Recalls


CampaignManufacturerManufacturing dateType# of units affectedDate Owner notified MfgRecall Initiated byManufacturers of recalled vehicles/productsReport Recieved DateRecord Creation DateRegulation Part NumberFMVSS Number
FUEL SYSTEM, OTHER - STORAGE - TANK ASSEMBLY - PRESSURE RELIEF DEVICES
07E021000DELPHI E (Equipment)74204/27/2007MFRGENERAL MOTORS CORP.03/12/200703/12/2007
Defect SummaryCertain delphi fuel pressure regulators, p/nos. fp10020-11b1, fp10026-11b1, and fp10027-11b1, sold after january 9, 2007, as aftermarket equipment for various passenger vehicles listed above. the universal pressure regulators (upr) were produced without an o'ring and retainer.
Consequence SummaryFuel may leak, possibly resulting in a fire.
Corrective SummaryDelphi will notify owners and replace the upr free of charge. the recall began on april 23, 2007. owners can contact delphi at 877-411-8770.
NotesThis recall only pertains to aftermarket delphi fuel pressure regulators and has no relation to any original equipment installed by general motors.customers may contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty: 1-800-424-9153); or go to http://www.safercar.gov.

Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
FUEL SYSTEM, GASOLINE
03110303/11/200310001904Complaints that are root caused to the fuel module and complaints of gauge accuracy that are root caused to the fuel level sensor. *tt *jb07/25/2003
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY - FILLER PIPE AND CAP
01086500111/01/2001627484Information regarding fuel filler door recessed into quarter panel. *yh02/08/2002
FUEL SYSTEM, OTHER
318910010629Crank no start, low or no fuel pressure. *tt12/02/2004
010604008C03/01/2002010604008B631306Some customers may comment about inaccurate or erratic fuel gauge readings. *slc05/22/2002
010604008B03/01/2002010604008A631237Customers may complain about inaccurate or erratic fuel gauge readings. *slc05/21/2002
18020202/18/2002629807Subject regarding proper repair for fuel gauge inaccuracy complaints. *tt04/09/2002
010604008A01/01/2002010604008628822Some customers may comment about inaccurate or erratic fuel gauge readings. *tt03/21/2002
01060400802/01/2001619180Some vehicles including my2001 toyota cavalier may experience inaccurate or erratic fuel gauge readings. it may appear from the gauge reading that there is fuel available, yet the tank is nearly empty. *tt05/17/2001
0010112/01/2000618100Vehicles may exhibit erratic fuel gauge. *jb04/04/2001
0010112/21/2000617748General motors has decided that certain j and n model vehicles equipped with plastic fuel tanks may exhibit a condition in which the fuel gauge displays incorrect readings. *tt03/26/2001

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
FUEL SYSTEM, GASOLINE
PE02066GENERAL MOTORS CORP.09/06/200211/03/2003ENGINE STALL DUE TO FUEL STARVATION
 Odi opened pe02-066 to evaluate the scope and consequence of engine power-loss due to fuel starvation induced by in-tank modular fuel pump strainer restriction.the subject pumps use an external
EA02028GENERAL MOTORS CORP.09/30/200212/30/2003ERRATIC FUEL GAUGE
 Odi opened ea 02-028 to review complaints of consumers reporting that their fuel gauge was incorrectly displaying the amount of fuel in the gas tank.the fuel gauge receives an electrical signal from a fuel tank sending sensor circuit card.a float arm in the tank moves electrical contacts that rub against the card as the level of fuel rises and falls.disruption of the electrical signal (such as caused by corrosion of the circuit card) will cause incorrect readings to register on the fuel gauge.gm reported in their response to odi dated january 13, 2003 that the primary cause of erratic fuel gauge operation is excess elemental sulfur in fuel.gm reported that abnormal levels of sulfur sporadically occurred in certain parts of canada and the u.s. resulting in reports of fuel gauge malfunction.gm modified the sending sensor for vehicles built after october 2000.it made a second sensor modification for vehicles built after january 2003.gm also issued a customer satisfaction campaign (gm number 00101) in december 2000 for u.s. customers in the state of maine and issued several service bulletins informing dealers of the availability of sensors with improved corrosion resistance.the complaint trend indicates that complaints peaked in late 2000 to early 2001.warranty claims declined since peaking in april 2002.based on the number of complaints and the indication of a declining trend, further use of agency resources does not appear to be warranted.the closing of this investigation does not constitute a finding by nhtsa that no safety-related defect exists.the agency reserves the right to take further action if warranted by the circumstances.
