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
65,000 miles · Dec 22, 2008
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. ONCE THE CONTACT STOPPED THE VEHICLE AND EXITED, THE ENGINE FAILED TO RESTART FIVE MINUTES LATER. THE ELECTRICAL SYSTEM (LIGHTS AND RADIO) STILL WORKED, BUT THE ENGINE WOULD NOT START. THE VEHICLE WAS TOWED TO A DEALER AND THEY STATED THAT THE FUEL PUMP FAILED AND NEEDED TO BE RE…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. ONCE THE CONTACT STOPPED THE VEHICLE AND EXITED, THE ENGINE FAILED TO RESTART FIVE MINUTES LATER. THE ELECTRICAL SYSTEM (LIGHTS AND RADIO) STILL WORKED, BUT THE ENGINE WOULD NOT START. THE VEHICLE WAS TOWED TO A DEALER AND THEY STATED THAT THE FUEL PUMP FAILED AND NEEDED TO BE REPLACED. THE CONTACT FOUND INVESTIGATION NUMBER EA07015 ONLINE, BUT THE INVESTIGATION WAS CLOSED WITH NO RECALL ISSUED. HE BELIEVES THAT IT SHOULD BE RECALLED. THE VEHICLE HAS BEEN REPAIRED. THE FAILURE MILEAGE WAS 65,000 AND CURRENT MILEAGE WAS 125,000.
NHTSA ODI #10252498
97,000 miles · Dec 19, 2008
Fuel System, Gasoline
2003 CHEVROLET CAVALIER, WOULD NOT START, THEN HARD START BUT GAS PEDAL NOT RESPONSIVE. PRELIMINARY RESEARCH LIKELY FUEL PUMP MALFUNCTION. *TR
NHTSA ODI #10252265
54,000 miles · Dec 19, 2008
Fuel System, Gasoline
I HAVE A 2003 CHEVY CAVALIER WITH 55,540 MILES AND MY FUEL INDICATOR HAS RECENTLY STARTED TO STAY ON FULL AND THEN 2 DAYS LATER IT STARTS TO COME DOWN AND THEN GOES BACK UP TO FUEL AND DOWN AGAIN. MY MECHANIC SAYS THAT IT IS THE FUEL PUMP AND I WENT ONLINE AND FOUND MANY COMPLAINTS THAT OTHER PEOPLE HAD TO GET A NEW FUEL PUMP TH…
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I HAVE A 2003 CHEVY CAVALIER WITH 55,540 MILES AND MY FUEL INDICATOR HAS RECENTLY STARTED TO STAY ON FULL AND THEN 2 DAYS LATER IT STARTS TO COME DOWN AND THEN GOES BACK UP TO FUEL AND DOWN AGAIN. MY MECHANIC SAYS THAT IT IS THE FUEL PUMP AND I WENT ONLINE AND FOUND MANY COMPLAINTS THAT OTHER PEOPLE HAD TO GET A NEW FUEL PUMP THAT COSTS FORM $600 AND UP AND SOME OF THE CAVALIERS HAD LESS THAN 50, 000 MILES AND 2 WERE BOUGHT BRAND NEW. WITH ALL OF THESE COMPLAINTS SHOULDN'T THERE HAD BEEN A RECALL AND HAVE CHEVROLET REPLACE THE FUEL PUMP AT NO COST TO THE OWNER? *TR
NHTSA ODI #10252262
95,000 miles · Dec 18, 2008
Fuel System, Gasoline
I WAS SITTING IN MY CAR WAITING FOR MY FRIEND TO GET IN. AFTER HE DID I PUT MY CAR IN REVERSE AND THE ENGINE STALLED. IT THEN WOULD NOT START AGAIN. COME TO FIND OUT MY FUEL PUMP WENT OUT. *TR
NHTSA ODI #10252252
22,000 miles · Dec 18, 2008
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 70MPH WITH HIS CRUISE CONTROL ON, THE VEHICLE SHUT OFF AND LOST POWER. THERE WERE NO WARNING LIGHTS PRIOR TO THE VEHICLE SHUTTING OFF. THE WEATHER WAS NOT A FACTOR. THE CONTACT WAS ABLE TO DRIVE THE VEHICLE TO THE EMERGENCY LANE. THE VEHICLE WAS TOWED TO AN INDEPENDENT…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 70MPH WITH HIS CRUISE CONTROL ON, THE VEHICLE SHUT OFF AND LOST POWER. THERE WERE NO WARNING LIGHTS PRIOR TO THE VEHICLE SHUTTING OFF. THE WEATHER WAS NOT A FACTOR. THE CONTACT WAS ABLE TO DRIVE THE VEHICLE TO THE EMERGENCY LANE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO STATED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE FAILURE MILEAGE WAS 22,000.
