NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
43 reportsClear category filter700 miles · Jul 21, 2004
Electrical SystemEngine And Engine CoolingEquipment
VARIOUS PROBLEMS WITH 2003 CHEVROLET CAVALIER.*MR THE VEHICLE TAIL LIGHT SHORTED OUT THREE TIMES THEN THE CIRCUIT SHORTED OUT. THE GAS GAUGE WOULD FLUCTUATE. COLD STARTS. THE VEHICLE WOULD HESITATE AT STOP LIGHT OR STALL OUT COMPLETELY. THE DRIVER' S SIDE SPEAKER BLEW. THE CD PLAYER WOULD EJECT THE CD WHILE IT WAS PLAYING.…
Read full complaint
VARIOUS PROBLEMS WITH 2003 CHEVROLET CAVALIER.*MR THE VEHICLE TAIL LIGHT SHORTED OUT THREE TIMES THEN THE CIRCUIT SHORTED OUT. THE GAS GAUGE WOULD FLUCTUATE. COLD STARTS. THE VEHICLE WOULD HESITATE AT STOP LIGHT OR STALL OUT COMPLETELY. THE DRIVER' S SIDE SPEAKER BLEW. THE CD PLAYER WOULD EJECT THE CD WHILE IT WAS PLAYING. THE RPM GAUGE BOUNCED. THE FUEL PUMP WAS REPLACED. THE ALTERNATOR MADE NOISE. *NM
NHTSA ODI #10083543
6,000 miles · Jun 16, 2004
Engine And Engine Cooling
2003 CHEVROLET CAVALIER. STALLS CONSTANTLY WHEN AIR CONDITIONING IS ON AND CAR IS IDLING (IE AT A TRAFFIC LIGHT, IN TRAFFIC OR STOP SIGN) ENGINE FAILURE OVER 20 TIMES IN THE LAST YEAR CAR WAS TAKEN IN FOR SERVICE FOUR TIMES WITH NO RESULT. *AK
NHTSA ODI #10078348
27,000 miles · Apr 5, 2004
Engine And Engine Cooling
4/1/2004-CHECK ENGINE LIGHT CAME ON. FUCILLO STATED THAT IT WAS THE EMISSION CONTROL AND THAT THE PART WAS ON NATIONAL BACKORDER. TERRY STATED HE DID NOT KNOW WHEN PART WILL BE IN. REAR AXEL RATTLES AND TIRES ARE WORN ON THE INSIDE. FUCILLO STATED THAT THERE IS ANOTHER CAVALIER IN WITH THE SAME PROBLEM AND THEY HAVE NO IDEA WH…
Read full complaint
4/1/2004-CHECK ENGINE LIGHT CAME ON. FUCILLO STATED THAT IT WAS THE EMISSION CONTROL AND THAT THE PART WAS ON NATIONAL BACKORDER. TERRY STATED HE DID NOT KNOW WHEN PART WILL BE IN. REAR AXEL RATTLES AND TIRES ARE WORN ON THE INSIDE. FUCILLO STATED THAT THERE IS ANOTHER CAVALIER IN WITH THE SAME PROBLEM AND THEY HAVE NO IDEA WHAT IT IS. THEY CHANGED DEFECTIVE MUFFLER AND REPLACED BRACKETS. 4/5/2004-TOOK CAR TO BRESEE CHEVROLET. THEY WILL NOT WORK ON IT BECAUSE FUCILLO DID SO MUCH WORK ON IT. BRESEE HAD NO IDEA OF NATIONAL BACK ORDER ON PART. THEY SAID THEY WOULD SHIP THE PART UP TO FUCILLO. SVC MGR STATED THAT THE REAR AXLE IS NOT ALIGNED. THEY SAID THAT WE HAVE A LEMON AND THAT IF THEY HAD SOLD THIS CAR TO US, THEY WOULD HAVE REPLACED IT BY NOW. CALLED FUCILLO BACK & TALKED TO TERRY RIORDAN AND GOT NOWHERE. *JB
NHTSA ODI #10064551
7,000 miles · Jan 15, 2004
Engine And Engine CoolingService Brakes, HydraulicStructure
