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2002 Chevrolet Malibu

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 Malibu.

Body PASSENGER CARTransmission Automatic 4-spd

The 2002 Chevrolet Malibu is a midsize passenger car equipped with an automatic four‑speed transmission and a 4.5‑quart capacity engine that uses 5W‑30 API oil, delivering EPA fuel‑economy ratings of 18 mpg city, 26 mpg highway and a combined 21 mpg. Its modest powertrain is paired with a conventional chassis that, while unremarkable, benefits from a relatively low total of 597 owner complaints, the majority of which cluster in the electrical system, and it carried four manufacturer recalls. Positioned between the model‑year peak of 1,697 complaints in 2004 and the record low of just seven complaints in 2025, the 2002 Malibu occupies a middle ground in the Malibu’s reliability timeline, indicating a generally average durability record for researchers to consider.

Model year2025 2024 2023 2022 2021 2020 2019 2018 2002

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity4.5 qtOEM · verified

Engine oil type5W-30 APIOEM · verified

Lug nut torque100 ft-lbsOEM · verified

EPA fuel economy18/26/21 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 75 · 600 CCA battery, OE oil filter 12731175. Note the factory fuel filter is now discontinued — plan on a superseded or quality aftermarket equivalent, which the part pages below list where known. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 75 · 600 CCAOEM · verified

OE service part numbers OEM · verified

Engine oil filter	12731175 alt 25322835
Engine air filter	25161977
Fuel filter	25121293 discontinued
Spark plug	12681664
Front wiper blades	19120758 alt 22700263
Serpentine belt	12588408
Thermostat	24507563 alt 10226107

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

Transmission

Automatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length	190.6 in
Overall width	69.3 in
Overall height	57.1 in
Wheelbase	107.1 in
Curb weight	3051 lb
Track (front / rear)	59.1 / 59.4 in
Weight distribution (front / rear)	64/36

Ratings & economy EPA / vPIC

EPA city / highway / combined	18 / 26 / 21 mpg
Drivetrain	Front-Wheel Drive
Passenger volume	99 cu ft
Cargo volume	16 cu ft
Recommended fuel	Regular Gasoline

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the Malibu of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

8.2–9.0 sec0–60 mph (tested)quickest 8.20 sec — 1997 LS V6

Year	Trim / engine	0–60	¼ mile	HP	Drivetrain
1997	LS V6 3.1L V6	8.20 sec	16.20 sec	155 hp	FWD
1997	LS V6 3.1L V6	8.30 sec	16.40 sec	155 hp	FWD
1997	LS V6 3.1L V6	9.00 sec	16.60 sec	155 hp	FWD

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 4.5 qt of 5W-30 API engine oil. Torque lug nuts to 100 ft-lbs, the oil drain plug to 18.0 ft-lbs. The firing order is 1-2-3-4-5-6.

Lubricants & capacities

Engine Oil	5W-30 · API
Engine Oil Capacity	4.5 qt

Engine torques

Crankshaft Pulley and/or Damper Bolts	52 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	12 ft-lbs
Engine Oil Pan Drain Plug	18.0 ft-lbs
Engine Valve Cover Bolts	7.4 ft-lbs

Chassis torques

Lug Nuts	100 ft-lbs
Front Wheel Hub	159 ft-lbs

Ignition

Cylinder Firing Order	1-2-3-4-5-6
Ignition Coil Secondary Resistance	5000-7000 ohms
Spark Plug Manufacturer	AC Delco
Spark Plug Type	AC 41-940
Spark Plug Gap	0.060 in
Spark Plug Torque	11.0 ft-lbs

Battery & A/C

Refrigerant	R134a
Refrigerant Capacity	1.35 lbs
Oil Group	PAG
Oil Capacity	9.00 oz
Standard BCI Group Number	75
Standard BCI Cranking Performance	600 cca

Service checks

Pressure Test	15, Pressure should not exceed 20 psi.
Radiator Cap Pressure Relief	15 psi
Thermostat Opening Temperature	185-205 °F
Fuel Pump Pressure Minimum	59.0 psi
Key ON Engine OFF (KOEO)	52-59
RPM	42-56 @ Idle rpm
Engine Compression	100
Engine Compression	100 Minimum psi

Brakes

Torque Caliper to Bracket	85 ft-lbs / 23 ft-lbs
Torque to Knuckle	100 ft-lbs / 85 ft-lbs
Minimum Pad Thickness	Front: 0.030; Rear: 0.030 specification
Rotor Max Parallel Variation	0.001 in
Rotor Runout Limit	0.0015 in
Rotor Nominal Thickness From	1.031 in / 0.433 in
Rotor Nominal Thickness To	1.031 in / 0.433 in
Rotor Minimum Machining	0.98 in / 0.388 in

