General Information Chevrolet Malibu VII

US English/Metric Conversion

Decimal and Metric Equivalents

Arrows and Symbols

This service manual uses various symbols in order to describe different service operations.

Scheme 1

Customer Concern Verification Sheets

Note. This procedure is not used in Brazil.

The GM Customer Concern Verification Sheets have been designed to improve communications between the service customer and the technician. The more clearly the technician understands the concern and its symptoms, the more likely the concern will be fixed right the first time.

The GM-wide Customer Concern Verification Sheets are available in DealerWorld. The Customer Concern Verification Sheets may be printed and reproduced locally.

Dealers

All U.S. Dealers participating in the Common Training Program can enroll through the Common Training System Website at https://www.gmtraining.com. Within the website, there are individual training paths that are designed to assist in planning the training needs for each individual. Technicians should advise their Service Manager of their training needs including course names and course numbers. Dealers who have questions about Common Training should contact the Common Training help desk at 1-888-748-2686. The help desk is available Monday through Friday, 8:00 am-8:00pm Eastern Standard Time, excluding holidays. For GM Access support, contact the GM Access Help Desk at 1-888-337-1010.

Fleets

GM Fleet customers with GM Warranty In-Shop agreements are able to participate in service technical training through Common Training/GM Service Technical College (STC).

Assistance for all GM fleet customers using GM STC products and services is provided on the Internet via www.gmtraining.com using the "Contact Us" button on the site and/or the Common Training Help Desk at 1-888-748-2687. To order GM STC Training Materials, please contact the GM Training Materials Headquarters at 1-800-393-4831.

Most GM STC course materials have associated charges.

To purchase authentic GM STC Training Materials, contact the GM Training Materials Headquarters at 1-800-393-4831.

Non-GM Dealer Technicians

Technicians training for non-GM dealers is available through ACDelco. This training is for ACDelco customers employed in the automotive or truck service industry.

ACDelco courses are available at all approved GM Training Centers. Availability and schedules can be obtained by calling 1-800-825-5886 or contact us via the web at www.acdelcotechconnect.com and select the training button. Clinics are also offered through ACDelco Warehouse Distributors. Contract your dealer directly for more information.

Scheme 2

The VIN plate is the legal identifier of the vehicle. The VIN plate is located on the upper left corner of the instrument panel (I/P) and can be seen through the windshield from the outside of the vehicle

2.4L LAT, LE5 and LE9 Engine ID and VIN Derivative Location

Refer to Engine Identification .

3.5L LZ4 and LZE Engine ID and VIN Derivative Location

Refer to Engine Identification .

3.6L LY7 Engine ID and VIN Derivative Location

Refer to Engine Identification .

4T45-E Transmission ID and VIN Derivative Location

Refer to Transmission Identification Information .

6T40/6T45 Transmission ID and VIN Derivative Location

Refer to Transmission Identification Information .

6T70/6T75 Transmission ID and VIN Derivative Location

Refer to Transmission Identification Information .

Scheme 3

RPO Code List

The following table provides the description of the Regular Production Option (RPO) codes that are available on the vehicle. The vehicle's RPO list is printed on the Service Parts Identification Label.

Metric Fasteners

This vehicle provides fastener dimensions using the metric system. Most metric fasteners are approximate in diameter to equivalent English fasteners. Make replacements using fasteners of the same nominal diameter, thread pitch, and strength.

A number marking identifies the OE metric fasteners except cross-recess head screws. The number also indicates the strength of the fastener material. A Posidrive® or Type 1A cross-recess identifies a metric cross-recess screw. For best results, use a Type 1A cross-recess screwdriver, or equivalent, in Posidrive® recess head screws.

GM Engineering Standards and North American Industries have adopted a portion of the ISO-defined standard metric fastener sizes. The purpose was to reduce the number of fastener sizes used while retaining the best thread qualities in each thread size. For example, the metric M6.0 X 1 screw, with nearly the same diameter and 25.4 threads per inch replaced the English 1/4-20 and 1/4-28 screws. The thread pitch is midway between the English coarse and fine thread pitches.

Scheme 4

The most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is embossed on the head of each bolt. The English, inch strength classes range from grade 2 to grade 8. Radial lines are embossed on the head of each bolt in order to identify the strength class. The number of lines on the head of the bolt is 2 lines less than the actual grade. For example, a grade 8 bolt will have 6 radial lines on the bolt head. Some metric nuts are marked with a single digit strength identification number on the nut face.

