engine CHEVROLET MALIBU 2009 7.G Repair Manual

Service............................................................5-3
Accessories and Modications..........................5-3
California Proposition 65 Warning.....................5-4
California Perchlorate Materials Requirements.....5-4
Doing Your Own Service Work.........................5-4
Adding Equipment to the Outside of the
Vehicle......................................................5-5
Fuel................................................................5-5
Gasoline Octane............................................5-6
Gasoline Specications....................................5-6
California Fuel...............................................5-6
Additives.......................................................5-7
Fuel E85 (85% Ethanol)..................................5-8
Fuels in Foreign Countries.............................5-10
Filling the Tank............................................5-10
Filling a Portable Fuel Container.....................5-13
Checking Things Under the Hood....................5-14
Hood Release..............................................5-14
Engine Compartment Overview.......................5-16
Engine Oil...................................................5-21
Engine Oil Life System..................................5-24
Engine Air Cleaner/Filter................................5-26
Automatic Transmission Fluid.........................5-28
Cooling System............................................5-28
Engine Coolant.............................................5-29
Pressure Cap...............................................5-33Coolant Surge Tank Pressure Cap..................5-33
Engine Overheating.......................................5-34
Overheated Engine Protection
Operating Mode........................................5-36
Power Steering Fluid.....................................5-36
Windshield Washer Fluid................................5-38
Brakes........................................................5-39
Battery........................................................5-42
Jump Starting...............................................5-43
Headlamp Aiming...........................................5-47
Bulb Replacement..........................................5-47
Halogen Bulbs..............................................5-47
Taillamps, Turn Signal, and Stoplamps............5-48
License Plate Lamp......................................5-49
Replacement Bulbs.......................................5-50
Windshield Wiper Blade Replacement..............5-50
Tires..............................................................5-51
Winter Tires.................................................5-52
Tire Sidewall Labeling...................................5-53
Tire Terminology and Denitions.....................5-56
Ination - Tire Pressure.................................5-59
High-Speed Operation...................................5-60
Tire Pressure Monitor System.........................5-61
Tire Pressure Monitor Operation.....................5-62
Tire Inspection and Rotation...........................5-66
Section 5 Service and Appearance Care
5-1

When It Is Time for New Tires.......................5-67
Buying New Tires.........................................5-68
Different Size Tires and Wheels......................5-70
Uniform Tire Quality Grading..........................5-70
Wheel Alignment and Tire Balance..................5-72
Wheel Replacement......................................5-72
Tire Chains..................................................5-74
If a Tire Goes Flat........................................5-75
Changing a Flat Tire.....................................5-76
Removing the Spare Tire and Tools................5-77
Removing the Flat Tire and Installing the
Spare Tire................................................5-79
Storing a Flat or Spare Tire and Tools............5-85
Compact Spare Tire......................................5-89
Appearance Care............................................5-90
Interior Cleaning...........................................5-90
Fabric/Carpet...............................................5-91
Leather.......................................................5-92
Instrument Panel, Vinyl, and Other Plastic
Surfaces..................................................5-92
Care of Safety Belts......................................5-93
Weatherstrips...............................................5-93
Washing Your Vehicle...................................5-93Cleaning Exterior Lamps/Lenses.....................5-94
Finish Care..................................................5-94
Windshield and Wiper Blades.........................5-95
Aluminum Wheels.........................................5-95
Tires...........................................................5-96
Sheet Metal Damage.....................................5-96
Finish Damage.............................................5-96
Underbody Maintenance................................5-97
Chemical Paint Spotting.................................5-97
Vehicle Identication......................................5-97
Vehicle Identication Number (VIN).................5-97
Service Parts Identication Label.....................5-98
Electrical System............................................5-98
Add-On Electrical Equipment..........................5-98
Windshield Wiper Fuses................................5-98
Power Windows and Other Power Options.......5-98
Fuses.........................................................5-99
Instrument Panel Fuse Block..........................5-99
Engine Compartment Fuse Block...................5-102
Rear Compartment Fuse Block.....................5-105
Capacities and Specications........................5-108
Section 5 Service and Appearance Care
5-2

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.
California Perchlorate Materials
Requirements
Certain types of automotive applications, such as
airbag initiators, seat belt pretensioners, and lithium
batteries contained in remote keyless transmitters,
may contain perchlorate materials. Special handling
may be necessary. For additional information, see
www.dtsc.ca.gov/hazardouswaste/perchlorate.
Doing Your Own Service Work
{CAUTION:
You can be injured and the vehicle could be
damaged if you try to do service work on a vehicle
without knowing enough about it.
Be sure you have sufficient knowledge,
experience, the proper replacement parts,
and tools before attempting any vehicle
maintenance task.
Be sure to use the proper nuts, bolts, and
other fasteners. English and metric fasteners
can be easily confused. If the wrong fasteners
are used, parts can later break or fall off.
You could be hurt.
5-4

