Engine Cooling System Chevrolet Malibu VI рестайлинг

Fastener Tightening Specifications

Fastener Tightening Specifications

Scheme 1

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Coolant Level Switch Connector Part Information

Coolant Level Switch Connector Terminal Identification

Scheme 6

Cooling Fan Connector Part Information (Left)

Cooling Fan Connector Terminal Identification (Left)

Cooling Fan - Right

Cooling Fan Connector Part Information (Right)

Cooling Fan Connector Terminal Identification (Right)

DIAGNOSTIC CODE INDEX

DIAGNOSTIC CODE INDEX

Diagnostic Starting Point - Engine Cooling

Begin the system diagnosis with the diagnostic system check. Refer to Diagnostic System Check - Vehicle . The Diagnostic System Check - Vehicle will provide the following information

1. The identification of the control modules which command the system
2. The ability of the control modules to communicate through the serial data circuits
3. The identification of any stored DTCs and their status

The use of the Diagnostic System Check - Vehicle will identify the correct procedure for diagnosing the system and where the procedure is located.

Scan Tool Output Controls

Powertrain Control Module (PCM) or Engine Control Module (ECM) Scan Tool Output Controls

Scan Tool Data List

Engine Control Module (ECM)

Diagnostic Fault Information

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.

DTC P0480 or P0481

Circuit/System Description

The engine control module (ECM) commands the fans ON in high speed or low speed. In low speed, the fans are configured in series. In high speed, the fans are configured in parallel.

In low speed operation, the ECM applies ground to the coil side of the low speed relay. Voltage is applied directly to the left cooling fan through the switch side of the low speed relay. The right fan is connected in series to the left fan through the de-energized series/parallel relay so that both fans operate at low speed.

In high speed operation, the ECM applies a ground to the coil side of the low speed relay, the series/parallel relay, and the high speed relay. Voltage is applied directly to the right cooling fan through the switch side of the high speed relay. The left cooling fan obtains voltage through the low speed relay and ground through the series/parallel relay.

When the ECM is commanding a fan relay ON, the voltage of the control circuit should be low, near 0 volts. When the ECM is commanding a fan relay OFF, the voltage of the control circuit should be high, near battery voltage. If the ECM detects that the actual voltage of the relay control circuit is different than the expected voltage, DTC P0480 or P0481 will set and the affected ECM driver will be disabled.

Conditions for Running the DTC

1. The ignition is ON.
2. The system voltage is between 9-18 volts.
3. The relay control circuit is transitioned from OFF to ON, or ON to OFF.
4. The engine speed is more than 40 RPM.

Conditions for Setting the DTC

1. An improper voltage level has been detected on the cooling fan relay control circuit.
2. The condition must be present for a minimum of 30 seconds.

Action Taken When the DTC Sets

1. DTC P0480 is a Type B DTC.
2. DTC P0481 is a Type B DTC.

Conditions for Clearing the DTC

1. DTC P0480 is a Type B DTC.
2. DTC P0481 is a Type B DTC.

Reference Information

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

1. «Cooling System Component Views»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Cooling System Connector End Views»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
3. «Engine Control Module Connector End Views»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2)

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__circuit-testing)
2. «Connector Repairs»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__testing-for-intermittent-conditions-and-poor)
4. «Wiring Repairs»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__wiring-repairs)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

1. «Scan Tool Data List»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-1-of-2__scan-tool-data-list)
2. «Scan Tool Data Definitions»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-1-of-2__scan-tool-data-definitions)
3. «Scan Tool Output Controls»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-1-of-2__scan-tool-output-controls)

Circuit/System Verification

Ignition ON, command each relay ON and OFF with a scan tool. Feel or listen to verify that each relay turns ON and OFF with each command.

Circuit/System Testing

1. Ignition OFF, disconnect the series/parallel relay.
2. Connect a 30A fused jumper between the normally-open switch contact terminals at the series/parallel relay connector in order to complete the fan ground circuit. Leave this jumper in place for the remainder of this procedure.
3. Ignition OFF, disconnect the affected relay.
4. Ignition ON, connect a test lamp between the positive terminal at the battery and the affected relay control circuit terminal.
5. Command the affected relay ON and OFF with a scan tool. The test lamp should turn ON and OFF when changing between the commanded states. If the test lamp is always ON, test the relay control circuit for a short to ground. If the circuit tests normal, replace the ECM. If the test lamp is always OFF, test the relay control circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the ECM.
6. Connect a 30A fused jumper between the positive voltage terminal at the battery and the fan voltage supply circuit terminal at the affected relay connector and verify fan activation. If the fan does not activate, test the fan voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the fan.
7. Ignition ON, connect a 30A fused jumper between the relay switch voltage supply circuit terminal and the fan voltage supply circuit terminal at the affected relay connector and verify fan activation. If the fan does not activate, test the affected relay switch voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal and its fuse is open, test all connected components and replace as necessary.
8. Ignition ON, verify that a test lamp illuminates between the affected relay coil voltage supply circuit terminal and ground. If the test lamp does not illuminate, test the affected relay coil voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal and its fuse is open, test all connected components and replace as necessary.
9. If all circuits and the ECM test normal, replace the affected relay.

Repair Procedures

1. Perform the «Diagnostic Repair Verification»(/chevrolet/malibu/vi-2006-2008/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-repair-verification) after completing the diagnostic procedure.
2. «Cooling Fan and Shroud Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling Fan and Shroud Replacement (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
3. «Engine Control Module Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2__engine-control-module-replacement)

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.

The engine control module (ECM) uses the engine coolant temperature (ECT) sensor to monitor the engine for an over-temperature condition. This condition occurs when the coolant temperature is above a calibrated value. The ECM will alternately disable 2 groups of cylinders by turning OFF the fuel injectors. By switching between the 2 groups of cylinders, the ECM is able to reduce the temperature of the coolant.

1. The engine is running.
2. DTC P0116, P0117, P0118, or P0128 are not set.

The coolant temperature is more than 131°C (267.8°F) for more than 7 seconds.

1. DTC P1258 is a Type A DTC.
2. The engine will operate in the Overheated Engine Protection Operating Mode.
3. The IP will illuminate the coolant indicator lamp and the driver information center (DIC), if equipped, may display a message.

DTC P1258 is a Type A DTC.

Description and Operation

1. «Cooling System Description and Operation»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Instrument Cluster Description and Operation»(/chevrolet/malibu/vi-2006-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-and-gauges)
3. «Indicator/Warning Message Description and Operation»(/chevrolet/malibu/vi-2006-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-and-gauges__indicatorwarning-message-description-and-operation)
4. «Audible Warnings Description and Operation»(/chevrolet/malibu/vi-2006-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-and-gauges__audible-warnings-description-and-operation)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

1. «Scan Tool Data List»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__scan-tool-data-list)
2. «Scan Tool Data Definitions»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
3. «Scan Tool Output Controls»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__scan-tool-output-controls)

1. If DTC P0480 or P0481 are set, diagnose those DTCs first.
2. Observe the engine coolant level. The engine coolant level should be within the operating range. Refer to Capacities - Approximate Fluid, and Engine Coolant in the Owner's Manual.
3. Ensure that the vehicle has the correct engine coolant with correct concentration and is not old, contaminated, or contains additives. Refer to Recommended Fluids and Lubricants in the Owner's Manual.
4. Inspect the cooling system for the following: Leaks Kinked or pinched hoses, especially at the radiator Loose, missing, or damaged radiator air seals or deflectors Air flow obstructions or bent fins at the radiator or the A/C condenser. Refer to «Symptoms - Engine Cooling»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Command the cooling fans ON and OFF, low and high speed. The engine cooling fans should turn ON and OFF with each command. If the cooling fans do not function as indicated, refer to «Cooling Fan Inoperative»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Test the thermostat for correct operation. Refer to «Thermostat Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Test the engine cooling system for overheating. Refer to «Engine Overheating»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__engine-overheating) .
3. Inspect the water pump and coolant flow for correct operation. Refer to «Water Pump Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__water-pump-cleaning-and-inspection) for 3.5L or «Water Pump Cleaning and Inspection»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__water-pump-cleaning-and-inspection) for 3.9L.
4. Inspect the engine mechanical for worn/leaking/cracked cylinder heads or engine block. Refer to «Coolant in Combustion Chamber»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__coolant-in-combustion-chamber) for 3.5L or «Coolant in Combustion Chamber»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__coolant-in-combustion-chamber) for 3.9L. Also refer to «Coolant in Engine Oil»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__coolant-in-engine-oil) for 3.5L or «Coolant in Engine Oil»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__coolant-in-engine-oil) for 3.9L.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

Important Preliminary Inspections Before Starting

Before using the Symptom diagnosis, perform the following

1. Perform «Diagnostic System Check - Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-system-check-vehicle) and verify all of the following items: Ensure that the engine control module (ECM) and indicator lamp are operating correctly. Ensure that there are no diagnostic trouble codes (DTCs) that are stored. Scan tool data is within a normal operating range. Refer to «Scan Tool Data List»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__scan-tool-data-list) .
2. Verify the customer concern.
3. Perform the Visual/Physical Inspection in this section. The visual/physical inspection is extremely important, and can lead to correcting a condition without additional testing. It may also help reveal the cause of an intermittent condition.
4. Locate the correct symptom. Perform the tests and inspections associated with the symptom.

Review the system operation in order to familiarize yourself with the system functions. Refer to Cooling System Description and Operation and Cooling Fan Description and Operation .

Visual/Physical Inspection

Note. Use the connector test adapter kit J 35616-A for any test that requires probing the following items: The PCM harness connectors The electrical center fuse/relay cavities The component terminals The component harness connector Using this kit will prevent damage caused by the improper probing of connector terminals.

