engine CHEVROLET MALIBU 2003 5.G Manual PDF

Battery
Your new vehicle comes with a maintenance free
ACDelcožbattery. When it's time for a new battery, get
one that has the replacement number shown on the
original battery's label. We recommend an ACDelco
ž
battery. SeeEngine Compartment Overview on
page 5-12for battery location.
Warning:Battery posts, terminals and related
accessories contain lead and lead compounds,
chemicals known to the State of California to cause
cancer and reproductive harm. Wash hands after
handling.
Vehicle Storage
If you're not going to drive your vehicle for 25 days or
more, remove the black, negative (-) cable from
the battery. This will help keep your battery from
running down.
{CAUTION:
Batteries have acid that can burn you and gas
that can explode. You can be badly hurt if you
aren't careful. See ªJump Startingº next for
tips on working around a battery without
getting hurt.Contact your dealer to learn how to prepare your
vehicle for longer storage periods.
Also, for your audio system, see
Theft-Deterrent
Feature (Non-RDS Radios) on page 3-57orTheft-Deterrent Feature (RDS Radios) on page 3-57.
Jump Starting
If your battery has run down, you may want to use
another vehicle and some jumper cables to start your
vehicle. Be sure to follow the steps below to do it safely.
{CAUTION:
Batteries can hurt you. They can be dangerous
because:
·They contain acid that can burn you.
·They contain gas that can explode or
ignite.
·They contain enough electricity to
burn you.
If you don't follow these steps exactly, some
or all of these things can hurt you.
5-36

Notice:Ignoring these steps could result in costly
damage to your vehicle that wouldn't be covered
by your warranty.
Trying to start your vehicle by pushing or pulling it
won't work, and it could damage your vehicle.
1. Check the other vehicle. It must have a 12-volt
battery with a negative ground system.
Notice:If the other system isn't a 12-volt system
with a negative ground, both vehicles can be
damaged.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles aren't touching
each other. If they are, it could cause a ground
connection you don't want. You wouldn't be able to
start your vehicle, and the bad grounding could
damage the electrical systems.
To avoid the possibility of the vehicles rolling, set
the parking brake ®rmly on both vehicles involved in
the jump start procedure. Put an automatic
transaxle in PARK (P) or a manual transaxle in
NEUTRAL before setting the parking brake.
Notice:If you leave your radio on, it could be badly
damaged. The repairs wouldn't be covered by
your warranty.
3. Turn off the ignition on both vehicles. Unplug
unnecessary accessories plugged into the cigarette
lighter or in the accessory power outlet. Turn off
the radio and all lamps that aren't needed. This will
avoid sparks and help save both batteries. And it
could save your radio!
4. Open the hoods and locate the batteries. Find the
positive (+) and negative (-) terminal locations on
each vehicle. See
Engine Compartment Overview
on page 5-12for more information on location.
{CAUTION:
An electric fan can start up even when the
engine is not running and can injure you.
Keep hands, clothing and tools away from
any underhood electric fan.
5-37

{CAUTION:
Using a match near a battery can cause battery
gas to explode. People have been hurt doing
this, and some have been blinded. Use a
¯ashlight if you need more light.
Be sure the battery has enough water. You
don't need to add water to the ACDelco
ž
battery installed in your new vehicle. But if a
battery has ®ller caps, be sure the right
amount of ¯uid is there. If it is low, add water
to take care of that ®rst. If you don't, explosive
gas could be present.
Battery ¯uid contains acid that can burn you.
Don't get it on you. If you accidentally get it in
your eyes or on your skin, ¯ush the place with
water and get medical help immediately.5. Check that the jumper cables don't have loose or
missing insulation. If they do, you could get a
shock. The vehicles could be damaged, too.
Before you connect the cables, here are some
things you should know. Positive (+) will go
to positive (+) or to a remote positive (+) terminal if
the vehicle has one. Negative (-) will go to a
heavy, unpainted metal engine part or to a remote
negative (-) terminal if the vehicle with the dead
battery has one.
Don't connect positive (+) to negative (-) or you'll
get a short that would damage the battery and
maybe other parts, too. And don't connect
the negative (-) cable to the negative (-) terminal
on the dead battery because this can cause sparks.
{CAUTION:
Fans or other moving engine parts can injure
you badly. Keep your hands away from moving
parts once the engine is running.
5-38

