Last post on Aug 25, 2012 at 4:03 PM
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Chevrolet Malibu, Engine
#82 of 110 Re: Intake Manifold Gasket [barky]
Oct 12, 2010 (12:33 pm)
I have a 2003 Malibu with 150,540 miles and I am the original owner. This past week-end, I replaced the upper and lower intake manifold gaskets, because of an external coolant leak near the thermostat housing. I purchased the gasket set from Autozone. It came with the upper and lower gaskets, black RTV sealant and some o-rings. After taking it all apart, I inspected the gaskets and mounting surfaces. Everything appeared to be in order. After hearing the horror stories of the leaking intake manifold gaskets, I considered myself lucky to get 150K miles out it. I cleaned everything up and put it all back together. I started to refill the system. I got about a gallon in, when I thought I heard something leaking onto the ground. I took a look underneath and saw coolant dripping from the transaxle end of the engine. I looked around the top side and saw coolant pooled up on top of the transaxle to engine area. Further inspection revealed coolant weeping from the heater pipe to intake manifold inlet below the thermostat housing. I re-checked the parts box to see if I had any left-over parts. The only part remaining from the kit was an o-ring used for the distributor seal. I disassembled enough to gain access to remove the heater pipe. When I got it out, the o-ring looked worn-out. I had to get a replacement o-ring from the Chevy Service Dept. Total cost of the replacement o-ring: $1.22. Don't be surprised if a simple part is causing you major problems!
#83 of 110 Re: Intake Manifold Gasket [maddog0324]
by MrShift@Edmunds HOST
Oct 12, 2010 (12:52 pm)
I like to get all my gaskets right from the dealer because I know they aren't sitting around for a long time. But sounds like you did all right.
#84 of 110 Re: Intake Manifold Gasket [Mr_Shiftright]
Oct 12, 2010 (1:22 pm)
Since this is my wife's car, I need to keep it up. She says it seems to be running better. I noticed that the idle is much smoother than before. Hopefully, I can get another 150K out of it.
#85 of 110 Re: Intake Manifold Gasket [maddog0324]
Oct 20, 2010 (9:23 pm)
The major problems with GM's OHV V6's (3.1, 3.8, 3.4, 4.3) tend to be the intake gasket and piston scuffing, with the gasket problem more serious. Looks like you caught it in time. It's not uncommon to put 300k on these engines. Good luck.
#86 of 110 Re: 2009 Malibu stress crack in engine [missourigrl]
Jan 26, 2011 (4:10 pm)
How did the replacement engine from GM work out with your 4 cylinder Malibu. ------- Were you able to get a copy of the "GM bulletin" dealing with a stress crack in the engine allowing coolant to leak into the oil? ----- Kindly advise! ----- Best regards. -------- Dwayne
#87 of 110 3.6L, PF48 filter, timing chain
Jan 27, 2011 (5:53 am)
I've been doing a bit of research. I now have 3.6L, 2011.
It came with PF48 filter installed, manual calls for PF63. This is a GM change and they may not have had new filters at production time. Filter is not yet available at dealers. And new dexos oil is not either.
Another forum has a lot of timing chain failures on 3.6L. Mostly pre-2010. Is this an issue on Malibu?
I changed oil with 22% life left and used a PF22500 because it crosses directly from the PF63. What I found was that the removed PF48 did not have an anti-drainback valve. My first thought was maybe the reason for the part change. I posted about the lack of valve on PF48 and some got back to me that I was wrong. PF48's do have valve. OK, but mine does not!
The oil looked particularly bad for mileage so I had already elected to keep some and the filter just in case. Because of the horizontal mounting, dirty filtered oil could drain back to pan and lack of part might effect bypass valve, opening early.
You may wish to do the same. Maybe even update to 2011 filter when they become available.
Since new to about 2500 miles, MPG dropped suddenly after that about 3 MPG, both local and highway. Related, Unknown.
#88 of 110 Re: 2009 Malibu stress crack in engine [missourigrl]
Jan 27, 2011 (12:38 pm)
I just purchased an 09 Malibu and drove it less than 5 weeks when it blew a head gasket. The dealership replaced all of the head gaskets and 2 weeks later gave it back to me. Drove it less than 15 miles when it blew another head gasket the day after we got it back. Received a call from the dealership stating that they had just received a bulletin (not a recall) stating if the car was having these certain problems, then it had a crack in the engine block. So, now they are replacing the entire motor. All of my coolant leaked also which caused my temperature gauge to shoot way up and then started having a burnt smell coming through the air vents. Shut the car off and turned it back on a few minutes later and it sounded like a gush of water went out of something. looked under the car, no liquids found. Must have went into the busted seal on the head gasket (assumption). I also have the 4 cylinder engine. Have you had any problems since they replaced your engine?
#89 of 110 Re: 2009 Malibu stress crack in engine [sunshine48]
Jan 28, 2011 (8:24 am)
Some 4 cyl have had that problem. The liner is steel and when cast in the aluminum block, the block may develop a stress crack.
The Trailblazer had that same problem with there 6 cyl inline engine. Testing for cracks must be done by the customer for GM.
#90 of 110 4 cyl GM engines
Feb 06, 2011 (10:14 am)
The Asian guys have long been superior in the production of hi-reving 4 bangers..They use forged internal parts such as cranks and rods..The Big3 have used castings for the cranks and rods limiting the performance..The Asians started out with motorcycles and applied the same knowledge to the car engine..Having been involved in the hot-forging market from 1984 thru 2002 one learns that the Big3 only used the good stuff with hi-performance engines and the cast junk with the high-volume production..
I am considering buying a new V-6 Malibu w/3.6, sunroof, cloth interior, and any suspension upgrades available, and would enjoy any comments as to troubles or negative input with the latest addition of the Malibu series..
Currently own a 2006 V-6 Pontiac GT w/3.8 S/C engine and a 2010 Mustang GT w/track Pkg, and would like to spin the Pontiac off, no problems with it, bought it cheap w/4300 miles some 42 months ago, now showing 53k..Live in Fla, retired and enjoy the open road..hi-end cruise..
The top end of the V-6 Malibu can be increased easily by tweaking the electronics, and upgrading to H-rated tires..however I am running T-rated on Pontiac, using Michelin Harmony that have excellent tread life and no problem with the high end..H-rated tire was std from factory on the Pontiac..
The neatest little 4-banger from GM was the 260hp, turbo-charged with a great suspension setup in the Chevy Cobalt SS..which was phased out in 2010..I think it was also put in the HHR..Owned 53 cars over my 77 yrs..
#91 of 110 2002 malibu moneypit
Feb 11, 2011 (1:55 pm)
my malibu's latest problem is overheating and running out of coolant, this car is a moneypit I bought it a year ago used and since that time have replaced a fuel pump, battery, crankshaft sensor, tires and several other things that i can't remember off hand, the car also has an intermittant starting problem which while it usually willstart after an hour or so is incredibly annoying and inconveniant and no its not the ignition switch although I'll probably be replacing that at some point. I usually prefer American make cars-I'll never buy another chevy this car has soured me on them for good.