NHTSA owner reports · September 18, 2026 snapshot.
Structure complaints
11 reportsClear category filterMileage unknown · May 6, 2016
Electrical SystemStructureUnknown Or Other
"CHECK ENGINE" LIGHT KEEPS COMING BACK ON FOR THE SAME ISSUE, SUPPOSEDLY THE "AIR INTAKE TEMP SENSOR, REPLACED THAT ONE AND SEVERAL SENSORS REPEATEDLY, HAD THE COMPLETE WIRING HARNESS CONNECTIONS CHECKED AND CLEANED, EVEN REPLACED MY ECM AND BCM [NEITHER OF WHICH WAS CHEAP], AND STILL HAS "CHECK ENGINE" LIGHT, EVEN AFTER BEING "…
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"CHECK ENGINE" LIGHT KEEPS COMING BACK ON FOR THE SAME ISSUE, SUPPOSEDLY THE "AIR INTAKE TEMP SENSOR, REPLACED THAT ONE AND SEVERAL SENSORS REPEATEDLY, HAD THE COMPLETE WIRING HARNESS CONNECTIONS CHECKED AND CLEANED, EVEN REPLACED MY ECM AND BCM [NEITHER OF WHICH WAS CHEAP], AND STILL HAS "CHECK ENGINE" LIGHT, EVEN AFTER BEING "CLEARED" OVER AND OVER AGAIN -- THIS CAR WAS WELL MAINTAINED AND THE BODY AND SUB-FRAME ARE SEVERELY ROTTING OUT LEFT AND RIGHT -- HAD A WEIRD LEAK ON THE PASS. SIDE FRONT, UNDER THE DASH. IT COMES AND GOES. THE CAR SMELLS LIKE AN OLD SNEAKER INSIDE. WATER WOULD POUR OUT OF THE PASSENGER SIDE HEATER DUCT, BUT THERE WAS NO RHYME OR REASON TO IT. ONE I EVEN HAD SOAP FOAM FROM A DRIVE THRU CAR WASH LITERALLY COME BLOWING IN TO THE CABIN, THRU THE VERY SAME HEATER DUCT. THANKFULLY IT HAS SEEMINGLY CLEARED UP, BUT IT IS STILL A HEAD SCRATCHER. I'VE TAKEN MY CAR TO SEVERAL DEALERSHIPS, PRIVATELY OWNED SHOPS, AND EVEN HAD SOME "CAR SAVVY" FRIENDS LOOK HER OVER, AS WELL AS MY DAD [ANDS ASE CERTIFIED TECH], AND THE CHECK ENGINE LIGHT STILL COMES BACK EVERY TIME. IF I WOULD HAVE KNOWN I'D PUT THIS MUCH MONEY INTO A CAR THAT LITERALLY READY TO BREAK APART, I WOULD HAVE SAVED MY MONEY TO PUT TOWARDS ANOTHER CAR. LIVE AND LEARN, I GUESS. SHE WAS DOING SO WELL FOR 10 OR 11 YEARS AND IT'S LIKE SHE JUST STARTED "GIVING UP" ON ME. SHE'S GOT 165K ON HER AND THE PAIN HAS GONE TO CRAP, BUT THAT'S GM FOR YOU, KEPT HER GARAGED, WAXED REGULARLY, HAD HER LOOKING SHOWROOM NEW, UNTIL RECENTLY, THE PAINT'S CLEAR COAT STARTED TO "STIPPLE" [SHARP BUMPS] AND BUBBLE ALL OVER TOP PANELS, STARTING WITH THE ROOF, THEN HOOD, AND NOW TRUNK. IT'S EMBARRASSING TO DRIVE HER, AND I AM NOT PAYING TO REPAINT HER, I ALREADY HAVE WAY TOO MUCH INTO A CAR THAT LIKELY WILL NOT PASS INSPECTION COMING UP IN AUGUST. I'M NOW HANDICAP'D AND DISABLED, FIXED INCOME, CAN'T AFFORD A NEW CAR.
