NHTSA owner reports · September 18, 2026 snapshot.
What owners actually said
678 reports275,200 miles · Oct 12, 2011
Fuel System, Gasoline
AT APPROX. 67K MY FUEL PUMP FAILED. I PURCHASED AND INSTALLED A NEW FUEL PUMP, ADHERING TO THE MANUFACTURERS INSTALLATION RECOMMENDATIONS. LESS THAN 6 MONTHS LATER THE NEW PUMP FAILED. THE HAS BEEN A RECURRING PROBLEM NOW FOR AT LEAST 10 FUEL PUMPS. THIS INSTALLATION RECOMMENDATIONS HAVE NOT CHANGED AND I HAVE HAD THE ELECTRICAL…
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AT APPROX. 67K MY FUEL PUMP FAILED. I PURCHASED AND INSTALLED A NEW FUEL PUMP, ADHERING TO THE MANUFACTURERS INSTALLATION RECOMMENDATIONS. LESS THAN 6 MONTHS LATER THE NEW PUMP FAILED. THE HAS BEEN A RECURRING PROBLEM NOW FOR AT LEAST 10 FUEL PUMPS. THIS INSTALLATION RECOMMENDATIONS HAVE NOT CHANGED AND I HAVE HAD THE ELECTRICAL SYSTEM THAT POWERS THE PUMP CHECKED OUT AS WELL. IN EACH CONDITION IT WAS A NO START "FAILURE", LEAVING ME STRANDED IN EACH CASE AND COSTING ME HUNDREDS OF DOLLARS IN TOWING FEES THAT ARE NON-REFUNDABLE. EVEN THOUGH THE AUTO PARTS STORES HAVE BEEN KIND ENOUGH TO HONOR THE WARRANTY MOST TIMES I HAVE STILL HAD TO PAY FOR AT LEAST 5 OF THE 10 FUEL PUMPS. THAT'S A 1 TO 1 RATIO. I HAVE ALSO READ ABOUT THE CONDITION WITH BRUSHES IN THE MOTOR WEARING OUT. SOME OF THESE PUMPS HAVE PROVIDED 30K MILES OR MORE AND OTHERS NOT 3K MI. THIS IS A HUGE PROBLEM AND I FOR ONE WILL NOT BE SHOPPING FOR ANOTHER CHEVY UNTIL THIS PROBLEM ACKNOWLEDGED AND RESOLVED. I AM RESEARCHING MY PURCHASES/EXCHANGES TO VERIFY THE DATES AND WILL REGISTER EACH ONE OF THEM INDIVIDUALLY. *KB
NHTSA ODI #10429628
87,738 miles · Sep 17, 2011
Fuel System, Gasoline
I WAS DRIVING AT APPROXIMATELY 6 AM ON A DECEMBER MORNING IN 2010 WHEN THE 2003 CHEVROLET CAVALIER I WAS DRIVING CUT OFF IN THE MIDDLE OF THE ROAD. I HAD TO PUSH THE VEHICLE INTO A PARKING LOT TO BE TOWED TO A BODY SHOP. I WAS INFORMED THAT THE FUEL PUMP HAD WENT OUT AND IT WOULD COST ROUGHLY $450 TO FIX. THE MILEAGE AT THE TIME…
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I WAS DRIVING AT APPROXIMATELY 6 AM ON A DECEMBER MORNING IN 2010 WHEN THE 2003 CHEVROLET CAVALIER I WAS DRIVING CUT OFF IN THE MIDDLE OF THE ROAD. I HAD TO PUSH THE VEHICLE INTO A PARKING LOT TO BE TOWED TO A BODY SHOP. I WAS INFORMED THAT THE FUEL PUMP HAD WENT OUT AND IT WOULD COST ROUGHLY $450 TO FIX. THE MILEAGE AT THE TIME OF THE INCIDENT WAS ROUGHLY AROUND 87,000 MILES. *TT
NHTSA ODI #10425854
60,000 miles · Sep 7, 2011
Electrical SystemFuel System, Gasoline
SPEEDOMETER GOES HAYWIRE SO YOU HAVE NO IDEA HOW FAST YOU ARE GOING. OTHER GAUGES (FUEL, TEMP) ALSO ERRATIC. SEEMS THIS IS A COMMON PROBLEM WITH MANY GM VEHICLES AND IS VERY DANGEROUS! *TR
NHTSA ODI #10424123
100,000 miles · Sep 6, 2011
Fuel System, Gasoline
