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2000 Chevrolet Cavalier

Owner reports · Recalls · Investigations

More warning signs than most Cavalier years

Owner complaints for the 2000 Chevrolet Cavalier are substantially higher than the model-year median of 140.

About this comparison →

When problems were reported

Mileage at the reported incident

120 reports with mileage · 195 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Electrical System. Review the 69 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 54 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Service Brakes, Hydraulic. Review the 41 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

25 crash reports8 fire reports13 injury reports

Unknown Or Other complaints

19 reports
Clear category filter
97,000 miles · Aug 23, 2015
EngineUnknown Or Other

I HAD THE AIR CONDITIONER REPLACED. THE TECH SAID THE TENSIONER NEEDED TO BE REPLACED. ONE WEEK LATER I RETURNED AND HAD A NEW BELT TENSIONER INSTALLED. ABOUT A MONTH LATER THE NEW AIR CONDITIONER HAD PREMATURE FAILURE. I HAD IT REPAIRED UNDER WARRANTY AND ALSO HAD A NEW DRIVE BELT INSTALLED DURING THE REPAIR. ABOUT ONE YEAR LAT…

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I HAD THE AIR CONDITIONER REPLACED. THE TECH SAID THE TENSIONER NEEDED TO BE REPLACED. ONE WEEK LATER I RETURNED AND HAD A NEW BELT TENSIONER INSTALLED. ABOUT A MONTH LATER THE NEW AIR CONDITIONER HAD PREMATURE FAILURE. I HAD IT REPAIRED UNDER WARRANTY AND ALSO HAD A NEW DRIVE BELT INSTALLED DURING THE REPAIR. ABOUT ONE YEAR LATER I BEGAN HEARING A CHATTER WHEN ACCELERATING FROM STOP POSITION AND HAD EXCESSIVE VIBRATION. I TOOK TO THE SHOP AND THEY SAID THE BELT TENSIONER WAS BAD. THIS SEEMS EXCESSIVELY SHORT LIFE SPAN FOR A REPLACEMENT PART OF GOOD QUALITY. TODAY THE SHOP TRIED THREE DIFFERENT TENSIONERS AND STILL IT WAS NOT CORRECTING THE ISSUE. I EVEN DOUBLE CHECKED THE BELT ROUTING PATTERN TO ENSURE IT WAS CORRECT. I DONT UNDERSTAND WHAT THE PROBLEM IS WITH THE BELT TENSIONERS FOR THIS VEHICLE. ALL MY PRIOR FORD VEHICLE NEVER HAD THIS PROBLEM WITH THEIR TENSIONERS OF SAME DESIGN. PLEASE LOOK INTO THIS PROBLEM AS A BELT THAT BREAKS OR SLIDES OF A PULLEY DUE TO A FAULTY TENSIONER CAN CAUSE IMMEDIATE LOSS OF POWER STEERING RESULTING IN HAZARDOUS AND POTENTIALLY FATAL DRIVING CONDITIONS AND SITUATIONS. ALSO THE BACKLIGHTING ON THE ODOMETER DOES NOT WORK.THE ODOMETER REGISTERS MILAGE DRIVEN BUT THE BACKLIGHT DOES NOT WORK AT ALL.PLEASE LOOK INTO AND DONT WAIT FOR SOMEONE TO HAVE TO DIE BEFORE THIS ISSUE BECOME IMPORTANT.THANKS.

NHTSA ODI #10758684

50,000 miles · Mar 16, 2011
Electrical SystemEngine And Engine CoolingExterior Lighting

PURCHASED USED 2000 CAVALIER IN 2006. FIRST PROBLEM (WHICH HAS CONTINUED FOR 5 YEARS) IS THAT THE SERVICE LIGHT WILL COME ON WHEN THE CAR IS CRANKED UNLESS THE HEADLIGHTS ARE FIRST TURNED ON. IF YOU TURN THE HEADLIGHTS OFF WHILE DRIVING, THE SERVICE LIGHT COMES ON. IT WILL NOT GO OFF UNLESS YOU TURN THE CAR OFF AND RESTART …

