2003 CHEVROLET MALIBU brakes

Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts in
the proper sequence to GM torque speci®cations.
Your rear drum brakes don't have wear indicators, but if
you ever hear a rear brake rubbing noise, have the
rear brake linings inspected immediately. Also, the rear
brake drums should be removed and inspected each
time the tires are removed for rotation or changing.
When you have the front brake pads replaced, have the
rear brakes inspected, too.
Brake linings should always be replaced as complete
axle sets.
See
Brake System Inspection on page 6-20.
Brake Pedal Travel
See your dealer if the brake pedal does not return to
normal height, or if there is a rapid increase in
pedal travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you make a moderate brake stop, your disc
brakes adjust for wear. If you rarely make a moderate or
heavier stop, then your brakes might not adjust correctly.
If you drive in that way, then Ð very carefully Ð make a
few moderate brake stops about every 1,000 miles
(1 600 km), so your brakes will adjust properly.If your brake pedal goes down farther than normal, your
rear drum brakes may need adjustment. Adjust them
by pumping the brake pedal repeatedly while the engine
is running with the shift lever in PARK (P).
Replacing Brake System Parts
The braking system on a vehicle is complex. Its many
parts have to be of top quality and work well together if
the vehicle is to have really good braking. Your
vehicle was designed and tested with top-quality GM
brake parts. When you replace parts of your braking
system Ð for example, when your brake linings
wear down and you need new ones put in Ð be sure
you get new approved replacement parts. If you
don't, your brakes may no longer work properly. For
example, if someone puts in brake linings that are wrong
for your vehicle, the balance between your front and
rear brakes can change Ð for the worse. The braking
performance you've come to expect can change in
many other ways if someone puts in the wrong
replacement brake parts.
5-35

Engine Compartment Fuse Block
The engine compartment fuse block is located on the
driver's side of the vehicle, near the engine air
cleaner/®lter. See
Engine Compartment Overview on
page 5-12for more information on location.
Fuses Usage
1 Ignition Switch
2Right Electrical Center-Fog Lamps,
Radio, Body Function Control
Module, Interior LampsFuses Usage
3Left Electrical Center-Stoplamps,
Hazard Lamps, Body Function
Control Module, Cluster, Climate
Control System
4 Anti-Lock Brakes
5 Ignition Switch
6 Not Used
7Left Electrical Center-Power Seats,
Power Mirrors, Door Locks, Trunk
Release and Remote Lock Control
8 Cooling Fan #1
Relays Usage
9 Rear Defogger
10 Not Used
11 Not Used
12 Cooling Fan #1
13 HVAC Blower (Climate Control)
14 Cooling Fan #2
15 Cooling Fan
16 Air Conditioning Compressor
17 Not Used
18 Fuel Pump
19 Automatic Headlamp System
5-80

Relays Usage
20 Automatic Headlamp System
21 Horn
22 Daytime Running Lamps (DRL)
Fuses Usage
23±32 Spare Fuse Holder
33 Rear Defogger
34Accessory Power Outlets,
Cigar Lighter
35 Generator
36 Not Used
37Air Conditioning Compressor,
Body Function Control Module
38 Automatic Transaxle
39Powertrain Control Module (PCM),
Ignition
40 Anti-Lock Brakes (ABS)
41 Ignition System
42Back-Up Lamps, Automatic
Transaxle Shift Lock Control SystemFuses Usage
43 Horn
44 PCM
45 Parking Lamps
46 Climate Control System
47Canister Purge Valve, PCM, Exhaust
Gas Recirculation, Heated Oxygen
Sensor
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 Used
5-81

Every 50,000 Miles (83 000 km):Automatic Transaxle
Service (severe conditions only).
Every 100,000 Miles (166 000 km):Spark Plug Wire
Inspection. Spark Plug Replacement.
Every 150,000 Miles (240 000 km):Cooling System
Service (or every 60 months, whichever occurs
®rst). Engine Accessory Drive Belt Inspection.
These intervals only summarize maintenance services.
Be sure to follow the complete scheduled maintenance
on the following pages.
Short Trip/City Scheduled
Maintenance
The services shown in this schedule up to 100,000 miles
(166 000 km) should be repeated after 100,000 miles
(166 000 km) at the same intervals for the life of
this vehicle. The services shown at 150,000 miles
(240 000 km) should be repeated at the same interval
after 150,000 miles (240 000 km) for the life of this
vehicle.
See
Part B: Owner Checks and Services on page 6-15andPart C: Periodic MaintenanceInspections on
page 6-19.
Footnotes
²The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle 's useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
+A good time to check your brakes is during tire
rotation. See Brake System Inspection on page 6-20.
3,000 Miles (5 000 km)
qChange engine oil and ®lter (or every 3 months,
whichever occurs ®rst).An Emission Control Service.
6,000 Miles (10 000 km)
qChange engine oil and ®lter (or every 3 months,
whichever occurs ®rst).An Emission Control Service.
qRotate tires. SeeTire Inspection and Rotation
on page 5-50for proper rotation pattern and
additional information.(See footnote +.)
9,000 Miles (15 000 km)
qChange engine oil and ®lter (or every 3 months,
whichever occurs ®rst).An Emission Control Service.
6-6