Several of the symptom procedures call for a careful visual and physical inspection. This can lead to correcting a condition without further tests and can save time. This inspection should include the following areas

1. Ensure that the control module grounds are clean, tight, and correctly located. Refer to «Master Electrical Component List»(/chevrolet/malibu/vi-2006-2008/remont/electrical-component-locations/#wiring-systems-power-management-component-locator-component-views-and-power-ground-and-inline-harness-connector-views__master-electrical-component-list) and «Power and Grounding Connector End Views»(/chevrolet/malibu/vi-2006-2008/remont/electrical-component-locations/#wiring-systems-power-management-component-locator-component-views-and-power-ground-and-inline-harness-connector-views) .
2. Inspect cooling system hoses and pipes for splits, kinks, and proper connections. Inspect thoroughly for any type of a leak or a restriction.
3. Inspect for a dirty or restricted radiator and HVAC condenser.
4. Inspect for aftermarket devices which could affect the operation of the Cooling System. Refer to «Checking Aftermarket Accessories»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__checking-aftermarket-accessories) .
5. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
6. Inspect the surge tank reservoir for the proper coolant level.

Identifying Intermittent Conditions

Many intermittent conditions occur with harness or connector movement due to engine torque, rough pavement, vibration or physical movement of a component. Refer to the following for a list to help determine an intermittent condition

1. Moisture and water intrusion in connectors, terminals, and components
2. Connector mating
3. Terminal contact
4. High circuit or component resistance-High resistance can include any resistance, regardless of the amount, which can interrupt the operation of the component.
5. Harness that is located too tight, or chaffed circuits
6. High or low ambient temperature
7. High or low engine coolant temperatures
8. High underhood temperatures
9. Heat build up in component or circuit due to circuit resistance, poor terminal contact, or high electrical load
10. High or low system voltage
11. High vehicle load conditions
12. Rough road surface
13. Electro-magnetic interference (EMI)/circuit interference from relays, solenoids or other electrical surge
14. Incorrect installation of non-factory, aftermarket, and after factory add on accessories

If an intermittent is determined, refer to Testing for Intermittent Conditions and Poor Connections for specific strategies in diagnosing intermittent conditions.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Engine Coolant Temperature Indicator Always On»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Cooling Fan Always On»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
3. «Cooling Fan Inoperative»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
4. «Engine Overheating»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__engine-overheating)
5. «Loss of Coolant»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__loss-of-coolant)
6. «Thermostat Diagnosis»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
7. «Coolant Heater Inoperative»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
8. «Engine Fails To Reach Normal Operating Temperature»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__engine-fails-to-reach-normal-operating)

Perform the Diagnostic System Check - Vehicle .

The instrument panel cluster (IPC) illuminates the TEMP indicator when the engine control module (ECM) determines that the coolant temperature is more than 128°C (262°F). The IPC receives a discrete input from the ECM requesting illumination.

The IPC illuminates the TEMP indicator during the display test at the start of each ignition cycle.

With the engine running within the normal operating temperature range, the engine coolant temperature (ECT) indicator should not be illuminated.

1. If the engine coolant is not within the normal operating range, repair the overheating condition.
2. If the engine coolant is within the normal operating range, replace the IPC.

Perform the Diagnostic Repair Verification after completing the repair.

1. «Engine Overheating»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__engine-overheating)
2. «Instrument Cluster Replacement»(/chevrolet/malibu/vi-2006-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-and-gauges)

Repair Verification

Verify that the ECT indicator is OFF while the engine is operating.

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.

Low Engine Coolant Indicator Always On

The low engine coolant level indicator lamp on the instrument panel cluster (IPC) is controlled by the body control module (BCM) through the low speed GM LAN Serial Data line to the engine control module (ECM). When the engine coolant level switch is closed for 30 seconds or longer indicating low coolant, the BCM will signal the ECM to turn ON the coolant level lamp. The lamp will also illuminate for approximately 3 seconds during the display test at the start of each ignition cycle.

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

Cooling System Connector End Views

Description and Operation

Cooling System Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__circuit-testing)
2. «Connector Repairs»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__testing-for-intermittent-conditions-and-poor)
4. «Wiring Repairs»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__wiring-repairs)

Scan Tool Reference

Scan Tool Data List

Scan Tool Output Controls

Turn ON the ignition with the engine OFF.

Command the instrument cluster indicators ON and OFF with a scan tool.

The low coolant indicator lamp should turn ON and OFF on command.

The low coolant indicator should be OFF with the engine coolant at the proper level.

1. Turn ON the ignition with the engine OFF.
2. Verify that the low coolant indicator turns ON and OFF with each command when the instrument cluster indicators are commanded ON and OFF with a scan tool. If the low coolant level indicator does NOT turn OFF, test for poor connections at the IPC or a faulty IPC.
3. Ignition ON, disconnect the coolant level switch. If the low coolant level indicator turns OFF with the switch disconnected, replace the coolant level switch. If the low coolant level indicator does not turn OFF with the switch disconnected, test the signal circuit of the coolant level switch for a short to ground. If the signal circuit tests normal, inspect for poor connections at the BCM or a faulty BCM.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

1. «Surge Tank Replacement»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Control Module References»(/chevrolet/malibu/vi-2006-2008/remont/communication-devices/#programming-and-setup-all-systems__control-module-references)
3. «Instrument Cluster Replacement»(/chevrolet/malibu/vi-2006-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-and-gauges)

Verify that the low coolant indicator is OFF with the engine coolant at the proper level.

The engine control module (ECM) commands the fans ON in high speed or low speed. In low speed, the fans are configured in series. In high speed, the fans are configured in parallel.

In low speed operation, the ECM applies ground to the coil side of the low speed relay. Voltage is applied directly to the left cooling fan through the switch side of the low speed relay. The right fan is connected in series to the left fan through the de-energized series/parallel relay so that both fans operate at low speed.

In high speed operation, the ECM applies a ground to the coil side of the low speed relay, the series/parallel relay, and the high speed relay. Voltage is applied directly to the right cooling fan through the switch side of the high speed relay. The left cooling fan obtains voltage through the low speed relay and ground through the series/parallel relay.

When the ECM is commanding a fan relay ON, the voltage of the control circuit should be low, near 0 volts. When the ECM is commanding a fan relay OFF, the voltage of the control circuit should be high, near battery voltage. If the ECM detects that the actual voltage of the relay control circuit is different than the expected voltage, DTC P0480 or P0481 will set and the affected ECM driver will be disabled.

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

1. «Cooling System Component Views»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Cooling System Connector End Views»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
3. «Engine Control Module Connector End Views»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2)

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__circuit-testing)
2. «Connector Repairs»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__testing-for-intermittent-conditions-and-poor)
4. «Wiring Repairs»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__wiring-repairs)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

1. «Scan Tool Data List»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-1-of-2__scan-tool-data-list)
2. «Scan Tool Data Definitions»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-1-of-2__scan-tool-data-definitions)
3. «Scan Tool Output Controls»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-1-of-2__scan-tool-output-controls)

1. Verify that the following DTCs are not set: P0480, P0481. If any of the DTCs are set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-trouble-code-dtc-list) .
2. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
3. Ignition ON, observe that the fans are not activated.

1. Ignition OFF, disconnect the relays.
2. Ignition ON, observe that the fans are not activated. If the fans are not activated, replace the faulty relay. If a fan is activated, test the fan voltage supply circuits for a short to voltage.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

1. «Cooling Fan and Shroud Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling Fan and Shroud Replacement (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Engine Control Module Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2__engine-control-module-replacement)

1. Ignition ON, verify with a scan tool that the ECM is not commanding fan activation.
2. Ignition ON, observe that the fan is not activated.

The engine control module (ECM) commands the fans ON in high speed or low speed. In low speed, the fans are configured in series. In high speed, the fans are configured in parallel.

In low speed operation, the ECM applies ground to the coil side of the low speed relay. Voltage is applied directly to the left cooling fan through the switch side of the low speed relay. The right fan is connected in series to the left fan through the de-energized series/parallel relay so that both fans operate at low speed.

In high speed operation, the ECM applies a ground to the coil side of the low speed relay, the series/parallel relay, and the high speed relay. Voltage is applied directly to the right cooling fan through the switch side of the high speed relay. The left cooling fan obtains voltage through the low speed relay and ground through the series/parallel relay.

When the ECM is commanding a fan relay ON, the voltage of the control circuit should be low, near 0 volts. When the ECM is commanding a fan relay OFF, the voltage of the control circuit should be high, near battery voltage. If the ECM detects that the actual voltage of the relay control circuit is different than the expected voltage, DTC P0480 or P0481 will set and the affected ECM driver will be disabled.

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

1. «Cooling System Component Views»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Cooling System Connector End Views»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
3. «Engine Control Module Connector End Views»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2)

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__circuit-testing)
2. «Connector Repairs»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__testing-for-intermittent-conditions-and-poor)
4. «Wiring Repairs»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__wiring-repairs)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

1. «Scan Tool Data List»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-1-of-2__scan-tool-data-list)
2. «Scan Tool Data Definitions»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-1-of-2__scan-tool-data-definitions)
3. «Scan Tool Output Controls»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-1-of-2__scan-tool-output-controls)

1. If DTCs P0480 or P0481 are set, then perform those diagnostics first.
2. Ignition ON, command each relay ON and OFF with a scan tool. Observe to verify that the fan turns ON and OFF with each command.

