Engine Cooling System: Other Chevrolet Malibu VIII рестайлинг

Temperature Versus Resistance

Temperature Versus Resistance

Reference Information

Schematic Reference

Engine Controls Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Electrical Information Reference

1. «Circuit Testing»(ref-609142-S10104287192014041500000)
2. «Connector Repairs»(ref-609142-S09769844092014041500000)
3. «Testing for Intermittent Conditions and Poor Connections»(ref-609142-S01252147272014041500000)
4. «Wiring Repairs»(ref-609142-S33200196142014041500000)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

Circuit/System Verification

1. Ignition ON.
2. Verify the scan tool Radiator Coolant Temperature Sensor parameter is between -39 to + 120°C (-38 to +248°F) and changes with engine run time. If not between -39 to + 120°C (-38 to +248°F) or does not change Refer to Circuit/System Testing (below). If between -39 to + 120°C (-38 to +248°F) and changes
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.
4. Verify the DTC does not set. If the DTC sets Refer to Circuit/System Testing (below). If the DTC does not set
5. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

1. «Engine Coolant Temperature Sensor Replacement - Radiator (LUK LTG)»(ref-609148-S40539279822014041500000) for radiator coolant temperature sensor replacement.
2. «Engine Control Module Replacement (LTG)»(ref-609171-S01383956392014041500000) , «Engine Control Module Replacement (LKW)»(ref-609171-S20550585252014041500000) for engine control module replacement, programming, and setup.

Schematic Reference

Engine Controls Schematics

Electrical Information Reference

1. «Circuit Testing»(ref-609142-S10104287192014041500000)
2. «Connector Repairs»(ref-609142-S09769844092014041500000)
3. «Testing for Intermittent Conditions and Poor Connections»(ref-609142-S01252147272014041500000)
4. «Wiring Repairs»(ref-609142-S33200196142014041500000)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

1. Ignition ON.
2. Verify that DTC P00B3, P00B4, P0480, P0481, P0597, P0598, or P0599 are not set. If DTC P00B3, P00B4, P0480, P0481, P0597, P0598, or P0599 are set Refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(ref-609122-S17202613242014041500000) . If DTC P00B3, P00B4, P0480, P0481, P0597, P0598, or P0599 are not set
3. Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks. If the coolant in the radiator surge tank is not at the correct level or there are engine coolant leaks Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) , and «Loss of Coolant»(ref-609148-S07951242992014041500000) . If the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks
4. Verify the engine cooling fan operates. If the engine cooling fan does not operate Refer to «Cooling Fan Inoperative»(ref-609148-S28948602692014041500000) . If the engine cooling fan operates
5. Engine idling for 15 min with the A/C OFF.
6. Command the Engine Coolant Thermostat Heater to 100% with a scan tool. Increase the engine speed to 3 000 RPM. Observe the scan tool ECT sensor parameters. The temperature should decrease to less than 85°C (185°F). If the temperature does not decrease to less than 85°C (185°F). Refer to Circuit/System Testing (below). If the temperature does decrease to less than 85°C (185°F).
7. All OK.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

Engine Coolant Thermostat Housing Replacement (LUK) , Engine Coolant Thermostat Housing Replacement (LTG) , Engine Coolant Thermostat Housing Replacement (LKW)

Schematic Reference

Engine Heating/Cooling Schematics

Connector End View Reference

1. «COMPONENT CONNECTOR END VIEWS - INDEX»(ref-609269-S10785872492014041500000)
2. «Electrical Center Identification Views»(ref-609191-S00548360612014041500000)

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(ref-609142-S10104287192014041500000)
2. «Connector Repairs»(ref-609142-S09769844092014041500000)
3. «Testing for Intermittent Conditions and Poor Connections»(ref-609142-S01252147272014041500000)
4. «Wiring Repairs»(ref-609142-S33200196142014041500000)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

1. Ignition ON.
2. Verify an audible click is heard or felt from each cooling fan relay when commanding the cooling fans ON and OFF with a scan tool. If a click is not heard or felt at one or more of the relays Refer to Circuit/System Testing (below). If a click is heard or felt at each of the relays
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.
4. Verify the DTC does not set. If the DTC sets Refer to Circuit/System Testing (below). If the DTC does not set
5. All OK.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

