RoadVitals

2004 Chevrolet Cavalier Fuel system Problems

Owner-reported complaints naming the fuel system system, filed with NHTSA

Data refreshed

Fuel system reportsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
15
Latest Apr 22, 2015
Share of all reportsThis category as a share of every owner report on file for this model year. One report can name more than one component, so the categories overlap.
5%
of 330 total
Crash or fire reportedReports in this category whose submitter recorded that a crash or a fire occurred. The reporter's own answer on the NHTSA form, not a verified finding.
1
Injuries or deaths reportedTotals the submitters entered on their own reports in this category. Not verified by NHTSA and not a casualty statistic.
3

What this page shows

Reports naming fuel storage or delivery — tanks, pumps, lines, injectors and fuel leaks. Every record below is an owner-reported complaint about the 2004 Chevrolet Cavalier submitted to NHTSA — not a confirmed defect, not a recall and not a manufacturer bulletin. 15 reports on file name it.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

Owner reports naming fuel system

Shown in the owner’s own words, exactly as filed

ElectricalFuel system
Filed Apr 22, 2015

AT TIMES, DURING THE PAST SEVERAL MONTHS THIS VEHICLE HAS BEEN HARD TO START. HAD THE FUEL PUMP AND IGNITION SWITCH REPLACED, BUT DID NOT SEEM TO SOLVE THE PROBLEM. RECENTLY, THE CAR STALLED OUT WHILE DRIVING AND TOOK 15 MINUTES TO FINALLY RE-START. I HAVE READ ONLINE WHERE THIS HAS BEEN A PROBLEM FOR OTHER OWNERS OF CHEVY CAVALIERS- HARD TO START AND STALLS OUT SOMETIMES. NOT SURE WHAT IS CAUSING THE PROBLEM, BECAUSE THE CHECK ENGINE LIGHT DOES NOT COME ON AND THERE IS NO CODE TO DIAGNOSIS/READ. *TR

NHTSA ID
10712311
Incident
Feb 13, 2015
ElectricalFuel systemExterior lighting
Filed Aug 2, 2014

ALL OF THE TROUBLE LIGHTS COME ON INCLUDING THE SERVICE LIGHT WITH A WRENCH. THEN, ALL OF THE GAUGES DROP TO NOTHING; YOU DON'T KNOW HOW FAST YOU'RE TRAVELING, WHAT YOUR FUEL CAPACITY IS, THE TEMPERATURE GAUGE DROPS TO NOTHING ALONG WITH THE TACHOMETER DROPPING TO NOTHING. IN THE ODOMETER AND "ERROR" MESSAGE REPLACES THE ODOMETER READING. THE GAUGES WILL INTERMITTENTLY GO OFF AND ON OR ALL OF THEM WILL DROP OF WITH NO READING. THE OTHER EVENING, I WAS COMING HOME ON A WINDING BACK COUNTRY ROAD AND ALL OF MY LIGHTS WENT OUT. I HAVE TO LIMIT MY DRIVING TO DAYTIME DRIVING AND ONLY USE THE RUNNING LIGHTS AS IT APPEARS TO ONLY AGGRAVATE THE PROBLEM WHEN I USE MY HEADLIGHTS. TODAY, EVERYTHING ABOVE HAPPENED ALONG WITH SOME NEWS THINGS. THE VEHICLE WAS SHUT OFF, THE KEY WAS REMOVED FROM THE IGNITION AND THE RUNNING LIGHTS REMAINED ON AS DID THE WARNING ALARM AS THOUGH THE KEY WERE LEFT IN THE IGNITION. I LEFT THE CAR ONLY AFTER I PULLED THE LEFT AND RIGHT FUSE FROM THE PANEL. WHEN I RETURNED TO THE CAR, I INSERTED THE FUSES AND STARTED THE VEHICLE BUT WAS UNABLE TO SHIFT THE CAR INTO GEAR AS THE CAR WOULD NOT LET ME DEPRESS THE BUTTON ON THE SHIFTER TO DO SO. I HAVE TO NOW SHUT THE CAR OFF AND PULL THE IGNITION FUSE AND THEN REINSERT IT TO GET THE CAR IN GEAR. WHAT THE HECK? *TR

