GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 2.8L, 3.0L, 3.2L, or 3.6L 🢒 Engine Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  2. Remove the intake manifold cover. Refer to Fuel Injector Sight Shield Replacement.
  3. Drain the cooling system. Refer to Cooling System Draining and Filling.
  4. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
  5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  6. Remove the hood. Refer to Hood Replacement.
  7. Remove the engine mount snubber. Refer to Engine Mount Snubber Replacement.
  8. Remove the drive belt. Refer to Drive Belt Replacement.
  9. Disconnect the front knock sensor (KS).

    10. Object Number: 1839728 Size: SH
  10. Disconnect the rear KS (1) and the crank sensor. Refer to Crankshaft Position Sensor Replacement.

    11. Object Number: 1839729 Size: SH
  11. Re-position the plastic wire loom/shield on each valve cover, then disconnect the camshaft position (CMP) sensor (1-8).

    12. Object Number: 1838990 Size: SH
  12. Disconnect the manifold absolute pressure (MAP) sensor (1).

    13. Object Number: 1839426 Size: SH
  13. Disconnect the evaporative emission (EVAP) canister purge solenoid (2).

    14. Object Number: 1839726 Size: SH
  14. Disconnect the front and rear ignition coils (2).

    15. Object Number: 1839013 Size: SH
  15. Disconnect the A/C compressor (1).

    16. Object Number: 1838989 Size: SH
  16. Disconnect the coolant temperature sensor (1).
  17. Disconnect the following electrical connectors:
    18. • The heated oxygen sensor HO2S
    • The electronic throttle control
    • Unclip harness as necessary and lay harnesses off to the side.
  18. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  19. Remove the catalytic converters. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side.
  20. Remove the left exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side

    21. Object Number: 1843817 Size: SH
  21. Remove the engine wiring harness grounds and negative cable from the cylinder head.

    22. Object Number: 2097923 Size: SH
  22. Remove the engine mount lower nuts (1).
  23. Remove the starter motor. Refer to Starter Motor Replacement.
  24. Remove the air conditioning (A/C) compressor. DO NOT discharge the A/C system. Support the compressor. Refer to Air Conditioning Compressor Replacement.
  25. Remove the power steering pump and position aside. Refer to Power Steering Pump Replacement.
  26. Mark flywheel to torque converter.
  27. Remove the torque converter bolts.
  28. Allow engine to rest on a hard block of wood. Keep the lifthooks in place to use.

    29. Object Number: 1843991 Size: SH
  29. Remove the transaxle to oil pan brace bolts and brace.

    30. Object Number: 2095942 Size: SH
  30. Remove the lower transaxle-to-engine bolts (1).
  31. Unbolt intermediate shaft support frame engine block rotate support away from block leaving intermitted shaft and axle in place
  32. Remove the radiator outlet hose from the engine. Refer to Radiator Outlet Hose Replacement.
  33. Remove the engine coolant thermostat housing from the engine. Refer to Engine Coolant Thermostat Housing Replacement.
  34. Remove the vacuum hoses from the upper intake manifold.
  35. Remove the radiator inlet hose from the engine. Refer to Radiator Inlet Hose Replacement.
  36. Install the engine lifting device to the engine.
  37. Remove the upper transaxle-to-engine bolts.
  38. Remove the engine from the vehicle.
  39. Remove the flywheel. Refer to Engine Flywheel Replacement.
  40. Install the engine to the engine stand.
  41. Transfer parts as needed.

Installation Procedure

    Object Number: 2095942 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. Caution: Refer to Fastener Caution in the Preface section.

  4. Install the upper transaxle-to-engine bolts (1) and tighten 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 battery ground to the rear of engine.
  8. Install the fuel lines to the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement.
  9. Install the brake booster vacuum hose to the upper intake manifold.
  10. Install the vacuum hoses to the upper intake manifold.
  11. Install the engine coolant thermostat housing to the engine. Refer to Engine Coolant Thermostat Housing Replacement.
  12. Raise the vehicle and remove the transaxle support.
  13. Install the radiator outlet hose to the engine. Refer to Radiator Outlet Hose Replacement.
  14. Install the lower transaxle-to-engine bolt (6) and the stud (1) and tighten to 75 N·m (55 lb ft).

    15. Object Number: 1843991 Size: SH
  15. Position the transaxle to oil pan brace and install the bolts. Tighten the bolts to 50 N·m (37 lb ft)
  16. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement - Right Side.
  17. Install the torque converter bolts.
  18. Install the power steering pump. Refer to Power Steering Pump Replacement.
  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: 2097923 Size: SH
  22. Install the engine mount lower bolts (2) and tighten to 50 N·m (38 lb ft).

    23. Object Number: 1843817 Size: SH
  23. Install the engine wiring harness grounds to the transaxle.
  24. Install the engine wiring harness ground nut to the transaxle stud. Tighten the nut to 35 N·m (26 lb ft)
  25. Install the catalytic converters. Refer to Catalytic Converter Replacement - Left Side and Catalytic Converter Replacement - Right Side.
  26. Lower the vehicle.
  27. Connect the following electrical connectors:
    28. • The body wiring harness-to-engine harness
    • The electronic throttle control
    • The EGR valve
    • The HO2S

    Object Number: 1838989 Size: SH
  28. Connect the coolant temperature sensor (1).

    29. Object Number: 1839013 Size: SH
  29. Connect the A/C compressor (1).

    30. Object Number: 1839726 Size: SH
  30. Connect the front and rear ignition coils (2).

    31. Object Number: 1839426 Size: SH
  31. Connect the EVAP canister purge solenoid (2).

    32. Object Number: 1838990 Size: SH
  32. Connect the MAP sensor (1).

    33. Object Number: 1839729 Size: SH
  33. Connect the CMP sensor (1-8), then re-position the plastic wire loom/shield on each valve cover.

    34. Object Number: 1839728 Size: SH
  34. Connect the rear KS (1).

    35. Object Number: 1839727 Size: SH
  35. Connect the front KS (2) and the crank sensor. Refer to Crankshaft Position Sensor Replacement.
  36. Install the drive belt. Refer to Drive Belt Replacement.
  37. Install the engine mount snubber. Refer to Engine Mount Snubber Replacement.
  38. Install the hood. Refer to Hood Replacement.
  39. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  40. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  41. Fill the crankcase with engine oil. Refer to Engine Oil and Oil Filter Replacement.
  42. Fill cooling system. Refer to Cooling System Draining and Filling.
  43. Perform a Crankshaft Position System Variation Learn procedure. Refer to Crankshaft Position System Variation Learn.
  44. Install the intake manifold cover. Refer to Fuel Injector Sight Shield Replacement.
  45. Inspect for leaks.