NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
678 reports72,000 miles · Oct 14, 2008
Fuel System, Gasoline
2003 CHEVY CAVALIER FUEL PUMP. WHILE DRIVING DOWN THE INTERSTATE THE VEHICLE WAS STARTING TO ACT AS IF IT WAS NOT GETTING ANY GAS. THERE WERE NO SIGNS OF A PROBLEM LEADING UP TO THE FUEL PUMP GOING OUT. ALL OF A SUDDEN THE VEHICLE JUST DIED AND I WAS LEFT ROLLING WHILE ATTEMPTING TO MERGE ON TO A LOCAL HIGHWAY. I FOUND OUT TH…
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2003 CHEVY CAVALIER FUEL PUMP. WHILE DRIVING DOWN THE INTERSTATE THE VEHICLE WAS STARTING TO ACT AS IF IT WAS NOT GETTING ANY GAS. THERE WERE NO SIGNS OF A PROBLEM LEADING UP TO THE FUEL PUMP GOING OUT. ALL OF A SUDDEN THE VEHICLE JUST DIED AND I WAS LEFT ROLLING WHILE ATTEMPTING TO MERGE ON TO A LOCAL HIGHWAY. I FOUND OUT THAT THIS PROBLEM COSTS WELL OVER 800.00 DOLLARS TO REPAIR. I THEN BEGAN TO RESEARCH AND NOTICED THAT AROUND 60,000 TO 70,000 MILES THAT THERE IS QUITE A LOT OF PEOPLE WITH THE SAME PROBLEM. I BELIEVE THAT THIS CAN BE DANGEROUS AND SHOULD BE INVESTIGATED. *TR
NHTSA ODI #10245362
110,200 miles · Oct 13, 2008
Engine And Engine CoolingFuel System, Gasoline
MY 2003 CHEVY CAVALIER HAS BEEN EXPERIENCING INTERMITTENT STARTUP ISSUES AND OCCASIONAL "CHUGGING" WHILE DRIVING - SEEMED LIKE THE CAR WOULD LURCH AHEAD AT TIMES, HAS ALSO BRIEFLY STALLED AT LIGHTS. ON 10/11/08, THE CAR WOULD BRIEFLY TURN OVER AND START FOR LESS THAN A MINUTE, SHUT OFF, AND AFTERWARDS REFUSED TO START. HAD CAR T…
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MY 2003 CHEVY CAVALIER HAS BEEN EXPERIENCING INTERMITTENT STARTUP ISSUES AND OCCASIONAL "CHUGGING" WHILE DRIVING - SEEMED LIKE THE CAR WOULD LURCH AHEAD AT TIMES, HAS ALSO BRIEFLY STALLED AT LIGHTS. ON 10/11/08, THE CAR WOULD BRIEFLY TURN OVER AND START FOR LESS THAN A MINUTE, SHUT OFF, AND AFTERWARDS REFUSED TO START. HAD CAR TOWED FROM MY RESIDENCE TO MECHANIC SHOP WHO ALERTED ME THAT FUEL PRESSURE WAS LOW. FUEL ELECTRONICS WERE FUNCTIONING AS PER COMPUTER CHECK, TURNED OUT TO BE A BAD FUEL PUMP. CAR IS AT ~110,300 MILES. HAD SPARK PLUGS, FUEL FILTER, ENGINE BELT REPLACED IN MARCH & APRIL OF 2008. *TR
NHTSA ODI #10245280
49,846 miles · Oct 11, 2008
Fuel System, Gasoline
I WAS DRIVING MY 2003 CAVALIER DOWN THE STREET AND WENT TO MAKE A RIGHT TURN INTO A GAS STATION MY CAR STOPPED. I GOT TWO MEN TO PUSH ME INTO THE STATION AND THEN TO THE GAS PUMP THINKING I RAN OUT OF GAS. GOT GAS CAR STILL WOULDN'T START. HAD CAR TOWED THIS HAPPENED 10-2-08 SOMEONE THE N LOOKED AT CAR 10-10-08. I WAS IT THE FU…
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I WAS DRIVING MY 2003 CAVALIER DOWN THE STREET AND WENT TO MAKE A RIGHT TURN INTO A GAS STATION MY CAR STOPPED. I GOT TWO MEN TO PUSH ME INTO THE STATION AND THEN TO THE GAS PUMP THINKING I RAN OUT OF GAS. GOT GAS CAR STILL WOULDN'T START. HAD CAR TOWED THIS HAPPENED 10-2-08 SOMEONE THE N LOOKED AT CAR 10-10-08. I WAS IT THE FUEL PUMP. *TR
NHTSA ODI #10245150
82,600 miles · Oct 9, 2008
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THERE WERE NO EVENTS LEADING UP TO THE FAILURE. HE STARTED THE VEHICLE AND IT IMMEDIATELY STALLED. THE VEHICLE WAS NOT TOWED TO A DEALER. AN INDEPENDENT MECHANIC DIAGNOSED THE FAILURE AND STATED THAT IT WAS DUE TO A FUEL PUMP DEFECT. THE MANUFACTURER AND…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT THERE WERE NO EVENTS LEADING UP TO THE FAILURE. HE STARTED THE VEHICLE AND IT IMMEDIATELY STALLED. THE VEHICLE WAS NOT TOWED TO A DEALER. AN INDEPENDENT MECHANIC DIAGNOSED THE FAILURE AND STATED THAT IT WAS DUE TO A FUEL PUMP DEFECT. THE MANUFACTURER AND THE DEALER WERE NOT NOTIFIED. THE CURRENT AND FAILURE MILEAGES WERE 82,600.
