engine CHEVROLET MALIBU 2004 5.G Workshop Manual

Then, shut the engine off and close the window almost
all the way to preserve the heat. Start the engine
again and repeat this only when you feel really
uncomfortable from the cold. But do it as little as
possible. Preserve the fuel as long as you can. To help
keep warm, you can get out of the vehicle and do
some fairly vigorous exercises every half hour or so until
help comes.
If You Are Stuck: In Sand, Mud, Ice
or Snow
In order to free your vehicle when it is stuck, you will
need to spin the wheels, but you do not want to
spin your wheels too fast. The method known as
“rocking” can help you get out when you are stuck, but
you must use caution.
{CAUTION:
If you let your tires spin at high speed, they can
explode, and you or others could be injured.
And, the transaxle or other parts of the vehicle
can overheat. That could cause an engine
compartment re or other damage. When you
are stuck, spin the wheels as little as possible.
Do not spin the wheels above 35 mph (55 km/h)
as shown on the speedometer.
Notice:Spinning your wheels can destroy parts of
your vehicle as well as the tires. If you spin the
wheels too fast while shifting your transaxle back
and forth, you can destroy your transaxle. See
“Rocking Your Vehicle To Get It Out.”
For information about using tire chains on your vehicle,
seeTire Chains on page 5-64.
4-30

4. To prevent your battery from draining while the
vehicle is being towed, remove the following
fuse from the engine compartment fuse block: 20)
IBCM 1. See “Engine Compartment Fuse Block”
underFuses on page 5-88
5. Turn the ignition switch to ACCESSORY.
6. Shift your transaxle to NEUTRAL (N).
7. Release the parking brake.
Remember to install the fuses once you reach your
destination. To reinstall a fuse do the following:
1. Set the parking brake.
2. Remove the key from the ignition switch.
3. Reinstall the fuse.
Notice:If you exceed 65 mph (110 km/h) while
towing your vehicle, it could be damaged. Never
exceed 65 mph (110 km/h) while towing your vehicle.Notice:Towing your vehicle from the rear could
damage it. Also, repairs would not be covered by
the warranty. Never have your vehicle towed
from the rear.
4-33

Towing a Trailer
{CAUTION:
If you do not use the correct equipment and
drive properly, you can lose control when you
pull a trailer. For example, if the trailer is too
heavy, the brakes may not work well — or even
at all. You and your passengers could be
seriously injured. You may also damage your
vehicle; the resulting repairs would not be
covered by your warranty. Pull a trailer only if
you have followed all the steps in this section.
Ask your dealer for advice and information
about towing a trailer with your vehicle.Your vehicle can tow a trailer if it is equipped with a 3.5 L
V6 engine and the proper trailer towing equipment. To
identify what the vehicle trailering capacity is for your
vehicle, you should read the information in “Weight of the
Trailer” that appears later in this section. But trailering is
different than just driving your vehicle by itself. Trailering
means changes in handling, durability and fuel economy.
Successful, safe trailering takes correct equipment, and it
has to be used properly.
That’s the reason for this part. In it are many time-tested,
important trailering tips and safety rules. Many of
these are important for your safety and that of your
passengers. So please read this section carefully before
you pull a trailer.
Load-pulling components such as the engine, transaxle,
wheel assemblies and tires are forced to work harder
against the drag of the added weight. The engine
is required to operate at relatively higher speeds and
under greater loads, generating extra heat. What’s more,
the trailer adds considerably to wind resistance,
increasing the pulling requirements.
4-40

If You Do Decide To Pull a Trailer
If you do, here are some important points:
There are many different laws, including speed limit
restrictions, having to do with trailering. Make sure
your rig will be legal, not only where you live
but also where you’ll be driving. A good source for
this information can be state or provincial police.
Consider using a sway control. You can ask a hitch
dealer about sway controls.
Don’t tow a trailer at all during the rst
1,000 miles (1 600 km) your new vehicle is
driven. Your engine, axle or other parts could
be damaged.
Then, during the rst 500 miles (800 km) that you
tow a trailer, don’t drive over 50 mph (80 km/h)
and don’t make starts at full throttle. This helps your
engine and other parts of your vehicle wear in at
the heavier loads.
Obey speed limit restrictions when towing a trailer.
Don’t drive faster than the maximum posted speed
for trailers, or no more than 55 mph (90 km/h),
to save wear on your vehicle’s parts.Three important considerations have to do with weight:
the weight of the trailer,
the weight of the trailer tongue
and the total weight on your vehicle’s tires.
Weight of the Trailer
How heavy can a trailer safely be?
It should never weigh more than 1,000 lbs. (450 kg). But
even that can be too heavy.
It depends on how you plan to use your rig. For
example, speed, altitude, road grades, outside
temperature and how much your vehicle is used to pull
a trailer are all important. And, it can also depend
on any special equipment that you have on your vehicle.
You can ask your dealer for our trailering information
or advice, or you can write us at:
Chevrolet Customer Assistance
P.O. Box 33170
Detroit, MI 48232-5170
In Canada, write to:
General Motors of Canada Limited
Customer Communication Centre, 163-005
1908 Colonel Sam Drive
Oshawa, Ontario L1H 8P7
4-41

