IllustrationI HAVE TO IDENTICAL 2003 CHEVY CAVALIERS AND THE WINDOW MOTORS BOTH FAILED AROUND THE EXACT SAME TIME AND I HAVE BEEN TO NUMEROUS SITES THAT HAVE ALSO REPORTED THIS FAILURE AND CHEVY SAYS THAT THIS ISNT THEIR PROBLEM. *TR
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
What owners actually said
678 reportsI HAVE HAD A 2003 CHEVROLET CAVALIER AND THE FUEL PUMP KEEPS GOING BAD COSTING ME A PRETTY PENNY EVERY TIME IT GOES. AFTER DOING SOME RESEARCH ONLINE IT APPEARS THAT THERE ARE MANY PEOPLE WITH BAD FUEL PUMPS FOR CHEVROLET CAVALIERS. JUST REPORTING THE PROBLEM TO ADD MY NAME TO THE LIST OF UNHAPPY 2003 CHEVROLET CAVALIER OWNER…
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I HAVE HAD A 2003 CHEVROLET CAVALIER AND THE FUEL PUMP KEEPS GOING BAD COSTING ME A PRETTY PENNY EVERY TIME IT GOES. AFTER DOING SOME RESEARCH ONLINE IT APPEARS THAT THERE ARE MANY PEOPLE WITH BAD FUEL PUMPS FOR CHEVROLET CAVALIERS. JUST REPORTING THE PROBLEM TO ADD MY NAME TO THE LIST OF UNHAPPY 2003 CHEVROLET CAVALIER OWNERS. THE INCIDENT THAT I LIST BELOW IS THE LATEST DATE THE FUEL PUMP WENT BAD, TODAY AS A MATTER OF FACT. THE LAST TIME IT WENT BAD WAS LESS THAN A MONTH AGO. *TR
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE SPEEDOMETER DISPLAYS 60 MPH WHEN HE IS TRAVELING AT MUCH LOWER SPEEDS. THE SPEEDOMETER ALSO BECOMES STUCK AT A LOWER SPEED WHEN HE IS DRIVING AT A MUCH FASTER RATE. THE RPM'S IN THE VEHICLE WILL EITHER NOT MOVE AT ALL OR GO UP AS FAR AS POSSIBLE WHILE …
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE SPEEDOMETER DISPLAYS 60 MPH WHEN HE IS TRAVELING AT MUCH LOWER SPEEDS. THE SPEEDOMETER ALSO BECOMES STUCK AT A LOWER SPEED WHEN HE IS DRIVING AT A MUCH FASTER RATE. THE RPM'S IN THE VEHICLE WILL EITHER NOT MOVE AT ALL OR GO UP AS FAR AS POSSIBLE WHILE DRIVING IN FIRST GEAR ONLY. THE RPM'S WILL THEN BECOME STUCK AND NOT MOVE BACK DOWN. THE VEHICLE HAS NOT BEEN INSPECTED BY THE DEALER. HE MUST RESTART THE VEHICLE IN ORDER FOR THE SPEEDOMETER DIAL TO RETURN TO ITS REGULAR POSITION. THE DIAL DOES NOT MOVE AT ALL IN COLD WEATHER CONDITIONS. THE CONTACT HAS GOTTEN PULLED OVER WHILE DRIVING 20 MPH (85 MPH) OVER THE SPEED LIMIT WHEN HE THOUGHT HE WAS TRAVELING 65 MPH. HE BELIEVES THAT THE FAILURE COULD HAVE BEEN A MANUFACTURER DEFECT. THE FAILURE MILEAGE WAS 50,000 AND CURRENT MILEAGE WAS 86,000. UPDATED 03-06-09 *BF THE SPEEDOMETER WOULD STICK AT 50 MPH. THE CONSUMER STATED WHEN HE INCREASED OR DECREASED HIS SPEED THE SPEEDOMETER WOULD STILL REGISTER AT 50 MPH. UPDATED 03/11/09. *JB
FUEL PUMP DIED WITH NO WARNING ON DANGEROUS HIGHWAY. HAD TO GET A TOW AND REPAIR AT A SHOP NOT FAMILIAR WITH TOTAL BILL INCLUDING TOWING AND REPAIR 1,200 SOME VEHICLE FORUMS HAVE UPWARDS OF 500 INDIVIDUALS WITH SAME PROBLEM DEFINITE SAFETY HAZARD AND WARRANTS A RECALL. *TR
