This service bulletin provides information on replacing the intake manifold when the engine is replaced after severe internal engine damage.
full bulletin at NHTSA ↗2016 Chevrolet Malibu engine problems
moderate Owners of the 2016 Chevrolet Malibu have filed 94 NHTSA complaints about the engine, typically surfacing around 57,000 miles at roughly $3,100 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See engine across all vehicles →
Failure mileage
Complaints
94
Recalls
0
Avg fix
$3,100
| Model year | engine complaints |
|---|---|
| 2012 Malibu | 30 |
| 2013 Malibu | 78 |
| 2014 Malibu | 66 |
| 2015 Malibu | 24 |
| 2016 Malibu (this page) | 94 |
| 2017 Malibu | 81 |
| 2018 Malibu | 92 |
| 2019 Malibu | 20 |
| 2020 Malibu | 17 |
When does it fail?
Of the 94 engine complaints filed for the 2016 Chevrolet Malibu, here's the actual mileage breakdown — failures cluster heaviest at 150,000+ mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Of the 18 model years of Chevrolet Malibu we track for engine problems, this one carries the most owner complaints on file — 94.
Owners have filed 94 engine 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.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine 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.
The service bulletin advises the tech of a normal transmission shift condition and the delay in throttle response when the throttle plate is opened rapidly and advises the customer that it is normal for the delay.
full bulletin at NHTSA ↗This service bulletin provides information to dealership personnel for new vehicles with less than 1,000 miles that may not pass California smog inspection or smog inspection in other states.
full bulletin at NHTSA ↗This service bulletin provides a service procedure to correct conditions of Poor Engine Performance in Extremely cold weather conditions, CAC Icing, MIL Illuminated with DTCs set.
full bulletin at NHTSA ↗This bulletin advises the technician to flush the cooling system multiple times if oil has been found in the cooling system and replace the parts that may be contaminated due to oil in system.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners describe two main engine hazards: sudden, unwarned power loss on highways and catastrophic piston failures.
The power-loss issue strikes unpredictably. Owners doing 65–75 mph get hit with "Engine Power Reduced" on the dash, and the car drops to 20–40 mph instantly—no gradual slowdown. This happens in traffic, at intersections, on turnpikes. Owners report near-misses with semis, cars swerving around them, one case where a vehicle nearly hit a wall. Multiple owners say restarting the engine temporarily restores power. Diagnostics trace this to throttle position sensors (P2138 code) or accelerator pedal sensors, but dealers struggle to replicate it. GM extended warranty on that sensor but no recall.
The piston failures emerge as low-pressure, recurring misfire and rough running that shops address with "temporary fixes." Around 37,000–80,000 miles, scuffed cylinder walls or cracked pistons show up on borescope. Recall 17019 (2017) was supposed to fix pre-ignition by retarding timing—it didn't work for many. One owner's vehicle cracked piston despite recall service completed in 2017; by 80,000 miles, diagnosis showed the pre-ignition condition never resolved. Engine replacement runs $10,000; out-of-warranty owners get partial reimbursement or nothing.
Intercooler piping detaches from plastic fittings, fuel pump welds fail, head gaskets blow, and rod bearings seize—each causes loss of power or stalling. A fuel injector seal defect creates fire risk when backed-out seals leak fuel onto hot heads.
Owners report "shift to park" errors trapping the engine in a running state, sometimes requiring 15 minutes of shifting to clear. Dealers label these known issues but issue no recalls.
Same Chevrolet Malibu engine reports on nearby years: 2013 · 2014 · 2015 · 2017 · 2018
Failure modes owners describe
Stochastic Pre-Ignition (SPI) / Cracked Piston
Engine pistons crack or develop scuffs on cylinder walls due to stochastic pre-ignition, a condition where fuel ignites unpredictably before the spark plug fires. This causes misfires, rough running, excessive oil consumption, and eventually catastrophic engine failure requiring complete engine replacement.
When: Reported as early as 37,000 miles and continuing through 80,000+ miles, even after recall 17019 service in 2017
Symptoms owners cite: Check engine light (CEL) and service engine light illumination; Engine misfires on one or more cylinders; Rough idle and rough running; Excessive oil consumption; Engine vibration felt in steering wheel; Steam or smoke from engine compartment; Low engine compression on affected cylinder; Scuffs visible on cylinder walls during borescope inspection
Codes mentioned: P0300 (general misfire), Cylinder-specific misfire codes (e.g., P0301 for cylinder 1), Codes consistent with oil system or ignition issues
Repairs/costs cited: Complete engine replacement required; owner reports estimate near $10,000. Dealerships confirm the issue but refuse coverage after warranty expires. Powertrain warranty typically covers this, but out-of-warranty owners face full cost.
Recalls/TSBs owners mention: GM issued Recall 17019 in 2017 to address SPI-induced cracked pistons; however, the fix (timing retard) did not resolve the underlying issue for all vehicles. GM's Predictive Monitoring Service (C.S.P. N182195660) released in 2019 acknowledges SPI on 1.5L LFV engines in 2016–2017 Malibus but does not cover all affected VINs. Owners report GM extending warranty on certain defective parts but refusing full coverage for out-of-warranty repairs.
