I have a 2009 Malibu LT and the 2.4L Eco tech engine. It has 4600 miles on it and it keeps having the same reoccurring problem beginning at a little under 2000 miles. I have now had it in the shop 6 times including dropping it off at the shop today.

This is the problem: When I fill up and let my car sit overnight the check gas light comes on after having 2-3 miles on the tank. It doesn't happen if i continue to drive it right away. When i fill up at the station the tank shows full but when i get to my car in the morning it says that it is at 7/8 tank, after driving less than 0.9 miles home from the gas station. This light only stays on for a few miles and then it clears itself. This has happened probably ten or more times. This morning like always the gas cap light came on with a little over 2 miles on the tank. Today on my way home from work not only did the check gas cap light come on so did the check engine light for the first time. The check gas cap light cleared itself but the check engine light did not and it ended up at the dealership. This mid day occurrence of the check gas cap light was only the second time it has gone off more than once in a day.

I have taken it into the dealership for now what is the 6th time (it is there right now.) And they have done the following:

Time # 1 run diagnostics and fog the system; no leaks found
Time # 2 run diagnostics and fog the system; no leaks found
Time # 3 run diagnostics and fog the system and replaced gas cap for a pinhole leak
Time # 4 drop the gas tank and readjust the lever arm
Time # 5 drop the gas tank and replace the sensor
Time # 6 ?

Every time they give it back they keep it for an extra night to check and this problem doesn't happen before they give it back. When i get it back i top it off and let it sit over night and it happens exactly the way it always does. The dealership has replicated the problem multiple times when the car is in their possession.

So now according to Nebraska law my car is technically a lemon, i have filed a complaint with the BBB and GM we are trying to work this out. So far all GM has done is offer me a free year of oil changes and tire rotation on a car that they cannot fix. The dealership has done all they can do and from the last time and here out they just have to follow the guidance from GM over the phone.

Has anyone else had this problem? If so what did they do?

edit: you have to force them to fix the issue. one way or another. with under 5k miles i would just ask the dealership to switch you cars

Update... the dealership called today and said GM wants them to replace the entire gas tank we will see how that goes. They said Maude may have a hairline crack in the tank, but they have never had that on a new car.

If it comes on again scream "FACK YOU" (replace it with the real word) and it'll turn off.

That's what a Masshole with road rage would do!

Where you park it overnight, is it on an incline? My driveway has a slight incline and the fuel gauge will show more or less than actual depending on whether I pull straight in or back in.

ATM

It really isn't a major issue. At the worst you may be adding some additional gasoline vapors to the atmosphere. There are a number of places in the evaporative emissions system where a leak could occur. Years ago we just let the tanks vent into the atmosphere. Depending on how you top off the tank you may be getting enough gas into the tank that the expansion space at the top of the tank isn't large enough to handle the fluid's expansion thus causing a leak. What happens if you don't top off the tank?

Bill

As for parking it after it is filled up, it has been on a flat surface and it has also been on a slight incline, either way it goes off and the gas gauge drops.

The last time the gas light went off during the day and the check engine light came on as well. When the check engine light goes on my remote start doesn't work. My problem is it's a new car it should work. Someday down the road i'm not going to be able to sell my car because no one is going to buy it if i say "don't worry the gas light and check engine light, it might come on but it's been doing it since 1,960 miles."

When you top it off do you fill it up until the gas pump clicks, or do you keep pumping more and more gas in after it's clicked? If you're doing the latter STOP! That may be the problem.

I had almost essentially the EXACT same problem with my ex '08 Pontiac G6 GT coupe, starting the very first morning I had it, the day after picking it up. I drove a mile after it sat overnight and ding-ding-ding "Check Gas Cap" came up on the DIC. I thought it was just a randomly loose gas cap that time, but it eventually turned into 3 months of it happening every week, usually a full day or two after I filled up over the weekend and had then driven to work and back once, and in a few occasions I also had the smell of gas in the car--that was rare, however.

