Engine Cooling System Chevrolet Malibu VIII

Fastener Tightening Specifications

Fastener Tightening Specifications

Adhesives, Fluids, Lubricants, and Sealers

Adhesives, Fluids, Lubricants, and Sealers

Scheme 1

Diagnostic Code Index

DIAGNOSTIC CODE INDEX

Diagnostic Instructions

1. Perform the «Diagnostic System Check - Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-procedure-instructions) provides an overview of each diagnostic category.

Diagnostic Fault Information

Typical Scan Tool Data

FC Relay 1, and FC Relays 2 and 3 Ckt Open, Short Gnd, and Short Volts Test Status with component OFF

FC Relay 1, and FC Relays 2 and 3 Ckt Open, Short Gnd, and Short Volts Test Status with component ON

Circuit/System Description

The engine cooling fan system consists of a cooling fan assembly containing two electric cooling fans. The engine control module (ECM) uses two fan control circuits and a series of three relays to command the fans ON in either high speed or low speed, depending on cooling requirements. In low speed, both fans are turned ON at a reduced speed. High speed has both fans turned ON at full speed.

Conditions for Running the DTC

1. The ignition voltage is between 11-26 V.
2. The engine speed is greater than 400 RPM.
3. The ECM driver transitions from ON to OFF or from OFF to ON.
4. DTC P0480 and P0481 run continuously when the conditions above are met.

Conditions for Setting the DTC

P0480

The commanded state of the ECM driver and the actual state of the control circuit do not match for greater than 5 seconds.

P0481

The commanded state of the ECM driver and the actual state of the control circuit do not match for greater than 5 seconds.

Action Taken When the DTC Sets

DTCs P0480 and P0481 are Type B DTCs.

Conditions for Clearing the MIL/DTC

DTCs P0480 and P0481 are Type B DTCs.

Diagnostic Aids

1. The scan tool cooling fan output control operates as follows: Fan Relay 1 operates both fans at a low speed Fan Relay 2 and 3 operates one fan at a high speed Fan Relay 1, 2 and 3 operates both fans at a high speed
2. KR20 cooling fan relay identification: KR20C cooling fan low speed FAN 1 Relay KR20D cooling fan high speed FAN 2 Relay KR20E cooling fan speed control FAN 3 or S/P Relay
3. When disconnecting or removing fuses and relays from a fuse block, always inspect the component electrical terminals for corrosion and the correct orientation in the fuse block. Test the mating electrical terminals for tightness.

Reference Information

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__circuit-testing)
2. «Connector Repairs»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__testing-for-intermittent-conditions-and-poor)
4. «Wiring Repairs»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__wiring-repairs)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Engine operating, observe the DTC information with a scan tool. DTC P0480 and P0481 should not set.
2. Command the cooling fans ON and OFF at high speed while observing the scan tool circuit test status parameters listed below: FC Relay 1 Ckt Open, Short Gnd, and Short Volts Test Status FC Relay 2 and 3 Ckt Open, Short Gnd, and Short Volts Test Status The parameters should display OK or Not Run in each of the commanded states.
3. Operate the vehicle within the Conditions for Running the DTC to verify the DTC does not reset. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.

Circuit/System Testing

1. Ignition OFF, disconnect all of the KR20 cooling fan relays.
2. Ignition ON, verify that a test lamp illuminates between ground and the relay coil ignition circuit terminal listed below: KR20C cooling fan low speed relay terminal 86 KR20D cooling fan high speed relay terminal 86 KR20E cooling fan speed control relay terminal 85 If the test lamp does not illuminate, test the relay coil ignition circuit for a short to ground or an open/high resistance. If the circuit tests normal and the relay coil ignition circuit fuse is open, test all components connected to the ignition circuit and replace as necessary.
3. Connect the red lead of the DMM to a control circuit terminal listed below. Connect the black lead to ground. Set the DMM on the diode setting. The DMM should display OL. KR20C cooling fan low speed relay terminal 85 KR20D cooling fan high speed relay terminal 85 KR20E cooling fan speed control relay terminal 86 If less than the specified range, test the appropriate relay coil control circuit for a short to ground. If the circuit tests normal, replace the K20 ECM.
4. Command the cooling fan relay ON and OFF with a scan tool. The DMM should transition from OL when commanded OFF to less than 1 V when commanded ON. If the circuit voltage does not correspond to the specified values, test the control circuit for an open/high resistance or for a short to voltage. If the circuit tests normal, replace the K20 ECM.
5. If all circuits test normal, test or replace the appropriate KR20 relay.

Component Testing

1. Ignition OFF, disconnect the KR20 cooling fan relay.
2. Test for 70-110 ohms between terminals 85 and 86. If not within the specified range, replace the KR20 cooling fan relay.
3. Measure the resistance between the terminals listed below. The DMM should display OL. 30 and 86 30 and 87 30 and 85 85 and 87 If not the specified range, replace the KR20 cooling fan relay.
4. Test for less than 2 ohms between terminals 30 and 87A. If greater than the specified range, replace the KR20E cooling fan relay.
5. Install a 20 A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 2 ohms between terminals 30 and 87. If greater than the specified range, replace the KR20 cooling fan relay.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

1. «Relay Replacement (Within an Electrical Center)»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-repair-instructions) , «Relay Replacement (Attached to Wire Harness)»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-repair-instructions)
2. «Control Module References»(/chevrolet/malibu/viii-2011-2014/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) for ECM replacement, setup, and programming

1. Perform the «Diagnostic System Check - Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-procedure-instructions) provide an overview of each diagnostic category.

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

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

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

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

Conditions for Clearing the DTC

DTC P1258 is a Type A DTC.

