Engine Controls and Fuel - 3.6l - Repair Instructions Chevrolet Malibu VII

Crankshaft Position System Variation Learn

Note. The crankshaft position 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 crankshaft position sensor replacement Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship.

Note. The ECM monitors certain component signals to determine if all the conditions are met to continue with the Crankshaft Position 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: Crankshaft position sensors activity-If there is a crankshaft position sensor condition, refer to the applicable DTC that set. Camshaft position signal activity-If there is a camshaft position 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 Crankshaft Position 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. NOTE: 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 crankshaft position 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 s after the learn procedure is completed successfully in order to store the crankshaft position system variation values in the ECM memory.

Engine Control Module Replacement

Note. It is necessary to record the remaining engine oil life. If the replacement module is not programed 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. Record the preset radio stations.
3. Turn the ignition OFF.
4. 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) .
5. Lift and gently pull the ECM up and out of the retainer on the battery tray.
6. Disconnect the engine wiring harness electrical connectors (1) from the ECM.
7. Disconnect the body wiring harness electrical connector (2) from the ECM.

Installation Procedure

1. Connect the engine wiring harness electrical connectors (1) to the ECM.
2. Connect the body wiring harness electrical connector (2) to the ECM.
3. Position the ECM above the retainer in the battery tray and slide the ECM down into the retainer.
4. 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) .
5. Reset the clock and preset radio stations.
6. If a NEW ECM was installed, the ECM must be programmed. Refer to «Control Module References»(/chevrolet/malibu/vii-2008-2012/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) .

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.

1. Disconnect the engine wiring harness electrical connector (1) from the engine coolant temperature (ECT) sensor.
2. Remove the ECT sensor.

1. Install the ECT sensor and tighten to 22 N.m (16 lb ft).
2. Connect the engine wiring harness electrical connector (1) to the ECT sensor.

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-36l-repair-instructions) .
2. Disconnect the engine wiring harness electrical connector 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 and tighten to 4 N.m (35 lb in).
4. Connect the engine wiring harness electrical connector 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-36l-repair-instructions) .

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
2. Disconnect the engine wiring harness electrical connector (1) from the manifold absolute pressure (MAP) sensor.
3. Remove the MAP sensor bolt and sensor.

1. Lubricate the MAP sensor O-ring seal with clean engine oil.
2. Install the MAP sensor and bolt and tighten the bolt to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connector (1) to the MAP sensor.
4. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .

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 engine wiring harness heated oxygen sensor (HO2S) electrical connector clip from the engine harness.
3. Remove the connector position assurance (CPA) retainer (5) from the HO2S electrical connection.
4. Disconnect the engine wiring harness electrical connector (2) from the HO2S electrical connector (1).
5. Raise and support the vehicle to an appropriate height to reach the HO2S. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
6. Remove the HO2S from the exhaust manifold.

Note. A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to reinstalled, the threads must have anti-seize compound applied before the reinstallation.

1. If reinstalling the old sensor, coat the threads 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 to the exhaust manifold and tighten the sensor to 42 N.m (31 lb ft).
3. Lower the vehicle.
4. Connect the engine wiring harness electrical connector (2) to the HO2S electrical connector (1).
5. Install the engine wiring harness HO2S electrical connector clip to the engine harness.
6. Install the CPA retainer (5) to the HO2S electrical connection.

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 from the HO2S electrical connection.
3. Disconnect the heated oxygen sensor (HO2S) electrical connector (2) from the engine wiring harness electrical connector.
4. Remove the bank 1 sensor 2 HO2S (2) from the catalytic converter.

Note. A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to reinstalled, the threads must have anti-seize compound applied before the reinstallation.

1. If reinstalling the old sensor, coat the threads 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 bank 1 sensor 2 HO2S (2) to the catalytic converter and tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector.
4. Install the CPA retainer to the HO2S electrical connection.
5. Lower the vehicle.

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
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-36l-repair-instructions) .
3. Remove the connector position assurance (CPA) retainer (3) from the HO2S electrical connection.
4. Disconnect the engine wiring harness electrical connector (2) from the heated oxygen sensor (HO2S) electrical connector (3).
5. Remove the HO2S electrical connector clip from the engine wiring harness tab.
6. Remove the HO2S from the exhaust manifold.

Note. A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to reinstalled, the threads must have anti-seize compound applied before the reinstallation.

