GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 3.1L 🢒 Engine Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Remove the engine air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1L.
  4. Remove the hood. Refer to Hood Replacement in Body Front End.
  5. Remove the drive belt. Refer to Drive Belt Replacement .

    6. Object Number: 63668 Size: SH
  6. Remove the hoses from the surge tank.
  7. Remove the cruise control module. Refer to Cruise Control Module Replacement in Cruise Control.
  8. Remove the engine wiring harness from the top of the engine. Refer to Harness Routing Views in Wiring Systems.

    9. Set the harness aside.

  9. Disconnect the throttle cable.
  10. Disconnect the cruise control cable. Refer to Cruise Control Cable Replacement in Cruise Control.
  11. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  12. Remove the starter. Refer to Starter Motor Replacement .
  13. Remove the air conditioning (A/C) compressor with the lines attached. Refer to Air Conditioning Compressor Replacement .

    14. Position the air conditioning (A/C) compressor aside.

  14. Disconnect and position aside the lower engine wiring harness. Refer to Harness Routing Views in Wiring Systems.
  15. Disconnect the catalytic converter flange from the rear exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
  16. Remove the torque converter cover and the torque converter to flywheel bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle 4T40 - E/4T45 - E.
  17. Remove the engine splash shields. Refer to Wheelhouse Splash Shield Replacement in Body Front End.
  18. Remove the transaxle to engine brace. Refer to Transmission Replacement in Automatic Transaxle 4T40 - E/4T45 - E.
  19. Remove the 2 outer transmission mounting bolts. Refer to Transmission Replacement in Automatic Transaxle 4T40 - E/4T45 - E.
  20. Disconnect the upper and the lower radiator hoses. Refer to Radiator Hose Replacement in Engine Cooling.
  21. Lower the vehicle.
  22. Disconnect the fuel lines from the engine. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 3.1L.
  23. Disconnect the engine vacuum hoses to the brake booster.

    24. Object Number: 545 Size: SH
  24. Disconnect the heater hoses.
  25. Install the engine support fixture. Refer to Engine Support Fixture .
  26. Raise the engine.
  27. Remove the engine mount and the adapter. Refer to Engine Mount Replacement .
  28. Remove the power steering pump.
  29. Install the engine lifting device.
  30. Remove the engine support fixture. Refer to Engine Support Fixture .
  31. Remove the transaxle to the engine retaining bolts. Refer to Transmission Replacement in Automatic transaxle 4T40 - E/4T45 - E.
  32. Remove the engine from the vehicle.
  33. Remove the engine flywheel. Refer to Engine Flywheel Replacement .
  34. Mount the engine onto a suitable engine stand.

Installation Procedure
  1. Attach the engine lifting device.

    2. Remove the engine from the engine stand.

  2. Install the engine flywheel. Refer to Engine Flywheel Replacement .
  3. Position the engine in the vehicle.

    4. Align the engine with the transaxle. Refer to Transmission Replacement in Automatic transaxle 4T40 - E/4T45 - E.

  4. Install the upper transaxle mounting bolts. Refer to Transmission Replacement in Automatic transaxle 4T40 - E/4T45 - E.
  5. Install the engine support fixture. Refer to Engine Support Fixture .
  6. Remove the engine lifting device.
  7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  8. Install the power steering pump to the engine front cover.
  9. Install the engine mount bracket and the engine mount. Refer to Engine Mount Replacement .
  10. Attach the power steering pressure and the return lines.
  11. Connect the upper and the lower radiator hoses. Refer to Radiator Hose Replacement .
  12. Install the 2 outer transaxle to engine mounting bolts. Refer to Transmission Replacement in Automatic Transaxle 4T40 - E/4T45 - E.
  13. Install the transaxle to engine brace. Refer to Transmission Replacement in Automatic Transaxle 4T40 - E/4T45 - E..
  14. Install the right splash shield. Refer to Wheelhouse Splash Shield Replacement in Body Front End.
  15. Install the flywheel to torque converter bolts and the flywheel inspection cover. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle 4T40 - E/4T45 - E..
  16. Install the air conditioning (A/C) compressor. Refer to Air Conditioning Compressor Replacement in HVAC Systems with A/C - Manual.
  17. Install the starter. Refer to Starter Motor Replacement in Engine Electrical.
  18. Install the engine mount nuts. Refer to Engine Mount Replacement .
  19. Install the catalytic converter to the rear exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
  20. Install a new oil filter.
  21. Install the lower engine wiring harness and the retainers. Refer to Harness Routing Views in Wiring Systems.
  22. Lower the vehicle.
  23. Install the engine wiring harness and the retainers at the top of the engine. Refer to Harness Routing Views in Wiring Systems.
  24. Connect the vacuum hoses.
  25. Connect the cruise control cable. Refer to Cruise Control Cable Replacement .
  26. Connect the throttle control cable.
  27. Install and connect the cruise control module. Refer to Cruise Control Module Replacement .
  28. Install the drive belt. Refer to Drive Belt Replacement .
  29. Connect the surge tank hoses.
  30. Install the hood. Refer to Hood Replacement in Body Front End.
  31. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.1L.
  32. Fill the engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
  33. Fill the crankcase to the appropriate level. Use the recommended oil. Refer to Engine Oil and Oil Filter Replacement .
  34. Start the engine.

    35. Inspect the engine for leaks.

  35. Stop the engine.

    36. Inspect the fluid levels.