NHTSA ID
10618412
Incident
Mar 15, 2014
Mileage
68,000 mi
ElectricalEngineFuel system
Filed May 17, 2014

2004 CAVALIER, 2.2L DOHC, 5-SPEED MANUAL TRANSMISSION. WHILE DRIVING AT 60 MPH VEHICLE FELT AS IF CRUISE CONTROL WAS ENGAGED. RPMS WOULD NOT FALL OFF AS FAST AS USUAL WHEN FOOT TAKEN OFF GAS, AND WHEN I DEPRESSED THE CLUTCH (WHICH WAS JUST REPLACED LAST WEEK DUE TO ANOTHER KNOWN ISSUE THAT CHEVY REFUSES TO RECALL) RPMS WENT ABOVE 4,000. TAPPED GAS PEDAL THINKING MAYBE IT WAS STUCK AND IT ONLY REVVED HIGHER AND DID NOT COME DOWN ON ITS OWN. RPMS CONTINUED TO CLIMB AS I CAME TO A STOP, AROUND 6,000 BY THE TIME I PULLED OVER. SHUT THE CAR OFF AND IMMEDIATELY BACK ON, NO PROBLEMS FOR THE REST OF THE TRIP HOME (ANOTHER 8 MILES). I CANNOT RISK MY CAR REVVING AT 6,000 RPMS IN STOP AND GO TRAFFIC WHICH I'M IN EVERY WEEKDAY AND I CAN'T SHUT IT OFF AND TURN IT BACK ON TO FIX THE PROBLEM, SO I HAVE TO FIND OUT WHAT CAUSES IT AND FIX IT ASAP. THANKS FOR ANOTHER SPENDY REPAIR, CHEVY. *JS

NHTSA ID
10592115
Incident
May 16, 2014
Mileage
152,000 mi
Fuel system
Filed Jun 30, 2012

SO WHEN MY GAS GAUGES GET DOWN BELOW THE HALF LINE THE CHECK GAUGES LIGHT COMES UP AND I KNOW FOR SURE THAT MY CAR ISN'T YET EMPTY. WHAT DO I DO? *TR

NHTSA ID
10463660
Incident
Apr 30, 2012
Mileage
450,000 mi
ElectricalFuel system
Filed Oct 4, 2011

AS SOON AS THIS CAR REACHED @50,000 MILES, THE SPEEDOMETER AND FUEL GAUGES STOPPED WORKING. UPON CHECKING WITH A CHEVROLET DEALER, I WAS INFORMED THAT THE ENTIRE DASHBOARD NEEDS TO BE DISMANTLED AND NEW GAUGES INSTALLED BY AN OUTSIDE SOURCE, WHEREUPON CAR IS RETURNED TO DEALERSHIP AND ODOMETER IS RESET TO CORRECT MILEAGE. COST IS APPROXIMATELY $400.00 AND UP. UPON RESEARCH, I FOUND THIS TO BE A COMMON COMPLAINT. THIS IS A SAFETY HAZARD BECAUSE YOU CANNOT TELL HOW FAST YOU ARE DRIVING AND IF YOU HAVE ENOUGH FUEL. ALSO, FUEL GAUGE NEEDLE GOES HAYWIRE WHEN I FILL UP. THE NEEDLE GOES INTO THE GAUGE THAT TELLS YOU IF YOUR CAR IS RUNNING HOT - PREVENTING THAT NEEDLE FROM OPERATING PROPERLY. TO MY KNOWLEDGE NO RECALL HAS BEEN ISSUED REGARDING THESE PROBLEMS. *TR

NHTSA ID
10428724
Incident
Nov 3, 2008
Fuel system
Filed Apr 26, 2011

TL* THE CONTACT OWNS A 2004 CHEVROLET CAVALIER. THE CONTACT STATED THAT THE FUEL EVAPORATIVE EMISSION LIGHT ILLUMINATED. HE INSPECTED THE VEHICLE AND NOTICED THAT THE FUEL FILLER TUBE WAS COVERED WITH RUST. AN AUTHORIZED DEALER STATED THAT THE PROBLEM WAS COMMON BECAUSE OF THE ROAD SALTS USED IN HIS PARTICULAR STATE. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE CURRENT AND FAILURE MILEAGE WAS APPROXIMATELY 83,000. UPDATED 05/13/11 *BF UPDATED 07/08/11

