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Hybrid Engine Controls - Repair Instructions Chevrolet Malibu VII

Engine Control Systems 1 illustration ~3638 words

Special Tools

J 38185 Hose Clamp Pliers

Removal Procedure

  1. Disconnect the hybrid battery. Refer to «Hybrid Battery Service Disconnect/Connect»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#hybrid-energy-storage-system-repair-instructions) .
  2. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
  3. Remove the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  4. Reposition the power brake booster vacuum hose (2) clamp at the intake manifold.
  5. Remove the power brake booster vacuum hose from the intake manifold.
  6. Remove the power brake booster vacuum hose from the clamp (2) on the generator control module coolant outlet hose.
  7. Reposition the power brake booster vacuum hose out of the way.
  8. Remove the 2 connector position assurance (CPA) retainers (3).
  9. Disconnect the 2 engine wiring harness electrical connectors (2) from the generator control module.
  10. WAIT at least 5 minutes in order to allow the voltage stored in the generator control module to discharge.
  11. Reposition the generator control module coolant inlet hose clamp (1) at the generator control module using the J 38185 or equivalent.
  12. Remove the generator control module coolant inlet hose (2) from the generator control module.
  13. Remove the generator control module bracket reinforcement bolt (1) and nuts (2).
  14. Remove the generator control module bracket reinforcement (3).
  15. Loosen the generator control module cover integral bolts (1) and remove the cover (2).
  16. The generator control module will have to be checked for voltage potential using a voltmeter. First, verify that the voltmeter works: Set the voltmeter to DC voltage. Measure the vehicle 12-volt battery voltage. The meter should read greater than +12 volts DC.
  17. Now, check the generator control module for voltage potential, in order to ensure that the module has been disabled. Measure from the 36-volt positive terminal (3) to a known good chassis ground. The voltage should be less than 3 volts. Measure from the 12-volt positive terminal (2) to a known good chassis ground. The voltage should be less than 3 volts. Measure from the ground terminal (4) to a known good chassis ground, checking for continuity.
  18. Verify that the generator control module 3-phase cables are disabled. Measure from each phase 1, 2, and 3 connection (1) to a known good chassis ground. The voltage should be less than 3 volts. After verifying that there is no voltage present, the generator control module 3-phase cables can now be removed from the generator control module.
  19. Disconnect the engine wiring harness electrical connectors (1 and 2) from the generator starter.
  20. Reposition the wiring harness out of the way.
  21. Remove the 36-volt terminal block nuts (1) from the generator control module.
  22. Lift up, and reposition the 36-volt terminal block (2), secure the block out of the way. Discard the terminal block seal.
  23. Remove the generator control module 3-phase cable terminal block nuts (1) from the generator control module.
  24. Lift up, and reposition the generator control module 3-phase cable terminal block (2) from the generator control module. Discard the terminal block seal.
  25. Remove the air conditioning (A/C) condenser/evaporator tube clip (1) from the front end upper tie bar reinforcement.
  26. Reposition the A/C condenser/evaporator tube (2) out of the way.
  27. Remove the starter 3-phase cable clip bolt (2) from the oil level indicator tube bracket.
  28. Remove the upper generator starter bolt (1).
  29. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  30. Remove the 2 lower generator starter bolts (1).
  31. Lower the vehicle.
  32. Remove the generator starter (with the generator control module 3-phase cables attached) (3) from the vehicle and place on a clean work surface.
  33. Remove the generator starter cover bolts (1) and cover (2).
  34. Remove the generator control module 3-phase cable bracket bolts (3) and bracket (4).
  35. From inside the generator starter, remove the generator control module 3-phase cable to generator starter nuts.
  36. Remove the rear generator control module 3-phase cable bolts (1).
  37. Remove the generator control module 3-phase cable assembly (2) from the generator starter (1).

