2004 CHEVROLET MALIBU fuel cap

Seats and Restraint Systems........................... 1-1
Front Seats
............................................... 1-2
Rear Seats
............................................... 1-7
Safety Belts
.............................................1-10
Child Restraints
.......................................1-31
Air Bag Systems
......................................1-52
Restraint System Check
............................1-60
Features and Controls..................................... 2-1
Keys
........................................................ 2-3
Doors and Locks
......................................2-10
Windows
.................................................2-16
Theft-Deterrent Systems
............................2-18
Starting and Operating Your Vehicle
...........2-22
Mirrors
....................................................2-35
OnStar
®System
......................................2-38
HomeLink®Transmitter
.............................2-40
Storage Areas
.........................................2-44
Sunroof
..................................................2-48
Instrument Panel............................................. 3-1
Instrument Panel Overview
.......................... 3-4
Climate Controls
......................................3-21
Warning Lights, Gages, and Indicators
........3-31Driver Information Center (DIC)
..................3-45
Audio System(s)
.......................................3-52
Driving Your Vehicle....................................... 4-1
Your Driving, the Road, and Your Vehicle
..... 4-2
Towing
...................................................4-31
Service and Appearance Care.......................... 5-1
Service
..................................................... 5-3
Fuel
......................................................... 5-5
Checking Things Under the Hood
...............5-12
Bulb Replacement
....................................5-45
Windshield Wiper Blade Replacement
.........5-49
Tires
......................................................5-50
Appearance Care
.....................................5-78
Vehicle Identication
.................................5-86
Electrical System
......................................5-87
Capacities and Specications
.....................5-96
Maintenance Schedule..................................... 6-1
Maintenance Schedule
................................ 6-2
Customer Assistance and Information.............. 7-1
Customer Assistance and Information
........... 7-2
Reporting Safety Defects
...........................7-11
Index................................................................ 1
2004 Chevrolet Malibu Owner ManualM

If the Light Is On Steady
You may be able to correct the emission system
malfunction by considering the following:
Did you recently put fuel into your vehicle?
If so, reinstall the fuel cap, making sure to fully
install the cap. SeeFilling Your Tank on page 5-8.
The diagnostic system can determine if the fuel cap has
been left off or improperly installed. A loose or missing
fuel cap will allow fuel to evaporate into the atmosphere.
A few driving trips with the cap properly installed
should turn the light off.
Did you just drive through a deep puddle of water?
If so, your electrical system may be wet. The condition
will usually be corrected when the electrical system
dries out. A few driving trips should turn the light off.
Have you recently changed brands of fuel?
If so, be sure to fuel your vehicle with quality fuel.
SeeGasoline Octane on page 5-5. Poor fuel quality will
cause your engine not to run as efficiently as designed.
You may notice this as stalling after start-up, stalling
when you put the vehicle into gear, misring, hesitation
on acceleration or stumbling on acceleration. (These
conditions may go away once the engine is warmed up.)
This will be detected by the system and cause the
light to turn on.If you experience one or more of these conditions,
change the fuel brand you use. It will require at least
one full tank of the proper fuel to turn the light off.
If none of the above steps have made the light turn off,
your dealer can check the vehicle. Your dealer has the
proper test equipment and diagnostic tools to x any
mechanical or electrical problems that may have
developed.
Emissions Inspection and Maintenance
Programs
Some state/provincial and local governments have or
may begin programs to inspect the emission control
equipment on your vehicle. Failure to pass this inspection
could prevent you from getting a vehicle registration.
Here are some things you need to know to help your
vehicle pass an inspection:
Your vehicle will not pass this inspection if the Check
Engine light is on or not working properly.
Your vehicle will not pass this inspection if the
OBD (on-board diagnostic) system determines that
critical emission control systems have not been
completely diagnosed by the system. The vehicle
would be considered not ready for inspection.
3-41

Here are four things that some owners ask about.
These are normal and do not indicate a problem with
your fuel gage:
At the service station, the gas pump shuts off
before the gage reads full.
It takes a little more or less fuel to ll up than the
gage indicated. For example, the gage may have
indicated the tank was half full, but it actually took
a little more or less than half the tank’s capacity
to ll the tank.
The indicator moves a little when you turn a corner
or speed up.
The gage goes back to empty when you turn off
the ignition.
Driver Information Center (DIC)
The Driver Information Center (DIC) provides the
following:
A way to personalize your vehicle
Trip information and
Warning messagesThe buttons used to
activate the DIC are
located on the left side
of the vehicle’s audio
controls.
The buttons used to activate the DIC are located on
the left side of the vehicle’s audio controls.
INFO (
4):Press this button to scroll through the
vehicle information mode displays.
MENU:Press this button to enter and scroll through
the menu mode.
ENTER (
r):Press this button to select a menu
option or to acknowledge a warning message.
The DIC messages will be read through your audio
system display.Unites States version
shown, Canada similar
3-45

