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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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- 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
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2004 Chevrolet Malibu car and truck
repair procedures including Chevrolet engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Chevrolet Malibu automobile. Try the Automotix DIY solution today!
A/C & HEATER SERVICE PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Manual Air Conditioning & Heater System Diagnosis & Testing -> Malibu -> Component Diagnosis & Testing -> Blower Motor -> Control Panel
Vehicle: 2004 Chevrolet Malibu LT 3.5 V6 GAS
Blower Motor
Refer to "Diagnostic Tests" and for blower motor diagnosis an...
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BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Disc Brakes -> AC-Delco Single Piston Front Disc Brake -> Caliper Service -> Assemble -> Disassemble -> Inspection -> Replacement
Vehicle: 2004 Chevrolet Malibu LT 3.5 V6 GAS
Replacement
- Remove approximately 2/3 of brake fluid from master cylinder.
- Raise and support front of vehicle, then remove wheel and tire assembly.
- Push piston back into caliper bore using suitable C-clamp, Fig. .
- Remove inlet fitting mounting bolt, copper washer and inlet fitting from caliper housing. Plug opening in inlet fitting. Do not crimp brake hose.
- Remove caliper mounting bolts and caliper, Fig. . If there are signs of corrosion, replace bolts when installing caliper assembly.
- Reverse procedure to install.
Disassemble
- Clean outside of caliper, then drain brake fluid from caliper...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Component Locations -> Aveo, GTO, G6, LaCrosse, Lucerne, Solstice, Vibe & 2004-06 Malibu & Malibu Maxx
Vehicle: 2004 Chevrolet Malibu Maxx 3.5 V6 GAS
On Aveo, GTO, G6, LaCrosse, Lucerne, Solstic...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2004 Chevrolet Malibu 2.2 L4 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
Starter, Replace
Vehicle: 2004 Chevrolet Malibu LS 3.5 V6 GAS
- Disconnect battery ground cable.
- Raise and support vehicle.
- Remove flywheel inspection cover.
- Remove starter electrical connectors.
- Remove mounting bolts and starter.
- Reverse procedure to install, noting the following:
- Tor...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
General Motors Corp./Saturn Cars -> Change Oil, Change Oil Now Or Change Oil Soon Lamp & Messages -> 2004-09 Malibu
Vehicle: 2004 Chevrolet Malibu 2.2 L4 GAS
- Turn ignition on, but do not start engine.
- Display OIL LIFE RESET on Driver Information Center (DIC).
- Press and hold ENTER button for at least one...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2004 Chevrolet Malibu 2.2 L4 GAS
Inlet
- Drain cooling system into a suitable container.
- Remove evaporator hose assembly.
- Remove condenser tube.
- Reposition heater hose inlet clamp at heater core using hose clamp pliers J 38185 or equivalent.
- Remove heater inlet hose from heater core.
- Reposition heater core inlet hose clamp at engine using hose clamp pliers J 38185 or equivalent.
- Remove hose from engine.
- Remove hose from vehicle.
- Reverse procedure to in...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Chevrolet Malibu LT 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+.
 Wheel Speed Sensors Diagram for 2004 Chevrolet Malibu Maxx 3.5 V6 GASComponents on diagram: |
 Under Driver Seat Diagram for 2004 Chevrolet Malibu 2.2 L4 GASComponents 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 LT 3.5 V6 GAS Wiring DiagramComponents 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+.
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Document: Revised General Motors New Vehicle Tire Warranty Program Vehicle: 2004 Chevrolet Malibu 2.2 L4 GAS Auto Systems: |
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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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