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PURCHASED USED 2000 CAVALIER IN 2006. FIRST PROBLEM (WHICH HAS CONTINUED FOR 5 YEARS) IS THAT THE SERVICE LIGHT WILL COME ON WHEN THE CAR IS CRANKED UNLESS THE HEADLIGHTS ARE FIRST TURNED ON. IF YOU TURN THE HEADLIGHTS OFF WHILE DRIVING, THE SERVICE LIGHT COMES ON. IT WILL NOT GO OFF UNLESS YOU TURN THE CAR OFF AND RESTART IT (WITH HEADLIGHTS ON). SECOND PROBLEM IS THAT FUEL HAND DOES NOT REFLECT ACCURATE AMOUNT OF GASOLINE IN TANK. IT GOES UP AND DOWN WHILE DRIVING (WITH THE CHECK GAUGES LIGHT ON). OR SOMETIMES IT IS STUCK ON E OR STUCK ON F REGARDLESS OF HOW MUCH FUEL IS ACTUALLY PRESENT. THIRD PROBLEM IS THAT CAR INTERMITTENTLY OVERHEATS AND IS ALWAYS LOSING COOLANT. I HAVE REPLACED THERMOSTAT, WATER PUMP, & RADIATOR. THREE DIFFERENT MECHANICS CANNOT FIND A LEAK IN THE COOLING SYSTEM (DESPITE PRESSURE TESTING, COMPRESSION TESTING, & BLOCK TESTING). WE ARE BAFFLED WHY IT CANNOT RETAIN CONSTANT COOLANT LEVELS. THIS IS A VERY FRUSTRATING SITUATION AS I AM LEFT WITHOUT RELIABLE TRANSPORTATION. *TR

NHTSA ODI #10390337

12,000 miles · Jul 7, 2008
StructureUnknown Or Other

TL*THE CONTACT OWNS A 2000 CHEVROLET CAVALIER Z24. THE CONTACT STATED THAT THE PAINT ON THE HOOD, ROOF, TRUNK AND SPOILER OF THE VEHICLE BEGAN TO CHIP AND PEEL OFF. AS TIME PROGRESSED, HE NOTICED THAT OTHER VEHICLES OF THE SAME MODEL WERE EXPERIENCING THE SAME FAILURES. THE DEALER AND MANUFACTURER HAVE NOT BEEN NOTIFIED. THE…

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TL*THE CONTACT OWNS A 2000 CHEVROLET CAVALIER Z24. THE CONTACT STATED THAT THE PAINT ON THE HOOD, ROOF, TRUNK AND SPOILER OF THE VEHICLE BEGAN TO CHIP AND PEEL OFF. AS TIME PROGRESSED, HE NOTICED THAT OTHER VEHICLES OF THE SAME MODEL WERE EXPERIENCING THE SAME FAILURES. THE DEALER AND MANUFACTURER HAVE NOT BEEN NOTIFIED. THE FAILURE MILEAGE WAS 12,000 AND CURRENT MILEAGE WAS 36,000. UPDATED 09/16/08. *LJ UPDATED 09/18/08. *JB

NHTSA ODI #10233354

Mileage unknown · Feb 21, 2006
Unknown Or Other

2000 CAVALIER Z-24 CURVED PLASTIC PIECE THAT WRAPS AROUND THE UPPER INSIDE OF THE DASH STRETCHING FROM WINDSHIELD POST TO WINDSHIELD POST CRACKS AND FALLS APART. *TS THE DEALER REPAIRED THE CRACKED DASHBOARD. *JB

NHTSA ODI #10151907

23,000 miles · Jan 15, 2004
Unknown Or Other

PAINT, CEYENNE PEPPER. METAL FLAKE PAINT IS STARTING TO TURN WHITE IN MILLIONS OF LITTLE POCKETS BELOW THE CLEAR COAT. GM REP. STATES THE CAR IS OUT OF WARRANTY AND THE CAR JUST NEEDS TO BE DETAILED. THE DEALER JOHN L. SULIVAN. JUST PAINTED THE SPOILER A MONTH AGO FOR THE SAME CAUSE. THE SPOILER IS STARTING TO SHOW SOME OF THE …

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PAINT, CEYENNE PEPPER. METAL FLAKE PAINT IS STARTING TO TURN WHITE IN MILLIONS OF LITTLE POCKETS BELOW THE CLEAR COAT. GM REP. STATES THE CAR IS OUT OF WARRANTY AND THE CAR JUST NEEDS TO BE DETAILED. THE DEALER JOHN L. SULIVAN. JUST PAINTED THE SPOILER A MONTH AGO FOR THE SAME CAUSE. THE SPOILER IS STARTING TO SHOW SOME OF THE EARLY SIGNS ALREADY OF THE ADVANCING PROBLEMS. THE SERVICE MANAGER STATED THE PAINT IS DAMAGED DUE TO ATMOSPHERIC CONDITIONC. THEY ARE REFUSING TO REPAINT THE CAR.