Don't let the other end touch anything until the next
step. The other end of the negative (-) cable
doesn't go to the dead battery. It goes to a heavy,
unpainted metal engine part or to a remote
negative (-) terminal on the vehicle with the dead
battery.
9. Connect the other end of the negative (-) cable at
least 18 inches (45 cm) away from the dead battery,
but not near engine parts that move. The electrical
connection is just as good there, and the chance
of sparks getting back to the battery is much less.If the THEFT SYSTEM light ¯ashes, wait until the
light stops ¯ashing.
10. Now start the vehicle with the good battery and run
the engine for a while.
11. Try to start the vehicle that had the dead battery.
If it won't start after a few tries, it probably needs
service.
Notice:Damage to your vehicle may result from
electrical shorting if jumper cables are removed
incorrectly. To prevent electrical shorting, take care
that the cables don't touch each other or any
other metal. The repairs wouldn't be covered by
your warranty.
5-40

A. Heavy, Unpainted Metal Engine Part
B. Good Battery
C. Dead BatteryTo disconnect the jumper cables from both vehicles,
do the following:
1. Disconnect the black negative (-) cable from the
vehicle that had the dead battery.
2. Disconnect the black negative (-) cable from the
vehicle with the good battery.
3. Disconnect the red positive (+) cable from the
vehicle with the good battery.
4. Disconnect the red positive (+) cable from the
other vehicle.
Jumper Cable Removal
5-41

Changing a Flat Tire
If a tire goes ¯at, avoid further tire and wheel damage
by driving slowly to a level place. Turn on your
hazard warning ¯ashers.
{CAUTION:
Changing a tire can cause an injury. The
vehicle can slip off the jack and roll over you
or other people. You and they could be badly
injured. Find a level place to change your tire.
To help prevent the vehicle from moving:
1. Set the parking brake ®rmly.
2. Put the shift lever in PARK (P).
3. Turn off the engine.
To be even more certain the vehicle won't
move, you can put blocks at the front and rear
of the tire farthest away from the one being
changed. That would be the tire on the other
side of the vehicle, at the opposite end.The following steps will tell you how to use the jack and
change a tire.
5-57

Vehicle Identi®cation
Vehicle Identi®cation Number (VIN)
This is the legal identi®er for your vehicle. It appears on
a plate in the front corner of the instrument panel, on
the driver's side. You can see it if you look through the
windshield from outside your vehicle. The VIN also
appears on the Vehicle Certi®cation and Service Parts
labels and the certi®cates of title and registration.
Engine Identi®cation
The 8th character in your VIN is the engine code. This
code will help you identify your engine, speci®cations
and replacement parts.
Service Parts Identi®cation Label
You'll ®nd this label on the bottom of your spare
tire cover. It's very helpful if you ever need to order
parts. On this label is:
·your VIN,
·the model designation,
·paint information and
·a list of all production options and special
equipment.
Be sure that this label is not removed from the vehicle.
5-75

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.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 reinstall the door, insert the hooks at the front end
®rst, then push the door into the instrument panel
to secure it.
5-77

Engine Compartment Fuse Block
The engine compartment fuse block is located on the
driver's side of the vehicle, near the engine air
cleaner/®lter. See
Engine Compartment Overview on
page 5-12for more information on location.
Fuses Usage
1 Ignition Switch
2Right Electrical Center-Fog Lamps,
Radio, Body Function Control
Module, Interior LampsFuses Usage
3Left Electrical Center-Stoplamps,
Hazard Lamps, Body Function
Control Module, Cluster, Climate
Control System
4 Anti-Lock Brakes
5 Ignition Switch
6 Not Used
7Left Electrical Center-Power Seats,
Power Mirrors, Door Locks, Trunk
Release and Remote Lock Control
8 Cooling Fan #1
Relays Usage
9 Rear Defogger
10 Not Used
11 Not Used
12 Cooling Fan #1
13 HVAC Blower (Climate Control)
14 Cooling Fan #2
15 Cooling Fan
16 Air Conditioning Compressor
17 Not Used
18 Fuel Pump
19 Automatic Headlamp System
5-80

Capacities and Speci®cations
The following approximate capacities are given in English and metric conversions. Please refer toPart D: Recommended Fluids and Lubricants on page 6-21for more information.
All capacities are approximate. When adding, be sure to ®ll to the appropriate level, as recommended in this manual.
Capacities
ApplicationCapacities
English Metric
Air Conditioning Refrigerant R134a
Use Refrigerant Oil, R134a Systems1.4 lbs. 0.6 kg
Automatic Transaxle Complete Overhaul 9.5 quarts 9.0 L
Cooling System 13.6 quarts 12.9 L
Engine Oil with Filter 4.5 quarts 4.3 L
Fuel Tank 14.1 gallons 53.4 L
Wheel Nut Torque 100 lb-ft 140Y
Engine Speci®cations
Engine VIN Code Transaxle Spark Plug Gap
V6 J Automatic 0.06 inch, (1.52 mm)
5-82