NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
678 reports36,000 miles · Jan 16, 2009
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 75 MPH, THE VEHICLE STALLED AND THE ENGINE SHUT OFF WITHOUT WARNING. THE VEHICLE WAS TOWED TO A REPAIR SHOP AND THE MECHANIC STATED THAT THE FUEL PUMP FAILED. THE MANUFACTURER STATED THAT NOTHING COULD BE DONE BECAUSE THERE WAS NO RECALL OR WARRANTY. THE VEHICLE HA…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 75 MPH, THE VEHICLE STALLED AND THE ENGINE SHUT OFF WITHOUT WARNING. THE VEHICLE WAS TOWED TO A REPAIR SHOP AND THE MECHANIC STATED THAT THE FUEL PUMP FAILED. THE MANUFACTURER STATED THAT NOTHING COULD BE DONE BECAUSE THERE WAS NO RECALL OR WARRANTY. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 36,000.
NHTSA ODI #10255366
Mileage unknown · Jan 15, 2009
Equipment
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STARTED THE VEHICLE AND ACTIVATED THE AIR CONDITIONING CONTROL SWITCH, WHICH OPERATED ONLY ON THE HIGH TEMPERATURE MODE SELECTOR. THERE WERE NO WARNING INDICATORS ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION AND THE…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STARTED THE VEHICLE AND ACTIVATED THE AIR CONDITIONING CONTROL SWITCH, WHICH OPERATED ONLY ON THE HIGH TEMPERATURE MODE SELECTOR. THERE WERE NO WARNING INDICATORS ILLUMINATED ON THE INSTRUMENT PANEL. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION AND THEY REPLACED A COMPONENT IN THE BLOWER UNIT. OVER A PERIOD OF TIME, THE HEATER AND AIR CONDITIONING SYSTEM FAILED TO OPERATE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER ON TWO SEPARATE OCCASIONS FOR IDENTICAL FAILURES, IN WHICH THE BLOWER UNIT WAS REPLACED. THE VEHICLE IS CURRENTLY BEING REPAIRED AGAIN. THE FAILURE MILEAGE WAS UNKNOWN AND THE CURRENT MILEAGE WAS 25,600.
NHTSA ODI #10255152
65,400 miles · Jan 13, 2009
Fuel System, Other
I OWN A 2003 CHEVROLET CAVALIER WITH 65000 MILES AND THE FUEL PUMP JUST FAILED LEAVING ME STRANDED ON THE SIDE OF THE ROAD. THERE WAS NO WARNING AND NO INDICATION THAT A PROBLEM WAS COMING, THE CAR JUST STOPPED. NOW I AM TOLD THAT I MUST PAY $1000 TO HAVE A NEW FUEL PUMP INSTALLED. THE NEW PART IS THE SAME AS THE OLD OEM PART…
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I OWN A 2003 CHEVROLET CAVALIER WITH 65000 MILES AND THE FUEL PUMP JUST FAILED LEAVING ME STRANDED ON THE SIDE OF THE ROAD. THERE WAS NO WARNING AND NO INDICATION THAT A PROBLEM WAS COMING, THE CAR JUST STOPPED. NOW I AM TOLD THAT I MUST PAY $1000 TO HAVE A NEW FUEL PUMP INSTALLED. THE NEW PART IS THE SAME AS THE OLD OEM PART. I HAVE BEEN READING THAT 2003 CAVALIER'S HAVE BEEN HAVING THE SAME PROBLEM FOR YEARS AND THAT CHEVROLET HAS HAD NO RECALL FOR AN OBVIOUSLY DEFECTIVE PART FORM THE FACTORY. THIS IS RIDICULOUS! I FEEL THAT SOME SORT OF COMPENSATION SHOULD BE MADE TO THE HUNDREDS OF GM CUSTOMERS THAT HAVE HAD THIS KIND OF PROBLEM. THIS IS NOT A PART OF THE GM BAILOUT! THIS IS A PROBLEM THAT MUST BE RESOLVED AT THE MANUFACTURER LEVEL.... *TR