1. Ignition OFF, disconnect the relays.
2. Install a 30A fused jumper between the relay switch supply circuit terminal and the normally open relay switch contact circuit terminal at the series/parallel relay connector. Leave this jumper installed for the remainder of this procedure.
3. Install a 30A fused jumper at the positive terminal at the battery.
4. One at a time, connect the other end of the jumper to each fan voltage supply circuit terminal at each relay connection and verify fan activation. If the appropriate fan does not activate, test the fan voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal, test the fan ground circuit for an open/high resistance. If the fan does not activate and the circuits test normal, replace the fan.
5. Ignition ON, install a 30A fused jumper between the relay switch voltage supply circuit terminal and the fan voltage supply circuit terminal at the low speed relay connection and verify fan activation. If the fan does not activate, test the relay switch voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal and its fuse is open, test all connected components and replace as necessary.
6. Ignition ON, install a 30A fused jumper between the relay switch voltage supply circuit terminal and the fan voltage supply circuit terminal at the high speed relay connection and verify fan activation. If the fan does not activate, test the relay switch voltage supply circuit for a short to ground or an open/high resistance. If the circuit tests normal and its fuse is open, test all connected components and replace as necessary.
7. If the circuits test normal, test and replace the faulty relay.

1. Perform the «Diagnostic Repair Verification»(/chevrolet/malibu/vi-2006-2008/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-repair-verification) after completing the diagnostic procedure.
2. «Cooling Fan and Shroud Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling Fan and Shroud Replacement (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
3. «Engine Control Module Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2__engine-control-module-replacement)

Ignition ON, command each relay ON and OFF with a scan tool. Observe to verify that the fans turn ON and OFF with each command.

Engine Overheating

Engine Overheating

Loss of Coolant

Loss of Coolant

Thermostat Test Procedure Using Glycol

Inspect the operation of the thermostat by hanging the thermostat on a hook in a 33 percent glycol solution.

In order to inspect if the thermostat valve is opening properly, perform the following test

1. Completely submerge the thermostat in a glycol solution. The solution should be 11°C (22°F) above the temperature indicated on the thermostat valve.
2. Thoroughly agitate the solution. Under these conditions, the thermostat valve should open.

In order to inspect if the thermostat valve is closing properly, perform the following test

1. Completely submerge the thermostat in a glycol solution. The solution should be 6°C (10°F) below the temperature indicated on the thermostat valve.
2. Thoroughly agitate the solution. Under these conditions, the thermostat valve should close completely.

The optional coolant heater operates using 110 volt AC external power and is designed to warm the coolant in the engine block area for improved starting in very cold weather. There is an internal thermal switch in the power cord that prevents operation above -18°C (0°F). The coolant heater helps reduce fuel consumption when a cold engine is warming up. The unit is equipped with a detachable AC power cord. A weather shield on the cord is provided to protect the plug when not in use.

Electrical Information Reference

1. «Circuit Testing»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__circuit-testing)
2. «Connector Repairs»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__testing-for-intermittent-conditions-and-poor)
4. «Wiring Repairs»(/chevrolet/malibu/vi-2006-2008/remont/ignition-switchsteering-lock/#wiring-systems-power-management-service-troubleshooting-diagnosis__wiring-repairs)

1. Test the engine coolant heater for an open or short to ground. If open or shorted, replace the heater.
2. If the heater tests normal, replace the coolant heater power cord.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

1. «Coolant Heater Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Coolant Heater Replacement (LZ4/LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Coolant Heater Cord Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Coolant Heater Cord Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Coolant Heater Cord Replacement (LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system)

Engine Fails To Reach Normal Operating Temperature

Engine Fails To Reach Normal Operating Temperature

Pressure Cap Testing

Tools Required

1. J 24460-01 Cooling System Pressure Tester. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
2. J 42401 Radiator Cap/Surge Tank Test Adapter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .

1. Remove the pressure cap.
2. Wash the pressure cap sealing surface with water.
3. Use the J 24460-01 (1) with J 42401 (2) in order to test the pressure cap. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
4. Test the pressure cap for the following conditions: Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) . Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss.
5. Replace the pressure cap under the following conditions: The pressure cap does not release pressure which exceeds the rated pressure of the cap. The pressure cap does not hold the rated pressure.

Cooling System Leak Testing

Tools Required

1. J 24460-01 Cooling System Pressure Tester. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
2. J 42401 Radiator Cap/Surge Tank Test Adapter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .

1. Remove the pressure cap.
2. Test the operation of the pressure cap. Refer to «Pressure Cap Testing»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__pressure-cap-testing) .
3. Wash the pressure cap mating surface with water.
4. Use the J 24460-01 with J 42401 in order to apply pressure to the cooling system. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) . Do not exceed the pressure cap rating.
5. The cooling system should hold the rated pressure for at least 2 minutes. Observe the gage for any pressure loss.
6. Repair any leaks as required.

Tools Required

J 26568 Coolant and Battery Fluid Tester. See Special Tools .

Draining Procedure

1. Unscrew the surge tank cap to remove vacuum when draining coolant.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
3. Place a container under the radiator drain.
4. Unscrew the radiator drain plug until coolant flows out the radiator drain.
5. If a complete block drain is required, remove the coolant drain plugs. Refer to «Draining Fluids and Oil Filter Removal»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__draining-fluids-and-oil-filter-removal) for the 3.5L engine or «Draining Fluids and Oil Filter Removal»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__draining-fluids-and-oil-filter-removal) for the 3.9L engine.
6. Follow the appropriate procedure based on the condition of the coolant: Normal in appearance-Follow the filling procedure. Discolored-Follow the flush procedure. Refer to «Flushing»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__flushing) .

Fill Procedure

1. Install the engine block coolant drain plugs. Refer to «Engine Block Assemble»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-block-assemble) for the 3.5L engine or «Engine Block Assemble»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-block-assemble) for the 3.9L engine.
2. Close the radiator drain plug.
3. Lower the vehicle.
4. Vehicle should be level.
5. Add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water until the level stabilizes approximately 1 in (25.4 mm) above the weld seam on the surge tank Refer to «Capacities - Approximate Fluid»(/chevrolet/malibu/vi-2006-2008/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) .
6. Install the surge tank cap.
7. Start the engine and run at 2,000 RPM until the engine cooling fans turn ON.
8. Let the engine idle for 30 seconds.
9. Turn the engine OFF and allow the engine to cool down.
10. Remove the surge tank cap.
11. Refill to approximately 1 in (25.4 mm) above the weld seam on the surge tank.
12. Inspect the concentration of the engine coolant using J 26568 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
13. Install the surge tank cap.
14. Rinse away any excess coolant from the engine and the engine compartment.

Draining and Filling Cooling System (GE 47716)

Tools Required

1. J 26568 Coolant and Battery Fluid Tester. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
2. J 42401 Radiator Pressure Adapter. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
3. GE-47716 Vac N Fill Coolant Refill Tool

1. Unscrew the surge tank cap to remove vacuum when draining the coolant.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
3. Place a container under the radiator drain.
4. Unscrew the radiator drain plug until coolant flows out the radiator drain.
5. If a complete block drain is required, remove the drain plugs. Refer to the following: «Draining Fluids and Oil Filter Removal»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__draining-fluids-and-oil-filter-removal) for the 2.2L engine «Draining Fluids and Oil Filter Removal»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__draining-fluids-and-oil-filter-removal) for the 3.5L engine «Draining Fluids and Oil Filter Removal»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__draining-fluids-and-oil-filter-removal) for the 3.9L engine
6. Follow the appropriate procedure based on the condition of the coolant. Normal in appearance-follow the filling procedure. Discolored-follow the flush procedure. Refer to «Flushing»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__flushing) .

Vac N Fill Procedure

If a complete engine block drain was required, install the engine block drain plugs. Refer to the appropriate procedure

1. «Engine Block Assemble»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__engine-block-assemble) for the 2.2L engine
2. «Engine Block Assemble»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-block-assemble) for the 3.5L engine
3. «Engine Block Assemble»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l__engine-block-assemble) for the 3.9L engine

1. Install J-42401-2 into the surge tank fill neck.
2. Install J-42401-3 to the surge tank fill neck.
3. Attach the Vac N Fill cap to the J-42401-3.
4. Attach the Vac N Fill cap to the vehicles coolant fill port.
5. Attach the vacuum gage assembly to the Vac N Fill cap.
6. Attach the fill hose to the barb fitting on the vacuum gage assembly. Ensure the valve is closed.
7. Pour the coolant mixture into the graduated reservoir.
8. Place the fill hose in the graduated reservoir.
9. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank.
10. Attach the venturi assembly to the vacuum tank.
11. Attach a shop air hose to the venturi assembly. Ensure the valve on the venturi assembly is closed.
12. Attach the vacuum hose to the vacuum gage assembly and the vacuum tank.
13. Open the valve on the venturi assembly. The vacuum gage will begin to rise and a hissing noise will be present.
14. Continue to draw vacuum until the needle stops rising. This should be 610-660 mm Hg (24-26 in Hg). Cooling hoses may start to collapse. This is normal due to vacuum draw.
15. To aid in the fill process, position the graduated reservoir above the coolant fill port.
16. Slowly open the valve on the vacuum gage assembly. When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.
17. Close the valve on the venturi assembly.
18. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss. If vacuum loss is observed, refer to «Loss of Coolant»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__loss-of-coolant) .
19. Open the valve on the vacuum gage assembly. The vacuum gage will drop as coolant is drawn into the system.
20. Once the vacuum gage reaches zero, close the valve on the vacuum gage assembly and repeat steps 11-17.
21. Remove the J-42401-3 from the surge tank fill neck.
22. Remove J-42401-2 from the surge tank fill neck.
23. Detach the Vac N Fill cap from the vehicles coolant fill port.
24. Add coolant to the system as necessary.
25. Inspect the concentration of the coolant mixture using J 26568 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
26. Detach the vacuum hose from the vacuum gage assembly.
27. Attach the extraction hose to the vacuum hose.
28. Open the valve on the venturi assembly to start a vacuum draw.
29. Use the extraction hose to draw out coolant to the proper level.
30. Install the surge tank cap.
31. The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the vacuum tank into a suitable container for disposal.