Reduced Engine Power / Limp Mode Activation (Sensor-Related)
Engine enters limp mode (restricted to 20–40 mph) due to throttle position, accelerator pedal, or throttle body sensor faults. The vehicle displays 'Engine Power Reduced' warning and check engine light, forcing drivers to pull over or creep at unsafe speeds on highways.
When: Can occur at any mileage from low miles (4,500–36,000) to high mileage (100,000+); intermittent or recurring within single commutes
Symptoms owners cite: Sudden loss of acceleration and power; Vehicle speed capped at 20–40 mph without warning; Check engine light illuminates; 'Engine Power Reduced' message on dashboard; Limp mode can resolve temporarily after restart or oil change (coincidental); Loss of steering power assist reported in one incident; No prior warning or symptoms before onset
Codes mentioned: P2138 (Throttle/Pedal Position Sensor), P0228 (reported in at least one case involving high-pressure fuel pump)
Repairs/costs cited: Accelerator pedal position sensor or throttle body sensor replacement is typical repair; parts on backorder for some owners. Dealership diagnosis cost cited as $115. One owner reports parts unavailable due to backorder.
Recalls/TSBs owners mention: GM has extended warranty coverage on the throttle position/pedal sensor defect across multiple vehicles (noted by owners) but has not issued an official recall. Owners describe dealers as aware of 'a common issue' but unwilling to provide recalls. Multiple owners report dealers confirming GM awareness.
Reduced Engine Power / Limp Mode Activation (Fuel System)
High-pressure fuel pump detaches from its mounting due to weld failure, causing loss of fuel pressure, engine power reduction, and limp mode activation. This directly correlates with NHTSA Recall 18V-358, which warned of fire risk from fuel leaks.
When: Reported at 129,264 miles (outside typical warranty coverage)
Symptoms owners cite: Sudden loss of power while driving; Check engine light; 'Engine Power Reduced' message; Engine power restricted to low speeds
Codes mentioned: P228C (reported in one case)
Repairs/costs cited: High-pressure fuel pump requires replacement; weld failure on pump mounting caused pump to detach and sustain damage
Recalls/TSBs owners mention: Recall 18V-358 (GM Campaign 18188/18268) addresses this exact defect but GM Customer Assistance denied coverage citing vehicle age and mileage, despite federal recalls being age/mileage-independent obligations. Owner's VIN not listed as open for recall despite identical failure mode.
Engine Stalling and No-Restart Condition
Engine stalls unexpectedly while driving, often at low speeds or during deceleration before auto-stop engagement. Vehicle fails to restart immediately or requires multiple restart attempts. One case reports key seized in ignition.
When: Reported at ~62,000 miles and 88,000 miles
Symptoms owners cite: Sudden engine shutdown while driving; 'Reduce Engine Power' light comes on before stall; No warning prior to failure; Vehicle comes to dead stop in roadway; Inability to restart vehicle immediately; One case: key jammed in ignition
Codes mentioned: Unable to retrieve fault codes in most cases; mechanics unable to duplicate failure
Repairs/costs cited: No repairs completed; dealers could not diagnose the issue. One owner told by dealership it is 'a known problem' with no formal recall.
Recalls/TSBs owners mention: Dealers acknowledge the issue is known but no recall issued. Manufacturer contacted but did not assist. One dealership (Bosak Chevrolet, Hammond, IN) explicitly told owner the problem is known but unrecalled.
Intercooler Pipe Detachment
Intercooler piping comes loose from plastic intercooler connections and throttle body, causing abrupt loss of boost pressure and engine power during highway driving. Dealership confirmed this is a common issue with a recall issued for 2019 models only.
When: Multiple occurrences during highway driving
Symptoms owners cite: Abrupt transition from full power to no power; Loss of boost pressure instantaneously; Near-accident incidents with semi-trucks and large vehicles
Repairs/costs cited: Plastic intercooler connections and throttle body attachment points need inspection and repair (exact repair not specified in narrative)
Recalls/TSBs owners mention: Dealership confirmed this is a 'very common issue' with a recall issued for the same engine in 2019 models only. No recall extension to 2016 model year despite identical issue.
Head Gasket Failure / Oil Leakage
Blown or deteriorated head gasket causes oil leakage, abnormal engine operation, violent shaking, and loud engine noise. One case involved no oil in the vehicle upon inspection.
When: Reported at 40,000 miles (under warranty) and 100,000 miles
Symptoms owners cite: Engine vibration and violent shaking; Loud noise from engine compartment; Loss of oil or no oil detected; Engine light illumination; Abnormal behavior and fluid loss; Fire risk from oil contacting hot engine components
Repairs/costs cited: Head gasket replacement required; one case involved no oil in the vehicle, suggesting seal failure allowing oil to leak past gasket
Recalls/TSBs owners mention: One owner (at 40,000 miles, within powertrain warranty) initially informed repair would be covered due to blown piston but dealership later delayed decision indefinitely. Another owner (at 100,000 miles, out of warranty) was referred by manufacturer to NHTSA to file complaint.
