IllustrationCAR STALLED WHILE DRIVING ON INTERSTATE. NOT A VERY GOOD SITUATION TO BE IN. 60,000 MILES PURCHASED BRAND NEW. FUEL PUMP REPLACEMENT AND TOWING COSTS. STRANDED ON MAJOR INTERSTATE. VERY UNSAFE CONDITIONS. WHAT A POOR PRODUCT. EVIDENTLY THIS IS NOTORIOUS FOR THE 03 CHEVY CAVALIER. THANKS GM. WHERE IS THE RECALL? *TR
2003 Chevrolet Cavalier
Owner reports · Recalls · Investigations
More warning signs than most Cavalier years
Owner complaints for the 2003 Chevrolet Cavalier are substantially higher than the model-year median of 140.
About this comparison →How this year compares
Owner complaints by model year
Compare all Cavalier years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
810–25K
9225–50K
19750–75K
10875–100K
58100–150K
17150K+
553 reports with mileage · 125 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Fuel System, Gasoline. Review the 340 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 106 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Exterior Lighting. Review the 57 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
31 crash reports6 fire reports16 injury reports
Fuel System, Gasoline complaints
340 reportsOUR DAUGHTER WAS DRIVING OUR CAR WHEN THE MOTOR SUDDENLY DIED. SHE WAS LUCKY TO BE ABLE TO GET OFF THE HIGHWAY SAFELY. I HAD OUR REPAIR SHOP TOW THE CAR FOR REPAIR. BILL: $706. PART: FUEL PUMP/UNIT. IT IS A GOOD THING THAT SHE WAS NOT ON THE INTERSTATE. THESE FUEL PUMPS ARE DEFECTIVE AND REPRESENT A DANGER TO THE OCCUPANTS OF TH…
Read full complaint
OUR DAUGHTER WAS DRIVING OUR CAR WHEN THE MOTOR SUDDENLY DIED. SHE WAS LUCKY TO BE ABLE TO GET OFF THE HIGHWAY SAFELY. I HAD OUR REPAIR SHOP TOW THE CAR FOR REPAIR. BILL: $706. PART: FUEL PUMP/UNIT. IT IS A GOOD THING THAT SHE WAS NOT ON THE INTERSTATE. THESE FUEL PUMPS ARE DEFECTIVE AND REPRESENT A DANGER TO THE OCCUPANTS OF THESE CARS. GM NEEDS TO BE MADE TO INITIATE A RECALL! *TR
FUEL PUMP STOPPED WORKING YESTERDAY AT 92,000 MILES. *TR
IT SEEMS EVER ONE HAD 60 GRAND OR BETTER UNTIL A FUEL PUMP WENT. MY CAR HAD 35,000 WHEN IT WENT ON ME. NOW I HAVE A QUESTION: I STILL HAVE THE SAME 2003 CAVACRAP AND NOW IT HAS AN INSTRUMENT CLUSTER PROBLEM. IT FIRST STARTED WITH THE WATER TEMP. GAUGE NEEDLE MOVING ALL THE WAY TO THE SPEEDOMETER GAUGE. THIS PROBLEM WOULD C…
Read full complaint
