Chevrolet Malibu (2004–2007): How to Remove the Bumpers

General Information

  • Production years: 2003–2007 (sold as 2004–2008 models)
  • Class: Mid-size sedan (D-segment)
  • Platform: GM Epsilon I (shared with Opel Vectra C, Saab 9-3)
  • Body: 4-door sedan
  • Assembly: USA, Canada

 

Engines

Displacement Type Power Torque Transmission
2.2 L L4 Ecotec 144 hp 210 Nm 4-speed automatic
3.5 L V6 LX9 201–211 hp 298–311 Nm 4-speed automatic

From 2006, the base version received a 2.4 L LE5 (164 hp), and the V6 was upgraded to 217 hp.

 

Trim Levels (USA)

  • Base: 2.2 L, air conditioning, power windows.
  • LS: 3.5 L V6, leather-wrapped steering wheel, upgraded audio system.
  • LT: Climate control, heated seats, leather upholstery (optional).

 

Model Features

  • Safety: 4-star NHTSA rating (frontal crash), ABS and ESC (V6 only).
  • Interior: Spacious cabin (trunk volume: 447 L), but cheap plastics in the base model.
  • Common Issues:
    • Cracked intake manifold (2.2 L)
    • Transmission overheating (especially V6 models)
    • Brake line corrosion

 

Markets

  • USA/Canada: Primary market, ~500,000 units sold.
  • Middle East: Equipped with the 3.5 L V6.
  • Russia: Not officially sold, but imported by "gray" dealers.

Mounting points may vary slightly depending on the production year.

How to Remove the Front Bumper

  1. Open the hood.
  2. Remove the four push pins securing the radiator grille.
  3. Unscrew the four bolts and remove the headlights.
  4. Turn the wheels to the side.
  5. In the wheel arches, remove three push pins on each side securing the fender liners (front section).
  6. Unscrew three screws on each side (fastened bottom-up) attaching the bumper to the fenders (marked with blue arrows; no need to fully remove, just loosen by two turns).
  7. Remove two push pins from the lower grille (inserted bottom-up).
  8. Release the clips in the fenders.
  9. With an assistant, pull the bumper forward (mind the wiring).
  10. Disconnect any electrical connectors (if equipped).

Chevrolet Malibu VI (2004-2007) Front Bumper Mounting Locations

Chevrolet Malibu VI (2004-2007) Headlight Mounting Diagram

Chevrolet Malibu VI Front Bumper Mounting Diagram (2004-2007)

How to Remove the Rear Bumper

⇒Useful tips on how to remove the bumper and not break anything.⇐

  1. Open the trunk lid.
  2. Remove the weatherstrip.
  3. In the trunk opening, remove four push pins securing the upper part of the rear bumper.
  4. Underneath, remove four push pins (inserted bottom-up) securing the lower part.
  5. In the wheel arches, remove three push pins on each side securing the rear fender liners.
  6. Pull back the liners and unscrew one screw on each side attaching the bumper corners to the fenders.
  7. Release the clips in the fenders (pull the corners outward).
  8. With an assistant, pull the bumper backward (mind the wiring).
  9. Disconnect the license plate light connectors.

Chevrolet Malibu VI Rear Bumper Mounting Diagram (2004-2007)

Interesting Facts About the 2004–2007 Chevrolet Malibu

The First Malibu on a Global Platform

This Malibu was the first in the model’s history built on the GM Epsilon platform, shared with:

  • Opel Vectra C (Europe)
  • Saab 9-3 (premium segment)
  • Pontiac G6 (sporty US version)
    Despite the shared platform, the Malibu featured a softer, comfort-oriented suspension.

Ford Taurus Rivalry — An Unexpected Loss

GM positioned the 2004 Malibu as a "Taurus killer," but sales fell short:

  • 2004 sales: ~180,000 Malibus vs. ~250,000 Tauruses.
  • Reasons: Conservative design and weak marketing.

The "Secret" Police Version

In 2006–2007, a limited-run Malibu 9C1 was produced for police use, featuring:

  • Reinforced suspension
  • Upgraded 3.5 L V6 (230 hp)
  • Protected wiring
    These cars were used in small-town patrols but never gained widespread adoption.

The "Disappearing" Badge Problem

Owners reported that the chrome "Malibu" trunk lettering often fell off during car washes or gravel road driving. Dealers initially replaced the emblems under warranty.

The Unreleased Coupe Prototype

In 2005, GM unveiled a Malibu Coupe concept with Corvette C6-inspired styling. Despite positive feedback, it was shelved in favor of the sedan.

Record-Breaking Mileage

In 2016, a Canadian taxi driver claimed his 2004 Malibu with the 2.2 L engine reached 1.2 million km without major repairs. GM verified the original engine and transmission had never been rebuilt.

Hollywood Appearances

The Malibu appeared in several films and TV shows:

  • Prison Break (2005) — driven by a prison guard.
  • Dexter (2006) — owned by a minor character.
  • Fast & Furious 4 (2009) — featured in a street racing scene.

Rare Paint Option

An exclusive "Midnight Blue Metallic" paint (with a pearl/metallic effect) was offered. Due to its complex application, these cars are now rare collectibles.

 

Conclusion

The 2004–2007 Malibu wasn’t revolutionary but stood out for:

  • Losing the battle against the Ford Taurus
  • Its police variant
  • The 2.2 L engine’s legendary reliability