GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 3.5L 🢒 Engine Coolant Crossover Pipe Replacement

Engine Coolant Crossover Pipe Replacement LZ4

Removal Procedure

    Object Number: 1774996 Size: SH
  1. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement.
  2. Remove the generator. Refer to Generator Replacement.
  3. Remove the drive belt idler pulleys. Refer to Drive Belt Idler Pulley Replacement.
  4. Remove the power steering pump. Refer to Power Steering Pump Replacement.
  5. Reposition the radiator surge tank inlet hose clamp (1) at the surge tank inlet pipe.
  6. Remove the radiator surge tank inlet hose from the inlet pipe. Position the hose out of the way.

    7. Object Number: 1774997 Size: SH
  7. Remove the radiator surge tank pipe bolts (2).
  8. Remove the radiator surge tank pipe from the crossover pipe.

    9. Object Number: 1583647 Size: SH
  9. Reposition the radiator inlet hose clamp at the crossover pipe.
  10. Remove the radiator inlet hose from the crossover pipe.

    11. Object Number: 1584078 Size: SH
  11. Reposition the thermal bypass hose clamp at the crossover pipe.
  12. Remove the thermal bypass hose from the crossover pipe.

    13. Object Number: 1584086 Size: SH
  13. Remove the coolant crossover pipe bolts (1-4).
  14. Remove the coolant crossover pipe.

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1584086 Size: SH
  1. Position the coolant crossover pipe to the cylinder heads.
  2. Install the coolant crossover pipe bolts (1-4) and tighten to 50 N·m (37 lb ft).

    3. Object Number: 1584078 Size: SH
  3. Install the thermal bypass hose to the crossover pipe.
  4. Position the thermal bypass hose clamp at the crossover pipe.

    5. Object Number: 1583647 Size: SH
  5. Install the radiator inlet hose to the crossover pipe.
  6. Position the radiator inlet hose clamp at the crossover pipe.

    7. Object Number: 1774997 Size: SH
  7. Install the radiator surge tank pipe to the crossover pipe.
  8. Install the radiator surge tank pipe bolts (2) and tighten to 10 N·m (89 lb in).

    9. Object Number: 1774996 Size: SH
  9. Install the radiator surge tank inlet hose to the inlet pipe.
  10. Position the radiator surge tank inlet hose clamp (1) at the surge tank inlet pipe.
  11. Install the power steering pump. Refer to Power Steering Pump Replacement.
  12. Install the drive belt idler pulleys. Refer to Drive Belt Idler Pulley Replacement.
  13. Install the generator. Refer to Generator Replacement.
  14. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement.