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2005 Chevrolet Malibu Technical Service Bulletins (TSBs)

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TSB Date Problem Area TSB Text
12/21/17 NHTSA ID: 10126014
TSB ID: GCUS-9-3664

16188 special coverage. some vehicles may have a condition where increased resistance in the body control module (bcm) connection system can result in voltage fluctuations or intermittency in the brake apply sensor (bas) circuit that can ca
02/01/17 NHTSA ID: 10090080
TSB ID: 14327

14327 - special coverage. some vehicles may have been built without a steering gear umbrella seal. without the seal, water and dirt may enter the system and could cause the rack and pinion parts to corrode. if corrosion exists, the ?feel?
10/20/16 NHTSA ID: 10083080
TSB ID: PIP4786C

This preliminary information communication provides information to the technician about vehicles that may have low oil pressure message. technician may also find a diagnostic trouble code p0521 in the engine control module. technician shoul
10/19/16 NHTSA ID: 10082869
TSB ID: PI1394A

This informational bulletin provides additional information on how to install pistons and suggest what tools to use.
10/18/16 NHTSA ID: 10082823
TSB ID: 030604017I

This informational bulletin explains the use of diesel fuel additives in an engine, are not required unless the customer desires additives to prevent fuel concerns depending on fuel or temperature related conditions.
10/18/16 NHTSA ID: 10082820
TSB ID: 000601026I

This informational bulletins provides information on the intake manifold inspection/replacement after servere internal engine damage.
NHTSA's feed only includes summaries. For the full text of TSBs:

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10/18/16 NHTSA ID: 10082814
TSB ID: 000601012F

This informational bulletin provides information to gm dealers on the correct cleaning methods when cleaning engine gasket sealing surfaces.
10/18/16 NHTSA ID: 10082822
TSB ID: 030603004R

This informational bulletin provides information on how to test a battery and what is needed to warranty a battery.
03/31/16 NHTSA ID: 10061096
TSB ID: SB-0000188787-A

Summary to be provided on a future date.
02/03/16 NHTSA ID: 10059101
TSB ID: SB-15-08-45-001

Pontiac/saturn/chevrolet: some vehicles are experiencing multiple issues/symptoms caused by body harness hard contact against floor edge panel under left rear seat cushion. model 2004-12 malibu, malibu maxx, 2007-09 aura, 2005-10 g6.
07/17/15 NHTSA ID: 10057960
TSB ID: 14327

This tsb comntains an owner notification letter. general motors 2004-2005 chevrolet malibu, malibu maxx , pontiac g6: bulletin coverage regarding loss of steering due to water intrusion vehicles may have been built without a steering
08/30/10 NHTSA ID: 10033624
TSB ID: SB-10183

Saturn\pontiac\chevrolet service campaign: see document search button for owner letter. special coverage adjustment-power steering assist. some vehicles equipped with electric power steering may experience a loss of power steering assist
03/01/10 NHTSA ID: 10032292
TSB ID: SB-09-02-35-006

Chevrolet/pontiac/saturn: steering column tilt wheel release lever inoperative/broken (replace tilt wheel release lever kit and/or release lever retainer (tilt teeth)).
02/17/10 NHTSA ID: 10032204
TSB ID: SB-07-06-04-023A

Chevrolet/saturn: difficulty filling fuel tank, mil/ses light illuminated dtc p0446 - evaporative emissions (evap) vent system performance (inspect/clean evap canister vent valve solenoid and install screen).
11/10/09 NHTSA ID: 10030685
TSB ID: SB-09-06-04-007A

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
03/20/09 NHTSA ID: 10028285
TSB ID: PIC--4330B

Chevrolet: unable to relearn the brake pedal position (bpp) sensor.
10/03/08 NHTSA ID: 10026163
TSB ID: PIC-4330A

Gmc: unable to relearn the brake pedal position (bpp) sensor. have difficulty performing the brake pedal position (bpp) relearn. models chevrolets, pontiacs and saturns.
08/28/08 NHTSA ID: 10025672
TSB ID: 08-02-32-005

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. updated 3/25
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01/18/08 NHTSA ID: 10023644
TSB ID: 07126

Chevrolet\pontiac service campaign: see document search button for owner letter. special coverage adjustment - loss of power steering assist. *nj
03/07/07 NHTSA ID: 10021117
TSB ID: 060601014

L36, l67, l26, l32, la1, lx9, mn7, m15. ticking or knocking type noise coming from the engine or transmission area.
01/23/07 NHTSA ID: 10020816
TSB ID: 060232007

Clunk, knock or rattle noise from front of vehicle while driving or turning over bumps at low speeds. (diagnose noise - lubricate inner and outer steering shaft, reposition i-shaft, add foam to radiator surge tank mounting bracket
03/16/06 NHTSA ID: 10019478
TSB ID: 060232002

Normal operating characteristics of electric power steering (eps) system during extended lock-to-lock (maximum steering wheel rotation) usage. updated 3/30/11.
12/02/05 NHTSA ID: 10017817
TSB ID: 050601005A