1. If reinstalling the old sensor, coat the threads 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 to the exhaust manifold and tighten the sensor to 42 N.m (31 lb ft).
3. Connect the engine wiring harness electrical connector (2) to the HO2S electrical connector (3).
4. Install the HO2S electrical connector clip to the engine wiring harness tab.
5. Install the CPA retainer (3) to the HO2S electrical connection.
6. 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-36l-repair-instructions) .
7. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .

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 (4) from the HO2S electrical connection.
3. Disconnect the heated oxygen sensor (HO2S) electrical connector (3) from the engine wiring harness electrical connector (2).
4. Remove the bank 2 sensor 2 HO2S (1) from the catalytic converter.

Note. A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to reinstalled, the threads must have anti-seize compound applied before the reinstallation.

1. If reinstalling the old sensor, coat the threads 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 bank 2 sensor 2 HO2S (1) to the catalytic converter and tighten the sensor to 42 N.m (31 lb ft).
3. Connect the HO2S electrical connector (3) to the engine wiring harness electrical connector (2).
4. Install the CPA retainer (4) to the HO2S electrical connection.
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.

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-36l-repair-instructions) .
2. Disconnect the engine wiring harness electrical connector (2) from the electronic throttle control (ETC).
3. Remove the throttle body bolts.
4. Remove the throttle body and gasket. Discard the gasket.

1. Position a NEW throttle body gasket to the upper intake manifold.
2. Position the throttle body to the upper intake manifold.
3. Install the throttle body bolts and tighten to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector (2) to the ETC.
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-36l-repair-instructions) .
6. 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 Inspection and Cleaning

Note. Over extended time and mileage, deposits may accumulate on the back of the throttle valve plate. The source of the deposit is exhaust gas recirculation (EGR) gas. Typically these deposits pose no problem. Occasionally the deposit may accumulate to a point where perceived pedal effort or throttle valve movement is effected. This procedure should not be performed on vehicles with mileage under 80 450 km (50,000 mi).

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-36l-repair-instructions) .
2. Inspect the throttle body bore and the throttle valve plate for deposits. You will need to open the throttle valve in order to inspect all surfaces.
3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM top engine cleaner. 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) .
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-36l-repair-instructions) .
5. Perform the throttle/idle 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 (w/o CH 48027-100)

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.

Special Tools

CH-48027-100 Digital Pressure Gauge

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

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (w/o CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions__fuel-pressure-relief-wo-ch-48027-100) or «Fuel Pressure Relief (with CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-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.

J 37088-A: Fuel Line Disconnect Tool Set

1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (w/o CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions__fuel-pressure-relief-wo-ch-48027-100) or «Fuel Pressure Relief (with CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Remove the fuel feed line quick connect fitting retainer.
3. Blow dirt out of the fitting using compressed air.
4. Choose the correct tool from the J 37088-A: Tool Set 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.

Scheme 50

Note. There are several types of plastic collar fuel and evaporative emission quick connect fittings used on this vehicle. Bartholomew (1) Q Release (2) Squeeze to Release (3) Sliding Retainer (4)

1. Relieve the fuel system pressure. Refer to the «Fuel Pressure Relief (w/o CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions__fuel-pressure-relief-wo-ch-48027-100) or «Fuel Pressure Relief (with CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Using compressed air, blow any dirt out of the quick-connect fitting.
3. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs.
4. This step applies to Q Release 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 Squeeze to Release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting.
6. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by 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. Pull the connection apart.

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 quick-connect fitting in order to make sure the connection is secure.

J 45004 Fuel Tank Drain Hose

Draining

1. Remove the fuel fill cap.
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
3. Loosen the fuel fill pipe hose clamp (3) at the fuel tank.
4. Separate the fuel fill pipe hose from the fuel tank.
5. Insert the J 45004 into the fuel tank until the hose reaches the bottom of the fuel tank.
6. Use an hand or air operated pump device in order to drain as much fuel 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-24l-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-24l-repair-instructions) .
2. Drain the fuel tank. Refer to «Fuel Tank Draining (Non E-85)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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-24l-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-24l-repair-instructions) .
10. Cap the chassis fuel and EVAP pipes in order to prevent possible fuel and/or EVAP system contamination.
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-24l-repair-instructions) .
12. Place a jackstand under the muffler assembly.
13. With the aid of an assistant, separate the muffler insulators (1) from the underbody hangers.
14. 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 (LY7)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) .
15. Have assistants support either side of the fuel tank.
16. Place a suitable adjustable jack under the fuel tank, and have the assistants rest the fuel tank on the adjustable jack.
17. Remove fuel tank strap bolts and straps.
18. If applicable, in order to clear the muffler assembly, slowly lower the right side of the fuel tank.
19. 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.
20. 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-24l-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-24l-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-24l-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

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-24l-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-24l-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-24l-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 (LY7)»(/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-24l-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-24l-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-24l-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.

