NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
340 reportsClear category filter95,000 miles · Mar 19, 2011
Fuel System, Gasoline
MY WIFE WAS PICKING OUR CHILDREN UP FROM SCHOOL. WHEN SHE PULLED OUT INTO THE FLOW OF TRAFFIC HER CAR DIED IN THE MIDDLE OF THE ROAD. THIS OF THE SECOND TIME THE FUEL PUMP HAS GONE OUT THE FIRST TIME WAS ABOUT 60K MILES THE CAR NOW HAS 95K AND I ALREADY HAVE TO REPLACE IT. I'VE READ ABOUT MANY OTHER PEOPLE HAVING THE SAME PROBLE…
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MY WIFE WAS PICKING OUR CHILDREN UP FROM SCHOOL. WHEN SHE PULLED OUT INTO THE FLOW OF TRAFFIC HER CAR DIED IN THE MIDDLE OF THE ROAD. THIS OF THE SECOND TIME THE FUEL PUMP HAS GONE OUT THE FIRST TIME WAS ABOUT 60K MILES THE CAR NOW HAS 95K AND I ALREADY HAVE TO REPLACE IT. I'VE READ ABOUT MANY OTHER PEOPLE HAVING THE SAME PROBLEM AND EVERYONE IS WONDERING WHY NO RECALL. *TR
NHTSA ODI #10392207
85,000 miles · Mar 7, 2011
Fuel System, Gasoline
WAS DRIVING VEHICLE AND WITH NO WARNING IT STALLED OUT. IT IS CURRENTLY AT THE GARAGE WITH AN ESTIMATE OF 700-900 TO REPLACE THE FUEL PUMP. I DO NOT HAVE THIS MONEY SO I AM NOW A SINGLE PARENT WITHOUT A VEHICLE FOR A PROBLEM THAT SHOULD HAVE BEEN RECALLED PREVIOUSLY. I THANK GOD MY CHILD WAS NOT IN THE VEHICLE. *TR
NHTSA ODI #10386759
78,000 miles · Feb 16, 2011
Fuel System, Gasoline
DRIVING DOWN THE HIGHWAY AT 70 MPH. THE CAR BEGAN TO SHUDDER AND LOSE ACCELERATION. I GOT OFF AT THE NEAREST EXIT AND AS I PASSED THROUGH THE EXIT INTERSECTION, THE ENGINE DIED. I COASTED INTO A GAS STATION, WHERE THE ENGINE WOULD TURN OVER AND THEN DIE RIGHT AWAY. AFTER 15 MINUTES IT NO LONGER TURNED OVER....THE TOW TRUCK MA…
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DRIVING DOWN THE HIGHWAY AT 70 MPH. THE CAR BEGAN TO SHUDDER AND LOSE ACCELERATION. I GOT OFF AT THE NEAREST EXIT AND AS I PASSED THROUGH THE EXIT INTERSECTION, THE ENGINE DIED. I COASTED INTO A GAS STATION, WHERE THE ENGINE WOULD TURN OVER AND THEN DIE RIGHT AWAY. AFTER 15 MINUTES IT NO LONGER TURNED OVER....THE TOW TRUCK MAN TRIED IT. TURNS OUT THE FUEL PUMP IS SHOT AND APPARENTLY THIS IS A COMMON PROBLEM FOR 03 CAVALIERS. THE CAR ONLY HAS 78,000 MILES ON IT. *TR
NHTSA ODI #10382870
60,000 miles · Jan 20, 2011
Fuel System, Gasoline
FUEL PUMP FAILURE RESULTING IN THE ENGINE DYING AND NOT BEING ABLE TO RESTART. THE CAR WAS RUNNING FINE WITH ABOUT A HALF TANK OF GAS WHEN THE ENGINE DIED IN TRAFFIC. I WAS ABLE TO SAFELY STOP THE CAR BUT NOT IN ALL CIRCUMSTANCES WOULD THAT BE POSSIBLE. THE CAR AS AROUND 60,000 MILES ON IT AND A COMPLETE FUEL PUMP FAILURE WHILE …
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FUEL PUMP FAILURE RESULTING IN THE ENGINE DYING AND NOT BEING ABLE TO RESTART. THE CAR WAS RUNNING FINE WITH ABOUT A HALF TANK OF GAS WHEN THE ENGINE DIED IN TRAFFIC. I WAS ABLE TO SAFELY STOP THE CAR BUT NOT IN ALL CIRCUMSTANCES WOULD THAT BE POSSIBLE. THE CAR AS AROUND 60,000 MILES ON IT AND A COMPLETE FUEL PUMP FAILURE WHILE IN OPERATION IS UNACCEPTABLE ON A VEHICLE UNDER TEN YEARS OLD WITH UNDER 100,000 MILES ON IT. I UNDERSTAND THAT THIS IS A COMMON PROBLEM. *TR
