brake CHEVROLET MALIBU LIMITED 2016 8.G Service Manual

Chevrolet Malibu Limited Owner Manual (GMNA-Localizing-U.S/Canada-
9086425) - 2016 - crc - 7/30/15
240 Vehicle Care
Caution (Continued)
freezing occurs, which could
damage the tank if it is
completely full.
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 can
be heard all the time when the
vehicle is moving, except when
applying the brake pedal firmly.
{Warning
The brake wear warning sound
means that soon the brakes will
not work well. That could lead to
a crash. When the brake wear
warning sound is heard, have the
vehicle serviced.
Caution
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 first 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
specifications. See Capacities and
Specifications 0323.
Brake pads should be replaced as
complete sets.
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
that brake service may be required.
Replacing Brake System Parts
Always replace brake system parts
with new, approved replacement
parts. If this is not done, the brakes
may not work properly. The braking
performance expected can change
in many other ways if the wrong
replacement brake parts are
installed or if parts are improperly
installed.
Brake Fluid
The brake master cylinder reservoir
is filled with GM approved DOT 3
brake fluid as indicated on the
reservoir cap. See Engine
Compartment Overview 0229 for
the location of the reservoir.

Chevrolet Malibu Limited Owner Manual (GMNA-Localizing-U.S/Canada-
9086425) - 2016 - crc - 7/30/15
Vehicle Care 241
Checking Brake Fluid
With the vehicle in P (Park) on a
level surface, the brake fluid level
should be between the minimum
and maximum marks on the brake
fluid reservoir.
There are only two reasons why the
brake fluid level in the reservoir may
go down:
.Normal brake lining wear. When
new linings are installed, the
fluid level goes back up.
. A fluid leak in the brake
hydraulic system. Have the
brake hydraulic system fixed.
With a leak, the brakes will not
work well.
Always clean the brake fluid
reservoir cap and the area around
the cap before removing it.
Do not top off the brake fluid.
Adding fluid does not correct a leak.
If fluid is added when the linings are
worn, there will be too much fluid
when new brake linings are
installed. Add or remove fluid, as
necessary, only when work is done
on the brake hydraulic system.{Warning
If too much brake fluid is added, it
can spill on the engine and burn,
if the engine is hot enough. You
or others could be burned, and
the vehicle could be damaged.
Add brake fluid only when work is
done on the brake hydraulic
system.
When the brake fluid falls to a low
level, the brake warning light comes
on. See Brake System Warning
Light 0107.
Brake fluid absorbs water over time
which degrades the effectiveness of
the brake fluid. Replace brake fluid
at the specified intervals to prevent
increased stopping distance. See
Maintenance Schedule 0309.
What to Add
Use only GM approved DOT 3
brake fluid from a clean, sealed
container. See Recommended
Fluids and Lubricants 0319.
{Warning
The wrong or contaminated brake
fluid could result in damage to the
brake system. This could result in
the loss of braking leading to a
possible injury. Always use the
proper GM approved brake fluid.
Caution
If brake fluid is spilled on the
vehicle's painted surfaces, the
paint finish can be damaged.
Immediately wash off any painted
surface.
Battery - North America
The original equipment battery is
maintenance free. Do not remove
the cap and do not add fluid.
This vehicle has a standard 12-volt
battery under the hood. See Engine
Compartment Overview 0229.

Chevrolet Malibu Limited Owner Manual (GMNA-Localizing-U.S/Canada-
9086425) - 2016 - crc - 7/30/15
Vehicle Care 243
Starter Switch Check
{Warning
When you are doing this
inspection, the vehicle could
move suddenly. If the vehicle
moves, you or others could be
injured.
1. Before starting this check, be sure there is enough room
around the vehicle.
2. Apply both the parking brake and the regular brake.
Do not use the accelerator
pedal, and be ready to turn off
the engine immediately if it
starts.
3. Try to start the engine in each gear. The vehicle should start
only in P (Park) or N (Neutral).
If the vehicle starts in any other
position, contact your dealer for
service.
Automatic Transmission
Shift Lock Control
Function Check
{Warning
When you are doing this
inspection, the vehicle could
move suddenly. If the vehicle
moves, you or others could be
injured.
1. Before starting this check, be sure there is enough room
around the vehicle. It should be
parked on a level surface.
2. Apply the parking brake. Be ready to apply the regular
brake immediately if the vehicle
begins to move.
3. With the engine off, turn the ignition on, but do not start the
engine. Without applying the
regular brake, try to move the
shift lever out of P (Park) with
normal effort. If the shift lever
moves out of P (Park), contact
your dealer for service.
Ignition Transmission
Lock Check
If equipped with a key type ignition,
while parked and with the parking
brake set, try to turn the ignition to
LOCK/OFF in each shift lever
position.
.The ignition should turn to
LOCK/OFF only when the shift
lever is in P (Park).
. The ignition key should come
out only in LOCK/OFF.
Contact your dealer if service is
required.
Park Brake and P (Park)
Mechanism Check
{Warning
When you are doing this check,
the vehicle could begin to move.
You or others could be injured
and property could be damaged.
Make sure there is room in front
of the vehicle in case it begins to (Continued)

