NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
678 reportsMileage unknown · Mar 14, 2009
Electrical System
MY SPEEDOMETER WAS ACTING UP FOR A YEAR. WHILE I WAS DRIVING IT WOULD STOP. WHEN I WOULD COME TO A COMPLETE STOP IT WAS STUCK ON 65MPH. MADE DRIVING HAZARDOUS NOT KNOWING EXACTLY HOW FAST I WAS DRIVING.IF I LET IT SIT FOR AWHILE AND COOL OF I WOULD START IT BACK UP AND THE SPEEDOMETER METER WOULD GO DOWN ABOUT 10 MPH SO I WOULD …
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MY SPEEDOMETER WAS ACTING UP FOR A YEAR. WHILE I WAS DRIVING IT WOULD STOP. WHEN I WOULD COME TO A COMPLETE STOP IT WAS STUCK ON 65MPH. MADE DRIVING HAZARDOUS NOT KNOWING EXACTLY HOW FAST I WAS DRIVING.IF I LET IT SIT FOR AWHILE AND COOL OF I WOULD START IT BACK UP AND THE SPEEDOMETER METER WOULD GO DOWN ABOUT 10 MPH SO I WOULD BEAT 55MPH INSTEAD OF 65MPH. EVERYTIME I WOULD START THE CAR IT WOULD GO DOWN FURTHER. THEN IT WOULD WORK PROPERLY FOR A FEW MONTHS W/O ACTING UP AND THEN START ALL OVER AGAIN. THIS WENT ON FOR ABOUT A YEAR. WHEN I FINALLY HAD IT REPLACED IT COMPLETELY STOPPED WORKING THE NEEDLE REGISTERED 110 MPH AND WAS NOT COMING BACK DOWN. I HAD TO WAIT 2 WEEKS BEFORE THE DEALERSHIP WAS ABLE TO REPLACE THE INSTRUMENT PANEL B/C THE HAD TO ORDER THE PART THEY WERE COMPLETELY OUT OF STOCK. THEY TOLD ME THEY'VE HAD TO REPLACE THE IP IN ALOT OF VEHICLES LATELY. *TR
NHTSA ODI #10261802
51,000 miles · Mar 7, 2009
Fuel System, Gasoline
BOUGHT 2003 CAVALIER 7-26-2003, BRAND NEW. STALLED WHILE DRIVING 3-31-04 - SMELLED BURNING/CHEMICAL SMELL- CAR RESTARTED - TOOK TO DEALER - DEALER FOUND NO PROBLEM. TO DEALER 3 TIMES TO FIX DETECTIVE EXTERIOR LIGHTING 2004/2005. SEVERAL ADDITIONAL ENGINE STALLS 2004-2009 - CAR RESTARTED. ON 3-6-09 STALLED WHILE DRIVING - WOUL…
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BOUGHT 2003 CAVALIER 7-26-2003, BRAND NEW. STALLED WHILE DRIVING 3-31-04 - SMELLED BURNING/CHEMICAL SMELL- CAR RESTARTED - TOOK TO DEALER - DEALER FOUND NO PROBLEM. TO DEALER 3 TIMES TO FIX DETECTIVE EXTERIOR LIGHTING 2004/2005. SEVERAL ADDITIONAL ENGINE STALLS 2004-2009 - CAR RESTARTED. ON 3-6-09 STALLED WHILE DRIVING - WOULDN'T START - TOWED TO DEALER- DEALER SAID FUEL PUMP WENT BAD - WILL REPAIR AT MY EXPENSE - OVER $1,000. DEALER ASKED IF I HAVE EXTENDED WARRANTY - I DON'T. WHEN THE CAR STALLS OUT I HAVE NO BRAKES, NO POWER STEERING - IT IS TERRIFYING AND VERY UNSAFE. AND IF THE CAR IS REPAIRED IS IT GOING TO BE ANY SAFER? WILL THE SAME PROBLEM KEEP RECURRING AS IT DID WITH THE LIGHTING SIGNALS? I AM A SAFE DRIVER, I AM THE ONLY DRIVER