2004-2008 Chevrolet Malibu Service and Repair Manual

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🏷️ Basic Information Identification Make: Chevrolet Model: Malibu Years Covered: 2004, 2005, 2006, 2007, 2008 Codes Platform: GM Epsilon platform 👋 Introduction Market Position Segment: Mid-size sedan Competitive Analysis Competitors:...

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Taper: Car

Distributeur:

UGS: 583877

Mots clés: 2004 2005 2006 2007 2008 Car Cars Chevrolet Malibu

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Chevrolet

Model:

Malibu

Years Covered:

2004, 2005, 2006, 2007, 2008

Codes

Platform:

GM Epsilon platform

👋 Introduction

Market Position

Segment:

Mid-size sedan

Competitive Analysis

Competitors:

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

Key Features

Design Era:

Represents the first generation of the Epsilon platform Malibu in North America, known for improved styling and chassis over previous generations.

Manual Advantage:

This service manual provides the essential technical data and repair procedures required to maintain and repair the 2004-2008 Chevrolet Malibu effectively.

📋 Manual Details

Coverage Areas

All Systems:

Engine Mechanical:

Engine Performance:

Fuel And Emissions:

Transmission Manual:

Transmission Automatic:

Drivetrain:

Suspension And Steering:

Brakes:

Wheels And Tires:

Body And Frame:

Exterior And Interior Trim:

HVAC System:

Electrical System:

Lighting System:

Audio And Infotainment:

Safety Restraint System:

Diagnostics And Troubleshooting:

Wiring Diagrams:

Page Count

Estimated Pages:

2000+

Manual Type

Type:

Factory Service Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

All Major Systems:

Comprehensive coverage of all mechanical, electrical, and body systems.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs.

Scheduled Maintenance:

Detailed schedules and procedures for all manufacturer-recommended maintenance intervals.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and complex issues.

Repair Procedures:

Step-by-step instructions for component removal, disassembly, repair, assembly, and reinstallation.

Component Replacement:

Detailed guides for replacing parts such as alternators, starters, water pumps, radiators, and more.

Diagnosis And Testing:

Procedures for testing sensors, actuators, electrical circuits, and mechanical components.

Specifications And Tolerances:

Precise torque values, clearances, and alignment specifications for critical components.

Technical Depth

Depth:

Expert level. Suitable for professional technicians and advanced DIY enthusiasts.

Diagnostic Troubleshooting:

Detailed flowcharts and diagnostic trees for pinpointing issues.

Rebuilding Procedures:

Includes procedures for engine and transmission rebuilding where applicable.

📊 Manual Specifications

File Format

Digital Format:

Searchable PDF for quick access to information.

Print Quality

Image Resolution:

High-resolution diagrams and illustrations for clarity.

Binding Type

Physical Binding:

N/A (Digital)

Paper Type

Physical Paper:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Base Engine 2004-2006:

2.2L Ecotec DOHC L61 I4

2.2L Ecotec Horsepower:

144 hp @ 5600 rpm

2.2L Ecotec Torque:

156 lb-ft @ 4000 rpm

2.2L Ecotec Fuel System:

Sequential Port Fuel Injection (SFI)

Optional Engine

Optional Engine 2004-2007:

3.5L High Value V6 LX9

3.5L V6 Horsepower:

201 hp @ 5400 rpm

3.5L V6 Torque:

220 lb-ft @ 3200 rpm

3.5L V6 Fuel System:

Sequential Port Fuel Injection (SFI)

Performance Engine 2006-2008:

3.9L High Feature V6 LZ9

Performance Engine

3.9L V6 Horsepower:

240 hp @ 6400 rpm

3.9L V6 Torque:

240 lb-ft @ 2800 rpm

3.9L V6 Fuel System:

Sequential Port Fuel Injection (SFI)

Fuel System

Recommended Fuel:

87 Octane Regular Unleaded (all engines)

🔧 Transmission

Standard

Standard Transmission 2.2L:

4-speed automatic (4T40-E / 4T45-E)

Optional

Optional Transmission 3.5L/3.9L:

4-speed automatic (4T65-E)

Features

Transmission Fluid Spec:

Dexron VI (or Dexron III/H compatible for earlier fills)

📐 Dimensions

Exterior

Length:

190.5 in (4839 mm)

Width:

70.3 in (1786 mm)

Height:

58.0 in (1473 mm)

Wheelbase

Wheelbase:

109.5 in (2781 mm)

Cargo

Trunk Volume:

15.1 cu ft (428 L)

Weights

Curb Weight Approx:

3200-3500 lbs (1450-1590 kg)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

★★★★★ (5/5 stars)

NHTSA Frontal Passenger:

★★★★★ (5/5 stars)

NHTSA Side Driver:

★★★★☆ (4/5 stars)

NHTSA Side Passenger:

★★★★☆ (4/5 stars)

NHTSA Side Rear Passenger:

★★★★☆ (4/5 stars)

IIHS Frontal Offset:

IIHS Side Impact:

Good (with optional side airbags)

Active Features

Standard on all models

Traction Control:

Available on certain trims

Passive Features

Airbags Front:

Standard dual-stage front airbags

Airbags Side:

Optional front and rear side-impact airbags and head curtain airbags

Seatbelts:

Front pretensioners and load limiters

💡 Technology Features

Infotainment

Audio Options:

AM/FM stereo with CD player, optional premium audio system, and in-dash 6-disc CD changer.

Driver Assistance

Cruise Control:

Standard on most trims

Tire Pressure Monitoring:

Available on higher trims

Connectivity

Onstar:

Available as an option, providing emergency services and vehicle diagnostics.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles (12,000 km) or 12 months, whichever comes first, using synthetic blend oil.

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed. Replace every 30,000 miles (48,000 km) as a general guideline.

Spark Plug Replacement 2.2L:

Every 100,000 miles (160,000 km) with iridium-tipped plugs.

Spark Plug Replacement 3.5L/3.9L:

Every 100,000 miles (160,000 km) with iridium-tipped plugs.

Fluid Specifications

Engine Oil:

SAE 5W-30 Full Synthetic (for 2.2L Ecotec) or SAE 3000 Synthetic Blend (for 3.5L/3.9L V6). Consult manual for exact specifications and API service category.

Coolant:

GM Dex-Cool (Orange) 50/50 mixture with distilled water.

Brake Fluid:

DOT 3

Power Steering Fluid:

GM Power Steering Fluid or equivalent

Known Issues

Engine Mounts:

Premature wear and failure of engine mounts, especially the torque strut mount.

Egr Valve:

Clogging of the EGR valve, leading to rough idling and performance issues.

Coil Packs:

Failure of ignition coil packs, causing misfires and check engine lights.

Power Steering Pump:

Noise or failure of the power steering pump.

Transmission Shifting:

Erratic shifting or 'limp mode' engagement in the automatic transmission, often related to solenoid or valve body issues.

📚 Vehicle History

Brand Heritage

Chevrolet History:

Chevrolet, founded in 1911, is a division of General Motors known for its broad range of vehicles, from economy cars to performance trucks.

Model Evolution

Malibu Legacy:

The Malibu nameplate has a long history dating back to the 1960s as a Chevrolet Chevelle model, evolving into its own distinct line of mid-size sedans.

Production

Generation Designation:

This generation (2004-2008) marked a significant redesign and move to the GM Epsilon platform, shared with vehicles like the Opel Vectra and Saab 9-3.

Manufacturing Location:

Assembled in Kansas City, Kansas, USA.

🏆 Awards & Recognition

Recognitions

Jdpowers Initial Quality:

Received varied ratings in J.D. Power's Initial Quality Study, reflecting market reception and competitor performance.

Ratings

Consumer Reports:

Consumer Reports ratings were generally average to below average for reliability during this period, particularly for the early years.