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2004 Chevrolet Malibu CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Manual Air Conditioning & Heater System Diagnosis & Testing -> Technical Service Bulletins -> Poor Air Conditioning Performance -- Will Not Blow Cold Enough -> 2003 Sierra & Silverado
Vehicle: 2004 Chevrolet Malibu 2.2 L4 GAS
2003 Sierra & Silverado
On some of these models equipped with 6.6L diesel engine the air conditioning performance is less than desirable, especially when ambient temperature is more than 90°F.
To correct this condition perform system inspects as follow:
- Calibrate actuators
- Inspect lower condenser deflector for proper installation. Deflector should be positioned at lower part of condenser and extend forward into top of front bumper and below two fresh air intake holes.
- Inspect engine coo...
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BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Hydraulic Brake Systems -> Hydraulic Brake System Flush
Vehicle: 2004 Chevrolet Malibu Maxx 3.5 V6 GAS
If brake fluid is old, rusty or contaminated or whenever new components are installed in hydraulic system, the system must be flushed. Bleed brakes...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Fuel Filter Scheduled Maintenance -> 1980-06 Gasoline Engine Models Except Catera, LeMans (1988-93) Metro, Nova (1985-88), Saturn & Sprint -> Normal Service -> Severe Service
Vehicle: 2004 Chevrolet Malibu LT 3.5 V6 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2004 Chevrolet Malibu LS 3.5 V6 GAS
- Raise and support vehicle on a hoist.
- Remove tire and wheel assembly.
- Disconnect tie rod from knuckle.
- Insert a drift into rotor and against caliper in order to prevent rotor from turning.
- Remove wheel drive shaft nut.
- Remove stabilizer link.
- Be sure that wheel speed sensor wiring harness is repositioned away from ball joint after disconnecting electrical connector from sensor. Disconnect ele...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Alternator, Replace
Vehicle: 2004 Chevrolet Malibu 2.2 L4 GAS
- Disconnect battery ground cable.
- Remove serpentine drive belt using a suitable to rotate tensioner.
- Remove mounting bolts and studs.
- Disconnect electrical lead...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
General Motors Corp./Saturn Cars -> Low Coolant Lamp ->
Vehicle: 2004 Chevrolet Malibu Maxx 3.5 V6 GAS
This lamp should light when engine coolant level in the radiator drops below a predetermined le...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2004 Chevrolet Malibu 2.2 L4 GAS
Lower
- Drain cooling system into a suitable container.
- Reposition hose clamp from thermostat housing using hose clamp pliers J 38185 or equivalent.
- Remove radiator outlet hose from thermostat housing.
- Reposition hose clamp from radiator using hose clamp pliers J 38185 or equivalent.
- Remove radiator outlet hose from radiator and from vehicle.
- Reverse procedure to ...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Chevrolet Malibu LS 3.5 V6 GAS
- Disconnect battery ground cable.
- Remove air cleaner assembly.
- Remove engine mount snubber bracket.
- Rotate tensioner counterclockwise using suitable tool to relieve tension from driv...
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COMPONENT LOCATION DIAGRAMS FOR 2004 Chevrolet Malibu AUTOMOBILES
Component location diagrams for most 2004 Chevrolet Malibu cars and light trucks sold in the U.S. from 1990+.
Rear Package Shelf Diagram for 2004 Chevrolet Malibu LT 3.5 V6 GAS Components on diagram: |
Lower Right B Pillar Diagram for 2004 Chevrolet Malibu LS 3.5 V6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2004 Chevrolet Malibu AUTOMOBILES
OEM drawn wiring diagrams for most 2004 Chevrolet Malibu cars and light trucks sold in the U.S.
2004 Chevrolet Malibu 2.2 L4 GAS Wiring Diagram Components on diagram: |
2004 Chevrolet Malibu LS 3.5 V6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2004 Chevrolet Malibu AUTOMOBILES
OEM TSB listings for most 2004 Chevrolet Malibu cars and light trucks sold in the U.S. from 1985+.
Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2004 Chevrolet Malibu 2.2 L4 GAS Auto Systems: |
Document: New Website for AFIT, TPM, and VDR Updates Vehicle: 2004 Chevrolet Malibu 2.2 L4 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2004 Chevrolet Malibu AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2004 Chevrolet Malibu cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2004 Chevrolet Malibu cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2004 Chevrolet Malibu cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2004 Chevrolet Malibu cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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