Description and Operation

1. «Cooling Fan Description and Operation»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Instrument Cluster Description and Operation»(/chevrolet/malibu/viii-2011-2014/remont/gauges-instrument-panels/#instrument-panel-system-displays-and-gauges)
3. «Indicator/Warning Message Description and Operation»(/chevrolet/malibu/viii-2011-2014/remont/gauges-instrument-panels/#instrument-panel-system-displays-and-gauges)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

1. If DTC P0480 or P0481 are set, diagnose those DTCs first.
2. Observe the engine coolant level. The engine coolant level should be within the operating range. Refer to Capacities - Approximate Fluid, and Engine Coolant in the Owner's Manual.
3. Ensure that the vehicle has the correct engine coolant with correct concentration and is not old, contaminated, or contains additives. Refer to Recommended Fluids and Lubricants in the Owner's Manual.
4. Inspect the cooling system for the following: Leaks Kinked or pinched hoses, especially at the radiator Loose, missing, or damaged radiator air seals or deflectors Air flow obstructions or bent fins at the radiator or the A/C condenser-Refer to «Symptoms - Engine Cooling»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Command the cooling fans ON and OFF, low and high speed. The engine cooling fans should turn ON and OFF with each command. If the cooling fans do not function as indicated, refer to «Cooling Fan Inoperative»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Test the thermostat for correct operation. Refer to «Thermostat Diagnosis»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Test the engine cooling system for overheating. Refer to «Engine Overheating»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system__engine-overheating) .
3. Inspect the water pump and coolant flow for correct operation. Refer to «Water Pump Cleaning and Inspection»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-repair-instructions-off-vehicle) for the 3.6L engine.
4. Inspect the engine mechanical for worn/leaking/cracked cylinder heads or engine block. Refer to «Coolant in Combustion Chamber»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-diagnostic-information-and-procedures__coolant-in-combustion-chamber) , for the 3.6L engine. Also refer to «Coolant in Engine Oil»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-diagnostic-information-and-procedures__coolant-in-engine-oil) for the 3.6L engine.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

Important Preliminary Inspections Before Starting

Before using the Symptom diagnosis, perform the following

1. Perform «Diagnostic System Check - Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information) and verify all of the following items: Engine control module (ECM) and indicator lamp are operating correctly. There are no diagnostic trouble codes (DTCs) stored. Scan tool data is within a normal operating range.
2. Verify the customer concern.
3. Perform the Visual/Physical Inspection in this section. The visual/physical inspection is extremely important, and can lead to correcting a condition without additional testing. It may also help reveal the cause of an intermittent condition.
4. Locate the correct symptom. Perform the tests and inspections associated with the symptom.

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

Visual/Physical Inspection

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

1. Ensure that the control module grounds are clean, tight, and correctly located.
2. Inspect cooling system hoses and pipes for splits, kinks, and improper connections. Inspect thoroughly for any type of leak or restriction.
3. Inspect for a dirty or restricted radiator or HVAC condenser.
4. Inspect for aftermarket devices which could affect the operation of the cooling system.
5. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
6. Inspect the surge tank reservoir for proper coolant level.

Identifying Intermittent Conditions

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

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

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

Symptom List

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

1. «Cooling Fan Always On»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Cooling Fan Inoperative»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system)
3. «Engine Overheating»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system__engine-overheating)
4. «Loss of Coolant»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system__loss-of-coolant)
5. «Thermostat Diagnosis»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system)
6. «Engine Fails To Reach Normal Operating Temperature»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system__engine-fails-to-reach-normal-operating)

The engine cooling fan system consists of a cooling fan assembly containing two electric cooling fans. The engine control module (ECM) uses two fan control circuits and a series of three relays to command the fans ON in either high speed or low speed, depending on cooling requirements. In low speed, both fans are turned ON at a reduced speed. High speed has both fans turned ON at full speed.

1. The scan tool cooling fan output control operates as follows: Cooling Fan Relay 1 operates both fans at a low speed Cooling Fan Relay 2 and 3 operates one fan at a high speed Cooling Fan Relay 1, 2 and 3 operates both fans at a high speed
2. KR20 cooling fan relay identification: KR20C cooling fan low speed FAN 1 Relay KR20D cooling fan high speed FAN 2 Relay KR20E cooling fan speed control FAN 3 or S/P Relay
3. When disconnecting or removing fuses and relays from a fuse block, always inspect the component electrical terminals for corrosion and the correct orientation in the fuse block. Test the mating electrical terminals for tightness.

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__circuit-testing)
2. «Connector Repairs»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__testing-for-intermittent-conditions-and-poor)
4. «Wiring Repairs»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__wiring-repairs)

Scan Tool Reference

Control Module References for scan tool information

1. Ignition ON, observe the DTC information with a scan tool. Verify that DTC P0480 or P0481 is not set. If a DTC is set, refer to «DTC P0480 or P0481»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Ignition ON, observe the scan tool FC Relay 1 and FC Relay 2 and 3 Command parameters. The parameters should display OFF.
3. Ignition ON, observe that the fan is not activated.

1. Ignition OFF, disconnect each KR20 cooling fan relay one at a time.
2. Ignition ON, observe that the cooling fans are not activated. If the fans are activated, test for a short to voltage in the relay controlled output circuit. If the fans are not activated, test or replace the appropriate KR20 cooling fan relay.

1. Ignition OFF, disconnect the KR20 cooling fan relay.
2. Test for 70-110 ohms between terminals 85 and 86. If not within the specified range, replace the KR20 cooling fan relay.
3. Measure the resistance between the terminals listed below. The DMM should display OL. 30 and 86 30 and 87 30 and 85 85 and 87 If not the specified range, replace the KR20 cooling fan relay.
4. Test for less than 2 ohms between terminals 30 and 87A. If greater than the specified range, replace the KR20E cooling fan relay.
5. Install a 20 A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 2 ohms between terminals 30 and 87. If greater than the specified range, replace the KR20 cooling fan relay.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

Relay Replacement (Within an Electrical Center) , Relay Replacement (Attached to Wire Harness)

1. Perform the «Diagnostic System Check - Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-procedure-instructions) provides an overview of each diagnostic category.

The engine cooling fan system consists of a cooling fan assembly containing two electric cooling fans. The engine control module (ECM) uses two fan control circuits and a series of three relays to command the fans ON in either high speed or low speed, depending on cooling requirements. In low speed, both fans are turned ON at a reduced speed. High speed has both fans turned ON at full speed.

1. The scan tool cooling fan output control operates as follows: Cooling Fan Relay 1 operates both fans at a low speed Cooling Fan Relay 2 and 3 operates one fan at a high speed Cooling Fan Relay 1, 2 and 3 operates both fans at a high speed
2. KR20 cooling fan relay identification: KR20C cooling fan low speed FAN 1 Relay KR20D cooling fan high speed FAN 2 Relay KR20E cooling fan speed control FAN 3 or S/P Relay
3. When disconnecting or removing fuses and relays from a fuse block, always inspect the component electrical terminals for corrosion and the correct orientation in the fuse block. Test the mating electrical terminals for tightness.

Schematic Reference

Engine Cooling Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__circuit-testing)
2. «Connector Repairs»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__connector-repairs)
3. «Testing for Intermittent Conditions and Poor Connections»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__testing-for-intermittent-conditions-and-poor)
4. «Wiring Repairs»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__wiring-repairs)

Scan Tool Reference

Control Module References for scan tool information

1. Ignition ON, observe the DTC information with a scan tool. Verify that DTC P0480 or P0481 is not set. If a DTC is set, refer to «DTC P0480 or P0481»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Ignition ON, command the appropriate fan relay ON and OFF with a scan tool. Verify that the fans turn ON and OFF when changing between the commanded states.

