2004 CHEVROLET MALIBU headlamp

Appearance Care............................................5-78
Cleaning the Inside of Your Vehicle.................5-78
Care of Safety Belts......................................5-81
Weatherstrips...............................................5-81
Cleaning the Outside of Your Vehicle..............5-81
Sheet Metal Damage.....................................5-83
Finish Damage.............................................5-83
Underbody Maintenance................................5-84
Chemical Paint Spotting.................................5-84
Vehicle Care/Appearance Materials..................5-84Vehicle Identication......................................5-86
Vehicle Identication Number (VIN).................5-86
Service Parts Identication Label.....................5-86
Electrical System............................................5-87
Add-On Electrical Equipment..........................5-87
Headlamp Wiring..........................................5-87
Windshield Wiper Fuses................................5-87
Power Windows and Other Power Options.......5-87
Fuses.........................................................5-88
Capacities and Specications..........................5-96
Section 5 Service and Appearance Care
5-2

Bulb Replacement
For bulb types, seeReplacement Bulbs on page 5-49.
For any bulb changing procedures not listed in this
section, contact your dealer.
Halogen Bulbs
{CAUTION:
Halogen bulbs have pressurized gas inside
and can burst if you drop or scratch the bulb.
You or others could be injured. Be sure to
read and follow the instructions on the bulb
package.
Headlamps
A. High-Beam Headlamp
B. Low-Beam Headlamp
C. Front Turn Signal/Park Lamp/DRL
5-45

1. Open the hood.
2. Carefully remove the two bolts attaching the
headlamp assembly to the vehicle.
3. Remove the lamp assembly from the vehicle by
pulling it forward. Use care not to scratch the
vehicle with the lamp or the lamp with the fender.4. Remove the rubber covers from the individual
sockets.
5. Unclip the wiring
harness and twist
the socket less than
one-quarter turn
counterclockwise
and remove it.
5-46

6. Gently wiggle the
bulb from the socket.
Replace the old
bulb with a new bulb.
7. Turn the socket back into place and reconnect
the wiring harness to the socket.
8. Return the lamp assembly to its original position.
Be sure to line up the holes in the lamp assembly
to the round ends of the mounting pins.
9. Reinstall the two bolts attaching the headlamp
assembly to the vehicle.
Center High-Mounted Stoplamp
(CHMSL)
It is recommended that this component be replaced
as a unit. See your dealer.
Taillamps, Turn Signal, Stoplamps
and Back-up Lamps
1. Open the trunk.
A. Taillamp
B. Back-Up Lamp
C. Taillamp/Stoplamp/Turn Signal Lamp
5-47

Replacement Bulbs
Exterior Lamp Bulb Number
Back-Up 921
Front Parking/Turn Signal Lamp 3157KX
High-Beam Headlamp H-9
Low-Beam Headlamp H-11
Taillamp/Stoplamp/Turn
Signal Lamp3057
For any bulb not listed here, contact your dealer.
Windshield Wiper Blade
Replacement
Windshield wiper blades should be inspected at least
twice a year for wear and cracking.
To replace the wiper blade assembly, do the following:
1. Pull the windshield wiper arm away from the
windshield.2. Press the tab that holds the wiper blade to the arm.
3. Pull the assembly down to release it from the
U-hooked end of the wiper arm and slide the
assembly away from the arm.
4. Slide in the new wiper blade assembly and snap
it into place.
5. Repeat Steps 1 through 4 for the other wiper,
if necessary.
5-49

Each new wheel should have the same load-carrying
capacity, diameter, width, offset and be mounted
the same way as the one it replaces.
If you need to replace any of your wheels, wheel bolts
or wheel nuts, replace them only with new GM original
equipment parts. This way, you will be sure to have the
right wheel, wheel bolts and wheel nuts for your vehicle.
{CAUTION:
Using the wrong replacement wheels, wheel
bolts or wheel nuts on your vehicle can be
dangerous. It could affect the braking and
handling of your vehicle, make your tires lose
air and make you lose control. You could have
a collision in which you or others could be
injured. Always use the correct wheel, wheel
bolts and wheel nuts for replacement.Notice:The wrong wheel can also cause problems
with bearing life, brake cooling, speedometer or
odometer calibration, headlamp aim, bumper height,
vehicle ground clearance and tire or tire chain
clearance to the body and chassis.
SeeChanging a Flat Tire on page 5-66for more
information.
Used Replacement Wheels
{CAUTION:
Putting a used wheel on your vehicle is
dangerous. You can’t know how it’s been
used or how far it’s been driven. It could fail
suddenly and cause a crash. If you have to
replace a wheel, use a new GM original
equipment wheel.
5-63

Electrical System
Add-On Electrical Equipment
Notice:Don’t add anything electrical to your
vehicle unless you check with your dealer rst. Some
electrical equipment can damage your vehicle and
the damage wouldn’t be covered by your warranty.
Some add-on electrical equipment can keep other
components from working as they should.
Your vehicle has an air bag system. Before attempting
to add anything electrical to your vehicle, seeServicing
Your Air Bag-Equipped Vehicle on page 1-60.
Headlamp Wiring
The headlamp wiring is protected by fuses, one for
each headlamp, in the fuse block. An electrical overload
will cause the lamps to turn off. If this happens, have
your headlamp wiring checked right away.
Windshield Wiper Fuses
The windshield wiper motor is protected by an internal
circuit breaker and a fuse. If the motor overheats due
to heavy snow, etc., the wiper will stop until the
motor cools. If the overload is caused by some electrical
problem and not snow, etc., be sure to get it xed.
Power Windows and Other Power
Options
Fuses in the fuse block protect the power windows
and other power accessories. When the current load is
too heavy, the fuse opens protecting the circuit until
the problem is xed or goes away.
5-87

Fuses Usage
7 Left Headlamp Low-Beam
8 Horn
9 Right Headlamp Low-Beam
10 Front Fog Lamps
11 Left Headlamp High-Beam
12 Right Headlamp High-Beam
13Powertrain Control
Module (Batt)
14 Windshield Wiper
15 Anti-Lock Brake System
16Powertrain Control
Module (IGN 1)
17 Cooling Fan 1
18 Cooling Fan 2
19 RUN RELAY
20 IBCM 1
21 IBCM (R/C)
22 RBEC 1
23 RBEC 2
24 Anti-lock Brake System
25 IBCM 2Fuses Usage
26 STARTER
27 (DIODE) Windshield Wiper
41 Electric Power Steering
42 (Resistor) Brake Lamp Diagnostic
Relays Usage
28 Cooling Fan 1
29 Cooling Fan Mode
30 Cooling Fan 2
31 STARTER
32 RUN/CRANK Ignition
33 POWERTRAIN
34 A/C CLUTCH
35 High-Beam Headlamps
36 Front Fog Lamps
37 Horn
38 Low-Beam Headlamps
39 Windshield Wiper 1
40 Windshield Wiper 2
5-92