NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
340 reportsClear category filter61,246 miles · Sep 3, 2011
Fuel System, Gasoline
I HAD LEFT MY MOTHERS AND DROVE APPROXIMATELY 35 MILES AND STARTED SLOWING TO MAKE A TURN INTO OUR LOCAL GROCERY STORE WHEN MY 2003 CAVALIER STALLED AND WOULD NOT RESTART BACK. UPON CHECKING I DISCOVERED THERE WAS NO FUEL TO THE FUEL RAIL.I HAD JUST OVER 1/2 TANK OF FUEL IN THE TANK. I HAD ANOTHER TURN KEY AND THERE WAS NO WHIR…
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I HAD LEFT MY MOTHERS AND DROVE APPROXIMATELY 35 MILES AND STARTED SLOWING TO MAKE A TURN INTO OUR LOCAL GROCERY STORE WHEN MY 2003 CAVALIER STALLED AND WOULD NOT RESTART BACK. UPON CHECKING I DISCOVERED THERE WAS NO FUEL TO THE FUEL RAIL.I HAD JUST OVER 1/2 TANK OF FUEL IN THE TANK. I HAD ANOTHER TURN KEY AND THERE WAS NO WHIRRING TO INDICATE FUEL PUMP WAS OPERATING. I CALLED TOW SERVICE AND TOWED IT HOME. I DROPPED THE TANK AND REPLACED THE FUEL PUMP AND PROBLEM WAS RESOLVED. ANOTHER SYMPTOM NOT LISTED IN THE COMPLAINTS WHEN MY PUMP FAILED ALL THE GAUGES ON THE DASHBOARD WOULD REGISTER (FUEL GAUGE AND TEMP GAUGE) THEN WOULD DROP TO 0 AND WOULD FLICKER CONTINUOUSLY WHEN KEY WAS TURNED TO THE ON POSITION. UPON PURCHASING NEW PUMP ASSEMBLY THAT THE WIRING HARNESS NEEDED TO BE REPAIRED AS WELL. YOU CAN NOT PURCHASE A NEW HARNESS TO RESOLVE ISSUE HAD TO CUT THE FUEL PUMP LEADS OFF OF PUMP WIRING HARNESS AND PURCHASE A NEW CONNECTOR AND SPLICE THEM TOGETHER. I FEEL THERE MAYBE MORE CUSTOMERS WITH THESE VEHICLES THAT HAD SERVICE DONE IN A LOCAL SHOP THAT WAS NOT REPORTED TO NHTSA OR TO GM. AS THIS REPAIR WAS VERY EXPENSIVE AT THE TIME AND MANY WOULD SEEK REPAIRS FOR LOWER RATES THEN OFFERED BY A DEALERSHIP. *TR
NHTSA ODI #10423133
63,000 miles · Aug 26, 2011
Electrical SystemFuel System, Gasoline
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING MPH AND ABOVE, THE SPEEDOMETER AND TEMPERATURE GAUGES WOULD NOT ILLUMINATE. IN ADDITION, THE FUEL GAUGE WAS PROVIDING INACCURATE FUEL LEVEL READINGS. THE VEHICLE WAS NEITHER INSPECTED NOR REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERE…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING MPH AND ABOVE, THE SPEEDOMETER AND TEMPERATURE GAUGES WOULD NOT ILLUMINATE. IN ADDITION, THE FUEL GAUGE WAS PROVIDING INACCURATE FUEL LEVEL READINGS. THE VEHICLE WAS NEITHER INSPECTED NOR REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 63,000.
