IllustrationTHERE IS A VENT FOR MY DEFROSTER/HEATER/AIR CONDITIONER-ON TOP OF THE DASH--THAT DOES NOT WORK. I HAVE A FRIEND, THAT HAS THE SAME MODEL CAR. SHE TOO HAS THE SAME PROBLEM. IT SEEMS LIKE A DEFECT. *JB MY WINDSHIELD KEEPS ICING UP AND GETS FOGGY.
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
Visibility complaints
37 reportsSINCE I PURCHASED THE VEHICLE THE RADIO HAS TURNED OFF BY ITSELF IT ALSO ERASES ANY PROGRAMMED STATIONS. THE WINDOWS DON'T ALWAYS GO UP , IT HAPPENS OFF AND ON , IT HAPPENS TO ONE WINDOW AND NOT THE OTHER AND THEN REVERSES. *JB
I BOUGHT MY 2003 CHEVROLET CAVALIER IN FEB 03.THE CABLE THAT CONNECTS TO THE ADJUSTMENT KNOB FOR THE AC,DEFROST HAS BROKE 4 TIMES SINCE I HAVE OWNED MY CAR. IT GETS STUCK WHERE IT JUST BLOWS OUT OF THE VENT AND ONLY THE VENT. NO DEFROST SO IN THE WINTER AS YOU ARE DRIVING DOWN THE ROAD THE WINDOWS ARE FOGGING UP BECAUSE YOU HA…
Read full complaint
I BOUGHT MY 2003 CHEVROLET CAVALIER IN FEB 03.THE CABLE THAT CONNECTS TO THE ADJUSTMENT KNOB FOR THE AC,DEFROST HAS BROKE 4 TIMES SINCE I HAVE OWNED MY CAR. IT GETS STUCK WHERE IT JUST BLOWS OUT OF THE VENT AND ONLY THE VENT. NO DEFROST SO IN THE WINTER AS YOU ARE DRIVING DOWN THE ROAD THE WINDOWS ARE FOGGING UP BECAUSE YOU HAVE NO DEFROST. THE LAST TIME I TOOK MY CAR INTO THE DEALERSHIP THEY SAID IT WAS THE CABLE THAT BINDS UP THEY DID FIX IT BUT HERE WE GO AGAIN IT BREAKS. SO NOW THAT MY WARRANTY IS OVER IN ORDER FOR IT TO BE FIXED I WILL HAVE TO FORK THE MONEY OUT OF MY POCKET AND TO ME IF IT HAS BROKE 4 TIMES THERE IS SOMETHING WRONG. TO ME THIS SHOULD BE A SAFETY ISSUE. *NM
KNOB TO TURN THE CONTROLLER FOR DEFROSTER, HEATER FOR FEET OR VENT. THE ONLY AREA IT BLOWS OUT IS OUT THE VENT PANEL IN THE FRONT OF CAR. I AM UNABLE TO USE THE DEFROSTER FOR THE FRONT OF CAR, OR RECEIVE HEAT AT MY FEET. I JUST CANT BELIEVE THAT THIS ITEM HAS ALREADY FAILED. THE CAR IS ONLY 3 YEARS OLD. I WOULD THINK THIS IS A S…
Read full complaint
KNOB TO TURN THE CONTROLLER FOR DEFROSTER, HEATER FOR FEET OR VENT. THE ONLY AREA IT BLOWS OUT IS OUT THE VENT PANEL IN THE FRONT OF CAR. I AM UNABLE TO USE THE DEFROSTER FOR THE FRONT OF CAR, OR RECEIVE HEAT AT MY FEET. I JUST CANT BELIEVE THAT THIS ITEM HAS ALREADY FAILED. THE CAR IS ONLY 3 YEARS OLD. I WOULD THINK THIS IS A SAFETY ISSUE SINCE YOU ARE REQUIRED TO HAVE DEFROSTER TO USE. AND NEED HEAT IN THE CAR. THIS OTHER KNOBS ON THE CONTROL PANEL WORK FINE THERE IS 3 KNOBS. 1 FOR THE AMOUNT OF BLOWER THAT YOU WANT, THE SECOND ONE IS FOR THE TEMP SETTING AND THE 3RD ONE IS FOR WHERE YOU WANT THE BLOWER TO COME OUT OF. I HAVE HAD NOTHING BUT PROBLEMS WITH THE CAR SINCE DAY ONE. FIRST IT WAS THE TAIL LIGHTS, THEN THE POWER WINDOWS THEM SELF AND NOW THIS. *JB
