(1) 2002 CHEVY MALIBU. 3100 V6 ENGINE. GASKET FAILURE/FACTORY DEFAULT. (2) ONLY 22,200 MILES, AND INTAKE GASKET HAS FAILED. (3) WHAT NEEDS TO BE DONE, IS A GM FACTORY RECALL TO FIX THIS ISSUE. *TR
2002 Chevrolet Malibu
Owner reports · Recalls · Investigations
Similar to other model years
Owner complaints for the 2002 Chevrolet Malibu do not stand out strongly from the model-year median of 310.5.
About this comparison →How this year compares
Owner complaints by model year
Compare all Malibu years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
391 reports with mileage · 176 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Electrical System. Review the 259 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Exterior Lighting. Review the 143 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Engine And Engine Cooling. Review the 63 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
63 reportsGM V6 DEFECTIVE INTAKE MANIFOLD GASKET FAILED, CAUSING COOLANT TO DISAPPEAR THROUGH ENGINE OR INTO ENGINE OIL. CAUSES ENGINE TO OVERHEAT, AND POSSIBLE SEVER INTERNAL DAMAGE. LAST FAILURE WAS ON 2002 CHEVROLET MALIBU AT 39000 MILES,IT FAILED 2 TIMES ON 1998 PONTIAC MONTANA UNDER 80000 MILES, FAILED 2 TIMES ON 2000 CHEVROLET VENT…
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GM V6 DEFECTIVE INTAKE MANIFOLD GASKET FAILED, CAUSING COOLANT TO DISAPPEAR THROUGH ENGINE OR INTO ENGINE OIL. CAUSES ENGINE TO OVERHEAT, AND POSSIBLE SEVER INTERNAL DAMAGE. LAST FAILURE WAS ON 2002 CHEVROLET MALIBU AT 39000 MILES,IT FAILED 2 TIMES ON 1998 PONTIAC MONTANA UNDER 80000 MILES, FAILED 2 TIMES ON 2000 CHEVROLET VENTURE UNDER 80000 MILES. FAILED 1 TIME ON 2002 MALIBU. MANUFACTURER WAS AWARE OF DEFECT, BUT DID NOT TELL CUSTOMER. *AK
TL* - THE CONTACT OWNS A 2002 CHEVROLET MALIBU, WHICH WAS PURCHASED ON 02/28/2007, AND WORKED WELL UNTIL 03/16/2007 WHEN THE ENGINE LIGHT TURNED ON. ON 03/23/2007 THE VEHICLE WOULD NOT START, AND WAS TAKEN TO THE DEALER, AND THE DEALER HAS BEEN UNABLE TO GET THE VEHICLE TO TURN ON SINCE THAT TIME. THE CONTACT STATED THAT THER…
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TL* - THE CONTACT OWNS A 2002 CHEVROLET MALIBU, WHICH WAS PURCHASED ON 02/28/2007, AND WORKED WELL UNTIL 03/16/2007 WHEN THE ENGINE LIGHT TURNED ON. ON 03/23/2007 THE VEHICLE WOULD NOT START, AND WAS TAKEN TO THE DEALER, AND THE DEALER HAS BEEN UNABLE TO GET THE VEHICLE TO TURN ON SINCE THAT TIME. THE CONTACT STATED THAT THERE WAS A 3 YEAR WARRANTY ON THE VEHICLE. THE FAILURE MILEAGE WAS 54,700 AND THE CURRENT MILEAGE WAS 54,667. *AK
ENGINE COOLANT LIGHT CAME ON. I REPLACED 1/2 GALLON OF COOLANT. AT MY NEXT OIL CHANGE, I NOTICED AN ORANGE GEL ON MY OIL CAP. I FIGURED IT WAS AN INTERNAL COOLANT LEAK; THEREFORE, IT WAS PROBABLY A HEAD GASKET LEAK. I TOOK MY CAR TO LOCAL CHEVROLET DEALERSHIP FOR SERVICE. THE SERVICE TECHNICIAN DETERMINED IT WAS AN INTAKE M…