1. BOTH BRAKE LIGHTS WENT OUT W/IN MONTH OF EACH OTHER. IN THE MONTHS OF JULY AND AUGUST. 2. BRAKES NOISY, SEPTEMBER 3. TRUNK WOULD NOT OPEN, OCTOBER 4. BRAKES NOISY, AGAIN, NOVEMBER 5. CAR TURNS OFF IN THE MIDDLE OF AN INTERSECTION AFTER MAKING A COMPLETE STOP AND TRYING TO SPEED UP. FREAKING OUT, I PRESSED THE GAS AND MOVED TH…
Read full complaint
1. BOTH BRAKE LIGHTS WENT OUT W/IN MONTH OF EACH OTHER. IN THE MONTHS OF JULY AND AUGUST. 2. BRAKES NOISY, SEPTEMBER 3. TRUNK WOULD NOT OPEN, OCTOBER 4. BRAKES NOISY, AGAIN, NOVEMBER 5. CAR TURNS OFF IN THE MIDDLE OF AN INTERSECTION AFTER MAKING A COMPLETE STOP AND TRYING TO SPEED UP. FREAKING OUT, I PRESSED THE GAS AND MOVED THE KEY IN THE IGNITION, THEN PUT CAR IN PARK AND GOT IT TO START, NOVEMBER. IT JUST SEEMS TO ME THAT I HAVE A DISFUNCTIONAL CAR THAT WHEN I DONT HAVE SOMETHING WRONG WITH ONE THING I HAVE TO GO IN TO THE DEALER FOR ANOTHER. ITS A NEW CAR AND ITS COSTING ME MORE PROBLMES AND INCONVINIENCES THAN THE OLD '96 I HAD TILL I BOUGHT THIS ONE.
NHTSA ODI #10071186
Mileage unknown · Dec 23, 2003
Engine And Engine Cooling
WHEN THE CLUTCH IS DEPRESSED AFTER HIGHWAY DRIVING AT 55-70MPH FOR 30-60 MINUTES, THE ENGINE RPM RATE INCREASES FROM AROUND 2500 TO 3500 INSTEAD OF FALLING TO 1000 (NORMAL IDLE). IF THE CLUTCH IS RE-ENGAGED THEN THE RPM RATE RETURNS TO THE NORMAL RANGE FOR THE GEAR/SPEED OF TRAVEL. IF THE CAR IS BRAKED TO A COMPLETE STOP, THE …
Read full complaint
WHEN THE CLUTCH IS DEPRESSED AFTER HIGHWAY DRIVING AT 55-70MPH FOR 30-60 MINUTES, THE ENGINE RPM RATE INCREASES FROM AROUND 2500 TO 3500 INSTEAD OF FALLING TO 1000 (NORMAL IDLE). IF THE CLUTCH IS RE-ENGAGED THEN THE RPM RATE RETURNS TO THE NORMAL RANGE FOR THE GEAR/SPEED OF TRAVEL. IF THE CAR IS BRAKED TO A COMPLETE STOP, THE RPM RATE FALLS TO THE NORMAL IDLE RATE AFTER 20-40 SECONDS OF STANDSTILL. THE BEHAVIOR HAS BEEN OBSERVED EVERYTIME EXTENDED HIGHWAY DRIVING IS COMPLETED. THE PROBLEM HAS BEEN REPORTED TO THE DEALERSHIP AND THE ON-BOARD DIAGNOSTIC SHOWS NO PROBLEM AND THE DEALERSHIP CAN NOT RECREATE THE PROBLEM.
NHTSA ODI #10051021
6,500 miles · Dec 23, 2003
Engine And Engine Cooling
AFTER ENGINE WARMS UP ON HOT DAY, ENGINE STALLS WHEN CLUTCH IS DEPRESSED AS WHEN COASTING TO A STOP. ENIGINE WILL RESTART, BUT ACCELLERATOR MUST BE DEPRESSED TO REV THE ENGINE IN ORDER TO PREVENT STALLING. IF VEHICLE IS PARKED FOR SEVERAL MINUTES, THEN RESTARTED, PROBLEM WITH STALLING IS GONE. THIS PROBLEM IS VERY INTERMITTEN…
Read full complaint
AFTER ENGINE WARMS UP ON HOT DAY, ENGINE STALLS WHEN CLUTCH IS DEPRESSED AS WHEN COASTING TO A STOP. ENIGINE WILL RESTART, BUT ACCELLERATOR MUST BE DEPRESSED TO REV THE ENGINE IN ORDER TO PREVENT STALLING. IF VEHICLE IS PARKED FOR SEVERAL MINUTES, THEN RESTARTED, PROBLEM WITH STALLING IS GONE. THIS PROBLEM IS VERY INTERMITTENT. THE SAME PROBLEM IS DESCRIBED IN OID NUMBERS 10049266, 10039337 AND 10037496.
