Contents Wiring diagrams Section: Procedures All sections

Maintenance Information Chevrolet Malibu V

Procedures 6 illustrations ~1647 words

VIN LOCATION

The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the code characters.

VIN CODE ID EXPLANATION

Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN example below.

VIN Code ID Explanation. Scheme 1

Scheme 1: VIN Code ID Explanation

SHORT TRIP/CITY & LONG TRIP/HIGHWAY SERVICE DEFINITIONS

Note. General Motors has renamed their maintenance schedules. One is referred to as the Short-Trip/City and the other is the Long Trip/Highway schedule. These schedule requirements are similar to the familiar Severe Service and Normal schedules and can be used in place of one another.

SEVERE & NORMAL SERVICE DEFINITIONS

Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating conditions

Normal Service

  1. No Severe Service Operating Conditions

Severe Service

Note. Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or more) of these conditions

  1. Most Trips Are Less Than 5 To 10 Miles (8 To 16 km). This is particularly important when outside temperatures are below freezing.
  2. Most Trips Include Extensive Idling (Such As Frequent Stop & Go Traffic)
  3. Most Trips Are Through Dusty Areas
  4. You Frequently Tow A Trailer Or Use A Car Top Carrier.
  5. If The Vehicle Is Used In Delivery Service, Police, Taxi, Or Other Commercial Application

Scheme 2

Scheme 2: SERVICE POINT LOCATIONS

Scheme 3

Scheme 3

TIRE REPLACEMENT

Replace tires with the same Tire Performance Criteria Specification number shown on the original tire's sidewall. If tires are replaced with those that do not have a TPC Specification number then replace tires that are the same size, load range, speed rating, and construction type.

TIRE INFLATION

The tire specification decal is located on rear of the driver's door.

WHEEL TIGHTENING

Tighten wheel lug nuts to 100 ft. lbs. (136 N.m).

BATTERY SPECIFICATIONS

CAUTIONWhen battery is disconnected, vehicles equipped with computers may lose memory data. When battery power is restored, driveability problems may exist on some vehicles. These vehicles may require a relearn procedure. See COMPUTER RELEARN PROCEDURES article in the GENERAL INFORMATION section.

SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)

Note. See the AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT Section.

Modifications or improper maintenance, including incorrect removal and installation of the Supplemental Restraint System (SRS), can adversely affect system performance. DO NOT cover, obstruct or change the steering wheel horn pad in any way, as such action could cause improper function of the system. Use only plain water when cleaning the horn pad. Solvents or cleaners could adversely affect the air bag cover and cause improper deployment of the system.

WARNINGTo avoid injury from accidental air bag deployment, read and carefully follow all warnings and service precautions. See appropriate AIR BAGS article in ACCESSORIES/SAFETY EQUIPMENT.

Modification to the air bag system component or wiring can adversely affect system performance and possibly cause injury.

CAUTIONThe Diagnostic Energy Reserve Module (DERM) can maintain enough voltage to cause a deployment of the inflator module for up to 10 minutes after the ignition switch is turned off and the battery is disconnected. Many of the service procedures require disconnection of the inflator module to avoid an accidental deployment.
CAUTIONDisconnect negative battery cable before servicing any air bag system, steering column or passenger side dash component. After any repair, turn ignition key to the ON position from passenger's side of vehicle in case of accidental air bag inflation

AIR CONDITIONING SERVICING

WARNINGAvoid breathing R-134a refrigerant and PAG lubricant vapors, exposure may irritate eyes, nose and throat. To remove R-134a from system use R-134a recycling equipment that meets SAE J2210 specifications. If accidental system discharge occurs, ventilate work area before resuming service.
WARNINGR-134a service equipment or vehicle A/C systems SHOULD NOT be pressure tested or leak tested with compressed air. Some mixtures of air/R134a have shown to be combustible at elevated pressures. These mixtures are dangerous and may cause fire and/or explosions. See AIR CONDITIONING SERVICE article in GENERAL INFORMATION section.

ANTI-LOCK BRAKE SYSTEM

CAUTIONThe anti-lock brake system contains electronic equipment that can be susceptible to interference caused by improperly installed or high output radio transmitting equipment. Since this interference could cause the possible loss of the anti-lock braking capability, such equipment should be installed by qualified professionals.

On models equipped with anti-lock brake systems, ALWAYS observe the following cautions

  1. DO NOT attempt to bleed hydraulic system without first referring to the appropriate «ANTI-LOCK BRAKE SYSTEM»(ref-47836) article in the BRAKES Section.
  2. DO NOT mix tire sizes. As long as tires remain close to the original diameter, increasing the width is acceptable. Rolling diameter must be identical for all 4 tires. Some manufacturers recommend tires of the same brand, style and type. Failure to follow this precaution may cause inaccurate wheel speed readings.
  3. Use ONLY recommended brake fluids. DO NOT use silicone brake fluids in an ABS-equipped vehicle.

REPLACING BLOWN FUSES

CAUTIONBefore replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system overload.

BRAKE PAD WEAR INDICATOR

CAUTIONIndicator will cause a squealing or scraping noise, warning that brake pads need replacement.