Whistle type noise coming from engine.
09/14/05 NHTSA ID: 10016502
TSB ID: 05548A

Program bulletin (customer satisfaction program)-engine harmonic balancer not seated. *sc
NHTSA's feed only includes summaries. For the full text of TSBs:

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05/13/05 NHTSA ID: 10014975
TSB ID: 050235001

Steering column tilt/telescope wheel lever available for service use.
04/07/05 NHTSA ID: 10013093
TSB ID: 08232004

Instrument panel fuel gauge will only go to 7/8ths full even with a full tank of fuel or that can only add 12 or 13 gallons of fuel to tank after the low fuel light comes on.
03/14/05 NHTSA ID: 10012739
TSB ID: 040849025

Fuel gauge does not read full when fuel tank is full, service engine soon (ses) light on, diagnostic trouble code (dtc) p0455.
12/28/04 NHTSA ID: 10011064
TSB ID: 040306001

Vehicle leads/pulls characteristics and diagnosis.
11/04/04 NHTSA ID: 10010205
TSB ID: 3088A

Fuel gauge not reading full after a customer fill. *sc
11/03/16 Electrical and Air Conditioning NHTSA ID: 10083898
TSB ID: PIT5485B

This preliminary information communication advises the technician if unable to place an onstar call in the ignition on mode after the onstar canada upgrade, to contact the gm technical assistance center onstar group for further assistance.
NHTSA's feed only includes summaries. For the full text of TSBs:

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11/03/16 Electrical and Air Conditioning NHTSA ID: 10083884
TSB ID: PIT5389A

This preliminary information communication advises the technician on the steps for diagnosing the concern. the vehicle may be unable to connect to onstar using the white, blue or red onstar buttons.
11/03/16 Electrical and Air Conditioning NHTSA ID: 10083900
TSB ID: PIT5485A

This preliminary information communication advises the technician, if unable to place an onstar call in the ignition on mode after the onstar canada upgrade to contact the gm technical assistance center onstar group for further assistance.
10/25/16 Electrical and Air Conditioning NHTSA ID: 10083489
TSB ID: PIC5050A

This preliminary information communication advises the technician the steps on repairing the concern. a customer may identify a concern of unable to reactivate a vehicle's onstar that has been previously disabled by onstar. dealer is to ca
10/25/16 Electrical and Air Conditioning NHTSA ID: 10083509
TSB ID: PIC5088F

This preliminary information communication advises the technician on the steps to diagnose and repair the concern. the vehicle's xm radio only has xm preveiw channels.
10/25/16 Electrical and Air Conditioning NHTSA ID: 10083484
TSB ID: PIC4935E

This preliminary information communication provides information to help the dealership technicians perform a parasitic drain test for the onstar module. when performing battery parasitic drain test, there may be some confusion as to what th
10/21/16 Electrical and Air Conditioning NHTSA ID: 10083241
TSB ID: PIT5074J

This preliminary information communication provides information to the technician about the use of j-35616-64b terminal test probe, replacement terminals, and terminated leads. the j-35616-64b is the latest test probe released for checking
NHTSA's feed only includes summaries. For the full text of TSBs:

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10/17/16 Electrical and Air Conditioning NHTSA ID: 10082506
TSB ID: 16NA260

This technical bulletin provides a procedure to reprogram the media disc player with the latest calibrations to correct a condition of the rear entertainment system not operating as intended in colder ambient temperature areas due to calibr
09/26/16 Electrical and Air Conditioning NHTSA ID: 10081022
TSB ID: PIP5094A

This preliminary information communication advises the technician that ,when testing any circuit for open or resistance, it is imperative that all related terminal pin fit and tension be checked when the test steps require disconnection of
08/16/16 Electrical and Air Conditioning NHTSA ID: 10078735
TSB ID: PIC-4935-E

This preliminary information communication provides information to help the dealership technicians perform a parasitic drain test for the onstar module. when performing battery parasitic drain test, there may be some confusion as to what th
08/16/16 Electrical and Air Conditioning NHTSA ID: 10078734
TSB ID: PIC-5050-A

This preliminary information communication advises the technician the steps on repairing the concern. a customer may identify a concern of unable to reactivate a vehicle's onstar that has been previously disabled by onstar. dealer is to ca
03/31/16 Electrical and Air Conditioning NHTSA ID: 10061213
TSB ID: SB-0000191931-A

Summary to be provided on a future date.
02/17/10 Electrical and Air Conditioning NHTSA ID: 10032206
TSB ID: SB-08-05-22-009A

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). updated 5/11/11.
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02/09/09 Electrical and Air Conditioning NHTSA ID: 10027804
TSB ID: 08089-B

General motors corp: special coverage adjustment; analog onstar deactivation. updated 2/17/09.
11/14/08 Electrical and Air Conditioning NHTSA ID: 10026586
TSB ID: 08-089

