brake CHEVROLET MALIBU 2008 6.G Workshop Manual

A. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-24.
B. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-36.
C. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-19.
D. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-19.
E. Engine Coolant Surge Tank. SeeEngine Coolant on
page 5-26.F. Pressure Cap. SeePressure Cap on page 5-29.
G. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-39.
H. Battery. SeeBattery on page 5-42.
I. Engine Compartment Fuse Block. SeeEngine
Compartment Fuse Block on page 5-102.
J. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-38.
5-17

A. Engine Air Cleaner/Filter. SeeEngine Air
Cleaner/Filter on page 5-24.
B. Power Steering Fluid Reservoir. SeePower Steering
Fluid on page 5-36.
C. Engine Oil Fill Cap. See “When to Add Engine Oil”
underEngine Oil on page 5-19.
D. Engine Oil Dipstick. See “Checking Engine Oil”
underEngine Oil on page 5-19.
E. Electric Engine Cooling Fans (Out of View).
SeeCooling System on page 5-32.
F. Engine Coolant Surge Tank. SeeEngine Coolant on
page 5-26.
G. Pressure Cap. SeePressure Cap on page 5-29.
H. Brake Master Cylinder Reservoir. See “Brake Fluid”
underBrakes on page 5-39.
I. Automatic transmission Fluid Dipstick. See “Checking
the Fluid Level” underAutomatic Transmission
Fluid on page 5-26.
J. Battery. SeeBattery on page 5-42.
K. Underhood Fuse Block. SeeEngine Compartment
Fuse Block on page 5-102.
L. Windshield Washer Fluid Reservoir. See “Adding
Washer Fluid” underWindshield Washer Fluid
on page 5-38.Engine Oil
Checking Engine Oil
It is a good idea to check the engine oil every time you
get fuel. In order to get an accurate reading, the oil
must be warm and the vehicle must be on level ground.
The engine oil dipstick handle is a yellow loop.
SeeEngine Compartment Overview on page 5-14
for the location of the engine oil dipstick.
1. Turn off the engine and give the oil several minutes
to drain back into the oil pan. If you do not do this,
the oil dipstick might not show the actual level.
2. Pull the dipstick and clean it with a paper towel or
cloth, then push it back in all the way. Remove it
again, keeping the tip down and check the level.
5-19

Brakes
Brake Fluid
The brake master cylinder
reservoir is lled with
DOT-3 brake uid. See
Engine Compartment
Overview on page 5-14for
the location of the reservoir.
There are only two reasons why the brake uid level in
the reservoir might go down. The rst is that the brake
uid goes down to an acceptable level during normal
brake lining wear. When new linings are put in, the uid
level goes back up. The other reason is that uid is
leaking out of the brake hydraulic system. If it is, have
the brake hydraulic system xed, since a leak means
that sooner or later the brakes will not work well.It is not a good idea to top off the brake uid. Adding
brake uid will not correct a leak. If uid is added when
the linings are worn, there will be too much uid when
new brake linings are installed. Add or remove brake
uid, as necessary, only when work is done on the brake
hydraulic system.
{CAUTION:
If your vehicle has too much brake uid, it can
spill on the engine. The uid will burn if the
engine is hot enough. You or others could be
burned, and your vehicle could be damaged.
Add brake uid only when work is done on the
brake hydraulic system.
When the brake uid falls to a low level, the brake
warning light comes on. SeeBrake System Warning
Light on page 3-37.
5-39

What to Add
When you need brake uid, use only DOT-3 brake
uid. Use new brake uid from a sealed container
only. SeeRecommended Fluids and Lubricants on
page 6-12.
Always clean the brake uid reservoir cap and the area
around the cap before removing it. This helps keep
dirt from entering the reservoir.
{CAUTION:
With the wrong kind of uid in the brake
hydraulic system, the brakes might not work
well. This could cause a crash. Always use the
proper brake uid.Notice:
Using the wrong uid can badly damage brake
hydraulic system parts. For example, just a
few drops of mineral-based oil, such as engine
oil, in the brake hydraulic system can damage
brake hydraulic system parts so badly that they
will have to be replaced. Do not let someone
put in the wrong kind of uid.
If you spill brake uid on your vehicle’s painted
surfaces, the paint nish can be damaged.
Be careful not to spill brake uid on your
vehicle. If you do, wash it off immediately.
SeeWashing Your Vehicle on page 5-92.
5-40