NHTSA ODI #10421599
67,800 miles · Aug 16, 2011
Fuel System, Gasoline
2003 CHEVROLET CAVALIER GIVING OFF FUMES FIRST TIME I FILLED IT TO THE TOP WITH GASOLINE. THAT EVENTUALLY SET OFF A CHECK ENGINE LIGHT ON THE DASH. I USED MY OBD2 SCANNER AND IT WAS A CODE FOR A HIGH EVAP LEAK. IT WAS TOO DIFFICULT TO FIND THE LEAK AT MY HOME, SO I HAD THE DEALERSHIP DO A SMOKE TEST AND REVEALED A CRACK AT THE S…
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2003 CHEVROLET CAVALIER GIVING OFF FUMES FIRST TIME I FILLED IT TO THE TOP WITH GASOLINE. THAT EVENTUALLY SET OFF A CHECK ENGINE LIGHT ON THE DASH. I USED MY OBD2 SCANNER AND IT WAS A CODE FOR A HIGH EVAP LEAK. IT WAS TOO DIFFICULT TO FIND THE LEAK AT MY HOME, SO I HAD THE DEALERSHIP DO A SMOKE TEST AND REVEALED A CRACK AT THE SEAMS OF THE GAS TANK. DEALERSHIP SAID NO RECALL FOR THAT MAKE AND MODEL. ESTIMATE FOR REPLACEMENT AND LABOR WAS $1,000. I FOUND A SALVAGE YARD GAS TANK FROM A LOW MILEAGE OLDSMOBILE ALERO AND THE LOCAL REPAIR SHOP REPLACED IT. MECHANIC MENTIONED IT IS A COMMON OCCURRENCE TO FIND A CRACK AT THE SEAMS OF A NEWER GM SMALL CAR WITH A PLASTIC GAS TANK. I RESET THE CHECK ENGINE LIGHT CODE MYSELF AND THE PROBLEM NEVER REAPPEARED. *KB
NHTSA ODI #10419653
80,340 miles · Aug 14, 2011
Fuel System, Gasoline
FUEL PUMP FAILURE AT 80,340 MILES. PUMP FAILED IN THE DRIVEWAY. REPAIR COST: $695 + TOWING. *TR
NHTSA ODI #10419368
30,000 miles · Jul 5, 2011
Electrical SystemEngine And Engine CoolingFuel System, Gasoline
I AM THE OWNER OF A 2003 CHEVY CAVALIER AND I HAVE 2 COMPLAINTS THAT SHOULD HAVE BEEN RECALLS AS THERE ARE MANY WITH THE SAME 2 PROBLEMS, FIRST EVERY GAUGE IN MY CAR QUIT WORKING NO RPM, NO GAS GUAGE AND NO SPEEDOMETER. SECOND EVER SINCE I BOUGHT MY CAR FOR NO REASON AT ALL IT WOULD JUST STALL AT REDLIGHTS WHEN I WOULD TAKE OFF,…
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I AM THE OWNER OF A 2003 CHEVY CAVALIER AND I HAVE 2 COMPLAINTS THAT SHOULD HAVE BEEN RECALLS AS THERE ARE MANY WITH THE SAME 2 PROBLEMS, FIRST EVERY GAUGE IN MY CAR QUIT WORKING NO RPM, NO GAS GUAGE AND NO SPEEDOMETER. SECOND EVER SINCE I BOUGHT MY CAR FOR NO REASON AT ALL IT WOULD JUST STALL AT REDLIGHTS WHEN I WOULD TAKE OFF, DEALER SAID NO PROBLEM, I HAVE NEARLY WRECKED MANY TIMES BECAUSE OF THIS, THE LATEST WAS TODAY I HAVE READ MANY FORUMS THAT SAY THEY FOUND OUT IT WAS THE FAULTY PLASTIC FUEL PUMP, WHY NO RECALL THIS IS GOING TO GET SOMEONE KILLED. *KB
NHTSA ODI #10410423
60,000 miles · Jun 29, 2011
Fuel System, Gasoline
ON MAY 31, MY 2003 CHEVROLET CAVALIER LS SPORT STALLED ON A HIGHWAY. I WAS IN HEAVY TRAFFIC AND MY POWER STEERING WENT OUT, BUT I WAS LUCKILY ABLE TO MAKE IT TO THE SIDE OF THE ROAD. I IMMEDIATELY EXITED MY VEHICLE AND CALLED ROADSIDE ASSISTANCE FOR A TOW. AFTER RECEIVING DIAGNOSTICS AT A CHEVY DEALERSHIP, IT WAS DETERMINED…
