install the power steering pump pulley.
70. Connect the engine wiring harness electrical connector (2) to the CKP sensor.
71. Connect the engine wiring harness electrical connector (1) to the knock sensor.
72. Install the engine wiring harness electrical connector (2) rosebud to the transaxle mount.
73. Connect the lower rear HO2S electrical connector to the engine wiring harness electrical connector (2).
74. Install the lower rear CPA retainer (1).
75. Install the engine wiring harness electrical connector clip (2) to the thermostat housing stud.
76. Connect the lower front HO2S electrical connector to the engine wiring harness electrical connector (1).
77. Install the CPA retainer (3).
78. Connect the engine wiring harness electrical connector to the A/C compressor.
79. Install the engine wiring harness clip (2) to the engine boss.
80. Install the engine wiring harness clip bolt (3). Tighten: Tighten the bolt to 25 N. m (18 lb ft).
81. Install the engine wiring harness clip (1) to the A/C compressor bracket.
82. Install the engine wiring harness ground terminal (2) to the engine boss.
83. Install the engine wiring harness ground bolt (1). Tighten: Tighten the bolt to 25 N. m (18 lb ft).
84. Connect the engine wiring harness electrical connector (2) to the knock sensor.
85. Connect the engine wiring harness electrical connector (1) to the oil pressure sensor.
86. Install the oil pressure sensor heat shield and nuts. Tighten: Tighten the nuts to 10 N. m (89 lb in).
87. Install the starter motor. Refer to «Starter Motor Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
88. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
89. Install the engine mount strut. Refer to «Engine Mount Strut Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
90. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
91. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2) .
92. Install the hood. Refer to «Hood Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-body-panels/#bolted-exterior-body-panels-and-closures) .
93. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «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) .
94. 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) .
95. Prelube the engine. Refer to «Engine Prelubing»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-prelubing) .
96. Perform the CKP system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-35l-introduction-2-of-2__crankshaft-position-system-variation-learn) . IMPORTANT: After an overhaul the engine should be tested. Use the following procedure after the engine is installed in the vehicle. Disable the ignition system. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding. Enable the ignition system. Start the engine and listen for unusual noises. Check the vehicle oil pressure gage or light and confirm that the engine has acceptable oil pressure. Run the engine speed at about 1,000 RPM until the engine has reached normal operating temperature. Listen for sticking lifters or other unusual noises. Inspect for fuel, oil, and/or coolant leaks while the engine is running. Perform a final inspection for the proper oil and coolant levels.
97. Close the hood.

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. Position a suitable drain pan under the oil pan drain plug.
3. Remove the oil pan plug.
4. Allow the engine oil to drain completely.
5. Clean and inspect the oil pan drain plug sealing surface. Replace the oil pan if necessary.
6. Wipe any remaining oil from the drain plug hole and reinstall the oil pan drain plug until snug.
7. Position a suitable drain pan under the oil filter.
8. Remove the oil filter.
9. Ensure that the oil filter gasket is still on the old filter. If not remove the oil filter gasket from the adapter.

1. Apply clean engine oil to the NEW oil filter gasket.
2. Install the NEW oil filter Tighten: Tighten the new filter to 3/4 to 1 full turn, after the oil filter gasket contacts the adapter.
3. Tighten the oil pan drain plug. Tighten: Tighten the plug to 26 N. m (19 lb ft).
4. Remove the oil drain pan from under the vehicle.
5. Lower the vehicle.
6. Fill the engine with new engine oil. Refer to «Capacities - Approximate Fluid»(/chevrolet/malibu/vi-2006-2008/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) and «Fluid and Lubricant Recommendations»(/chevrolet/malibu/vi-2006-2008/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations) .
7. Start the engine.
8. Inspect for oil leaks after engine start up.
9. Turn OFF the engine and allow the oil a few minutes to drain back into the oil pan.
10. Remove the oil level indicator from the oil level indicator tube.
11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth.
12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube.
13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down.
14. Check the level if the engine oil on the oil level indicator.
15. If necessary, adjust the oil level by adding or draining oil.
16. Check for oil leaks.

Draining Fluids and Oil Filter Removal

1. Remove the oil pan drain plug.
2. Drain the engine oil.
3. Remove the oil filter.
4. Remove the coolant drain plug from the left side.
5. If equipped with an oil cooler (RPO-KC4), reposition the upper inlet hose clamp (1).
6. Remove the oil cooler inlet hose from the block outlet.
7. If not equipped with an oil cooler (RPO-KC4), remove the coolant drain plug from the right side.
8. Drain the coolant.

Crankshaft Balancer Removal

Tools Required

1. J 41816 Crankshaft Balancer Remover. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. EN 46359 Puller End Protector. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

1. Remove the crankshaft balancer bolt and washer.
2. Remove the crankshaft balancer using the J 41816 along with EN 46359 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

Engine Flywheel Removal (Automatic Transmission)

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

Engine Flywheel Removal (Manual Transmission)

1. Remove the flywheel/pressure plate bolts.
2. Remove the flywheel/pressure plate.
3. Remove the clutch pilot bearing.

Drive Belt Tensioner Removal

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

Coolant Crossover Pipe Removal

1. Loosen thermal bypass hose clamp (3) and remove hose from the coolant crossover pipe.
2. Remove the heater inlet/outlet pipe bolt (1) and remove the heater inlet/outlet pipe.
3. Remove the coolant vent pipe bolt (2) and the coolant vent pipe.
4. Remove the idler pulley bolts and pulleys (1, 2).
5. Remove the coolant crossover pipe bolts (2, 3), engine lift bracket (1), and the coolant crossover pipe assembly.

Engine Lift Bracket Removal - Rear

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

Oil Level Indicator and Tube Removal

1. Remove the oil level indicator tube bolt.
2. Remove the oil level indicator and oil level indicator tube.

Oil Filter Adapter Removal

1. Remove the oil filter adapter heat shield nuts.
2. Remove the oil filter adapter heat shield (2).
3. Remove the oil filter adapter bolts.
4. Remove the oil filter adapter (1) and gasket.

Exhaust Manifold Removal - Left Side

1. Remove the heated oxygen sensor.
2. Remove the spark plug wires from the spark plugs and set aside.
3. Remove the spark plugs.
4. Remove the exhaust manifold heat shield bolts.
5. Remove the exhaust manifold heat shield.
6. Remove the exhaust manifold bolts.
7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket.

Exhaust Manifold Removal - Right Side

1. Remove the heated oxygen sensor.
2. Remove the spark plug wires.
3. Remove the spark plugs.
4. Remove the exhaust manifold heat shield bolts.
5. Remove the exhaust manifold heat shields.
6. Remove the exhaust manifold bolts.
7. Remove the exhaust manifold.
8. Remove the exhaust manifold gasket.

Water Outlet and Thermostat Removal

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

Valve Rocker Arm Cover Removal - Left Side

1. Remove the positive crankcase ventilation (PCV) tube.
2. Remove and discard both PCV tube O-rings.
3. Remove the valve rocker arm cover bolts.
4. Remove the valve rocker arm cover.
5. Cut the room temperature vulcanizing (RTV) in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
6. Remove the valve rocker arm cover gasket.

