Need to locate freeze plug under front passenger side to repair. Need sizes and diagram and tools needed to do so.
Jan 24, 2026 at 3:08 AM
Coolant leaking and engine running hot?
2005 CHEVROLET MALIBU
CHRISTOPHER BERGMAN
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- 3 POSTS
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Repair Safety Notice:
This information is for general instructional purposes only. Vehicle repair can be dangerous.
Verify all information, follow manufacturer service procedures, use proper tools and safety equipment,
and consult a qualified repair shop when needed.
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This can be a tough job, make sure you drain the cooling system first. This video can help you remove and install the freeze plug.
https://www.youtube.com/watch?v=2Qf7LT3LAX8
GM lists an engine block core plug at 40 mm (OEM size listing).
Tools you’ll want (and what they’re for)
MANDATORY
Cooling system pressure tester (to locate leak)
1. Drain pan + funnel
2. Jack + jack stands / wheel chocks
3. Safety glasses
Removal / install
1. Socket set + extensions + wobble (tight access)
2. Hammer
3. Punch / chisel (to rotate the old plug)
4. Vise-grips or pliers (to pull the rotated plug)
5. Freeze plug driver set or a socket that matches the plug OD (to drive it in square)
Prep / seal
1. Emery cloth / Scotch-Brite (clean bore)
2. Brake cleaner (final wipe)
Sealant: a thin coat of Permatex #2 or similar non-hardening sealer on the plug OD (common practice)
Then reassemble and refill with coolant. If you run into an issues please upload a short video or image so I can help walk you through the repairs, Ken
https://www.youtube.com/watch?v=2Qf7LT3LAX8
GM lists an engine block core plug at 40 mm (OEM size listing).
Tools you’ll want (and what they’re for)
MANDATORY
Cooling system pressure tester (to locate leak)
1. Drain pan + funnel
2. Jack + jack stands / wheel chocks
3. Safety glasses
Removal / install
1. Socket set + extensions + wobble (tight access)
2. Hammer
3. Punch / chisel (to rotate the old plug)
4. Vise-grips or pliers (to pull the rotated plug)
5. Freeze plug driver set or a socket that matches the plug OD (to drive it in square)
Prep / seal
1. Emery cloth / Scotch-Brite (clean bore)
2. Brake cleaner (final wipe)
Sealant: a thin coat of Permatex #2 or similar non-hardening sealer on the plug OD (common practice)
Then reassemble and refill with coolant. If you run into an issues please upload a short video or image so I can help walk you through the repairs, Ken
Jan 24, 2026 at 11:12 AM
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And of course money is an issue, please give me a ballpark fix my car figure. Again, thank you Ken L.
Jan 24, 2026 at 12:40 PM
Hello Christopher,
Most shops will charge between 2 and 4 hours + parts depending on what they need to do to get at the freeze plug that is leaking, if you upload an image of the leaking freeze plug I can get closer.
Most shops will charge between 2 and 4 hours + parts depending on what they need to do to get at the freeze plug that is leaking, if you upload an image of the leaking freeze plug I can get closer.
Jan 25, 2026 at 8:30 AM
I can't see it directly. It's on passenger side up front, but closer to the feet underneath my Malibu.
Jan 25, 2026 at 12:04 PM
Yep, these are on the side of the block and will very on price and effort. A good garage should be able to change it out for you. Let me know what they say..
Jan 26, 2026 at 7:59 AM