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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 →

When problems were reported

Mileage at the reported incident

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

Exterior Lighting complaints

57 reports
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Mileage unknown · Jun 23, 2004
Exterior Lighting

THIS LETTER WAS SENT TO THE CHEVROLET CORPORATION BUT I STILL HAVE NOT HAD SUFFICIENT HELP IN CORRECTING THE PROBLEM. I SEEM TO GET MORE EXCUSES AND PROPER PROCEDURES QUOTES; OPPOSED TO ADEQUATE HELP ON THIS DANGEROUS PROBLEM WITH MY BRAKE AND SIGNAL LIGHTS. THIS HAS BEEN ON GOING SINCE THE DATE OF PURCHASE. *AK VEHICLE …

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THIS LETTER WAS SENT TO THE CHEVROLET CORPORATION BUT I STILL HAVE NOT HAD SUFFICIENT HELP IN CORRECTING THE PROBLEM. I SEEM TO GET MORE EXCUSES AND PROPER PROCEDURES QUOTES; OPPOSED TO ADEQUATE HELP ON THIS DANGEROUS PROBLEM WITH MY BRAKE AND SIGNAL LIGHTS. THIS HAS BEEN ON GOING SINCE THE DATE OF PURCHASE. *AK VEHICLE : 2003 CAVALIER VIN :[XXX] MILEAGE : 24000 DEALER : FOXS SECURITY COMMENTS : I HAVE BEEN TRYING TO FIND A RESOLUTION TO THE ONGOING PROBLEM WITH MY VEHICLES TURN AND BREAK LIGHTS. I PURCHASED MY CAR BRAND NEW WITH ZERO MILEAGE. I HAVE BEEN BACK AND FOURTH TO THE DEALERSHIP TO HAVE MY LIGHTS REPAIRED FAITHFULLY EVERY OTHER MONTH. THIS PROBLEM IS SERIOUS BECAUSE IN MOST CASES; I DON'T REALIZE MY LIGHTS ARE OUT UNTIL IM ON THE BELTWAY TRAVELING 60 MILES AN HOUR OR MORE WHEN IT OCCURS TO ME MY SIGNALS ARE NOT WORKING OR ANOTHER DRIVER GESTURES MY LIGHTS ARE OUT AGAIN. THIS PROBLEM IS EXTREMELY DANGEROUS AND IM IN TOTAL DISTRESS BECAUSE THE DEALERSHIP CANT OR WONT RESOLVE THE PROBLEM. I HAVE BEEN GOING BACK AND FOURTH EVERY 3 TO 4 WEEKS FOR THE SAME PROBLEM. THE LIGHTS ON THE LEFT SIDE WILL GO OUT AND THE RIGHT SIDE WILL FOLLOW A WEEK LATER OR VICE VERSA. I DIDN'T PURCHASE A NEW VEHICLE TO CONSTANTLY USE HAND SIGNALS OR ENDANGER MY FAMILIES LIVES DAILY; THIS IS TOTALLY UNACCEPTABLE AND I WANT SOMEONE TO RESOLVE THIS PROBLEM IMMEDIATELY. *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ODI #10078665

6,000 miles · Jun 22, 2004
Exterior Lighting

THE LEFT AND RIGHT TURN SIGNALS/BRAKE LIGHTS IN CAR STOPPED WORKING. I TOOK THE CAR TO THE DEALERSHIP WHERE IT WAS REPAIRED. THEY TOLD ME THERE WAS A SHORT IN THE WIRING IN THE REAR OF THE CAR. THE RIGHT TURN SIGNAL/BRAKE LIGHT STOPPED WORKING AGAIN ABOUT 1 WEEK AFTER THE REPAIRS. *AK