If doing some of your own service work, use the proper
service manual. It tells you much more about how to
service the vehicle than this manual can. To order the
proper service manual, seeService Publications Ordering
Information on page 7-16.
This vehicle has an airbag system. Before attempting
to do your own service work, seeServicing Your
Airbag-Equipped Vehicle on page 1-71.
Keep a record with all parts receipts and list the
mileage and the date of any service work performed.
SeeMaintenance Record on page 6-16.
Adding Equipment to the Outside of
the Vehicle
Things added to the outside of the vehicle can affect the
airow around it. This can cause wind noise and can
affect fuel economy and windshield washer performance.
Check with your dealer/retailer before adding equipment
to the outside of the vehicle.
Fuel
Use of the recommended fuel is an important part of
the proper maintenance of this vehicle. To help keep the
engine clean and maintain optimum vehicle performance,
we recommend the use of gasoline advertised as
TOP TIER Detergent Gasoline.
The 8th digit of the Vehicle Identication Number (VIN)
shows the code letter or number that identies
the vehicle’s engine. The VIN is at the top left of
the instrument panel. SeeVehicle Identification
Number (VIN) on page 5-97.
If the vehicle has the 3.5L V6 engine (VIN Code K),
you can use either unleaded gasoline or ethanol fuel
containing up to 85% ethanol (E85). SeeFuel E85
(85% Ethanol) on page 5-8. In all other engines, use only
the unleaded gasoline described underGasoline Octane
on page 5-6.
5-5

Gasoline Octane
If the vehicle has the 2.4L L4 engine (VIN Code B),
the 3.5L V6 engine (VIN Code K), or the 3.5L V6 engine
(VIN Code N), use regular unleaded gasoline with a
posted octane rating of 87 or higher. If the octane rating is
less than 87, you might notice an audible knocking noise
when you drive, commonly referred to as spark knock.
If this occurs, use a gasoline rated at 87 octane or higher
as soon as possible. If you are using gasoline rated at
87 octane or higher and you hear heavy knocking, the
engine needs service.
If the vehicle has the 3.6L V6 engine (VIN Code 7),
use regular unleaded gasoline with a posted octane
rating of 87 or higher. For best performance or trailer
towing, you could choose to use middle grade 89 octane
unleaded gasoline. If the octane rating is less than 87,
you might notice an audible knocking noise when you
drive, commonly referred to as spark knock. If this occurs,
use a gasoline rated at 87 octane or higher as soon as
possible. If you are using gasoline rated at 87 octane or
higher and you hear heavy knocking, the engine needs
service.
Gasoline Specications
At a minimum, gasoline should meet ASTM specication
D 4814 in the United States or CAN/CGSB-3.5 or 3.511 in
Canada. Some gasolines contain an octane-enhancing
additive called methylcyclopentadienyl manganese
tricarbonyl (MMT). We recommend against the use of
gasolines containing MMT. SeeAdditives on page 5-7
for additional information.
California Fuel
If the vehicle is certied to meet California Emissions
Standards, it is designed to operate on fuels that meet
California specications. See the underhood emission
control label. If this fuel is not available in states adopting
California emissions standards, the vehicle will operate
satisfactorily on fuels meeting federal specications, but
emission control system performance might be affected.
The malfunction indicator lamp could turn on and the
vehicle might fail a smog-check test. SeeMalfunction
Indicator Lamp on page 3-38. If this occurs, return to your
authorized dealer/retailer for diagnosis. If it is determined
that the condition is caused by the type of fuel used,
repairs might not be covered by the vehicle warranty.
5-6

