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2004 Chevrolet Malibu CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Chevrolet REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- 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
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 -> Precautions -> Air Bag System Disarming & Arming -> Battery Ground Cable
Vehicle: 2004 Chevrolet Malibu LS 3.5 V6 GAS
Air Bag System Disarming & Arming
Refer to and for air bag system disarming and arming proced...
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BRAKE SERVICE PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Power Brake Units -> Power Brake Unit Service
Vehicle: 2004 Chevrolet Malibu Maxx 3.5 V6 GAS
Hydro-boost brake boosters are...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
General Motors Corp./Saturn Passenger Cars -> Fuel Pressure Relief -> G6, Malibu (2004-06) & Malibu Maxx
Vehicle: 2004 Chevrolet Malibu Maxx 3.5 V6 GAS
Do not smoke or allow an open flame of any type when working on or near any fuel system related components. The highly flammable vapor mixtures may ignite, resulting in serious personal injury.
Prior to disconnecting fuel lines, the fuel system pressure must be relieved to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to ...
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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 Maxx 3.5 V6 GAS
- Disconnect battery ground cable.
- Remove air cleaner assembly.
- Remove engine mount strut from front of engine and radiator support.
- Rotate drive belt tensioner using suitable removal tool, then remove serpent...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
General Motors Corp./Saturn Cars -> Air Bag Warning Lamp ->
Vehicle: 2004 Chevrolet Malibu LS 3.5 V6 GAS
This lamp should light for a approximately 6-8 seconds when the ignition is turned on as a bulb check. If the air b...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Radiator, Replace
Vehicle: 2004 Chevrolet Malibu LS 3.5 V6 GAS
- Remove intake manifold cover.
- Remove lefthand inner fender brace.
- Remove air cleaner outlet duct from throttle body.
- Disconnect PCV tube from air inlet duct.
- Disconnect Mass Air Flow (MAF) sensor electrical connector.
- Remove upper air cleaner housing.
- Remove Powertrain Control Module (PCM) and harness from lower air cleaner housing. Do not disconnect connectors.
- Remove Transmission Control Module (TCM) and harness from lower air cleaner housing. Do not disconnect connectors.
- Loosen clamp and remove air cleaner outlet duct from air cleaner.
- Disconnect two rubber grommets on inner rail a...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2004 Chevrolet Malibu AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2004 Chevrolet Malibu Maxx 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+.
 Instrument Panel Diagram for 2004 Chevrolet Malibu 2.2 L4 GASComponents on diagram: |
 Side Impact Modules Diagram for 2004 Chevrolet Malibu Maxx 3.5 V6 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 2.2 L4 GAS Wiring DiagramComponents on diagram: |
 2004 Chevrolet Malibu 2.2 L4 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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