2004-2008 Chevrolet Malibu Service & Repair Manual

Replacing Your Windshield Wipers Although we swear to ourselves not to wait until the next hurricane, rain storm, or blizzard to realize we need new wipers, we usually do. Inevitably, we're just trying to get home from a long day at the office when a sudden downpour starts; we fire up the wipers and they can't clear the water. There we are squinting through the blurry windshield trying to make out the radar blip of distant taillights, cursing ourselves for not changing the wipers the last time we said we were going to. If you get your oil changed regularly, you're probably in good shape. Service stations check the wipers for you. But, if you're a do-it-yourselfer, then you just might let the wipers deteriorate to rubber bits until the day you need them. To prevent this frustration, the next time you're at a gas station or auto parts store, pick up a couple of replacements to have on hand. Depending on what part of the county you are in, the rubber wiper portions generally only last six months to one year. And just because you live in a region country where it barely drips rain, do not be misled into thinking your wipers are immortal. They aren't. The sun is bakes and cracks them into oblivion. Plus, if you use your wipers to constantly clear road gunk from the windshield, those bits of debris that are seeming tossed to the wayside slowly eat away at the wipers. If you do have a pair of wipers handy, they are easy to change. You can opt to switch out only the rubber portion of the blade that squeegees the windshield, but in most cases you'll change the whole blade. The entire gadget consists of an arm and a blade. The blade directly attaches to the arm, and is comprised of a mount and the metal-covered-by-rubber slab. Before you purchase refill blades or replacement rubber strips, either check the length with a tape measure or look in the manual for the proper size (usually they range from 16-21 inches). Also, your local auto parts store should have manuals that match up every car ever manufactured with a correct replacement. Signs You Need to Replace Your Wipers • Windshield streaking • Windshield smearing • Wiper screeching • Wiper is brittle with rubber flaking off at the touch

• Wiper is frayed Tools for the Change • Screwdriver • Tape measure • Needle-nose pliers Three Types of Wiper-Arm Mounts Hook Slot Connector―This type of blade is the easiest to change. Bring the arm to a right angle and search out the flap that attaches the wiper in the slot. Either push it in or unlatch it. One way or the other will release the blade and allow you to pull it out. If it poses any difficulty, tug it with pliers. Insert the new wiper and slide it along the slot until you feel or hear it snap into place. Pin Type Arm― Basically uses the same concept of the hook-slot arm, except you will see a pin rather than a tab. Press on the pin from behind the blade or lift the pin out (most likely will entail the use of a screwdriver). Jiggle the blade until it fully releases. Lock the new blade into the pins. Straight-End Connector―Changing this type can be a drag, because it tends to be more difficult. If there is a notch or tab that secures the blade, you only need to release it using your screwdriver. Pull the blade out and install the new one by sliding it in and locking it. This is the simplified version. The other involves having to deal with screws the size of ants that hold the blade in. Take out the screws to remove the old blade and install the new one. Note that the screws are fragile so take it easy when securing them. Now that your new wiper blades are in place, you should be able to have a clear view of the road ahead―regardless of the weather. Changing a Fuse Fuses seem to break all the time, but they're designed to. Huh? When when one circuit has too much electricity flowing through it, the fuse blows to prevent serious damage and even fire. Fuses are inexpensive and easy to replace. You can store extra fuses in your vehicle's fuse panel. If your fuse panel doesn't have a storage space, the second best place to keep such tiny parts is in your glove compartment or a special compartment in your toolbox.

Step-by-Step: How to Change a Fuse Locate the Fuse Panel Your owner's manual will tell you where your vehicle's fuse panel is. Most models situate the fuse panel on the driver's side of the dashboard and under the steering wheel, or in the engine compartment, but location varies from vehicle to vehicle. Other are found in the front dash door jambs or in the glove box. Remove the fuse panel's cover; you'll see several different color-coded fuses plugged in. These colors, along with the numbers stamped on the fuses, indicate different amperage ratings. Now, turn the fuse panel cover over to see a helpful fuse diagram. This diagram shows you which fuse works with which electrical component. Remove the Blown Fuse Before you can change a fuse, you must find the faulty one. It will have a broken filament (the thin strip of metal inside) or will be black inside. Some vehicles come with special "pullers" to remove fuses, but tweezers work just as well. You can also use your trusty fingers. Just make sure you carefully remove and replace the fuses until you find the culprit. Note that the vehicle's electrical problems may need a mechanic's attention if none of the fuses look blown, or if the fuse immediately blows again. Replace the Fuse Replace the blown fuse with a new fuse of the same amperage. Use your owner's manual, the fuse panel diagram, and the numbered, color-coded fuses themselves to help you determine the correct amperage. If you use the wrong amperage, you could cause much worse damage to your vehicle than just a blown fuse. Once you have located a fuse of the right amperage, place it into the correct slot. Push it down with your finger to ensure it's completely installed, and then replace the fuse panel's cover. Remember, if you don't have a spare fuse, you can always temporarily use the fuse of another less-used electrical component―as long as the amperage is correct. Consider using the fuse for your cigarette lighter, the radio, or the back window heater. Check the Circuit Once the fuse is replaced and the panel is covered, turn your vehicle's ignition and check to see if the troubled circuit is working properly. If it's working correctly, chances are you just had a temporary overload of electricity that caused the fuse to blow. If this is the case, then you just solved the problem.

