Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2004MALIBU V6-3.5L VIN 8REPAIR AND DIAGNOSISSPECIFICATIONSMECHANICAL SPECIFICATIONSENGINECYLINDER HEAD ASSEMBLYSYSTEM SPECIFICATIONS
2004 Chevrolet Malibu V6-3.5L VIN 8
System Specifications
2004 Chevrolet Malibu V6-3.5L VIN 8SECTION System Specifications
Camshaft Sprocket Bolt 140 Nm (103 inch lbs.)
Camshaft Thrust Plate Screw 10 Nm (89 inch lbs.)
Exhaust Manifold Heat Shield Bolt 10 Nm (89 inch lbs.)
Exhaust Manifold Nut 16 Nm (12 ft. lbs.)
Exhaust Manifold Stud 18 Nm (13 ft. lbs.)
Intake Manifold Coolant Pipe Bolt 10 Nm (89 inch lbs.)
Throttle Body Bolt 10 Nm (89 inch lbs.)
Throttle Body Stud 6 Nm (53 inch lbs.)
Block
Camshaft Bearing Bore Diameter - Front and Rear 51.03-51.08 mm (2.009-2.011 inch)
Camshaft Bearing Bore Diameter - Middle #2, #3 50.77-50.82 mm (1.999-2.001 inch)
Cylinder Head Deck Height 224 mm (8.818 inch)
Cylinder Head Deck Surface Flatness 0.05 mm (per 152 mm (0.0019 inch) per 6 inch)
Camshaft
Camshaft Bearing Inside Diameter 47.523-47.549 mm (1.871-1 872 inch)
Camshaft Journal Diameter 47.45-47.48 mm (1.868-1 869 inch)
Camshaft Journal Out-of-Round 0 025 mm (0 001 inch)
Camshaft Lobe Lift - Exhaust 6.9263 mm (0.2727 inch)
Camshaft Lobe Lift - Intake 6.9263 mm (0.2727 inch)
Cylinder Head
Combustion Chamber Depth - at Measurement Point 2.2 mm (1 0.087 inch)
Surface Finish - Maximum 2.8 RA
Surface Flatness - Block Deck 0.08 mm (Per 152 mm (0.003 inch) Per 6 inch)
Surface Flatness - Exhaust Manifold Deck 0.1 mm (0.004 inch)
Surface Flatness - Intake Manifold Deck 0.1 mm (0.004 inch)

Cylinder Head Installation - Left
Cylinder Head Bolt
First Pass 60 Nm ( 44 ft. lbs.)
Final Pass 95 degrees

Cylinder Head Installation - Right
Cylinder Head Bolt
First Pass 60 Nm ( 44 ft. lbs.)
Final Pass 95 degrees

Intake Manifold Installation - Lower
Lower Intake Manifold Bolt - Center
First Pass 7 Nm (62 inch lbs.)
Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence
Final Pass 13 Nm (115 inch lbs.)
Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence
Lower Intake Manifold Bolt - Corner
First Pass 13 Nm (115 inch lbs.)
Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence
Final Pass 25 Nm (18 ft. lbs.)
Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence
Camshaft Thrust Plate Screw 10 Nm (89 inch lbs.)
Exhaust Manifold Heat Shield Bolt 10 Nm (89 inch lbs.)
Exhaust Manifold Nut 16 Nm (12 ft. lbs.)
Exhaust Manifold Stud 18 Nm (13 ft. lbs.)
Intake Manifold Coolant Pipe Bolt 10 Nm (89 inch lbs.)
Throttle Body Bolt 10 Nm (89 inch lbs.)
Throttle Body Stud 6 Nm (53 inch lbs.)
Block
Camshaft Bearing Bore Diameter - Front and Rear 51.03-51.08 mm (2.009-2.011 inch)
Camshaft Bearing Bore Diameter - Middle #2, #3 50.77-50.82 mm (1.999-2.001 inch)
Cylinder Head Deck Height 224 mm (8.818 inch)
Cylinder Head Deck Surface Flatness 0.05 mm (per 152 mm (0.0019 inch) per 6 inch)
Camshaft
Camshaft Bearing Inside Diameter 47.523-47.549 mm (1.871-1 872 inch)
Camshaft Journal Diameter 47.45-47.48 mm (1.868-1 869 inch)
Camshaft Journal Out-of-Round 0 025 mm (0 001 inch)
Camshaft Lobe Lift - Exhaust 6.9263 mm (0.2727 inch)
Camshaft Lobe Lift - Intake 6.9263 mm (0.2727 inch)
Cylinder Head
Combustion Chamber Depth - at Measurement Point 2.2 mm (1 0.087 inch)
Surface Finish - Maximum 2.8 RA
Surface Flatness - Block Deck 0.08 mm (Per 152 mm (0.003 inch) Per 6 inch)
Surface Flatness - Exhaust Manifold Deck 0.1 mm (0.004 inch)
Surface Flatness - Intake Manifold Deck 0.1 mm (0.004 inch)
Cylinder Head Installation - Left
Cylinder Head Bolt
First Pass 60 Nm ( 44 ft. lbs.)
Final Pass 95 degrees
Cylinder Head Installation - Right
Cylinder Head Bolt
First Pass 60 Nm ( 44 ft. lbs.)
Final Pass 95 degrees
Intake Manifold Installation - Lower
Lower Intake Manifold Bolt - Center
First Pass 7 Nm (62 inch lbs.)
Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence
Final Pass 13 Nm (115 inch lbs.)
Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence
Lower Intake Manifold Bolt - Corner
First Pass 13 Nm (115 inch lbs.)
Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence
Final Pass 25 Nm (18 ft. lbs.)
Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.