FUEL SYSTEM, GASOLINE - DELIVERY - FUEL PUMP
PE02066GENERAL MOTORS CORP.09/06/200211/03/2003ENGINE STALL DUE TO FUEL STARVATION
 Odi opened pe02-066 to evaluate the scope and consequence of engine power-loss due to fuel starvation induced by in-tank modular fuel pump strainer restriction.the subject pumps use an external
FUEL SYSTEM, OTHER
PE02066GENERAL MOTORS CORP.09/06/200211/03/2003ENGINE STALL DUE TO FUEL STARVATION
 Odi opened pe02-066 to evaluate the scope and consequence of engine power-loss due to fuel starvation induced by in-tank modular fuel pump strainer restriction.the subject pumps use an external
FUEL SYSTEM, OTHER - DELIVERY - FUEL PUMP
PE02066GENERAL MOTORS CORP.09/06/200211/03/2003ENGINE STALL DUE TO FUEL STARVATION
 Odi opened pe02-066 to evaluate the scope and consequence of engine power-loss due to fuel starvation induced by in-tank modular fuel pump strainer restriction.the subject pumps use an external
FUEL SYSTEM, OTHER - STORAGE - FUEL GAUGE SYSTEM
EA02028GENERAL MOTORS CORP.09/30/200212/30/2003ERRATIC FUEL GAUGE
 Odi opened ea 02-028 to review complaints of consumers reporting that their fuel gauge was incorrectly displaying the amount of fuel in the gas tank.the fuel gauge receives an electrical signal from a fuel tank sending sensor circuit card.a float arm in the tank moves electrical contacts that rub against the card as the level of fuel rises and falls.disruption of the electrical signal (such as caused by corrosion of the circuit card) will cause incorrect readings to register on the fuel gauge.gm reported in their response to odi dated january 13, 2003 that the primary cause of erratic fuel gauge operation is excess elemental sulfur in fuel.gm reported that abnormal levels of sulfur sporadically occurred in certain parts of canada and the u.s. resulting in reports of fuel gauge malfunction.gm modified the sending sensor for vehicles built after october 2000.it made a second sensor modification for vehicles built after january 2003.gm also issued a customer satisfaction campaign (gm number 00101) in december 2000 for u.s. customers in the state of maine and issued several service bulletins informing dealers of the availability of sensors with improved corrosion resistance.the complaint trend indicates that complaints peaked in late 2000 to early 2001.warranty claims declined since peaking in april 2002.based on the number of complaints and the indication of a declining trend, further use of agency resources does not appear to be warranted.the closing of this investigation does not constitute a finding by nhtsa that no safety-related defect exists.the agency reserves the right to take further action if warranted by the circumstances.

Consumer Complaints


Fail datemilesoccurencesPurchase date
FUEL SYSTEM, GASOLINE
09/20/2011
 This car will not start.and when it does start it back fires. i have replaced the starter, the flex plate the sensors, and the muffler, and nothing seems to work and no mechanic can tell me whats wrong with. i even went out and bought a car code reader and it says emissions but still no luck.