However, if the circuit doesn't work, or it does work but only briefly before it needs to be replaced again, your vehicle's electrical problems go beyond just a blown fuse. It's best to see a mechanic at this point. Replacing Brake Fluid Adding vs. Changing Brake Fluid Adding brake fluid is usually not part of routine vehicle maintenance. Low brake fluid typically means that your brake pads are low and soon need to be changed. If you notice a sudden drop in the brake fluid level, it could indicate a problem with your brake system, or that you simply need to change your brakes. Have a professional check your brakes if you are unsure. If you are sure that your brake pads are in serviceable condition and your brake fluid is below the add line, only then should you add fluid. Symptoms of Brake Problems Some braking problems have to do with the brake fluid. If your brakes have developed a "mushy" feel, or if they need to be pumped, then, rarely, air may have entered the line. Check the brake fluid level; if the reservoir is empty, then bleeding the brake lines to remove the air may improve the condition. However, if the reservoir still holds brake fluid, have the brakes checked as soon as possible. Brake Fluid Facts Keep these facts in mind while handling brake fluid: • Never use DOT 5 brake fluid in a vehicle designed for DOT 3 or DOT 4 fluids. It is ok to use DOT 4 fluid in a vehicle that requires DOT 3, but not vice-versa. • NEVER substitute any other fluid for brake fluid. • Wash your hands immediately after coming in contact with brake fluid. It eats paint, so imagine what it'll do to skin. • Properly discard brake fluid that's been unsealed for more than one year. Check with your city for recycling days or centers. How to Check and Add Brake Fluid • Determine the location of the brake fluid reservoir.

• Look inside the reservoir to determine the current fluid level. If it's at the "full" mark, close the reservoir and mark the date of the inspection in your maintenance log. • If the fluid level is below the ""add" line, have your disc brakes checked. As disc brakes wear done, the fluid is displaced into the brake calipers. Most brake fluid reservoirs are designed so you should not have to add or "top off" the fluid. If the fluid looks dark, it is time to have it changed. Bleeding the Brake Lines to Remove Air Two people are required to bleed a brake line; one to depress the brake pedal and one to drain the fluid into a container. These directions are the basic procedure for bleeding a brake line. Consult your service manual before you begin to bleed your own lines; this WILL NOT work for newer cars. Have the following items handy: • A section of plastic, vinyl or rubber tubing, 3/16" diameter, long enough to reach from the brake caliper to the clear plastic container. • A wrench to open and close the bleeder valve. • A clear plastic container containing at least one inch of clean brake fluid, or enough to submerge the plastic tubing. Clear plastic is important so you can see the air bubbles as they exit the brake line. Here are the basic instructions for the process: • Open the reservoir and add brake fluid up to the full line. • Replace the cap on the master cylinder reservoir before you begin bleeding the line. Never remove the reservoir cap while the brake pedal is depressed. • Starting with the wheel rear wheels, locate the brake cylinder or caliper and find the bleed valve on the back side. It will look line a bolt with a nipple on it and may have a rubber cap that you will have to remove. • Place one end of the clear tube into the clear container to which you have added approximately one inch of brake fluid. Be sure to do this step before you connect the other end of the tube to the bleed valve. • With the tube end in the container of brake fluid, connect the other end of the tube to the bleed valve. • Use a wrench to loosen the valve on the brake caliper just slightly. Do not allow the brake fluid to begin to flow; just loosen the valve enough to make it easy to release when you are ready to bleed the line.