NHTSA ODI #10254863
67,000 miles · Jan 7, 2009
Fuel System, GasolineVisibility
I HAVE A 2003 CAVALIER AND HAD THE FUEL PUMP GO BAD AT 67,000 MILES. I RESEARCHED ON THE WEB AND IT SEEMS THAT THERE IS A TREMENDOUS AMOUNT OF 2003 CAVALIERS THAT HAVE HAD THIS SAME ISSUE. I HAVE REPLACED 3 OF THE 4 WINDOW MOTORS IN THE PAST 18 MONTHS. I HAVE TWICE HAD MY CLIMATE CONTROL SWITCH FIXED, AS IT WAS STUCK ONLY ON …
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I HAVE A 2003 CAVALIER AND HAD THE FUEL PUMP GO BAD AT 67,000 MILES. I RESEARCHED ON THE WEB AND IT SEEMS THAT THERE IS A TREMENDOUS AMOUNT OF 2003 CAVALIERS THAT HAVE HAD THIS SAME ISSUE. I HAVE REPLACED 3 OF THE 4 WINDOW MOTORS IN THE PAST 18 MONTHS. I HAVE TWICE HAD MY CLIMATE CONTROL SWITCH FIXED, AS IT WAS STUCK ONLY ON VENT. AND MOST RECENTLY AT 69000 MILES I HAVE TO REPLACE MY FUEL PRESSURE REGULATOR. IN MY EDUCATED OPINION, THIS SEEMS TO BE AN AWFUL LOT OF REPAIRS FOR A VEHICLE OF THIS AGE AND WITH THIS RECORD. *TR
NHTSA ODI #10254145
65,000 miles · Jan 2, 2009
Fuel System, Gasoline
I HAVE A 2003 CAVALIER OF WHICH I HAD TO HAVE THE FUEL PUMP REPLACED ABOUT A YEAR AND A HALF AGO. NOW LOOKING ON THE INTERNET I SEE THAT THIS HAPPENS A LOT. I WANTED TO KNOW IF POSSIBLY THERE IS A RECALL COMING OR ANYTHING OF THAT NATURE. MY CAR HAD BETWEEN 60 K AND 70K MILES AT THE TIME. *TR
NHTSA ODI #10253566
35,000 miles · Jan 1, 2009
Fuel System, Gasoline
MANUAL TRANSMISSION MODEL - PROBLEM BEGAN @ 35,000 MILES, CURRENT MILES 38,000. ENGINE ROUGH IDLES/STALLS WHEN CLUTCH IS ENGAGED. I WAS NEARLY STRUCK BY ONCOMING TRAFFIC WHILE TURNING LEFT WHEN ENGINE STALLED AFTER CLUTCH WAS ENGAGED. LOST POWER STEERING AND BREAKS, WOUND UP RIDING OVER CURB AND ONTO SIDEWALK BEFORE VEHICLE S…
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MANUAL TRANSMISSION MODEL - PROBLEM BEGAN @ 35,000 MILES, CURRENT MILES 38,000. ENGINE ROUGH IDLES/STALLS WHEN CLUTCH IS ENGAGED. I WAS NEARLY STRUCK BY ONCOMING TRAFFIC WHILE TURNING LEFT WHEN ENGINE STALLED AFTER CLUTCH WAS ENGAGED. LOST POWER STEERING AND BREAKS, WOUND UP RIDING OVER CURB AND ONTO SIDEWALK BEFORE VEHICLE STOPPED. NOONE WAS INJURED, HOWEVER THIS WAS ON A COLLEGE CAMPUS IN THE EVENING, HAD IT OCCURRED EARLIER IN THE DAY ALMOST CERTAIN PEDESTRIAN WOULD HAVE BEEN STRUCK BY MY OUT OF CONTROL CAR. WILL BE REPLACING THE PUMP AS SOON AS I CAN. THIS IS A SERIOUS DANGER TO THE DRIVER AND OTHER DRIVERS ON THE ROAD. *TR
NHTSA ODI #10253422