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ON MAY 31, MY 2003 CHEVROLET CAVALIER LS SPORT STALLED ON A HIGHWAY. I WAS IN HEAVY TRAFFIC AND MY POWER STEERING WENT OUT, BUT I WAS LUCKILY ABLE TO MAKE IT TO THE SIDE OF THE ROAD. I IMMEDIATELY EXITED MY VEHICLE AND CALLED ROADSIDE ASSISTANCE FOR A TOW. AFTER RECEIVING DIAGNOSTICS AT A CHEVY DEALERSHIP, IT WAS DETERMINED THAT MY FUEL PUMP HAD GONE OUT AND HAD TO BE REPLACED. THE COST OF THIS AND REPLACING A FUEL FILTER WAS CLOSE TO $1,000. MY CAR ONLY HAS 60,000 MILES ON IT, I HAD PREVIOUSLY REPLACED THE FUEL FILTER 1 YEAR BEFORE AT ANOTHER GM DEALERSHIP, AND I PERFORMED REGULAR MAINTENANCE ON THE VEHICLE IN ACCORDANCE WITH THE USER MANUAL. WHEN I WENT HOME I RESEARCHED THE ISSUE WITH THE CAR, AND LO AND BEHOLD I CAME ACROSS HUNDREDS OF PAGES WHICH DESCRIBED THE EXACT SAME PROBLEM I HAD. ON ONE FORUM ALONE, THERE WERE OVER 700 POSTS WHERE OWNERS OF THE 2003 MODEL CAVALIER HAD FUEL PUMPS GO OUT AT AROUND THE SAME MILEAGE AS MY CAR, WITH REPAIR COSTS RANGING FROM $300-$900. I CONTINUED TO RESEARCH THE ISSUE, AND FOUND THAT THE NHTSA HAD RESEARCHED A LARGE NUMBER OF CONSUMER COMPLAINTS REGARDING FUEL PUMP FAILURES WITH THE 2003 MODEL CAVALIER ' INVESTIGATION #EA07015 AND #PE07033. GM DOCUMENTS IN BOTH OF THESE CASES INDICATED A LARGE NUMBER OF MALFUNCTIONS IN MODELS UP TO 2003, THEN A SHARP DECREASE IN FAILURES IN THE 2004 MODEL. *TR
NHTSA ODI #10409339
120,000 miles · May 24, 2011
Fuel System, Gasoline
MY FIANCE PURCHASED A USED 2003 CHEVY CAVALIER ABOUT TWO YEARS AGO AND WE HAD THE FUEL PUMP GO OUT ABOUT TWO MONTHS AGO. I INSTALLED A USED ONE FROM A JUNK YARD AND IT WENT OUT AGAIN LAST WEEK. I REALIZE THAT I CAN'T NECESSARILY EXPECT A USED FUEL PUMP TO LAST FOR A SIGNIFICANT AMOUNT OF TIME, BUT I NOTICED THAT THERE HAVE BEEN…
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MY FIANCE PURCHASED A USED 2003 CHEVY CAVALIER ABOUT TWO YEARS AGO AND WE HAD THE FUEL PUMP GO OUT ABOUT TWO MONTHS AGO. I INSTALLED A USED ONE FROM A JUNK YARD AND IT WENT OUT AGAIN LAST WEEK. I REALIZE THAT I CAN'T NECESSARILY EXPECT A USED FUEL PUMP TO LAST FOR A SIGNIFICANT AMOUNT OF TIME, BUT I NOTICED THAT THERE HAVE BEEN MANY OTHERS COMPLAINTS IN REGARDS TO FUEL PUMPS ON THIS YEAR MODEL. I HAVE OWNED A FEW CARS MUCH OLDER THAN THIS ONE AND WITH HIGHER MILEAGE AND HAVE NEVER HAD TO MESS WITH A FUEL PUMP. IT CURRENTLY HAS 120K MILES. *TR
NHTSA ODI #10402581
180,000 miles · Apr 27, 2011
Fuel System, Gasoline
I STOPPED AT A CONSTRUCTION STOP SIGN AND MY CAR JUST STARTED TO STALL. I TRIED RESTARTING IT A FEW TIMES BUT IT WOULD JUST PUTTER OUT AFTER RUNNING FOR A FEW SECONDS. I HAVE BEEN INFORMED THAT THE FUEL PUMP NEEDS TO BE REPLACED FOR ABOUT $800. THANKS A LOT GM. *TR
NHTSA ODI #10398033
85,000 miles · Apr 17, 2011
Fuel System, Gasoline
FUEL PUMP DEAD WHILE DRIVING ON THE HIGHWAY, 60 MI/HR. HAD TO REPLACE IT FOR 700$. NO MORE GM'S PRODUCTS FOR ME !! *TR
NHTSA ODI #10396547
92,800 miles · Mar 21, 2011
Fuel System, Gasoline
THE CAR JUST WOULD NOT START ONE MORNING AFTER NO WARNINGS! I HAD IT TOWED TO THE SHOP AND WAS TOLD THE FUEL PUMP, FUEL FILTER AND SOME TYPE OF MODULE WOULD HAVE TO BE REPLACED, AT A COST OF $900.00!!! *TR
NHTSA ODI #10392339
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.
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