NHTSA ODI #10378084
75,000 miles · Jan 8, 2011
EquipmentFuel System, GasolineService Brakes, Hydraulic
TRANS AXLE WENT OUT APRIL 09 WITH A HORRIBLE MESS OF OIL, STEERING RACK REPLACED 6 MONTHS LATER, DRIVER SIDE WINDOW/ MOTOR PROBLEM, FUEL PUMP WENT 75,000 A BIT SHY OF A YEAR LATER. NOW MY DEFROST ISN'T WORKING; POSSIBLY THE SWITCH 85,000. HAD BRAKES DONE TWICE SO FAR WITH LEAKS; THIS INCLUDES HYDRAULICS, ROTORS, PADS, SHOES ET…
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TRANS AXLE WENT OUT APRIL 09 WITH A HORRIBLE MESS OF OIL, STEERING RACK REPLACED 6 MONTHS LATER, DRIVER SIDE WINDOW/ MOTOR PROBLEM, FUEL PUMP WENT 75,000 A BIT SHY OF A YEAR LATER. NOW MY DEFROST ISN'T WORKING; POSSIBLY THE SWITCH 85,000. HAD BRAKES DONE TWICE SO FAR WITH LEAKS; THIS INCLUDES HYDRAULICS, ROTORS, PADS, SHOES ETC. MY STEERING HAS SEIZED WHILE DRIVING. THIS CAR HAS BEEN A VERY EXPENSIVE INCONVENIENCE. *LN
NHTSA ODI #10375199
Mileage unknown · Dec 28, 2010
Fuel System, Gasoline
2003 CHEVROLET CAVALIER. CONSUMER WRITES REGARDING RUPTURE OF FUEL INJECTOR *TGW THE DEALER REPLACED THE #4 FUEL INJECTOR DUE TO IT LEAKING EXTERNALLY. *JB
NHTSA ODI #10373056
88,478 miles · Dec 11, 2010
Electrical SystemFuel System, Gasoline
DRIVING AT 60 MPH JUST DIED ON THE INTERSTATE,PULLED OVER STARTED BACK UP ALSO AT 60,000 MILES FUEL PUMP WENT OUT NOTHING BUT PROBLEMS WITH THIS 2003 CAVALIER THEY ARE A LEMON,WHY ISN'T SOMETHING DONE????? BEFORE SOMEONE GETS KILLED IF THEY HAVEN'T ALREADY!! *TR
NHTSA ODI #10369977
69,214 miles · Nov 12, 2010
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING 72 MPH, THE VEHICLE STALLED AND THE OIL AND SEAT BELT LIGHTS ILLUMINATED. THE CONTACT PUSHED THE VEHICLE TO THE SIDE OF THE ROAD AND HAD IT TOWED TO AN AUTHORIZED DEALER; THE DEALER STATED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WA…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING 72 MPH, THE VEHICLE STALLED AND THE OIL AND SEAT BELT LIGHTS ILLUMINATED. THE CONTACT PUSHED THE VEHICLE TO THE SIDE OF THE ROAD AND HAD IT TOWED TO AN AUTHORIZED DEALER; THE DEALER STATED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED AT THE CONTACT'S EXPENSE. THE CURRENT AND FAILURE MILEAGES WERE 69,214.
NHTSA ODI #10365447
115,000 miles · Sep 29, 2010
Fuel System, Gasoline
WHILE DRIVING MY CAR ON MAIN ROADS, IT TENDS TO STALL OUT OF NO WHERE. I HAVE HAD THE FUEL PUMP REPLACED AROUND 70,000 MILES. AT 115,000 MILES IT SEEMS AS THOUGH I NEED TO REPLACE IT AGAIN. IT STALLS WHILE DRIVING, IN TRAFFIC, BUT THEN STARTS RIGHT BACK UP. IT IS NOT SAFE. I HAVE IT A SHOP YET AGAIN TO SEE WHAT'S WRONG. *TR
NHTSA ODI #10358353
Mileage unknown · Sep 24, 2010
Fuel System, Gasoline
I HAVE A 2003 CHEVY CAVALIER AND THE FUEL PUMP CONTINUES TO GO OUT. IT IS EXTREMELY FRUSTRATING. IT HAS GONE OUT ONCE BEFORE AND COST ME 800 DOLLARS TO REPLACE. I WISH I KNEW ABOUT HOW FREQUENT THIS HAPPENS WITH THIS CAR BEFORE PURCHASING IT. *TR
NHTSA ODI #10357303
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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