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.
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HOMESERVICE MANUALSCHEVROLET2004MALIBU V6-3.5L VIN 8REPAIR AND DIAGNOSISPOWERTRAIN MANAGEMENTCOMPUTERS AND CONTROL SYSTEMSRELAYS AND MODULES - COMPUTERS AND CONTROL SYSTEMSBODY CONTROL MODULETECHNICAL SERVICE BULLETINSCUSTOMER INTERESTELECTRICAL - VARIOUS ELECTRICAL SYSTEMS MALFUNCTIONS
2004 Chevrolet Malibu V6-3.5L VIN 8
Electrical - Various Electrical Systems Malfunctions
2004 Chevrolet Malibu V6-3.5L VIN 8SECTION Electrical - Various Electrical Systems Malfunctions
TECHNICAL
Bulletin No.: 08-05-22-009C
Date: September 30, 2010
Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined)
Models:
2004-2008 Chevrolet Malibu, Malibu Maxx
2008 Chevrolet Malibu Classic
2008-2011 Chevrolet Malibu
2005-2010 Pontiac G6
2007-2009 Saturn AURA
Supercede:
This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes).
Condition
Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set.
Cause
The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59).
Correction
DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion.
1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM).
2. Locate the C2 or X2 connector on the BCM.
3. Unlatch the connector and disconnect the connector from the BCM.
4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion.
5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant.
6. Reinstall the right side front floor console side trim panel.
7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed.
- If they are equal, the brake lamps should be operating correctly and no further steps are necessary.
- If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair.
8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
Bulletin No.: 08-05-22-009C
Date: September 30, 2010
Subject: Intermittently Brake Lights (Stop Lamps) Do Not Function Correctly, Extended Travel to Shift Out of Park, Cruise Control Inoperative, DTCs C0131, C0161 or C0277 Set (Perform Repair as Outlined)
Models:
2004-2008 Chevrolet Malibu, Malibu Maxx
2008 Chevrolet Malibu Classic
2008-2011 Chevrolet Malibu
2005-2010 Pontiac G6
2007-2009 Saturn AURA
Supercede:
This bulletin is being revised to update the models. Please discard Corporate Bulletin Number 08-05-22-009B (Section 05 - Brakes).
Condition
Some customers may comment that intermittently the brake lights do not function correctly. Other symptoms may include extended pedal travel required to shift out of PARK, cruise control does not function correctly, and DTC C0131, C0161 and/or C0277 may be set.
Cause
The most likely cause of this condition is high resistance due to terminal fretting corrosion in the body control module (BCM) C2 or X2 connector (specifically pins 18, 31 and 59).
Correction
DO NOT replace the BCM for this condition. Disconnecting the C2 or X2 connector, adding dielectric lubricant and reconnecting the connector per the procedure below will correct the high resistance condition due to terminal fretting corrosion.
1. Remove the right side front floor console side trim panel to access to the Body Control Module (BCM).
2. Locate the C2 or X2 connector on the BCM.
3. Unlatch the connector and disconnect the connector from the BCM.
4. Apply dielectric lubricant (clear gel), GM P/N 12377900 (in Canada, use P/N 10953529) or equivalent, on all the connector pins (apply with a one-inch nylon bristle brush). This will treat the pins against fretting corrosion.
5. Reconnect the connector back on the BCM and re-latch. Wipe away any excess lubricant.
6. Reinstall the right side front floor console side trim panel.
7. Using the Tech 2(R), check that the BPPS ratio is equal to BPPS learned home when the brake pedal is not depressed.
- If they are equal, the brake lamps should be operating correctly and no further steps are necessary.
- If they are not equal, perform the Brake Pedal Position Sensor Calibration procedure in SI to complete the repair.
8. Verify proper operation of the brake lights. If incorrect, refer to SI and perform normal diagnostics.
Warranty Information
For vehicles repaired under warranty, use the table.
Disclaimer
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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.