Thread Repair Specifications. Chevrolet Malibu 2004

For 1990-2009 cars only

Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 2.2L (L61) 🢒 Thread Repair Specifications

Table 1:	Engine Block - Front View
Table 2:	Engine Block - Back View
Table 3:	Engine Block - Left Side View
Table 4:	Engine Block - Bottom View
Table 5:	Engine Block - Right Side View
Table 6:	Engine Block - Top View
Table 7:	Lower Crankcase - Front View
Table 8:	Lower Crankcase - Back View
Table 9:	Lower Crankcase - Bottom View
Table 10:	Lower Crankcase - Left View
Table 11:	Lower Crankcase - Right View
Table 12:	Cylinder Head - Top View
Table 13:	Cylinder Head - Intake Manifold Deck View
Table 14:	Cylinder Head - Exhaust Manifold Deck View
Table 15:	Cylinder Head - Front View
Table 16:	Cylinder Head - Back View
Table 17:	Cylinder Head - Bottom View

Engine Block - Front View

Engine Block - Front View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M10 x 1.5	215	211	212	213	214	24.5	0.96	19.5	0.77
2	M8 x 1.25	210	206	207	208	209	23.5	0.93	18.5	0.73
3	M12 x 1.75	855	856	857	858	859	33.5	1.32	26.5	1.04
4	M8 x 1.25	210	206	207	208	209	23.5	0.93	18.5	0.73
5	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
6	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
7	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
8	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
9	M8 x 1.25	210	206	207	208	209	25.5	1.00	THRU
10	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
11	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
12	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
13	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
14	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
15	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
16	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
17	M6 x 1	205	201	202	203	204	20	0.787	16	0.63
18	M8 x 1.25	210	206	207	208	209	23.5	0.93	18.5	0.73
19	M8 x 1.25	210	206	207	208	209	55	2.17	THRU
20	M8 x 1.25	210	206	207	208	209	23.5	0.93	18.5	0.73
21	M12 x 1.75	855	856	857	858	859	33.5	1.32	26.5	1.04
22	M12 x 1.75	855	856	857	858	859	33.5	1.32	26.5	1.04

Engine Block - Back View

Engine Block - Back View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M12 x 1.75	855	856	857	858	859	39	1.535	33.5	1.32
2	M16 x 1.5	860	861	862	863	864	21	0.827	15	0.59
3	M10 x 1.5	215	211	212	213	214	29	1.161	THRU
4	M8 x 1.25	210	206	207	208	209	18	0.709	THRU
5	M8 x 1.25	854 No Flange	206	207	208	209	18	0.709	THRU
6	M16 x 1.5	860	861	862	863	864	21	0.827	15	0.59
7	M12 x 1.75	855	856	857	858	859	39	1.535	33.5	1.32

Engine Block - Left Side View

Engine Block - Left Side View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M12 x 1.75	865	856	857	858	859	19.50	0.768	12.5	0.49
2	M6 x 1.0	205	201	202	203	204	--	--	--	--
3	M12 x 1.75	865	856	857	858	859	19.50	0.768	12.5	0.49
4	M10 x 1.5	215	211	212	213	214	23.50	0.925	18.5	0.73
5	M10 x 1.5	215	211	212	213	214	23.50	0.925	18.5	0.73
6	M6 x 1.0	205	201	202	203	204	20.50	0.807	16.0	0.63
7	M6 x 1.0	205	201	202	203	204	20.50	0.807	16.0	0.63
8	M6 x 1.0	205	201	202	203	204	20.50	0.807	16.0	0.63
9	M6 x 1.0	205	201	202	203	204	--	--	--	--
10	M12 x 1.75	865	856	857	858	859	19.50	0.768	12.5	0.49

