GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 3.9L 🢒 Engine Coolant Crossover Pipe Installation

    Object Number: 1608913 Size: SH
  1. Install the coolant crossover pipe assembly onto the engine.

    2. 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.

  2. Install the engine lift bracket (1) and the front coolant crossover pipe bolts (3).

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

  3. Install the side coolant crossover pipe bolt (2).

    4. Tighten
    Tighten the bolt to 10 N·m (89 lb in).


    Object Number: 1608911 Size: SH
  4. Install the idler pulleys and bolts.

    5. Tighten

        • Tighten the bolts (1) to 50 N·m (37 lb ft).
        • Tighten the bolt (2) to 30 N·m (22 lb ft).

    Object Number: 1608908 Size: SH
  5. Install the coolant vent pipe and bolt (2).

    6. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  6. Install the heater inlet/outlet pipe and bolt (1).

    7. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  7. Install the thermal bypass hose and securely fasten the clamp (3).