🏷️ Basic Information

Make:

Chevrolet

Model:

Malibu

Year:

2006

Platform:

Epsilon (Global Epsilon)

👋 Introduction

Segment:

Mid-size sedan

Competitors:

Ford Fusion, Toyota Camry, Honda Accord, Nissan Altima, Chrysler Sebring.

Design Philosophy:

Emphasized European styling influences (shared Epsilon platform with Opel Vectra) and improved interior quality over previous generations.

Powertrain Options:

Offered a range of efficient and powerful V6 engines and an economical four-cylinder option.

📋 Manual Details

Systems Covered:

Engine mechanical, engine performance, fuel system, ignition system, emission control, transmission (automatic and manual), drivetrain, brakes, steering, suspension, body and frame, HVAC, electrical system, lighting, body control module, instrument panel, airbags, anti-lock braking system (ABS), traction control system (TCS), diagnostics, troubleshooting, wiring diagrams, maintenance, repair procedures, specifications, torque values.

Estimated Pages:

2000+

Type:

Complete Workshop Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine:

Detailed coverage of 3.5L V6 OHV, 3.9L V6 OHV and 2.2L Ecotec I4 engines. Includes disassembly, assembly, inspection, and overhaul of all major engine components.

Transmission:

Comprehensive coverage of the 4-speed automatic transmission (4T65-E) and 5-speed manual transmission (Getrag F23). Includes removal, installation, diagnosis, overhaul, and fluid specifications.

Brakes:

Front and rear disc brake systems. Covers inspection, rotor and pad replacement, caliper service, hydraulic system bleeding, and ABS/TCS component diagnosis.

Electrical:

Extensive coverage of the entire electrical system. Includes power distribution, grounds, starter, alternator, battery, lighting systems (headlamps, taillamps, interior), gauges, warning indicators, horns, and power accessories.

HVAC:

Air conditioning, heating, ventilation, climate control systems. Includes refrigerant handling, component diagnosis, blower motor, evaporator, condenser, and heater core service.

Body:

Exterior body panels, doors, windows, mirrors, bumpers, hood, trunk lid, interior trim, seats, and convertible top operation (if applicable). Includes bodywork repair and panel alignment.

Suspension Steering:

Front and rear suspension components (struts, springs, control arms, ball joints, bushings, sway bars), wheel alignment specifications, power steering system diagnosis and repair, steering column and rack and pinion service.

Maintenance:

Regular scheduled maintenance, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, brake fluid changes, transmission fluid service, tire rotations.

Diagnostics Troubleshooting:

Systematic diagnostic procedures for common and uncommon issues. Includes diagnostic trouble codes (DTCs), symptom analysis, and step-by-step troubleshooting guides for all major systems.

Repair Rebuild:

Detailed instructions for component removal, disassembly, inspection, repair or replacement, reassembly, and installation. Covers engine internal repairs, transmission overhauls, brake caliper rebuilds, suspension component replacements, and electrical component diagnostics.

Wiring Diagrams:

Comprehensive, high-quality wiring diagrams for all electrical systems, including powertrain control, chassis electronics, comfort and convenience features, and safety systems.

Depth:

Expert-level technical information. Suitable for professional mechanics, experienced DIY enthusiasts, and vocational training. Includes detailed specifications, tolerances, torque values, and diagnostic strategies.

📊 Manual Specifications

File Type:

PDF

Searchability:

Fully searchable text for quick information retrieval.

Resolution:

High-resolution, suitable for printing individual pages or the entire manual.

Binding:

N/A (Digital Format)

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Engine 1 Name:

3.5L V6 LX9 (GM High Value)

Engine 2 Name:

3.9L V6 LZ9 (High Output)

Engine 3 Name:

2.2L Ecotec L61

Engine 1 Horsepower Hp:

200

Engine 1 Torque Lb Ft:

218

Engine 2 Horsepower Hp:

233

Engine 2 Torque Lb Ft:

240

Engine 3 Horsepower Hp:

144

Engine 3 Torque Lb Ft:

154

Fuel Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity Liters:

61

🔧 Transmission

Transmission Type Standard:

4-speed automatic (4T65-E)

