NHTSA owner reports · September 18, 2026 snapshot.
Visibility complaints
37 reportsClear category filter90,000 miles · Aug 22, 2011
VisibilityFire
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT WAS DRIVING 30 MPH WHEN THE DEFROSTER WAS ENGAGED AND THE CONTACT BEGAN TO SEE BLACK SMOKE COMING THE VENTS. THE CONTACT MERGED ONTO THE SIDE SHOULDER AND SECONDS LATER, THE VEHICLE CAUGHT FIRE FROM THE VENTILATION SYSTEM. NEITHER THE DEALER NOR THE MANUFACTURER WERE…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT WAS DRIVING 30 MPH WHEN THE DEFROSTER WAS ENGAGED AND THE CONTACT BEGAN TO SEE BLACK SMOKE COMING THE VENTS. THE CONTACT MERGED ONTO THE SIDE SHOULDER AND SECONDS LATER, THE VEHICLE CAUGHT FIRE FROM THE VENTILATION SYSTEM. NEITHER THE DEALER NOR THE MANUFACTURER WERE NOTIFIED OF THE FAILURE. A POLICE REPORT WAS FILED. THE VEHICLE WAS DESTROYED. THE FAILURE AND CURRENT MILEAGE WAS 90,000. THE VIN WAS UNAVAILABLE. UPDATED 9/27/11 *CN UPDATED 3/29/12 *CN
NHTSA ODI #10421039
Mileage unknown · Sep 22, 2010
Electrical SystemFuel System, OtherVisibility
2003 CAVALIER, THE DEFROSTER KNOB CABLE HAS GONE BAD 2X'S BEFORE IT IS GONE AGAIN, THE DRIVER SIDE WINDOW MOTOR WENT LAST YEAR, LAST MONTH THE FUEL PUMP WENT, THE PASSENGER SIDE MOTOR IS GOING, THE SPEEDOMETER IS MESSED UP ALONG WITH THE TACK, IT STICKS. MY DAUGHTER DRIVES THIS CAR JUST TURNED 17, THE SPEEDOMETER SAID SHE WAS …
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2003 CAVALIER, THE DEFROSTER KNOB CABLE HAS GONE BAD 2X'S BEFORE IT IS GONE AGAIN, THE DRIVER SIDE WINDOW MOTOR WENT LAST YEAR, LAST MONTH THE FUEL PUMP WENT, THE PASSENGER SIDE MOTOR IS GOING, THE SPEEDOMETER IS MESSED UP ALONG WITH THE TACK, IT STICKS. MY DAUGHTER DRIVES THIS CAR JUST TURNED 17, THE SPEEDOMETER SAID SHE WAS GOING 105, WHEN SHE SHUTS THE CAR OFF IT SAYS SHE'S STILL DOING 35, AT TIMES THE CAR WONT START, DON'T KNOW EXACTLY WHY, THIS IS BS, THERE IS ONLY 72000 MILES ON IT, GM NEEDS TO START FIXING THESE PROBLEMS, SOME ONE IS GOING TO GET KILLED. *TR
NHTSA ODI #10357087
87,000 miles · Mar 14, 2010
Visibility
MY DRIVER'S SIDE POWER WINDOW WILL INITIALLY GO DOWN. WHEN I ATTEMPT TO POWER THE WINDOW UP, IT GOES APPROXIMATELY ONE TO TWO INCHES THEN STOPS. I HAVE TO CONTINUE DRIVING OR LEAVE MY CAR RUNNING UNTIL THE WINDOW IS UP. IT IS VERY UNSAFE TO LEAVE MY CAR IN ANY LOT OR PARKING SPACE WITH THE WINDOW DOWN. ON AVERAGE EVERY 10 MINUTE…
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MY DRIVER'S SIDE POWER WINDOW WILL INITIALLY GO DOWN. WHEN I ATTEMPT TO POWER THE WINDOW UP, IT GOES APPROXIMATELY ONE TO TWO INCHES THEN STOPS. I HAVE TO CONTINUE DRIVING OR LEAVE MY CAR RUNNING UNTIL THE WINDOW IS UP. IT IS VERY UNSAFE TO LEAVE MY CAR IN ANY LOT OR PARKING SPACE WITH THE WINDOW DOWN. ON AVERAGE EVERY 10 MINUTES IT WILL GO UP ANOTHER INCH OR TWO. THIS HAPPENS EVERY TIME I POWER THE WINDOW DOWN. I WILL NOT LEAVE MY WINDOW DOWN. ELEMENTS WILL DAMAGE THE INTERIOR, AND IT LEAVES ME SUSCEPTIBLE TO VANDALS. I HAVE TWO CHILDREN AND I CONSIDER THIS MALFUNCTION UNSAFE FOR ME THE DRIVER AND MY CHILDREN. I PAID $18,000 FOR THE VEHICLE, I WILL NOT ALLOW THIS TO GO UNFIXED, HOWEVER I FEEL IT IS THE COMPANY'S RESPONSIBILITY TO RECALL AND REPAIR THE ISSUE. *TR
NHTSA ODI #10319578
108,000 miles · Mar 10, 2010
Electrical SystemVisibilityFire
I OWN A 2003 CHEVROLET CAVALIER LS AND ON DEC. 25 WHEN I TURNED ON THE REAR DEFROST BUTTON SMOKE STARTED TO COME OUT FROM INSIDE THE STEERING WHEEL COLUMN. I COULD NOT GET THE REAR DEFROST TO TURN OFF SO I HAD TO TURN OFF THE CAR AND REMOVE THE FUSE TO IT. SHORTLY AFTER THIS INCIDENT THE POWER WINDOWS HAVE STOPPED WORKING AND TH…
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I OWN A 2003 CHEVROLET CAVALIER LS AND ON DEC. 25 WHEN I TURNED ON THE REAR DEFROST BUTTON SMOKE STARTED TO COME OUT FROM INSIDE THE STEERING WHEEL COLUMN. I COULD NOT GET THE REAR DEFROST TO TURN OFF SO I HAD TO TURN OFF THE CAR AND REMOVE THE FUSE TO IT. SHORTLY AFTER THIS INCIDENT THE POWER WINDOWS HAVE STOPPED WORKING AND THE FUSE TO THEM IS STILL GOOD, I REPLACED IT JUST IN CASE BUT THE WINDOWS STILL DO NOT WORK. THE ODOMETER HAS ALSO STOPPED WORKING SO I HAVE HAD TO GUESS MY SPEED. I FEEL THAT THIS IS A HUGE SAFETY CONCERN SINCE THE REAR DEFROST DOES NOT WORK I CANNOT SEE OUT THE REAR WINDOW ON COLD DAYS, I ALSO CANNOT TELL HOW FAST I AM DRIVING WHICH CAN CAUSE AN ACCIDENT, AND THE POWER WINDOWS HAVE STOPPED WORKING. THE CAR IS DUE FOR INSPECTION NEXT MONTH AND I CANNOT AFFORD TO FIX THESE PROBLEMS, THIS IS MY ONLY VEHICLE AND RELY ON IT TO GET TO AND FROM WORK EVERYDAY. I HAVE ALSO PLACED A COMPLAINT WITH GENERAL MOTORS CONCERNING THIS ISSUE AS I FEEL THAT THE PROBLEMS THAT HAVE OCCURRED ARE A RESULT OF POOR OR HURRIED WORKMANSHIP IN THAT AREA OF THE VEHICLE'S MANUFACTURE. *TR
NHTSA ODI #10318711
50,000 miles · Nov 13, 2009
Visibility
HVAC CABLE BENT AND THEN SNAPPED. NOW I CAN'T DEFROST THE WINDSHIELD I RAN OFF THE ROAD TODAY BECAUSE I COULD NOT SEE. I REPORTED THIS PROBLEM TO GM OVER A YEAR AGO AND THEY DIDN'T SEEM TO CARE. THEY NEVER RESPONDED TO MY LETTER. THIS IS A BIG SAFETY ISSUE. I HAVE HAD IT FIXED BY A MECHANIC 2X AND SHOULD NOT ONLY BE REIMBURSED, …
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HVAC CABLE BENT AND THEN SNAPPED. NOW I CAN'T DEFROST THE WINDSHIELD I RAN OFF THE ROAD TODAY BECAUSE I COULD NOT SEE. I REPORTED THIS PROBLEM TO GM OVER A YEAR AGO AND THEY DIDN'T SEEM TO CARE. THEY NEVER RESPONDED TO MY LETTER. THIS IS A BIG SAFETY ISSUE. I HAVE HAD IT FIXED BY A MECHANIC 2X AND SHOULD NOT ONLY BE REIMBURSED, BUT SHOULD HAVE THIS PROBLEM FIXED. IT STILL DOES NOT WORK RIGHT. HAD THE ACTUAL CABLE REPLACED AND THEN JUST HAD THE KINK CORRECTED ON IT AND IT BROKE AGAIN THE NEXT DAY. *TR
NHTSA ODI #10292080
30,000 miles · Mar 25, 2009
Visibility
HVAC CABLE BENT AND THEN SNAPPED. NOW I CAN'T DEFROST THE WINDSHIELD & THIS COULD CAUSE AN ACCIDENT SINCE I CAN'T SEE WHERE I'M GOING! *TR
NHTSA ODI #10263055
Mileage unknown · Feb 12, 2009
Visibility
I HAVE TO IDENTICAL 2003 CHEVY CAVALIERS AND THE WINDOW MOTORS BOTH FAILED AROUND THE EXACT SAME TIME AND I HAVE BEEN TO NUMEROUS SITES THAT HAVE ALSO REPORTED THIS FAILURE AND CHEVY SAYS THAT THIS ISNT THEIR PROBLEM. *TR
NHTSA ODI #10258444
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
76,500 miles · Nov 17, 2008
Visibility
2003 CHEVY CAVALIER - DEFROSTERS DO NOT WORK (REAR AND SIDE WINDOWS), PASSENGER WINDOW STOP WORKING (INTERMITTENT) AND LOUD SCREECHING NOISE WHEN STARTING ENGINE. *TR
NHTSA ODI #10248997
66,000 miles · Nov 10, 2008
Fuel System, GasolineVisibility
WHILE STOP AT A RED LIGHT VEH.CUT OFF AND WOULD NOT RE-STAR. TOWED TO THE DEALER AND I WAS TOLD THAT IT WAS THE FUEL PUMP. COST $1,050. I ALSO HAVE PROBLEMS WITH ELECTRIC WINDOWS,TWO MOTORS REPLACED ,ONE SWITCH AND STILL HAVING PROBLEMS. BESIDES THAT NO COMPLAIN. *TR
NHTSA ODI #10248249
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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