NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
340 reportsClear category filter66,000 miles · Feb 15, 2009
Fuel System, Gasoline
MY CAR HAS BEEN RUNNING FINER AND THEN AL OF A SUDDEN IN THE MIDDLE OF RUSH HOUR TRAFFIC IT DIES. NO WARNING. NOTHING. THE FUEL PUMP HAS GONE OUT AND WILL COST $600+ TO REPLACE. THERE HAVE BEEN MANY MANY COMPLAINTS ABOUT THIS VERY ISSUE AND IT HAPPENS AT APPROX THE SAME MILEAGE OF THE CAR. BETWEEN 60000 AND 70000 MILES. THIS NEE…
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MY CAR HAS BEEN RUNNING FINER AND THEN AL OF A SUDDEN IN THE MIDDLE OF RUSH HOUR TRAFFIC IT DIES. NO WARNING. NOTHING. THE FUEL PUMP HAS GONE OUT AND WILL COST $600+ TO REPLACE. THERE HAVE BEEN MANY MANY COMPLAINTS ABOUT THIS VERY ISSUE AND IT HAPPENS AT APPROX THE SAME MILEAGE OF THE CAR. BETWEEN 60000 AND 70000 MILES. THIS NEEDS TO BE ADDRESSED! *TR
NHTSA ODI #10258724
86,000 miles · Feb 14, 2009
Fuel System, Gasoline
2003 CAVALIER- 86,000 MILES. FUEL PUMP FAILURE. USUALLY DO MY OWN MECHANICAL WORK BUT OPTED TO LET A SHOP WORK ON THIS ONE. TOTAL COST 800.00. SHOP STATED THAT THIS IS A VERY COMMON PROBLEM. *TR
NHTSA ODI #10258683
91,000 miles · Feb 11, 2009
Fuel System, Gasoline
I HAVE HAD A 2003 CHEVROLET CAVALIER AND THE FUEL PUMP KEEPS GOING BAD COSTING ME A PRETTY PENNY EVERY TIME IT GOES. AFTER DOING SOME RESEARCH ONLINE IT APPEARS THAT THERE ARE MANY PEOPLE WITH BAD FUEL PUMPS FOR CHEVROLET CAVALIERS. JUST REPORTING THE PROBLEM TO ADD MY NAME TO THE LIST OF UNHAPPY 2003 CHEVROLET CAVALIER OWNER…
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I HAVE HAD A 2003 CHEVROLET CAVALIER AND THE FUEL PUMP KEEPS GOING BAD COSTING ME A PRETTY PENNY EVERY TIME IT GOES. AFTER DOING SOME RESEARCH ONLINE IT APPEARS THAT THERE ARE MANY PEOPLE WITH BAD FUEL PUMPS FOR CHEVROLET CAVALIERS. JUST REPORTING THE PROBLEM TO ADD MY NAME TO THE LIST OF UNHAPPY 2003 CHEVROLET CAVALIER OWNERS. THE INCIDENT THAT I LIST BELOW IS THE LATEST DATE THE FUEL PUMP WENT BAD, TODAY AS A MATTER OF FACT. THE LAST TIME IT WENT BAD WAS LESS THAN A MONTH AGO. *TR
NHTSA ODI #10258409
121,568 miles · Feb 3, 2009
Fuel System, Gasoline
FUEL PUMP DIED WITH NO WARNING ON DANGEROUS HIGHWAY. HAD TO GET A TOW AND REPAIR AT A SHOP NOT FAMILIAR WITH TOTAL BILL INCLUDING TOWING AND REPAIR 1,200 SOME VEHICLE FORUMS HAVE UPWARDS OF 500 INDIVIDUALS WITH SAME PROBLEM DEFINITE SAFETY HAZARD AND WARRANTS A RECALL. *TR
NHTSA ODI #10257325
56,000 miles · Feb 2, 2009
Fuel System, Gasoline
2003 CHEVY CAVALIER SHUT OFF ON ME WHILE DRIVING DOWN STEEP HILL. NO POWER STEERING AND BRAKES, LUCKILY MADE IT TO SAFE SPACE AT BOTTOM OF HILL. CAR WOULD NOT RESTART. NOW IN GARAGE. DIAGNOSED WITH BAD FUEL PUMP. IT WILL COST $600.00 TO FIX WHEN PART COMES IN. THIS IS RIDICULOUS, CAR HAS ONLY 56,000 MILES ON IT! THIS IS A SEVERE…