NHTSA ODI #10863655
200,000 miles · Feb 9, 2016
StructureSuspension
I HAVE NOTICED A LOT AND I MEAN A LOT OF THESE CAVALIERS HAVE HAD HORRIBLE FRAME PROBLEMS I USE TO WORK ON CARS EVERYDAY UNTIL THE LAST YEAR WHEN I GOT OUT OF THE MECHANICS FIELD AN NOW I OWN A 03 CHEVY CAVALIER ITS A TWO DOOR 5 SPEED 2.2 I WAS ON MY WAY HOME FROM THE STORE AND I FELT SOMETHING RUBBING SO I STOPPED AN GOT OUT TO…
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I HAVE NOTICED A LOT AND I MEAN A LOT OF THESE CAVALIERS HAVE HAD HORRIBLE FRAME PROBLEMS I USE TO WORK ON CARS EVERYDAY UNTIL THE LAST YEAR WHEN I GOT OUT OF THE MECHANICS FIELD AN NOW I OWN A 03 CHEVY CAVALIER ITS A TWO DOOR 5 SPEED 2.2 I WAS ON MY WAY HOME FROM THE STORE AND I FELT SOMETHING RUBBING SO I STOPPED AN GOT OUT TO FIND OUT MY K FRAME WAS HORRIBLY ROTTED AN BROKE NOW THIS VEHICLE IS 13 YEARS OLD BUT AS ROTTED OUT AS IT WAS IT WASN'T SOMETHING THAT JUST HAPPENED ITS BEEN BAD I WAS JUST THE LUCKY OWNER THAT THE FRAME GAVE OUT ON AN I DEMAND TO KNOW WHY THIS ISN'T A RECALL ANOTHER THING IS I OWNED A 98 FORD F150 WHICH HAD RECALLS AN WHEN I WAS SENT THE LETTER ABOUT THE RECALLS I ASKED FORD WHY THE FRAMES ON THE F150 OR RANGER WASN'T A RECALL THEY HAD NO ANSWER. I PUT MY CHILD IN THESE AUTO MAKERS CARS AND TRUST THEIR WORK TO KEEP HIM SAFE BUT THEY HAVE NO ANSWER FOR WHY ONE OF THE MOST IMPORTANT PART ON THE WHOLE VEHICLE IS FALLING APART. I DON'T KNOW IF THEY NEED TO USE STAINLESS STEEL, ALUMINUM, OR WHAT BUT IT NEEDS FIXED OR THE VEHICLES NEED REIMBURSED AN CRUSHED. I COULD OF BEEN DOING 70 MPH DOWN THE HIGHWAY WITH MY WOMAN AN SON IN THE CAR AN THE FRAME COULD OF WENT AND KILLED US ALL. IS THAT WHAT ITS GONNA TAKE TO GET THIS [XXX] FIXED SOMEONE ELSE TO DIE/HURT. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
NHTSA ODI #10825225
Mileage unknown · Sep 9, 2015
StructureUnknown Or Other
THE DASHBOARD PIECES HAVE STARTED TO CRACK BAD. I REPLACED THE CONSOLE PIECE BUT THEY DONT MAKE A REPLACEMENT FOR THE STRIP ALONG THE BOTTOM OF WINDSHIELD. ITS GOT CHUNKS MISSING OUT OF IT.
NHTSA ODI #10762383
189,587 miles · Jan 31, 2015
Electrical SystemSteeringStructureCrash
POWER SUDDENLY SHUT OFF, CAUSING POWER STEERING TO FAIL, WHICH MADE ME WRECK INTO A DITCH. IT ALSO CAUSED THE AIRBAGS TO NOT DEPLOY AND PREVENTED SEATBELTS FROM LOCKING INTO PLACE WHEN THE BRAKES WERE HIT. *TR
NHTSA ODI #10680126
109,801 miles · Mar 18, 2014
Structure
ON OR ABOUT MARCH 8TH, 2014, I NOTICED THAT HOLES HAD APPEARED ON THE DRIVERS AND PASSENGER SIDE OF THE VEHICLE ON THE BOTTOM AND WHEN I WENT TO FURTHER EXAM THE HOLE, I THEN REALIZED THE UNDERSIDE OF THE CAR IS COMPLETELY CORRODED. THE SHEET METAL ON THE PASSENGERS SIDE IS COMING OFF IN SHEETS AND THE HOLE HAS BECOME MUCH LAR…
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ON OR ABOUT MARCH 8TH, 2014, I NOTICED THAT HOLES HAD APPEARED ON THE DRIVERS AND PASSENGER SIDE OF THE VEHICLE ON THE BOTTOM AND WHEN I WENT TO FURTHER EXAM THE HOLE, I THEN REALIZED THE UNDERSIDE OF THE CAR IS COMPLETELY CORRODED. THE SHEET METAL ON THE PASSENGERS SIDE IS COMING OFF IN SHEETS AND THE HOLE HAS BECOME MUCH LARGER IN SIZE. ALSO, THE VEHICLE PULLS TO THE LEFT AND RIGHT PRETTY STRONGLY. THE INSIDE FLOOR OF THE CAR FEELS SQUISHY LIKE THE FLOOR IS GOING TO FALL OUT. HIGHER SPEEDS SEEM TO MAKE MORE SHEET METAL FALL OFF. *TR