Rod Bearing Failure
Rod bearing fails, causing catastrophic engine damage. Vehicle exhibits hesitation during acceleration after idle and abnormal vibration during idle.
When: Reported at approximately 62,000 miles
Symptoms owners cite: Hesitation during acceleration after idle; Abnormal vibration while idling; Engine blown (confirmed by dealership diagnosis)
Repairs/costs cited: Complete engine replacement required (not completed)
Recalls/TSBs owners mention: Manufacturer was contacted by dealer and informed of failure; no further action specified
Fuel Injector Seal Failure / Fire Hazard
Fuel injector backing ring fails, causing o-ring to dislodge and rupture under high-pressure fuel. Fuel leaks onto hot cylinder head and ignition coils, creating serious fire hazard. GM seal kits do not include backing ring, leading to repeat failures.
When: <UNKNOWN>
Symptoms owners cite: Engine misfire; Fuel smell; Possible no-start condition; Fire hazard from fuel on hot engine components
Repairs/costs cited: Fuel injector seal kits (part 12673056) must include backing ring; replacement without backing ring will fail. Seal kit alone is insufficient.
Recalls/TSBs owners mention: GM sells seal kits without backing ring, leading to failures. Owner states the part should not be sold without backer ring.
Vacuum Pump Deterioration / Engine Damage
Vacuum pump deteriorates and particles enter the engine, causing 'Reduced Power Engine' message and loss of power. Eventually requires complete engine replacement.
When: Reported at 138,000 miles
Symptoms owners cite: 'Reduced Power Engine' message displayed; Vehicle decelerates inadvertently; Brake pedal remains firm but vehicle fails to stop immediately
Repairs/costs cited: Complete engine replacement required due to vacuum pump deterioration contaminating the engine (repair not completed)
Recalls/TSBs owners mention: <UNKNOWN>
Check Engine Light / Misfire (Unresolved)
Check engine light illuminates intermittently or persistently, often accompanied by misfires or abnormal engine sounds. Mechanics unable to diagnose root cause in multiple cases.
When: Reported at various mileages from 4,561 miles to 176,051 miles
Symptoms owners cite: Check engine light illuminates intermittently or persistently; Engine misfire (cylinder-specific or general); Abnormal sound of liquid moving in dashboard or under hood; Engine performance issues variable and hard to replicate
Codes mentioned: P0097 (Post Catalyst Fuel Trim System Too Rich Bank 1) – reported at only 5,000 miles
Repairs/costs cited: Multiple visits to dealers and independent mechanics without resolution; no repairs completed in most cases
Recalls/TSBs owners mention: Dealers unable to provide diagnosis when failure cannot be duplicated. Manufacturer not notified in most cases.
Shift to Park Error / Ignition Lock
Vehicle displays 'Shift to Park' error message when vehicle is already in park, preventing engine shutdown. Requires multiple restart and shift cycles to clear. Issue recurs after temporary repair. Battery can drain if vehicle left running with error.
When: First occurrence at 90,000 miles; recurrence at 188,000 miles; also reported at undisclosed mileage in early complaint
Symptoms owners cite: 'Shift to Park' error message appears when already in park; Cannot shut engine off with error present; Must restart car and shift from park to neutral and back multiple times to clear error; Takes 10–15 minutes to resolve; Occurs 90% of the time (in one case); Battery drains if car is left running with error displayed
Repairs/costs cited: Shifter assembly or shifter cable replacement; one owner paid ~$200 for cable replacement at dealership in 2018, issue resolved temporarily but recurred. Full shifter assembly replacement likely needed.
Recalls/TSBs owners mention: <UNKNOWN>
Synthesized from 94 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
The contact owns a 2016 Chevrolet Malibu. The contact stated while driving approximately 70 MPH, the check engine warning light illuminated, and the RPM decreased by approximately 4,000 revs per minute. The contact was able to pull over to the shoulder and cruised until the vehicle began to accelerate as needed. The vehicle was taken to a local mechanic where it was diagnosed with needing the…
While driving, the vehicle experienced a mechanical failure involving the engine and lubrication system. Oil leakage was observed, and the engine began operating abnormally. This created a risk of sudden engine failure while the vehicle was in motion, which could result in loss of power, stalling, or loss of control, especially at highway speeds or in traffic. Prior to the failure, warning signs…
Had engine trouble with your 2016 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 engine problem on the 2016 Chevrolet Malibu?
It's a documented issue but not catastrophic. 94 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Across the 56 complaints that reported odometer mileage, most engine failures cluster between 37,690 and 90,000 miles, with the median around 57,000. A quarter of owners report trouble before 37,690; a quarter make it past 90,000. 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 $3,100 for engine 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 engine?
No active recalls currently cover engine 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/2016/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.