1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-24l-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-24l-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»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-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-36l-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-36l-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-36l-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-36l-repair-instructions) .
4. Tighten the fuel fill pipe hose clamp (3) at the fuel tank 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-36l-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-36l-repair-instructions) .
8. Install the fuel tank fill pipe bolt (2) to the underbody side rail and 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 and tighten the bolts 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.

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-36l-repair-instructions) .
2. Disconnect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) from the fuel pressure sensor 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-36l-repair-instructions) .
4. Remove the fuel feed pipe from the retaining features (1) built into the fuel tank.
5. Install the J 45722 to the fuel pump module lock ring.
6. Using the J 45722 and a long breaker-bar, rotate the lock ring in a counterclockwise direction in order to unlock the lock ring.
7. Remove the J 45722 from the fuel pump module lock ring.
8. 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-36l-repair-instructions) .
9. 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.
10. Remove the fuel pump module.
11. Remove and discard the fuel pump module seal.
12. Clean the fuel pump module sealing surfaces.

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-36l-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. Install the fuel feed pipe to the retaining features (1) built into the fuel tank.
11. 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-36l-repair-instructions) .
12. Connect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) to the fuel pressure sensor and the module.
13. Install the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

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) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (w/o CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions__fuel-pressure-relief-wo-ch-48027-100) or «Fuel Pressure Relief (with CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
3. Remove the fuel feed pipe clip nut (2) from the intake manifold stud.
4. Disconnect the fuel feed pipe (1) 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-36l-repair-instructions) .
5. Disconnect the evaporative emission (EVAP) pipe (3) quick connect fitting from the EVAP purge solenoid. Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-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. Partially remove the right engine frame to body bracket. Refer to «Frame Replacement (3.6L)»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
11. 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-36l-repair-instructions) .
12. 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-36l-repair-instructions) .
13. Cap the chassis fuel and EVAP pipes in order the prevent possible fuel and/or EVAP system contamination.
14. Remove the brake, fuel and EVAP pipe retainers (5) from the underbody studs.
15. Remove the brake pipes from the retainers.
16. Remove the fuel feed/EVAP pipe assembly from the vehicle.
17. Place the pipe assembly on a work bench.
18. Open and remove the upper fuel feed/EVAP pipe retainer (3).
19. Open and remove the front of dash fuel feed/EVAP pipe retainers (4).
20. Open and remove the underbody retainers (5).
21. 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-36l-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-36l-repair-instructions) .
10. Install the right engine frame to body bracket. Refer to «Frame Replacement (3.6L)»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
11. Lower the vehicle.
12. Install the brake pipes to the clips.
13. Install the brake, fuel, and EVAP pipe clips (1, 2) to the studs on the front of dash.
14. Remove the caps from the fuel rail pipe and the EVAP purge solenoid.
15. Connect the EVAP pipe (3) quick connect fitting 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-36l-repair-instructions) .
16. Connect the fuel feed pipe (1) 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-36l-repair-instructions) .
17. Install the fuel feed pipe clip nut (2) to the intake manifold stud and tighten the nut to 10 N.m (89 lb in).
18. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
19. 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) .
20. Tighten the fuel fill cap.
21. 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

1. Remove the fuel tank module. Refer to «Fuel Tank Module Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-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-36l-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-36l-repair-instructions) .
9. Install the fuel tank module. Refer to «Fuel Tank Module Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
2. Disconnect the engine wiring harness electrical connector (1) from the fuel injector wiring harness electrical connector.
3. Disconnect the fuel feed pipe (1) 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-36l-repair-instructions) .
4. Remove the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
5. Use compressed air in order to remove any debris from the around the area where the fuel injectors enter the lower intake manifold.
6. Remove the fuel rail bolts.
7. Remove the fuel rail with fuel injectors from the lower intake manifold.
8. Lift up the fuel injector electrical connector retainer (2).
9. Push in the fuel injector electrical connector tab (1) in order to disconnect the connector from the injector.
10. Remove the fuel injector retainer clip.
11. Remove the fuel injector.
12. Remove and discard the fuel injector seals.