• Now, have the person inside the vehicle pump the brake pedal a few times to build up pressure in the line, and then have them hold the brake pedal down firmly, without further pumping. • While the brake pedal is held in place, loosen the bleed valve enough to allow a small amount of brake fluid to flow out of the brake line and into your container. • Watch for the air bubbles to exit the tube placed in the clear plastic container with the brake fluid. • The person inside the vehicle should only allow the pedal to travel about 2/3rds of the way to the floor. Allowing the pedal to reach the floor may damage a master cylinder. Once the pedal reaches this position, the person inside should signals you with an "OK" so you know to tighten the bleeder screw. After the screw is tightened, signal the person inside with an "OK" so he may release the pedal. • Repeat this action of pumping the brakes and bleeding the fluid until there are no more bubbles remaining in the line. It is very important to remember to periodically check the fluid level in the reservoir, and always replace the cap before actuating the brake pedal. • Repeat the process above for the three remaining brake lines. Be sure your helper pumps and holds the brake pedal each time. • Once all four brake lines have been bled, fill the brake fluid reservoir to the "full" line, then close the cap, Thoroughly rinse any spilled brake fluid spilled in the engine compartment off with water. • If you are in any doubt about the condition of your braking system,make an appointment for a brake inspection as soon as possible. Changing an Air Filter Before you start heaving luggage out of your car's side windows or imposing passenger weight restrictions to improve your vehicle's mileage, check the air filter. A dirty or clogged air filter can alter your vehicle's gas mileage by up to 10%. An air filter serves as an engine's protection device against grit and grime―your car's Achilles' heel. An air filter that is blocked with debris essentially chokes your vehicle and restricts air intake. Fortunately, changing an air filter usually takes under five minutes. When to Change the Air Filter An air filter should be replaced once a year, or every 15,000 miles. If you regularly travel on dirt roads, however, you will need to check your air filter every few months. You don't need a mechanic's eye to determine the air filter's condition. If you see dust build-up within the filter's accordion-like folds, change is needed. Or, for absolute certainty, shine a flashlight from the

inside out. If the beam cannot penetrate the folds, you need to spring into air-filter-maintenance mode. How to Change an Air Filter To find your air filter, pop the hood and look for a black plastic casing―about the size of a bread loaf―fastened with clips or screws. If you're still unsure, consult your car's manual. Open the clips. You can do this with your hands, or if you're intent on keeping the fingers grime- free, use a screwdriver. If you drive an older car, you'll find the air filter above the engine, encased in a round black covering that looks like it could contain a pillbox hat. Unscrew the center wing nut to open. Next, remove the filter and inspect it for dirt by bending back the paper ridges. If deemed filthy, go purchase a new one. Insert the new filter and make sure the casing is tightly secured. Not only is this fast, but cost efficient. Most quick lube shops charge up $20 to change an air filter. For a few minute's time, you can save yourself half the cost by self-installing. Changing a Headlight Changing the Headlight in a Newer Model Vehicle In the old days, replacing a headlight seemed to be as complicated as a root canal. The lamp had to be completely removed. Today, cars and trucks come with headlight bulbs that plug into the back of the headlight lens housing. If your headlight goes out, replacing the bulb is simple and takes very little time. What Type of Bulb? First, find out what type of bulb you need. It may be listed in the owner's manual for your vehicle. If you cannot locate the correct bulb information, ask the service clerk at the auto parts store. They have reference material and can find this information for you quickly. Tools to Change a Newer Headlight Bulb You'll need a few supplies in order to change a single or both headlights on your vehicle. Remember, if you are using a different type bulb for a burned-out headlight, you must place that same type bulb in the working headlight.

Here's what you need: • The correct bulb for your vehicle's make, model and year. • Service manual for your vehicle's make, model and year. • Any tools required, as indicated in the service manual. Changing the Newer Vehicle Headlight Bulb Follow these steps to change the headlight bulb on your vehicle: 1. Open the engine compartment hood. 2. Locate the back of the headlight to determine the lamp and bulb type. 3. Decide which bulb you need to replace. 4. Purchase the correct bulb for your headlamp. 5. Follow the directions in the service manual for the correct way to replace the bulb. Changing the Headlight in an Older Model Vehicle Older models are a bit trickier. First find the part number, which can usually be found as a raised impression on the front of the glass covering the headlamp. If it's not there, check the service manual, the owner's manual, or with the auto parts shop to buy the correct headlight. Tools to Change an Older Headlight To change out the whole headlight in an older vehicle: • Correct lamp for the vehicle's make and model. • Screwdriver to disconnect the frame holding the lamp in the bracket. Changing the Older Vehicle Headlight Follow these steps to change the headlight bulb on an older vehicle: 1. Remove the screws that connect the headlamp frame to the bracket holding the headlamp. Make certain you turn only the screws that hold the lamp frame, not the adjusting screws. 2. Disconnect the electrical connector in the back of the lamp by pulling the socket away from the headlamp with your hand. 3. Remove the headlight from the bracelet area and discard it. 4. Replace with the new headlight, making sure that it is positioned right side up. 5. Plug the wire socket into the new headlight, which holding the headlight securely. 6. Replace the headlight into the frame. 7. Place the frame onto the headlight bracket. 8. Reattach the screws to hold the frame and bracket in place.

