Illustration2003 CHEVY CAVALIER 2.2L, SEDAN. FUEL PUMP FAILURE AT 70,000 MILES. THIS SEEMS EXTREMELY EARLY FOR SUCH A MAJOR COMPONENT TO FAIL AND NEED REPLACED. THE TANK NEEDED TO BE DRAINED, DROPPED AND FUEL PUMP REPLACED AT A COST OF OVER $800. *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 reportsTHERE WAS A TOTAL FAILURE OF THE FUEL PUMP WHILE THE CAR WAS IN OPERATION ON A BUSY ROAD AT RUSH HOUR. THE CAR SUDDENLY LOSS POWER AND STALLED WHILE DRIVING. SOLELY DUE TO PURE LUCK, I HAD NOT YET ENTERED ONTO THE LOCAL INTERSTATE HIGHWAY AND DID NOT HAVE AN ACCIDENT. THE CAR WAS TOWED TO THE CHEVROLET DEALERSHIP AND THE FUEL…
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THERE WAS A TOTAL FAILURE OF THE FUEL PUMP WHILE THE CAR WAS IN OPERATION ON A BUSY ROAD AT RUSH HOUR. THE CAR SUDDENLY LOSS POWER AND STALLED WHILE DRIVING. SOLELY DUE TO PURE LUCK, I HAD NOT YET ENTERED ONTO THE LOCAL INTERSTATE HIGHWAY AND DID NOT HAVE AN ACCIDENT. THE CAR WAS TOWED TO THE CHEVROLET DEALERSHIP AND THE FUEL PUMP HAD TO BE REPLACED. THE CAR WAS NO LONGER UNDER GM WARRANTY AND THE TOTAL COST OF REPAIR TO ME WAS OVER $800. *TR
MY 2003 CAVALIER (49,198 MILES) BROKE DOWN ON THE HIGHWAY AT 9:30 AT NIGHT. HAD IT TOWED TO THE DEALERSHIP AND FOUND OUT IT WAS THE FUEL PUMP/ FUEL FILTER. QUOTED ME $900 FOR EVERYTHING (DIAGNOSTIC, FUEL PUMP, AND LABOR). HAD A FRIEND WHO DID IT FOR ALOT CHEAPER THEN THAT. THEN THE WARRANTY I HAD ON IT EXPIRED AND GM FAILED TO T…
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MY 2003 CAVALIER (49,198 MILES) BROKE DOWN ON THE HIGHWAY AT 9:30 AT NIGHT. HAD IT TOWED TO THE DEALERSHIP AND FOUND OUT IT WAS THE FUEL PUMP/ FUEL FILTER. QUOTED ME $900 FOR EVERYTHING (DIAGNOSTIC, FUEL PUMP, AND LABOR). HAD A FRIEND WHO DID IT FOR ALOT CHEAPER THEN THAT. THEN THE WARRANTY I HAD ON IT EXPIRED AND GM FAILED TO TELL ME. I BOUGHT A EXTENDED WARRANTY AND APPARENTLY IT STARTED ON THE DAY I SIGNED THE PAPERWORK. WHY WOULD I WANT DOUBLE COVERAGE (MANUFACTURER'S AND EXTENDED)? *TR
WHILE DRIVING DOWN THE HIGHWAY AT 65 MPH, 2003 CHEVROLET CAVALIER WITH 88,505 MILES BEGAN LOSING SPEED/ACCELERATION. DRIVER WAS ABLE TO PULL TO THE SHOULDER BEFORE ENGINE STOPPED. DRIVER TURNED OFF IGNITION AND WAS NOT ABLE TO RESTART ENGINE. FUEL PUMP FAILED AND WAS REPLACED AT A LOCAL GARAGE. RE: NHTSA ACTION NUMBER EA0701…
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WHILE DRIVING DOWN THE HIGHWAY AT 65 MPH, 2003 CHEVROLET CAVALIER WITH 88,505 MILES BEGAN LOSING SPEED/ACCELERATION. DRIVER WAS ABLE TO PULL TO THE SHOULDER BEFORE ENGINE STOPPED. DRIVER TURNED OFF IGNITION AND WAS NOT ABLE TO RESTART ENGINE. FUEL PUMP FAILED AND WAS REPLACED AT A LOCAL GARAGE. RE: NHTSA ACTION NUMBER EA07015. *TR
