1997-2003 Malibu, Alero, Cutlass, and Grand Am DIY repair and service manual by Haynes, covers:
- Chevy Malibu, 1997-2003
- Oldsmobile Alero, 1999-2003
- Oldsmobile Cutlass, 1997-2000
- Pontiac Grand Am, 1999-2003
Complete maintenance, service and repair information for the do-it-yourself mechanic. Includes detailed, easy-to-understand text how-to instructions, accompanied by hundreds of close-up photos and illustrations.
Book Excerpt: 1997-2003 Chevy Malibu, Oldsmobile Alero and Cutlass, Pontiac Grand Am Repair Manual
2.2L FOUR-CYLINDER ENGINE
CYLINDER HEAD | REMOVAL AND INSTALLATION
SUSPENSION AND STEERING SYSTEMS
CAUTION: The engine must be completely cool when the head is removed. Failure to allow the engine to cool off could result in head warpage.
- Disconnect the cable from the negative battery terminal (see Chapter 5).
- Wait until the engine is completely cool, and then drain the cooling system (see Chapter 1).
- Remove the drivebelt (see Chapter 1) and the drivebelt tensioner.
- Remove the exhaust manifold (see Section 6).
- Remove the intake manifold (see Section 5).
- Remove the timing chain (see Section 8).
- Label and disconnect the electrical connectors form the cylinder head that will interfere with removal. Use tape and mark each connector to insure correct reassembly.
- Remove the cylinder head bolts and discard them, following the reverse of the tightening sequence (see illustration 12.16). Loosen the bolts in sequence 1/4-turn at a time. If the head is to be completely overhauled, refer to Section 11 for removal of the camshafts, rocker arms and hydraulic lash adjusters.
- Use a prybar at the corners of the head-to-block mating surface to break the gasket seal. Do not pry between the cylinder head and engine block in the gasket sealing area.
- Lift the cylinder head off the engine. If resistance is felt, place a wood block against the end and strike the wood block with a hammer. Store the cylinder head on wood blocks to prevent damage to the gasket sealing surfaces.
- Remove the old cylinder head gasket. Before removing, note the correct orientation of the gasket for correct installation.
STABILIZER BAR AND BUSHINGS (FRONT) | REMOVAL AND INSTALLATION
REMOVAL (Refer to illustrations 6.3, 6.4, 6.5 and 6.6)
- Loosen the lug nuts on both front wheels, raise the front of the vehicle and support it securely on jackstands. Apply the parking brake and block the rear wheels to keep the vehicle from rolling off the jackstands. Remove the front wheels.
- Detach the tie-rod ends from the steering knuckles (see Section 16).
- Remove the nuts from the upper ends of the link bolts that connect the stabilizer bar to the control arms (see illustration). Note the order in which the bushings, spacers and washers are installed on the links; they must be installed in exactly the same order in which they are removed.
- Remove the stabilizer bar bushing clamp bolts and bushing clamps from the upper side of the subframe (see illustration).
- Unbolt the rear engine mount bracket from the subframe (see illustration).
- Support the rear of the subframe with a jack, and then remove the rear subframe retaining bolts (see illustration). Loosen the subframe front mounting bolts, and then lower the subframe about three inches.
- Remove the stabilizer bar and bushings through the wheel well.
Subject: 1997, 1998, 1999, 2000, 2001, 2002, 2003. Chevy Malibu, Oldsmobile Alero, Cutlass, Pontiac Grand Am service, maintenance, repair. ISBN-10: 1563925370 | ISBN-13: 9781563925375 | Haynes 38026