Problems with 2002 Chevrolet Malibu ENGINE AND ENGINE COOLING

2002 chevrolet malibu. consumer writes in regard to intake manifold gasket leaking.* ld the consumer stated gm used dex-cool engine coolant which caused problems with the engine. the repair shop flushed out the dex-cool and replaced the coolant, with a different type of coolant. also, the intake manifold was replaced at a cost of $477.31. *jb

2002 chevrolet malibu. consumer writes in regards to vehicle just would not start. *smd the cam shaft sensor was replaced. *jb

I was driving down the road at 35mph when the car just started smoking. *tr

I been running errands. i stopped the car to go into the store, got back into the vehicle and the ignition would not turn over. i was stranded with my 5 year old, had to get a tow to repair shop. i was told the ignition switch was bad, cost me $347.00. on 12/29/11 same issue, car would not start this time luckily i was at home. i had to get a tow to the repair another $51.00 and was told the ignition switch must have had a default and i received a new ignition switch, at no charge. two days ago, almost 2 weeks after last repair, it happened again this time in the parking lot 12 degrees outside car would not turn over called a tow to the repair shop and was told all this time it was the auto theft system was bad and caused the car to not start and also was the cause of the ignition switch to not start the car. i was charged 388.00, plus a tow fee, for the repair of a new ignition lock cylinder( the part used a the auto theft system). basically , this auto theft system has caused me over 700 in a month time and left me in dangerous areas with no way of getting home. this needs to reimbursed by gm because if this auto theft system was placed on the car as a benefit and protection to the owner of the car to stop theft it is not helping the owner at all only putting the owner in more harm because it is causing the owner to not be able to start the car with the key. how much since does that make? this is something extra added to the car that is not needed; that is why we have car alarms. i don't need them to add an auto theft system to my car and it stops me from being able to get into the car and drive. what if there was an emergency i needed to deal with, i have children in the home. the last time the car wouldn't start it was only 12 degrees outside and freezing cold. please tell me how to get a petition of a recall for reimbursement for repairs. this is unsafe! *tr

Tl* the contact owns a 2002 chevrolet malibu. while driving approximately 30 mph, the engine stalled without any illumination of the warning indicators. the engine failed to restart and the vehicle was towed to an independent mechanic who was unable to duplicate the problem. the failure recurred however, the vehicle had not been repaired. the manufacturer was not notified of the malfunction. the approximate failure mileage was 77,000. the vin was unavailable.

Having coolant leak, did not see any coolant leaking on the ground. changed water pump, thermostat, and radiator; still did not fix the problem. found out intake gasket was cracked and had it fixed. coolant still leaking, having to add coolant every day to every other day. was told reservoir cap did not fit well. replaced reservoir and cap and had vehicle bled. ran fine for 3 days, then coolant starting leaking out again. cant seem to find the problem of what is wrong with this vehicle. for a 2002 this vehicle does not have bad mileage, only 84,000 miles. this vehicle was bought brand new. i have read so many problems with this vehicle on the internet. someone should do something about this. chevrolet needs to do something about this. chevrolet sold lemons when they sold these cars, that's for sure!!! *tr

Tl* the contact owns a 2002 chevrolet malibu. the contact stated the vehicle would not start. the ecm was repaired to correct the failure. the failure recurred within one year. the contact believed the failure was associated with the pass lock security system. the dealer advised the contact to bring the vehicle in for diagnosis. the vehicle was neither diagnosed nor repaired. the vin was not available. the current and failure mileages were approximately 110,000.

Chevy malibu 2002 v6 - coolant leak problem. *tr

Tl* the contact owns a 2002 chevrolet malibu. the contact stated the vehicle would turn over but would not start. the vehicle was towed to a local repair facility six times where three crankshaft sensors along with two other unknown sensors were replaced. in addition, the vehicle was taken to the dealer yet the dealer was unable to diagnose the failure. the manufacturer was not contacted. the current mileage was approximately 65,000 and the failure mileage was approximately 55,000.

