light CHEVROLET MALIBU 2000 5.G Manual PDF

6-18
NOTICE:
We recommend you use only fluid labeled
DEXRON-III, because fluid with that label is
made especially for your automatic transaxle.
Damage caused by fluid other than
DEXRON
-III is not covered by your new
vehicle warranty.
Engine Coolant
The cooling system in your vehicle is filled with
DEX
-COOL engine coolant. This coolant is designed
to remain in your vehicle for 5 years or 150,000 miles
(240 000 km), whichever occurs first, if you add only
DEX
-COOL extended life coolant.
The following explains your cooling system and how to
add coolant when it is low. If you have a problem with
engine overheating, see ªEngine Overheatingº in
the Index.A 50/50 mixture of clean, drinkable water and
DEX
-COOL coolant will:

Give freezing protection down to
-34F (-37C).

Give boiling protection up to 265F (129C).

Protect against rust and corrosion.

Help keep the proper engine temperature.

Let the warning lights and gages work as
they should.
NOTICE:
When adding coolant, it is important that you
use only DEX
-COOL (silicate-free) coolant.
If coolant other than DEX-COOL is added to
the system, premature engine, heater core or
radiator corrosion may result. In addition, the
engine coolant will require change sooner
-- at
30,000 miles (50 000 km) or 24 months,
whichever occurs first. Damage caused by the
use of coolant other than DEX
-COOL is not
covered by your new vehicle warranty.

6-20 Checking Coolant
The surge tank is located on the passenger's side of the
engine compartment.
CAUTION:
Turning the surge tank pressure cap when the
engine and radiator are hot can allow steam and
scalding liquids to blow out and burn you badly.
Never turn the surge tank pressure cap
-- even a
little
-- when the engine and radiator are hot.
The vehicle must be on a level surface. When your
engine is cold, the coolant level should be at the
FULL COLD mark or slightly higher.
If the low coolant light
comes on and stays on, it
means you're low on
engine coolant.
Adding Coolant
If you need more coolant, add the proper DEX
-COOL

coolant mixture at the surge tank, but only when the
engine is cool.

6-24
There are only two reasons why the brake fluid level in
the reservoir might go down. The first is that the brake
fluid goes down to an acceptable level during normal
brake lining wear. When new linings are put in, the fluid
level goes back up. The other reason is that fluid is
leaking out of the brake system. If it is, you should have
your brake system fixed, since a leak means that sooner
or later your brakes won't work well, or won't work
at all.
So, it isn't a good idea to ªtop offº your brake fluid.
Adding brake fluid won't correct a leak. If you add fluid
when your linings are worn, then you'll have too much
fluid when you get new brake linings. You should add
(or remove) brake fluid, as necessary, only when work is
done on the brake hydraulic system.
CAUTION:
If you have too much brake fluid, it can spill on the
engine. The fluid will burn if the engine is hot
enough. You or others could be burned, and your
vehicle could be damaged. Add brake fluid only
when work is done on the brake hydraulic system.
United States Canada
When your brake fluid falls to a low level, your brake
warning light will come on. See ªBrake System Warning
Lightº in the Index.
What to Add
When you do need brake fluid, use only DOT
-3 brake
fluid. Use new brake fluid from a sealed container only.
Refer to ªRecommended Fluids and Lubricantsº in the
Maintenance Schedule.
Always clean the brake fluid reservoir cap and the area
around the cap before removing it. This will help keep
dirt from entering the reservoir.

6-26
Some driving conditions or climates may cause a brake
squeal when the brakes are first applied or lightly
applied. This does not mean something is wrong with
your brakes.
Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly torque wheel nuts in the
proper sequence to GM specifications.
Your rear drum brakes don't have wear indicators, but if
you ever hear a rear brake rubbing noise, have the rear
brake linings inspected immediately. Also, the rear
brake drums should be removed and inspected each time
the tires are removed for rotation or changing. When
you have the front brake pads replaced, have the rear
brakes inspected, too.
Brake linings should always be replaced as complete
axle sets.
See ªBrake System Inspectionº in Section 7 of this
manual under Part C ªPeriodic Maintenance
Inspections.º
Brake Pedal Travel
See your dealer if the brake pedal does not return to
normal height, or if there is a rapid increase in pedal
travel. This could be a sign of brake trouble.
Brake Adjustment
Every time you make a moderate brake stop, your disc
brakes adjust for wear. If you rarely make a moderate or
heavier stop, then your brakes might not adjust correctly. If
you drive in that way, then
-- very carefully -- make a few
moderate brake stops about every 1,000 miles (1 600 km),
so your brakes will adjust properly.
If your brake pedal goes down farther than normal, your
rear drum brakes may need adjustment. Adjust them by
pumping the brake pedal repeatedly while the engine is
running with the shift lever in PARK (P).
Replacing Brake System Parts
The braking system on a vehicle is complex. Its many
parts have to be of top quality and work well together if
the vehicle is to have really good braking. Your vehicle
was designed and tested with top
-quality GM brake parts.
When you replace parts of your braking system
-- for
example, when your brake linings wear down and you
have to have new ones put in
-- be sure you get new
approved GM replacement parts. If you don't, your brakes
may no longer work properly. For example, if someone
puts in brake linings that are wrong for your vehicle, the
balance between your front and rear brakes can
change
-- for the worse. The braking performance
you've come to expect can change in many other ways if
someone puts in the wrong replacement brake parts.

6-41 Uniform Tire Quality Grading
The following information relates to the system
developed by the United States National Highway
Traffic Safety Administration, which grades tires by
treadwear, traction and temperature performance. (This
applies only to vehicles sold in the United States.) The
grades are molded on the sidewalls of most passenger
car tires. The Uniform Tire Quality Grading system does
not apply to deep tread, winter
-type snow tires,
space
-saver or temporary use spare tires, tires with
nominal rim diameters of 10 to 12 inches (25 to 30 cm),
or to some limited
-production tires.
While the tires available on General Motors passenger
cars and light trucks may vary with respect to these
grades, they must also conform to Federal safety
requirements and additional General Motors Tire
Performance Criteria (TPC) standards.Treadwear
The treadwear grade is a comparative rating based on
the wear rate of the tire when tested under controlled
conditions on a specified government test course. For
example, a tire graded 150 would wear one and a half
(1 1/2) times as well on the government course as a tire
graded 100. The relative performance of tires depends
upon the actual conditions of their use, however, and
may depart significantly from the norm due to variations
in driving habits, service practices and differences in
road characteristics and climate.
Traction -- AA, A, B, C
The traction grades, from highest to lowest, are AA, A,
B, and C. Those grades represent the tire's ability to stop
on wet pavement as measured under controlled
conditions on specified government test surfaces of
asphalt and concrete. A tire marked C may have poor
traction performance. Warning: The traction grade
assigned to this tire is based on straight
-ahead braking
traction tests, and does not include acceleration,
cornering, hydroplaning, or peak traction characteristics.

6-52
GM Vehicle Care/Appearance Materials
PART NUMBERSIZEDESCRIPTIONUSAGE
99495423 in. x 25 in.Polishing Cloth ± Wax TreatedExterior polishing cloth
105017216 oz. (0.473 L)Tar and Road Oil RemoverRemoves tar, road oil and asphalt
105017316 oz. (0.473 L)Chrome Cleaner and PolishUse on chrome, stainless steel, nickel, copper and brass
105017416 oz. (0.473 L)White Sidewall Tire CleanerRemoves soil and black marks from whitewalls
105021432 oz. (0.946 L)Vinyl CleanerCleans vinyl tops, upholstery and convertible tops
105042723 oz. (0.680 L)Glass CleanerRemoves dirt, grime, smoke and fingerprints
1052918**8 oz. (0.237 L)Armor All
ProtectantProtects leather, wood, acrylics, Plexiglas
, plastic,
rubber and vinyl
105292516 oz. (0.473 L)Multi-Purpose Interior
CleanerCleans carpets, seats, interior trim, door panels
and floor mats
105292916 oz. (0.473 L)Wheel CleanerSpray on and rinse with water
10529308 oz. (0.237 L)Capture Dry Spot RemoverAttracts, absorbs and removes soils on fabric
123457212.5 sq. ft.Synthetic ChamoisShines vehicle without scratching
1234572512 oz. (0.354 L)Silicone Tire ShineSpray on tire shine
12377964*16 oz. (0.473 L)Finish EnhancerRemoves dust, fingerprints and surface contaminants
12377966*16 oz. (0.473 L)Cleaner WaxRemoves light scratches and oxidation and protects finish
12377984*16 oz. (0.473 L)Surface CleanerRemoves contaminants, blemishes and swirl marks
See your General Motors Parts Department for these products. * For exterior use only.
See ªRecommended Fluids and Lubricantsº in the Index. ** Not recommended for use on instrument panels.

