Engine Mechanical - 2.4l - Repair Instructions - on Vehicle Chevrolet Malibu VII

Special Tools

J 44811 Accessory Belt Tensioner Unloader. See Special Tools .

Removal Procedure

1. Remove the engine splash shield. Refer to «Engine Splash Shield Replacement - Right Side»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
3. Install the J 44811 to the drive belt tensioner. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
4. Using the J 44811 , rotate the tensioner counterclockwise in order to release the tensioner from the drive belt. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
5. Remove the drive belt.
6. Slowly rotate the J 44811 and the tensioner clockwise in order to allow the tensioner to rest. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
7. Remove the J 44811 from the drive belt tensioner. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .

Installation Procedure

1. Install and position the drive belt around all of the pulleys except for the drive belt tensioner.
2. Install the J 44811 to the drive belt tensioner. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
3. Using the J 44811 , rotate the tensioner counterclockwise. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
4. Position the drive belt under the tensioner pulley.
5. Using the J 44811 , rotate the tensioner clockwise in order to seat the tensioner pulley onto the drive belt. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
7. Install the engine splash shield. Refer to «Engine Splash Shield Replacement - Right Side»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .

EN-48932: Hydraulic Belt Tensioner Compressor

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. If equipped, remove the tensioner stop fastener (1) and stop (2).
3. Install the EN-48932: compressor (1) to the drive belt tensioner spring.
4. Compress the drive belt tensioner spring fully using the EN-48932: compressor (1).
5. Reposition the idler pulley (2) to release tension off the drive belt.
6. Remove the drive belt from under the middle idler pulley.
7. Remove the drive belt from the vehicle.

1. Install and position the drive belt around all of the pulleys except for the middle idler pulley.
2. Install the drive belt under the middle idler pulley.
3. Reposition the idler pulley (2) to install the drive belt.
4. Install the drive belt under the middle idler pulley.
5. Ensure the drive belt tensioner idler pulley is fully seated against the drive belt.
6. Loosen the forcing bolt on the EN-48932: compressor (1) and remove from the drive belt tensioner spring.
7. Ensure that the drive belt tensioner idler is fully seated against the drive belt.
8. If equipped, install the tension stop (2) and fastener (1), then tighten to 10 N.m (89 lb in).
9. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

1. Remove the drive belt. Refer to «Drive Belt Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the right engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
3. Remove the drive belt tensioner bolt.
4. Remove the drive belt tensioner.

1. Position the drive belt tensioner. Ensure that the tensioner is flush with the front cover.
2. Install the drive belt tensioner bolt and tighten to 45 N.m (33 lb ft).
3. Install the right engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
4. Install the drive belt. Refer to «Drive Belt Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. Remove the drive belt. Refer to «Drive Belt Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the right side engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
3. Remove the drive belt tensioner bolts (2).
4. Remove the drive belt tensioner (1) with drive belt tensioner bolt (2) from top of vehicle.

1. Install the lower tensioner bolt (2) into the tensioner (1).
2. Position the tensioner assembly in place.
3. Install but do not tighten the drive belt tensioner bolts (2).
4. Tighten the bolts (2) in sequence. Tighten the top bolt to 22 N.m (16 lb ft). Tighten the lower bolt to 50 N.m (37 lb ft) +90 degrees.
5. Install the drive belt. Refer to «Drive Belt Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
6. If tensioner assembly is new, use a 6 point socket on the drive belt tensioner hex boss (1) and rotate hex boss clockwise to release the tension and remove the shipping retainer by hand. Discard the shipping retainer.
7. Install the right side engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. Remove the starter. Refer to «Starter Replacement (LE5 or LE9)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Disconnect the engine wiring harness electrical connector (2) from the oil pressure switch.
3. Remove the engine oil pressure switch.

1. Install the engine oil pressure switch. Tighten the switch to 22 N.m (16 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the oil pressure switch.
3. Install the starter. Refer to «Starter Replacement (LE5 or LE9)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

Engine Mount Inspection

1. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Raise the engine slightly and observe the engine mount. Raising the engine removes the weight from the engine mount and creates a slight tension on the rubber portion.
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/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. Remove the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the engine mount bracket to engine bolts (1).
3. Remove the engine mount bracket (2).

1. Position the engine mount bracket (2) to the engine.
2. Install the engine mount bracket bolts (1) in the following locations: The long bolts through the engine mount bracket to the engine block The short bolt through the engine lift bracket to the engine mount bracket
3. Tighten the engine mount bracket bolts in the following sequence: Tighten the engine mount bracket to engine block bolts to 90 N.m (66 lb ft). Tighten the engine lift bracket to engine mount bracket bolts to 33 N.m (24 lb ft).
4. Install the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

Powertrain Mount Balancing

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Remove the battery tray. Refer to «Battery Tray Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Tray Replacement (LZ4, LY7, and LE5)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
4. Loosen the front transaxle mount through bolt (1).
5. Loosen the rear transaxle mount through bolt (1).
6. Lower the vehicle.
7. Position two floor jacks with wood blocks under the engine and transaxle in order to support the powertrain assembly.
8. Loosen the transaxle mount bolts (1).
9. Loosen the engine mount to bracket bolts (1).
10. Reposition both floor jacks in order to allow a 1/8 inch gap between the mount and bracket.
11. Tighten the transaxle mount bolts (1) in the following sequence. Rear Front Middle Tighten: Tighten the bolts to 45 N.m (33 lb ft).
12. Tighten the engine mount to bracket bolts (1) in the following sequence. Rear Front Tighten: Tighten the bolts to 50 N.m (37 lb ft).
13. Remove the floor jacks from under the oil pan.
14. Shake the powertrain vigorously from front to rear and allow the powertrain to settle.
15. Raise the vehicle.
16. Tighten the rear transaxle mount through bolt (1). Tighten: Tighten the bolt to 100 N.m (74 lb ft).
17. Tighten the front transaxle mount through bolt (1). Tighten: Tighten the bolt to 100 N.m (74 lb ft).
18. Lower the vehicle.
19. Install the battery tray. Refer to «Battery Tray Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Tray Replacement (LZ4, LY7, and LE5)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
20. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Support the engine with a hydraulic floor jack. Use a piece of wood between the floor jack and the oil pan.
3. Remove the engine mount to bracket bolts (1).
4. Remove the engine mount to side rail bolts (2).
5. Remove the engine mount from the engine compartment.

1. Place the engine mount onto the side rail studs.
2. Install the engine mount to side rail bolts (2) and tighten to 50 N.m (37 lb ft).
3. Install the engine mount to bracket bolts (1) and tighten to 50 N.m (37 lb ft).
4. Remove the hydraulic floor jack from under the oil pan.
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

1. J 28467-B Universal Engine Support Fixture
2. J 28467-7A Bolt Hook
3. J-28467-13 Engine Support Fixture Adapters
4. J 28467-34 Lift Hook Wing Nut and Washer
5. J 36462-A Engine Support Adapter Leg Set

Installation

1. Remove the front compartment sight shield. Refer to «Front Compartment Sight Shields Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exterior-body-panels/#bolted-exterior-body-panels-and-closures) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
3. Install three J-28467-13 (1) and two J-28467-5 strut tower adapters (2) to the top of the left and right strut tower.
4. Install a 127 cm (50 in) engine support fixture cross bar J 28467-B (3) transversely across the vehicle between both J-28467-5 strut tower adapters (2).
5. Insert safety pins J-28467-10 (4) through the J-28467-5 strut tower adapters (2) and the cross bar (3) to prevent movement.
6. Position two 58 cm (23 in) engine support fixture cross bars (1) longitudinally with two J 36462-A leg assembly (2).
7. Install two J-28467-1A clamp (3) to secure the longitudinal mounted cross bar to the transverse mounted cross bar.
8. Assemble the lift hook wing nut J 28467-34 , lift hook bracket J-28467-6A and lift hook J 28467-7A to the engine lift bracket on the engine.
9. Install the lift hook and bracket assembly (1) to the longitudinal mounted cross bar (2).
10. Position the J 28467-7A lift hook to the rear engine lift bracket.
11. Assemble the lift hook wing nut J 28467-34 and the lift hook bracket J-28467-6A to the lift hook J 28467-7A .
12. Install the lift hook and bracket assembly (1) to the longitudinal mounted cross bar (2).
13. Position the J 28467-7A bolt hook (1) to the front engine lift bracket.
14. Evenly tighten both wing nuts J 28467-34 (1) until the engine weight is supported by the engine support fixture and no longer carried by the engine mounts.

1. Remove the oil level indicator.
2. Remove the engine harness clip (1) from the oil level indicator tube.
3. Remove the oil level indicator tube bolt.
4. Remove the oil level indicator tube.

1. Lubricate the oil level indicator tube O-ring seal with engine oil lubricant.
2. Install the oil level indicator tube.
3. Install the oil level indicator tube bolt and tighten to 10 N.m (89 lb in).
4. Install the engine harness clip (1) to the oil level indicator tube.
5. Install the oil level indicator.

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Remove the oil level indicator.
3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
4. Remove the engine wiring harness clip (1) from the oil level indicator tube bracket (2).
5. Remove the knock sensor electrical connector lead (1) from the oil level indicator tube bracket (2).
6. Lower the vehicle.
7. Remove the oil level indicator tube bolt.
8. Remove the oil level indicator tube.
9. Remove the oil level indicator tube O-ring seals, if necessary.

1. Install NEW oil level indicator tube O-ring seals, if necessary.
2. Install the oil level indicator tube.
3. Install the oil level indicator tube bolt and tighten to 10 N.m (89 lb in).
4. Raise and support the vehicle.
5. Install the knock sensor electrical connector lead (1) to the oil level indicator tube bracket (2).
6. Install the engine wiring harness clip (1) to the oil level indicator tube bracket (2).
7. Lower the vehicle.
8. Install the engine wiring harness clip (1) to the oil level indicator tube bracket (2).
9. Install the oil level indicator.
10. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Reposition the positive crankcase ventilation (PCV) hose clamp (1) at the camshaft cover.
3. Remove the PCV hose (2) from the camshaft cover.

1. Install the PCV hose (2) to the camshaft cover.
2. Position the PCV hose clamp (1) at the camshaft cover.
3. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Reposition the positive crankcase ventilation (PCV) hose clamp (1) at the camshaft cover.
3. Remove the PCV hose (2) from the camshaft cover.