Valve Rocker Arm Cover Removal - Right Side

1. Remove any remaining spark plug wires from their retainers.
2. Remove the ignition coil assembly bolts and nuts.
3. Remove the ignition coil assembly.
4. Remove the ignition coil assembly studs, if necessary.
5. Remove the fresh air tube from the valve rocker arm cover.
6. Remove the valve rocker arm cover bolts.
7. Remove the valve rocker arm cover.
8. Cut the room temperature vulcanizing (RTV) in the channel where the intake, cylinder head and valve rocker arm cover meet with a suitable tool.
9. Remove the valve rocker arm cover gasket.

Upper Intake Manifold Removal

1. Remove the upper intake manifold bolts and stud.
2. Remove the manifold absolute pressure (MAP) sensor bracket.
3. Remove the upper intake manifold and gaskets.

Lower Intake Manifold Removal

1. Disconnect the coolant temperature sensor (1).
2. Disconnect the camshaft position (CMP) sensor (2).
3. Remove the fuel injector rail bolts.
4. Remove the fuel rail assembly.
5. Remove the lower intake manifold bolts and discard.
6. Remove the lower intake manifold.

Valve Rocker Arm and Push Rod Removal

1. Loosen the valve rocker arm bolts.
2. Remove the valve rocker arms.
3. Remove the push rods. The intake push rods measure 147. 51 mm (5. 81 in). The exhaust push rods measure 154. 87 mm (6. 1 in).
4. Remove the intake manifold gaskets.

Valve Lifter Removal

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

Water Pump Removal

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

Cylinder Head Removal - Left Side

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

Cylinder Head Removal - Right Side

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

Oil Pan Removal

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

Oil Pump Removal

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

Camshaft Position Actuator Magnet Removal

1. Remove the camshaft position actuator magnet bolts.
2. Remove the camshaft position actuator magnet and O-ring seal.

Oil Pump Drive Removal

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

Scheme 67

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

Engine Front Cover Removal

1. Remove the engine front cover bolts.
2. Remove the engine front cover.
3. Remove the engine front cover gasket.

Timing Chain and Sprockets Removal

1. Install the camshaft position actuator fastener (1).
2. Remove the camshaft sprocket bolts.
3. Remove the timing chain and sprockets.
4. Remove the timing chain tensioner bolts.
5. Remove the timing chain tensioner.

Camshaft Removal

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

Piston, Connecting Rod, and Bearing Removal

Tools Required

1. J 24270 Cylinder Bore Ridge Reamer. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. J 41556 Connecting Rod Guide. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

1. Mark the piston with the number of the cylinder from which the piston is being removed.
2. Mark the connecting rod and the connecting rod cap in order to ensure correct assembly.
3. Use the J 24270 in order to remove the cylinder bore ring ridge. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) . Complete the following steps: Turn the crankshaft until the piston is at the bottom of the stroke. Cover the piston with a cloth. Remove the cylinder ring ridge. Turn the crankshaft until the piston is at the top of the stroke. Remove the cloth. Remove the metal shavings from the cylinder and piston.
4. Remove the connecting rod bolts.
5. Remove the connecting rod cap.
6. Remove the connecting rod bearing half.
7. Install J 41556 into the connecting rod. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
8. Remove the connecting rod and piston assembly from the engine with a suitable tool.

Crankshaft Rear Oil Seal Removal

1. Remove crankshaft rear main oil seal using one of the following techniques: Refer to step #2 for the removal of new style crankshaft rear main oil seal. Refer to step #3 for the removal of old style crankshaft rear main oil seal.
2. If removing a new style seal-seal lip is facing outward, insert a flat-bladed or similar tool between the sealing lip and the outer casing of the seal at an angle, and gently pry seal out by moving tool towards the center of the crankshaft.
3. If removing an old style-seal lip faces inward, insert a flat-bladed or similar tool between the outer seal casing and the engine block casting and gently pry seal out.
4. Repeat above steps as necessary around the crankshaft rear oil seal, until the seal is removed.

Crankshaft and Bearings Removal

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

Piston Oil Nozzle Removal

1. Remove the bolts retaining the piston oil nozzles to the engine block.
2. Remove the piston oil nozzles.

Camshaft Bearing Removal

Tools Required

J 33049 Camshaft Bearing Service Set. See Special Tools .

1. Select the expander assembly and driving washer.
2. Assemble the J 33049 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
3. Drive out the camshaft bearings. Use the J 33049 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

Engine Block Disassemble

1. Remove the camshaft rear bearing hole plug.
2. Remove the rear oil gallery plugs (102, 103).
3. Remove the front oil gallery plugs (107, 110, 137).
4. Remove the engine front cover locating pins (546).
5. Remove the engine block plug.
6. Remove the transmission locating pins (A).
7. Remove the knock sensors.
8. Remove the engine oil pressure indicator switch.

Scheme 68

Remove the engine block heater from engine block.

Engine Block Cleaning and Inspection

Tools Required

1. J 8001 Dial Indicator Set
2. J 8087 Cylinder Bore Gage

1. Clean the sealing material from the gasket mating surfaces.
2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes.
8. Clean the holes with a tap. Drill out the holes and install thread inserts, as needed.
9. Use a straight edge and a feeler gauge in order to test the deck surface for flatness. Replace the block if it is outside of the specification limit.
10. Inspect the oil pan rail for nicks.
11. Inspect the front cover attaching area for nicks. Use a flat mill file in order to remove any nicks.
12. Inspect the mating surfaces of the transmission case.
13. Use the following procedure in order to measure the engine block flange runout at the 6 mounting bolt hole bosses: Temporarily install the crankshaft. Measure the crankshaft flange runout. Hold the J 8001 gage plate flat against the crankshaft flange. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the indicator to 0. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0. 25 mm (0. 010 in). Retest the crankshaft flange runout if the readings vary more than 0. 25 mm (0. 010 in). If the crankshaft flange runout is not within the specification, replace the engine block.
14. Inspect the crankshaft main bearing bores. Use the J 8087 in order to measure the bearing bore concentricity and alignment at the following locations: The camshaft The crankshaft
15. Replace the engine block if the bores are out of specification.
16. Use the J 8087 in order to inspect the cylinder bores. Inspect the bores for the following conditions: Wear Taper Runout Ridging
17. Leave sufficient material in order to allow honing when fitting the piston.

Boring Procedure

1. Before honing or boring, measure all of the new pistons. Select the smallest piston for the piston fitting. Slightly varied pistons in a set may provide correction, if the first piston is too loosely fitted.
2. Before using any type of boring bar, file the top of the engine block to remove any dirt or burrs. If the cylinder block is not straight, the boring bar may be tilted, causing the bored cylinder wall to have incorrect right angles to the crankshaft.
3. Carefully follow the instructions furnished by the manufacturer regarding use of equipment.
4. Install all crankshaft main bearing caps to specification when boring cylinders. Cover or tape the crankshaft bearings and other internal parts to protect these parts during the boring or honing operation.
5. Leave 0. 03 mm (0. 001 in) on the diameter for finish honing when performing the final cut with a boring bar. Carefully perform the honing and boring operation to maintain the specified clearances between pistons, rings, and cylinder bores.

