ChevroletMalibu2004Overview/chevrolet/malibu/2004/base/

2004 Chevrolet Malibu

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 Malibu.

Body PASSENGER CAR

The 2004 Chevrolet Malibu is a passenger car utilizing 5 quarts of 5W-30 API engine oil. This model year represents the highest point of owner complaints in the vehicle's 1997-2025 history, totaling 1,697 reports compared to a low of 7 in 2025. This reliability record is further defined by 10 recalls and a primary concentration of complaints regarding the steering.

Model year202520242023202220212020201920182004

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5 qtOEM · verified
Engine oil type5W-30 APIOEM · verified
Lug nut torque100 ft-lbsOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 75 · 525 CCA battery, OE oil filter 12731175. Note the factory front wiper blades is now discontinued — plan on a superseded or quality aftermarket equivalent, which the part pages below list where known. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 75 · 525 CCAOEM · verified
Tire sizeP205/65R15OEM · verified
Wheel / rim6-JJ inOEM · verified

OE service part numbers OEM · verified

Engine oil filter12731175 alt 25322835
Engine air filter19166106
Spark plug12681664 alt 12681661
Battery88866120 alt 88865311
Front wiper blades22675854 discontinued · alt 22675853
Serpentine belt12591059 alt 12634321
Thermostat12622410 alt 24507563

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length188.2 in
Overall width70.1 in
Overall height57.5 in
Wheelbase106.3 in
Curb weight3175 lb
Track (front / rear)59.8 / 59.1 in
Weight distribution (front / rear)63/37

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the Malibu of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

7.8–8.3 sec0–60 mph (tested)quickest 7.80 sec — 2004 LT V6
YearTrim / engine0–60¼ mileHPDrivetrain
2004LT V6 3.5L V67.80 sec15.64 sec200 hpFWD
2004Maxx LT V6 3.5L V67.80 sec16.10 sec200 hpFWD
2004LT V6 3.5L V67.90 sec16.10 sec200 hpFWD
2004LT V6 3.5L V68.00 sec16.10 sec200 hpFWD
2004Maxx LT V6 3.5L V68.10 sec16.30 sec200 hpFWD
2004Maxx LT V6 3.5L V68.30 sec16.02 sec200 hpFWD
2005Maxx LT V6 3.5L V68.30 sec16.00 sec200 hpFWD
2006Maxx SS V6 3.9L V66.90 sec15.30 sec240 hpFWD

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5 qt of 5W-30 API engine oil, DOT 3 brake fluid. Torque lug nuts to 100 ft-lbs, the oil drain plug to 18.0 ft-lbs. The firing order is 1-2-3-4-5-6. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Automatic Transmission FluidATF
Automatic Transmission Fluid Capacity7.4
Brake FluidDOT 3
Engine CoolantDEX-COOL OR EQUIVALENT
Engine Oil5W-30 · API
Engine Oil Capacity5 qt
Engine Oil5W-30 · API · SAE 5W · SYNTHETIC · SAE OW
Engine Oil Capacity5.0 qt

Engine torques

Intake Manifold to Engine Bolts7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts10 ft-lbs
Engine Oil Pan Drain Plug18.0 ft-lbs
Engine Oil Pan Drain Plug18.0 ft-lbs
Engine Valve Cover Bolts7.4 ft-lbs

Chassis torques

Lug Nuts100 ft-lbs
Front Wheel Hub159 ft-lbs

Ignition

Cylinder Firing Order1-3-4-2
Cylinder Firing Order1-2-3-4-5-6
Spark Plug ManufacturerAC Delco
Spark Plug TypeAC 41-981
Spark Plug Gap0.042 in
Spark Plug Torque15.0 ft-lbs
Spark Plug ManufacturerAC Delco
Spark Plug TypeAC 41-101

Battery & A/C

RefrigerantR134a
Refrigerant CapacityExcept Malibu Classic, 1.10; Malibu Classic, 1.35. lbs
Oil GroupPAG
Oil Type46
Oil Capacity5.00 oz
Standard BCI Group Number75
Standard BCI Cranking Performance525 cca
Standard BCI Group Number75

Service checks

Pressure Test15, Pressure should not exceed 20 psi.
Radiator Cap Pressure Relief15 psi
Thermostat Opening Temperature185-205 °F
Fuel Pump Pressure Minimum60.0 psi
Key ON Engine OFF (KOEO)50-60
RPM40-57 @ Idle rpm
Key ON Engine OFF (KOEO)50-60
Injector Primary Resistance11-14 @ 50-95 degreesF ohms

Brakes

Torque Caliper to Bracket85 ft-lbs
Torque to Knuckle100 ft-lbs
Torque Caliper to Bracket23 ft-lbs
Torque to Knuckle85 ft-lbs
Torque Caliper to Bracket26 ft-lbs
Torque to Knuckle85 ft-lbs
Minimum Pad ThicknessFront: 0.030; Rear: 0.030 specification
Rotor Max Parallel Variation0.001 in