NHTSA ODI #10244998
46,000 miles · Oct 8, 2008
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT IS EXPERIENCING ISSUES WITH THE FUEL PUMP. THROUGH THE INTERNET, HE HAS FOUND MANY VEHICLES WITH THE IDENTICAL FAILURE. THE DEALER STATED THAT THEY WOULD REPAIR IT AT THE CONTACT'S EXPENSE. THEY FURTHER STATED THAT THERE WERE NO RECALLS AVAILABLE. THE VEHICLE WAS TO…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT IS EXPERIENCING ISSUES WITH THE FUEL PUMP. THROUGH THE INTERNET, HE HAS FOUND MANY VEHICLES WITH THE IDENTICAL FAILURE. THE DEALER STATED THAT THEY WOULD REPAIR IT AT THE CONTACT'S EXPENSE. THEY FURTHER STATED THAT THERE WERE NO RECALLS AVAILABLE. THE VEHICLE WAS TOWED TO A PRIVATE MECHANIC FOR DIAGNOSTIC TESTING. THE VIN WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 46,000.
NHTSA ODI #10244749
119,419 miles · Oct 8, 2008
Fuel System, Gasoline
2003 CHEVROLET CAVALIER, FAILED TO START. HAD TO REPLACE THE FUEL PUMP. YOU ARE CURRENTLY INVESTIGATING THIS TYPE OF INCIDENT FOR MY 2001- 2003 CAVALIERS. *TR
NHTSA ODI #10244700
84,000 miles · Oct 2, 2008
Fuel System, Gasoline
I WAS DRIVING ON THE INTERSTATE AT 70 MILES PER HOUR WHEN ALL OF THE SUDDEN I LOST ALL POWER--CALLED A TOW TRUCK AND THE DRIVER SAID IT WAS THE FUEL PUMP-STARTED LOOKING FOR INFO ON LINE ABOUT IT AND FOUND ABOUT 500 OR MORE COMPLAINTS-THE CAR IS STILL SITTING IN MY DRIVEWAY WAITING TO BE FIXED-A FRIEND LET ME USE HIS TRUCK UNTIL…
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I WAS DRIVING ON THE INTERSTATE AT 70 MILES PER HOUR WHEN ALL OF THE SUDDEN I LOST ALL POWER--CALLED A TOW TRUCK AND THE DRIVER SAID IT WAS THE FUEL PUMP-STARTED LOOKING FOR INFO ON LINE ABOUT IT AND FOUND ABOUT 500 OR MORE COMPLAINTS-THE CAR IS STILL SITTING IN MY DRIVEWAY WAITING TO BE FIXED-A FRIEND LET ME USE HIS TRUCK UNTIL I CAN SAVE ABOUT 700 DOLLARS *TR
NHTSA ODI #10244247
51,348 miles · Oct 2, 2008
Fuel System, Gasoline
RELATED TO NHTSA ACTION NUMBER EA07015 MY DAUGHTER WAS DRIVING HER 2003 CHEVY CAVALIER ON THE INTERSTATE HWY. 43 WHEN THE ENGINE STALLED. SHE WAS ABLE TO MAKE IT SAFELY TO THE SHOULDER OF THE ROAD. THE FUEL PUMP ASSEMBLY HAD TO BE REPLACED. *TR
NHTSA ODI #10244180
108,000 miles · Sep 26, 2008
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING APPROXIMATELY 30 MPH, THE VEHICLE STALLED AND SHUT OFF. THE CONTACT WAS UNABLE TO RESTART THE VEHICLE AND IT WAS TOWED TO A REPAIR SHOP. THE MECHANIC STATED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE IS CURRENTLY BEING REPAIRED. THE MANUFACTURER WAS NOT…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING APPROXIMATELY 30 MPH, THE VEHICLE STALLED AND SHUT OFF. THE CONTACT WAS UNABLE TO RESTART THE VEHICLE AND IT WAS TOWED TO A REPAIR SHOP. THE MECHANIC STATED THAT THE FUEL PUMP NEEDED TO BE REPLACED. THE VEHICLE IS CURRENTLY BEING REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE VIN WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 108,000.
NHTSA ODI #10243565
86,000 miles · Sep 26, 2008
EquipmentFuel System, Other
I WANT TO MAKE IT CLEAR I HAVE TAKEN OVER PAYMENTS OF THIS CAR AND WILL HAVE TITLE WHEN IT IS PAID OFF. THE CAR HAD BEEN RUNNING GREAT EXCEPT FOR THE A/C NO LONGER WORKS, AND I WAS DRIVING GETTING UP TO 40 MPH AND THE CAR JUST DIED, I COULDN'T GET IT TO RESTART IT ENDED UP BEING THE FUEL PUMP WENT OUT, IT WAS QUITE EXPENSIVE TO …
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I WANT TO MAKE IT CLEAR I HAVE TAKEN OVER PAYMENTS OF THIS CAR AND WILL HAVE TITLE WHEN IT IS PAID OFF. THE CAR HAD BEEN RUNNING GREAT EXCEPT FOR THE A/C NO LONGER WORKS, AND I WAS DRIVING GETTING UP TO 40 MPH AND THE CAR JUST DIED, I COULDN'T GET IT TO RESTART IT ENDED UP BEING THE FUEL PUMP WENT OUT, IT WAS QUITE EXPENSIVE TO FIX. *TR
NHTSA ODI #10243485
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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