IllustrationAT A DRIVING SPEED OF 55 THE CAR STALLED AND WOULD NOT RESTART. THERE WERE NO PRIOR WARNINGS SUCH AS STALLS OR SLUGGISH ENGINE, ETC. WAS DIAGNOSED AS A FUEL PUMP FAILURE. *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 reportsI WAS DRIVING HOME FROM MY DAUGHTERS TRACK MEET AND WAS IN THE PASSING LANE WHEN I FELT A STRONG HESITATION. I QUICKLY GOT INTO THE DRIVING LANE AND TRIED TO GIVE IT GAS, BUT IT WOULDN'T GO. I PULLED OVER TO THE SIDE AND IT STALLED, AND I COULD NOT GET IT RESTARTED. AFTER WAITING 40 MIN. FOR A TOW(OVER 40 MILES) WE GOT IT TO MY …
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I WAS DRIVING HOME FROM MY DAUGHTERS TRACK MEET AND WAS IN THE PASSING LANE WHEN I FELT A STRONG HESITATION. I QUICKLY GOT INTO THE DRIVING LANE AND TRIED TO GIVE IT GAS, BUT IT WOULDN'T GO. I PULLED OVER TO THE SIDE AND IT STALLED, AND I COULD NOT GET IT RESTARTED. AFTER WAITING 40 MIN. FOR A TOW(OVER 40 MILES) WE GOT IT TO MY DEALER. THE DEALER CALLED THE NEXT DAY AND TOLD ME IT WAS THE FUEL PUMP AT A COST OF $900.00. *TR
I HAVE REPLACED FUEL PUMP 3 TIMES. CLUSTER PANEL WORKS OCCASIONALLY. *TR
I WAS DRIVING ABOUT 15 MPH, ENTERING A ROUNDABOUT, WHEN MY CAR SHUT OFF. I COULD NOT RESTART IT. AFTER GETTING IT TOWED HOME, I GOT A MECHANIC TO TAKE A LOOK AT IT, AND HE SAYS MY FUEL PUMP FAILED. I HAVE READ SEVERAL REPORTS THAT OTHERS WITH THE SAME MAKE AND MODEL HAVE COMPLAINED OF THIS ISSUE, AND I THOUGHT IT BEST TO ADD …
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I WAS DRIVING ABOUT 15 MPH, ENTERING A ROUNDABOUT, WHEN MY CAR SHUT OFF. I COULD NOT RESTART IT. AFTER GETTING IT TOWED HOME, I GOT A MECHANIC TO TAKE A LOOK AT IT, AND HE SAYS MY FUEL PUMP FAILED. I HAVE READ SEVERAL REPORTS THAT OTHERS WITH THE SAME MAKE AND MODEL HAVE COMPLAINED OF THIS ISSUE, AND I THOUGHT IT BEST TO ADD MINE TO THE LIST. THE COST TO REPLACE THE PART IS GOING TO BE $700. *TR
I DRIVE A 2003 CHEVY CAVALIER WITH ONLY 31,000 MILES. I WAS DRIVING HOME AND THE CAR SPUTTERED AND DIED IN THE MIDDLE OF A BUSY HIGHWAY. I HAD TO WAIT FOR A TOW TRUCK TO TOW MY CAR OVER 30 MILES TO THE NEAREST SERVICE CENTER TO MY HOME TO HAVE IT FIXED. I PAID FOR A DIAGNOSTIC AND WAS TOLD THAT IT WAS THE FUEL PUMP. THE TOTAL CO…
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I DRIVE A 2003 CHEVY CAVALIER WITH ONLY 31,000 MILES. I WAS DRIVING HOME AND THE CAR SPUTTERED AND DIED IN THE MIDDLE OF A BUSY HIGHWAY. I HAD TO WAIT FOR A TOW TRUCK TO TOW MY CAR OVER 30 MILES TO THE NEAREST SERVICE CENTER TO MY HOME TO HAVE IT FIXED. I PAID FOR A DIAGNOSTIC AND WAS TOLD THAT IT WAS THE FUEL PUMP. THE TOTAL COST FOR LABOR AND PARTS WAS 799.00, PLUS $135 FOR A RENTAL CAR DURING THE TIME IT TOOK FOR THE CAR TO BE FIXED. THE NEXT DAY, THE "TRAC OFF" LIGHT CAME ON. I HAD NEVER HAD ANY PROBLEMS WITH MY CAR BEFORE. MY EXTENDED WARRANTY HAD JUST RUN OUT EARLIER IN THE YEAR. I HAVE BEEN CONDUCTING AN INTERNET SEARCH AND IT SEEMS THAT THESE CARS ARE PRONE TO THIS PROBLEM AND THE FUEL PUMPS ARE UNDER INVESTIGATION FOR RECALL. *TR
MY 19 YEAR OLD DAUGHTER DURING REGULAR DRIVING FROM WORK, CAR JUST DIED ON THE HIGHWAY. CAR HAS 60,000 MILES ON IT TURNS OUT TO BE THE FUEL PUMP AND AFTER RESEARCHING THE REMOVAL PROCESS.I NOTICED THAT EVERY CAVALIER FROM 01 ON HAS THE SAME ISSUE WITH THE FUEL PUMP. THIS IS OBVIOUSLY A MANUFACTURE DEFECT AND SHOULD BE RECALLE…
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MY 19 YEAR OLD DAUGHTER DURING REGULAR DRIVING FROM WORK, CAR JUST DIED ON THE HIGHWAY. CAR HAS 60,000 MILES ON IT TURNS OUT TO BE THE FUEL PUMP AND AFTER RESEARCHING THE REMOVAL PROCESS.I NOTICED THAT EVERY CAVALIER FROM 01 ON HAS THE SAME ISSUE WITH THE FUEL PUMP. THIS IS OBVIOUSLY A MANUFACTURE DEFECT AND SHOULD BE RECALLED IMMEDIATELY. *TR
I OWN A 2003 CHEVROLET CAVALIER LS SEDAN WITH APPROXIMATELY 86,300 MILES ON IT. WITHOUT WARNING THE CAR DIED AND WOULD NOT START ON A BUSY JULY 4TH WEEKEND ALONG I-55 NORTH BOUND NEAR LITICHFIELD, IL. I T WOULD NOT RESTART, AND SUBSEQUENT INVESTIGATION RESULTED IN THE FACT FINDING THAT IT WAS THE FUEL PUMP. APPARENTLY THIS IS A …
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I OWN A 2003 CHEVROLET CAVALIER LS SEDAN WITH APPROXIMATELY 86,300 MILES ON IT. WITHOUT WARNING THE CAR DIED AND WOULD NOT START ON A BUSY JULY 4TH WEEKEND ALONG I-55 NORTH BOUND NEAR LITICHFIELD, IL. I T WOULD NOT RESTART, AND SUBSEQUENT INVESTIGATION RESULTED IN THE FACT FINDING THAT IT WAS THE FUEL PUMP. APPARENTLY THIS IS A MAJOR PROBLEM WITH THIS MAKE AND MODEL VEHICLE. I REQUEST THAT GM BE REQUIRED TO RECALL THIS MAKE AND MODEL TO ADDRESS THE PROBLEM AND REIMBURSE OWNERS FOR OUT OF POCKET EXPENSES. I HAVE ALWAYS OWNED AMERICAN CARS, BUT AN SERIOUS CONSIDERING A TOYOTA NEXT YEAR. *TR
MY 2003 CHEVROLET CAVALIER WITH ~61000 MILES NEEDS A NEW FUEL PUMP; A FUEL PUMP SHOULD LAST MUCH LONGER THAN THAT. *TR
MY CAVALIER RAN PERFECTLY UNTIL THE OTHER DAY WHEN MY HUSBAND TRIED TO START IT AND IT WOULD START AND THE DIE. HE TRIED STARTING IT A COUPLE OF TIMES. SOMETIMES IT WOULDN'T START AND THEN SOMETIMES IT WOULD START THEN DIE. THE FUEL PUMP HAD TO BE REPLACED. MY CAR HAS 85,000 MILES ON IT AND I BOUGHT IT WITH A SALVAGE TITLE I…
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MY CAVALIER RAN PERFECTLY UNTIL THE OTHER DAY WHEN MY HUSBAND TRIED TO START IT AND IT WOULD START AND THE DIE. HE TRIED STARTING IT A COUPLE OF TIMES. SOMETIMES IT WOULDN'T START AND THEN SOMETIMES IT WOULD START THEN DIE. THE FUEL PUMP HAD TO BE REPLACED. MY CAR HAS 85,000 MILES ON IT AND I BOUGHT IT WITH A SALVAGE TITLE IN JANUARY 2006. THE FUEL PUMP MY CAR HAS IT THE ORIGINAL MANUFACTURERS. *TR
I HAVE A 2003 CAVALIER AND I HAD TO REPLACE THE FUEL PUMP AT 90,000MILES AGAIN !!!THIS IS SHAMEFUL 4 CHEVY , I SAVED MY RECIPE BECAUSE IT COST ME 600 DOLLARS TO FIX IT,GOOD BYE SUMMER SCHOOL LOOKS LIKE MY GRADUATION IS GOING BE DELAYED HALF YEAR. *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.