GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 3.5L (LX9) 🢒 Engine Replacement

Removal Procedure

    Object Number: 96002 Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Drain the cooling system. Refer to Cooling System Draining and Filling .
  3. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  5. Remove the hood. Refer to Hood Replacement .
  6. Remove the engine mount strut. Refer to Engine Mount Strut Replacement .
  7. Remove the drive belt. Refer to Drive Belt Replacement .
  8. Disconnect the following electrical connectors:
    9. • The knock sensor (KS)
    • The camshaft position (CMP) sensor
    • The crankshaft position (CKP) sensor
    • The heated oxygen sensor (HO2S)
    • The manifold absolute pressure (MAP) sensor
    • The exhaust gas recirculation (EGR) valve
    • The evaporative emission (EVAP) canister purge solenoid
    • The electronic throttle control
    • The ignition coil
    • The body wiring harness-to-engine harness
  9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  10. Remove the catalytic converters. Refer to Catalytic Converter Replacement .
  11. Remove the engine wiring harness grounds from the transaxle.
  12. Remove the engine mount lower nuts.
  13. Remove the torque converter covers.
  14. Remove the starter motor. Refer to Starter Motor Replacement .
  15. Remove the air conditioning (A/C) compressor. DO NOT discharge the A/C system. Support the compressor. Refer to Air Conditioning Compressor Replacement .
  16. Remove the torque converter bolts.

    17. Object Number: 1229785 Size: SH
  17. Remove the engine mount bracket bolts and bracket.

    18. Object Number: 1736971 Size: SH
  18. Remove the engine wiring harness clip from the rear of the transaxle brace.
  19. Remove the transaxle brace bolts (5 and 6) and remove the brace (7).

    20. Object Number: 160965 Size: SH
  20. Remove the lower transaxle-to-engine bolt (6) and the stud (1).
  21. Remove the radiator outlet hose from the engine. Refer to Radiator Outlet Hose Replacement .
  22. Lower the vehicle and support the transaxle.
  23. Remove the heater outlet and inlet hoses from the engine.
  24. Remove the vacuum hoses from the upper intake manifold.
  25. Remove the brake booster vacuum hose from the upper intake manifold.
  26. Remove the fuel lines from the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  27. Remove the radiator inlet hose from the engine. Refer to Radiator Inlet Hose Replacement .
  28. Install the engine lifting device to the engine.
  29. Remove the upper transaxle-to-engine bolts (3, 4, 5) and the stud (2).
  30. Remove the engine from the vehicle.
  31. Remove the flywheel. Refer to Engine Flywheel Replacement .
  32. Install the engine to the engine stand.

Installation Procedure

    Object Number: 160965 Size: SH
  1. Remove the engine from the engine stand.
  2. Install the flywheel. Refer to Engine Flywheel Replacement .
  3. Install the engine to the vehicle.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Install the upper transaxle-to-engine bolts (3, 4, 5) and the stud (2).

    5. Tighten
    Tighten the bolts (3, 4, 5) and the stud (2) to 75 N·m (55 lb ft).

  5. Remove the engine lifting device.
  6. Install the radiator inlet hose to the engine. Refer to Radiator Inlet Hose Replacement .
  7. Install the fuel lines to the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  8. Install the brake booster vacuum hose to the upper intake manifold.
  9. Install the vacuum hoses to the upper intake manifold.
  10. Install the heater inlet and outlet hoses to the engine.
  11. Raise the vehicle and remove the transaxle support.
  12. Install the radiator outlet hose to the engine. Refer to Radiator Outlet Hose Replacement .
  13. Install the lower transaxle-to-engine bolt (6) and the stud (1).

    14. Tighten
    Tighten the bolt (6) and the stud (1) to 75 N·m (55 lb ft).


    Object Number: 1736971 Size: SH
  14. Position the transaxle brace (7) to the transaxle and install the bolts (5 and 6) until snug.
  15. Install the engine wiring harness clip to the rear of the transaxle brace.

    16. Object Number: 1229785 Size: SH
  16. Position the engine mount bracket to the engine and install the bolts until snug.
  17. Tighten the engine mount bracket bolts and transaxle brace bolts.

    18. Tighten

        • Tighten the engine mount bracket upper bolt to 90 N·m (66 lb ft).
        • Tighten the engine mount bracket lower bolts to 50 N·m (37 lb ft).
        • Tighten the transaxle brace bolts to 72 N·m (53 lb ft).
  18. Install the torque converter bolts.
  19. Install the A/C compressor. Refer to Air Conditioning Compressor Replacement .
  20. Install the starter motor. Refer to Starter Motor Replacement .
  21. Install the torque converter covers.

    22. Object Number: 96002 Size: SH
  22. Install the engine mount lower nuts.

    23. Tighten
    Tighten the nuts to 43 N·m (32 lb ft).

  23. Install the engine wiring harness grounds to the transaxle.
  24. Install the engine wiring harness ground nut to the transaxle stud.

    25. Tighten
    Tighten the nut to 35 N·m (26 lb ft).

  25. Install the catalytic converters. Refer to Catalytic Converter Replacement t.
  26. Lower the vehicle.
  27. Connect the following electrical connectors:
    28. • The body wiring harness-to-engine harness
    • The ignition coil
    • The electronic throttle control
    • The EVAP canister purge solenoid
    • The EGR valve
    • The MAP sensor
    • The HO2S
    • The CKP sensor
    • The CMP sensor
    • The KS
  28. Install the drive belt. Refer to Drive Belt Replacement .
  29. Install the engine mount strut. Refer to Engine Mount Strut Replacement .
  30. Install the hood. Refer to Hood Replacement in Body Front End.
  31. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  32. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  33. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement .
  34. Fill cooling system. Refer to Cooling System Draining and Filling .
  35. Perform a CKP system variation learn procedure. Refer to Crankshaft Position System Variation Learn .
  36. Inspect for leaks.