Additives
To provide cleaner air, all gasolines in the United States
are now required to contain additives that help prevent
engine and fuel system deposits from forming, allowing
the emission control system to work properly. In most
cases, you should not have to add anything to the fuel.
However, some gasolines contain only the minimum
amount of additive required to meet U.S. Environmental
Protection Agency regulations. To help keep fuel injectors
and intake valves clean, or if the vehicle experiences
problems due to dirty injectors or valves, look for gasoline
that is advertised as TOP TIER Detergent Gasoline.
For customers who do not use TOP TIER Detergent
Gasoline regularly, one bottle of GM Fuel System
Treatment PLUS, added to the fuel tank at every engine
oil change, can help clean deposits from fuel injectors
and intake valves. GM Fuel System Treatment PLUS
is the only gasoline additive recommended by General
Motors.
Also, your dealer/retailer has additives that will help
correct and prevent most deposit-related problems.Gasolines containing oxygenates, such as ethers and
ethanol, and reformulated gasolines might be available in
your area. We recommend that you use these gasolines,
if they comply with the specications described earlier.
However, E85 (85% ethanol) and other fuels containing
more than 10% ethanol must not be used in vehicles that
were not designed for those fuels.
Notice:This vehicle was not designed for fuel that
contains methanol. Do not use fuel containing
methanol. It can corrode metal parts in the fuel
system and also damage plastic and rubber parts.
That damage would not be covered under the
vehicle warranty.
Some gasolines that are not reformulated for
low emissions can contain an octane-enhancing
additive called methylcyclopentadienyl manganese
tricarbonyl (MMT); ask the attendant where you buy
gasoline whether the fuel contains MMT. We recommend
against the use of such gasolines. Fuels containing MMT
can reduce the life of spark plugs and the performance
of the emission control system could be affected.
The malfunction indicator lamp might turn on. If this
occurs, return to your dealer/retailer for service.
5-7

Fuel E85 (85% Ethanol)
The 8th digit of the Vehicle Identication Number (VIN)
shows the code letter or number that identies the
vehicle’s engine. The VIN is at the top left of the
instrument panel. SeeVehicle Identification
Number (VIN) on page 5-97.
If the vehicle has the 3.5L V6 engine (VIN Code K),
you can use either unleaded gasoline or ethanol
fuel containing up to 85% ethanol (E85). SeeFuel on
page 5-5. In all other engines, use only the unleaded
gasoline described underGasoline Octane on page 5-6.
Only vehicles that have the 3.5L V6 engine
(VIN Code K) can use 85% ethanol fuel (E85).
We encourage the use of E85 in vehicles that are
designed to use it. The ethanol in E85 is a “renewable”
fuel, meaning it is made from renewable sources such
as corn and other crops.Many service stations will not have an 85% ethanol fuel
(E85) pump available. The U. S. Department of Energy
has an alternative fuels website (www.eere.energy.gov/
afdc/infrastructure/locator.html) that can help you nd
E85 fuel. Those stations that do have E85 should have
a label indicating ethanol content. Do not use the fuel if
the ethanol content is greater than 85%.
At a minimum, E85 should meet ASTM Specication
D 5798. By denition, this means that fuel labeled E85
will have an ethanol content between 70% and 85%.
Filling the fuel tank with fuel mixtures that do not meet
ASTM specications can affect driveability and could
cause the malfunction indicator lamp to come on.
To ensure quick starts in the wintertime, the E85 fuel
must be formulated properly for your climate according
to ASTM specication D 5798. If you have trouble
starting on E85, it could be because the E85 fuel
is not properly formulated for your climate. If this
happens, switching to gasoline or adding gasoline
to the fuel tank can improve starting.
5-8

Fuels in Foreign Countries
If you plan on driving in another country outside the
United States or Canada, the proper fuel might be hard
to nd. Never use leaded gasoline or any other fuel
not recommended in the previous text on fuel. Costly
repairs caused by use of improper fuel would not
be covered by the vehicle warranty.
To check the fuel availability, ask an auto club, or
contact a major oil company that does business in
the country where you will be driving.
Filling the Tank
{CAUTION:
Fuel vapor burns violently and a fuel re can
cause bad injuries. To help avoid injuries to you
and others, read and follow all the instructions on
the pump island. Turn off the engine when you are
refueling. Do not smoke if you are near fuel or
refueling the vehicle. Do not use cellular phones.
Keep sparks, ames, and smoking materials away
from fuel. Do not leave the fuel pump unattended
when refueling the vehicle. This is against the law
in some places. Do not re-enter the vehicle while
pumping fuel. Keep children away from the fuel
pump; never let children pump fuel.
The fuel door is located on the passenger side of the
vehicle.
5-10

Checking Things Under
the Hood
{CAUTION:
An electric fan under the hood can start up and
injure you even when the engine is not running.
Keep hands, clothing, and tools away from any
underhood electric fan.
{CAUTION:
Things that burn can get on hot engine parts and
start a re. These include liquids like fuel, oil,
coolant, brake uid, windshield washer and other
uids, and plastic or rubber. You or others could
be burned. Be careful not to drop or spill things
that will burn onto a hot engine.
Hood Release
To open the hood, do the following:
1. Pull the hood release
handle with this symbol
on it. It is located
inside the vehicle to
the left of the steering
column.
5-14

Engine Compartment Overview
When you open the hood on the 2.4L L4 engine, this is what you see:
5-16