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 r
12/10/07 Electrical and Air Conditioning NHTSA ID: 10023415
TSB ID: PIC-4658

Adjustable pedals will not adjust inoperative. *nj updated 3/13/09. updated 8/1/11.
01/04/07 Electrical and Air Conditioning NHTSA ID: 10020735
TSB ID: 060849016

Instrument panel cluster (ipc) backlighting inoperative during daylight hours.
05/05/06 Electrical and Air Conditioning NHTSA ID: 10019834
TSB ID: 060842004

Front park/turn/drl or rear stop/turn/tail lamp inoperative. (replace bulb and inspect socket) updated. updated 11/02/07 *nj
01/11/05 Electrical and Air Conditioning NHTSA ID: 10011220
TSB ID: 0408110004

Rear sunshade comes unhooked from rear sunroof trim. this bulletin replaces previous bulletin number 04-08-110-004.
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12/01/04 Electrical and Air Conditioning NHTSA ID: 10010552
TSB ID: 3170

Service engine soon light on and or various electrical concerns. *eh updated 1/29/08. *nj
03/16/17 Other NHTSA ID: 10095317
TSB ID: PIT3271G

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
11/23/16 Other NHTSA ID: 10084683
TSB ID: PI0373A

This preliminary informational bulletin provides a procedure for relearning the power folding mirriors and road testin to verify they correct a condtion of the power folding mirriors glass shakes, flutters at normal driving conditions.
10/25/16 Other NHTSA ID: 10083512
TSB ID: PIC5260A

This preliminary information communication advises the technician the steps on diagnosing the concern. vehicle's sunroof operation intermittent, bind, noise, auto-reverse, and/or water leaks.
08/10/16 Other NHTSA ID: 10078604
TSB ID: PIC-5260-A

This preliminary information communication advises the technician the steps on diagnosing the concern. vehicle's sunroof operation intermittent, bind, noise, auto-reverse, and/or water leaks.
05/25/11 Other NHTSA ID: 10037570
TSB ID: PIT-3749D

Gm: on some truck models there is some frame corrosion. updated on 5/2/2012.
NHTSA's feed only includes summaries. For the full text of TSBs:

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05/11/11 Other NHTSA ID: 10037184
TSB ID: 05-09-40-002E

Gm: service bulletin explaining when the safety belts are supposed to lock. updated 12/6/11.
12/19/08 Other NHTSA ID: 10026805
TSB ID: 08-089B

Buick\chevrolet\gmc service campaign: see document search button for owner letter. special coverage adjustment-analog onstar deactivation. csc letter was received.
01/25/06 Other NHTSA ID: 10018948
TSB ID: 05094

Sun visor mirror cover nonnfunctional/breakage. *ak
12/05/05 Other NHTSA ID: 10017853
TSB ID: 0508110005

Sunshade mirror cover breaks off at the hinge pins.
09/13/05 Other NHTSA ID: 10016455
TSB ID: 708

Loose shift knob. *sc
05/13/05 Other NHTSA ID: 10015018
TSB ID: 050846006A

Information on upgrading certain onstar generation 5 analog/digital-ready systems to onstar generation 6 dual-mode (analog/digital).
NHTSA's feed only includes summaries. For the full text of TSBs:

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04/21/05 Other NHTSA ID: 10013580
TSB ID: 01172005

Rear door does not stay closed in cold weather.
04/19/05 Other NHTSA ID: 10013448
TSB ID: 050850002

Front set head restraint uncomfortable, positioned too far forward.
04/19/05 Other NHTSA ID: 10013450
TSB ID: 050853001

Front seat rear trim panels falling off.

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Chevrolet Malibu TSBs (Technical Service Bulletins)

Some things are often misunderstood about recalls and technical service bulletins (TSBs). Plus a disclaimer.

  1. Recalls do not have to be issued only because something is prone to failure. NHTSA (a government agency) can only require a recall if a failure will affect safety, emissions, fuel economy, or compliance with some other regulation or law. Manufacturers can voluntarily recall cars for problems that do not affect these, though.
  2. Recalls often apply to only some cars of a specific model year, rather than all of them. You should receive a letter from the manufacturer if your car has been recalled. You can also check with the dealer, which will know which (if any) recalls pertain to your car.
  3. The primary purpose of TSBs is to inform dealers about known problems with a car and how to fix them. They are not the same as recalls. As with recalls, TSBs often only apply to some cars, not the entire model year.
  4. Dealers often will not provide a preventive repair just because a problem described in a TSB might happen to your car. They'll usually want to observe symptoms that the problem is already affecting your car.
  5. Even if there are symptoms, a manufacturer doesn't have to pick up the cost of a TSB repair if the car is out of warranty, though sometimes they do.

We provide the text of recalls and TSBs as provided by NHTSA. There can be errors in the text. If you sign up for notifications in My Garage, we will try to get these to do, but for various reasons (some beyond our control) cannot guarantee you will receive them. When in doubt about a recall or TSB, contact the dealer.