2003 CHEVY CAVALIER SHUT OFF ON ME WHILE DRIVING DOWN STEEP HILL. NO POWER STEERING AND BRAKES, LUCKILY MADE IT TO SAFE SPACE AT BOTTOM OF HILL. CAR WOULD NOT RESTART. NOW IN GARAGE. DIAGNOSED WITH BAD FUEL PUMP. IT WILL COST $600.00 TO FIX WHEN PART COMES IN. THIS IS RIDICULOUS, CAR HAS ONLY 56,000 MILES ON IT! THIS IS A SEVERE…
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2003 CHEVY CAVALIER SHUT OFF ON ME WHILE DRIVING DOWN STEEP HILL. NO POWER STEERING AND BRAKES, LUCKILY MADE IT TO SAFE SPACE AT BOTTOM OF HILL. CAR WOULD NOT RESTART. NOW IN GARAGE. DIAGNOSED WITH BAD FUEL PUMP. IT WILL COST $600.00 TO FIX WHEN PART COMES IN. THIS IS RIDICULOUS, CAR HAS ONLY 56,000 MILES ON IT! THIS IS A SEVERE SAFETY HAZARD. I SEARCHED ON-LINE AND IT IS A COMMON COMPLAINT WITH THIS VEHICLE. SOMETHING MUST BE DONE BEFORE A FATALITY OCCURS, IF IT HAS NOT ALREADY! *TR
I HAVE 165,000KM ON MY 2003 CHEVROLET CAVALIER. IT IS CONSTANTLY STALLING, MOSTLY AT STOP LIGHTS AND WHEN I SLOW DOWN, HOWEVER TODAY IT STALLED ON THE HIGHWAY. THE MECHANICS THINK IT MIGHT BE THE FUEL PUMP BUT IT IS HARD TO TELL FOR SURE WHAT IT IS AND I DON'T WANT TO SPEND ALL THIS MONEY IF IT IS NOT THAT. I HAVE HEARD FROM MAN…
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I HAVE 165,000KM ON MY 2003 CHEVROLET CAVALIER. IT IS CONSTANTLY STALLING, MOSTLY AT STOP LIGHTS AND WHEN I SLOW DOWN, HOWEVER TODAY IT STALLED ON THE HIGHWAY. THE MECHANICS THINK IT MIGHT BE THE FUEL PUMP BUT IT IS HARD TO TELL FOR SURE WHAT IT IS AND I DON'T WANT TO SPEND ALL THIS MONEY IF IT IS NOT THAT. I HAVE HEARD FROM MANY PEOPLE THIS IS A COMMON ISSUE WITH THIS CAR. I FEEL QUITE UNSAFE DRIVING SINCE IT COULD STALL OR SHUT DOWN AT ANY POINT. A CAR SHOULD NOT STALL WHILE DRIVING OR AT STOP LIGHTS. PLEASE RECALL THIS PART!! *TR
THE GAUGES IN THESE CARS GO CRAZY I DIDN'T SPEND MONEY TO FIX IT INSTEAD I WENT ONLINE AND FOUND A TON F PEOPLE THIS HAPPENED TO THE GAUGE CLUSTER IN THE CARS GO HAYWIRE AND YOU CAN NOT TELL. SOME GO IN THE SPEEDOMETER MINE WENT IN THE TEMP GAUGE AND THE FUEL GAUGE NOW PEOPLE HAVE BEEN TO MECHANICS AND THEY CAN NOT FIND WHAT IS …
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THE GAUGES IN THESE CARS GO CRAZY I DIDN'T SPEND MONEY TO FIX IT INSTEAD I WENT ONLINE AND FOUND A TON F PEOPLE THIS HAPPENED TO THE GAUGE CLUSTER IN THE CARS GO HAYWIRE AND YOU CAN NOT TELL. SOME GO IN THE SPEEDOMETER MINE WENT IN THE TEMP GAUGE AND THE FUEL GAUGE NOW PEOPLE HAVE BEEN TO MECHANICS AND THEY CAN NOT FIND WHAT IS WRONG WITH THEM MINE FIRST WENT ABOUT 4 MONTHS AGO AND THE ONLY WAY FOR ME TO RESET MY GAUGES IS TO PULL THE FUSE OUT AND RESET IT OTHERWISE IT WILL NOT RESET BACK TO E OR 0 AND THE THERMO GAUGE HAS GONE INTO MY SPEEDO NEEDLE SO THEN I CAN NOT TELL HOW FAST I AM GOING AT FIRST I THOUGHT IT WAS JUST ME AND NO BIG DEAL BUT THEN I WENT ONLINE AND FOUND SO MANY PEOPLE WIT THIS PROBLEM WHY SHOULD WE HAVE TO FIX SOMETHING THAT GM OBVIOUSLY DIDN'T GET RIGHT I DON'T THINK ITS RIGHT AT ALL ESPECIALLY BECAUSE ITS WITH ALOT OF PEOPLE NOW THE GAUGES GO CRAZY ALL THE TIME NOT JUST WHEN IT RAINS OR ITS COLD BUT CONSTANTLY I AM PULLING THE FUSES OUT. *TR