1. «Relay Replacement (Within an Electrical Center)»(ref-609162-S34875168452014041500000) , «Relay Replacement (Attached to Wire Harness)»(ref-609162-S40990188582014041500000)
2. «Control Module References»(ref-609132-S00827563312014041500000) for ECM replacement, setup, and programming

Schematic Reference

Engine Heating/Cooling Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Electrical Information Reference

1. «Circuit Testing»(ref-609142-S10104287192014041500000)
2. «Connector Repairs»(ref-609142-S09769844092014041500000)
3. «Testing for Intermittent Conditions and Poor Connections»(ref-609142-S01252147272014041500000)
4. «Wiring Repairs»(ref-609142-S33200196142014041500000)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

1. Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks. «Loss of Coolant»(ref-609148-S07951242992014041500000) , and «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) If the coolant level is not correct Repair as necessary If the coolant level is correct
2. Ignition ON
3. Verify the parameters listed below do not display Malfunction when commanding the Engine Coolant Thermostat Heater ON and OFF with a scan tool. Engine Coolant Thermostat Heater Control Circuit Low Voltage Test Status Engine Coolant Thermostat Heater Control Circuit Open Test Status Engine Coolant Thermostat Heater Control Circuit High Voltage Test Status If Malfunction is displayed Refer to Circuit/System Testing (below). If Malfunction is not displayed
4. Operate the vehicle within the conditions for running the DTC. You may also operate the vehicle within the conditions that you observed from the freeze frame/failure records data.
5. Verify the DTC does not set. If any DTC sets Refer to Circuit/System Testing (below). If the DTC does not set
6. All OK.

Perform the Diagnostic Repair Verification after completing the repair.

1. «Engine Coolant Thermostat Housing Replacement (LUK)»(ref-609148-S06706011772014041500000) , «Engine Coolant Thermostat Housing Replacement (LTG)»(ref-609148-S26501347022014041500000) , «Engine Coolant Thermostat Housing Replacement (LKW)»(ref-609148-S23827458682014041500000) for E41 engine coolant thermostat heater replacement.
2. «Control Module References»(ref-609132-S00827563312014041500000) engine control module replacement, programming, and setup.

Schematic Reference

Engine Controls Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Electrical Information Reference

1. «Circuit Testing»(ref-609142-S10104287192014041500000)
2. «Connector Repairs»(ref-609142-S09769844092014041500000)
3. «Testing for Intermittent Conditions and Poor Connections»(ref-609142-S01252147272014041500000)
4. «Wiring Repairs»(ref-609142-S33200196142014041500000)

DTC Type Reference

Powertrain Diagnostic Trouble Code (DTC) Type Definitions

Scan Tool Reference

Control Module References for scan tool information

1. Ignition ON.
2. Verify the scan tool Radiator Coolant Temperature Sensor parameter is between -39 to + 120°C (-38 to +248°F) and changes with engine run time. If not between -39 to + 120°C (-38 to +248°F) or does not change Refer to Circuit/System Testing (below). If between -39 to + 120°C (-38 to +248°F) and changes
3. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.
4. Verify the DTC does not set. If the DTC sets Refer to Circuit/System Testing (below). If the DTC does not set
5. All OK.

Perform the Diagnostic Repair Verification after completing the repair.

1. «Engine Coolant Temperature Sensor Replacement - Radiator (LUK LTG)»(ref-609148-S40539279822014041500000)
2. «Engine Control Module Replacement (LTG)»(ref-609171-S01383956392014041500000) , «Engine Control Module Replacement (LKW)»(ref-609171-S20550585252014041500000) for ECM replacement, setup, and programming

Schematic Reference

Engine Controls Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Cooling System Description and Operation

Electrical Information Reference

1. «Circuit Testing»(ref-609142-S10104287192014041500000)
2. «Connector Repairs»(ref-609142-S09769844092014041500000)
3. «Testing for Intermittent Conditions and Poor Connections»(ref-609142-S01252147272014041500000)
4. «Wiring Repairs»(ref-609142-S33200196142014041500000)

