NHTSA owner reports · September 18, 2026 snapshot.
Fuel System, Gasoline complaints
340 reportsClear category filter117,000 miles · Feb 24, 2010
Fuel System, Gasoline
STARTED THE CAR UP IN THE MORNING AS NORMAL TO WARM THE CAR UP ( ABOUT 5 MINS). DROVE ABOUT 1 MILE TO ROYAL FARMS. I SHUT DOWN THE CAR TO GO INSIDE AND I RETURNED TO THE CAR TO START IT UP. AT FIRST IT STARTED UP BUT VERY RUFF AND THEN STALLED OUT AFTER THAT IT DID NOT FIRE UP ANYMORE. I HAD THE CAR TOWED HOME WHERE I FOUND…
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STARTED THE CAR UP IN THE MORNING AS NORMAL TO WARM THE CAR UP ( ABOUT 5 MINS). DROVE ABOUT 1 MILE TO ROYAL FARMS. I SHUT DOWN THE CAR TO GO INSIDE AND I RETURNED TO THE CAR TO START IT UP. AT FIRST IT STARTED UP BUT VERY RUFF AND THEN STALLED OUT AFTER THAT IT DID NOT FIRE UP ANYMORE. I HAD THE CAR TOWED HOME WHERE I FOUND OUT THAT THE FUEL PUMP HAS GONE UP. I HAVE HAD IDLE PROBLEMS WITH THE CAR SINCE I HAD BOUGHT THE CAR AND THE DEALERSHIP COULD NOT FIND ANY PROBLEMS WITH IT. I DO NOT KNOW IF THESE PROBLEM GO SIDE BY SIDE. *TR
NHTSA ODI #10313880
65,062 miles · Feb 19, 2010
Fuel System, Gasoline
RECENTLY PURCHASED PRE-OWNED 2003 CHEVROLET CAVALIER STALLED, THE ENGINE DIED IN THE MIDDLE OF TRAFFIC. I HAVE BEEN UNABLE TO START THE VEHICLE SINCE. IT SOUNDS AS IF IT WANTS TO START BUT WILL NOT. I BELIEVE THAT THERE IS AN ISSUE WITH THE FUEL PUMP. I HAVE READ OTHER COMPLAINTS AND THIS IS THE EXACT SAME THING THAT HAPPENE…
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RECENTLY PURCHASED PRE-OWNED 2003 CHEVROLET CAVALIER STALLED, THE ENGINE DIED IN THE MIDDLE OF TRAFFIC. I HAVE BEEN UNABLE TO START THE VEHICLE SINCE. IT SOUNDS AS IF IT WANTS TO START BUT WILL NOT. I BELIEVE THAT THERE IS AN ISSUE WITH THE FUEL PUMP. I HAVE READ OTHER COMPLAINTS AND THIS IS THE EXACT SAME THING THAT HAPPENED TO ME... *TR
NHTSA ODI #10311961
Mileage unknown · Feb 13, 2010
Electrical SystemFuel System, Gasoline
THE FUEL GAUGE BEGAN TO MALFUNCTION ABOUT A YEAR AGO. ASSUMING IT WAS JUST THE FLOAT, I DECIDED I WOULD IGNORE IT AND USE THE TRIP ODOMETER TO DETERMINE HOW MUCH GAS I HAD LEFT. UNFORTUNATELY, BECAUSE THE GAS GAUGE WENT WELL PAST FULL, INTO THE REALM OF WHAT WOULD BE CONSIDERED TWO TANKS OF FULL, THE TEMPERATURE GAUGE NEEDLE C…
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THE FUEL GAUGE BEGAN TO MALFUNCTION ABOUT A YEAR AGO. ASSUMING IT WAS JUST THE FLOAT, I DECIDED I WOULD IGNORE IT AND USE THE TRIP ODOMETER TO DETERMINE HOW MUCH GAS I HAD LEFT. UNFORTUNATELY, BECAUSE THE GAS GAUGE WENT WELL PAST FULL, INTO THE REALM OF WHAT WOULD BE CONSIDERED TWO TANKS OF FULL, THE TEMPERATURE GAUGE NEEDLE COULD NOT MOVE. EVENTUALLY, THE GAS GAUGE NEEDLE WENT PAST THE TEMPERATURE GAUGE (NOW AT WHAT WOULD BE CONSIDERED TWO AND A HALF TANKS) WHICH FREED THE TEMPERATURE NEEDLE TO ACTUALLY REGISTER. NOW, THE TEMPERATURE GAUGE IS MALFUNCTIONING, RESTING AT THE HALF WAY POINT EVEN AFTER THE CAR SAT ALL NIGHT IN OUR RECENT FRIGID TEMPERATURES. IT NOW RUNS IN THE RED EVEN