2004 Chevrolet Malibu Problem Reports

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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.

The ignition module or an ignition coil may fail causing the engine to misfire which can cause the Check Engine Light to illuminate or begin flashing.

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.

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.

Vehicles with a 6speed automatic transmission may develop one or more of the following faults related to a broken 35R clutch wave plate inside the transmission: Illumination of the Check Engine Light with code P0716, P0776, P0717, P0777, P2714, P2715, and/or P02723, loss of reverse gear, slipping or harsh 3rd or 5th gear shift. Removal and dis-assembly of the transmission will be required to replace the broken 35R wave plate. It is also extremely important that all debris from the failed part be cleaned from the transmission while it is disassembled in order to try and prevent future problems.

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 automatic transmission shifter may fail causing the ignition key to become stuck in the ignition lock cylinder.

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.

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.

Various issues with the electric power steering system may develop and could require replacement of steering column assembly.