MY CAR WOULD NOT START AFTER I TURNED IT OFF. I BANGED ON THE GAS TANK WITH A HAMMER, WHILE A COWORKER CRANKED THE ENGINE OVER AND THE FUEL PUMPED KICKED IN. THIS RESULTED IN THE CAR STARTING; HOWEVER I PLAYED IT SAFE AND HAD IT TOWED HOME. I REPLACED THE FUEL PUMP AND HAVE NOT HAD ANY PROBLEMS SINCE. STILL UNFORTUNATE THAT THE …
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MY CAR WOULD NOT START AFTER I TURNED IT OFF. I BANGED ON THE GAS TANK WITH A HAMMER, WHILE A COWORKER CRANKED THE ENGINE OVER AND THE FUEL PUMPED KICKED IN. THIS RESULTED IN THE CAR STARTING; HOWEVER I PLAYED IT SAFE AND HAD IT TOWED HOME. I REPLACED THE FUEL PUMP AND HAVE NOT HAD ANY PROBLEMS SINCE. STILL UNFORTUNATE THAT THE FUEL PUMP BARELY LASTED 100K. I BELIEVE CHEVY SHOULD GIVE YOU A FUEL PUMP FREE OF CHARGE IF THERE IS A FAILURE WITHIN THE FIRST 200K MILES. PLAIN AND SIMPLE FUEL PUMPS SHOULD NOT FAIL AS OFTEN AS THEY DO WITH THIS MAKE/MODEL. IT'S IS DANGEROUS TO EVERYONE'S HEALTH, AND I HOPE NO ONE EVER GETS HURT FROM IT. *TR
NHTSA ODI #10423826
Mileage unknown · Sep 3, 2011
Fuel System, Gasoline
MY HUSBAND AND I WENT LOOKING FOR A CAR AT THIS DEALERSHIP ON OCT. 31, 2010. WE FOUND THIS CHEVROLET CAVALIER (2003). WHEN WE BOUGHT THE CAR IT HAD NO INFORMATION ON IT; SO I CHECKED ON CARFAX AND FOUND THAT IT HAD COUPLE OF RECALLS ON IT; BUT NOTHING ABOUT THE FUEL PUMP. SO NOW THE CAR GO'S OUT WON'T START. I DON'T KNOW WHA…
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MY HUSBAND AND I WENT LOOKING FOR A CAR AT THIS DEALERSHIP ON OCT. 31, 2010. WE FOUND THIS CHEVROLET CAVALIER (2003). WHEN WE BOUGHT THE CAR IT HAD NO INFORMATION ON IT; SO I CHECKED ON CARFAX AND FOUND THAT IT HAD COUPLE OF RECALLS ON IT; BUT NOTHING ABOUT THE FUEL PUMP. SO NOW THE CAR GO'S OUT WON'T START. I DON'T KNOW WHAT TO DO ABOUT THIS. WE ARE ON A FIXED INCOME AND CAN'T AFFORD THIS RIGHT NOW. THERE WAS A RECALLED THE CARS FROM 1998 TO 2002 AND FIXED THE PROBLEM. WE WILL HAVE TO HAVE IT FIXED OR GET RID OF IT OR TRADE IT IN. *TR
NHTSA ODI #10423173
61,246 miles · Sep 3, 2011
Fuel System, Gasoline
I HAD LEFT MY MOTHERS AND DROVE APPROXIMATELY 35 MILES AND STARTED SLOWING TO MAKE A TURN INTO OUR LOCAL GROCERY STORE WHEN MY 2003 CAVALIER STALLED AND WOULD NOT RESTART BACK. UPON CHECKING I DISCOVERED THERE WAS NO FUEL TO THE FUEL RAIL.I HAD JUST OVER 1/2 TANK OF FUEL IN THE TANK. I HAD ANOTHER TURN KEY AND THERE WAS NO WHIR…
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I HAD LEFT MY MOTHERS AND DROVE APPROXIMATELY 35 MILES AND STARTED SLOWING TO MAKE A TURN INTO OUR LOCAL GROCERY STORE WHEN MY 2003 CAVALIER STALLED AND WOULD NOT RESTART BACK. UPON CHECKING I DISCOVERED THERE WAS NO FUEL TO THE FUEL RAIL.I HAD JUST OVER 1/2 TANK OF FUEL IN THE TANK. I HAD ANOTHER TURN KEY AND THERE WAS NO WHIRRING TO INDICATE FUEL PUMP WAS OPERATING. I CALLED TOW SERVICE AND TOWED IT HOME. I DROPPED THE TANK AND REPLACED THE FUEL PUMP AND PROBLEM WAS RESOLVED. ANOTHER SYMPTOM NOT LISTED IN THE COMPLAINTS WHEN MY PUMP FAILED ALL THE GAUGES ON THE DASHBOARD WOULD REGISTER (FUEL GAUGE AND TEMP GAUGE) THEN