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