Chevrolet Malibu Limited Owner Manual (GMNA-Localizing-U.S/Canada-
9086425) - 2016 - crc - 7/30/15
244 Vehicle Care
Warning (Continued)
roll. Be ready to apply the regular
brake at once should the vehicle
begin to move.
Park on a fairly steep hill, with the
vehicle facing downhill. Keeping
your foot on the regular brake, set
the parking brake.
. To check the parking brake's
holding ability: With the engine
running and the transmission in
N (Neutral), slowly remove foot
pressure from the regular brake
pedal. Do this until the vehicle is
held by the parking brake only.
. To check the P (Park)
mechanism's holding ability:
With the engine running, shift to
P (Park). Then release the
parking brake followed by the
regular brake.
Contact your dealer if service is
required.
Wiper Blade Replacement
Windshield wiper blades should be
inspected for wear or cracking.
It is a good idea to clean the wiper
blade assembly on a regular basis.
When worn, or when cleaning is
ineffective, replace the wiper blade.
For proper windshield wiper blade
length and type, see Maintenance
Replacement Parts 0320.
Caution
Allowing the wiper arm to touch
the windshield when no wiper
blade is installed could damage
the windshield. Any damage that
occurs would not be covered by
the vehicle warranty. Do not allow
the wiper arm to touch the
windshield.
To replace the wiper blade: 1. Pull the wiper assembly away from the windshield.
2. Lift up on the latch in the
middle of the wiper blade
where the wiper arm attaches.
3. With the latch open, pull the wiper blade down toward the
windshield far enough to
release it from the J-hooked
end of the wiper arm.
4. Remove the wiper blade.
5. Reverse Steps 1–3 for wiper blade replacement.

Chevrolet Malibu Limited Owner Manual (GMNA-Localizing-U.S/Canada-
9086425) - 2016 - crc - 7/30/15
256 Vehicle Care
The vehicle may not be equipped
with all of the fuses, relays, and
features shown.Mini
Fuses Usage
1 Transmission Control Module Battery
2 Engine Control Module Battery (LTG)/
Air Conditioning
Compressor
Clutch (LKW)
3 Air Conditioning Compressor
Clutch (LTG)
4 Air Conditioning Compressor
Clutch (LTG)
5 Engine Control Module Battery (LKW)
7 Engine Control Module Ignition (LKW)
8 Spare
9 Ignition Coils
10 Engine Control Module Mini
Fuses Usage
11 Emissions
13 Transmission Module Ignition
14 Cabin Heater Coolant Pump
15 Spare
16 Aero Shutter
17 Spare
18 R/C Dual Battery Isolator Module
20 Transmission Auxiliary Oil
Pump (LKW)
23 Spare (LKW)
29 Left Seat Power Lumber Control
30 Right Seat Power Lumber Control
31 Chassis Control Module
32 Back-Up Lamps/ Interior Lamps Mini
Fuses Usage
33 Front Heated Seats
34 Antilock Brake System Valve
35 Amplifier
37 Right High Beam
38 Left High Beam
46 Cooling Fan
47 Emissions
48 Foglamp
49 Low Beam HID Headlamp Right
50 Low Beam HID Headlamp Left
51 Horn/Dual Horn
52 Cluster Ignition
53 Inside Rearview Mirror/Rear Camera/
Fuel Module Ignition
54 Heating, Ventilation, and Air Conditioning
Module Ignition

