Step 2: Using the flathead screwdriver, loosen and remove the clamps (2) at each end of the air intake hose. Also, loosen and remove the 10mm bolt (1). Loosen and remove the T25 Torx screws (2) that secure the top of the air box to the assembly. You can now pull the hose/air box cover from the vehicle. Disconnect the wiring harness (1).
Step 3: Loosen and remove the 10mm bolts (2) that secure the bottom of the air box to the engine. You can now lift and remove the rest of this assembly.
Step 4: Insert the square end of the 3/8 drive ratchet into the opening on the belt tensioner (located BENEATH the alternator). Turn the tensioner COUNTER CLOCKWISE, releasing the tension on the belt. You can now remove the belt from the upper pulley. SLOWLY release the tensioner to its resting position.
Step 5: Loosen and remove the 15mm bolts (2) that secure the bracket to the assembly. You can now slide the bracket aside and remove the belt.
Step 6: Using the routing diagram posted near the belt assembly, on the UNDERSIDE of the hood, or in the owner's manual, route the belt around the proper pulleys.
Step 7: Once the belt is in place, turn the tensioner (with the 3/8 ratchet) CLOCKWISE, increasing tension on the belt, securing its position.
NOTE: The belt should be taut, but not overly tight or stretched.
Step 8: Tighten the 15mm bolts (2) to secure the bracket to the assembly.
Step 9: Mount the air box by tightening the 10mm bolts (2). Connect the top of the air box assembly by tightening the T25 Torx screws (2).
Step 10: Attach the air intake hose by tightening the clamps and 10mm bolt (1). Connect the wiring harness (1).
These Part Change / Installation Instructions Apply to
08 2008, 07 2007, 06 2006, 05 2005, 04 2004 Chevrolet Malibu Serpentine Belt Replacement Instructions