Chevrolet Malibu fuel system problems, 2016–2025
282 of the 2,995 complaints owners filed with NHTSA about the Chevrolet Malibu 2016–2025 name the fuel system (NHTSA’s “Fuel/Propulsion System” heading — fuel tanks, lines, pumps and injection — and on an EV, the propulsion battery and motors). The loudest years: 2018 (104), 2017 (62), 2016 (52). Filed under the same heading across these years: 2 recall campaigns. Every figure is a linked federal record; none is a failure rate, none a repair cost, and none a verdict on one car.
Chevrolet Malibu fuel system problems by model year
Source: NHTSA complaints, recalls, investigations and manufacturer communicationsOne row per model year on file, newest first. A year marked in depth has its own page: the complaints, the owners’ words and every document under this heading for that year.
| Model year | Complaints naming the fuel system | Share of the year’s | Typically at | On file under the heading | |
|---|---|---|---|---|---|
| 2025 | 0 | — | — | — | the year → |
| 2024 | 0 | — | — | — | the year → |
| 2023 | 8 | 11% | — | — | the year → |
| 2022 | 10 | 10% | — | — | the year → |
| 2021 | 10 | 11% | — | 40 TSBs | the year → |
| 2020 | 18 | 9% | — | — | the year → |
| 2019 | 18 | 9% | — | — | the year → |
| 2018 in depth | 104 | 15% | 40k | 2 recalls | the record → |
| 2017 in depth | 62 | 9% | 52k | 1 recall | the record → |
| 2016 in depth | 52 | 6% | 54k | 72 TSBs · 1 recall | the record → |
Two things the counts carry that are not the car: how many of each year were sold, and how long each has been on the road — an older year out-counts a newer one before anything is wrong with it. The share column is the honest comparison across years: what part of that year’s complaints named the fuel system. Nothing here is a rate.
When the fuel system complaints were filed, and at what mileage
Source: NHTSA complaint databaseFiled per calendar year, every model year together: 2017: 4 · 2018: 8 · 2019: 52 · 2020: 39 · 2021: 46 · 2022: 28 · 2023: 16 · 2024: 18 · 2025: 45 · 2026: 26
Across the model years, half of the 124 owners who gave an odometer reading reported the fuel system problem between 20,000 and 69,000 miles. A median of reports, not the life of a part.
In owners’ own words
Source: NHTSA complaint databaseFiled with NHTSA by the people who own these cars, about the fuel system, from the model years with the most to say. Quoted as written, with anything identifying removed; unverified reports — what was said, not a finding that it was true.
One of my first problems with this car is the “shift to park” error message. This message on the dashboard indicating that my gear is not in P (park) when in fact it is . This error will not allow me to turn off my car even though I am parked.
The contact owns a 2018 Chevrolet Malibu. The contact stated while driving at an undisclosed speed, the vehicle lost motive power and failed to restart. The contact stated while restarting the vehicle, the contact heard a rattling sound. The vehicle was driven to the shoulder of the road.
Car voltage stays very high (between 14.8 and 15 volts) for extended periods of time. At which point the windows have fogged up and there is a raw egg smell in the cabin - probably Sulfur. Both the hybrid and the 12v car battery are located in the truck and there are vents that draw air from the cabin to ventilate those batteries.
Fuel tank will not fill completely. It will only fill to 7/8ths at best. There are other complaints about this in online forums
I was driving on a highway approx 60 miles an hour when a message came in my dashboard stating reduction in engine power, the vehicle abruptly slowed to 20 mph without any warning and I was barely able to pull my vehicle off to the side of the road without being rear ended by the vehicle behind me on the highway
What is on file about the fuel system, across the years
Source: NHTSA recalls, investigations and manufacturer communicationsRecall campaigns filed under this heading, any model year
- 19V642000 ModerateSep 6, 2019 · 177,282 vehicles
- General Motors LLC (GM) is recalling certain 2018 Chevrolet Malibu vehicles equipped with 1.5L turbo engines. An error in the Engine Control Module (ECM) software may result in the fuel injectors being disabled.
- 18V358000 HighMay 31, 2018 · 895 vehicles
- General Motors LLC (GM) is recalling certain 2015-2018 GMC Canyon, 2016-2017 Buick Envision, 2016-2018 Chevrolet Colorado and Malibu, 2017-2018 GMC Acadia, 2018 Buick LaCrosse, Cadillac ATS, Chevrolet Equinox, and GMC Terrain vehicles. The high pressure fuel pump may detach from its mounting flange, possibly resulting in the pump damaging the high pressure fuel line.
Other systems with a record on the Chevrolet Malibu
Source: the same files- engine problems
- transmission and drivetrain problems
- electrical problems
- brake problems
- stability control problems
Every system, every model year: Chevrolet Malibu problems by year →
Common questions
Source: NHTSA complaint database, recalls and manufacturer communicationsWhich Chevrolet Malibu years have the most fuel system complaints?
2018, 104; 2017, 62; 2016, 52. Raw counts, and an older year has had longer to collect them; by share of each year's own complaints the loudest is the 2018 (15%).
Is there a recall for the fuel system on the Chevrolet Malibu?
Yes — 2 campaigns are filed under this heading across these model years: 19V642000 (2018), 18V358000 (2018). A recall is matched by VIN, and applies to specific years; check yours at nhtsa.gov/recalls.
When do fuel system problems show up on the Chevrolet Malibu?
Owners who gave an odometer reading reported it at a median of 50,000 miles across the model years; half of them between 20,000 and 69,000. That is when reports cluster, not the life of a part.
What does NHTSA's "Fuel/Propulsion System" heading cover?
Fuel tanks, lines, pumps and injection — and on an EV, the propulsion battery and motors. Owners choose the heading when they file, so it says which area of the vehicle the complaint is about, not which part failed.