Honing Procedure

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

Engine Block Assemble

1. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the oil pressure switch threads.
2. Install the engine oil pressure switch. Tighten: Tighten the engine oil pressure switch to 16 N. m (12 lb ft).
3. Install the knock sensors. Tighten: Tighten the knock sensors to 25 N. m (18 lb ft).
4. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the engine block plug.
5. Install a NEW engine block plug. Tighten: Tighten the engine block plug to 60 N. m (44 lb ft).
6. Install the transmission locating pins. The installation height should be 8. 3-9. 3 mm (0. 327-0. 366 in) (A).
7. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the front oil gallery plug threads (110, 137).
8. Install the front oil gallery plug (110). Tighten: Tighten the front oil gallery plug to 19 N. m (14 lb ft).
9. Install the front oil gallery plug (137). Tighten: Tighten the front oil gallery plug to 33 N. m (24 lb ft).
10. Apply sealer GM P/N 12377901 (Canadian P/N 10953504), or equivalent to the front oil gallery plug (107).
11. Install the front oil gallery plug (107) so that it is 1. 5 mm (0. 06 in) below flush of the engine block.
12. Install the engine front cover locating pins (546). The installation height should be 5. 8-8. 2 mm (0. 228-0. 323 in) (A).
13. Apply Sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the rear oil gallery plugs.
14. Install the rear oil gallery plugs (103). Tighten: Tighten the rear oil gallery plugs to 19 N. m (14 lb ft).
15. Install the rear oil gallery plugs (102). Tighten: Tighten the rear oil gallery plugs to 33 N. m (24 lb ft).
16. Apply sealer GM P/N 12377901 (Canadian P/N 10953504), or equivalent to the camshaft rear bearing hole plug.
17. Install the camshaft rear bearing hole plug.
18. Apply sealer GM P/N 12346004 (Canadian P/N 10953480), or equivalent to the left and right coolant drain plug threads.
19. Install the left coolant drain plug. Tighten: Tighten the left coolant drain plug to 19 N. m (14 lb ft).
20. Install the right coolant drain plug. Tighten: Tighten the right coolant drain plug to 19 N. m (14 lb ft).

Engine Block Heater Installation

1. Apply sealer GM P/N 12346004 (Canadian P/N 1095380), or equivalent to the engine block heater.
2. Install the engine block heater into the engine block. Tighten: Tighten engine block heater to 50 N. m (37 lb ft).

Piston Oil Nozzle Cleaning and Inspection

1. Clean the piston oil nozzle in cleaning solvent using GM P/N 10953463 (Canadian P/N 88901148) or equivalent.
2. Dry the nozzle with compressed air.
3. Inspect the piston oil nozzle for the following: For cracks or damage Plugged oil passages (1) Bent, misaligned, or cracked oil nozzle tubes (2) Bent or broken clip (3)

Crankshaft and Bearings Cleaning and Inspection

Tools Required

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

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

Bearing Selection

Measure the bearing clearance to determine the correct replacement bearing insert size. There are two methods to measure bearing clearance. Method A gives more reliable results and is preferred.

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

Method A

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

Method B

1. Clean the used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width.
4. Install the bearing caps. NOTE: In order to prevent the possibility of cylinder block or crankshaft bearing cap damage, the crankshaft bearing caps are tapped into the cylinder block cavity using a brass, lead, or a leather mallet before the attaching bolts are installed. Do not use attaching bolts to pull the crankshaft bearing caps into the seats. Failure to use this process may damage a cylinder block or a bearing cap.
5. Install the bearing cap bolts to specification using J 45059 .
6. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic adheres to the journal or to the bearing cap.
7. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
9. Select a set of bearing inserts that will produce the desired clearance.

Crankshaft Balancer Cleaning and Inspection

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

Engine Flywheel Cleaning and Inspection

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

Piston, Connecting Rod, and Bearings Cleaning and Inspection

Tools Required

1. J 8087 Cylinder Bore Gage
2. EN-46745 Piston Pin Retainer Remover and Installer. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

1. Clean the piston and connecting rod in solvent.
2. Dry off the piston and connecting rod with compressed air.
3. Clean the piston ring grooves with a suitable ring groove cleaning tool.
4. Clean the piston oil lubrication holes and slots.
5. Inspect the piston for the following: Eroded areas (1) on the top of the piston Scuffed or damaged skirt (2) Damage to the pin bore (3) Cracks in the piston ring lands, the piston skirt, or the pin bosses Piston ring grooves for nicks, burrs, or other warpage which may cause the piston ring to bind
6. Inspect the piston pin for scoring, wear or other damage.
7. Measure the piston ring-to-piston ring groove side clearance. Insert the edge of the piston ring into the piston ring groove. Roll the piston ring completely around the piston ring groove. If binding is caused by distorted piston ring groove, replace the piston. If binding is caused by a distorted piston ring, replace the piston ring.
8. Measure the piston ring side clearance with a feeler gage.
9. If the side clearance is too small try another ring set.
10. If the proper piston ring-to-piston ring groove clearance cannot be achieved, replace the piston and pin assembly. Proper ring-to-piston ring groove clearance for the top ring is 0. 03-0. 065 mm (0. 001-0. 002 in). Proper ring-to-piston ring groove clearance for the second ring is 0. 04-0. 078 mm (0. 002-0. 003 in).
11. Using the EN-46745 , remove the piston pin retainers (1). See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
12. Discard the oil piston pin retainers.
13. Slide the piston pin (4) out of the piston (2), disconnecting the piston from the connecting rod (3).
14. Measure the piston pin diameter using and ouside micrometer.
15. Measure the piston pin bore using an inside micrometer.
16. Subtract the piston pin diameter from the piston pin bore diameter in order to determine the piston pin-to-piston pin bore clearance.
17. Piston-to-piston pin bore clearance must measure 0. 002-0. 010 mm (0. 00008-0. 0004 in). Replace the piston and the piston pin if the piston and the piston pin are not within specifications.
18. Measure the piston diameter with a micrometer at a right angle to the piston bore with the piston pin removed, and record the measurement. Measure the piston at 43 mm (1. 692 in) from dome of piston. Piston diameter must measure no less than 98. 950 mm (3. 895 in). Replace the piston and the pin as an assembly if the piston is not within specifications.
19. Measure the cylinder bore, using J 8087 .
20. Measure the J 8087 . Record this reading.
21. Subtract the diameter of the piston from the diameter of the cylinder bore to determine the piston-to-bore clearance. The cylinder bore clearance must be no more than 0. 080 mm (0. 003 in).
22. If a used piston is not acceptable, inspect the service piston size and determine if a new piston may be selected. Service pistons are available in standard and 0. 5 mm (0. 012 in) oversize.
23. When a piston has been selected, mark the piston in order to identify the cylinder for which the piston was fitted.
24. Inspect the connecting rod for an out-of-round bearing bore. If the out-of-round measurement exceeds 0. 005 mm (0. 0002 in) the connecting rod must be replaced.
25. Inspect the connecting rod for twisting. Install the connecting rod cap. Place the connecting rod assembly on a checking fixture. Inspect the assembly for bending or twisting. Do not attempt to straighten the connecting rod. Ensure that the connecting rod meets the following conditions: The connecting rods are not bent more than 0. 18 mm (0. 007 in). The connecting rods are not twisted more than 0. 38 mm (0. 015 in). Replace any bent or twisted connecting rods. Inspect the new connecting rods before using the new rods.
26. Inspect the connecting rod for damage to the bearing cap and bolt threads.
27. Measure the piston compression ring end gap. IMPORTANT: Fit each compression ring to the cylinder in which it will be used. Place the compression ring into the cylinder bore. Push the compression ring into the bottom of the cylinder bore to approximately 6. 5 mm (0. 25 in) above ring travel. The ring must be square to the cylinder wall. Use a feeler gage in order to measure the end gap. The first compression ring end gap must measure 0. 15-0. 30 mm (0. 006-0. 011 in), the second compression ring must measure 0. 25-0. 45 mm (0. 009-0. 017 in). Select another size ring set if the end gap exceeds specifications. If ring gap clearance is below specifications, increase the gap by carefully filing off excess material.
28. Inspect the connecting rod bearings for craters or pockets. Flattened sections on the connecting rod bearing halves may indicate fatigue.
29. Inspect the connecting rod bearings for excess scoring or discoloration.
30. Inspect the connecting rod bearings for dirt or debris imbedded into the connecting rod bearing halves.
31. Inspect the connecting rod bearings for improper seating indicated by bright, polished sections of the bearings.
32. Inspect the inside of the connecting rod bearing and the outside diameter of the connecting rod bearing journal for wear. This indicates high spots.

