Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ENGINE AND ENGINE COOLING
61010/01/200410015768Engine idle flare when the clutch is depressed. also low speed engine decel stall when coming to a stop. gm tech link. *tt08/11/2005
03060101807/01/200410012103New cylinder bore liner replacement procedure. this service bulletin replaces 030601018a. *eh02/11/2005
ENGINE AND ENGINE COOLING - COOLING SYSTEM
07100307/10/200310003815This vme message is a water pump replacement due to a known cam driveline. some customers may question about whine noise coming from the front engine area. *tt11/03/2003
07150307/15/200310003789Coolant lose, evidence fluid on the garage floor, etc., or coolant warning light coming on. *tt10/31/2003
01060201212/01/2001628890Some owners may comment on leakage of a few drops of coolant after parking their vehicle. *tt03/21/2002
ENGINE AND ENGINE COOLING - ENGINE
PIP-4495C03/01/201110038510Gm: there may be noise coming from the cylinder head, because of low oil pressure which is caused by debris. *rm06/16/2011
PIP-4495C03/01/201110038510Ready06/16/2011
38593859A10020923Low oil pressure - inspect oil filter for damage. *kb updated 10/18/07. *nj01/30/2007
174901910019208Information on transferring original fuel rail to goodwrench engine. *ak02/17/2006
05060402605/01/2005050604026A10017407Vehicle hesitates, no start, lack of power, low fuel pressure. *tt11/07/2005
34333433D10017032Service engine soon (ses) light and severe engine misfire on cylinders 1 and 4 or cylinders 2 and 3. *tt updated 08-15-07. *kb10/20/2005
03060102201/01/2004030601022A10011117Guidelines for cylinder bore liner/piston sleeve replacement on the l4 ecotec engine. *tt01/03/2005
0400806/22/200410008726Special policy adjustment 04008 - air cleaner cover - replace. *tt08/18/2004
0400806/01/200410008727Special policy adjustment - air cleaner cover - replace. bi-fuel (compressed natural gas and gasoline) engine may experience a higher rate of backfire than on gasoline engine cavaliers. *tt08/18/2004
0135301/01/200401353A10007937Engine misfire due to injector fretting corrosion. *tt07/16/2004
0043401/01/200400434A10007528Engine will crank but not start, also makes noise while cranking. 2.2 l61 engine. *tt06/30/2004
0199501/01/200410007055Replacing a 02 or 03 2.2l l61 with a 04 2.2l l61 engine replacement.*mr05/25/2004
0306412/01/200310005744On-board diagnostic system software upgrade - obd system improvements. *tt03/12/2004
0145111/18/200310004249Cng equipped vehicles may require crank times up to 6 seconds when starting on cng. *tt11/24/2003
07110307/11/200310003816This vme message concerns a cylinder boreliner tool now available for the l61 2.2 liter engine. the tool is referenced in service bulletin 030601018. the purpose of the tool is to extend the total service life of the block. *tt11/03/2003
03060403003/01/2007030604030C10002166Multiple driveability symptoms of long or hard starts, chuggle, rough idle and light or intermittent misfire due to clogged fuel injectors. *tt08/14/2003
03060101806/01/200310002130New cylinder bore liner replacement procedure. *tt08/13/2003
02060404609/01/200210000066Service engine soon light on intermittently and diagnostic trouble code p1441 stored. *tt02/10/2003
28020202/28/2002629853Subject regarding oil filter leaks. *tt04/09/2002
01010201/01/2002629446Subject regarding product feedback request with 2.2l ln2 engines exhibiting an oil filter leak. *jg04/02/2002
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
0202005/24/2002634191Customer satisfaction program - engine cylinder bore liner. *tt09/28/2002
02060404508/01/2002634249Subject regarding revised dtc p0327 - this bulletin is being issued to revise step 3 of dtc p0327 in the engine controls. nlm09/28/2002
020601001A03/01/2002020601001631251Customers may complain on a drone noise coming from the engine area. *slc05/21/2002
16010201/16/2002629703Customers may comment that the engine lags power, stalls, won't start or is hard to start. *tt04/05/2002
01010201/01/2002628395Subject regarding engines exhibiting diagnostic trouble code p0141 with no prior repair attemps. *jg03/08/2002
29100110/29/2001628051Customer complaint of extended crank time. *tt03/05/2002
22100110/22/2001628020Some vehicles may exhibit diagnostic trouble codes such as rough running, miss fires or a no start condition. *tt03/01/2002
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
05090109/05/2001626045Subject regarding front oxygen sensor connector retention. *slc12/12/2001

Consumer Complaints


Fail datemilesoccurencesPurchase date
ENGINE AND ENGINE COOLING
03/17/201072000
 Timing chain broke on 2002 chevrolet cavalier ls causing catostrophic engine failure. automobile only has 70,000 miles on a well maintained motor. gm installed faulty oil nozzle as well as timing chain tensioner in motor originally but refuses responsibility even though checked at gm certified service center 4 months prior complaining of timing symptoms. no repair has been done at this time. after much research it seems that this is a common problem in all vehicles from 2002 and 2003 that have 2.2l ecotec motors.