THOUGH THERE IS NOTHING WRONG WITH THE ENGINE. NOW, THE SPEEDOMETER IS SHOWING SIGNS OF MALFUNCTIONING, AS IT READS 5 MPH THOUGH I AM AT A COMPLETE STOP. RESEARCH ON VARIOUS INTERNET MESSAGE BOARDS SUGGEST THIS IS A VERY COMMON PROBLEM IN NOT ONLY 2003 CHEVROLET CAVALIERS, BUT OTHER YEARS AND MODELS OF CHEVY VEHICLES. WHEN I COMPLAINED TO GM THAT A MALFUNCTIONING SPEEDOMETER WAS A SAFETY ISSUE, I WAS GREETED WITH "THERE'S NO RECALL, IT'S NO LONGER UNDER WARRANTY, CAN'T HELP, YOUR PROBLEM, DEAL WITH IT." FOLLOWING THIS LOGIC, WHAT'S STOPPING GM FROM CREATING MORE DEFECTIVE VEHICLES, IF THE PROBLEM HAPPENS AFTER THE WARRANTY EXPIRES? THEY'VE ADOPTED THE ATTITUDE IT'S "NOT THEIR PROBLEM." AT WHAT POINT IS A DEFECTIVE SPEEDOMETER NOT A SAFETY PROBLEM WORTHY OF A RECALL? *TR
NHTSA ODI #10310236
60,000 miles · Jan 19, 2010
Fuel System, Gasoline
FUEL PUMP GOES OUT AFTER ONLY 60,000 MILES. THIS IS UNACCEPTABLE, I OWN OTHER VEHICLES THAT HAVE 3 TIMES THIS MILEAGE BEFORE I HAD TO REPLACE A FUEL PUMP. *TR
NHTSA ODI #10300333
83,000 miles · Jan 5, 2010
Fuel System, Gasoline
2003 CHEVY CAVALIER, ~83,000 MILES. DEC 3 IN NE OHIO, TRAVELING AT HIGHWAY SPEEDS ON OHIO ROUTE 11 AT ~11:50PM. CAR SUDDENLY STARTED TO SLOW DOWN, TRAC LIGHT AND OIL LIGHT CAME ON. ABLE TO PULL OVER TO SIDE OF ROAD. ENGINE STILL RUNNING BUT ROUGH. NO POWER WHEN TRIED TO MAKE CAR MOVE. HAD TO HAVE CAR TOWED HOME $200. TOOK ~3HRS …
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2003 CHEVY CAVALIER, ~83,000 MILES. DEC 3 IN NE OHIO, TRAVELING AT HIGHWAY SPEEDS ON OHIO ROUTE 11 AT ~11:50PM. CAR SUDDENLY STARTED TO SLOW DOWN, TRAC LIGHT AND OIL LIGHT CAME ON. ABLE TO PULL OVER TO SIDE OF ROAD. ENGINE STILL RUNNING BUT ROUGH. NO POWER WHEN TRIED TO MAKE CAR MOVE. HAD TO HAVE CAR TOWED HOME $200. TOOK ~3HRS IN FREEZING COLD AND SNOWSTORM. CAR WOULD NOT START THE NEXT DAY. COULD NOT HEAR CHARACTERISTIC WHIR OF FUEL PUMP WHEN KEY FIRST TURNED. DIAGNOSIS OF ELECTRICAL SHOWED FUEL PUMP WAS RECEIVING VOLTAGE. TAPPING ON BOTTOM OF FUEL TANK WHILE TRYING TO START CAR RESULTED IN CAR STARTING. DIAGNOSIS: NEW FUEL PUMP REQUIRED. ANTICIPATED COST $250 + LABOR. TOTAL ANTICIPATED COST: $450 + LABOR. FORTUNATELY NO OR LITTLE TRAFFIC. ALSO FORTUNATE TOW TRUCK RESPONDED QUICKLY OTHERWISE PERSONAL INJURY FROM COLD COULD HAVE OCCURRED. THIS SHOULD NOT HAVE HAPPENED AT THIS LOW MILEAGE. FUEL PUMPS SHOULD BE LIFETIME ENGINEERED. *TR
NHTSA ODI #10298292
88,000 miles · Jan 2, 2010
Fuel System, Gasoline
2003 CHEVY CAVALIER FUEL PUMP HAS TO BE DEFECTIVE FOR ALL THE PROBLEMS PEOPLE ARE HAVING WITH IT. MINE JUST WENT ON MY CAR WITHOUT ANY WARNING . *TR
NHTSA ODI #10297837
10,000 miles · Dec 28, 2009
Fuel System, Gasoline
I HAD PURCHASED BRAND NEW CHEVROLET CAVALIER BACK IN 2003 AFTER 10K OR SO, IT STARTED STALLING DURING DRIVING WHEN THE CLUTCH IS PRESSED TO CHANGE THE GEAR OR AT TRAFFIC STOPS. THIS PROBLEMS REPEATS EVERY WEEK OR SO AND IT IS VERY DANGEROUS AS ALL THE POWER TO THE STEERING AND BRAKES IS LOST. I THINK THIS SHOULD NOT BE HAPPENING…
