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HOMESERVICE MANUALSCHEVROLET2002MALIBU LSREPAIR AND DIAGNOSISENGINE PERFORMANCETESTING & DIAGNOSISENGINE CONTROL SYSTEM - BASIC DIAGNOSTIC PROCEDURESNO-START DIAGNOSISNO START - ENGINE CRANKS OKAY (3.8L)IGNITION SYSTEM DIAGNOSIS (ALL MODELS)
2002 Chevrolet Malibu LS

Ignition System Diagnosis (All Models)

2002 Chevrolet Malibu LSSECTION Ignition System Diagnosis (All Models)
  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. NOTE: If any ignition DTCs are stored as Failed Since Code Clear, diagnose those DTCs before continuing with this diagnosis. See appropriate SELF-DIAGNOSTICS article.
  2. Check fuses which supply ignition 1 voltage to the Ignition Control Module (ICM) and PCM. If either fuse is open, locate and repair short to ground in the affected circuit. See WIRING DIAGRAMS article. Did you find and correct the condition? If yes, go to step  33. If no, go to next step.
  3. Connect a scan tool. Turn ignition on, with engine off. Select the Engine Data 1 display on scan tool. Observe engine RPM while cranking engine. Does scan tool indicate an engine RPM? If yes, go to step  15. If no, go to next step.
  4. Turn ignition off. Disconnect ICM connector. Turn ignition on. Connect a test light between the ignition positive feed terminal and ground terminal in the ICM connector. Does the test light illuminate? If yes, go to step  6. If no, go to next step.
  5. Leave the ICM connector disconnected. Connect test light between ICM ignition 1 voltage and engine ground. Does the test light illuminate? If yes, go to step  28. If no, go to step  29.
  6. Turn ignition off. Reconnect the ICM connector. Disconnect the Crankshaft Position (CKP) sensor. Turn ignition on. Connect a DVOM between the 10-volt reference terminal and ground terminal in the CKP sensor connector. Does the voltage about battery voltage. If yes, go to next step. If no, go to step  9.
  7. Connect the DVOM between the CKP sensor 1 signal terminal and ground terminal in connector. Does voltage measure within 6-8 volts? If yes, go to next step. If no, go to step  12.
  8. Check for faulty terminal connections at the CKP sensor. Repair any connections if necessary. Did you find and correct the condition? If yes, go to step  33. If no, go to step  31.
  9. Connect the DVOM between the CKP 10-volt reference circuit and engine ground. Does the voltage measure about battery voltage. If yes, go to next step. If no, go to step  11.
  10. Turn ignition off. Leave the CKP sensor disconnected. Disconnect the ICM connector. Test the CKP sensor ground for an open. Repair the circuit if necessary. Did you find and correct the condition? If yes, go to step  33. If no, go to step  27.
  11. Turn ignition on. Leave the CKP sensor disconnected. Disconnect the ICM connector. Test the CKP 10-volt reference circuit for an open and for a short to ground. Repair circuit if necessary. If yes, go to step  33. If no, go to step  27.
  12. Leave the DVOM connected. Turn ignition off. Disconnect ICM connector. Turn ignition on. Does the voltage measure about battery voltage? If yes, go to next step. If no, go to step  14.
  13. Locate and repair the short to voltage in the CKP sensor 1 signal circuit. After repairs, go to step  33.
  14. Test the CKP sensor 1 signal circuit for an open, short to ground or a short to sensor ground Repair the circuit if necessary. Did you find and correct the condition? If yes, go to step  33. If no, go to step  27.
  15. Turn ignition off. Disconnect a spark plug wire from a spark plug. Install Spark Tester (J-26792) in the end of the spark plug wire. Jump the companion cylinder's ignition wire to engine ground. The companion cylinder is the cylinder that shares the same ignition coil . Crank engine while observing the spark tester . A spark should be observed. Repeat the test for each ignition wire, noting any cylinders that DO NOT have spark. Do all of the cylinders have spark? If yes, go to step  25. If no, go to next step.
  16. Do any of the cylinders have spark? If yes, go to step  21. If no, go to next step.
  17. Turn ignition off. Disconnect the CKP sensor connector. Turn ignition on. Connect the DVOM between the CKP sensor 2 signal circuit and ground. Does the voltage measure within 6-8 volts? If yes, go to next step. If no, go to step  19.
  18. Test for faulty terminal connections at the CKP sensor. Repair any terminals as necessary. Did you find and correct the condition? If yes, go to step  33. If no, go to step  30.
  19. Turn ignition off. Disconnect the ICM connector. Turn ignition on. Test the CKP sensor 2 signal circuit for a short to voltage or a short to the sensor 10-volt reference circuit. Repair the circuit as necessary. Did you find and correct the condition? If yes, go to step  33. If no, go to next step.
  20. Test CKP sensor 2 signal circuit for a short to ground and for a short to sensor ground. Check for open CKP sensor 2 signal circuit. Repair as necessary. Did you find and correct the condition? If yes, go to step  33. If no, go to step  27.
    21. NOTE: If carbon tracking is detected on any component, replace that component and mate.
  21. Inspect the ignition coils and ignition wires associated with the cylinders that did not have spark. Verify that the ignition components are free of cracks and carbon tracking. Replace any damaged ignition components. Did you find and correct the condition? If yes, go to step  33. If no, go to next step.
  22. Measure the secondary resistance of ignition coils. If any of the ignition coil resistance is not within 5000-8000 ohms? If yes, go to step  33. If no, go to next step.
  23. Measure the resistance of the ignition wires associated with the cylinders that did not have spark. Replace ignition wires that have a resistance of greater than 3000 ohms/ft. Did you find and correct the condition? If yes, go to step  33. If no, go to next step.
  24. Remove coils associated with the cylinder that did not have spark. Connect a test light across the ignition module primary circuit, between the ICM terminals, for the coils. Observe test light while cranking engine. Does test light flash continuously while engine is being cranked? If yes, go to step  32. If no, go to step  31.
  25. Remove spark plugs from all of the cylinders. Inspect spark plug electrodes. Are any of the spark plugs fouled? If yes, diagnose for and engine mechanical problem. If no, go to next step.
  26. Check for a short between CKP sensor 1 and CKP sensor 2 signal inputs to ICM. Check for short between the medium resolution and low resolution engine speed signal inputs to PCM. If a problem is found, repair as necessary. Did you find and correct the condition? If yes, go to step  33. If no, diagnose for an engine mechanical problem.
  27. Check for faulty terminal connections at ICM. Repair any terminals as necessary. Did you find and correct the condition? If yes, go to step  33. If no, go to step  31.
  28. Locate and repair an open in ICM ground circuit. After repairs, go to step  33.
  29. Locate and repair an open in the ignition 1 voltage circuit to ICM. After repairs, go to step  33.
  30. Replace CKP sensor. After replacing sensor, go to step  33.
  31. Replace the ignition control module. After replacing module, go to step  33.
  32. Replace the ignition coils associated with the cylinders that did not have spark. After replacing ignition coil(s), go to next step.
  33. Remove all test equipment. Connect any disconnected components. Turn ignition off for 30 seconds. Start engine and operate vehicle. Observe the MIL and note the vehicle performance and driveability. Does the vehicle operate normally, with no MIL and no stored DTCs? If yes, system is okay. If no, go to step  2.
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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.