2009 Chevy Malibu 3.5L Code P0411

Alejandro from San Diego Technician Posted   Latest   Edited  
Case Study
Electrical
Emissions
2009 Chevrolet Malibu 2.4L 4-spd
P0411 - AIR System "A" Incorrect Flow Detected

Good evening everyone

Today I have a 2009 Chevy Malibu 3.5L V6 with 277,210 miles with code P0411. 

In the past two years ago, the engine was replaced because the driver had overheated the Motor. It also had a problem with the code P0411 when the engine was replaced because the wrong engine was installed since it did not have the Secondary Air Injection Ports on the head where the Exhaust Manifolds are.

Anyway now in this case it is something different. Both Secondary Air Injection Solenoids were replaced with some spares lying around the shop, and it has returned with the same issue. 

I then received the vehicle preceded with a code scan, and of course as already stated above the code P0411 was there. 

Next I ran an Air System test on the Scan tool for the Secondary Air Injection system.

Upon test, the Secondary Air Injection Pump, and solenoids would work, and turn on. I don’t know what got to my head to do it, but glad it did but I prompted to unplug one Air Injection Solenoid, and then proceed to unplug the next, and I can only get an audible click from the Solenoid on the Bank 1 side Air Injection Solenoids, and not the Bank 2 side.

This the Bank 1 side

And this is the Bank 2 side

Pulled out the Wiring Diagram for the Secondary Air Injection Solenoid 

*Note from Freeze frame fault data I had a suspicion that there was some kind of wiring issue because the data had indicated that the fault took place when the Air Injection System was not commanded on, so I thought that was bit odd. 

Anyway I proceeded to Check Voltage to Secondary Air Injection Solenoid, Ground, and 5V Ref. all were there but the Ground. No ground when I applied an incandescent test light to power to the ground pin and the test light did not light up, Aha! 

With the Black Ground wire pierced and with 12V being applied through the test light I tugged some wiring around the vicinity of the Air Solenoid, and the test light would flicker on, and off as I tugged on the harness. I was able to narrow it down to the Ground on top of the transmission casing. 

Went on to repair the ground, and routed some of the ground connections back to the top of the transmission casing, and some of the other to the grounds Left of the chassis as pictured so I just wouldn’t over clutter the same area with terminals.

diag​.​net/file/f6rj75fpw…

+3

Felix from Miami

 

Diagnostician
 

very good article , thanks for sharing

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Alejandro from San Diego

 

Technician
 

Thank you!

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James from Bishop

 

Diagnostician
 

Great write up and diagnostics !

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Alejandro from San Diego

 

Technician
 

Thank you!

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Geoff from Lahaina

 

Diagnostician
 

what is the red Matco tool you are using there for soldering? Looks interesting!!

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Alejandro from San Diego

 

Technician
 

Glad you asked, its a Soldering tool from Matco its made out of aluminum billet, and each end has a clamp so as you solder the wire it can hold both ends of the wire together. The black nob is so you can turn it to feed some solder as you heat the wires with the soldering iron with your other hand. Inside the handle there is a spool of soldering iron where you can refill it. I mainly just use it to hold both wires together as I solder. 

+2

Geoff from Lahaina

 

Diagnostician
 

Thank you! I have found it on their site;

matcotools​.​com/catalog/produc…

I'll have to check with my Matco man to see if he has one.

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Alejandro from San Diego

 

Technician
 

Your welcome!

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Angel from Boston

 

Technician
 

Thanks for sharing, good case study and diagnosis! 

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Alejandro from San Diego

 

Technician
 

Thank you

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