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
31,242 miles · Jul 4, 2007
Fuel System, Gasoline
THERE WAS NO LEAD IN TO FUEL PUMP FAILURE. STOPPED AFTER WORK TO PURCHASE A GROCERY ITEM AND THEN RETURNED TO VEHICLE. AT THAT POINT THE CHEVY CAVALIER WOULD NOT START. AAA CAME AND TOWED VEHICLE TO REPAIR FACILITY. I WAS SHOCKED THAT A VEHICLE WITH LESS THEN 35,000 MILE WOULD HAVE A SUDDEN FAILURE OF THIS SORT WITHOUT ANY WAR…
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THERE WAS NO LEAD IN TO FUEL PUMP FAILURE. STOPPED AFTER WORK TO PURCHASE A GROCERY ITEM AND THEN RETURNED TO VEHICLE. AT THAT POINT THE CHEVY CAVALIER WOULD NOT START. AAA CAME AND TOWED VEHICLE TO REPAIR FACILITY. I WAS SHOCKED THAT A VEHICLE WITH LESS THEN 35,000 MILE WOULD HAVE A SUDDEN FAILURE OF THIS SORT WITHOUT ANY WARNING OR SYMPTOM. I FEEL FORTUNATE THAT I WAS NOT DRIVING AT THE TIME.
NHTSA ODI #10195316
64,999 miles · Jul 4, 2007
Fuel System, Gasoline
2003 CHEVY CAVALIER. FUEL PUMP FAILED WHILE TRAVELING ON INTERSTATE I-70. THEREFORE, CAR STALLED AND HAD TO SECURE A TOW TRUCK. CAR WAS TOWED TO THE NEAREST CHEVROLET DEALER, MOLLE CHEVRELOT IN BLUE SPRINGS, MISSOURI. REPAIRS WERE APPROXIMATELY $1,000 TO REPLACE FUEL PUMP WHICH IS LOCATED IN THE GAS TANK. I PAID FOR THE REPAI…
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2003 CHEVY CAVALIER. FUEL PUMP FAILED WHILE TRAVELING ON INTERSTATE I-70. THEREFORE, CAR STALLED AND HAD TO SECURE A TOW TRUCK. CAR WAS TOWED TO THE NEAREST CHEVROLET DEALER, MOLLE CHEVRELOT IN BLUE SPRINGS, MISSOURI. REPAIRS WERE APPROXIMATELY $1,000 TO REPLACE FUEL PUMP WHICH IS LOCATED IN THE GAS TANK. I PAID FOR THE REPAIRS AND FEEL THAT I SHOULD BE REIMBURSED FROM GENERAL MOTORS.
NHTSA ODI #10195303
Mileage unknown · Jul 1, 2007
Fuel System, Gasoline
I WAS DRIVING DOWN THE HIGHWAY WHEN MY 2003 CAVALIER BEGAN TO SLOW DOWN, I THOUGHT THIS WAS ODD BECAUSE I WAS STILL HOLDING DOWN THE ACCELERATOR. THE CAR SEEMED TO BE ABLE TO MAINTAIN A SPEED OF ABOUT 60MPH FOR ABOUT ANOTHER MILE WHEN THE CAR BEGAN TO SLOW AGAIN THEN THE CAR COULD NOT ACCELERATE OVER 40MPH AND IT EVENTUALLY DIE…
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I WAS DRIVING DOWN THE HIGHWAY WHEN MY 2003 CAVALIER BEGAN TO SLOW DOWN, I THOUGHT THIS WAS ODD BECAUSE I WAS STILL HOLDING DOWN THE ACCELERATOR. THE CAR SEEMED TO BE ABLE TO MAINTAIN A SPEED OF ABOUT 60MPH FOR ABOUT ANOTHER MILE WHEN THE CAR BEGAN TO SLOW AGAIN THEN THE CAR COULD NOT ACCELERATE OVER 40MPH AND IT EVENTUALLY DIED COMPLETELY IN THE MIDDLE OF THE HIGHWAY WITH CARS DOING 70MPH ZOOMING PAST ME. I FINALLY MADE IT TO THE SHOULDER OF THE HIGHWAY AND HAD THE CAR TOWED, AFTER PERFORMING TROUBLESHOOTING, I FOUND OUT IT IS THE FUEL PUMP THAT HAS GONE OUT AND NEEDS TO BE REPLACED. MY CAR ONLY HAS 57,000 MILES ON IT AND AT THE TIME I STILL HAD HALF OF A TANK FULL OF FUEL, I NEVER LET THE TANK GET BELOW HALF WAY SINCE I HAVE OWNED THE CAR. AFTER DOING SOME RESEARCH I CAME ACROSS HUNDREDS OF OTHER PEOPLE THAT HAVE THE SAME EXACT YEAR, MAKE AND MODEL AS MY CAR THAT ARE HAVING THE SAME PROBLEM AND IT SEEMS TO HAPPEN WHEN THE CAR GETS AROUND 55,000 - 68,000 MILES ON IT. THIS IS VERY UNSAFE ISSUE AND THERE NEEDS TO BE A RECALL. *TR
NHTSA ODI #10195080
56,000 miles · Jun 27, 2007
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING APPROXIMATELY 35-40 MPH, THE VEHICLE HESITATED AND ALL OF THE INSTRUMENT PANEL LIGHTS ILLUMINATED. SHORTLY AFTER, THE VEHICLE BEGAN OPERATING NORMALLY. ONE MINUTE LATER, THE FAILURE RECURRED AND ALL OF THE INSTRUMENT PANEL GAUGES ILLUMINATED AND BEGAN TO GO IN REVER…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING APPROXIMATELY 35-40 MPH, THE VEHICLE HESITATED AND ALL OF THE INSTRUMENT PANEL LIGHTS ILLUMINATED. SHORTLY AFTER, THE VEHICLE BEGAN OPERATING NORMALLY. ONE MINUTE LATER, THE FAILURE RECURRED AND ALL OF THE INSTRUMENT PANEL GAUGES ILLUMINATED AND BEGAN TO GO IN REVERSE. THE CONTACT PRESSED THE ACCELERATOR PEDAL, BUT NOTHING HAPPENED. SHE PULLED OVER AND ATTEMPTED TO RESTART THE VEHICLE TWICE. IT STARTED FOR A SECOND AND THEN SHUT OFF. THE VEHICLE FAILED TO START AFTER THE THIRD ATTEMPT. THE VEHICLE WAS TOWED TO HER RESIDENCE WHERE HER HUSBAND/MECHANIC STATED THAT THE FAILURE MAY BE CAUSED BY THE FUEL PUMP. THE CURRENT AND FAILURE MILEAGES WERE 56,000.