Total Weight on Your Vehicle’s Tires
Be sure your vehicle’s tires are inated to the upper limit
for cold tires. You’ll nd these numbers on the Tire
and Loading Information label. SeeLoading Your
Vehicle on page 4-34. Then be sure you don’t go over
the GVW limit for your vehicle, including the weight
of the trailer tongue.
Hitches
It’s important to have the correct hitch equipment.
Crosswinds, large trucks going by and rough roads are
a few reasons why you’ll need the right hitch. Here
are some rules to follow:
The rear bumper on your vehicle is not intended for
hitches. Do not attach rental hitches or other
bumper-type hitches to it. Use only a
frame-mounted hitch that does not attach to the
bumper.
Will you have to make any holes in the body of
your vehicle when you install a trailer hitch? If
you do, then be sure to seal the holes later when
you remove the hitch. If you don’t seal them, deadly
carbon monoxide (CO) from your exhaust can get
into your vehicle. SeeEngine Exhaust on
page 2-33. Dirt and water can, too.
Safety Chains
You should always attach chains between your vehicle
and your trailer. Cross the safety chains under the
tongue of the trailer so that the tongue will not drop to
the road if it becomes separated from the hitch.
Instructions about safety chains may be provided by the
hitch manufacturer or by the trailer manufacturer.
Follow the manufacturer’s recommendation for attaching
safety chains and do not attach them to the bumper.
Always leave just enough slack so you can turn
with your rig. And, never allow safety chains to drag on
the ground.
Trailer Brakes
Does your trailer have its own brakes?
Be sure to read and follow the instructions for the trailer
brakes so you’ll be able to install, adjust and maintain
them properly. And because you may have anti-lock
brakes, do not try to tap into your vehicle’s hydraulic
brake system. If you do, both systems won’t work well,
or at all.
4-43

Making Turns
Notice:Making very sharp turns while trailering
could cause the trailer to come in contact with the
vehicle. Your vehicle could be damaged. Avoid
making very sharp turns while trailering.
When you’re turning with a trailer, make wider turns than
normal. Do this so your trailer won’t strike soft shoulders,
curbs, road signs, trees or other objects. Avoid jerky or
sudden maneuvers. Signal well in advance.
Turn Signals When Towing a Trailer
When you tow a trailer, your vehicle may need additional
wiring. Check with your dealer. The arrows on your
instrument panel will ash whenever you signal a turn or
lane change. Properly hooked up, the trailer lamps
will also ash, telling other drivers you’re about to turn,
change lanes or stop.
When towing a trailer, the arrows on your instrument
panel will ash for turns even if the bulbs on the trailer
are burned out. Thus, you may think drivers behind
you are seeing your signal when they are not. It’s
important to check occasionally to be sure the trailer
bulbs are still working.
Driving On Grades
Notice:Do not tow on steep continuous grades
exceeding 6 miles (9.6 km). Extended, higher
than normal engine and transaxle temperatures may
result and damage your vehicle. Frequent stops
are very important to allow the engine and transaxle
to cool.
Reduce speed and shift to a lower gearbeforeyou start
down a long or steep downgrade. If you don’t shift
down, you might have to use your brakes so much that
they would get hot and no longer work well.
Pay attention to the engine coolant gage. If the indicator
is in the red area, turn off the air conditioning to reduce
engine load. SeeEngine Overheating on page 5-27.
4-45

