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NHTSA Defect Investigations for the 2001 Chevrolet Malibu

The Office of Defects Investigations (ODI) is an office within the NHTSA which investigates serious safety problems in the design, construction or performance of vehicles. The NHTSA is authorized to order manufacturers to recall and repair vehicles, if the ODI finds a safety issue. NHTSA investigations for the 2001 Chevrolet Malibu, both ongoing and closed, are listed below:

  1. TURN SIGNAL FAILURE NHTSA Preliminary Evaluation #PE02064

    • Status:
      CLOSED
    • Date Opened: August 22, 2002
    • Date Closed: December 23, 2002
    • Recall: no recall issued

    Component(s): Exterior Lighting:Hazard Flashing Warning Lights
    Exterior Lighting:Hazard Flashing Warning Lights:Switch
    Exterior Lighting:Turn Signal
    Exterior Lighting:Turn Signal:Switch

    Summary: ODI opened the investigation based on 9 complaints of turn signals operating sporadically on the 2000-2001 Chevrolet Malibu.the turn signals quit working without warning and may occur while the vehicle is in motion or standing still.GM identified the hazard switch as the root cause of this problem.electrical current to the turn signal passes through the hazard switch.failure of the hazard switchresults in loss of turn signals and hazard lights.GM reports 318, 184 and 201 consumer complaints for the Malibu, Alero and Grand Am respectively.GM also reports the following models have the same design turn signal/hazard switch as the Chevrolet Malibu: Chevrolet corvette, Monte Carlo, and Impala; Oldsmobile intrigue and Alero; and the Pontiac Grand Am.the complaint and warranty data show the highest occurance of the problem in the MY 2000-2001 Malibu, Alero, and Grand Am.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE02064 »

  2. TURN SIGNAL FAILURES NHTSA Engineering Analysis #EA02037

    Component(s): Exterior Lighting:Hazard Flashing Warning Lights
    Exterior Lighting:Hazard Flashing Warning Lights:Switch
    Exterior Lighting:Turn Signal
    Exterior Lighting:Turn Signal:Switch

    Summary: By letter dated August 27, 2003, GM notified the Agency that it is conducting a voluntary safety recall (NHTSA recall no. 03V327) involving certain model year (MY) 2000-2001 Chevrolet Malibu, Oldsmobile Alero, and Pontiac Grand Am.GM's recall covers 670,740 vehicles manufactured beginning February 1, 2000 through May 1, 2001 (Alero and Grand Am) and February 1, 2000 through May 31, 2001 (Malibu).GM reports that turn signal failure is due to solder joint cracking in the hazard switch, and has identified rapid temperature transitions of the hazard switch and the soldering process as the cause of cracking.electrical current to the turn signals flows through the hazard switch and an open circuit in the hazard switch will cause the exterior turn/hazard lamps to become intermittent or inoperative.GM will replace the hazard switch on all involved vehicles.based on GM's safety recall action, this investigation is closed.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA02037 »

  3. ERRATIC FUEL GAUGE NHTSA Engineering Analysis #EA02028

    • Status:
      CLOSED
    • Date Opened: September 30, 2002
    • Date Closed: December 30, 2003
    • Recall: no recall issued

    Component(s): Fuel System, Gasoline
    Fuel System, Other:Storage:