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
101,000 miles · Feb 11, 2008
Fuel System, Gasoline
FOR THE PAST YEAR MY VEHICLE HAS STALLED IN TRAFFIC WHILE RUNNING GOING TO 0 RPM BUT RESTARTING. THE I FOUND IS EFFECTING ALL 2003 CAVILIERS , IT WAS MY FUEL PUMP. I AM AT A ROCK AND A HARD PLACE BECAUSE I HAD TO GET FIXED AND COULD NOT SHOP AROUND. I HAD TO SPEND OVER 600.00 AND I COULD NOT AFFIORD TO EVERYTHING THAT RECOMENDE…
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FOR THE PAST YEAR MY VEHICLE HAS STALLED IN TRAFFIC WHILE RUNNING GOING TO 0 RPM BUT RESTARTING. THE I FOUND IS EFFECTING ALL 2003 CAVILIERS , IT WAS MY FUEL PUMP. I AM AT A ROCK AND A HARD PLACE BECAUSE I HAD TO GET FIXED AND COULD NOT SHOP AROUND. I HAD TO SPEND OVER 600.00 AND I COULD NOT AFFIORD TO EVERYTHING THAT RECOMENDED DONE . THE CAR IS NOT EVEN PAID OFF, IF THERE IS A PROBLEM THE CARS SHOULD HAVE THERECALL. I WAS ON INTERSTATE 95 WHERE SPEED LIMIT IS 70 MILES PER HOUR IT IS A MIRACLE THAT I WAS NOT KILLED BY A TRUCK THIS IS A TRUCKING ROUTE IN FLORIDA. PLEASE LOOK INTO THIS IT IS SO DANGEROUS AND IT IS HAPPENING WITH ALL CAVALIERS. *TR
NHTSA ODI #10217647
56,937 miles · Feb 10, 2008
Fuel System, Gasoline
I BOUGHT A 2003 CHEVY CAVALIER A FEW MONTHS AGO. IT HAS 56,000 MILES ON IT AND THE FUEL PUMP WENT OUT ON IT. AT FIRST I DIDN'T THINK IT WAS A BIG PROBLEM WITH THE CAVALIERS SO I GOOGLED IT AND IT TURNS OUT THERE WERE ALMOST 400 COMPLAINTS FROM PEOPLE WHO HAVE HAD THERE FUEL PUMPS GO OUT ON THEIR 2003 CAVALIERS AT LOW MILEAGE, AN…
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I BOUGHT A 2003 CHEVY CAVALIER A FEW MONTHS AGO. IT HAS 56,000 MILES ON IT AND THE FUEL PUMP WENT OUT ON IT. AT FIRST I DIDN'T THINK IT WAS A BIG PROBLEM WITH THE CAVALIERS SO I GOOGLED IT AND IT TURNS OUT THERE WERE ALMOST 400 COMPLAINTS FROM PEOPLE WHO HAVE HAD THERE FUEL PUMPS GO OUT ON THEIR 2003 CAVALIERS AT LOW MILEAGE, AND THOSE ARE JUST THE ONES ON GOOGLE. IM SURE THERE ARE MANY MORE! AS FAR AS I KNOW THERE AREN'T ANY RECALLS FOR THIS PROBLEM, BUT WITH AS MANY CASES AS THERE ARE THAN IT WOULD BE A DEFECT AND THERE SHOULD BE A RECALL. THE AVERAGE PRICE TO REPAIR THE FUEL PUMP IS AROUND $700 AND I REALLY CANT AFFORD THAT MUCH. ANY KIND OF HELP YOU COULD GIVE ME WOULD BE GREATLY APPRECIATED. THANKS *TR
NHTSA ODI #10217583
45,000 miles · Feb 8, 2008
Fuel System, Gasoline
MY CHEVY CAVALIER 2003 JUST STOPPED ON ME WITHOUT ANY NOTICE. GOT TO GO TO WORK AND CAR WOULD NOT START. IT HAS 45, 000 MILES AND ONLY USE IT FOR WORK COMMUTE WHICH IS 1 MILE ROUND TRIP. I HAVE HAD OIL CHANGES REGULARLY. WHEN MECHANIC LOOKED AT IT--HE SAID NOT ANOTHER ONE! COME TO FIND OUT THAT FUEL INJECTION/PUMP FAILURE FOR…
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MY CHEVY CAVALIER 2003 JUST STOPPED ON ME WITHOUT ANY NOTICE. GOT TO GO TO WORK AND CAR WOULD NOT START. IT HAS 45, 000 MILES AND ONLY USE IT FOR WORK COMMUTE WHICH IS 1 MILE ROUND TRIP. I HAVE HAD OIL CHANGES REGULARLY. WHEN MECHANIC LOOKED AT IT--HE SAID NOT ANOTHER ONE! COME TO FIND OUT THAT FUEL INJECTION/PUMP FAILURE FOR THESE CARS IS NOTORIOUS. MY MECHANIC SAID THAT MY CAR WAS THE SEVENTH IN THE LAST 8 MONTH. SAME MO--NO INDICATION OF PROBLEMS AND SUDDENLY YOUR CAR JUST STOPS! REGARDLESS OF WEAR AND TEAR OR CAR MILEAGE. SO I GUESS I WAS LUCKY--I WAS NOT DRIVING IN TRAFFIC WHEN THIS OCCURRED. AND MECHANIC CUT ME A BREAK AT $700. THIS IS OUTRAGEOUS! AND YOU WONDER WHY THE GERMAN, JAPANESE CARS ARE OUT SELLING GOOD OLE USA. THIS WAS MY FIRST PURCHASE OF AMERICAN CAR, AND UNFORTUNATELY I WISH I HAD INSTEAD BOUGHT ANOTHER HONDA, OR MAZDA. *TR