OF THIS CAR, THE CAR HAS ONLY 51,000 MILES ON IT, I ONLY DRIVE 10 MILES TO AND FROM WORK, IT IS GARAGE KEPT. I HAVE OWNED SEVERAL CARS AND HAVE KEPT THEM ALL FOR MANY YEARS AND I HAVE NEVER HAD A MAJOR REPAIR SUCH AS THIS OCCUR ON SUCH A YOUNG CAR. THIS PROBLEM HAS BEEN APPARENT SINCE I BOUGHT THE CAR BUT THE DEALER HAS IGNORED AND NEGLECTED IT AT THE EXPENSE OF ME AND MY FAMILY'S HEALTH. I HAVE CHILDREN AND GRANDCHILDREN THAT ARE DRIVEN IN THIS VEHICLE AND COULD BE VICTIMS OF THIS DEFECT. FOR THE PUBLIC SAFETY IN THE U.S. PLEASE REQUEST A RECALL OF THIS COMPONENT (FUEL PUMP). THIS IS A SERIOUS MATTER AND SHOULD BE REMEDIATED AS SOON AS POSSIBLE. PLEASE HELP BEFORE A DEADLY ACCIDENT OCCURS. *TR
NHTSA ODI #10261053
97,000 miles · Mar 5, 2009
Fuel System, Other
FUEL PUMP WENT OUT LIKE 99.9% OF ALL THE OTHER CAVALIERS GM HAS MADE. *TR
NHTSA ODI #10260765
40,000 miles · Mar 3, 2009
Fuel System, Gasoline
MY FUEL PUMP WENT OUT ON MY 2003 CHEVY CAVALIER WITH 40,000 MILES ON IT. I'VE NOTICED ON TOPIX COMMENT BOARDS THIS HAS HAPPENED TO A LOT OF PEOPLE WITH THE 03 CAVALIER. THERE REALLY NEEDS TO BE A RECALL FROM GM, THIS IS NOT SAFE. *TR
NHTSA ODI #10260626
86,000 miles · Feb 26, 2009
Fuel System, Gasoline
I AM HAVING TO REPLACE MY FUEL PUMP ON MY 2003 CHEVY CAVALIER FOR THE 2ND TIME, THE FIRST TIME IT WAS STILL UNDER WARRANTY. NOTHING LEAD UP TO THIS, TURNED OFF THE CAR TO GO INTO THE STORE, CAME OUT CAR WOULD START, NO GETTING ANY GAS. *TR
NHTSA ODI #10260022
8,000 miles · Feb 26, 2009
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT EXPERIENCES ISSUES WHEN ATTEMPTING TO RESTART THE ENGINE. THE INSTRUMENT PANEL GAUGES ILLUMINATE, BUT THE ENGINE DOES NOT START. HE DOES NOT SMELL GASOLINE, BUT BELIEVES THE FUEL PUMP COULD BE THE CAUSE OF THE FAILURE. THE FAILURE OCCURRED THREE MONTHS AFTER THE VEHI…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT EXPERIENCES ISSUES WHEN ATTEMPTING TO RESTART THE ENGINE. THE INSTRUMENT PANEL GAUGES ILLUMINATE, BUT THE ENGINE DOES NOT START. HE DOES NOT SMELL GASOLINE, BUT BELIEVES THE FUEL PUMP COULD BE THE CAUSE OF THE FAILURE. THE FAILURE OCCURRED THREE MONTHS AFTER THE VEHICLE WAS PURCHASED. THE FUEL PUMP WAS REPLACED UNDER WARRANTY; HOWEVER, THE FAILURE HAS RECURRED. THE VEHICLE IS CURRENTLY AT A GAS STATION AND UNABLE TO BE STARTED. THE VEHICLE HAS NOT BEEN DIAGNOSED A SECOND TIME SINCE THE FIRST REPAIR. THE CONTACT FOUND SEVERAL COMPLAINTS ONLINE FOR THE SAME ISSUE AND BELIEVES A RECALL SHOULD BE ISSUED. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 8,000 AND CURRENT MILEAGE WAS 72,000.
