Home ReviewsRefund
Home/Chevrolet/Malibu/Chevrolet Malibu VII (2008-2012)/Repair manual/Testing & Diagnostics/Engine Controls and Fuel - 3.5l - Repair Instructions
Contents Wiring diagrams Section: Testing & Diagnostics All sections

Engine Controls and Fuel - 3.5l - Repair Instructions Chevrolet Malibu VII

Testing & Diagnostics 8 illustrations ~11947 words

Engine Control Module Replacement

CAUTIONTurn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable, powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent internal control module damage. Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when servicing a control module, using battery booster cables, or when charging the vehicle battery. In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit board. Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module. The replacement control module must be programmed.

Note. It is necessary to record the remaining engine oil life. If the replacement module is not programmed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change.

Removal Procedure

  1. Using a scan tool, retrieve the percentage of remaining engine oil. Record the remaining engine oil life.
  2. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LE5, LE9, LZ4, LZE, or LY7)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  3. Slide the lever locks to the up position in order to release the engine wiring harness electrical connectors.
  4. Disconnect the engine wiring harness electrical connectors (1) from the engine control module (ECM).
  5. Release the retaining tab located in the battery tray using a small screwdriver or other suitable tool.
  6. Remove the ECM by lifting upward after releasing the tab.

Installation Procedure

  1. Slide the ECM into the bracket on the battery tray.
  2. Push down on the ECM until the retaining tab snaps into place.
  3. Connect the engine wiring harness electrical connectors (1) to the ECM.
  4. Slide the lever locks to the down position in order to engage the engine wiring harness electrical connectors.
  5. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LE5, LE9, LZ4, LZE, or LY7)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  6. If a NEW ECM was installed, program the ECM. Refer to «Control Module References»(/chevrolet/malibu/vii-2008-2012/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .

Crankshaft Position System Variation Learn

IMPORTANTThe Crankshaft Position (CKP) system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: An engine replacement A engine control module (ECM) replacement A crankshaft balancer replacement A crankshaft replacement A CKP sensor replacement Any engine repairs which disturb the crankshaft to CKP sensor relationship.
IMPORTANTThe ECM monitors certain component signals to determine if all the conditions are met to continue with the CKP System Variation Learn Procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool displays the signals of the following components: CKP sensors activity-If there is a CKP sensor condition, refer to the applicable DTC that set. Camshaft position (CMP) signal activity-If there is a CMP signal condition, refer to the applicable DTC that set. Engine coolant temperature (ECT)-If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature.
  1. Install a scan tool.
  2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for the applicable DTC that set.
  3. With a scan tool, select the CKP System Variation Learn Procedure and perform the following: Block drive wheels. Set parking brake. DO NOT apply brake pedal. Cycle ignition from OFF to ON. Apply and hold brake pedal for the duration of the procedure. Start and idle engine. Turn the air conditioning (A/C) OFF. The vehicle must remain in Park or Neutral. IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. Accelerate to wide open throttle (WOT) and release when the fuel cut-off occurs.
  4. The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, or another DTC is present, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) and perform the appropriate diagnostic procedure.
  5. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully in order to store the CKP system variation values in the ECM memory.

Description

The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to throttle body coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned.

An engine that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero.

The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.

Conditions for Running the Throttle Learn Procedure

Reset Procedure

  1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set.
  2. Ignition ON, engine OFF.
  3. The vehicle speed sensor (VSS) is 0 km/h (0 mph).

Learn Procedure

  1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0120, P0122, P0123, P0128, P0171, P0172, P0174, P0175, P0201, P0202, P0203, P0204, P0205, P0206, P0220, P0222, P0223, P0300, P0351, P0352, P0353, P0496, P0601, P0604, P0606, P060D, P0641, P0651, P1516, P2101, P2119, P2120, P2122, P2123, P2125, P2127, P2128, P2135, P2138, or P2176 are not set.
  2. The engine speed is between 450-4,000 RPM.
  3. The manifold absolute pressure (MAP) is greater than 5 kPa.
  4. The mass air flow (MAF) is greater than 2 g/s.
  5. The ignition voltage is greater than 10 volts.

Throttle Learn

Reset Procedure (Performed after the throttle body is cleaned or replaced)

  1. Ignition ON, engine OFF, perform the Idle Learn Reset in Module Setup with a scan tool.
  2. Start the engine and monitor the TB Idle Airflow Compensation parameter. The TB Idle Airflow Compensation value should equal 0 percent and the engine should be idling at a normal idle speed.
  3. Clear the DTCs and return to the diagnostic that referred you here.

Learn Procedure (Performed after the ECM is flashed or replaced)

  1. Start and idle the engine for 3 minutes.
  2. With a scan tool, monitor the Desired Idle Speed and the actual Engine Speed.
  3. The ECM will start to learn the new idle cells and Desired Idle Speed should start to decrease.
  4. Ignition OFF for 60 seconds.
  5. Start and idle the engine for 3 minutes.
  6. After the 3 minute run time the engine should be idling normal. NOTE: During the drive cycle the check engine light may come on with idle speed DTCs. If idle speed codes are set, clear codes so the ECM can continue to learn. If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles.
  7. After the drive cycle, the engine should be idling normally. If the engine idle speed has not been learned, turn OFF the ignition for 60 seconds and repeat step 6.
  8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here.
CAUTIONUse care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system.
  1. Drain the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  2. Remove the intake manifold cover, if necessary. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  3. Disconnect the fuel injector wiring harness electrical connector from the engine coolant temperature (ECT) sensor.
  4. Remove the ECT sensor.
CAUTIONReplacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.
  1. Coat the threads of the ECT sensor with sealer. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
  2. Install the ECT sensor. Tighten: Tighten the sensor to 20 N.m (15 lb ft).
  3. Connect the fuel injector wiring harness electrical connector to the ECT sensor.
  4. Install the intake manifold cover, if necessary. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  5. Fill the cooling system. Refer to «Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Disconnect the engine wiring harness electrical connector (1) from the mass airflow (MAF)/intake air temperature (IAT) sensor.
  3. Remove the MAF/IAT sensor screws.
  4. Remove the MAF/IAT sensor.
  5. Remove and discard the MAF/IAT sensor seal.
  1. Install a NEW MAF/IAT sensor seal.
  2. Install the MAF/IAT sensor.
  3. Install the MAF/IAT sensor screws. Tighten: Tighten the screws to 5 N.m (44 lb in).
  4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor.
  5. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
  3. Remove the spark plug wire clip from the MAP sensor bracket, if necessary.
  4. Remove the upper intake manifold bolt.
  5. Remove the MAP sensor bracket (5).
  6. Remove the MAP sensor (6) and seal from the upper intake manifold. Discard the seal.
  1. Lubricate the NEW MAP sensor seal with clean engine oil.
  2. Install the MAP sensor (6) into the upper intake manifold.
  3. Place the MAP sensor bracket (5) into position.
  4. Install the upper intake manifold bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  5. Install the spark plug wire clip to the MAP sensor bracket, if necessary.
  6. Connect the engine wiring harness electrical connector (1) to the MAP sensor.
  7. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .

Special Tools

J 39194-B Heated Oxygen Sensor Wrench

  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  2. Remove the connector position assurance (CPA) retainer (3).
  3. Disconnect the engine wiring harness electrical connector (2) from the heated oxygen sensor (HO2S) electrical connector.
  4. Remove the HO2S electrical connector rosebud clip (1) from the ignition coil bracket.
  5. Remove the HO2S using the J 39194-B .
  1. Coat the threads of the HO2S with anti-seize compound. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
  2. Install the HO2S. Tighten: Tighten the sensor to 42 N.m (31 lb ft) using the J 39194-B .
  3. Connect the engine wiring harness electrical connector (2) to the HO2S electrical connector.
  4. Install the CPA retainer (3).
  5. Install the HO2S electrical connector rosebud clip (1) to the ignition coil bracket.
  6. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .

J 39194-B Heated Oxygen Sensor Wrench

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  2. Remove the connector position assurance (CPA) retainer (1).
  3. Disconnect the engine heated oxygen sensor (HO2S) electrical connector from the engine wiring harness electrical connector (2).
  4. Remove the HO2S (2) using the J 39194-B .
  1. Coat the threads of the HO2S with anti-seize compound. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
  2. Install the HO2S (2). Tighten: Tighten the sensor to 42 N.m (31 lb ft) using the J 39194-B .
  3. Connect the engine HO2S electrical connector to the engine wiring harness electrical connector (2).
  4. Install the CPA retainer (1).
  5. Lower the vehicle.

J 39194-B Heated Oxygen Sensor Wrench

  1. Remove the connector position assurance (CPA) retainer (5).
  2. Disconnect the engine wiring harness electrical connector (4) from the heated oxygen sensor (HO2S) electrical connector (3).
  3. Remove the HO2S rosebud clip from the oil level indicator tube tab.
  4. Remove the HO2S using the J 39194-B .
  1. Coat the threads of the HO2S with anti-seize compound. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
  2. Install the HO2S. Tighten: Tighten the sensor to 42 N.m (31 lb ft) using the J 39194-B .
  3. Connect the engine wiring harness electrical connector (4) to the HO2S electrical connector (3).
  4. Install the CPA retainer (5).
  5. Install the HO2S rosebud clip to the oil level indicator tube tab.

J 39194-B Heated Oxygen Sensor Wrench

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  2. Remove the connector position assurance (CPA) retainer (3).
  3. Disconnect the heated oxygen sensor (HO2S) electrical connector from the engine wiring harness electrical connector (2).
  4. Remove the HO2S (1) using the J 39194-B .
  1. Coat the threads of the HO2S with anti-seize compound. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
  2. Install the HO2S (1). Tighten: Tighten the sensor to 42 N.m (31 lb ft) using the J 39194-B .
  3. Connect the HO2S electrical connector to the engine wiring harness electrical connector (2).
  4. Install the CPA retainer (3).
  5. Lower the vehicle.
  1. Disconnect the accelerator pedal position (APP) sensor electrical connector.
  2. Remove the APP sensor bolts (1).
  3. Remove the APP sensor (2).
  1. Install the APP sensor (2).
  2. Install the APP bolts (1) and tighten to 10 N.m (89 lb in).
  3. Connect the APP sensor electrical connector.
  4. Confirm that the APP sensor connector locking clip is fully secured.
CAUTIONDo not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result. Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces.
  1. Remove the intake manifold cover. Refer «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  3. Disconnect the engine wiring harness electrical connector (2) from the electronic throttle control (ETC).
  4. Remove the heater inlet and outlet pipe nuts (1).
  5. Remove the heater inlet and outlet pipe bracket from the throttle body studs. Reposition the pipes.
  6. Remove the throttle body bolts (9) and nuts (10).
  7. Remove the throttle body (8).
  8. Remove and discard the throttle body gasket (7).
  1. Install a NEW throttle body gasket (7).
  2. Install the throttle body (8).
  3. Install the throttle body bolts (9) and nuts (10). Tighten: Tighten the bolts/nuts to 10 N.m (89 lb in).
  4. Reposition the heater inlet and outlet pipes and install the pipe bracket to the throttle body studs.
  5. Install the heater inlet and outlet pipe nuts (1). Tighten: Tighten the nuts to 10 N.m (89 lb in).
  6. Connect the engine wiring harness electrical connector (2) to the ETC.
  7. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  8. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  9. Perform the Throttle Learn Procedure. Refer to «Throttle/Idle Learn»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

Throttle Body Cleaning

  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) . WARNING: Turn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury. CAUTION: Do not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate.
  2. Inspect the throttle body bore and the throttle plate for deposits. You will need to open the throttle plate in order to inspect all surfaces. CAUTION: Do not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components.
  3. Clean the throttle body bore and the throttle plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 or AC-Delco Carburetor Tune-Up Conditioner, P/N X66-P, or an equivalent product.
  4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  5. Perform the Throttle Learn Procedure. Refer to «Throttle/Idle Learn»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

Fuel Pressure Relief (Without CH 48027-100)

WARNINGRemove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
  1. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  2. Remove the engine cover, if required.
  3. Remove the fuel rail service port cap.
  4. Wrap a shop towel around the fuel rail service port and using a small flat bladed tool, depress (open) the fuel rail test port valve.
  5. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  6. Install the fuel rail service port cap.
  7. Install the engine cover, if required.
  8. Tighten the fuel fill cap.

CH-48027-100 Digital Pressure Gauge

Relief

WARNINGRemove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
  1. Remove the engine cover, if required.
  2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  3. Remove the fuel rail service port cap.
  4. Wrap a shop towel around the fuel rail service port.
  5. Connect the CH-48027-3 (3) to the fuel rail service port.
  6. Connect the CH-48027-2 (2) to the CH-48027-3 (3).
  7. Place the hose on the CH-48027-2 (2) into an approved gasoline container.
  8. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail.
  9. Close the valve on the CH-48027-2 (2).
  10. Remove the hose on the CH-48027-2 (2) from the approved gasoline container.
  11. Disconnect the CH-48027-2 (2) from the CH-48027-3 (3).
  12. Disconnect the CH-48027-3 (3) from the fuel rail service port.
  13. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  14. Install the fuel rail service port cap.
  15. Install the engine cover, if required.
  16. Tighten the fuel fill cap.

CH-48027-100 Digital Pressure Gauge

WARNINGRemove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) or «Fuel Pressure Relief (With CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Connect the CH-48027-1 (1) to the CH-48027-2 (2).
  3. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  4. Perform any tests and/or diagnostics as needed. For the proper usage of the CH-48027-100 , refer to the manufacture's directions.
  1. Relieve the fuel system pressure, if required. Perform the following steps: WARNING: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Wrap a shop towel around the fuel rail service port. Place the hose on the CH-48027-2 (2) into an approved gasoline container. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. Close the valve on the CH-48027-2 (2). Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
  3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (3).
  4. Disconnect the CH-48027-3 (3) from the fuel rail service port.
  5. Install the fuel rail service port cap.
  6. Tighten the fuel fill cap.

Special Tool

J 37088-A Fuel Line Disconnect Tool Set

  1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Remove the retainer from the quick-connect fitting.
  3. Blow dirt out of the fitting using compressed air.
  4. Choose the correct tool from the J 37088-A for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs.
  5. Pull the connection apart.
  6. Use a clean shop towel in order to wipe off the male pipe end.
  7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.
  1. Apply a few drops of clean engine oil to the male pipe end.
  2. Push both sides of the fitting together in order to snap the retaining tabs into place.
  3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
  4. Install the retainer to the quick-connect fitting.

Disconnect Procedure

  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) or «Fuel Pressure Relief (With CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Using compressed air, blow any dirt or debris from around the connection.
  3. This step applies to Bartholomew style connector ONLY. Squeeze the plastic quick connect fitting release tabs.
  4. This step applies to Release Tab style connectors ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting.
  5. This step applies to the Squeeze to Release style connector ONLY. Squeeze where indicated by the arrow shown above on both sides of the plastic ring surrounding the quick connect fitting.
  6. This step applies to the Sliding Retainer style connector ONLY. Release the fitting be pressing on one side of the release tab causing it to push in slightly. If the tab doesn't move try pressing the tab in from the opposite side. The tab will only move in one direction.
  7. This step applies to the Push Down TI style connector ONLY. Release the fitting by pressing on the tab indicate by the arrow.
  8. Pull the connection apart.
  9. Wipe off the male pipe end using a clean shop towel.
  10. Inspect both ends of the fitting for dirt and burrs.
  11. Clean or replace the components as required.

Connect Procedure

WARNINGRefer to Fuel Pipe Fitting Warning .
  1. Apply a few drops of clean engine oil to the male connection end.
  2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
  3. Once installed, pull on both sides of the connection in order to make sure the connection is secure.
  1. J 36850 Transjel Lubricant
  2. J 42960-2 Fuel Flapper Door Holder
  3. J 45004 Fuel Tank Drain Hose

Draining

WARNINGNever drain or store fuel in an open container. Always use an approved fuel storage container in order to reduce the chance of fire or explosion.
WARNINGPlace a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury.
  1. Remove the fuel filler cap.
  2. Install the J 42960-2 into the fuel fill pipe in order to hold the door open.
  3. Insert the J 45004 into the fuel tank until the hose reaches the bottom of the fuel tank.
  4. Use an hand or air operated pump device in order to drain as much fuel through the fuel fill pipe as possible.