NHTSA ODI #10217446
99,000 miles · Jan 30, 2008
Fuel System, Gasoline
I HAD TO REPLACE MY FUEL PUMP. WHEN I WAS LOOKING FOR INFORMATION ON THE TOPIC I FOUND THAT OVER 300 OTHERS, HAD THE SAME PROBLEM WHEN DEALING WITH THE SAME ISSUE AFTER OWNING THE CAR FOR SHORT PERIODS OF TIME. I FEEL THAT IF THIS IS HAPPENING WITH THIS MODEL 2003 IN PARTICULAR THAT CHEVY SHOULD LOOK INTO WHAT IS CAUSING THIS …
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I HAD TO REPLACE MY FUEL PUMP. WHEN I WAS LOOKING FOR INFORMATION ON THE TOPIC I FOUND THAT OVER 300 OTHERS, HAD THE SAME PROBLEM WHEN DEALING WITH THE SAME ISSUE AFTER OWNING THE CAR FOR SHORT PERIODS OF TIME. I FEEL THAT IF THIS IS HAPPENING WITH THIS MODEL 2003 IN PARTICULAR THAT CHEVY SHOULD LOOK INTO WHAT IS CAUSING THIS FAILURE. *TR
NHTSA ODI #10216543
Mileage unknown · Jan 28, 2008
Electrical System
I HAVE REPLACED THE IGNITION CONTROL MODULE 4 TIMES IN THIS CAR. IT FAILS SUCH THAT THE ENGINE IN ONLY RUNNING ON 2 CYLINDERS. TESTING HAS SHOWN THE COIL PACKS ARE OK AND THE PROBLEM IS WITH THE ICM COMPUTER. *TR
NHTSA ODI #10216331
64,026 miles · Jan 28, 2008
Fuel System, Other
I OWN A 2003 CHEVROLET CAVALIER, AND EARLIER THIS MORNING, THE VEHICLE FAILED TO CRANK AFTER I WAS ABLE TO ROLL IT INTO A PARKING SPOT. AFTER SOME TROUBLE SHOOTING, I WAS ABLE TO NARROW IT DOWN TO THE FUEL PUMP WAS NOT COMING ON WHEN THE IGINITION WAS TURNED ON. I CAUGHT A RIDE BACK TO MY HOUSE AND BEGAN DOING A LITTLE RESEARCH …
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I OWN A 2003 CHEVROLET CAVALIER, AND EARLIER THIS MORNING, THE VEHICLE FAILED TO CRANK AFTER I WAS ABLE TO ROLL IT INTO A PARKING SPOT. AFTER SOME TROUBLE SHOOTING, I WAS ABLE TO NARROW IT DOWN TO THE FUEL PUMP WAS NOT COMING ON WHEN THE IGINITION WAS TURNED ON. I CAUGHT A RIDE BACK TO MY HOUSE AND BEGAN DOING A LITTLE RESEARCH AND NOTICED THIS WAS A COMMON TRAIT FOR THE 2003 CHEVROLET CAVALIER. THAT IS FUEL PUMP FAILURE AROUND 60,000+ MILES. MY CAVALIER HAS JUST A LITTLE OVER 64,000 MILES ON IT. MY CAR'S FAILURE WAS PERFECTLY DESCRIBED IN THE MANY FORUMS I READ OVER. THAT'S WHEN I DECIDED TO CHECK FOR ANY OTHER RECALLS ON THIS YEAR CAR. I NOTICED THAT THE NHTSA #PE07033 AND THE ENGINEERING ANALYSIS #EA07-015 PERTAINED DIRECTLY TO MY PERSONAL EXPERIENCE WITH THIS PROBLEM. *CN
NHTSA ODI #10216267
40,500 miles · Jan 25, 2008
Fuel System, Gasoline
NO START/NON-START SITUATION VEHICLE TOWED TO DEALER FUEL PUMP FAILURE DIAGNOSED. VEHICLE FIXED NEXT DAY AT COST TO OWNER. *TR
NHTSA ODI #10216051
Mileage unknown · Jan 24, 2008
Fuel System, Gasoline
CAR COMPLETELY SHUT DOWN WHILE DRIVING. NEED TO REPLACE THE FUEL PUMP. *TR
NHTSA ODI #10215866
84,000 miles · Jan 18, 2008
Fuel System, Gasoline
2003 CHEVROLET CAVALIER UNEXPECTED FUEL PUMP FAILURE AT 84,000 MILES. TURNED IGNITION OFF CAR AFTER DRIVING 50 MILES, TRIED TO IMMEDIATELY RESTART. FUEL PUMP WOULD NOT RUN, CAR WOULD NOT RESTART. *TR
NHTSA ODI #10215357
65,000 miles · Jan 17, 2008
Fuel System, Gasoline
2003 CAVALIER HAS ONLY 65,000 MILES ON IT WITH NO OTHER MAJOR ISSUES HAVING OCCURRED IN THE PAST. THE FUEL PUMP SUDDENLY WENT OUT ACCORDING TO MY MECHANIC AFTER IT STALLED WHILE TRYING IT. *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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