NHTSA ODI #10573211
90,000 miles · Jun 11, 2013
Structure
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE AT AN INDEPENDENT MECHANIC FOR THE REPLACEMENT OF CORRODED BRAKE LINES, THE MECHANIC NOTICED THAT THE FRAME WAS ALSO CORRODED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE …
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE AT AN INDEPENDENT MECHANIC FOR THE REPLACEMENT OF CORRODED BRAKE LINES, THE MECHANIC NOTICED THAT THE FRAME WAS ALSO CORRODED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 90,000. *TR
NHTSA ODI #10516215
60,000 miles · Oct 16, 2011
Structure
DARK GREEN EXTERIOR PAINT STARTED FADING IN 2008 NOW IS SEVERE & COVERS ROOF & HOOD. *TR
NHTSA ODI #10430410
1,666 miles · Mar 25, 2005
Air BagsExterior LightingService Brakes, Hydraulic
CHEVROLET CAVALIER Z 2003, MULTIPLE FAILURES. *BF THE DEFROSTER WOULD NOT CLEAR THE WINDOWS, THE HEATER DID NOT WORK, THE AIR BAG LIGHT ILLUMINATED BECAUSE THERE WAS A SPLIT IN THE CENTER OF THE STEERING WHEEL. WHEN THE CONSUMER MADE A RIGHT TURN A NOISE WAS HEARD. THE LEFT REAR TURN SIGNAL BULB WAS REPLACED, THE RIGHT REA…
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CHEVROLET CAVALIER Z 2003, MULTIPLE FAILURES. *BF THE DEFROSTER WOULD NOT CLEAR THE WINDOWS, THE HEATER DID NOT WORK, THE AIR BAG LIGHT ILLUMINATED BECAUSE THERE WAS A SPLIT IN THE CENTER OF THE STEERING WHEEL. WHEN THE CONSUMER MADE A RIGHT TURN A NOISE WAS HEARD. THE LEFT REAR TURN SIGNAL BULB WAS REPLACED, THE RIGHT REAR BRAKE LIGHT BULB. THERE WAS A NOISE COMING FROM THE FRONT OF THE VEHICLE, THE DEALER LUBED THE FRONT SWAY BAR BUSHING. THE TIRES WERE OVER INFLATED, SO THE VEHICLE WOULD SWAY WHEN GOING OVER BUMPS, THE BLOWER MOTOR, AND HEATER CONTROL WAS REPLACED. THE ABS LAMP ILLUMINATED. THE VEHICLE NEEDED BRAKE PADS. THERE WAS MOLD ON THE DRIVERS FRONT DOOR. THE AC COMPRESSOR WAS REPLACED. THE WINDOW WENT DOWN EXTREMELY SLOW, THE DEALER LUBED THE WINDOW TRACK AND REGULATOR. THE FOG LIGHT BULB WAS INOPERATIVE, THE DOOR LATCH WAS INOPERATIVE. *JB
NHTSA ODI #10115838
7,000 miles · Jan 15, 2004
Engine And Engine CoolingService Brakes, HydraulicStructure
1. BOTH BRAKE LIGHTS WENT OUT W/IN MONTH OF EACH OTHER. IN THE MONTHS OF JULY AND AUGUST. 2. BRAKES NOISY, SEPTEMBER 3. TRUNK WOULD NOT OPEN, OCTOBER 4. BRAKES NOISY, AGAIN, NOVEMBER 5. CAR TURNS OFF IN THE MIDDLE OF AN INTERSECTION AFTER MAKING A COMPLETE STOP AND TRYING TO SPEED UP. FREAKING OUT, I PRESSED THE GAS AND MOVED TH…
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1. BOTH BRAKE LIGHTS WENT OUT W/IN MONTH OF EACH OTHER. IN THE MONTHS OF JULY AND AUGUST. 2. BRAKES NOISY, SEPTEMBER 3. TRUNK WOULD NOT OPEN, OCTOBER 4. BRAKES NOISY, AGAIN, NOVEMBER 5. CAR TURNS OFF IN THE MIDDLE OF AN INTERSECTION AFTER MAKING A COMPLETE STOP AND TRYING TO SPEED UP. FREAKING OUT, I PRESSED THE GAS AND MOVED THE KEY IN THE IGNITION, THEN PUT CAR IN PARK AND GOT IT TO START, NOVEMBER. IT JUST SEEMS TO ME THAT I HAVE A DISFUNCTIONAL CAR THAT WHEN I DONT HAVE SOMETHING WRONG WITH ONE THING I HAVE TO GO IN TO THE DEALER FOR ANOTHER. ITS A NEW CAR AND ITS COSTING ME MORE PROBLMES AND INCONVINIENCES THAN THE OLD '96 I HAD TILL I BOUGHT THIS ONE.
