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
What owners actually said
678 reports
102,034 miles · May 23, 2009
Fuel System, Other
FUEL PUMP FAILURE - REPLACEMENT LEARNED OF REPLACEMENT WIRING HARNESS - RECOMMENDED BY GENERAL MOTORS DUE TO POSSIBILITY OF FUEL TANK CATCHING FIRE DUE TO A DEFECTIVE CONNECTOR REPLACEMENT WAS NOT A HARNESS BUT A CONNECTOR THAT HAD TO BE SPLICED INTO EXISTING CABLE WHICH WAS AROUND 30 OR SO INCHES LONG DEALERSHIP SAYS SPLI…
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FUEL PUMP FAILURE - REPLACEMENT LEARNED OF REPLACEMENT WIRING HARNESS - RECOMMENDED BY GENERAL MOTORS DUE TO POSSIBILITY OF FUEL TANK CATCHING FIRE DUE TO A DEFECTIVE CONNECTOR REPLACEMENT WAS NOT A HARNESS BUT A CONNECTOR THAT HAD TO BE SPLICED INTO EXISTING CABLE WHICH WAS AROUND 30 OR SO INCHES LONG DEALERSHIP SAYS SPLICE CONNECTOR IS ONLY ALTERNATIVE TO REPLACING THE ENTIRE CABLE WHICH WOULD RUN OVER $500 AND WOULD HAVE TO CUT AND SPLICE THAT TOGETHER AS WELL AS NEW ONE WOULD HAVE THE DEFECTIVE CONNECTOR AS WELL ** MY COMPLAINT ON THIS - THIS IS A FACTORY DEFECT OR SO THE DEALERSHIP SAYS AND IS AWARE OF THE PROBLEM WHICH INDICATED THAT THE HARNESS NEEDS REPLACEMENT DUE TO FACT THAT USING EXISTING CONNECTOR INSTALLED BY THE MANUFACTURER COULD CAUSE A FIRE IN THE FUEL TANK - WHICH I WOULD THINK THIS IS A SAFETY ISSUE THAT SHOULD HAVE HAD A RECALL TO IT. ** ALSO REPLACING A CONNECTOR BY SPLICING IS PRETTY MUCH POINTLESS ON SUCH A SHORT CABLE TO BEGIN WITH AND IF A DIY WAS TO DO THIS THE CONNECTION MAY NOT BE SOLID AND TIGHT THEREFORE A HEAT BUILD UP COULD OCCUR AND A FIRE COULD RESULT AS WELL. *TR
NHTSA ODI #10269766
44,000 miles · May 11, 2009
Fuel System, Gasoline
I HAVE A 2003 CHEVY CAVALIER. IT ONLY HAS 43000 MILES ON IT. THE CAR SUDDENLY DIED IN THE MIDDLE OF THE ROAD WITH NO WARNING AND I ALMOST GOT HIT BY THE CAR THAT WAS BEHIND ME. HAD TO HAVE IT TOWED AND THEY SAID IT WAS THE FUEL PUMP. COST $800. AT 44000 MILES YOU SHOULD NOT BE REPLACING THE FUEL PUMP. *TR
NHTSA ODI #10268439
10,000 miles · May 11, 2009
Electrical SystemFire
JANUARY 14,2009 MY CAR ALMOST CAUGHT ON FIRE DUE TO ACID FROM MY BATTERY LIKING INTO THE BATTERY PAN. I HAD TO UNHOOK THE BATTERY AND TAKE IT OUT OF THE CAR. MY STEP SON WAS DRIVING BY MY HOUSE WHEN MY CARS LIGHTS WERE ON ANDTHE CAR HAD BEEN SITTING FOR ABOUT 3 HOURS. I WENT OUTSIDE AND THE LIGHTS WERE VERY DIM. I TRIED TO S…
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JANUARY 14,2009 MY CAR ALMOST CAUGHT ON FIRE DUE TO ACID FROM MY BATTERY LIKING INTO THE BATTERY PAN. I HAD TO UNHOOK THE BATTERY AND TAKE IT OUT OF THE CAR. MY STEP SON WAS DRIVING BY MY HOUSE WHEN MY CARS LIGHTS WERE ON ANDTHE CAR HAD BEEN SITTING FOR ABOUT 3 HOURS. I WENT OUTSIDE AND THE LIGHTS WERE VERY DIM. I TRIED TO START IT UP AND THE CAR STARTED SMOKING AND I IMMEDIATELY TURNED THE CAR OFF. THERE WERE SPARKS SO I HAD TO PUT OUT THE SMALL FLAME AND REMOVE THE BATTERY. I HAD THE CAR TOWED TO PARKER PONTIAC BUICK GMC THAT SAME DAY. THE SMALL FIRE BURNED THROUGH MY WINDSHIELD WASHER FLUID LINE THE COST TO ME FOR REPAIR OF THE SMALL FIRE WAS ABOUT 487.00. *TR
NHTSA ODI #10268359
44,453 miles · May 11, 2009
Fuel System, Other
I OWN A 2003 CHEVY CAVALIER LS4D AND HAD TO REPLACE MY FUEL PUMP. I HAD MY CAR TOWED TO PARKER PONITAC, BUICK GMC. THEY REPLACED MY FUEL PUMP AND FILTER AND THE COST WAS 613.99. NOW EVEN AFTER REPLACING THE FUEL PUMP MY CAR IS STILL STALLING AND CUTTING OFF. *TR
NHTSA ODI #10268358
57,449 miles · May 5, 2009
Fuel System, Gasoline
CHEVROLET CAVALIER 2003 FUEL PUMP FAILURE STALLS VEHICLE IN HEAVY TRAFFIC. THERE ARE HUNDREDS OF INSTANCES OF THIS FAILURE IN THE 2003 MODEL STRANDING MOTORISTS IN UNSAFE CONDITIONS. *TR
NHTSA ODI #10267797
70,000 miles · May 2, 2009
