IllustrationFUEL PUMPS IS DEAD 60K MILES. *TR
2003 Chevrolet Cavalier
Owner reports · Recalls · Investigations
More warning signs than most Cavalier years
Owner complaints for the 2003 Chevrolet Cavalier are substantially higher than the model-year median of 140.
About this comparison →How this year compares
Owner complaints by model year
Compare all Cavalier years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
810–25K
9225–50K
19750–75K
10875–100K
58100–150K
17150K+
553 reports with mileage · 125 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.
- Fuel System, Gasoline. Review the 340 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 106 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Exterior Lighting. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
31 crash reports6 fire reports16 injury reports
Fuel System, Gasoline complaints
340 reportsFUEL PUMP ON 2003 CAVALIER WITH APPROX. 66K MILES FAILED ABRUPTLY AND WITHOUT WARNING. CAR WAS PARKED IN A SHOPPING PLAZA PARKING LOT AND WOULD NOT START. HAD TO BE TOWED TO SERVICE GARAGE. *TR
I WAS MANEUVERING MY 2003 CAVALIER INTO A PARKING SPOT, AND IT JUST DIED. IT WOULDN'T RESTART, WE HAD TO PUSH IT INTO THE PARKING SPOT. THE DIAGNOSIS IS A BAD FUEL PUMP. AFTER RECEIVING A QUOTE FOR NEARLY $800, NOT FROM THE DEALER! I WENT ONLINE TO SEE IF I COULD GET AN IDEA OF COST AND AVAILABILITY FOR A NON-OEM PART. THE F…
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I WAS MANEUVERING MY 2003 CAVALIER INTO A PARKING SPOT, AND IT JUST DIED. IT WOULDN'T RESTART, WE HAD TO PUSH IT INTO THE PARKING SPOT. THE DIAGNOSIS IS A BAD FUEL PUMP. AFTER RECEIVING A QUOTE FOR NEARLY $800, NOT FROM THE DEALER! I WENT ONLINE TO SEE IF I COULD GET AN IDEA OF COST AND AVAILABILITY FOR A NON-OEM PART. THE FIRST THINGS I FOUND WERE THE FORUMS WITH HUNDREDS OF UNHAPPY CAVALIER OWNERS. AFTER READING THE FORUMS, I'M THANKFUL I WASN'T IN TRAFFIC WHEN THE PUMP FAILED. I WAS UNPLEASANTLY SURPRISED TO SEE HOW MANY PEOPLE HAVE BEEN HAVING THIS SAME PROBLEM. THE COST FOR THIS REPAIR IS SUBSTANTIAL; GM APPARENTLY KNOWS THIS BUT IS UNWILLING TO STEP UP AND TAKE RESPONSIBILITY FOR THEIR BAD DECISION IN CHOOSING THIS PART. PLEASE INVESTIGATE THIS MATTER AND APPLY WHATEVER PRESSURE YOU CAN TO MAKE GM ACCOUNTABLE FOR THEIR ERROR. PLEASE CONTACT ME IF YOU NEED MY HELP WITH THIS MATTER. *TR
THE FUEL PUMP ON MY 2003 CHEVY CAVALIER WENT OUT WITHOUT WARNING WHILE TRAVELING ON INTERSTATE 25 IN DENVER, COLORADO. THIS IS AN EXTREMELY DANGEROUS SITUATION THAT CAN POTENTIALLY CAUSE SERIOUS INJURY OR DEATH DUE TO AN ACCIDENT. I BROUGHT THE CAR TO A MECHANIC AND WAS INFORMED THAT IT WAS THE FUEL PUMP THAT WAS THE CULPRIT. I…
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THE FUEL PUMP ON MY 2003 CHEVY CAVALIER WENT OUT WITHOUT WARNING WHILE TRAVELING ON INTERSTATE 25 IN DENVER, COLORADO. THIS IS AN EXTREMELY DANGEROUS SITUATION THAT CAN POTENTIALLY CAUSE SERIOUS INJURY OR DEATH DUE TO AN ACCIDENT. I BROUGHT THE CAR TO A MECHANIC AND WAS INFORMED THAT IT WAS THE FUEL PUMP THAT WAS THE CULPRIT. I REALLY THINK THAT IT IS IMPERATIVE THAT THIS ISSUE IS ADDRESSED BEFORE SOME GETS SERIOUSLY INJURED OR DIES AS A RESULT OF THIS FAULTY PART. *TR
I BOUGHT A BRAND NEW 2003 CAVALIER IN MAY OF 03. I DRIVE TO AND FROM WORK, A TOTAL OF MAYBE 14 MILES. I HAVE TAKEN EXCELLENT CARE OF THIS VEHICLE. OUT OF THE BLUE I AM STRANDED IN A PARKING LOT DUE THE CAR NOT WANTING TO START. I HAD 3/4 OF A TANK OF GAS, YET IT ACTED LIKE THERE WAS NONE. HAD CAR TOWED TO DEALERSHIP. WOULD…
