IllustrationFUEL PUMP WENT OUT ON 2003 CHEVROLET CAVALIER. LEFT MY WIFE STRANDED IN THE MIDDLE OF THE ROAD! SHE ALMOST WRECKED BECAUSE THERE WAS NO POWER STEERING AFTER THE MOTOR QUIT. *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 reportsMY 2003 CHEVY CAVALIER, AT 77,000 MILES, QUIT WITHOUT ANY WARNING. I WAS LUCKY TO BE ON A LOW TRAFFIC STREET. AFTER HAVING IT TOWED HOME AND GETTING ON LINE, I FOUND NUMEROUS COMPLAINS ABOUT THE SAME YEAR AND MAKE. EVERYONE COMPLAINED THAT THEIR FUEL PUMP WENT OUT. AFTER PURCHASING THE FUEL PUMP MODULE AND DOING THE WORK MYSELF…
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MY 2003 CHEVY CAVALIER, AT 77,000 MILES, QUIT WITHOUT ANY WARNING. I WAS LUCKY TO BE ON A LOW TRAFFIC STREET. AFTER HAVING IT TOWED HOME AND GETTING ON LINE, I FOUND NUMEROUS COMPLAINS ABOUT THE SAME YEAR AND MAKE. EVERYONE COMPLAINED THAT THEIR FUEL PUMP WENT OUT. AFTER PURCHASING THE FUEL PUMP MODULE AND DOING THE WORK MYSELF (DUE TO LACK OF FUNDS) THE CAR RAN FINE. WHEN WILL THE RECALL BEGIN, AFTER SOMEONE DIES? *TR
I WAS HEADING OUT OF MY HOUSE IN THE EVENING AND GOT ABOUT 2 OR 3 MILES FROM MY HOME WHEN I WENT TO MAKE A LEFT TURN THROUGH AN INTERSECTION. MIDDLE OF THE INTERSECTION MY VEHICLE STARTED TO SPUTTER AND WOULD NOT ACCELERATE WHEN I APPLIED PRESSURE TO GAS PEDAL. I WAS ONLY ABLE TO COAST JUST ENOUGH TO CLEAR THE INTERSECTION AND M…
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I WAS HEADING OUT OF MY HOUSE IN THE EVENING AND GOT ABOUT 2 OR 3 MILES FROM MY HOME WHEN I WENT TO MAKE A LEFT TURN THROUGH AN INTERSECTION. MIDDLE OF THE INTERSECTION MY VEHICLE STARTED TO SPUTTER AND WOULD NOT ACCELERATE WHEN I APPLIED PRESSURE TO GAS PEDAL. I WAS ONLY ABLE TO COAST JUST ENOUGH TO CLEAR THE INTERSECTION AND MY VEHICLE ENDED UP SHUTTING DOWN IN THE MIDDLE OF THE ROAD. THIS PROBLEM OCCURRED WITH OUT WARNING, NO SIGNS, NO LIGHTS MY VEHICLE JUST GAVE OUT ON ME IN THE MIDDLE OF AN INTERSECTION HAD IT OCCURRED JUST 5 SECONDS BEFORE I CLEARED THE INTERSECTION I MAY HAVE BEEN SERIOUSLY INJURED OR WORST IT COULD HAVE BEEN A FATAL ACCIDENT. I DO KNOW THAT THERE ARE PLENTY OF 2003 CHEVY CAVALIER OWNERS WHO HAVE EXPERIENCED THIS SAME PROBLEM AND IT NEEDS TO BE ADDRESSED. CARCOMPLAINTS.COM AND OTHER CONSUMER REVIEW SITES GIVE DETAILED SCENARIOS OF THIS DANGEROUS FUEL PUMP FAILURE AND ITS ABRUPT OCCURRENCE. THIS PROBLEM HAS OCCURRED AT MILEAGE AS LOW AS 7,000 AND WORKS ITS WAY UP. I WOULD LIKE TO BE SPOKEN WITH PERSONALLY BY SOMEONE ON THE BOARD AND FOR REASONS WHY THIS PROBLEM DOESN'T SEEM TO BE AN IMPORTANT SAFETY ISSUE. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
2003 CHEVY CAVALIER STALLED WHILE DRIVING. HAD TOWED TO SHOP AND FUEL PUMP WAS BAD. REPLACED AT 69,000 MILES AT A COST OF $760.00. THE WARRANTY ON THE NEW FACTORY FUEL PUMP WAS FOR 12 MONTHS OR 12,000 MILES. AFTER 14 MONTHS AND AT 78,000 MILES THE 2ND FUEL PUMP HAS GONE BAD. UNEMPLOYED AND DON'T HAVE THE MONEY TO FIX IT AGA…
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2003 CHEVY CAVALIER STALLED WHILE DRIVING. HAD TOWED TO SHOP AND FUEL PUMP WAS BAD. REPLACED AT 69,000 MILES AT A COST OF $760.00. THE WARRANTY ON THE NEW FACTORY FUEL PUMP WAS FOR 12 MONTHS OR 12,000 MILES. AFTER 14 MONTHS AND AT 78,000 MILES THE 2ND FUEL PUMP HAS GONE BAD. UNEMPLOYED AND DON'T HAVE THE MONEY TO FIX IT AGAIN! PLEASE RECALL. *TR
THE FUEL PUMP FAILED ON MY 2003 CHEVY CAVALIER LEAVING MY CAR POWER LESS (OFF) AT 65 MPH. THEN WOULD NOT START, LEAVING ME STRANDED ON A BUSY HIGHWAY. I AM HAVING TO BUY A NEW FUEL PUMP COSTING AROUND $200 AND TAKE TIME OFF OF WORK TO FIX IT.