Mine, in total, occurred 17 times in 3 months and it was into the dealer either 3 or 4 times for it, along with a couple of other things that were ongoing. They tested it, it was okay, tested again, okay...kept happening and eventually I filed a BBB Autoline claim, started that process with GM, etc. requesting either a fix or an equivalent replacement, and eventually the "final repair attempt" was scheduled. Dropped the tank, replaced the sending unit & fuel pump, did more checking, and gave it back to me 3 days later. Ran just as it had before, and within a day or two the "Check Gas Cap" alert was back, along with a newly fluctuating gas gauge up and down randomly, and the Check Engine light randomly a few days later. From the start I videotaped & uploaded everything, sending it to my GM rep along with the other dealer, etc. docs, and always did an Onstar diagnostics call when it would come on, and a week after the repair when I confirmed it not only didn't work but things were worse, I was offered the trade buyback just as I had requested. In came then my '09 Malibu 2LT, now also gone for other reasons.

So, yeah, I've had the issue and with the same platform/family of cars, but rather the 3.5L and a G6. At the time my dealer actually told me they had one case a couple of years earlier with a lady's G6 and the same Check Engine light, and after a few unsuccessful attempts, GM said to swap out the sending unit and such--which fixed it. Didn't for mine, and only resulted in more problems. Still have no idea what might have been the problem as the car was repurchased, sent through the GM process and then resold at a dealer...but I continue to wonder. It was truly bizarre.

This would drive me crazy as well! I know this might sound stupid but are you using the same brand gas and gas station?

I have tried topping it off and not topping it off, either way it goes off. Also I usually use the same gas station or brand, but i'm not sure what the dealership uses but they have replicated the problem multiple times, so it's not me or anything i am doing.


They called me and think they have fixed it (crossing my fingers since they have said that 5 other times) but they replaced the gas tank and realized that the tank was molded wrong which was probably the reason the mass evap was going off. I should get my car back today, they said that the fuel gauge isn't dropping like it was, so I am hoping this is the solution, this whole dropping the car off at the dealership is getting old.

I have tried topping it off and not topping it off, either way it goes off. Also I usually use the same gas station or brand, but i'm not sure what the dealership uses but they have replicated the problem multiple times, so it's not me or anything i am doing.


They called me and think they have fixed it (crossing my fingers since they have said that 5 other times) but they replaced the gas tank and realized that the tank was molded wrong which was probably the reason the mass evap was going off. I should get my car back today, they said that the fuel gauge isn't dropping like it was, so I am hoping this is the solution, this whole dropping the car off at the dealership is getting old.

Fingers crossed...hope they give you a full tank of fresh gas and not was in your old tank.

I just got back from driving the car on the normal morning route and no problems. As long as nothing else comes up I will talk to the corporate GM offices on Monday and come up with some kind of deal for what they are going to do for all the inconvenience they caused. Thank you all for your input and suggestions.

It's been a little over 2 weeks and the problem is back. I thought it was fixed and GM already installed a clear bra for "customer satisfaction." But now It's back in the shop for the 7th time, the BBB Lemon Law claim is in process hopefully they will just give me a replacement car pretty much at this point I don't want it back, the gas gauge is broken once again and check gas cap light went off.

Dude, that sucks big, fat, donkey balls. Good Luck.

ATM

Wow, this is making me feel great. I just got back from the dealer. They fixed the window that wouldn't roll down all the way (foam insualation shifted into the way), and ordered a clip for a recall on the shifter, but I forgot to mention that EVERY time I fill up the CHECK GAS CAP light comes on the following morning in almost the exact same spot 1.5 miles from home. If this is what I have to look forward to... :( Guess I better get the fuel pump replaced in my Buick. Looks like it may be getting driven more than I thought.

Hey closer9,

Could you tell me which plant and what month it was made? I am curious to find out because I have had mine in the shop 7 times (currently in). Since mine is a 1LT as well I want to see if there is a link. Also with both of us having the same problem it might help in dealing with GM.

Hey closer9,

Could you tell me which plant and what month it was made? I am curious to find out because I have had mine in the shop 7 times (currently in). Since mine is a 1LT as well I want to see if there is a link. Also with both of us having the same problem it might help in dealing with GM.

Sure, no problem. Is it on the car somewhere, or is there a VIN decoder online?

They should be on the frame or the end of the drivers side door where the latch is (i can't remember if it is on the male or female part.) I told the dealership that I found someone with the same problem as me and he said that he had never heard of this problem before and I don't think GM has either at least on the Malibu's.