NHTSA ODI #10071186
Mileage unknown · Jan 13, 2004
Structure
I PURCHASED MY CAR WITH 2 MILES ON IT IN MAY 2003.AFTER 2 WEEKS OF HAVING IT THERE WAS A KNOCKING NOISE THAT STARTED UNDER THE FRONT END.THE SERVICE DEPT. SAID THAT IT WAS JUST A NEW CAR SOUND AND IT WOULD GO AWAY.AFTER SEVERAL MONTHS I TOOK IT BACK TO THE SERVICE DEPT. AND HE FOUND THAT THERE WERE MANY BOLTS TO THE FRONT END FR…
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I PURCHASED MY CAR WITH 2 MILES ON IT IN MAY 2003.AFTER 2 WEEKS OF HAVING IT THERE WAS A KNOCKING NOISE THAT STARTED UNDER THE FRONT END.THE SERVICE DEPT. SAID THAT IT WAS JUST A NEW CAR SOUND AND IT WOULD GO AWAY.AFTER SEVERAL MONTHS I TOOK IT BACK TO THE SERVICE DEPT. AND HE FOUND THAT THERE WERE MANY BOLTS TO THE FRONT END FRAME WERE NEVER TIGHTENED OR PUT IN FROM THE FACTORY.SO THEY PUT IN BOLTS AND TIGHTENED THE REST.HOPING THAT WOULD SOLVE THE PROBLEM I LEFT.IT CONTINUED TO MAKE A POPPING TYPE SOUND AND I TOOK IT BACK WHERE THIS TIME THEY HEARD IT BUT COULD NOT FIND WHAT IT WAS.TO THIS DAY IT SOUNDS AS THOUGH THE FRONT END IS GOING TO FALL OUT AND THE STEERING HAS CHANGED.THE SERVICE DEPT. SAID IF THEY CAN'T FIND THE PROBLEM THEN THEY CAN'T FIX IT AND TO DRIVE IT UNTIL WHATEVER IT IS BREAKS OR FALLS OUT! I STILL HAVE THE PROBLEM AND I AM TERRIFIED TO DRIVE IT.ALSO THE SEAT BELT LIGHT DOES NOT WORK PROPERLY,THE DASH HAS A LOUD VIBRATING NOISE,THE HEAT AND AIR MAKES A LOUD BUZZING SOUND, THE GAS GAUGE DOES NOT WORK PROPERLY AND THE CAR DOES NOT ACCELERATE AND DECELERATE PROPERLY.I HAVE CONTACTED THE MANUFACTURER ABOUT THE PROBLEM AND THEY SAID THEY WERE SORRY ABOUT THE BOLTS NEVER BEING PUT IN AND THAT THEIR VEHICLES ARE INSPECTED AND ARE SAFE.WELL HOW IS THAT WHEN THEY DID NOT EVEN PUT IN BOLTS THAT HOLDS THE MOTOR IN?WHAT ELSE HAVE THEY FORGOTTEN?I FEEL UNSAFE IN MY CAR AND AM VERY ANGRY THAT THIS PROBLEM PERSISTS!
NHTSA ODI #10053128
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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