2002 Chevrolet Malibu Problems: 2 Issues Every Owner Should Know
2002 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated May 2026
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Chevrolet Malibu has 2 documented known issues. No issues are rated critical, indicating generally reliable ownership. Across all issues, repair costs range from $50 to $800. DIY maintenance guides at au7o.io.
All 2 Known Issues
On the 2000-2003 Chevrolet Malibu, the multifunction hazard switch on 2000-2003 Malibu models is a well-known failure point that can cause intermittent or inoperative turn signals and, in some cases, affect brake lamp operation. The internal contacts overheat or wear, leading to erratic flashing, no turn signal output, or lamps that work only when the hazard button is pressed a certain way. GM issued a recall for hazard warning switch defects on related N-body vehicles including Malibu.
Common Symptoms
- Turn signals intermittently stop working
- No left or right turn signal
- Rapid or erratic flashing
- Brake lamps behave inconsistently
- Signals work when hazard switch is pressed or moved
How to Fix
Diagnosis is usually straightforward when turn signals work intermittently and the fault changes when the hazard switch is pressed or wiggled. The standard repair is replacement of the hazard warning switch assembly in the center dash, followed by verification of turn signal and brake lamp operation. Inspect connectors for heat damage if the switch has been failing for a long time.
What Owners Are Using
Parts and tips from 0+ owners who fixed this issue
- TipIf turn signals are intermittent, test the hazard switch first before replacing the flasher or multifunction stalk.
- TipCheck the switch connector for melted plastic or loose terminals when installing the replacement part.
On the 2000-2005 Chevrolet Malibu, a common failure on early-2000s Malibu models is the Passlock security system falsely detecting a theft condition, which can disable fuel delivery and prevent the engine from starting. Owners report the SECURITY light flashing, long wait times before restart, and in some cases intermittent stalling or crank-no-start behavior. The root cause is typically failure in the ignition lock cylinder sensor/housing or related wiring causing incorrect resistance/voltage readings to the body control module.
Common Symptoms
- SECURITY light flashing or staying on
- Crank but no start
- Starts after waiting 10 minutes
- Intermittent stalling
- No injector pulse/fuel disable
- Random no-start especially in hot weather
How to Fix
Diagnosis usually starts by checking for SECURITY lamp behavior, BCM-related codes, and verifying Passlock sensor data during crank. Repairs commonly involve replacing the ignition lock cylinder housing/switch assembly, repairing wiring at the column, and performing the Passlock relearn procedure. Some owners also replace the ignition switch if heat-related internal contact failure is present.
What Owners Are Using
Parts and tips from 0+ owners who fixed this issue
- TipIf the SECURITY light is on and the car cranks but will not start, try the 10-minute Passlock relearn before replacing parts; many owners use this as a temporary confirmation of a Passlock fault.
- TipInspect the ignition switch and lock cylinder wiring at the steering column for looseness or heat damage before condemning the BCM.
- UpgradeOwners commonly replace the ignition switch first because worn internal contacts can mimic Passlock faults and cause intermittent no-start issues. (ACDelco Ignition Switch)
- UpgradeA replacement lock cylinder housing/sensor assembly is often used when the Passlock sensor in the housing fails and triggers the SECURITY light. (Dorman Ignition Lock Housing / Passlock Sensor Assembly)