How to Replace Engine on Chevrolet Malibu?

The detailed procedure is mentioned for 2.2L, 3.5L and 3.9L Engine models.

In this chapter Chevy Malibu Engine removal procedure is provided.


The procedure is as follows:-----

2.2L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Relieve the fuel system pressure.
3. Drain the engine oil.
4. Drain the engine coolant.
5. With the tires in the straight forward position, remove the key from the ignition.
6. Secure the cooling module to the upper body structure.
7. Remove or disconnect the following:
   
   
   Negative battery cable

   Air intake assembly

   Fuel lines from the fuel rail

   Coolant hoses

   Heater hoses

   Throttle control electrical connector

   MAP sensor electrical connector

   Crankshaft sensor electrical connector

   Oil pressure electrical connector

   Purge solenoid electrical connector

   Ignition coil electrical connector

   O ₂ sensor electrical connector

   Vehicle speed sensor (VSS) electrical connector

   Coolant temperature sensor electrical connector

   Back-up lamp switch electrical connector
8. Raise and support the vehicle.
9. Remove or disconnect the following:
   
   
   Accessory drive belt

   A/C compressor mounting bolts and set compress aside

   Starter electrical connectors

   Alternator electrical connector

   Front exhaust down pipe from the exhaust manifold

   Transmission harness connectors

   Transmission shift cable from the transmission
10. Support the powertrain assembly between the frame and the powertain using a block of wood or suitable equivalent.
11. Remove or disconnect the following:
    
    WARNING

    In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.
    
    
    
    
    Engine mount

    Side transmission mount, if equipped with automatic transmission

    Stabilizer links

    Outer tie rods from steering knuckles

    Intermediate shaft from the steering gear
    
    
    
    
    Lower control arms from the steering knuckles

    Halfshafts from the steering knuckles
12. Matchmark the frame to body position.
13. Position a lift table under the frame to support the frame assembly.
14. Slowly remove the front frame bolts.
15. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
16. Slowly lower the lift table.
17. Attach an engine lift hoist to the engine.
18. Remove the starter.
19. Remove the torque converter to flywheel bolts, if equipped.
20. Remove the transmission to engine bolts.
21. Separate the engine from the transmission.
22. Remove the clutch pressure plate and disc, if equipped.
23. Remove or disconnect the following:
    
    
    Exhaust manifold and studs

    Catalytic converter assembly

    Engine mount bracket

    Engine block heater, if equipped

    Thermostat housing and feed pipe

    Alternator

To install:

1. If removed, install or connect the following:
   
   
   Exhaust manifold

   Engine mount bracket

   Fuel rail

   Engine block heater, if equipped

   Thermostat housing and feed pipe

   Alternator

   Flywheel

   Clutch pressure plate and disc, if equipped
2. Align the engine to the transmission. Tighten to the engine-to-transmission bolts to 55 ft. lbs. (75 Nm).
3. Install the torque converter bolts, if equipped. Tighten bolts to 46 ft. lbs. (62 Nm).
4. Install the starter.
5. Reinstall the powertrain assembly to the frame assembly. Raise and position the frame/powertrain assembly to the vehicle.
6. Hand start all the frame bolts while aligning the frame to the body matchmarks. Tighten the frame bolts to 74 ft. lbs. (100 Nm) plus 180 degrees.
7. Remove the lift table.
8. Install or connect the following:
   
   
   Halfshafts to the steering knuckles

   Lower control arms to the steering knuckles

   Intermediate steering shaft to the steering gear

   Outer tie rods to the steering knuckles

   Stabilizer links

   Side transmission mount, if equipped with automatic transmission

   Engine mount

   Transmission shift cable to the transmission

   Transmission wiring harness connector

   Front exhaust down pipe to the exhaust manifold. Tighten nuts to 22 ft. lbs. (30 Nm).

   Alternator electrical connectors

   Starter harness connectors

   A/C compressor

   Accessory drive belt

   Throttle control electrical connector

   MAP sensor electrical connector

   Oil pressure electrical connector

   Purge solenoid electrical connector

   Ignition coil electrical connector

   O ₂ sensor electrical connector

   VSS electrical connector

   Coolant temperature sensor electrical connector

   Heater hoses

   Coolant hoses

   Fuel line to fuel rail

   Air intake assembly

   Negative battery cable
9. Release the cooling module from the upper body structure.
10. Fill with engine oil to the correct level.
11. Fill the cooling system to the correct level.
12. Start the engine and check for leaks.