J 26568 Coolant and Battery Fluid Tester. See Special Tools .

1. Unscrew the surge tank cap to remove vacuum when draining coolant.
2. Place a container under the radiator drain.
3. Unscrew the radiator drain plug until coolant flows out of the radiator drain.
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
5. Place a container under the water pump housing and open the water pump drain plug.
6. Follow the appropriate procedure based on the condition of coolant. Normal in appearance-Follow filling procedure. Discolored-Follow flush procedure. Refer to «Flushing»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__flushing) .

1. Close the radiator drain plug.
2. Close the water pump drain plug. Refer to «Water Pump Installation»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__water-pump-installation) for the 2.2L.(L61) engine.
3. Lower the vehicle.
4. Vehicle should be level.
5. Add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water until the level stabilizes approximately 25.4 mm (1.0 in) above the weld seam on the surge tank. Refer to «Capacities - Approximate Fluid»(/chevrolet/malibu/vi-2006-2008/remont/lubrication-system/#maintenance-and-lubrication__capacities-approximate-fluid) .
6. Install the surge tank cap.
7. Start the engine and run at 2,000 RPM until the engine cooling fans turn ON.
8. Turn the engine OFF and allow the engine to cool down.
9. Remove the surge tank cap.
10. Refill to approximately 25.4 mm (1.0 in) above the weld seam on the surge tank.
11. Inspect the concentration of engine coolant using J 26568 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
12. Install the surge tank cap.
13. Rinse away any excess coolant from the engine and the engine compartment.

Flushing

1. Apply the park brake.
2. Drain the coolant. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Fill the coolant system with clean drinkable water. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Start the engine and run at 2,000 RPM until the thermostat opens.
5. Turn OFF the engine.
6. Drain the coolant system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Repeat the above procedure until the water from the coolant system is colorless.
8. Drain the coolant system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
9. Add 3.8 liters (1.0 gal) of concentrated antifreeze since there will be some water in the system.
10. Add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water until the level stabilizes at the weld seam on the surge tank. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .

Radiator Cleaning

Note. The radiator fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer.

1. Some conditions may require the use of warm water and a mild detergent.
2. Clean the A/C condenser fins.
3. Clean between the A/C condenser and radiator.
4. Clean the radiator cooling fins.
5. Straighten any damaged cooling fins.

Scheme 7

Surge Tank Replacement

Scheme 8

Surge Tank Hose/Pipe Replacement - Inlet (LZ4, LZ9)

J 38185 Hose Clamp Pliers. See Special Tools .

Removal Procedure

1. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
2. Remove the surge tank inlet hose from the surge tank.
3. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
4. Remove the surge tank inlet hose from the engine.
5. Remove the surge tank inlet hose clamps from the surge tank inlet hose.

Installation Procedure

1. Install the surge tank inlet hose clamps to the surge tank hose.
2. Install the surge tank inlet hose to the engine.
3. Reposition the surge tank inlet hose clamp at the engine using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
4. Install the surge tank inlet hose to the surge tank.
5. Reposition the surge tank inlet hose clamp at the surge tank using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .

Scheme 9

Surge Tank Hose/Pipe Replacement - Outlet (L61)

Scheme 10

Surge Tank Hose/Pipe Replacement - Outlet (LZ4, LZ9)

J 38185 Hose Clamp Pliers. See Special Tools .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
3. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
4. Remove the radiator inlet hose from the radiator.
5. Reposition the radiator inlet hose clamp at the engine using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
6. Remove the radiator inlet hose at the engine.
7. Remove the radiator inlet hose clamps from the radiator inlet hose.

1. Install the radiator inlet hose clamps to the radiator inlet hose.
2. Install the radiator inlet hose to the engine.
3. Reposition the radiator inlet hose clamp at the engine using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
4. Install the radiator inlet hose to the radiator.
5. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
6. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
7. Fill the coolant. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 11

Radiator Inlet Hose Replacement (LZ4, LZ9)

J 38185 Hose Clamp Pliers. See Special Tools .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
3. Remove the radiator outlet hose from the radiator.
4. Reposition the radiator outlet hose clamp at the engine using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
5. Remove the radiator outlet hose from the engine.
6. Remove the radiator outlet hose clamps from the radiator outlet hose.

1. Install the radiator outlet hose clamps to the radiator outlet hose.
2. Install the radiator outlet hose to the engine.
3. Reposition the radiator outlet hose clamp at the engine using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
4. Install the radiator outlet hose to the radiator.
5. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
6. Fill the coolant. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 12

Radiator Outlet Hose Replacement (LZ4, LZ9)

1. Remove the left and right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
2. Unclip the upper transmission oil cooler pipe from the fan shroud. Do not disconnect transmission oil cooler pipe from transmission or radiator.
3. Loop a rope around each of the upper 2 tabs on the condenser and tie a rope around the upper tie bar.
4. Remove the upper radiator support bracket bolts.
5. Remove the upper radiator support brackets.
6. Pry upward on the fan shroud tabs at the radiator clips.
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
8. Remove the lower radiator air deflector retainers.
9. Remove the lower radiator air deflector.
10. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
11. Remove the right radiator air deflector retainers.
12. Remove the right radiator air deflector.
13. Remove the left radiator air deflector retainers.
14. Remove the left radiator air deflector.
15. Remove the lower radiator support bracket bolts.
16. Remove the lower radiator support brackets.
17. Remove the fan wire harness connectors.
18. Remove the fan shroud assembly.

1. Install the fan shroud assembly.
2. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
3. The radiator air side seals must be in the proper position for proper air flow.
4. Install the lower radiator support brackets.
5. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
6. Install the fan wire harness connectors.
7. Install the left radiator air deflector.
8. Install the left radiator air deflector retainers.
9. Install the right radiator air deflector.
10. Install the right radiator air deflector retainers.
11. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
12. Install the lower radiator air deflector.
13. Install the lower radiator air deflector retainers.
14. Lower the vehicle.
15. Snap the fan shroud tabs into the radiator clips.
16. Remove the rope attached to the condenser and upper tie bar.
17. Install the upper radiator support brackets.
18. Install the upper radiator support bracket bolts. Tighten: Tighten the bolts to 10 N.m (7 lb ft).
19. Clip the upper transmission oil cooler pipe to the shroud.
20. Install the right and left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .

J 38185 Hose Clamp Pliers. See Special Tools .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the left and right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
3. Remove the upper transmission oil cooler pipe from the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
4. Loop a rope around each of the upper 2 tabs of the condenser and tie a rope around the upper tie bar.
5. Remove the upper radiator support bracket bolts.
6. Remove the upper radiator support brackets.
7. Pry upward on the fan shroud tabs at the radiator clips.
8. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
9. Remove the lower radiator air deflector retainers.
10. Remove the lower radiator air deflector.
11. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
12. Remove the right radiator air deflector retainers.
13. Remove the right radiator air deflector.
14. Remove the left radiator air deflector retainers.
15. Remove the left radiator air deflector.
16. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
17. Remove the radiator outlet hose from the radiator.
18. Remove the fan wire harness connectors.
19. Remove the lower radiator support bracket bolts.
20. Remove the lower radiator support brackets.
21. Place a drain pan under the transmission oil cooler pipes.
22. Remove the transmission oil cooler pipes attachment nut from the transmission.
23. Remove both transmission oil cooler pipes from the transmission.
24. Remove the transmission oil cooler pipe clip from the fan shroud.
25. Remove the lower transmission oil cooler pipe from the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
26. Remove the transmission oil cooler pipes.
27. Remove the fan wire harness connectors.
28. Remove the fan shroud assembly.

1. Install the fan shroud assembly.
2. Install the transmission oil cooler pipes.
3. Install the lower transmission oil cooler pipe to the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
4. Install the transmission oil cooler pipe clip to the fan shroud.
5. Install both transmission oil cooler pipes to the transmission.
6. Install the transmission oil cooler pipe attachment nut to the transmission. Tighten: Tighten the nut to 7 N.m (62 lb in).
7. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
8. The radiator air side seals must be in the proper position for proper air flow.
9. Install the lower radiator support brackets.
10. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
11. Install the fan wire harness connectors.
12. Install the radiator outlet hose to the radiator.
13. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
14. Install the left radiator air deflector.
15. Install the left radiator air deflector retainers.
16. Install the right radiator air deflector.
17. Install the right radiator air deflector retainers.
18. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
19. Install the lower radiator air deflector.
20. Install the lower radiator air deflector retainers.
21. Lower the vehicle.
22. Snap fan shroud tabs into the radiator clips.
23. Remove the rope attached to the condenser and upper tie bar.
24. Install the upper radiator support brackets.
25. Install the upper radiator support bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
26. Install the upper transmission oil cooler pipe to the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
27. Install the right and left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
28. Fill the coolant. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
29. Inspect the transmission fluid level. Refer to «Transmission Fluid Checking»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#how-to-diagnosis-troubleshooting-the-automatic-transaxle-4t45-e-service) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the water pump drain plug and drain the coolant from the engine block at the water pump drain.
3. Lower the vehicle.
4. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
5. Disconnect the heated oxygen sensor (HO2S) electrical connector clip from the bracket.
6. Remove the ECT sensor.
7. Reposition the radiator outlet hose clamp at the surge tank.
8. Remove the radiator outlet hose from the surge tank.
9. Reposition the radiator outlet hose clamp at the thermostat housing.
10. Remove the radiator outlet hose from the thermostat housing.
11. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
12. Disconnect the heater inlet (2) and outlet (1) hoses from the thermostat housing pipes.
13. Remove the fuel feed pipe clips (2) from the fuel feed pipe bracket.
14. Remove the fuel feed pipe bracket bolt and bracket.
15. Remove the exhaust heat shield studs.
16. Remove the exhaust heat shield.
17. Remove the thermostat housing bolts.
18. Remove the thermostat housing from the vehicle.
19. Remove the water transfer pipe from the thermostat housing, if necessary.
20. Remove and discard the water transfer pipe O-ring seals, if necessary.
21. Remove the thermostat housing cover bolts and cover, if necessary.
22. Remove the thermostat, if necessary.
23. Remove and discard the thermostat housing O-ring seal, if necessary.
24. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.

