Recall 16V521 affects 534 2016 Chevrolet Malibu Hybrid vehicles because the battery service disconnect can stall while driving. Free repair at a franchised Chevrolet dealer.
Chevrolet is recalling 534 2016 Malibu Hybrid vehicles under recall 16V521 because the manual service disconnect switch for the high-voltage battery can be installed incorrectly and fail to lock into position. If it disconnects while driving, the vehicle can stall and increase crash risk; Chevrolet dealers will inspect and repair it free of charge.
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What's wrong?
The 2016 Chevrolet Malibu Hybrid uses a high-voltage battery to help drive the hybrid propulsion system. The manual service disconnect is a removable plug in that high-voltage system, used by technicians to shut off battery power before service work. In normal driving, it stays seated and locked so high-voltage power keeps flowing to the propulsion system.
On affected Malibu Hybrids, that disconnect plug was not latched into the locked position during assembly. If it works loose while the vehicle is moving, high-voltage power cuts out and the car loses propulsion energy, which stalls the vehicle. GM found that low-voltage systems remain powered, so gauges, airbags, pretensioners, and other electronics still work.
There is no warning sign before failure. The first thing an owner notices can be the vehicle losing drive power while driving.
Who's affected?
| 2016 Chevrolet Malibu Hybrid | Hybrid propulsion system |
|---|---|
| Units affected | 534 |
| Field incidents | NHTSA has logged 1 field incident to date. |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether your specific sedan is included.
What's the safety risk?
A vehicle stall raises crash risk because the 2016 Malibu Hybrid can lose propulsion while in traffic. If your VIN is included, schedule the repair soon and contact a Chevrolet dealer if the vehicle stalls before your appointment. Repair is free at any franchised Chevrolet dealer.
What should I do?
- Check your VIN to confirm your 2016 Chevrolet Malibu Hybrid is included in this recall.
- Contact a franchised Chevrolet dealer to schedule the free MSD inspection and installation correction that addresses the high-voltage disconnect and stall risk.
- Bring the recall notice if Chevrolet mailed one. If not, reference recall number 16V521 and recall 51230 when you call.
- Call Chevrolet customer service at 1-800-222-1020 with questions about scheduling or the free repair.
- Drive cautiously until the repair is complete. Pull over safely if the vehicle loses power while driving.
What happens at the repair
At the dealer, a Chevrolet technician inspects the manual service disconnect switch for the high voltage battery and corrects its installation if needed so the switch locks into position. The recall repair is free, with parts and labor covered. Out-of-pocket repairs already paid are handled through the existing warranty, not through a separate reimbursement program, because all covered vehicles are under warranty. Ask the service desk how warranty coverage applies if you have prior repair paperwork.
| Reimbursement | Warranty coverage applies |
|---|
Timeline
| July 7, 2016 | Dealer notification began |
|---|---|
| July 7, 2016 | Dealer notification ended |
| July 8, 2016 | NHTSA published the recall |
| August 10, 2016 | Owner notification mailed |
Frequently asked questions
What is recall 16V521?
Recall 16V521 covers 534 2016 Chevrolet Malibu Hybrid vehicles with a manual service disconnect switch for the high-voltage battery that can unlock while driving and stall the vehicle. Chevrolet dealers will inspect the switch and correct the installation for free.
What should I do if my 2016 Chevrolet Malibu Hybrid is on this recall?
Check your VIN to confirm your specific Malibu Hybrid is included in recall 16V521. If it is, contact a franchised Chevrolet dealer to schedule the manual service disconnect inspection and installation correction. Reference recall number 16V521 when you call. The repair is free.
Is the recall repair free?
Yes. Federal recall law requires manufacturers to perform recall repairs at no cost. Chevrolet's remedy says dealers will inspect the manual service disconnect switch and correct the installation, as necessary, free of charge.
What is the safety risk?
The safety risk is a vehicle stall while driving. The manual service disconnect switch can unexpectedly disconnect high-voltage power, which stops propulsion. A stall increases crash risk, so confirm your VIN and schedule the free dealer repair if your vehicle is included.
What if I bought my Chevrolet Malibu Hybrid used?
The free recall repair still applies. Recall coverage follows the vehicle, not the first owner. If you never received the owner notice from 2016, check your VIN and contact a franchised Chevrolet dealer with recall number 16V521.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/16V521000 |
|---|---|
| Chevrolet customer service | 1-800-222-1020 |
| NHTSA recall # | 16V521 |
| NHTSA recall # (full) | 16V521000 |
Source documents
-
Download Recall Document (PDF) (PDF) - Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Quarterly Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 31, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →