Target Audience:
Do-it-yourself (DIY) car owners and professional mechanics.
Value Proposition:
Provides dealer-level repair information at a fraction of the cost, enabling cost-effective vehicle maintenance and repair.
Illustration Detail:
Hundreds of photos, illustrations, and exploded views to clarify repair procedures.
Instruction Format:
Numbered, step-by-step instructions with detailed substeps, notes, cautions, and warnings.
Navigation:
Numbered table of contents for quick access to information.
Accessibility:
Instant high-speed download, eliminating shipping wait times.
Engine Systems:
Engine mechanical, lubrication, fuel system, cooling system, intake and exhaust systems, emission control systems, ignition system, starting and charging system.
Drivetrain:
Automatic transmission, manual transmission, clutch, transfer case (if applicable), drive shafts, differential, axles, wheel bearings.
Suspension Steering:
Front and rear suspension components, shock absorbers, springs, steering column, power steering system, steering gear.
Brakes:
Brake system operation, front and rear brakes (disc/drum), ABS, parking brake, brake control systems.
Electrical:
12-volt electrical system, battery, charging system, starting system, lighting, instrument panel, gauges, horn, wipers, washers, power accessories, multiplex/CAN communication system.
Climate Control:
Air conditioning system, heating, ventilation.
Safety Restraint:
Supplemental Restraint System (SRS) / Airbags, seat belts, pretensioners, engine immobilizer.
Body Interior Exterior:
Doors, door locks, windows, mirrors, windshield, glass, interior trim, instrument panel, seats, engine hood, exterior trim, body panels.
Cruise Control:
Cruise control system operation and troubleshooting.
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements, lubrication.
Diagnostics:
Troubleshooting procedures for all major systems, diagnostic trouble codes (DTCs), electrical system diagnostics.
Repair:
Step-by-step repair instructions for component removal, disassembly, assembly, and installation for all major systems.
Electrical Repair:
Detailed wiring diagrams, component testing, circuit tracing, connector information.
Depth:
Extensive, covering from basic maintenance to complete engine and transmission rebuilds. Includes detailed torque specifications, clearances, and alignment data.
Quality:
High-resolution PDF, ensuring clear text and readable images.
Searchability:
Typically searchable text for quick information retrieval.
Printability:
Fully printable, allowing users to print specific sections or the entire manual.
Binding:
Not applicable (Digital Download)
Paper:
Not applicable (Digital Download)
Engine Options:
2.2L Ecotec L61 I4, 3.5L LZ9 V6, 3.8L L36 V6 (Series II), 3.9L LZ8/LZ9 V6.
2.2L Ecotec (L61) Horsepower:
144 hp @ 5600 rpm
2.2L Ecotec (L61) Torque:
150 lb-ft @ 4000 rpm
3.5L Lz9 V6 Horsepower:
201 hp @ 5200 rpm (2005-2006), 217 hp @ 5400 rpm (2007-2008)
3.5L Lz9 V6 Torque:
220 lb-ft @ 4000 rpm (2005-2006), 227 lb-ft @ 4000 rpm (2007-2008)
3.8L L36 V6 (Series Ii) Horsepower:
200 hp @ 5200 rpm
3.8L L36 V6 (Series Ii) Torque:
225 lb-ft @ 3200 rpm
3.9L Lz8/Lz9 V6 Horsepower:
235 hp @ 5600 rpm
3.9L Lz8/Lz9 V6 Torque:
249 lb-ft @ 3200 rpm
Fuel Delivery:
Multi-port Fuel Injection (MPFI) for all engines.
Fuel Type:
Unleaded gasoline (87 octane recommended, higher for performance).
ECU Type:
GM's Engine Control Module (ECM), often referred to by its OS number.
NHTSA Front Impact Driver:
5-Star (for 2004-2008 models, depending on specific year and equipment)
NHTSA Front Impact Passenger:
5-Star (for 2004-2008 models, depending on specific year and equipment)
IIHS Front Offset Crash Rating:
Good (for 2006-2008 models)
Active Safety:
Anti-lock Braking System (ABS), Traction Control System (TCS) often available or standard on higher trims.
Passive Safety:
Front airbags, side-impact airbags (often optional), front seatbelt pretensioners.
Audio Systems:
AM/FM stereo with CD player, optional CD changer, optional Bose premium audio system, auxiliary input (on later models).
Navigation:
Optional factory navigation system available on some higher trim levels.
Cruise Control:
Standard on most trims, with steering wheel mounted controls.
Onstar:
Available as an option or subscription service.
Oil Change Interval:
Typically every 3,000-7,500 miles (4,800-12,000 km) or 6 months, depending on oil type and driving conditions (refer to manual for exact specifications).
Engine Air Filter Replacement:
Recommended every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Varies by engine type: Ecotec (Iridium) 100,000 miles; V6 (Platium) 60,000-100,000 miles.
Engine Oil Type:
SAE 5W-30 synthetic blend or full synthetic recommended for most engines. Check manual for specific viscosity for climate.
Transmission Fluid Type:
Dexron VI (for 4T65-E automatic transmission). Check manual for specific fluid type and capacity.
Coolant Type:
GM's recommended Dex-Cool (Orange) or equivalent G-05 compatible coolant (50/50 mix with distilled water).
Common Problems:
Potential issues include: transmission solenoid failures (especially in early 4T65-E), wheel bearing noise, power steering pump leaks, HVAC actuator failures, engine oil consumption (on some Ecotec models), intake manifold gasket leaks (on some V6 engines).
Manufacturer:
Chevrolet, a division of General Motors (GM).
Platform:
This generation of Malibu (2004-2008) was based on the GM Epsilon platform, shared with vehicles like the Saab 9-3 and Opel Vectra.
Design Changes 2004-2008:
Significant redesign for 2004, moving to the Epsilon platform. Minor styling updates and powertrain refinements occurred throughout the generation.
Manufacturing Locations:
Primarily manufactured in Kansas City, Kansas, USA.