Fuel System, Gasoline
CAR DIED ON ROAD - NO WARNING. BAD FUEL PUMP...PROBLEM IS WIDESPREAD FROM WHAT I'VE HEARD AND DANGEROUS...LOST POWER STEERING AND POWER BRAKES AT 50+ MPH. *TR
NHTSA ODI #10267531
101,670 miles · Apr 20, 2009
Fuel System, Gasoline
CAME TO A STOP. ACCELERATED FROM STOP. VEHICLE HAD PROBLEM ACCELERATING. FINALLY STALLED OUT ABOUT 1/8 MILE LATER. WILL NOT RESTART. TURNS OVER BUT WILL NOT START FROM WHAT I HAVE READ FROM OTHERS WITH THIS SAME PROBLEM WITH THIS YEAR AND MODEL. EVERY ONE OF THEM HAS STATED THAT THE FUEL PUMP NEEDED TO BE REPLACED. *TR
NHTSA ODI #10266105
74,959 miles · Apr 16, 2009
Fuel System, Gasoline
1. I WAS JUST DRIVING MY CAR IT WAS RUNNING FINE, I PARKED IT ON A HILL AND WHEN I CAME BACK TO START IT, IT JUST WOULDN'T START. 2. IT WAS MAKING HORRIBLE NOISES, THE TANK WAS AT 1/4 I NEVER LET IT GET BELOW THAT. AFTER AN HOUR OF TRYING TO GET IT TO START SOMEONE MENTIONED THAT IT COULD BE THE FUEL PUMP AND TO HAVE SOMEONE H…
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1. I WAS JUST DRIVING MY CAR IT WAS RUNNING FINE, I PARKED IT ON A HILL AND WHEN I CAME BACK TO START IT, IT JUST WOULDN'T START. 2. IT WAS MAKING HORRIBLE NOISES, THE TANK WAS AT 1/4 I NEVER LET IT GET BELOW THAT. AFTER AN HOUR OF TRYING TO GET IT TO START SOMEONE MENTIONED THAT IT COULD BE THE FUEL PUMP AND TO HAVE SOMEONE HIT THE GAS TANK WHILE I TRIED STARTING IT, SURE ENOUGH IT STARTED, I DROVE IT HOME, THE NEXT DAY I DROVE TO FILL UP THINKING IT WOULD HELP, IT DIED ON THE WAY HOME AND WOULDN'T START AT ALL WITH ANY AMOUNT OF HELP. 3. I HAD TO HAVE THE CAR TOWED TO GET FIXED, IT WAS THE FUEL PUMP, THEY REPLACED IT AND IT COST A TOTAL OF $613. *TR
NHTSA ODI #10265654
79,000 miles · Apr 16, 2009
Engine And Engine Cooling
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 65 MPH, THE CONTACT STATED THAT THE VEHICLE SHUT OFF AND THE BRAKES FAILED. SHE THEN NOTICED THAT THE STEERING BECAME STIFF. SHE WAS ABLE TO SAFELY MANEUVER THE VEHICLE TO THE SHOULDER AND HAD IT TOWED TO HER DESTINATION. THE CONTACT DID NOT NOTICE ANY WARNINGS PRI…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 65 MPH, THE CONTACT STATED THAT THE VEHICLE SHUT OFF AND THE BRAKES FAILED. SHE THEN NOTICED THAT THE STEERING BECAME STIFF. SHE WAS ABLE TO SAFELY MANEUVER THE VEHICLE TO THE SHOULDER AND HAD IT TOWED TO HER DESTINATION. THE CONTACT DID NOT NOTICE ANY WARNINGS PRIOR TO THE FAILURE. SHE IS IN THE PROCESS OF TAKING THE VEHICLE TO THE DEALER FOR INSPECTION. THE MANUFACTURER ADVISED HER TO TAKE THE VEHICLE TO THE DEALER FOR INSPECTION. SHE WOULD NOT BE COMPENSATED FOR THE REPAIRS BECAUSE THERE WAS NO RECALL AVAILABLE. THE FAILURE MILEAGE WAS 79,000.
NHTSA ODI #10265603
68,000 miles · Apr 15, 2009
Electrical System
THE CLUSTER BOARD HAS GONE OUT. IT DOES NOT LIGHT UP, THE SPEEDOMETER, THE FUEL GAGE AND RPM GAGE ALL DOES NOT WORK. CHEVY HAS ALREADY RECALLED TRUCKS FOR THIS PROBLEM BUT I HAVE A CAVALIER AND ON EBAY YOU CAN BUY A FIXED CLUSTER BOARD AND SEND BACK YOUR OLD ONE AND GET 100.00 BACK SO IT MUST BE A BIG PROBLEM NOT JUST MY CAR. *T…
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THE CLUSTER BOARD HAS GONE OUT. IT DOES NOT LIGHT UP, THE SPEEDOMETER, THE FUEL GAGE AND RPM GAGE ALL DOES NOT WORK. CHEVY HAS ALREADY RECALLED TRUCKS FOR THIS PROBLEM BUT I HAVE A CAVALIER AND ON EBAY YOU CAN BUY A FIXED CLUSTER BOARD AND SEND BACK YOUR OLD ONE AND GET 100.00 BACK SO IT MUST BE A BIG PROBLEM NOT JUST MY CAR. *TR
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 ↗
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.
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.
2003 Chevrolet Cavalier Problems, Complaints & Recalls | Skip That Year
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