NHTSA ID
10397527
Incident
Apr 25, 2011
Mileage
83,000 mi
Fuel system
Filed Mar 6, 2011

FUEL PUMP FAILURE. ON MARCH 2ND 2011 I HAD A FUEL PUMP FAIL AS I WAS DRIVING HOME FROM WORK ALMOST CAUSING AN ACCIDENT. AFTER RESEARCH I DISCOVERED THIS IS A VERY COMMON OCCURRENCE FOR THIS VEHICLE WHICH IS A 2004 CHEVY CAVALIER. THIS COULD RESULT IN A VERY DANGEROUS SITUATION FOR CAVALIER OWNERS SUCH AS MYSELF. IS THERE ANYTHING AT ALL THAT IS BEING DONE TO LOOK INTO THIS PROBLEM? *TR

NHTSA ID
10386620
Incident
Mar 2, 2011
Mileage
108,000 mi
Fuel system
Filed Jan 25, 2011

96,000 MILES FUEL PUMP FAILS WHILE SITTING IDLE IN DRIVE WAY. *TR

NHTSA ID
10378619
Incident
Dec 22, 2009
Mileage
96,698 mi
Fuel system
Filed Aug 8, 2009
Crash reported3 injuries reported

MY 2004 CHEVY CAVALIER 2.2L BASE/SEDAN IS WELL MAINTAINED. THREE MONTHS AFTER THE PURCHASE THE FUEL PUMP STOPPED WORKING. REPLACED BY DEALERSHIP UNDER WARRANTY. A YEAR LATER THE FUEL PUMP WAS REPLACED AGAIN. WARRANTY PERIOD OVER. COST ME $896. RECENTLY THE FUEL PUMP STOPPED WORKING WHILE I WAS DRIVING. I WAS MAKING A LEFT TURN AT THE INTERSECTION AND PROCEEDED TO MAKE THE LEFT AND ALL OF A SUDDEN THE ENGINE STALLED AND STEERING FROZE FORCING ME INTO THE LIGHT POST AFTER THE TURN. THIS CAUSED TWO OTHER VEHICLES TO COLLIDE TO AVOID HITTING ME. THE SERVICE GARAGE DIAGNOSED THE PROBLEM TO BE THE FUEL PUMP. COST ME $750 AND $1900 FOR FRONT END DAMAGE. I CONTACTED THE DEALERSHIP HEAD OFFICE AND THE DECLINED COMMENT. INSTEAD THEY BLAMED BE FOR NOT REPLACING THE FUEL FILTER. AGAIN, THIS VEHICLE HAS ALWAYS BEEN MAINTAINED AND SERVICED AT THE DEALERSHIP, AS WELL AS THE FILTER/FUEL PUMP. MY FRIEND HAD A SIMILAR EXPERIENCE 2 YRS AGO AND GAVE ME THIS WEBSITE TO FILE A COMPLAINT. 2 YRS AND NOTHING YET? THANK YOU FOR ALLOWING THE MANUFACTURERS AND ALL INVOLVED TO GET AWAY WITH THIS! AFTER DOING RESEARCH, THIS VEHICLE IS KNOWN FOR THIS PROBLEM. I WILL NOT SELL THIS VEHICLE AND WILL NOT DRIVE THIS VEHICLE TO PROTECT THE PUBLIC FROM FATALITIES. THIS VEHICLE IS GOING STRAIGHT TO THE JUNKYARD. GOD BLESS AMERICA. *TR

NHTSA ID
10279773
Incident
Aug 5, 2009
Mileage
110,000 mi
Heating & air conditioningFuel systemVisibility
Filed Mar 30, 2009

