2002 CHEVROLET MALIBU fuel

6-58
Mirco Relay Usage
16 Air Conditioning Compressor
17 Not Used
18 Fuel Pump
19 Automatic Light Control
20 Automatic Light Control
21 Horn
22 Daytime Running Lamps (DRL)
Minifuse Usage
23
- 32Spare Fuse Holder
33 Rear Defogger
34 Accessory Power Outlets,
Cigar Lighter
35 Generator
36 Not Used Minifuse Usage
37 Air Conditioning Compressor, Body
Function Control Module
38 Automatic Transaxle
39 Powertrain Control
Module (PCM), Ignition
40 Anti
-Lock Brakes (ABS)
41 Ignition System
42 Back
-Up Lamps, Brake Transaxle
Shift Interlock Control
43 Horn
44 PCM
45 Parking Lamps
46 Climate Control System
47 Canister Purge Valve, PCM, Exhaust
Gas Recirculation, Heated O
2 Sensor

6-59
Minifuse Usage
48 Fuel Pump Injectors
49 Not Used
50 Right Headlamp
51 Left Headlamp
52 Cooling Fan
53 HVAC Blower (Climate Control)
54 Not Used
55 Cooling Fan #2 Ground
56 Fuse Puller
57 Not UsedReplacement Bulbs
Exterior Lamp Bulb. . . . . . . . . . . . . . . . . . . . . . . . .
High
-Beam Headlamp 9005. . . . . . . . . . . . . . . . . . . .
Low
-Beam Headlamp 9006. . . . . . . . . . . . . . . . . . . .
Front Parking/Turn 3157A or 3157NA. . . . . . . . . . . .
Front Sidemarker 24. . . . . . . . . . . . . . . . . . . . . . . . . .
Back
-Up/Rear Turn 3156. . . . . . . . . . . . . . . . . . . . . .
Center High
-Mounted
Stoplamp (Interior Mounted) 912. . . . . . . . . . . . . .
Tail/Stoplamp 3057. . . . . . . . . . . . . . . . . . . . . . . . . . .
For any bulb not listed here, contact your dealer.

6-60
Capacities and Specifications
The following approximate capacities are given in
English and metric conversions. Please refer to
ªRecommended Fluids and Lubricantsº in the Index for
more information.
Capacities
Automatic Transaxle
Complete Overhaul 9.5 quarts (9.0 L). . . . . . . . . . . .
Cooling System13.6 quarts (12.9 L) . . . . . . . . . . . . .
Engine Oil with Filter4.5 quarts (4.3 L) . . . . . . . . .
Fuel Tank14.1 U.S. gallons (53.4 L) . . . . . . . . . . . .
All capacities are approximate. When adding, be
sure to fill to the appropriate level, as recommended
in this manual.
Engine Specifications
VIN Engine Code J. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type V6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Nut Torque
100 lb-ft (140 N´m)
Air Conditioning
Refrigerant Capacity
If you do your own service work, you'll need the proper
service manual. See ªDoing Your Own Service Workº in
the Index for additional information. It is recommended
that service work on your air conditioning system be
performed by a qualified technician.
Air Conditioning
Refrigerant R134a 1.4 lbs. (0.6 kg). . . . . . . . . . . . .
Use Refrigerant Oil, R134a Systems
Normal Maintenance
Replacement Parts
Engine Air Cleaner/Filter A-1279C* . . . . . . . . . . . . . .
Engine Oil Filter PF
-47* . . . . . . . . . . . . . . . . . . . . . .
Spark Plugs 41
-940* . . . . . . . . . . . . . . . . . . . . . . . . . .
Gap: 0.060 inch (1.52 mm)
Windshield Wiper Blades
Passenger's Side 19.0 inches (48.0 cm). . . . . . . . . . . .
Driver's Side 22.0 inches (56.0 cm). . . . . . . . . . . . . .
*ACDelco

part number.

7-4
Part A: Scheduled Maintenance
Services
Using Your Maintenance Schedule
We at General Motors want to help you keep your
vehicle in good working condition. But we don't know
exactly how you'll drive it. You may drive very short
distances only a few times a week. Or you may drive
long distances all the time in very hot, dusty weather.
You may use your vehicle in making deliveries.
Or you may drive it to work, to do errands or in many
other ways.
Because of all the different ways people use their
vehicles, maintenance needs vary. You may need more
frequent checks and replacements. So please read the
following and note how you drive. If you have any
questions on how to keep your vehicle in good
condition, see your dealer.
This part tells you the maintenance services you should
have done and when you should schedule them. If you
go to your dealer for your service needs, you'll know
that GM
-trained and supported service people will
perform the work using genuine GM parts.The proper fluids and lubricants to use are listed in
Part D. Make sure whoever services your vehicle
uses these. All parts should be replaced and all
necessary repairs done before you or anyone else
drives the vehicle.
These schedules are for vehicles that:

carry passengers and cargo within recommended
limits. You will find these limits on your vehicle's
Tire
-Loading Information label. See ªLoading Your
Vehicleº in the Index.

are driven on reasonable road surfaces within legal
driving limits.

use the recommended fuel. See ªFuelº in the Index.
Selecting the Right Schedule
First you'll need to decide which of the two schedules is
right for your vehicle. Here's how to decide which
schedule to follow:

7-26
Part B: Owner Checks and Services
Listed in this part are owner checks and services which
should be performed at the intervals specified to help
ensure the safety, dependability and emission control
performance of your vehicle.
Be sure any necessary repairs are completed at once.
Whenever any fluids or lubricants are added to your
vehicle, make sure they are the proper ones, as shown
in Part D.
At Each Fuel Fill
It is important for you or a service station attendant to
perform these underhood checks at each fuel fill.
Engine Oil Level Check
Check the engine oil level and add the proper oil
if necessary. See ªEngine Oilº in the Index for
further details.Engine Coolant Level Check
Check the engine coolant level and add DEX
-COOL

coolant mixture if necessary. See ªEngine Coolantº in
the Index for further details.
Windshield Washer Fluid Level Check
Check the windshield washer fluid level in the
windshield washer tank and add the proper fluid if
necessary. See ªWindshield Washer Fluidº in the
Index for further details.
At Least Once a Month
Tire Inflation Check
Make sure tires are inflated to the correct pressures.
Don't forget to check your spare tire. See ªTiresº in the
Index for further details.
Cassette Deck Service
Clean cassette deck. Cleaning should be done every
50 hours of tape play. See ªAudio Systemsº in the
Index for further details.

7-32 Fuel System Inspection
Inspect the complete fuel system for damage or leaks.
Engine Cooling System Inspection
Inspect the hoses and have them replaced if they are
cracked, swollen or deteriorated. Inspect all pipes,
fittings and clamps; replace as needed. Clean the outside
of the radiator and air conditioning condenser. To help
ensure proper operation, a pressure test of the cooling
system and pressure cap is recommended at least once
a year.
Throttle System Inspection
Inspect the throttle system for interference or binding,
and for damaged or missing parts. Replace parts as
needed. Replace any components that have high effort
or excessive wear. Do not lubricate accelerator and
cruise control cables.
Brake System Inspection
Inspect the complete system. Inspect brake lines and
hoses for proper hook
-up, binding, leaks, cracks,
chafing, etc. Inspect disc brake pads for wear and rotors
for surface condition. Also inspect drum brake linings
for wear and cracks. Inspect other brake parts, including
drums, wheel cylinders, calipers, parking brake, etc. The
parking brake is self
-adjusting and no manual
adjustment is required. You may need to have your
brakes inspected more often if your driving habits or
conditions result in frequent braking.

8-7
Roadside Courtesy Care provides:

Roadside Basic Care services (as outlined
previously) Plus:

FREE Non
-Warranty Towing (to the closest dealer
from a legal roadway)

FREE Locksmith/Key Service (when keys are lost
on the road or locked inside)

FREE Flat Tire Service (spare installed on the road)

FREE Jump Start (at home or on the road)

FREE Fuel Delivery ($5 of fuel delivered on the road)
Chevrolet offers Courtesy Transportation for customers
needing warranty service. Courtesy Transportation will
be offered in conjunction with the coverage provided by
the Bumper
-to-Bumper New Vehicle Limited Warranty
to eligible purchasers of 2002 Chevrolet passenger cars
and light duty trucks. (Please see your selling dealer
for details.)Courtesy Care is available to retail and retail lease
customers operating 2002 and newer Chevrolet vehicles
for a period of 3 years/36,000 miles (60 000 km),
whichever occurs first. All Courtesy Care services
must be pre
-arranged by Chevrolet Roadside or dealer
service management.
Basic Care and Courtesy Care are not part of or
included in the coverage provided by the New Vehicle
Limited Warranty. Chevrolet reserves the right to
modify or discontinue Basic Care and Courtesy Care
at any time.
The Roadside Assistance Center uses companies
that will provide you with quality and priority service.
When roadside services are required, our advisors will
explain any payment obligations that may be incurred
for utilizing outside services.

8-9
If the dealer requests that you simply drop the vehicle
off for service, you are urged to do so as early in the
work day as possible to allow for same day repair.
Transportation Options
Warranty service can generally be completed while you
wait. However, if you are unable to wait Chevrolet helps
minimize your inconvenience by providing several
transportation options. Depending on the circumstances,
your dealer can offer you one of the following:
Shuttle Service
Participating dealers can provide you with shuttle service
to get you to your destination with minimal interruption
of your daily schedule. This includes a one way shuttle
ride to a destination up to 10 miles from the dealership.
Public Transportation or Fuel Reimbursement
If your vehicle requires overnight warranty repairs,
reimbursement up to $30 per day (five days maximum)
may be available for the use of public transportation
such as taxi or bus. In addition, should you
arrange transportation through a friend or relative,
reimbursement for reasonable fuel expenses up to
$10 per day (five day maximum) may be available.
Claim amounts should reflect actual costs and be
supported by original receipts.Courtesy Rental Vehicle
When your vehicle is unavailable due to overnight
warranty repairs, your dealer may arrange to provide
you with a courtesy rental vehicle or reimburse you
for a rental vehicle you obtained, at actual cost, up to
a maximum of $30.00 per day supported by receipts.
This requires that you sign and complete a rental
agreement and meet state, local and rental vehicle
provider requirements. Requirements vary and may
include minimum age requirements, insurance coverage,
credit card, etc. You are responsible for fuel usage
charges and may also be responsible for taxes, levies,
usage fees, excessive mileage or rental usage beyond the
completion of the repair.
Generally it is not possible to provide a like
-vehicle as
a courtesy rental.
Additional Program Information
Courtesy Transportation is available during the
Bumper
-to-Bumper warranty coverage period,
but it is not part of the New Vehicle Limited Warranty.
A separate booklet entitled ªWarranty and Owner
Assistance Informationº furnished with each new
vehicle provides detailed warranty coverage information.