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I BOUGHT A BRAND NEW 2003 CAVALIER IN MAY OF 03. I DRIVE TO AND FROM WORK, A TOTAL OF MAYBE 14 MILES. I HAVE TAKEN EXCELLENT CARE OF THIS VEHICLE. OUT OF THE BLUE I AM STRANDED IN A PARKING LOT DUE THE CAR NOT WANTING TO START. I HAD 3/4 OF A TANK OF GAS, YET IT ACTED LIKE THERE WAS NONE. HAD CAR TOWED TO DEALERSHIP. WOULD NOT START OFF OF TOW TRUCK. NEXT DAY, STARTS FINE. IT HAS TAKEN 3 DAYS FOR THEM TO FINALLY CONCLUDE IT'S THE FUEL PUMP! FIX = +$950.00!!!! I HAVE 34,000 MILES!!!! WE HAVE HAD VEHICLES MUCH OLDER THAN MINE AND WITH +100,000 MILES NEVER HAVE THIS PROBLEM. THIS IS RIDICULOUS! I AM PARTIALLY DISABLED DUE TO A SEVERE BACK INJURY AND NOW NEED TO WORRY ABOUT IF THIS IS GOING TO HAPPEN AGAIN. PER PRIOR POSTS, SEVERAL PEOPLE HAVE HAD THIS HAPPEN MORE THAN ONCE. THIS IS AN ISSUE THAT PLACES NOT ONLY THE DRIVER'S LIFE, BUT THAT OF OTHER MOTORISTS. HOW IS IT POSSIBLE THAT CHEVY HAS NOT TAKEN ACTION? SOMETHING NEEDS TO BE DONE! *TR
BOUGHT 2003 CAVALIER 7-26-2003, BRAND NEW. STALLED WHILE DRIVING 3-31-04 - SMELLED BURNING/CHEMICAL SMELL- CAR RESTARTED - TOOK TO DEALER - DEALER FOUND NO PROBLEM. TO DEALER 3 TIMES TO FIX DETECTIVE EXTERIOR LIGHTING 2004/2005. SEVERAL ADDITIONAL ENGINE STALLS 2004-2009 - CAR RESTARTED. ON 3-6-09 STALLED WHILE DRIVING - WOUL…
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BOUGHT 2003 CAVALIER 7-26-2003, BRAND NEW. STALLED WHILE DRIVING 3-31-04 - SMELLED BURNING/CHEMICAL SMELL- CAR RESTARTED - TOOK TO DEALER - DEALER FOUND NO PROBLEM. TO DEALER 3 TIMES TO FIX DETECTIVE EXTERIOR LIGHTING 2004/2005. SEVERAL ADDITIONAL ENGINE STALLS 2004-2009 - CAR RESTARTED. ON 3-6-09 STALLED WHILE DRIVING - WOULDN'T START - TOWED TO DEALER- DEALER SAID FUEL PUMP WENT BAD - WILL REPAIR AT MY EXPENSE - OVER $1,000. DEALER ASKED IF I HAVE EXTENDED WARRANTY - I DON'T. WHEN THE CAR STALLS OUT I HAVE NO BRAKES, NO POWER STEERING - IT IS TERRIFYING AND VERY UNSAFE. AND IF THE CAR IS REPAIRED IS IT GOING TO BE ANY SAFER? WILL THE SAME PROBLEM KEEP RECURRING AS IT DID WITH THE LIGHTING SIGNALS? I AM A SAFE DRIVER, I AM THE ONLY DRIVER OF THIS CAR, THE CAR HAS ONLY 51,000 MILES ON IT, I ONLY DRIVE 10 MILES TO AND FROM WORK, IT IS GARAGE KEPT. I HAVE OWNED SEVERAL CARS AND HAVE KEPT THEM ALL FOR MANY YEARS AND I HAVE NEVER HAD A MAJOR REPAIR SUCH AS THIS OCCUR ON SUCH A YOUNG CAR. THIS PROBLEM HAS BEEN APPARENT SINCE I BOUGHT THE CAR BUT THE DEALER HAS IGNORED AND NEGLECTED IT AT THE EXPENSE OF ME AND MY FAMILY'S HEALTH. I HAVE CHILDREN AND GRANDCHILDREN THAT ARE DRIVEN IN THIS VEHICLE AND COULD BE VICTIMS OF THIS DEFECT. FOR THE PUBLIC SAFETY IN THE U.S. PLEASE REQUEST A RECALL OF THIS COMPONENT (FUEL PUMP). THIS IS A SERIOUS MATTER AND SHOULD BE REMEDIATED AS SOON AS POSSIBLE. PLEASE HELP BEFORE A DEADLY ACCIDENT OCCURS. *TR
MY FUEL PUMP WENT OUT ON MY 2003 CHEVY CAVALIER WITH 40,000 MILES ON IT. I'VE NOTICED ON TOPIX COMMENT BOARDS THIS HAS HAPPENED TO A LOT OF PEOPLE WITH THE 03 CAVALIER. THERE REALLY NEEDS TO BE A RECALL FROM GM, THIS IS NOT SAFE. *TR
I AM HAVING TO REPLACE MY FUEL PUMP ON MY 2003 CHEVY CAVALIER FOR THE 2ND TIME, THE FIRST TIME IT WAS STILL UNDER WARRANTY. NOTHING LEAD UP TO THIS, TURNED OFF THE CAR TO GO INTO THE STORE, CAME OUT CAR WOULD START, NO GETTING ANY GAS. *TR