1. Ignition OFF, disconnect the KR20 cooling fan relays.
2. Connect a 30 A fused jumper between the KR20E S/P relay switch circuit terminal 30 and the ground circuit terminal 87.
3. Ignition ON, verify that a test lamp illuminates between ground and the relay switched ignition circuit terminal listed below: KR20C low speed FAN 1 relay terminal 30 KR20D high speed FAN 2 relay terminal 30 If the test lamp does not illuminate, test the appropriate relay switch B+ circuit for a short to ground or an open/high resistance. If the circuit tests normal and the relay switch B+ circuit fuse is open, test the relay controlled output circuit for a short to ground. If the circuit tests normal, test or replace the appropriate G10 cooling fan motor.
4. Connect a 30 A fused jumper between the KR20 cooling fan relay circuit terminals listed below. Verify the appropriate fan is activated. KR20D high speed FAN 2 relay terminals 87 and 30 KR20C low speed FAN 1 relay terminals 87 and 30 If the corresponding cooling fan does not activate, test the relay controlled output circuit and the cooling fan ground circuit for an open/high resistance. If the circuits tests normal, replace the appropriate G10 cooling fan motor. If the corresponding cooling fan activates, replace the appropriate KR20 cooling fan relay.
5. Install the KR20E S/P relay. Verify both fans activate at low speed. If both fans do not activate, test the relay controlled output circuit terminal 87A of the KR20E fan S/P relay for a short to ground or an open/high resistance.
6. If the circuits test normal, test or replace the KR20E cooling fan speed control relay.

1. Ignition OFF, disconnect the KR20 cooling fan relay.
2. Test for 70-110 ohms between terminals 85 and 86. If not within the specified range, replace the KR20 cooling fan relay.
3. Measure the resistance between the terminals listed below. The DMM should display OL. 30 and 86 30 and 87 30 and 85 85 and 87 If not the specified range, replace the KR20 cooling fan relay.
4. Test for less than 2 ohms between terminals 30 and 87A. If greater than the specified range, replace the KR20E cooling fan relay.
5. Install a 20 A fused jumper wire between relay terminal 85 and 12 volts. Install a jumper wire between relay terminal 86 and ground. Test for less than 2 ohms between terminals 30 and 87. If greater than the specified range, replace the KR20 cooling fan relay.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

1. «Relay Replacement (Within an Electrical Center)»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-repair-instructions) , «Relay Replacement (Attached to Wire Harness)»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-repair-instructions)
2. «Cooling Fan and Shroud Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system)

Engine Overheating

Engine Overheating

Loss of Coolant

Loss of Coolant

Thermostat Test Procedure Using Glycol

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

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

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

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

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

1. Perform the «Diagnostic System Check - Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information) prior to using this diagnostic procedure.
2. Review «Strategy Based Diagnosis»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information__strategy-based-diagnosis) for an overview of the diagnostic approach.
3. «Diagnostic Procedure Instructions»(/chevrolet/malibu/viii-2011-2014/remont/oem-general-information/#vehicle-diagnostic-information__diagnostic-procedure-instructions) provides an overview of each diagnostic category.

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

Electrical Information Reference

1. «Circuit Testing»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__circuit-testing)
2. «Connector Repairs»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__connector-repairs)
3. «Wiring Repairs»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures-and-connector-repair__wiring-repairs)

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

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

1. «Coolant Heater Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Coolant Heater Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system)
2. «Coolant Heater Cord Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Coolant Heater Cord Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system)

Engine Fails To Reach Normal Operating Temperature

Engine Fails To Reach Normal Operating Temperature

Pressure Cap Testing

Special Tools

1. J 24460-01 Cooling System Pressure Tester
2. J 42401 Radiator Cap/Surge Tank Test Adapter

1. Remove the pressure cap.
2. Wash the pressure cap sealing surface with water.
3. Use the J 24460-01 cooling system pressure tester (1) with J 42401 radiator cap/surge tank test adapter (2) in order to test the pressure cap.
4. Test the pressure cap for the following conditions: Pressure release when the J 24460-01 cooling system pressure tester exceeds the pressure rating of the pressure cap. Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss.
5. Replace the pressure cap under the following conditions: The pressure cap does not release pressure which exceeds the rated pressure of the cap. The pressure cap does not hold the rated pressure.

Special Tools

1. J 24460-01 Cooling System Pressure Tester
2. J 42401 Radiator Cap/Surge Tank Test Adapter

Cooling System Leak Testing

1. Remove the pressure cap.
2. Test the operation of the pressure cap. Refer to «Pressure Cap Testing»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system__pressure-cap-testing) .
3. Wash the pressure cap mating surface with water.
4. Use the J 24460-01 cooling system pressure tester with J 42401 radiator cap/surge tank test adapter in order to apply pressure to the cooling system. Do not exceed the pressure cap rating.
5. The cooling system should hold the rated pressure for at least 2 minutes. Observe the gauge for any pressure loss.
6. Repair any leaks as required.

J 26568 Coolant and Battery Fluid Tester

Draining Procedure

1. Unscrew the surge tank cap to remove vacuum when draining coolant.
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
3. Place a container under the radiator drain.
4. Unscrew the radiator drain plug until coolant flows out the radiator drain.
5. If a complete block drain is required, remove the coolant drain plugs. Refer to «Engine Block Disassemble»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-repair-instructions-off-vehicle__engine-block-disassemble) .
6. Follow the appropriate procedure based on the condition of the coolant: Normal in appearance-Follow the filling procedure. Discolored-Follow the flush procedure. Refer to «Flushing»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system__flushing) .

Fill Procedure

1. Install the engine block coolant drain plugs. Refer to «Engine Block Assemble»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-repair-instructions-off-vehicle__engine-block-assemble)
2. Close the radiator drain plug.
3. Lower the vehicle.
4. Vehicle should be level.
5. Add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water until the level stabilizes approximately 1" (25.4 mm) above the weld seam on the surge tank. Refer to «Approximate Fluid Capacities»(/chevrolet/malibu/viii-2011-2014/remont/lubrication-system/#maintenance-and-lubrication__approximate-fluid-capacities) .
6. Install the surge tank cap.
7. Start the engine and run at 2, 000 RPM until the engine cooling fans turn ON.
8. Turn the engine OFF and allow the engine to cool down.
9. Remove the surge tank cap.
10. Refill to approximately 1" (25.4 mm) above the weld seam on the surge tank.
11. Inspect the concentration of the engine coolant using J 26568 coolant and battery fluid tester.
12. Install the surge tank cap.
13. Rinse away any excess coolant from the engine and the engine compartment.