1. Install a NEW thermostat housing cover O-ring seal into the recess groove.
2. Install the thermostat, if necessary.
3. Install the thermostat housing cover bolts, if necessary. Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Install a NEW thermostat housing to engine O-ring seal onto the thermostat housing.
5. Load the thermostat housing assembly into position while the vehicle is lowered.
6. Install NEW O-ring seals onto the water feed pipe.
7. Install the water feed pipe into the thermostat housing aligning locator tab.
8. Align the water pipe to water pump.
9. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
10. Position the thermostat housing against the engine.
11. Install the thermostat housing bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
12. Install the exhaust heat shield.
13. Install the exhaust heat shield studs. Tighten: Tighten the studs to 22 N.m (17 lb ft).
14. Install the fuel feed pipe bracket and bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
15. Install the fuel feed pipe clips (2) to the fuel feed pipe bracket.
16. Connect the heater inlet (2) and outlet (1) hoses to the thermostat housing pipes.
17. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
18. Install the radiator outlet hose to the thermostat housing.
19. Position the radiator outlet hose clamp at the thermostat housing.
20. Install the radiator outlet hose to the surge tank.
21. Position the radiator outlet hose clamp at the surge tank.
22. Apply sealant to the threads of the ECT sensor. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__sealers-adhesives-and-lubricants) .
23. Install the ECT sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
24. Connect the ECT sensor electrical connector (1).
25. Connect the HO2S electrical connector clip to the bracket.
26. Apply sealant to the water pump drain plug. Refer to «Sealers, Adhesives, and Lubricants»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-22l-l61__sealers-adhesives-and-lubricants) .
27. Install the water pump drain plug. Tighten: Tighten the drain plug to 20 N.m (15 lb ft).
28. Verify the drain valves at the radiator and water pump are closed.
29. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
30. Verify the repair and inspect for any leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
3. Reposition the radiator outlet hose clamp at the thermostat housing.
4. Remove the radiator outlet hose from the thermostat housing.
5. Remove the thermostat housing bolt/stud.
6. Remove the thermostat housing and gasket.
7. Clean the gasket surfaces.

1. Position a NEW gasket and the thermostat housing to the engine block.
2. Install the thermostat housing bolt/stud. Tighten: Tighten the bolt/stud to 25 N.m (18 lb ft).
3. Install the radiator outlet hose to the thermostat housing.
4. Position the radiator outlet hose clamp at the thermostat housing.
5. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Inspect the system for leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-39l-introduction-2-of-2) .
3. Reposition the radiator outlet hose clamp at the thermostat housing.
4. Remove the radiator outlet hose from the thermostat housing.
5. Remove the thermostat housing bolt/stud.
6. Remove the thermostat housing and gasket.
7. Clean the gasket surfaces.

1. Position a NEW gasket and the thermostat housing to the engine block.
2. Install the thermostat housing bolt/stud. Tighten: Tighten the bolt/stud to 25 N.m (18 lb ft).
3. Install the radiator outlet hose to the thermostat housing.
4. Position the radiator outlet hose clamp at the thermostat housing.
5. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-39l-introduction-2-of-2) .
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Inspect the system for leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Reposition the radiator outlet hose clamp at the surge tank.
3. Remove the radiator outlet hose from the surge tank.
4. Reposition the radiator outlet hose clamp at the thermostat housing.
5. Remove the radiator outlet hose from the thermostat housing.
6. Remove the thermostat housing cover bolts and cover.
7. Remove the thermostat.
8. Remove and discard the thermostat housing O-ring seal.

1. Install a NEW thermostat housing cover O-ring seal.
2. Install the thermostat.
3. Install the thermostat housing cover bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
4. Install the radiator outlet hose to the thermostat housing.
5. Position the radiator outlet hose clamp at the thermostat housing.
6. Install the radiator outlet hose to the surge tank.
7. Position the radiator outlet hose clamp at the surge tank.
8. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
3. Reposition the radiator outlet hose clamp at the thermostat housing.
4. Remove the radiator outlet hose from the thermostat housing.
5. Remove the thermostat housing bolt/stud.
6. Remove the thermostat housing and gasket.
7. Remove the thermostat.
8. Clean the gasket surfaces.

1. Install a NEW thermostat.
2. Position a NEW gasket and the thermostat housing to the engine block.
3. Install the thermostat housing bolt/stud. Tighten: Tighten the bolt/stud to 25 N.m (18 lb ft).
4. Install the radiator outlet hose to the thermostat housing.
5. Position the radiator outlet hose clamp at the thermostat housing.
6. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Resonator Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-22l-l61-introduction-2-of-2) .
7. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Inspect the system for leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-39l-introduction-2-of-2) .
3. Reposition the radiator outlet hose clamp at the thermostat housing.
4. Remove the radiator outlet hose from the thermostat housing.
5. Remove the thermostat housing bolt/stud.
6. Remove the thermostat housing and gasket.
7. Remove the thermostat.
8. Clean the gasket surfaces.

1. Install a NEW thermostat.
2. Position a NEW gasket and the thermostat housing to the engine block. NOTE: Refer to «Fastener Notice»(/chevrolet/malibu/vi-2006-2008/remont/oem-general-information/#warnings-and-cautions__fastener-notice) .
3. Install the thermostat housing bolt/stud. Tighten: Tighten the bolt/stud to 25 N.m (18 lb ft).
4. Install the radiator outlet hose to the thermostat housing.
5. Position the radiator outlet hose clamp at the thermostat housing.
6. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vi-2006-2008/remont/testing-diagnostics/#engine-controls-fuel-39l-introduction-2-of-2) .
7. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Inspect the system for leaks.

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
2. Remove the generator. Refer to «Generator Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Remove the drive belt idler pulleys. Refer to «Drive Belt Idler Pulley Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
4. Remove the power steering pump. Refer to «Power Steering Pump Replacement»(/chevrolet/malibu/vi-2006-2008/remont/manual-power-steering/#rack-pinion-power-steering-system) .
5. Reposition the radiator surge tank inlet hose clamp (1) at the surge tank inlet pipe.
6. Remove the radiator surge tank inlet hose from the inlet pipe. Position the hose out of the way.
7. Remove the radiator surge tank pipe bolts (2).
8. Remove the radiator surge tank pipe from the crossover pipe.
9. Reposition the radiator inlet hose clamp at the crossover pipe.
10. Remove the radiator inlet hose from the crossover pipe.
11. Reposition the thermal bypass hose clamp at the crossover pipe.
12. Remove the thermal bypass hose from the crossover pipe.
13. Remove the coolant crossover pipe bolts (1-4).
14. Remove the coolant crossover pipe.

1. Position the coolant crossover pipe to the cylinder heads.
2. Install the coolant crossover pipe bolts (1-4). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the thermal bypass hose to the crossover pipe.
4. Position the thermal bypass hose clamp at the crossover pipe.
5. Install the radiator inlet hose to the crossover pipe.
6. Position the radiator inlet hose clamp at the crossover pipe.
7. Install the radiator surge tank pipe to the crossover pipe.
8. Install the radiator surge tank pipe bolts (2). Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Install the radiator surge tank inlet hose to the inlet pipe.
10. Position the radiator surge tank inlet hose clamp (1) at the surge tank inlet pipe.
11. Install the power steering pump. Refer to «Power Steering Pump Replacement»(/chevrolet/malibu/vi-2006-2008/remont/manual-power-steering/#rack-pinion-power-steering-system) .
12. Install the drive belt idler pulleys. Refer to «Drive Belt Idler Pulley Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
13. Install the generator. Refer to «Generator Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
14. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .

1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-39l) .
2. Remove the generator. Refer to «Generator Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
3. Remove the drive belt idler pulleys. Refer to «Drive Belt Idler Pulley Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-39l) .
4. Remove the power steering pump. Refer to «Power Steering Pump Replacement»(/chevrolet/malibu/vi-2006-2008/remont/manual-power-steering/#rack-pinion-power-steering-system) .
5. Reposition the radiator surge tank inlet hose clamp at the surge tank inlet pipe.
6. Remove the radiator surge tank inlet hose from the inlet pipe. Position the hose out of the way.
7. Remove the radiator surge tank pipe bolts.
8. Remove the radiator surge tank pipe from the crossover pipe.
9. Reposition the radiator inlet hose clamp at the crossover pipe.
10. Remove the radiator inlet hose from the crossover pipe.
11. Reposition the thermal bypass hose clamp at the crossover pipe.
12. Remove the thermal bypass hose from the crossover pipe.
13. Remove the coolant crossover pipe bolts (1-4).
14. Remove the coolant crossover pipe.

1. Position the coolant crossover pipe to the cylinder heads.
2. Install the coolant crossover pipe bolts (1-4). Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the thermal bypass hose to the crossover pipe.
4. Position the thermal bypass hose clamp at the crossover pipe.
5. Install the radiator inlet hose to the crossover pipe.
6. Position the radiator inlet hose clamp at the crossover pipe.
7. Install the radiator surge tank pipe to the crossover pipe.
8. Install the radiator surge tank pipe bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
9. Install the radiator surge tank inlet hose to the inlet pipe.
10. Position the radiator surge tank inlet hose clamp at the surge tank inlet pipe.
11. Install the power steering pump. Refer to «Power Steering Pump Replacement»(/chevrolet/malibu/vi-2006-2008/remont/manual-power-steering/#rack-pinion-power-steering-system) .
12. Install the drive belt idler pulleys. Refer to «Drive Belt Idler Pulley Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-39l) .
13. Install the generator. Refer to «Generator Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) or «Generator Replacement (LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/charging-system/#battery-charging-system-and-starting-system) .
14. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-39l) .

