GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 Engine 🢒 Engine Electrical 🢒 Frame Replacement

Removal Procedure
  1. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.1L.
  2. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  4. Remove the splash shields. Refer to Front Fender Liner Replacement in Body Front End.
  5. Disconnect the Antilock Brake System (ABS) harness from the wheel speed sensor and frame. Refer to Antilock Brake System Component Views in Antilock Brake System.
  6. Remove the lower ball joints from the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement .
  7. Remove the brake modulator assembly from the front suspension crossmember. Refer to Brake Pressure Modulator Valve Bracket Replacement in Antilock Brake System.
  8. Remove the tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
  9. Remove the bolt from the steering gear to intermediate shaft and disconnect the shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  10. Remove the power steering lines from the steering gear. Refer to Steering Gear Replacement in Power Steering System.
  11. Remove the front transmission mount bracket bolts. Refer to Transmission Front Mount Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  12. Remove the rear transmission mount bracket bolts. Refer to Transmission Rear Mount Replacement in Automatic Transaxle - 4T40-E/4T45-E.

    13. Object Number: 486720 Size: SH
  13. Remove the brake lines from the retainers on the front suspension crossmember (3).
  14. Lower the vehicle until the front suspension crossmember (3) rests on the jack stands.
  15. Remove the front suspension crossmember front support bolts (4).
  16. Remove the front suspension crossmember rear support bolts (1).
  17. Remove the front suspension Control Arm to body bolts (2).
  18. Raise the vehicle off of the front suspension crossmember (3).
  19. Remove the following components if replacing the front suspension crossmember:
    20. • The lower control arms. Refer to Lower Control Arm Replacement .
    • The power steering gear. Refer to Steering Gear Replacement in Power Steering System.
    • The front transmission mount. Refer to Transmission Front Mount Replacement in Automatic Transaxle- 4T40-E/4T45-E.
    • The rear transmission mount. Refer to Transmission Rear Mount Replacement in Automatic Transaxle- 4T40-E/4T45-E.
    • The stabilizer shaft. Refer to Stabilizer Shaft Replacement .
    • The lower radiator mounting panel. Refer to Radiator Support Replacement in Engine Cooling.

Installation Procedure
  1. Install the following components on the front suspension crossmember if removed:
    2. • The lower control arms. Refer to Lower Control Arm Replacement .
    • The power steering gear. Refer to Steering Gear Replacement in Power Steering System.
    • The front transmission mount. Refer to Transmission Front Mount Replacement in Automatic Transaxle- 4T40-E/4T45-E.
    • The rear transmission mount. Refer to Transmission Rear Mount Replacement in Automatic Transaxle- 4T40-E/4T45-E.
    • The stabilizer shaft. Refer to Stabilizer Shaft Replacement .
    • The lower radiator mounting panel. Refer to Radiator Support Replacement in Engine Cooling.

    Object Number: 486720 Size: SH
  2. Lower the vehicle on to the front suspension crossmember (3).
  3. Install the front suspension Control Arm to body bolts (2). Hand tighten the bolts.
  4. Install the front suspension crossmember rear bolts (1). Hand tighten the bolts.
  5. Install the front suspension crossmember front bolts (4). Hand tighten the bolts.

    6. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  6. Tighten the front suspension crossmember bolts in the following order:
    7. 6.1. Tighten the front suspension crossmember rear bolts (1) to 70 N·m (52 lb ft).
    6.2. Tighten the front suspension crossmember front bolts (4) to 245 N·m (180 lb ft).
    6.3. Tighten the front suspension Control Arm to body bolts (2) to 245 N·m (180 lb ft).
  7. Raise the vehicle and support with jack stands. Refer to Lifting and Jacking the Vehicle in General Information.
  8. Install the brake lines to the retainers on the front suspension crossmember (3).
  9. Install the rear transmission mount bracket bolts. Refer to Transmission Rear Mount Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  10. Install the front transmission mount bracket bolts. Refer to Transmission Front Mount Replacement in Automatic Transaxle - 4T40-E/4T45-E.
  11. Install the power steering lines to the steering gear. Refer to Steering Gear Replacement in Power Steering System.
  12. Install the bolt from the steering gear to intermediate shaft. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  13. Install the tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
  14. Install the brake modulator assembly to the front suspension crossmember. Refer to Brake Pressure Modulator Valve Bracket Replacement in Antilock Brake System.
  15. Install the lower ball joints to the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement .
  16. Connect the ABS sensor to the wheel speed sensor and front suspension crossmember. Refer to Antilock Brake System Component Views in Antilock Brake System.
  17. Install the splash shields. Refer to Front Fender Liner Replacement in Body Front End.
  18. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  19. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.1L.
  20. Bleed the power steering system. Refer to Power Steering System Bleeding in Power Steering System.