CATALYTIC CONVERTER

CAUTIONTo prevent catalytic converter overheating, DO NOT allow engine to idle for more than 20 minutes.

COOLANT

CAUTIONAll models have DEX-COOL engine coolant installed at the factory. DEX-COOL coolant is a silicate-free coolant that is orange in color.

Note. It should not be mixed with regular ethylene-glycol coolant. To avoid possible damage to vehicle cooling system, visually check engine coolant color before adding and/or changing engine coolant. Vehicle should have an identification label placed under the hood stating what type coolant is installed.

WARNINGDo NOT add only plain water to the cooling system. Plain water, or some other liquid like alcohol, can boil before the proper coolant mix will. The vehicle's coolant warning system is set for the proper coolant mix only. With plain water or the wrong mix, the engine could get too hot, but the overheat warning may not appear. The engine could catch fire and passengers in the vehicle could be seriously injured.

Use a 50/50 mixture of distilled water and DEX-COOL engine coolant.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

WARNINGMany solid state electrical components can be damaged by static electricity (ESD). Some will display a warning label, but many will not. Discharge personal static electricity by touching a metal ground point on the vehicle prior to servicing any ESD sensitive component.

FUEL SYSTEM SERVICE

WARNINGRelieve fuel system pressure prior to servicing any fuel system component.

HALOGEN BULBS

WARNINGHalogen bulbs contain pressurized gas which may explode if overheated. DO NOT touch glass portion of bulb with bare hands. Eye protection should be worn when handling or working around halogen bulbs.

METHANOL GASOLINE

CAUTIONFuel that is more than 5% methanol should not be used in this vehicle. It can corrode metal parts in the fuel system, and damage plastic and rubber parts. Even at 5% methanol or less, solvents and corrosion preventers must be used with this fuel to avoid these problems.

RADIATOR CAP

CAUTIONAlways disconnect the fan motor when working near the radiator fan. The fan is temperature controlled and could start at any time even when the ignition key is in the OFF position. DO NOT loosen or remove radiator cap when cooling system is hot.

RADIATOR FAN

WARNINGKeep hands away from radiator fan. Fan is controlled by a thermostatic switch which may come on or run for up to 15 minutes even after engine is turned off.

SPARK PLUGS

Note. Allow engine to cool before removing spark plugs from aluminum cylinder heads.

WARRANTY INFORMATION

CAUTIONDue to the different warranties offered in various regions and the variety of after-market extended warranties available, please refer to the warranty package that came with the vehicle to verify all warranty options.

BUMPER-TO-BUMPER PLUS COVERAGE LIMITED WARRANTY

Everything is covered for 3 years or 36,000 miles, whichever occurs first. Also covered by this warranty are any repairs to vehicle which have proven defective during material and workmanship in normal use. Warranty repairs (parts and labor) will be made by the Dealer at no charge using new or remanufactured parts by the Dealer. This warranty is subject to a 100 deductible for each repair visit after the first year or 12,000 miles, whichever occurs first. Maintenance items are covered up to their first scheduled replacement interval only.

TIRE COVERAGE

The tires supplied with the vehicle are covered against defects in material or workmanship under the Bumper-To-Bumper coverage. Any tire replaced under the Bumper-To-Bumper coverage will continue to be covered for the remaining portion of the New Vehicle Limited Warranty.

CORROSION & RUST-THROUGH COVERAGE (ALL MODELS)

Body sheet metal panels are covered against for 3 years or 36,000 miles, whichever occurs first.

Covers any body-sheet metal panel that rusts through continues to be covered 6 years or 100,000 miles whichever occurs first.

Note. Cosmetic or surface corrosion (resulting from stone chips or scratches in the paint, for example) in not included in sheet metal coverage.

SUPPLEMENTAL INFLATABLE RESTRAINT COVERAGE (ALL MODELS)

Covers supplemental restraint system (if equipped) for 3 years, regardless of mileage.

EMISSIONS "DEFECT" & "PERFORMANCE" WARRANTIES (EXCEPT CALIFORNIA)

Defect Warranty ensures that vehicle meets applicable EPA regulations and that vehicle's emission control system is free from defects in materials and workmanship for a period of 2 years or 24,000 miles, whichever occurs first.

The Performance Warranty covers all costs of repairing or adjusting any components or parts as needed in order for the vehicle to pass a federally required state or local emissions test for a period of 2 years or 24,000 miles, whichever occurs first.

Other emission control parts related to these components are covered by the Performance Warranty, where applicable. If another part fails due to the failure of one of these components, both parts are covered. See customer's copy of warranty information for specific items covered.

If a catalytic converter or vehicle (powertrain) control module is found to be defective under either of these warranties, those parts are warranted for a period of 8 years or 80,000 miles, whichever occurs first.

EMISSION "PERFORMANCE" WARRANTY (CALIFORNIA)

If vehicle fails a Smog Check inspection, all necessary repairs and adjustments will be made by manufacturer to ensure that vehicle passes the inspection. Warranty begins at warranty start date and lasts for a period of 3 years or 50,000 miles, whichever occurs first.