I JUST GOT THIS CAR AT A USED CAR LOT ABOUT TWO WEEKS AGO AND IT RAINED ONE NIGHT AND THE FRONT WINDSHIELD BECAME FOGGY SO I TRIED TO PUT ON THE DEFROSTER AND IT WOULD NOT WORK NO MATTER WHERE I MOVED THE SWITCH IT WOULD ONLY BLOW THE AIR FORWARD SO I HAD TO PULL OVER EVERY LITTLE WHILE AND WIPE IT OFF JUST SO I COULD GET HOME.…
Read full complaint
I JUST GOT THIS CAR AT A USED CAR LOT ABOUT TWO WEEKS AGO AND IT RAINED ONE NIGHT AND THE FRONT WINDSHIELD BECAME FOGGY SO I TRIED TO PUT ON THE DEFROSTER AND IT WOULD NOT WORK NO MATTER WHERE I MOVED THE SWITCH IT WOULD ONLY BLOW THE AIR FORWARD SO I HAD TO PULL OVER EVERY LITTLE WHILE AND WIPE IT OFF JUST SO I COULD GET HOME. THE NEXT MORNING I TOOK IT TO A MECHANIC AND HE LOOKED AT IT AND SAID THE CABLE THAT CONTROLS THE FLOW OF AIR WAS BROKEN AND HE TRIED TO GET ONE FROM THE JUNK YARD AND SAID 3 OUT OF 5 CAVALIERS OF AROUND THE SAME YEAR 2003 HAD THE SAME CABLE BROKEN THE SAME WAY AND HE TOLD ME THE FLAP THAT THE CABLE CONTROLS WAS STICKING AND CAUSING IT TO BREAK SO I TOLD HIM TO LEAVE THE SAME CABLE ON THE CAR AND HE PUT THE FLAP TO THE DEFROST POSITION MANUALLY IN CASE IT RAINS AGAIN IT SEEMS VERY DANGEROUS IF YOU CANT SEE WHERE YOU ARE GOING THIS IS IN THE SUMMER TIME THAT I AM HAVING THIS PROBLEM I DON'T EVEN WANT TO THINK ABOUT WHAT MIGHT HAPPEN IN THE WINTER TIME. *JB
THE WIPER BLADE ARM HAD DISCONNECTED FROM THE WASHER/WIPER HOUSING ON THE PASSENGER SIDE DURING INCLEMENT WEATHER CONDITIONS, WHICH OBSTRUCTED THE DRIVERS VISION WHILE DRIVING. THE DEALER WAS NOTIFIED. THE DEALER INFORMED THE CONSUMER THAT THE PART WAS NOT COVERED UNDER A WARRANTY OR A MANUFACTURER RECALL. *JB *SB *NM
DT: CONTACT HEARD A LOUD "POP" NOISE, SHE TURNED AROUND AND THE BACK WINDOW WAS COMPLETELY SHATTERED. THE CONTACT SEARCHED AROUND THE VEHICLE AND THE ROAD SURROUNDING THE VEHICLE, THERE WAS NOTHING THAT WOULD HAVE CAUSED THE WINDOW TO SHATTER.*AK
2003 CHEVROLET CAVALIER EXPERIENCED PROBLEMS WITH BRAKE LIGHTS, TURN SIGNALS, AND TAIL LIGHTS.***NO ANSWER REQUIRED***. *MR THE BRAKE LIGHTS AND TAIL LIGHTS SHORTED OUT MANY TIMES, THE TAIL LIGHT SOCKET WAS ALSO REPLACED. THE CONSUMER RECEIVED A RECALL LETTER #04V524000. THE CONSUMER TOOK THE VEHICLE TO HAVE THE SERVICE PER…
Read full complaint