03/17/201072000
 Timing chain broke on 2002 chevrolet cavalier ls causing catostrophic engine failure. automobile only has 70,000 miles on a well maintained motor. gm installed faulty oil nozzle as well as timing chain tensioner in motor originally but refuses responsibility even though checked at gm certified service center 4 months prior complaining of timing symptoms. no repair has been done at this time. after much research it seems that this is a common problem in all vehicles from 2002 and 2003 that have 2.2l ecotec motors.
03/17/201072000
 Timing chain broke on 2002 chevrolet cavalier ls causing catostrophic engine failure. automobile only has 70,000 miles on a well maintained motor. gm installed faulty oil nozzle as well as timing chain tensioner in motor originally but refuses responsibility even though checked at gm certified service center 4 months prior complaining of timing symptoms. no repair has been done at this time. after much research it seems that this is a common problem in all vehicles from 2002 and 2003 that have 2.2l ecotec motors.
03/17/201072000
 Timing chain broke on 2002 chevrolet cavalier ls causing catostrophic engine failure. automobile only has 70,000 miles on a well maintained motor. gm installed faulty oil nozzle as well as timing chain tensioner in motor originally but refuses responsibility even though checked at gm certified service center 4 months prior complaining of timing symptoms. no repair has been done at this time. after much research it seems that this is a common problem in all vehicles from 2002 and 2003 that have 2.2l ecotec motors.
03/17/201072000
 Timing chain broke on 2002 chevrolet cavalier ls causing catostrophic engine failure. automobile only has 70,000 miles on a well maintained motor. gm installed faulty oil nozzle as well as timing chain tensioner in motor originally but refuses responsibility even though checked at gm certified service center 4 months prior complaining of timing symptoms. no repair has been done at this time. after much research it seems that this is a common problem in all vehicles from 2002 and 2003 that have 2.2l ecotec motors.
01/11/200625507310/30/2001
 Dt*: the contact stated without warning, the vehicle looses power while driving. after a few minutes, the vehicle restarts. the vehicle is driven a short distance and it looses power again. this continues until the vehicle reaches the dealership. the dealership has replaced the fuel pump on three separate occasions. no other repairs have been attempted. updated 02/21/06. *jb
09/14/20041
 The driver was driving vehicle stalled. the driver tried to restart,but was unable to. the consumer had the vehicle towed to the dealer for inspection. the mechanic informed the driver that the problem can not be duplicated. please fill in additional information.