J 45722 Fuel Sender Lock Ring Wrench

Note. Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order the avoid possible system contamination.

  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) or «Fuel Pressure Relief (With CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Drain the fuel tank. Refer to «Fuel Tank Draining (Without E-85)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  3. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  4. Disconnect the fuel tank fuel pump module wiring harness electrical connector (1) from body wiring harness electrical connector (2).
  5. Remove the body wiring harness electrical connector clip (3) from the EVAP canister.
  6. Disconnect the body wiring harness electrical connector (2) from the rear antilock brake system (ABS) wiring harness electrical connector (1).
  7. Remove the rear ABS wiring harness electrical connector (3) clip from the EVAP canister.
  8. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  9. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  10. Cap the chassis fuel and EVAP pipes in order to prevent possible fuel and/or EVAP system contamination.
  11. Loosen the fuel fill pipe hose clamp (3) at the fuel tank.
  12. Separate the fuel fill pipe hose from the fuel tank.
  13. Disconnect the fuel tank fill EVAP emission pipe quick connect fitting (2) from the fuel tank vent pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  14. Place a jackstand under the muffler assembly.
  15. With the aid of an assistant, separate the muffler insulators (1) from the underbody hangers.
  16. Slowly lower the muffler assembly allowing it to rest on the jackstand. If this is not possible, remove the muffler assembly. Refer to «Exhaust Muffler Replacement (LZ4)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) .
  17. Have assistants support either side of the fuel tank.
  18. Remove fuel tank strap bolts and straps.
  19. Place a suitable adjustable jack under the fuel tank, and have the assistants rest the fuel tank on the adjustable jack.
  20. If applicable, in order to clear the muffler assembly, slowly lower the right side of the fuel tank.
  21. Once the tank is clear of the right frame rail, lower the fuel tank down and remove forward toward the right side of the vehicle.
  22. If replacing the fuel tank, proceed to the disassembly procedure, if not proceed to the Installation Procedure.

Disassembly Procedure

  1. Disconnect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) from the fuel pressure sensor and the module.
  2. Disconnect the fuel tank fuel pump module wiring harness electrical connector (1) from the EVAP canister vent solenoid.
  3. Disconnect the fuel tank vent pipe quick connect fitting (1) from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  4. Disconnect the fuel tank vent pipe quick connect fittings (3, 4) from the module. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  5. Remove the EVAP emission canister purge pipe from the retaining features (3) built into the fuel tank.
  6. Remove the fuel tank fuel pump module wiring harness from the retaining features (5) built into the fuel tank.
  7. Remove the fuel tank vent pipe from the retaining features (1) built into the fuel tank.
  8. Remove the fuel feed pipe from the retaining features (2, 4) built into the fuel tank.
  9. Insert and gently push a small flat-bladed tool between the EVAP canister vent solenoid and the retaining bracket, disengaging the retaining tab (1).
  10. Remove the EVAP canister bolt.
  11. Remove the fuel tank fuel pump module wiring harness from around the EVAP canister.
  12. Remove the EVAP canister and EVAP canister vent solenoid as an assembly.
  13. Remove the fuel tank fuel pump module wiring harness.
  14. Remove the fuel tank vent pipe from the fuel tank.
  15. Install the J 45722 to the fuel pump module lock ring.
  16. Using the J 45722 and a long breaker-bar, rotate the lock ring in a counterclockwise direction in order to unlock the lock ring.
  17. Remove the J 45722 from the fuel pump module lock ring.
  18. Lift the fuel pump module up slightly in order to disconnect the fuel tank vent pipe quick connect fitting (1) from the module cover. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  19. Raise the fuel pump module up from the fuel tank. Tilt the module in order to allow the fuel level sensor arm and float to clear the module opening.
  20. Remove the fuel pump module.
  21. Remove and discard the fuel pump module seal.
  22. Remove the fuel tank shield retainers and shield.
  23. Clean the fuel pump module sealing surfaces.

Assembly Procedure

WARNINGIn order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

Note. Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW fuel pump module. Inspect the lock ring for flatness as best as possible. If the lock ring is warped, replace the fuel pump module.

  1. Install the fuel tank shield and retainers.
  2. Clean any contamination from the male pipe ends of the fuel pump module.
  3. Place a NEW fuel tank module seal onto the fuel tank.
  4. Insert the fuel pump module into the fuel tank allowing the sensor arm and float to clear the module opening.
  5. Lower the module down into the fuel tank until the fuel tank vent pipe quick connect fitting can be connected.
  6. Connect the fuel tank vent pipe quick connect fitting (1) at the module cover. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  7. Press the fuel tank module downward.
  8. Install the J 45722 to the fuel pump module lock ring.
  9. Using the J 45722 and a long breaker-bar, rotate the lock ring in a clockwise direction in order the lock the lock ring.
  10. Remove the J 45722 from the fuel pump module lock ring.
  11. Install the EVAP canister and the EVAP canister vent solenoid as an assembly. Slide the EVAP canister vent solenoid onto the fuel tank bracket until the retaining tab is engaged.
  12. Install the EVAP canister bolt. Tighten: Tighten the bolt to 3.5 N.m (31 lb in).
  13. Install the fuel tank fuel pump module wiring harness.
  14. Connect the fuel tank fuel pump module wiring harness electrical connector (1) to the EVAP canister vent solenoid.
  15. Connect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) to the fuel pressure sensor and the module.
  16. Install the fuel tank vent pipe to the fuel tank.
  17. Connect the fuel tank vent pipe quick connect fitting (1) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  18. Connect the fuel tank vent pipe quick connect fittings (3, 4) to the module. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  19. Install the fuel feed pipe to the retaining features (2, 4) built into the fuel tank.
  20. Install the fuel tank vent pipe to the retaining features (1) built into the fuel tank.
  21. Install the fuel tank fuel pump module wiring harness to the retaining features (5) built into the fuel tank.
  22. Install the EVAP emission canister purge pipe to the retaining features (3) built into the fuel tank.
  1. Have assistants support either side of the fuel tank.
  2. If applicable, begin to install the right side of the fuel tank over the muffler assembly.
  3. If applicable, raise the right side of the fuel tank into position inboard of the right frame rail. Use care in feeding the fuel feed, EVAP line wiring harness over the muffler assembly.
  4. If applicable and the muffler assembly was removed, have assistants raise the fuel tank into position.
  5. Install fuel tank straps and bolts. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  6. Raise the muffler assembly into position if applicable, otherwise install the muffler assembly. Refer to «Exhaust Muffler Replacement (LZ4)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) .
  7. With the aid of an assistant, install the muffler insulators (1) to the underbody hangers.
  8. Remove the jackstand from under the muffler assembly.
  9. Install the fuel fill pipe hose to the fuel tank.
  10. Connect the fuel tank fill EVAP emission pipe quick connect fitting (2) to the fuel tank vent pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  11. Tighten the fuel fill pipe hose clamp (3) at the fuel tank. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  12. Remove the caps from the fuel and EVAP pipes.
  13. Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  14. Connect the fuel tank fuel feed pipe quick connect fitting (1) to the chassis fuel feed pipe (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  15. Install the rear ABS wiring harness electrical connector (2) clip to the EVAP canister.
  16. Connect the body wiring harness electrical connector (1) to the rear ABS wiring harness electrical connector (2).
  17. Install the body wiring harness electrical connector clip (3) to the underbody.
  18. Connect the fuel tank fuel pump module wiring harness electrical connector (1) to the body wiring harness electrical connector (2).
  19. Lower the vehicle.
  20. Refill the fuel tank.
  21. Tighten the fuel fill cap.
  22. Inspect for leaks. Turn ON the ignition, with the engine OFF for 10 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.