1. Install the PCV hose (2) to the camshaft cover.
2. Position the PCV hose clamp (1) at the camshaft cover.
3. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

1. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Remove the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
3. Remove the evaporative emission (EVAP) canister purge solenoid valve tube. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
4. Reposition the brake booster vacuum hose clamp at the intake manifold.
5. Remove the brake booster hose from the intake manifold.
6. Remove the oil level indicator tube bolt.
7. Disconnect the engine harness electrical connector (1) from the fuel injector inline electrical connector (2).
8. Remove the fuel injector inline connector clip from the intake manifold.
9. Disconnect the engine harness electrical connector (1) from the knock sensor harness.
10. Remove the knock sensor connector clip from the oil level indicator tube.
11. Remove the intake manifold bolts and nuts.
12. Remove the intake manifold.
13. Remove the intake manifold gasket, if necessary.

1. Install the intake manifold gasket, if necessary.
2. Install the intake manifold. CAUTION: Refer to «Fastener Caution»(/chevrolet/malibu/vii-2008-2012/remont/oem-general-information/#dangers-warnings-and-cautions__fastener-caution) .
3. Install the intake manifold bolts and nuts and tighten to 10 N.m (89 lb in).
4. Connect the engine harness electrical connector (1) to the knock sensor harness.
5. Install the knock sensor connector clip to the oil level indicator tube.
6. Connect the engine harness electrical connector (1) to the fuel injector inline electrical connector (2).
7. Install the fuel injector inline connector clip to the intake manifold.
8. Install the oil level indicator tube bolt and tighten to 10 N.m (89 lb in).
9. Install the brake booster hose to the intake manifold.
10. Position the brake booster vacuum hose clamp at the intake manifold.
11. Install the EVAP canister purge solenoid valve tube. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
12. Install the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
13. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Remove the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator control (TAC).
4. Disconnect the engine wiring harness electrical connector (2) from the generator starter.
5. Disconnect the engine wiring harness electrical connector (4) from the generator starter.
6. Remove the fuel injector wiring harness electrical connector retainer (6) from the generator starter.
7. Disconnect the fuel injector wiring harness electrical connector (7) from the engine wiring harness electrical connector (8).
8. Remove the engine wiring harness clips (5) from the intake manifold.
9. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
10. Remove the vacuum brake booster hose (2) from the intake manifold.
11. Remove the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
12. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor.
13. Disconnect the evaporative emission (EVAP) canister purge tube from the intake manifold and the EVAP solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
14. Remove the oil level indicator tube. Refer to «Oil Level Indicator Tube Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
15. Remove the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
16. Remove the 3-phase voltage cable bracket bolt (1) at the oil level indicator tube.
17. Remove the generator starter bolts.
18. Reposition and secure the generator starter out of the way.
19. Remove the intake manifold lower bolts (1).
20. Remove the intake manifold upper bolt and nuts.
21. Remove the intake manifold.
22. Remove and inspect the intake manifold gasket.

1. Install a NEW intake manifold gasket if necessary, otherwise install the old gasket.
2. Install the intake manifold.
3. Install the intake manifold upper bolt and nuts.
4. Install the intake manifold lower bolts (1). Tighten the bolts/nuts (1) to 10 N.m (89 lb in).
5. Position the starter/generator to the bracket.
6. Install the starter/generator bolts until snug.
7. Tighten the starter generator bolts in the following sequence: Front Bottom Tighten the bolts to 58 N.m (43 lb ft).
8. Install the 3-phase voltage cable bracket to the tie bar.
9. Install the 3-phase voltage cable bracket bolt (1) at the oil level indicator tube. Tighten the bolt to 10 N.m (89 lb in).
10. Install the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
11. Install the oil level indicator tube. Refer to «Oil Level Indicator Tube Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
12. Connect the EVAP canister purge tube to the intake manifold and the EVAP solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
13. Connect the engine wiring harness electrical connector to the MAP sensor.
14. Install the throttle body. Refer to «Throttle Body Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
15. Install the vacuum brake booster hose (2) to the intake manifold.
16. Position the vacuum brake booster hose clamp (1) at the intake manifold.
17. Install the engine wiring harness clips (5) to the intake manifold.
18. Connect the fuel injector wiring harness electrical connector (7) to the engine wiring harness electrical connector (8).
19. Install the fuel injector wiring harness electrical connector retainer (6) to the generator starter.
20. Connect the engine wiring harness electrical connector (4) to the generator starter.
21. Connect the engine wiring harness electrical connector (2) to the generator starter.
22. Connect the engine wiring harness electrical connector (1) to the TAC.
23. Install the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
24. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

1. J 38122-A Harmonic Balancer Holder. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
2. J 45059 Angle Meter

1. Remove the drive belt. Refer to «Drive Belt Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Use J 38122-A to prevent the crankshaft from rotating while loosening the crankshaft balancer bolt. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
3. Remove and discard the crankshaft balancer bolt.
4. Remove the crankshaft balancer.

1. Position the crankshaft balancer.
2. Install a NEW crankshaft balancer bolt.
3. Use the J 38122-A to hold the crankshaft balancer in order to prevent the balancer from rotating while tightening the bolt. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
4. Tighten the crankshaft balancer bolt to 100 N.m (74 lb ft) plus an additional 125 degrees using the J 45059 .
5. Install the drive belt. Refer to «Drive Belt Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. J 38122-A Harmonic Balancer Holder. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
2. J 45059 Angle Meter

1. Remove the drive belt. Refer to «Drive Belt Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Install the J 38122-A (1), and a breaker bar to the balancer in order to prevent the balancer from rotating when loosening the balancer bolt. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
3. Remove the J 38122-A (1) and breaker bar. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
4. Remove and discard the crankshaft balancer bolt.
5. Remove the crankshaft balancer.

1. Position the crankshaft balancer.
2. Install a NEW crankshaft balancer bolt.
3. Install the J 38122-A (1), and a breaker bar to the balancer in order to prevent the balancer from rotating while tightening the bolt. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
4. Tighten the crankshaft balancer bolt to 100 N.m (74 lb ft) plus an additional 125 degrees using the J 45059 .
5. Install the drive belt. Refer to «Drive Belt Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

Tools Required

J 35268-A Camshaft/Front Main Seal Installer

1. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Crankshaft Balancer Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Use a flat-bladed tool to remove the seal from the front cover.

1. Use the J 35268-A in order to install the crankshaft front oil seal to the engine front cover.
2. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Crankshaft Balancer Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Drive Belt Tensioner Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the crankshaft balancer. Refer to «Crankshaft Balancer Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Crankshaft Balancer Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
3. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
4. Remove the engine mount and bracket. Refer to «Engine Mount Bracket Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
5. Remove the engine front cover to water pump bolt.
6. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
7. Remove the engine front cover bolts.
8. Remove the engine front cover.
9. Remove and discard the engine front cover gasket.

1. Install a NEW engine front cover gasket to the dowel pins.
2. Install the engine front cover.
3. Install the engine front cover bolts and tighten to 25 N.m (18 lb ft).
4. Lower the vehicle.
5. Install the engine front cover to water pump bolt and tighten to 25 N.m (18 lb ft).
6. Position the engine mount and bracket. Refer to «Engine Mount Bracket Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
7. Remove the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
8. Install the crankshaft balancer. Refer to «Crankshaft Balancer Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Crankshaft Balancer Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
9. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Drive Belt Tensioner Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. J 45027 Tensioner Tool. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
2. J 45059 Angle Meter

1. Remove the number 1 cylinder spark plug. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Rotate the crankshaft in the engine rotational direction clockwise, until the number 1 piston is at top dead center (TDC) on the exhaust stroke.
3. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
4. Remove the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
5. Remove the upper timing chain guide bolts and guide.
6. Remove the timing chain tensioner.
7. Install a 24 mm wrench on the hex on the exhaust camshaft in order to hold the camshaft.
8. Remove and discard the exhaust camshaft actuator bolt (2).
9. Remove the exhaust camshaft actuator (1, 3) from the camshaft and timing chain.
10. Remove the timing chain tensioner guide bolt and guide.
11. Remove the fixed timing chain guide access plug.
12. Remove the fixed timing chain guide bolts and guide.
13. Install a 24 mm wrench on the hex on the intake camshaft in order to hold the camshaft.
14. Remove and discard the intake camshaft actuator bolt (2).
15. Remove the intake camshaft actuator (3), and the timing chain through the top of the cylinder head.
16. Remove the crankshaft sprocket (2) and friction washers (1), if equipped.
17. If replacing the balance shaft timing chain and sprocket, perform the following steps, if not proceed to step 10 in the installation procedure.
18. Remove the balance shaft drive chain tensioner bolts and tensioner.
19. Remove the adjustable balance shaft chain guide bolt and guide.
20. Remove the small balance shaft drive chain guide bolts and guide.
21. Remove the upper balance shaft drive chain guide bolts and guide.
22. Remove the balance shaft drive chain (7).
23. Remove the balance shaft drive sprocket.

