18-NA-069

Service Bulletin
Bulletin No.:
18-NA-069
Date:
July, 2023
TECHNICAL
Subject:
Poor Engine Performance in Extremely Cold Weather Conditions for LFV Engines,
Charge Air Cooler Icing - Malfunction Indicator Lamp (MIL) Illuminated - DTC P0299,
P0234, P2227 and/or P00C7 Set
Brand:
Model:
Chevrolet
Malibu
Model Year:
VIN:
from
to
from
to
2016
2023
—
—
Engine:
Transmission:
1.5L (LFV)
—
Involved Region or Country
North America, China
Condition
Some customers may comment on one or more of the following conditions when driving
in extremely cold weather conditions (-18°C or less / 0°F or less):
• Loss of power
• Hesitation on acceleration
• Stalling condition
• MIL Illuminated
Technicians may find one or more of the following DTCs set:
• P0299
• P0234
• P2227
• P00C7
Cause
This condition may be caused by ice accumulation in the charge air cooler (CAC),
restricting air flow.
Copyright 2023 General Motors LLC. All Rights Reserved.
Page 2
July, 2023
Bulletin No.: 18-NA-069
Important: The DTCs and symptoms above are not exclusively related to freezing/icing
conditions. Only follow this bulletin when the condition is directly correlated with extreme
cold of -18°C or less / 0°F or less. System leaks should always be ruled out first for
P0299. Signs of moisture will always be present in the CAC system and are not a reliable
indicator of freezing/icing.
Note: DO NOT replace the CAC if the service part is already installed.
Correction
If any of the above conditions are present, allow time for possible ice buildup in the CAC
to melt by allowing the vehicle to thaw in a warm environment, and drain the moisture
from the CAC.
If any of the above conditions are confirmed to be caused by freezing/icing, replace the
original CAC with the new design wide fin service part. Confirmation should include:
• P0299 and/or P0234 present.
• >100 mL (3.4 oz) moisture drained from thawed CAC.
• Confirmed no leaks in CAC / CAC ducts.
• Recent vehicle use in extreme cold (-18°C / 0°F or less).
If not recently performed, an oil change may be necessary to remove any moisture from
the engine.
If there is a check engine light with a P0234 or P0299 DTC during cold weather driving,
refer to the following information:
– Frozen oil/water contaminant in the Turbocharger Wastegate Regulator Solenoid Valve
(TCV) is often concurrent with vehicle operating conditions that cause CAC freezing.
Cleaning or replacing the TCV solenoid should be performed in addition to CAC
protection measures specified in this bulletin.
For 2016-2018 Malibu, a new winter grille cover has been released to prevent this issue
from occurring in extreme cold weather (-18°C or less/0°F or less). The winter grille cover
needs be added to avoid the customer from returning with concerns related to charge air
cooler icing.
Perform the TCV thermo-wrap procedure below.
The winter grille cover can be installed by the technician during the repair procedure as
listed in this bulletin. After the repair is complete, dealer service personnel must educate
the customer on the installation and removal procedure of the winter grille cover.
Installation instructions are included with the winter grille cover.
Note: The Engine Control Module calibration should be updated. The new calibration will
enable a revised transmission shift pattern during cold weather operation, which does not
use overdrive as frequently. As a result, some customers may notice elevated engine
RPMs during highway operation. This operating mode will reduce the potential for ice to
build up inside the charge air cooler, and the potential for setting P0299 or P0234
diagnostic codes.
The customer must be informed by dealership personnel by explaining the new engine
control module calibration and its effects on transmission shift patterns at highway
speeds during cold weather to avoid a customer return to the dealership after the
programming is completed.
Important: The winter grille cover should be installed in the extreme cold weather and
removed when the winter season changes.
Additional covers and repeat installation are customer pay.
Note: Clean the surface before installing the winter grille cover.
Bulletin No.: 18-NA-069
July, 2023
Page 3
Important: Service agents must comply with all
International, Federal, State, Provincial, and/or
Local laws applicable to the activities it performs
under this bulletin, including but not limited to
handling, deploying, preparing, classifying,
packaging, marking, labeling, and shipping
dangerous goods. In the event of a conflict between
the procedures set forth in this bulletin and the
laws that apply to your dealership, you must follow
those applicable laws.
Service Procedure
Important: Do Not replace the CAC ducts as part of
this repair unless there is evidence of damage and/or a
leak from the CAC ducts.
