| 1 | 0 | 3 | 4 | 3 | 4 |
2004 Chevrolet Malibu repairs by problem area
Engine (29%)
Transmission and Drivetrain (4%)
Brakes and Traction Control (6%)
Suspension and Steering (29%)
Electrical and Air Conditioning (20%)
Paint, Rust, Leaks, Rattles, and Trim (6%)
Other (6%)
Chart based on 163 repairs.
2004 Chevrolet Malibu engine repair cost distribution
$2500+ (0%)
$1000 - $2499 (5%)
$500 - $999 (2%)
$100 - $499 (42%)
< $100 (51%)
Chart based on 43 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.
2004 Chevrolet Malibu 4dr Sedan
200-horsepower 3.5L V6 4-speed shiftable automatic FWD
| 53000 mi US $357 |
Body Control Module Replacement - Heater did not work. Vehicle was in the shop for 1 business day. |
| 177000 mi | Radiator issues and blown head gasket. Not worth fixing. Also needed a new exhaust. |
| 106000 mi US $140 |
Check Engine Light was illuminated due to error code indicating failing thermostat. Thermostat was stuck open. Replaced thermostat. Check Engine Light also stored EGR error code. EGR valve was replaced about a year ago and was tested and found to be working. Cleaned EGR system and valve and reinstalled. No further codes found. |
| 115000 mi | Check Engine Light gave EGR Insufficient Flow code. Tested all components to be working. Removed throttle body and thoroughly clean all passages per TSB. |
| 133000 mi US $136 |
Rough idle. Check engine light eventually came on and code was mis-fire on cyl 1. Decided to try replacing coil assembly. This fixed it. |
| 138000 mi US $112 |
Engine warning light came on with no other symptoms. Code indicated "low engine temperature condition". Replaced Thermostat, problem solved. |
| 158000 mi US $390 |
Muffler and exhaust pipe rusted and were leaking. Previously replaced just 3 years ago. The original lasted 7 years! I guess the aftermarket parts really are inferior. |
| 79560 mi | Ignition switch replaced |
| 43500 mi US $10 |
Check engine light went on. Auto parts store read code and indicated that the cooling system thermostat was likely stuck open. Replaced the thermostat myself and the problem was resolved. |
| 100300 mi US $194 |
Replaced exhaust y-pipe. I purchased part and had it installed at a local garage where my friend is the shop manager. I received a discount on the labor. Other shops quoted over $600 |
| 123000 mi US $120 |
Motor mount and transmission mounts replaced. Work completed by myself in about 4 hours Car was exhibiting a noise that sounded like a whine. Dealer mechanic noticed a vacuum hose that had fallen off so he cut off the end and reattached. |
| 123000 mi US $64 |
Replaced the camshaft position sensor and the oil pressure sensor/switch to resolve check engine light |
2004 Chevrolet Malibu 4dr Sedan
145-horsepower 2.2L I4 4-speed shiftable automatic FWD
| 91520 mi C $200 |
Thermostat required replacement |
| 110360 mi C $400 |
Catalytic converter plugged and had to be changed |
| 110360 mi C $350 |
Exhaust rotten from front to back. Had to be replaced |
| 79670 mi | The engine would shut down and engine light would come on 4 times while driving in the city and on the highway. They replaced the crankshaft sensor and said it was not a common problem. Free at 128,400km. because warranty coverage up to 130,000 km. camshaft or crankshaft sensor replaced because car was stalling out on engine disabled while driving.While driving the car would shut down and I would have to restart. |
| 79980 mi C $215 |
Flexible piece in the exhaust line before the resonator broke and they had to weld a new piece inline and guarantee for 1 year at Canadian Tire.They could not locate exact part and welded a piece in line. |
| 157000 mi | Had rebuilt engine 3 times before. Will not do it again. This car was scrapped. |
2004 Chevrolet Malibu 4dr Hatch
200-horsepower 3.5L V6 4-speed shiftable automatic FWD
| 130000 mi US $350 |
Vapor recovery valve assembly cracked under hood, throwing 'gas cap' light and check engine light. |
| 15700 mi | Replaced accessory drive belt (Was slipping) Replaced fuel tank. (tank has collapsed and could only be filled 3/4 with gas |
| 32500 mi | Reprogram ECU to cure hot start issue |
| 51000 mi | Replace fuel pump. Hot starting issue. |
| 10392 mi | Noise still heard in rear suspension - unable to determine |
| 22014 mi | Noise in rear suspension found! - turned out to be fuel filler neck rubbing on car frame. All gauges would not work after starting car, but resumed operation after stopping and restarting - dealer unable to duplicate the problem. |
| 42426 mi C $1009 |
New brake pads and rotors, front and rear - Fuel injection service - Knocking in steering - replaced steering shaft |
| 100000 mi US $12 |
Fault Code P046 - Evap Emission system fault Replaced Fuel Cap Reset fault |
| 102300 mi US $35 |
Fault Code P046 - Evap Emission system fault Replaced Evap vent valve. |
| 123000 mi US $50 |
Fault Code P0128 - Replaced thermostat and coolant temperature sensor |
| 127720 mi | CEL on but unknown cause; no discernable issues with driveability etc. |
| 41000 mi US $20 |
Long starting problem. |
| 74900 mi US $300 |
Purge solenoid value replace. |
| 113000 mi US $100 |
Exhaust, replaced muffler |
| 66200 mi | Flushed cooling system, replaced hoses and new water pump installed. Water pump was leaking coolant. |
| 127000 mi US $1500 |
Full new exhaust system including two new catalytic converters. |
| 228000 mi US $500 |
Radiator had hole in the bottom. |
| 94200 mi US $146 |
Car would lose power, engine light came on with codes P2101, P0120, P0220, P1516, P2135. Decided problem was throttle body. Dealer wanted $300 for part. Bought ACDelco Part 217-2295 on Amazon.com for $146. Installed new part. Problem solved |
| 99000 mi US $5 |
Replaced failed engine coolant temperature sensor. Preventive maintenance was replacement of water pump, thermostat, engine drive belt, coolant, radiator hoses. |
| 131000 mi US $90 |
Rust hole in muffler |
| 136000 mi US $100 |
Rusted out exhaust flex pipe |
| 137000 mi US $53 |
CarMD code: O2 sensor Bank 1 [rear cylinders] Sensor 1 [upstream of converter]. Replaced both upstream O2 sensors with Denso 234-4668 purchased on Amazon. |
| 147000 mi US $173 |
Replace exhaust system flex pipe. |
| 188000 mi | replaced fuel injectors. One was faulty (partially clogged), but I replaced them all as I got a deal on a set from eBay. |
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