Chevrolet Malibu Limited Owner Manual (GMNA-Localizing-U.S/Canada-
9086425) - 2016 - crc - 7/30/15
Vehicle Care 257
Mini
Fuses Usage
55 Front Power Windows/Mirrors
56 Windshield Washer
57 Spare
60 Heated Mirror
62 Canister Vent Solenoid
66 Spare
67 Fuel Module
69 Battery Voltage Sensor
70 Lane Departure/Rear Parking Aid/Side
Blind Zone Assist
71 PEPS BATT
J-Case Fuses Usage
6 Front Wiper
12 Starter 1
21 Rear Power Window J-Case
Fuses Usage
22 Sunroof
24 Front Power Window
25 PEPS MTR
26 Antilock Brake System Pump
27 Not Used
28 Rear Defogger
41 Brake Vacuum Pump
42 Cooling Fan K2
44 Starter 2
45 Cooling Fan K1
59 Air Pump Emissions
Mini
Relays Usage
7 Powertrain
9 Cooling Fan K2
13 Cooling Fan K1
15 Run/Crank
16 Spare Mini
Relays Usage
17 Window/Mirror Defogger
Micro
Relays Usage
1 Air Conditioning Compressor Clutch
2 Starter Solenoid
4 Front Wiper Speed
5 Front Wiper On
6 Spare
8 Transmission Auxiliary Oil
Pump (LKW)
10 Cooling Fan K3 11 Starter 2 Solenoid (LKW)
14 Headlamp Low Beam/DRL

Chevrolet Malibu Limited Owner Manual (GMNA-Localizing-U.S/Canada-
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272 Vehicle Care
TPMS Sensor Matching
Process
Each TPMS sensor has a unique
identification code. The identification
code needs to be matched to a new
tire/wheel position after rotating the
vehicle’s tires or replacing one or
more of the TPMS sensors. The
TPMS sensor matching process
should also be performed after
replacing a spare tire with a road
tire containing the TPMS sensor.
The malfunction light and the DIC
message should go off at the next
ignition cycle. The sensors are
matched to the tire/wheel positions,
using a TPMS relearn tool, in the
following order: driver side front tire,
passenger side front tire, passenger
side rear tire, and driver side rear.
See your dealer for service or to
purchase a relearn tool. A TPMS
relearn tool can also be purchased.
See Tire Pressure Monitor Sensor
Activation Tool at
www.gmtoolsandequipment.com or
call 1-800-GM TOOLS
(1-800-468-6657).There are two minutes to match the
first tire/wheel position, and
five minutes overall to match all four
tire/wheel positions. If it takes
longer, the matching process stops
and must be restarted.
The TPMS sensor matching
process is:
1. Set the parking brake.
2. Turn the ignition to ON/RUN with the engine off or place the
vehicle power mode in ON/
RUN/START. See Ignition
Positions (Keyless Access)
0 187 orIgnition Positions (Key
Access) 0189.
3. Use the MENU button to select the Vehicle Information Menu
in the Driver Information
Center (DIC).
4. Use the thumbwheel to scroll to the Tire Pressure Menu Item
screen.
5. Press the SET/CLR button to begin the sensor matching
process. A message asking if the
process should begin should
appear.
6. Press the SET/CLR button again to confirm the selection.
The horn sounds twice to
signal the receiver is in relearn
mode and the TIRE
LEARNING ACTIVE message
displays on the DIC screen.
7. Start with the driver side front tire.
8. Place the relearn tool against the tire sidewall, near the valve
stem. Then press the button to
activate the TPMS sensor.
A horn chirp confirms that the
sensor identification code has
been matched to this tire and
wheel position.
9. Proceed to the passenger side front tire, and repeat the
procedure in Step 8.
10. Proceed to the passenger side rear tire, and repeat the
procedure in Step 8.

Chevrolet Malibu Limited Owner Manual (GMNA-Localizing-U.S/Canada-
9086425) - 2016 - crc - 7/30/15
Vehicle Care 275
tire manufacture date is the last four
digits of the DOT Tire Identification
Number (TIN) which is molded into
one side of the tire sidewall. The
first two digits represent the week
(01–52) and the last two digits, the
year. For example, the third week of
the year 2010 would have a
four-digit DOT date of 0310.
Vehicle Storage
Tires age when stored normally
mounted on a parked vehicle. Park
a vehicle that will be stored for at
least a month in a cool, dry, clean
area away from direct sunlight to
slow aging. This area should be free
of grease, gasoline, or other
substances that can deteriorate
rubber.
Parking for an extended period can
cause flat spots on the tires that
may result in vibrations while
driving. When storing a vehicle for
at least a month, remove the tires or
raise the vehicle to reduce the
weight from the tires.
Buying New Tires
GM has developed and matched
specific tires for the vehicle. The
original equipment tires installed
were designed to meet General
Motors Tire Performance Criteria
Specification (TPC Spec)
system rating. When
replacement tires are needed,
GM strongly recommends
buying tires with the same TPC
Spec rating.
GM's exclusive TPC Spec
system considers over a dozen
critical specifications that impact
the overall performance of the
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 numberwill be followed by MS for mud
and snow. See
Tire Sidewall
Labeling 0262.
GM recommends replacing worn
tires in complete sets of four.
Uniform tread depth on all tires
will help to maintain the
performance of the vehicle.
Braking and handling
performance may be adversely
affected if all the tires are not
replaced at the same time.
If proper rotation and
maintenance have been done,
all four tires should wear out at
about the same time. See Tire
Rotation 0273. However, if it is
necessary to replace only one
axle set of worn tires, place the
new tires on the rear axle.
Winter tires with the same speed
rating as the original equipment
tires may not be available for H,
V, W, Y and ZR speed rated
tires. Never exceed the winter