6-55 Fuses and Circuit Breakers
The wiring circuits in your vehicle are protected from
short circuits by a combination of fuses, circuit breakers
and fusible thermal links in the wiring itself.
Look at the silver
-colored band inside the fuse. If the
band is broken or melted, replace the fuse. Be sure you
replace a bad fuse with a new one of the identical size
and rating.
If you ever have a problem on the road and don't have a
spare fuse, you can borrow one that has the same
amperage. Just pick a feature of your vehicle that you
can get along without
-- like the radio or cigarette
lighter
-- and use its fuse, if it is the correct amperage.
Replace it as soon as you can.
There are three fuse blocks in your vehicle: two
instrument panel fuse blocks and the engine
compartment fuse block.
There is a fuse puller located on the engine compartment
fuse block. It can be used to easily remove fuses from
the fuse block.Instrument Panel Fuse Block
The instrument panel fuse
blocks are located at each
end of the instrument panel.
To access the fuses, open
the fuse panel door by
pulling out.
To replace the door, insert the hooks at the front end
first, then push the door into the instrument panel to
secure it.

6-57
Instrument Panel Fuse Block-Right
Fuse Usage
A Instrument Panel Lights, Dimmer. . . . . . . . . . . .
B Cruise Control Switches. . . . . . . . . . . . . . . . . . . .
C Climate Control System. . . . . . . . . . . . . . . . . . . .
D Cruise Control. . . . . . . . . . . . . . . . . . . . . . . . . . . .
E Fog Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse Usage
F Interior Lamps, Body Function. . . . . . . . . . . . . .
Control Module
G Radio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H Sunroof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BRKR PWR WNDWS Power Windows.
MICRO RELAY FOG LPS Fog Lamps. . . . . . . . . .
Engine Compartment Fuse Block
The engine compartment fuse block is located on the
driver's side of the engine compartment, near the air
cleaner filter.

6-59
Micro-Relays
16 Air Conditioning Compressor. . . . . . . . . . . . . . . .
17 Not Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18 Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19 Automatic Light Control. . . . . . . . . . . . . . . . . . .
20 Automatic Light Control. . . . . . . . . . . . . . . . . . .
21 Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 Daytime Running Lamps. . . . . . . . . . . . . . . . . . .
Mini
-Fuses
23
- 32 Spare Fuse Holder. . . . . . . . . . . . . . . . . . . . .
33 Rear Defog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34 Accessory Power Outlets, Cigar Lighter. . . . . . .
35 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36 Not Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37 Air Conditioning Compressor, Body . . . . . . . . . .
Function Control Module
38 Automatic Transaxle. . . . . . . . . . . . . . . . . . . . . . .
39 Powertrain Control Module, Ignition. . . . . . . . . .
40 Anti
-Lock Brakes . . . . . . . . . . . . . . . . . . . . . . . . .
41 Ignition System. . . . . . . . . . . . . . . . . . . . . . . . . . .
42 Back
-Up Lamps, Brake Transaxle . . . . . . . . . . . .
Shift Interlock ControlMini
-Fuses
43 Horn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44 Powertrain Control Module. . . . . . . . . . . . . . . . .
45 Parking Lamps. . . . . . . . . . . . . . . . . . . . . . . . . . .
46 Climate Control System. . . . . . . . . . . . . . . . . . . .
47 Canister Purge Valve, Powertrain. . . . . . . . . . . . .
Control Module, Exhaust Gas Recirculation,
Heated O
2 Sensor
48 Fuel Pump Injectors. . . . . . . . . . . . . . . . . . . . . . .
49 Not Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 Right Headlamp. . . . . . . . . . . . . . . . . . . . . . . . . .
51 Left Headlamp. . . . . . . . . . . . . . . . . . . . . . . . . . .
52 Cooling Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53 HVAC Blower (Climate Control ). . . . . . . . . . . .
54 Not Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55 Cooling Fan #2 Ground. . . . . . . . . . . . . . . . . . . .
56 Fuse Puller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57 Not Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-28 At Least Twice a Year
Restraint System Check
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. Have any torn or frayed safety belts replaced.
Also look for any opened or broken air bag coverings,
and have them repaired or replaced. (The air bag system
does not need regular maintenance.)
Wiper Blade Check
Inspect wiper blades for wear or cracking. Replace blade
inserts that appear worn or damaged or that streak or
miss areas of the windshield. Also see ªWiper Blades,
Cleaningº in the Index.
Weatherstrip Lubrication
Silicone grease on weatherstrips will make them last
longer, seal better, and not stick or squeak. Apply
silicone grease with a clean cloth. During very cold,
damp weather more frequent application may be
required. (See ªRecommended Fluids and Lubricantsº in
the Index.)Automatic Transaxle Inspection
It is not necessary to check the transaxle fluid level.
A transaxle fluid leak is the only reason for fluid loss.
Check for leaks. If a leak occurs, take the vehicle to
your Chevrolet dealership service department and have
it repaired as soon as possible.
At Least Once a Year
Key Lock Cylinders Service
Lubricate the key lock cylinders with the lubricant
specified in Part D.
Body Lubrication Service
Lubricate all the body door hinges and latches, including
those for the hood and the trunk lid. Part D tells you
what to use. More frequent lubrication may be required
when exposed to a corrosive environment.