2004 CHEVROLET MALIBU service

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

{CAUTION:
When an air bag inates, there is dust in the
air. This dust could cause breathing problems
for people with a history of asthma or other
breathing trouble. To avoid this, everyone in
the vehicle should get out as soon as it is safe
to do so. If you have breathing problems but
can’t get out of the vehicle after an air bag
inates, then get fresh air by opening a
window or a door. If you experience breathing
problems following an air bag deployment, you
should seek medical attention.
In many crashes severe enough to inate an air bag,
windshields are broken by vehicle deformation.
Additional windshield breakage may also occur from the
right front passenger air bag.
Air bags are designed to inate only once. After an
air bag inates, you’ll need some new parts for your
air bag system. If you don’t get them, the air bag
system won’t be there to help protect you in another
crash. A new system will include air bag modules
and possibly other parts. The service manual for your
vehicle covers the need to replace other parts.
Your vehicle is equipped with a crash sensing and
diagnostic module, which may record information
about the air bag system. The module records
information about the readiness of the system, when
the system commands air bag ination and driver’s
safety belt usage at deployment.
Let only qualied technicians work on your air bag
system. Improper service can mean that your air bag
system won’t work properly. See your dealer for
service.
Notice:If you damage the covering for the driver’s
or the right front passenger’s air bag, or the side
impact air bag covering on the ceiling near the side
windows, the bag may not work properly. You
may have to replace the air bag module in the
steering wheel, both the air bag module and
the instrument panel for the right front passenger’s
air bag, or side impact air bag module and ceiling
covering for the roof-mounted side impact air
bag. Do not open or break the air bag coverings.
1-59

Servicing Your Air Bag-Equipped
Vehicle
Air bags affect how your vehicle should be serviced.
There are air bag system parts in several places around
your vehicle. You don’t want the system to inate
while someone is working on your vehicle. Your dealer
and the service manual have information about
servicing your vehicle and the air bag system. To
purchase a service manual, seeService Publications
Ordering Information on page 7-12.
{CAUTION:
For up to 10 minutes after the ignition key is
turned off and the battery is disconnected, an
air bag can still inate during improper
service. You can be injured if you are close to
an air bag when it inates. Avoid yellow
connectors. They are probably part of the air
bag system. Be sure to follow proper service
procedures, and make sure the person
performing work for you is qualied to do so.
Air bag systems do not need regular maintenance.
Restraint System Check
Checking Your Restraint Systems
Now and then, make sure the safety belt reminder light
and all your belts, buckles, latch plates, retractors
and anchorages are working properly. Look for any other
loose or damaged safety belt system parts. If you see
anything that might keep a safety belt system from doing
its job, have it repaired.
Torn or frayed safety belts may not protect you in a
crash. They can rip apart under impact forces. If a belt
is torn or frayed, get a new one right away.
Also look for any opened or broken air bag covers, and
have them repaired or replaced. (The air bag system
does not need regular maintenance.)
1-60

Remote Keyless Entry System
If equipped, the keyless entry system operates on a
radio frequency subject to Federal Communications
Commission (FCC) Rules and with Industry Canada.
This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
1. This device may not cause interference, and
2. This device must accept any interference received,
including interference that may cause undesired
operation of the device.
This device complies with RSS-210 of Industry Canada.
Operation is subject to the following two conditions:
1. This device may not cause interference, and
2. This device must accept any interference received,
including interference that may cause undesired
operation of the device.
Changes or modications to this system by other than
an authorized service facility could void authorization to
use this equipment.At times you may notice a decrease in range. This is
normal for any remote keyless entry system. If the
transmitter does not work or if you have to stand closer
to your vehicle for the transmitter to work, try this:
Check the distance. You may be too far from your
vehicle. You may need to stand closer during
rainy or snowy weather.
Check the location. Other vehicles or objects may
be blocking the signal. Take a few steps to the
left or right, hold the transmitter higher, and
try again.
Check to determine if battery replacement is
necessary. See “Battery Replacement” under
Remote Keyless Entry System Operation on
page 2-6.
If you are still having trouble, see your dealer or a
qualied technician for service.
2-5

PASS-Key®III+
Your PASS-Key®III + system operates on a radio
frequency subject to Federal Communications
Commission (FCC) Rules and with Industry Canada.
This device complies with Part 15 of the FCC Rules.
Operation is subject to the following two conditions:
1. this device may not cause harmful interference, and
2. this device must accept any interference received,
including interference that may cause undesired
operation.
This device complies with RSS-210 of Industry Canada.
Operation is subject to the following two conditions:
1. this device may not cause interference, and
2. this device must accept any interference received,
including interference that may cause undesired
operation of the device.
Changes or modications to this system by other than
an authorized service facility could void authorization to
use this equipment.
PASS-Key
®III + uses a radio frequency transponder in
the key that matches a decoder in your vehicle.
PASS-Key®III+ Operation
Your vehicle is equipped with PASS-Key®III +
(Personalized Automotive Security System)
theft-deterrent system. PASS-Key
®III + is a passive
theft-deterrent system. This means you don’t have to do
anything special to arm or disarm the system. It works
when you insert or remove the key from the ignition.
When the PASS-Key
®III + system senses that someone
is using the wrong key, it shuts down the vehicle’s starter
and fuel systems. The starter will not work and fuel will
stop owing to the engine. Anyone using a trial-and-error
method to start the vehicle will be discouraged because
of the high number of electrical key codes.
When trying to start the vehicle if the engine does not
start and the SECURITY light in the instrument
panel cluster comes on, the key may have a damaged
transponder. Turn the ignition off and try again.
If the engine still does not start, and the key appears to
be undamaged, try another ignition key. At this time,
you may also want to check the fuse, seeFuses
on page 5-88. If the engine still does not start with the
other key, your vehicle needs service. If your vehicle
does start, the rst key may be faulty. See your dealer
who can service the PASS-Key
®III + to have a new
key made. In an emergency, contact Chevrolet Roadside
Assistance. SeeRoadside Assistance Program on
page 7-6for more information.
2-20