04/15/200650000
 Purchased used 2000 cavalier in 2006. first problem (which has continued for 5 years) is that the service light will come on when the car is cranked unless the headlights are first turned on. if you turn the headlights off while driving, the service light comes on. it will not go off unless you turn the car off and restart it (with headlights on). second problem is that fuel hand does not reflect accurate amount of gasoline in tank. it goes up and down while driving (with the check gauges light on). or sometimes it is stuck on e or stuck on f regardless of how much fuel is actually present. third problem is that car intermittantly overheats and is always losing coolant. i have replaced thermostat, water pump, & radiator. three different mechanics cannot find a leak in the cooling system (despite pressure testing, compression testing, & block testing). we are baffled why it cannot retain constant coolant levels. this is a very frustrating situation as i am left without reliable transportation.
09/20/20081010001
 My car would intermittently not start. would run fine, start several times while driving to different locations and then not start. left me and my young daughter stranded, would not have been good if it were in a bad part of town or had i not had family close to come get me. now i can't get it to start at all, don't hear the fuel pump prime. a mechanic told me to hit gas tank with mallet while trying to start it. it started by doing that, and i was told the fuel pump is bad and needs to be replaced, which is going to cost over $700...money i don't have. this i am finding to be a very common problem with this car....check out this discussion forum for many more complaints of the same problem at........ http://www.topix.com/forum/autos/chevrolet-cavalier/tvinic5tfu5sfsi5h ............. this car really needs to be recalled for the fuel pump, it is defective and dangerous. *tr
05/24/200350702/23/2001
 Stalling, hesitating, loss of power, decreasing of horse power.*ak
04/24/200304/24/2003
 When i purchased my used 2000 chevrolet cavalier in april 2003 about 1 month i started having problems. after putting gas in my car i would drive a little and then the gas gauge would go down to appear that the car was almost empty but it wasn't. while driving one day the car just shut off it had gas in it i had just put gas in it but the gauge dropped to appear to be almost empty. i had to get my car towed to the shop i was told my fuel injection went out. not even a month after that my car stalled at a red light and my temperature gage went in the hot zone my car wouldn't start i had to get it towed again to the shop but they could not find the problem. now here it is june 2003 my car is sitting in the drive way right now as i am typing this information. my son was driving home at 1:00 a.m. this morning from work when the car overheated again and started smoking. he said smoke was also coming out of the battery and he also heard noise coming from the rear of the car today is saturday and my car has to sit in the driveway until monday morning that when the dealer opens. i feel that something should be done. i don't think it is fair for dealers to be able to sale cars that are in this kind of condition and the car is suppose to be certified. i am making payments on the car and i am having all these problems. it is dangerous to be driving and the car decides to cut off especially at 1:00 a.m. i have to be at work at 3:45 a.m. and my son gets off work at 1:00 a.m. this is very, very dangerous for the both of us. *nlm
04/27/2001403/22/2000
 While driving on three different occasions at 65 mph and without prior warning vehicle cutt off, causing loos of all power. also, vehicle has lost a great amount of fuel, problem may be linked, causing occupants of vehicle to get sick. (ak consumer states no one knows as of yet, the first time dealer replaced battery, the second time they did nothing, the third time they replaced filter in gas line or tank.*jb
FUEL SYSTEM, GASOLINE - DELIVERY - FUEL PUMP
03/25/200890000108/14/1999
 When traveling at highway speeds the car cuts out and dies and then doesn't restart. this is due to a premature failure of the fuel pump. i believe the problem is design related. the pump failed at 90,000 mi. *tr
05/13/200776828307/05/2001