Engine Block - Bottom View

Engine Block - Bottom View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
2	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
3	M8 x 1.25	210	206	207	208	209	28	1.102	22	0.87
4	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
5	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
6	M8 x 1.25	210	206	207	208	209	28	1.102	22	0.87
7	M8 x 1.25	210	206	207	208	209	28	1.102	22	0.87
8	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
9	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
10	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
11	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
12	M8 x 1.25	210	206	207	208	209	28	1.102	22	0.87
13	M8 x 1.25	210	206	207	208	209	28	1.102	22	0.87
14	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
15	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
16	M8 x 1.25	210	206	207	208	209	28	1.102	22	0.87
17	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
18	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
19	M8 x 1.25	210	206	207	208	209	28	1.102	22	0.87
20	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
21	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
22	M8 x 1.25	210	206	207	208	209	28	1.102	22	0.87
23	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
24	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
25	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
26	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
27	M8 x 1.25	210	206	207	208	209	28	1.102	22	0.87
28	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
29	M10 x 1.5	514	511	N/A	512	513	60	2.362	53.5	2.11
30	M8 x 1.25	210	206	207	208	209	28	1.102	22	0.87

Engine Block - Right Side View

Engine Block - Right Side View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M12 x 1.75	865	856	857	858	859	19.50	0.778	12.5	0.49
2	M12 x 1.75	865	856	857	858	859	19.50	0.778	12.5	0.49
3	M6 x 1.0	205	201	202	203	204	20.50	0.807	16.5	.065
4	M12 x 1.75	865	856	857	858	859	15.50	0.610	12.5	0.49
5	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.0	0.71
6	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.0	0.71
7	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.0	0.71
8	M12 x 1.75	855	856	857	858	859	33.50	1.319	26.5	1.04
9	M8 x 1.25	210	206	207	208	209	30.50	1.201	22.5	0.89
10	M8 x 1.25	210	206	207	208	209	30.50	1.201	22.5	0.89
11	M8 x 1.25	210	206	207	208	209	30.50	1.201	22.5	0.89
12	M8 x 1.25	210	206	207	208	209	30.50	1.201	22.5	0.89
13	M8 x 1.25	210	206	207	208	209	30.50	1.201	22.5	0.89
14	M12 x 1.75	855	856	857	858	859	33.50	1.319	26.5	1.04
15	M12 x 1.75	865	856	857	858	859	19.50	0.778	12.5	0.49

Engine Block - Top View

Engine Block - Top View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M11 x 1.5	507	504	N/A	505	506	113.30	4.461	107.3	4.22
2	M12 x 1.75	865	856	857	858	859	13.50	0.531	12.5	0.49
3	M11 x 1.5	507	504	N/A	505	506	113.30	4.461	107.3	4.22
4	M11 x 1.5	507	504	N/A	505	506	113.30	4.461	107.3	4.22
5	M11 x 1.5	507	504	N/A	505	506	113.30	4.461	107.3	4.22
6	M11 x 1.5	507	504	N/A	505	506	113.30	4.461	107.3	4.22
7	M11 x 1.5	507	504	N/A	505	506	113.30	4.461	107.3	4.22
8	M11 x 1.5	507	504	N/A	505	506	113.30	4.461	107.3	4.22
9	M11 x 1.5	507	504	N/A	505	506	113.30	4.461	107.3	4.22
10	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
11	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
12	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
13	M11 x 1.5	507	504	N/A	505	506	113.30	4.461	107.3	4.22
14	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
15	M11 x 1.5	507	504	N/A	505	506	113.30	4.461	107.3	4.22
16	M12 x 1.75	865	856	857	858	859	13.50	0.531	12.5	0.49

Lower Crankcase - Front View

Lower Crankcase - Front View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
2	M8 x 1.25	210	206	207	208	209	30.50	1.201	25.5	1.00
3	M8 x 1.25	210	206	207	208	209	30.50	1.201	25.5	1.00
4	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73

Lower Crankcase - Back View

Lower Crankcase - Back View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M10 x 1.5	215	211	212	213	214	29.50	1.161	THRU