4241877
1. Install the CAC (2). Refer to Charge Air Cooler
Replacement in SI.
Important: Do Not perform an oil change if the oil
change was recently done.
• If the oil change was recently done and no
signs of moisture have been confirmed,
proceed to step 3.
• If the oil change was not previously done or
moisture has been found in the oil, proceed
with procedure.
2. If required, perform an oil change. Refer to Engine
Oil and Oil Filter Replacement in SI.
Page 4
July, 2023
Turbocharger Wastegate Regulator
Solenoid Valve (TCV) Thermo-Wrap
1. Remove the inlet duct/PCV tank to have better
access to the TCV.
Bulletin No.: 18-NA-069
Note: Check port #2 to assure the spring gets lifted off
the seat. This will be determined by the compressed air
not dead heading when applied to port #2. When
applying air to this port, a small amount of air should be
observed at port #3 and even less air will be noticed at
port #1. If this does not happen, the TCV plunger may
have hardened deposits from hot operating conditions
which will impede TCV plunger movement, and the
TCV should be replaced.
4. Using clean shop air regulated to 80-100 PSI, blow
through all three ports (1, 2 & 3) for 5
seconds each.
⇒ Repeat step 4 twice.
4823346
2. Remove the turbocharger wastegate regulator
solenoid valve (TCV) (2). Refer to Turbocharger
Wastegate Regulator Solenoid Valve Replacement
in SI.
3. Drain the TCV by turning the valve upside down.
6055077
5. Prior to reinstalling the TCV, pre-position the
thermal wrap. This will aid in installation of the
wrap once the TCV is reinstalled.
6055068
6046314
Bulletin No.: 18-NA-069
July, 2023
Note: The end result of the wrap will surround the TCV
as shown in the graphic above.
6. Install the TCV. Refer to Turbocharger Wastegate
Regulator Solenoid Valve Replacement in SI.
6046334
7. Once the mounting bolt and hoses are properly
installed, pull the lower portion of the wrap upward
and snap it into position.
8. Clear all DTCs using GDS and evaluate.
Page 5
Page 6
July, 2023
Bulletin No.: 18-NA-069
Turbocharger Air Pressure Sensor
Inspection
4233269
1. Remove the turbocharger air pressure sensor (3).
Refer to Turbocharger Air Pressure Sensor
Replacement in SI.
2. Inspect the sensor of any contaminates.
5020216
4910683
Important: Due to the sensitivity of the sensor, Do Not
use any chemical cleaners including water and Do Not
use compressed air to remove contaminates.
3. Allow time for any ice build-up to melt by placing
the sensor port down.
4. Clean the sensor with a clean towel.
5. Install the sensor.
Bulletin No.: 18-NA-069
July, 2023
Page 7
Front License Plate Mount Grille Cover
Modification (2016-2018 Malibu with
RPO-VK3)
5982680
Important: It is recommended to practice on a piece of
cardboard before modifying the plastic grille cover.
5982604
1.
2.
3.
4.
If installed, remove the license plate bracket.
Remove the mounting clips (1) from the cover.
Locate the center (2) on the grille cover.
Cut the cover in half.
Page 8
July, 2023
Bulletin No.: 18-NA-069
5989765
5. Apply painters tape across the entire height of the
grille cover, approximately 17.8 cm (7 in) from the
center of the cut end of the cover.
6. Measure 17.8 cm (6 in) across the top (1) of the
cover and leave a mark.
7. Measure approximately 17.8 cm (6 in) across the
center as indicated in the graphic above of the
cover and leave a mark.
8. Draw a vertical line between the two marks.
5989766
9. Measure approximately 47.6 mm (1 7/8ths of an
inch) (2) from the top and from the bottom and
leave a mark.
Bulletin No.: 18-NA-069
July, 2023
Page 9
5989767
10. From the top and bottom marks, measure towards
the center of the cover 50.8 mm (2 in) (3).
5989768
Note: The box created (4) should measure 50.8 mm x
76.2 mm (2 x 3 in).
11. Join the outer edges of the lines together to form
a box.
Page 10
July, 2023
Bulletin No.: 18-NA-069
5982613
12. Utilizing a cutoff wheel or equivalent, cut along the
outer edge of the lines.
5982625
13. Install the cover onto the grille utilizing the eight
mounting clips.
14. install the license plate bracket.
Engine Control Module Programming
for 2018–2022 Model Years
Important: Updated Engine Control Module
calibration: The updated calibration will enable a
revised transmission shift pattern during cold weather
operation, which does not use overdrive as frequently.