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ENGINE COOLANT LIGHT CAME ON. I REPLACED 1/2 GALLON OF COOLANT. AT MY NEXT OIL CHANGE, I NOTICED AN ORANGE GEL ON MY OIL CAP. I FIGURED IT WAS AN INTERNAL COOLANT LEAK; THEREFORE, IT WAS PROBABLY A HEAD GASKET LEAK. I TOOK MY CAR TO LOCAL CHEVROLET DEALERSHIP FOR SERVICE. THE SERVICE TECHNICIAN DETERMINED IT WAS AN INTAKE MANIFOLD GASKET LEAK. IF THE GASKET WAS NOT REPLACED PROMPTLY, THE ENGINE OIL WOULD FAIL TO LUBRICATE THE ENGINE PROPERLY. THE RESULT COULD BE CATASTROPHIC DAMAGE TO THE ENGINE. 8JB
FIRST INCIDENT OF LEAKING HAPPENED AFTER DEALERSHIP WORKED ON CAR. ARRIVED HOME COOLANT POURED OUT ON GROUND TOWED BACK. DEALERSHIP SAID RESERVOIR CAP SEAL. 10/2006 OR 11/2006, PICKING UP AT SCHOOL AND SMELLED NOT ENGINE. PARKED SAW COOLANT ON GROUND. NO ENGINE LIGHT ON BUT NEEDLE WAS PAST MIDDLE. FAMILY BROUGHT COOLANT FI…
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FIRST INCIDENT OF LEAKING HAPPENED AFTER DEALERSHIP WORKED ON CAR. ARRIVED HOME COOLANT POURED OUT ON GROUND TOWED BACK. DEALERSHIP SAID RESERVOIR CAP SEAL. 10/2006 OR 11/2006, PICKING UP AT SCHOOL AND SMELLED NOT ENGINE. PARKED SAW COOLANT ON GROUND. NO ENGINE LIGHT ON BUT NEEDLE WAS PAST MIDDLE. FAMILY BROUGHT COOLANT FILLED IT UP AND WENT 5 BLOCKS TO DEALERSHIP. THEY SAID NOTHING WAS WRONG. YESTERDAY, 1/9/2007 CAR OVERHEATED IN THE SCHOOL LINE. ADDED COOLANT. I BROUGHT IT TO A NON DEALERSHIP RADIATOR SHOP OWNER THINKS INTAKE MANIFOLD GASKET LEAKING. CAR AT DEALERSHIP. I REALLY DON'T KNOW WHAT THE REAL PROBLEM IS BUT BECAUSE MY WARRANTY EXPIRED FEEL DEALERSHIP WILL TELL ME IT IS A NEW PROBLEM FROM THE FIRST EVENT SO I WILL BE RESPONSIBLE. AT LEAST TWO ROTORS REPLACED ON THE FRONT DRIVER'S WHEEL & 5 SETS OF PADS. REPORTED TO GM THEY CLAIM IT IS THE WAY I DRIVE! A NON DEALERSHIP TIRE COMPANY HAD THE PADS REPLACED WITH A GOOD BRAND. 1 1/2 YEARS SINCE I HAD TO HAVE PADS. PROBLEM WITH THE RIGHT FRONT PASSENGER DOOR LOCKS. CAR IS RUNNING AND THE DRIVER GETS OUT LEAVING CAR ON AND THEN THE PASSENGER TURNS OFF THE CAR AND GETS OUT, LOCKS CAR, THE RADIO STAYS ON. I WENT INSIDE THE STORE AND CAME OUT AND THE RADIO WAS STILL PLAYING. WHEN YOU UNLOCK THE CAR BUT ENTER ONLY THE PASSENGER FRONT DOOR AND THEN CLOSE IT AND WALK AWAY, THE CAR LOCKS ITSELF. HAPPENED SEVERAL TIMES. I HAD NOT PLACED THE KEYS ON THE SEAT OF THE CAR AND SHUT THE DOOR OR I WOULD HAVE BEEN LOCKED OUT. I REPORTED THIS BUT NO ONE SEEMED TO CARE. RADIO WAS REPLACED FOR LEFT BUTTON PAINT (NOT SURE IF IT IS PAINT OR COVER ON BUTTON) RUBS OFF. IGNITION SWITCH WAS REPLACED. FUEL PUMP REPLACED.. I TRANSPORT GRANDCHILDREN AND I NEED A SAFE CAR. *JB
2002 CHEVY MALIBU (85,000 MILES) = APPROXIMATELY A YEAR AGO ENGINE OVERHEATED AND "NEED COOLANT" LIGHT CAME ON. OWNER REFILLED COOLANT. SEVERAL MONTHS LATER "COOLANT" LIGHT AGAIN CAME ON AND OWNER REFILLED COOLANT. NO VISIBLE LEAK OF COOLANT WAS NOTICED UNDER VEHICLE. AT NEXT OIL CHANGE OWNER ASKED TECHNICIAN TO CHECK COOLANT A…