Mileage unknown · Dec 31, 2008
Fuel System, Gasoline
FUEL PUMP NEEDS REPLACED ON 2003 CAVALIER. *TR
NHTSA ODI #10253410
745,000 miles · Dec 28, 2008
Engine And Engine Cooling
I PURCHASED MY 2003 CAVALIER BRAND NEW WITH 106 MILES ON IT (IT HAD TO BE DRIVEN FROM PITTSBURGH TO HARRISBURG). IN LATE SEPT. OR EARLY OCT. MY CAR BEGAN RATTLING AT STOP LIGHTS. THE DAY AFTER THE RATTLING STARTED, MY CAR STALLED AT MY PLACE OF BUSINESS AND WOULDN'T START AGAIN. A TRIPLE A MECHANIC WAS CALLED AND COULDN'T DETERM…
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I PURCHASED MY 2003 CAVALIER BRAND NEW WITH 106 MILES ON IT (IT HAD TO BE DRIVEN FROM PITTSBURGH TO HARRISBURG). IN LATE SEPT. OR EARLY OCT. MY CAR BEGAN RATTLING AT STOP LIGHTS. THE DAY AFTER THE RATTLING STARTED, MY CAR STALLED AT MY PLACE OF BUSINESS AND WOULDN'T START AGAIN. A TRIPLE A MECHANIC WAS CALLED AND COULDN'T DETERMINE WHAT THE PROBLEM WAS EXCEPT HE THOUGHT IT WAS THE FUEL PUMP. AFTER HAVING THE VEHICLE TOWED TO A GARAGE, I WAS TOLD THAT OIL WAS NOT MAKING ITS WAY THROUGH MY ENGINE CAUSING FRICTION AND IN TURN CAUSING MY ENGINE TO EXPAND BREAKING MY TIMING CHAIN AND BASICALLY RENDERING THE ENTIRE ENGINE USELESS. THE MECHANIC ASKED ME IF MY CHECK ENGINE LIGHT OR OIL LIGHT WAS LIT ON MY DASHBOARD BECAUSE WITH A PROBLEM WITH THE OIL PUMP, ONE OF THOSE LIGHTS WOULD HAVE LIT UP, WHICH I RESPONDED NO. HE THEN THOUGHT THAT THE DASHBOARD LIGHTS WERE NOT FUNCTIONING WHICH WAS NOT TRUE BECAUSE WHEN HE TURNED THE KEY, ALL THE DASHBOARD LIGHTS LIT UP. HE THEN WENT ON TO TELL ME THAT MY OIL LEVELS WERE NORMAL AND THAT MY TIMING CHAIN SHOULD LAST FOR 25+ YEARS. THE MECHANIC WENT ON TO EXPLAIN THAT I SHOULD CONTACT CHEVROLET BECAUSE HE BELIEVE THAT WITH THE LOW MILEAGE OF MY VEHICLE AND THE RELATIVE NEW-NESS OF THE VEHICLE, THE ONLY CAUSE FOR THIS ISSUE WOULD BE A DEFECT. I CONTACTED CHEVROLET VIA EMAIL AND WAS TOLD THAT I WOULD RECEIVE A RESPONSE IN NO MORE THAN 48 HOURS. AFTER HEARING NO RESPONSE, I FILED A COMPLAINT WITH THE BBB AND STILL HAVE NOT HEARD ANYTHING. *TR
NHTSA ODI #10252996
89,000 miles · Dec 25, 2008
Electrical SystemFuel System, Gasoline
I WAS CHECKING TO SEE IF THERE WAS A RECALL ON A 2003 CHEVY CAVALIER FUEL PUMP BECAUSE I WAS TRAVELING ON THE HIGHWAY AND THE FUEL PUMP WENT OUT COSTING ME ALMOST $800. ALSO THE MOTOR FOR TWO OF MY POWER WINDOWS HAVE WENT OUT. *TR
NHTSA ODI #10252786
33,168 miles · Dec 22, 2008
Fuel System, Gasoline
FUEL PUMP ON 2003 CHEVY CAVALIER WITH ONLY 33,000 MILES HAS GONE OUT. APPROX $700 TO REPLACE. WAY TO COMMON OF A PROBLEM FOR GM NOT TO ADDRESS WITH A RECALL. *TR
NHTSA ODI #10252582
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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