Print this page


pretty bad
Typical Repair Cost:
Average Mileage:
80,637 miles
Total Complaints:
118 complaints

Most Common Solutions:

  1. replaced intake manifold gasket (58 reports)
  2. not sure (31 reports)
  3. replace gasket (13 reports)
  4. run to the hills and buy an import (6 reports)
  5. submitted my name to class action lawsuit (4 reports)
  6. replaced with non-plastic gasket (3 reports)
2002 Chevrolet Malibu engine problems

engine problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2002 Chevrolet Malibu:

Unsubscribe any time. We don't sell/share your email.

2002 Chevrolet Malibu Owner Comments (Page 5 of 6)

« Read the previous 20 complaints

problem #38

Jun 292006

(reported on)


  • 79,000 miles


It really bothers me that there are so many similar problems with these GM engines. GM should do something about this. It will end up hurting them later when nobody trusts the engine they put in their cars. I went to 2 different mechanics and they both told me that they have fixed SEVERAL if not HUNDREDS of Malibu's with this same problem. They blame the engines. There should be some sort of recall on these to be fixed by the defective company that made them. SHAME ON YOU GM!!! I wont be buying another Chevrolet!

- , Fort Worth, TX, US

problem #37

Mar 062007

(reported on)

Malibu 3.1 V6

  • Automatic transmission
  • 81,000 miles

Had the check fluid level light come on so i check the antifreeze

level. There was globs of white sludge in the reservoir . I refilled it and it seemed to be ok , but when i would stop the car it had a smell like something getting really hot , i found fluid leaking on top of the engine under intake manifold . It wasn't leaking that bad so i thought i would wait till the weekend to fix it, well on the way home from work after getting off freeway the leak is getting worse. I get on the net and find this site ,

why is GM selling junk to it's customers ? I've always owned GM's

my next car will probably be Japanese !!

- , Yucaipa, CA, USA

problem #36

Mar 112007

(reported on)

Malibu V6

  • Automatic transmission
  • 120,000 miles

I had my catalytic converter replaced about 3 months ago. Now its almost clogged again because of leaking antifreeze. I havent had an estimate yet. Going to monday. If anyone knows how i can get gm to help with this any info would be appreciated. Its a real pain in the@$#&^%

- , Statesville, NC, USA

problem #35

Mar 082007

(reported on)

Malibu SE 3.1

  • Automatic transmission
  • 40,000 miles


My coolant level light turned-on on the dash. I smelled the Anti-freeze after driving for 15 mins. I had to replace the anti-freeze 3 times per week. The leak slowed down eventually.

I was told by a mechanic that its the Intake manifold gasket that has failed. I was also told its an $800 job and it takes 2 days. I cant afford to give up my car for any amount of time.

Why is GM still putting in defective gaskets at this day and age. Someone suggested that GM "might" do something for me because of the young age of the car (41k Miles). Is this true? I am a second owner and never received any bulletins or recall notices.

If there is a class action suit on this manifold gasket, please include me.


- , New York, NY, USA

problem #34

Jul 122006

(reported on)


  • 110,000 miles

I first thought that this was my fault someway for having taken my car to a different shop while out of town for a radiator flush.

Then I found this site.

- , Avondale, AZ, USA

problem #33

Sep 052006

(reported on)


  • 81,000 miles

My 2002 Chevy Malibu decided to not go forward yesterday when I hit the gas! I was on a 55 mph highway! My kids and I could have been killed! It just kept revving. I think GM should make this right. This is an engine/safety issue. I believe we should fight this one because someone is going to get hurt, let alone the cost to fix it. I love the car other than this one and only problem I've had with it. If they don't make good on this, I probably won't buy another GM vehicle. My warranty just expired also! I had an extended warranty for the first time in my life on a car, and as soon as it ran out, boom!