NHTSA ODI #10051018
5,000 miles · Dec 5, 2003
Engine And Engine CoolingSteering
WHEN COASTING TO A STOP AND DEPRESSING CLUTCH, CAR IDLE SPEED WILL DROP BELOW THE NORMAL IDLE SPEED OF 800 RPM. SOMETIMES, THE IDLE SPEED WILL BOUNCE AROUND BETWEEN 400 RPM AND 800 RPM. OTHER TIMES, THE ENGINE WILL STALL. PROBLEM IS INTERMITTENT, BUT WILL USUALLY OCCUR MULTIPLE TIMES BEFORE FIXING ITSELF. THE STALLING ENGINE…
Read full complaint
WHEN COASTING TO A STOP AND DEPRESSING CLUTCH, CAR IDLE SPEED WILL DROP BELOW THE NORMAL IDLE SPEED OF 800 RPM. SOMETIMES, THE IDLE SPEED WILL BOUNCE AROUND BETWEEN 400 RPM AND 800 RPM. OTHER TIMES, THE ENGINE WILL STALL. PROBLEM IS INTERMITTENT, BUT WILL USUALLY OCCUR MULTIPLE TIMES BEFORE FIXING ITSELF. THE STALLING ENGINE IS A CONCERN BECAUSE OF THE LOST OF POWER STEERING MAKING TURNS. DEALER UNABLE TO DUPLICATE PROBLEM. *JB
NHTSA ODI #10049266
200 miles · Nov 14, 2003
Engine And Engine Cooling
CAR STALLS. THIS HAS BEEN REPORTED TO THE DEALER. CAR HAS BEEN TO THE DEALER ON 2 OCCASIONS FOR THIS ISSUE. ALWAYS GET RESPONSE, "CANNOT DUPLICATE THE ISSUE." JUST PURCHASED 2003 CAVALIER IN JULY OF THIS YEAR. VEHICLE ONLY HAS 7000 MILES ON IT. THIS BEGAN IN AUGUST. HAVE BEEN REPORTING THESE INCIDENTS TO THE DEALER EVER S…
Read full complaint
CAR STALLS. THIS HAS BEEN REPORTED TO THE DEALER. CAR HAS BEEN TO THE DEALER ON 2 OCCASIONS FOR THIS ISSUE. ALWAYS GET RESPONSE, "CANNOT DUPLICATE THE ISSUE." JUST PURCHASED 2003 CAVALIER IN JULY OF THIS YEAR. VEHICLE ONLY HAS 7000 MILES ON IT. THIS BEGAN IN AUGUST. HAVE BEEN REPORTING THESE INCIDENTS TO THE DEALER EVER SINCE. *LA
NHTSA ODI #10046940
2,000 miles · Nov 5, 2003
Engine And Engine Cooling
VEHICLE STALLED WHILE DRIVING 65 MPH ON THE HIGHWAY. THE CAUSE OF THE PROBLEM HAD NOT BEEN DETERMINED. *AK
NHTSA ODI #10046420
1,500 miles · Oct 9, 2003
Engine And Engine CoolingService Brakes, HydraulicVehicle Speed Control
WHILE DRIVING AT ANY SPEED AND WHENEVER THE CONSUMER DEPRESSED THE BRAKE PEDAL VEHICLE LOST POWER. ALSO, INTERMITTENTLY CRUISE CONTROL ENGAGED ON ITS OWN. VEHICLE WOULD HAVE TO BE TURNED OFF TO DISENGAGE IT. VEHICLE WAS TAKEN TO DEALER SEVERAL TIMES, AND THE DEALER COULD NOT FIND THE CAUSES OF THE PROBLEMS.*AK
NHTSA ODI #10042665
NHTSA investigations
4EA07015 · Engine Stalling - Fuel Pump Failure
Opened Nov 1, 2007 · Closed Oct 28, 2008
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Additional source detail variants (3)
Fuel System, Gasoline:delivery:fuel Pump
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Fuel System, Gasoline:delivery
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Fuel System, Gasoline
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
PE07033 · Fuel Pump Failure
Opened Jun 28, 2007 · Closed Nov 1, 2007