As a result, the customer may notice elevated engine
RPMs during highway operation. This operating mode
will reduce the potential for ice to build up inside the
charge air cooler, and the potential for setting P0299 or
P0234 diagnostic codes.
• Ensure the programming tool is equipped with the
latest software and is securely connected to the
data link connector. If there is an interruption
during programming, programming failure or
control module damage may occur.
• Stable battery voltage is critical during
programming. Any fluctuation, spiking, over
voltage or loss of voltage will interrupt
programming. Install a GM Authorized
Programming Support Tool to maintain system
voltage. Refer to www.gmdesolutions.com for
further information. If not available, connect a fully
charged 12V jumper or booster pack disconnected
from the AC voltage supply. DO NOT connect a
battery charger.
• Follow the on-screen prompts regarding ignition
power mode, but ensure that anything that drains
excessive power (exterior lights, HVAC blower
motor, etc) is off.
• Please verify that the radio time and date are set
correctly before inserting USB drive into vehicle
for programming, otherwise an error will result.
• Clear DTCs after programming is complete.
Clearing powertrain DTCs will set the Inspection/
Maintenance (I/M) system status indicators to NO.
Bulletin No.: 18-NA-069
July, 2023
Important: The service technician always needs to
verify that the VIN displayed in the TLC left side drop
down menu and the top center window match the VIN
plate of the vehicle to be programmed prior to using
Service Programming System 2 (SPS2) for
programming or reprogramming a module.
• For the TLC application, service technicians need
to always ensure that the power mode (ignition) is
“ON” before reading the VIN from the vehicle’s
VIN master module and that they do not select a
VIN that is already in the TLC application memory
from a previous vehicle.
• If the VIN that shows up in the TLC top center
window after correctly reading the VIN from the
vehicle does not match the VIN plate of the
vehicle, manually type in the VIN characters from
the vehicle VIN plate into the TLC top center
window and use these for programming or
reprogramming the subject module with the
correct vehicle VIN and software and/or
calibrations.
• The Engine Control Module (ECM) is the master
module (for VIP vehicles) that TLC reads to
determine the VIN of the vehicle. If the VIN read
from the vehicle by TLC does not match the VIN
plate of the vehicle, the ECM also needs to be
reprogrammed with the correct VIN, software and
calibrations that match the vehicle’s VIN plate.
• The Body Control Module (BCM) is the master
module (for GEM vehicles) that TLC reads to
determine the VIN of the vehicle. If the VIN read
from the vehicle by TLC does not match the VIN
plate of the vehicle, the BCM also needs to be
reprogrammed with the correct VIN, software and
calibrations that match the vehicle’s VIN plate.
Page 11
Page 12
July, 2023
Bulletin No.: 18-NA-069
Caution: Be sure the VIN selected in the drop down
menu (1) is the same as the vehicle connected (2)
before beginning programming.
5743643
Important: If the vehicle VIN DOES NOT match, the
message below will be shown.
5877000
Bulletin No.: 18-NA-069
July, 2023
Page 13
5644477
Important: Techline Connect screen shown above.
Important: If the same calibration/software warning is
noted on the TLC or SPS Summary screen, select OK
and follow screen instructions. After a successful
programming event, the WCC is located in the Service
Programming System dialogue box of the SPS
Summary screen. Document the WCC on the job card.
No further action is required. Refer to the Warranty
Information section of this bulletin.
1. Reprogram the ECM. Refer to K20 Engine Control
Module: Programming and Setup in SI.
Page 14
July, 2023
Bulletin No.: 18-NA-069
5644478
Note: The screenshot above is an example of module
programming and may not be indicative of the specific
module that is being programmed. Module selection
and VIN information have been blacked out.
Important: To avoid warranty transaction rejections,
you MUST record the warranty claim code provided on
the Warranty Claim Code (WCC) screen shown above
on the job card. Refer to callout 1 above for the location
of the WCC on the screen.
2. Record the Warranty Claim Code on the job card
for warranty transaction submission.
Parts Information
Causal
Part
Description
Part
Number
Qty
N/A
COVER, GRILLE
(Malibu
2016–2018)
86786758
1
N/A
COOLER ASMCHRG AIR
84768953
1
N/A
SHIELD
ASM, TCV
25205589
1
N/A
Filter, Oil
N/A
Oil
Refer to the Electronic Parts
Catalog (EPC).
