NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
340 reportsClear category filter49,900 miles · Nov 12, 2009
Fuel System, Gasoline
WHILE ACTIVELY DRIVING MY 2003 CHEVY CAVALIER MY CAR WITHOUT WARNING JUST SHUT DOWN. I WAS UNABLE TO RESTART IT AND A TOW TO THE REPAIR SHOP WAS REQUIRED. I HAD TO HAVE MY FUEL PUMP REPLACED. THIS WAS A SHOCK BECAUSE MY CAR ONLY HAS 49,900 MILES ON IT. MY MECHANIC WAS EVEN IN SHOCK AND DOESN'T UNDERSTAND WHY THAT WOULD HAPPEN. I…
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WHILE ACTIVELY DRIVING MY 2003 CHEVY CAVALIER MY CAR WITHOUT WARNING JUST SHUT DOWN. I WAS UNABLE TO RESTART IT AND A TOW TO THE REPAIR SHOP WAS REQUIRED. I HAD TO HAVE MY FUEL PUMP REPLACED. THIS WAS A SHOCK BECAUSE MY CAR ONLY HAS 49,900 MILES ON IT. MY MECHANIC WAS EVEN IN SHOCK AND DOESN'T UNDERSTAND WHY THAT WOULD HAPPEN. I WAS LUCKY ENOUGH TO BE ABLE TO GLIDE TO THE SIDE OF THE ROAD AND AVOID AN ACCIDENT. *TR
NHTSA ODI #10292008
70,740 miles · Nov 8, 2009
Fuel System, Gasoline
I'D PURCHASED MY 2003 CHEVROLET CAVALIER IN LIKE-NEW CONDITION WITH ~20K MILES. MONTHS AFTER I'D STARTED DRIVING THE VEHICLE, I NOTICED THAT WHEN I WOULD PUT THE TRANSMISSION INTO NEUTRAL(MANUAL TRANSMISSION), THE RPM WOULD DROP WELL BELOW 1000 AND SOMETIMES IT WOULD STALL. WHEN IT WOULD STALL, IT WOULDN'T START AGAIN FOR A FE…
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I'D PURCHASED MY 2003 CHEVROLET CAVALIER IN LIKE-NEW CONDITION WITH ~20K MILES. MONTHS AFTER I'D STARTED DRIVING THE VEHICLE, I NOTICED THAT WHEN I WOULD PUT THE TRANSMISSION INTO NEUTRAL(MANUAL TRANSMISSION), THE RPM WOULD DROP WELL BELOW 1000 AND SOMETIMES IT WOULD STALL. WHEN IT WOULD STALL, IT WOULDN'T START AGAIN FOR A FEW MINUTES OF SITTING. I HAD THE VEHICLE LOOKED AT AND NO ONE COULD FIND A PROBLEM. THIS PROBLEM DIDN'T OCCUR AT A REGULAR INTERVAL, BUT INSTEAD HAPPENED RANDOMLY AT LEAST ONCE WITHIN 2 OR 3 MONTHS TIME. I HAVE HAD THE CAR FOR 4.5 YEARS AND THE FUEL PUMP HAS STOPPED OPERATING COMPLETELY. THE PROBLEM WASN'T APPARENT UNTIL I TRIED STARTING MY VEHICLE ON THE MORNING OF NOVEMBER 8TH 2009 AND THE VEHICLE WOULD NOT START. THE STARTER WAS FUNCTIONING PROPERLY, BUT THE ELECTRONIC FUEL INJECTION UNIT WAS MAKING A DIFFERENT NOISE. AFTER HAVING THE VEHICLE EVALUATED, IT WAS DETERMINED THAT THE FUEL PUMP HAD BECOME INOPERABLE. THE REPLACEMENT FUEL PUMPS PRICE RANGES BETWEEN $150-250 ON AVERAGE AND LABOR WOULD COST MORE. BY DOING A LITTLE RESEARCH, IT'S OBVIOUS THAT THIS IS A COMMON CASE. AN O.E.M. FUEL PUMP ON A CAR UNDER 75K MILES SHOULD LAST LONGER THAN 5 YEARS BEFORE DETERIORATION. *TR
