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 2004 Chevrolet Malibu owners, lightly cleaned up (personal details are redacted by NHTSA).
My car was recalled for a transmission shift cable problem. I took it to the dealer in February of 2015 and the dealer replaced it per the recall. On marc 27th 2016 the shift cable came off of the transmission shift lever and I could not shift out of drive. I turned the motor off and now the car started rolling backwards due to the incline I had stopped on. Since the car was in drive I was unable to start the car. The brakes were ineffective because the motor was not running. This actually happened in my garage so I had my wife put a scrap of wood behind the tire so it would not roll out into the street. I contacted the dealer that did the recall work and was told that the recall service was only waranteed for 1 year. I am having difficulty understanding that the original recalled part lasted for 11 years and the replacement part only lasted for 13 months. …
Tl* the contact owns a 2004 Chevrolet Malibu. The contact stated that the headlight bulbs constantly turned off. The vehicle was taken to repair shops and dealerships several times. The bulbs were replaced but the failure continued. The headlight bulb recently melted to the wiring harness. The vehicle had not been repaired at the time of the complaint. Additionally, the contact stated that the fuel gauge would fluctuate between full and empty and did produce correct readings. On three occasions, the contact ran out of fuel because of the faulty gauge. The vehicle had not been inspected or repaired for this problem at the time of the complaint. The contact called the manufacturer and was told , due to high mileage on the vehicle, they could not assist her. The current and failure mileages were approximately 60,000.
My check gas cap keeps coming on n my car is leaking gas from the fuel pressure line n upon doing some research I have found that several people have the same issue so I checked for a recall on the car which it seems to me it should have one but does'nt it's clearly a factor defect if alot of people are experiencing the same issue it leaks when the key is on I won't drive it for two reasons one who can afford to have their gas leaking and two I'm affraid it could blow-up while driving it. I just bought the car a month ago so really don't know when the issue actually began.
Tl* the contact owns a 2004 Chevrolet Malibu. The contact stated that the vehicle failed to start. The vehicle was towed to a dealer. The technician diagnosed that the fuel pump needed to be replaced. The vehicle was repaired. The contact was made aware of NHTSA campaign number: 11e009000 (fuel system, gasoline) but the VIN was not included. The manufacturer was not notified of the failure. The failure mileage was 163,629.
Tl* the contact owns a 2004 Chevrolet Malibu. While driving at 20 MPH, the power steering became difficult to maneuver and the power steering warning light illuminated. The contact also stated that the high pressure fuel line fractured and leaked fuel into the muffler. The failure recurred once. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was 159,672.
Tl* the contact owns a 2004 Chevrolet Malibu. While driving at approximately 30 MPH, the vehicle stalled without warning. The vehicle was taken to a local mechanic where it was diagnosed that the fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 140,000.
"Takata recall" there is alot of completion of the fuel gage reading wrong after u fill the tank up. I will fill up on gas and my gaga will read empty and will tell me low fuel. This will go and fix it self after it run for about 20 miles. Only happens after I fill it up.
There was a recall on fuel system my engine light is on and had it diagnosed and its reading I need a fuel pump cant understand why when work was already done sometimes when I accelerate to 25-30 stutters and putts
For about 3 years the theft light would come on when trying to start. Then you would have to wait 10 minutes to start. In December while driving at 60 mps the engine stopped, power steering was lost and the theft light was on. After 10 minutes the car started again. Then two times later the engine stopped while driving between 60 & 65 MPH, power steering was lost. One of these times the car started up again and power steering recovered. I took the unit to the Chevrolet dealer in emporia, kansas. They said the switch needed to be replaced and that the fuel pump cuts off because of the age of the vehicle. Both need to be replaced at a cost of over $1,100 according to them. Normally the car operates great! I can't understand why a product is allowed on the market with a fuel pump that works part-time. …
My 2004 Malibu has given me problems since I first purchased it. My check engine light has always been on. If I stopped and start the car 4 or 5 times a day it would not start right away. The car has been in the shop a few times. The dealership could never found out why it was on. Recently, I've been having this knocking sound when I turn the wheel, my fuel gauge stopped working. Took it to the shop, I was told that I needed a fuel reader which came with the fuel pump. The fuel pump was good. As long as I know how much gas I have in the car I'm good. A month later the car starts but doesn't stay on. I had the car towed to the shop. It took them 24 hours to tell me that I needed to replace the fuel pump. $997.00. This is after the computers had been going down all day. Thinking about getting a new car. Online looking at a Hyundai. Checked to see if they had any recalls. …
Fuel System complaints in other Malibu years
Frequently asked questions
How common are fuel system problems on the 2004 Chevrolet Malibu?
NHTSA has 29 complaints about the fuel & propulsion system of the 2004 Chevrolet Malibu, 3% of the model year's 1,147 complaints. The component named most often is storage › fuel gauge system (4 mentions).
Is there a recall for 2004 Chevrolet Malibu fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Chevrolet Malibu, though it has 6 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 2004 Chevrolet Malibu fuel system problems start?
Half of the complaints with a recorded mileage happened before about 114,000 miles, and 8% 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.