TL*THE CONTACT OWNS A 2004 CHEVROLET CAVALIER. WHILE DRIVING 55 MPH, THE VEHICLE STOPPED IN THE MIDDLE OF THE INTERSTATE WITHOUT WARNING. THE VEHICLE WAS TOWED TO A REPAIR SHOP AND THE MECHANIC STATED THAT THE FUEL PUMP FAILED. THE DEALER WAS NOT NOTIFIED. IN ADDITION, THE CONTACT HEARD A TAPPING NOSE IN THE HEATER AND THE CD PLAYER DOES NOT WORK. THERE WERE ALSO TWO MOTOR SWTICES REPAIRED IN THE WINDOWS. THE VEHICLE IS CURRENTLY BEING REPAIRED AT THE CONTACT'S EXPENSE. THE FAILURE AND CURRENT MILEAGES WERE 78,000.

NHTSA ID
10263642
Incident
Mar 29, 2009
Mileage
78,000 mi
Driver assistanceFuel systemVisibility
Filed Nov 18, 2008

I HAVE A 2004 CHEVY CAVALIER LS SPORT. WELL LETS FIRST START OFF WITH MY DRIVERS SIDE WINDOW MOTOR. IT WENT OUT ABOUT A YEAR AND HALF AGO AND WE FIXED IT THIS SUMMER. APPARENTLY IT IS A HUGE PROBLEM BUT OF COURSE NO RECALL ON IT SO PAID ALMOST 300 DOLLARS MYSELF TO FIX IT. THEN AFTER THAT WHEN I WOULD START MY CAR AND PUT IT INTO DRIVE, THE CAR WOULD SPUTTER AND THE ABS AND TRAC OFF LIGHTS WOULD COME ON. NEXT ABOUT 5 MONTHS AGO I NOTICED THAT MY GAS GAUGE WAS FLUCTUATING A LITTLE. DIDN'T GIVE IT MUCH THOUGHT BUT THEN 2 MONTHS AGO MY TEMP GAUGE WAS GOING HAYWIRE. CALLED THE DEALER AND THEY SAID THAT THERE WAS NO RECALL AND WE WOULD HAVE TO PAY TO HAVE IT FIXED. WELL WE ALL KNOW MONEY IS TIGHT SO I HAVE LEFT IT. LOW AND BEHOLD LATE LAST WEEK, THE MPH GAUGE SAID I WAS GOING 100 MPH IN A 35 ZONE. I HAD TO TAKE A DOUBLE LOOK. DEALER AGAIN SAYS NO RECALLS. AFTER SPEAKING TO A FRIEND, HE SAID THAT HIS TRUCK DID THE SAME THING ALONG WITH ANOTHER CO-WORKERS TRUCK (GM TRUCKS) AND THAT THEY TOOK IT IN BECAUSE IT HAD A RECALL ON THE "INSTRUMENT CLUSTER" AND THERE WAS NO CHARGE. HOW COME CAVALIERS ARE HAVING THE PROBLEM AND NOTHING, BUT THERE TRUCKS HAVE IT AND THERE IS A RECALL. I CANT TELL HOW FAST I AM GOING. NOW I AM PROBABLY GOING TO HAVE TO JUST GO WITH THE FLOW OF TRAFFIC SINCE I CANT AFFORD TO FIX IT. COME ON GM OWN UP TO ALL OF YOUR MISTAKES PLEASE..........THERE ARE TONS OF LOGGED COMPLAINTS ON HERE ABOUT IT, OBVIOUSLY IT IS A REAL PROBLEM GM. THIS IS WHY WE ARE GOING FOREIGN WITH OUR CARS NOW. *TR

NHTSA ID
10249107
Incident
Nov 1, 2008
Mileage
51,862 mi
Fuel system
Filed Jul 12, 2007

ON 2004 CHEVROLET CAVALIER FUEL PUMP WENT OUT A TONLY 76000 MILES. BEEN HAVING PROBLEMS IDLING. *AK

NHTSA ID
10196231
Incident
Jul 12, 2006
Mileage
76,000 mi
ElectricalFuel systemInterior & seats+1 more
Filed Aug 30, 2006