NHTSA ODI #10078639

12,125 miles · Jun 15, 2004
Exterior Lighting

OWNER SAYS THAT THE VEHICLE IS EXPERIENCING ELECTRICAL PROBLEMS. THE HEADLIGHTS, TAIL LIGHTS, AND THE DIRECTIONAL SIGNALS ARE MALFUNCTIONING. OWNER TOOK THE VEHICLE TO THE DEALER WHO HAS REPLACED THE BRAKE AND HEADLIGHT BULBS ON FIVE OCCASSIONS. HOWEVER, THE PROBLEM STILL OCCURS. PROVIDE FURTHER DETAILS. *LA

NHTSA ODI #10079288

Mileage unknown · Jun 6, 2004
Exterior LightingCrash

I PURCHASED A 2003 CHEVROLET CAVALIER FROM FRED DIEHL MOTORS OF PHILSIPBURG, PA (814-342-3223). I AM HAVING PROBLEMS WITH THE REAR BRAKE LIGHTS AND NOW ALL REAR LIGHTING. FIST THE CAR WAS SERVICED AT VALLEY TIRES WHO REPLACED THE BULB LAMPS. *AK SECOND, FRED DIEHLS REPLACED THE LEFT SIDE SOCKET AND TIGHTENED THE RIGHT BULB. T…

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I PURCHASED A 2003 CHEVROLET CAVALIER FROM FRED DIEHL MOTORS OF PHILSIPBURG, PA (814-342-3223). I AM HAVING PROBLEMS WITH THE REAR BRAKE LIGHTS AND NOW ALL REAR LIGHTING. FIST THE CAR WAS SERVICED AT VALLEY TIRES WHO REPLACED THE BULB LAMPS. *AK SECOND, FRED DIEHLS REPLACED THE LEFT SIDE SOCKET AND TIGHTENED THE RIGHT BULB. THE THIRD TIME, I WAS STOPPED BY LOCAL POLICE FOR NO BRAKE LIGHTS. FRED DIEHLS REPLACED BOTH THE SOCKETS AND BULBS BECAUSE OF A SHORT IN THE SYSTEM. I CALLED GENERAL MOTORS WOTH A COMPLAINT (CUSTOMER RELATIONSHIP MANAGER ALVIN JOHNSON 1-866-942-4368 EXT. 47590). MR. JOHNSON SENT ME A LETTER APRIL 20 STATING THEY WOULD MAKE THE REPAIRS UP TO 75,000 MILES. ON MAY 28, 2004, I WAS INVOLVED IN AN ACCIDENT. THERE WERE NO INJURIES, BUT THE VEHICLE WAS DAMAGED. I SIGNALED AND APPLIED MY BRAKES TO MAKE A LEFT TURN. A FLAT BED TRUCK BEHIND ME STARTED TO PASS ME AS I PROCEEDED TO TURN AND STRUCK THE DRIVER'S SIDE. THE MAN TOLD STATE POLICE THERE WERE NO LIGHTS, BUT HE WAS FINED ANYWAY FOR PASSING IN A NO PASSING ZONE. ON JUNE 1 AND 2 I CALLED GM AND MR. JOHNSON RETURNED MY CALL AND TOOK THE ACCIDENT REPORT. ON JUNE 3, DARRIN TRANUSE OF GM (1-800-231-1841 EXT 58932) CALLED ME AND TOLD ME TO TAKE THE VEHICEL TO THE NEAREST CHEVY DEALER. MY BROTHER-IN-LAW FOLLOWED ME TO FRED DIEHLS BECAUSE I HAD NO REAR LIGHTS. THEY CHECKED THE CAR AND FOUND NO LIGHTS ALSO. THEY CALLED GM AND WERE GIVEN SPECIAL ORDERS TO ALLOW NO ONE AROUND THE VEHICLE UNTIL THEY COULD LOOK AT IT. I HAVE TWICE CALLED MR. TRANUSE BUT NEVER RECEIVED A RETURN CALL. THE HAD THE VEHICEL SERVICED THREE TIMES AND THE FOURTH TIME RESULTED IN AN ACCIDENT. RIGHT NOW, I'M AFRAID TO DRIVE IT.