NHTSA ODI #10071192

35,900 miles · Jun 13, 2003
Engine And Engine CoolingEquipmentService Brakes, Hydraulic

I HAVE A 2000 CHEVROLET CAVALIER. THE FIRST PROBLEM I EXPERIENCED WAS IN OCT 2001,WHILE DRIVING THE TEMPERATURE GAUGE WENT TO THE MAXIMUM READING WITHOUT WARNING, I PULLED OFF THE HIGHWAY AND TURNED OFF VEHICLE. WAITED A WHILE STARTED BACK WENT APPROXIMATELY 1/4 MI AND SAME PROBLEM,AFTER STOPPING 3-4 TIMES I STARTED BACK ON TH…

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I HAVE A 2000 CHEVROLET CAVALIER. THE FIRST PROBLEM I EXPERIENCED WAS IN OCT 2001,WHILE DRIVING THE TEMPERATURE GAUGE WENT TO THE MAXIMUM READING WITHOUT WARNING, I PULLED OFF THE HIGHWAY AND TURNED OFF VEHICLE. WAITED A WHILE STARTED BACK WENT APPROXIMATELY 1/4 MI AND SAME PROBLEM,AFTER STOPPING 3-4 TIMES I STARTED BACK ON THE HIGHWAY AND CONTINUED TO DRIVE WITH TEMP GAUGE IN THE RED FOR A APPROX 1 MILE AND ALL GAUGES RETURNED TO NORMAL. CHEVROLET GARAGE COULD NOT FIND ANY PROBLEMS WITH COOLING SYSTEM..MY SECOND PROBLEM I KEEP HEARING A CLANGING/RATTLING SOUND FROM THE FRONT AREA OF VEHICLE WHILE SITTING STILL IF YOU TURN STEERING WHEEL YOU CAN HEAR A THUMP FROM THE FRONT LEFT AREA WHERE STRUT IS LOCATED..MY THIRD PROBLEM IS MY CHECK ENGINE/SERVICE ENGINE LIGHT KEEPS COMING ON AT VARIOUS TIMES. MY FOURTH PROBLEM I HAVE HAD TO REPLACE MY FRONT ROTORS THREE TIMES NOW DUE TO THEM WARPING,THE FIRST TIME I HAD LESS THEN 10,000 MILES....... *NLM

NHTSA ODI #10023001

Mileage unknown · Nov 13, 2002
Fuel System, OtherUnknown Or OtherVehicle Speed Control

CAR WAS BEING DRIVEN ON HIGHWAY, ACCELERATED BEYOND DRIVER'S CONTROL, WITH BRAKES APPLIED DRIVER PUT CAR IN NEUTRAL, GUIDED CAR OFF ROAD AND SHUT OFF ENGINE. MECHANIC WHERE CAR WAS TOWED EXPLAINED THAT THE AIR FILTER COVER HAD BROKEN AND A PIECE FROM AIR FILTER COVER WAS SUCKED INTO AIR DUCT TO THROTTLE BODY CAUSING THROTTLE TO …

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CAR WAS BEING DRIVEN ON HIGHWAY, ACCELERATED BEYOND DRIVER'S CONTROL, WITH BRAKES APPLIED DRIVER PUT CAR IN NEUTRAL, GUIDED CAR OFF ROAD AND SHUT OFF ENGINE. MECHANIC WHERE CAR WAS TOWED EXPLAINED THAT THE AIR FILTER COVER HAD BROKEN AND A PIECE FROM AIR FILTER COVER WAS SUCKED INTO AIR DUCT TO THROTTLE BODY CAUSING THROTTLE TO BE STUCK OPEN. CAR IS BIFUEL CNG. IS THIS IS A FACTOR IN AIR FILTER COVER CRACKING? IS THERE PARTS TRACKING FOR REPLACEMENT OF AIR FILTER COVERS AND IS IT KNOWN HOW MANY OF THOSE WENT TO BIFUEL CARS. WHY IS AIR FILTER COVER CRACKING? OR IS THERE A FIX TO PREVENT PIECES FROM LODGING IN THROTTLE? DT