100,000 Miles (166 000 km)
qInspect spark plug wires.An Emission Control
Service.
qReplace spark plugs.An Emission Control Service.
qChange automatic transaxle ¯uid and ®lter if the
vehicle is mainly driven under one or more of
these conditions:
þ In heavy city traffic where the outside
temperature regularly reaches 90ÉF (32ÉC)
or higher.
þ In hilly or mountainous terrain.
þ When doing frequent trailer towing.
þ Uses such as found in taxi, police or delivery
service.
If you do not use your vehicle any of these conditions,
the ¯uid and ®lter do not require changing.
150,000 Miles (240 000 km)
qDrain, ¯ush and re®ll cooling system (or every
60 months since last service, whichever occurs ®rst).
See
Engine Coolant on page 5-19for what to use.
Inspect hoses. Clean radiator, condenser, pressure
cap and neck. Pressure test the cooling system
and pressure cap.
An Emission Control Service.
qInspect engine accessory drive belt.An Emission
Control Service.
Long Trip/Highway Scheduled
Maintenance
The services shown in this schedule up to 100,000 miles
(166 000 km) should be repeated after 100,000 miles
(166 000 km) at the same intervals for the life of
this vehicle. The services shown at 150,000 miles
(240 000 km) should be repeated at the same interval
after 150,000 miles (240 000 km) for the life of this
vehicle.
See
Part B: Owner Checks and Services on page 6-15andPart C: Periodic MaintenanceInspections on
page 6-19.
Footnotes
²The U.S. Environmental Protection Agency or the
California Air Resources Board has determined that the
failure to perform this maintenance item will not nullify
the emission warranty or limit recall liability prior to
the completion of the vehicle's useful life. We, however,
urge that all recommended maintenance services be
performed at the indicated intervals and the
maintenance be recorded.
+A good time to check your brakes is during tire
rotation. See Brake System Inspection on page 6-20.
6-11

Engine Cooling System Inspection
Inspect the hoses and have them replaced if they
are cracked, swollen or deteriorated. Inspect all pipes,
®ttings 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,
cha®ng, 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.
6-20

If NHTSA receives similar complaints, it may open an
investigation, and if it ®nds that a safety defect exists in
a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in
individual problems between you, your dealer or
General Motors.
To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (or 366-0123 in
the Washington, D.C. area) or write to:
NHTSA, U.S. Department of Transportation
Washington, D.C. 20590
You can also obtain other information about motor
vehicle safety from the hotline.
Reporting Safety Defects to the
Canadian Government
If you live in Canada, and you believe that your vehicle
has a safety defect, you should immediately notify
Transport Canada, in addition to notifying General
Motors of Canada Limited. You may write to:
Transport Canada
330 Sparks Street
Tower C
Ottawa, Ontario K1A 0N5
Reporting Safety Defects to
General Motors
In addition to notifying NHTSA (or Transport Canada) in
a situation like this, we certainly hope you'll notify us.
Please call us at 1-800-222-1020, or write:
Chevrolet Motor Division
Chevrolet Customer Assistance Center
P.O. Box 33170
Detroit, MI 48232-5170
In Canada, please call us at 1-800-263-3777 (English)
or 1-800-263-7854 (French). Or, write:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
Service Publications Ordering
Information
Service Manuals
Service Manuals have the diagnosis and repair
information on engines, transmission, axle, suspension,
brakes, electrical, steering, body, etc.
RETAIL SELL PRICE: $120.00
7-9

B
Backing Up....................................................4-38
Battery Replacement......................................... 2-6
Battery Run-Down Protection............................3-16
Battery..........................................................5-36
Before Leaving on a Long Trip.........................4-20
Body Lubrication Service..................................6-16
Brake............................................................2-23
Parking......................................................2-23
System Inspection.......................................6-20
System Warning Light..................................3-27
Brake Adjustment............................................5-35
Brake Fluid....................................................5-32
Brake Pedal Travel.........................................5-35
Brake Wear...................................................5-34
Brakes..........................................................5-32
Braking in Emergencies..................................... 4-8
Braking........................................................... 4-6
Break-In, New Vehicle.....................................2-16
Bulb Replacement...........................................5-42
Center High-Mounted Stoplamp (CHMSL)........5-44
Front Turn Signal Lamps..............................5-44
Halogen Bulbs............................................5-42
Headlamps.................................................5-42
Replacement Bulbs......................................5-47Bulb Replacement (cont.)
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps........................................5-45
Buying New Tires...........................................5-52
C
California Fuel.................................................. 5-5
Canada ± Customer Assistance.......................... 7-4
Canadian Owners................................................ ii
Canadian Roadside Assistance........................... 7-6
Capacities and Speci®cations............................5-82
Carbon Monoxide...................4-23, 4-34, 2-11, 2-26
Care of.........................................................5-70
Safety Belts................................................5-70
Your Cassette Tape Player............................3-58
Your CD Player...........................................3-59
Your CDs ...................................................3-59
Cassette Tape Messages.................................3-54
Cassette Tape Player Service...........................6-15
CD Adapter Kits.............................................3-54
Center Console Storage Area...........................2-30
Center High-Mounted Stoplamp (CHMSL)...........5-44
Center Rear Passenger Position, Safety Belts.....1-24
Chains, Tires..................................................5-55
2