IT SEEMS EVER ONE HAD 60 GRAND OR BETTER UNTIL A FUEL PUMP WENT. MY CAR HAD 35,000 WHEN IT WENT ON ME. NOW I HAVE A QUESTION: I STILL HAVE THE SAME 2003 CAVACRAP AND NOW IT HAS AN INSTRUMENT CLUSTER PROBLEM. IT FIRST STARTED WITH THE WATER TEMP. GAUGE NEEDLE MOVING ALL THE WAY TO THE SPEEDOMETER GAUGE. THIS PROBLEM WOULD CORRECT ITSELF EVER ONCE IN A WHILE WHEN YOU SHUT OFF THE CAR. NOW ALL THE INSTRUMENTS ARE WHACKED OUT AND IT WILL NOT CORRECT ITSELF. THE CAR STILL RUNS FINE (45,000 ON IT NOW) EVEN WITH THE PROBLEM I HAVE NOW. ANY HELP?? THANKS IN ADVANCE I HAVE FILED A COMPLAINT BEFORE THIS BUT IT SEEMS THAT I CAN NOT FIND IT. SINCE THERE IS NO RECALL ON THE CAR FOR THE PROBLEMS A WAS HAVING, IT IS OBVIOUS THAT CHEVY DOES NOT TAKE CARE OF THERE PEOPLE!!! THIS IS MY WIFE'S CAR. I WAS IN THE MARKED AND DID NOT LOOK AT CHEVY FOR A MODE OF TRANSPORTATION. I BOUGHT A FORD RANGER. IT NOW HAS 120,000 MILES ON IT AND STILL GOING STRONG!!! I WAS A CHEVY MAN FOR 22 YEARS AND NOW I AM NOT!! *TR
ON 8/21/2008 MY DAUGHTER WAS PULLING INTO THE PARKING LOT OF HER SCHOOL. THE CAR STARTED BUCKING AND STALLED. IT WAS FORTUNATE THAT SHE HAD MADE IT TO SCHOOL BEFORE IT QUIT. HER SCHOOL IS ON HWY 90 OUTSIDE NEW ORLEANS AND IS A MAJOR ROAD WAY. THIS COULD HAVE BEEN UGLY HAD IT STALLED ON THE HIGHWAY. I HAVE BEEN TOLD IT IS THE F…
Read full complaint
ON 8/21/2008 MY DAUGHTER WAS PULLING INTO THE PARKING LOT OF HER SCHOOL. THE CAR STARTED BUCKING AND STALLED. IT WAS FORTUNATE THAT SHE HAD MADE IT TO SCHOOL BEFORE IT QUIT. HER SCHOOL IS ON HWY 90 OUTSIDE NEW ORLEANS AND IS A MAJOR ROAD WAY. THIS COULD HAVE BEEN UGLY HAD IT STALLED ON THE HIGHWAY. I HAVE BEEN TOLD IT IS THE FUEL PUMP B THE DEALERSHIP I PURCHASED THE CAR FROM. *TR
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 65-70 MPH, THE FUEL PUMP FAILED. THE VEHICLE LOST POWER STEERING ABILITY AND THEN SHUT OFF. THE VEHICLE WAS PUSHED TO THE SIDE OF THE ROAD, AND LATER TOWED TO A MECHANIC. THE VEHICLE HAS NOT YET BEEN DIAGNOSED. THE CURRENT AND FAILURE MILEAGES WERE 85,000.
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING APPROXIMATELY 55 MPH, THE TRACTION LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THERE WAS NO ACCELERATION AT THE TIME. THE VEHICLE WAS PULLED TO THE SIDE OF THE ROAD AND TESTED, BUT THERE STILL WAS NO ACCELERATION. THE VEHICLE WAS TOWED TO A MECHANIC AND THEN THE DEA…
Read full complaint
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING APPROXIMATELY 55 MPH, THE TRACTION LIGHT ILLUMINATED ON THE INSTRUMENT PANEL. THERE WAS NO ACCELERATION AT THE TIME. THE VEHICLE WAS PULLED TO THE SIDE OF THE ROAD AND TESTED, BUT THERE STILL WAS NO ACCELERATION. THE VEHICLE WAS TOWED TO A MECHANIC AND THEN THE DEALER. THE DEALER DIAGNOSED THE VEHICLE AS HAVING FUEL PUMP FAILURE. THE CURRENT AND FAILURE MILEAGES WERE 51,000.