It is possible for the PASS-Key®III + decoder to “learn”
the transponder value of a new or replacement key.
Up to 10 additional keys may be programmed for
the vehicle. The following procedure is for programming
additional keys only. If all the currently programmed
keys are lost or do not operate, you must see your
dealer or a locksmith who can service PASS-Key
®III +
to have keys made and programmed to the system.
See your dealer or a locksmith who can service
PASS-Key
®III + to get a new key blank that is cut
exactly as the ignition key that operates the system.
Canadian Owners:If you lose or damage your keys,
only a GM dealer can service PASS-Key
®III+to
have new keys made. To program additional keys, you
will need two current driver’s keys. You must add a
step to the following procedure. After Step 2, repeat
Steps 1 and 2 with the second current driver’s key. Then
continue with Step 3.
To program the new key do the following:
1. Verify that the new key has “+” stamped on it.
2. Insert the master key in the ignition and start the
engine. If the engine will not start, see your dealer
for service.3. After the engine has started, turn the key to OFF,
and remove the key.
4. Insert the key to be programmed and turn it to RUN
within ve seconds of removing the original key.
5. The SECURITY light turns off, once the key has
been programmed. It may not be apparent that
the SECURITY light went on due to how quickly the
key is programmed.
6. Repeat Steps 1 through 5 if additional keys are to
be programmed.
If you are ever driving and the SECURITY light comes
on and stays on, you will be able to restart your
engine if you turn it off. Your PASS-Key®III + system,
however, is not working properly and must be serviced
by your dealer. Your vehicle is not protected by the
PASS-Key
®III + system at this time.
If you lose or damage your PASS-Key
®III + key, see
your dealer or a locksmith who can service
PASS-Key
®III + to have a new key made.
2-21

Starting and Operating Your
Vehicle
New Vehicle Break-In
Notice:Your vehicle does not need an elaborate
“break-in.” But it will perform better in the long run
if you follow these guidelines:
Do not drive at any one speed — fast or
slow — for the rst 500 miles (805 km). Do not
make full-throttle starts.
Avoid making hard stops for the rst 200 miles
(322 km) or so. During this time your new
brake linings are not yet broken in. Hard stops
with new linings can mean premature wear
and earlier replacement. Follow this breaking-in
guideline every time you get new brake
linings.
Do not tow a trailer during break-in. SeeTowing
a Trailer on page 4-40for more information.
Ignition Positions
With the key in the ignition
switch, you can turn it to
four different positions.
Notice:If your key seems stuck in OFF and you
can not turn it, be sure you are using the correct
key; if so, is it all the way in? Turn the key only with
your hand. Using a tool to force it could break the
key or the ignition switch. If none of this works, then
your vehicle needs service.
9(OFF):This is the only position from which you
can remove the key. It also locks your ignition and
transaxle. A warning chime will sound if you open the
driver’s door while the ignition is off and the key is left in
the ignition.
2-22

Notice:Driving your vehicle if you notice that it is
moving slowly or not shifting gears as you
increase speed may damage the transaxle. Have
your vehicle serviced right away. You can drive in
LOW (L2) when you are driving less than 35 mph
(55 km/h) and AUTOMATIC OVERDRIVE (D) for
higher speeds until then.
LOW (L):This position gives you access to THIRD,
SECOND and FIRST gears for more power but
lower fuel economy than AUTOMATIC OVERDRIVE
(D). You can use it on very steep hills, or in deep snow
or mud. If the electronic range select is put in LOW
(L1), the transaxle won’t shift into lower gears until the
vehicle is going slow enough.
Electronic Range Select Mode
This feature allows you to select lower driving gears.
The button for this mode is located on the left side of the
shift lever knob.
The electronic range select mode only changes gear
when the shift lever is in LOW (L).
When the shift lever is rst moved into the LOW (L)
position, the display in the instrument panel shows L3.
Press the (−) end of the button on the shift lever
once for L2 and once more for L1. Press the (+) end of
the button to return to L2 and L3. The shift lever
must be moved back to DRIVE (D) to turn off the
electronic range select mode.
Parking Brake
To set the parking brake, push down the parking brake
pedal with your left foot. If the ignition is on, the
brake system warning light will come on. SeeBrake
System Warning Light on page 3-36.
To release the parking brake, hold the regular brake
pedal down with your right foot. Push down momentarily
on the parking brake pedal with your left foot until you
feel the pedal release. If the parking brake is not
released when you begin to drive, the brake system
warning light will be on and a chime will sound warning
you that the parking brake is still on.
A message will also appear in the Driver Information
Center (DIC) to remind you to release the parking brake.
SeeDIC Warnings and Messages on page 3-50.
Notice:Driving with the parking brake on can
overheat the brake system and cause premature
wear or damage to brake system parts. Verify that
the parking brake is fully released and the brake
warning light is off before driving.
If you are towing a trailer and are parking on a hill, see
Towing a Trailer on page 4-40.
2-29