Manifold/header/muffler/tail Pipe problems of the 2000 Chevrolet Malibu - part 1

2000 Chevrolet impala. Consumer writes in regards to vehicle fire and engine oil may deposit on the exhaust manifold recall notice. The consumer stated the vehicle caught of fire.

The contact owns a 2000 Chevrolet Malibu. While the contact was driving approximately 60 mph, the engine warning light intermittently illuminated. The vehicle was taken back to the independent mechanic for diagnosis. The technician stated there was a leakage within the intake manifold gasket which could result to the engine overheating and potentially causing a fire. The vehicle was not repaired. The failure mileage was 63,000. Updated 02/23/lj updated 02/28/11.

The contact owns a 2000 Chevrolet Malibu. While driving 40 mph, the vehicle shut off without warning. The contact took the vehicle to a mechanic and was informed that the intake manifold gasket caused the failure. The mechanic also stated that this was a common issue for this year, make, and model vehicle. The contact feels that this is a major defect and Chevrolet should be responsible for the repairs. The current and failure mileages were 144,000.

The contact owns a 2000 Chevrolet Malibu. While driving approximately 65 mph, the vehicle began to overheat. The vehicle was taken to a local repair shop and they stated that the intake manifold failed and needed to be replaced. The mechanic stated that the engine failure was common for this year, make, and model vehicle. The vehicle is currently being repaired. The failure mileage was 60,000 and current mileage was 63,000.

I bought the car at the end of 2000 and had to replace the intake manifold gaskets at around the same time (thanksgiving) in 2001. My fuel pump went out in 2002 and my mechanic just told me the intake manifold gaskets are leaking again. He suggest to replace them soon. It cost $900 to get it fixed the first time which was not under my extended warranty plan. I just paid the car off and have to fork out another $700-900 to get it fixed again. It is common knowledge to gm that there is a history of gaskets problems in several chevy models especially the Malibu, but no recall has been issued and no compensation has been awarded to all those hard working people who trust the chevy name. If nothing is done I will never buy chevy again. Pontiac had the same problem with some of its cars a few years back and recalled all models with less than 100,000 miles on them. Why wont chevy. There needs to be a recall or a lemon law on the Chevrolet Malibu!!! I am surprised that a class action lawsuit has not been filed against gm for selling such a defective product!!! I hope that no one has had an accident, injury, or even death result from this dangerously defective car!!!.

The contact owns a 2000 Chevrolet Malibu. The low coolant warning indicator light illuminated; however, the vehicle was filled with coolant. Thirty minutes later, the vehicle overheated while driving 70 mph. The low coolant warning indicator light illuminated again. The dealer stated that there was a leak in the intake manifold. No repairs were made. The contact verified his VIN; however, it was invalid. The engine size and number of cylinders were unknown. The current and failure mileages were 125,000.

The contact owns a 2000 Chevrolet Malibu. While driving 35 mph for approximately ten minutes, the temperature gauge displayed hot. The coolant light illuminated, which indicated that the coolant level was low. The contact stopped the vehicle and checked the level. He then took the vehicle to carmax and they confirmed that the lower intake manifold gasket caused the failure. Chevrolet stated that they were not aware of the failure. The current and failure mileages were 133,000. Updated 12/12/07 updated.

I have had ongoing problems 3 years. , approximately with frequent low coolant levels and low oil levels, in addition to noticing a strong odor of coolant after turning car off. I was informed recently , during a routine oil change in may, 2007, of a common problem often observed in gm 3. 1 l and 3. 4l v-6 engines. The intake manifold gasket leaked and allowed cross contamination of the coolant and oil systems. The oil system leaked into the coolant system, clogging the flow of engine coolant and damaging other systems, gaskets and fluids. The coolant leake d into the oil system as well, causing engine wear. Now I am told it will cost about $1000. 00 to replace the intake manifold gasket, in addition to all the other gaskets affected by this leak. The main expense is for the labor to reach the intake manifold gasket in mid-engine. I was also informed that this problem affects all gm 3. 1l and 3. 4l v-6 engines since 1996, and that these engines have not been recalled, in spite of the frequency of this complaint. My vehicle is no longer under warranty, but since this engine's problem has been known since before I purchased the car, I believe I am justified in requesting that gm cover the cost of any necessary repairs to replace this leaking gasket before the engine is destroyed.

2000 chevy Malibu intake manifold gasket failure, 800. 00 to fix. Replaced gasket at dealer, told car was a fixed and then the head gasket fails, within hours of leaving repair shop.