Installation Procedure

  1. Install the generator control module 3-phase cable assembly (2) to the NEW generator starter (1).
  2. Inside the generator starter, install the generator control module 3-phase cable to the studs and install the generator starter nuts. Tighten: Tighten the nuts to 8 N.m (71 lb in).
  3. Install the generator control module 3-phase cable bracket (4) and bolts (3). Tighten: Tighten the bolts to 8 N.m (71 lb in).
  4. Install the generator starter cover (2) and bolts (1). Tighten: Tighten the bolts to 5 N.m (44 lb in).
  5. Install the rear generator control module 3-phase cable bolts (1). Tighten: Tighten the bolts to 8 N.m (71 lb in).
  6. Position the generator starter (with the generator control module 3-phase cables attached) (3) to the vehicle and install the upper bolt (1) until snug.
  7. Raise and suitably support the vehicle.
  8. Install the 2 lower generator starter bolts (1) until snug.
  9. Install the generator starter 3-phase cable clip bolt (2) to the oil level indicator tube bracket. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  10. Tighten the generator starter bolts in the sequence shown. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
  11. Position the A/C condenser/evaporator tube (2) to the front end upper tie bar reinforcement.
  12. Install the A/C condenser/evaporator tube clip (1) to the front end upper tie bar reinforcement.
  13. Place a NEW terminal block seal onto the generator control module.
  14. Install the generator control module 3-phase cable terminal block (2) onto the generator control module.
  15. Install the generator control module 3-phase cable terminal block nuts (1) until snug.
  16. Tighten the generator control module 3-phase cable terminal block nuts in the sequence shown. Tighten: Tighten the nuts to 8 N.m (71 lb in).
  17. Place a NEW terminal block seal onto the generator control module.
  18. Unsecure, and position the 36-volt terminal block (2) to the generator control module.
  19. Install the 36-volt terminal block nuts (1) to the generator control module. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  20. Position the engine wiring harness.
  21. Connect the engine wiring harness electrical connectors (1 and 2) to the starter generator.
  22. Place the generator control module cover (2) on top of the generator control module and tighten the bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  23. Install the generator control module bracket reinforcement (3).
  24. Install the generator control module bracket reinforcement bolt (1) and nuts (2). Tighten: Tighten the bolt/nuts to 10 N.m (89 lb in).
  25. Install the generator control module coolant inlet hose (2) to the generator control module.
  26. Position the generator control module coolant inlet hose clamp (1) at the generator control module using the J 38185 or equivalent.
  27. Connect the 2 engine wiring harness electrical connectors (2) to the generator control module.
  28. Install the 2 CPA retainers (3).
  29. Position and install the power brake booster vacuum hose (2) to the intake manifold.
  30. Position the power brake booster vacuum hose clamp at the intake manifold.
  31. Install the power brake booster vacuum hose to the clamp (2) to the generator control module coolant outlet hose.
  32. Install the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  33. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
  34. Connect the hybrid battery. Refer to «Hybrid Battery Service Disconnect/Connect»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#hybrid-energy-storage-system-repair-instructions) .
  35. Using a Tech 2, command an autostart in order to verify that the system is working properly.
  1. Open the hood.
  2. Grasp the generator control module cover by the left side and lift up in order to disengage the cover from the ball studs.
  3. Remove the generator control module cover tab from the battery tray slot.
  4. Remove the generator control module cover (1).
  1. Place the generator control module cover (1) tab into the battery tray slot.
  2. Set the cover over the ball studs and press down on the cover directly over the ball studs in order to secure the cover.
  3. Close the hood.