NHTSA ODI #769654

Mileage unknown · Jul 18, 2002
Electrical SystemSteeringUnknown Or Other

WHILE DRIVING THEFT LIGHT AND ENGINE LIGHT ILLUMINATED ON DASHBOARD. DEALER WAS NOTIFIED. MECHANIC STATED IGNITION SWITCH MALFUNCTIONED. MECHANIC ADVISED CONSUMER TO REPLACE COMPONENT.*AK

NHTSA ODI #8014235

Mileage unknown · Apr 2, 2002
Power TrainStructureUnknown Or Other

WHILE RAINING WATER WILL ENTER INSIDE OF TRUCK WHILE CLOSING, AND SPARE TIRE IS FILLED WITH WATER. ALSO. ALSO, ENGINE CHECK LIGHT AND TRACTION CONTROL LIGHT WERE ON DASHBOARD.*AK

NHTSA ODI #8006868

Mileage unknown · Jan 30, 2002
Electrical SystemService Brakes, HydraulicUnknown Or Other

AFTER BUYING THE CAR HAD TO RETURN TO HAVE THE DOOR FIXED AFTER DOOR WAS FIXED THE KEYLESS ENTRY QUIT WORKING HAD THE CAR BACK TO GET KEYLESS ENTRY FIXED 4 TIMES, HAD TO HAVE FRONT ROTORS REPLACED AT 28000 MILES ALONG WITH THE BRAKES ,STILL HAVING PROBLEMS WITH THE BRAKING SYSTEM GRINDING AND CLICKING BAD VIBRATION IN THE FRONT …

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AFTER BUYING THE CAR HAD TO RETURN TO HAVE THE DOOR FIXED AFTER DOOR WAS FIXED THE KEYLESS ENTRY QUIT WORKING HAD THE CAR BACK TO GET KEYLESS ENTRY FIXED 4 TIMES, HAD TO HAVE FRONT ROTORS REPLACED AT 28000 MILES ALONG WITH THE BRAKES ,STILL HAVING PROBLEMS WITH THE BRAKING SYSTEM GRINDING AND CLICKING BAD VIBRATION IN THE FRONT END WHEN DRIVING IN STRAIGHT STRETCHES ALSO VIBRATION WHEN GOING AROUND TURNS AT TIMES IT FEELS LIKE THE TIRES ARE COMMING OFF CAR IS IN THE SHOP AT PRESENT TIME WITH THE BRAKE PROBLEMS AND DIMMING OF THE LIGHTS AND FUEL GAGE READS EMPTY AFTER FILLING THE TANK UP AND CHECK GAGES LIGHTS COME ON AND REMAIN ON FOR 50 - 100 MILES.THATS ALL AT THIS TIME. *AK

NHTSA ODI #757568

Official recalls

2

04V036000 · Electrical System:ignition:switch

Jan 27, 2004

ON CERTAIN PASSENGER VEHICLES. IF THE ENGINE FAILS TO START AND THE DRIVER HOLDS THE KEY IN THE "START" POSITION FOR AN EXTENDED PERIOD, HIGH CURRENT FLOWS THROUGH THE IGNITION SWITCH, AND SOMETIMES PRODUCES ENOUGH HEAT TO MELT INTERNAL SWITCH PARTS.

Consequence & remedy

Consequence: IF THE SWITCH IS DAMAGED, A FIRE COULD OCCUR IN THE STEERING COLUMN, EVEN WITH THE ENGINE OFF AND THE KEY REMOVED. THE FIRE COULD SPREAD TO THE INTERIOR OF THE CAR, WHICH COULD INJURE OCCUPANTS OR CAUSE DAMAGE TO ADJOINING STRUCTURES.

Remedy: DEALERS WILL INSTALL A RELAY KIT IN THESE VEHICLES TO PREVENT HIGH CURRENT FROM FLOWING THROUGH THE IGNITION SWITCH, AND CHECK THAT YOUR CAR WILL START WITH A PROPERLY CHARGED BATTERY AND, IF NECESSARY, REPLACE THE IGNITION SWITCH. OWNER NOTIFICATION WILL BEGIN ON MARCH 1, 2004. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-630-2438, PONTIAC AT 1-800-620-7668, BUICK AT 1-866-608-8080, OR OLDSMOBILE AT 1-800-630-6537. CUSTOMERS CAN ALSO CHECK THEIR VEHICLE ONLINE BY GOING TO WWW.MYGMLINK.COM AND ENTERING THE VEHICLE'S IDENTIFICATION NUMBER.

