How to replace Cylinder Head on Chevy Malibu?

Cylinder head removal procedure for 2.2L, 3.5L and 3.9L Engines.

In this chapter details are mentioned for Chevy Malibu cylinder head removal.

The procedure to remove and install cylinder head with complete help diagrams are as follows:-----

2.2L Engine

1. Drain the cooling system.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following: 
   
   
   Intake manifold

   Exhaust manifold

   Timing chain

   Cylinder head bolts in sequence

   Cylinder head 
   
   
   

   Fig. 2.2L engine cylinder head bolt removal sequence.

To install:

1. Install the cylinder head using new gaskets. Tighten the bolts in sequence to 22 ft. lbs. (30 Nm) plus 155 degrees.
2. Using new bolts, install the front cylinder head bolts. Tighten to 26 ft. lbs. (35 Nm).
3. Install or connect the following:
   
   
   Timing chain

   Exhaust manifold

   Intake manifold
4. Fill the cooling system to the correct level.
5. Start the engine and check for leaks.
   
   
   

   

   Fig. Location of the front four cylinder head bolts-2.2L engine
   
   
   
   

   

   Fig. 2.2L engine cylinder bolt sequence installation.

3.5L Engine
Left (Front)

1. Drain the engine oil.
2. Drain the cooling system.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Lower intake manifold

   Rocker arms and pushrods

   Exhaust crossover pipe

   Oil level indicator tube

   Spark plug wires and spark plugs

   Exhaust manifold

   Cylinder head bolts

   Cylinder head
   
   

   

   

   Fig. 3.5L engine cylinder head bolt torque sequence

To install:

1. Install or connect the following:
   
   
   Cylinder head using new gasket. Tighten the bolts in sequence to 44 ft. lbs. (60 Nm) plus 95 degrees.

   Exhaust manifold

   Spark plugs and spark plug wires

   Oil level indicator tube

   Exhaust crossover pipe

   Rocker arms and pushrods

   Lower intake manifold
2. Fill the engine with oil to the correct level.
3. Fill the cooling system to the correct level.
4. Start the engine and check for leaks.

Right (Rear)

1. Drain the cooling system.
2. Drain the engine oil.
3. Relieve the fuel system pressure.
4. Remove or disconnect the following:
   
   
   Negative battery cable

   Lower intake manifold

   Rocker arms and pushrods

   Exhaust crossover pipe

   Right side spark plug wires and spark plugs

   Fuel line bracket

   Alternator

   Right exhaust manifold

   Cylinder head bolts, in reverse order of the torque sequence

   Cylinder head

To install:

1. Install or connect the following:
   
   
   Cylinder head with new gasket. Torque the bolts to 44 ft. lbs. (60 Nm) plus and additional 95 degrees.

   Right exhaust manifold

   Alternator

   Fuel line bracket. Tighten bolt to 37 ft. lbs. (50 Nm).

   Right side spark plugs and spark plug wires

   Exhaust crossover pipe

   Pushrods and rocker arms

   Lower intake manifold

   Negative battery cable
2. Fill engine with oil to the correct level.
3. Fill the cooling system to the correct level.
4. Start the engine and check for leaks.

3.9L Engine
Left (Front)

1. Drain the engine oil.
2. Drain the cooling system.
3. Lower the vehicle.
4. Remove the upper and lower intake manifolds.
5. Remove the valve rocker arms and the pushrods.
6. Remove the exhaust manifold.
7. Remove the oil level indicator tube.
8. Remove the left spark plugs.
9. Remove and discard the cylinder head bolts.
10. Remove the cylinder head.
11. Remove and discard the cylinder head gasket.
12. Remove the cylinder head locator dowel pins, if necessary.
13. Clean and inspect the cylinder head.
    
    WARNING

    Head gaskets are specific for right hand and left hand applications, and also must be installed with the correct side facing up. Note the markings on the head gaskets for proper installation. Failure to do so may lead to engine damage.
    
    
    
    
    

    

    Fig. Cylinder head gasket markings shown
14. Install the cylinder head locator dowel pins, if previously removed
15. Inspect the cylinder head locator dowel pins for proper installation.
16. Install a new cylinder head gasket.
17. Install the cylinder head onto the locator pins and the engine.
    
    WARNING

    This component uses torque-to-yield bolts. When servicing this component do not reuse the bolts, New torque-to-yield bolts must be installed. Reusing used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield bolts may lead to engine damage.
18. Install new cylinder head bolts finger tight.
19. Tighten the cylinder head bolts in sequence to 44 ft. lbs. (60 Nm). plus an additional 140 degrees using the J 45059 angle meter.
    
    
    

    

    Fig. 3.9L Left cylinder head tightening sequence
20. Install the left spark plugs.
21. Install the oil level indicator tube.
22. Install the exhaust manifold.
23. Install the valve rocker arms and the pushrods.
24. Install the lower intake manifold.
25. Fill the engine with oil.
26. Fill and bleed the cooling system.
27. Start the engine and check for leaks.

Right (Rear)

1. Raise the vehicle.
2. Drain the cooling system.
3. Drain the engine oil.
4. Lower the vehicle.
5. Remove the upper and lower intake manifold.
6. Remove the valve rocker arms and pushrods.
7. Remove the exhaust manifold.
8. Remove the right spark plugs.
9. Remove the fuel line bracket bolt and stud.
10. Remove the fuel line bracket.
11. Remove the alternator.
12. Remove and discard the cylinder head bolts.
13. Remove the cylinder head.
14. Remove and discard the cylinder head gasket.
15. Remove the cylinder head locator dowel pins, if necessary.
    
    WARNING

    Head gaskets are specific for right hand and left hand applications, and also must be installed with the correct side facing up. Note the markings on the head gaskets for proper installation. Failure to do so may lead to engine damage.
16. Clean and inspect the cylinder head.

To install:

1. Install the cylinder head locator dowel pins, if previously removed
2. Install a new cylinder head gasket.
3. Install the cylinder head onto the locator pins and the engine.
   
   WARNING

   This component uses torque-to-yield bolts. When servicing this component do not reuse the bolts, New torque-to-yield bolts must be installed. Reusing used torque-to-yield bolts will not provide proper bolt torque and clamp load. Failure to install NEW torque-to-yield bolts may lead to engine damage.
4. Install new cylinder head bolts finger tight.
5. Tighten the cylinder head bolts in sequence to 44 ft. lbs. (60 Nm). plus an additional 140 degrees using the J 45059 angle meter.
   
   
   

   

   Fig. 3.9L Right cylinder head tightening sequence
6. Install the alternator.
7. Position the fuel line bracket to the cylinder head and tighten to 37 ft. lbs. (50 Nm).
8. Install the right spark plugs.
9. Install the exhaust manifold.
10. Install the valve rocker arms and pushrods.
11. Install the lower intake manifold.
12. Fill the engine with oil.
13. Fill and bleed the cooling system.
14. Start the engine and check for leaks.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html