Lower Crankcase - Bottom View

Lower Crankcase - Bottom View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
2	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
3	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
4	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
5	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
6	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
7	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
8	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
9	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
10	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
11	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
12	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
13	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
14	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73
15	M8 x 1.25	210	206	207	208	209	23.50	0.925	18.5	0.73

Lower Crankcase - Left View

Lower Crankcase - Left View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M10 x 1.5	215	211	212	213	214	28.50	1.122	22.5	0.89
2	M10 x 1.5	215	211	212	213	214	28.50	1.122	22.5	0.89
3	M10 x 1.5	215	211	212	213	214	28.50	1.122	22.5	0.89

Lower Crankcase - Right View

Lower Crankcase - Right View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M8 x 1.25	210	211	212	213	214	30.50	1.201	22.5	0.886

Cylinder Head - Top View

Cylinder Head - Top View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
2	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
3	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
4	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
5	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
6	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
7	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
8	M8 x 1.25	854 No Flange	206	207	208	209	THRU		THRU
9	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
10	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
11	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
12	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
13	M6 x 1.0	205	201	202	203	204	16	0.630	THRU
14	M6 x 1.0	205	201	202	203	204	16	0.630	THRU
15	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
16	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
17	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
18	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
19	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
20	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
21	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
22	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
23	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
24	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
25	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
26	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
27	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
28	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
29	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
30	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
31	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
32	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
33	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.787
34	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.787
35	M8 x 1.25	854 No Flange	853	N/A	208	209	25	0.984	20	0.787
36	M8 x 1.25	854 No Flange	853	N/A	208	209	25	0.984	20	0.787
37	M6 x 1.0	210	206	207	208	209	20	0.787	16	0.630
38	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
39	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
40	M6 x 1.0	210	206	207	208	209	20	0.787	16	0.630
41	M6 x 1.0	210	206	207	208	209	20	0.787	16	0.630
42	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787
43	M6 x 1.0	205	852	N/A	203	204	24	0.945	20	0.787

Cylinder Head - Intake Manifold Deck View

Cylinder Head - Intake Manifold Deck View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
2	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
3	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
4	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
5	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
6	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
7	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
8	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630
9	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630

Cylinder Head - Exhaust Manifold Deck View

Cylinder Head - Exhaust Manifold Deck View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78
2	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78
3	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78
4	M27 x 2.0	N/A	N/A	N/A	N/A	N/A	THRU		12	0.78
5	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78
6	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78
7	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78
8	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78
9	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78
10	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78
11	M6 x 1.0	205	201	202	203	204	20	0.78	16	0.630
12	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78
13	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78
14	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.78

Cylinder Head - Front View

Cylinder Head - Front View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.787
2	M6 x 1.0	205	201	202	203	204	20	0.787	16	0.630

Cylinder Head - Back View

Cylinder Head - Back View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M12 x 1.75	865	856	857	858	859	17	0.670	14	0.551
2	M12 x 1.75	865	856	857	858	859	17	0.670	14	0.551
3	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.787
4	M8 x 1.25	210	206	207	208	209	25	0.984	20	0.787
5	M12 x 1.75	865	856	857	858	859	17	0.670	14	0.551
6	M12 x 1.75	865	856	857	858	859	17	0.670	14	0.551
7	M8 x 1.25	210	206	207	208	209	25	0.984	THRU
8	M8 x 1.25	854 No Flange	206	207	208	209	25	0.984	THRU

Note: 1, 2, 5, 6 holes are oil passages.

Cylinder Head - Bottom View

Cylinder Head - Bottom View

Service Call Out	Thread Size	Insert	Drill	Counterbore Tool	Tap	Driver	Drill Depth (Maximum)		Tap Depth (Maximum)
J 42385-							MM	(IN)	MM	(IN)
1	M12 x 1.75	865	856	857	858	859	17	0.670	14	0.551
2	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
3	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
4	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A
5	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A	N/A