They should be on the frame or the end of the drivers side door where the latch is (i can't remember if it is on the male or female part.) I told the dealership that I found someone with the same problem as me and he said that he had never heard of this problem before and I don't think GM has either at least on the Malibu's.

Finally remembered to check on this. Lake Orion, Michigan, built December 2008. I just filled up the tank on the way home. I'm assuming I'll be notified in the morning that I need to check my cap...

Mine was built at the Lake Orion plant but in 9/08. I went to the dealership to grab some stuff out of my car and it sounds like GM really has no intention of doing anything to fix my car.. at least not in the near future. Today marks day 22 in the shop and attempt number 7. It looks more and more everyday that they are just going to give up and possibly give me a replacement car. I have a Canyon right now and they said as long as I am happy with it I can keep it and they will call me if and when they find out anything.

Correct me if I'm wrong, but the Canyon was provided by Chevrolet, not the dealership?

It was provided by the dealership through Enterprise. I've had a Vibe, 08 Malibu, Canyon and they also gave me a 09 Silverado LTZ they ripped the sticker off of the truck and gave it to me for the long weekend it is now one of their loaners. When I take my car in they just give me a rental in exchange for my car so they can keep it for as long as they need, this is never a 1 day deal anymore.

I didn't know buying a Malibu entitled me to try out the whole GM lineup.

It was provided by the dealership through Enterprise. I've had a Vibe, 08 Malibu, Canyon and they also gave me a 09 Silverado LTZ they ripped the sticker off of the truck and gave it to me for the long weekend it is now one of their loaners. When I take my car in they just give me a rental in exchange for my car so they can keep it for as long as they need, this is never a 1 day deal anymore.

I didn't know buying a Malibu entitled me to try out the whole GM lineup.

LOL, shoulda asked for a Vette... I'm just wondering if I'm going to be where you are in a few months. :(

My gas gauge reads at 7/8 of a tank with less than 3 miles on the tank in the morning after fill ups. I know if that goes so will the check gas cap light. I told the service tech if i had to take my car in one more time he had to give me his Monte Carlo, I also told them they need to start taking me out to lunch since I was going there daily.

Watch your gas gauge in the morning and see if it's dropped when you start your start your car, within a few mile the check gas cap light should go off.

I have a routine for the dealership of exactly what I do and they replicate the problem every time when they let it sit for 8 or so hours.

After fix #3 you are entitled to lemon law it (depending on your state). Just do it and get another car. Apparently yours has a freaking huge fix that GM/dealership cant figure out.

Nebraska is 4 times.. I filed all of the paperwork with the BBB and the GM side of the BBB so I am just waiting to go through arbitration and see what they will do for me. I want a replacement vehicle because I will never get the deal that I got on this car the week the stock market crashed and they needed to sell 4 cars for end of month quota.

I wish it was that easy but they make you jump through so many hoops to see if you really want to do something about it.

Again, almost exactly what happened with me and my G6, all eventually just handled through a GM rep after the BBB Auto Line complaint because nothing was "in 3x for each" yet. The rep got daily/weekly video updates, reviews from the dealer, set up the final repair attempt, and when that stretched for 3 days and I got a car back with more lights and issues than it started with, it took all of 24 hours to get the call of "we've decided you've had far too many issues with so few miles and will offer you a trade repurchase towards ANY new GM vehicle". I never actually had to do much with BBB except the initial filing and one quick call with a rep there, otherwise it was all GM.

Not sure how things work now, if at all different, but with similar issues and similar results from dealer repairs, hopefully you can get the same. I, of course, got a new Malibu out of it and even though it didn't work out for me either, I love my G8 and will continue with GM vehicles. The rep who handled my G6 case, especially, only re-affirmed that. It happens, it sucks, and hopefully you can get it resolved properly.

Funny how no one still could ever figure out my gas tank, gas cap alarm, etc. issues, no matter what. At 17 times, it happened so much along with other things (like a horribly creaky, poppy, rattly roof) that it became comical--and my video logs of it all were such a help.

We called the dealership today and they said the next step is to replace the computer module on the fuel pump. Who knows if this will work, I feel like they are just shooting in the dark here on ideas. At some point they just have to give up and say they can't fix it and stop wasting their money and my time.

Well, I made it to work this morning without the light coming on... Not sure what to think.