1. J 26568 Coolant and Battery Fluid Tester
2. J 42401 Radiator Pressure Adapter
3. GE-47716 Vac N Fill Coolant Refill Tool

1. Unscrew the surge tank cap to remove vacuum when draining the coolant.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
3. Place a container under the radiator drain.
4. Unscrew the radiator drain plug until coolant flows out the radiator drain.
5. If a complete block drain is required, remove the drain plugs. Refer to «Draining Fluids and Oil Filter Removal»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-24l__draining-fluids-and-oil-filter-removal) , for the 2.4L engine, or «Engine Block Disassemble»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-repair-instructions-off-vehicle__engine-block-disassemble) for the 3.6L engine.
6. Follow the appropriate procedure based on the condition of the coolant. Normal in appearance-follow the filling procedure. Discolored-follow the flush procedure. Refer to «Flushing»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system__flushing) .

Vac N Fill Procedure

Note. To prevent boiling of the coolant/water mixture in the vehicles cooling system, do not apply vacuum to a cooling system above 49°C (120°F). The tool will not operate properly when the coolant is boiling.

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

1. «Engine Block Assemble»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-24l__engine-block-assemble) for the 2.4L engine
2. «Engine Block Disassemble»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-repair-instructions-off-vehicle__engine-block-disassemble) for the 3.6L engine

1. Install J-42401-2 into the surge tank fill neck.
2. Install J-42401-3 to the surge tank fill neck.
3. Attach the Vac N Fill cap to the J-42401-3.
4. Attach the Vac N Fill cap to the vehicles coolant fill port.
5. Attach the vacuum gauge assembly to the Vac N Fill cap.
6. Attach the fill hose to the barb fitting on the vacuum gauge assembly. Ensure the valve is closed.
7. Pour the coolant mixture into the graduated reservoir.
8. Place the fill hose in the graduated reservoir.
9. Install the vacuum tank on the graduated reservoir with the fill hose routed through the cut-out area in the vacuum tank.
10. Attach the venturi assembly to the vacuum tank.
11. Attach a shop air hose to the venturi assembly. Ensure the valve on the venturi assembly is closed.
12. Attach the vacuum hose to the vacuum gauge assembly and the vacuum tank.
13. Open the valve on the venturi assembly. The vacuum gauge will begin to rise and a hissing noise will be present.
14. Continue to draw vacuum until the needle stops rising. This should be 610-660 mm Hg (24-26 in Hg). Cooling hoses may start to collapse. This is normal due to vacuum draw.
15. To aid in the fill process, position the graduated reservoir above the coolant fill port.
16. Slowly open the valve on the vacuum gauge assembly. When the coolant reaches the top of the fill hose, close the valve. This will eliminate air from the fill hose.
17. Close the valve on the venturi assembly.
18. If there is a suspected leak in the cooling system, allow the system to stabilize under vacuum and monitor for vacuum loss. If vacuum loss is observed, refer to «Loss of Coolant»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system__loss-of-coolant) .
19. Open the valve on the vacuum gauge assembly. The vacuum gauge will drop as coolant is drawn into the system.
20. Once the vacuum gauge reaches zero, close the valve on the vacuum gauge assembly and repeat steps 11-17.
21. Remove the J-42401-3 from the surge tank fill neck.
22. Remove J-42401-2 from the surge tank fill neck.
23. Detach the Vac N Fill cap from the vehicles coolant fill port.
24. Add coolant to the system as necessary.
25. Inspect the concentration of the coolant mixture using J 26568 coolant and battery fluid tester.
26. Detach the vacuum hose from the vacuum gauge assembly.
27. Attach the extraction hose to the vacuum hose.
28. Open the valve on the venturi assembly to start a vacuum draw.
29. Use the extraction hose to draw out coolant to the proper level.
30. Install the surge tank cap.
31. The vacuum tank has a drain valve on the bottom of the tank. Open the valve to drain coolant from the vacuum tank into a suitable container for disposal.

Flushing

1. Apply the park brake.
2. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Fill the coolant system with clean drinkable water. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Start the engine and run at 2, 000 RPM until the thermostat opens.
5. Turn OFF the engine.
6. Drain the coolant system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
7. Repeat the above procedure until the water from the coolant system is colorless.
8. Drain the coolant system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
9. Add 3.8 liters (1.0 gal) of concentrated antifreeze since there will be some water in the system.
10. Add a mixture of 50/50 DEX-COOL® antifreeze and clean drinkable water until the level stabilizes at the weld seam on the surge tank. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

Radiator Cleaning

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

Scheme 2

Radiator Surge Tank Replacement

Scheme 3

Radiator Surge Tank Inlet Hose/Pipe Replacement (LE5, LE9)

Scheme 4

Radiator Surge Tank Inlet Hose/Pipe Replacement (LY7)

Scheme 5

Radiator Surge Tank Outlet Hose/Pipe Replacement (LE5, LE9)

Scheme 6

Radiator Surge Tank Outlet Hose/Pipe Replacement (LY7)

Scheme 7

Radiator Inlet Hose Replacement (LE5, LE9)

Scheme 8

Radiator Inlet Hose Replacement (LY7)

J 38185 Hose Clamp Pliers

Removal Procedure

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Reposition the radiator outlet hose clamp at the radiator using the J 38185 hose clamp pliers.
3. Remove the radiator outlet hose from the radiator.
4. Reposition the radiator outlet hose clamp at the engine using the J 38185 hose clamp pliers.
5. Remove the radiator outlet hose from the engine.
6. Remove the radiator outlet hose clamps from the radiator outlet hose.