J 45722 Fuel Sender Lock Ring Wrench

  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Disconnect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) from the fuel pressure sensor if equipped, and the module.
  3. Disconnect the fuel tank vent pipe quick connect fittings (3, 4) from the module. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  4. Install the J 45722 to the fuel pump module lock ring.
  5. Using the J 45722 and a long breaker-bar, rotate the lock ring in a counterclockwise direction in order to unlock the lock ring.
  6. Remove the J 45722 from the fuel pump module lock ring.
  7. Lift the fuel pump module up slightly in order to disconnect the fuel tank vent pipe quick connect fitting (1) from the module cover. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  8. Raise the fuel pump module up from the fuel tank. Tilt the module in order to allow the fuel level sensor arm and float to clear the module opening.
  9. Remove the fuel pump module.
  10. Remove and discard the fuel pump module seal.
  11. Clean the fuel pump module sealing surfaces.
WARNINGDrain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container

Note. Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped. Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW fuel pump module. Inspect the lock ring for flatness as best as possible. If the lock ring is warped, replace the fuel pump module.

  1. Clean any contamination from the male pipe ends of the fuel pump module.
  2. Place a NEW fuel tank module seal onto the fuel tank.
  3. Insert the fuel pump module into the fuel tank allowing the sensor arm and float to clear the module opening.
  4. Lower the module down into the fuel tank until the fuel tank vent pipe quick connect fitting can be connected.
  5. Connect the fuel tank vent pipe quick connect fitting (1) at the module cover. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  6. Press the fuel tank module downward.
  7. Install the J 45722 to the fuel pump module lock ring.
  8. Using the J 45722 and a long breaker-bar, rotate the lock ring in a clockwise direction in order the lock the lock ring.
  9. Remove the J 45722 from the fuel pump module lock ring.
  10. Connect the fuel tank vent pipe quick connect fittings (3, 4) to the module. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  11. Connect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) to the fuel pressure sensor if equipped, and the module.
  12. Install the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Disconnect the fuel tank fuel pump module wiring harness electrical connector (2) from the fuel tank pressure sensor.
  3. Gently pull upward in order to remove the fuel tank pressure sensor from the fuel tank module.
  1. Lightly lubricate the sensor seal with clean engine oil.
  2. Press the sensor down fully into the fuel tank module.
  3. Connect the fuel tank fuel pump module wiring harness electrical connector (1) to the fuel tank pressure sensor.
  4. Install the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .

Scheme 51

Scheme 51: Fuel Tank Pressure Sensor Replacement (NU6)
Scheme 51: Fuel Tank Pressure Sensor Replacement (NU6)
CalloutComponent Name
Preliminary Procedure: Remove the fuel tank. Refer to Fuel Tank Replacement .
1Fuel Pressure Sensor Procedure: Disconnect the electrical connector.
  1. Remove the fuel tank module assembly. Refer to «Fuel Tank Module Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
  2. Remove the fuel level sensor wiring harness from the clip (2) on the module.
  3. Disconnect the fuel level sensor electrical connector from the pump module electrical connector.
  4. Push the tab (1) on the sensor in towards the sensor and remove the level sensor from the module alignment feature (3).
  1. Connect the fuel level sensor electrical connector to the pump module electrical connector.
  2. Align the tab opening on the rear of the fuel level senor with the module alignment feature (3).
  3. Press the tab (1) on the sensor out away from the sensor securing the sensor to the module.
  4. Install the fuel level sensor wiring harness to the clip (2) on the module.
  5. Install the fuel tank module assembly. Refer to «Fuel Tank Module Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

Note. Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order the avoid possible system contamination.

  1. Remove the fuel fill cap.
  2. Drain the fuel tank. Refer to «Fuel Tank Draining (Without E-85)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  3. Remove the fuel tank fill pipe bolts (1) from the fuel tank fill pipe housing.
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  5. Remove the fuel tank fill pipe bolt (2) from the underbody side rail.
  6. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  7. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  8. Cap the chassis fuel and EVAP pipes in order to prevent possible fuel and/or EVAP system contamination.
  9. Loosen the fuel fill pipe hose clamp (3) at the fuel tank.
  10. Separate the fuel fill pipe hose from the fuel tank.
  11. Disconnect the fuel tank fill EVAP emission pipe quick connect fitting (2) from the fuel tank vent pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  12. Remove the fuel tank fill pipe.
  1. Install the fuel tank fill pipe.
  2. Install the fuel fill pipe hose to the fuel tank.
  3. Connect the fuel tank fill EVAP emission pipe quick connect fitting (2) to the fuel tank vent pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  4. Tighten the fuel fill pipe hose clamp (3) at the fuel tank. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  5. Remove the caps from the fuel and EVAP pipes.
  6. Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  7. Connect the fuel tank fuel feed pipe quick connect fitting (1) to the chassis fuel feed pipe (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  8. Install the fuel tank fill pipe bolt (2) to the underbody side rail. Tighten: Tighten the bolt to 9 N.m (80 lb in).
  9. Lower the vehicle.
  10. Install the fuel tank fill pipe bolts (1) to the fuel tank fill pipe housing. Tighten: Tighten the bolt to 1.5 N.m (13 lb in).
  11. Refill the fuel tank.
  12. Tighten the fuel fill cap.
  13. Inspect for leaks. Turn ON the ignition, with the engine OFF for 10 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) or «Fuel Pressure Relief (With CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  3. Remove the fuel feed and evaporative emission (EVAP) clip (1) from the manifold absolute pressure (MAP) sensor bracket.
  4. Disconnect the fuel feed pipe quick connect fitting (3) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  5. Disconnect the EVAP pipe quick connect fitting (2) from the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  6. Cap the fuel rail pipe and the EVAP purge solenoid in order to prevent possible fuel and/or EVAP system contamination.
  7. Remove the brake, fuel, and EVAP pipe clips (1, 2) from the studs on the front of dash.
  8. Remove the brake pipes from the clips.
  9. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  10. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  11. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  12. Cap the chassis fuel and EVAP pipes in order the prevent possible fuel and/or EVAP system contamination.
  13. Remove the brake, fuel and EVAP pipe retainers (5) from the underbody studs.
  14. Remove the brake pipes from the retainers.
  15. Remove the fuel feed/EVAP pipe assembly from the vehicle.
  16. Place the pipe assembly on a work bench.
  17. Open and remove the upper fuel feed/EVAP pipe retainer (3).
  18. Open and remove the front of dash fuel feed/EVAP pipe retainers (4).
  19. Open and remove the underbody retainers (5).
  20. Replace any retainers as necessary.
  1. Install and close the underbody retainers (5).
  2. Install and close the front of dash fuel feed/EVAP pipe retainers (4).
  3. Install and close the upper fuel feed/EVAP pipe retainer (3).
  4. Position the fuel feed/EVAP pipe assembly to the vehicle.
  5. Install the brake pipes to the retainers.
  6. Install the brake, fuel and EVAP pipe retainers (5) to the underbody studs.
  7. Remove the caps from the chassis fuel and EVAP pipes.
  8. Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  9. Connect the fuel tank fuel feed pipe quick connect fitting (1) to the chassis fuel feed pipe (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  10. Lower the vehicle.
  11. Install the brake pipes to the clips.
  12. Install the brake, fuel, and EVAP pipe clips (1, 2) to the studs on the front of dash.
  13. Remove the caps from the fuel rail pipe and the EVAP purge solenoid.
  14. Connect the EVAP pipe quick connect fitting (2) to the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  15. Connect the fuel feed pipe quick connect fitting (3) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  16. Install the fuel feed and EVAP pipe clip (1) to the MAP sensor bracket.
  17. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  18. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LE5, LE9, LZ4, LZE, or LY7)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  19. Tighten the fuel fill cap.
  20. Inspect for leaks. Turn ON the ignition, with the engine OFF for 10 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.