Water Pump Replacement (L61)

Tools Required

1. J 25025-5 Dial Indicator Mounting Post
2. J 43651 Water Pump Holding Tool. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .

1. Remove the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Thermostat Housing Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Thermostat Housing Replacement (LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the coolant heater. Refer to «Coolant Heater Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Coolant Heater Replacement (LZ4/LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the water pump access plate from the front cover.
4. Install the J 43651 into position. See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
5. Tighten the bolts on the water pump holding tool into the threads on the water pump sprocket.
6. Install the access cover bolts that were removed earlier to secure the water pump holding tool to the front cover assembly.
7. Remove the 3 inner water pump sprocket to water pump bolts through the holes in the water pump holding tool.
8. Remove the 2 water pump bolts.
9. Remove the rear 2 water pump bolts.
10. Remove the engine wiring harness clip nut from the water pump stud.
11. Remove the engine wring harness clip from the stud.
12. Remove the water pump.

1. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the water pump drain plug.
2. Install the water pump drain plug. Tighten: Tighten the drain plug to 20 N.m (15 lb ft).
3. Using the J 25025-5 or a guide pin, align the pin with the water pump holding tool.
4. Position the water pump against the engine block and hand tighten the water pump bolts.
5. Install the inner water pump sprocket bolts. After 2 are snug, remove the guide pin and install the 3rd bolt. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Tighten the water pump sprocket bolts last. Tighten: Tighten the bolts to 10 N.m (89 lb in).
7. Remove the J 43651 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
8. Install the coolant heater. Refer to «Coolant Heater Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Coolant Heater Replacement (LZ4/LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
9. Install the water pump access plate and bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Install the thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Thermostat Housing Replacement (LZ4)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Engine Coolant Thermostat Housing Replacement (LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Loosen the water pump pulley bolts.
3. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
4. Remove the water pump pulley bolts and pulley.
5. Remove the water pump bolts.
6. Remove the water pump and gasket.
7. Clean the water pump mating surfaces.

1. Position a NEW water pump gasket and the water pump to the engine front cover.
2. Install the water pump bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the water pump pulley and bolts.
4. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-35l) .
5. Tighten the water pump pulley bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Inspect for leaks.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Loosen the water pump pulley bolts.
3. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-39l) .
4. Remove the water pump pulley bolts and pulley.
5. Remove the water pump bolts.
6. Remove the water pump and gasket.
7. Clean the water pump mating surfaces.

1. Position a NEW water pump gasket and the water pump to the engine front cover.
2. Install the water pump bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
3. Install the water pump pulley and bolts.
4. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2006-2008/remont/mechanical/#engine-mechanical-39l) .
5. Tighten the water pump pulley bolts. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
6. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Inspect for leaks.

J 38185 Hose Clamp Pliers. See Special Tools .

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

1. Drain the coolant. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
3. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
4. Loop a rope around each of the 2 tabs of the condenser and tie the rope around the upper tie bar.
5. Remove the upper radiator support bracket bolts.
6. Remove the upper radiator support brackets.
7. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
8. Remove the radiator outlet hose from the radiator.
9. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
10. Remove the radiator inlet hose from the radiator.
11. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
12. Remove the lower radiator air deflector retainers.
13. Remove the lower radiator air deflector.
14. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
15. Remove the right radiator air deflector retainers.
16. Remove the right radiator air deflector.
17. Remove the left radiator air deflector retainers.
18. Remove the left radiator air deflector.
19. Place a drain pan under the transmission oil cooler pipes.
20. Remove the transmission oil cooler pipes attachment nut from the transmission.
21. Remove the transmission oil cooler pipes from the transmission.
22. Remove the lower radiator support bracket bolts.
23. Remove the lower radiator support brackets.
24. Remove the radiator lower mounts.
25. Remove and discard the condenser mounting bolts.
26. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
27. Remove and discard the condenser mounting nuts from the radiator.
28. Remove the radiator air side seals.
29. Remove the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
30. Remove the transmission oil cooler pipes from the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
31. Pry upward on the fan shroud tabs at the radiator clips.
32. Remove the cooling fan and shroud assembly from the radiator.

Scheme 19

1. Install the cooling fan and shroud assembly to the radiator.
2. Snap the fan shroud tabs into the radiator clips.
3. Install the transmission oil cooler pipes to the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
4. Install the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
6. Install the condenser mounting nuts to the radiator.
7. Insert the condenser mounting tabs into the radiator clips.
8. Install the condenser mounting bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
10. The radiator air side seals must be in the proper position for proper air flow.
11. Install the radiator lower mounts.
12. Install the lower radiator support brackets.
13. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
14. Install the transmission oil cooler pipes to the transmission.
15. Install the transmission oil cooler pipes attachment nut to the transmission. Tighten: Tighten the nut to 7 N.m (62 lb in).
16. Install the left radiator air deflector.
17. Install the left radiator air deflector retainers.
18. Install the right radiator air deflector.
19. Install the right radiator air deflector retainers.
20. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
21. Install the lower radiator air deflector.
22. Install the lower radiator air deflector retainers.
23. Lower the vehicle.
24. Install the radiator inlet hose to the radiator.
25. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
26. Install the radiator outlet hose to the radiator.
27. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
28. Remove the rope attached to the condenser and upper tie bar.
29. Install the upper radiator support brackets.
30. Install the upper radiator support bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
31. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
32. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
33. Fill the coolant. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
34. Inspect the transmission fluid level. Refer to «Transmission Fluid Checking»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#how-to-diagnosis-troubleshooting-the-automatic-transaxle-4t45-e-service) .

J 38185 Hose Clamp Pliers. See Special Tools .

1. Drain the coolant. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
3. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
4. Loop a rope around each of the upper 2 tabs of the condenser and tie the rope around the upper tie bar.
5. Remove the upper radiator support bracket bolts.
6. Remove the upper radiator support brackets.
7. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
8. Remove the surge tank outlet hose from the radiator.
9. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
10. Remove the radiator inlet hose from the radiator.
11. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
12. Remove the lower radiator air deflector retainers.
13. Remove the lower radiator air deflector.
14. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
15. Remove the right radiator air deflector retainers.
16. Remove the right radiator air deflector.
17. Remove the left radiator air deflector retainers.
18. Remove the left radiator air deflector.
19. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
20. Remove the radiator outlet hose from the radiator.
21. Place a drain pan under the transmission oil cooler pipes.
22. Remove the transmission oil cooler pipe attachment nut from the transmission.
23. Remove the transmission oil cooler pipes from the transmission.
24. Remove the lower radiator support bracket bolts.
25. Remove the lower radiator support brackets.
26. Remove the radiator lower mounts.
27. Remove and discard the condenser mounting bolts from the radiator.
28. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
29. Remove and discard the condenser mounting nuts from the radiator.
30. Remove the radiator air side seals.
31. Remove the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
32. Remove the transmission oil cooler pipes from the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
33. Pry upward on the fan shroud tabs at the radiator clips.
34. Remove the cooling fan and shroud assembly.

1. Install the cooling fan and shroud assembly to the radiator.
2. Snap the fan shroud tabs into the radiator clips.
3. Install the transmission oil cooler pipes to the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Replacement»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#automatic-transaxle-4t45-e-introduction-2-of-2) .
4. Install the radiator, cooling fan shroud and transmission oil cooler pipe assembly.
5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
6. Install the condenser mounting nuts to the radiator.
7. Insert the condenser mounting tabs into the radiator clips.
8. Install the condenser to the radiator bolts. Tighten: Tighten the bolts to 6 N.m (53 lb in).
9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
10. The radiator air side seals must be in the proper position for proper air flow.
11. Install the radiator lower mounts.
12. Install the lower radiator support brackets.
13. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
14. Install the transmission oil cooler pipes to the transmission.
15. Install the transmission oil cooler pipes attachment nut to the transmission. Tighten: Tighten the nut to 7 N.m (62 lb in).
16. Install the radiator outlet hose to the radiator.
17. Reposition the radiator outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
18. Install the left radiator air deflector.
19. Install the left radiator air deflector retainers.
20. Install the right radiator air deflector.
21. Install the right radiator air deflector retainers.
22. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
23. Install the lower radiator air deflector.
24. Install the lower radiator air deflector retainers.
25. Lower the vehicle.
26. Install the radiator inlet hose to the radiator.
27. Reposition the radiator inlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
28. Install the surge tank outlet hose to the radiator.
29. Reposition the surge tank outlet hose clamp at the radiator using the J 38185 . See «Special Tools»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__special-tools) .
30. Remove the rope attached to the condenser and upper tie bar.
31. Install the upper radiator support brackets.
32. Install the upper radiator support bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
33. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
34. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
35. Fill the coolant. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
36. Inspect the transmission fluid level. Refer to «Transmission Fluid Checking»(/chevrolet/malibu/vi-2006-2008/remont/automatic-trans/#how-to-diagnosis-troubleshooting-the-automatic-transaxle-4t45-e-service) .

1. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
2. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
3. Loop a rope around each of the two tabs of the condenser and tie the rope around the upper tie bar.
4. Remove the upper radiator support bracket bolts.
5. Remove the upper radiator support brackets.
6. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
7. Remove the lower radiator air deflector retainers.
8. Remove the lower radiator air deflector.
9. Remove the lower radiator support bracket bolts.
10. Remove the lower radiator support brackets.
11. Remove the radiator lower mounts.