I first noticed that the coolant was leaking from below my car. It has 76,000 miles. The intake manifold gaskets are defective. This is a problem that I have researched and discovered that many, many others have experienced this. This is a $1000 problem that I feel chevy has refused to recall because at $1000 a pop, who would?.

We lost all of our anti-freeze thinking we lost a hose. Upon taking it in to a certified mechanic he had to replace the manifold intake gaskets for the 2nd time. Upon showing the manifold to a mechanic for gm he found a bubble in the manifold when it was molded.

: the contact stated an odor was detected and there was fluid leaking on the ground from the engine compartment. When the contact inspected the vehicle by raising the hood, there was fluid on the engine block. The dealership determined the manifold gasket needs to be replaced. Updated 03/28/06.

Had hazard lights replaced 5 years ago, problem continues. Water pump blew, intake manifold needs replaced. Dex cool problem car also refuses to start from time to time, takes about 10 minutes to decide to start.

Fuel pump went bad on 06/01/05 ($583). When service was done to replace fuel pump, mechanic informed me that the intake manifold gasket is leaking. To repair it will cost $1300.

The intake manifold gasket is defective on all 3. 1 l gm engines like the one in my 2000 Malibu. Gm dealers know that it always leaks around 70 k miles, and just keep trying to replace it. Every mechanic in the country seems to know this fact, and make about a thousand for it from each owner.

My wife's 3. 1 general motors v6 needed a manifold gasket and related items replaced on her 2000 Malibu which only has 48,000 miles and is well taken care of. My 1995 lumina had the same problem. After checking with many shops and gm dealers (and a CO-worker who had the same problem today). . . It is a very common defect @ every 40,000 miles. It could turn out to be a very bad deal for many consumers and it appears that the manufacturer knew of defect for years. Just a heads up for you.

Coolant was leaking from my 2000 Chevrolet Malibu engine intake manifold and my coolant pump. The car has only 52,000 miles. I took it to the dealer where they replaced the intake manifold gasket and coolant pump. The cost was $1250. I work at a company where I know all the other Chevrolet Malibu owners. There are two other: one owns a 1999 and the other owns a 2000 Malibu, both with less than 50,000 miles. The 2000 owner has had the intake manifold gasket replaced for $950. The 1999 owner has had the coolant pump replaced and will probably need the intake manifold gasket replaced. I feel that Chevrolet had initially installed defective cheap parts in this model and will not own up to it.

Abs light comes on intermittently, fan does not operate on speeds 1 & 2, brake rotors and pads need replaced every year, hazard/turn signal lights operate intermittently, and intake manifold gasket began leaking around 70,000 miles. The coolant is listed in the owner's manual as not needing service for 150,000 miles but it turned very acidic in less than half that time and ate the gasket causing the need for costly repairs or else risk permanent damage to the engine. Turn signal issue recalled but the recall did not apply to my vehicle's VIN. Vehicle was unable to signal intention to turn or switch lanes and was unsafe on highways. Have yet to experience common fuel pump failure that could cause stalling in highway traffic. Not recalled is the most common problem of the leaking intake manifold gasket because it is not deemed a safety issue. This can become safety issue if engines catch fire or fail on highway due to coolant leak into motor oil. Cost to repair leaking intake manifold gasket quoted at $743. Currently discussing with gm customer service because the problem is addressed in TSB 03-06-01-010b (10/24/2003) and there are several class-action lawsuits. TSB describes replacing faulty gasket with a new gasket that has improved sealing qualities. Gm customer service stated they have never heard of any TSB for 2000 Malibu other than turn signal recall. Gm is being intentionally dishonest when owners inquire about problems with an obviously defective vehicle. I hope that the NHTSA takes notice of the multitude of safety issues concerning this vehicle and can obtain a satisfiable resolution from gm to make this vehicle safe for owners or justly compensate them for the repairs necessary to make the vehicle safe.

I have a 2000 chevy Malibu with 38000 miles. The intake manifold gasket is leaking. I called the dealership to see if there is a recall. I was told there have been many gasket failures on the Malibu but there is no recall. Repair cost is estimated at $645. 00 by the dealer. I am now unable to afford the repair or safely drive the car for fear of damage to the engine. The car is now in storage.