THE EVENT LEADING UP TO THE FAILURE WAS WHILE THE CAR WAS TRAVELING DOWN THE ROAD, THE CAR STOPPED RUNNING. THE CAR WOULD NOT RESTART AND HAD TO BE TOWED TO A DEALERSHIP. THE DEALERSHIP DETERMINED THE FAILURE WAS THE FUEL PUMP AND TO CORRECT THE FAILURE THE FUEL PUMP NEEDED TO BE REPLACED. THE OLD PART IS NOT AVAILABLE. *TR
FUEL PUMP FAILED IN MY 2003 CHEVY CAVALIER AT 80,000 MILES. *TR
I HAVE A 2003 CHEVROLET CAVALIER LS SPORT COUPE WITH APPROXIMATELY 72,000 MILES ON IT. LAST NIGHT, WITHOUT ANY WARNING, MY VEHICLE WOULD NOT START AND I WAS LEFT STRANDED WITH GROCERIES IN MY CAR AT A GROCERY STORE PARKING LOT. I HAD IT TOWED TO A VERY REPUTABLE LOCAL REPAIR SHOP AND WAS INFORMED THIS MORNING THAT MY FUEL PUMP H…
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I HAVE A 2003 CHEVROLET CAVALIER LS SPORT COUPE WITH APPROXIMATELY 72,000 MILES ON IT. LAST NIGHT, WITHOUT ANY WARNING, MY VEHICLE WOULD NOT START AND I WAS LEFT STRANDED WITH GROCERIES IN MY CAR AT A GROCERY STORE PARKING LOT. I HAD IT TOWED TO A VERY REPUTABLE LOCAL REPAIR SHOP AND WAS INFORMED THIS MORNING THAT MY FUEL PUMP HAS TO BE REPLACED. THE REPAIRS ARE GOING TO COST ME APPROXIMATELY $700. IN SEARCHING THE INTERNET, I CAME ACROSS A MESSAGE BOARD WHERE OVER 330 POSTS HAVE BEEN MADE BY CONSUMERS WITH THE SAME PROBLEM I'M HAVING. THE WEBSITE ADDRESS IS HTTP://WWW.TOPIX.COM/FORUM/AUTOS/CHEVROLET-CAVALIER/TVINIC5TFU5SFSI5H ALSO, THE MECHANIC AT THE REPAIR SHOP INFORMED ME THAT HIS SHOP REPAIRS APPROXIMATELY 3-4 FUEL PUMPS ON CHEVROLET CAVALIERS EACH WEEK. HE STATED THAT THEY ARE DEFECTIVE WHEN THEY COME FROM THE MANUFACTURER, SO WHEN THEY GET BETWEEN 60,000-80,000 MILES ON THEM, THEY FAIL WITH NO WARNING SIGNS. *TR
FOR THE PAST YEAR MY VEHICLE HAS STALLED IN TRAFFIC WHILE RUNNING GOING TO 0 RPM BUT RESTARTING. THE I FOUND IS EFFECTING ALL 2003 CAVILIERS , IT WAS MY FUEL PUMP. I AM AT A ROCK AND A HARD PLACE BECAUSE I HAD TO GET FIXED AND COULD NOT SHOP AROUND. I HAD TO SPEND OVER 600.00 AND I COULD NOT AFFIORD TO EVERYTHING THAT RECOMENDE…
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FOR THE PAST YEAR MY VEHICLE HAS STALLED IN TRAFFIC WHILE RUNNING GOING TO 0 RPM BUT RESTARTING. THE I FOUND IS EFFECTING ALL 2003 CAVILIERS , IT WAS MY FUEL PUMP. I AM AT A ROCK AND A HARD PLACE BECAUSE I HAD TO GET FIXED AND COULD NOT SHOP AROUND. I HAD TO SPEND OVER 600.00 AND I COULD NOT AFFIORD TO EVERYTHING THAT RECOMENDED DONE . THE CAR IS NOT EVEN PAID OFF, IF THERE IS A PROBLEM THE CARS SHOULD HAVE THERECALL. I WAS ON INTERSTATE 95 WHERE SPEED LIMIT IS 70 MILES PER HOUR IT IS A MIRACLE THAT I WAS NOT KILLED BY A TRUCK THIS IS A TRUCKING ROUTE IN FLORIDA. PLEASE LOOK INTO THIS IT IS SO DANGEROUS AND IT IS HAPPENING WITH ALL CAVALIERS. *TR