Camshaft and Bearings Cleaning and Inspection

Tools Required

J 7872 Magnetic Base Dial Indicator

1. Remove and discard the camshaft position actuator filter (1).
2. Clean the camshaft with cleaning solvent.
3. Inspect the camshaft for the following conditions: Scored camshaft bearing journals (5) Damaged camshaft lobes (4) Damaged camshaft position sensor reluctor area (3) Damaged threads (2)
4. Measure the camshaft journals using a micrometer. If the camshaft journals are not within specifications, replace the camshaft.
5. Measure the camshaft runout using the J 7872 . Mount the camshaft in V-blocks between the centers. Use the J 7872 in order to measure the intermediate camshaft journal.
6. Measure the camshaft lobe lift using the J 7872 . Lubricate the camshaft using GM P/N 12345501 (Canadian P/N 992704) or the equivalent. Set the camshaft on V-blocks. Use the J 7872 in order to measure the lobe lift.
7. If the runout or lobe lift is not within specifications, replace the camshaft.
8. Install a NEW camshaft position actuator filter (1).

Timing Chain and Sprockets Cleaning and Inspection

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

Camshaft Position Actuator Magnet Cleaning and Inspection

1. Inspect the camshaft position actuator magnet for the following conditions: The camshaft position actuator magnet wiring connector (1) for damage. The camshaft position actuator magnet O-ring seal and sealing area (2) for damage.
2. Repair or replace the camshaft position actuator housing and/or components as necessary.

Camshaft Position Actuator Cleaning and Inspection

1. Clean the camshaft position actuator components with solvent.
2. Dry the camshaft position actuator components with compressed air.
3. Inspect the camshaft position actuator for the following conditions: The camshaft position actuator mounting bores (1) for damage The camshaft position actuator return spring (2) for nicks or damage The camshaft position actuator valve surface for pitting or damage (3)
4. Replace the camshaft position actuator as necessary.

Valve Lifters Cleaning and Inspection

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

Valve Rocker Arm and Push Rods Cleaning and Inspection

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

Cylinder Head Disassemble

Tools Required

1. EN-47823 Valve Spring Compressor Adapter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. J 5892-D Valve Spring Compressor. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

1. Remove the heater inlet pipe stud from the right cylinder head, if required.
2. Remove the coolant temperature sensor from the right cylinder head, if required.
3. Using caution so as not to damage the valve spring or valve spring dampener, compress the valve springs using the J 5892-D (1) and the EN-47823 (2). See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
4. Remove the valve spring cap keys.
5. Remove the valve spring caps.
6. Remove the valve spring assembly.
7. Remove the valves.
8. Remove the valve stem oil seals and spring seats as an assembly.
9. Inspect all valve components for any damage or excess wear. Repair or replace as necessary.

Cylinder Head Cleaning and Inspection

Tools Required

1. J 8089 Carbon Removing Brush. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. J 9666 Valve Spring Tester

1. Inspect the cylinder head gasket and the mating surfaces. Inspect for leaks, corrosion, and blowby.
2. If the gasket failed, determine the cause. The following conditions may cause gasket failure: Improper installation A loose or warped cylinder head Missing, off location, or not fully seated dowel pins Low torque on the cylinder head bolts Cylinder head bolts with the incorrect length A warped engine block surface Scratched surfaces Excessive intake manifold torque Cracked engine block threaded holes
3. Use the J 8089 in order to remove the carbon from the combustion chambers. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
4. Clean the following components: The gasket surfaces Do not use a motorized brush on any gasket sealing surface. Valve stems and heads on a buffing wheel The bolt hole threads Remove all dirt, debris, or threadlocking material from the bolt holes.
5. Inspect the cylinder head mating surfaces for flatness. Replace the cylinder head if it is outside of the specification limit.
6. Inspect the cylinder head for cracks.
7. Inspect the cylinder head deck for corrosion. Do not attempt to weld the cylinder head. If the cylinder head is damaged, replace the cylinder head.
8. Remove the valve spring dampener.
9. Inspect the valve springs for squareness.
10. Use the J 9666 in order to measure the valve spring tension. Replace the spring if the spring tension is not within specification.
11. Install the valve spring dampener.

Valve Guide Reaming/Valve and Seat Grinding

Tools Required

J 8520 Cam Lobe Lift Indicator. See Special Tools .

1. Inspect the valves for the following conditions: Burnt or eroded areas (1) A worn margin (2) A bent stem (3) A worn or scored stem (4) A worn key groove (5) A worn stem tip (6)
2. Inspect the valve face for the following conditions: Worn margin (4) No margin (1) Pitted surfaces (2) Burnt or eroded areas (3)
3. Inspect the valve seats for a loose fit in the cylinder head.
4. Inspect for excessive valve stem (1) to guide (2) clearance.
5. Use a dial indicator in order to measure the valve stem-to-guide clearance. Complete the following steps: Install the valve into the guide. Install the J 8520 onto the cylinder head. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) . Locate the dial indicator so that the movement of the valve stem from side to side, crosswise to the cylinder head, will cause a direct movement on the indicator stem. Ensure that the indicator stem contacts the side of the valve stem just above the valve guide. Drop the valve head about 2 mm (1/8 in) off the valve seat. Use light pressure and move the valve stem side to side in order to obtain a clearance reading. If the valve stem to guide clearance is not within specification, replace the valve and/or repair the guide in order to obtain the proper clearances.
6. Ream the valve guides for oversize valves if the clearance exceeds the specifications.
7. Ream the valve guide in order to obtain the proper specification.
8. Inspect the valves for excessive scoring.
9. Inspect the valve face. Replace the valve if the valve margin is not within specifications after grinding.
10. Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the head and the stem.
11. Recondition the valve seats after reaming the valve guide bores or installing the new valve guides.
12. The valve seats should be concentric to within 0. 05 mm (0. 031 in) total indicator reading.

