GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 2.2L (L61) 🢒 Engine Replacement

Removal Procedure
  1. With the tires in the straight forward position, remove the key from the ignition.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  3. Remove the air inlet duct and resonator . Refer to Air Cleaner Outlet Resonator Replacement .

    4. Object Number: 857193 Size: SH
  4. Secure the cooling module to the upper body structure.
  5. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

    6. Object Number: 854303 Size: SH
  6. Disconnect the fuel lines from the fuel rail.
  7. Drain the cooling system. Refer to Cooling System Draining and Filling .
  8. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement .
  9. Remove the surge tank to cylinder head hose. Refer to Radiator Surge Tank Inlet Hose/Pipe Replacement and Radiator Surge Tank Outlet Hose/Pipe Replacement .
  10. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement .

    11. Object Number: 786506 Size: SH
  11. Remove the inlet (1) and outlet (2) heater hoses. Refer to Heater Inlet Hose Replacement and to Heater Outlet Hose Replacement .

    12. Object Number: 851553 Size: SH
  12. Disconnect the following harness connectors:
    13. • The electronic throttle control
    • The map sensor
    • The crankshaft sensor
    • The oil pressure sensor
    • The purge solenoid
    • The ignition coil and module assembly
    • The O2 sensor
    • The vehicle speed sensor
    • The engine temperature sensor
    • The back-up lamp switch
  13. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
  14. Remove the engine drive belt. Refer to Drive Belt Replacement .
  15. Remove the AC compressor bolts and set the compressor aside.

    16. Object Number: 758469 Size: SH
  16. Disconnect the starter harness connectors (3, 4, 5).
  17. Disconnect the generator harness connectors.
  18. Drain the engine oil.
  19. Disconnect the front exhaust pipe from the exhaust manifold. Refer to Exhaust Manifold Replacement .
  20. Disconnect the transmission harness connectors.
  21. Disconnect the transmission shift cable from the transmission.
  22. Use blocks of wood to support the powertrain assembly between the frame and the powertrain.
  23. Remove the engine mount. Refer to Engine Mount Replacement .

    24. Object Number: 851558 Size: SH
  24. Remove the side transmission mount. Refer to Transmission Replacement .

    25. Object Number: 851720 Size: SH
  25. Disconnect the stabilizer links from the stabilizer bar. Refer to Stabilizer Shaft Link Replacement .

    26. Object Number: 854972 Size: SH
  26. Disconnect the outer tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .

    27. Object Number: 851655 Size: SH

    Important: In order to prevent possible SIR system deployment, do not attempt to rotate the steering shaft.

  27. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement .

    28. Object Number: 851659 Size: SH
  28. Disconnect the lower control arms from the steering knuckles. Refer to Lower Control Arm Replacement .

    29. Object Number: 851677 Size: SH
  29. Disconnect the drive axles from the steering knuckle. Refer to Wheel Drive Shaft Replacement .
  30. Use a paint pen or magic marker in order to mark the frame to body position.

    31. Object Number: 851651 Size: SH
  31. Lower the vehicle to about 3 feet off the ground in order to position the lift table under the frame.
  32. Use wood blocks as necessary between the lift table and the frame to support the assembly.
  33. Slowly remove the frame bolts using the following sequence:
    34. 33.1. Remove the front frame bolts.
    33.2. Partially unscrew the rear frame bolts until 1.5 inches of bolt shank is exposed.
  34. Slowly lower the table to the floor.
  35. Attach the engine lift hoist to the engine lift hooks.

    36. Object Number: 758470 Size: SH
  36. Remove the starter.

    37. Object Number: 1736973 Size: SH
  37. Remove the transaxle brace to engine bolts.
  38. Remove the transaxle brace to transaxle bolts and brace.
  39. Remove the torque converter to flywheel bolts, if applicable.
  40. Remove the transaxle to engine bolts.
  41. Separate the engine from the transaxle.
  42. Remove the clutch pressure plate and disc. if applicable.
  43. Remove the following components:
    44. • The exhaust manifold and catalytic converter assembly
    • The exhaust manifold studs
    • The engine mount bracket
    • The engine block heater
    • The thermostat housing and feed pipe
    • The generator
  44. Install the engine to a suitable engine stand.