1. Install NEW fuel injector seals.
2. Install the fuel injector.
3. Install the fuel injector retainer clip.
4. Install the fuel injector electrical connector.
5. Push down on the fuel injector electrical connector retainer (2), securing the electrical connector.
6. Install the fuel rail with fuel injectors to the lower intake manifold.
7. Install the fuel rail bolts and tighten to 10 N.m (89 lb in).
8. Install the upper intake manifold. Refer to «Upper Intake Manifold Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
9. Connect the fuel feed pipe (1) 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-36l-repair-instructions) .
10. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
11. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
2. Disconnect the chassis EVAP pipe (3) quick connect fitting 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-36l-repair-instructions) .
3. Disconnect the EVAP emission canister tube 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-36l-repair-instructions) .
4. Disconnect the engine wiring harness electrical connector (2) from the evaporative emission (EVAP) purge solenoid.
5. Remove the EVAP purge solenoid bracket bolt (1).
6. Remove the EVAP purge solenoid (2).

1. Position the EVAP purge solenoid (2).
2. Install the EVAP purge solenoid bracket bolt (1) and tighten to 10 N.m (89 lb in).
3. Connect the EVAP pipe quick connect fitting 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-36l-repair-instructions) .
4. Connect the engine wiring harness electrical connector (2) to the EVAP purge solenoid.
5. Connect the EVAP emission canister tube 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-36l-repair-instructions) .
6. Connect the chassis EVAP pipe (3) quick connect fitting 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-36l-repair-instructions) .
7. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .

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. Separate the fuel fill pipe hose from the fuel tank.
7. 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-36l-repair-instructions) .
8. Support the fuel tank with a suitable adjustable jackstand.
9. Loosen, DO NOT REMOVE the left side fuel tank strap (2) bolts.
10. Loosen, DO NOT REMOVE the right side front fuel tank strap (1) bolt.
11. Remove the right side rear fuel tank strap bolt.
12. Using the adjustable jack, lower the right side of the fuel tank enough to access the EVAP canister vent solenoid valve.
13. Disconnect the fuel tank fuel pump wiring harness electrical connector (1) from the EVAP canister vent solenoid valve.
14. 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-36l-repair-instructions) .
15. Insert and gently push a small flat-bladed tool between the EVAP canister vent solenoid and the retaining bracket, disengaging the retaining tab (1).
16. 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. 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-36l-repair-instructions) .
3. Connect the fuel tank fuel pump wiring harness electrical connector (1) to the EVAP canister vent solenoid valve.
4. Using the adjustable jack, raise the right side of the fuel tank.
5. Install the right side rear fuel tank strap (1) bolt.
6. Tighten the left side fuel tank strap (2) bolts.
7. Tighten the right side front fuel tank strap bolt to 20 N.m (15 lb ft).
8. Remove the support from the fuel tank.
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 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-36l-repair-instructions) .
11. Tighten the fuel fill pipe hose clamp (3) at the fuel tank to 4 N.m (35 lb in).
12. Raise the muffler assembly into position.
13. With the aid of an assistant, install the muffler insulators (1) to the underbody hangers.
14. Remove the jackstand from under the muffler assembly.
15. Lower the vehicle.

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
2. Disconnect evaporative emission (EVAP) canister purge tube quick connect fitting (1) at the upper intake manifold. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
3. Disconnect EVAP canister purge tube quick connect fitting (2) at the EVAP purge solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
4. Remove the EVAP canister purge tube from under the positive crankcase ventilation (PCV) tube and from the vehicle.

1. Install the EVAP canister purge tube to the vehicle and route the purge tube under the PCV tube.
2. Connect EVAP canister purge tube quick connect fitting (2) at the EVAP purge solenoid valve. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
3. Connect EVAP canister purge tube quick connect fitting (1) at the upper intake manifold. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
4. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .

1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief (w/o CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions__fuel-pressure-relief-wo-ch-48027-100) or «Fuel Pressure Relief (with CH 48027-100)»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
3. Remove the fuel feed pipe clip nut (2) from the intake manifold stud.
4. Disconnect the fuel feed pipe (1) 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-36l-repair-instructions) .
5. Disconnect the evaporative emission (EVAP) pipe (3) quick connect fitting 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-36l-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-36l-repair-instructions) .
11. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to «Metal Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
12. Cap the chassis fuel and EVAP pipes in order to 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 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-36l-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-36l-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 (3) quick connect fitting 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-36l-repair-instructions) .
15. Connect the fuel feed pipe (1) quick connect fitting to the fuel rail. Refer to «Plastic Collar Quick Connect Fitting Service»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
16. Install the fuel feed pipe clip nut (2) to the intake manifold stud and tighten to 10 N.m (89 lb in).
17. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
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 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-36l-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-36l-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-36l-repair-instructions) .
4. Remove the EVAP canister purge pipe from the retaining feature (3) built into the fuel tank.
5. Reposition the fuel tank fuel pump wiring harness from around the EVAP canister.
6. Remove the EVAP canister bolt.
7. Slide up and remove the EVAP canister.

1. Position and install the EVAP canister.
2. Install the EVAP canister bolt and tighten to 3.5 N.m (31 lb in).
3. Position the fuel tank fuel pump wiring harness around the EVAP canister.
4. Install the EVAP canister purge pipe to the retaining feature (3) built into the fuel tank.
5. 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-36l-repair-instructions) .
6. 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-36l-repair-instructions) .
7. Install the fuel tank. Refer to «Fuel Tank Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-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-36l-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-36l-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-36l-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-36l-repair-instructions) .
13. Return to the diagnostic table that sent you here.

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
2. Disconnect the engine wiring harness electrical connectors (3) from the ignition coils.
3. If removing the number 5 cylinder ignition coil, remove the evaporative emission (EVAP) canister purge tube. Refer to «Evaporative Emission Canister Purge Tube Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
4. If removing the number one ignition coil, remove the canister purge solenoid. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions)
5. Remove the ignition coil bolts.
6. Remove the ignition coils.

1. Install the ignition coils.
2. Install the ignition coil bolts and tighten to 10 N.m (89 lb in).
3. If the number 5 cylinder ignition coil was removed, install the EVAP canister purge tube. Refer to «Evaporative Emission Canister Purge Tube Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
4. If the number one ignition coil was removed, install the canister purge solenoid. Refer to «Evaporative Emission Canister Purge Solenoid Valve Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions)
5. Connect the engine wiring harness electrical connectors (3) to the ignition coils.
6. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
2. Disconnect the engine wiring harness electrical connector(s) (2) from the ignition coils.
3. Remove the ignition coil bolts.
4. Remove the ignition coils.

1. Install the ignition coils.
2. Install the ignition coil bolts and tighten to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connectors (2) to the ignition coils.
4. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .

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-36l-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-36l-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-36l-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.

1. Remove the ignition coil(s). Refer to «Ignition Coil Replacement - Bank 1»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) and/or «Ignition Coil Replacement - Bank 2»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Use compressed air in order to remove debris from the spark plug cavity.
3. Remove the spark plug.

1. Ensure that the spark plug gap is equivalent to the spark plug gap specification. Refer to «Ignition System Specifications»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-specifications__ignition-system-specifications) .
2. Install the spark plug and tighten to 20 N.m (15 lb ft).
3. Install the ignition coil(s). Refer to «Ignition Coil Replacement - Bank 1»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) and/or «Ignition Coil Replacement - Bank 2»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

1. Remove the exhaust manifold lower heat shield. Refer to «Exhaust Manifold Lower Heat Shield Replacement (LY7)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) .
2. Disconnect the engine wiring harness electrical connector (2) from the crankshaft position (CKP) sensor.
3. Remove the crankshaft sensor bolt.
4. Remove the crankshaft sensor.

1. Install the crankshaft position sensor.
2. Install the crankshaft position sensor bolt and tighten to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connector (2) to the CKP sensor.
4. Install the exhaust manifold lower heat shield. Refer to «Exhaust Manifold Lower Heat Shield Replacement (LY7)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) .
5. Perform the Crankshaft Position System Variation Learn procedure. Refer to «Crankshaft Position System Variation Learn»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions__crankshaft-position-system-variation-learn) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Disconnect the engine wiring harness electrical connector (3) from the bank 2 exhaust camshaft position (CMP) sensor.
3. Remove the CMP sensor bolt.
4. Remove the CMP sensor.