NHTSA ODI #10259995
92,000 miles · Feb 17, 2009
Electrical SystemFuel System, Gasoline
PURCHASED A 2003 CHEVY CAVALIER IN SEPT. 2008 FOR MY DAUGHTER TO GO TO COLLEGE. HAD A CARFAX REPORT DONE AND FOUND NOTHING, CLEAN REPORT. 2 DAYS AFTER PURCHASE, INST. CLUSTER WENT BAD, NOT WORKING AT ALL. DEC. 08 THE FUEL PUMP WENT BAD. AFTER RESEARCHING THE INTERNET, I HAVE FOUND THOUSANDS OF THE SAME COMPLAINTS AS MINE. I HAVE…
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PURCHASED A 2003 CHEVY CAVALIER IN SEPT. 2008 FOR MY DAUGHTER TO GO TO COLLEGE. HAD A CARFAX REPORT DONE AND FOUND NOTHING, CLEAN REPORT. 2 DAYS AFTER PURCHASE, INST. CLUSTER WENT BAD, NOT WORKING AT ALL. DEC. 08 THE FUEL PUMP WENT BAD. AFTER RESEARCHING THE INTERNET, I HAVE FOUND THOUSANDS OF THE SAME COMPLAINTS AS MINE. I HAVE EVEN FOUND WEBSITES ADVERTISING TO REBUILD THE CLUSTER AS SO MANY ARE DEFECTIVE. NOW IF THIS ISN'T ENOUGH TO SEE THE MAJOR PROBLEM, I DON'T KNOW WHAT IS. I FEEL THAT ENOUGH INFORMATION IS OUT ON THE INTERNET TO WARRANT A RECALL ON BOTH ISSUES BEFORE THE PUBLIC HAS TO SPEND ALL THEIR MONEY TO FIX GM'S FAULTY PARTS THAT BREAK DOWN SO QUICKLY. JUST THESE 2 REPAIRS COST $500.00 EACH. *TR
NHTSA ODI #10258897
55,000 miles · Feb 16, 2009
Electrical System
SPEEDOMETER FAILS TO READ CORRECT SPEED. HAS NOT READ CORRECT SPEED SINCE CAR REACHED 55,000 MILES ON ODOMETER. OCCASIONALLY SPEEDOMETER WILL RESET ITSELF, BUT AFTER 10-15 MINUTES DRIVING, WILL CLIMB ON ITS OWN AND STICK ABOVE 110 MPH. DEALER STATES IS GM MANUFACTURE ISSUE, BUT WILL NOT RECALL / REPAIR. *TR
NHTSA ODI #10258883
66,000 miles · Feb 15, 2009
Fuel System, Gasoline
MY CAR HAS BEEN RUNNING FINER AND THEN AL OF A SUDDEN IN THE MIDDLE OF RUSH HOUR TRAFFIC IT DIES. NO WARNING. NOTHING. THE FUEL PUMP HAS GONE OUT AND WILL COST $600+ TO REPLACE. THERE HAVE BEEN MANY MANY COMPLAINTS ABOUT THIS VERY ISSUE AND IT HAPPENS AT APPROX THE SAME MILEAGE OF THE CAR. BETWEEN 60000 AND 70000 MILES. THIS NEE…
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MY CAR HAS BEEN RUNNING FINER AND THEN AL OF A SUDDEN IN THE MIDDLE OF RUSH HOUR TRAFFIC IT DIES. NO WARNING. NOTHING. THE FUEL PUMP HAS GONE OUT AND WILL COST $600+ TO REPLACE. THERE HAVE BEEN MANY MANY COMPLAINTS ABOUT THIS VERY ISSUE AND IT HAPPENS AT APPROX THE SAME MILEAGE OF THE CAR. BETWEEN 60000 AND 70000 MILES. THIS NEEDS TO BE ADDRESSED! *TR
NHTSA ODI #10258724
86,000 miles · Feb 14, 2009
Fuel System, Gasoline
2003 CAVALIER- 86,000 MILES. FUEL PUMP FAILURE. USUALLY DO MY OWN MECHANICAL WORK BUT OPTED TO LET A SHOP WORK ON THIS ONE. TOTAL COST 800.00. SHOP STATED THAT THIS IS A VERY COMMON PROBLEM. *TR
NHTSA ODI #10258683
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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