1. If replacing the balance shaft timing chain, perform the following steps, if not proceed to step 10.
2. Install the balance shaft drive sprocket.
3. Install the balance shaft drive chain (1) with the colored link lined up with the marks on the balance shaft sprockets and the balance shaft drive sprocket. There are 3 colored links on the chain. Two are chrome and 1 is copper. Use the following steps in order to line up the links with the sprockets. Place the copper link (5) so that it lines up with the timing mark (2) on the intake side balance shaft sprocket. Working clockwise around the chain, place the chrome link (4) in line with the timing mark (3) on the balance shaft drive sprocket. (approximately 6 o'clock position on the sprocket). Place the chain (7) on the water pump drive sprocket. The alignment is not critical. Align the last chrome link (6) with the timing mark (1) on the exhaust side balance shaft drive sprocket.
4. Install the upper balance shaft drive chain guide and bolts and tighten to 15 N.m (11 lb ft).
5. Install the small balance shaft drive chain guide and bolts and tighten to 15 N.m (11 lb ft).
6. Install the adjustable balance shaft chain guide and bolt and tighten to 10 N.m (89 lb in).
7. Reset the timing chain tensioner by performing the following steps: Rotate the tensioner plunger 90 degrees in its bore and compress the plunger. Rotate the tensioner back to the original 12 o'clock position and insert a paper clip through the hole in the plunger body and into the hose in the tensioner plunger.
8. Install the balance shaft drive chain tensioner and bolts and tighten to 10 N.m (89 lb in).
9. Remove the paper clip from the balance shaft drive chain tensioner.
10. On 2.2L engines, ensure the intake camshaft notch is in the 10 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at TDC, crankshaft key at 12 o'clock.
11. On 2.4L engines, ensure the intake camshaft notch is in the 5 o'clock position (2) and the exhaust camshaft notch is in the 7 o'clock position (1). The number 1 piston should be at TDC, crankshaft key at 12 o'clock.
12. Install the friction washer, if applicable.
13. Install the timing chain drive sprocket to the crankshaft with the timing mark in the 5 o'clock position and the front of the sprocket facing.
14. Assemble the intake camshaft actuator into the timing chain with the timing mark lined up with the uniquely colored link (1).
15. Lower the timing chain through the opening in the cylinder head. Use care to ensure that the chain goes around both sides of the cylinder block bosses (1, 2).
16. Install the intake camshaft actuator onto the intake camshaft while aligning the dowel pin into the camshaft slot.
17. Hand tighten the new intake camshaft actuator bolt.
18. Route the timing chain around the crankshaft sprocket and line up the first matching colored link with the timing mark on the crankshaft sprocket, in approximately the 5 o'clock position.
19. Install the friction washer, if applicable.
20. Rotate the crankshaft clockwise to remove all chain slack. Do not rotate the intake camshaft.
21. Install the adjustable timing chain guide down through the opening in the cylinder head and install the adjustable timing chain bolt. Tighten the adjustable timing chain guide bolt to 10 N.m (89 lb in).
22. Install the exhaust camshaft actuator into the timing chain with the timing mark lined up with the second matching colored link.
23. Install the exhaust camshaft actuator onto the exhaust camshaft, aligning the dowel pin into the camshaft slot.
24. use 24 mm open ended wrench, rotate the exhaust camshaft approximately 45 degrees until the dowel pin in the camshaft actuator goes into the camshaft slot.
25. When the actuator seats on the cam, tighten the new exhaust camshaft actuator bolt hand tight.
26. Verify that all of the colored links and the appropriate timing marks are still aligned. If they are not aligned, repeat the portion of the procedure necessary to align the timing marks.
27. Install the fixed timing chain guide and bolts. Tighten the fixed timing chain guide bolts to 12 N.m (106 lb in).
28. Install the upper timing chain guide and bolts. Tighten the upper timing chain guide bolts to 10 N.m (89 lb in).
29. Reset the timing chain tensioner by performing the following steps: Remove the snap ring. Remove the piston assembly from the body of the timing chain tensioner. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston. Reinstall the piston assembly into the body of the tensioner. Install the snap ring.
30. Inspect the timing chain tensioner seal for damage. If damaged, replace the seal.
31. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
32. Install the timing chain tensioner assembly. Tighten the timing chain tensioner to 75 N.m (55 lb ft).
33. The timing chain tensioner is released by compressing it 2 mm (0.079 in), which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
34. Using a 24 mm wrench, engage the hex on the intake camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten the intake camshaft position actuator bolt to 30 N.m (22 lb ft) plus 100 degrees using the J 45059 .
35. Using a 24 mm wrench, engage the hex on the exhaust camshaft, and using a torque wrench, tighten the camshaft actuator bolt. Tighten the exhaust camshaft position actuator bolt to 30 N.m (22 lb ft) plus 100 degrees using the J 45059 .
36. Install the timing chain oiling nozzle. Tighten the timing chain oiling nozzle bolt to 10 N.m (89 lb in).
37. Apply sealant compound to the thread of the timing chain guide bolt access hole plug. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) for the recommended sealant.
38. Install the timing chain guide bolt access hole plug. Tighten the access hole plug to 90 N.m (66 lb ft).
39. Install the engine front cover. Refer to «Engine Front Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
40. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
41. Install the number 1 cylinder spark plug. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Remove the battery box cover, LAT only.
3. Disconnect the engine wiring harness electrical connectors (2, 3) from the intake and exhaust camshaft position actuator solenoid valves.
4. Remove the ignition coils. Refer to «Ignition Coil Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
5. Remove the engine harness clips (4) from the cover.
6. Reposition the engine wiring harness out of the way.
7. Remove the fuel feed line retainers (1, 2) from the engine brackets.
8. Remove the camshaft cover bolts.
9. Remove the camshaft cover.

1. Install the camshaft cover and bolts. Tighten the bolts to 10 N.m (89 lb in).
2. Install the feed line retainers (1, 2) to the engine brackets.
3. Install the ignition coils. Refer to «Ignition Coil Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
4. Position the engine wiring harness and install the clips (4) to the cover.
5. Connect the engine wiring harness electrical connectors (2, 3) to the intake and exhaust camshaft position actuator solenoid valves.
6. Install the battery box cover, LAT only.
7. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

J 45027 Tensioner Tool. See Special Tools .

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LE5, LE9, LZ4, LZE, or LY7)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
2. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
3. Remove the timing chain tensioner.
4. Remove the seal from the tensioner.

1. Inspect the timing chain tensioner. If the timing chain tensioner, O-ring seal, or washer is damaged, replace the timing chain tensioner or O-ring seal as applicable.
2. Measure the timing chain tensioner assembly from end to end. If the timing chain tensioner is to be replaced, a new tensioner should be supplied in the fully compressed non-active state. A tensioner in the compressed state will measure 72 mm (2.83 in) (a) from end to end. A tensioner in the active state will measure 85 mm (3.35 in) (a) from end to end.
3. If the timing chain tensioner is not in the compressed state, perform the following steps: Remove the piston assembly from the body of the timing chain tensioner by pulling it out. Install the J 45027-2 (2) into a vise. Install the notch end of the piston assembly into the J 45027-2 (2). Using the J 45027-1 (1), turn the ratchet cylinder into the piston.
4. Inspect the bore of the tensioner body for dirt, debris, and damage. If any damage appears, replace the tensioner. Clean dirt or debris out with a lint-free cloth.
5. Install the compressed piston assembly back into the timing chain tensioner body until it stops at the bottom of the bore. Do not compress the piston assembly against the bottom of the bore. If the piston assembly is compressed against the bottom of the bore, it will activate the tensioner, which will then need to be reset again.
6. At this point the tensioner should measure approximately 72 mm (2.83 in) (a) from end to end. If the tensioner does not read 72 mm (2.83 in) (a) from end to end, repeat steps 3-5.
7. Inspect to ensure all dirt and debris is removed from the timing chain tensioner threaded hole in the cylinder head.
8. Install the timing chain tensioner assembly. Tighten the timing chain tensioner to 75 N.m (55 lb ft).
9. The timing chain tensioner is released by compressing the tensioner 2 mm (0.079 in) which will release the locking mechanism in the ratchet. To release the timing chain tensioner, use a suitable tool with a rubber tip on the end. Feed the tool down through the cam drive chest to rest on the cam chain. Then give a sharp jolt diagonally downwards to release the tensioner.
10. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LE5, LE9, LZ4, LZE, or LY7)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. Remove the intake camshaft position actuator. Refer to «Camshaft Position Intake Actuator Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Mark the bearing caps to ensure they are installed in the original position.
3. Remove the bearing cap bolts.
4. Remove the bearing caps.
5. Remove the intake camshaft (1).
6. Remove the camshaft roller followers.
7. Remove the hydraulic element lash adjusters.

1. Install the hydraulic element lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) for the recommended lubricant.
3. Lubricate the valve tips. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) for the recommended lubricant.
4. Position the camshaft roller followers on the tip of the valve stem and on the lash adjuster. Lubricate the roller followers. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) for the recommended lubricant.
5. Install the intake camshaft (1) and lubricate. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) for the recommended lubricant.
6. Install the camshaft bearing caps. Hand tighten the cap bolts.
7. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten the bolts to 10 N.m (89 lb in).
8. Install the intake camshaft position actuator. Refer to «Camshaft Position Intake Actuator Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. Remove the exhaust camshaft position actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Mark the bearing caps to ensure they are installed in the original position.
3. Remove the bearing cap bolts.
4. Remove the bearing caps.
5. Remove the exhaust camshaft (3).
6. Remove the camshaft roller followers.
7. Remove the hydraulic element lash adjusters.

1. Install the hydraulic element lash adjusters into their bores in the cylinder head.
2. Lubricate the hydraulic lash adjusters Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
3. Lubricate the valve tips with «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
4. Position the roller followers on the tip of the valve stem and on the lash adjuster. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
5. Install the exhaust camshaft (3). Lubricate with «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
6. Install the camshaft bearing caps. Hand tighten the cap bolts.
7. Tighten the bearing cap bolts in increments of 3 turns until they are seated. Tighten the bolts to 10 N.m (89 lb in).
8. Install the exhaust camshaft position actuator. Refer to «Camshaft Position Exhaust Actuator Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. EN-48749 Timing Chain Retention Tool Kit
2. EN-48953 Camshaft Actuator Locking Tool
3. J 45059 Angle Meter

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
3. Rotate the crankshaft clockwise and install the camshaft actuator retainer EN-48953 (1).
4. Install the camshaft actuator retainer bolts and tighten to 10 N.m (89 lb in).
5. Loosen, but DO NOT remove the intake camshaft actuator bolt.
6. Remove the camshaft actuator locking tool, EN-48953 (1).
7. Clean the timing chain and gears with solvent.
8. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
9. Remove the upper timing chain guide bolts and guide.
10. Remove the timing chain tensioner.
11. Install the timing chain retention tool EN-48749 (1) to the intake side of the timing chain.
12. Install the timing chain retention tool EN-48749 (1) to the exhaust side of the timing chain.
13. Remove and discard the intake camshaft actuator bolt (2).
14. Rotate the exhaust camshaft clockwise slightly to take the tension off of the timing chain on the intake actuator.
15. Remove the intake camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the intake camshaft actuator.
2. Align the intake camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft rotating the exhaust camshaft clockwise, if required.
3. Install a NEW intake camshaft actuator bolt (2) until snug.
4. Remove the timing chain retention tool (1) from the intake side of the timing chain.
5. Remove the timing chain retention tool (1) from the exhaust side of the timing chain.
6. Reset and install the timing chain tensioner. Refer to «Timing Chain Tensioner Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle)
7. Install the camshaft actuator retainer (1) EN-48953: Camshaft Actuator Locking Tool.
8. Install the camshaft actuator retainer bolts and tighten to 10 N.m (89 lb in).
9. Tighten the NEW camshaft actuator bolt to 30 N.m (22 lb ft) plus an additional 100 degrees using the J 45059 .
10. To release the tensioner apply a counterclockwise rotational torque to the crankshaft balancer bolt of 45 N.m (33 lb ft).
11. Remove the camshaft actuator retainer EN-48953 (1).
12. Install the upper timing chain guide and bolts and tighten to 10 N.m (89 lb in).
13. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
14. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. EN-48749 Timing Chain Retention Tool Kit
2. EN-48953 Camshaft Actuator Locking Tool
3. J 45059 Angle Meter

1. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
3. Rotate the crankshaft clockwise and install the camshaft actuator retainer EN-48953 (1).
4. Install the camshaft actuator retainer bolts and tighten to 10 N.m (89 lb in).
5. Loosen, but do not remove the exhaust camshaft actuator bolt.
6. Clean the timing chain and gears with solvent.
7. Mark the intake and exhaust camshaft actuators and the respective locations on the timing chain.
8. Remove the upper timing chain guide bolts and guide.
9. Remove the timing chain tensioner.
10. Install the timing chain retention tool EN-48749 (1) to the exhaust side of the timing chain.
11. Remove and discard the exhaust camshaft actuator bolt (2).
12. Remove the exhaust camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.