Transmission Type Optional:

5-speed manual (Getrag F23) - available on 2.2L Ecotec models

Automatic Transmission Modes:

Driver Shift Control (DSC) with manual shifting capability

Automatic Transmission Fluid Type:

Dexron VI (GM Recommended)

Manual Transmission Fluid Type:

GM Synchromesh Friction Modified (or equivalent)

📐 Dimensions

Length Mm:

4843

Width Mm:

1786

Height Mm:

1445

Wheelbase Mm:

2700

Front Track Mm:

1534

Rear Track Mm:

1544

Trunk Volume Liters:

470

Curb Weight Kg Approx Min:

1470

Curb Weight Kg Approx Max:

1580

Gross Vehicle Weight Rating Kg Approx:

2020

🛡️ Safety Features

NHTSA Driver Front Impact:

5-Star

NHTSA Passenger Front Impact:

5-Star

NHTSA Driver Side Impact:

5-Star

NHTSA Passenger Side Impact:

4-Star

IIHS Front Offset Crash Rating:

Good

ABS:

Standard (Anti-lock Braking System)

TCS:

Standard (Traction Control System)

Ebs:

Available (Electronic Brake-force Distribution)

Airbags Front:

Standard: Dual-stage frontal airbags

Airbags Side:

Available: Front seat-mounted side-impact airbags

Seatbelts:

Front: Pretensioners and load limiters; Rear: All seating positions with three-point lap and shoulder belts

💡 Technology Features

Audio System:

Available: AM/FM stereo with CD player, MP3 playback, premium sound systems (e.g., Bose), steering wheel audio controls.

Navigation:

Optional factory-installed GPS navigation system.

Cruise Control:

Standard

Parking Assist:

Available: Rear parking assist sensors

Onstar:

Available: OnStar communications system

Auxiliary Input:

Some models may feature an auxiliary audio input jack.

🔧 Maintenance

Oil Change Recommendation:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first, with synthetic blend oil. Consult manual for specific engine oil type and capacity.

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

2.2L Ecotec: 100,000 miles (160,000 km) with Iridium plugs; 3.5L/3.9L V6: 100,000 miles (160,000 km) with Iridium plugs.

Coolant Flush:

Every 5 years or 100,000 miles (160,000 km) for Dex-Cool coolant.

Engine Oil Viscosity 3 5L 3 9L:

SAE 3.5W-30

Engine Oil Viscosity 2 2L:

SAE 5W-30

Engine Oil Capacity 3 5L Liters:

4.7

Engine Oil Capacity 3 9L Liters:

4.7

Engine Oil Capacity 2 2L Liters:

4.5

Coolant Type:

GM Approved Dex-Cool (Orange)

Engine Oil Leaks:

Common reports of intake manifold gaskets and valve cover gaskets leaking, particularly on the 3.5L V6.

Transmission Issues:

Some reports of rough shifting or slipping in the 4T65-E automatic transmission, often related to solenoid issues or fluid degradation.

Suspension Components:

Premature wear of front struts, ball joints, and bushings can occur, leading to noise and handling issues.

Climate Control Actuators:

HVAC blend door actuators can fail, resulting in improper temperature control or airflow direction.

Body Rust:

Depending on climate, rust can develop on rocker panels, rear wheel arches, and the subframe.

📚 Vehicle History

Chevrolet Legacy:

Chevrolet, founded by Louis Chevrolet and William C. Durant in 1911, has a long history of producing reliable and accessible vehicles for the American market.

Malibu History:

The Malibu nameplate has a history dating back to the 1960s as a premium trim level of the Chevrolet Chevelle. It was reintroduced as a standalone model in 1997 and significantly redesigned for the 2004 model year, adopting the global Epsilon platform.

Model Year Introduction:

2004 (as a distinct model on Epsilon platform)

Manufacturing Location:

Fairfax, Kansas, USA; Oshawa, Ontario, Canada

🏆 Awards & Recognition

Consumer Guide Rating:

Named a 'Best Buy' by Consumer Guide Automotive for 2006.

Jd Power Initial Quality Study:

Received generally positive ratings in initial quality studies for its segment in certain years.