Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Chevrolet Malibu owners, lightly cleaned up (personal details are redacted by NHTSA).
The anti-theft/ passlock system fault in this generation of GM vehicles is very widespread and effects a large percentage of vehicles in this generation. I am sure there have been hundreds if not thousands of complaints about same issue and GM refuses to fix the problem. The problem causes the car to randomly shut off due to anti theft fault and can happen on interstate, highway or in town driving. This is a very dangerous fault and very expensive for owners especially when dealerships themselves don't even know what they are dealing with. They will throw parts at the problem with no real knowledge. GM needs to be held accountable. Currently the ignition the BCM have been replaced and now the car will not start at all and I have no lights or gauges on my cluster.
Tl* the contact owns a 2002 Chevrolet Malibu. The contact stated that the engine hesitated when started. Also, the instrument panel lighting became very dim and the data on the screen was not visible. Also, the passenger door would not lock and the windows failed to roll down. All the warning indicators illuminated on the instrument panel. The contact jumped the battery and the engine restarted. Later, the vehicle decelerated while driving. The vehicle was taken to an independent mechanic who diagnosed that the anti-theft system failed. The mechanic was currently performing a second diagnostic test. The manufacturer and dealer were not made aware of the failures. The failure mileage was 46,786.
I had an ignition switch replaced by a dealer (dimmitt Chevrolet, clearwater, fl) because my key was stuck in it. The same dealer also replaced my key and key casing because of a recall. After that I starting noticing that my car would intermittently cut off forcing me to put in neutral and restart. I thought it May be a clogged fuel filter and had that replaced. The issue still exists and it is a dangerous situation to me and my family not knowing when my car will just stop running, especially while driving at highway speeds. I checked and do not see a GM recall on my model for some reason.
Tl* the contact owns a 2002 Chevrolet Malibu. The contact stated that the engine warning indicator illuminated and anti-freeze was leaking out of the vehicle. The contact took the vehicle to an unknown dealer where it was diagnosed that the head gasket blew out and needed to be replaced. The vehicle was repaired, but the failure recurred. The ourisman Chevrolet dealer stated that the engine needed to be replaced. The vehicle was not repaired. The manufacturer informed the contact that the vehicle was no longer under warranty. The approximate failure mileage was 10,333.
My car cuts off and goes into the anti-theft system while I'm going down the road when this happens my car has to be pushed off the roadway and then I have to sit with my driver side door open and my key turned on for 10 minutes until it resets itself this is very dangerous and it scared me because I was in the middle of highway 150 in danville kentucky. Plusmy heating system is messed up I can't get it to bleed out the air in the system.
Vehicle was running fine. Parked car for 1 hour went to start car it would turn over but not start. After checking all fuses and fuel pump I was advised it could be an anti theft malfunction. I followed a procedure to relearn the system and the car started. This has happened on 3 occasions and I fear the car will leave me stranded or malfunction while operating which could lead to a serious injury
There was a breakdown, of the upper and lower manifolds, caused by the dex coolant, and poor engine design. Coolant got into my engine, and needs to be repaired or a replacement engine replaced. Sending a picture of the oil cap with foam on it, and its like this inside the engine as well.
In January 2004, the ?low coolant? Light went on. It required more coolant to be added. There was no external leaking of the engine coolant. The light went on again about two weeks later. I took it to a private mechanic and the cap was replaced. The leak stopped. In feb. 2005, the ?low coolant? Light went on again and again I added coolant. Two weeks later, the ?low coolant? Light went on. This time I took my vehicle to a Chevrolet dealer. I was informed by the service dept. Of this dealer that my car required a new intake manifold gasket. Also, engine coolant might have leaked into my engine, so the oil and transmission fluid required flushing and filters needed to be replaced. The service department informed me that it needed to be done immediately otherwise serious damage could be done to my engine. …
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. …
Purchased vehicle used from a dealership. Over heating issues began within 3 months. Had thermostat replaced. Always seemed to have to be adding water as the reservoir was low or the indicator light would come on. 18 months later over heating issues returned while driving home on highway. When vehicle could no longer run, we had to have it towed home. Have now replaced thermostat and water pump. Issue remains, but worse. Low water and now check engine lights are on. All indications suggest head gasket issues which will ultimately result in complete engine failure. As such, the vehicle cannot be safely driven and remains parked. No such issues were disclosed at the time of purchase. Only learned extent of problem after researching issue online to find many, many other owners of this vehicle type experiencing same problems. Chevrolet showed little concern when contacted. …
Engine complaints in other Malibu years
Frequently asked questions
How common are engine problems on the 2002 Chevrolet Malibu?
NHTSA has 85 complaints about the engine & cooling of the 2002 Chevrolet Malibu, 15% of the model year's 567 complaints. The component named most often is cooling system (17 mentions).
Is there a recall for 2002 Chevrolet Malibu engine problems?
No. NHTSA lists no engine & cooling recall for the 2002 Chevrolet Malibu, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2002 Chevrolet Malibu engine problems start?
Half of the complaints with a recorded mileage happened before about 73,000 miles, and 8% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.