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2004 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┬┐
10/19/16 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: 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: 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.
03/31/16 NHTSA ID: 10061096
TSB ID: SB-0000188787-A

Summary to be provided on a future date.
NHTSA's feed only includes summaries. For the full text of TSBs:

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

Steering column tilt/telescope wheel lever available for service use.
04/29/05 NHTSA ID: 10014343
TSB ID: 0804

Malibu fuel tank cap for the 2004 malibu and malibu maxx is not interchangeable. *nm
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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.
02/10/05 NHTSA ID: 10012081
TSB ID: 04050

Customer satisfaction program 04050 power steering assist. product field action announcement. updated 2/7/12.
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
11/04/04 NHTSA ID: 10010228
TSB ID: 3092

Service engine light soon and evap codes setting intermittently. (2005 chevrolet malibu maxx) *sc
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10/14/04 NHTSA ID: 10009644
TSB ID: 3026

Brake pedal position sensor learn procedure. service vme.
09/17/04 NHTSA ID: 10009202
TSB ID: 04072004

Rattle or clunk steering column noise coming from the left lower instrument panel, or foot well area.
08/24/04 NHTSA ID: 10008849
TSB ID: 3000

Vehicle leads or pulls to the left.
12/01/03 NHTSA ID: 10004296
TSB ID: 030232005

Parts restriction program for electric power steering (eps) system components. update.
02/14/05 Transmission and Drivetrain NHTSA ID: 10012116
TSB ID: 040730021

Growl or howl type noise from transmission/engine compartment during light to moderate acceleration from a stop.
08/02/04 Transmission and Drivetrain NHTSA ID: 10008473
TSB ID: 040730027

Whistle/wind noise in passenger compartment of vehicle near shifter/floor console area.
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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.
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: 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
10/25/16 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: 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
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: 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
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
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
03/08/05 Electrical and Air Conditioning NHTSA ID: 10012630
TSB ID: 040864007

Proper removal of power window switch to avoid damage to door trim pad or power window switch remove trim pad first. *eh
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03/07/05 Electrical and Air Conditioning NHTSA ID: 10012531
TSB ID: 040844011

Tie strap removal during video display replacement.
03/07/05 Electrical and Air Conditioning NHTSA ID: 10012530
TSB ID: 040843006

Information to avoid pinching windshield washer hose when servicing battery or underhood electrical center.
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.
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
11/04/04 Electrical and Air Conditioning NHTSA ID: 10010132
TSB ID: 3106

Xm radio was working prior to july 26, 2004 and it is inoperative now. *jb
11/04/04 Electrical and Air Conditioning NHTSA ID: 10010219
TSB ID: 3084

Low coolant level light on. *sc
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07/12/04 Electrical and Air Conditioning NHTSA ID: 10007785
TSB ID: 02137

Repeat horn failures.
06/16/04 Electrical and Air Conditioning NHTSA ID: 10007379
TSB ID: 030306

Dvd player service.
06/04/04 Electrical and Air Conditioning NHTSA ID: 10007248
TSB ID: 01662

Xm error on a radio display.
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
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.
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.
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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
09/02/05 Other NHTSA ID: 10016193
TSB ID: 609

Malibu maxx rear sunshade. *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).
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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04/13/05 Other NHTSA ID: 10013256
TSB ID: 11172003

Gm training website. *eh
11/04/04 Other NHTSA ID: 10010211
TSB ID: 3080

Rear lift gate relatching after opening. (to include chevrolet malibu maxx) *sc
11/04/04 Other NHTSA ID: 10010227
TSB ID: 3093

Vertical grease streaks on the front door glass. *sc
11/03/04 Other NHTSA ID: 10009995
TSB ID: 3133

Remote keyless entry inoperative. *tc
11/03/04 Other NHTSA ID: 10009993
TSB ID: 3093

Vertical grease on the front door glass. *tc
11/02/04 Other NHTSA ID: 10009929
TSB ID: 3157

Phantom remote start intermittently. *tc
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08/02/04 Other NHTSA ID: 10008478
TSB ID: 040864011

Door handle sticks out, door will not latch. *mj
07/14/04 Other NHTSA ID: 10007872
TSB ID: 04027

Product safety recall driver's safety belt anchorage. *mj
03/04/04 Other NHTSA ID: 10005564
TSB ID: 030848005A

Compass zone adjustment and calibration procedure during pre-delivery inspection. various models including 2002-2004 light duty trucks. update to include 2005 buick allure.

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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.

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