EMISSION "DEFECT" WARRANTY (CALIFORNIA)

If any emission-related part on the vehicle is defective, the part will be repaired or replaced by manufacturer. Warranty begins at warranty start date and lasts for a period of 3 years or 50,000 miles, whichever occurs first.

Some emission-related parts are warranted for 7 years or 70,000 miles whichever occurs first, and will be repaired or replaced by manufacturer if found to be defective in material or workmanship. See customer's copy of warranty information for specific items covered.

TOWING

Towing is covered to the nearest dealer facility if the vehicle cannot be driven because of a warranted defect.

FUSE PANEL LOCATIONS

There are three fuse panel locations. There are two fuse panels located in the instrument panel. One is located on the right hand side of the instrument panel and the other is located on the left hand side. The third fuse panel is located in the engine compartment on the driver's side near the air cleaner.

Scheme 4

Scheme 4: INSTRUMENT PANEL FUSE BLOCK IDENTIFICATION - LEFT
  1. A - Radio
  2. B - Wipers
  3. C - Trunk Release & Remote Lock Control
  4. D - Turn Signals
  5. E - Power Mirrors
  6. F - Air Bag
  7. G - Body Function Control Module
  8. H - Powertrain Control Module
  9. J - Door Locks
  10. K - Body Function Control Module, Cluster
  11. STOP LPS - Stop Lamps
  12. HAZARD LPS - Hazard Lamps
  13. IPC/HVAC BATT - Cluster, Climate Control
  14. MICRO RELAY TRUNK REL - Remote Trunk Release
  15. CIRCUIT BRKR PWR SEATS - Power Seats
  16. MICRO RELAY DR UNLOCK - Door Locks
  17. MICRO RELAY DR LOCK - Door Locks
  18. MICRO RELAY DRIVERS DR LOCK - Not Used

Scheme 5

Scheme 5: INSTRUMENT PANEL FUSE BLOCK IDENTIFICATION - RIGHT
  1. A - Instrument Panel Lights, Dimmer
  2. B - Cruise Control
  3. C - Climate Control System
  4. D - Cruise Control
  5. E - Fog Lamps
  6. F - Interior Lamps, Body Function Control Module
  7. G - Radio
  8. H - Sunroof
  9. CIRCUIT BRKR PWR WINDOWS - Power Windows
  10. MICRO RELAY FOG LPS - Fog Lamps

Scheme 6

Scheme 6: ENGINE COMPARTMENT FUSE BLOCK IDENTIFICATION

Maxi-Fuses

  1. 1 - Ignition Switch
  2. 2 - Left Hand Electrical Center-Power Seats, Power Mirrors, Door Locks, Trunk Release & Remote Lock Control
  3. 3 - Left Hand Electrical Center-Stop Lamps, Hazard Lamps, Body Function Control Module, Cluster, Climate Control System
  4. 4 - Right Hand Electrical Center-Fog Lamps, Radio, Body Function Control Module, Interior Lamps
  5. 5 - Ignition Switch
  6. 6 - Not Used
  7. 7 - Anti-Lock Brakes
  8. 8 - Cooling Fans

Mini-Relays

  1. 9 - Rear Defog
  2. 10 - Not Used
  3. 11 - Anti-Lock Brakes
  4. 12 - Cooling Fan
  5. 13 - HVAC Blower (Climate Control)
  6. 14 - Cooling Fans
  7. 15 - Cooling Fans

Micro-Relays

  1. 16 - Air Conditioning Compressor
  2. 17 - Not Used
  3. 18 - Fuel Pump
  4. 19 - Automatic Light Control
  5. 20 - Automatic Light Control
  6. 21 - Horn
  7. 22 - Daytime Running Lamps

Mini-Fuses

  1. 23-32 - Spare Fuse Holder
  2. 33 - Rear Defog
  3. 34 - Accessory Power Outlets, Cigar Lighter
  4. 35 - Anti-Lock Brakes
  5. 36 - Anti-Lock Brakes
  6. 37 - Air Conditioning Compressor, Body Function Control Module
  7. 38 - Automatic Transaxle
  8. 39 - Powertrain Control Module, Ignition
  9. 40 - Anti-Lock Brakes
  10. 41 - Ignition System
  11. 42 - Back-Up Lamps, Brake Transaxle Shift Interlock
  12. 43 - Horn
  13. 44 - Powertrain Control Module
  14. 45 - Parking Lamps
  15. 46 - Rear Defog, Daytime Running Lamps, Climate Control System
  16. 47 - Canister Purge Valve, Powertrain Control Module, Exhaust Gas Recirculation, Heated O2 Sensor
  17. 48 - Fuel Pump, Injectors
  18. 49 - Generator
  19. 50 - Right-Hand Headlamp
  20. 51 - Left-Hand Headlamp
  21. 52 - Cooling Fan
  22. 53 - HVAC Blower (Climate Control)
  23. 54 - Fuse Puller For Mini-Fuses
  24. 55 - Tach Test Point for Diagnostic Testing