9. Do not adjust the setting screws for the direction the headlight shines. If you suspect that the positioning of your new headlight may have been disturbed while you changed it, have it checked before you drive at night. Otherwise, you are ready to go. Replacing Fuel Hoses Fuel hoses rarely need to be changed, but if yours leaks or was damaged while changing a fuel filter , you'll need to make this repair. NOTE: Because replacing a fuel hose can be quite dangerous, this is a fix better left to an experienced mechanic. Safety First Since dealing with fuel lines could end in a giant fireball, follow all gasoline safety precautions. Don't smoke, make sure there's plenty of ventilation, and properly dispose of all gasoline-soaked rags, old parts, hoses, and any other items contaminated by gasoline. Keep a current and charged fire extinguisher handy, and do not forget to disconnect the vehicle's battery before you begin. What You'll Need It's important to use the correct tools for the job. Using the wrong tool, or using the right in the wrong way, may cause sparking. So make sure you've got correct tools before you start. • The service manual for your vehicle year, make, and model. • A dozen or so clean, dry shop rags to catch excess fuel. • Screwdriver or other tool as required to remove the hose clamps. • Pair of regular pliers. • Standard razor knife with blade-locking capability. • Fuel filter for you vehicle's make and model. Don't worry if you if you can't figure out the diameter of the fuel line, because the auto parts store can look it up. You must always replace the fuel filter on your vehicle if you will be changing the fuel hose.

Remove the Old Fuel Line Once you have all your tools and new parts at the ready, you can begin the process of replacing your fuel hose. 1. Locate the fuse box and remove the fuel pump fuse. 2. Start the engine and run it until it stops. 3. Remove the fuel filter and trace the fuel line to the transfer unit. 4. Remove the air cleaner if you are changing the hose leading from the fuel filter to the carburetor. 5. Put rags under the end of the hose where the gasoline will come out. 6. Loosen the metal hose clamps just until the clamp slides back over the bump that is close to the end of the line. 7. Place a rag over the end of the hose as you remove it from the filter. 8. If the hose sticks and is difficult to remove, use the pliers to grip and turn the hose. 9. If the hose still does not come away easily, use the razor knife to split the hose along the direction of the line. 10. Have the shop rags ready, because the fuel in the line will begin to drain once the hose has been removed. 11. Remove the fuel line from the steel tube at the fuel block. Twist it a bit if it is stuck. 12. After you remove the hose, clean off any dirt, hardened rubber, fuel, or other contaminants from the steel tube. 13. Place the old hose on your work bench to measure the new hose, adding an extra two inches. Attach the New Fuel Hose Now that you've got the old hose removed, here's the steps you'll need to take: 1. Place the still-loose clamps over the new fuel hose. 2. Be sure the clamp screws face the correct direction for easy tightening. 3. Check the new fuel filter to be sure it faces the correct fuel-flow direction. 4. Place the hose ends on the steel tube and at the new fuel filter. 5. Check the new fuel line for fit. If there are any kinks in the hose, remove the hose and trim a bit from the ends. 6. Replace the clamps in the correct position and tighten the screws to hold them firmly in place. 7. Reattach the hose to the new fuel filter, and then tighten the clamp. 8. Reattach the vehicle's battery cables. 9. Dispose of gasoline soaked rags, the old fuel line, and any contaminated items properly. That's it! You've just replaced your fuel line. May you have excellent gas mileage, perfect performance, and a great ride! How To Check Tire Pressure Back in the days of full-service gas stations, checking the tires was part of the deal. Today, as many motorists pump their own gas, and as even full-service does not include a tire pressure check, it is important for drivers themselves to be aware of their tire conditions and pressure.

2004-2008 Chevrolet Malibu Service & Repair Manual

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