Scan Tool Reference

Control Module References for scan tool information

1. Engine running, observe the DTC information with a scan tool. DTC P00B3, P00B4, P00B6, P0117, P0118 or P112F should not be set. If a DTC is set, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(ref-609122-S17202613242014041500000) for further diagnosis.
2. Verify the coolant in the radiator surge tank is at the correct level and there are no engine coolant leaks. Refer to «Cooling System Draining and Filling (Static)»(ref-609148-S42216397922014041500000) , «Cooling System Draining and Filling (GE 47716)»(ref-609148-S18578079422014041500000) , and «Loss of Coolant»(ref-609148-S07951242992014041500000) .
3. Engine idling for 15 min with the A/C OFF. Verify the engine cooling fan is not ON at all times.
4. Command the Engine Coolant Thermostat Heater to 0 % with a scan tool. Increase the engine speed to 3,000 RPM. Observe the scan tool ECT sensor parameter. The temperature should increase to greater than 102°C (215°F). If less than the specified value, replace the E41 engine coolant thermostat heater.
5. 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.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

Engine Coolant Thermostat Housing Replacement (LUK) , Engine Coolant Thermostat Housing Replacement (LTG) , Engine Coolant Thermostat Housing Replacement (LKW)

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

Schematic Reference

Engine Heating/Cooling Schematics

Connector End View Reference

1. «COMPONENT CONNECTOR END VIEWS - INDEX»(ref-609269-S10785872492014041500000)
2. «Electrical Center Identification Views»(ref-609191-S00548360612014041500000)

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(ref-609142-S10104287192014041500000)
2. «Connector Repairs»(ref-609142-S09769844092014041500000)
3. «Testing for Intermittent Conditions and Poor Connections»(ref-609142-S01252147272014041500000)
4. «Wiring Repairs»(ref-609142-S33200196142014041500000)

Scan Tool Reference

Control Module References for scan tool information

1. Ignition ON.
2. Verify that DTC P0480, P0481, P0691, P0692, P0693, or P0694 is not set. If a DTC is set Refer to «DTC P0480, P0481, P0691, P0692, P0693, or P0694»(ref-609148-S17603066102014041500000) . If no DTC is set
3. Verify the scan tool parameters listed below display OFF: Cooling Fan Relay 1 Command Cooling Fan Relays 2 and 3 Command If a scan tool parameter displays ON Refer to Diagnostic Aids and «Symptoms - Engine Cooling»(ref-609148-S31825353812014041500000) for further diagnosis. If both scan tool parameters display OFF
4. Verify that the fans are not activated. If a fan is operating Refer to Circuit/System Testing (below). If both fans are OFF
5. All OK

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

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

Schematic Reference

Engine Heating/Cooling Schematics

Connector End View Reference

1. «COMPONENT CONNECTOR END VIEWS - INDEX»(ref-609269-S10785872492014041500000)
2. «Electrical Center Identification Views»(ref-609191-S00548360612014041500000)

Description and Operation

Cooling Fan Description and Operation

Electrical Information Reference

1. «Circuit Testing»(ref-609142-S10104287192014041500000)
2. «Connector Repairs»(ref-609142-S09769844092014041500000)
3. «Testing for Intermittent Conditions and Poor Connections»(ref-609142-S01252147272014041500000)
4. «Wiring Repairs»(ref-609142-S33200196142014041500000)

Scan Tool Reference

Control Module References for scan tool information

1. Ignition ON.
2. Verify that DTC P0480, P0481, P0691, P0692, P0693, or P0694 is not set. If a DTC is set Refer to «DTC P0480, P0481, P0691, P0692, P0693, or P0694»(ref-609148-S17603066102014041500000) . If no DTCs is set
3. Verify that both cooling fans turn ON and OFF and operate at low and high speed, when commanding the appropriate cooling fan relays ON and OFF with a scan tool. If a cooling fan does not operate Refer to Circuit/System Testing (below). If both cooling fans operate
4. All OK.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

1. «Relay Replacement (Within an Electrical Center)»(ref-609162-S34875168452014041500000) , «Relay Replacement (Attached to Wire Harness)»(ref-609162-S40990188582014041500000)
2. «Engine Coolant Fan Shroud Replacement (LKW)»(ref-609148-S24741233212014041500000) , «Engine Coolant Fan Shroud Replacement (LTG)»(ref-609148-S41968845182014041500000) , «Engine Coolant Fan Shroud Replacement (LUK)»(ref-609148-S38099078142014041500000)

Engine Overheating

Engine Overheating

Loss of Coolant

Loss of Coolant

Electrical Information Reference

1. «Circuit Testing»(ref-609142-S10104287192014041500000)
2. «Connector Repairs»(ref-609142-S09769844092014041500000)
3. «Testing for Intermittent Conditions and Poor Connections»(ref-609142-S01252147272014041500000)
4. «Wiring Repairs»(ref-609142-S33200196142014041500000)

Perform the Diagnostic Repair Verification after completing the diagnostic repair.