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2002 CHEVY MALIBU (85,000 MILES) = APPROXIMATELY A YEAR AGO ENGINE OVERHEATED AND "NEED COOLANT" LIGHT CAME ON. OWNER REFILLED COOLANT. SEVERAL MONTHS LATER "COOLANT" LIGHT AGAIN CAME ON AND OWNER REFILLED COOLANT. NO VISIBLE LEAK OF COOLANT WAS NOTICED UNDER VEHICLE. AT NEXT OIL CHANGE OWNER ASKED TECHNICIAN TO CHECK COOLANT AND TECHNICIAN NOTED THAT EVERYTHING SEEMED FINE, NO DISCERNIBLE LEAK. JULY 2006 ENGINE COOLANT LIGHT CAME ON, OWNER REFILLED, THIS OCCURRED AGAIN IN LATE AUGUST AND AGAIN IN OCTOBER. DECEMBER 22, 2006, OWNER HAD OIL CHANGE AND ASKED TECHNICIAN ABOUT THE PROBLEM. THE TECHNICIAN SUGGESTED THAT CHEVROLETS REGULARLY GET AIR BUBBLES IN THE COOLANT SYSTEM AND OFTEN HAVE PROBLEMS WITH COOLANT BECAUSE OF IT. HE CHECKED THE COOLANT PRESSURE, HE SAID IT WAS NORMAL AND SUGGESTED TO DO A FLUSH AND FILL, THE OWNER AGREED. ON DEC. 26, 2006, THE COOLANT LIGHT CAME ON AGAIN AND THE OWNER ADDED ADDITIONAL COOLANT. ON DEC. 29, 2006, OWNER TOOK VEHICLE TO A CHEVROLET DEALER SERVICE CENTER. THE TECHNICIAN DETERMINED THE VEHICLE TO HAVE A DAMAGED INTAKE MANIFOLD GASKET. THE CHEVROLET SERVICE CENTER PERFORMED THE SERVICE AND REPLACED THE INTAKE MANIFOLD GASKET ON DEC. 30, 2006. *NM
AT 62,000 MILES I NOTICED THAT MY ENGINE COOLANT LIGHT WAS ON. I FILLED THE COOLANT. THE LIGHT CONTINUED TO COME ON AND I FILLED IT A FEW MORE TIMES, BUT COULD NOT PINPOINT THE LEAK. THEN, I REALIZED THAT THIS WAS THE SAME PROBLEM THAT I HAD EARLIER THIS YEAR WITH MY 2002 CHEVY IMPALA. THE HEAD GASKETS NEEDED REPLACED. I WAS L…
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AT 62,000 MILES I NOTICED THAT MY ENGINE COOLANT LIGHT WAS ON. I FILLED THE COOLANT. THE LIGHT CONTINUED TO COME ON AND I FILLED IT A FEW MORE TIMES, BUT COULD NOT PINPOINT THE LEAK. THEN, I REALIZED THAT THIS WAS THE SAME PROBLEM THAT I HAD EARLIER THIS YEAR WITH MY 2002 CHEVY IMPALA. THE HEAD GASKETS NEEDED REPLACED. I WAS LEAKING WATER INTO MY ENGINE. CAN YOU IMAGINE BUYING TWO NEW CHEVY AUTOMOBILES IN THE SAME YEAR AND 4 YEARS LATER HAVING BOTH ENGINES FAIL FOR THE SAME REASON. SEEMS LIKE CHEVY IS HIDING A MAJOR PROBLEM. I SEE OTHER COMPLAINTS LIKE THIS ON THE INTERNET. I DID NOT CONTACT CHEVY SINCE THE WARRANTY EXPIRED. NOW, BECAUSE OF MY INTERNET RESEARCH AND THE SAME PROBLEM WITH MY IMPALA, I KNOW THIS IS A COMMON PROBLEM. SO, I TOOK MY 2002 CHEVY MALIBU AT 62,000 MILES TO THE SAME GARAGE AND THEY WERE ABLE TO REPLACE THE HEAD GASKETS AND GIVE ME A PRICE BREAK AND FIXED IT FOR $252.00. BOO TO CHEVY. *NM
DT*: THE CONTACT STATED THE ENGINE INTAKE MANIFOLD ALLOWED OIL TO MIX WITH ANTIFREEZE CAUSING A LEAK. THE ANTIFREEZE MIXTURE ATE THROUGH THE GASKET WHICH RESULTED IN REPLACEMENT OF THE INTAKE MANIFOLD. THE REPAIRS WERE PERFORMED BY AN INDEPENDENT REPAIR SHOP. THIS OCCURRED TWICE IN 10,000 MILES.