1. Install the radiator lower mounts.
2. Install the lower radiator support brackets.
3. Install the lower radiator support bracket bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
4. Install the lower radiator air deflector.
5. Install the lower radiator air deflector retainers.
6. Lower the vehicle.
7. Remove the rope attached to the condenser and upper tie bar.
8. Install the upper radiator support brackets.
9. Install the upper radiator bracket bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
10. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .
11. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-lights/#lighting-systems) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Remove the lower radiator air deflector retainers.
3. Remove the lower radiator air deflector.

1. Install the lower radiator air deflector.
2. Install the lower radiator air deflector retainers.
3. Lower the vehicle.

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Remove the left side radiator air deflector retainers.
3. Remove the left side radiator air deflector.
4. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
5. Remove the right side radiator air deflector retainers.
6. Remove the right side radiator air deflector.

1. Install the right side radiator air deflector.
2. Install the right side radiator air deflector retainers.
3. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2006-2008/remont/frames-subframes-crossmembers/#frame-and-underbody) .
4. Install the left side radiator air deflector.
5. Install the left side radiator air deflector retainers.
6. Lower the vehicle.

1. Remove the front bumper upper fascia support. Refer to «Front Bumper Fascia Upper Support Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-body-panels/#bumper-system-fascia) .
2. Remove the upper radiator air deflector retainers.
3. Remove the wire harness clips at the bumper beam.
4. Remove the upper radiator air deflector.

1. Install the upper radiator air deflector.
2. Install the wire harness clips at the bumper beam.
3. Install the upper radiator air deflector retainers.
4. Install the front bumper upper fascia support. Refer to «Front Bumper Fascia Upper Support Replacement»(/chevrolet/malibu/vi-2006-2008/remont/exterior-body-panels/#bumper-system-fascia) .

1. Disconnect the coolant heater cord from the coolant heater.
2. Remove the coolant heater bolt.
3. Remove the coolant heater.

1. Install the coolant heater.
2. Install the coolant heater bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
3. Connect the coolant heater cord to the coolant heater.

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Disconnect the engine coolant heater cord (1) from the engine coolant heater.
3. Remove the engine coolant heater.
4. Clean the engine coolant heater opening.

1. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the engine coolant heater, if necessary.
2. Install the engine coolant heater. Tighten: Tighten the coolant heater to 60 N.m (44 lb ft).
3. Connect the engine coolant heater cord (1) to the engine coolant heater.
4. Lower the vehicle.
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (LZ4, LZ9)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (GE 47716)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system-ge) or «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2006-2008/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Inspect for leaks.

1. Disconnect the coolant heater cord from the coolant heater.
2. Remove the coolant heater cord clip (2) from the air cleaner.
3. Remove the coolant heater cord clips (1) from the front compartment inner side upper rail.
4. Remove the coolant heater cord.

1. Install the coolant heater cord.
2. Install the coolant heater cord clips (1) to the front compartment inner side upper rail.
3. Install the coolant heater cord clip (2) to the air cleaner.
4. Connect the coolant heater cord to the coolant heater.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Disconnect the engine coolant heater cord (1) from the engine coolant heater.
3. Lower the vehicle.
4. Remove the coolant heater cord clip from the transaxle bracket.
5. Remove the coolant heater cord from the shock tower and the battery tray.

1. Install the coolant heater cord between the shock tower and the battery tray.
2. Install the coolant heater cord clip to the transaxle bracket.
3. Raise and support the vehicle.
4. Connect the engine coolant heater cord (1) to the engine coolant heater.
5. Lower the vehicle.

1. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2006-2008/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
2. Disconnect the engine coolant heater cord from the engine coolant heater.
3. Lower the vehicle.
4. Remove the coolant heater cord clips from the transmission range selector lever cable bracket.
5. Remove the coolant heater cord from between the shock tower and battery tray.

1. Install the coolant heater cord between the shock tower and battery tray.
2. Install the coolant heater cord clips to the transmission range selector lever cable bracket.
3. Raise and support the vehicle.
4. Connect the engine coolant heater cord to the engine coolant heater.
5. Lower the vehicle.

Cooling Fan Control

The engine cooling fan system consists of 2 electrical cooling fans and 3 fan relays. The relays are arranged in a series/parallel configuration that allows the powertrain control module (PCM) or engine control module (ECM) to operate both fans together at low or high speeds. The cooling fans and fan relays receive battery positive voltage from the underhood fuse block. The ground path is provided at G106.

During low speed operation, the PCM/ECM supplies the ground path for the low speed fan relay through the low speed cooling fan relay control circuit. This energizes the cooling fan 1 relay coil, closes the relay contacts, and supplies battery positive voltage from the cool fan 1 fuse through the cooling fan motor supply voltage circuit to the left cooling fan. The ground path for the left cooling fan is through the cooling fan S/P relay and the right cooling fan. The result is a series circuit with both fans running at low speed.

During high speed operation the PCM/ECM supplies the ground path for the cooling fan 1 relay through the low speed cooling fan relay control circuit. After a 3 second delay, the PCM/ECM supplies a ground path for the cooling fan 2 relay and the cooling fan S/P relay through the high speed cooling fan relay control circuit. This energizes the cooling fan 2 relay coil, closes the relay contacts, and provides a ground path for the left cooling fan. At the same time the cooling fan S/P relay coil is energized closing the relay contacts and provides battery positive voltage from the cool fan 2 fuse on the cooling fan motor supply voltage circuit to the right cooling fan. During high speed fan operation, both engine cooling fans have their own ground path. The result is a parallel circuit with both fans running at high speed.

The PCM/ECM commands Low Speed Fans on under the following conditions

1. Engine coolant temperature exceeds approximately 106°C (223°F).
2. When A/C is requested and the ambient temperature is more than 50°C (122°F).
3. A/C refrigerant pressure exceeds 1 310 kPa (190 psi).
4. After the vehicle is shut off if the engine coolant temperature at key-off is more than 140°C (284°F) and system voltage is more than 12 volts. The fans will stay on for approximately 3 minutes.

The PCM/ECM commands High Speed Fans on under the following conditions

1. Engine coolant temperature reaches 110°C (230°F).
2. A/C refrigerant pressure exceeds 1 655 kPa (240 psi).
3. When certain DTCs set

The engine cooling fan system consists of 2 electrical cooling fans and 3 fan relays. The relays are arranged in a series/parallel configuration that allows the powertrain control module (PCM) or engine control module (ECM) to operate both fans together at low or high speeds. The cooling fans and fan relays receive battery positive voltage from the underhood fuse block. The ground path is provided at G106.

During low speed operation, the PCM/ECM supplies the ground path for the low speed fan relay through the low speed cooling fan relay control circuit. This energizes the cooling fan 1 relay coil, closes the relay contacts, and supplies battery positive voltage from the cool fan 1 fuse through the cooling fan motor supply voltage circuit to the left cooling fan. The ground path for the left cooling fan is through the cooling fan S/P relay and the right cooling fan. The result is a series circuit with both fans running at low speed.

During high speed operation the PCM/ECM supplies the ground path for the cooling fan 1 relay through the low speed cooling fan relay control circuit. After a 3 second delay, the PCM/ECM supplies a ground path for the cooling fan 2 relay and the cooling fan S/P relay through the high speed cooling fan relay control circuit. This energizes the cooling fan 2 relay coil, closes the relay contacts, and provides a ground path for the left cooling fan. At the same time the cooling fan S/P relay coil is energized closing the relay contacts and provides battery positive voltage from the cool fan 2 fuse on the cooling fan motor supply voltage circuit to the right cooling fan. During high speed fan operation, both engine cooling fans have their own ground path. The result is a parallel circuit with both fans running at high speed.

The PCM/ECM commands Low Speed Fans on under the following conditions

1. Engine coolant temperature exceeds approximately 106°C (223°F).
2. When A/C is requested and the ambient temperature is more than 50°C (122°F).
3. A/C refrigerant pressure exceeds 1 310 kPa (190 psi).
4. After the vehicle is shut off if the engine coolant temperature at key-off is more than 140°C (284°F) and system voltage is more than 12 volts. The fans will stay on for approximately 3 minutes.

The PCM/ECM commands High Speed Fans on under the following conditions

1. Engine coolant temperature reaches 110°C (230°F).
2. A/C refrigerant pressure exceeds 1 655 kPa (240 psi).
3. When certain DTCs set

Engine Coolant Indicators

TEMP

1. The instrument panel cluster (IPC) illuminates the TEMP indicator when the powertrain control module (PCM) or engine control module (ECM) determines that the coolant temperature is more than 128°C (262°F). The IPC receives a discrete input from the PCM/ECM requesting illumination.
2. The IPC performs the display test at the start of each ignition cycle. The IPC illuminates the TEMP indicator.

Coolant Level Control

The engine cooling system contains an engine coolant level switch to alert the driver in the event of a low coolant level. When the engine coolant level in the coolant recovery reservoir falls below a certain level, the coolant level switch opens. When the body control module (BCM) detects an open or a high voltage level on the coolant level indicator control circuit, for at least 10 seconds, it will send a GM LAN message to the driver information center (DIC) requesting display of the low coolant level message. There is approximately a 10 second delay before the BCM sends the GM LAN message to prevent the message from being displayed, due to coolant sloshing in the surge tank.

Coolant Heater

The optional engine coolant heater (RPO K05) operates using AC external power and is designed to warm the coolant in the engine block area for improved starting in very cold weather -29°C (-20°F). The coolant heater helps reduce fuel consumption when a cold engine is warming up. The unit is equipped with a detachable AC power cord. A weather shield on the cord is provided to protect the plug when not in use.