00V201000 · Interior Lighting

Jul 20, 2000

VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH THE BI-FUEL OPTION FAIL TO COMPLY WITH FMVSS NO. 101, "CONTROL LOCATION, IDENTIFICATION, AND ILLUMINATION." THE INSTRUMENT PANEL LIGHTS IN THESE VEHICLES ARE AT FULL ILLUMINATION LEVELS AND CANNOT BE ADJUSTED. THE STANDARD REQUIRES AT LEAST TWO LEVELS OF ILLUMINATION.

Consequence & remedy

Consequence: THIS COULD MAKE IT MORE DIFFICULT TO SEE OBJECTS OUTSIDE THE VEHICLE WHEN DRIVING AT NIGHT.

Remedy: DEALERS WILL REPLACE THE FUEL TYPE INDICATOR SWITCH ASSEMBLY, WHICH INCLUDES THE INSTRUMENT PANEL ILLUMINATION CONTROL.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

3

EA02028 · Erratic Fuel Gauge

Opened Sep 30, 2002 · Closed Dec 30, 2003

Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Other:storage:fuel Gauge System

ODI OPENED EA 02-028 TO REVIEW COMPLAINTS OF CONSUMERS REPORTING THAT THEIR FUEL GAUGE WAS INCORRECTLY DISPLAYING THE AMOUNT OF FUEL IN THE GAS TANK.THE FUEL GAUGE RECEIVES AN ELECTRICAL SIGNAL FROM A FUEL TANK SENDING SENSOR CIRCUIT CARD.A FLOAT ARM IN THE TANK MOVES ELECTRICAL CONTACTS THAT RUB AGAINST THE CARD AS THE LEVEL OF FUEL RISES AND FALLS.DISRUPTION OF THE ELECTRICAL SIGNAL (SUCH AS CAUSED BY CORROSION OF THE CIRCUIT CARD) WILL CAUSE INCORRECT READINGS TO REGISTER ON THE FUEL GAUGE.GM REPORTED IN THEIR RESPONSE TO ODI DATED JANUARY 13, 2003 THAT THE PRIMARY CAUSE OF ERRATIC FUEL GAUGE OPERATION IS EXCESS ELEMENTAL SULFUR IN FUEL.GM REPORTED THAT ABNORMAL LEVELS OF SULFUR SPORADICALLY OCCURRED IN CERTAIN PARTS OF CANADA AND THE U.S. RESULTING IN REPORTS OF FUEL GAUGE MALFUNCTION.GM MODIFIED THE SENDING SENSOR FOR VEHICLES BUILT AFTER OCTOBER 2000.IT MADE A SECOND SENSOR MODIFICATION FOR VEHICLES BUILT AFTER JANUARY 2003.GM ALSO ISSUED A CUSTOMER SATISFACTION CAMPAIGN (GM NUMBER 00101) IN DECEMBER 2000 FOR U.S. CUSTOMERS IN THE STATE OF MAINE AND ISSUED SEVERAL SERVICE BULLETINS INFORMING DEALERS OF THE AVAILABILITY OF SENSORS WITH IMPROVED CORROSION RESISTANCE.THE COMPLAINT TREND INDICATES THAT COMPLAINTS PEAKED IN LATE 2000 TO EARLY 2001.WARRANTY CLAIMS DECLINED SINCE PEAKING IN APRIL 2002.BASED ON THE NUMBER OF COMPLAINTS AND THE INDICATION OF A DECLINING TREND, FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Additional source detail variants (2)