 Fuel pump on chevrolet cavalier z24 went out at 76,000 miles. it lost power and died all of a sudden in the middle of the highway. luckily, no cars were around as it was almost midnight. cost to repair was over $600, not including the towing. in doing some research i have found that numerous people had fuel pumps malfunction on their cavaliers, and on some cars newer and most with lower miles than on this car. same story, just loses power and died in the middle of the road. this was extremely unsafe. obviously this was a defect with the cavalier, yet they won't issue a recall. i have never heard from anyone that owned a cavalier that didn't have some sort of problem with it. also, had problems with the shifter cable and power window motor on the driver's side. extremely unhappy with the chevrolet. *ak
01/01/19011
 Consumer 2000 cavalier stall when turning or stopping at a red light. *ts after the recall work was done for the ignition the vehicle began to stall. the vehicle's transmission had to be overhauled. two sensors have been replaced. the catalytic converter has been replaced. the fuel pump has been replaced. *nm
10/01/200351300202/08/2002
 I was on my way hme from work on a very busy road all of sudden car just lost power car would not restart took to shop was told the fuel pump was bad and needed to $$700 repair for something that i feel should not needed to be done on such a new vehicle i only had 51000 miles on the vehicle i bought a new car for this reason to avoid major repairs as of this date the car has failed again with the same conditions as previous just stalled and wont restart and the warrenty has run out on that( 12,000 or 12 mth) so that wilkl be another cost to replace this pump in less than a years time. this is utterly ridiculous on a 2000 vehicle for this to happen and gm states not are problem things happen , yes things happen but not continuous on new vehicles and the same problem i think gm really needs to take a closer look at this for some type of defect this is very dangerous and very costly
08/28/200130000407/19/2000
 I had 3 fuel pumps with in 1 year and continue to have emissions problems, odometer and strange noises from under hood, several mechanics and thousands of dollars later the problems continue. *jb
01/19/2004106/01/2000
 Car would not start. was told by dealership service department that the fuel pump would need to be replaced. found out it was the strainer in the fuel pump. this part was revised by manufacturer. my parents had the same problem with their 2000 cavalier. *la
01/12/200434808/09/2000
 While traveling at speed limit over busy bridge 1/12/04 at 7a.m. and slippery road conditions car stopped and failed to take any gas causing 4 oncoming vehicles to swerve and almost hit me in the rear. the car then starts and runs fine for a couple days then the car stops again on 1/14/04 again on busy highway causing almost a 3 car collision. this has happened several times and in the middle of traffic. i believe that i could have been killed on two occasions and many others could have lost their lives. i believe this issue needs to be looked at as soon as possible, it is life threatening. i was told that the fuel pump could have been defective. i believe the manufacturer needs to look into the fuel pumps on this make and model of car. *cb
08/22/20034
 Fuel pump stopped working and vehicle became inoperable. independent dealer in the last past two years had replaced four fuel pumps.*ak
07/07/200339000208/23/1999
 My wife and i own a 2000 chevrolet cavalier. the steering is beginning to have a distinctive popping sound and loosening develop. i know there is a problem and i am taking it to a professional to avoid serious problems. it is difficult to believe that gm could not develop a better steering column than this. it would seem a recall should be placed on gm for inspections to this particular problem (part). i know that this may seem trivial but i have already had to replace a fuel pump ($700 plus) out of pocket at about 2000 miles over my warranty. just seems like gm has yet to understand quality in the small automobile. or at least giving a little on an obviously defective part. example: i owned a 87 3 series bmw that i put 425,000 plus miles on and never had to replace a steering column. i did replace the fuel pump after an accident when the tank had to be replaced at 310,000 miles. a fuel pump at 39,000 mile and a steering column at 46,000 miles. *ak
06/13/2003108/26/2000
 While driving home my car stalled then just cut off. the engine would crank but it would not stay running. i took it to a mechanic and he said it was the fuel pump. 8jb
06/09/2003111/01/1999
 Car would not start. service department determined the fuel pump needed replaced. suggested gas level not to go below 1/4 tank in future. *jb
05/19/20039775101/04/2000
 While driving, the vehicle stalled which was caused by a defective fuel pump. the old fuel pump was replaced with a redesigned fuel pump. *jb *cb *jb