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I HAD PURCHASED BRAND NEW CHEVROLET CAVALIER BACK IN 2003 AFTER 10K OR SO, IT STARTED STALLING DURING DRIVING WHEN THE CLUTCH IS PRESSED TO CHANGE THE GEAR OR AT TRAFFIC STOPS. THIS PROBLEMS REPEATS EVERY WEEK OR SO AND IT IS VERY DANGEROUS AS ALL THE POWER TO THE STEERING AND BRAKES IS LOST. I THINK THIS SHOULD NOT BE HAPPENING TO A BRAND NEW VEHICLE. BECAUSE OF THIS PROBLEM I AM NEVER GOING TO BUY A GM VEHICLE AGAIN AND WILL NOT RECOMMEND OTHERS. I WOULD LIKE GM TO FIX THIS FOR ME AS IT IS A MAJOR SAFETY CONCERN. *TR
NHTSA ODI #10297132
62,000 miles · Dec 9, 2009
Fuel System, Gasoline
THE FUEL PUMP IN MY 2003 CHEVROLET CAVALIER FAILED, WITH NO WARNING, LEAVING ME STRANDED IN MORNING RUSH HOUR TRAFFIC ON THE HIGHWAY. I HAVE READ ON SEVERAL WEBSITES THAT THIS IS A COMMON AND SOMETIMES CONTINUOUS PROBLEM WITH THIS PARTICULAR YEAR'S MODEL. I AM FILING A FORMAL COMPLAINT BECAUSE I WANT GM HELD RESPONSIBLE FOR USIN…
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THE FUEL PUMP IN MY 2003 CHEVROLET CAVALIER FAILED, WITH NO WARNING, LEAVING ME STRANDED IN MORNING RUSH HOUR TRAFFIC ON THE HIGHWAY. I HAVE READ ON SEVERAL WEBSITES THAT THIS IS A COMMON AND SOMETIMES CONTINUOUS PROBLEM WITH THIS PARTICULAR YEAR'S MODEL. I AM FILING A FORMAL COMPLAINT BECAUSE I WANT GM HELD RESPONSIBLE FOR USING DEFECTIVE FUEL PUMPS. *TR
NHTSA ODI #10295148
78,000 miles · Nov 23, 2009
Fuel System, Gasoline
FUEL PUMP FAILURE AT 125,000 KMS. DRIVING ON HIGHWAY, CAR FAILED TO ACCELERATE. EVENTUALLY HAD TO PULL OVER, VEHICLE STALLED AND WOULD NOT RE-START. TOWED, FUEL PUMP REPLACED. *TR
NHTSA ODI #10293303
36,100 miles · Nov 16, 2009
Fuel System, Gasoline
I WAS DRIVING DOWN A BUSY ROAD IN TOWN GOING 40 MPH WHEN MY CAR STARTED TO CHUG. IT ENDED UP STALLING AND I WAS IN THE BUSY LANE, STILL DRIVING!!! I HAD TO IMMEDIATELY TURN ON MY HAZARDS AND TRY TO SLOWLY GET OUT OF EVERY OTHER DRIVERS WAY. I HAD CARS THAT HAD TO SLOW DOWN QUITE QUICKLY BEHIND ME AS I COULD NOT ACCELERATE OR DO…
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I WAS DRIVING DOWN A BUSY ROAD IN TOWN GOING 40 MPH WHEN MY CAR STARTED TO CHUG. IT ENDED UP STALLING AND I WAS IN THE BUSY LANE, STILL DRIVING!!! I HAD TO IMMEDIATELY TURN ON MY HAZARDS AND TRY TO SLOWLY GET OUT OF EVERY OTHER DRIVERS WAY. I HAD CARS THAT HAD TO SLOW DOWN QUITE QUICKLY BEHIND ME AS I COULD NOT ACCELERATE OR DO ANYTHING BUT COAST OUT OF THEIR WAY. THIS WAS THE FIRST TIME SOMETHING HAS HAPPENED LIKE THIS, I HAD THE CAR TOWED THE NEXT MORNING AS WHEN IT STALLED I WAS ON MY WAY TO WORK. IT WAS THE FUEL PUMP. I HAD BROUGHT MY CAR TO THE DEALER WHERE I BOUGHT THE CAR. MY WARRANTY WAS JUST UP ABOUT A YEAR AGO, BUT I AM SURE THIS IS NOT UNDER WARRANTY, IT COST ME $900 AND THE FACT THAT I STALLED ON A BUSY STREET. TO ME THIS WAS A VERY DANGEROUS SITUATION TO BE IN. I WAS QUITE UPSET AFTER THE WHOLE ORDEAL. *TR
NHTSA ODI #10292367
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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