04/22/20043
 Consumer purchased a vehicle for daughter, and vehicle exhibited several major problems. vehicle overheated, and had a new thermostat and fuel filter replaced. when trying to start the vehicle it acted as if did not want to start. vehicle was just not firing correctly because it was very difficult to start. consumer wanted to know if there were any recalls on this vehicle.*ak the vehicle became even more difficult to start and the coolant and temperature gauges were illuminated. when the coolant was checked it was at a normal level but looked like something other than coolant was in the tank. the oil was checked and looked like brown merky liquid. *nm
01/28/20041
 While driving consumer heard a knocking noise coming from underneath the vehicle. consumer was able to drive the vehicle to sears mechanic shop, and mechanic determined that motor mount broke and cracked in half, causing the engine to drop down half shaft. consumer contacted manufacturer about the problem, and manufacturer insisted that consumer was responsible to pay for parts and labor because warranty expired. *ak
ENGINE AND ENGINE COOLING - COOLING SYSTEM
02/27/2010771151
 I bought this car a 2002 chevy cavalier in 2005, and at the time there was 25k original miles so i was told. since then i have found out there has been 5 recalls on this car for various safety hazards, none of which i was ever told about prior or during my purchase of this vehicle. the signals have failed, i had to pay for them to be replaced, the bearings on the tires caused dry rot and i had to pay to replace those, both were on the recall list. the engine would over heat in the idle position, and they replaced an air filter sitting that as the problem and it wasn't. the pedal sticks when i accelerate and sometimes gets stuck, the rockerarms have started to go bad and it has caused the valve stems to bend,thus causing the oilpump to seize up and now my cars engine has a blown gasket,this is under the engine component system recall, which was reported in 2007. i was never notified. and now im paying 350 per month for a car that is not running. *tr
07/09/2002204/02/2002
 Nar 9-10-03. safety defect in 2002 chevy cavalier. engine coolant leak. *cb
07/05/2004409/21/2001
 When driving, can smell coolant and see greasy film on windshield. which makes all occupants thirsty. (this was even before it hit more than a hundred miles) overflow compartment for coolant started overflowing and low coolant light came on. engine temperature gauge keeps moving around, and stays above normal most of the time. was driving and the car just died out on me, i restarted the car and moved off the busy highway. with all of these incidents, i took it to the dealer shop but was told there was nothing wrong with it. i took it to a mechanic and he told me that the heat sensor was out as well as the thermostat. the gauge continued to move up and down. i had a fuel pump replaced but it was a defective part. this was all in the course of three months. *jb
12/21/2002110/15/2002
 Compressor never worked when the car was bought. left rear turn signal continually shorted out, a wire needed to be replaced. driver side front window motor had to be replaced.*jb
ENGINE AND ENGINE COOLING - COOLING SYSTEM - FAN
01/03/200680580202/11/2003
 I started my car in the am and noticed my trac light was on(knowing it is not suppose to be on unless i am in 1st or 2nd gear. then i smelled burning electrical. took it to the chevy garage and found out my engine coolant fan internally shorted, they replaced the fan motor, a sensor an element and a fuse kit. at a substantial cost. i was without my car for 3 days and had to rent a vehicle to get back and forth to my job and home. *nm
ENGINE AND ENGINE COOLING - ENGINE
02/27/2010771151
 I bought this car a 2002 chevy cavalier in 2005, and at the time there was 25k original miles so i was told. since then i have found out there has been 5 recalls on this car for various safety hazards, none of which i was ever told about prior or during my purchase of this vehicle. the signals have failed, i had to pay for them to be replaced, the bearings on the tires caused dry rot and i had to pay to replace those, both were on the recall list. the engine would over heat in the idle position, and they replaced an air filter sitting that as the problem and it wasn't. the pedal sticks when i accelerate and sometimes gets stuck, the rockerarms have started to go bad and it has caused the valve stems to bend,thus causing the oilpump to seize up and now my cars engine has a blown gasket,this is under the engine component system recall, which was reported in 2007. i was never notified. and now im paying 350 per month for a car that is not running. *tr
11/21/200754000109/18/2007
 Tl*the contact owns a 2002 chevrolet cavalier. the engine light illuminated intermittently. the dealer was informed that the oxygen sensor needed to be replaced. the contact was charged $600 for the repair. she took a long trip and the light did not illuminate. on a shorter trip, the engine light began illuminating intermittently again and the vehicle overheated. when the vehicle was turned off and restarted, it operated normally. while driving 10 mph to the dealer, the engine failed and the dealer stated that the repair would cost $5,000 and could not guarantee that the vehicle would actually be repaired. the contact learned that the head failed before at 28,000 miles. she believes that her vehicle was mis-diagnosed the first time. the current and failure mileages were 54,000. updated 01-10-08. *kb 12/31/07. *jb