1. Install the timing chain onto the exhaust camshaft actuator.
2. Align the exhaust camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
3. Install a NEW exhaust camshaft actuator bolt (2) until snug.
4. Remove the timing chain retention tool EN-48749 (1) from the exhaust side of the timing chain.
5. Reset and install the timing chain tensioner. Refer to «Timing Chain Tensioner Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
6. Install the intake camshaft actuator retainer (1).
7. Install the camshaft actuator retainer bolts and tighten 10 N.m (89 lb in).
8. Tighten the NEW camshaft actuator bolt to 30 N.m (22 lb ft) plus an additional 100 degrees using the J 45059 .
9. To release the tensioner apply a counterclockwise rotational torque to the crankshaft balancer bolt of 45 N.m (33 lb ft).
10. Remove the camshaft actuator retainer EN-48953 (1).
11. Install the upper timing chain guide and bolts and tighten to 10 N.m (89 lb in).
12. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
13. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .

1. J 43649 Valve Spring Compressor. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
2. J 36017 Valve Guide Seal Remover. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
3. J 43653 Flywheel Holding Tool. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
4. J 43655 Sprocket Holding Tool. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .

1. If equipped, with a manual transmission leave the transmission in first gear with the vehicle on the ground and the parking brake set.
2. If equipped, with an automatic transmission, remove the starter. Refer to «Starter Replacement (LE5 or LE9)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Install J 43653 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
4. Remove the camshaft. Refer to «Intake Camshaft and Valve Lifter Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Exhaust Camshaft and Valve Lifter Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
5. Remove the camshaft roller followers.
6. Install the front section of the J 43649 to the second camshaft cover bolt hole. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
7. Install the remaining parts of the J 43649 to the cylinder head. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
8. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
9. Install an air hose adapter into the spark plug hole.
10. Attach an air hose to the adapter
11. Using the compressed air, pressurize the cylinder to 690 kPa (100 psi).
12. Compress the valve spring using the J 43649 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
13. Remove the valve spring keepers.
14. Remove the valve spring retainer.
15. Remove the valve spring.
16. Using the J 36017 remove the valve seal. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .

1. Using the J 36017 install the NEW valve seal. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) . Fully seat the seal onto the valve guide.
2. Install the valve spring.
3. Install the valve spring retainer.
4. Compress the valve spring using the J 43649 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
5. Install the valve spring keepers.
6. Disconnect the air hose from the adapter.
7. Remove the air hose adapter from the spark plug hole.
8. Remove the J 43649 from the cylinder head. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
9. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
10. Install the camshaft roller followers.
11. Install the camshaft. Refer to «Intake Camshaft and Valve Lifter Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Exhaust Camshaft and Valve Lifter Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
12. If used, remove the J 43653 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
13. If removed, install the starter. Refer to «Starter Replacement (LE5 or LE9)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .

1. J 38185 Hose Clamp Pliers
2. J 45059 Angle Meter
3. EN-48749 Timing Chain Retention Tool Kit
4. EN-48953 Camshaft Actuator Locking Tool

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the exhaust manifold. Refer to «Exhaust Manifold Replacement (LE5 or LE9)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement (LE5 or LE9 With MH8)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) .
3. Remove the intake manifold. Refer to «Intake Manifold Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Intake Manifold Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
4. Reposition the radiator surge tank air bleed hose clamp.
5. Remove the radiator surge tank air bleed hose from the cylinder head.
6. Reposition the radiator inlet hose clamp using the J 38185 .
7. Remove the radiator inlet hose from the cylinder head.
8. Disconnect all electrical connectors as necessary.
9. Remove the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions)
10. Remove the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
11. Rotate the crankshaft clockwise to install the camshaft actuator locking tool EN-48953: EGR Cooler Pressure Tester Adapter Set.
12. Install the EN-48953 (1).
13. Install the camshaft actuator tool and bolts tighten to 10 N.m (89 lb in).
14. Remove the upper timing chain guide bolts and guide.
15. Clean the timing chain and gears with solvent.
16. Mark the timing gear sprockets and the timing chain. It is recommended that the paint marks are located in the 12 o'clock position.
17. Loosen, but do not remove the intake and exhaust camshaft actuator bolts.
18. Remove the camshaft actuator locking tool, EN-48953 .
19. Install the timing chain retention tool EN-48749 (1) to the intake side of the timing chain.
20. Remove the timing chain tensioner.
21. Install the timing chain retention tool EN-48749 (1) to the exhaust side of the timing chain.
22. Remove and discard the exhaust camshaft actuator bolt (2).
23. Remove the exhaust cam actuator (3) from the exhaust camshaft while also removing the actuator from the chain.
24. Remove and discard the intake camshaft actuator bolt (2).
25. Remove the intake camshaft actuator (3) from the camshaft while also removing the actuator from the timing chain.
26. Mark the cylinder head (1) in relationship to the camshaft actuator notch is on the camshaft (2).
27. Remove the fixed timing chain guide access plug.
28. Remove the upper fixed timing chain guide bolt.
29. Install a rubber band (1) around the top of the upper timing chain guides (2) in order to pull the guides together.
30. Remove the cylinder head bolts in the sequence shown. Discard the bolts.
31. Remove the cylinder head.
32. Remove the cylinder head gasket.
33. Clean all of the gasket surfaces.
34. Use the following steps when cleaning the cylinder head and cylinder block surfaces: Use a razor blade gasket scraper to clean the cylinder head and cylinder block gasket surfaces. Do not scratch or gouge either surface. NOTE: DO NOT use any other method or technique to clean these gasket surfaces. Use a NEW razor blade on the cylinder head and a NEW blade on the cylinder block. NOTE: Be careful not to gouge or scratch the gasket surfaces. DO NOT gouge or scrape the combustion chamber surfaces. The feel of the gasket surface is important, not the appearance. There will be indentations from the gasket left in the cylinder head after all of the gasket material is removed. These small indentations will be filled in by the NEW gasket. Hold the razor blade as parallel to the gasket surface as possible.
35. Clean the old sealer/lube and any dirt from around the bolt holes.
36. Clean the bolts holes with a nylon bristle brush.
37. When cleaning the cylinder head bolt holes use suitable commercial spray liquid solvent and compressed air from an extended-tip blow gun in order to reach the bottom of the holes.
38. If replacing the cylinder head, transfer all parts as necessary.

1. Install the cylinder head gasket.
2. Install the cylinder head.
3. Install NEW cylinder head bolts.
4. Install and tighten the cylinder head bolts in the sequence shown to 30 N.m (22 lb ft) plus an additional 155 degrees using the J 45059 .
5. Install the NEW front cylinder head bolts and tighten the bolts to 35 N.m (26 lb ft).
6. Ensure the cylinder head (1) and the camshaft (2) are correctly aligned.
7. Remove the rubber band (1) from around the top of the upper timing chain guides (2).
8. Install the fixed guide bolt into the cylinder head and tighten to 12 N.m (106 lb in).
9. Apply sealant compound to thread and install the timing chain guide bolt access hole plug. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) for the correct part number.
10. Install the fixed timing chain guide access plug and tighten the plug to 90 N.m (59 lb ft).
11. Install the timing chain onto the intake camshaft actuator.
12. Align the intake camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
13. Install a NEW intake camshaft actuator bolt (2) until snug.
14. Remove the timing chain retention tool EN-48749 (1) from the intake side of the timing chain.
15. Install the timing chain onto the exhaust camshaft actuator.
16. Align the exhaust camshaft actuator alignment mark made previously with the timing chain mark and install the actuator onto the camshaft.
17. Install a NEW exhaust camshaft actuator bolt (2) until snug.
18. Remove the timing chain retention tool EN-48749 (1) from the exhaust side of the timing chain.
19. Reset and install the timing chain tensioner. Refer to «Timing Chain Tensioner Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
20. Install the EN-48953 (1) to the actuators.
21. Install the camshaft actuator locking tool bolts and tighten to 10 N.m (89 lb in).
22. Tighten the NEW camshaft actuator bolt to 30 N.m (22 lb ft), plus an additional 100 degrees using the J 45059 .
23. Release the tensioner by applying a counterclockwise rotational torque of 45 N.m (33 lb ft) to the harmonic balancer bolt.
24. Remove the camshaft actuator locking tool, EN-48953 .
25. Install the upper timing chain guide bolts and guide. Tighten the bolts to 10 N.m (89 lb in).
26. Install the camshaft cover. Refer to «Camshaft Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
27. Install the spark plugs. Refer to «Spark Plug Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
28. Connect all electrical connectors as necessary.
29. Install the radiator inlet hose to the cylinder head.
30. Position the radiator inlet hose clamp using the J 38185 .
31. Install the radiator surge tank air bleed hose to the cylinder head.
32. Position the radiator surge tank air bleed hose clamp.
33. Install the exhaust manifold. Refer to «Exhaust Manifold Replacement (LE5 or LE9)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) or «Exhaust Manifold Replacement (LE5 or LE9 With MH8)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) .
34. Install the intake manifold. Refer to «Intake Manifold Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
35. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the drive belt. Refer to «Drive Belt Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Drive Belt Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the oil level indicator tube. Refer to «Oil Level Indicator Tube Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Oil Level Indicator Tube Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
3. Install the engine support fixture. Refer to «Engine Support Fixture»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
4. Remove engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
5. Using the engine support fixture, raise the engine approximately 76 mm (3 in).
6. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
7. Loosen the upper air conditioning (A/C) compressor bolts.
8. Remove the lower A/C compressor bolt.
9. Place a suitable drain pan under the oil pan drain plug.
10. Remove the oil pan drain plug.
11. Drain the engine oil.
12. Reinstall the oil pan drain plug until snug.
13. LAT only: Disconnect the engine wiring harness electrical connector (1) from the generator control module coolant pump (2). Remove the generator control module coolant pump bolt (3). Remove the generator control module coolant pump from the oil pan.
14. Remove the 4 oil pan to transaxle bolts.
15. Remove the oil pan bolts.
16. Remove the oil pan
17. Remove any old oil pan sealant (1).

