Chevy Malibu Repair Manual 2004-2012

This Chilton 28691 DIY repair and service manual, covers 2004-2012 Chevy Malibu, all U.S. and Canadian models, powered by the following engines:

• 2.2L DOHC (Double Overhead Camshaft) 4-cylinder
• 2.4L DOHC (Double Overhead Camshaft) 4-cylinder
• 3.5L V6
• 3.6L V6
• 3.9L V6

PISTON RING INSTALLATION
(Refer to illustrations 10.13, 10.14, 10.15, 10.19a, 10.19b and 10.22)

11. Before installing the new piston rings, the ring end gaps must be checked. It's assumed that the piston ring side clearance has been checked and verified correct.
12. Lay out the piston/connecting rod assemblies and the new ring sets so the ring sets will be matched with the same piston and cylinder during the end gap measurement and engine assembly.
13. Insert the top (number one) ring into the first cylinder and square it up with the cylinder walls by pushing it in with the top of the piston (see illustration). The ring should be near the bottom of the cylinder, at the lower limit of ring travel.
14. To measure the end gap, slip feeler gauges between the ends of the ring until a gauge equal to the gap width is found (see illustration). The feeler gauge should slide between the ring ends with a slight amount of drag. A typical ring gap should fall between 0.010 and 0.020 in (0.25 to 0.50mm) for compression rings up to 0.030 inch (0.76mm) for the oil ring steel rails. If the gap is larger or smaller than specified, double-check to make sure you have the correct rings before proceeding.

STEERING GEAR BOOTS | REMOVAL AND INSTALLATION
(Refer to illustration 17.3)

1. Loosen the lug nuts, raise the vehicle and support it securely on jackstands. Remove the wheel.
2. Remove the tie-rod end and jam nut (see Section 16).
3. Remove the outer steering gear boot clamp with a pair of pliers (see illustration). Cut off the inner boot clamp with diagonal cutters and slide the boot off the rod.
4. Before installing the new boot, wrap the threads and spines on the end of the steering rod with a layer of tape so the small end of the new boot isn't damaged.
5. Slide the new book into position on the steering gear until it seats in the groove in the steering rod and install new clamps.
6. Remove the tape and install the tie-rod end (see Section 16).
7. Install the wheel and lug nuts. Lower the vehicle and tighten the lug nuts to the torque listed in the Chapter 1 Specifications.