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Additional source detail variants (3)
Fuel System, Gasoline:delivery:fuel Pump
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Fuel System, Gasoline:delivery
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Fuel System, Gasoline
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
EA04028 · Turn Signal Malfunction
Opened Sep 14, 2004 · Closed Nov 22, 2004
Status: closed (inferred from source dates) · Exterior Lighting:turn Signal
ON MAY 14, 2004 THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-043) BASED ON CONSUMER COMPLAINTS ALLEGING THAT THE BRAKE/TAIL TURN SIGNAL LAMPS WOULD NOT OPERATE PROPERLY WHEN EITHER THE TAIL LIGHTS WERE TURNED ON, THE BRAKE PEDAL WAS DEPRESSED, OR WHEN THE TURN SIGNAL SWITCH WAS ACTIVATED.ON SEPTEMBER 14, 2004 ODI UPGRADED PE 04-043 TO AN ENGINEERING ANALYSIS (EA04-028).GM STATES THAT SOME BRAKE/TAIL/TURN SIGNAL LAMP BULBS CAN PREMATURELY BECOME INOPERATIVE DUE TO EXCESSIVE HEAT BUILDUP WITHIN THE BULB SOCKETS.THE CAUSE OF THE EXCESSIVE HEAT BUILD UP WAS DETERMINED TO BE A LACK OF THERMAL GREASE PLACED IN BETWEEN THE BULB AND THE SOCKET. BY LETTER DATED OCTOBER 27, 2004 GM NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA # 04V524) COVERING ALL MY 2003 VEHICLES.GM DEALERS WILL INSPECT THE REAR LAMP BULB SOCKET ASSEMBLIES AND APPLY THERMAL GREASE TO THEM OR REPLACE THEM WITH NEW ASSEMBLIES WITH THERMAL GREASE ALREADY ATTACHED.MODEL YEAR 2004 AND NEWER VEHICLES HAVE THE THERMAL GREASE INSTALLED FROM THE FACTORY. THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
PE04043 · Turn Signal Malfunction
Opened May 14, 2004 · Closed Sep 14, 2004
Status: closed (inferred from source dates) · Exterior Lighting:turn Signal
COMPLAINANTS ALLEGE THAT THE REAR TURN SIGNALS FAIL TO ILLUMINATE AND DO NOT PROVIDE A SIGNAL TO DRIVERS IN FOLLOWING VEHICLES.ODI HAS RECEIVED ONE REPORT OF A CRASH WHERE THE COMPLAINANT BRAKED AND ATTEMPTED TO MAKE A LEFT TURN AND THE FOLLOWING VEHICLE IMPACTED THE COMPLAINANT'S VEHICLE IN THE DRIVER-SIDE DOOR.IN MAY 2002, GM'S SUPPLIER MADE CHANGES TO THE BULB SOCKET THAT INCLUDED STOPPING THE USE OF THERMAL-MASTIC GREASE IN THE BULB SOCKET.GM REPORTS THAT THE GREASE REDUCES ARCING AT THE CONTACTS AND DISSIPATES HEAT THUS PREVENTING MELTING OF THE SOCKET MATERIAL OR BURNING OF THE CONTACTS.MOST OF THE SUBJECT VEHICLES WERE PRODUCED WITHOUT GREASE APPLIED TO THE BULB SOCKET.IN JUNE 2003, GM DIRECTED THE SUPPLIER TO RESUME THE USE OF GREASE IN THE SOCKET.GM ISSUED TECHNICAL SERVICE BULLETIN (TSB) 04-08-42-004A ON JULY 15, 2004 ADVISING TECHNICIANS TO MAKE SURE THAT ADEQUATE AMOUNTS OF GREASE WERE ADDED TO THE BULB SOCKETS ON ALL SERVICE PARTS.ODI WILL UPGRADE THIS INVESTIGATION TO EA 04-028 TO FURTHER EXAMINE THE ISSUE.
Illustration