Parking on Hills
{CAUTION:
You really should not park your vehicle, with a
trailer attached, on a hill. If something goes
wrong, your rig could start to move. People
can be injured, and both your vehicle and the
trailer can be damaged.
But if you ever have to park your rig on a hill, here’s
how to do it:
1. Apply your regular brakes, but don’t shift into
PARK (P) yet.
2. Have someone place chocks under the trailer
wheels.
3. When the wheel chocks are in place, release the
regular brakes until the chocks absorb the load.
4. Reapply the regular brakes. Then apply your
parking brake and shift into PARK (P).
5. Release the regular brakes.
When You Are Ready to Leave After
Parking on a Hill
1. Apply your regular brakes and hold the pedal down
while you:
start your engine,
shift into a gear, and
release the parking brake.
2. Let up on the brake pedal.
3. Drive slowly until the trailer is clear of the chocks.
4. Stop and have someone pick up and store the
chocks.
Maintenance When Trailer Towing
Your vehicle will need service more often when you’re
pulling a trailer. Things that are especially important
in trailer operation are automatic transaxle uid (don’t
overll), engine oil, drive belt, cooling system and brake
system. Each of these is covered in this manual, and
the Index will help you nd them quickly. If you’re
trailering, it’s a good idea to review this information
before you start your trip.
Check periodically to see that all hitch nuts and bolts
are tight.
Engine Cooling When Trailer Towing
Your cooling system may temporarily overheat during
severe operating conditions. SeeEngine Overheating on
page 5-27.
4-46

Service............................................................5-3
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of Your
Vehicle......................................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-5
Gasoline Specications....................................5-6
California Fuel...............................................5-6
Additives.......................................................5-7
Fuels in Foreign Countries...............................5-8
Filling Your Tank............................................5-8
Filling a Portable Fuel Container.....................5-11
Checking Things Under the Hood....................5-12
Hood Release..............................................5-12
Engine Compartment Overview.......................5-14
Engine Oil...................................................5-17
Engine Air Cleaner/Filter................................5-22
Automatic Transaxle Fluid..............................5-23
Engine Coolant.............................................5-24
Coolant Surge Tank Pressure Cap..................5-26
Engine Overheating.......................................5-27
Cooling System............................................5-29
Windshield Washer Fluid................................5-34Brakes........................................................5-35
Battery........................................................5-38
Jump Starting...............................................5-39
Bulb Replacement..........................................5-45
Halogen Bulbs..............................................5-45
Headlamps..................................................5-45
Center High-Mounted Stoplamp (CHMSL).........5-47
Taillamps, Turn Signal, Stoplamps and
Back-up Lamps.........................................5-47
Replacement Bulbs.......................................5-49
Windshield Wiper Blade Replacement..............5-49
Tires..............................................................5-50
Ination - Tire Pressure.................................5-57
Tire Inspection and Rotation...........................5-58
When It Is Time for New Tires.......................5-59
Buying New Tires.........................................5-60
Uniform Tire Quality Grading..........................5-61
Wheel Alignment and Tire Balance..................5-62
Wheel Replacement......................................5-62
Tire Chains..................................................5-64
If a Tire Goes Flat........................................5-65
Changing a Flat Tire.....................................5-66
Compact Spare Tire......................................5-77
Section 5 Service and Appearance Care
5-1

Service
Your dealer knows your vehicle best and wants you to
be happy with it. We hope you will go to your dealer
for all your service needs. You will get genuine GM parts
and GM-trained and supported service people.
We hope you will want to keep your GM vehicle all GM.
Genuine GM parts have one of these marks:
California Proposition 65 Warning
Most motor vehicles, including this one, contain and/or
emit chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm. Engine exhaust, many parts and systems
(including some inside the vehicle), many uids, and
some component wear by-products contain and/or emit
these chemicals.
5-3

Adding Equipment to the Outside
of Your Vehicle
Things you might add to the outside of your vehicle can
affect the airow around it. This may cause wind noise
and affect windshield washer performance. Check with
your dealer before adding equipment to the outside of
your vehicle.
Fuel
Use of the recommended fuel is an important part of the
proper maintenance of your vehicle.
Gasoline Octane
Use regular unleaded gasoline with a posted octane of 87
or higher. If the octane is less than 87, you may get a
heavy knocking noise when you drive. If this occurs,
use a gasoline rated at 87 octane or higher as soon as
possible. Otherwise, you might damage your engine.
A little pinging noise when you accelerate or drive uphill is
considered normal. This does not indicate a problem
exists or that a higher-octane fuel is necessary. If you are
using 87 octane or higher-octane fuel and hear heavy
knocking, your engine needs service.
5-5