DT*: THE CONTACT STATED THE VEHICLE'S INTAKE MANIFOLD GASKET CRACKED WHICH CAUSED ANTIFREEZE TO LEAK ONTO THE ENGINE. THE AUTO BODY SHOP STATED THE LEAK COULD LEAD TO THE ENGINE GETTING LOCKED.
ON SEPT. 5, 2006, MY HUSBAND, 2 CHILDREN, AND I WERE DRIVING DOWN A 55 MPH HIGHWAY, WHEN I PUSHED ON THE ACCELERATOR, AND MY CAR JUST DECIDED IT WAS ONLY GOING TO GO 35-45 MPH! LUCKILY, THERE WAS NO ONE BEHIND ME. I HAD TIME TO PUT MY FLASHERS ON AND GET THE CAR DOWN THE ROAD TO THE MECHANIC. I WAS ON A CAR COMPLAINT WEBSITE …
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ON SEPT. 5, 2006, MY HUSBAND, 2 CHILDREN, AND I WERE DRIVING DOWN A 55 MPH HIGHWAY, WHEN I PUSHED ON THE ACCELERATOR, AND MY CAR JUST DECIDED IT WAS ONLY GOING TO GO 35-45 MPH! LUCKILY, THERE WAS NO ONE BEHIND ME. I HAD TIME TO PUT MY FLASHERS ON AND GET THE CAR DOWN THE ROAD TO THE MECHANIC. I WAS ON A CAR COMPLAINT WEBSITE TRYING TO DISCOVER WHAT IS WRONG WITH MY CAR WHEN I FOUND OUT I'M NOT THE ONLY ONE. AT WWW.CARCOMPLAINTS.COM FOR THE 2002 CHEVY MALIBU THERE ARE ABOUT 9 PEOPLE DISCUSSING HOW THEIR ENGINE WAS LEAKING COOLANT. LIKE ME, AT FIRST IT EITHER DIDN'T SHOW THE LEAK, OR IT WAS MINIMAL, AND NOT WORRISOME, WE THOUGHT; HOWEVER, WE (MECHANICS THAT WE ARE NOT) WERE WRONG. SOMEONE SAID THIS REPLACEMENT PART IS $1200+. DEALERS AREN'T HELPING. MY WARRANTY JUST RAN OUT. I HAVE NO IDEA WHAT I'M GOING TO DO. I'M 38 YEARS OLD WITH A HEART CONDITION AND I NEED MY CAR, BUT I CAN'T DRIVE IT LIKE IT IS, NOR CAN I AFFORD TO FIX IT. *JB
Official recalls
214V400000 · Electrical System:ignition
Jul 3, 2014
This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on July 3, 2014, that they are recalling 5,877,718 model year 2000-2005 Chevrolet Impala and Monte Carlo, 1997-2003 Chevrolet Malibu, 2004-2005 Malibu Classic, 1999-2004 Oldsmobile Alero, 1998-2002 Oldsmobile Intrigue, 1999-2005 Pontiac Grand Am and 2004-2008 Pontiac Grand Prix vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine.
Consequence & remedy
Consequence: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.
Remedy: GM will notify owners, and dealers will install two key rings and an insert in the key slot or a cover over the key head on all ignition keys, free of charge. The recall began on September 9, 2014. GM's number for this recall is 14350.
02V107000 · Exterior Lighting:headlights
Apr 10, 2002
CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." SOME OF THESE VEHICLES WERE PRODUCED WITH A LEFT LOW-BEAM HEADLAMP THAT DOES NOT MEET THE PHOTOMETRIC PERFORMANCE REQUIREMENTS OF THE STANDARD.
Consequence & remedy
Consequence: LIGHT INTENSITIES BELOW THE MINIMUM INTENSITY REQUIREMENTS CAUSE REDUCTION IN VISIBILITY DOWN THE ROAD FOR THE DRIVER OF THE VEHICLE AND INTENSITIES ABOVE THE MAXIMUM INTENSITY REQUIREMENTS CAUSE INCREASE IN GLARE FOR DRIVERS AHEAD OF, OR APPROACHING, THE VEHICLE.