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2003 CHEVY CAVALIER SHUT OFF ON ME WHILE DRIVING DOWN STEEP HILL. NO POWER STEERING AND BRAKES, LUCKILY MADE IT TO SAFE SPACE AT BOTTOM OF HILL. CAR WOULD NOT RESTART. NOW IN GARAGE. DIAGNOSED WITH BAD FUEL PUMP. IT WILL COST $600.00 TO FIX WHEN PART COMES IN. THIS IS RIDICULOUS, CAR HAS ONLY 56,000 MILES ON IT! THIS IS A SEVERE SAFETY HAZARD. I SEARCHED ON-LINE AND IT IS A COMMON COMPLAINT WITH THIS VEHICLE. SOMETHING MUST BE DONE BEFORE A FATALITY OCCURS, IF IT HAS NOT ALREADY! *TR
NHTSA ODI #10257269
165,000 miles · Jan 30, 2009
Fuel System, Gasoline
I HAVE 165,000KM ON MY 2003 CHEVROLET CAVALIER. IT IS CONSTANTLY STALLING, MOSTLY AT STOP LIGHTS AND WHEN I SLOW DOWN, HOWEVER TODAY IT STALLED ON THE HIGHWAY. THE MECHANICS THINK IT MIGHT BE THE FUEL PUMP BUT IT IS HARD TO TELL FOR SURE WHAT IT IS AND I DON'T WANT TO SPEND ALL THIS MONEY IF IT IS NOT THAT. I HAVE HEARD FROM MAN…
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I HAVE 165,000KM ON MY 2003 CHEVROLET CAVALIER. IT IS CONSTANTLY STALLING, MOSTLY AT STOP LIGHTS AND WHEN I SLOW DOWN, HOWEVER TODAY IT STALLED ON THE HIGHWAY. THE MECHANICS THINK IT MIGHT BE THE FUEL PUMP BUT IT IS HARD TO TELL FOR SURE WHAT IT IS AND I DON'T WANT TO SPEND ALL THIS MONEY IF IT IS NOT THAT. I HAVE HEARD FROM MANY PEOPLE THIS IS A COMMON ISSUE WITH THIS CAR. I FEEL QUITE UNSAFE DRIVING SINCE IT COULD STALL OR SHUT DOWN AT ANY POINT. A CAR SHOULD NOT STALL WHILE DRIVING OR AT STOP LIGHTS. PLEASE RECALL THIS PART!! *TR
NHTSA ODI #10256910
47,000 miles · Jan 21, 2009
Fuel System, Gasoline
MY WIFE WAS DRIVING WITH OUR TWO BOYS TO THE LIBRARY WHEN THE CAR JUST STOPPED AS SHE WAS GOING INTO A BUSY INTERSECTION. SHE CALLED ME AT WORK IN A PANIC. LUCKILY, ANOTHER DRIVER CALMED HER DOWN AND HELPED PUSH THE CAR OFF TO THE SIDE OF THE ROAD. ISSUE WAS THAT THE FUEL PUMP WENT BAD. CAR ONLY HAS 47,000 MILES. COST OF RE…
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MY WIFE WAS DRIVING WITH OUR TWO BOYS TO THE LIBRARY WHEN THE CAR JUST STOPPED AS SHE WAS GOING INTO A BUSY INTERSECTION. SHE CALLED ME AT WORK IN A PANIC. LUCKILY, ANOTHER DRIVER CALMED HER DOWN AND HELPED PUSH THE CAR OFF TO THE SIDE OF THE ROAD. ISSUE WAS THAT THE FUEL PUMP WENT BAD. CAR ONLY HAS 47,000 MILES. COST OF REPAIR WAS $660 PLUS THE TOWING FROM THE INTERSECTION TO THE SHOP. *TR
NHTSA ODI #10255875
36,000 miles · Jan 16, 2009
Fuel System, Gasoline
