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
What owners actually said
678 reports
Mileage unknown · Mar 24, 2008
Fuel System, Gasoline
I HAVE A 2003 CHEVY CAVALIER AND IT HAS LESS THAN 50,000 MILES ON IT. ABOUT A WEEK AGO, IT JUST QUIT ON ME. TURNS OUT IT WAS THE FUEL PUMP. NOT ONLY DO I HAVE THE INCONVENIENCE AND COST OF HAVING TO REPLACE IT, BUT IT IS NOT AN EASY THING TO REPLACE. YOU HAVE TO COMPLETELY DROP THE FUEL TANK. MOST NEWER CARS HAVE ANOTHER (E…
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I HAVE A 2003 CHEVY CAVALIER AND IT HAS LESS THAN 50,000 MILES ON IT. ABOUT A WEEK AGO, IT JUST QUIT ON ME. TURNS OUT IT WAS THE FUEL PUMP. NOT ONLY DO I HAVE THE INCONVENIENCE AND COST OF HAVING TO REPLACE IT, BUT IT IS NOT AN EASY THING TO REPLACE. YOU HAVE TO COMPLETELY DROP THE FUEL TANK. MOST NEWER CARS HAVE ANOTHER (EASIER) WAY TO DO IT, BUT NOT THE CAVALIER. *TR
NHTSA ODI #10222204
65,000 miles · Mar 22, 2008
Fuel System, Gasoline
FUEL PUMP WENT OUT DURING SNOW STORM. *TR
NHTSA ODI #10222007
54,000 miles · Mar 19, 2008
Fuel System, Gasoline
ENGINE STALLED WHILE TURNING VEHICLE. VEHICLE HAD TO BE PUSHED FROM THE ROADWAY. ATTEMPTED TO RESTART BUT WOULD NOT IDLE, CONTINUED TO STALL. VEHICLE IS NOW AT RESIDENCE AND WILL NOT START. *TR
NHTSA ODI #10221807
71,000 miles · Mar 18, 2008
Fuel System, Gasoline
AFTER DRIVING THE CAR TO THE STORE, I RETURNED TO ATTEMPT TO START THE CAR, IT STUTTERED AND I TRIED AGAIN. CAR WOULD NOT START, AFTER INSPECTING INTAKE I NOTICED ANTIFREEZE AND OIL IN IT. I CALLED FOR A TOW AND A DIAGNOSTIC FROM A SHOP TO FIND THAT I HAD 30PSI IN CYLINDERS 2,3 AND 170 IN CYL 1 AND 4. I NOW HAD A BLOWN HEAD GASK…
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AFTER DRIVING THE CAR TO THE STORE, I RETURNED TO ATTEMPT TO START THE CAR, IT STUTTERED AND I TRIED AGAIN. CAR WOULD NOT START, AFTER INSPECTING INTAKE I NOTICED ANTIFREEZE AND OIL IN IT. I CALLED FOR A TOW AND A DIAGNOSTIC FROM A SHOP TO FIND THAT I HAD 30PSI IN CYLINDERS 2,3 AND 170 IN CYL 1 AND 4. I NOW HAD A BLOWN HEAD GASKET. AFTER HAVING IT REPAIRED, WENT TO START THE CAR TO GIVE SYMPTOMS OF A BAD FUEL PUMP. CAR NOW HAS 71,000 MILES. 3 DAYS AFTER BUYING A NEW IMPALA. PERHAPS CHEVY IS NOT THE BEST BRAND TO COMMIT TO. *TR
NHTSA ODI #10221545
83,934 miles · Mar 18, 2008
Fuel System, Gasoline
ON FRIDAY NIGHT I PARKED MY CAR AS I USUALLY DO AND ON MONDAY MORNING AT 7:00 AM IT STARTED FINE. AFTER DROPPING OFF MY EIGHT YEAR OLD SON AT THE BEFORE CARE OF HIS SCHOOL, I DROVE 2.73 MILES AND MY CAR WENT COMPLETELY DEAD AND THE LIGHTS TURNED ON AFTER APPLYING SLIGHTLY MORE PRESSURE ON THE GAS PEDAL GOING NOT MORE THAN 30 MPH…
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ON FRIDAY NIGHT I PARKED MY CAR AS I USUALLY DO AND ON MONDAY MORNING AT 7:00 AM IT STARTED FINE. AFTER DROPPING OFF MY EIGHT YEAR OLD SON AT THE BEFORE CARE OF HIS SCHOOL, I DROVE 2.73 MILES AND MY CAR WENT COMPLETELY DEAD AND THE LIGHTS TURNED ON AFTER APPLYING SLIGHTLY MORE PRESSURE ON THE GAS PEDAL GOING NOT MORE THAN 30 MPH IN A 35 ZONE IN ORDER TO GO UP A SLIGHT, HARDLY NOTICEABLE INCLINE AND MY MILEAGE HAD JUST REACHED 83,934. I WAS ON THE LEFT HAND SIDE OF THE ROAD WITHOUT A SIDE TO PULL OVER TO AND LUCKILY THERE WAS NO CAR IN THE RIGHT HAND LANE BECAUSE I BARELY HAD ENOUGH TIME TO MOVE OVER INTO THE RIGHT HAND LANE AND AS FAR TO THE SIDE AS I POSSIBLY COULD. HERE I WAS NOW WITH MY TWO YEAR OLD DAUGHTER STUCK NEAR ANOTHER SCHOOL WHERE PARENTS WERE HURRIEDLY TRYING TO DROP OFF THEIR CHILDREN AND TRAFFIC WAS BUILDING UP AROUND ME QUICKLY. I HAD TO GET OUT OF MY CAR AND TRY TO PUSH MY CAR AS FAR OUT OF THE WAY AS POSSIBLE (I AM ONLY A 119 LBS GIRL SO OF COURSE I DID NOT MAKE IT FAR). MY HUSBAND WAS STILL SLEEPING AND HE DID NOT HEAR MY FRANTIC CALLS, SO I HAD TO CALL A GIRL THAT LIVED ACROSS TOWN WHO I WORKED WITH TO REQUEST HER TO PICK-UP MY TWO YEAR OLD DAUGHTER, CALL A TOW-TRUCK TO REQUEST THEM TO COME AND GET MY CAR OUT THE COMMUTERS WAY ASAP, AND I THEN WROTE A NOTE, PUT IT ON THE WINDSHIELD OF THE CAR WITH MY CELL # STATING THAT I WALKED TO SAFEWAY WHICH WAS 1.71 MILES BACK DOWN THE STREET IN ORDER TO MEET MY RIDE AS WE WERE NOT IN A SAFE AREA AND I WAS AFRAID OF THE ANGRY PEOPLE TRYING TO DRIVE AROUND US AS FAST AS POSSIBLE AND MY TWO YEAR OLD BABY WAS UPSET. A FEW MINUTES AFTER WE WALKED INTO THE SAFEWAY, A POLICE OFFICE WHO HAD READ MY NOTE CALLED ME, TOLD ME THAT I HAD DONE THE RIGHT THING, AND MADE SURE THAT WE DIDN'T NEED A RIDE AND WE WERE OKAY. FIVE MINUTES LATER MY RIDE PICKED US UP, TOOK US TO MY CAR WHERE WE WAITED FOR THE TOW TRUCK, AND THEN HELPED GUIDE THE TOW TRUCK TO MY HOME. TOW BILL WAS $78 & WILL BE $554 + TO GET THIS REPAIRED. *TR
NHTSA ODI #10221522
63,000 miles · Mar 9, 2008
VisibilityCrashInjury
WINDSHIELD ON PASSENGER SIDE FAILED. PLASTIC CAP THAT BY FRICTION HOLDS ELBOW/JOINT OF BOTH CONTROL ARMS TO WIPER PIVOT POINT SEPARATED AND IS WORN AND WILL NOT HOLD. NOW THE DRIVER SIDE CHEAP PLASTIC CAP HAS FAILED. THE MOTOR WORKS FINE. INDEPENDANT REPAIR MAN SAYS HE SEES THIS " ALL THE TIME" PART VERY POORLY ENGINEERED NO RE…
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WINDSHIELD ON PASSENGER SIDE FAILED. PLASTIC CAP THAT BY FRICTION HOLDS ELBOW/JOINT OF BOTH CONTROL ARMS TO WIPER PIVOT POINT SEPARATED AND IS WORN AND WILL NOT HOLD. NOW THE DRIVER SIDE CHEAP PLASTIC CAP HAS FAILED. THE MOTOR WORKS FINE. INDEPENDANT REPAIR MAN SAYS HE SEES THIS " ALL THE TIME" PART VERY POORLY ENGINEERED NO RETAINING CLIP, COTTER NUT,OR SCREW TO GIVE STRUCTURAL SUPPORT. *TR
NHTSA ODI #10220509
34,772 miles · Mar 9, 2008
Fuel System, Gasoline
VEHICLE STALLED ON I-26 (IN RUSH HOUR TRAFFIC) AND WOULD NOT RESTART. FUEL PUMP FAILURE CAUSED STALL (SEE NHTSA ACTION # EA07015). *TR
NHTSA ODI #10220486
70,200 miles · Mar 3, 2008
Fuel System, Gasoline
2003 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
NHTSA ODI #10219921
45,571 miles · Mar 2, 2008
Fuel System, Gasoline
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…
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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
NHTSA ODI #10219838
49,198 miles · Feb 29, 2008
Fuel System, Gasoline
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
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 ↗
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.
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.
2003 Chevrolet Cavalier Problems, Complaints & Recalls | Skip That Year
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