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HOMESERVICE MANUALSCHEVROLET2002MALIBU LSREPAIR AND DIAGNOSISENGINE PERFORMANCESYSTEMENGINE CONTROL SYSTEM - BASIC DIAGNOSTIC PROCEDURESNO-START DIAGNOSISNO START - ENGINE CRANKS OKAY (3.1L & 3.4L)IGNITION SYSTEM DIAGNOSIS (3.1L & 3.4L)
2002 Chevrolet Malibu LS

Ignition System Diagnosis (3.1L & 3.4L)

2002 Chevrolet Malibu LSSECTION Ignition System Diagnosis (3.1L & 3.4L)
  1. If diagnostic system check has already been performed, go to next step. If diagnostic system check has not been performed, go to DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS in appropriate SELF-DIAGNOSTICS article.
  2. Attempt to start engine. Does engine start and continue to run? If yes, problem is intermittent. If no, go to next step.
  3. Disconnect the 24X crank sensor (sensor is located behind harmonic balancer). Crank engine. Using scan tool, observe the 3X crank sensor parameter. Does scan tool indicate 3X crank sensor signal is present? If yes, go to next step. If no, go to step  11.
  4. Reconnect the 24X crank sensor. Test for spark at each cylinder using Spark Tester (J-26792). Did you observe any non-sparking cylinders? If yes, go to next step. If no, go to step  8.
    5. NOTE: An arcing spark plug wire or an arcing ignition coil to Ignition Control (IC) module may cause a stall or a no start condition.
  5. Inspect and test the affected cylinder spark plug wires, ignition coils and spark plugs for a short to ground or an arcing to ground. If carbon tracking or corrosion is present, replace both components that are affected. Did you find and correct the condition? If yes, go to step  23. If no, go to next step.
  6. Test affected spark plug wires for proper resistance. Replace spark plug wires not near specification. Did you find and correct the condition? If yes, go to step  23. If no, go to next step.
  7. Switch the affected cylinder coil with a known-good one. If fault follows the affected coil, then replace coil. Did you find and correct the condition? If yes, go to step  23. If no, go to step  15.
  8. Inspect spark plug wires for proper routing and for correct firing order. Reroute as necessary. Did you find and correct the condition? If yes, go to step  23. If no, go to next step.
  9. Using DVOM, check spark plugs for internal short to ground. Replace any grounded spark plugs. Did you find and correct the condition? If yes, go to step  23. If no, go to next step.
  10. Remove spark plugs. Inspect spark plugs for damage. Replace affected spark plugs. After replacing spark plugs, go to step  23. If spark plugs are okay, go to next step.
  11. Reconnect the 24X crank sensor. Disconnect the IC module harness connectors. Turn ignition on. Using a test light connected to a good ground, probe the IC module ignition 1 voltage circuit. Does the test light illuminate? If yes, go to next step. If no, go to step  17.
  12. Connect a test light between the IC module ignition 1 voltage circuit and IC module ground circuit. Does the test light illuminate? If yes, go to next step. If no, go to step  20.
  13. Disconnect the 7X crank sensor connector from the IC module. With a test light connected to battery voltage, probe both the 7X crank sensor 1 signal and low reference circuits. Does test light illuminate when probing either circuits? If yes, go to step  18. If no, go to next step.
  14. Connect test light to ground. Probe the 7X crank sensor 1 signal and reference low circuits. Does test light illuminate when probing either circuits? If yes, go to step  19. If no, go to next step.
  15. Ensure battery voltage is within specifications. Turn ignition off. Connect DVOM between 7X crank sensor 1 signal circuit and low reference circuit at IC module harness connector. Crank engine while observing AC duty cycle percent. Does the DVOM indicate an AC duty cycle present? If yes, go to step  21. If no, go to next step.
  16. Test the 7X crank sensor circuits for open circuit. Check 7X crank sensor 1 signal and low reference circuits that are shorted together. Repair any damaged wiring. Did you find and correct the condition? If yes, go to step  23. If no, go to step  22.
  17. Repair open or short to ground in IC module ignition 1 voltage circuit. Replace fuse if necessary. After repairs, go to step  23.
  18. Repair short to ground in circuit which illuminated the test light. After repairs, go to step  23.
  19. Repair short to voltage in circuit which illuminated the test light. After repairs, go to step  23.
  20. Repair open in IC module ground circuit. After repairs, go to step  23.
  21. Replace IC module. After replacing module, go to step  23.
  22. Replace the 7X crank sensor (located on lower right of engine block). After repairs, go to next step.
  23. Remove all test equipment. Connect any disconnected components or any disconnected fuses. Turn ignition off for 30 seconds. Start engine and operate vehicle. Observe MIL, vehicle performance and driveability. Does vehicle operate correctly, without any MIL illumination and without any stored DTCs? If yes, system is okay. If no, diagnose affected DTC(s). See appropriate SELF-DIAGNOSTICS article.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.