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 2005 Chevrolet Malibu owners, lightly cleaned up (personal details are redacted by NHTSA).
This problem has occurred many times and I have taken to the internet to find out what I could to try to remedy it myself as I don't have endless disposable income to have someone else fix it. I have not had it seen by a professional, only consulted with a manager of a gm dealership repairs department over the phone as well as various mechanics and locksmiths. As I said I don't have endless disposable money to throw at this. The car will completely shut off in the middle of driving, I lose all power. The antitheft system engages in the middle of driving. Then I get no crank no start. I get stuck in the middle of the road. …
These are the photos take of the fuel pump after it was removed by mathis auto service (see the attached invoice). As you can see the tag has only a small part of a bar code, I didn't know whether or not this was the part number or not, but it seem there was no number. The top of the pump was very dirty and wet from gasoline. I had the fuel pump replace after I was transporting a client and the car started sputtering and lost power from 45-miles-per hour to about 10-miles per hour, before I was able to turn into a parking lot. This scared the client and lead them to report to lyft about the incident. I also reported the issue to lyft ride share and they shut down my vehicle for safety reasons by deactivating my account. Since then I have had the Chevrolet dealership to complete 4 recalls, which did not clear up the problem. Or correct the fuel pump from seizing up and stalling out. …
Starting around two years ago, fuel gauge after filling tank and then starting car would fall to empty along with low fuel light coming on. When restart car was okay. So, did not fill tank anymore, alleviated problem for a year. In past year got worst, and check engine light would come on until using up until at least 2 gallons was used when gasoline was added. Then engine light went off. As time went on, fuel gauge acting up more, never reading accurately how much gas is in car. In last month, no matter how much or little fuel is added, reads full for a long time, then gauge drops suddenly to empty and low fuel light comes on, and check engine light comes on. Had checked, indicates the fuel sensor is entirely not working now /or fuel pump May not work soon. So every 100 miles, guess how much fuel to add. Not knowing, could run out of gas anytime, and car shut down. …
When I am driving, highway or local, my engine will stutter and shut down, or just quietly shut down right in the middle of traffic. It is happening a lot. I have found myself facing oncoming traffic during some of these stalls. Sometimes I can get it to restart snd other times I cannot. Also. I am having trouble get gas into the tank when fueling. I hear air escaping and the pump will shut off. Local mechanics do not want to tackle that issue. The dealer I bought it from says since I bought it used, as-is, that the problem is on me. I have read online that many people are having this same problem. I don't want me ire anyone to become a fatality because of this. What can be done?
Tl* the contact owns a 2005 Chevrolet Malibu. The contact stated that while driving at an undisclosed speed, the vehicle loss power steering assist. An audible chime was heard during the failure. The vehicle was stopped, and the power steering assist returned independently. Additionally, the check fuel cap warning light was illuminated. The vehicle was not taken to a dealer nor independent mechanic to be diagnosed. The contact stated that the vehicle was previously repaired under NHTSA campaign number: 14e044000 (steering) however, the repair failed to prevent the failure. The manufacturer was notified of the failure. The failure mileage was 140,000.
Tl* the contact owns a 2005 Chevrolet Malibu. While driving approximately 25 MPH, the vehicle stalled without warning. The vehicle was towed to an independent mechanic for diagnostic testing. The diagnosis was that the fuel pump needed to be replaced. The vehicle was repaired, but the failure recurred. The vehicle was taken to the dealer, but was not diagnosed or repaired. The contact was made aware of NHTSA campaign number: 11e009000 (fuel system, gasoline); however, the VIN was not included. The manufacturer was not notified of the failure. The approximate failure mileage was 100,000. Updated 7/16/15
Tl* the contact owns a 2005 Chevrolet Malibu. After the vehicle was filled with fuel, the contact had to make several attempts to start the vehicle. The vehicle was driven to the contact's residence and failed to start the following day. The check engine warning indicator illuminated permanently and the fuel gauge fluctuated between empty and full. The vehicle was taken to an independent mechanic, but did not register any failure codes. The manufacturer was not notified of the failure. The VIN was unknown. The approximate failure mileage was 109,000.
Tl* the contact owns a 2005 Chevrolet Malibu. While driving 30 MPH, the steering wheel seized and became difficult to maneuver. The power steering warning indicator illuminated and the brakes failed to respond. When the vehicle was being refueled, the fuel spewed out the fuel filler pipe. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failures. The VIN was included in NHTSA campaign number: 14V153000 (steering). The failure mileage was 295,000.
Tl* the contact owns a 2005 Chevrolet Malibu. The contact stated that the fuel sensor level failed, and the fuel sensor and check engine indicator illuminated. The contact mentioned that the fuel tank would be full, but the fuel level sensor showed half a tank. In addition, the vehicle failed the state inspection due to the fuel sensor and codes. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was 139,200.
Gas gauge reads incorrectly and bounces erratically from full to empty and back again turning on the check-engine light and setting off the audible low fuel warning. This happens have every fill-up. In between fill-ups, gas gauge "sticks": to some arbitrary intermediate value. It never displays accurate fuel-remaining. I must used the odometer mileage to know when to get gas. This erratic behavior occurs when vehicle is in motion or stopped at a red light.
Fuel System complaints in other Malibu years
Frequently asked questions
How common are fuel system problems on the 2005 Chevrolet Malibu?
NHTSA has 70 complaints about the fuel & propulsion system of the 2005 Chevrolet Malibu, 7% of the model year's 975 complaints. The component named most often is storage › tank assembly (2 mentions).
Is there a recall for 2005 Chevrolet Malibu fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2005 Chevrolet Malibu, though it has 3 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 2005 Chevrolet Malibu fuel system problems start?
Half of the complaints with a recorded mileage happened before about 99,000 miles, and 4% 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.