Installation Procedure

1. Install the radiator outlet hose clamps to the radiator outlet hose.
2. Install the radiator outlet hose to the engine.
3. Reposition the radiator outlet hose clamp at the engine using the J 38185 hose clamp pliers.
4. Install the radiator outlet hose to the radiator.
5. Reposition the radiator outlet hose clamp at the radiator using the J 38185 hose clamp pliers.
6. Fill the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 9

Radiator Outlet Hose Replacement (LY7)

Scheme 10

Radiator Outlet Pipe Replacement

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner air duct. Refer to the following: «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/viii-2011-2014/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) for the 2.4L engine «Air Cleaner Inlet Duct Replacement»(/chevrolet/malibu/viii-2011-2014/remont/testing-diagnostics/#engine-controlsfuel-36l-repair-instructions) for the 3.6L engine
3. Remove the upper radiator air deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove the transmission oil cooler pipes from the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(/chevrolet/malibu/viii-2011-2014/remont/automatic-trans/#automatic-transmission-6t70-repair-instructions-on-vehicle) .
5. Loop a rope around each of the upper 2 tabs of the condenser and tie a rope around the upper tie bar.
6. Remove the upper radiator support bracket bolts.
7. Remove the upper radiator support brackets.
8. Pry upward on the fan shroud tabs at the radiator clips to release the fan shroud from the radiator.
9. Remove the lower radiator air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
10. Lower the vehicle.
11. Remove the radiator inlet hose from the radiator. Refer to «Radiator Inlet Hose Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Radiator Inlet Hose Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
12. Remove the radiator outlet hose from the radiator. Refer to «Radiator Outlet Hose Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Radiator Outlet Hose Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
13. Disconnect the cooling fan wire harness connectors.
14. Remove the A/C compressor and condenser hose assembly. Refer to «Air Conditioning Compressor and Condenser Hose Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Air Conditioning Compressor and Condenser Hose Replacement (LE5)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
15. Raise the vehicle.
16. Remove the lower radiator support bracket bolts.
17. Remove the lower radiator support brackets.
18. Remove the transmission oil cooler pipe clip from the fan shroud.
19. Remove the fan shroud assembly.

1. Install the fan shroud assembly.
2. Install the transmission oil cooler pipes to the radiator. Refer to «Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection»(/chevrolet/malibu/viii-2011-2014/remont/automatic-trans/#automatic-transmission-6t40-repair-instructions-on-vehicle) for the 4T45-E transaxle.
3. Install the transmission oil cooler pipe clip to the fan shroud.
4. Install the lower radiator support brackets.
5. Install the lower radiator support bracket bolts and tighten to 60 N.m (44 lb ft).
6. Install the cooling fan wire harness connectors.
7. Install the radiator outlet hose to the radiator. Refer to «Radiator Outlet Hose Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Radiator Outlet Hose Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Install the lower radiator air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
9. Lower the vehicle.
10. Snap fan shroud tabs into the radiator clips.
11. Remove the rope attached to the condenser and upper tie bar.
12. Install the upper radiator support brackets.
13. Install the upper radiator support bracket bolts and tighten to 10 N.m (89 lb in).
14. Install the radiator inlet hose to the radiator. Refer to «Radiator Inlet Hose Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Radiator Inlet Hose Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
15. Install the A/C compressor and condenser hose assembly. Refer to «Air Conditioning Compressor and Condenser Hose Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Air Conditioning Compressor and Condenser Hose Replacement (LE5)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
16. Install the upper radiator air deflector. Refer to «Radiator Air Upper Baffle and Deflector Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
17. Install the air cleaner air duct. Refer to the following: «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/viii-2011-2014/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) for the 2.4L engine «Air Cleaner Inlet Duct Replacement»(/chevrolet/malibu/viii-2011-2014/remont/testing-diagnostics/#engine-controlsfuel-36l-repair-instructions) for the 3.6L engine
18. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
19. Inspect the transmission fluid level. Refer to «Transmission Fluid Level and Condition Check»(/chevrolet/malibu/viii-2011-2014/remont/automatic-trans/#automatic-transmission-6t70-diagnostic-information-and-procedures__transmission-fluid-level-and-condition-check) .

1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/viii-2011-2014/remont/testing-diagnostics/#engine-controlsfuel-36l-repair-instructions)
3. Remove the radiator outlet hose from the thermostat housing.
4. Remove the heater inlet and outlet hoses.
5. Remove the surge tank outlet hose.
6. Remove the thermostat housing bolts (1).
7. Remove the housing.

1. Install the thermostat housing bolts and tighten to 10 N.m (89 lb in).
2. Install the surge tank outlet hose.
3. Install the heater inlet and outlet hoses.
4. Install the radiator outlet hose to the thermostat housing.
5. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/chevrolet/malibu/viii-2011-2014/remont/testing-diagnostics/#engine-controlsfuel-36l-repair-instructions)
6. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the water pump drain plug and drain the coolant from the engine block at the water pump drain.
3. Lower the vehicle.
4. Disconnect the engine coolant temperature (ECT) sensor electrical connector (1).
5. Disconnect the heated oxygen sensor (HO2S) electrical connector clip from the bracket.
6. Remove the ECT sensor.
7. Remove the surge tank outlet hose from the thermostat housing.
8. Reposition the radiator outlet hose clamp at the thermostat housing.
9. Remove the radiator outlet hose from the thermostat housing.
10. Remove the exhaust heat shield bolts.
11. Remove the exhaust heat shield.
12. Reposition the heater inlet and outlet hose clamps at the thermostat housing pipes.
13. Disconnect the heater inlet (1) and outlet (2) hoses from the thermostat housing pipes.
14. Remove the thermostat housing bolts.
15. Remove the thermostat housing from the vehicle.
16. Remove the water transfer pipe from the thermostat housing, if necessary.
17. Remove and discard the water transfer pipe O-ring seals, if necessary.
18. Remove the thermostat housing cover bolts and cover, if necessary.
19. Remove the thermostat, if necessary.
20. Remove and discard the thermostat housing O-ring seal, if necessary.
21. Remove all debris and thread sealant from the engine coolant temperature sensor and bolt holes if the housing is being re-used.

1. Install a NEW thermostat housing cover O-ring seal into the recess groove.
2. Install the thermostat, if necessary.
3. Install the thermostat housing cover bolts, if necessary. Tighten the bolts to 10 N.m (89 lb in).
4. Install a NEW thermostat housing to engine O-ring seal onto the thermostat housing.
5. Load the thermostat housing assembly into position while the vehicle is lowered.
6. Install NEW O-ring seals onto the water feed pipe.
7. Install the water feed pipe into the thermostat housing aligning locator tab.
8. Align the water pipe to water pump.
9. Seat the water feed O-ring seal by pushing inward toward the water pump. Take care not to tear or damage the O-ring.
10. Position the thermostat housing against the engine.
11. Install the thermostat housing bolts and tighten to 10 N.m (89 lb in).
12. Connect the heater inlet (1) and outlet (2) hoses to the thermostat housing pipes.
13. Position the heater inlet and outlet hose clamps at the thermostat housing pipes.
14. Install the exhaust heat shield.
15. Install the exhaust heat shield bolts and tighten to 23 N.m (17 lb ft).
16. Install the radiator outlet hose to the thermostat housing.
17. Position the radiator outlet hose clamp at the thermostat housing.
18. Install the radiator outlet hose to the surge tank.
19. Position the radiator outlet hose clamp at the surge tank.
20. Apply sealant to the threads of the ECT sensor. Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system__adhesives-fluids-lubricants-and-sealers) .
21. Install the ECT sensor and tighten to 20 N.m (15 lb ft).
22. Connect the ECT sensor electrical connector (1).
23. Connect the HO2S electrical connector clip to the bracket.
24. Apply sealant to the water pump drain plug.Refer to «Adhesives, Fluids, Lubricants, and Sealers»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system__adhesives-fluids-lubricants-and-sealers)
25. Install the water pump drain plug and tighten to 20 N.m (15 lb ft).
26. Verify the drain valves at the radiator and water pump are closed.
27. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
28. Verify the repair and inspect for any leaks.

