GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1998 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 2.4L 🢒 Engine Replacement

Removal Procedure

Tools Required

    • J 28467-360 Engine Support Fixture
    •  J 23742 Ball Joint Separator
    •  J 34730-250 Fuel Pressure Gauge
    •  J 36018 Belt Tension Gauge

    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. Remove drain and recover coolant. Refer to Cooling System Draining and Filling .
  3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging in HVAC Systems with A/C - Manual.
  4. Remove the left sound insulator. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gauges and Console.
  5. Disconnect the heater hose at the thermostat housing.
  6. Disconnect the radiator inlet (upper) hose.
  7. Remove the air cleaner assembly.
  8. Remove the coolant fan. Refer to Engine Cooling Fan Replacement in Engine Cooling.
  9. Remove the compressor/condenser hose assembly at the compressor and discard the O-rings. Refer to Compressor Hose Assembly Replacement in HVAC System with A/C - Manual.
  10. Disconnect the vacuum hoses from the front of the engine.
  11. Remove the following electrical connections:
    12. • The generator
    • The A/C compressor, if equipped
    • The injector harness
    • The IAC and TP sensor at the throttle body
    • The MAP sensor
    • The Intake Air Temperature (IAT) sensor
    • The EVAP Canister Purge solenoid
    • The starter solenoid
    • The ground connections
    • The negative battery cable from the transmission
    • The Electronic Ignition Coil and Module assembly
    • The two Engine Coolant Temperature sensors
    • The Oil Pressure sensor/switch
    • The O2S (Oxygen sensor)
    • The Crankshaft Position sensor
    • The Backup Lamp switch and position the harness aside
    • The Camshaft Position sensor
  12. Remove the power brake vacuum hose from the throttle body.
  13. Remove the throttle cable.
  14. Remove the throttle cable bracket.
  15. Remove the power steering bolts.

    16. Object Number: 33640 Size: SH
  16. Remove the power steering pump. Position the pump aside with the lines attached.

    17. Caution: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

  17. Disconnect the fuel lines. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 2.4L.
  18. Disconnect the shift cables.

    19. Object Number: 33609 Size: SH
  19. Remove the exhaust manifold.

    20. Object Number: 33611 Size: SH
  20. Remove the heat shield.
  21. Disconnect the radiator outlet (lower) hose from the radiator.
  22. Install the J 28467-360 .
  23. Remove the one bolt attaching the coolant recovery tank. Position the tank aside with the hoses connected.
  24. Remove the engine mount assembly. Refer to Engine Mount Replacement .
  25. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  26. Remove the front wheel and tire assemblies. Refer to Wheel Removal .
  27. Remove the right splash shield.
  28. Remove the following electrical connections:
    29. • The VSS
    • The knock sensor
    • The starter solenoid
    • Both of the front ABS wheel speed sensors
  29. Remove the transmission mount. Refer to Transmission Front Mount Replacement , Transmission Rear Mount Replacement , or Transmission Mount Replacement - Side in Automatic Transaxle - 4T40E.
  30. Separate the ball joints from the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  31. Remove the suspension supports and the stabilizer shaft as an assembly. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  32. Disconnect the heater outlet hose from the radiator outlet pipe.
  33. Remove the axle shaft from the transmission. Position the axle shaft aside. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  34. Remove the flywheel housing cover.
  35. Position suitable support below the engine and lower the car into the support.
  36. Mark the threads on the support fixture hooks in order to duplicate the setting when reinstalling the engine.
  37. Remove the engine support fixture J-hooks.
  38. Raise the vehicle slowly off of the engine and transmission assembly. It may be necessary to move the engine/transmission assembly rearward in order to clear the intake manifold.
  39. Separate the engine from the transmission.

Installation Procedure

    Important: Make certain the bolts are in their correct locations.

  1. Assemble the engine to the transmission.
  2. Position the engine and the transmission assembly under the engine compartment.
  3. Slowly lower the vehicle over the assembly until the transmission mount is indexed.
  4. Install the bolt.
  5. Install the J 28467-360 adjust to the previous setting.
  6. Install the engine mount assembly. Refer to Engine Mount Replacement .
  7. Install the transmission mount. Refer to Transmission Front Mount Replacement , Transmission Rear Mount Replacement , or Transmission Mount Replacement - Side in Automatic Transaxle - 4T40E.
  8. Raise the vehicle off of the support.
  9. Install the axle shafts to the transmission. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  10. Connect the heater outlet hose to the radiator outlet pipe.
  11. Install the suspension supports. Refer to Strut Assembly Replacement in Front Suspension.
  12. Install the stabilizer shaft assembly. Refer to Stabilizer Shaft Replacement in Front Suspension.
  13. Install the ball joint nuts. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
  14. Connect the following electrical connections:
    15. • The VSS
    • The knock sensor
    • The starter solenoid
    • Both front ABS wheel speed sensors
  15. Install the flywheel housing cover.
  16. Connect the lower radiator hose.
  17. Install the right splash shield.
  18. Install the front tires and wheels. Refer to Wheel Installation in Tires and Wheels.
  19. Lower the vehicle.
  20. Remove the J 28467-360 .
  21. Install the coolant recovery tank. Refer to Radiator Surge Tank Replacement in Engine Cooling.
  22. Install the following electrical connections:
    23. • The generator
    • The injector harness
    • The A/C compressor, if equipped
    • The IAC and TP sensor at the throttle body
    • The MAP sensor
    • The IAT sensor
    • The EVAP Canister Purge solenoid
    • The starter solenoid
    • The ground connections
    • The negative battery cable to the transmission
    • The two Engine Coolant Temperature sensors
    • The Oil Pressure sensor/switch
    • The O2S (Oxygen Sensor)
    • The crankshaft position sensor
    • The Backup Light switch
    • The Electronic Ignition Coil and Module assembly
    • The camshaft position sensor
  23. Connect the vacuum hoses.
  24. Connect the compressor/condenser hose assembly to the compressor.

    25. Object Number: 33612 Size: SH
  25. Install the exhaust manifold

    26. Object Number: 33611 Size: SH
  26. Install the heat shield.
  27. Connect the fuel lines. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 2.4L
  28. Connect the positive battery cable to the battery.

    29. Object Number: 33640 Size: SH
  29. Install the power steering pump to the block. Refer to Power Steering Pump Replacement .
  30. Install the power steering pump bolts.
  31. Connect the vacuum hoses to intake manifold.
  32. Install the throttle cable bracket.
  33. Install the throttle cable. Refer to Accelerator Control Cable Replacement in Engine Controls.
  34. Install the coolant fan. Refer to Engine Cooling Fan Replacement in Engine Cooling.
  35. Install the air cleaner assembly.
  36. Install the radiator outlet (upper) hose.
  37. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  38. Install the left sound insulator and disconnect the clutch push rod from the pedal assembly, on manual transmission only. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gauges and Console.
  39. Connect the heater hose at the thermostat housing.
  40. Fill the transmission with fluid. Refer to Fluid Capacity Specifications in Automatic Transaxle - 4T40E.
  41. Fill engine oil.
  42. Connect the negative battery cable.
  43. Evaluate, charge and leak test the A/C system. Refer to Refrigerant Recovery and Recharging in HVAC System with A/C - Manual.