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 75 MPH, THE VEHICLE STALLED AND THE ENGINE SHUT OFF WITHOUT WARNING. THE VEHICLE WAS TOWED TO A REPAIR SHOP AND THE MECHANIC STATED THAT THE FUEL PUMP FAILED. THE MANUFACTURER STATED THAT NOTHING COULD BE DONE BECAUSE THERE WAS NO RECALL OR WARRANTY. THE VEHICLE HA…
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TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 75 MPH, THE VEHICLE STALLED AND THE ENGINE SHUT OFF WITHOUT WARNING. THE VEHICLE WAS TOWED TO A REPAIR SHOP AND THE MECHANIC STATED THAT THE FUEL PUMP FAILED. THE MANUFACTURER STATED THAT NOTHING COULD BE DONE BECAUSE THERE WAS NO RECALL OR WARRANTY. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 36,000.
NHTSA ODI #10255366
67,000 miles · Jan 7, 2009
Fuel System, GasolineVisibility
I HAVE A 2003 CAVALIER AND HAD THE FUEL PUMP GO BAD AT 67,000 MILES. I RESEARCHED ON THE WEB AND IT SEEMS THAT THERE IS A TREMENDOUS AMOUNT OF 2003 CAVALIERS THAT HAVE HAD THIS SAME ISSUE. I HAVE REPLACED 3 OF THE 4 WINDOW MOTORS IN THE PAST 18 MONTHS. I HAVE TWICE HAD MY CLIMATE CONTROL SWITCH FIXED, AS IT WAS STUCK ONLY ON …
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I HAVE A 2003 CAVALIER AND HAD THE FUEL PUMP GO BAD AT 67,000 MILES. I RESEARCHED ON THE WEB AND IT SEEMS THAT THERE IS A TREMENDOUS AMOUNT OF 2003 CAVALIERS THAT HAVE HAD THIS SAME ISSUE. I HAVE REPLACED 3 OF THE 4 WINDOW MOTORS IN THE PAST 18 MONTHS. I HAVE TWICE HAD MY CLIMATE CONTROL SWITCH FIXED, AS IT WAS STUCK ONLY ON VENT. AND MOST RECENTLY AT 69000 MILES I HAVE TO REPLACE MY FUEL PRESSURE REGULATOR. IN MY EDUCATED OPINION, THIS SEEMS TO BE AN AWFUL LOT OF REPAIRS FOR A VEHICLE OF THIS AGE AND WITH THIS RECORD. *TR
NHTSA ODI #10254145
65,000 miles · Jan 2, 2009
Fuel System, Gasoline
I HAVE A 2003 CAVALIER OF WHICH I HAD TO HAVE THE FUEL PUMP REPLACED ABOUT A YEAR AND A HALF AGO. NOW LOOKING ON THE INTERNET I SEE THAT THIS HAPPENS A LOT. I WANTED TO KNOW IF POSSIBLY THERE IS A RECALL COMING OR ANYTHING OF THAT NATURE. MY CAR HAD BETWEEN 60 K AND 70K MILES AT THE TIME. *TR
NHTSA ODI #10253566
NHTSA investigations
4EA07015 · Engine Stalling - Fuel Pump Failure
Opened Nov 1, 2007 · Closed Oct 28, 2008
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Additional source detail variants (3)
Fuel System, Gasoline:delivery:fuel Pump
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Fuel System, Gasoline:delivery
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Fuel System, Gasoline
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
PE07033 · Fuel Pump Failure
Opened Jun 28, 2007 · Closed Nov 1, 2007
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Additional source detail variants (3)
Fuel System, Gasoline:delivery:fuel Pump