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT EXPERIENCES ISSUES WHEN ATTEMPTING TO RESTART THE ENGINE. THE INSTRUMENT PANEL GAUGES ILLUMINATE, BUT THE ENGINE DOES NOT START. HE DOES NOT SMELL GASOLINE, BUT BELIEVES THE FUEL PUMP COULD BE THE CAUSE OF THE FAILURE. THE FAILURE OCCURRED THREE MONTHS AFTER THE VEHI…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT EXPERIENCES ISSUES WHEN ATTEMPTING TO RESTART THE ENGINE. THE INSTRUMENT PANEL GAUGES ILLUMINATE, BUT THE ENGINE DOES NOT START. HE DOES NOT SMELL GASOLINE, BUT BELIEVES THE FUEL PUMP COULD BE THE CAUSE OF THE FAILURE. THE FAILURE OCCURRED THREE MONTHS AFTER THE VEHICLE WAS PURCHASED. THE FUEL PUMP WAS REPLACED UNDER WARRANTY; HOWEVER, THE FAILURE HAS RECURRED. THE VEHICLE IS CURRENTLY AT A GAS STATION AND UNABLE TO BE STARTED. THE VEHICLE HAS NOT BEEN DIAGNOSED A SECOND TIME SINCE THE FIRST REPAIR. THE CONTACT FOUND SEVERAL COMPLAINTS ONLINE FOR THE SAME ISSUE AND BELIEVES A RECALL SHOULD BE ISSUED. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 8,000 AND CURRENT MILEAGE WAS 72,000.
PURCHASED A 2003 CHEVY CAVALIER IN SEPT. 2008 FOR MY DAUGHTER TO GO TO COLLEGE. HAD A CARFAX REPORT DONE AND FOUND NOTHING, CLEAN REPORT. 2 DAYS AFTER PURCHASE, INST. CLUSTER WENT BAD, NOT WORKING AT ALL. DEC. 08 THE FUEL PUMP WENT BAD. AFTER RESEARCHING THE INTERNET, I HAVE FOUND THOUSANDS OF THE SAME COMPLAINTS AS MINE. I HAVE…
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PURCHASED A 2003 CHEVY CAVALIER IN SEPT. 2008 FOR MY DAUGHTER TO GO TO COLLEGE. HAD A CARFAX REPORT DONE AND FOUND NOTHING, CLEAN REPORT. 2 DAYS AFTER PURCHASE, INST. CLUSTER WENT BAD, NOT WORKING AT ALL. DEC. 08 THE FUEL PUMP WENT BAD. AFTER RESEARCHING THE INTERNET, I HAVE FOUND THOUSANDS OF THE SAME COMPLAINTS AS MINE. I HAVE EVEN FOUND WEBSITES ADVERTISING TO REBUILD THE CLUSTER AS SO MANY ARE DEFECTIVE. NOW IF THIS ISN'T ENOUGH TO SEE THE MAJOR PROBLEM, I DON'T KNOW WHAT IS. I FEEL THAT ENOUGH INFORMATION IS OUT ON THE INTERNET TO WARRANT A RECALL ON BOTH ISSUES BEFORE THE PUBLIC HAS TO SPEND ALL THEIR MONEY TO FIX GM'S FAULTY PARTS THAT BREAK DOWN SO QUICKLY. JUST THESE 2 REPAIRS COST $500.00 EACH. *TR
Official recalls
104V524000 · Exterior Lighting:turn Signal
Nov 1, 2004
ON CERTAIN PASSENGER VEHICLES, THE REAR LAMPS THAT PROVIDE STOP AND TURN SIGNALS AND TAIL LAMP FUNCTIONS STOP WORKING BECAUSE OF INADEQUATE CONTACT BETWEEN THE BULB AND SOCKET. IN ADDITION, IF ONE BULBS WERE TO BECOME INOPERATIVE WHILE THE VEHICLE WAS OPERATING IN CRUISE CONTROL, THE CRUISE CONTROL WOULD DISENGAGE WHEN THE REMAINING BULB WAS ACTIVATED. IF BOTH LAMPS WERE TO BECOME INOPERATIVE, THE CRUISE CONTROL WOULD NOT ENGAGE.
Consequence & remedy
Consequence: AN INOPERATIVE BRAKE LAMP WILL NOT CONVEY THE DRIVER'S INTENTION OF STOPPING TO DRIVERS IN FOLLOWING VEHICLES, AND AN INOPERATIVE REAR TURN SIGNAL LAMP WILL NOT CONVEY THE DRIVER'S INTENTION TO TURN TO DRIVERS IN FOLLOWING VEHICLES. BOTH OF THESE FAILURES CAN INCREASE THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE REAR LAMP BULB SOCKET ASSEMBLIES AND APPLY GREASE OR REPLACE THEM IF NECESSARY. THE RECALL BEGAN ON JANUARY 18, 2005. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR PONTIAC AT 1-800-620-7668.
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
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.