Multi-step torque procedures OEM · verified

Cylinder Head — tightening sequence 2 stages

1	44 ft. lbs.	44 ft. lbs
2	95

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 100,000 mi; coolant at 150,000 mi. The big-interval services (at 150,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 7,500 mi	Engine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
Every 30,000 mi	Engine Air Filter Element (replace)
Every 60,000 mi	Accessory Drive Belt (inspect)
Every 100,000 mi	Spark Plug Wires (inspect) · Spark Plugs (replace)
At 150,000 mi	Engine Coolant System (drain, flush & refill)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2002 Chevrolet Malibu sits near the end of its generation, and the federal data shows a clear downward trend in owner complaints from a peak of 1,084 in 1998 to just 597 in 2002—the second-lowest in the 1997–2003 generation. Recalls also declined to 4, matching the 2001 level and lower than the 6 recalls seen in 1997, while investigations dropped to a single case, the fewest of any year in that generation. This arc suggests that many early-generation issues were addressed by the time the 2002 model was produced, though the top complaint areas—electrical system, exterior lighting, engine and cooling, and service brakes—still warrant a careful pre-purchase inspection. Compared to the dramatic spike to 1,697 complaints and 10 recalls that immediately followed with the redesigned 2004 model, the 2002 Malibu stands out as a relatively mature and stable choice. Overall, the data indicates that the 2002 model year is a solid buy within this generation, offering a lower likelihood of major problems than both its predecessors and the next-generation successor.

Open recalls

NHTSA campaigns

406

Service bulletins

Manufacturer communications

ODI investigations

Office of Defects Investigation

597

Owner complaints

20 involved a crash · 1 a fire

NHTSA crash-test rating federal NCAP · out of 5 stars

Rollover★★★★★

Owner complaints by model year NHTSA · this generation & adjacent

’97 ’98 ’99 ’00 ’01’02’03 ’04 ’05 ’06 ’07 ’08 ’09 ’10 ’11 ’12 ’13 ’14 ’15 ’16 ’17 ’18 ’19 ’20 ’21 ’22 ’23 ’24 ’25

Owner complaints filed with NHTSA, by component

All 597 complaints on record, top 8 components.

Electrical System205

Exterior Lighting109

Engine & Engine Cooling49

Service Brakes, Hydraulic29

Electrical System,Exterior Lighting21

Unknown Or Other12

Air Bags11

Electrical System,Engine8

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 4 campaigns on record for this vehicle.

14V400000Electrical System:IgnitionReported 03/07/2014

This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should… Remedy: GM will notify owners, and dealers will install two key rings and an insert in the key slot or a cover over the key head on all ignition keys, free of charge. The recall began on…

09E012000Exterior LightingReported 07/04/2009

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE… Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT…

Technical service bulletins NHTSA · verified

Showing 5 of 406 bulletins on record with NHTSA.

Bulletin	Date	Component	Summary
PIP5601C	2025-07-18	Unknown Or Other	This PI communicates the requirement to provide a pico file to receive diagnostic…
PIP5358D	2025-02-19	Unknown Or Other	This Preliminary Information communication provides information to the technician about…
PIP4723J	2024-10-25	Electrical System	This Preliminary Information communicates to the dealer the process for downloading or…
PIT5099H	2024-09-12	Unknown Or Other	This Preliminary Information communication provides information to the technician about…
PIT5099H	2024-09-12	Unknown Or Other	This Preliminary Information communication provides information to the technician about…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420

Catalyst system efficiency below threshold — Bank 1

P0300

Random / multiple cylinder misfire detected

P0171

System too lean — Bank 1

P0455

Evaporative emission system leak detected — large leak

P0128

Coolant thermostat below regulating temperature

P0442

Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN

Decode a VIN to confirm the transmission and build data for a specific Malibu. OEM

Build data

Plant, GVWR class, engine and body data for any 17-character VIN.

Recalls

Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Group 75 battery Vehicles taking 4.5 qt Engine oil filter 12731175 Engine air filter 25161977 Fuel filter 25121293 Spark plug 12681664

Reference guides

Cross-vehicle references for the kinds of data on this page.

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

How much oil does the 2002 Malibu take?

4.5 qt of 5W-30 API, per the factory manual.

Does the 2002 Malibu have open recalls?

NHTSA lists 4 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Malibu get?

EPA figures are 18 city / 26 highway / 21 combined mpg.