Brake Wear
Your vehicle has disc brakes. Disc brake pads have
built-in wear indicators that make a high-pitched warning
sound when the brake pads are worn and new pads are
needed. The sound can come and go or be heard all the
time your vehicle is moving, except when you are pushing
on the brake pedal rmly.
{CAUTION:
The brake wear warning sound means that
soon the brakes will not work well. That could
lead to an accident. When you hear the brake
wear warning sound, have your vehicle
serviced.
Notice:Continuing to drive with worn-out brake
pads could result in costly brake repair.Some driving conditions or climates can cause a brake
squeal when the brakes are rst applied or lightly applied.
This does not mean something is wrong with the brakes.
Properly torqued wheel nuts are necessary to help
prevent brake pulsation. When tires are rotated, inspect
brake pads for wear and evenly tighten wheel nuts
in the proper sequence to torque specications
inCapacities and Specifications on page 5-108.
Brake linings should always be replaced as complete
axle sets.
Brake Pedal Travel
See your dealer/retailer 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 that brake service
might be required.
Brake Adjustment
Every time you apply the brakes, with or without the
vehicle moving, the brakes adjust for wear.
5-41

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 brake parts.
When you replace parts of the braking system — for
example, when the brake linings wear down and you
need new ones put in — be sure you get new approved
replacement parts. If you do not, the brakes might not
work properly. For example, if someone puts in brake
linings that are wrong for your vehicle, the balance
between the front and rear brakes can change — for
the worse. The braking performance you have come to
expect can change in many other ways if someone puts
in the wrong replacement brake parts.
Battery
Your vehicle has a maintenance free battery. When
it is time for a new battery, see your dealer/retailer
for one that has the replacement number shown on
the original battery’s label. SeeEngine Compartment
Overview on page 5-14for 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
{CAUTION:
Batteries have acid that can burn you and
gas that can explode. You can be badly hurt
if you are not careful. SeeJump Starting on
page 5-43for tips on working around a battery
without getting hurt.
Infrequent Usage: If you drive your vehicle infrequently,
remove the black, negative (−) cable from the battery.
This will help keep the battery from running down.
Extended Storage: For extended storage of your vehicle,
remove the black, negative (−) cable from the battery
or use a battery trickle charger. This will help maintain
the charge of the battery over an extended period
of time.
5-42

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 use the following steps 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 do not follow these steps exactly, some
or all of these things can hurt you.Notice:Ignoring these steps could result in costly
damage to your vehicle that would not be covered
by your warranty.
Trying to start your vehicle by pushing or pulling it
will not 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 vehicle’s system is not a 12-volt
system with a negative ground, both vehicles can
be damaged. Only use vehicles with 12-volt systems
with negative grounds to jump start your vehicle.
2. Get the vehicles close enough so the jumper cables
can reach, but be sure the vehicles are not touching
each other. If they are, it could cause a ground
connection you do not want. You would not 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 transmission in P (Park) or a manual
transmission in NEUTRAL before setting the
parking brake.
5-43

(C) Aspect Ratio:A two-digit number that
indicates the tire height-to-width measurements.
For example, if the tire size aspect ratio is 60, as
shown in item C of the illustration, it would mean
that the tire’s sidewall is 60 percent as high as it
is wide.
(D) Construction Code
:A letter code is used to
indicate the type of ply construction in the tire. The
letter R means radial ply construction; the letter D
means diagonal or bias ply construction; and the
letter B means belted-bias ply construction.
(E) Rim Diameter
:Diameter of the wheel in
inches.
(F) Service Description
:These characters
represent the load range and speed rating of the
tire. The load index represents the load carry
capacity a tire is certied to carry. The load index
can range from 1 to 279. The speed rating is the
maximum speed a tire is certied to carry a load.
Speed ratings range from A to Z.
Tire Terminology and Denitions
Air Pressure:The amount of air inside the
tire pressing outward on each square inch of the
tire. Air pressure is expressed in pounds per
square inch (psi) or kilopascal (kPa).
Accessory Weight
:This means the combined
weight of optional accessories. Some examples of
optional accessories are, automatic transmission,
power steering, power brakes, power windows,
power seats, and air conditioning.
Aspect Ratio
:The relationship of a tire’s height
to its width.
Belt
:A rubber coated layer of cords that is
located between the plies and the tread. Cords
may be made from steel or other reinforcing
materials.
Bead
:The tire bead contains steel wires wrapped
by steel cords that hold the tire onto the rim.
Bias Ply Tire
:A pneumatic tire in which the plies
are laid at alternate angles less than 90 degrees
to the centerline of the tread.
5-57