COMING HOME FROM MILWAUKEE AT 12:30 AM WITH SON AFTER SEEING RACE IN SLINGER, WI. ON INTERSTATE, CAR LOST COMPLETE ENGINE POWER AND BECAME DEAD. CLOSEST GM DEALERSHIP IN WATERTOWN, WI WENT OUT OF BUSINESS LAST YEAR (PER TOW TRUCK DRIVER). HAD TOWED TO DEALERSHIP WHERE THEY DIAGNOSED A BAD FUEL PUMP AND A PRICE OF OVER $800. …
Read full complaint
COMING HOME FROM MILWAUKEE AT 12:30 AM WITH SON AFTER SEEING RACE IN SLINGER, WI. ON INTERSTATE, CAR LOST COMPLETE ENGINE POWER AND BECAME DEAD. CLOSEST GM DEALERSHIP IN WATERTOWN, WI WENT OUT OF BUSINESS LAST YEAR (PER TOW TRUCK DRIVER). HAD TOWED TO DEALERSHIP WHERE THEY DIAGNOSED A BAD FUEL PUMP AND A PRICE OF OVER $800. CAME TO PICK UP WITH A TRAILER AND ASKED FOR HELP PUSHING CAR ON TRAILER. THEY SAID YOU COULD DRIVE IT UP AS THE MECHANIC TAPPED THE FUEL TANK AND IT STARTED. DROVE AROUND THE BLOCK A FEW TIMES LAST WEEK WITH NO PROBLEMS. I EXPLAINED THIS TO GM, TOLD THEM ABOUT THEIR POOR DESIGN AND THAT THIS IS NOT SAFE BECAUSE IT WILL FAIL AT ANY TIME AND COULD CAUSE A MAJOR ACCIDENT. WAS GIVEN CASE #71-648948392 (TOLD NO RECALLS WERE AVAILABLE PER MY VIN #). CHECKED ON INTERNET (TOPIX.COM) AND OVER 400 HAVE HAD SIMILAR PROBLEMS. *TR
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. AFTER PULLING AWAY FROM A STOP LIGHT, THE VEHICLE STALLED AND SHUT OFF. THE CONTACT WAS ABLE TO RESTART THE VEHICLE AND COAST TO A GAS STATION. THE VEHICLE WAS TOWED TO A LOCAL REPAIR SHOP AND THE FUEL PUMP WAS REPLACED AT THE COST OF $722. THE FAILURE AND CURRENT MILEAGES WERE …
Read full complaint
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. AFTER PULLING AWAY FROM A STOP LIGHT, THE VEHICLE STALLED AND SHUT OFF. THE CONTACT WAS ABLE TO RESTART THE VEHICLE AND COAST TO A GAS STATION. THE VEHICLE WAS TOWED TO A LOCAL REPAIR SHOP AND THE FUEL PUMP WAS REPLACED AT THE COST OF $722. THE FAILURE AND CURRENT MILEAGES WERE 73,500.
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 30 MPH, THE VEHICLE SHUT DOWN WITHOUT WARNING AND WAS TOWED TO THE CONTACT'S RESIDENCE. THE FAMILY MECHANIC STATED THAT THE FUEL PUMP FAILED AND WOULD COST $900 TO REPLACE. THE MANUFACTURER STATED THAT THEY WOULD CALL THE CONTACT BACK. THE VIN WAS UNKNOWN. THE CUR…
Read full complaint
TL*THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. WHILE DRIVING 30 MPH, THE VEHICLE SHUT DOWN WITHOUT WARNING AND WAS TOWED TO THE CONTACT'S RESIDENCE. THE FAMILY MECHANIC STATED THAT THE FUEL PUMP FAILED AND WOULD COST $900 TO REPLACE. THE MANUFACTURER STATED THAT THEY WOULD CALL THE CONTACT BACK. THE VIN WAS UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 61,000.
Official recalls
104V524000 · Exterior Lighting:turn Signal
Nov 1, 2004
ON CERTAIN PASSENGER VEHICLES, THE REAR LAMPS THAT PROVIDE STOP AND TURN SIGNALS AND TAIL LAMP FUNCTIONS STOP WORKING BECAUSE OF INADEQUATE CONTACT BETWEEN THE BULB AND SOCKET. IN ADDITION, IF ONE BULBS WERE TO BECOME INOPERATIVE WHILE THE VEHICLE WAS OPERATING IN CRUISE CONTROL, THE CRUISE CONTROL WOULD DISENGAGE WHEN THE REMAINING BULB WAS ACTIVATED. IF BOTH LAMPS WERE TO BECOME INOPERATIVE, THE CRUISE CONTROL WOULD NOT ENGAGE.