Fuel System, Gasoline

ODI OPENED EA 02-028 TO REVIEW COMPLAINTS OF CONSUMERS REPORTING THAT THEIR FUEL GAUGE WAS INCORRECTLY DISPLAYING THE AMOUNT OF FUEL IN THE GAS TANK.THE FUEL GAUGE RECEIVES AN ELECTRICAL SIGNAL FROM A FUEL TANK SENDING SENSOR CIRCUIT CARD.A FLOAT ARM IN THE TANK MOVES ELECTRICAL CONTACTS THAT RUB AGAINST THE CARD AS THE LEVEL OF FUEL RISES AND FALLS.DISRUPTION OF THE ELECTRICAL SIGNAL (SUCH AS CAUSED BY CORROSION OF THE CIRCUIT CARD) WILL CAUSE INCORRECT READINGS TO REGISTER ON THE FUEL GAUGE.GM REPORTED IN THEIR RESPONSE TO ODI DATED JANUARY 13, 2003 THAT THE PRIMARY CAUSE OF ERRATIC FUEL GAUGE OPERATION IS EXCESS ELEMENTAL SULFUR IN FUEL.GM REPORTED THAT ABNORMAL LEVELS OF SULFUR SPORADICALLY OCCURRED IN CERTAIN PARTS OF CANADA AND THE U.S. RESULTING IN REPORTS OF FUEL GAUGE MALFUNCTION.GM MODIFIED THE SENDING SENSOR FOR VEHICLES BUILT AFTER OCTOBER 2000.IT MADE A SECOND SENSOR MODIFICATION FOR VEHICLES BUILT AFTER JANUARY 2003.GM ALSO ISSUED A CUSTOMER SATISFACTION CAMPAIGN (GM NUMBER 00101) IN DECEMBER 2000 FOR U.S. CUSTOMERS IN THE STATE OF MAINE AND ISSUED SEVERAL SERVICE BULLETINS INFORMING DEALERS OF THE AVAILABILITY OF SENSORS WITH IMPROVED CORROSION RESISTANCE.THE COMPLAINT TREND INDICATES THAT COMPLAINTS PEAKED IN LATE 2000 TO EARLY 2001.WARRANTY CLAIMS DECLINED SINCE PEAKING IN APRIL 2002.BASED ON THE NUMBER OF COMPLAINTS AND THE INDICATION OF A DECLINING TREND, FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

Fuel System, Other:storage:fuel Gauge System

ODI OPENED EA 02-028 TO REVIEW COMPLAINTS OF CONSUMERS REPORTING THAT THEIR FUEL GAUGE WAS INCORRECTLY DISPLAYING THE AMOUNT OF FUEL IN THE GAS TANK.THE FUEL GAUGE RECEIVES AN ELECTRICAL SIGNAL FROM A FUEL TANK SENDING SENSOR CIRCUIT CARD.A FLOAT ARM IN THE TANK MOVES ELECTRICAL CONTACTS THAT RUB AGAINST THE CARD AS THE LEVEL OF FUEL RISES AND FALLS.DISRUPTION OF THE ELECTRICAL SIGNAL (SUCH AS CAUSED BY CORROSION OF THE CIRCUIT CARD) WILL CAUSE INCORRECT READINGS TO REGISTER ON THE FUEL GAUGE.GM REPORTED IN THEIR RESPONSE TO ODI DATED JANUARY 13, 2003 THAT THE PRIMARY CAUSE OF ERRATIC FUEL GAUGE OPERATION IS EXCESS ELEMENTAL SULFUR IN FUEL.GM REPORTED THAT ABNORMAL LEVELS OF SULFUR SPORADICALLY OCCURRED IN CERTAIN PARTS OF CANADA AND THE U.S. RESULTING IN REPORTS OF FUEL GAUGE MALFUNCTION.GM MODIFIED THE SENDING SENSOR FOR VEHICLES BUILT AFTER OCTOBER 2000.IT MADE A SECOND SENSOR MODIFICATION FOR VEHICLES BUILT AFTER JANUARY 2003.GM ALSO ISSUED A CUSTOMER SATISFACTION CAMPAIGN (GM NUMBER 00101) IN DECEMBER 2000 FOR U.S. CUSTOMERS IN THE STATE OF MAINE AND ISSUED SEVERAL SERVICE BULLETINS INFORMING DEALERS OF THE AVAILABILITY OF SENSORS WITH IMPROVED CORROSION RESISTANCE.THE COMPLAINT TREND INDICATES THAT COMPLAINTS PEAKED IN LATE 2000 TO EARLY 2001.WARRANTY CLAIMS DECLINED SINCE PEAKING IN APRIL 2002.BASED ON THE NUMBER OF COMPLAINTS AND THE INDICATION OF A DECLINING TREND, FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.