I am the owner of a Chevrolet Malibu. This car is very dangerous and should be recalled. The car will shut off when driving speeds of 55 or more. I have had nothing but problems since I purchased this car. First, it was the intake manifold gasket. Second, it was something wrong with the fuel system. Third, the car quit on me and my daughter when we were driving on the express way going 60 miles per hour. We could have killed ourselves and someone else.

Manufacturer used plastic intake manifold gasket which caused engine to leak coolant and overheat. Why use plastic? what happens to plastic when it continuously heats and cools, it fails. A relative has the same engine in a different model car from this manufacturer and has the same issue. Not model specific, but engine specific. Chevrolet 2000 Malibu.

After stopping for an errand and seeing a puddle of coolant on the ground, the vehicle was taken to the local repair shop to have the leak checked on. The repair shop found a leak in the lower intake gasket. The shop advised that this repair was common and possibly caused by the type of coolant used and possibly defects with the gaskets or intake manifold. They provided and estimate for repairs between $600. 00 and $800. 00 depending if any further problems were found. The dealer where the car was purchased (polar chev in white bear lake, mn) was contacted about the repair and refused to offer any assistance in repairing the vehicle. The dealer stated they do a lot of these repairs on the Malibu and impala but the repair is not a warranty issue. Their customer service was contacted also. They said no special consideration or bulletins issued about coolant leaks on the 200 chev Malibu. From research on the issue it appears to be a large problem with the vehicles and chev refuses to provide any assistance.

Oil leaked into coolant system of our 2000 Chevrolet Malibu requiring replacement of the intake manifold gasket and flushing out of the engine. This engine only had 40,900 miles on it. Research has shown numerous complaints for this problem on this particular gm engine (3. 1 liter).

Had to replace the intake manifold and gasket on my 2000 chevy Malibu.

My car has had the signal lights replaced, the fuel pump replaced, & the intake manifold gasket replaced all problems w/ my car before I had replaced were very dangerous for me & my 2 children. I will never buy or refer anyone to buy a chevorlet Malibu .

2000 Chevrolet Malibu bought with 120,000 miles on it. Less than a week after getting this car for 5500. 00, when retail on the car was 8300. 00, I had to replace the intake manifold gasket and the valve cover gaskets because they were leaking coolant. Also, the brakes shudder and vibrate whenever applied, even at speeds less than 25 mph. Half a week later, the gas gauge fell to zero while normal driving and the low gas light came on, even though I had just filled the car up two days prior. There was plenty of gas in the car, about 3/4 of a tank. Also, the tranmission is slipping now when I speed up. When I speed up the car does not shift into 1st gear right away until 4000 rpm. When it does shift, it shift with a large jolt that shakes the entire car. There was no warning before the gas light came on, and I find the car to only now have all of these problems. Also, the car smells of gasoline and leaks, even though I had it fixed.

Intake manifold gasket failed at 49000 miles. Gm is aware of the problem but will not take action on it. The most discouraging thing about the problem is the contempt that gm seems to have for their consumers. They released a technical service bulletin to their dealers regarding the problem, yet they do nothing for those affected by an obvious product defect. My request for cost assistance from general motors was met with a flippant attitude toward the loss of my loyalty as a customer.

Vehicle : 2000 Malibu VIN : 1g1nd52j9y6203970 I've read that there are technician notes, sent by gm corp. , about a design problem with the 2000/2001 Malibu v6 3. 1 engine for intake manifold gasket leaking and for pistons,valve guides and lifters with valves 1,2,3,4 and gm's remedy with updated parts list to remedy the design problems. My vehicle is one of these with the appropriate VIN #. I have contacted gm assistance but have only received a person that transmits but does not receive in the conversation. I have all the maintenance records for oil changes, air & fuel filters etc. Since I have owned the car. I also have copies of gm corporate bulletins to the technicians acknowledging the design flaws and the corrections and parts list to remedy the design flaws. I purchased this vehicle used, one year old with 26,879 miles. I have also talked to 3 different technicians who have stated this is a design problem that gm has known about and is an ongoing problem. I presently have the vehicle at don's brooklyn Chevrolet where they are repairing the intake manifold gasket and diagnosing further problem with the pistons and lifters. Robby states the pistons need replacing to elimnate the problem. I am a loyal Chevrolet customer for over 30yrs and currently own a 1993 chevy lumina eurosport, purchased new, 2000 chevy Malibu, purchased used 1 yr old, and a 2002 chevy impala LS, purchased new, being a loyal customer and never had a need before, I need assistance as this has been a design flaw that gm knew about, I don't feel I should have to pay for gm's problem. Gm should repair the problems now before and engine blows on the freeway or anywhere else and someone is either injured or killed. Please give me a call at 216-475-2062.