2002 chevy malibu, 80,000 miles brakes always noisy even when new..brakes and calipers have to be replaced every 2-3 months with minimal use......hazard light and turn signal failure...works intermittently.....ignition lock-out....could not start car or remove key from the ignition....lower intake manifold gasket failure......left headlamp field of vision narrow and short. *tr

Low coolant light kept coming on. had this checked during an oil change and oil was found in the coolant. intake manifold gasket was replaced for the 2nd time. the intake manifold gasket was previously replaced 2 1/2 years ago. starting in the spring/summer of 2008 started having problems with the turn signals only working part of the time. this was checked at a dealership and i was told that since the signals seemed to work fine for them and the problem couldn't be reproduced they weren't able to determine what was wrong to be able to fix it. the problem continues. *tr

Intake gasket went in car cost $740.00 to fix,the coolant was mixing with oil. i didn't have heat couldn't see out back window. the signals work when they want,the rear defroster don't work,my husband has fixed it 2x and put in shop,still don't work. my car gets service when its time. there's a sound in the dashboard sound like wires rubbing together and you get a little shock when you get out car. i hope i don't be driving and my car catch on fire with me in it. i think my car was in the bad batch section. *tr

2002 chevy malibu won't start occasionally passlode problem diag at local dealer ignition replaced and keys reprogrammed cost $398.60 .still have problem that we took car to dealer in first place for. dealer can not fix problem what do we do this is unsafe for wife and young child to become stranded on a daily bases. i have done some research and have come to find out that this is an ongoing problem with the passlock systems from gm. we have also had to replace the intake manifold gasket and have sense learned about the ongoing problems with the dexcool coolant causing gasket failure .we need help. *tr

2002 chevrolet malibu engine service light steadily on; intake manifold gasket leaks w/engine coolant going into engine. was notified of a class action lawsuit against chevrolet for malibu having this problem, but in order to obtain service, the owner must have had the problem and incurred expense in obtaining reimbursement. the cost of repairing this is $1500. research on internet indicates many others are having same problem. *tr

This gm/ chevy malibu was diagnosed to require a head gasket because the coolant leaked inside the engine. after a little research on the internet, there are several complaints of other owners with the same problem. *tr

The car continue to run hot i am in the process of getting it fix i was told that there is a defect with the water pump and the engine. the water comes out of the exhaust pipe on to the engine. *tr

Tl*the contact owns a 2002 chevrolet malibu. while leaving the highway at an unknown speed, the contact noticed that the turn signals failed. the failure has occurred several times. the vehicle was taken to the dealer, but they could not determine the cause of the intermittent failure. the dealer replaced the upper and lower head gasket seal, but the failure was not corrected. the rack and pinion failed and was replaced in 2006 and again in october of 2008. the failure mileage was 30,000 and current mileage was 52,300.

Intake manifold gasket leaking,causing contamination of antifreeze and motor oil. repairs cost mr $770 dollars. it seems to be a common problem on 2002 chevrolet malibu's. *tr

Had to replace the intake manifold gasket on 2002 chevy malibu. was informed by several mechanics that this is a very common problem. *tr

I found out that my intake manifold is leaking and that gm knew about this problem with the 02 malibu. when i called to ask about it they said that my vin # was not included even though i am having the same problem. *tr

I am continually having problems with my 2002 chevy malibu. i had the theft system continually come on and paid $700 to fix that. fuel pump went bad...$500. i had the coolant system leak and paid $800 to fix that. every time i get my brake pads replaced, the rotors need replaced too, until the last time when the calibers had to be replaced as well $900. now i am having difficulty starting my piece of junk. *tr

Tl*the contact owns a 2002 chevrolet malibu. the contact stated that there is engine coolant leaking into the engine. the failure could possibly start a fire. the dealer stated that they were willing to pay 25% of the cost for a new engine. the mechanic at the dealer stated that this was a common failure with her year, make, and model vehicle. general motors advised the contact to drive her vehicle to the dealer instead of having it towed, even though it could catch fire. the powertrain was unknown. the failure and current mileages were 74,000.

My abs system or brakes whatever it might of been made the car easily hydroplan. the tires made a vibrating sound along with vibration through the car. due to the fact that im a decent driver i was able to maintain the car very well at times most wouldn't. furthermore my car started overheating at times, making it very unsafe with whole system failure leading up to the lasts day i drove it. *tr

The anti-freeze holding tank keeps getting an oil residue in it and the anti-freeze keeps disappearing into the engine and has to keep being refilled. after speaking with a mechanic it is possible that the intake manifold gasket is failing. the a/c switch also turns off on its own. rotors and brakes have been replaced three times. *jb

Antifreeze is going bad at low mileage (75,000 miles below life expectancy), becoming caustic, and causing intake manifold gaskets to dissolve causing a leak, also causing head gaskets to leak leading to major engine failure. this leads to an expensive repair at best and engine replacement at worst. the anti freeze is obviously a bad formulation and/or interacts with components to became caustic. this is a defect and repair should be covered by the manufacturer. it is all over the internet how prevalent this problem is. no notice to owners was ever sent to replace the antifreeze before it became caustic. *tr

My car has an anti-freeze leak and i have to fill it once a week. i went to chevy and had a test down on it. the test showed that my low intake gaskets are bad. chevy quoted me $900.00 for fix. *tr

(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

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

Chevrolet malibu intake manifold gaskets" begins to leak anywhere around 80,000 miles of driving. this causes the car to leak coolant, to overheat, and motor will lock, burn out. this car was not even 5 years old, and i have spoken to other malibu owners who had this work done of their cars costing $500.00 to $700.00 i felt as though the manufacturer needed to improve this gasket and replace the cars that already had this defective part. *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 there was a 3 year warranty on the vehicle. the failure mileage was 54,700 and the current mileage was 54,667. *ak

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

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 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 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

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

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.