I OWN A 2003 CHEVROLET CAVALIER. 65,000 KM (NOT MILES ON IT). WORKS GREAT, ONE MINUTE, THEN THE NEXT WON'T START. HAVE HAD IT TOWED TWICE ... TOLD NO REAL PROBLEM, THEN TOLD THAT THE FUEL PUMP IS GONE. CHECKED ONLINE AND THERE ARE HUNDREDS OF COMPLAINTS, BUT NO RECALL. SEEMS ABSOLUTELY UNREASONABLE, ESPECIALLY WHEN IT APPEA…
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I OWN A 2003 CHEVROLET CAVALIER. 65,000 KM (NOT MILES ON IT). WORKS GREAT, ONE MINUTE, THEN THE NEXT WON'T START. HAVE HAD IT TOWED TWICE ... TOLD NO REAL PROBLEM, THEN TOLD THAT THE FUEL PUMP IS GONE. CHECKED ONLINE AND THERE ARE HUNDREDS OF COMPLAINTS, BUT NO RECALL. SEEMS ABSOLUTELY UNREASONABLE, ESPECIALLY WHEN IT APPEARS TO BE HAPPENING WHILE DRIVING ... THAT WOULD SEEM TO ME TO BE A SAFETY ISSUE. *TR
I WAS DRIVING MY CAVALIER TO PICK UP MY WIFE. AS I APPROACHED AN INTERSECTION, THE SYSTEM COMPLETELY SHUT OFF AND I COULD NOT RESTART THE CAR. I WAS ABLE TO STOP AT THE BEGINNING OF A LEFT TURN LANE AND PUT MY HAZARDS ON. WITH THE HELP OF MY PASSENGER AND A POLICE OFFICER, WE MOVED THE CAR ACROSS 2 LANES OF TRAVEL TO THE SHOULDE…
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I WAS DRIVING MY CAVALIER TO PICK UP MY WIFE. AS I APPROACHED AN INTERSECTION, THE SYSTEM COMPLETELY SHUT OFF AND I COULD NOT RESTART THE CAR. I WAS ABLE TO STOP AT THE BEGINNING OF A LEFT TURN LANE AND PUT MY HAZARDS ON. WITH THE HELP OF MY PASSENGER AND A POLICE OFFICER, WE MOVED THE CAR ACROSS 2 LANES OF TRAVEL TO THE SHOULDER. THE CAR HAD 116,000 MILES AT THE TIME OF THE INCIDENT. THE ONLY WARNING BEFORE THE CAR LOST ALL POWER AND DRIVE-ABILITY WAS THE BATTERY LIGHT TURNING ON BRIEFLY. *TR
HAVE A 2003 CAVALIER 66,000 MILES AND WAS WORKING BEAUTIFULLY DROVE INTO WORK AND WAS COMING HOME STOPPED TO GET GROCERIES AND CAME OUT TO START MY CAR AND FUEL PUMP WAS DEAD. THERE WAS NO WARNING FOR THIS PROBLEM AT ALL WOULD LIKE TO FIND IF GM IS DOING ANYTHING ABOUT THIS SINCE THERE ARE A LOT OF COMPLAINTS FOR THE SAME ISSUE…
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HAVE A 2003 CAVALIER 66,000 MILES AND WAS WORKING BEAUTIFULLY DROVE INTO WORK AND WAS COMING HOME STOPPED TO GET GROCERIES AND CAME OUT TO START MY CAR AND FUEL PUMP WAS DEAD. THERE WAS NO WARNING FOR THIS PROBLEM AT ALL WOULD LIKE TO FIND IF GM IS DOING ANYTHING ABOUT THIS SINCE THERE ARE A LOT OF COMPLAINTS FOR THE SAME ISSUE. *TR
2003 CHEVY CAVALIER STALLED WHILE DRIVING. ALMOST GOT KILLED. JUST ANOTHER DEFECT IN THIS CAR. I KEEP REPORTING STUFF AND NO ONE SEEMS TO BE LISTENING. *TR
I WAS RETURNING HOME AND WHEN I PULLED INTO MY DRIVEWAY MY CAR HAD AN EXTREME LOSS OF POWER. I WAS SURPRISED BY THIS BECAUSE IT WAS A SUDDEN CHANGE IN MY CARS PERFORMANCE. I HAD NOT BEEN HAVING ANY TROUBLE BEFORE THIS. AFTER I PARKED MY CAR AND TURNED IT OFF I LATER ATTEMPTED TO LEAVE. IT WOULD NOT START. THE ENGINE AND EVERYTHI…
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I WAS RETURNING HOME AND WHEN I PULLED INTO MY DRIVEWAY MY CAR HAD AN EXTREME LOSS OF POWER. I WAS SURPRISED BY THIS BECAUSE IT WAS A SUDDEN CHANGE IN MY CARS PERFORMANCE. I HAD NOT BEEN HAVING ANY TROUBLE BEFORE THIS. AFTER I PARKED MY CAR AND TURNED IT OFF I LATER ATTEMPTED TO LEAVE. IT WOULD NOT START. THE ENGINE AND EVERYTHING TURNED OVER FINE IT JUST DID NOT SEEM TO BE GETTING FUEL. I THEN TURNED THE KEY ON AND OFF AND REALIZED THAT THE FUEL PUMP WAS NOT RUNNING. I RESEARCHED ONLINE AND FOUND THIS TO BE A VERY COMMON ISSUE WITH THE 2003 CAVALIERS. THANKFULLY I WAS IN MY DRIVEWAY WHEN THIS HAPPENED AND NOT IN THE LEFT LANE OF THE FREEWAY IN RUSH HOUR. I WILL BE SPENDING MY WEEKEND REPLACING MY FUEL PUMP. I WILL KEEP THE DEAD PUMP IF IT IS NEEDED FOR INVESTIGATION. *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.