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Reposition the radiator outlet hose clamp at the thermostat cover.
3. Remove the radiator outlet hose from the thermostat cover.
4. Remove the thermostat cover bolts and cover.
5. Remove the thermostat.
6. Remove and discard the thermostat cover O-ring seal.

1. Install a NEW thermostat cover O-ring seal.
2. Install the thermostat.
3. Install the thermostat cover bolts and tighten to 10 N.m (89 lb in).
4. Install the radiator outlet hose to the thermostat cover.
5. Position the radiator outlet hose clamp at the thermostat cover.
6. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Partially drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the radiator outlet hose from the thermostat housing.
3. Remove the heater inlet and outlet hoses.
4. Remove the surge tank outlet hose.
5. Remove the thermostat housing bolts (1).
6. Remove the housing.
7. Remove the thermostat (2) and discard the thermostat gasket.

1. Install the thermostat (2) with a NEW thermostat gasket.
2. Install the thermostat housing bolts (1) and tighten to 10 N.m (89 lb in).
3. Install the surge tank outlet hose.
4. Install the heater inlet and outlet hoses.
5. Install the radiator outlet hose to the thermostat housing.
6. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the intake manifold cover. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) .
2. Remove the surge tank inlet hose. Refer to «Radiator Surge Tank Inlet Hose/Pipe Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Radiator Surge Tank Inlet Hose/Pipe Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the fuel feed pipe line nut (2).
4. Remove the fuel feed line clip from the stud and reposition the fuel feed line.
5. Remove the coolant air bleed hose/pipe bolt (3) from the upper intake manifold.
6. Reposition the coolant air bleed hose clamp (2) at the water outlet.
7. Remove the coolant air bleed hose from the water outlet.
8. Remove the coolant air bleed hose/pipe from the engine.

1. Install the coolant air bleed hose/pipe to the engine.
2. Install the coolant air bleed hose to the water outlet.
3. Position the coolant air bleed hose clamp (2) at the water outlet.
4. Install the coolant air bleed hose/pipe bolt (3) to the upper intake manifold and tighten to 10 N.m (89 lb in).
5. Position the fuel feed line and install the fuel feed line clip to the stud.
6. Install the fuel feed pipe line nut (2) and tighten to 10 N.m (89 lb in).
7. Install the surge tank inlet hose. Refer to «Radiator Surge Tank Inlet Hose/Pipe Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Radiator Surge Tank Inlet Hose/Pipe Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
8. Install the intake manifold cover. Refer to «Fuel Injector Sight Shield Replacement»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) .

Scheme 11

Water Outlet Replacement (LY7)

EN 46104 Water Pump Pulley Holding Tool

1. Drain the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) .
3. Use the EN 46104 water pump pulley holding tool in order to retain the water pump pulley.
4. Remove the water pump pulley bolts and DISCARD the bolts.
5. Remove the water pump pulley.
6. Remove the water pump bolts and DISCARD the bolts.
7. Remove the water pump.
8. Remove and DISCARD the water pump seal.
9. Carefully clean the water pump sealing surfaces.

1. Install a NEW water pump seal.
2. Install the water pump.
3. Install the NEW water pump bolts and hand tighten the water pump bolts.
4. Tighten the water pump bolts in sequence. On the initial pass, tighten the bolts in sequence to 10 (89 lb in). On the second pass, tighten the bolts in sequence to 10 (89 lb in). On the final pass, tighten the bolts in sequence shown an additional 45 degrees.
5. Install the water pump pulley and the NEW water pump pulley bolts.
6. Use the EN 46104 water pump pulley holding tool in order to retain the water pump pulley.
7. Install the water pump pulley bolts and tighten to 10 (89 lb in).
8. Install the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) .
9. Fill the cooling system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

EN-43651 Water Pump Holding Tool

For equivalent regional tools, refer to Special Tools .

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/viii-2011-2014/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) .
2. Remove the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LE5 or LE9 With MH8)»(/chevrolet/malibu/viii-2011-2014/remont/exhaust/#engine-exhaust-system) .
3. If equipped, remove the coolant heater. Refer to «Coolant Heater Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Coolant Heater Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove the catalytic converter. Refer to «Catalytic Converter Replacement (LAT, LE9 or LE5)»(/chevrolet/malibu/viii-2011-2014/remont/exhaust/#engine-exhaust-system) , «Catalytic Converter Replacement (LE5 or LE9 With MH8)»(/chevrolet/malibu/viii-2011-2014/remont/exhaust/#engine-exhaust-system) .
5. Remove the engine coolant thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Engine Coolant Thermostat Housing Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Remove the water pump cover (2), fasteners (3) and gasket (1) from the engine front cover.
7. Drain the coolant from the water pump using the plug at the bottom of the pump. Install the plug when finished.
8. Align the EN-43651 water pump holding tool (1) with the threads on the water pump sprocket. Tighten the water pump holding tool fasteners (2).
9. Secure the water pump holding tool with the previously removed water pump cover fasteners (1) into the engine front cover.
10. Remove the water pump sprocket to water pump fasteners (1).
11. Remove the front water pump fasteners (1).
12. Remove the rear water pump fasteners (1).
13. Remove the water pump (1).
14. If replacing the water pump cover remove the water pump rear cover fasteners (4).
15. Separate the water pump cover (1) from the water pump (3)
16. Remove and discard the water pump O-ring seal (2).