Fuel System Cleaning

IMPORTANTIf the fuel filter is plugged, the fuel tank should be inspected internally and cleaned if necessary.
  1. Remove the fuel pump module assembly. Refer to «Fuel Tank Fuel Pump Module Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
  2. Inspect the fuel pump module strainer. Replace the pump module assembly if the fuel strainer is contaminated.
  3. Flush the fuel tank with hot water.
  4. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is complete.
  5. Allow the tank to dry completely before reassembly.
  6. Disconnect the fuel feed pipe at the engine fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
  7. Clean the fuel pipes by applying air pressure in the opposite direction of the fuel flow.
  8. Connect the fuel feed pipe to the engine fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
  9. Install the fuel pump module assembly. Refer to «Fuel Tank Fuel Pump Module Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
WARNINGIn order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.
CAUTIONCap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages.

An 8-digit identification number is stamped on the fuel rail. Refer to this number if servicing or part replacement is required.

  1. Disconnect the fuel feed pipe quick connect fitting from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Remove the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  3. Disconnect the fuel injector wiring harness electrical connector from the engine coolant temperature (ECT) sensor.
  4. Disconnect the fuel injector wiring harness electrical connector from the camshaft position (CMP) sensor.
  5. Remove the fuel injector wiring harness electrical connector bracket bolt from the intake manifold.
  6. Remove the fuel rail bolts.
  7. Remove the fuel rail (1).
  8. Remove the fuel injector O-ring seal from the spray tip end of each injector, if the fuel rail was removed for other purposes.
  9. If replacing the fuel rail proceed to the disassembly procedure, otherwise proceed to the Installation Procedure.
  1. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  2. Remove the fuel injector wiring harness retainers from the fuel rail.
  3. Remove the fuel injector wiring harness.
  4. Remove the fuel injector retainers (1).
  5. Remove the fuel injectors (3).
  6. Remove the fuel injector upper (2) and lower (4) O-ring seals.
  1. Lubricate the NEW injector O-ring seals with clean engine oil.
  2. Install the NEW fuel injector upper (2) and lower (4) O-ring seals.
  3. Install the fuel injectors (3).
  4. Instal the fuel injector retainers (1).
  5. Position the fuel injector wiring harness.
  6. Install the fuel injector wiring harness retainers to the fuel rail.
  7. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
CAUTIONUse care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination. Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components. Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.
  1. Install NEW fuel injector O-ring seals onto the spray tip end of each injector, if the fuel rail was removed for other purposes.
  2. Install the fuel rail (1).
  3. Install the fuel rail bolts. Tighten: Tighten the bolts to 10 N.m (89 lb in).
  4. Align the bracket pin to the hole in the lower intake manifold.
  5. Install the fuel injector wiring harness electrical connector bracket bolt to the intake manifold. Tighten: Tighten the bolt to 14 N.m (10 lb ft).
  6. Connect the fuel injector wiring harness electrical connector to the CMP sensor.
  7. Connect the fuel injector wiring harness electrical connector to the ECT sensor.
  8. Install the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  9. Connect the fuel feed pipe quick connect fitting to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  10. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LE5, LE9, LZ4, LZE, or LY7)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  11. Tighten the fuel fill cap.
  12. Inspect for leaks. Turn ON the ignition, with the engine OFF for 10 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition for 10 seconds. Inspect for fuel leaks.
CAUTIONUse care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.

Note. If the fuel injectors are found to be leaking, the engine oil may be contaminated with fuel.

  1. Remove the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Remove the fuel injector retainers (1).
  3. Remove the fuel injectors (3).
  4. Remove the fuel injector upper (2) and lower (4) O-ring seals.

Note. The fuel injector assembly is stamped with a part number identification. Be sure to use the correct part number when ordering replacement fuel injectors.

  1. Lubricate the NEW injector O-ring seals with clean engine oil.
  2. Install the NEW fuel injector upper (2) and lower (4) O-ring seals.
  3. Install the fuel injectors (3).
  4. Instal the fuel injector retainers (1).
  5. Install the fuel rail. Refer to «Fuel Injection Fuel Rail Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  1. J 37287 Fuel Line Shut-Off Adapters
  2. J 35800-A Fuel Injector Cleaner
  3. J 42873-1 3/8 Fuel Line Shut-Off Valve
  4. J 42873-2 5/16 Return Pipe Shut-Off Valve
  5. J 42964-1 3/8 Fuel Pipe Shut-Off Valve
  6. J 42964-2 5/16 Fuel Pipe Shut-Off Valve
CAUTIONGM Upper Engine and Fuel Injector Cleaner is the only injector cleaning agent recommended. DO NOT USE OTHER CLEANING AGENTS AS THEY MAY CONTAIN METHANOL, WHICH CAN DAMAGE FUEL SYSTEM COMPONENTS. Under NO circumstances should the GM Upper Engine and Fuel Injector Cleaner be added to the vehicle fuel tank, as it may damage the fuel pump and other system components. Do not exceed the recommended cleaning solution concentration. Higher concentrations may damage fuel system components. Testing has demonstrated that exceeding the recommended cleaning solution concentration does not improve the effectiveness of this procedure.

Note. Vehicles with less than 160 km (100 mi) on the odometer should not have the injectors cleaned. These vehicles should have the injectors replaced.

