Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
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).
This is the second report I have had to make about a problem with my 2002 Chevy Malibu. I went to start my car yesterday and the car would not start and instead would just crank. After reading in my owner's manual that the passlock anti-theft system in the car needed to be reset, I had to sit with my car key in the on position for 10 minutes; then I turned my car off and my car started fine. I just had my car towed last week to a dealership where they found nothing wrong with it because I did not know about this problem. If you do a simple internet search anyone can see this is a flaw in the 2002 Chevy Malibu and other years of this same make and model. I do not always have time to wait the 10 minutes to reset this problem and am afraid it is only going to get worse and worse. In the event of an emergency what would I do if my car wouldn't start and I had to get somewhere urgently. …
I tried to start my car yesterday morning after having it only sit for an hour when the car would crank but not start. It seemed as if the car was not getting fuel and less than 3 weeks ago had a new fuel pump fixed on it because of this same issue. As I stated before, the car would crank but not start. I had it towed to the local Chevy dealership and they were unable to find anything wrong with the car and had it starting and running every time they tried to diagnose the problem. After doing research online, it appears this is a common problem with Chevy Malibu's as it deals with an error in the anti-theft device for the car and deals with the passlock system. This is an inconvenience for owners of Chevy Malibu's and is such a common problem it needs to be fixed by the manufacturer or this vehicle.
Tl* the contact owns a 2002 Chevrolet Malibu. When the driver turned the ignition to the on position, the vehicle did not start. The vehicle was examined by an independent mechanic while at the contact's residence who diagnosed that the fuel pump failed and needed to be replaced. The vehicle was repaired, but the failure recurred numerous times. The vehicle was later taken to a dealer where the vehicle was not diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 125,000. The VIN was unavailable.
Tl* the contact owns a 2002 Chevrolet Malibu. When the engine was turned off, the vehicle failed to restart and the security light blinked on and off. The vehicle was towed to a mechanic who replaced the fuel pump; however, the failure recurred. The vehicle was taken to a mechanic who diagnosed that the pass lock sensor failed. The vehicle was not repaired. The VIN was unknown. The approximate failure mileage was 140,000.
Dt: consumer stated: had a fire under the hood, fuel evaporation hose which melted caused the fire. Chevrolet stated hoses broke. No for warning, found out when catalytic converter went bad, and sensors burnt. Any thing in the stream of that was burnt or melted.
I walked out the door ready to go to work got in the car turned the key it would not start. So first I had to wake someone up with a phone call because this is our only car. Got a ride to work late and called the place where I am buying this car for them to tow it two miles to there shop and charge me seventy eight dollars. I get the call from them saying its the fuel pump(another common unnecessary fix that you here repeat over and over. He also said the antitheft light was on and that I somehow demagnitized the key(wasn't possible because I was given a all silver key no chip in it) so that cost almost a extra hundred for the key.so after im riding almost fine torque could be more v6ish but I digress Tuesday sep 4 2012 not a month later it doesn't start again, and again on my way to work. This time I had it towed and by the time it made it to the mechanic its was starting fine. …
My vehicle is messing up on me and it was shut off my vehicle is messing up on me it will shut off well driving ill pull over and wait a couple mins and I will pull out the fuel fuse and wait a couple mins and will put it back and it will start again after a week it shut off on me and would not start had to have it towed took it to a mechanic he changed the fuel pump and marjoram worked for 5days then the same problem again changed the sensors worked OK for 2days and the problem came back again so I changed the spark plugs fuel filter all fuses still nothing its been sitting for 3 to 4 months now I can't seem to find the problem I changed everything u can thing of now the check engine and test system light is on
My 2002 Chevrolet Malibu ls left me stranded at a busy fueling station. The car refused to start due to the faulty passlock ignition switch system. These parts were replaced at an authorized GM service center at approximately 47,000 miles due to the same issue of refusing to start. Now at around 21,000 miles later the parts have failed again. GM and NHTSA need to resolve these safety issues. I don't feel safe in this car, and I don't believe it is reliable. Wake up this is yet another GM ignition problem that has been known for decades! Anyone in doubt just do an internet search on GM passlock or Chevrolet Malibu ignition problems.
May 2013: car hard to start; multiple attempts before engine started May 2013: had new key made at local Chevrolet dealer December 2013: continued problems starting car; replaced ignition switch July 1, 2014: GM announces expanded recall to include 2002 Malibu; called local Chevrolet dealer; they said we have to wait for the letter from GM; dealer did not know about expanded recall July 14, 2014: car engine turned off while driving July 15, 2014: called local Chevrolet dealer again; still knew nothing about expanded recall; couldn't advise as to whether car is safe to drive.
Car coughs/hesitates when driving between 65-75 MPH. Began doing when I moved to arizona. Did not do it in fl using regular grade gas. Dealer said my fuel filter was all clogged and dirty and the fuel was getting dark colored. Said I need to use chevron or arco gas as they put a detergent in their gas that GMC is recommending for all their cars. Dealer changed fuel filters and air filter. I tried regular grade gas from arco. No difference. Am taking it back to service at dealer again.
Fuel System complaints in other Malibu years
Frequently asked questions
How common are fuel system problems on the 2002 Chevrolet Malibu?
NHTSA has 29 complaints about the fuel & propulsion system of the 2002 Chevrolet Malibu, 5% of the model year's 567 complaints. The component named most often is delivery › fuel pump (9 mentions).
Is there a recall for 2002 Chevrolet Malibu fuel system problems?
No. NHTSA lists no fuel & propulsion system 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 71,000 miles, and 18% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
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.