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Fuel System, Gasoline:delivery
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Fuel System, Gasoline
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
EA04028 · Turn Signal Malfunction
Opened Sep 14, 2004 · Closed Nov 22, 2004
Status: closed (inferred from source dates) · Exterior Lighting:turn Signal
ON MAY 14, 2004 THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-043) BASED ON CONSUMER COMPLAINTS ALLEGING THAT THE BRAKE/TAIL TURN SIGNAL LAMPS WOULD NOT OPERATE PROPERLY WHEN EITHER THE TAIL LIGHTS WERE TURNED ON, THE BRAKE PEDAL WAS DEPRESSED, OR WHEN THE TURN SIGNAL SWITCH WAS ACTIVATED.ON SEPTEMBER 14, 2004 ODI UPGRADED PE 04-043 TO AN ENGINEERING ANALYSIS (EA04-028).GM STATES THAT SOME BRAKE/TAIL/TURN SIGNAL LAMP BULBS CAN PREMATURELY BECOME INOPERATIVE DUE TO EXCESSIVE HEAT BUILDUP WITHIN THE BULB SOCKETS.THE CAUSE OF THE EXCESSIVE HEAT BUILD UP WAS DETERMINED TO BE A LACK OF THERMAL GREASE PLACED IN BETWEEN THE BULB AND THE SOCKET. BY LETTER DATED OCTOBER 27, 2004 GM NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA # 04V524) COVERING ALL MY 2003 VEHICLES.GM DEALERS WILL INSPECT THE REAR LAMP BULB SOCKET ASSEMBLIES AND APPLY THERMAL GREASE TO THEM OR REPLACE THEM WITH NEW ASSEMBLIES WITH THERMAL GREASE ALREADY ATTACHED.MODEL YEAR 2004 AND NEWER VEHICLES HAVE THE THERMAL GREASE INSTALLED FROM THE FACTORY. THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
PE04043 · Turn Signal Malfunction
Opened May 14, 2004 · Closed Sep 14, 2004
Status: closed (inferred from source dates) · Exterior Lighting:turn Signal
COMPLAINANTS ALLEGE THAT THE REAR TURN SIGNALS FAIL TO ILLUMINATE AND DO NOT PROVIDE A SIGNAL TO DRIVERS IN FOLLOWING VEHICLES.ODI HAS RECEIVED ONE REPORT OF A CRASH WHERE THE COMPLAINANT BRAKED AND ATTEMPTED TO MAKE A LEFT TURN AND THE FOLLOWING VEHICLE IMPACTED THE COMPLAINANT'S VEHICLE IN THE DRIVER-SIDE DOOR.IN MAY 2002, GM'S SUPPLIER MADE CHANGES TO THE BULB SOCKET THAT INCLUDED STOPPING THE USE OF THERMAL-MASTIC GREASE IN THE BULB SOCKET.GM REPORTS THAT THE GREASE REDUCES ARCING AT THE CONTACTS AND DISSIPATES HEAT THUS PREVENTING MELTING OF THE SOCKET MATERIAL OR BURNING OF THE CONTACTS.MOST OF THE SUBJECT VEHICLES WERE PRODUCED WITHOUT GREASE APPLIED TO THE BULB SOCKET.IN JUNE 2003, GM DIRECTED THE SUPPLIER TO RESUME THE USE OF GREASE IN THE SOCKET.GM ISSUED TECHNICAL SERVICE BULLETIN (TSB) 04-08-42-004A ON JULY 15, 2004 ADVISING TECHNICIANS TO MAKE SURE THAT ADEQUATE AMOUNTS OF GREASE WERE ADDED TO THE BULB SOCKETS ON ALL SERVICE PARTS.ODI WILL UPGRADE THIS INVESTIGATION TO EA 04-028 TO FURTHER EXAMINE THE ISSUE.
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