2004 Chevrolet Malibu Technical Service Bulletins

494 technical service bulletins (TSBs) are on record for the 2004 Chevrolet Malibu. TSBs are notes manufacturers send to dealers about repair procedures for issues seen in the field. They are not recalls and do not by themselves mean a vehicle has a fault.

• 10032206Oct 1, 2010Transmission and drivetrain, Exterior lighting, Vehicle speed control. Chevrolet/pontiac/saturn: intermittently brake lights (stop lamps) do not function correctly, extended travel to shift out of park, cruise control inoperative, dtcs c0161/c0277 set (perform repair as outlined). *pe updated 5/11/11.
• 10025672Jun 1, 2010Steering. Loss of power steering assist, power steering warning message displayed in dic, ipc/radio displays erratic, dtc c0900, b1325 set (replace ignition coil/module assembly and add ground strap). Vehicles with 3.5l engine. *pe updated 3/25/11.
• 10019478Jun 1, 2010Steering. Normal operating characteristics of electric power steering (eps) system during extended lock-to-lock (maximum steering wheel rotation) usage. *tt updated 3/30/11.
• 10030685Apr 1, 2009Fuel system, Engine cooling. Saturn/pontiac/chevrolet: the fuel gauge does not rise above the 3/4 mark after a fill up or the fuel gauge appears stuck. An illumination of the check engine light. On rare occasions, the fuel gauge does not read the correct level which may result in a no start condition due to a low fuel level.
• 10028285Dec 1, 2008Brakes. Chevrolet: unable to relearn the brake pedal position (bpp) sensor.
• 10027804Nov 1, 2008Equipment, Electrical system. General motors corp: special coverage adjustment; analog onstar deactivation. *pe updated 2/17/09.
• 10026805Sep 1, 2008Equipment. Buick chevrolet gmc service campaign: see document search button for owner letter. Special coverage adjustment-analog onstar deactivation. Csc letter was received.
• 10026163Jul 1, 2008Brakes. Gmc: unable to relearn the brake pedal position (bpp) sensor. Have difficulty performing the brake pedal position (bpp) relearn. Models chevrolets, pontiacs and saturns.
• 10026586Jun 1, 2008Equipment. Buick cadillac chevrolet gmc hummer oldsmobile pontiac saab saturn service campaign: see document search button for owner letter. Special coverage adjustment-analog onstar deactivation. Fcc ruled in 2002 wireless carriers would no longer re required to support analog wireless network starting in 2008. *pe csc letter was received. Updated 12/1/08.
• 10020816Mar 1, 2008Steering. Clunk, knock or rattle noise from front of vehicle while driving or turning over bumps at low speeds. *kb (diagnose noise - lubricate inner and outer steering shaft, reposition I-shaft, add foam to radiator surge tank mounting bracket and/or replace steering gear, if necessary). Updated 5/15/08.
• 10020916Feb 1, 2008Electrical system. Repeated park lps fuse open. *kb (additional information) updated 4/1/08.
• 10023171Oct 31, 2007Brakes. Abs pump running when not needed.
• 10023942Oct 1, 2007Transmission and drivetrain. Information on 4t40-e (mn4) and 4t45-e (mn5) front wheel drive automatic transmission valve body reconditioning, dtc p0741, p0742, p0751, p0752, p0756, p0757, p1811, harsh shifts, slips, no drive, no reverse.
• 10019834Sep 1, 2007Exterior lighting. Front park/turn/drl or rear stop/turn/tail lamp inoperative. (replace bulb and inspect socket) *tt updated. *kb updated 11/02/07
• 10021412Mar 1, 2007Brakes. Incorrect outer backing plate. Outer backing plate has short centre protusion. Outer backing plate should have tall center protrusion.
• 10021074Mar 1, 2007Other or unknown. Parts update - timing chain tensioner design change.
• 10020923Jan 30, 2007Engine cooling. Low oil pressure - inspect oil filter for damage. *kb updated 10/18/07.
• 10014974Jan 1, 2007Steering. Increased steering effort. *tt update. *tt updated 03-07-07.
• 10020726Nov 1, 2006Engine cooling. L61 front end wobble or vibration on acceleration. (refer to si procedure for powertrain mount balance-lower mount).
• 10020690Nov 1, 2006Fuel system. Special coverage adjustment-fuel tank cap.
• 10020735Sep 1, 2006Electrical system. Instrument panel cluster (ipc) backlighting inoperative during daylight hours.
• 10020217Aug 18, 2006Steering. Loss of power steering assist at high engine rpm. *tt updated 08-15-07. *kb updated on 10/03/07.
• 10020838Jun 1, 2006Engine cooling. Engine malfunction indicator lamp (mil)/service engine soon (ses) lamp illuminated with dtc p0171.
• 10011242May 1, 2006Latches, locks and linkages. Rear liftgate may relatch after opening with power release.
• 10019450Mar 15, 2006Electrical system. Ses light during low speed driving after a hot soak with a p0171 dtc.
• 10019233Feb 22, 2006Electrical system. Starter stays engaged after engine starts.
• 10019188Feb 17, 2006Exterior lighting. Headlamp replacement due to moisture - service vme.
• 10019186Feb 16, 2006Exterior lighting, Interior lighting. Ipc, interior lights and/or headlamps flicker. *ak fb2
• 10018915Jan 25, 2006Electrical system. Hesitation on acceleration after internal engine repairs - check injector harness orientation.
• 10018600Jan 7, 2006Engine cooling. No start after engine harness replacement (non-abs).
• 10018552Jan 6, 2006Electrical system. Battery draw additional info.
• 10018551Jan 6, 2006Electrical system. (retained accessory power) rap deactivates from drivers door only.
• 10018550Jan 6, 2006Brakes. Service vme - the parts catalog lists incorrect front brake pads.
• 10018531Jan 5, 2006Steering. Intermittent steering wheel dither after front end alignment was performed.
• 10019020Nov 1, 2005Suspension. Revised rear shock absorber replacement and fastener tightening specifications.
• 10018699Nov 1, 2005Seats. Addition of front seat track synchronization procedure.
• 10017222Oct 28, 2005Exterior lighting. Backlighting is inoperative during daylight conditions (headlight switch turned on manually).
• 10017136Oct 26, 2005Visibility (wipers, defrost, mirrors). Power mirrors working opposite of the switch direction.
• 10017096Oct 24, 2005Transmission and drivetrain. Vehicle will not move in either direction. Transmission may show over full. P90 4t40e 4t45e no movement drive or reverse. Converter may be empty of fluid.
• 10017086Oct 24, 2005Transmission and drivetrain. 4t40e or 4t45e will not shift no diagnostic trouble codes.
• 10017032Oct 21, 2005Engine cooling. Service engine soon (ses) light and severe engine misfire on cylinders 1 and 4 or cylinders 2 and 3. *tt updated 08-15-07.
• 10017009Oct 20, 2005Engine cooling. Crank no start (lx9) only.
• 10017006Oct 20, 2005Exterior lighting. Backlighting is inop during daylight conditions (headlight switch turned on manually)
• 10016549Sep 21, 2005Electrical system. Repeated park lps fuse open (additional information).
• 10016547Sep 21, 2005Electrical system. Intermittent long crank but will not start or intermittent no crank.
• 10016520Sep 20, 2005Vehicle speed control. Supplement to 05-06-01-003a - wrong throttle gasket part number.
• 10018126Sep 1, 2005Engine cooling. Oil life system reset procedures - cars. Gm tech link.
• 10017853Sep 1, 2005Body and structure. Sunshade mirror cover breaks off at the hinge pins.
• 10017844Sep 1, 2005Electrical system. Addition of instrument cluster bulb replacement procedure.
• 10015018Sep 1, 2005Equipment. Information on upgrading certain onstar generation 5 analog/digital-ready systems to onstar generation 6 dual-mode (analog/digital).

← All problems reported for the 2004 Chevrolet Malibu