IllustrationFUEL PUMP WENT OUT ON MY 2003 CHEVY CAVALIER UNDER 40000 MILES. I HEAR THIS I S PRETTY COMMON WITH THIS MODEL SO I WOULD LIKE A RECALL OPENED ON IT. *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 reportsMY 2003 CHEVROLET CAVALIER STARTED TO STALL ON THE I-5 FREEWAY IN SAN DIEGO CALIFORNIA. I MANAGED TO COAST TO AN EXIT RAMP WHERE MY CAR COMPLETELY STALLED AT THE BOTTOM OF THE RAMP IN THE MIDDLE OF A LANE. I HAD TO CALL AND HAVE MY CAR TOWED TO THE DEALERSHIP. IT WAS THE DEALERSHIP THAT DETERMINED THE FUEL PUMP WAS FAULTY AND…
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MY 2003 CHEVROLET CAVALIER STARTED TO STALL ON THE I-5 FREEWAY IN SAN DIEGO CALIFORNIA. I MANAGED TO COAST TO AN EXIT RAMP WHERE MY CAR COMPLETELY STALLED AT THE BOTTOM OF THE RAMP IN THE MIDDLE OF A LANE. I HAD TO CALL AND HAVE MY CAR TOWED TO THE DEALERSHIP. IT WAS THE DEALERSHIP THAT DETERMINED THE FUEL PUMP WAS FAULTY AND NEEDED TO BE REPLACED. IT WAS REPLACED AND HAS BEEN FINE SINCE. THIS REPAIR COST ME APPROXIMATELY $800. *TR
MY FUEL PUMP WENT OUT ON MY 2003 CHEVY CAVALIER. MY VEHICLE HAS 61,000 MILES AND AS I WAS DRIVING UP A HILL IT DIED. WHEN I GOT IT TOWED TO A SHOP THEY INFORMED ME THAT IT WAS MY FUEL PUMP AND THAT IT IS A COMMON PROBLEM WITH THIS VEHICLE. NEEDLESS TO SAY I PAID THE $748.00 TO REPLACE THE PUMP AND THEN WAS INFORMED THAT THE W…
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MY FUEL PUMP WENT OUT ON MY 2003 CHEVY CAVALIER. MY VEHICLE HAS 61,000 MILES AND AS I WAS DRIVING UP A HILL IT DIED. WHEN I GOT IT TOWED TO A SHOP THEY INFORMED ME THAT IT WAS MY FUEL PUMP AND THAT IT IS A COMMON PROBLEM WITH THIS VEHICLE. NEEDLESS TO SAY I PAID THE $748.00 TO REPLACE THE PUMP AND THEN WAS INFORMED THAT THE WIRE THAT CONTROLS THE FUEL PUMP HAD TO BE REPLACED AS WELL BECAUSE IT HAD FUSED TO THE FRAME. *TR
I HAVE A 2003 CHEVY CAVALIER. WHILE DRIVING THE CAR LOSES POWER AND WON'T START FOR A WHILE. I CHANGED THE GAS FILTER NEAR THE AXLE AND ADDED FUEL ADDITIVE IN CASE THERE WAS WATER IN THE FUEL IT WAS FINE FOR TWO WEEKS AND THEN THE SAME THING HAPPENED TO MY WIFE ON THE INTERSTATE. I HAVE BEEN READING ON THE INTERNET AND PEOPLE AR…
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I HAVE A 2003 CHEVY CAVALIER. WHILE DRIVING THE CAR LOSES POWER AND WON'T START FOR A WHILE. I CHANGED THE GAS FILTER NEAR THE AXLE AND ADDED FUEL ADDITIVE IN CASE THERE WAS WATER IN THE FUEL IT WAS FINE FOR TWO WEEKS AND THEN THE SAME THING HAPPENED TO MY WIFE ON THE INTERSTATE. I HAVE BEEN READING ON THE INTERNET AND PEOPLE ARE SAYING IT IS A FUEL PUMP PROBLEM AND COST AROUND 6 TO 7 HUNDRED BUCKS TO FIX THERE NEEDS TO BE A RECALL. *TR
I WAS DRIVING MY CAR DOWN A BUSY STREET. WHEN I SLOWED DOWN TO STOP AT A RED LIGHT, MY CAR STALLED OUT ON ME. FORTUNATELY, I WAS ABLE TO RESTART IT, BUT WITHIN LESS THAN 30 SECONDS, IT STALLED OUT AGAIN. I WAS FORTUNATE ENOUGH TO BE ABLE TO PULL INTO A PARKING LOT AND OUT OF THE WAY OF OTHER CARS. HOWEVER, AT THAT POINT, THE…
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I WAS DRIVING MY CAR DOWN A BUSY STREET. WHEN I SLOWED DOWN TO STOP AT A RED LIGHT, MY CAR STALLED OUT ON ME. FORTUNATELY, I WAS ABLE TO RESTART IT, BUT WITHIN LESS THAN 30 SECONDS, IT STALLED OUT AGAIN. I WAS FORTUNATE ENOUGH TO BE ABLE TO PULL INTO A PARKING LOT AND OUT OF THE WAY OF OTHER CARS. HOWEVER, AT THAT POINT, THE CAR WOULD NOT START UP AGAIN. I HAD TO HAVE THE CAR TOWED AND THE FUEL AND AIR FILTER REPLACED. BEYOND THAT, I WAS TOLD THE FUEL GAUGE DID NOT READ CORRECTLY. THE CAR RAN FINE AFTER THAT, BUT A COUPLE OF WEEKS LATER THE CAR STALLED OUT AGAIN. I'VE BEEN TOLD I NEED A NEW FUEL PUMP. AMAZING...THE CAR IS ONLY 5 YEARS OLD! *TR
2003 CHEVY CAVALIER SUDDENLY LOSS POWER ON MAJOR STREET. MY DAUGHTER WAS DRIVING AND TODDLER GRANDSON WAS RIDING IN HIS CAR SEAT IN THE BACK SEAT. THANKFULLY NO ONE WAS BEHIND HER TO REAR END HER AND SHE WAS NEAR THE POLICE STATION SO A POLICE OFFICER ASSISTED HER OFF OF THE ROAD. THE FUEL PUMP WAS REPLACED THE FOLLOWING DAY A…
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2003 CHEVY CAVALIER SUDDENLY LOSS POWER ON MAJOR STREET. MY DAUGHTER WAS DRIVING AND TODDLER GRANDSON WAS RIDING IN HIS CAR SEAT IN THE BACK SEAT. THANKFULLY NO ONE WAS BEHIND HER TO REAR END HER AND SHE WAS NEAR THE POLICE STATION SO A POLICE OFFICER ASSISTED HER OFF OF THE ROAD. THE FUEL PUMP WAS REPLACED THE FOLLOWING DAY AT THE COST OF $557.00. THE VEHICLE ONLY HAS 40K MILES. I'VE NEVER REPLACED A FUEL PUMP ON ANY CAR THAT I'VE EVER OWNED EVEN THOSE THAT I KEPT LONG ENOUGH TO HAVE 4 TIMES THAT NUMBER OF MILES. AFTER RESEARCHING AND FINDING THAT TOO MANY OWNERS OF THIS MAKE, MODEL AND YEAR HAVE HAD THIS PROBLEM FOR IT TO BE INCIDENTAL I AM FILING THIS COMPLAINT AS WELL. *TR
PURCHASED 2003 CHEVY. CAVALIER USED AND THE DEFROSTER AND FLOOR HEATING VENTS DO NOT WORK. AIR ONLY COMES THROUGH THE FACE VENTS. MAKES IT DIFFICULT IN COLD TEMPS. TO SEE THROUGH THE WINDOW AND IF THE CAR IS NOT COMPLETELY HEATED INSIDE, I WILL SOMETIMES HAVE TO PULL OVER AND SCRAPE THE INSIDE OF MY WINDOWS SO I CAN SEE OUT. *…