  1. Obtain J 35800-A (2).
  2. For 4, 5, and 6 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline.
  3. For 8 cylinder engines, empty two of the 30 ml (1 oz) reservoirs of the GM Upper Engine and Fuel Injector Cleaner twin reservoir container into the J 35800-A , injector cleaning tank, then add 420 ml (14 oz) of regular unleaded gasoline. If you are using any other brand of cleaning tank, you will need a total of 60 ml (2 oz) of GM Upper Engine and Fuel Injector Cleaner mixed with 420 ml (14 oz) of regular unleaded gasoline. This procedure will need to be repeated for an 8 cylinder engine. The 8 cylinder engines receive 960 ml total fluid-120 ml (4 oz) of GM Upper Engine and Fuel Injector Cleaner and 840 ml (28 oz) of gasoline.
  4. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool.
  5. Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped.
  6. Disconnect the fuel feed and return line, if equipped, at the fuel rail. Plug the fuel feed and return line, if equipped, coming off the fuel rail with J 37287 , or J 42964-1 , and J 42964-2 or J 42873-1 , and J 42873-2 as appropriate for the fuel system.
  7. Connect the J 35800-A to the vehicle fuel rail.
  8. Pressurize the J 35800-A to 510 kPa (75 psi).
  9. Start and idle the engine until it stalls due to lack of fuel. This should take approximately 15-20 minutes.
  10. Turn the ignition to the OFF position.
  11. Injectors should be flow-tested at this point. If further cleaning is needed, a repeat of the above procedure should be done. When the injector restriction returns to zero, proceed to step 12.
  12. Disconnect the J 35800-A from the fuel rail.
  13. Reconnect the vehicle fuel pump relay and oil pressure switch connector, if equipped.
  14. Remove the J 37287 , or J 42964-1 and J 42964-2 , or J 42873-1 and J 42873-2 and reconnect the vehicle fuel feed and return lines.
  15. Start and idle the vehicle for an additional two minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines.
  16. Pour the entire contents of GM Fuel System Treatment Plus, into a nearly empty tank and advise the customer to refuel with up to 76 L (20 gal) of fuel. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-specifications__adhesives-fluids-lubricants-and-sealers) .
  17. Advise the customer to use only a Top Tier Detergent gasoline and to add a bottle of GM Fuel System Treatment Plus to the fuel tank at every oil change. Regular use of GM Fuel System Treatment Plus should keep the customer from having to repeat the injector cleaning procedure.
  18. Road test the vehicle to verify that the customer concern has been corrected.
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  2. Disconnect the engine wiring harness electrical connector (1) from the evaporative emission (EVAP) canister purge solenoid.
  3. Disconnect the EVAP pipe quick connect fitting (2) from the EVAP canister purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  4. Remove the EVAP canister purge solenoid bolt (1).
  5. Remove the EVAP canister purge solenoid (2) from the upper intake manifold.
  6. Remove and discard the EVAP canister purge solenoid O-ring seal (3).
  1. Install a NEW EVAP canister purge solenoid O-ring seal (3) to the upper intake manifold.
  2. Install the EVAP canister purge solenoid (2) to the upper intake manifold.
  3. Install the EVAP canister purge solenoid bolt (1). Tighten: Tighten the bolt to 16 N.m (12 lb ft).
  4. Connect the EVAP pipe quick connect fitting (2) to the EVAP canister purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  5. Connect the engine wiring harness electrical connector (1) to the EVAP canister purge solenoid.
  6. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  2. Place a jackstand under the muffler assembly.
  3. With the aid of an assistant, separate the muffler insulators (1) from the underbody hangers.
  4. Slowly lower the muffler assembly allowing it to rest on the jackstand.
  5. Loosen the fuel fill pipe hose clamp (3) at the fuel tank.
  6. Drain the fuel tank if over 3/4 (75 percent) full. Refer to «Fuel Tank Draining (Non E-85)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-repair-instructions) .
  7. Separate the fuel fill pipe hose from the fuel tank.
  8. Disconnect the fuel tank fill evaporative emission (EVAP) pipe quick connect fitting (2) from the fuel tank fill EVAP emission pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  9. Loosen, DO NOT REMOVE the left side fuel tank strap (2) bolts.
  10. Support the fuel tank with a suitable adjustable jackstand.
  11. Loosen, DO NOT REMOVE the right side front fuel tank strap (1) bolt.
  12. Remove the right side rear fuel tank strap bolt.
  13. Using the adjustable jack, lower the right side of the fuel tank enough to access the EVAP canister vent solenoid valve.
  14. Disconnect the fuel tank fuel pump wiring harness electrical connector (1) from the EVAP canister vent solenoid valve.
  15. Disconnect the EVAP canister line quick connect fitting (2) from the EVAP canister vent solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  16. Insert and gently push a small flat-bladed tool between the EVAP canister vent solenoid and the retaining bracket, disengaging the retaining tab (1).
  17. Slide the EVAP canister vent solenoid valve toward the rear of the vehicle.
  1. Slide the EVAP canister vent solenoid valve onto the bracket on the fuel tank.
  2. Slide the EVAP canister vent solenoid valve toward the front of the vehicle.
  3. Connect the EVAP canister line quick connect fitting (2) to the EVAP canister vent solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  4. Connect the fuel tank fuel pump wiring harness electrical connector (1) to the EVAP canister vent solenoid valve.
  5. Using the adjustable jack, raise the right side of the fuel tank.
  6. Install the right side rear fuel tank strap (1) bolt.
  7. Tighten the left side fuel tank strap (2) bolts.
  8. Tighten the right side front fuel tank strap bolt. Tighten: Tighten the bolts to 20 N.m (15 lb ft).
  9. Remove the support from the fuel tank.
  10. Install the fuel fill pipe hose to the fuel tank.
  11. Connect the fuel tank fill EVAP emission pipe quick connect fitting (2) to the fuel tank fill EVAP emission pipe (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  12. Tighten the fuel fill pipe hose clamp (3) at the fuel tank. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  13. Raise the muffler assembly into position.
  14. With the aid of an assistant, install the muffler insulators (1) to the underbody hangers.
  15. Remove the jackstand from under the muffler assembly.
  16. Lower the vehicle.
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (Without CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions__fuel-pressure-relief-without-ch-48027-100) or «Fuel Pressure Relief (With CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle)
  3. Disconnect the fuel feed pipe quick connect fitting (3) from the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  4. Disconnect the EVAP pipe quick connect fitting (2) from the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  5. Cap the fuel rail pipe and the EVAP purge solenoid in order to prevent possible fuel and/or EVAP system contamination.
  6. Remove the brake, fuel, and EVAP pipe clips (1, 2) from the studs on the front of dash.
  7. Remove the brake pipes from the clips.
  8. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  9. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  10. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  11. Cap the chassis fuel and EVAP pipes in order to prevent possible fuel and/or EVAP system contamination.
  12. Remove the brake, fuel and EVAP pipe retainers (5) from the underbody studs.
  13. Remove the brake pipes from the retainers.
  14. Remove the fuel feed/EVAP pipe assembly from the vehicle.
  15. Place the pipe assembly on a work bench.
  16. Open and remove the upper fuel feed/EVAP pipe retainer (3).
  17. Open and remove the front of dash fuel feed/EVAP pipe retainers (4).
  18. Open and remove the underbody retainers (5).
  19. Replace any retainers as necessary.
  1. Install and close the underbody retainers (5).
  2. Install and close the front of dash fuel feed/EVAP pipe retainers (4).
  3. Install and close the upper fuel feed/EVAP pipe retainer (3).
  4. Position the fuel feed/EVAP pipe assembly from the vehicle.
  5. Install the brake pipes to the retainers.
  6. Install the brake, fuel and EVAP pipe retainers (5) to the underbody studs.
  7. Remove the caps from the chassis fuel and EVAP pipes.
  8. Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  9. Connect the fuel tank fuel feed pipe quick connect fitting (1) to the chassis fuel feed pipe (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  10. Lower the vehicle.
  11. Install the brake pipes to the clips.
  12. Install the brake, fuel, and EVAP pipe clips (1, 2) to the studs on the front of dash.
  13. Remove the caps from the fuel rail pipe and the EVAP purge solenoid.
  14. Connect the EVAP pipe quick connect fitting (2) to the EVAP purge solenoid. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  15. Connect the fuel feed pipe quick connect fitting (3) to the fuel rail. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  16. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle)
  17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection (LE5, LE9, LZ4, LZE, or LY7)»(/chevrolet/malibu/vii-2008-2012/remont/charging-system/#battery-charging-system-and-starting-system) .
  18. Tighten the fuel fill cap.
  19. Inspect for leaks. Turn OFF the ignition, with the engine OFF for 10 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Disconnect the fuel tank vent pipe quick connect fitting (1) from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  3. Disconnect the evaporative emission (EVAP) canister pipe quick connect fitting (2) from the EVAP canister vent solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  4. Remove the EVAP canister purge pipe from the retaining feature (3) built into the fuel tank.
  5. Disconnect the fuel pressure sensor electrical connector from the canister, if equipped.
  6. Reposition the fuel tank fuel pump wiring harness from around the EVAP canister.
  7. Remove the EVAP canister bolt.
  8. Slide up and remove the EVAP canister.
  1. Position and install the EVAP canister.
  2. Install the EVAP canister bolt. Tighten: Tighten the bolt 3.5 N.m (31 lb in).
  3. Position the fuel tank fuel pump wiring harness around the EVAP canister.
  4. Connect the fuel pressure sensor electrical connector at the canister, if equipped.
  5. Install the EVAP canister purge pipe to the retaining feature (3) built into the fuel tank.
  6. Connect the EVAP canister pipe quick connect fitting (2) to the EVAP canister vent solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  7. Connect the EVAP canister vent pipe quick connect fitting (1) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  8. Install the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .

J 41413 EVAP Pressure and Purge Station

Inspection Procedure

  1. Turn OFF the ignition.
  2. Remove the EVAP canister purge valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  3. Lightly tap the EVAP canister purge valve on a hard surface.
  4. Inspect for carbon particles exiting either of the vacuum ports. If no carbon particles were detected, but a blockage was detected during a diagnostic procedure, install the original EVAP canister purge valve. Continue with the cleaning procedure. If carbon particles are found during the inspection procedure, continue with the cleaning procedure. If a diagnostic procedure directed you to replace the EVAP canister purge valve and no carbon particles were detected, replace the EVAP canister purge valve. Return to the published service procedure.