PE02066 · Engine Stall Due To Fuel Starvation

Opened Sep 6, 2002 · Closed Nov 3, 2003

Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery:fuel Pump; Fuel System, Other; Fuel System, Other:delivery:fuel Pump

ODI OPENED PE02-066 TO EVALUATE THE SCOPE AND CONSEQUENCE OF ENGINE POWER-LOSS DUE TO FUEL STARVATION INDUCED BY IN-TANK MODULAR FUEL PUMP STRAINER RESTRICTION.THE SUBJECT PUMPS USE AN EXTERNAL ?SOCK? STRAINER TO FILTER FUEL FLOWING TO THE PUMP INLET.THIS FILTER CAN SOMETIMES BECOME CLOGGED, RESULTING IN A REDUCED FLOW OF FUEL TO THE ENGINE.GM HAS SUBSEQUENTLY MODIFIED THE STRAINERS TO REDUCE THIS RESTRICTION.ANALYSIS OF THE ODI COMPLAINT DATABASE SHOWS THAT DESPITE THESE RESTRICTIONS, THE SUBJECT VEHICLES STALL AT A RATE THAT IS COMPARABLE TO THOSE OF MANY PEER VEHICLES.ADDITIONALLY, NONE OF THE RELEVANT WARRANTY REPAIR RATES EXCEED 1% AT 36 MONTHS OF EXPOSURE.ONE RELATED CRASH INVOLVES A STALLED VEHICLE THAT WAS REAR-ENDED ON THE ROADWAY, WHILE THE REMAINDER INVOLVED MINOR COLLISIONS OR SCRAPES.THE SOLE INJURY CONSISTED OF BRUISING FROM A LOW SPEED FRONTAL CRASH. GIVEN THESE CIRCUMSTANCES, FURTHER EXPENDITURE OF AGENCY RESOURCES IS NOT JUSTIFIED IN THIS MATTER.THE PRELIMINARY EVALUATION IS THEREFORE CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

Additional source detail variants (4)

Fuel System, Gasoline:delivery:fuel Pump

ODI OPENED PE02-066 TO EVALUATE THE SCOPE AND CONSEQUENCE OF ENGINE POWER-LOSS DUE TO FUEL STARVATION INDUCED BY IN-TANK MODULAR FUEL PUMP STRAINER RESTRICTION.THE SUBJECT PUMPS USE AN EXTERNAL ?SOCK? STRAINER TO FILTER FUEL FLOWING TO THE PUMP INLET.THIS FILTER CAN SOMETIMES BECOME CLOGGED, RESULTING IN A REDUCED FLOW OF FUEL TO THE ENGINE.GM HAS SUBSEQUENTLY MODIFIED THE STRAINERS TO REDUCE THIS RESTRICTION.ANALYSIS OF THE ODI COMPLAINT DATABASE SHOWS THAT DESPITE THESE RESTRICTIONS, THE SUBJECT VEHICLES STALL AT A RATE THAT IS COMPARABLE TO THOSE OF MANY PEER VEHICLES.ADDITIONALLY, NONE OF THE RELEVANT WARRANTY REPAIR RATES EXCEED 1% AT 36 MONTHS OF EXPOSURE.ONE RELATED CRASH INVOLVES A STALLED VEHICLE THAT WAS REAR-ENDED ON THE ROADWAY, WHILE THE REMAINDER INVOLVED MINOR COLLISIONS OR SCRAPES.THE SOLE INJURY CONSISTED OF BRUISING FROM A LOW SPEED FRONTAL CRASH. GIVEN THESE CIRCUMSTANCES, FURTHER EXPENDITURE OF AGENCY RESOURCES IS NOT JUSTIFIED IN THIS MATTER.THE PRELIMINARY EVALUATION IS THEREFORE CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

Fuel System, Gasoline

ODI OPENED PE02-066 TO EVALUATE THE SCOPE AND CONSEQUENCE OF ENGINE POWER-LOSS DUE TO FUEL STARVATION INDUCED BY IN-TANK MODULAR FUEL PUMP STRAINER RESTRICTION.THE SUBJECT PUMPS USE AN EXTERNAL ?SOCK? STRAINER TO FILTER FUEL FLOWING TO THE PUMP INLET.THIS FILTER CAN SOMETIMES BECOME CLOGGED, RESULTING IN A REDUCED FLOW OF FUEL TO THE ENGINE.GM HAS SUBSEQUENTLY MODIFIED THE STRAINERS TO REDUCE THIS RESTRICTION.ANALYSIS OF THE ODI COMPLAINT DATABASE SHOWS THAT DESPITE THESE RESTRICTIONS, THE SUBJECT VEHICLES STALL AT A RATE THAT IS COMPARABLE TO THOSE OF MANY PEER VEHICLES.ADDITIONALLY, NONE OF THE RELEVANT WARRANTY REPAIR RATES EXCEED 1% AT 36 MONTHS OF EXPOSURE.ONE RELATED CRASH INVOLVES A STALLED VEHICLE THAT WAS REAR-ENDED ON THE ROADWAY, WHILE THE REMAINDER INVOLVED MINOR COLLISIONS OR SCRAPES.THE SOLE INJURY CONSISTED OF BRUISING FROM A LOW SPEED FRONTAL CRASH. GIVEN THESE CIRCUMSTANCES, FURTHER EXPENDITURE OF AGENCY RESOURCES IS NOT JUSTIFIED IN THIS MATTER.THE PRELIMINARY EVALUATION IS THEREFORE CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