I BOUGHT MY CAR, A 2004 CHEVY CAVALIER WITH 21 MILES ON IT. SINCE THEN I HAVE TRIED TO RETURN IT AND NOW THE MINOR BUT FREQUENT ISSUES ARE MUCH BIGGER AND MORE FREQUENTLY! FIRST MY TRUNK LATCH BROKE A WEEK AFTER PURCHASE. THE CD BROKE THE NEXT WEEK, CIGARETTE LIGHTER BROKE, AND PASSENGER SEAT WOULDN'T MOVE. THIS WAS THE FIRST TWO MONTHS OF OWNERSHIP. A FEW MONTHS AGO THE FUEL GAUGE BROKE, TEMP GAUGE AND AC. THEY COULDN'T VERIFY IT SO COULDN'T REPAIR, UNTIL IT COMPLETELY FAILED THIS MONTH. ALSO, I WAS LEFT STRANDED AT 2:30 AM WITH MY 3 YEAR OLD SON WHEN THE CLUTCH FELL THROUGH THE FLOOR. IT WAS REPAIRED AND NOW THE RPMS SHOOT UP TO 6000, IS UNRESPONSIVE TO ANY PEDALS, AND REQUIRES TURNING THE ENGINE OFF. THIS HAPPENED IN SAN FRANCISCO ON HIGHWAY 101, I AM TRULY AFRAID FOR THE SAFETY OF MYSELF. SON, AND OTHERS DRIVING THIS CAR OR NEAR ONE. THERE ARE MANY OTHER UNMENTIONED THINGS THAT HAVE OCCURRED, TOO MANY TO TELL IN THIS SUMMARY. THEY OF COURSE CAN'T DUPLICATE THIS MAJOR PROBLEM AND THEREFORE CAN'T "CORRECT." ALSO THEY STATE IT DOESN'T FALL UNDER LEMON, BUT WHAT IS AT STAKE OUR LIVES. *JB

NHTSA ID
10167018
Incident
Aug 20, 2006
Mileage
5,000 mi
Fuel system
Filed Feb 3, 2005

THE VEHICLE WOULD JERK FORWARD UNEXPECTEDLY AS SOON AS BEING FILLED UP WITH GAS. THE CONSUMER TOOK THE VEHICLE TO A MECHANIC AND RESULTS SHOWED THAT THE GAS CAP NEEDED TO BE REPLACED BECAUSE IT WAS CRACKED AND RELEASING GAS. *JB

NHTSA ID
10109706
Incident
Jan 31, 2005
Body & structureElectricalEngine+1 more
Filed Jun 4, 2004

A STRONG FUEL ODOR ENTERED THE INSIDE OF THE VEHICLE WHEN THE VENTS WERE USED. THIS ODOR CAUSED NAUSEA AND HEADACHES TO ANY ONE RIDING IN THE VEHICLE. AT ANY TEMPERATURE, THE VEHICLE TOOK A VERY LONG TIME TO CRANK UP. ALSO, WHILE DRIVING AT 50 MPH, THE VEHICLE SUDDENLY DECELERATED AND BOGGED DOWN. THE VEHICLE WOULD EVENTUALLY PICK UP SPEED AND ACT AS IF NOTHING EVER HAPPENED. THESE PROBLEMS OCCURRED EIGHT TIMES. *AK THERE WAS RATTLE IN THE DRIVERS SIDE DOOR PANEL DUE TO THE REGULATOR, THERE WAS ALSO AN INTERMITTENT NOISE ON THE PASSENGER SIDE REAR, THE VEHICLE WOULD NOT START DUE TO THE POWER TRAIN CONTROL MODULE, THE ENGINE WAS HARD TO START AT TIMES AND WAS UNABLE TO BE DUPLICATED, THE ENGINE WOULD LOSE POWER, THE DRIVER DOOR MADE A RUBBING NOISE, THE FLOOR AREA WAS BUCKLING, AND THE A/C DISPLAYED A BURNING SMELL. *SC *JB

NHTSA ID
10073471
Incident
Dec 10, 2003
Mileage
100 mi

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers.

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Data sources

Data on this page last refreshed .