NHTSA ODI #10074883

Mileage unknown · May 25, 2004
Exterior Lighting

THE TAIL LIGHT HAS BLOWN SEVERAL TIMES CAUSING THE TURN SIGNAL TO BLINK ERRATIC. PLEASE PROVIDE ANY ADDITIONAL INFORMATION. *NM

NHTSA ODI #10074227

13,900 miles · May 1, 2004
Exterior Lighting

I HAVE BEEN HAVING A PROBLEM WITH MY 2003 CHEVROLET CAVALIER. THE REAR BRAKE/SIGNAL LIGHTS KEEP BURNING OUT DUE TO BAD SOCKETS AND BULBS. COMBINED, I HAVE HAD TO REPLACE FIVE (5) LIGHT BULBS (THREE (3) ON THE RIGHT AND TWO (2) ON THE LEFT). THE FIRST TIME WAS APRIL OR MAY 2003 ON THE RIGHT SIDE, WHEN I WAS STILL IN PITTSBURGH…

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I HAVE BEEN HAVING A PROBLEM WITH MY 2003 CHEVROLET CAVALIER. THE REAR BRAKE/SIGNAL LIGHTS KEEP BURNING OUT DUE TO BAD SOCKETS AND BULBS. COMBINED, I HAVE HAD TO REPLACE FIVE (5) LIGHT BULBS (THREE (3) ON THE RIGHT AND TWO (2) ON THE LEFT). THE FIRST TIME WAS APRIL OR MAY 2003 ON THE RIGHT SIDE, WHEN I WAS STILL IN PITTSBURGH. THE SECOND TIME WAS IN SEPTEMBER OR OCTOBER 2003, ALSO ON THE RIGHT SIDE, BUT THIS TIME WAS IN PORT ORANGE, FL, WHERE I FOUND OUT ABOUT THE SOCKET PROBLEM. THE THIRD TIME WAS TWO WEEKS FOLLOWING THE SECOND INCIDENT, THIS TIME ON THE LEFT SIDE, BUT THE DEALERSHIP HAD THE SOCKETS ON BACK ORDER. THE FOURTH TIME WAS IN JANUARY 2004, AGAIN ON THE LEFT SIDE, THIS TIME THE DEALERSHIP REPLACED THE SOCKET. THE FIFTH TIME WAS APRIL 30, 2004, AGAIN ON THE RIGHT SIDE, AFTER THE SOCKET WAS REPLACED.*AK

NHTSA ODI #10068157

Mileage unknown · Apr 16, 2004
Exterior LightingService Brakes, AirSuspension

I'VE OWNED MY 2003 CAVALIER FOR 1 YR. 3 MONTHS. I'M VERY IRRITATED WITH HAVING TO GO TO THE DEALERSHIP EVERY OTHER MONTH FOR THE SAME PROBLEM. I'VE HAD MY CAR IN 7 TIMES TO GET THE TAILLIGHT FIXED. THE FIRST 2 TIMES THE LIGHT BLEW OUT, MY RADIO COMPLETELY WIPED OUT MY PRESET STATIONS. I ALSO HAD MY CAR IN 2 MONTHS AFTER I BOUGHT…

