GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 Engine 🢒 Engine Mechanical - 3.5L (LX9) 🢒 Engine Front Cover Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  3. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  4. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement .
  5. Remove the oil pan. Refer to Oil Pan Replacement .
  6. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  7. Remove the thermostat bypass pipe from the engine front cover. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
  8. Remove the radiator outlet hose from the engine front cover. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  9. Remove the water pump from the engine front cover. Refer to Water Pump Replacement in Engine Cooling.
  10. Remove the CKP sensor wiring harness bracket.

    11. Object Number: 95865 Size: SH
  11. Remove the engine front cover bolts (1, 2, 3).
  12. Remove the engine front cover.

    13. Object Number: 61818 Size: SH
  13. Remove the engine front cover gasket.
  14. Clean and inspect the engine front cover. Refer to Engine Front Cover Cleaning and Inspection .
  15. If replacing the engine front cover, remove the drive belt shield bolt and the drive belt shield.
  16. If replacing the engine front cover, remove the water pump. Refer to Water Pump Replacement in Engine Cooling.

Installation Procedure
  1. If removed install the water pump. Refer to Water Pump Replacement in Engine Cooling.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. If removed, install the drive belt shield.
  3. Install the drive belt shield bolt.

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


    Object Number: 61819 Size: SH
  4. Apply sealant to both sides of the lower tabs of the engine front cover gasket. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.

    5. Object Number: 61818 Size: SH
  5. Install the engine front cover gasket.
  6. Install the engine front cover.

    7. Object Number: 1526763 Size: SH
  7. Apply sealer to the bolts in the locations pointed out in the graphic. Refer to Adhesives, Fluids, Lubricants, and Sealers for the correct part number.

    8. Object Number: 95865 Size: SH
  8. Install the engine front cover bolts (1, 2, and 3).

    9. Tighten

        • Tighten the small engine front cover bolts (1) to 27 N·m (20 lb ft).
        • Tighten the large engine front cover bolts (2, 3) to 55 N·m (41 lb ft).
  9. Install the radiator outlet hose to the engine front cover. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
  10. Install the thermostat bypass pipe to the engine front cover. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
  11. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement .
  12. Install the oil pan. Refer to Oil Pan Replacement .
  13. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement .
  14. Fill the crankcase with new engine oil. Refer to Engine Oil and Oil Filter Replacement .
  15. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
  16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.