NHTSA ODI #10291420
60,000 miles · Nov 6, 2009
Fuel System, Gasoline
I OWN A 2003 CHEVY CAVALIER. THE FUEL PUMP WENT OUT ON IT. THE CAR ONLY HAS 60,000 MILES ON IT. EVERYTHING WAS WORKING GREAT I PULLED UP TO A STORE TURNED OFF THE CAR, RAN AN ERRAND, THEN THE CAR WOULDN'T START. I CHECKED ALL FUSES AND RELAYS, AND HIT THE BLEED OFF IN THE FUEL LINE. THE PUMP JUST QUIT. I DID SOME RESEARCH AND MA…
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I OWN A 2003 CHEVY CAVALIER. THE FUEL PUMP WENT OUT ON IT. THE CAR ONLY HAS 60,000 MILES ON IT. EVERYTHING WAS WORKING GREAT I PULLED UP TO A STORE TURNED OFF THE CAR, RAN AN ERRAND, THEN THE CAR WOULDN'T START. I CHECKED ALL FUSES AND RELAYS, AND HIT THE BLEED OFF IN THE FUEL LINE. THE PUMP JUST QUIT. I DID SOME RESEARCH AND MANY PPL BELIEVE THAT THE FUEL PUMP IN 2003 AND 2001 CAVALIERS HAS A DEFECT. IM ONE OF THOSE PEOPLE. *TR
NHTSA ODI #10291244
84,000 miles · Oct 7, 2009
Fuel System, Gasoline
CAR LOST ALL POWER DUE TO ENGINE STALLING ON A BUSY HIGHWAY. WAS ABLE TO PULL TO THE SIDE, CAR WOULD NOT RESTART. WE HAD IT TOWED TO A MECHANIC AND IT WAS DETERMINED THAT THE FUEL PUMP IS DEFECTIVE. *TR
NHTSA ODI #10286683
66,000 miles · Sep 12, 2009
Fuel System, Gasoline
FUEL PUMP FAILURE DURING HEAVY MORNING TRAFFIC ON AN EIGHT LANE HIGHWAY. CAR ONLY HAD 66,000 MILES ON IT, AND IT COST $980 FOR REPAIR. I HAVE RECENTLY LEARNED THAT THIS SEEMS TO BE A COMMON OCCURRENCE WITH THIS PART, AND THAT GM IS PRETENDING IT DOESN'T HAVE A PROBLEM. THE LAST PART TO GO ON A VEHICLE SHOULD BE THE FUEL PUMP. I…
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FUEL PUMP FAILURE DURING HEAVY MORNING TRAFFIC ON AN EIGHT LANE HIGHWAY. CAR ONLY HAD 66,000 MILES ON IT, AND IT COST $980 FOR REPAIR. I HAVE RECENTLY LEARNED THAT THIS SEEMS TO BE A COMMON OCCURRENCE WITH THIS PART, AND THAT GM IS PRETENDING IT DOESN'T HAVE A PROBLEM. THE LAST PART TO GO ON A VEHICLE SHOULD BE THE FUEL PUMP. I HAD A 73 OLDS DELTA 88 WITH 380,000 MILES ON IT, AND THE FUEL NEVER HAD TO BE REPLACED. GM SHOULD BE FORCED TO HAVE A RECALL ON THIS DEFECTIVE PART, ESPECIALLY CONSIDERING IT CREATES A REAL SAFETY HAZARD AS WELL AS AN UNNECESSARY EXPENSE. *TR
NHTSA ODI #10283779
72,000 miles · Sep 2, 2009
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THE FUEL PUMP FAILED WHILE DRIVING AT 25 MPH. THE VEHICLE WAS TAKEN TO A MECHANIC. THE TECHNICIAN REPLACED THE FUEL PUMP. THE MANUFACTURE WAS CONTACTED. THE FAILURE MILEAGE IS 72,000.THE VIN NUMBER IS UNKNOWN. THE FAILURE MILEAGE IS 72,000. BL
NHTSA ODI #10282612
108,000 miles · Aug 31, 2009