My 2002 chevrolet malibu shut off while driving at approximately 35 mph down an incline which leads to a rotary. all power steering and braking ability were lost. the car kept gaining speed as it drove down the incline. i had to force the car into park and use the foot emergency brake to stop it after it rolled through a stop sign and unto the rotary. *jb

Malibu 2002 purchased on may 18, 2003 with 33,000 miles . on july 15, 2003 there was a problem with the coolant system and car overheated. according to dealer car was fixed. on june 1, 2004 there was a problem with the electrical system. june 27, 2006 with 72, 000 miles, there is oil in coolant reservoir and a coolant leak. there was a lower intake leak and leak at water pump. the lower intake and water pump was replaced but on july 17, 2006 the same problem came again. july 17, 2006 only a few weeks after the problem with oil in the coolant reservoir, same problem occurred and dealer does not want to take responsibility for it. *jb

Dt*: the contact stated that the head gasket of the vehicle began to leak at approximately 13000 miles. there were no warning signs prior to the failure. updated 07/05/06. *jb

Car started leaking anti-freeze from intake manifold gasket on engine at 45000 miles. was told that there was a technical service bulletin on this problem but that since there was no recall i would have to pay $900.00 for this repair out of pocket. this could lead to a fire and overheating engine failure. *nm

Car has failed to start on numerous occasions and no one has been able to tell us why. we have had to replace the head gasket, which had not fixed the problem. our wipers only work on high. our heat only works on number 4 and 5. while driving home on the freeway during rush hour with my baby daughter in the car, the car just decided to die on me. i had to try to get out of the passing lane, so that i could pull off of the road. my radio and heat still worked, but car would not restart. my oil and battery and cruise control lights were on (i had not even used the cruise control) and my car just would not start. it took me an hour to get my car to start again, now i am afraid to drive it any distance for fear of being stranded. *jb

3 weeks ago my 2002 chevy malibu started to run like #@$% (hesitation between 0- 35 mph and going up hill, loss in power, and slow at catching up to freeway speed). i have replaced spark plugs, coils, and the egr valve and the problem still occurs. well, after further investigation online, i found other people to have the same problem and it turns out that it's with their cat converter. i can't even order the part online because of strict emission control in california, i need a mechanic to do it,get it straight from the dealer, or have auto zone do a special order for me (i found a mechanic that will do it for $800). next is my head gasket, which looks like it has to be replaced. on 4-8-06 i got an oil change and was told that there was oil in my coolant reservoir tank, which means i have an oil leak. so now i have to take my car in and have the head gasket replaced which won't be cheap either. i looked online for recalls and i came upon this website www.nhtsa.dot.gov , i realized that other consumers also have the same problem. so with so many people experiencing the similar problems why doesn't gm do recalls. now i may need to fork out a couple hundred dollars if not a thousand or more to fix (correct) a faulty cat converter and head gasket. *nm

1. vehicle is low mileage garage kept and well maintained. an odor was noticeable for a couple of days. drove car a few miles and parked, when came out a half an hour later. 2. started car, tried to turn on to driveway to leave and had no power steering. smelled bad. 3. the keefers auto service related the ac compressor clutch had frozen up. they replaced this part and recharged the ac system etc. i believe the loss of power steering in the vehicle, especially with only 11000 miles, is very serious and could cause an accident. this repair was just completed today 4/3/6 so if you interested in the old parts or anything to do with the service please contact tom keefer at keefer's auto sales and service (717) 334 2923. he is very nice and reputable. *nm

First noticed problem when driving on freeway and attempting to make a lane change vehicle did not speed as usual and had to return to lane to avoid accident. while driving vehicle from a complete stop, vehicle struggled from 0 to 25 mph. when going up bridge vehicle would not go faster than 20 mph. vehicle does not have much power. vehicle was taken to mechanic and replaced sensors but problem still occurs. after further investigation of problem mechanic realized that the problem is the catalytic converter. the repairs have not been made. i entered the website to find out if there are any recalls on this vehicle for this problem (recommendation from mechanic).*jb