2003 CHEVROLET CAVALIER EXPERIENCED PROBLEMS WITH BRAKE LIGHTS, TURN SIGNALS, AND TAIL LIGHTS.***NO ANSWER REQUIRED***. *MR THE BRAKE LIGHTS AND TAIL LIGHTS SHORTED OUT MANY TIMES, THE TAIL LIGHT SOCKET WAS ALSO REPLACED. THE CONSUMER RECEIVED A RECALL LETTER #04V524000. THE CONSUMER TOOK THE VEHICLE TO HAVE THE SERVICE PERFORMED, HOWEVER THAT DID NOT SEEM TO REMEDY THE PROBLEM. THE VEHICLE HAS BEEN IN THE SHOP ON NUMEROUS OCCASIONS REGARDING THIS PROBLEM, THE CONSUMER DID NOT BELIEVE HER VEHICLE WAS SATISFACTORILY REPAIRED. THE CD WOULD NOT EJECT. THE RIGHT SIDE POWER WINDOW MADE A NOISE WHEN IT WAS ROLLED DOWN. *JB
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…
Read full complaint
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
THERE ARE NUMEROUS THINGS, AND THE DELAERSHIP HAS CONVINCED GM, BECAUSE I WROTE GM ABOUT THE PROBLEMS WITH THIS, THAT I AM MAKING THIS STUFF UP TO GET AN SUV. FIRST THE RADIO WASN'T WORKING, THEY PUT THE CABLE BACK ON SAID IT WAS LOOSE, ITS STILL NOT SOUNDING LIKE A RADIO SHOULD. NEXT WAS THE POPPING IN THE FRONT END, DEALERSH…
Read full complaint
THERE ARE NUMEROUS THINGS, AND THE DELAERSHIP HAS CONVINCED GM, BECAUSE I WROTE GM ABOUT THE PROBLEMS WITH THIS, THAT I AM MAKING THIS STUFF UP TO GET AN SUV. FIRST THE RADIO WASN'T WORKING, THEY PUT THE CABLE BACK ON SAID IT WAS LOOSE, ITS STILL NOT SOUNDING LIKE A RADIO SHOULD. NEXT WAS THE POPPING IN THE FRONT END, DEALERSHIP TURNED ROTORS, UNDER WARRANTY BACK BRAKES SQUEALED REAL LOUD THEY SAID IT WAS DUST I HAD TO PAY FOR THAT. BACK BRAKES STILL SQUEAL, FRONT END STILL POPS LIKE A BAD CV JOINT. TRUNK WOULDN'T SHUT HAD TO KEEP SLAMMING IT. TOOK IT BACK THEY GREASED IT WORKED FOR AWHILE STARTING TO GET HARD TO SHUT SOMETIMES. BRAKE LIGHTS AND BACK LIGHTS AND CRUISE CONTROL QUIT WORKING . TOOK IT TO DEALERSHIP AT LEAST 5 OR 6 TIMES TILL THEY FINALLY REPLACED IT HOW LONG IT WILL LAST I DON'T KNOW. FRONT SUN VISOR POPPED WHEN IT HUNG UP IN REAR VIEW MIRROR REAL FLOPPY CAN'T USE IT NO MORE DEALER SAID THEY ORDERED IT IN DECEMBER. STILL WAITING NOT FIXED. REAL BAD ODOR OF GAS IN CAR WHEN TANK IS HALF FULL, NO EXPLANATION AS TO WHY. SEAT BELT MAKES A FUNNY NOISE WHEN YOU ARE WEARING IT, PINS YOU BACK AGAINST SEAT REAL HARD. NO EXPLANATION FOR THAT. HAVE TO STOP AND JERK ON IT TO LOOSEN IT LIKE A SEAT BELT SHOULD WORK. DEALER SAYS I AM IMAGINING THIS STUFF BECAUSE I DO NOT WANT CAR, BOUGHT IT NEW STILL PAYING FOR IT. BEEN TRYING TO GET RID OF IT THEY HAVE EVERYONE CONVINCED I AM A PSYCHO WOMAN WANTING AN SUV AND THATS WHY I AM COMPLAINING THAT IS ALL FALSE. JUST PLAIN HATE A CAR I AM PAYING FOR.*AK
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.