NHTSA ODI #10252171
51,000 miles · Dec 17, 2008
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE IDLING IN TRAFFIC, THE MOTOR STOPPED FUNCTIONING. THE VEHICLE WAS TOWED TO AN AUTO REPAIR SHOP AND THE MECHANIC STATED THAT THE FUEL PUMP BURNED OUT AND CAUSED THE FAILURE. THE MANUFACTURER STATED THAT THEY COULD NOT ASSIST BECAUSE THE VEHICLE WAS OUT OF WARRANTY AND WAS NO…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE IDLING IN TRAFFIC, THE MOTOR STOPPED FUNCTIONING. THE VEHICLE WAS TOWED TO AN AUTO REPAIR SHOP AND THE MECHANIC STATED THAT THE FUEL PUMP BURNED OUT AND CAUSED THE FAILURE. THE MANUFACTURER STATED THAT THEY COULD NOT ASSIST BECAUSE THE VEHICLE WAS OUT OF WARRANTY AND WAS NOT TAKEN TO A DEALER. THE CORPORATE OFFICE ADVISED HIM TO TAKE THE DEFECTIVE PART TO A DEALER. IF THE DEALER CONFIRMED THAT THE PART WAS DEFECTIVE, THE CONTACT COULD PROVE THAT THE REPLACEMENT PART WAS A MANUFACTURER'S DEFECT AND POSSIBLY RECEIVE REIMBURSEMENT. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 51,000.
NHTSA ODI #10252076
110,000 miles · Dec 16, 2008
Fuel System, Gasoline
FUEL PUMP FAILS AND CAR WILL NOT START. HAVE PUT 4 FUEL PUMPS IN CAR SO FAR. EACH TIME CAR WORKS FOR UP TO A YEAR AND THEN PUMP DIES. *TR
NHTSA ODI #10251990
75,000 miles · Dec 14, 2008
Electrical System
MY SPEEDOMETER STOPPED WORKING PROPERLY. THE NEEDLE DOES NOT RETURN TO ZERO AT STOP OR WHEN THE CAR IS TURNED OFF. IT REGISTERS IN EXCESS OF 110 MPH WHEN THE CAR IS IN MOTION. THIS SEEMS TO BE A VERY COMMON PROBLEM WITH ALL GM CARS AND TRUCKS MADE BETWEEN 2002 AND 2005. GM OFFERS FREE REPAIR FOR TRUCKS AND SUV'S, BUT NOT ALL…
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MY SPEEDOMETER STOPPED WORKING PROPERLY. THE NEEDLE DOES NOT RETURN TO ZERO AT STOP OR WHEN THE CAR IS TURNED OFF. IT REGISTERS IN EXCESS OF 110 MPH WHEN THE CAR IS IN MOTION. THIS SEEMS TO BE A VERY COMMON PROBLEM WITH ALL GM CARS AND TRUCKS MADE BETWEEN 2002 AND 2005. GM OFFERS FREE REPAIR FOR TRUCKS AND SUV'S, BUT NOT ALL DEALERSHIPS KNOW OF THE DIRECTIVE SINCE IT HAS NOT BEEN PUBLICIZED. ALL CAR BUYERS MUST PAY FOR THE FIX - WHICH EXCEEDS $500 - BECAUSE GM WON'T ACKNOWLEDGE THE PROBLEM EXISTS IN THE CARS. *TR
NHTSA ODI #10251713
70,000 miles · Dec 6, 2008
Fuel System, Gasoline
FUEL PUMP WENT ON MY 2003 CAVALIER.MY CAR WON'T RUN HAD TO FIX AND COST ME 300.00 AS I AM OUT OF WORK THIS IS AN EXPENSE I COULD NOT AFFORD BUT HAD TO PAY AS I HAVE TO BE ABLE TO GET AROUND TO LOOK FOR WORK.I AM A LAID OFF AUTO WORKER.LOOKS LIKE I AM EATING PEANUT BUTTER AND TOAST THIS MONTH. *TR
NHTSA ODI #10250944
47,735 miles · Dec 5, 2008
Fuel System, Gasoline
I OWN A 2003 CHEVY CAVALIER WITH 47,700 MILES ON THE CAR, IN MID SEPTEMBER DRIVING HOME FROM WORK MY CAR DIED AND HAVING A MECHANIC LOOK AT MY CAR SAID THAT IT WAS THE FUEL PUMP THAT FAILED, I HAD NO PROBLEMS WITH THE CAR UP TO THIS POINT, HE SAID THAT IT WAS STRANGE THAT THE PUMP WENT OUT WITH THE LOW MILES ON MY CAR. I WAS ON …
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I OWN A 2003 CHEVY CAVALIER WITH 47,700 MILES ON THE CAR, IN MID SEPTEMBER DRIVING HOME FROM WORK MY CAR DIED AND HAVING A MECHANIC LOOK AT MY CAR SAID THAT IT WAS THE FUEL PUMP THAT FAILED, I HAD NO PROBLEMS WITH THE CAR UP TO THIS POINT, HE SAID THAT IT WAS STRANGE THAT THE PUMP WENT OUT WITH THE LOW MILES ON MY CAR. I WAS ON THE INTERNET LOOKING INTO THE CAVALIER PROBLEMS WITH THE FUEL PUMP AND THERE WAS A LOT OF COMPLAINTS ABOUT THE FUEL PUMP IN THIS MODEL AND YEAR OF CAR. I HAD THE FUEL PUMP REPLACED NOVEMBER 26 2008 AT A COST OF $605.88, I DO NOT HAVE THE REPLACED PARTS, I SAW ON THE WEB SITE ABOUT A INVESTIGATION INTO A RECALL, I ALSO PLAN TO FILE A COMPLAINT WITH GM. PLEASE CONTACT ME VIA E-MAIL WITH ANY QUESTIONS. *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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