1. If replacing the water pump cover (1), install a new O-ring (2) to the water pump (3) and tighten the fasteners (4) to 25 N.m (18 lb ft)
2. Using a guide pin (2), align the pin with the water pump holding tool.
3. Position the water pump (1) against the engine block and hand tighten the water pump fasteners (3).
4. Install 2 water pump sprocket to water pump fasteners (1). After the fasteners are snug, remove the guide pin (2) and install the 3rd Fastener (3) and tighten to 10 N.m (89 lb in).
5. Install the water pump fasteners (1) at the front of the engine. Hand tighten at this time.
6. Tighten the water pump fasteners at the front and rear of the water pump to 25 N.m (18 lb ft).
7. Remove the water pump cover fasteners (1) from the engine front cover and water pump holding tool.
8. Remove the EN-43651 water pump holding tool (1) from the water pump sprocket.
9. Install the water pump access plate (2) gasket (1) and fasteners (3) and tighten to 10 N.m (89 lb in).
10. If equipped, Install the coolant heater. Refer to «Coolant Heater Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Coolant Heater Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
11. Install the engine coolant thermostat housing. Refer to «Engine Coolant Thermostat Housing Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Engine Coolant Thermostat Housing Replacement (LE5, LE9)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
12. Install the catalytic converter. Refer to «Catalytic Converter Replacement (LAT, LE9 or LE5)»(/chevrolet/malibu/viii-2011-2014/remont/exhaust/#engine-exhaust-system) , «Catalytic Converter Replacement (LE5 or LE9 With MH8)»(/chevrolet/malibu/viii-2011-2014/remont/exhaust/#engine-exhaust-system)
13. Install the exhaust manifold heat shield. Refer to «Exhaust Manifold Heat Shield Replacement (LE5 or LE9 With MH8)»(/chevrolet/malibu/viii-2011-2014/remont/exhaust/#engine-exhaust-system) .
14. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/viii-2011-2014/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) .
15. Refill the coolant system. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the cooling fan and shroud assembly. Refer to «Cooling Fan and Shroud Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove and discard the condenser mounting bolts.
3. Push upward on the condenser and downward on the radiator to unsnap the condenser mounting tabs from the radiator clips.
4. Remove and discard the condenser mounting nuts from the radiator.
5. Remove the radiator from the vehicle.

1. Install the radiator to the vehicle.
2. Push upward on the radiator and downward on the condenser to snap the condenser mounting tabs into the radiator clips.
3. Install new condenser mounting nut to the radiator and tighten to 6 N.m (53 lb in).
4. Install new condenser mounting bolts and tighten to 6 N.m (53 lb in).
5. Install the cooling fan and shroud assembly. Refer to «Cooling Fan and Shroud Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Loop a rope around each of the upper 2 tabs of the condenser and tie the rope around the upper tie bar.
3. Remove the upper radiator support brackets. Refer to «Radiator Support Bracket Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Reposition the radiator inlet hose clamp at the radiator using J 38185 hose clamp pliers.
5. Remove the radiator inlet hose from the radiator.
6. Remove the right engine splash shield retainers.
7. Remove the right engine splash shield.
8. Remove the left engine splash shield retainers.
9. Remove the left engine splash shield.
10. Reposition the radiator outlet hose clamp at the radiator using J 38185 hose clamp pliers.
11. Remove the radiator outlet hose from the radiator.
12. Remove the transmission oil cooler pipes from the radiator.
13. Remove the lower radiator support bracket bolts.
14. Remove the lower radiator support brackets.
15. Remove the radiator lower mounts.
16. Remove and discard the condenser mounting bolts from the radiator.
17. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clips.
18. Remove and discard the condenser mounting nuts from the radiator.
19. Remove the radiator air side seals.
20. Remove the radiator and cooling fan shroud assembly from the vehicle.
21. Pry upward on the fan shroud tabs at the radiator clips.
22. Remove the cooling fan and shroud assembly from the radiator.

1. Install the cooling fan and shroud assembly to the radiator.
2. Snap the fan shroud tabs into the radiator clips.
3. Install the radiator and cooling fan shroud assembly to the vehicle.
4. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
5. Install the condenser mounting nuts to the radiator.
6. Insert the condenser mounting tabs into the radiator clips.
7. Install the condenser to the radiator bolts and tighten to 6 N.m (53 lb in).
8. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
9. The radiator air side seals must be in the proper position for proper air flow.
10. Install the radiator lower mounts.
11. Install the lower radiator support brackets.
12. Install the lower radiator support bracket bolts and tighten to 60 N.m (44 lb ft).
13. Install the transmission oil cooler pipes to the radiator.
14. Install the radiator outlet hose to the radiator.
15. Reposition the radiator outlet hose clamp at the radiator using J 38185 hose clamp pliers.
16. Install the left engine splash shield.
17. Install the left engine splash shield retainers.
18. Install the right engine splash shield.
19. Install the right engine splash shield retainers.
20. Lower the vehicle.
21. Install the radiator inlet hose to the radiator.
22. Reposition the radiator inlet hose clamp at the radiator using J 38185 hose clamp pliers.
23. Remove the rope attached to the condenser and upper tie bar.
24. Install the upper radiator support brackets. Refer to «Radiator Support Bracket Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
25. Fill the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
26. Inspect the transmission fluid level. Refer to «Transmission Fluid Level and Condition Check»(/chevrolet/malibu/viii-2011-2014/remont/automatic-trans/#automatic-transmission-6t70-diagnostic-information-and-procedures__transmission-fluid-level-and-condition-check) .

Scheme 12

Radiator Support Bracket Replacement

Scheme 13

Radiator Support Replacement

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
2. Remove the lower radiator air deflector retainers.
3. Remove the lower radiator air deflector.

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

1. Remove the upper front fascia. Refer to «Front Bumper Fascia Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exterior-body-panels/#bumpers-and-fascias) .
2. Remove the lower radiator air baffle. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the side radiator air deflector retainer.
4. Remove the side radiator air deflector.

1. Install the side radiator air deflector.
2. Install the side radiator air deflector retainer.
3. Install the lower radiator air baffle. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Install the upper front fascia. Refer to «Front Bumper Fascia Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exterior-body-panels/#bumpers-and-fascias) .

1. Remove the front fascia. Refer to «Front Bumper Fascia Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exterior-body-panels/#bumpers-and-fascias) .
2. Remove the upper radiator air deflector.

1. Install the upper radiator air deflector.
2. Install the front fasica. Refer to «Front Bumper Fascia Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exterior-body-panels/#bumpers-and-fascias) .

1. Remove the air cleaner assembly.
2. Disconnect the coolant heater cord.
3. Remove the coolant heater bolt.
4. Remove the coolant heater.

1. Install the coolant heater.
2. Install the coolant heater bolt and tighten to 10 N.m (89 lb in).
3. Connect the coolant heater cord.
4. Install the air cleaner assembly.