The correct fasteners are available through GM SPO. Many metric fasteners available in the aftermarket parts channels are designed to metric standards of countries other than the United States, and may exhibit the following

1. Lower strength
2. No numbered head marking system
3. Wrong thread pitch

The metric fasteners on GM products are designed to new, international standards. The following are the common sizes and pitches, except for special applications

1. M6.0 X 1
2. M8 X 1.25
3. M10 X 1.5
4. M12 X 1.75
5. M14 X 2.00
6. M16 X 2.00

Prevailing Torque Fasteners

Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening.

All Metal Prevailing Torque Fasteners

These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener.

Nylon Interface Prevailing Torque Fasteners

These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads.

Adhesive Coated Fasteners

These fasteners accomplish the thread interface by the presence of a thread-locking compound on the fastener threads. Refer to the appropriate repair procedure in order to determine if the fastener may be reused and the applicable thread-locking compound to apply to the fastener.

Scheme 5

A prevailing torque fastener may be reused ONLY if

1. The fastener and the fastener counterpart are clean and not damaged
2. There is no rust on the fastener
3. The fastener develops the specified minimum torque against its counterpart prior to the fastener seating

Metric Prevailing Torque Fastener Minimum Torque Development

English Prevailing Torque Fastener Minimum Torque Development

Thread Inserts

General Purpose Thread Repair Kits.

These kits are available commercially.

Repair Procedure

1. Determine the size, the pitch, and the depth of the damaged thread. If necessary, adjust the stop collars on the cutting tool and tap to the required depth.
2. Drill out the damaged threads. Clean out any chips.
3. Lubricate the tap with light engine oil. Tap the hole. Clean the threads.
4. Thread the thread insert onto the mandrel of the installer. Engage the tang of the insert onto the end of the mandrel.
5. Lubricate the insert with light engine oil, except when installing in aluminum and install the insert.
6. If the tang of the insert does not break off when backing out the installer, break the tang off with a drift.

Abbreviations and Meanings

Registered and Non-Registered Trademarks

Listed below are Registered Trademarks (®) or Non-Registered Trademarks (™) which may appear in this service manual.

Ignition Lock Cylinder

The ignition lock cylinder uses 8 of the 10 key cut positions, 1-8. The tumbler positions are staggered from side to side, four on one side and four on the other.

1. Hold the cylinder assembly (1) so the retainer pin pocket is facing upward.
2. Insert one tumbler spring (2) into each of the 4 spring wells.
3. The first tumbler (3) to be loaded will be the first key cut position, the first number in the key code. Install the first tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 3, 5 and 7. It may be necessary to move the sidebar (already pre-assembled into the cylinder assembly) out slightly to fully install the tumbler into the correct slot.
4. Check the correct loading by holding the tumblers (3) in position and fully inserting the key into the cylinder assembly. All tumblers and the sidebar should be flush with the outside diameter of the cylinder assembly body.
5. Rotate the cylinder assembly (1) so that the retention lug is facing upward and then remove the key, always holding all tumblers so they do not fall out.
6. Insert one tumbler spring (2) into each of the 4 spring wells.
7. The first tumbler (3) to be loaded will be the second key cut position, the second number in the key code. Install the tumbler in the slot nearest the head of the lock cylinder. Install the remaining tumblers following the key code into the slots at the key cut positions 4, 6 and 8.
8. Check for the correct loading by holding the tumblers (3) in position and fully inserting the key into the cylinder assembly (1).
9. Lightly lubricate the tumbler (3) surfaces and the small detent recess on the side of the cylinder assembly (1) using the lubrication provided.
10. With the key fully inserted, rotate the cylinder assembly so that the side with the retaining pin (4) pocket is facing upward.
11. Insert the retaining pin spring (5) and then retaining pin (4) into the pocket located behind the 4 tumblers. The retaining pin spring and retaining pin are not self-retaining and must be held in place until the cylinder is installed into the case assembly (6).
12. With the key fully inserted into the cylinder assembly and the retaining pin (4) fully depressed into the cylinder, align the retainer lug on the cylinder with the groove on the inside diameter of the case assembly (6). This groove extends the full length of the case assembly.
13. Install the cylinder assembly into the case assembly (6) being very careful to hold the retainer pin spring (5) and retainer pin (4) in the cylinder until they enter into the case assembly. With the cylinder fully inserted into the case assembly, rotate the cylinder counterclockwise until the retainer pin snaps into place limiting the rotation of the cylinder assembly.
14. With the cylinder assembly in the Off-Lock position, insert the detent ball (7), and detent spring (8) into the hole in the side of the case assembly (6). Install the anti-rattle spring (9) into the case assembly over the detent spring. The anti-rattle spring should capture the detent ball and spring in the case assembly. Make sure both ends of the anti-rattle spring (9) are fully seated, pressed into, the case assembly.
15. Remove the key and install the ignition cylinder bezel (10) onto the case assembly (6). Make sure the retaining clips of the ignition cylinder bezel are correctly positioned and fully snapped onto the case assembly.