Consequence & remedy
Consequence: AN INOPERATIVE BRAKE LAMP WILL NOT CONVEY THE DRIVER'S INTENTION OF STOPPING TO DRIVERS IN FOLLOWING VEHICLES, AND AN INOPERATIVE REAR TURN SIGNAL LAMP WILL NOT CONVEY THE DRIVER'S INTENTION TO TURN TO DRIVERS IN FOLLOWING VEHICLES. BOTH OF THESE FAILURES CAN INCREASE THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE REAR LAMP BULB SOCKET ASSEMBLIES AND APPLY GREASE OR REPLACE THEM IF NECESSARY. THE RECALL BEGAN ON JANUARY 18, 2005. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR PONTIAC AT 1-800-620-7668.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
4EA07015 · Engine Stalling - Fuel Pump Failure
Opened Nov 1, 2007 · Closed Oct 28, 2008
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Additional source detail variants (3)
Fuel System, Gasoline:delivery:fuel Pump
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Fuel System, Gasoline:delivery
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
Fuel System, Gasoline
ODI'S ANALYSIS OF THE STALLING INCIDENTS THAT HAVE RESULTED FROM SUBJECT COMPONENT FAILURES FOUND THAT THEY CAN OCCUR AT ANY SPEED AND GENERALLY RESULT IN A NO RESTART CONDITION.THESE ARE GENERALLY CONSIDERED TO BE FACTORS THAT INCREASE THE POTENTIAL SEVERITY OF STALLING INCIDENTS.HOWEVER, THESE INCIDENTS HAVE OCCURRED AT RELATIVELY LOW RATES IN THE SUBJECT VEHICLE POPULATION WHEN COMPARED WITH PRIOR INVESTIGATIONS INVOLVING SIMILAR CATEGORIES OF ENGINE STALL CONSEQUENCES.EVEN FOR THE EARLY MY 2003 PRODUCTION, WHERE HIGHER FAILURE RATES WERE NOTED, THE RATES OF PUMP FAILURES RESULTING IN ENGINE STALL ARE LOWER THAN RATES RECORDED IN PRIOR INVESTIGATIONS OF POPULATIONS THAT WERE NOT RECALLED.FURTHER INVESTIGATION OF THIS MATTER WOULD NOT BE AN EFFICIENT ALLOCATION OF AGENCY RESOURCES.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL CONTINUE TO MONITOR COMPLAINTS AND OTHER INFORMATION RELATING TO THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND TAKE FURTHER ACTION IN THE FUTURE IF WARRANTED.SEE DOCUMENT FILE FOR MORE INFORMATION ABOUT THIS CLOSING RESUME.
PE07033 · Fuel Pump Failure
Opened Jun 28, 2007 · Closed Nov 1, 2007
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Additional source detail variants (3)
Fuel System, Gasoline:delivery:fuel Pump
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Fuel System, Gasoline:delivery
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
Fuel System, Gasoline
AN ENGINEERING ANALYSIS HAS BEEN OPENED TO FURTHER INVESTIGATE THE SCOPE, FREQUENCY AND POTENTIAL SAFETY-RELATED CONSEQUENCES OF THE ALLEGED DEFECT.GENERAL MOTORS (GM) HAS IDENTIFIED AN ISSUE WITH ACCELERATED MOTOR BRUSH WEAR IN THE FUEL PUMP ASSEMBLY OF MODEL YEAR (MY) 2001 THROUGH 2003 CHEVROLET VEHICLES THAT CAN CAUSE THE PUMP TO STOP OPERATING.GENERAL MOTORS INDICATED THAT PEROXIDE OR SULFUR, WHICH ARE BOTH PRESENT IN VARYING AMOUNTS IN GASOLINE, CAN REACT WITH THE COPPER COMMUTATOR OF THE PUMP MOTOR AND CORRODE/ROUGHEN THE SURFACE.A ROUGH COMMUTATOR SURFACE INCREASES THE RATE OF BRUSH WEAR.THE INCREASED ELECTRICAL RESISTANCE CAUSED BY DEGRADATION OF THE BRUSH-COMMUTATOR INTERFACE INHIBITS CURRENT FLOW THROUGH THE MOTOR WINDINGS.ACCORDING TO GM, THE CONDITION WILL USUALLY RESULT IN A NO-START CONDITION BECAUSE OF THE HIGH CURRENT REQUIRED DURING START-UP.WHEN THE ALLEGED DEFECT DOES CAUSE A STALL WHILE DRIVING INCIDENT, THE VEHICLE TYPICALLY CANNOT BE RESTARTED.GM'S ANALYSIS OF WARRANT CLAIMS SHOWED THAT NO START/HARD START WAS THE MOST COMMON CONDITION AND THE FREQUENCY OF CLAIMS ASSOCIATED WITH STALL WHILE DRIVING INCIDENTS WAS TOO LOW TO WARRANT FIELD ACTION. THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-015) TO FURTHER ASSESS THE COMPLAINT AND WARRANTY CLAIM DATA AND THE ANALYSES PROVIDED BY GM.