The intake manifold gasket in the consumer's 2002 chevrolet malibu was defective. *nm the consumer contacted the manufacturer to see about getting the vehicle repaired free of charge. the consumer was told that the intake manifold gasket would not be replaced because the vehicle was no longer under warranty. the consumer believes the repair should be covered since the manufacturer was aware of a problem with the intake manifold because a bulletin was issued oct 24, 2003. *nm

The latest incident is the catalytic converter. the car began to hesitate at 50-60 mph and started losing power. i took it in and was told it was fine. pickup became non existent and the dealer finally diagnosed the problem after changing the fuel filter and other regular maintenance items. i limped into the dealer and was told it would cost $1600. i took it to a garage and it cost $150. the aggravation with this car is frustrating to say the least. warning malibu owners...the converter is a known failure item they don't want us to know about!! *jb

I first purchased this malibu 2002 in feb 2002. nov 02 ( 9 mos later) i had to have my ignition switch replaced which was under warranty. around the same time my turn/hazard signal went out and i haven't had it replaced yet after 4yrs of having this car. if i want to use it i have to keep pressing the hazard button to make it come on. nov 2005 i tried to start my car, but it kept cutting off. my dad stated it was the fuel pump. i had the fuel pump,crank sensor and module replaced. my car still didn't start. finally my dad went under the steering wheel and pressed this black button (cut off switch) and that was the only way it would start. i have to travel 25 miles to work so i was tired of worrying about the car. i thought it was the theft system. i took my car to the dealer 11/29/2005 they had the car until 12/15/2005. i was told that it was my ignition switch, crank sensor and my alarm/automatic starter. i was out of $366.73 to the dealer and taking a cab to work at 5:30am for x7dy coasted$210.00. i was also out of money for a rental car for the last 7ys they had my car plus gas on both because they used all gas in my car. i have had x2 ignition switches put on my car, i have to change my tail/park/brake bulb seemingly every 6mos. i am only getting my hazard/turn signal replaced when nhtsa reviews it as being an defect. i am having a hard time with the speed of my car also on the e way. i have to put my foot to the floor in order to make it take off at 60mph. i have to put gas in my car every 3dys. i last changed my fuel filter 1yr ago and again having it replaced 1/1/06. my check engine light came on 1wk after i got my car out of the shop on 12/22 and it has been on since. my coolant light comes and goes off every now and then. i have had my coolant/fuel flushed. i had it winterized what's the problem. if we ...

Two weeks ago my water level light came on. i added dexcool coolant per manufacturers recommendation. the light continued to come on and go off for approx 1 week. i added dexcool coolant each time. after approx. 1 week of doing this, the light stopped coming on. yesterday, when i returned to my vehicle after work, there was coolant in the lot under my vehicle. i filled the reservoir up again and drove the vehicle home. today, i took the car to a repair garage who informed me that i needed to replace my lower intake gasket and thermostat gasket and valve cover gasket at a cost of $890.00. the mechanic informed me that gm has had several complaints in reference to this type of problem. they fixed four of this type of problem in the last two years. apparently the problem is possibly due to the use of the gm-recommended dexcool which gm has since discontinued use of. *nm

I bought a 2002 chevrolet malibu on august 10, 2004. the mileage was 45,281. since that time i have had 2 problems with my vehicle. 1.gm dex-cool/intake manifold gasket. 2.anti-theft light comes on. after car has been stopped, the car will not restart again. with regard to item number 1 above, i understand there is a class action lawsuit pending. with regard to item number 2 above, these are the circumstances concerning my problems associated with the anti theft system. from august to october 2006 i had to tow my vehicle to the chevrolet dealership to address the problem of my car not starting. it was towed 4 times, the first 3 times and all the dealership said was that the battery needed to be charged. on the last time, october 13, 2006 the dealership said their ?educated guess? was the need to change the starter switch and ignition lock cylinder for which they charged me for a starter switch - $96.15, an ignition lock cylinder - $154.79, recode the lock cylinder - $15.00, and $46.00 to correct the pass lock sensor data, plus a $10.00 environmental disposal fee. my son looked on the internet to see if anyone else has had similar problems with their same model car. it appears quite a few owners have had similar problems. the anti-theft problem fix was to allow the car to sit for 10 minutes, and then try to start the vehicle again, and it worked, sometimes after 2-3 attempts. the dealership had also said to try the same fix procedure, it might work. it appears that general motors knows about this two problem, and is only addressing the gm dex cool intake manifold gasket. general motors should recall to fix both problems at no charge to the owner. it's only a matter of time before either of these two items becomes a safety issue and causes a loss of life or limb. the current mileage is 55,340. *tr

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.