Got the light again this morning. Car goes back to the dealer next Friday for the shift indicator recall and check out the gas cap light... :(

The fuel pump assembly didn't work either. They drove it a couple of times over the last few days, when I got in the car this morning it went off like clockwork, the gas gauge dropped and then the "check gas cap" light came on and cleared itself within a mile. We are working on the next step to see what they can do now. If it wasn't for the dealership going above and beyond for us, I would be really be heated now. The next step is having a field tech work on the car exclusively at the dealership.

Any progress? I just got back from the dealer. Got my new shift indicator clip recall work done, and they're ordering a new gas cap... and so it begins... :( I really hope the cap works, but I'm pretty sure it won't...

I'm still waiting on them to complete the final repair attempt. It's just a waiting game now to see what happens.

So far so good.. Ive had the car back since Tuesday and I have topped it off a couple of times. We met with the GM rep and they are going to put a data recorder in my car to try and figure this whole thing out in case it goes off again. They mentioned that they might have to extend a recall to some cars and fix this problem on them as well. I will let you know when anything else comes up.

So far so good.. Ive had the car back since Tuesday and I have topped it off a couple of times. We met with the GM rep and they are going to put a data recorder in my car to try and figure this whole thing out in case it goes off again. They mentioned that they might have to extend a recall to some cars and fix this problem on them as well. I will let you know when anything else comes up.

I had one of those for a week or so in my '09 Malibu 2LT V6 (that replaced the lemon '08 G6 and it's weekly Check Gas Cap) as directed by 2 GM field engineers who came to test & investigate an ongoing trans shuddering problem. A.K.A., the "Family Feud button". Hah.

http://i26.photobucket.com/albums/c101/caddycruiser/My%20Cars%20Stuff/09%20Malibu/February%203%202009/Image00001.jpg
http://i26.photobucket.com/albums/c101/caddycruiser/My%20Cars%20Stuff/09%20Malibu/February%203%202009/Image00003.jpg
http://i26.photobucket.com/albums/c101/caddycruiser/My%20Cars%20Stuff/09%20Malibu/February%203%202009/Image00005.jpg

Hopefully, if the issue returns again, this will record something useful for them. I have no idea if it did in mine because I got fed up, removed the monitor so it wasn't showing, got a trade price on the car and week later bye it went before I heard back from them on what they had found. It basically will take snap shots of the systems at any given moment when you hit it, up to 4 and then reset/start over.

So far so good.. Ive had the car back since Tuesday and I have topped it off a couple of times. We met with the GM rep and they are going to put a data recorder in my car to try and figure this whole thing out in case it goes off again. They mentioned that they might have to extend a recall to some cars and fix this problem on them as well. I will let you know when anything else comes up.

So, what was this last (and hopefully successful) fix? I just realized I still haven't got a call about my gas cap...

They turned the vent hose 2 times clockwise. This solution was derived from a problem they were having on the Corvette. I told them GM rep about your car and that they might have some more fixing to do. We are waiting to see if this option fixes it and then they will be able to call your dealership and tell that what to do.

Hello all,

I am new to this conversation, and have read all of your threads. I just bought a used 2008 Malibu LS, and experienced the same problem you all are having (Check gas cap message comes up around 7/8 of tank, gas gauge drops, and then returns to normal after a minute or two). The ONLY time the message occurs is at 7/8 tank, and at no other time so far. Did you guys have the message pop up on any other occasions besides at 7/8 of a tank, or more than once over the course of a full tank? Over 2 weeks, I have experienced it occur twice over 1.5 tanks of gasoline. Has turning the vent hose proved to be the solution yet? Any input would be greatly appreciated. Thanks.

MJG, that sounds like what happens with mine, but only seems to happen if I fill up and park the car over night. I either drive 30 miles home then park it (which then the light comes on the next morning every time), or have filled up then driven close to 100 miles (without a light).

So, last Thursday the car got a new gas cap, and I filled up for the first time on the way home from work. I'm expecting the light to come on in the morning. Maude, any updates? Can I give them your dealerships name if/when I have to call them?

I have filled up 3 times so far... no problems yet. Yes it only goes off at 7/8 of a tank, it will be full when i fill up and when i get in the car in the morning it will be under full when i turn the car on (i usually remote start it for 5 minutes) the gauge will then drop to 7/8 of a tank and the light goes off like clockwork. I have had it go off i think 2 or 3 times in a day.