EA04028 · Turn Signal Malfunction
Opened Sep 14, 2004 · Closed Nov 22, 2004
Status: closed (inferred from source dates) · Exterior Lighting:turn Signal
ON MAY 14, 2004 THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-043) BASED ON CONSUMER COMPLAINTS ALLEGING THAT THE BRAKE/TAIL TURN SIGNAL LAMPS WOULD NOT OPERATE PROPERLY WHEN EITHER THE TAIL LIGHTS WERE TURNED ON, THE BRAKE PEDAL WAS DEPRESSED, OR WHEN THE TURN SIGNAL SWITCH WAS ACTIVATED.ON SEPTEMBER 14, 2004 ODI UPGRADED PE 04-043 TO AN ENGINEERING ANALYSIS (EA04-028).GM STATES THAT SOME BRAKE/TAIL/TURN SIGNAL LAMP BULBS CAN PREMATURELY BECOME INOPERATIVE DUE TO EXCESSIVE HEAT BUILDUP WITHIN THE BULB SOCKETS.THE CAUSE OF THE EXCESSIVE HEAT BUILD UP WAS DETERMINED TO BE A LACK OF THERMAL GREASE PLACED IN BETWEEN THE BULB AND THE SOCKET. BY LETTER DATED OCTOBER 27, 2004 GM NOTIFIED NHTSA THAT IT WILL CONDUCT A SAFETY RECALL (NHTSA # 04V524) COVERING ALL MY 2003 VEHICLES.GM DEALERS WILL INSPECT THE REAR LAMP BULB SOCKET ASSEMBLIES AND APPLY THERMAL GREASE TO THEM OR REPLACE THEM WITH NEW ASSEMBLIES WITH THERMAL GREASE ALREADY ATTACHED.MODEL YEAR 2004 AND NEWER VEHICLES HAVE THE THERMAL GREASE INSTALLED FROM THE FACTORY. THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
PE04043 · Turn Signal Malfunction
Opened May 14, 2004 · Closed Sep 14, 2004
Status: closed (inferred from source dates) · Exterior Lighting:turn Signal
COMPLAINANTS ALLEGE THAT THE REAR TURN SIGNALS FAIL TO ILLUMINATE AND DO NOT PROVIDE A SIGNAL TO DRIVERS IN FOLLOWING VEHICLES.ODI HAS RECEIVED ONE REPORT OF A CRASH WHERE THE COMPLAINANT BRAKED AND ATTEMPTED TO MAKE A LEFT TURN AND THE FOLLOWING VEHICLE IMPACTED THE COMPLAINANT'S VEHICLE IN THE DRIVER-SIDE DOOR.IN MAY 2002, GM'S SUPPLIER MADE CHANGES TO THE BULB SOCKET THAT INCLUDED STOPPING THE USE OF THERMAL-MASTIC GREASE IN THE BULB SOCKET.GM REPORTS THAT THE GREASE REDUCES ARCING AT THE CONTACTS AND DISSIPATES HEAT THUS PREVENTING MELTING OF THE SOCKET MATERIAL OR BURNING OF THE CONTACTS.MOST OF THE SUBJECT VEHICLES WERE PRODUCED WITHOUT GREASE APPLIED TO THE BULB SOCKET.IN JUNE 2003, GM DIRECTED THE SUPPLIER TO RESUME THE USE OF GREASE IN THE SOCKET.GM ISSUED TECHNICAL SERVICE BULLETIN (TSB) 04-08-42-004A ON JULY 15, 2004 ADVISING TECHNICIANS TO MAKE SURE THAT ADEQUATE AMOUNTS OF GREASE WERE ADDED TO THE BULB SOCKETS ON ALL SERVICE PARTS.ODI WILL UPGRADE THIS INVESTIGATION TO EA 04-028 TO FURTHER EXAMINE THE ISSUE.