This Preliminary information communicates provides information to the technician on the use of R-99 or R-95 Renewable diesel fuel.
full bulletin at NHTSA ↗2006 Chevrolet Malibu fuel system problems
moderate 35 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
35
Recalls
0
Avg fix
$1,200
1crash
What stands out
Owners have filed 35 fuel system complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Among the 11 model years of Chevrolet Malibu in our records for fuel system problems, this one ranks #2 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.
full bulletin at NHTSA ↗This service bulletin provides diagnostic tips/steps on testing for possible EVAP leaks in the system to correct a customer concern of an MIL Illuminated with DTCs P0442 and/or P0455 Set.
full bulletin at NHTSA ↗This Preliminary Information communication provides information to the technician about engine block of possible cylinder bore damage, scoring or out of round as the possible cause of engine oil consumption, misfire, cylinder leakage or blow by. Technician will need to inspect the engine for Cylinder damage or scoring, An out of round cylinder bore, Dirt intrusion, and Catalytic Converter failure.
full bulletin at NHTSA ↗This Preliminary information communicates the use of Winter grade fuel during the warm months of 2020 and the potential rivability issues that it can cause. The ongoing Coronavirus (COVID-19) pandemic has caused significant reductions in driving and fuel use. Due to the surplus of winter grade fuel sitting in storage (pipelines/stations) the EPA is waiving the fuel vapor requirement. This will extend the use of winter fuel into the summer months. The drivability concerns should not be single events but should be multiple occurrences associated with hot days.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The fuel system on this Malibu is trouble. Most common complaint: the fuel gauge swings between full and empty without warning, often right after filling up. Owners can't trust what they're seeing on the dash, so they're tracking fuel with the trip odometer instead. Multiple owners ran out of gas because the gauge said they had fuel, and one stranded person with two children in the car barely made it to safety. Check engine light comes on with it almost every time.
The fuel pump also fails, causing no-start and stalling at highway speeds. A few owners replaced the pump, only to have the same problem come back. One owner took the car in five or six times and still couldn't get it fixed.
Some tanks are cracking and leaking fuel—strong gasoline smell inside and outside the vehicle.
There's a GM recall (NHTSA Campaign 11E009000) for fuel system issues on 2004–2007 Malibu models, but owners report getting denied coverage. One owner's daughter was in an accident caused by engine stall from this known issue, and the dealership refused repair under the claim that the limited recall had expired. When repair happens, it's expensive: $300–$700 to replace sensors or pump, and dealers charge for diagnosis even before refusing warranty coverage.
Same Chevrolet Malibu fuel system reports on nearby years: 2005 · 2007
Failure modes owners describe
Fuel Gauge Malfunction / Erratic Readings
Fuel gauge displays inaccurate readings, often showing empty when tank is full or vice versa. Gauge frequently bounces between full and empty extremes without intermediate readings. Low fuel light and check engine light illuminate intermittently or continuously.
When: Occurs after refueling or during driving; reported at mileages ranging from 30,000 to 147,414 miles. One owner noted issues starting in 2007 when car was purchased.
Symptoms owners cite: Fuel gauge drops to empty immediately after filling tank or shortly thereafter; Gauge bounces erratically between full and empty; Low fuel warning light comes on unexpectedly; Check engine light illuminates and remains on; Fuel cap warning light illuminates; Owner unable to trust fuel gauge and must track fuel manually using trip odometer
Codes mentioned: Fuel level sensor failure, Fuel level sending unit malfunction
Repairs/costs cited: Repair typically involves replacing fuel level sensor and/or fuel level sending unit. One owner cited $500+ repair cost; another paid $322. Dealerships sometimes claim the vehicle is not included in recall coverage despite similar failures being recalled on other VINs.
Recalls/TSBs owners mention: Recall NHTSA Campaign 11E009000 exists for fuel system issues on 2004–2007 Malibu models, but multiple owners report their VINs were excluded from coverage. GM advised one owner that their VIN was not included in the fuel sensor recall. One dealership claimed a limited recall had expired.
Fuel Pump Failure / Starting Problems
Vehicle fails to start or starts intermittently; cranks multiple times before starting or dies immediately after starting. Owners initially suspect fuel pump failure, but replacement does not always resolve the issue.
When: Reported across mileage range from 65,000 to 153,101 miles. Issues began as early as 2007 when vehicles were purchased used.
Symptoms owners cite: Engine will not crank or cranks only after multiple attempts; Engine starts then dies within seconds; Check engine and fuel lights illuminate when starting or stalling occurs; Loss of power while driving at highway speeds (55–70 mph); Vehicle stalls while in idle position; Problem recurs even after fuel pump replacement
Codes mentioned: Fuel pump failure diagnosis
Repairs/costs cited: Fuel pump replacement cost approximately $700 per owner; one owner also replaced a throttle body assembly (part ACD12568796) in a fuel system kit for $654.92. Multiple owners report the problem persisted after fuel pump replacement, suggesting either misdiagnosis or an underlying systemic issue.
Recalls/TSBs owners mention: Recall NHTSA Campaign 11E009000 (fuel system, gasoline) addresses intermittent stalling. One owner received recall notice and was turned away by dealership claiming the limited recall had expired. Another owner's daughter was involved in an accident caused by engine stalling related to this recall, but the dealership denied repair coverage.
Fuel Tank Crack / Fuel Leak
Fuel tank develops cracks, typically at seams, causing fuel to leak from the tank. Strong gasoline odor detected inside and outside the vehicle.
When: Reported at mileages of 83,089 and 102,000 miles.
Symptoms owners cite: Strong gasoline smell inside and outside vehicle; Visible fuel leaking from top rear of fuel tank; Excessive fuel leakage
Repairs/costs cited: One dealership diagnosed a cracked fuel pump and advised replacement; the dealer also warned that the failure could recur. Another owner contacted dealer and was told no recalls existed for the issue.
Recalls/TSBs owners mention: One owner contacted a dealer in Fresno, CA who stated there were no recalls for fuel tank cracks on this vehicle.
Shift Interlock / Shifter Mechanical Problem
Owner unable to shift vehicle from Park to Drive. Shifter requires extreme force to move.
When: Timing not specified in narrative.
Symptoms owners cite: Vehicle stuck in Park; Requires extreme pulling force on shifter to disengage Park
Synthesized from 35 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had fuel system trouble with your 2006 Chevrolet Malibu?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2006 Chevrolet Malibu?
It's a documented issue but not catastrophic. 35 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Across the 30 complaints that reported odometer mileage, most fuel system failures cluster between 65,000 and 108,000 miles, with the median around 82,000. A quarter of owners report trouble before 65,000; a quarter make it past 108,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Chevrolet/Malibu.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.