J 38185 Hose Clamp Pliers

  1. Disconnect the hybrid battery. Refer to «Hybrid Battery Service Disconnect/Connect»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#hybrid-energy-storage-system-repair-instructions) .
  2. Remove the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
  3. Remove the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  4. Reposition the power brake booster vacuum hose (2) clamp at the intake manifold.
  5. Remove the power brake booster vacuum hose from the intake manifold.
  6. Remove the power brake booster vacuum hose from the clamp (2) on the generator control module coolant outlet hose.
  7. Reposition the power brake booster vacuum hose out of the way.
  8. Remove the 2 connector position assurance (CPA) retainers (3).
  9. Disconnect the 2 engine wiring harness electrical connectors (2) from the generator control module.
  10. WAIT at least 5 minutes in order to allow the voltage stored in the generator control module to discharge.
  11. Reposition the generator control module coolant inlet hose clamp (1) at the generator control module using the J 38185 or equivalent.
  12. Remove the generator control module coolant inlet hose (2) from the generator control module.
  13. Remove the generator control module bracket reinforcement bolt (1) and nuts (2).
  14. Remove the generator control module bracket reinforcement (3).
  15. Loosen the generator control module cover integral bolts (1) and remove the cover (2).
  16. The generator control module will have to be checked for voltage potential using a voltmeter. First, verify that the voltmeter works: Set the voltmeter to DC voltage. Measure the vehicle 12-volt battery voltage. The meter should read greater than +12 volts DC.
  17. Now, check the generator control module for voltage potential, in order to ensure that the module has been disabled. Measure from the 36-volt positive terminal (3) to a known good chassis ground. The voltage should be less than 3 volts. Measure from the 12-volt positive terminal (2) to a known good chassis ground. The voltage should be less than 3 volts. Measure from the ground terminal (4) to a known good chassis ground, checking for continuity.
  18. Verify that the generator control module 3-phase cables are disabled. Measure from each phase 1, 2, and 3 connection (1) to a known good chassis ground. The voltage should be less than 3 volts. After verifying that there is no voltage present, the generator control module 3-phase cables can now be removed from the generator control module.
  19. Disconnect the engine wiring harness electrical connectors (1 and 2) from the generator starter.
  20. Reposition the wiring harness out of the way.
  21. Remove the 36-volt terminal block nuts (1) from the generator control module.
  22. Lift up, and reposition the 36-volt terminal block (2), secure the block out of the way. Discard the terminal block seal.
  23. Remove the generator control module 3-phase cable terminal block nuts (1) from the generator control module.
  24. Lift up, and reposition the generator control module 3-phase cable terminal block (2) from the generator control module. Discard the terminal block seal.
  25. Remove the air conditioning (A/C) condenser/evaporator tube clip (1) from the front end upper tie bar reinforcement.
  26. Reposition the A/C condenser/evaporator tube (2) out of the way.
  27. Remove the starter 3-phase cable clip bolt (2) from the oil level indicator tube bracket.
  28. Remove the upper generator starter bolt (1).
  29. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  30. Remove the 2 lower generator starter bolts (1).
  31. Lower the vehicle.
  32. Remove the generator starter (with the generator control module 3-phase cables attached) (3) from the vehicle and place on a clean work surface.
  33. Remove the generator starter cover bolts (1) and cover (2).
  34. Remove the generator control module 3-phase cable bracket bolts (3) and bracket (4).
  35. From inside the generator starter, remove the generator control module 3-phase cable to generator starter nuts.
  36. Remove the rear generator control module 3-phase cable bolts (1).
  37. Remove the generator control module 3-phase cable assembly (2) from the generator starter (1).
  1. Install the a NEW generator control module 3-phase cable assembly (2) to the generator starter (1).
  2. Inside the generator starter, install the generator control module 3-phase cable to the studs and install the generator starter nuts. Tighten: Tighten the nuts to 8 N.m (71 lb in).
  3. Install the generator control module 3-phase cable bracket (4) and bolts (3). Tighten: Tighten the bolts to 8 N.m (71 lb in).
  4. Install the generator starter cover (2) and bolts (1). Tighten: Tighten the bolts to 5 N.m (44 lb in).
  5. Install the rear generator control module 3-phase cable bolts (1). Tighten: Tighten the bolts to 8 N.m (71 lb in).
  6. Position the generator starter (with the generator control module 3-phase cables attached) (3) to the vehicle and install the upper bolt (1) until snug.
  7. Raise and suitably support the vehicle.
  8. Install the 2 lower generator starter bolts (1) until snug.
  9. Install the generator starter 3-phase cable clip bolt (2) to the oil level indicator tube bracket. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  10. Tighten the generator starter bolts in the sequence shown. Tighten: Tighten the bolts to 58 N.m (43 lb ft).
  11. Position the A/C condenser/evaporator tube (2) to the front end upper tie bar reinforcement.
  12. Install the A/C condenser/evaporator tube clip (1) to the front end upper tie bar reinforcement.
  13. Place a NEW terminal block seal onto the generator control module.
  14. Install the generator control module 3-phase cable terminal block (2) onto the generator control module.
  15. Install the generator control module 3-phase cable terminal block nuts (1) until snug.
  16. Tighten the generator control module 3-phase cable terminal block nuts in the sequence shown. Tighten: Tighten the nuts to 8 N.m (71 lb in).
  17. Place a NEW terminal block seal onto the generator control module.
  18. Unsecure, and position the 36-volt terminal block (2) to the generator control module.
  19. Install the 36-volt terminal block nuts (1) to the generator control module. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  20. Position the engine wiring harness.
  21. Connect the engine wiring harness electrical connectors (1 and 2) to the starter generator.
  22. Place the generator control module cover (2) on top of the generator control module and tighten bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  23. Install the generator control module bracket reinforcement (3).
  24. Install the generator control module bracket reinforcement bolt (1) and nuts (2). Tighten: Tighten the bolt/nuts to 10 N.m (89 lb in).
  25. Install the generator control module coolant inlet hose (2) to the generator control module.
  26. Position the generator control module coolant inlet hose clamp (1) at the generator control module using the J 38185 or equivalent.
  27. Connect the 2 engine wiring harness electrical connectors (2) to the generator control module.
  28. Position and install the power brake booster vacuum hose (2) to the intake manifold.
  29. Position the power brake booster vacuum hose clamp at the intake manifold.
  30. Install the power brake booster vacuum hose to the clamp (2) to the generator control module coolant outlet hose.
  31. Install the radiator inlet hose. Refer to «Radiator Inlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  32. Install the drive belt tensioner. Refer to «Drive Belt Tensioner Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) .
  33. Connect the hybrid battery. Refer to «Hybrid Battery Service Disconnect/Connect»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#hybrid-energy-storage-system-repair-instructions) .
  34. Using a Tech 2, command an autostart in order to verify that the system is working properly.