- , Youngsville, NC, USA

problem #32

Feb 242007

(reported on)

Malibu 3.1L

  • Automatic transmission
  • 45,000 miles


Here's a head's up that might help some of you. See my full comments on the 2001 Malibu complaint listing. Here's a brief summary. My 2001 Malibu with 45,000 needed the lower intake manifold gasket replaced. After the dealer told me that GM wouldn't do anything, I spoke with GM customer service 800-222-1020 and they agreed to pay half the cost ($700). I even had the repair done at an independent garage.

GM was professional and helpful. A total shock. By the way, I bought the malibu used and never had service done at the dealer. Don't know if it made any difference but I told GM that I wanted to "request cost assitance" for this repair and was aware that a class action suit regarding this "engine defect" had been filed against GMCanada.

Good luck.

- , Nashville, TN, USA

problem #31

Feb 212007

(reported on)

Malibu 3.1L V6

  • Automatic transmission
  • 75,000 miles

Coolant began leaking and continues to increase. Local mechanic said intake gasket was the problem. I called Bill Gatton Chevrolet from whom I purchased the car. I was told this was not an uncommon problem for a 2002 Malibu. They said since I didn't have an extended warranty General Motors could (would) not help. Approximate cost of repair, I was told, will be $750.00

- , Bristol, VA, USA

problem #30

Feb 192007

(reported on)

Malibu LS 3.2

  • Automatic transmission
  • 67,000 miles

When I took the car in for my last oil change I was told the intake manifold is leaking badly and that it would cost $897.00 to have it I paid up, had no choice! I was also told I should not drive the car any more than necessary. I am afraid there is now motor damage. I am close to retirement and do not want to purchase another vehicle. I keep my car service properly to avoid unnecessary car repairs. I have owned GMAC cars since 1967 and my family since 1947. I will not purchase another GMAC product. I have a Saturn which is my daughter's. I pray nothing happens to that one.

- , Kansas City, KS, USA

problem #29

Feb 182007

(reported on)

Malibu 3.2L V6

  • Automatic transmission
  • 49,000 miles

You can bank on the start of major car repair bills when an American made car turns five years old. The problem started with the smell of coolant in the car when the heater was on. Also, it was taking forever for the car to get warm. I added coolant several times before taking it in for repair, fearing that it would not be a minor expense.

- , Frederick, MD, USA

problem #28

Feb 152007

(reported on)

Malibu 3.1

  • Automatic transmission
  • 73,000 miles


Bad intake manifold gasket. This is my only transportation so I had to pay to have it fixed. Only if I had known about this problems before I had bought this car......

- , Carmichael, CA, US

problem #27

Feb 042007

(reported on)


  • Automatic transmission
  • 72,000 miles

My Malibu has 72,000 miles on it, we use the Dex-Cool anti-freeze in it. When we bought it we were told that this is what we needed to use in it and nothing else. Well it seems that this may be the root of the problem, the intake gasket is leaking and our mechanic is charging almost 600.00 to replace it. Needless to say, I have to borrow this money for the repairs. I understand there is a class action lawsuit against GM. How do I sign up for this? This is a rip off, and if anyone is considering buying a Malibu, I say steer clear of this piece of crap.

- , Berea, KY, USA

problem #26

Feb 022007

(reported on)

Malibu 3.1L V6

  • Automatic transmission
  • 77,000 miles

I had brought my car down to the dealership in June of 2006. I was having problems with my coolant level and the car was starting to over heat. I had a few people look at it before i brought it down so i could know what was wrong with it. The dealership told me it was a leaking intake manifold gasket and this was common on this vehicle. They "fixed the problem" and now its February of 2007 and the gasket is leaking again. I contacted the dealership and this time around they are not so nice. I argued with them they told me to bring it down in a week i said if this causes my car to break they are going to be held responsible they said no then i asked for a loner car for the week and they said no. I asked them then what do they want me to do he said i don't recommended driving the car. So i argues my point and i get to bring it down to the dealership the day after the phone call. Now i liked my car but its ending up being more of a hassle then it should be.