Loading Your Vehicle
Item Description Total
AVehicle Capacity Weight
for Example 3=1,000 lbs (453 kg)
BSubtract Occupant
Weight 200 lbs
(91 kg)×5=1,000 lbs (453 kg)
CAvailable Cargo
Weight=0 lbs (0 kg)
Refer to your vehicle’s Tire and Loading Information
label for specic information about your vehicle’s
capacity weight and seating positions. The combined
weight of the driver, passengers, and cargo should
never exceed your vehicle’s capacity weight.
Certication Label
The other label is the Certication label, found on the rear
edge of the driver’s door. It tells you the gross weight
capacity of your vehicle, called the Gross Vehicle Weight
Rating (GVWR). The GVWR includes the weight of the
vehicle, all occupants, fuel and cargo. Never exceed the
GVWR for your vehicle, or the Gross Axle Weight
Rating (GAWR) for either the front or rear axle.
And, if you do have a heavy load, you should spread it
out. Don’t carry more than 132 lbs. (60 kg) in your trunk. Example 3
4-38

Towing a Trailer
{CAUTION:
If you do not use the correct equipment and
drive properly, you can lose control when you
pull a trailer. For example, if the trailer is too
heavy, the brakes may not work well — or even
at all. You and your passengers could be
seriously injured. You may also damage your
vehicle; the resulting repairs would not be
covered by your warranty. Pull a trailer only if
you have followed all the steps in this section.
Ask your dealer for advice and information
about towing a trailer with your vehicle.Your vehicle can tow a trailer if it is equipped with a 3.5 L
V6 engine and the proper trailer towing equipment. To
identify what the vehicle trailering capacity is for your
vehicle, you should read the information in “Weight of the
Trailer” that appears later in this section. But trailering is
different than just driving your vehicle by itself. Trailering
means changes in handling, durability and fuel economy.
Successful, safe trailering takes correct equipment, and it
has to be used properly.
That’s the reason for this part. In it are many time-tested,
important trailering tips and safety rules. Many of
these are important for your safety and that of your
passengers. So please read this section carefully before
you pull a trailer.
Load-pulling components such as the engine, transaxle,
wheel assemblies and tires are forced to work harder
against the drag of the added weight. The engine
is required to operate at relatively higher speeds and
under greater loads, generating extra heat. What’s more,
the trailer adds considerably to wind resistance,
increasing the pulling requirements.
4-40

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-6
California Fuel...............................................5-6
Additives.......................................................5-7
Fuels in Foreign Countries...............................5-8
Filling Your Tank............................................5-8
Filling a Portable Fuel Container.....................5-11
Checking Things Under the Hood....................5-12
Hood Release..............................................5-12
Engine Compartment Overview.......................5-14
Engine Oil...................................................5-17
Engine Air Cleaner/Filter................................5-22
Automatic Transaxle Fluid..............................5-23
Engine Coolant.............................................5-24
Coolant Surge Tank Pressure Cap..................5-26
Engine Overheating.......................................5-27
Cooling System............................................5-29
Windshield Washer Fluid................................5-34Brakes........................................................5-35
Battery........................................................5-38
Jump Starting...............................................5-39
Bulb Replacement..........................................5-45
Halogen Bulbs..............................................5-45
Headlamps..................................................5-45
Center High-Mounted Stoplamp (CHMSL).........5-47
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-47
Replacement Bulbs.......................................5-49
Windshield Wiper Blade Replacement..............5-49
Tires..............................................................5-50
Ination - Tire Pressure.................................5-57
Tire Inspection and Rotation...........................5-58
When It Is Time for New Tires.......................5-59
Buying New Tires.........................................5-60
Uniform Tire Quality Grading..........................5-61
Wheel Alignment and Tire Balance..................5-62
Wheel Replacement......................................5-62
Tire Chains..................................................5-64
If a Tire Goes Flat........................................5-65
Changing a Flat Tire.....................................5-66
Compact Spare Tire......................................5-77
Section 5 Service and Appearance Care
5-1

Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel may be hard
to nd. Never use leaded gasoline or any other fuel
not recommended in the previous text on fuel. Costly
repairs caused by use of improper fuel would not
be covered by your warranty.
To check the fuel availability, ask an auto club, or
contact a major oil company that does business in the
country where you will be driving.
Filling Your Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to you
and others, read and follow all the instructions
on the pump island. Turn off your engine when
you are refueling. Do not smoke if you are near
fuel or refueling your vehicle. Keep sparks,
ames and smoking materials away from fuel.
CAUTION: (Continued)
CAUTION: (Continued)
Do not leave the fuel pump unattended when
refueling your vehicle — this is against the law
in some places. Keep children away from the
fuel pump; never let children pump fuel.
The fuel cap is located behind a hinged door on the
passenger’s side of your vehicle. To open the door,
insert your nger into the nger depression next to
the fuel door.
5-8

While refueling, hang the tethered cap inside the
fuel door.
To remove the fuel cap, turn it slowly to the left
(counterclockwise). The fuel cap has a spring in it;
if you let go of the cap too soon, it will spring back
to the right.
{CAUTION:
If you spill fuel and then something ignites it,
you could be badly burned. Fuel can spray out
on you if you open the fuel cap too quickly. This
spray can happen if your tank is nearly full, and
is more likely in hot weather. Open the fuel cap
slowly and wait for any “hiss” noise to stop.
Then unscrew the cap all the way.
Be careful not to spill fuel. Don’t top off or overll your
tank, and wait a few seconds after you’ve nished
pumping before you remove the nozzle. Clean fuel from
painted surfaces as soon as possible. SeeCleaning
the Outside of Your Vehicle on page 5-81.
5-9