J 38185 Hose Clamp Pliers

  1. Disconnect the hybrid battery. Refer to «Hybrid Battery Service Disconnect/Connect»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#hybrid-energy-storage-system-repair-instructions) .
  2. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  3. Remove the battery tray. Refer to «Battery Tray Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  4. Reposition the power brake booster vacuum hose (2) clamp at the intake manifold.
  5. Remove the power brake booster vacuum hose from the intake manifold.
  6. Remove the power brake booster vacuum hose from the clamp (2) on the generator control module coolant outlet hose.
  7. Reposition the power brake booster vacuum hose out of the way.
  8. Remove the 2 connector position assurance (CPA) retainers (3).
  9. Disconnect the 2 engine wiring harness electrical connectors (2) from the generator control module.
  10. WAIT at least 5 minutes in order to allow the voltage stored in the generator control module to discharge.
  11. Remove the generator control module bracket reinforcement bolt (1) and nuts (2).
  12. Remove the generator control module bracket reinforcement (3).
  13. Reposition the generator control module coolant inlet hose clamp (1) at the generator control module using the J 38185 or equivalent.
  14. Remove the generator control module coolant inlet hose (2) from the generator control module.
  15. Reposition the generator control module coolant outlet hose clamp (1) at the generator control module using the J 38185 or equivalent.
  16. Remove the generator control module coolant outlet hose (2) from the generator control module.
  17. Loosen the generator control module cover integral bolts (1) and remove the cover (2).
  18. The generator control module will have to be checked for voltage potential using a voltmeter. First, verify that the voltmeter works: Set the voltmeter to DC voltage. Measure the vehicle 12-volt battery voltage. The meter should read greater than +12 volts DC.
  19. Check the generator control module for voltage potential, in order to ensure that the module has been disabled. Measure from the 36-volt positive terminal (3) to a known good chassis ground. The voltage should be less than 3 volts. Measure from the 12-volt positive terminal (2) to a known good chassis ground. The voltage should be less than 3 volts. Measure from the ground terminal (4) to a known good chassis ground, checking for continuity.
  20. Verify that the generator control module 3-phase cables are disabled. Measure from each phase 1, 2, and 3 connection (1) to a known good chassis ground. The voltage should be less than 3 volts. After verifying that there is no voltage present, the generator control module 3-phase cables can now be removed from the generator control module.
  21. Remove the 36-volt terminal block nuts (1) from the generator control module.
  22. Lift up, and reposition the 36-volt terminal block (2), secure the block out of the way. Discard the terminal block seal.
  23. Remove the generator control module 3-phase cable terminal block nuts (1) from the generator control module.
  24. Lift up, and reposition the generator control module 3-phase cable terminal block (2), secure the block out of the way. Discard the terminal block seal.
  25. Disconnect the engine wiring harness electrical connector (1) from the transaxle auxiliary pump module.
  26. Remove the generator control module ground strap nut (1) and strap (2) from the module stud.
  27. Remove the engine wiring harness clips (1) from the battery tray bracket studs.
  28. Remove the generator control module nuts (1).
  29. Remove the generator control module (with bracket) (2) from the vehicle.
  30. Place the generator control module assembly on a clean work surface.
  31. Remove the generator control module bracket to module bolts (2). Separate the generator control module (1) from the bracket (3).
  32. If replacing the generator control module. remove the transaxle auxiliary pump control module. Refer to «Auxiliary Fluid Pump Control Module Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-4t45-e-repair-instructions-on-vehicle) .