1. «Coolant Heater Replacement (LUK)»(ref-609148-S24787297542014041500000) , «Coolant Heater Replacement (LKW)»(ref-609148-S40075330412014041500000)
2. «Coolant Heater Cord Replacement (LTG)»(ref-609148-S17672546572014041500000) , «Coolant Heater Cord Replacement (LUK)»(ref-609148-S11932282112014041500000) , «Coolant Heater Cord Replacement (LKW)»(ref-609148-S17799764872014041500000)

Electrical Information Reference

1. «Circuit Testing»(ref-609142-S10104287192014041500000)
2. «Connector Repairs»(ref-609142-S09769844092014041500000)
3. «Testing for Intermittent Conditions and Poor Connections»(ref-609142-S01252147272014041500000)
4. «Wiring Repairs»(ref-609142-S33200196142014041500000)

Perform the Diagnostic Repair Verification after completing the diagnostic repair.

1. «Coolant Heater Replacement (LUK)»(ref-609148-S24787297542014041500000) , «Coolant Heater Replacement (LKW)»(ref-609148-S40075330412014041500000)
2. «Coolant Heater Cord Replacement (LTG)»(ref-609148-S17672546572014041500000) , «Coolant Heater Cord Replacement (LUK)»(ref-609148-S11932282112014041500000) , «Coolant Heater Cord Replacement (LKW)»(ref-609148-S17799764872014041500000)

Filling Procedure

1. Close the radiator drain cock.
2. Install the right front wheelhouse liner.
3. If a complete engine block drain was required, install the coolant drain plugs to the engine block. .
4. Slowly fill the cooling system with a 50/50 coolant mixture until the coolant level is visible and stable. Refer to «Approximate Fluid Capacities»(ref-609117-S37557216362014041500000) .
5. Install the pressure cap loosely (threaded on about one turn).
6. Start the engine and raise the engine speed to 2500 RPM and hold it there for 40 seconds, then shut engine off.
7. Remove the pressure cap and fill the coolant system until the level is visible and stable.
8. Install the pressure cap loosely (threaded on about one turn).
9. Start the engine and raise the engine speed to 2500 RPM and hold it there for 30 seconds, then shut engine off.
10. Remove the pressure cap and fill the coolant system until the level is visible and stable.
11. Install the pressure cap loosely (threaded on about one turn).
12. Start the engine and raise the engine speed to 2500 RPM and hold it there for 20 seconds, then shut engine off.
13. Remove the pressure cap and fill the coolant system until the level is visible and stable.
14. Install the pressure cap, fully threaded on.
15. Fill the coolant recovery bottle to the indicator line, then add 400 milliliters (13.5 ounces) more.
16. Start the engine and run it above 2500 RPM until it is hot enough to open the thermostat, this will allow the trapped air to be purged from the engine.
17. Complete a series of three, 4-second-duration idles with 4-second-duration 3000 RPM cycles.
18. Turn the engine off and allow it to cool down to room temperature.
19. Fill the coolant recovery bottle to the indicator line.
20. Inspect the concentration of the engine coolant using the J 26568 tester.
21. Rinse away any excess coolant from the engine and the engine compartment.

Repair Procedure

1. Pressure test the cooling system. Refer to «Cooling System Leak Testing»(ref-609148-S13807576842014041500000) .
2. Grind the fracture surface (1) with a proper tool.
3. Drill a hole in the center of the fractured surface, using a 6 mm (0.24 in) drill.
4. Install the new radiator mounting pin (2). Install the nut (3). NOTE: The bolt should not be longer than 35 mm (1.38 in). Install the radiator mounting pin (2) with the bolt (1).
5. Tighten the bolt 5 N.m (45 lb in).

Scheme 53

Radiator Lower Bracket Replacement (LKW)

Scheme 54

Radiator Upper Bracket Replacement (LKW)

Scheme 55

Radiator Upper Bracket Replacement (LTG)

Scheme 56

Engine Coolant Fan Replacement (LTG)

Scheme 57

Engine Coolant Fan Replacement (LUK)