Cylinder Head Assemble

Tools Required

1. EN-47823 Valve Spring Compressor Adapter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. J 5892-D Valve Spring Compressor. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

1. Lubricate the valve stem with clean engine oil.
2. Install the valves.
3. Lightly tap the new or reconditioned valves into the valve seat.
4. Install the valve stem oil seals, ensuring proper intake - black seal and exhaust - brown seal, seals are installed.
5. Install the valve springs.
6. Install the valve spring caps.
7. Using caution so as not to damage the valve spring or valve spring dampener, compress the valve springs using the J 5892-D (1) and the EN-47823 (2). See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
8. Install the valve spring cap keys. Hold the valves in place with grease, if necessary.
9. Release the valve springs.
10. Ensure that the valve locks are seated.
11. Apply sealer P/N 21485278 to the coolant temperature sensor.
12. Install the coolant temperature sensor, if required. Tighten: Tighten the coolant temperature sensor to 23 N. m (17 lb ft).
13. Install the heater inlet pipe stud, if required. Tighten: Tighten the heater inlet pipe stud to 35 N. m (26 lb ft).

Oil Pump Disassemble

1. Remove the oil pump driveshaft and oil pump driveshaft retainer.
2. Remove the oil pump screen, if necessary. The oil pump screen has a press fit into the oil pump cover.
3. Remove the oil pump cover bolts.
4. Remove the oil pump cover.
5. Remove the oil pump drive gear and the oil pump driven gear.
6. Matchmark the gear teeth for assembly.
7. Remove the following items: The oil pump pressure relief valve spring straight pin. The oil pump pressure relief spring. CAUTION: Refer to «Cleaning Solvent Caution»(/chevrolet/malibu/vi-2006-2008/remont/oem-general-information/#warnings-and-cautions__cleaning-solvent-caution) in Cautions and Notices. The oil pump pressure relief valve. If the valve is stuck, soak the pump housing in cleaning solvent.

Oil Pump Cleaning and Inspection

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

Oil Pump Assemble

Tools Required

J 22144 Oil Suction Pipe Installer. See Special Tools .

1. Lubricate all the internal oil pump parts using engine oil during assembly.
2. Install the oil pump gears.
3. Install the oil pump cover.
4. Install the oil pump cover bolts. Tighten: Tighten the oil pump cover bolts to 10 N. m (89 lb in).
5. Install the pressure regulator valve.
6. Install the pressure regulator spring.
7. Install the cotter pin.
8. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the new suction pipe.
9. Tap the new suction pipe into place using a plastic hammer and J 22144 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

Engine Front Cover Cleaning and Inspection

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

Valve Rocker Arm Cover Cleaning and Inspection

1. Remove all rubber grommets from the valve rocker arm covers.
2. Clean the valve rocker arm covers with solvent.
3. Dry the valve rocker arm covers with compressed air.
4. Inspect the valve rocker arm covers for damage and replace if necessary.

Positive Crankcase Ventilation (PCV) Valve Cleaning and Inspection

1. Flush the carbon from the PCV valve orifices (1) using solvent.
2. Dry the PCV valve orifices using compressed air.

Oil Pan Cleaning and Inspection

1. Remove the oil level sensor.
2. Inspect the O-ring seal (2) and the electrical connector (1) for wear or damage. Repair or replace as necessary.
3. Clean the oil pan with solvent. Remove all sludge and debris from the oil pan.
4. Dry the oil pan with compressed air.
5. Inspect the oil pan sealing surface for damage and replace if necessary.
6. Install the oil level sensor and bolt. Tighten: Tighten the oil level sensor bolt to 10 N. m (89 lb in).

Lower Intake Manifold Cleaning and Inspection

1. Clean the intake manifold gasket mating surfaces (3) using GM P/N 12346139 (Canadian P/N 10953463) or equivalent.
2. Clean the fuel injector bores (1).
3. Inspect the lower intake manifold locating pins (2) for damage. Replace as necessary.
4. Inspect the intake manifold for damage.
5. Repair or replace the intake manifold as necessary.

Coolant Crossover Pipe Cleaning and Inspection

1. Clean the coolant crossover pipe with solvent.
2. Dry the coolant crossover pipe with compressed air.
3. Inspect the front of the coolant crossover pipe for the following: Damage to the coolant fill adapter sealing surface (1) Damage or restrictions to the radiator hose connection (2) Damage or restrictions to the thermal bypass hose connection (3) Damage, blockage, or excessive corrosion to the engine coolant passages Damage or restrictions to any fastener threads Damage or restrictions to any mounting holes
4. Inspect the rear of the coolant crossover pipe for the following: Damage to the heater inlet/outlet sealing surface (1) Damage to the coolant crossover pipe-to-cylinder head sealing surfaces (2) Damage, blockage, or excessive corrosion to the engine coolant passages Damage or restrictions to any fastener threads Damage or restrictions to any mounting holes
5. Repair or replace the coolant crossover pipe as necessary.

Upper Intake Manifold Cleaning and Inspection

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

Exhaust Manifold Cleaning and Inspection

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

Water Pump Cleaning and Inspection

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

Thread Repair

General purpose thread repair kits are available commercially.

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

Service Prior to Assembly

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

Camshaft Bearing Installation

Tools Required

J 33049 Camshaft Bearing Service Set. See Special Tools .

1. Assemble the J 33049 according to the manufacturer's instructions. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. Install the camshaft bearings in the following order: Index the camshaft bearing oil holes with the engine block oil passages. Place the bearing on the J 33049 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) . Install the third camshaft bearing. Install the second camshaft bearing. Install the outer camshaft bearings.
3. Apply sealer GM P/N 12377901 (Canadian P/N 10953504) or the equivalent to the camshaft rear bearing hole plug.
4. Install the camshaft rear bearing hole plug.

Piston Oil Nozzle Installation

1. Position the piston oil nozzles in the engine block.
2. Install the bolts retaining the piston oil nozzles to the engine block. Tighten: Tighten the bolt to 10 N. m (89 lb in).

Crankshaft and Bearings Installation

Tools Required

J 45059 Angle Meter

1. Dip the crankshaft bearing cap bolts in clean engine oil.
2. Place the crankshaft bearing inserts into the crankshaft bearing cap and into the engine block.
3. Lubricate the crankshaft main bearing surface with clean engine oil.
4. Install the crankshaft.
5. Install the crankshaft main bearing caps. Apply a small amount of sealer GM P/N 1052942 (Canadian P/N 10953466) to the rear of the #4 crankshaft main bearing cap sealing surface.
6. Install the crankshaft main bearing cap bolts. Tighten: Use the J 45059 in order to tighten the crankshaft main bearing cap bolts to 50 N. m (37 lb ft) plus 77 degrees.
7. Measure the crankshaft end play. Thrust the crankshaft forward or rearward. Insert a feeler gage between the number 3 crankshaft bearing and the bearing surface of the crankshaft and measure the bearing clearance. The proper crankshaft end play clearance is 0. 06-0. 21 mm (0. 002-0. 008 in). If the bearing clearance is not within specifications, inspect the thrust surfaces for nicks, gouges or raised metal. Minor inperfections may be removed with a fine stone.
8. Install the crankshaft position sensor into the side of the engine block.
9. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the crankshaft position sensor stud threads.
10. Install the crankshaft position sensor stud. Tighten: Tighten the crankshaft position sensor stud to 11 N. m (98 lb in).
11. Install the crankshaft position sensor shield and nut. Tighten: Tighten the crankshaft position sensor shield nut to 11 N. m (98 lb in).

Crankshaft Rear Oil Seal Installation

Tools Required

EN-48108 Rear Main Oil Seal Installer. See Special Tools .