I BOUGHT A 2003 CHEVY CAVALIER A FEW MONTHS AGO. IT HAS 56,000 MILES ON IT AND THE FUEL PUMP WENT OUT ON IT. AT FIRST I DIDN'T THINK IT WAS A BIG PROBLEM WITH THE CAVALIERS SO I GOOGLED IT AND IT TURNS OUT THERE WERE ALMOST 400 COMPLAINTS FROM PEOPLE WHO HAVE HAD THERE FUEL PUMPS GO OUT ON THEIR 2003 CAVALIERS AT LOW MILEAGE, AN…
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I BOUGHT A 2003 CHEVY CAVALIER A FEW MONTHS AGO. IT HAS 56,000 MILES ON IT AND THE FUEL PUMP WENT OUT ON IT. AT FIRST I DIDN'T THINK IT WAS A BIG PROBLEM WITH THE CAVALIERS SO I GOOGLED IT AND IT TURNS OUT THERE WERE ALMOST 400 COMPLAINTS FROM PEOPLE WHO HAVE HAD THERE FUEL PUMPS GO OUT ON THEIR 2003 CAVALIERS AT LOW MILEAGE, AND THOSE ARE JUST THE ONES ON GOOGLE. IM SURE THERE ARE MANY MORE! AS FAR AS I KNOW THERE AREN'T ANY RECALLS FOR THIS PROBLEM, BUT WITH AS MANY CASES AS THERE ARE THAN IT WOULD BE A DEFECT AND THERE SHOULD BE A RECALL. THE AVERAGE PRICE TO REPAIR THE FUEL PUMP IS AROUND $700 AND I REALLY CANT AFFORD THAT MUCH. ANY KIND OF HELP YOU COULD GIVE ME WOULD BE GREATLY APPRECIATED. THANKS *TR
MY CHEVY CAVALIER 2003 JUST STOPPED ON ME WITHOUT ANY NOTICE. GOT TO GO TO WORK AND CAR WOULD NOT START. IT HAS 45, 000 MILES AND ONLY USE IT FOR WORK COMMUTE WHICH IS 1 MILE ROUND TRIP. I HAVE HAD OIL CHANGES REGULARLY. WHEN MECHANIC LOOKED AT IT--HE SAID NOT ANOTHER ONE! COME TO FIND OUT THAT FUEL INJECTION/PUMP FAILURE FOR…
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MY CHEVY CAVALIER 2003 JUST STOPPED ON ME WITHOUT ANY NOTICE. GOT TO GO TO WORK AND CAR WOULD NOT START. IT HAS 45, 000 MILES AND ONLY USE IT FOR WORK COMMUTE WHICH IS 1 MILE ROUND TRIP. I HAVE HAD OIL CHANGES REGULARLY. WHEN MECHANIC LOOKED AT IT--HE SAID NOT ANOTHER ONE! COME TO FIND OUT THAT FUEL INJECTION/PUMP FAILURE FOR THESE CARS IS NOTORIOUS. MY MECHANIC SAID THAT MY CAR WAS THE SEVENTH IN THE LAST 8 MONTH. SAME MO--NO INDICATION OF PROBLEMS AND SUDDENLY YOUR CAR JUST STOPS! REGARDLESS OF WEAR AND TEAR OR CAR MILEAGE. SO I GUESS I WAS LUCKY--I WAS NOT DRIVING IN TRAFFIC WHEN THIS OCCURRED. AND MECHANIC CUT ME A BREAK AT $700. THIS IS OUTRAGEOUS! AND YOU WONDER WHY THE GERMAN, JAPANESE CARS ARE OUT SELLING GOOD OLE USA. THIS WAS MY FIRST PURCHASE OF AMERICAN CAR, AND UNFORTUNATELY I WISH I HAD INSTEAD BOUGHT ANOTHER HONDA, OR MAZDA. *TR
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.