1. Ensure that the oil pan and the sealing surface on the lower crankcase are free of all oil and debris.
2. Apply a 2 mm bead of sealant (1) around the perimeter of the oil pan and the oil suction port opening. DO NOT over apply the sealant. More than a 2 mm bead is not required. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
3. Install the oil pan.
4. Install the oil pan bolts.
5. Install the 4 oil pan to transaxle bolts and tighten to 75 N.m (55 lb ft).
6. Tighten the oil pan bolts in the sequence shown to 25 N.m (18 lb ft).
7. LAT only: Install the generator control module coolant pump to the oil pan. Ensure that the anti-rotation tab is inserted into the hole in the oil pan. Install the generator control module coolant pump bolt (3) and tighten to 25 N.m (18 lb ft). Connect the engine wiring harness electrical connector (1) to the generator control module coolant pump (2).
8. Lower the vehicle.
9. Using the engine support fixture, lower the engine.
10. Install the engine mount. Refer to «Engine Mount Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
11. Remove the engine support fixture.
12. Install the oil level indicator tube. Refer to «Oil Level Indicator Tube Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Oil Level Indicator Tube Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
13. Install the drive belt. Refer to «Drive Belt Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Drive Belt Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
14. Fill the engine oil to the proper level.

1. Remove the engine oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Rotate the crankshaft so that cylinders 1 and 4 are at top dead center (TDC).
3. Remove the piston oil nozzles from cylinders 1 and 4 using a 3/8 inch wobble extension drive with a 6 mm hex drive bit. Remove the piston oil nozzles. (Crankshaft removed for illustrative purposes.)
4. Rotate the crankshaft so that cylinders 2 and 3 are at TDC. Remove the piston oil nozzles.

1. Install new piston oil nozzles. Turn the extension by hand to ensure that the threads are aligned. Use a long screwdriver to ensure that the nozzle does not rotate and make sure that the locating pin is properly indexed in its hole. Tighten the piston oil nozzle bolts to 15 N.m (11 lb ft).
2. Install the engine oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
3. Lower the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
4. Replace the oil filter and fill the engine with new engine oil. Refer to «Engine Mechanical Specifications (LAT, LE5, LE9)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-specifications__engine-mechanical-specifications-lat-le5-le9) .
5. Reset the engine oil life monitor. Refer to «GM Oil Life System Resetting»(/chevrolet/malibu/vii-2008-2012/remont/lubrication-system/#maintenance-and-lubrication__gm-oil-life-system-resetting) .

1. J 8037 Ring Compressor
2. J 24270 Cylinder Bore Ridge Reamer
3. J-43966-1 Connecting Rod Guides. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
4. J 45059 Angle Meter

1. Remove the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Remove the cylinder head. Refer to «Cylinder Head Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
3. If a ring ridge is present, remove the ring ridge as follows: Turn the crankshaft until the piston is at the bottom of the stroke. Place a cloth on top of the piston. Use a J 24270 to remove the ring ridge. Turn the crankshaft so the piston is at top of the stroke. Remove the cloth and cutting debris.
4. Remove the connecting rod nuts and the connecting rod cap. Discard the bolts and nuts.
5. Remove the connecting rod and the piston out of the top of the engine block using the J-43966-1 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
6. Clean the cylinder bores with hot water and detergent or with a light honing.
7. Swab the bores with the engine oil and a clean, dry cloth.

1. Coat the following parts with engine oil: The piston The piston rings The cylinder bore The bearing surfaces
2. Install the piston into its original bore using the J-43966-1 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
3. Lightly tap the top of the piston with a wooden hammer handle.
4. When installing the piston and the connecting rod, the stamped mark on the piston must point to the front of the engine.
5. Hold the J 8037 firmly against the engine block until all the piston rings have entered the cylinder bore.
6. Install the connecting rod caps onto their original connecting rods.
7. Align the numbers placed on the connecting rod and the connecting rod cap during removal.
8. Install the new connecting rod bolts and nuts. On the first pass, tighten the nuts evenly to 25 N.m (18 lb ft). On the final pass, use the J 45059 in order to tighten the nuts an additional 100 degrees.
9. Measure the connecting rod side clearance with a feeler gauge. The correct clearance is 0.070-0.370 mm (0.0027-0.0145 in).
10. Install the cylinder head. Refer to «Cylinder Head Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
11. Install the oil pan. Refer to «Oil Pan Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

EN-45680-880 Cylinder Liner Removal and Installation Kit

1. Remove the piston and connecting rod. Refer to «Piston, Connecting Rod, and Bearing Replacement (LAF)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Inspect the condition of the piston. Refer to «Piston, Connecting Rod, and Bearing Cleaning and Inspection»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-off-vehicle-1-of-2) .
3. Rotate the crankshaft so that the counterweight is to the right side and the connecting rod journal is to the left side and not in alignment with the cylinder bore.
4. Install the EN 45680-882 cylinder bore sleeve puller (1) through the cylinder bore.
5. Align the shoe (1) of the EN 45680-882 cylinder bore sleeve puller to the bottom of the cylinder bore sleeve (2).
6. Hold the threaded shaft of the EN 45680-882 cylinder bore sleeve puller upward in order to retain the shoe alignment to the bottom of the cylinder bore sleeve.
7. Install the EN 456850-881 fixture (4) onto the threaded shaft of the EN 456850-882 cylinder bore sleeve puller and the engine block.
8. Install the bearing (3) and the nut (1).
9. Tighten the nut (1) to the bearing (3).
10. Install and tighten the 4 attaching bolts (2) into the cylinder head bolt holes of the block. Tighten the bolts to 15 N.m (11 lb ft).
11. Rotate the nut clockwise in order to remove the cylinder bore liner.
12. Remove EN 45680-881 fixture, EN 45680-882 cylinder bore sleeve puller, and the cylinder bore sleeve from the engine block.
13. Inspect the cylinder bore in the cylinder block for cracks or damage. If cracked or damaged, replace the cylinder block.

1. Place the NEW cylinder bore sleeve onto the cylinder block.
2. Install EN 45680-881 fixture and EN 45680-883 cylinder bore sleeve installer assembly over the cylinder bore sleeve and onto the cylinder block. Do not apply downward pressure to the cylinder bore sleeve.
3. Insert the 4 attachment bolts into the legs of the EN 45680-881 fixture (1). Do not apply downward pressure to the cylinder bore sleeve (2). Tighten the 4 attachment bolts to 15 N.m (11 lb ft).
4. Align the bottom of the cylinder bore sleeve (1) with the cylinder bore of the block (2).
5. Align the installation arbor (1) onto the top of the cylinder bore sleeve (2).
6. Align the pusher block (2) of EN 45680-883 cylinder bore sleeve installer into the groove of EN 45680-881 fixture (1).
7. Using a ratchet, rotate the threaded shaft of EN 45680-88 fixture and EN 45680-883 cylinder bore sleeve installer assembly in order to install the cylinder bore sleeve into the engine block.
8. Do not completely seat the cylinder bore sleeve in the block. Leave approximately 1.60 mm (1/16 inch) of the cylinder bore sleeve above the surface of the cylinder block.
9. Using a torque wrench, tighten the threaded shaft of the EN 45680-881 fixture and EN 45680-883 cylinder bore sleeve installer assembly to 102 N.m (75 lb ft) in order to completely seat the cylinder bore sleeve in the cylinder block. With the cylinder bore sleeve properly installed, a minimal portion of the cylinder bore liner flange will protrude above the block deck surface.
10. Remove the EN 45680-881 fixture and EN 45680-883 cylinder bore sleeve installer assembly (1) from the cylinder block (2).

Scheme 1

1. EN 45680-885 Debris Collector (3)
2. EN 45680-881 Trim Tool Assembly (2)
3. Air Control Valve (1)
4. Drill Motor with 1/2 inch chuck, 1 1/8 hp, 7 amps, triple gear reduction, and a 450-600 RPM rotational speed in a clockwise direction

Scheme 2

1. Trim Tool Preloader (1)
2. EN 45680-882 Set Gauge Ring (2)
3. EN 45680-883 Metal Shavings Catch Plug (3)
4. EN 45680-886 Drive Adapter (4)
5. EN 45680-884 Bolts (5)

1. After installing the NEW cylinder bore sleeve(s) into the engine block, trim the excess material from the cylinder bore sleeve flange.
2. Place the EN 45680-883 metal shaving catch plug into the cylinder bore sleeve to be trimmed. Position the top of the EN 45680-883 approximately 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
3. Place additional EN 45680-883 metal shaving catch plugs into all remaining cylinder bore sleeves.
4. Ensure that the EN 45680-883 metal shaving catch plug is 3.0 mm (0.12 in) below the top surface of the cylinder bore sleeve.
5. The groove side of the EN 45680-882 set gauge ring (1) should be positioned upward on a flat surface.
6. Carefully position EN 45680-881 trim tool assembly onto the EN 45680-882 set gauge ring.
7. Loosen the shaft collar screw (2).
8. Push the shaft collar (2) downward using the trim tool preloader (1) until the shaft collar is positioned against the top of the flange bearing (3).
9. Apply downward pressure on the collar and inner drive shaft using the trim tool preloader (1), then tighten the shaft collar screw to 19 N.m (14 lb ft).
10. Place the EN 45680-881 trim tool assembly onto the cylinder to be trimmed with the directional arrow pointing in line with the crankshaft centerline and the front of the block.
11. Install the EN 45680-884 4 bolts into the cylinder head bolt holes in the block and tighten to 20 N.m (15 lb ft).
12. Fasten the drive adapter EN 45680-886 into the drill chuck.
13. Connect a compressed air supply (75-125 psi) to the male quick connect located on EN 45680-881 trim tool assembly. Turn the compressed air valve to the open position. This starts the venturi vacuum system that will catch the metal shavings.
14. Place the EN 45680-886 drive adapter and the drill assembly vertically onto the EN 45680-881 drive adapter end of trim tool assembly. Do not apply downward force on the drill until full rotational speed has been reached. After reaching full rotational speed, gradually apply downward force until the cutting action is complete in approximately 5 seconds.
15. Remove the EN 45680-886 drive adapter (1) and the drill assembly from the EN 45680-881 trim tool assembly.
16. Turn OFF the compressed air valve.
17. Remove the EN 45680-881 trim tool assembly from the engine block.
18. Wipe the cylinder bore sleeve and the surrounding areas of any powder residue. Remove the EN 45680-883 metal shaving catch plug.
19. Install a straight edge on the cylinder block perpendicular to the crankshaft centerline.
20. Using a light, illuminate the backside of the straight edge.
21. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder bore sleeve flange. If light is present on either side of both sides of the cylinder bore sleeve, the cylinder bore sleeve is cut incorrectly and a new cylinder bore sleeve needs to be installed.
22. Looking at the front of the straight edge, inspect to see if light is protruding through the bottom of the straight edge and the top of the cylinder block deck surface. If light is present on both sides of the cylinder block, the cylinder bore sleeve is cut correctly.
23. Proceed to the next bore sleeve to be trimmed, repeating steps 10-19 if necessary.
24. Install the piston and the connecting rod. Refer to «Piston, Connecting Rod, and Bearing Replacement (LAF)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