1. Raise and support vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
2. Disconnect the coolant heater cord (1).
3. Remove the coolant heater bolt.
4. Remove the coolant heater.

1. Install the coolant heater.
2. Install the coolant heater bolt and tighten to 10 N.m (89 lb in).
3. Connect the coolant heater cord (1).
4. Lower the vehicle.

1. Disconnect the engine coolant heater cord.
2. Disconnect the clip from the air conditioning (A/C) line.
3. Disconnect the clip from the front compartment inner side upper rail.
4. Remove the heater cord.

1. Install the heater cord.
2. Connect the clip to the front compartment inner side upper rail.
3. Connect the clip to the A/C line.
4. Connect the engine coolant heater cord.

1. Remove the surge tank fasteners and reposition the tank aside. Refer to «Radiator Surge Tank Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Disconnect the engine coolant heater cord (1).
3. Disconnect the clip (1) from the transmission range selector lever cable bracket (2).
4. Remove the heater cord (1).

1. Install the heater cord (1).
2. Connect the clip (1) to the transmission range selector lever cable bracket (2).
3. Connect the engine coolant heater cord (1).
4. Reposition the surge tank and install the fasteners. Refer to «Radiator Surge Tank Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 14

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

During low speed operation, the ECM supplies the ground path for the low speed fan relay, which is cool/fan 1 relay 28, through the low speed cooling fan relay control circuit. This energizes the low speed fan relay coil, closes the relay contacts, and supplies battery positive voltage from the cool fan 1 fuse 17 through the cooling fan motor supply voltage circuit to the left cooling fan. The ground path for the left cooling fan is through the series/parallel relay, which is cool/fan ser/par relay 29, and the right cooling fan. The result is a series circuit with both fans running at low speed.

During high speed operation the ECM supplies the ground path for the low speed fan relay through the low speed cooling fan relay control circuit. The ECM supplies a ground path for the high speed fan relay, which is cool/fan 2 relay 30, and the series/parallel relay through the high speed cooling fan relay control circuit. This energizes the series/parallel relay coil, closes the relay contacts, and provides a ground path for the left cooling fan. At the same time the high fan speed relay coil is energized closing the relay contacts and provides battery positive voltage from the cool fan 2 fuse 18 on the cooling fan motor supply voltage circuit to the right cooling fan. During high speed fan operation, both engine cooling fans have their own ground path. The result is a parallel circuit with both fans running at high speed.

When the request for fan activation is withdrawn, the fan may not turn OFF until the ignition switch is moved to the OFF position or the vehicle speed exceeds approximately 10 mph. This is to prevent a fan from cycling ON and OFF excessively at idle.

Cooling Fan Control

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

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

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

The PCM or ECM commands Low Speed Fans ON under the following conditions

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

The PCM or ECM commands High Speed Fans ON under the following conditions

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

Engine Coolant Indicators

TEMP

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

Coolant Level Control

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

Coolant Heater

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

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

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

Cooling Cycle

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

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

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

Coolant is also directed to the throttle body. There the coolant circulates through passages in the casting. During initial start up, the coolant assists in warming the throttle body.

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

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

Coolant

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

Radiator

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

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

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

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

Pressure Cap

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

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

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

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

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

Coolant Recovery System

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

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

Air Baffles and Seals

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

Water Pump

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

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

Thermostat

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

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

Transmission Oil Cooler

The transmission oil cooler is a heat exchanger and is located inside the right side end tank of the radiator. The transmission fluid temperature is regulated by the temperature of the engine coolant that surrounds the oil cooler as the transmission fluid passes through the cooler.

The transmission oil pump circulates the fluid through the feed line to the oil cooler. The fluid then flows through the cooler while the engine coolant absorbs heat from the fluid. The fluid is then pumped through the return line to the transmission.

Illustration Tool Number/ Description GE 47622 Hose Clamp Pliers Brazil- Use local equivalent GE 47716 Vac N Fill Coolant Refill Tool Brazil- Use local equivalent J 24460-01 Radiator Pressure Tester J 24731 Tempil Stick J 25025-5 Dial Indicator Mounting Post Brazil- Use local equivalent J 26568 Coolant and Battery Fluid Tester Brazil- Use local equivalent J 38185 Hose Clamp Pliers Brazil- Use local equivalent J 42220 Universal 12V Leak Detection Lamp Brazil- Use local equivalent J 42401 Radiator Cap/Surge Tank Tester Adapter J 43244 Relay Puller Pliers Brazil- Use local equivalent J 43651 Water Pump Holding Tool

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See also:
• Diagnostic System Check - Vehicle
• Strategy Based Diagnosis
• Diagnostic Procedure Instructions
• COMPONENT CONNECTOR END VIEWS - INDEX
• Circuit Testing
• Connector Repairs
• Testing for Intermittent Conditions and Poor Connections
• Wiring Repairs
• Control Module References
• Diagnostic Repair Verification
• Relay Replacement (Within an Electrical Center)
• Instrument Cluster Description and Operation
• Water Pump Cleaning and Inspection
• Coolant in Combustion Chamber
• Coolant in Engine Oil
• Engine Coolant Temperature Sensor Replacement
• Engine Coolant Temperature Sensor Replacement
• Moving Parts and Hot Surfaces Warning
• Approximate Fluid Capacities
• Heater Core Replacement
• Engine Coolant/Water in Transmission
• Engine Coolant/Water in Transmission
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Engine Will Not Crank - Crankshaft Will Not Rotate
• Coolant in Combustion Chamber
• Coolant in Engine Oil
• Lower Engine Noise, Regardless of Engine Speed
• Lower Engine Noise, Regardless of Engine Speed
• Lifting and Jacking the Vehicle
• Engine Block Disassemble
• Engine Block Assemble
• Draining Fluids and Oil Filter Removal
• Engine Block Assemble
• Fastener Caution
• Engine Control Module Replacement (LE5)
• Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
• Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection
• Transmission Fluid Level and Condition Check
• Fuel Injector Sight Shield Replacement
• Power Steering Fluid Reservoir Replacement
• Exhaust Manifold Heat Shield Replacement (LE5 or LE9 With MH8)
• Front Compartment Sight Shields Replacement
• Front Bumper Fascia Replacement
• DTC P0480 or P0481
• Engine Overheating
• Loss of Coolant
• Engine Fails To Reach Normal Operating Temperature
• Flushing
• Cooling System Leak Testing
• Pressure Cap Testing
• Adhesives, Fluids, Lubricants, and Sealers