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definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
25,640 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2002 Chevrolet Malibu exhaust system problems

exhaust system problem

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2002 Chevrolet Malibu Owner Comments

problem #5

Sep 272007

Malibu 6-cyl

  • Automatic transmission
  • 68,200 miles


The anti-freeze holding tank keeps getting an oil residue in it and the anti-freeze keeps disappearing into the engine and has to keep being refilled. After speaking with a mechanic it is possible that the intake manifold gasket is failing. The A/C switch also turns off on its own. Rotors and brakes have been replaced three times.

- Arcadia, WI, USA

problem #4

Mar 012007

Malibu 6-cyl

  • miles
Chevrolet Malibu intake manifold gaskets" begins to leak anywhere around 80,000 miles of driving. This causes the car to leak coolant, to overheat, and motor will lock, burn out. This car was not even 5 years old, and I have spoken to other Malibu owners who had this work done of their cars costing $500 to $700 I felt as though the manufacturer needed to improve this gasket and replace the cars that already had this defective part.

- Bedford, OH, USA

problem #3

Feb 102007


  • miles
GM V6 defective intake manifold gasket failed, causing coolant to disappear through engine or into engine oil. Causes engine to overheat, and possible sever internal damage. Last failure was on 2002 Chevrolet Malibu at 39000 miles, it failed 2 times on 1998 Pontiac Montana under 80000 miles, failed 2 times on 2000 Chevrolet Venture under 80000 miles. Failed 1 time on 2002 Malibu. Manufacturer was aware of defect, but did not tell customer.

- Irvinec, CA, USA

problem #2

Mar 242005

Malibu 6-cyl

  • Automatic transmission
  • miles
Hello, on Chevy malabu cars, they have defecitve input manufold valves. Online thousans of people are in forms that show it is in alot of people cars and GM is not helping

- New Lenox, IL, USA

problem #1

Jul 192003

Malibu 6-cyl

  • Automatic transmission
  • 60,000 miles
Catalytic converter went out while traveling 500 miles from home. Mileage was only 60000 miles. Was under warranty but part was on nationwide back order. Chevrolet customer service would not authorize rental or towing. We were stuck for two extra days while someone took coverter off and drove home without it. Then I was informed by customer service that I had voided warranty. Dealership was able to get coverter replaced under warranty only after a huge fit was thrown on my behalf. Second, gas cap seal is bad; after fill up sometimes have to restart car because empty light comes on. Third, at 80000 miles the intake air gasket had to be replaced. Cost of $1200. Fourth, while trying to install after market cd player discovered that you have to buy $100 wire harness and new front speaker in order for stereo to work, the way Chevy made it to be.

- Columbus, GA, USA

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