1. J 38122-A Crankshaft Balancer Holder. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
2. J 45059 Angle Meter

1. Remove the transaxle. Refer to «Transmission Replacement (2.4L (LAT) W/ME7)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-4t45-e-repair-instructions-on-vehicle) .
2. Have an assistant install the J 38122-A , and a breaker bar to the crankshaft balancer in order to prevent the flywheel from rotating when loosening the flywheel bolts. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
3. Loosen, remove and discard the flywheel bolts.
4. Remove the flywheel.
5. Clean the thread adhesive from the flywheel bolt holes. Use a nylon bristle brush to clean the holes in the crankshaft.

1. Position the flywheel to the crankshaft.
2. Install the NEW flywheel bolts until snug.
3. Have an assistant install the J 38122-A , and a breaker bar to the crankshaft balancer in order to prevent the flywheel from rotating when tightening the flywheel bolts. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
4. Tighten the flywheel bolts. Tighten: Tighten the bolts to 53 N.m (39 lb ft) plus an additional 25 degrees using the J 45059 .
5. Remove the J 38122-A and breaker bar. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
6. Install the transaxle. Refer to «Transmission Replacement (2.4L (LAT) W/ME7)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-4t45-e-repair-instructions-on-vehicle) .

J 42067 Rear Main Seal Installer. See Special Tools .

1. Remove the flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
2. Pry out the crankshaft rear oil seal using a flat-bladed tool.

1. Using the J 42067 , install a NEW crankshaft real oil seal. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-special-tools-and-equipment) .
2. Install the flywheel. Refer to «Engine Flywheel Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .

J-38185: Hose Clamp Pliers

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (without CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) or «Fuel Pressure Relief (with CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
3. Disconnect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
4. Disconnect the evaporative emission (EVAP) line (3) quick connect fitting from the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
5. Disconnect the fuel feed pipe clip (2) from the fuel line bracket.
6. Disconnect the transaxle shift cable clip (1) from the fuel line bracket.
7. Remove the battery tray. Refer to «Battery Tray Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
8. Remove the generator starter. Refer to «Generator with Starter Replacement»(/chevrolet/malibu/vii-2008-2012/remont/engine-control-systems/#hybrid-engine-controls-repair-instructions) .
9. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
10. Disconnect the vacuum brake booster hose (2) from the intake manifold. Reposition the brake booster hose out of the way.
11. Reposition the coolant recovery inlet hose clamp (2) at the cylinder head.
12. Disconnect the coolant recovery inlet pipe clip from the fuel rail.
13. Disconnect the coolant recovery inlet hose (1) from the cylinder head. Reposition the hose/pipe out of the way.
14. Reposition the radiator inlet hose clamp using the J-38185: pliers.
15. Disconnect the radiator inlet hose from the cylinder head.
16. Remove the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
17. Reposition the generator control module coolant hose clamp (1) at the generator control module.
18. Remove the generator control module coolant hose from the generator control module.
19. Disconnect the engine wiring harness electrical connector (1) from the transaxle auxiliary pump module.
20. Reposition the heater inlet hose clamp (1) at the thermostat housing.
21. Disconnect the heater inlet hose (2) from the thermostat housing.
22. Reposition the coolant recovery reservoir/heater inlet hose (3) clamp at the thermostat housing.
23. Disconnect the coolant recovery reservoir/heater inlet hose (4) from the thermostat housing.
24. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
25. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement (LAF)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
26. Disconnect the engine wiring harness electrical connector (1) from the generator control module coolant pump.
27. Disconnect the engine wiring harness electrical connector (2) from the air conditioning (A/C) compressor.
28. Remove the generator control module coolant pump bolt (3) and pump (2).
29. Unbolt the A/C compressor and reposition out of the way.
30. Remove the positive battery cable to starter motor nut (4).
31. Disconnect the positive battery cable lead (1) from the starter motor.
32. Reposition the positive battery cable from in between the starter and the engine.
33. Disconnect the engine wiring harness electrical connector (2) from the auxiliary heater water pump.
34. Remove the auxiliary heater water pump bolt and pump.
35. Lower the vehicle.
36. Remove the transaxle shift cable from the range select lever.
37. Release the shift control cable retaining clip and remove the cable from the shift control cable bracket.
38. Using long tie straps, secure the radiator/condenser/fan assembly to the radiator support.
39. Raise the vehicle and remove the front wheels and tires. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/wheel-tire-system/#tires-wheels) .
40. Remove the front wheelhouse panel. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
41. Install a piece of hardwood 1 x 2 x 4 between the transaxle and the frame.
42. Install a piece of hardwood 1 x 2 x 4 between the oil pan and the frame.
43. Drain the transaxle fluid.
44. Remove the transaxle oil cooler hose to transaxle nut (1).
45. Remove the transaxle oil cooler hoses from the transaxle. Refer to «Transmission Fluid Cooler Hose Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-4t45-e-repair-instructions-on-vehicle) .
46. Remove the catalytic converter.
47. Disconnect the intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/chevrolet/malibu/vii-2008-2012/remont/steering-column-switches/#steering-wheel-steering-column) .
48. Disconnect the tie rods from the steering knuckles. Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/malibu/vii-2008-2012/remont/electronic-steering/#power-steering-system) .
49. Disconnect the stabilizer links from the stabilizer shaft. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/malibu/vii-2008-2012/remont/suspension-front/#front-suspension-system) .
50. Disconnect the lower control arms from the steering knuckles. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vii-2008-2012/remont/suspension-front/#front-suspension-system) .
51. Remove the wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vii-2008-2012/remont/axle-shafts/#wheel-drive-shafts) .
52. Lower the vehicle.
53. Remove the engine mount to bracket bolts (1).
54. Remove the transaxle mount to transaxle bolts.
55. Raise the vehicle.
56. Position an engine support table under the powertrain assembly.
57. With the table positioned, fully raise the table to contact with the powertrain assembly.
58. Remove the frame to body bolts. Discard the bolts.
59. Lower the engine table and raise the body on the hoist until the engine/transaxle and frame are separated from the vehicle.
60. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator.
61. Disconnect the engine wiring harness electrical connector (8) from the fuel injector wiring harness electrical connector (7).
62. Disconnect the engine wiring harness clip (3) from the oil level indicator tube bracket.
63. Disconnect the engine wiring harness electrical connectors (1) from the ignition coils.
64. Disconnect the engine wiring harness electrical connectors (2, 3) from the camshaft actuators.
65. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
66. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
67. Disconnect the engine wiring harness electrical connector (3) from the knock sensor.
68. Disconnect the engine wiring harness electrical connector (1) from the intake camshaft position (CMP) sensor.
69. Disconnect the engine wiring harness electrical connector (2) from the EVAP emission canister purge solenoid valve.
70. Disconnect the engine wiring harness electrical connector (1) from the exhaust CMP sensor.
71. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor.
72. Disconnect the engine wiring harness electrical connector (3) from the heated oxygen sensor (HO2S) electrical connector.
73. Remove the engine wiring harness clip (5) from the stud.
74. Remove the engine wiring harness ground bolt (1) and reposition the ground terminal from the engine.
75. Gather all branches of the engine wiring harness and reposition the harness out of the way.
76. Remove the starter motor bolts and the starter.
77. Remove the torque converter to flexplate bolts (1).
78. Install a suitable lifting device to the engine.
79. Remove the transaxle bolts from the engine.
80. Separate the engine from the transaxle.
81. Install the engine to a suitable engine stand.