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I'VE OWNED MY 2003 CAVALIER FOR 1 YR. 3 MONTHS. I'M VERY IRRITATED WITH HAVING TO GO TO THE DEALERSHIP EVERY OTHER MONTH FOR THE SAME PROBLEM. I'VE HAD MY CAR IN 7 TIMES TO GET THE TAILLIGHT FIXED. THE FIRST 2 TIMES THE LIGHT BLEW OUT, MY RADIO COMPLETELY WIPED OUT MY PRESET STATIONS. I ALSO HAD MY CAR IN 2 MONTHS AFTER I BOUGHT IT BECAUSE THERE WAS A BAD SNOW AND AS I WAS DRIVING 5 MPH I BUMPED OVER A POT HOLE WHICH ENDED UP CRACKING MY SPRING AND STRUT ON THE FRONT PASS. SIDE. I HAD TO PAY OUT OF POCKET BECAUSE THE REPAIR WAS $100 LESS THAN MY DEDUCTIBLE. AND I WAS IN THE SERVICE DEPT. A WEEK BEFORE COMPLAINING OF A SQUEAK COMING FROM MY FRONT TIRE THAT THEY PUT OFF AS THE WHEEL COVER.COINCIDENCE?THERE WAS NO REASON THAT THE SPRING AND STRUT SHOULD HAVE CRACKED LIKE THAT! I'VE ALSO, JUST FOR THE RECORD, ASKED THEM TWICE TO CHECK MY BRAKES BECAUSE AS I COME TO A STOP THEY BEGIN TO PULSATE. THE SERVICE DEPT. TOLD ME I NEEDED NEW BRAKES.I'VE ONLY HAD MY CAR FOR 1 YEAR, 24,000 MOSTLY HIGHWAY MILES!!! THEY WANT $250.00 TO FIX MY BRAKES AND THEY SHOULD STILL BE UNDER WARRANTY. EVEN MIDAS GURANTEES THEIR BRAKES W/ A LIFETIME WARRANTY. YOU'D THINK THE MANUFACTURER WOULD FOR AN ORIGINAL OWNER.IT'S ONLY 2 PADS FOR GOODNESS SAKE! IF I KNEW HOW, I'D DO IT MYSELF. A SERVICE TECH TOLD ME THAT GM IS WELL AWARE OF THESE SAFETY HAZARDS THAT OTHER GM CUSTOMERS LIKE MYSELF ARE EXPERIENCING, YET THEY AREN'T DOING A RECALL. SOMETHING NEEDS TO BE DONE BEFORE SOMETHING BAD HAPPENS TO SOMEONE WHILE IN THEIR VEHICLE. NOT DOING ANYTHING IS BAD BUSINESS!! CUSTOMERS SHOULD BE FIRST PRIORITY. AS A MANUFACTURER, YOUR RESPONSIBILITY IS TOWARD YOUR CUSTOMER IF SOMETHING YOU SELL OR MANUFACTURE IS DEFECTIVE!!!*AK

NHTSA ODI #10066312

Mileage unknown · Apr 14, 2004
Exterior Lighting

WHILE DRIVING AT NIGHT WITH HEADLIGHTS ON THE HEAD LIGHT CUT OFF WITHOUT PRIOR WARNING, LEAVING CONSUMER BETWEEN FOUR TO SIX SECONDS WITHOUT A VISION OF THE ROAD. DEALER WAS CONTACTED. *AK

NHTSA ODI #10067168

6,500 miles · Mar 24, 2004
Exterior LightingService Brakes, HydraulicSuspension

WHEN APPLYING THE BRAKES AT NIGHT, THE HEADLIGHTS AND DASH LIGHTS DIM TO A SOFTER SHADE OF LIGHT. I HAVE ALSO CHANGED THE REAR SINGLE LIGHTS IN MY CAR THREE TIMES IN THE PAST 6 MONTHS. THIS CAR HAS A BAD BRAKE PROBLEM. THE FRONT OF THE CAR SHAKES VERY BAD WHEN YOU APPLY THE BRAKES WHILE EXITING A HIGHWAY. CITY DRIVING IS NOT …