NHTSA ODI #10194743
64,000 miles · Jun 27, 2007
Fuel System, Gasoline
2003 CHEVY CAVALIER FUEL PUMP FAILED. FOUND OUT THAT THERE WERE SEVERAL PEOPLE WITH THIS PROBLEM AND THAT THERE IS AN INVESTIGATION GOING ON EITHER BY YOU OR THE NATIONAL TRANSPORTATION SAFETY BOARD. WOULD LIKE TO FILE A COMPLAINT TO BE LOOKED INTO BY SOMEONE OTHER THAN THE CHEVY COMPANY.
NHTSA ODI #10194722
63,500 miles · Jun 26, 2007
Fuel System, Gasoline
AFTER ONLY 63,000 I HAVE TO REPLACE THE FUEL PUMP IN THE 03 CAVALIER. I HAVE NOTICED UP TO 150 ENTRIES ON A SITE WHERE THIS IS THE SITUATION. GM HAS SOLD A PRODUCT TO ONLY RUN FOR 3 YEARS. I WENT OUT WITH OUT WARNING, I MISSED HALF A DAY OF WORK AND NOW HOW KNOWS HOW MANY HOURS TO REPAIR SINCE I CAN ONLY AFFORD THE PART NOT THE …
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AFTER ONLY 63,000 I HAVE TO REPLACE THE FUEL PUMP IN THE 03 CAVALIER. I HAVE NOTICED UP TO 150 ENTRIES ON A SITE WHERE THIS IS THE SITUATION. GM HAS SOLD A PRODUCT TO ONLY RUN FOR 3 YEARS. I WENT OUT WITH OUT WARNING, I MISSED HALF A DAY OF WORK AND NOW HOW KNOWS HOW MANY HOURS TO REPAIR SINCE I CAN ONLY AFFORD THE PART NOT THE HOURS AT A GARAGE. I WILL KEEP THE PART FOR INSPECTION IF YOU NEED IT. *AK
NHTSA ODI #10194715
78,400 miles · Jun 26, 2007
Fuel System, Other
FAILED FUEL PUMP ON A 2003 CHEVY CAVALIER. *AK
NHTSA ODI #10194242
Mileage unknown · Jun 25, 2007
Engine And Engine Cooling
CHECK ENIGINE LIGHTS AND ETC. *AK
NHTSA ODI #10194176
60,000 miles · Jun 22, 2007
Fuel System, Gasoline
1.ON JUNE 21 MY 2003 CHEVROLET CAVALIER STOPPED IN THE MIDDLE OF A STREET WITH NO WARNING. 2.THE FUEL PUMP HAD QUIT WORKING SO I HAD IT TOWED AND HAD TO REPLACE THE PUMP. 3. OLD PART IS AVAILABLE. MY CAR ONLY HAS 60,000 MILES ON IT. FROM LOOKING IN GOOGLE, THERE ARE HUNDREDS OF IDENTICAL COMPLAINTS FROM OWNER OF 2003 CAVALIERS…
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1.ON JUNE 21 MY 2003 CHEVROLET CAVALIER STOPPED IN THE MIDDLE OF A STREET WITH NO WARNING. 2.THE FUEL PUMP HAD QUIT WORKING SO I HAD IT TOWED AND HAD TO REPLACE THE PUMP. 3. OLD PART IS AVAILABLE. MY CAR ONLY HAS 60,000 MILES ON IT. FROM LOOKING IN GOOGLE, THERE ARE HUNDREDS OF IDENTICAL COMPLAINTS FROM OWNER OF 2003 CAVALIERS. *TR
NHTSA ODI #10194029
Mileage unknown · Jun 22, 2007
Fuel System, Gasoline
FUEL PUMP FAILED AND NEEDS TO BE REPLACED AFTER ONLY 70,000 MILES ON A 2003 MODEL VEHICLE. *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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