The fuel gauge may not read correctly and/or the Check Engine Light may illuminate with code P0455/P0461 stored for a fuel level sensor issue. These faults may be caused by a fuel vapor line inside the fuel take interfering with the fuel level sensor. If this is found to be the case, repositioned and securing the vapor line should correct this concern. If no fault is found with the fuel vapor line, the fuel level sensor itself may be at fault.
Problems for specific Chevrolet Malibu years:
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Most reported 2004 Chevrolet Malibu problems
The passlock sensor in the ignition lock cylinder may fail causing an anti-theft system fault and a no start condition. Our technicians tell us that the ignition lock cylinder should be replace to correct this condition.
The intake manifold gasket may develop and external engine oil or coolant leak. In some cases, an internal coolant leak may occur causing coolant to mix with the engine oil. Our technicians tell us that operating the engine with a coolant/oil mix can result in internal engine damage. Replacing the intake manifold gasket should correct these leaks.
Illumination of the Check Engine Light can be caused by a loose or worn gas cap.
The turn signal switch may fail causing the hazard/turn signal flasher to continue to click even when the turn signal switch is off. Replacing the faulty turn signal switch will commonly correct this condition.
The ignition switch may fail causing a no start condition. This is not generally a theft system (passlock) issue because the security light does not illuminate or flash.
Various issues with the electric power steering system may develop and could require replacement of steering column assembly.
Various electrical issues may be caused by poor terminal contact at the body control module (BCM) electrical connectors. Proper diagnoses will be required to confirm faults are related to poor BCM connections.