3.5L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Relieve the fuel system pressure.
3. Drain the engine oil.
4. Drain the engine coolant.
5. Remove or disconnect the following:
   
   
   Negative battery cable

   Air intake assembly

   Hood

   Engine mount strut

   Accessory drive belt

   Knock sensor (KS) electrical connector

   Camshaft position (CMP) sensor electrical connector

   Crankshaft position (CKP) sensor electrical connector

   Heated oxygen sensor (HO2S) electrical connector

   Manifold absolute pressure (MAP) sensor electrical connector

   Exhaust gas recirculation (EGR) valve electrical connector

   Evaporative emission (EVAP) canister purge solenoid electrical connector

   Throttle control electrical connector

   Ignition coil electrical connector

   Body wiring harness
6. Raise and support the vehicle.
7. Remove or disconnect the following:
   
   
   Catalytic converters

   Engine wiring harness grounds

   Engine mount lower nuts

   Torque converter covers

   Starter

   A/C compressor mounting bolts and support the compress aside

   Torque converter bolts

   Transmission support brace

   Lower transmission-to-engine bolt

   Radiator hoses
8. Lower the vehicle and support the transmission.
9. Remove or disconnect the following:
   
   
   Heater hoses

   Vacuum hoses from upper intake manifold

   Fuel lines from the fuel rail
10. Install a suitable engine lifting device to the engine.
11. Remove the remaining transmission-to-engine bolts.
12. Remove the engine from the vehicle.

To install:

1. Install the engine to the transmission. Tighten the upper bolts to 55 ft. lbs. (75 Nm).
2. Remove the engine lifting device.
3. Install or connect the following:
   
   
   Radiator hoses

   Fuel lines to the fuel rail

   Brake booster vacuum hose to the upper intake manifold

   Heater hoses

   Lower transmission bolt and tighten to 55 ft. lbs. (75 Nm)

   Transmission support brace. Tighten bolts to 53 ft. lbs. (72 Nm)

   Torque converter bolts

   A/C compressor mounting bolts

   Starter

   Torque converter covers

   Engine mount lower nuts. Tighten nuts to 32 ft. lbs. (43 Nm).

   Engine wiring grounds. Tighten nut to 26 ft. lbs. (35 Nm).

   Catalytic converters

   Body wiring harness

   Ignition coil electrical connector

   Throttle control electrical connector

   EVAP canister purge solenoid electrical connector

   EGR valve electrical connector

   MAP sensor electrical connector

   HO2S electrical connector

   CKP sensor electrical connector

   CMP sensor electrical connector

   KS electrical connector

   Accessory drive belt

   Engine mount strut

   Hood

   Air intake assembly

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

3.9L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Relieve the fuel system pressure.
3. Disconnect the negative battery cable.
4. Remove the air cleaner assembly.
5. Remove the hood.
6. Remove the intake manifold cover.
7. Remove the engine mount strut.
8. Remove the drive belt.
9. Drain the cooling system.
10. Drain the engine oil.
11. Remove the starter motor.
12. Remove the oil pressure sensor heat shield nuts and shield.
13. Disconnect the engine wiring harness electrical connector from the oil pressure sensor.
14. Disconnect the engine wiring harness electrical connector from the knock sensor.
15. Remove the engine wiring harness clip from the Air Conditioning (A/C) compressor bracket.
16. Remove the engine wiring harness clip bolt.
17. Separate the engine wiring harness clip from the engine boss
18. Disconnect the engine wiring harness electrical connector from the A/C compressor.
19. Disconnect the engine wiring harness electrical connector from the oil level sensor.
20. Remove the engine wiring harness clips from the transaxle bracket.
21. Remove the engine wiring harness clip from the transaxle bracket.
22. Remove the Connector Position Assurance (CPA) retainer.
23. Disconnect the lower front Heated Oxygen Sensor (HO2S) electrical connector from the engine wiring harness electrical connector.
24. Remove the engine wiring harness electrical connector from the thermostat housing stud.
25. Disconnect the lower rear HO2S electrical connector.
26. Remove the engine wiring harness electrical connector rosebud from the transaxle mount.
27. Disconnect the Knock Sensor (KS) and Crankshaft Position (CKP) sensor.
28. Lower the vehicle.
29. Remove all wiring harness clips.
30. Using the J 25034-C, remove power steering pump pulley.
31. Remove power steering pump.
32. Disconnect the Evaporative Emission (EVAP) canister purge solenoid.
33. Disconnect the Electronic Throttle Control (ETC).
34. Disconnect the Heated Oxygen Sensor (HO2S).
35. Disconnect the Manifold Absolute Pressure (MAP) sensor and the ignition control module.
36. Disconnect the alternator electrical connectors.
37. Disconnect the inlet manifold valve and the fuel injector inline electrical connector.
38. Disconnect the electrical connector from the camshaft phasor.
39. Disconnect the engine wiring harness electrical connectors from the body wiring harness electrical connector.
40. Disconnect the engine wiring harness electrical connectors from the Powertrain Control Module (PCM).
41. Disconnect the engine harness electrical connector from the Transmission Control Module (TCM).
42. Disconnect the vehicle speed sensor and transaxle wiring harness.
43. Remove engine wiring harness bolts and ground connections.
44. Remove battery cable ground terminal.
45. Reposition all of the harnesses out of the way.
46. Remove the catalytic converters.
47. Remove the engine mount.
48. Remove the torque converter cover.
49. Remove the flexplate to torque converter bolts.
50. Unbolt and reposition the A/C compressor to the side. DO NOT discharge the A/C system.
51. Remove the transaxle brace to oil pan bolts.
52. Remove the transaxle brace to transaxle bolts and remove the brace.
53. Remove the radiator outlet hose from the thermostat housing.
54. Lower the vehicle and support the transaxle.
55. Reposition the radiator surge tank hose clamp at the surge tank pipe.
56. Remove the radiator surge tank hose from the surge tank pipe.
57. Remove the brake booster vacuum hose from the intake manifold.
58. Remove the heater outlet and inlet hoses from the engine.
59. Disconnect the fuel feed line from the fuel rail.
60. Disconnect the EVAP purge line from the canister purge solenoid.
61. Remove the radiator inlet hose from the engine.
62. Install an engine lifting device to the engine.
63. Remove all the transaxle-to-engine bolts and studs.
64. Separate the engine from the transaxle and remove the engine from the vehicle.