Cleaning Procedure

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  2. Remove the EVAP canister. Refer to «Evaporative Emission Canister Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  3. Turn OFF the main valve on the J 41413 .
  4. Disconnect the hose from the diagnostic station pressure regulator.
  5. Using a section of vacuum hose, connect one end onto the EVAP pressure/purge diagnostic station pressure regulator.
  6. Connect the other end of the vacuum hose to the canister side of the purge pipe.
  7. Turn ON the main nitrogen cylinder valve and continue to discharge nitrogen for 15 seconds.
  8. If the nitrogen does not clear the blockage, replace the purge pipe.
  9. Return the EVAP pressure/purge diagnostic station to the stations original condition.
  10. Install a new EVAP canister. Refer to «Evaporative Emission Canister Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  11. Lower the vehicle.
  12. Install a new EVAP canister purge valve. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  13. Return to the diagnostic table that sent you here.
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
  3. Disconnect the engine wiring harness electrical connector (2) from the ignition coil.
  4. Reposition the brake booster vacuum hose clamp at the upper intake manifold.
  5. Remove the brake booster vacuum hose from the upper intake manifold.
  6. Remove the left side spark plug wires (1) from the ignition coils.
  7. Remove the right side spark plug wires (2) from the ignition coils.
  8. Remove the heated oxygen sensor (HO2S) electrical connector rosebud clip (1) from the ignition coil bracket.
  9. Remove the ignition coil bolts and nuts.
  10. Remove the ignition coil.
  1. Install the ignition coil.
  2. Install the ignition coil bolts and nuts. Tighten: Tighten the bolts/nuts to 25 N.m (18 lb ft).
  3. Install the HO2S electrical connector rosebud clip (1) to the ignition coil bracket.
  4. Install the right side spark plug wires (2) to the ignition coils.
  5. Install the left side spark plug wires (1) to the ignition coils.
  6. Install the brake booster vacuum hose to the upper intake manifold.
  7. Position the brake booster vacuum hose clamp at the upper intake manifold.
  8. Connect the engine wiring harness electrical connector (2) to the ignition coil.
  9. Connect the engine wiring harness electrical connector (1) to the MAP sensor.
  10. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .

Spark Plug Wire Inspection

Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Refer to the list below for items to be inspected.

  1. Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing. Refer to «Spark Plug Wire Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Inspect each wire for any signs of cracks or splits in the wire.
  3. Inspect each boot for the following conditions: Tearing Piercing Arcing Carbon Tracking Corroded terminal

If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal both the wire and the component connected to the wire should be replaced.

CAUTIONTwist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug wire or the wire could be damaged.
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  2. Disconnect the left side spark plug wires from the spark plugs.
  3. Disconnect the left side spark plug wires from the ignition coil.
  4. Remove the spark plug wire clips from the manifold absolute pressure (MAP) sensor bracket and the heater inlet and outlet pipe tab.
  5. Remove the spark plug wire assembly.
  6. If replacing only one plug wire, open the retaining clips and remove the appropriate spark plug wire.
  7. Disconnect the right side spark plug wires from the spark plugs.
  8. Disconnect the right side spark plugs from the ignition coils.
  9. Remove the spark plug wire assembly.
  10. If replacing only one plug wire, open the retaining clip and remove the appropriate spark plug wire.
  1. Install the spark plug wire assembly.
  2. Connect the right side spark plugs to the ignition coils.
  3. Connect the right side spark plug wires to the spark plugs.
  4. If replacing only one plug wire, open the retaining clip and install the appropriate spark plug wire.
  5. Install the spark plug wire assembly.
  6. Connect the left side spark plug wires to the spark plugs.
  7. Connect the left side spark plug wires to the ignition coil.
  8. Install the spark plug wire clips to the MAP sensor bracket and the heater inlet and outlet pipe tab.
  9. If replacing only one plug wire, open the retaining clips and install the appropriate spark plug wire.
  10. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .

Spark Plug Usage

  1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to «Ignition System Specifications»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-specifications__ignition-system-specifications) for the correct spark plug.
  2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug Pre-ignition causing spark plug and/or engine damage-Hotter plug

Spark Plug Inspection

  1. Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move.
  2. Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground.
  3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
  4. Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to «Ignition System Specifications»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-specifications__ignition-system-specifications) . An excessively wide electrode gap can prevent correct spark plug operation. Inspect for the correct spark plug torque. Refer to «Ignition System Specifications»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-specifications__ignition-system-specifications) . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug, causes the insulator (2) to crack. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). Inspect for a broken or worn side electrode (3). Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. A rattling sound indicates internal damage. A loose center electrode (4) reduces the spark intensity. Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped. Inspect for excessive fouling.
  5. Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation.

Spark Plug Visual Inspection

  1. Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
  2. Carbon Fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures Leaking fuel injectors Excessive fuel pressure Restricted air filter element Incorrect combustion Reduced ignition system voltage output Weak coils Worn ignition wires Incorrect spark plug gap Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
  3. Deposit Fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode.
CAUTIONObserve the following service precautions: Allow the engine to cool before removing the spark plugs. Attempting to remove spark plugs from a hot engine can cause the spark plugs to seize. This can damage the cylinder head threads. Clean the spark plug recess area before removing the spark plug. Failure to do so can result in engine damage due to dirt or foreign material entering the cylinder head, or in contamination of the cylinder head threads. Contaminated threads may prevent proper seating of the new spark plug. Use only the spark plugs specified for use in the vehicle. Do not install spark plugs that are either hotter or colder than those specified for the vehicle. Installing spark plugs of another type can severely damage the engine.
  1. Remove the intake manifold cover, if required. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  2. Remove the air cleaner outlet duct, if required. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  3. Remove the left side spark plug wires from the spark plugs, if required.
  4. Remove the right side spark plug wires from the spark plugs, if required.
  5. Remove the spark plugs from the engine.
CAUTIONIt is important to check the gap of all new and reconditioned spark plugs before installation. Pre-set gaps may have changed during handling. Use a round wire feeler gauge to be sure of an accurate check, particularly on used plugs. Installing plugs with the wrong gap can cause poor engine performance and may even damage the engine.
CAUTIONBe sure plug threads smoothly into cylinder head and is fully seated. Use a thread chaser if necessary to clean threads in cylinder head. Cross-threading or failing to fully seat spark plug can cause overheating of plug, exhaust blow-by, or thread damage. Follow the recommended torque specifications carefully. Over or under-tightening can also cause severe damage to engine or spark plug.
  1. Gap the NEW spark plugs. Refer to «Ignition System Specifications»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-specifications__ignition-system-specifications) .
  2. Install the NEW spark plugs. Tighten: Tighten the plugs to 20 N.m (15 lb ft).
  3. Install the right side spark plug wires to the spark plugs, if required.
  4. Install the left side spark plug wires to the spark plugs, if required.
  5. Install the air cleaner outlet duct, if required. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  6. Install the intake manifold cover, if required. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  2. Disconnect the engine wiring harness electrical connector (2) from the crankshaft position (CKP) sensor.
  3. Remove the CKP sensor stud.
  4. Remove the CKP sensor.
  1. Lubricate the CKP sensor O-ring with clean engine oil.
  2. Remove the CKP sensor.
  3. Remove the CKP sensor stud. Tighten: Tighten the stud to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (2) to the CKP sensor.
  5. Lower the vehicle.
  6. Perform the CKP system variation learn procedure. Refer to «Crankshaft Position System Variation Learn»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions__crankshaft-position-system-variation-learn) .
  1. Remove the intake manifold cover. if required. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  2. Remove the power steering pump, if required. Refer to «Power Steering Pump Replacement (LZ4)»(/chevrolet/malibu/vii-2008-2012/remont/electronic-steering/#power-steering-system) .
  3. Disconnect the fuel injector wiring harness electrical connector from the camshaft position (CMP) sensor.
  4. Remove the CMP sensor bolt.
  5. Remove the CMP sensor.
  6. Inspect the sensor O-ring for wear, cracks, or leakage if the sensor is not being replaced.
  1. Replace the O-ring seal if damaged, lubricate the NEW O-ring with clean engine oil.
  2. Install the CMP sensor.
  3. Install the CMP sensor bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  4. Connect the fuel injector wiring harness electrical connector to the CMP sensor.
  5. Install the power steering pump, if required. Refer to «Power Steering Pump Replacement (LZ4)»(/chevrolet/malibu/vii-2008-2012/remont/electronic-steering/#power-steering-system) .
  6. Install the intake manifold cover. if required. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  2. Disconnect the engine wiring harness electrical connector (1) from the knock sensor.
  3. Remove the knock sensor bolt and sensor.
  1. Position the knock sensor to the engine block and install the knock sensor bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  2. Connect the engine wiring harness electrical connector (1) to the knock sensor.
  3. Lower the vehicle.
  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
  2. Disconnect the engine wiring harness electrical connector (2) from the knock sensor.
  3. Remove the knock sensor bolt and sensor.
  1. Position the knock sensor to the engine block and install the knock sensor bolt. Tighten: Tighten the bolt to 25 N.m (18 lb ft).
  2. Connect the engine wiring harness electrical connector (2) to the knock sensor.
  3. Lower the vehicle.