1. Install a suitable lifting device to the engine.
2. Using the lifting device, position and install the engine to the transaxle.
3. Install the transaxle bolts to the engine and tighten to 75 N.m (55 lb ft).
4. Install the torque converter to flexplate bolts (1) and tighten to 60 N.m (44 lb ft).
5. Remove the engine lifting device.
6. Install the starter motor and bolts and tighten to 53 N.m (39 lb ft).
7. Gather all branches of the engine wiring harness and position the harness to the engine.
8. Position the engine wiring harness ground terminal to the engine and install the engine wiring harness ground bolt (1) and tighten to 20 N.m (15 lb ft).
9. Connect the engine wiring harness electrical connector (1) to the ECT sensor.
10. Connect the engine wiring harness electrical connector (3) to the HO2S electrical connector.
11. Install the engine wiring harness clip (5) to the stud.
12. Connect the engine wiring harness electrical connector (1) to the exhaust CMP sensor.
13. Connect the engine wiring harness electrical connector (1) to the intake CMP sensor.
14. Connect the engine wiring harness electrical connector (2) to the EVAP emission canister purge solenoid valve.
15. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
16. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
17. Connect the engine wiring harness electrical connector (3) to the knock sensor.
18. Connect the engine wiring harness electrical connectors (1) to the ignition coils.
19. Connect the engine wiring harness electrical connectors (2, 3) to the camshaft actuators.
20. Connect the engine wiring harness electrical connector (1) to the throttle actuator.
21. Connect the engine wiring harness electrical connector (8) to the fuel injector wiring harness electrical connector (7).
22. Install the engine wiring harness clip (3) to the oil level indicator tube bracket.
23. Position the powertrain support table under the vehicle.
24. Raise the powertrain into position under the vehicle.
25. With the table positioned, if required, lower the vehicle over the powertrain.
26. Align the lower radiator pins with the frame. Ensure all hoses and electrical harnesses are correctly routed and free from the loading path of the powertrain.
27. Install the NEW frame to body bolts and tighten to 155 N.m (114 lb ft).
28. Lower the vehicle.
29. Install the transaxle mount to transaxle bolts and tighten to 55 N.m (41 lb ft).
30. Install the engine mount to bracket bolts (1) and tighten to 50 N.m (37 lb ft).
31. Raise and support the vehicle.
32. Install the wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vii-2008-2012/remont/axle-shafts/#wheel-drive-shafts) .
33. Connect the control arm to the steering knuckles. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vii-2008-2012/remont/suspension-front/#front-suspension-system) .
34. Connect the stabilizer links to the stabilizer shaft. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/malibu/vii-2008-2012/remont/suspension-front/#front-suspension-system) .
35. Connect the outer tie rods to the steering knuckles. Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/malibu/vii-2008-2012/remont/electronic-steering/#power-steering-system) .
36. Connect the intermediate shaft to the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/chevrolet/malibu/vii-2008-2012/remont/steering-column-switches/#steering-wheel-steering-column) .
37. Install the catalytic converter.
38. Connect the transaxle oil cooler hoses to the transaxle. Refer to «Transmission Fluid Cooler Hose Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-4t45-e-repair-instructions-on-vehicle) .
39. Install the transaxle oil cooler hose to transaxle nut (1) and tighten to 4 N.m (27 lb in).
40. Remove the wood from between the oil pan and the frame.
41. Remove the wood from between the transaxle and the frame.
42. Install the front wheelhouse panel. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
43. Install the front wheels and tires. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/wheel-tire-system/#tires-wheels) .
44. Lower the vehicle.
45. Position the radiator/condenser/fan assembly. Remove the tie straps.
46. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.
47. Install the transaxle shift cable to the range select lever.
48. Raise and support the vehicle.
49. Install the auxiliary heater water pump and bolt and tighten to 9 N.m (80 lb in).
50. Connect the engine wiring harness electrical connector (2) to the auxiliary heater water pump.
51. Position and install the positive battery cable between the starter and the engine.
52. Connect the positive battery cable lead (1) to the starter motor.
53. Install the positive battery cable to starter motor nut (4) and tighten to 9 N.m (80 lb in).
54. Install the A/C compressor with the bolts and tighten to 50 N.m (37 lb ft).
55. Install the generator control module coolant pump (2) with the bolt (3) and tighten to 25 N.m (18 lb ft).
56. Connect the engine wiring harness electrical connector (1) to the generator control module coolant pump.
57. Connect the engine wiring harness electrical connector (2) to the A/C compressor.
58. Lower the vehicle.
59. Connect the coolant recovery reservoir/heater inlet hose (4) to the thermostat housing.
60. Position the coolant recovery reservoir/heater inlet hose clamp (3) at the thermostat housing.
61. Connect the heater inlet hose (3) to the thermostat housing.
62. Position the heater inlet hose clamp (1) at the thermostat housing.
63. Connect the engine wiring harness electrical connector (1) to the transaxle auxiliary pump module.
64. Connect the generator control module coolant hose to the generator control module.
65. Position the generator control module coolant hose clamp (1) at the generator control module.
66. Position the radiator inlet hose clamp using the J-38185: pliers.
67. Connect the radiator inlet hose to the cylinder head.
68. Install the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
69. Connect the coolant recovery inlet hose (1) to the cylinder head.
70. Connect the coolant recovery inlet pipe clip to the fuel rail.
71. Position the coolant recovery inlet hose clamp (2) at the cylinder head.
72. Connect the vacuum brake booster hose (2) to the intake manifold.
73. Position the vacuum brake booster hose clamp (1) at the intake manifold.
74. Install the generator starter. Refer to «Generator with Starter Replacement»(/chevrolet/malibu/vii-2008-2012/remont/engine-control-systems/#hybrid-engine-controls-repair-instructions) .
75. Install the battery tray. Refer to «Battery Tray Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
76. Connect the transaxle shift cable clip (1) to the fuel line bracket.
77. Connect the fuel feed pipe clip (2) to the fuel line bracket.
78. Connect the EVAP line (3) quick connect fitting to the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
79. Connect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
80. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
81. Fill the transaxle with fluid. Refer to «Transmission Fluid Level and Condition Check»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-4t45-e-symptom-troubleshooting-and-diagnosis) .
82. Refill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
83. Perform the CKP system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__crankshaft-position-system-variation-learn) .
84. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.

J-38185: Hose Clamp Pliers

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (without CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) or «Fuel Pressure Relief (with CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
3. Disconnect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
4. Disconnect the evaporative emission (EVAP) line (3) quick connect fitting from the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
5. Disconnect the fuel feed pipe clip (2) from the fuel line bracket.
6. Disconnect the transaxle shift cable clip (1) from the fuel line bracket.
7. Remove the battery tray. Refer to «Battery Tray Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Tray Replacement (LZ4, LY7, and LE5)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
8. Reposition the vacuum brake booster hose clamp (1) at the intake manifold.
9. Disconnect the vacuum brake booster hose (2) from the intake manifold. Reposition the brake booster hose out of the way.
10. Reposition the coolant recovery inlet hose clamp (2) at the cylinder head.
11. Disconnect the coolant recovery inlet pipe clip from the fuel rail.
12. Disconnect the coolant recovery inlet hose (1) from the cylinder head. Reposition the hose/pipe out of the way.
13. Reposition the radiator inlet hose clamp using the J-38185: pliers.
14. Disconnect the radiator inlet hose from the cylinder head.
15. Remove the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
16. Reposition the heater inlet hose clamp (1) at the thermostat housing.
17. Disconnect the heater inlet hose (2) from the thermostat housing.
18. Reposition the coolant recovery reservoir/heater inlet hose (3) clamp at the thermostat housing.
19. Disconnect the coolant recovery reservoir/heater inlet hose (4) from the thermostat housing.
20. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
21. Drain the engine oil. Refer to «Engine Oil and Oil Filter Replacement (LAF)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
22. Unbolt the A/C compressor and reposition out of the way.
23. Remove the positive battery cable to starter motor nut (4).
24. Disconnect the positive battery cable lead (1) from the starter motor.
25. Reposition the positive battery cable from in between the starter and the engine.
26. If equipped with the LE5 engine, perform the following steps: Disconnect the generator electrical connector (1). Reposition the engine harness boot (3). Remove the generator nut (2). Remove the engine harness lead (4) from the generator.
27. Lower the vehicle.
28. Remove the transaxle shift cable from the range select lever.
29. Release the shift control cable retaining clip and remove the cable from the shift control cable bracket.
30. Using long tie straps, secure the radiator/condenser/fan assembly to the radiator support.
31. Raise the vehicle and remove the front wheels and tires. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/wheel-tire-system/#tires-wheels) .
32. Remove the front wheelhouse panel. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
33. Install a piece of hardwood 1 x 2 x 4 between the transaxle and the frame.
34. Install a piece of hardwood 1 x 2 x 4 between the oil pan and the frame.
35. Drain the transaxle fluid.
36. If equipped with the 4T45, remove the transaxle oil cooler hose to transaxle nut (1).
37. If equipped with the 4T45, disconnect the transaxle oil cooler hoses from the transaxle. Refer to «Transmission Fluid Cooler Hose Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-4t45-e-repair-instructions-on-vehicle) .
38. If equipped with the 6T40, disconnect the fluid cooler hoses at the transmission. Refer to «Fluid Cooler Inlet Hose Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-6t306t406t45-repair-instructions-on-vehicle) and «Fluid Cooler Outlet Hose Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-6t306t406t45-repair-instructions-on-vehicle) .
39. If equipped with the 6T70, disconnect the fluid cooler pipes from the transmission. Refer to «Transmission Fluid Cooler Pipe Replacement - Front»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-6t706t75-repair-instructions-on-vehicle) and «Transmission Fluid Cooler Pipe Replacement - Rear»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-6t706t75-repair-instructions-on-vehicle) .
40. Remove the catalytic converter. Refer to «Exhaust Manifold Pipe Replacement (LE5 or LE9)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) .
41. Disconnect the intermediate shaft from the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/chevrolet/malibu/vii-2008-2012/remont/steering-column-switches/#steering-wheel-steering-column) .
42. Disconnect the tie rods from the steering knuckles. Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/malibu/vii-2008-2012/remont/electronic-steering/#power-steering-system) .
43. Disconnect the stabilizer links from the stabilizer shaft. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/malibu/vii-2008-2012/remont/suspension-front/#front-suspension-system) .
44. Disconnect the lower control arms from the steering knuckles. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vii-2008-2012/remont/suspension-front/#front-suspension-system) .
45. Remove the wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vii-2008-2012/remont/axle-shafts/#wheel-drive-shafts) .
46. Lower the vehicle.
47. Remove the engine mount to bracket bolts (1).
48. Remove the transaxle mount to transaxle bolts.
49. Raise the vehicle.
50. Position an engine support table under the powertrain assembly.
51. With the table positioned, fully raise the table to contact with the powertrain assembly.
52. Remove the frame to body bolts. Discard the bolts.
53. Lower the engine table and raise the body on the hoist until the engine/transaxle and frame are separated from the vehicle.
54. Disconnect the engine wiring harness electrical connector (1) from the throttle actuator.
55. Disconnect the engine wiring harness electrical connector (8) from the fuel injector wiring harness electrical connector (7).
56. Disconnect the engine wiring harness clip (3) from the oil level indicator tube bracket.
57. Disconnect the engine wiring harness electrical connectors (1) from the ignition coils.
58. Disconnect the engine wiring harness electrical connectors (2, 3) from the camshaft actuators.
59. Disconnect the engine wiring harness electrical connector (1) from the crankshaft position (CKP) sensor.
60. Disconnect the engine wiring harness electrical connector (2) from the oil pressure sensor.
61. Disconnect the engine wiring harness electrical connector (3) from the knock sensor.
62. Disconnect the engine wiring harness electrical connector (1) from the intake camshaft position (CMP) sensor.
63. Disconnect the engine wiring harness electrical connector (2) from the EVAP emission canister purge solenoid valve.
64. Disconnect the engine wiring harness electrical connector (1) from the exhaust CMP sensor.
65. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor.
66. Disconnect the engine wiring harness electrical connector (3) from the heated oxygen sensor (HO2S) electrical connector.
67. Remove the engine wiring harness clip (5) from the stud.
68. Remove the engine wiring harness ground bolt (1) and reposition the ground terminal from the engine.
69. Gather all branches of the engine wiring harness and reposition the harness out of the way.
70. Remove the starter motor bolts and the starter.
71. Remove the torque converter to flexplate bolts (1).
72. Install a suitable lifting device to the engine.
73. If equipped with the 4T45, remove the transaxle bolts from the engine.
74. If equipped with the 6T40, remove the transaxle bolts (1, 2, 3, 4) from the engine.
75. If equipped with the 6T70, remove the bolts (1, 2,) from the engine.
76. If equipped with the 6T40, remove the intermediate drive shaft. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vii-2008-2012/remont/axle-shafts/#wheel-drive-shafts) .
77. Separate the engine from the transaxle.
78. Install the engine to a suitable engine stand.