Chevrolet Malibu Limited Owner Manual (GMNA-Localizing-U.S/Canada-
9086425) - 2016 - crc - 7/30/15
276 Vehicle Care
tires’maximum speed capability
when using winter tires with a
lower speed rating.
{Warning
Tires could explode during
improper service. Attempting
to mount or dismount a tire
could cause injury or death.
Only your dealer or authorized
tire service center should
mount or dismount the tires.
{Warning
Mixing tires of different sizes,
brands, or types may cause
loss of control of the vehicle,
resulting in a crash or other
vehicle damage. Use the
correct size, brand, and type
of tires on all wheels.
{Warning
Using bias-ply tires on the
vehicle may cause the wheel
rim flanges to develop cracks
after many miles of driving.
A tire and/or wheel could fail
suddenly and cause a crash.
Use only radial-ply tires with
the wheels on the vehicle.
If the vehicle tires must be
replaced with a tire that does not
have a TPC Spec number, make
sure they are the same size,
load range, speed rating, and
construction (radial) as the
original tires.
Vehicles that have a tire
pressure monitoring system
could give an inaccurate
low-pressure warning if non-TPC
Spec rated tires are installed.
See Tire Pressure Monitor
System 0269. The Tire and Loading
Information label indicates the
original equipment tires on the
vehicle. See
Vehicle Load Limits
0 183.
Different Size Tires and
Wheels
If wheels or tires are installed that
are a different size than the original
equipment wheels and tires, vehicle
performance, including its braking,
ride and handling characteristics,
stability, and resistance to rollover
may be affected. If the vehicle has
electronic systems such as antilock
brakes, rollover airbags, traction
control, electronic stability control,
or All-Wheel Drive, the performance
of these systems can also be
affected.
{Warning
If different sized wheels are used,
there may not be an acceptable
level of performance and safety if
(Continued)

Chevrolet Malibu Limited Owner Manual (GMNA-Localizing-U.S/Canada-
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Vehicle Care 279
Some aluminum wheels can be
repaired. See your dealer if any of
these conditions exist.
Your dealer will know the kind of
wheel that is needed.
Each new wheel should have the
same load-carrying capacity,
diameter, width, offset, and be
mounted the same way as the one it
replaces.
Replace wheels, wheel bolts, wheel
nuts, or Tire Pressure Monitor
System (TPMS) sensors with new
GM original equipment parts.
{Warning
Using the wrong replacement
wheels, wheel bolts, or wheel
nuts can be dangerous. It could
affect the braking and handling of
the vehicle. Tires can lose air,
and cause loss of control, causing
a crash. Always use the correct
wheel, wheel bolts, and wheel
nuts for replacement.
Caution
The wrong wheel can also cause
problems with bearing life, brake
cooling, speedometer or
odometer calibration, headlamp
aim, bumper height, vehicle
ground clearance, and tire or tire
chain clearance to the body and
chassis.
Used Replacement Wheels
{Warning
Replacing a wheel with a used
one is dangerous. How it has
been used or how far it has been
driven may be unknown. It could
fail suddenly and cause a crash.
When replacing wheels, use a
new GM original equipment
wheel.
Tire Chains
{Warning
Do not use tire chains. There is
not enough clearance. Tire chains
used on a vehicle without the
proper amount of clearance can
cause damage to the brakes,
suspension, or other vehicle
parts. The area damaged by the
tire chains could cause loss of
control and a crash.
Use another type of traction
device only if its manufacturer
recommends it for the vehicle's
tire size combination and road
conditions. Follow that
manufacturer's instructions. To
avoid vehicle damage, drive slow
and readjust or remove the
traction device if it contacts the
vehicle. Do not spin the wheels.
If traction devices are used, install
them on the front tires.