1. Install the CMP sensor.
2. Install the CMP sensor bolt and tighten to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connector (3) to the bank 2 exhaust CMP sensor.
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Disconnect the engine wiring harness electrical connector (1) from the bank 2 intake camshaft position (CMP) sensor.
3. Remove the CMP sensor bolt.
4. Remove the CMP sensor.

1. Install the CMP sensor.
2. Install the CMP sensor bolt and tighten to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connector (1) to the bank 2 intake CMP sensor.
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Disconnect the engine wiring harness electrical connector (6) from the bank 1 exhaust camshaft position (CMP) sensor.
3. Remove the CMP sensor bolt.
4. Remove the CMP sensor.

1. Install the CMP sensor.
2. Install the CMP sensor bolt and tighten to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connector (6) to the bank 1 exhaust CMP sensor.
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Disconnect the engine wiring harness electrical connector (8) from the bank 1 intake camshaft position (CMP) sensor.
3. Remove the CMP sensor bolt.
4. Remove the CMP sensor.

1. Install the CMP sensor.
2. Install the CMP sensor bolt and tighten to 10 N.m (89 lb in).
3. Connect the engine wiring harness electrical connector (8) to the bank 1 intake CMP sensor.
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Remove the air conditioning (A/C) line push pin retainer and reposition the line out of the way.
3. Loosen the bank 1 intake camshaft position (CMP) actuator solenoid valve bolt enough to disconnect the engine wiring harness electrical connector from the CMP actuator solenoid valve.
4. Disconnect the engine wiring harness electrical connector (7) from the CMP actuator solenoid valve.
5. Remove the CMP actuator solenoid valve bolt.
6. Remove the CMP actuator solenoid valve.
7. Inspect the CMP actuator solenoid valve seal and replace as necessary.

1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator solenoid valve.
3. Loosely install the CMP actuator solenoid valve bolt.
4. Connect the engine wiring harness electrical connector (7) to the bank 1 intake CMP actuator solenoid valve.
5. Tighten the CMP actuator solenoid valve bolt to 10 N.m (89 lb in).
6. Position the A/C line and install the push pin retainer.
7. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Disconnect the engine wiring harness electrical connector (5) from the bank 1 exhaust camshaft position (CMP) actuator solenoid valve.
3. Remove the CMP actuator solenoid valve bolt.
4. Remove the CMP actuator solenoid valve.
5. Inspect the CMP actuator solenoid valve seal and replace as necessary.

1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator solenoid valve.
3. Install the CMP actuator solenoid valve bolt and tighten to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector (5) to the bank 1 exhaust CMP actuator solenoid valve.
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

1. Remove the engine mount snubber bracket. Refer to «Engine Mount Snubber Bracket Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
2. Disconnect the engine wiring harness electrical connector (2) from the bank 2 intake camshaft position (CMP) actuator solenoid valve.
3. Remove the CMP actuator solenoid valve bolt.
4. Remove the CMP actuator solenoid valve.
5. Inspect the CMP actuator solenoid valve seal for damage and replace as necessary.

1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator solenoid valve.
3. Install the CMP actuator solenoid valve bolt and tighten to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector (2) to the bank 2 intake CMP actuator solenoid valve.
5. Install the engine mount snubber bracket. Refer to «Engine Mount Snubber Bracket Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .
2. Remove the engine mount snubber bracket. Refer to «Engine Mount Snubber Bracket Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
3. Disconnect the engine wiring harness electrical connector (4) from the bank 2 exhaust camshaft position (CMP) actuator solenoid valve.
4. Remove the CMP actuator solenoid valve bolt.
5. Remove the CMP actuator solenoid valve.
6. Inspect the CMP actuator solenoid valve seal for damage and replace as necessary.

1. Inspect the CMP actuator solenoid valve seal for damage. Replace the seal if necessary.
2. Install the CMP actuator solenoid valve.
3. Install the CMP actuator solenoid valve bolt and tighten to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector (4) to the bank 2 exhaust CMP actuator solenoid valve.
5. Install the engine mount snubber bracket. Refer to «Engine Mount Snubber Bracket Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-36l-repair-instructions) .