- , Manchester, NH, USA

problem #25

Jan 292007

(reported on)

Malibu 3.1 V.6

  • Automatic transmission
  • 67,229 miles

I took my car in for an inspection on 01/20/2007. I was told that I had a leak in my "INTAKE MANIFOLD GASKET." Of course I was PISSED. I have had this car for 4 years and I only have 67,299 miles on my car. After I did search on the computer regarding the "INTAKE MANIFOLD GASKET," I was shocked by all the complaints of the same issue on this site. I feel that it very sad! I was told that it would cost me over $800 to get it fix. But, you know something else will be found wrong and it will be more. Actually, today 01/29/2007, I called GM-1-800-222-1020, and was told to take my car to a GM dealer. I was giving a service request # and was told that I could call back once I had taken my car to GM. Bunch of Bull S*! So, I informed the Rep. "why would I take my car to GM, pay them money to tell me what I already know?" I have had to service mechanics tell me that I have a LEAK IN THE INTAKE MANIFOLD GASKET.

2) BY THE WAY IN 7/06... I was sent a letter from GM stating that the 2002 Chevrolet Mailbu had been recalled due to electric malfunction in the turn signals. Actually, before I received the letter, I had already took my car to GM service and had it fixed. The good thing was that I was refunded my back of $120. Which I was happy about. But, I am not sure HOW this issue with the INTAKE MANIFOLD GASKET ISSUE IS GOING TO TURN OUT. But I will fit to the end. The sad part is that my car will soon be paid off in another year.


- , Raleigh, NC, USA

problem #24

Jan 302007

(reported on)

Malibu 6cyl

  • Automatic transmission
  • 27,000 miles

i called chey and complained then i took it to ken wilson chey in vestal and i bitch some more so they called chevy and they fixed it for 100.00

- , Binghamton, NY, US

problem #23

Jan 182007

(reported on)

Malibu 3.1

  • Automatic transmission
  • 101,000 miles

I have had nothing but problems with this car. I had just spent $500 on repairs only to find that there was a problem with a cracked intake manifold gasket which is caused by faulty GM parts and the orange coolant called Dex-Cool! What a rip-off! We are told to use this coolant and it causes this problem. I keep hearing about others having the same problem! Is GM going to do anything about this? Who else can I contact for results. I want to be reimbursed for these repairs. I am on Social Security and cannot afford these problems constantly. I will never buy another Malibu!. Does anyone know of a class action lawsuit in the United States? If so, please contact me.

- , Owego, NY, US

problem #22

Jan 162007

(reported on)

Malibu 3.1

  • Automatic transmission
  • 69,000 miles

This car is a piece of crap!! We've only had it 6 months. The intake manifold gasket was cracked. we had to borrow money from two sources to get this fixed. Chevy is not a reliable product. Does anyone know about a class action law suit that may have been filed?? if so let me know PLEASE!!! the mechanic said that the cause is the sh--ty orange coolant (Dex-cool) that is being used by GM. i've heard several others say the same thing. we really need to go after GM and Dex-cool for this. I WANT MY MONEY BACK FOR THE CAR AND THE REPAIRS.

- , Apalachin, NY, USA

problem #21

Nov 052006

(reported on)

Malibu LX 3.2 V6

  • Automatic transmission
  • 94,000 miles

A have to add one liter of coolant every week. Just want to know how much it would cost

- , Yorktown, VA, USA

problem #20

Jan 022007

(reported on)

Malibu V6

  • Automatic transmission
  • 50,000 miles

I was told I have this problem also - I came here to see if anyone else had the same problem. I am having to go in to the dealer to get it fixed. I'm so sorry I got the car - I'll come back when I get it fixed.

- , Phoenix, AZ, USA

problem #19

Dec 272006

(reported on)

Malibu V6

  • Automatic transmission
  • 80,000 miles

Discovered cracked lower intake manifold. I understand that it is caused by the Crappy orange antifreeze (Dex-Cool) that GM uses. It turns to sludge and eats up gaskets, aluminum parts and more. The Malibu is my Son's car. I will never buy a GM Car!

- , Summerville, SC, US

Read the next 18 complaints »

Not what you are looking for?