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Home >> Chevrolet >> 2005 >> Malibu Maxx >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Mechanical - 2.2L (L61)) >> Repair Instructions >> On-Vehicle Repair Instructions >> Engine Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Attach the engine lift hoist to the engine lift hooks.
  2. Install the following components:
  3. If applicable, install the clutch pressure plate and disk.
  4. Align the engine to the transmission.
    5. Fig 1: Securing Engine To Transmission
    GM851293Courtesy of GENERAL MOTORS CORP.
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: The number 3 bolt location is not used.
  5. Secure the engine to the transmission.

    Tighten:  Tighten the transmission to engine bolts to 75 N.m (55 lb ft).

  6. If applicable, install the torque converter bolts.

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

    7. Fig 2: View Of Starter
    GM758470Courtesy of GENERAL MOTORS CORP.
  7. Install the starter. Refer to Starter Motor Replacement (L61) in Engine Electrical.
  8. Remove the engine lift from the engine.
    9. Fig 3: View Of Frame Bolts
    GM851651Courtesy of GENERAL MOTORS CORP.
  9. Raise and position the frame and powertrain assembly to the vehicle.
  10. Hand start all the frame bolts while aligning the frame to the paint marks.
  11. Tighten the frame bolts.

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

  12. Remove the lift table.
    13. Fig 4: View Of Drive Axle & Steering Knuckle
    GM851677Courtesy of GENERAL MOTORS CORP.
  13. Connect the drive axles to the steering knuckles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
    14. Fig 5: Identifying Lower Control Arm Ball Stud-To-Steering Knuckle Pinch Bolt
    GM851659Courtesy of GENERAL MOTORS CORP.
  14. Connect the lower control arm to the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.
    15. Fig 6: View Of Intermediate Shaft-To-Steering Gear Pinch Bolt
    GM851655Courtesy of GENERAL MOTORS CORP.
  15. Connect the intermediate steering shaft to the steering gear. Refer to Power Steering Gear Replacement in Power Steering System.
    16. Fig 7: View Of Tie Rod End To Steering Knuckle
    GM854972Courtesy of GENERAL MOTORS CORP.
  16. Connect the outer tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
    17. Fig 8: View Of Stabilizer Link At Stabilizer Shaft
    GM851720Courtesy of GENERAL MOTORS CORP.
  17. Connect the stabilizer links to the stabilizer bar. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
    18. Fig 9: View Of Side Transmission Mount
    GM851558Courtesy of GENERAL MOTORS CORP.
  18. Install the side transmission mount. Refer to Transmission Replacement in Automatic Transaxle - 4T40-E/4T45-E.
    19. Fig 10: View Of Engine Mount To Intermediate Bracket Bolts
    GM851553Courtesy of GENERAL MOTORS CORP.
  19. Install the engine mount. Refer to Engine Mount Replacement .
  20. Remove the wood blocks between the powertrain and frame.
  21. Connect the transmission shift cable to the transmission.
  22. Connect the transmission harness connector.
    23. Fig 11: View Of Exhaust Takedown Pipe
    GM878834Courtesy of GENERAL MOTORS CORP.
  23. Connect the exhaust takedown pipe to the exhaust manifold.

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

  24. Connect the generator harness connectors.

    Tighten:  Tighten the generator terminal nut to 20 N.m (15 lb ft).

    25. Fig 12: Identifying Starter Electrical Connectors
    GM758469Courtesy of GENERAL MOTORS CORP.
  25. Connect the starter harness connectors (3,4,5).

    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).

  26. Install the AC compressor to the engine. Refer to Compressor Replacement (L61) in Heating, Ventilation and Air Conditioning.
  27. Install the engine drive belt. Refer to Drive Belt Replacement .
  28. Connect the following harness connectors:
    • 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
    29. Fig 13: View Of Inlet & Outlet Heater Hose
    GM786506Courtesy of GENERAL MOTORS CORP.
  29. Install the inlet heater hose (1) and outlet heater hose (2). Refer to Heater Hose Replacement - Inlet (L61) and Heater Hose Replacement - Outlet (L61) in Heating, Ventilation and Air Conditioning.
  30. Install the radiator outlet hose. Refer to Radiator Hose Replacement - Inlet (L61) in Engine Cooling.
    31. Fig 14: Connecting/Disconnecting Fuel Feed Pipe
    GM854303Courtesy of GENERAL MOTORS CORP.
  31. Connect the fuel line to the fuel rail.
  32. Connect the brake booster hose at the brake booster.
    33. Fig 15: Cooling Module Secured To Upper Body Structure
    GM857193Courtesy of GENERAL MOTORS CORP.
  33. Release the cooling module from the upper body structure.
  34. Install the air inlet duct and resonator. Refer to Air Cleaner Outlet Resonator Replacement in Engine Controls - 2.2L (L61).
  35. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  36. Fill the engine with engine oil to the proper level. Refer to Fluid and Lubricant Recommendations in Maintenance and Lubrication.
  37. Fill the cooling system. Refer to Draining and Filling Cooling System (L61) in Engine Cooling.
  38. Road test the vehicle.
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