Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2004MALIBU V6-3.5L VIN 8REPAIR AND DIAGNOSISPOWER AND GROUND DISTRIBUTIONFUSE BLOCKSERVICE AND REPAIR
2004 Chevrolet Malibu V6-3.5L VIN 8
Fuse Block: Service and Repair
2004 Chevrolet Malibu V6-3.5L VIN 8SECTION Service and Repair
UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT
REMOVAL PROCEDURE

1. Remove the battery.

2. Remove the fasteners retaining the positive battery cable leads to the underhood electrical center, then reposition the cable lead away from the electrical center.
3. Remove the electrical center cover.
4. Remove all of the fuses and the relays.

5. Use a flat-bladed tool to disengage the 4 tabs that secure the electrical center to the battery tray.

6. Use a flat-bladed tool to remove the connector cover from the electrical center.

7. Loosen the 4 bolts across the top of the electrical center.

8. Use a flat-bladed tool to remove the locking pins from the body harness connector.
9. Disconnect the body harness connector.
10. Disconnect the remaining wiring harness connectors from the junction block.
INSTALLATION PROCEDURE

1. With the electrical center turned upside down, install the electrical center harness connectors into the electrical center.

2. Install the locking pin to the power supply connector
NOTE: Refer to Fastener Notice in Cautions in Notices.
3. Install the bolts retaining the engine, I/P, and forward lamp wiring harness connectors to the junction block.
Tighten
Tighten the electrical center junction block bolts to 7 N.m (62 lb in).

4. Install the electrical center connector cover.
5. Turn the electrical center right side up.
6. Install the electrical center to the battery tray by pushing the electrical center into the retainer tab.
7. Install all of the fuses and the relays.
8. Install the positive battery cable lead to the stud on underhood electrical center, then install the positive battery cable lead retaining nut.
Tighten
Tighten the positive battery cable lead retaining nut to 10 N.m (89 lb in).
9. Install the electrical center cover.
10. Install the battery.
REMOVAL PROCEDURE
Left Side Of Core Support:
1. Remove the battery.
2. Remove the fasteners retaining the positive battery cable leads to the underhood electrical center, then reposition the cable lead away from the electrical center.
3. Remove the electrical center cover.
4. Remove all of the fuses and the relays.
5. Use a flat-bladed tool to disengage the 4 tabs that secure the electrical center to the battery tray.
6. Use a flat-bladed tool to remove the connector cover from the electrical center.
7. Loosen the 4 bolts across the top of the electrical center.
8. Use a flat-bladed tool to remove the locking pins from the body harness connector.
9. Disconnect the body harness connector.
10. Disconnect the remaining wiring harness connectors from the junction block.
INSTALLATION PROCEDURE
1. With the electrical center turned upside down, install the electrical center harness connectors into the electrical center.
2. Install the locking pin to the power supply connector
NOTE: Refer to Fastener Notice in Cautions in Notices.
3. Install the bolts retaining the engine, I/P, and forward lamp wiring harness connectors to the junction block.
Tighten
Tighten the electrical center junction block bolts to 7 N.m (62 lb in).
4. Install the electrical center connector cover.
5. Turn the electrical center right side up.
6. Install the electrical center to the battery tray by pushing the electrical center into the retainer tab.
7. Install all of the fuses and the relays.
8. Install the positive battery cable lead to the stud on underhood electrical center, then install the positive battery cable lead retaining nut.
Tighten
Tighten the positive battery cable lead retaining nut to 10 N.m (89 lb in).
9. Install the electrical center cover.
10. Install the battery.
RENDER: 1.0x
NO RELATED
Recommended Tools & Savings
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
Affiliate disclosure: We may earn a commission at no extra cost to you.
When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.