Installation Procedure

1. The EN-48108 tool has a unique design to allow the technician to easily install the rear main seal squarely to the correct depth and direction. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) . Before proceeding with installation, review the above illustration to become familiar with the following components: Mandrel (1) Drive Drum (2) Drive Nut (3) Washer (4) Bearing (5)
2. Align the mandrel dowel pin to the dowel pin hole in the crankshaft.
3. Using a large flat blade screwdriver, tighten the two mandrel screws to the crankshaft, ensuring the mandrel is snug to the crankshaft hub.
4. Install the rear main seal, with the protective nylon sleeve attached, onto the mandrel.
5. Install the outer drive drum onto the mandrel.
6. Install the bearing, washer, and the drive nut onto the threaded shaft.
7. Using a wrench, turn the drive nut on the mandrel, which will push the seal into the engine block bore.
8. Turn the wrench until the drive drum is snug and flush against the engine block.
9. Loosen and remove the drive nut, washer, bearing and drive drum. Discard the nylon plastic seal protector.
10. Verify that the seal has seated properly.
11. Use a flat blade screwdriver to remove the two attachment screws from the mandrel and remove the mandrel from the crankshaft hub.

Piston, Connecting Rod, and Bearing Installation

Tools Required

1. J 8037 Ring Compressor. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. J 41556 Connecting Rod Guide. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
3. J 43654 Piston Pin Clip Remover and Installer
4. J 43690 Rod Bearing Clearance Checking Tool. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
5. J 43690-100 Rod Bearing Clearance Checking Tool-Adapter Kit. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
6. J 45059 Angle Meter

1. Lightly lubricate the following components with clean engine oil: The piston The piston pin The piston rings The cylinder bore The bearing surfaces
2. There are two styles of pistons in use in the LZ engine, and each piston must use the appropriate matching piston ring set. To identify which make you have, look on the bottom of the piston, in between the piston pin bores. If there is an "FM" marking, it is a Federal Mogul piston and must use the Federal Mogul piston rings. If there is no marking, it is a Mahle piston and must use Mahle piston rings. Failure to do so may result in engine damage.
3. Stagger the oil control ring end gaps a minimum of 90 degrees.
4. Stagger the compression ring end gaps a minimum of 25 mm (1 in).
5. Install the J 8037 onto the piston and compress the piston rings. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
6. Align the piston pin bore with the connecting rod pin bore.
7. Slide the piston pin (4) into the piston and the connecting rod (3).
8. Install NEW piston pin retainers (1) using the J 43654 .
9. Ensure that the piston pin retainers are fully seated in their grooves.
10. Repeat these procedures for the remaining pistons.
11. Install the J 41556 into the connecting rod. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
12. Install the piston and connecting rod assembly into the proper cylinder bore.
13. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore.
14. Using J 41556 , guide the connecting rod end onto the crankshaft journal. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
15. Install the bearing, bearing cap and bolts. Tighten: Tighten the connecting rod bearing cap bolts a first pass to 25 N. m (18 lb ft). Tighten the connecting rod bearing cap bolts a final pass to 110 degrees using the J 45059 .
16. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod assembly parallel to the crankpin to make sure that the rods have side clearance.
17. Measure the connecting rod side clearance using a feeler gage or dial indicator. Connecting rod side clearance should be within 0. 18-0. 44 mm (0. 007-0. 017 in).

Measuring Connecting Rod Bearing Clearance Using J 43690 and J 43690-100

J 43690 and J 43690-100 have been developed as a more accurate method to measure connecting rod bearing clearances. See Special Tools . The instructions below provide an overview of tool set and usage. For more detailed information, refer to the tool instruction sheets as supplied by the tool manufacturer.

1. J 43690 Rod Bearing Checking Tool includes:. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) . J 43690-20 Swivel Base (1) J 43690-19 Dial Indicator (2) J 43690-2 Base (3) J 43690-5,-6 Handle (4) J 43690-10,-11 Foot (5) 280307 Screw (6) J 43690-1 Pivot Arm Assembly (7) J 43690-3,-7,-8 Screws (8) 280319 Screw (9) 280311 Screw (10) J 43690-17,-18 Adapter (11) 280310 Pin (12)
2. J 43690-100 Rod Bearing Checking Tool - Adapter Kit includes:. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) . J 43690-104 Spacer (1) J 43690-105 Retainer Plate (2) 505478 Bolt (3) 511341 Bolt (4) J 43690-106 Retainer Plate (5) J 43690-107 Cap (6) J 43690-102 Foot (7) J 43690-101 Pivot Arm Assembly (8) J 43690-103 Adapter (9) 505439 Adapter (10)
3. Rotate the crankshaft until the journal/connecting rod to be measured is in the 12 o'clock position.
4. Remove the crankshaft main bearing cap bolts.
5. Remove the crankshaft main lower bearing cap.
6. Insert a piece of paper stock onto the crankshaft journal.
7. Install the crankshaft main bearing cap and bolts. Start the crankshaft main bearing cap bolts by hand. Ensure the bottom of the crankshaft main bearing cap is parallel to the bottom of the channel. Tighten: Tighten the crankshaft main bearing cap bolts in equal increments. Do not completely tighten one bolt at a time to prevent the cap from being cocked. Tighten the bolts to 50 N. m (37 lb ft) to fully seat the crankshaft main bearing caps. Loosen the bolts 360 degrees counterclockwise. Tighten the bolts to 20 N. m (15 lb ft), then 50 N. m (37 lb ft). Use J 45059 to tighten the bolts to 77 degrees.
8. Install the following: J 43690-101 (8) J 43690-5 (4) J 43690-2 (3) J 43690-7 (8) 280310 (12) J 43690-17 (11)
9. Install the swivel base (1) and dial indicator (2).
10. Adjust per the manufacturers instructions and measure the connecting rod bearing clearance. The connecting rod bearing clearance should be between 0. 0127-0. 0660 mm (0. 0005-0. 0026 in).

Camshaft Installation

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

Timing Chain and Sprockets Installation

Tools Required

EN-47719 Tensioner Compressor. See Special Tools .

1. Install the crankshaft sprocket.
2. Apply prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent to the crankshaft sprocket thrust surface.
3. Install the timing chain tensioner.
4. Install the timing chain tensioner bolts. Tighten: Tighten the timing chain tensioner bolts to 21 N. m (15 lb ft).
5. Using the EN-47719 , fully collapse the tensioner, and place the tensioner retaining pin into the retaining hole (1). See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
6. Align the crankshaft timing mark (1) to the timing mark on the bottom of the timing chain tensioner (2).
7. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the crankshaft gear.
8. Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain tensioner (3).
9. Align the dowel in the camshaft position actuator with the dowel hole in the camshaft.
10. Draw the camshaft sprocket onto the camshaft using the mounting bolts. Tighten: Tighten the bolts to 16 N. m (12 lb ft).
11. Remove the tensioner retaining pin.
12. Coat the crankshaft and camshaft sprocket with engine oil.

Engine Front Cover Installation

1. Install the front cover and the front cover gasket.
2. Install the front cover bolts. Tighten: Tighten the front cover bolts to 25 N. m (18 lb ft).

Crankshaft Front Oil Seal Installation

Tools Required

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

1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .

Oil Pump Drive Installation

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

Camshaft Position Actuator Magnet Installation

1. Install the camshaft position actuator magnet and O-ring seal into the front cover.
2. Install the camshaft position actuator magnet bolts. Tighten: Tighten the camshaft position actuator magnet bolts to 10 N. m (89 lb in).

Oil Pump Installation

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

Oil Pan Installation

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

Cylinder Head Installation - Left Side

Tools Required

J 45059 Angle Meter

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

Cylinder Head Installation - Right Side

Tools Required

J 45059 Angle Meter

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

Water Pump Installation

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

Valve Lifter Installation

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

Valve Rocker Arm and Push Rod Installation

1. Install the lower intake manifold gaskets.
2. Coat the ends of the push rods using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
3. Install the push rods in their original location.
4. Coat the rocker arm friction surfaces using prelube GM P/N 12345501 (Canadian P/N 992704) or the equivalent.
5. Install the valve rocker arms in their original positions.
6. Install the valve rocker arm bolts. Tighten: Tighten the valve rocker arm bolts to 34 N. m (25 lb ft).

Lower Intake Manifold Installation

1. With gaskets and seals in place apply a small drop 8-10 mm (0. 31-0. 39 in) of room temperature vulcanizing (RTV) sealer GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the 4 corners of the intake manifold to block joints (1).
2. Install the lower intake manifold.
3. Apply sealer GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the lower intake manifold bolt threads.
4. Install the new lower intake manifold bolts if applicable, in sequence. Tighten: Tighten the lower intake manifold bolts in sequence to 7 N. m (62 lb in) on the first pass. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 13 N. m (115 lb in) on the final pass. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N. m (18 lb ft) on the final pass.
5. Inspect the fuel rail, and fuel injectors for damage and replace if necessary.
6. Install NEW lower fuel injector O-rings.
7. Lubricate the fuel injector O-rings using GM P/N 12345616 (Canadian P/N 993182) or equivalent.
8. Install the injector nozzles into the lower intake manifold injector bores.
9. Press on the injector rail using the palms of both hands until the injectors are fully seated.
10. Install the fuel injector rail bolts. Tighten: Tighten the fuel injector rail bolts to 10 N. m (89 lb in).
11. Connect the coolant temperature sensor (1).
12. Connect the camshaft position (CMP) sensor (2).

Upper Intake Manifold Installation

1. Install the upper intake manifold gaskets and manifold.
2. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the upper intake manifold bolt threads.
3. Install the MAP sensor bracket, upper intake manifold bolts,and the upper intake manifold stud. Tighten: Tighten the upper intake manifold bolts and stud to 25 N. m (18 lb ft).

Valve Rocker Arm Cover Installation - Left Side

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

Valve Rocker Arm Cover Installation - Right Side

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

Water Outlet and Thermostat Installation

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

Exhaust Manifold Installation - Left Side

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts. Tighten: Tighten the exhaust manifold bolts in sequence to 20 N. m (15 lb ft).
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N. m (89 lb in).
6. Install the spark plugs. Tighten: Tighten the spark plugs to 15 N. m (11 lb ft).
7. Install the spark plug wires.
8. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N. m (31 lb ft).

Exhaust Manifold Installation - Right Side

1. Install the exhaust manifold gasket.
2. Install the exhaust manifold.
3. Install the exhaust manifold bolts. Tighten: Tighten the exhaust manifold bolts in sequence to 20 N. m (15 lb ft).
4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts. Tighten: Tighten the exhaust manifold heat shield bolts to 10 N. m (89 lb in).
6. Install the spark plugs. Tighten: Tighten the spark plugs to 15 N. m (11 lb ft).
7. Install the spark plug wires.
8. Install the heated oxygen sensor. Tighten: Tighten the heated oxygen sensor to 42 N. m (31 lb ft).

Oil Filter Adapter Installation

1. Install the oil filter adapter (1) and gasket.
2. Apply threadlocker P/N 21485277 to the bolt threads if required.
3. Install the oil filter adapter bolts. Tighten: Tighten the oil filter adapter bolts to 25 N. m (18 lb ft).
4. Install the oil filter adapter heat shield (2).
5. Install the oil filter adapter heat shield nuts. Tighten: Tighten the oil filter adapter heat shield nuts to 25 N. m (18 lb ft).
6. Install the oil filter. Tighten: Tighten the oil filter to 30 N. m (22 lb ft).

Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube and oil level indicator.
2. Install the oil level indicator tube bolt. Tighten: Tighten the oil level indicator tube bolt to 25 N. m (18 lb ft).

Engine Lift Bracket Installation - Rear

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

Coolant Crossover Pipe Installation

1. Install the coolant crossover pipe assembly onto the engine.
2. Install the engine lift bracket (1) and the front coolant crossover pipe bolts (3). Tighten: Tighten the bolts to 50 N. m (37 lb ft).
3. Install the side coolant crossover pipe bolt (2). Tighten: Tighten the bolt to 10 N. m (89 lb in).
4. Install the idler pulleys and bolts. Tighten: Tighten the bolts (1) to 50 N. m (37 lb ft). Tighten the bolt (2) to 30 N. m (22 lb ft).
5. Install the coolant vent pipe and bolt (2). Tighten: Tighten the bolt to 10 N. m (89 lb in).
6. Install the heater inlet/outlet pipe and bolt (1). Tighten: Tighten the bolt to 10 N. m (89 lb in).
7. Install the thermal bypass hose and securely fasten the clamp (3).

Drive Belt Tensioner Installation

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

Engine Flywheel Installation (Automatic Transmission)

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

Toos Required

J 45059 Angle Meter

1. Install the clutch pilot bearing.
2. Install the flywheel/pressure plate.
3. Install the flywheel/pressure plate bolts. Tighten: Tighten the flywheel/pressure plate bolts to 50 N. m (37 lb ft) plus an additional 70 degrees using the J 45059 .

Crankshaft Balancer Installation

Tools Required

1. J 29113 Balancer and Crank Sprocket Puller. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. J 45059 Angle Meter

1. Apply sealer GM P/N 12378521 (Canadian P/N 88901148) or the equivalent to the keyway of the crankshaft balancer.
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Install the J 29113 onto the crankshaft. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
4. Rotate the hex nut on the J 29113 to install the crankshaft balancer onto the crankshaft. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
5. Remove the J 29113 from the crankshaft. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
6. Install the crankshaft balancer washer and bolt. Tighten: Tighten the crankshaft balancer bolt a first pass to 125 N. m (92 lb ft). Tighten the crankshaft balancer bolt a final pass to 130 degrees using the J 45059 .

Engine Prelubing

Tools Required

1. J-21867-6 Oil Pressure Adapter Fitting. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
2. J 45299 Engine Preluber

1. Remove the engine oil filter, fill with clean engine oil, and reinstall. Tighten: Tighten the oil filter to 30 N. m (22 lb ft).
2. Locate the engine oil pressure indicator switch on the left side of the engine and remove.
3. Install the 1/4 inch adapter P/N 509373 and the J-21867-6 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__special-tools) .
4. Install the flexible hose to the adapter and open the valve.
5. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. Observe the flow of engine oil through the flexible hose and into the engine assembly.
6. Close the valve and remove the flexible hose and adapter from the engine.
7. Install the engine oil pressure indictor switch. Tighten: Tighten the engine oil pressure indictor switch to 16 N. m (12 lb ft).
8. Top off the engine oil to the proper level.