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WHEN APPLYING THE BRAKES AT NIGHT, THE HEADLIGHTS AND DASH LIGHTS DIM TO A SOFTER SHADE OF LIGHT. I HAVE ALSO CHANGED THE REAR SINGLE LIGHTS IN MY CAR THREE TIMES IN THE PAST 6 MONTHS. THIS CAR HAS A BAD BRAKE PROBLEM. THE FRONT OF THE CAR SHAKES VERY BAD WHEN YOU APPLY THE BRAKES WHILE EXITING A HIGHWAY. CITY DRIVING IS NOT AS BAD, BUT WHEN THE BRAKES GET WARMED UP THEY PULSATE WHEN I COME TO A STOP. AT THE END OF THE DAY, I PULL MY CAR INTO MY DRIVEWAY AND THE FIRST THING I SMELL WHEN I GET OUT IS A BURNING SMELL FROM THE BACK BRAKES. I CALLED THE FUCILLO CHEVY SERVICE DEPARTMENT IN DECEMBER 2003. I TALKED TO A SERVICEMAN ABOUT MY BRAKE PROBLEM. HE TOLD ME THAT MY PULSATING BRAKES IS THE ABS SYSTEM WORKING IN THE SNOW. NOW THE ROADS ARE DRY AND MY BRAKES ARE STILL PULSATING. I COULD NOT FIND ANYTHING IN MY ORIGINAL PAPERWORK ON MY CAR SHOWING THAT IT HAS THE ABS SYSTEM. NOW MY BRAKES ARE SHOT. THE CAR HAD ONLY 6500 HUNDRED MILES ON IT WHEN I FIRST CALLED IN DECEMBER OF 2003. IN JUNE OF 2003, I BOUGHT THIS CAR AND TEST DROVE IT. THE CAR SEEMED TO BE A GOOD CAR, EXCEPT FOR THE NOISE THAT I HEARD COMING FROM THE FRONT LEFT TIRE AREA. IT SOUNDED LIKE A RUBBER BAND WHEN IT SNAPS. I BROUGHT IT UP TO MY SALESMEN ROCKY FROM THE CHEVY DEPARTMENT. HE TOLD ME THAT IT'S A NEW CAR. NOW WHEN THE FRONT TIRES ARE TURNED TO THE RIGHT, IT MAKES A CRUNCHING NOISE. WHEN I DRIVE OVER ANY BUMP AT ANY SPEED, IT FEELS LIKE THERE ARE NO SHOCKS OR STRUTS ON THIS CAR AND MAKES A BAD CLUNKING SOUND. *NM

NHTSA ODI #10063761

Mileage unknown · Mar 19, 2004
Exterior LightingCrash

I AM A GM TECHNICIAN. GM IS HAVING A HUGE PROBLEM WITH "J" BODY CARS WITH NEW BODY STYLE. (CAVILER, SUNFIRE YEAR 2001-CURRENT) THE PROBLEM IS WITH POOR TERMINAL CONTACT WITH THE REAR BULBS DUE TO DEFECTIVE BULB SOCKETS. THE RESULT IS LOSS OF REAR TURN SIGNALS AND BRAKE LAMPS ON ONE OR OFTEN BOTH SIDES. THIS PROBLEM AFFECTS CARS …

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I AM A GM TECHNICIAN. GM IS HAVING A HUGE PROBLEM WITH "J" BODY CARS WITH NEW BODY STYLE. (CAVILER, SUNFIRE YEAR 2001-CURRENT) THE PROBLEM IS WITH POOR TERMINAL CONTACT WITH THE REAR BULBS DUE TO DEFECTIVE BULB SOCKETS. THE RESULT IS LOSS OF REAR TURN SIGNALS AND BRAKE LAMPS ON ONE OR OFTEN BOTH SIDES. THIS PROBLEM AFFECTS CARS OFTEN WITH LESS THEN 1000 MILES. IT IS A HUGE PROBLEM AND OUR SHOP MUST FIX 8 CARS A WEEK ON AVERAGE FOR THIS PROBLEM AND WE ARE NOT A LARGE GM SHOP. NOT HAVING REAR TURN SIGNALS OR BRAKE LAMPS IS SERIOUS FOR RISK OF REAR-END COLLISIONS.*AK

NHTSA ODI #10062651

Official recalls

1

04V524000 · 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

4

EA07015 · 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.