Fuel System, Gasoline
I OWN A 2003 CAVALIER SEDAN. THREE WKS AGO IT STARTED STALLING. HAD IT TOWED TO A GARAGE. THEY KEPT IT FOR A WEEK AND SAID THE COMPUTER WAS BAD. THEN THEY CAME BACK NEXT DAY AND SAID CONTACTS WERE DIRTY. THEY CLEANED THEM, I GOT CAR BACK AND IT RAN FINE FOR 2 WKS. AGAIN, IT STARTED STALLING ON THE ROAD OR NOT STARTING. TO…
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I OWN A 2003 CAVALIER SEDAN. THREE WKS AGO IT STARTED STALLING. HAD IT TOWED TO A GARAGE. THEY KEPT IT FOR A WEEK AND SAID THE COMPUTER WAS BAD. THEN THEY CAME BACK NEXT DAY AND SAID CONTACTS WERE DIRTY. THEY CLEANED THEM, I GOT CAR BACK AND IT RAN FINE FOR 2 WKS. AGAIN, IT STARTED STALLING ON THE ROAD OR NOT STARTING. TOOK TO GARAGE THIS AM AND HE IS SAYING FUEL PUMP FOR ANOTHER $500 ON TOP OF $300 ALREADY SPENT. I REALIZE THIS CAR IS 6 YEARS OLD BUT THIS IS RIDICULOUS. I HAVE ALWAYS HAD CHEVY'S AND NEVER HAD THIS PROBLEM WITH ANY OF THEM. I SPENT THE WEEK-END ON-LINE AND DISCOVERED THAT THIS IS A RECURRING THEME WITH THE CAVALIER FROM 1998 ONWARD. WE WHO ARE SENIORS AND HAVE LITTLE MONEY FOR THESE TYPES OF REPAIRS, NEED SOMEONE IN OUR CORNER. NEVER WILL I PURCHASE A CHEVY VEHICLE AGAIN! *TR
NHTSA ODI #10282377
75,000 miles · Aug 6, 2009
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING BETWEEN 50-55 MPH, THE ENGINE DRASTICALLY REDUCED POWER. THE DRIVER PULLED OVER TO THE SIDE OF THE ROAD. ROADSIDE ASSISTANCE WAS CALLED TO THE SCENE AND THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. A CERTIFIED MECHANIC INSPECTED THE VEHICLE AND STATED THAT THE…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING BETWEEN 50-55 MPH, THE ENGINE DRASTICALLY REDUCED POWER. THE DRIVER PULLED OVER TO THE SIDE OF THE ROAD. ROADSIDE ASSISTANCE WAS CALLED TO THE SCENE AND THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. A CERTIFIED MECHANIC INSPECTED THE VEHICLE AND STATED THAT THE FUEL PUMP FAILED. THE VEHICLE IS IN THE PROCESS OF BEING REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 75,000. UPDATED 09/16/09 *BF UPDATED 09/17/09.*JB
NHTSA ODI #10279548
77,324 miles · Jul 26, 2009
Fuel System, Gasoline
FUEL PUMP ON 2003 CHEVROLET GOES OUT WITHOUT WARNING. HAVE SEEN SEVERAL HUNDRED COMPLAINTS ABOUT THIS ONLINE. *TR
NHTSA ODI #10278333
65,192 miles · Jul 23, 2009
Fuel System, Gasoline
2003 CHEVROLET CAVALIER. FUEL PUMP WENT OUT HAD TO BE REPLACED AT A COST OF 467 DOLLARS. THE CAR ONLY HAS 65192 MILES ON IT. *TR
NHTSA ODI #10278030
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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