WOULD DROP TO 0 AND WOULD FLICKER CONTINUOUSLY WHEN KEY WAS TURNED TO THE ON POSITION. UPON PURCHASING NEW PUMP ASSEMBLY THAT THE WIRING HARNESS NEEDED TO BE REPAIRED AS WELL. YOU CAN NOT PURCHASE A NEW HARNESS TO RESOLVE ISSUE HAD TO CUT THE FUEL PUMP LEADS OFF OF PUMP WIRING HARNESS AND PURCHASE A NEW CONNECTOR AND SPLICE THEM TOGETHER. I FEEL THERE MAYBE MORE CUSTOMERS WITH THESE VEHICLES THAT HAD SERVICE DONE IN A LOCAL SHOP THAT WAS NOT REPORTED TO NHTSA OR TO GM. AS THIS REPAIR WAS VERY EXPENSIVE AT THE TIME AND MANY WOULD SEEK REPAIRS FOR LOWER RATES THEN OFFERED BY A DEALERSHIP. *TR
NHTSA ODI #10423133
63,000 miles · Aug 26, 2011
Electrical SystemFuel System, Gasoline
TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING MPH AND ABOVE, THE SPEEDOMETER AND TEMPERATURE GAUGES WOULD NOT ILLUMINATE. IN ADDITION, THE FUEL GAUGE WAS PROVIDING INACCURATE FUEL LEVEL READINGS. THE VEHICLE WAS NEITHER INSPECTED NOR REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERE…
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TL* THE CONTACT OWNS A 2003 CHEVROLET CAVALIER. THE CONTACT STATED THAT WHILE DRIVING MPH AND ABOVE, THE SPEEDOMETER AND TEMPERATURE GAUGES WOULD NOT ILLUMINATE. IN ADDITION, THE FUEL GAUGE WAS PROVIDING INACCURATE FUEL LEVEL READINGS. THE VEHICLE WAS NEITHER INSPECTED NOR REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 63,000.
NHTSA ODI #10421599
90,000 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
67,800 miles · Aug 16, 2011
Fuel System, Gasoline
2003 CHEVROLET CAVALIER GIVING OFF FUMES FIRST TIME I FILLED IT TO THE TOP WITH GASOLINE. THAT EVENTUALLY SET OFF A CHECK ENGINE LIGHT ON THE DASH. I USED MY OBD2 SCANNER AND IT WAS A CODE FOR A HIGH EVAP LEAK. IT WAS TOO DIFFICULT TO FIND THE LEAK AT MY HOME, SO I HAD THE DEALERSHIP DO A SMOKE TEST AND REVEALED A CRACK AT THE S…
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2003 CHEVROLET CAVALIER GIVING OFF FUMES FIRST TIME I FILLED IT TO THE TOP WITH GASOLINE. THAT EVENTUALLY SET OFF A CHECK ENGINE LIGHT ON THE DASH. I USED MY OBD2 SCANNER AND IT WAS A CODE FOR A HIGH EVAP LEAK. IT WAS TOO DIFFICULT TO FIND THE LEAK AT MY HOME, SO I HAD THE DEALERSHIP DO A SMOKE TEST AND REVEALED A CRACK AT THE SEAMS OF THE GAS TANK. DEALERSHIP SAID NO RECALL FOR THAT MAKE AND MODEL. ESTIMATE FOR REPLACEMENT AND LABOR WAS $1,000. I FOUND A SALVAGE YARD GAS TANK FROM A LOW MILEAGE OLDSMOBILE ALERO AND THE LOCAL REPAIR SHOP REPLACED IT. MECHANIC MENTIONED IT IS A COMMON OCCURRENCE TO FIND A CRACK AT THE SEAMS OF A NEWER GM SMALL CAR WITH A PLASTIC GAS TANK. I RESET THE CHECK ENGINE LIGHT CODE MYSELF AND THE PROBLEM NEVER REAPPEARED. *KB
NHTSA ODI #10419653
80,340 miles · Aug 14, 2011
Fuel System, Gasoline
FUEL PUMP FAILURE AT 80,340 MILES. PUMP FAILED IN THE DRIVEWAY. REPAIR COST: $695 + TOWING. *TR
NHTSA ODI #10419368
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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