Remedy: DEALERS WILL INSPECT THE LEFT LOW-BEAM HEADLAMP AND REPLACE IT IF IT DOES NOT MEET REQUIREMENTS. OWNER NOTIFICATION BEGAN MAY 23, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1PE05055 · Turn Signal Failures
Opened Sep 27, 2005 · Closed Jan 13, 2006
Status: closed (inferred from source dates) · Exterior Lighting:hazard Flashing Warning Lights:switch; Exterior Lighting:turn Signal:switch
IN DECEMBER 2004, GM ISSUED A SPECIAL POLICY FOR MY 1999-2000 ALERO, GRAND AM AND MALIBU VEHICLES NOT COVERED UNDER RECALL 03V327. THE POLICY COVERED TURN SIGNAL/HAZARD FLASHER FAILURE FOR A PERIOD OF 10 YEARS OR 150,000 MILES (WHICHEVER OCCURRED FIRST) TO PROVIDE A NO COST REPLACEMENT OF THE HAZARD SWITCH. GM SENT LETTERS TO OWNERS STARTING DECEMBER 30, 2004.IN JANUARY 2006, GM WILL UPDATE THE SPECIAL POLICY TO INCLUDE MY 2002 ALERO, GRAND AM AND MALIBU VEHICLES NOT COVERED UNDER RECALL 03V-327.THE POLICY COVERS TURN SIGNAL/HAZARD FLASHER FAILURE FOR A PERIOD OF 10 YEARS OR 150,000 MILES (WHICHEVER OCCURS FIRST) TO PROVIDE A NO COST REPLACEMENT OF THE HAZARD SWITCH.GM WILL SEND LETTERS TO OWNERS STARTING LATE APRIL 2006.THE ACTIONS TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FUTURE ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Additional source detail variants (2)
Exterior Lighting:hazard Flashing Warning Lights:switch
IN DECEMBER 2004, GM ISSUED A SPECIAL POLICY FOR MY 1999-2000 ALERO, GRAND AM AND MALIBU VEHICLES NOT COVERED UNDER RECALL 03V327. THE POLICY COVERED TURN SIGNAL/HAZARD FLASHER FAILURE FOR A PERIOD OF 10 YEARS OR 150,000 MILES (WHICHEVER OCCURRED FIRST) TO PROVIDE A NO COST REPLACEMENT OF THE HAZARD SWITCH. GM SENT LETTERS TO OWNERS STARTING DECEMBER 30, 2004.IN JANUARY 2006, GM WILL UPDATE THE SPECIAL POLICY TO INCLUDE MY 2002 ALERO, GRAND AM AND MALIBU VEHICLES NOT COVERED UNDER RECALL 03V-327.THE POLICY COVERS TURN SIGNAL/HAZARD FLASHER FAILURE FOR A PERIOD OF 10 YEARS OR 150,000 MILES (WHICHEVER OCCURS FIRST) TO PROVIDE A NO COST REPLACEMENT OF THE HAZARD SWITCH.GM WILL SEND LETTERS TO OWNERS STARTING LATE APRIL 2006.THE ACTIONS TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FUTURE ACTION IF WARRANTED BY THE CIRCUMSTANCES.
Exterior Lighting:turn Signal:switch
IN DECEMBER 2004, GM ISSUED A SPECIAL POLICY FOR MY 1999-2000 ALERO, GRAND AM AND MALIBU VEHICLES NOT COVERED UNDER RECALL 03V327. THE POLICY COVERED TURN SIGNAL/HAZARD FLASHER FAILURE FOR A PERIOD OF 10 YEARS OR 150,000 MILES (WHICHEVER OCCURRED FIRST) TO PROVIDE A NO COST REPLACEMENT OF THE HAZARD SWITCH. GM SENT LETTERS TO OWNERS STARTING DECEMBER 30, 2004.IN JANUARY 2006, GM WILL UPDATE THE SPECIAL POLICY TO INCLUDE MY 2002 ALERO, GRAND AM AND MALIBU VEHICLES NOT COVERED UNDER RECALL 03V-327.THE POLICY COVERS TURN SIGNAL/HAZARD FLASHER FAILURE FOR A PERIOD OF 10 YEARS OR 150,000 MILES (WHICHEVER OCCURS FIRST) TO PROVIDE A NO COST REPLACEMENT OF THE HAZARD SWITCH.GM WILL SEND LETTERS TO OWNERS STARTING LATE APRIL 2006.THE ACTIONS TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FUTURE ACTION IF WARRANTED BY THE CIRCUMSTANCES.
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