I WAS DRIVING BACK FROM WORK TO THE PLACE I WAS STAYING AT THE TIME AND WHEN I WAS ABOUT 5 MILES AWAY, MY CAR (2003 CHEVY CAVALIER) DIED IN THE MIDDLE OF ME DRIVING. I WAS LUCKILY ABLE TO PULL OVER TO THE SIDE OF THE ROAD IN TIME JUST BEFORE IT COMPLETELY CONKED OUT. THIS WAS THE FIRST OCCURRENCE. THE CHEVY WAS TOWED TO THE N…
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I WAS DRIVING BACK FROM WORK TO THE PLACE I WAS STAYING AT THE TIME AND WHEN I WAS ABOUT 5 MILES AWAY, MY CAR (2003 CHEVY CAVALIER) DIED IN THE MIDDLE OF ME DRIVING. I WAS LUCKILY ABLE TO PULL OVER TO THE SIDE OF THE ROAD IN TIME JUST BEFORE IT COMPLETELY CONKED OUT. THIS WAS THE FIRST OCCURRENCE. THE CHEVY WAS TOWED TO THE NEAREST SHOP WHERE I DIDN'T FIND OUT UNTIL THE NEXT MORNING THAT IT WAS THE FUEL PUMP THAT HAD DIED. THE REPAIR HAD COST $775.06. *TR
I HAVE WENT THROUGH OVER 10 BULBS IN MY BACK TAIL-LIGHT ON THE DRIVER SIDE. EVERY TIME I GO OUT AND ABOUT IT BLOWS AND WHEN I PULL THE BULB OUT THE PLASTIC IS ALWAYS MELTED OVER THE CONTACT WIRES. RECENTLY I WAS ON MY WAY TO MY GIRLFRIEND'S FAMILY'S CHRISTMAS EVENT AND I GOT PULLED OVER FOR MY TAIL LIGHT BEING OUT, WHICH HAD BEE…
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I HAVE WENT THROUGH OVER 10 BULBS IN MY BACK TAIL-LIGHT ON THE DRIVER SIDE. EVERY TIME I GO OUT AND ABOUT IT BLOWS AND WHEN I PULL THE BULB OUT THE PLASTIC IS ALWAYS MELTED OVER THE CONTACT WIRES. RECENTLY I WAS ON MY WAY TO MY GIRLFRIEND'S FAMILY'S CHRISTMAS EVENT AND I GOT PULLED OVER FOR MY TAIL LIGHT BEING OUT, WHICH HAD BEEN REPLACED A FEW DAYS BEFORE. I SHOWED THE POLICE AND HE ONLY GAVE ME A WARNING, ALTHOUGH I AM GETTING SICK OF THIS HAPPENING. I WENT INTO AN ADVANCE AUTO PARTS STORE TO JUST GO AHEAD AND REPLACE THE ENTIRE SOCKET, BUT WHEN THEY CALLED A CHEVROLET DEALERSHIP ALL THEY RECOMMENDED THAT I DO IS REPLACE THE BULB, AGAIN. I REPLACED THE BULB AND WHAT DO YOU KNOW IT BLEW WITHIN 3 DAYS. I AM STILL CURRENTLY IN THE PROCESS OF TRYING TO FIGURE OUT HOW TO FIX THIS INCONVENIENT PROBLEM BEFORE I JUST SELL MY CAR TO GET A BETTER ONE. *TR
MY WIFE WAS DRIVING WITH OUR TWO BOYS TO THE LIBRARY WHEN THE CAR JUST STOPPED AS SHE WAS GOING INTO A BUSY INTERSECTION. SHE CALLED ME AT WORK IN A PANIC. LUCKILY, ANOTHER DRIVER CALMED HER DOWN AND HELPED PUSH THE CAR OFF TO THE SIDE OF THE ROAD. ISSUE WAS THAT THE FUEL PUMP WENT BAD. CAR ONLY HAS 47,000 MILES. COST OF RE…
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MY WIFE WAS DRIVING WITH OUR TWO BOYS TO THE LIBRARY WHEN THE CAR JUST STOPPED AS SHE WAS GOING INTO A BUSY INTERSECTION. SHE CALLED ME AT WORK IN A PANIC. LUCKILY, ANOTHER DRIVER CALMED HER DOWN AND HELPED PUSH THE CAR OFF TO THE SIDE OF THE ROAD. ISSUE WAS THAT THE FUEL PUMP WENT BAD. CAR ONLY HAS 47,000 MILES. COST OF REPAIR WAS $660 PLUS THE TOWING FROM THE INTERSECTION TO THE SHOP. *TR
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.