I am still testing this out to see how it's going. I haven't gotten the data recorder yet.. he wanted to see how it goes before it gets installed but i think i might as for it when i go to get my recall fixed. I am hopeful now that my car is fixed but I completely forgot about the problem and after driving around 500 miles the light came on again... so who knows... hopefully it's fixed and my whole situation can make it easier on everyone else.

My dealership is Gregg Young Chevy in Omaha,NE their phone number is (402) 572-8080, that's the mainline. I have recently been working with Joe Tisthammer, he is the service manager and has been working with the GM rep so he would know the most on this problem.

Let me know if you need any more assistance on this issue... it sucks to go through this anything I could do to help just tell me..

Thanks a bunch!!!

Light came back on this morning. So, I'll be calling them again. I will pass on your dealer info though...

Well, car goes back next Friday. I gave them your dealer's info Maude. Hope they make the call, and get this figured out... :)

So, am I reading this correct? You had the light come on again since the last trip in? It isn't really fixed?

I haven't had the light go off in about 3 weeks. I still am not sold on how the gas gauge functions but no check gas cap light. I only do city driving on the way to work so it's hard to tell mileage, but I ran it down to E and the refuel light went off, so I know that actually works but so far no check gas cap light has come on.

Sitting at the dealer now. They can't find a problem and said no one is answering at Young Chevy. They're going to call the corporate guys now...

EDIT: Right after I posted this they came out, said it would be a while, and offered a loaner. I took the loaner and went home to wait for phone call. :(

EDIT 2: Dealership called. They're going to keep my car till at least Monday. :( :(

Well you guys can add my 09 2LT 3.6 (6,000+ miles) to list of cars of potential cars with the gas cap problem.

I filled my car up Monday night with a 1.6 mile drive home from the gas station....that next morning started the car on my way to work and 5.4 miles later - the gas cap light came on.

I drove another mile to find a safe location to pull over - I shut the car off - took the cap off and put it back on with '20 plus clicks' to ensure that it is on 'tight'

The light shut off and it hasnt turned on since.....I will refill my car again next week and see if it happens again.

Oh - I need to add that this is the first time this has happened since buying this car - so it could be a fluke thing but we shall see.

Keep you posted.

Dealership called, my car is ready to go. Said they replaced the sending unit AND fuel tank. Not sure why the tank, because he said there was a clip broke on the sending unit, and that there was a TSB out for it.

Hope that takes care of it. I think the wife is going to go pick it up for me after lunch... :)

Good luck... mine has been good so far.. but i won't get too confident because last time i thought it was fixed for good and there came the light again. But it's been about a month now since it was fixed.

Good thing they got it "fixed".

I know GM is still dealing with new car issues with the Malibu and probably will until the new model comes out. At least you didnt give up!!

Well, filled up last night, and no light this morning, and gas gauge stayed at F... :) So far so good!

I experienced the same issue with my '09 LT2. First noticed it while I was on vacation in Wisconsin. "Check Gas Cap" came up on the DIC. Pulled over and found that the cap was completely loose. When I got back in the car, I noticed that I was "missing" between 1/8 and 1/4 of a tank and had just filled up the night before. I immediately suspected a Wisconsiner had syphoned some gas out of my tank because Wisconsiners hate Illinoisian people. Thought nothing of it. Happened again two days later after I got back to Chicago. No fellow Chicagoan would steal my gas. Realized that it had to be something with the car itself. (Sorry Wisconsiners! You're innocent until proven guilty from this point forward.)

Took my Bu to the shop. They only had to replace the gas cap (free of charge) to correct the problem. Apparently if you tighten the cap down too much, you can strip the ratcheting mechanism in the cap. After that, no matter how many clicks you hear, you'll never ever be able to tighten it enough to get a good seal. I have not had any issues since the dealer replaced the gas cap (knock on the LT2 plastic woodgrain trim).

Just found this thread when doing a search in google. I have been having the exact same problem since I purchased my 09 LT in January. I seem to get the Gas Cap Warning light about every other time that I fill up the car. I haven't brought it in or called the dealer about it yet but it is a bit bothersome.

