FaultScore

2004 Chevrolet Cavalier fuel system problems

15 of the 428 complaints about the 2004 Chevrolet Cavalier are about the fuel system — 4% of everything reported for this model year. Half of the failures with a mileage on record happened before 80,500 miles.

C

15

Complaints

1

Crashes

0

Fires

1

Injuries

Exactly what failed

Fuel System, Gasoline 8 53.3%
Fuel/Propulsion System 3 20.0%
Fuel System, Other 1 6.7%
Filler Pipe AND CAP 1 6.7%
Fuel Gauge System 1 6.7%
Fuel Pump 1 6.7%

Fuel & Propulsion across every Chevrolet Cavalier year

1996 19 3.1%
1997 25 4.1%
1998 15 2.5%
1999 17 2.8%
2000 43 7.1%
2001 33 5.4%
2002 18 3.0%
2003 406 66.9%
2004 15 2.5%
2005 16 2.6%

What owners said

Filed with NHTSA, in their own words.

Mobile, AL

FUEL/PROPULSION SYSTEM

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.

NHTSA complaint #10712311 — an unverified report by a vehicle owner.

at 68,000 miles Carnegie, PA

FUEL SYSTEM, GASOLINE

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?

NHTSA complaint #10618412 — an unverified report by a vehicle owner.

at 152,000 miles Farmington, MN

FUEL/PROPULSION SYSTEM

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.

NHTSA complaint #10592115 — an unverified report by a vehicle owner.

at 450,000 miles Clarksville, NY

FUEL/PROPULSION SYSTEM

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?

NHTSA complaint #10463660 — an unverified report by a vehicle owner.

Upland, CA

FUEL SYSTEM, GASOLINE

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.

NHTSA complaint #10428724 — an unverified report by a vehicle owner.

at 83,000 miles Marshfield, WI

FUEL SYSTEM, GASOLINE

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 complaint #10397527 — an unverified report by a vehicle owner.

at 108,000 miles Byhalia, MS

FUEL SYSTEM, OTHER

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?

NHTSA complaint #10386620 — an unverified report by a vehicle owner.

at 96,698 miles MT Wolf, PA

FUEL SYSTEM, GASOLINE

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

NHTSA complaint #10378619 — an unverified report by a vehicle owner.

at 110,000 miles Atlanta, GA Crash 3 injured

FUEL SYSTEM, GASOLINE

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.

NHTSA complaint #10279773 — an unverified report by a vehicle owner.

at 78,000 miles Cincincati, OH

FUEL SYSTEM, GASOLINE

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 complaint #10263642 — an unverified report by a vehicle owner.

at 51,862 miles Germantown, OH

FUEL SYSTEM, GASOLINE

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.

NHTSA complaint #10249107 — an unverified report by a vehicle owner.

at 76,000 miles Clendenin, WV

FUEL SYSTEM, OTHER:DELIVERY:FUEL PUMP

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

NHTSA complaint #10196231 — an unverified report by a vehicle owner.

at 5,000 miles Paradise, CA

FUEL SYSTEM, OTHER:STORAGE:FUEL GAUGE SYSTEM

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.

NHTSA complaint #10167018 — an unverified report by a vehicle owner.

Chicago, IL

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

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.

NHTSA complaint #10109706 — an unverified report by a vehicle owner.

at 100 miles Sumter, SC

FUEL SYSTEM, GASOLINE

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

NHTSA complaint #10073471 — an unverified report by a vehicle owner.

Other 2004 Chevrolet Cavalier problems

← Full 2004 Chevrolet Cavalier report