Scheme 6

The door lock cylinder only uses 7 of the 10 cut positions, 3 through 9. The tumbler positions are staggered from side to side, 4 on one side and 3 on the other side, are self-retaining. The left and right door lock cylinders are identical. The lever assembly determines which side of the vehicle the lock cylinder is for. After removing the current lock, record which lever is used and the orientation of rod clip.

1. Rotate the cylinder (1) so the side with the 4 tumbler spring wells faces up.
2. Insert the tumbler springs (2) into the 4 spring wells.
3. Install the tumbler (3) for key cut position 3 in the slot closest to the cylinder head. Install the remaining tumblers, key cut positions 5, 7 and 9, following the key code and same process. Press the tumblers in place until they are secure.
4. Check the correct loading of the tumblers by inserting the key into the cylinder. All tumblers should be flush with the lock cylinder body.
5. Turn the cylinder so the side with the 3 tumbler spring wells faces up.
6. Insert the tumbler springs into the 3 spring wells.
7. The first tumbler closest to the front of the lock cylinder to be loaded will be the fourth key cut position. Install the remaining tumblers for key cut positions 6 and 8. Press the tumblers in place until they are secure.
8. Check the correct loading of the tumblers by inserting the key into the cylinder. All of the tumblers should be flush with the lock cylinder body.
9. Apply lubricant to the cylinder body and tumbler surfaces along with a small amount in the head of the cylinder using the supplied grease.
10. Install 2 springs (4) into the spring wells in the head of the lock cylinder.
11. Snap the shutter assembly (5) into the cylinder.
12. Assemble the cylinder into the case (6).
13. Align dimples of the cylinder cap (7) with the 4 recesses in the cap. Secure by pressing the cap into place with light hand pressure.
14. If required, assemble the rod clip (9) to the lever (8) using the recorded lever information.
15. Assemble the lever to the lock. Use E-clip (10) to retain the lever assembly.
16. If supplied, assemble the gasket to the lock.
17. Insert the key into the lock and function the lock to check for proper assembly and smooth operation.

Special Tools

J 43625 Lift Pad Adapter

Note. The use of a LOW PROFILE LIFT ARMS SYSTEM may be required to avoid unwanted contact with the vehicle's body and structure depending on lifting equipment used. Refer to the manufacture's recommendation for their applications of low profile lift arms system for their lifting equipment.

Scheme 7

Front Lift Pads

When lifting the vehicle with a frame-contact lift, place the front lift pads on the front lower brackets, inboard of the rocker pinch weld flange and outboard of the front frame rail, at the torque box location, as shown.

Rear Lift Pads

When lifting the vehicle with a frame-contact lift, place the rear lift pads on the rear frame rail, at the torque box location, as shown.

Vehicle Jacking

Note. When you are lifting a vehicle with a service jack, block the wheels at the opposite end from which you are lifting. Use jack stands to provide additional support.

Front of Vehicle

When using a service jack under the front of the vehicle use one of the following locations

1. Place the service jack pad in the same location as shown for the front lift pads.
2. Under the front frame crossmember, as shown.

Rear of Vehicle

Note. Place jackstands ONLY under strong and stable vehicle structures.

When using a service jack under the rear of the vehicle place the jack pad on the rocker panel flange, at the torque box location, as shown.

See also:
• Engine Identification
• Engine Identification
• Engine Identification
• Transmission Identification Information
• Transmission Identification Information
• Transmission Identification Information
• Safety Glasses Warning