Bulletin No.: 18-NA-069
July, 2023
Warranty Information
Important: The 2888378 Labor code for ECM
reprogramming is covered under the E2 coverage and
NOT Powertrain.
Coverage code E2 applies for this module
programming event. ECM reprogramming is covered
for 8 years/80,000 miles (U.S.) or 8 years/130,000 km
(Canada).
Note: Warranty Coverage Codes E, E1 apply to Labor
Operation 4086058.
For vehicles repaired under the Powertrain coverage,
use the following labor operation. Reference the
Applicable Warranties section of Investigate Vehicle
History (IVH) for coverage information.
Labor
Operation
Description
Labor Time
4086058*
Charge Air Cooler
Replacement
2.6 hrs
Add
To Recover and Recharge
R-1234yf A/C System
1.2 hrs
Add
To Recover and Recharge
R-134a A/C System
0.3 hr
Add
IAPT Inspection
0.2 hr
Add
Oil Change
0.3 hr
Add
Install grille Cover on 20162018 Malibu
0.2 hr
Add
Grill Cover License Plate
Modification
0.5 hr
Add
TCV Cleaning and Wrap
Install
0.2 hr
2888378**
Engine Control Module Reprogramming with SPS for
2018-2022 Malibu
0.3 hr
*This is a unique Labor Operation for bulletin use only.
Important: **To avoid warranty transaction rejections,
carefully read and follow the instructions below:
• The Warranty Claim Code must be accurately entered
in the “SPS Warranty Claim Code” field of the
transaction.
• When more than one Warranty Claim Code is
generated for a programming event, it is required to
document all Warranty Claim Codes in the “Correction”
field on the job card. Dealers must also enter one of the
codes in the “SPS Warranty Claim Code” field of the
transaction, otherwise the transaction will reject. It is
best practice to enter the FINAL code provided
by SPS2.
Page 15
Warranty Claim Code Information Retrieval
If the SPS Warranty Claim Code was not recorded on
the Job Card, the code can be retrieved in the SPS2
system as follows:
1. Open TLC/TIS on the computer used to program
the vehicle.
2. Select and start SPS2.
3. Select Settings.
4. Select the Warranty Claim Code tab.
The VIN, Warranty Claim Code and Date/Time will be
listed on a roster of recent programming events. If the
code is retrievable, dealers should resubmit the
transaction making sure to include the code in the SPS
Warranty Claim Code field.
Page 16
July, 2023
Bulletin No.: 18-NA-069
Version
12
Modified
Released March 05, 2018
Revised January 24, 2019 – Added the 2019 Model Year, China to Involved Region or
Country, updated the Service Procedure and Warranty Information.
Revised October 28, 2019 – Updated the Part Number in the Parts Information.
Revised February 21, 2020 – Added the 2020 Model Year and updated the Correction
information.
Revised March 12, 2020 – Added an Important statement at the beginning of the Service
Procedure advising not to replace the CAC ducts.
Revised March 02, 2021 – Added the 2021 Model Year and updated the Warranty
Information.
Revised September 02, 2021 – Added the 2022 Model Year.
Revised January 12, 2022 – Added information to reference PIP5812C and winter grille
information to Correction section, grille cover for 2016–2018 Malibu to Parts Information
section, Engine Control Module Programming section, updated the Warranty coverage
information and added ECM Re-programming Labor Operation to Warranty Information.
Revised February 22, 2022 – Added Front License Plate Mount Grille Cover Modification
section, updated the Engine Control Module Programming procedure, updated the Winter
Grille Cover Part Number in Parts Information section and updated the Important
statement under Warranty Information.
Revised May 24, 2022 – Changed P0236 to P0234, Added Turbocharger Wastegate
Regulator Solenoid Valve (TCV) Thermo-Wrap section, changed RPO VKS to VK3 in
Front License Plate Mount Grille Cover Modification title, removed first Caution in Engine
Control Module Programming section and updated Parts and Warranty Information.
Revised October 11, 2022 – Added the first Important statement to the Correction
section, the first Important statement above the Service Procedure, a graphic to Step 4
under Turbocharger Wastegate Regulator Solenoid Valve (TCV) Thermo-Wrap section,
specific model years to Engine Control Module Programming title and a Note under
Warranty Information.
Revised July 20, 2023 – Added the 2023 Model Year.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these
technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper
service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a
job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your
vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.
WE SUPPORT VOLUNTARY
TECHNICIAN
CERTIFICATION