To install:

1. Install the engine to the vehicle and install the engine to the transaxle.
2. Install the transaxle-to-engine bolts and studs.
3. Install the remaining transaxle-to-engine bolts and studs and tighten to 55 ft. lbs. (75 Nm).
4. Install the radiator inlet hose and tighten clamp.
5. Connect the EVAP purge line to the canister purge solenoid.
6. Connect the fuel feed line from the fuel rail.
7. Install the heater outlet and inlet hoses and tighten clamps.
8. Install the brake booster vacuum hose to the intake manifold.
9. Install the radiator surge tank hose to the surge tank pipe and tighten clamp.
10. Remove the support from the transaxle and raise the vehicle.
11. Install the radiator outlet hose to the thermostat housing.
12. Snug all the transaxle brace to engine block bolts and oil pan lower bolts.
13. Tighten the bolts to 37 ft. lbs. (50 Nm).
14. Install A/C compressor and tighten to 37 ft. lbs. (50 Nm).
15. Install the flexplate to torque converter bolts and tighten to 46 ft. lbs. (62 Nm).
16. Install the torque converter cover.
17. Install the engine mount and tighten the frame nuts to 37 ft. lbs. (50 Nm).
18. Install the catalytic converters and tighten to 23 ft. lbs. (31 Nm).
19. Position the branches of the engine wiring harness over the engine.
20. Install the battery cable ground terminal and the engine harness ground terminal to the transaxle stud.
21. Tighten the harness retaining nut to 18 ft. lbs. (25 Nm).
22. Install the engine wiring harness ground bolt and tighten to 18 ft. lbs. (25 Nm).
23. Install and tighten all additional harness mounting bolts and tighten to 18 ft. lbs. (25 Nm).
24. Connect the engine wiring harness electrical connector to the transaxle and the vehicle speed sensor.
25. Reconnect the PCM and TCM electrical connectors.
26. Connect all the engine wiring harness electrical connectors to the body wiring harness electrical connectors.
27. Install all wiring harness clips and any remaining wiring harness bolts.
28. Reconnect the camshaft phasor, fuel injector inline electrical connector and the inlet manifold valve.
29. Reconnect the alternator electrical connectors and tighten stud nut to 15 ft. (20 Nm).
30. Reconnect the rear upper HO2S electrical connector, ignition control module and the MAP sensor.
31. Reconnect the front HO2S electrical connector, the ETC and the EVAP canister purge solenoid.
32. Install the power steering pump and tighten mounting bolts to 18 ft. lbs. (25 Nm).
33. Using the J 25033-C, install power steering pump pulley.
34. Install the engine wiring harness clip to the power steer pump bracket.
35. Raise the vehicle.
36. Reconnect the CKP sensor and the KS sensor.
37. Install the engine wiring harness electrical connector rosebud to the transaxle mount.
38. Connect the lower rear HO2S electrical connector. 
39. Install the engine wiring harness electrical connector to the thermostat housing stud.
40. Connect the lower front HO2S electrical connector. 
41. Install the entire remaining engine wiring harness clips to the transaxle.
42. Reconnect the oil level sensor and the A/C compressor electrical connectors.
43. Install the engine wiring harness clip to the engine boss.
44. Reconnect to the knock sensor and oil pressure sensor electrical connectors.
45. Install the oil pressure sensor heat shield tighten the mounting nuts to 89 inch. lbs. (10 Nm).
46. Install the starter motor and tighten mounting bolts to 32 ft. lbs. (43 Nm).
47. Tighten the solenoid mounting nut to 89 inch. lbs. (10 Nm).
48. Install the drive belt.
49. Install the engine mount strut and tighten bots to 37 ft. lbs. (50 Nm).
50. Install the intake manifold cover.
51. Install the air cleaner assembly.
52. Install the hood and tighten bolts to 89 inch. lbs. (10 Nm).
53. Fill the cooling system.
54. Refill crankcase with engine oil.
55. Connect the negative battery cable.
56. Perform the CKP system variation learn procedure.
57. Check for leaks and recheck all fluid levels.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

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