The cooling systems function is to maintain an efficient engine operating temperature during all engine speeds and operating conditions. The cooling system is designed to remove approximately one-third of the heat produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the radiator until the thermostat opens. This allows the engine to warm quickly.

Cooling Cycle

Coolant flows from the radiator outlet and into the water pump inlet. Some coolant flows from the water pump, to the heater core, then back to the water pump. This provides the passenger compartment with heat and defrost capability as the coolant warms up.

Coolant also flows from the water pump outlet and into the engine block. In the engine block, the coolant circulates through the water jackets surrounding the cylinders where the coolant absorbs heat.

The coolant then flows through the cylinder head gasket openings and into the cylinder heads. In the cylinder heads, the coolant flows through the water jackets surrounding the combustion chambers and valve seats, where the coolant absorbs additional heat.

From the cylinder heads, the coolant flows to the thermostat. The flow of coolant will either be stopped at the thermostat until the engine reaches normal operating temperature, or the coolant will flow through the thermostat and into the radiator where the coolant is cooled. At this point, the coolant flow cycle is completed.

Efficient operation of the cooling system requires proper functioning of all cooling system components. The cooling system consists of the following components.

Coolant

The engine coolant is a solution made up of a 50/50 mixture of DEX-COOL and suitable drinking water. The coolant solution carries excess heat away from the engine to the radiator, where the heat is dissipated to the atmosphere.

Radiator

The radiator is a heat exchanger consisting of a core and 2 tanks. The aluminum core is a tube and fin crossflow design that extends from the inlet tank to the outlet tank. Fins are placed around the outside of the tubes to improve heat transfer to the atmosphere.

The inlet and outlet tanks are a molded, high temperature, nylon reinforced plastic material. A high temperature rubber gasket seals the tank flange edge to the aluminum core. The tanks are clamped to the core with clinch tabs. The tabs are part of the aluminum header at each end of the core.

The radiator also has a drain cock located in the bottom of the end tank. The drain cock unit includes the drain cock and drain cock seal.

Heat is removed from the coolant as the coolant passes through the radiator. The fins on the core transfer heat from the coolant passing through the tubes. Air passing between the fins absorbs the heat and cools the coolant.

Pressure Cap

The pressure cap seals and pressurizes the cooling system. The cap contains a blow off, or pressure valve and a vacuum, or an atmospheric valve

1. The pressure valve is held against the seat by a spring that protects the radiator by relieving pressure that exceeds 15 psi.
2. The vacuum valve is held against the seat by a spring that permits opening of the valve to relieve vacuum created when the cooling system cools. The vacuum, if not relieved, might cause the radiator to collapse.

The pressure cap allows the cooling system pressure to build up when the temperature increases. As the pressure builds, the boiling point of the coolant increases. Therefore, the engine coolant can be safely run at a temperature much higher than the boiling point of the coolant at atmospheric pressure. The hotter the coolant becomes, the faster the heat transfers from the radiator into the cooler air.

The pressure in the cooling system can get too high. When the pressure exceeds the strength of the spring, the pressure valve rises, venting the excess pressure.

As the engine cools, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum causes the vacuum valve to open. This equalizes the pressure in the cooling system with the atmospheric pressure, preventing the radiator from collapsing.

Coolant Recovery System

The coolant recovery system consists of a plastic coolant recovery reservoir and overflow tube. The recovery reservoir is also called a recovery tank or expansion tank. This tank is partially filled with coolant and is connected to the radiator fill neck with the overflow tube. Coolant can flow back and forth between the radiator and the reservoir.

In effect, a cooling system with a coolant recovery reservoir is a closed system. When the pressure within the cooling system gets too high, the pressure valve in the pressure cap will open. This allows the coolant, which has expanded due to heat, to flow through the overflow tube and into the recovery reservoir. As the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling system. This vacuum opens the vacuum valve in the pressure cap, allowing some of the coolant in the reservoir to be siphoned back into the radiator. Under normal operating conditions, no coolant is lost. Although the coolant level in the recovery reservoir goes up and down, the radiator and cooling system are kept full. An advantage to using a coolant recovery reservoir is the elimination of almost all air bubbles from the cooling system. Coolant without bubbles absorbs heat much better than coolant with bubbles.

Air Baffles and Seals

The cooling system uses deflectors, air baffles and air seals to increase cooling system capability. Deflectors are installed under the vehicle to redirect airflow beneath the vehicle and through the radiator to increase engine cooling. Air baffles are also used to direct airflow through the radiator and increase cooling capability. Air seals prevent air from bypassing the radiator and A/C condenser, and prevent recirculation of hot air for better hot weather cooling and A/C condenser performance.

Water Pump

The water pump is a centrifugal vane impeller type pump. The pump consists of a housing with coolant inlet and outlet passages and an impeller. The impeller is a flat plate mounted on the pump shaft with a series of flat or curved blades or vanes. When the impeller rotates, the coolant between the vanes is thrown outward by centrifugal force. The impeller shaft is supported by one or more sealed bearings, which never need to be lubricated. With a sealed bearing, grease cannot leak out, and dirt and water cannot get in.

The water pump circulates coolant throughout the cooling system. The pump is driven by the crankshaft from the drive belt.

Thermostat

The thermostat is a coolant flow control component, whose purpose is to regulate the operating temperature of the engine. The thermostat utilizes a temperature sensitive wax-pellet element, which connects to a valve through a piston. Heating causing the element to expand and exert pressure against a rubber diaphragm. This pressure forces the valve to open. Cooling causes the element to contract. This contraction allows a spring to push the valve closed.

When the coolant temperature is below 91°C (195°F), the thermostat valve remains closed. This prevents circulation of the coolant to the radiator and allows the engine to warm up quickly. After the coolant temperature reaches 91°C (195°F), the thermostat valve will open. The coolant is then allowed to circulate through the thermostat to the radiator where the engine heat is dissipated to the atmosphere. The thermostat also provides a restriction in the cooling system, even after opening. This restriction creates a pressure difference which prevents cavitation at the water pump and forces coolant to circulate through the engine block.

Engine Oil Cooler

The engine oil cooler is a heat exchanger which is located external to the radiator. The oil temperature is cooled by the air passing through the oil cooler fins. The oil pump pumps the oil through the feed line to the oil cooler. The oil flows through the cooler where the air absorbs heat from the oil. The oil is then pumped through the cooler return line to the oil filter and returns to the main oil passage.

Transmission Oil Cooler - Internal

The transmission oil cooler is a heat exchanger that is located inside one of the radiator end tanks. The transmission fluid temperature is regulated by the temperature of the engine coolant in the radiator. The oil pump pumps the fluid through the transmission oil cooler feed line to the oil cooler. The fluid flows through the cooler where the engine coolant absorbs heat from the fluid. The fluid is then pumped through the oil cooler return line back to the transmission.

Transmission Oil Cooler - External

The transmission oil cooler is a heat exchanger that is located external to the radiator. Air passing through the oil cooler fins cools the transmission fluid temperature. Within the transmission system, the oil pump pumps the fluid through the feed line to the oil cooler. The fluid then flows through the cooler where air absorbs heat from the fluid. The fluid is then pumped through the oil cooler return line back to the transmission.

Special Tools

Special Tools Illustration Tool Number/Description J 24460-01 Cooling System Pressure Tester J 26568 Coolant and Battery Fluid Tester J 38185 Hose Clamp Pliers J 42401 Radiator Cap and Surge Tank Test Adapter J 43651 Water Pump Holding Tool

Scheme 20

Scheme 21

Scheme 22

Scheme 23

See also:
• Diagnostic System Check - Vehicle
• Engine Control Module Connector End Views
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor Connections
• Wiring Repairs
• Powertrain Diagnostic Trouble Code (DTC) Type Definitions
• Scan Tool Data List
• Scan Tool Data Definitions
• Scan Tool Output Controls
• Diagnostic Repair Verification
• Engine Control Module Replacement
• Instrument Cluster Description and Operation
• Indicator/Warning Message Description and Operation
• Audible Warnings Description and Operation
• Water Pump Cleaning and Inspection
• Coolant in Combustion Chamber
• Coolant in Engine Oil
• Master Electrical Component List
• Power and Grounding Connector End Views
• Checking Aftermarket Accessories
• Control Module References
• Diagnostic Trouble Code (DTC) List - Vehicle
• Engine Coolant Temperature Sensor Replacement
• Heater Core Replacement
• Engine Coolant/Water in Transmission
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Coolant in Combustion Chamber
• Coolant in Engine Oil
• Lower Engine Noise, Regardless of Engine Speed
• Lower Engine Noise, Regardless of Engine Speed
• Lifting and Jacking the Vehicle
• Draining Fluids and Oil Filter Removal
• Engine Block Assemble
• Capacities - Approximate Fluid
• Draining Fluids and Oil Filter Removal
• Engine Block Assemble
• Water Pump Installation
• Fastener Notice
• Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement
• Front Fender Liner Replacement
• Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Replacement
• Transmission Fluid Checking
• Sealers, Adhesives, and Lubricants
• Air Cleaner Outlet Duct Replacement
• Intake Manifold Cover Replacement
• Generator Replacement (L61)
• Power Steering Pump Replacement
• Intake Manifold Cover Replacement
• Front Bumper Fascia Upper Support Replacement
• DTC P0480 or P0481
• Scan Tool Data List
• Scan Tool Output Controls
• Engine Overheating
• Loss of Coolant
• Engine Fails To Reach Normal Operating Temperature
• Draining and Filling Cooling System (GE 47716)
• Flushing
• Water Pump Replacement (L61)
• Cooling System Leak Testing
• Pressure Cap Testing
• Special Tools