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Home >> Chevrolet >> 2005 >> Malibu Base >> Repair and Diagnosis >> External Pages >> Different car >> Section 120 (Engine Mechanical - 3.6L (Ly7) (Repair Instructions -- 2 Of 5)) >> Repair Instructions (On-Vehicle - Part 2 And Off-Vehicle - Part 1) >> On-Vehicle Repair Instructions - Part 2 >> Engine Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2005 Buick LaCrosse and 2005 Buick Allure. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  2. Remove the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.6L (LY7).
    3. IMPORTANT: Do not disconnect the battery negative cable from the vehicle.
  3. Disconnect the battery negative cable from the engine block. Refer to Battery Negative Cable Replacement in Engine Electrical.
    4. IMPORTANT: Do not disconnect the battery positive cable from the vehicle, underhood electrical center or the battery.
  4. Disconnect the battery positive cable from the generator and the starter. Refer to Battery Positive Cable Replacement in Engine Electrical.
  5. Drain the cooling system. Refer to Draining and Filling Cooling System (LY7) or Draining and Filling Cooling System (L26) in Engine Cooling.
  6. Disconnect the radiator hoses from the engine. Refer to Radiator Hose Replacement - Inlet (3.8L) or Radiator Hose Replacement - Inlet (3.6L) and Radiator Hose Replacement - Outlet (3.8L) or Radiator Hose Replacement - Outlet (3.6L) in Engine Cooling.
  7. Disconnect the heater hoses from the engine. Refer to Heater Hose Replacement - Inlet (L26) and Heater Hose Replacement - Outlet (L26) in HVAC Systems - Manual.
  8. Remove the engine mount struts. Refer to Engine Mount Strut Replacement - Left and Engine Mount Strut Replacement - Right .
    9. Fig 1: Locating Fuel Pressure & Evaporative Emission (EVAP) Pipes
    GM1404630Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 3.6L (LY7).
  9. Disconnect the fuel pressure and evaporative emission (EVAP) pipes from the engine. Refer to Quick Connect Fitting(s) Service (Metal Collar) and Quick Connect Fitting(s) Service (Plastic Collar) in Engine Controls - 3.6L (LY7).
    10. Fig 2: Identifying Engine Control Module Side Electrical Connector
    GM1394047Courtesy of GENERAL MOTORS CORP.
  10. Remove the ECM chassis (outboard) side electrical connector from the ECM.
    11. Fig 3: Identifying Wiring Harness Ground From Transmission
    GM1394068Courtesy of GENERAL MOTORS CORP.
  11. Remove the wiring harness ground from the transmission.
  12. Remove the vacuum brake booster hose from the intake manifold.
  13. Evacuate the air conditioning system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.
  14. Remove the A/C compressor hose from the A/C compressor. Refer to Compressor Hose Assembly Replacement (L26) or Compressor Hose Assembly Replacement (LY7) in Heating, Ventilation and Air Conditioning.
  15. Relocate the compressor hose to the side.
    16. Fig 4: View Of Wiring Harness Ground From Transmission
    GM1394067Courtesy of GENERAL MOTORS CORP.
  16. Remove the transmission electrical connector.
  17. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  18. If you will be separating the engine from the transmission, remove the torque converter bolts. Refer to Flywheel to Torque Converter Bolt Replacement in Automatic Transaxle - 4T65-E.
  19. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  20. Remove the catalytic converter. Refer to Catalytic Converter Replacement (RPOs L26/L32) or Catalytic Converter Replacement (LY7) in Engine Exhaust.
  21. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  22. Remove lower radiator air baffle. Refer to Radiator Air Baffle and Deflector Replacement - Lower in Engine Cooling.
  23. Remove the engine splash shields. Refer to Splash Shield Replacement - Engine in Body Front End.
  24. Disconnect the vehicle speed sensor (VSS) electrical connector and secure the wiring harness to the vehicle.
  25. Remove the front wheel speed sensor wiring harnesses from the lower control arms and the frame.
  26. Remove the tie rod ends from the steering knuckles. Refer to Steering Knuckle Replacement in Front Suspension.
  27. Remove the lower ball joints from the knuckles. Refer to Lower Ball Joint Replacement in Front Suspension.
  28. Disconnect the drive axles from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
  29. Rotate the struts and reposition the drive axles toward the rear of the vehicle in order to provide clearance for the powertrain to be removed.
    30. CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion steering gear stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage may cause loss of steering control which could result in an accident and possible personal injury
  30. Separate the intermediate steering shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column.
  31. Remove the engine mount lower nuts. Refer to Engine Mount Replacement - Right .
  32. Remove the transmission mount lower nuts. Refer to Transmission Mount Replacement - Left in Automatic Transaxle - 4T65-E.
  33. Position a powertrain lift table below the powertrain.
  34. Lower the vehicle until the powertrain is supported by the powertrain lift table.
  35. Remove the frame bolts. Refer to Frame Replacement in Frame and Underbody.
  36. Carefully raise the vehicle or lower the powertrain table in order to remove the powertrain from the vehicle.
  37. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement (RPOs L26/L32) or Exhaust Crossover Pipe Replacement (RPO LY7) in Engine Exhaust.
  38. Remove the coolant inlet pipe. Refer to Radiator Hose Replacement - Inlet (3.8L) or Radiator Hose Replacement - Inlet (3.6L) in Engine Cooling.
  39. Remove the power steering pressure pipe/hose from the pump. Refer to Power Steering Pressure Pipe/Hose Replacement (3.8L) or Power Steering Pressure Pipe/Hose Replacement (3.6L (LY7) in Power Steering System.
  40. Remove the power steering cooler lines from the reservoir. Refer to Power Steering Cooler Pipe/Hose Replacement (L26) or Power Steering Cooler Pipe/Hose Replacement (LY7) in Power Steering Systems.
  41. Remove the accessory drive belt. Refer to Drive Belt Replacement .
  42. Remove the power steering reservoir. Refer to Remote Power Steering Fluid Reservoir Replacement in Power Steering System.
  43. Remove the transmission lower brace. Refer to Automatic Transmission Brace Replacement in Automatic Transaxle - 4T65-E.
    44. Fig 5: Identifying Transmission Upper Brace Nut
    GM1395483Courtesy of GENERAL MOTORS CORP.
  44. Remove the transmission upper brace nut located behind the power steering pump.
  45. Remove the engine to transmission (bell housing) bolts. Refer to Transmission Replacement in Automatic Transmission - 4T65-E.
    46. Fig 6: Locating Engine Lift Bracket
    GM1337483Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
  46. Use 4 M1 0x1.5x40 GM P/N 11519182, or equivalent bolts to install the EN 46114  engine lift brackets to the left rear and right front cylinder heads.

    Tighten:  Tighten the lift bracket bolts to 65 N.m (48 lb ft).

  47. Use an engine hoist in order to separate the engine from the transmission and the frame.
  48. Install the engine to a suitable engine stand.
  49. Refer to the appropriate service information in order to remove the necessary components from the engine.
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