Fuel System, Other:delivery:fuel Pump

ODI OPENED PE02-066 TO EVALUATE THE SCOPE AND CONSEQUENCE OF ENGINE POWER-LOSS DUE TO FUEL STARVATION INDUCED BY IN-TANK MODULAR FUEL PUMP STRAINER RESTRICTION.THE SUBJECT PUMPS USE AN EXTERNAL ?SOCK? STRAINER TO FILTER FUEL FLOWING TO THE PUMP INLET.THIS FILTER CAN SOMETIMES BECOME CLOGGED, RESULTING IN A REDUCED FLOW OF FUEL TO THE ENGINE.GM HAS SUBSEQUENTLY MODIFIED THE STRAINERS TO REDUCE THIS RESTRICTION.ANALYSIS OF THE ODI COMPLAINT DATABASE SHOWS THAT DESPITE THESE RESTRICTIONS, THE SUBJECT VEHICLES STALL AT A RATE THAT IS COMPARABLE TO THOSE OF MANY PEER VEHICLES.ADDITIONALLY, NONE OF THE RELEVANT WARRANTY REPAIR RATES EXCEED 1% AT 36 MONTHS OF EXPOSURE.ONE RELATED CRASH INVOLVES A STALLED VEHICLE THAT WAS REAR-ENDED ON THE ROADWAY, WHILE THE REMAINDER INVOLVED MINOR COLLISIONS OR SCRAPES.THE SOLE INJURY CONSISTED OF BRUISING FROM A LOW SPEED FRONTAL CRASH. GIVEN THESE CIRCUMSTANCES, FURTHER EXPENDITURE OF AGENCY RESOURCES IS NOT JUSTIFIED IN THIS MATTER.THE PRELIMINARY EVALUATION IS THEREFORE CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

Fuel System, Other

ODI OPENED PE02-066 TO EVALUATE THE SCOPE AND CONSEQUENCE OF ENGINE POWER-LOSS DUE TO FUEL STARVATION INDUCED BY IN-TANK MODULAR FUEL PUMP STRAINER RESTRICTION.THE SUBJECT PUMPS USE AN EXTERNAL ?SOCK? STRAINER TO FILTER FUEL FLOWING TO THE PUMP INLET.THIS FILTER CAN SOMETIMES BECOME CLOGGED, RESULTING IN A REDUCED FLOW OF FUEL TO THE ENGINE.GM HAS SUBSEQUENTLY MODIFIED THE STRAINERS TO REDUCE THIS RESTRICTION.ANALYSIS OF THE ODI COMPLAINT DATABASE SHOWS THAT DESPITE THESE RESTRICTIONS, THE SUBJECT VEHICLES STALL AT A RATE THAT IS COMPARABLE TO THOSE OF MANY PEER VEHICLES.ADDITIONALLY, NONE OF THE RELEVANT WARRANTY REPAIR RATES EXCEED 1% AT 36 MONTHS OF EXPOSURE.ONE RELATED CRASH INVOLVES A STALLED VEHICLE THAT WAS REAR-ENDED ON THE ROADWAY, WHILE THE REMAINDER INVOLVED MINOR COLLISIONS OR SCRAPES.THE SOLE INJURY CONSISTED OF BRUISING FROM A LOW SPEED FRONTAL CRASH. GIVEN THESE CIRCUMSTANCES, FURTHER EXPENDITURE OF AGENCY RESOURCES IS NOT JUSTIFIED IN THIS MATTER.THE PRELIMINARY EVALUATION IS THEREFORE CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT NO SAFETY-RELATED DEFECT EXISTS.THE AGENCY WILL TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.

SQ01002 · Erratic Fuel Gauge

Opened Jan 26, 2001 · Closed Sep 30, 2002

Status: closed (inferred from source dates) · Vehicle Speed Control:linkages

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