2008-2010 Chevrolet Malibu Hybrid Service & Repair Manual
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2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Brakes | Antilock Brake System | Specifications |
Document ID: 2041215
Fastener Tightening Specifications
Application
Specification
Metric English
Brake Pipe Fitting 20 N·m 15 lb ft
Brake Pressure Modulator Valve (BPMV) Bolt 10 N·m 89 lb in
BPMV Bracket Nut 10 N·m 89 lb in
Electronic Brake Control Module (EBCM) Bolt 3 N·m 27 lb in
Yaw Sensor Nut 10 N·m 89 lb in
© 2010 General Motors Corporation. All rights reserved.
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2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Brakes | Antilock Brake System | Repair Instructions |
Document ID: 2041886
Antilock Brake System Automated Bleed Procedure
Warning: Refer to Brake Fluid Irritant Warning in the Preface section.
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface
section.
Note:
The ABS Automated Bleed Procedure uses a scan tool to cycle the system solenoid valves and run
the pump in order to purge any air from the secondary circuits. These circuits are normally closed
off, and are only opened during system initialization at vehicle start up and during ABS operation.
The automated bleed procedure opens these secondary circuits and allows any air trapped in these
circuits to flow out away from the brake modulator assembly, which is then forced out at the brake
corners by the pressure bleeder.
Automated Bleed Procedure
Caution: The Auto Bleed Procedure may be terminated at any time during the process by
pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed
procedure will be given. After exiting the bleed procedure, relieve bleed pressure and
disconnect bleed equipment per manufacturers instructions. Failure to properly relieve
pressure may result in spilled brake fluid causing damage to components and painted
surfaces.
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
3. Inspect the brake system for leaks and visual damage. Refer to Symptoms - Hydraulic
Brakes . Repair or replace components as needed.
4. Lower the vehicle.
5. Prepare the brake bleeding equipment and the vehicle for a pressure bleed of the base
hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
6. Inspect the battery state of charge. Refer to Battery Inspection/Test .
7. Install a scan tool.
8. Turn the ignition ON, with the engine OFF.
9. With the scan tool, perform the following steps:
• Before performing the ABS Automated Bleed Procedure, first perform a manual or pressure
bleed of the base hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
• The automated bleed procedure must be performed when a new brake pressure modulator
valve (BPMV) is installed, because the secondary circuits of the new BPMV are not prefilled
with brake fluid.
• The automated bleed procedure is recommended when one of the following conditions exist:
• Base brake system bleeding does not achieve the desired pedal height or feel
• Extreme loss of brake fluid has occurred
• Air ingestion is suspected in the secondary circuits of the brake modulator assembly
9.1. Select Diagnostics
9.2. Select the appropriate vehicle information
9.3. Select Chassis
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10. With an assistant ready, raise and support the vehicle. Refer to Lifting and Jacking the
Vehicle .
Note:
11. Perform the automated bleed procedure as instructed by the scan tool.
12. If the automated bleed procedure is aborted, a malfunction exists. If a DTC is detected, refer
to Diagnostic Trouble Code (DTC) List - Vehicle to diagnose the DTC.
13. After completion of the automated bleed procedure, press and hold the brake pedal to
inspect for pedal firmness.
14. If the brake pedal feels spongy, repeat the bleed procedure completely.
15. Remove the scan tool.
16. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .
17. Lower the vehicle.
18. Adjust the brake fluid level. Refer to Master Cylinder Reservoir Filling .
19. Road test the vehicle while confirming the brake pedal remains high and firm.
9.4. Select Electronic Brake Control Module (EBCM)
9.5. Select Special Functions
9.6. Select Automated Bleed
• Apply the brake pedal when instructed, using moderate effort.
• Ensure the pedal remains applied until instructed to release by the scan tool.
• Do not exceed the time period allowed by the scan tool for having the bleeder valves
open.
• The bleed sequence for each corner is as follows:
- Left front
- Right front
- Right rear
- Left rear
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2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Brakes | Antilock Brake System | Repair Instructions |
Document ID: 2041846
Electronic Brake Control Module Replacement
Removal Procedure
Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with
the ignition switch in the OFF position. Failure to observe this precaution could result in damage to
the EBCM/EBTCM.
1. Turn the ignition switch to the OFF position.
2. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV)
area of any accumulated dirt and foreign material.
3. Disconnect the electrical connector from the EBCM.
4. Remove the 4 EBCM bolts (1).
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5. Separate the EBCM (1) from the BPMV by carefully pulling the components apart.
Installation Procedure
1. Clean the sealing surface of the BPMV with denatured alcohol and a clean shop cloth.
2. Carefully install the EBCM (1) to the BPMV.
Caution: Refer to Fastener Caution in the Preface section.
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3. Install the 4 EBCM bolts (1). Tighten the bolts in a cross pattern to 3 N·m (27 lb in).
Note: Ensure the electrical connector is correctly inserted into the EBCM prior to placing the
locking lever into position. Failure to make a proper connection may cause communication
problems with the module.
4. Connect the electrical connector to the EBCM.
5. If installing a new EBCM, it is necessary to program the EBCM. Refer to Control Module
References .
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2009 Chevrolet Malibu | Malibu (VIN Z) Service Manual | Brakes | Antilock Brake System | Repair Instructions |
Document ID: 2041850
Brake Pressure Modulator Valve Replacement
Warning: Refer to Brake Fluid Irritant Warning in the Preface section.
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution in the Preface
section.
Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with
the ignition switch in the OFF position. Failure to observe this precaution could result in damage to
the EBCM/EBTCM.
Removal Procedure
1. Turn the ignition switch to the OFF position.
2. Clean the brake pressure modulator valve (BPMV) pipe fitting areas of any accumulated dirt
and foreign material.
3. Disconnect the electrical connector from the electronic brake control module (EBCM).
4. Place a shop towel under the BPMV to catch any brake fluid loss.
5. Disconnect the RF brake pipe fitting (1).
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
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6. Disconnect the LR brake pipe fitting (1).
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
7. Disconnect the rear brake pipe fitting (1).
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
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8. Disconnect the left front brake pipe fitting (1).
Cap the brake pipe fitting and plug the BPMV outlet port to prevent brake fluid loss and
contamination.
9. Disconnect the master cylinder primary brake pipe fitting (1).
Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and
contamination.
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10. Disconnect the master cylinder secondary brake pipe fitting (1).
Cap the brake pipe fitting and plug the BPMV inlet port to prevent brake fluid loss and
contamination.
11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
12. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation .
13. Remove the 3 BPMV bracket nuts (1).
14. Remove the BPMV and bracket assembly.
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The Chevrolet Malibu Hybrid Complete Workshop Manual is a comprehensive guide suitable for professional mechanics and do-it-yourself enthusiasts. It provides detailed information and step-by-step instructions for maintaining, repairing, and servicing the Chevy Malibu Hybrid.
This manual covers the 2008, 2009, and 2010 models of the Chevrolet Malibu Hybrid, offering detailed specifications, diagrams, illustrations, and troubleshooting tips for various components including the engine, transmission, electrical system, brakes, steering, and suspension.
Key features of the Chevrolet Malibu Hybrid Complete Workshop Manual include:
- Step-by-step instructions for all repair and maintenance procedures.
- Easy-to-follow diagrams and illustrations.
- Comprehensive troubleshooting guide.
- Detailed specifications and technical data.
- Tips and tricks from experienced mechanics.
- Opportunity to save time and money by performing repairs yourself.
- Ensures the longevity and optimal performance of your Chevy Malibu Hybrid.
Whether you need to replace a faulty component, perform routine maintenance, or simply want to understand your vehicle better, the Chevrolet Malibu Hybrid Complete Workshop Manual is an essential tool for any Malibu Hybrid owner.
