2004 Chevrolet Malibu Service and Repair Manual

4.7 · Trusted by 14,000+ mechanics & DIYers
Regular price $29.99 USD
  • Lightning-Fast Downloads
    Optimized files — even slow connections handle it
  • Instant Search & Navigation
    Jump to any procedure or spec with one click
  • Print One or All Pages
    Bring only the pages you need to the shop
  • Covers Every System & Component
    Every procedure for the 2004 Chevrolet Malibu
Sample Preview

Unlock the Full Manual

Complete repair procedures
Wiring diagrams & schematics
Torque specifications
Full search & bookmarks
$29.99
Buy 2+ Manuals, Save 20% Discount applied automatically at checkout
20% OFF
Secure Checkout
No Subscriptions
Factory-Grade Data

2004 Chevrolet Malibu service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • Base Sedan 4-Door
  • LT Sedan 4-Door
  • LS Sedan 4-Door
  • Maxx LS Hatchback 4-Door
  • Maxx Hatchback 4-Door
  • Maxx LT Hatchback 4-Door

Engines covered

  • 2.2L 2198CC 134Cu. In. l4 GAS DOHC Naturally Aspirated
  • 3.5L 213Cu. In. V6 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

Payment & Security

Payment methods

  • American Express
  • Apple Pay
  • Bancontact
  • Google Pay
  • Maestro
  • Mastercard
  • PayPal
  • Union Pay
  • Visa

Your payment information is processed securely. We do not store credit card details nor have access to your credit card information.

Vehicle Safety Data

2004 Chevrolet Malibu Recalls & Complaints

NHTSA #11E00900028/02/2011Component: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

TI AUTOMOTIVE IS RECALLING CERTAIN FUEL PUMPS, PART NUMBERS TU456 AND TU303, SOLD UNDER VARIOUS BRAND NAMES AS AFTERMARKET AND REPLACEMENT EQUIPMENT FOR THE MOTOR VEHICLES LISTED A

Consequence

A VEHICLE CRASH COULD OCCUR SHOULD THE ENGINE STALL WHILE IN USE.

Remedy

TI AUTOMOTIVE WILL NOTIFY OWNERS OF RECORD AND WILL REPLACE ANY DEFECTIVE FUEL PUMP WITH A

NHTSA #04V09400024/02/2004Component: EQUIPMENT:OTHER:LABELS

CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD (FMVSS) NO. 208, "OCCUPANT CRASH PROTECTION." SOME OF THESE VEHICLES THAT

Remedy

OWNERS WILL BE SENT REPLACEMENT LABELS WITH INSTRUCTIONS ON HOW TO INSTALL THEM. OWNER NO

NHTSA #04V19000019/04/2004Component: SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED

SOME OF THESE PASSENGER VEHICLES HAVE AN ELECTRONIC CONTROL UNIT (ECU) THAT MAY CALCULATE A HIGHER THAN ACTUAL VEHICLE SPEED BECAUSE OF AN ERRATIC REAR-WHEEL SPEED SENSOR SIGNAL, A

Consequence

UNEXPECTED ABS ACTIVIATION COULD INCREASE STOPPING DISTANCE UP TO ABOUT 11 FEET DPENDING O

Remedy

DEALERS WILL REPROGRAM THE ABS CONTROLLER. OWNER NOTIFICATION BEGAN ON JUNE 16, 2004. OW

NHTSA #04V18800016/04/2004Component: SEAT BELTS:FRONT:ANCHORAGE

ON CERTAIN PASSENGER VEHICLES, ANALYSIS OF AN A SIDE IMPACT CRASH TEST CONDUCTED BY THE NHTSA;S NEW CAR ASSESSMENT PROGRAM (NCAP) INDICATED THAT THE OUTBOARD ANCHORAGE OF THE DRIVE

Consequence

IF THIS OCCURRED IN A CRASH, THE DRIVER COULD RECEIVE GREATER INJURIES.

Remedy

DEALERS WILL INSERT A RETAINER ON BOTH THE DRIVER'S AND PASSENGER'S BELT ANCHORAGES. OWNER

NHTSA #09E01200007/04/2009Component: EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11014455

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the

TSB #11009156

This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and

TSB #11007744

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have hi

TSB #11007743

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have hi

TSB #11007208

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed fo

TSB #11006621

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected mo

TSB #11006421

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the deal

Showing the 8 most recent of 630 technical service bulletins on file with NHTSA.

20080408Component: AIR BAGS:FRONTALCrash reportedFire reported2 injured

THE CONTACT OWNS A 2004 CHEVROLET MALIBU SEDAN. WHILE DRIVING 30 MPH, SHE CRASHED INTO A DIRT MOUND AND BLACKED OUT. WHEN THE DRIVER SIDE AIR BAG DEPLOYED, THE STEERING WHEEL WAS D

20080408Component: SEAT BELTS:FRONTCrash reportedFire reported2 injured

THE CONTACT OWNS A 2004 CHEVROLET MALIBU SEDAN. WHILE DRIVING 30 MPH, SHE CRASHED INTO A DIRT MOUND AND BLACKED OUT. WHEN THE DRIVER SIDE AIR BAG DEPLOYED, THE STEERING WHEEL WAS D

20160817Component: AIR BAGSCrash reportedFire reported

TL* THE CONTACT OWNS A 2004 CHEVROLET MALIBU. WHILE DRIVING APPROXIMATELY 23 MPH IN THE RAIN, THE VEHICLE SPUN OUT OF CONTROL AND CRASHED INTO A CEMENT BARRIER. THE AIR BAGS DID NO

20160817Component: ELECTRICAL SYSTEMCrash reportedFire reported

TL* THE CONTACT OWNS A 2004 CHEVROLET MALIBU. WHILE DRIVING APPROXIMATELY 23 MPH IN THE RAIN, THE VEHICLE SPUN OUT OF CONTROL AND CRASHED INTO A CEMENT BARRIER. THE AIR BAGS DID NO

Showing the 4 most serious of 1639 complaints filed with NHTSA.

All Model Years

Other Years of the Chevrolet Malibu

Need a manual for a different year? Browse every Chevrolet Malibu we cover.

Explore More

More Chevrolet Models

Browse service and repair manuals for other Chevrolet models in our catalog.