Scheme 52

Scheme 52: Secondary Air Injection Pump Replacement
Scheme 52: Secondary Air Injection Pump Replacement
CalloutComponent Name
Preliminary Procedure: Remove the secondary injection feed tube. Refer to Secondary Air Injection Feed Tube Replacement .
1Secondary Air Injection Pump Nut (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 50 N.m(37 lb ft)
2Secondary Air Injection Pump Nut Tighten: 25 N.m(18 lb ft)
3Secondary Air injection Pump Procedure: Disconnect the electrical connector.
CAUTION
Refer to Fastener Caution .

Scheme 53

Scheme 53: Secondary Air Injection Pump Inlet Hose Replacement
Scheme 53: Secondary Air Injection Pump Inlet Hose Replacement
CalloutComponent Name
1Secondary Air Injection Inlet Hose Procedure: Disconnect the quick disconnects. Refer to Plastic Collar Quick Connect Fitting Service

Scheme 54

Scheme 54: Secondary Air Injection Feed Tube Replacement
Scheme 54: Secondary Air Injection Feed Tube Replacement
CalloutComponent Name
1Secondary Air injection Feed Tube Procedure: Disconnect the quick disconnects. Refer to Plastic Collar Quick Connect Fitting Service

Scheme 55

Scheme 55: Secondary Air Injection Shutoff and Check Valve Replacement (Bank 2)
Scheme 55: Secondary Air Injection Shutoff and Check Valve Replacement (Bank 2)
CalloutComponent Name
Preliminary Procedure: Remove the air injection pump. Refer to Secondary Air Injection Pump Replacement .
1Secondary Air Injection Check Valve Bolt (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 50 N.m (37 lb ft)
2Secondary Air Injection Check Valve Nut (Qty: 2) Tighten: 10 N.m (89 lb in)
3Secondary Air Injection Check Valve Gasket
4Secondary Air Injection Check Valve Procedure: Disconnect the electrical connector.
CAUTION
Refer to Fastener Caution .

Scheme 56

Scheme 56: Secondary Air Injection Shutoff and Check Valve Replacement (Bank 1)
Scheme 56: Secondary Air Injection Shutoff and Check Valve Replacement (Bank 1)
CalloutComponent Name
Preliminary Procedure: Remove the air injection feed tube. Refer to Secondary Air Injection Feed Tube Replacement .
1Secondary Air Injection Check Valve Bolt (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 50 N.m (37 lb ft)
2Secondary Air Injection Check Valve Nut (Qty: 2) Tighten: 10 N.m (89 lb in)
3Secondary Air Injection Check Valve Gasket
4Secondary Air Injection Check Valve Procedure: Disconnect the electrical connector.
CAUTION
Refer to Fastener Caution .

Scheme 57

Scheme 57: Secondary Air Injection Pipe Replacement (Bank 2)
Scheme 57: Secondary Air Injection Pipe Replacement (Bank 2)
CalloutComponent Name
Preliminary Procedure: Remove the left side exhaust manifold. Refer to Exhaust Manifold Replacement - Left Side (LY7) or Exhaust Manifold Replacement - Left Side (LZ4)
1Secondary Air Injection Check Valve Nut (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 10 N.m(89 lb in).
2Secondary Air Injection Pipe Bolt (Qty: 4) Tighten: 10 N.m(89 lb in).
3Secondary Air Injection Check Valve Gasket
4Secondary Air Injection Pipe Gasket
5Secondary Air Injection Pipe
CAUTION
Refer to Fastener Caution .

Scheme 58

Scheme 58: Secondary Air Injection Pipe Replacement (Bank 1)
Scheme 58: Secondary Air Injection Pipe Replacement (Bank 1)
CalloutComponent Name
Preliminary Procedure: Remove the right side exhaust manifold. Refer to Exhaust Manifold Replacement - Right Side (LZ4) .
1Secondary Air Injection Check Valve Nut (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 10 N.m(89 lb in).
2Secondary Air Injection Pipe Bolt (Qty: 4) Tighten: 10 N.m(89 lb in).
3Secondary Air Injection Check Valve Gasket
4Secondary Air Injection Pipe Gasket
5Secondary Air Injection Pipe
CAUTION
Refer to Fastener Caution .
  1. Remove the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/wheel-tire-system/#tires-wheels) .
  2. Remove the right front fender liner. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  3. Remove the air cleaner inlet duct bolt and push pin retainers.
  4. Remove the air cleaner inlet duct.
  1. Install the air cleaner inlet duct.
  2. Install the air cleaner inlet duct bolt and push pin retainers. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  3. Install the right front fender liner. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
  4. Install the right front tire and wheel. Refer to «Tire and Wheel Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/wheel-tire-system/#tires-wheels) .
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  2. disconnect the positive crankcase ventilation (PCV) fresh air tube quick connect fitting from the air cleaner outlet duct. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  3. Reposition the tube out of the way.
  4. Loosen the air cleaner outlet duct clamps (1, 2) at the mass air flow (MAF)/intake air temperature (IAT) sensor and throttle body.
  5. Remove the air cleaner outlet duct bolt (5).
  6. Remove the air cleaner outlet duct spacer (4) and insulator (5), if required.
  7. Remove the air cleaner outlet duct.
  1. Position and install the air cleaner outlet duct to the MAF/IAT sensor and the throttle body.
  2. Position the air cleaner outlet duct insulator (5) and spacer (4), if required.
  3. Install the air cleaner outlet duct bolt (5). Tighten: Tighten the bolt to 10 N.m (89 lb in).
  4. Tighten the air cleaner outlet duct clamps (1, 2) at the MAF/IAT sensor and throttle body. Tighten: Tighten the clamp to 4 N.m (35 lb in).
  5. Position the PCV tube.
  6. Connect the PCV fresh air tube quick connect fitting to the air cleaner outlet duct. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions)
  7. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) .
  1. Disengage the air cleaner cover latches (1).
  2. Open the air cleaner cover.
  3. Remove and discard the air filter assembly (2).
  1. Install a NEW air filter assembly (2).
  2. Close the air cleaner cover.
  3. Engage the air cleaner cover latches.
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
  2. Disconnect the engine wiring harness electrical connector (1) from the mass airflow (MAF)/intake air temperature (IAT) sensor.
  3. Remove the air cleaner housing rear bolt.
  4. Reposition the air conditioning (A/C) condenser and evaporator tube clamp as required.
  5. Remove the air cleaner assembly from the upper tie bar.
  1. Install the air cleaner assembly to the upper tie bar.
  2. Position the A/C condenser and evaporator tube clamp as required.
  3. Install the air cleaner housing rear bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
  4. Connect the engine wiring harness electrical connector (1) to the MAF/IAT sensor.
  5. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .

See also:
• Battery Negative Cable Disconnection and Connection (LE5, LE9, LZ4, LZE, or LY7)
• Control Module References
• Diagnostic Trouble Code (DTC) List - Vehicle
• Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4)
• Intake Manifold Cover Replacement
• Adhesives, Fluids, Lubricants, and Sealers
• Fastener Caution
• Heated Oxygen Sensor Resistance Learn Reset Caution
• Lifting and Jacking the Vehicle
• Throttle/Idle Learn
• Gasoline/Gasoline Vapors Warning
• Safety Glasses Warning
• Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution
• Relieving Fuel Pressure Warning
• Fuel Pipe Fitting Warning
• Exhaust Muffler Replacement (LZ4)
• Fuel Tank Fuel Pump Module Replacement
• Ignition System Specifications
• Power Steering Pump Replacement (LZ4)
• Tire and Wheel Removal and Installation
• Front Wheelhouse Panel Splash Shield Replacement
• Air Cleaner Outlet Duct Replacement
• Fuel Pressure Relief (Without CH 48027-100)
• Crankshaft Position System Variation Learn

More articles — Engine Performance