Installation Procedure
  1. Attach the engine lift hoist to the engine lift hooks.
  2. Install the following components:
    3. • The exhaust manifold - Refer to Exhaust Manifold Replacement .
    • The engine mount bracket - Refer to Engine Mount Bracket Replacement .
    • The fuel rail - Refer to Fuel Injection Fuel Rail Assembly Replacement .
    • The engine block heater, if equipped - Refer to Coolant Heater Replacement .
    • The drive belt tensioner - Refer to Drive Belt Tensioner Replacement .
    • The thermostat housing and feed pipe - Refer to Engine Coolant Thermostat Replacement .
    • The generator - Refer to Generator Replacement .
    •  The flywheel - Refer to Engine Flywheel Replacement .
  3. If applicable, install the clutch pressure plate and disk.
  4. Align the engine to the transmission.

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


    Object Number: 851293 Size: SH

    Important: The number 3 bolt location is not used.

  5. Secure the engine to the transaxle.

    6. Tighten
    Tighten the bolts to 75 N·m (55 lb ft).

  6. If applicable, install the torque converter bolts.

    7. Tighten
    Tighten the bolts to 62 N·m (46 lb ft).


    Object Number: 1736973 Size: SH
  7. Position the transaxle brace to the engine and transaxle and install the brace to transaxle bolts.
  8. Install the transaxle brace to engine block bolts.

    9. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).


    Object Number: 758470 Size: SH
  9. Install the starter. Refer to Starter Motor Replacement .
  10. Remove the engine lift from the engine.

    11. Object Number: 851651 Size: SH
  11. Raise and position the frame and powertrain assembly to the vehicle.
  12. Hand start all the frame bolts while aligning the frame to the paint marks.
  13. Tighten the frame bolts.

    14. Tighten
    Tighten the frame bolts to 100 N·m (74 lb ft) plus 180 degrees.

  14. Remove the lift table.

    15. Object Number: 851677 Size: SH
  15. Connect the drive axles to the steering knuckles. Refer to Wheel Drive Shaft Replacement .

    16. Object Number: 851659 Size: SH
  16. Connect the lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement .

    17. Object Number: 851655 Size: SH
  17. Connect the intermediate steering shaft to the steering gear. Refer to Steering Gear Replacement .

    18. Object Number: 854972 Size: SH
  18. Connect the outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement .

    19. Object Number: 851720 Size: SH
  19. Connect the stabilizer links to the stabilizer bar. Refer to Stabilizer Shaft Link Replacement .

    20. Object Number: 851558 Size: SH
  20. Install the side transmission mount. Refer to Transmission Replacement .

    21. Object Number: 851553 Size: SH
  21. Install the engine mount. Refer to Engine Mount Replacement .
  22. Remove the wood blocks between the powertrain and frame.
  23. Connect the transmission shift cable to the transmission.
  24. Connect the transmission harness connector.

    25. Object Number: 878834 Size: SH
  25. Connect the exhaust takedown pipe to the exhaust manifold.

    26. Tighten
    Tighten the nuts to 30 N·m (22 lb ft).

  26. Connect the generator harness connectors.

    27. Tighten
    Tighten the nut to 20 N·m (15 lb ft).


    Object Number: 758469 Size: SH
  27. Connect the starter harness connectors  (3,4,5).

    28. Tighten

        • Tighten the battery terminal nut to 17 N·m (13 lb ft).
        • Tighten the S-terminal nut to 3 N·m (27 lb in).
  28. Install the AC compressor to the engine. Refer to Air Conditioning Compressor Replacement .
  29. Install the engine drive belt. Refer to Drive Belt Replacement .
  30. Connect the following harness connectors:
    31. • The electronic throttle control
    • The map sensor
    • The crankshaft sensor
    • The oil pressure sensor
    • The purge solenoid
    • The ignition coil and module assembly
    • The O2 sensor
    • The vehicle speed sensor
    • The engine temperature sensor

    Object Number: 786506 Size: SH
  31. Install the inlet heater hose (1) and outlet heater hose (2). Refer to Heater Inlet Hose Replacement and Heater Outlet Hose Replacement .
  32. Install the radiator outlet hose. Refer to Radiator Inlet Hose Replacement .

    33. Object Number: 854303 Size: SH
  33. Connect the fuel line to the fuel rail.
  34. Connect the brake booster hose at the brake booster.

    35. Object Number: 857193 Size: SH
  35. Release the cooling module from the upper body structure.
  36. Install the air inlet duct and resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  37. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  38. Fill the engine with engine oil to the proper level. Refer to Fluid and Lubricant Recommendations .
  39. Fill the cooling system. Refer to Cooling System Draining and Filling .
  40. Road test the vehicle.