  1. If the generator control module was replaced. install the transaxle auxiliary pump control module. Refer to «Auxiliary Fluid Pump Control Module Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-trans/#automatic-transaxle-4t45-e-repair-instructions-on-vehicle) .
  2. Position the generator control module (1) to the bracket (3), and install the generator control module bracket to module bolts (2). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  3. Install the generator control module (with bracket) (2) to the vehicle.
  4. Install the generator control module bracket nuts. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  5. Install the generator control module ground strap (2) to the stud and install the ground strap nut (1) to the module. Tighten: Tighten the nut to 10 N.m (89 lb in).
  6. Connect the engine wiring harness electrical connector (1) to the transaxle auxiliary pump.
  7. Place a NEW terminal block seal onto the generator control module.
  8. Install the generator control module 3-phase cable terminal block (2) onto the generator control module.
  9. Install the generator control module 3-phase cable terminal block nuts (1) until snug.
  10. Tighten the generator control module 3-phase cable terminal block nuts in the sequence shown. Tighten: Tighten the nuts to 8 N.m (71 lb in).
  11. Place a NEW terminal block seal onto the generator control module.
  12. Unsecure, and position the 36-volt terminal block (2) to the generator control module.
  13. Install the 36-volt terminal block nuts (1) to the generator control module. Tighten: Tighten the nuts to 10 N.m (89 lb in).
  14. Place the generator control module cover (2) on top of the generator control module and tighten bolts (1). Tighten: Tighten the bolts to 10 N.m (89 lb in).
  15. Install the generator control module coolant outlet hose (2) to the generator control module.
  16. Position the generator control module coolant outlet hose clamp (1) at the generator control module using the J 38185 or equivalent.
  17. Install the generator control module coolant inlet hose (2) to the generator control module.
  18. Position the generator control module coolant inlet hose clamp (1) at the generator control module using the J 38185 or equivalent.
  19. Install the generator control module bracket reinforcement (3).
  20. Install the generator control module bracket reinforcement bolt (1) and nuts (2). Tighten: Tighten the bolt/nuts to 10 N.m (89 lb in).
  21. Connect the 2 engine wiring harness electrical connectors (2) to the generator control module.
  22. Install the 2 CPA retainers (3).
  23. Position and install the power brake booster vacuum hose (2) to the intake manifold.
  24. Position the power brake booster vacuum hose clamp at the intake manifold.
  25. Install the power brake booster vacuum hose to the clamp (2) to the generator control module coolant outlet hose.
  26. Install the battery tray. Refer to «Battery Tray Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  27. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  28. Connect the hybrid battery. Refer to «Hybrid Battery Service Disconnect/Connect»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#hybrid-energy-storage-system-repair-instructions) .
  29. If the generator control module was replaced, program the NEW module. Refer to «Control Module References»(/chevrolet/malibu/vii-2008-2012/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .
  30. Using a Tech 2, command an autostart in order to verify that the system is working properly.

Scheme 1

Scheme 1: Generator Control Module Bracket Reinforcement Replacement
Scheme 1: Generator Control Module Bracket Reinforcement Replacement
CalloutComponent Name
Preliminary Procedure: Remove the generator control module cover. Refer to Generator Control Module Cover Replacement
1Generator Control Module Bracket Reinforcement Fasteners (Qty: 3) CAUTION: Refer to Fastener Caution . Tighten: 10 N.m(89 lb in).
2Generator Control Module Bracket Reinforcement
CAUTION
Refer to Fastener Caution .

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