TPMS Sensor Matching Process
Each TPMS sensor has a unique identication code.
Any time you replace one or more of the TPMS sensors
or rotate the vehicle’s tires, the identication codes
need to be matched to the new tire/wheel location.
The sensors are matched, to the tire/wheel locations,
in the following order: driver side front tire, passenger
side front tire, passenger side rear tire, and driver
side rear tire using a TPMS diagnostic tool. See your
dealer/retailer for service.
The TPMS sensors can also be matched to each
tire/wheel position by increasing or decreasing the tire’s
air pressure. When increasing the tire’s pressure, do
not exceed the maximum ination pressure indicated on
the tire’s sidewall. To decrease the tire’s air-pressure
use the pointed end of the valve cap, a pencil-style
air pressure gage, or a key.
You have two minutes to match each tire and wheel
position. If it takes longer than two minutes to match
any tire and wheel position, the matching process stops
and you need to start over.The TPMS matching process is outlined below:
1. Set the parking brake.
2. Turn the ignition switch to ON/RUN with the
engine off.
3. Press and hold the Remote Keyless Entry (RKE)
transmitter’s LOCK and UNLOCK buttons, at the
same time, for about ve seconds to start the TPMS
learn mode. The horn sounds twice indicating the
TPMS receiver is ready and in learn mode.
4. Start with the driver side front tire. The driver side
front turn signal also comes on to indicate that
corner’s sensor is ready to be learned.
5. Remove the valve cap from the tire’s valve
stem. Activate the TPMS sensor by increasing
or decreasing the tire’s air pressure for about
eight seconds. The horn chirp, can take up to
30 seconds to sound. It chirps one time and then
all the turn signals ash one time to conrm the
sensor identication code has been matched to
the tire/wheel position.
6. The passenger side front turn signal comes on to
indicate that corner sensor is ready to be learned.
Proceed to the passenger side front tire and
repeat the procedure in Step 5.
5-66

Buying New Tires
GM has developed and matched specic tires for
your vehicle. The original equipment tires installed
on your vehicle, when it was new, were designed
to meet General Motors Tire Performance Criteria
Specication (TPC Spec) system rating. If you need
replacement tires, GM strongly recommends that
you get tires with the same TPC Spec rating. This
way, your vehicle will continue to have tires that are
designed to give the same performance and vehicle
safety, during normal use, as the original tires.
GM’s exclusive TPC Spec system considers
over a dozen critical specications that impact the
overall performance of your vehicle, including brake
system performance, ride and handling, traction
control, and tire pressure monitoring performance.
GM’s TPC Spec number is molded onto the tire’s
sidewall near the tire size. If the tires have an
all-season tread design, the TPC Spec number
will be followed by an MS for mud and snow. See
Tire Sidewall Labeling on page 5-54for additional
information.GM recommends replacing tires in sets of four.
This is because uniform tread depth on all tires
will help keep your vehicle performing most like
it did when the tires were new. Replacing less
than a full set of tires can affect the braking
and handling performance of your vehicle.
SeeTire Inspection and Rotation on page 5-67
for information on proper tire rotation.
{CAUTION:
Mixing tires could cause you to lose
control while driving. If you mix tires of
different sizes, brands, or types (radial
and bias-belted tires), the vehicle may
not handle properly, and you could have
a crash. Using tires of different sizes,
brands, or types may also cause damage
to your vehicle. Be sure to use the correct
size, brand, and type of tires on all wheels.
It is all right to drive with your compact
spare temporarily, as it was developed for
use on your vehicle. SeeCompact Spare
Tire on page 5-88.
5-70