2003 Chevrolet Cavalier

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.

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.

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.

There is a recall on the vehicle I need to get fixed.

NHTSA ID

11671800

Incident

Jan 9, 2005

THE STEERING WHEEL IS LOOSE. PINS ON TILT MECHANISM ARE GONE. DON'T KNOW WHEN IT FELL OUT. NOTICED WHEN CLEANING CAR WHEN I TILTED THE STEERING WHEEL UP.

NHTSA ID

11414792

Incident

May 4, 2012

Mileage

50,000 mi

MY CAR HAS THE SAME PROBLEM WITH THE INSTRUMENT CLUSTER THAT WAS RECALLED FOR OTHER GM VEHICLES. THE FUEL LEVEL GAUGE, TEMPERATURE GAUGE, RPM, SPEEDOMETER.... NONE OF MY GAUGES WORK. THEY GAVE THE WRONG READINGS, THE HAND WOULDN'T RETURN TO THEIR STARTING POSITIONS, THEN THE HANDS WENT LOWER THAN THEIR STARTING POSITIONS TO THE POINT THEY ALL DIDN'T WORK ANYMORE. THIS CAR NEEDS TO BE ADDED TO THE GM RECALL LIST FOR THE SAME PROBLEM.

NHTSA ID

11414789

Incident

May 3, 2012

Mileage

50,000 mi

TAKATA RECALL

NHTSA ID

11083515

Incident

May 17, 2017

Mileage

200,000 mi

CLUSTER OF DASHBOARD INDICATORS (SPEEDOMETER, GAS GUAGE , ENGINE TEMP, RPM) ALL ARE NOT WORKING NOW. THEY WERE GOING OFF AND ON AT TIMES WHEN DRIVING BUT NOW NOTHING WORKS...MY MECHANIC INFORMS ME THIS IS A COMMON PROBLEM WITH THIS MAKE AND MODEL. NO RECALL FOUND. VERY DANGEROUS TO DRIVE WHY WASN'T THIS COMMON PROBLEM LISTED AS A RECALL WHEN MANY HAVE COMPLAINED??

NHTSA ID

11065548

Incident

Nov 10, 2017

Mileage

198,000 mi

I WAS ONE BLOCK FROM HOME AND MY CAR STALLED IT WOULDN'T START BACK UP. I FOUND MY SELF AT THE INTERSECTION. THE MECHANIC SAID IT IS A BAD FUEL PUMP. THE CAR ONLY HAS 60,000 MILES. THIS HAPPENED ABOUT THIS TIME LAST YEAR . ALSO LAST YEAR MY GAUGE TO MY ENGINE TEMPERATURE WENT OUT OF CONTROL. I CAN'T TELL THE ENGINE TEMP. ANYMORE.

NHTSA ID

10899679

Incident

Aug 15, 2015

Mileage

59,925 mi

MY 2003 CHEVROLET CAVALIER RECENTLY BEGAN TO MAKE A CLUNKING NOISE, WHICH CAN ALSO BE FELT, IN THE FRONT END. WHEN I PUT IT UP ON A LIFT, I NOTICED THAT THE SUB-FRAME WAS RUSTING (DETERIORATING). I KNOW IT IS 13 YEARS OLD, BUT MY PARENTS OWNED A 1989 CAVALIER Z24 FOR 20 YEARS, AND THEY DIDN'T HAVE ANY PROBLEMS WITH ITS FRAME. I'VE READ THAT OTHER PEOPLE HAVE HAD THIS SAME ISSUE WITH THEIR 2003 CHEVY CAVALIERS. WHY IS THIS? WHY HAS THERE NOT BEEN A RECALL? MY FAMILY HAS OWNED SEVERAL NEW AND USED VEHICLES, ALL GM, AND WE HAVE NEVER SEEN A SUB-FRAME RUST TO THIS EXTENT. WE ARE A GM FAMILY AND ARE EXTREMELY DISAPPOINTED IN GM'S LACK OF RESPONSE TO THIS SAFETY HAZARD.

NHTSA ID

10876674

Incident

Jun 26, 2016

Mileage

113,000 mi

"CHECK ENGINE" LIGHT KEEPS COMING BACK ON FOR THE SAME ISSUE, SUPPOSEDLY THE "AIR INTAKE TEMP SENSOR, REPLACED THAT ONE AND SEVERAL SENSORS REPEATEDLY, HAD THE COMPLETE WIRING HARNESS CONNECTIONS CHECKED AND CLEANED, EVEN REPLACED MY ECM AND BCM [NEITHER OF WHICH WAS CHEAP], AND STILL HAS "CHECK ENGINE" LIGHT, EVEN AFTER BEING "CLEARED" OVER AND OVER AGAIN -- THIS CAR WAS WELL MAINTAINED AND THE BODY AND SUB-FRAME ARE SEVERELY ROTTING OUT LEFT AND RIGHT -- HAD A WEIRD LEAK ON THE PASS. SIDE FRONT, UNDER THE DASH. IT COMES AND GOES. THE CAR SMELLS LIKE AN OLD SNEAKER INSIDE. WATER WOULD POUR OUT OF THE PASSENGER SIDE HEATER DUCT, BUT THERE WAS NO RHYME OR REASON TO IT. ONE I EVEN HAD SOAP FOAM FROM A DRIVE THRU CAR WASH LITERALLY COME BLOWING IN TO THE CABIN, THRU THE VERY SAME HEATER DUCT. THANKFULLY IT HAS SEEMINGLY CLEARED UP, BUT IT IS STILL A HEAD SCRATCHER. I'VE TAKEN MY CAR TO SEVERAL DEALERSHIPS, PRIVATELY OWNED SHOPS, AND EVEN HAD SOME "CAR SAVVY" FRIENDS LOOK HER OVER, AS WELL AS MY DAD [ANDS ASE CERTIFIED TECH], AND THE CHECK ENGINE LIGHT STILL COMES BACK EVERY TIME. IF I WOULD HAVE KNOWN I'D PUT THIS MUCH MONEY INTO A CAR THAT LITERALLY READY TO BREAK APART, I WOULD HAVE SAVED MY MONEY TO PUT TOWARDS ANOTHER CAR. LIVE AND LEARN, I GUESS. SHE WAS DOING SO WELL FOR 10 OR 11 YEARS AND IT'S LIKE SHE JUST STARTED "GIVING UP" ON ME. SHE'S GOT 165K ON HER AND THE PAIN HAS GONE TO CRAP, BUT THAT'S GM FOR YOU, KEPT HER GARAGED, WAXED REGULARLY, HAD HER LOOKING SHOWROOM NEW, UNTIL RECENTLY, THE PAINT'S CLEAR COAT STARTED TO "STIPPLE" [SHARP BUMPS] AND BUBBLE ALL OVER TOP PANELS, STARTING WITH THE ROOF, THEN HOOD, AND NOW TRUNK. IT'S EMBARRASSING TO DRIVE HER, AND I AM NOT PAYING TO REPAINT HER, I ALREADY HAVE WAY TOO MUCH INTO A CAR THAT LIKELY WILL NOT PASS INSPECTION COMING UP IN AUGUST. I'M NOW HANDICAP'D AND DISABLED, FIXED INCOME, CAN'T AFFORD A NEW CAR.

NHTSA ID

10863655

Incident

May 1, 2010

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This service bulletin provides information for dealers/technicians on OnStar Module 2G Sunset Information.

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the noise for assessment by engineering. Technician will need to call General Motors Technical Assistance Center for further assistance.

This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester  and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.

This Preliminary Information communication provides information to the technician about vehicles that the Heater-Vent-Air Conditioning blows warm air. Before calling General Motors Technical Assistance Center technician will need to have high and low pressures, outside temperature, humidity, and vent temperature.