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PURCHASED 2003 CHEVY. CAVALIER USED AND THE DEFROSTER AND FLOOR HEATING VENTS DO NOT WORK. AIR ONLY COMES THROUGH THE FACE VENTS. MAKES IT DIFFICULT IN COLD TEMPS. TO SEE THROUGH THE WINDOW AND IF THE CAR IS NOT COMPLETELY HEATED INSIDE, I WILL SOMETIMES HAVE TO PULL OVER AND SCRAPE THE INSIDE OF MY WINDOWS SO I CAN SEE OUT. *TR
THE FIRST INCIDENT OCCURRED WHILE I WAS AT HIGHWAY SPEED USING CRUISE CONTROL. THE ENGINE BEGAN TO LOPE BADLY, THE CAR LOST VELOCITY AND SLOWED, THEN REVVED BACK UP AND CONTINUED ON. THE NEXT TIME I HAD AN ISSUE, THE CAR WOULD NOT START. THE STARTER WOULD CLICK, BUT THERE WAS AN IGNITION ISSUE. RELIABLE CHEVROLET (DALLAS) RE…
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THE FIRST INCIDENT OCCURRED WHILE I WAS AT HIGHWAY SPEED USING CRUISE CONTROL. THE ENGINE BEGAN TO LOPE BADLY, THE CAR LOST VELOCITY AND SLOWED, THEN REVVED BACK UP AND CONTINUED ON. THE NEXT TIME I HAD AN ISSUE, THE CAR WOULD NOT START. THE STARTER WOULD CLICK, BUT THERE WAS AN IGNITION ISSUE. RELIABLE CHEVROLET (DALLAS) REPORTED THAT THE FUEL PUMP HAD FAILED. THEY REPLACED IT FOR $900 INCLUDING LIFETIME WARRANTY ON THE PART, THEN THE NEXT WEEK AN IGNITION SENSOR FAILED. THIS WAS REPLACED FREE-OF-CHARGE FOR MISSING IT ON THE DIAGNOSTIC. *TR
I OWN A 2003 CHEVY CAVALIER. LATELY WHEN I WOULD BE SLOWING DOWN OR STOPPING THE CAR FELT LIKE IT WAS GOING TO STALL. @ DAYS AGO IT FELT THE SAME WHILE I WAS DRIVING. IT FELT LIKE THE CAR WOULDN'T ACCELERATE WHEN I PUSHED ON THE GAS. THEN IT DIED WHILE I WAS DRIVING SO I IMMEDIATELY PULLED INTO A PARKING LOT OFF THE ROAD. THE CA…
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I OWN A 2003 CHEVY CAVALIER. LATELY WHEN I WOULD BE SLOWING DOWN OR STOPPING THE CAR FELT LIKE IT WAS GOING TO STALL. @ DAYS AGO IT FELT THE SAME WHILE I WAS DRIVING. IT FELT LIKE THE CAR WOULDN'T ACCELERATE WHEN I PUSHED ON THE GAS. THEN IT DIED WHILE I WAS DRIVING SO I IMMEDIATELY PULLED INTO A PARKING LOT OFF THE ROAD. THE CAR WANTED TO START BUT WOULD NOT STAY RUNNING. I HAD IT TOWED TO MY HOUSE. THE CAR DOCTOR CAME TO MY HOUSE AND SAID IT IS THE FUEL PUMP AND NEEDS TO BE REPLACED. COST WAS $760.00. *TR
FUEL PUMP WENT OUT ON MY WIFE'S CAR WHILE DRIVING DOWN THE ROAD WAS ABLE TO GET IT PUSHED OFF TO THE SIDE WITHOUT INCIDENT DUE TO LOW TRAFFIC AT THE TIME. *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.