Just found this thread when doing a search in google. I have been having the exact same problem since I purchased my 09 LT in January. I seem to get the Gas Cap Warning light about every other time that I fill up the car. I haven't brought it in or called the dealer about it yet but it is a bit bothersome.

Well, mine has been doing great since they replaced the sending unit and tank. If it would be of any help I had the service done at Hendren Chevrolet in Pineville, MO.

Mine has been doing great too. Hopefully this whole gas cap thing is something I don't have to worry about as long as I have this car.

Had same problem with our 2009 Malibu, started about 3500 miles, took about 6 trips to dealer and replacing gas tank assembly to finally fix.

MaudetheMalibu, what was the final operation that fixed your Malibu? Was rotating the vent hose what fixed it? Also, did replacing the gas gap actually work for anyone?

MaudetheMalibu, what was the final operation that fixed your Malibu? Was rotating the vent hose what fixed it? Also, did replacing the gas gap actually work for anyone?


Replacing the gas cap did nothing for me. But turning the vent hose is what seemed to have fixed it for me. Are you having problems with yours still, what have they done to fix it?

Same problem on my '08 1LT but, sadly, more intermittent than some here. Occurring since "birth" and have had the gas cap replaced but it's back. Thanks to all for the useful posts, which I'll cite with my Service Advisor.

if you have the same problem more than three times, GM will buy the car back. right?

i have noticed my gas cap light comes on too, but i don't really care about it. i'll get out and make sure i tightened it down more than 3 clicks. but it never lasts more than 10 minutes.

Just had a 4-day adventure for the "Check Gas Cap" code... After much activity, including the TAN Forum for Chevy Technicians, a TSB was identified: 09-06-04-0074.

The Correction section includes mention of diagnostic code P0455. This turns out to be misleading, as a full pressure test evidenced no problems at all. The code actually clears itself from the DIC after about 5 minutes, but is retained in the system.

The fix applied was: "Remove Fuel Pump and reposition vapor line". This is probably what "MaudetheMalibu" meant by "the vent hose". The vent hose is actually rather immovable - it's the "vapor line" that can be adjusted...

Next fill-up will prove "fixed or not"...

Many thanks to Maude, by the way. Without her copious documentation, this wouldn't have been taken seriously because the Dealer couldn't reproduce the P0455 code...

I was at the dealership the other day getting my creeky break pedal fixed and they said they have another car with the same problem that had been in the shop several times they tried everything they did for mine and it still did not fix it, they are going to probably end up buying that one back.

Welp, i've got 2050 miles on my Malibu now. This morning when driving to work the "Check Gas CaP" message displayed. Five minutes later my check engine light came on. On Star called shortly after and ran a diag on the car to send to the dealership.

Hopefully it's just a bad gas cap for me. I'll have to take her in on Monday. My wife admitted to possibly capping off the gas when she last put gas in it, arrgghh!

Anyone who has had the tank replaced have any updates?

I am having this same problem also. Been to the dealer 2 times now. They have a new fuel tank on order and I will let you all know after they put it in. I was told by my Dealership they are plastic tanks
and they are having problems with the tanks expanding and contracting with the change in temps.

Anyone who has had the tank replaced have any updates?

I've got almost 24k miles on mine now, and no problems since... I need to be careful saying that. Friday I told a friend I hadn't needed my generator in 3 years. Sunday the electricity went out, and I fired up the generator... :)

August 4th 2010:

After replacing the breather pipe, and the sender and the level-sensor and STILL getting the ping-ping after three different fill-up-and-use scenarios, Chevy replaced the entire tank in July 2010.

Haven't repeated any of my usual 3 scenarios yet (local gas prices way higher than out-and-about prices) but so far so good.

Beware! I did find that although you can press the cap down and ratchet it on, there are times when you can simply pull it back off!!! Happened to me twice and I'm no weakling in pushing the cap on...

Hopefully my problem is fixed, but I've thought that before...

Sadly, California Lemon Law requires the vehicle to be repeatedly repaired for a problem that causes significant loss of use - this is just a pain and doesn't qualify for a buy-back. That said, I'd still buy another Malibu - they are that good...

2008 1LT with 41K miles - White

Well I got the car back from the dealer on fri. and they replaced the fuel tank and pump assembly. They said they found a soft spot in the plastic fuel tank causing it to expand and contract. I filled it up last night and will test it today. I'm keeping my fingers crossed.