Scheme 69

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

Scheme 70

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

Drive Belt System Description

The drive belt system consists of the following components

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

The drive belt system uses one belt. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belt is made of different types of rubbers (chloroprene or EPDM) and have different layers or plys containing either fiber cloth or cords for reinforcement.

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

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

Engine Component Description

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

The left - front bank cylinders are 2, 4, 6. The right - rear bank cylinders are 1, 3, 5. Firing order is 1-2-3-4-5-6.

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

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

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

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

The pistons are cast aluminum using 2 compression rings and 1 oil control ring. The pistons also have 2 polymer coated patches on the skirt for noise reduction. The piston pin is offset 0. 8 mm (0. 031 in) towards the major thrust side. This placement allows for a gradual change in thrust pressure against the cylinder wall as the piston travels its path. The pins are made of chromium steel and have a floating fit in the pistons. The pins are retained in the connecting rods by piston pin retainer clips.

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

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

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

The exhaust manifolds are cast nodular iron.

New Product Information

The purpose of New Product Information is to highlight or indicate important product changes from the previous model year.

Changes may include one or more of the following items

1. A component comparison from the previous year
2. Fastener changes
3. Torque values and/or fastener tightening strategies
4. Changed engine specifications
5. New sealants and/or adhesives
6. Disassembly and assembly procedure revisions
7. Engine mechanical diagnostic procedure revisions
8. New special tools required

Component Comparison

New rubber isolator on the EVAP purge solenoid.

Fastener Changes

No fastener changes for 2007.

Torque Values and/or Fastener Tightening Strategies

Updated crankshaft balancer torque.

Changed Engine Specifications

No specification changes for 2007.

New Sealants and/or Adhesives

No new sealants and or adhesives for 2007.

Disassembly and Assembly Procedure Revisions

Updated identification steps in the piston, connecting rod, and bearing installation procedure.

Engine Mechanical Diagnostic Procedure Revisions

No revisions for 2007.

New Special Tools Required

New rear crankshaft oil seal installer.

Scheme 71

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

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

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

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

A priority oil delivery system supplies oil first to the crankshaft journals. The oil from the crankshaft main bearings is supplied to the connecting rod bearings by intersecting the passages drilled in the crankshaft. The passages supply the oil to the crankshaft main bearings and the camshaft bearings through the intersecting vertical drilled holes. The oil passages from the camshaft journals supply oil to the hydraulic lifters, and the piston oil nozzles. The camshaft phaser is fed oil from the number 1 camshaft bearing journal.

The piston oil nozzles lubricate the pistons and cylinder walls. A not-serviceable check valve integrated into the nozzle prevents oil bleed down from the nozzle when the engine is not running.

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

Scheme 72

Scheme 73

Cleanliness and Care

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

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

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

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

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

Disconnect the negative battery cables before you perform any major work on the engine. For more information on the disconnection of the battery, refer to BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION in Engine Electrical article.

Separating Parts

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

Replacing Engine Gaskets

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

Use of Room Temperature Vulcanizing (RTV) and Anaerobic Sealer

The following 2 types of sealer are commonly used in engines

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

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

Applying RTV Sealer

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

These methods of cleaning may damage the part.

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

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

Applying Anaerobic Sealer

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

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

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

These methods of cleaning may damage the part.

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

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

Tools and Equipment

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

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

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

Special Tools

Special Tools Illustration Tool Number/Description EN-46359 Puller End Protector EN-46745 Piston Pin Clip Remover/Installer EN-47719 Tensioner Compressor EN-47823 Valve Spring Compressor Adapter EN-48108 Rear Main Oil Seal Installer J 5892-D Valve Spring Compressor J 7872 Magnetic Base Dial Indicator J 8001 Dial Indicator Set J 8037 Ring Compressor J 8087 Cylinder Bore Gage J 8089 Carbon Removal Brush J 8520 Cam Lobe Lift Indicator J 9666 Valve Spring Tester J 21867-6 Oil Pressure Adapter Fitting J 22144 Oil Suction Pipe Installer J 22794 Spark Plug Port Adapter J 24270 Cylinder Bore Ridge Reamer J 25087-C Oil Pressure Tester and Pump Primer J 28428-E High Intensity Black Light Kit J 28467-B Universal Engine Support Fixture J 29113 Balancer and Crank Sprocket Puller J 33049 Camshaft Bearing Service Set J 35468 Cover Aligner and Seal Installer J 35667-A Cylinder Leakdown Tester J 36462 Engine Support Adapter Leg J 37096 Flywheel Holder J 38722 Compression Tester J 39505 Torque Wrench Adapter J 41556 Connecting Rod Guide J 41816 Crankshaft Balancer Remover J 43690 Rod Bearing Clearance Checking Tool J 43690-100 Rod Bearing Clearance Checking Tool - Adapter Kit J 45059 Angle Meter J 45299 Engine Preluber

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Scheme 96

See also:
• Disassembled Views
• Drive Belt System Description
• Strategy Based Diagnosis
• Checking Aftermarket Accessories
• Diagnostic Starting Point - Engine Cooling
• Spark Plug Inspection
• Electronic Ignition (EI) System Diagnosis
• Cylinder Leakage Test
• Lower Engine Noise, Regardless of Engine Speed
• Electrical Center Identification Views
• BATTERY DISCONNECT CAUTION
• Spark Plug Replacement
• Battery Negative Cable Disconnection and Connection
• Lifting and Jacking the Vehicle
• Belt Dressing Notice
• Fastener Notice
• Vibration Analysis - Engine
• Water Pump Replacement (LZ4)
• Tire and Wheel Removal and Installation
• Draining and Filling Cooling System (GE 47716)
• Heater Hose/Pipe Replacement - Inlet/Outlet (LZ4, LZ9)
• Exhaust Manifold Replacement - Left Side (LZ4)
• Transmission Replacement
• Hood Replacement
• Crankshaft Position System Variation Learn
• Capacities - Approximate Fluid
• Fluid and Lubricant Recommendations
• Cleaning Solvent Caution
• SAFETY GLASSES CAUTION
• Engine Component Description
• Lubrication Description
• Drive Belt System Description
• Base Engine Misfire without Internal Engine Noises
• Base Engine Misfire with Abnormal Internal Lower Engine Noises
• Base Engine Misfire with Abnormal Valve Train Noise
• Base Engine Misfire with Coolant Consumption
• Base Engine Misfire with Excessive Oil Consumption
• Engine Compression Test
• Engine Noise on Start-Up, but Only Lasting a Few Seconds
• Upper Engine Noise, Regardless of Engine Speed
• Lower Engine Noise, Regardless of Engine Speed
• Engine Noise Under Load
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Oil Consumption Diagnosis
• Drive Belt Tensioner Diagnosis
• Special Tools
• Cylinder Head Cleaning and Inspection
• Piston, Connecting Rod, and Bearings Cleaning and Inspection
• Engine Block Cleaning and Inspection
• Diagnostic Starting Point - Engine Mechanical
• Fastener Tightening Specifications
• Engine Support Fixture
• Sealers, Adhesives, and Lubricants
• Crankshaft Balancer Replacement
• Engine Prelubing
• Camshaft and Bearings Cleaning and Inspection