08/08/2005626571
 Consumer engine makes a popping sound as if it is going to exploded. *ts the consuemr replaced the timing gear, chain, tensioner, and pulley on 2/22/2005. the vehicle continues to make loud noises. *nm
12/12/200406/23/2002
 Since purchasing my 2002 vehicle i have had to already put a new battery, new alternator, new tires (acceptable) two sets of brakes and the check engine light still is on and no one can find out why so therefore i can't get an inspection of the vehicle until light is off. help. *nm
8663405/24/2002
 Engine check light stayed on. when driving lights turned off then flickered. also, windshield wipers and automatic locks operated poorly. vehicle was taken to dealership on several occasions for the same problems.*ak on for occasions consumer was driving when vehicle headlights went out. another problem consumer is experiencing is the windshield wipers come to a complete stop while in use. there is also a problem with the door locks. vehicle has been serviced on various occasions for electrical problems. during one service visit the body control module was replaced and the theft deterrent system was programmed. even after several service visits vehicle still experiencing problems with windshield wipers, door locks, turn signals, and hazard lights.*mr
04/01/200365001
 Car surges when cold, under slow acceleration. gives a feeling of holding back, under slow acceleration. runs fine when warm. first 3 minutes then clears up. *la
07/07/20035424612/14/2001
 Engine and vehicle speed sometimes, but intermittently, do not respond to driver control - vehicle accelerates on its own. when that happens, had to ride brakes to control speed. this happened five times with increasing severity over a period of time - on the sixth time the vehicle reached 60mph without the accelerator being touched. review of odi compliants shows an increasing number of similar related complaints on this model with age. had purchased car to give to my newly licensed daughter, who, due to lack of experience, was initially unsure if the problem was with her or the car. the last time scared her, and the dealer's rep said it was an accident waiting to happen. dealer did a good job in persisting with the problem, which was finally (after two days) traced to the accelerator control cable dust cover coming loose and wedging itself between the cable an actuator in a difficult to detect location.*ak
07/08/20035600611/25/2002
 While driving 60 mph, the service engine light came on and the engine stalled. the dealership serviced the vehicle, and replaced several components, but the problem still continued. *ak *cb. the fuel filter and oxygen senor was replaced however the problem continued. the consumer believed the problem was electrical. *jb
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE
07/16/200656000107/16/2006
 We were told the car was inspected before we bought it! head light out of adjustment brake and tail lights not working engine stared running rough few hours after we drove off a cd was found stuck in the player door needed alignment parking brakes not working right. *nm
07/29/2002107/23/2002
 Vehicle stalls without warning. dealer is aware of problem. *ak *slc
ENGINE AND ENGINE COOLING - ENGINE - GASOLINE - BELTS AND ASSOCIATED PULLEYS
02/01/200553906206/05/2002
 Dt: 2002 chevrolet cavalier. the consumer stated there was a constant problem with the timing chain gear, tensioner, and chain itself. it was replaced on february 22, 2005, and needed to replaced again. the dealership spotted the problem, but since the vehicle was out of warranty it was taken to a firestone service station. the engine sounded like it about to fall out. there was a lot of popping and cracking noise, that was how this was noticed. *ak
10/09/20041
 Timing chain broke at about 45 mph, causing engine to fail. results determined by the dealer showed that timing chain shattered, tearing up the engine.*ak
ENGINE AND ENGINE COOLING - EXHAUST SYSTEM - EMISSION CONTROL
06/04/2005540332
 Dt: the consumer complained that the 2002, chevrolet cavalier had a dash cluster problem. the dash cluster had to be repaired, and the consumer could not tell them how much gas she had. the consumer wanted satisfaction and the truth about the vehicle. the consumer took the vehicle to the dealer and had it repaired. the consumer said that the individual changing the oil told her that the car was too new to have these problems. also, there was an oxygen sensor problem. the consumer had a new one put in. the consumer noticed that there was something wrong before the car was diagnosed and the gas lever was working. she didn't know if she contacted gm or not. she contacted a dealer. *ak the dash cluster was inoperative along with the gauges not working since the #2 sensor was replaced and the engine and the traction light had illuminated. *sc