05/02/20021
 Fuel pump has stopped working and the vehicle has become inoperable. contacted dealer, and the dealer was taking a look at vehicle.*ak.*mj
05/31/2001204/02/2001
 When turning steering wheel sharply there was a popping sound at all times. dealer replaced power steering shaft.*ak consumer states engine light comes on while driving, squealing noise from passengers side of engine especially on cold starts, and engine is slow to crank up-intermittent, battery was replaced, also vehicle would not start, dealer found fuel pump was inoperative and replaced fuel pump. *yd
09/18/2000901/18/2000
 Vehicle is not able to start anytime of the day. contacted dealer ,and dealer is not willing to do anything. *ak when the vehicle stall first time the dealer replaced ignition control module. when it stall again, the fuel pump was replaced. however, the vehicle continued stalling. *yh
FUEL SYSTEM, GASOLINE - FUEL INJECTION SYSTEM
05/03/200558000302/08/2003
 There have been two issues with my vehicle that i feel should be recalls due to the same problems that has happened to my car has also happend to other cavalier owners. recently the fuel tank gauge went out without any kind of warning, which cased me to run out of gas and have to call a family member to pick me up. the second issue is the plastic behind the windsheild on the dashboard cracked in two different places. i work with a girl that has the same vehicle i do and both of these issues also happend to her car. i just think these issues should be looked into. its kinda weird that the same malfunctions happen to two cars of the same make and model. another issue is i had never received a recall notice on the failed ignition switch. i had to find out about it online when looking for a new part for my car. thats kind of scary! thanks you for your time, and i hope you take great consideration in my issues.
01/18/20033200008/18/2000
 Nov.7,2002 car won't start. dec.11,2002 won't start. took car to potamkin chevorlet dec.19,2002. i was told there's was nothing wrong with the car and they would not replace battery. jan.13,2003 car won't start. car was towed to liberty chevorlet. was told car needed battery and starter. also told if proper test was done, potamkin should have picked up the problem. currently having problems with car. car stops while driving. liberty unable to find problem. also since i purchased the car,new, my interior lights flash on and off when i brake hard or go over bumps in road. either dealer unable to find out why.
FUEL SYSTEM, GASOLINE - STORAGE
03/20/20032503030
 When the fuel in the tank reached a quarter empty, vehicle stalls without warning. the dealership indicated that this is due to the fuel tank cap was screwed on to tight. the consumer feels this information is untrue because the cap can only be tighten to a certain point. *la
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY
09/28/2000406/28/2000
 The gas cylinder is being corroded by the sulfur in the gasoline, the gas gauge will read that there is gas and then the vehicle will just stop without any warning. *slc
07/06/2000
 Defective fuel tank was leaking which may cause a fire if there is a source of ignition. dealer said that he shouldnt fill up the tank. dealer is replacing the fuel tank. please provide further information.*ak
08/08/19991
 While driving a rental vehicle fuel tank, made of plastic, was punctured, causing fuel to leak out. vehicle was towed to dealership. garage was filled with gas fumes.*ak fuel tank was punctured by road debris and replaced. *yh
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY - FILLER PIPE AND CAP
03/22/2000103/20/2000
 Check the engine light came on due to loose fuel cap. yh
FUEL SYSTEM, OTHER
02/23/20091690001
 2000 cavalier fuel pump went out chevrolet ---this seems to be a very common problem with a very expensive solution 280 for a new one plus the aggravation of trying to take apart and replace the hoses why don't they just recall these cars 200-2004 at least to replace the weak junky fuel pumps with better ones. *tr
09/25/2003305/14/2000
 On 3 seperate occasions my car has now while driving just shut off w/ no warning. we have replaced fuel filter and still is doing it. i have been told it could be fuel pump or in the electrical system. i have contacted the chev company and they are not willing to pay any part of the repair. i feel this is a safety issue and feel it should be made a recall or taken care of before someone does get hurt.my car now sits in my yard unable to drive and want something to be done about the situation or i will have to go to a lawyer.