1. Remove the exhaust manifold lower heat shield. Refer to «Exhaust Manifold Lower Heat Shield Replacement (LY7)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) .
2. Disconnect the engine wiring harness electrical connector (1) from the bank 1 knock sensor.
3. Loosen the knock sensor bolt and remove the knock sensor.

1. Position the knock sensor and tighten the knock sensor bolt to 23 N.m (17 lb ft).
2. Connect the engine wiring harness electrical connector (1) to the bank 1 knock sensor.
3. Instal the exhaust manifold lower heat shield. Refer to «Exhaust Manifold Lower Heat Shield Replacement (LY7)»(/chevrolet/malibu/vii-2008-2012/remont/exhaust/#engine-exhaust-system) .

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 bank 2 knock sensor.
3. Loosen the knock sensor bolt and remove the knock sensor.

1. Position the knock sensor and tighten the knock sensor bolt to 23 N.m (17 lb ft).
2. Connect the engine wiring harness electrical connector (2) to the bank 2 knock sensor.
3. Lower the vehicle.

1. Remove the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
2. Disconnect the engine wiring harness electrical connector (1) from the intake manifold tuning valve.
3. Unbolt and reposition the power steering pump reservoir bracket.
4. Remove the intake manifold tuning valve bolts.
5. Remove the intake manifold tuning valve.

1. Lubricate the intake manifold tuning valve O-ring seal with clean engine oil.
2. Install the intake manifold tuning valve.
3. Install the intake manifold tuning valve bolts and tighten to 10 N.m (89 lb in.
4. Position the power steering pump reservoir bracket and install the bolts and tighten to 9 N.m (80 lb in).
5. Connect the engine wiring harness electrical connector (1) to the intake manifold tuning valve.
6. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .

1. Disengage the air cleaner cover latches (1).
2. Open the air cleaner cover.
3. Remove and discard the air filter assembly.

1. Install a NEW air filter assembly.
2. Engage the air cleaner cover retainers to the lower air cleaner housing, and close the cover.
3. Engage the air cleaner cover latches (1).
4. Ensure that the air cleaner cover is secured to the lower air cleaner housing.

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-36l-repair-instructions) .
2. Disconnect the engine wiring harness electrical connector 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 and tighten to 10 N.m (89 lb in).
4. Connect the engine wiring harness electrical connector 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-36l-repair-instructions) .

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 wheelhouse panel splash shield. 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 wheelhouse panel splash shield. 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 fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .
2. Disconnect the positive crankcase ventilation (PCV) fresh air tube (1) fitting from the air cleaner outlet duct.
3. Reposition the tube out of the way.
4. Loosen the air cleaner outlet duct clamps (1, 3) at the mass air flow (MAF)/intake air temperature (IAT) sensor and throttle body.
5. Remove the air cleaner outlet duct bolt (2).
6. 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. Install the air cleaner outlet duct bolt (2) and tighten to 10 N.m (89 lb in).
3. Tighten the air cleaner outlet duct clamps (1, 3) at the MAF/IAT sensor and throttle body to 4 N.m (35 lb in).
4. Position the PCV tube.
5. Connect the PCV fresh air tube (1) quick connect fitting to the air cleaner outlet duct.
6. Install the fuel injector sight shield. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) .

See also:
• Diagnostic Trouble Code (DTC) List - Vehicle
• Battery Negative Cable Disconnection and Connection (LE5, LE9, LZ4, LZE, or LY7)
• Control Module References
• Fastener Caution
• Fuel Injector Sight Shield Replacement
• Heated Oxygen and Oxygen Sensor Caution
• Lifting and Jacking the Vehicle
• Adhesives, Fluids, Lubricants, and Sealers
• Gasoline/Gasoline Vapors Warning
• Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution
• Relieving Fuel Pressure Warning
• Fuel Pipe Fitting Warning
• Safety Glasses Warning
• Fuel Pressure Relief (without CH 48027-100)
• Fuel Pressure Relief (with CH 48027-100)
• Exhaust Muffler Replacement (LY7)
• Frame Replacement (3.6L)
• Safety Glasses and Compressed Air Warning
• Ignition System Specifications
• Tire and Wheel Removal and Installation
• Air Cleaner Outlet Duct Replacement
• Fuel Pressure Relief (w/o CH 48027-100)
• Crankshaft Position System Variation Learn