1. Install a suitable lifting device to the engine.
2. Using the lifting device, position and install the engine to the transaxle.
3. Install the transaxle bolts to the engine and tighten to 75 N.m (55 lb ft).
4. Install the torque converter to flexplate bolts (1) and tighten to 60 N.m (44 lb ft).
5. Remove the engine lifting device.
6. Install the starter motor and bolts and tighten to 53 N.m (39 lb ft).
7. Gather all branches of the engine wiring harness and position the harness to the engine.
8. Position the engine wiring harness ground terminal to the engine and install the engine wiring harness ground bolt (1) and tighten to 20 N.m (15 lb ft).
9. Connect the engine wiring harness electrical connector (1) to the ECT sensor.
10. Connect the engine wiring harness electrical connector (3) to the HO2S electrical connector.
11. Install the engine wiring harness clip (5) to the stud.
12. Connect the engine wiring harness electrical connector (1) to the exhaust CMP sensor.
13. Connect the engine wiring harness electrical connector (1) to the intake CMP sensor.
14. Connect the engine wiring harness electrical connector (2) to the EVAP emission canister purge solenoid valve.
15. Connect the engine wiring harness electrical connector (1) to the CKP sensor.
16. Connect the engine wiring harness electrical connector (2) to the oil pressure sensor.
17. Connect the engine wiring harness electrical connector (3) to the knock sensor.
18. Connect the engine wiring harness electrical connectors (1) to the ignition coils.
19. Connect the engine wiring harness electrical connectors (2, 3) to the camshaft actuators.
20. Connect the engine wiring harness electrical connector (1) to the throttle actuator.
21. Connect the engine wiring harness electrical connector (8) to the fuel injector wiring harness electrical connector (7).
22. Install the engine wiring harness clip (3) to the oil level indicator tube bracket.
23. Position the powertrain support table under the vehicle.
24. Raise the powertrain into position under the vehicle.
25. With the table positioned, if required, lower the vehicle over the powertrain.
26. Align the lower radiator pins with the frame. Ensure all hoses and electrical harnesses are correctly routed and free from the loading path of the powertrain.
27. Install the NEW frame to body bolts and tighten to 155 N.m (114 lb ft).
28. Lower the vehicle.
29. Install the transaxle mount to transaxle bolts and tighten to 55 N.m (41 lb ft).
30. Install the engine mount to bracket bolts (1) and tighten to 50 N.m (37 lb ft).
31. Raise and support the vehicle.
32. Install the wheel drive shafts. Refer to «Wheel Drive Shaft Replacement»(/chevrolet/malibu/vii-2008-2012/remont/axle-shafts/#wheel-drive-shafts) .
33. Connect the control arm to the steering knuckles. Refer to «Lower Control Arm Replacement»(/chevrolet/malibu/vii-2008-2012/remont/suspension-front/#front-suspension-system) .
34. Connect the stabilizer links to the stabilizer. Refer to «Stabilizer Shaft Link Replacement»(/chevrolet/malibu/vii-2008-2012/remont/suspension-front/#front-suspension-system) .
35. Connect the outer tie rods to the steering knuckles. Refer to «Steering Linkage Outer Tie Rod Replacement»(/chevrolet/malibu/vii-2008-2012/remont/electronic-steering/#power-steering-system) .
36. Connect the intermediate shaft to the steering gear. Refer to «Intermediate Steering Shaft Replacement»(/chevrolet/malibu/vii-2008-2012/remont/steering-column-switches/#steering-wheel-steering-column) .
37. Install the catalytic converter. Refer to «Exhaust Manifold Pipe Replacement (LE5 or LE9)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) .
38. If equipped with the 4T45, connect the transaxle oil cooler hoses to the transaxle. Refer to «Transmission Fluid Cooler Hose Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-4t45-e-repair-instructions-on-vehicle) .
39. If equipped with the 4T45, install the transaxle oil cooler hose to transaxle nut (1) and tighten to 4 N.m (27 lb in).
40. If equipped with the 6T40, connect the fluid cooler hoses to the transaxle. Refer to «Fluid Cooler Inlet Hose Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-6t306t406t45-repair-instructions-on-vehicle) and «Fluid Cooler Outlet Hose Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-6t306t406t45-repair-instructions-on-vehicle) .
41. If equipped with the 6T70, connect the fluid cooler pipes to the transmission. Refer to «Transmission Fluid Cooler Pipe Replacement - Front»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-6t706t75-repair-instructions-on-vehicle) and «Transmission Fluid Cooler Pipe Replacement - Rear»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-6t706t75-repair-instructions-on-vehicle) .
42. Remove the wood from between the oil pan and the frame.
43. Remove the wood from between the transaxle and the frame.
44. Install the front wheelhouse panel. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
45. Install the front wheels and tires. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/wheel-tire-system/#tires-wheels) .
46. Lower the vehicle.
47. Position the radiator/condenser/fan assembly. Remove the tie straps.
48. Install the shift control cable to the shift control cable bracket and engage the shift control cable retaining clip.
49. Install the transaxle shift cable to the range select lever.
50. Raise and support the vehicle.
51. If equipped with the LE5 engine, perform the following steps: Install the engine harness lead (4) to the generator. Install the generator nut (2) and tighten to 20 N.m (15 lb ft). Seat the engine harness boot (3). Connect the generator electrical connector (1).
52. Position and install the positive battery cable between the starter and the engine.
53. Connect the positive battery cable lead (1) to the starter motor.
54. Install the positive battery cable to starter motor nut (4) and tighten to 9 N.m (80 lb in).
55. Install the A/C compressor with the bolts and tighten to 50 N.m (37 lb ft).
56. Lower the vehicle.
57. Connect the coolant recovery reservoir/heater inlet hose (4) to the thermostat housing.
58. Position the coolant recovery reservoir/heater inlet hose clamp (3) at the thermostat housing.
59. Connect the heater inlet hose (3) to the thermostat housing.
60. Position the heater inlet hose clamp (1) at the thermostat housing.
61. Position the radiator inlet hose clamp using the J-38185: pliers.
62. Connect the radiator inlet hose to the cylinder head.
63. Install the radiator outlet hose. Refer to «Radiator Outlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
64. Connect the coolant recovery inlet hose (1) to the cylinder head.
65. Connect the coolant recovery inlet pipe clip to the fuel rail.
66. Position the coolant recovery inlet hose clamp (2) at the cylinder head.
67. Connect the vacuum brake booster hose (2) to the intake manifold.
68. Position the vacuum brake booster hose clamp (1) at the intake manifold.
69. Install the generator starter. Refer to «Generator with Starter Replacement»(/chevrolet/malibu/vii-2008-2012/remont/engine-control-systems/#hybrid-engine-controls-repair-instructions) .
70. Install the battery tray. Refer to «Battery Tray Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) or «Battery Tray Replacement (LZ4, LY7, and LE5)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
71. Connect the transaxle shift cable clip (1) to the fuel line bracket.
72. Connect the fuel feed pipe clip (2) to the fuel line bracket.
73. Connect the EVAP line (3) quick connect fitting to the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
74. Connect the fuel feed pipe (1) quick connect fitting at the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
75. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
76. Fill the transaxle with fluid. Refer to the appropriate procedure: «Transmission Fluid Level and Condition Check»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-4t45-e-symptom-troubleshooting-and-diagnosis) for the 4T45 transmission «Transmission Fluid Level and Condition Check»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-6t306t406t45-symptom-troubleshooting-and-diagnosis__transmission-fluid-level-and-condition-check) for the 6T40 transmission «Transmission Fluid Level and Condition Check»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-6t706t75-symptom-troubleshooting-and-diagnosis__transmission-fluid-level-and-condition-check) for the 6T70 transmission
77. Refill the engine with oil. Refer to «Engine Oil and Oil Filter Replacement (LAF)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
78. Perform the CKP system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions__crankshaft-position-system-variation-learn) .
79. Start the engine and allow the engine to run, inspect for leaks. Correct as necessary.

1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
2. Place a drain pan under the oil drain plug.
3. Remove the oil pan drain plug.
4. Allow the oil to drain completely.
5. Install the oil pan drain plug and tighten to 25 N.m (18 lb ft).
6. Lower the vehicle.
7. use an oil filter wrench on the outside diameter of the oil filter cap.
8. Remove the oil filter cap and filter.
9. Remove the filter from the cap.

1. Install the NEW oil filter to the cap.
2. Install the oil filter cap and filter.
3. use an oil filter wrench on the outside diameter of the oil filter cap. Tighten the oil filter cap until fully seated. DO NOT exceed 25 N.m (18 lb ft).
4. Fill the engine with oil. Refer to «Fluid and Lubricant Recommendations (USA and Canada)»(/chevrolet/malibu/vii-2008-2012/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations-usa-and) .

See also:
• Special Tools
• Engine Splash Shield Replacement - Right Side
• Air Cleaner Assembly Replacement
• Fastener Caution
• Starter Replacement (LE5 or LE9)
• Lifting and Jacking the Vehicle
• Front Compartment Sight Shields Replacement
• Radiator Inlet Hose Replacement (LAT)
• Adhesives, Fluids, Lubricants, and Sealers
• Exhaust Manifold Replacement (LE5 or LE9)
• Engine Mechanical Specifications (LAT, LE5, LE9)
• GM Oil Life System Resetting
• Piston, Connecting Rod, and Bearing Cleaning and Inspection
• Transmission Replacement (2.4L (LAT) W/ME7)
• Fuel Pressure Relief (without CH 48027-100)
• Generator with Starter Replacement
• Tire and Wheel Removal and Installation
• Intermediate Steering Shaft Replacement
• Steering Linkage Outer Tie Rod Replacement
• Stabilizer Shaft Link Replacement
• Wheel Drive Shaft Replacement
• Transmission Fluid Level and Condition Check
• Crankshaft Position System Variation Learn
• Fluid Cooler Inlet Hose Replacement
• Transmission Fluid Cooler Pipe Replacement - Front
• Transmission Fluid Level and Condition Check
• Transmission Fluid Level and Condition Check
• Fluid and Lubricant Recommendations (USA and Canada)
• Drive Belt Replacement (LE5)