10/21/2002109/01/2000
 Car was being driven on highway, accelerated beyond driver's control, with brakes applied driver put car in neutral, guided car off road and shut off engine. mechanic where car was towed explained that the air filter cover had broken and a piece from air filter cover was sucked into air duct to throttle body causing throttle to be stuck open. car is bifuel cng. is this is a factor in air filter cover cracking? is there parts tracking for replacement of air filter covers and is it known how many of those went to bifuel cars. why is air filter cover cracking? or is there a fix to prevent pieces from lodging in throttle? dt
07/25/2001105/01/2000
 This vehicle has a dual fuel system; gasoline and natural gas. the default fuel is natural gas (ng). on a hot, 92degree day, on ng fuel, i accelerated hard through a 4 lane, stoplight intersection. the engine stalled and i barely coasted through. the ng fuel tank was 1/4 - 1/3 full. i was concerned about my safety. *ak
FUEL SYSTEM, OTHER - STORAGE - FUEL GAUGE SYSTEM
01/04/200887555104/01/2000
 Fuel gauge does not work correctly. only ever goes down to half when it should really be reading empty. never know how much gas is really in the tank. *tr
11/19/200482500101/17/2001
 I was driving to working on november 19 2004 at approximately 8:30am when my car stalled at a stop light on a major street. i tried to give it gas but it would not accerate. i tried to start it a couple of times but it would not start. the car was on a 1/4 of gas when this happened so i thought it wasn't the fuel. i had to call my boss, who came out to try to help but had no luck in getting it to start or figuring out what the problem was so we had to call aaa and have them tow my car to an automotive shop. after 2 days of having my car in the shop, i was told by my mechanic that my fuel pump was completely shot due to my fuel guage readings not reading correctly. when my fuel reading was at 1/4 it was actually of empty. my mechanic then informed me that this has been a known defect for my year, make and model car. i was then informed by my mechanic that it would cost $675.00 which included parts and labor to fix this problem. at that time, i called the gm dealer because i thought that since this was a known defect that they should have it covered under some kind of warranty. i spoke with the service manager of the santa clarita, california dealer, who informed me that it has been a known problem, but that its not under any kind of extended warranty. when i heard that, i was very angry because i felt that if this is a known complaint/defect that these certain cars may have, why should i, the customer of chevrolet, have to pay for their defective parts? since i am in need of my reliable transportation, i paid for a new fuel pump (all $675.00 worth of it).*ak
02/08/20045000025
 Inaccurate or erratic fuel gauge readings. *ak
1
 Fuel gauge is not reading the correct amount of fuel in the tank, causing the vehicle to shut down while driving on the highway. *ak
08/01/200335500105/15/2003
 Over the past several months the fuel gauge on my 2000 cavalier has failed to show the proper amoun of fuel remaining in the tank. i have had the car run out of fuel while the gauge shows 1/2 tank remaining. also, after refueling i have had the gauge show an empty tank, or the needle will varie between full and empty while i am driving.*ak
02/28/2002207/03/2000
 Gas gauge has started to register more gas than actually in tank and check gauge light does not come on, causing highway break down while gauge registering ample supply of gas. filled tank up again this week, have traveled approximately 160 miles and gauge still registering over 3/4 tank full. my car averages 30 miles to a gallon. for 15 gallon tank gauge should be registering under quarter tank when five gallons of gas consumed.*jb
10/30/2002
 Fuel sending unit fail while driving cause the vehicle stop operating dealer notified. ts
01/08/2001209/29/1999
 Going uphill vehicle stalled, after 10 minutes. started again, and a while later, on uphill vehicle stalled . had vehicle towed to dealer, mechanic took vehicle on test drive, and it stalled uphill. dealer replaced fuel sending unit. in november 2000, head gasket had to be replaced.*ak
FUEL SYSTEM, OTHER - STORAGE - TANK ASSEMBLY - MOUNTING
 Consumer called complaining about having problems with the bolts that hold the motor mounting felt out wich caused the bracket to shift and cause a whole on the oil pan wich cause the oil to come out of the oil pan. dealer was not contacted tbut the vehicle was taking to a private mechanic. mr