Multi-step torque procedures OEM · verified

Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
174 ft. lbs., step 2: 7574 ft. lbs
Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
152 ft. lbs., step 2: 7052 ft. lbs
Cylinder Head — tightening sequence 2 stages
122 ft. lbs.22 ft. lbs
2155 degrees155 degrees
126
Cylinder Head — tightening sequence 2 stages
144 ft. lbs.44 ft. lbs
295
Intake Manifold to Engine Bolts — tightening sequence 1 stages
15 ft. lbs., step 2: bolts 1-4, 9.6 ft. lbs., step 3: bolts 5-8, 18 ft. lbs., upper 185 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the spark plugs every 100,000 mi; coolant at 150,000 mi. The big-interval services (at 150,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 25,000 miExhaust System (Complete) (inspect) · Fuel System (inspect)
Every 50,000 miEngine Air Filter Element (replace)
Every 100,000 miSpark Plug Wires (inspect) · Spark Plugs (replace)
At 150,000 miAccessory Drive Belt (inspect) · Engine Coolant System (drain, flush & refill)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2004 Chevrolet Malibu represents a significant anomaly in the model's long-term record. While complaints from 1997 through 2003 fluctuated between 514 and 979 annually, the 2004 model year surged to 1,697 complaints—nearly triple the 2003 figure and the second-highest level in the entire dataset. This spike coincided with the generation's peak recall activity (10 recalls) and elevated NHTSA investigations (4). The complaint trend then partially normalized in 2005–2008 before experiencing another surge in 2009, suggesting that the early Malibu generation (2004–2012) suffered from persistent quality issues rather than a single-year aberration. Within the 2004 data, steering complaints dominate overwhelmingly at 870 of 1,697 total complaints—accounting for over 51% of all reported issues. This concentration is unusual and indicates a specific structural flaw rather than diffuse problems. The 81 crash complaints and 15 fire complaints further underscore serious safety concerns. The 2004 Malibu sits at the epicenter of the generation's quality crisis. Given the highest complaint volume in the early dataset, the outsized steering failures, and the elevated recall/investigation counts, this is not a recommended model year for prospective buyers seeking reliability.

10
Open recalls
NHTSA campaigns
646
Service bulletins
Manufacturer communications
4
ODI investigations
Office of Defects Investigation
1,697
Owner complaints
81 involved a crash · 15 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★

Owner complaints filed with NHTSA, by component

All 1,697 complaints on record, top 8 components.

Steering870
Seats137
Electrical System112
Exterior Lighting69
Power Train42
Steering,Electrical System31
Service Brakes, Hydraulic23
Unknown Or Other18

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 9 campaigns on record for this vehicle.

14V252000Electrical System:WiringReported 14/05/2014

General Motors LLC (GM) is recalling certain model year 2004-2012 Chevrolet Malibu vehicles manufactured May 16, 2003, through October 11, 2012, 2004-2007 Malibu Maxx vehicles manufactured June 25, 2003, through April… Remedy: GM will notify owners, and dealers will attach the wiring harness to the BCM with a spacer, apply dielectric lubricant to both the BCM and harness connector and the BAS and…

14V153000Steering:Electric Power Assist SystemReported 31/03/2014

General Motors LLC (GM) is recalling certain model year 2004-2006 and 2008-2009 Chevrolet Malibu, 2004-2006 Malibu Maxx, 2009-2010 HHR (non-turbo), 2010 Cobalt, 2008-2009 Saturn Aura and 2004-2007 Ion, and 2005-2009… Remedy: GM will notify owners, and dealers will perform one of four bulletins. Parts are not currently available. GM expects to send an interim notification around May 28, 2014. When…

Technical service bulletins NHTSA · verified

Showing 5 of 646 bulletins on record with NHTSA.

BulletinDateComponentSummary
PIP5601C2025-07-18Unknown Or OtherThis PI communicates the requirement to provide a pico file to receive diagnostic…
PIP5358D2025-02-19Unknown Or OtherThis Preliminary Information communication provides information to the technician about…
PIP4723J2024-10-25Electrical SystemThis Preliminary Information communicates to the dealer the process for downloading or…
PIT5099H2024-09-12Unknown Or OtherThis Preliminary Information communication provides information to the technician about…
PIT5099H2024-09-12Unknown Or OtherThis Preliminary Information communication provides information to the technician about…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Malibu. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2004 Malibu take?

5 qt of 5W-30 API, per the factory manual.

Does the 2004 Malibu have open recalls?

NHTSA lists 10 recall campaign(s) for this model year. Check your specific vehicle by VIN.