Antifreeze used in our 2000 Malibu has been found to frequently cause deterioration and failure of the intake manifold gasket. There hve been many cases sited on the internet with names and specifics and chevy/GMC refuses to admit it is the antifreeze. They told me last night it has to do with the plant where the car was made.

On your site I have found many complaints regarding coolant leak due to poor sealing of the maniflod gasket that according the sevice bulletin on this site, requires new gasket type to replace the old, and the intake manifold bolts cleaned and coated with thredlocker and torqued to a revised spec. This has already been done once to my car at about 30k miles and fortunately cover under warranty, if not it would have cost me $1050, problem is now the car is doing the same thing again at 79k miles and is no longer under warranty. . . . How many times should this happen? was the service bulletin put out as a permamant solution for this problem? if not how long should this work be guaranteed? why was there not a recall on this problem? does there have to be a fatality to recall a vechicle? in addition I also have had the problem with the hazard warning switch that also effected the wipers, neither would work, again this repair was submitted as warranty work. I have complained several times to bob bell chevy about how hot the dash instruments get to touch and have already had to have related electrical problems repaired, to note. . When I first complained about the heat when touched to change intrument settings I was told "that's normal". Granted my extended warranty covered some of the work but I still had to pay a $250 deductable w/each problem. All these problems have been reported on this NHTSA site by many people and addition others I know personally and who I have had many discussions with also have the same year Malibu with all the same problems. . . . Why hasn't the manufact. Recalled the car for theses problems, surely all can cause fire safety problems. How are recalls determined and what can we all do????????????? I never dreamed Chevrolet would be so cheesy. My last car was 12 years old and olds custom cruiser wagon - never gave me a problem that was so major as these noted here, I should have never got rid of it for this Malibu!.

Vehicle over-heated, taken to dealer which had been servicing the vehicle since new. Dealer replaced intake manifold gaskets and water pump charging $1400. 00 the vehicle only had 24000 miles on it and was less then six months out of warranty. Dealer would not work with me as a goodwill gesture.

Independent shop replaced the intake manifold at owner expense of $800. Dollars and has had problems with the air conditioner. Dealer notified. Please provide further information.

Intake manifold began leaking at 45000 miles (500 dollars to replace), have replaced the brakes and rotors 4 times in 65,000 miles. The turn signals quit working. While driving down the road the engine just dies. If I let it sit for a while it will crank back up. Ase mechanic told me it was the ignition module, so I paid to have it replaced and that did not fix it. I have been reviewing forums on-line and have discovered that this is a wide spread and severe problem, I understand normal wear and tear on a vehicle but this is ridiculous. And last but not least, the fan switch has quit working on positons (speeds) 1 and 2. . . That happened when the car had about 37,000 miles on (not under factory warranty) . . . . I once was a die hard chevy man. . Thanks to this car I will not buy another gm product.

Leaking coolant from around engine block. Dealer diagnosis: lower intake manifold gasket leak. Mileage 30,000. Previous repair completed on water pump for bad bearings at 28,800 miles. Manufacturer should be held accountable for a defective component used in the building of these motors.

Previously submitted this report/complaint on this site, to gm and to the ftc around 2004 with no response. The Chevrolet Malibu from 2000 has similar ignition and engine issues now reported on the news in the cobalt and other cars. Owner had to replace the intake manifold several times, the ignition,starter, key system, idle control valve, and other parts numerous times due to the car engine smoking, "turning off" or not starting after stopping, parking, and not starting upon inserting the key, idling high or timing off. This began within 2-3 years of owning the car. The engine light came on when driving or starting the car. Multiple times the security light would blink and owner would have to wait 15 minutes to turn it on. Gm even has this listed in the manual (in security feature/lock system). Owner first told it was due to problems with the engine, then key, then it was a security programming issue, then it was the intake manifold (not covered under warranty for some reason). Some of the repairs cost hundreds of dollars and costs for towing. Eventually the car will not start at all and it must be reprogrammed, worked on by dealer. The Malibu and other cars such as Saturn have this issue. May be related to the engine and ignition issue mentioned in the news. At times owner was stuck far from home and had to tow the car. Highway driving was nerve wracking because you never knew what the car would do. There are hundreds of internet complaints about the Malibu from 2000 and onward related to engine and ignition failures.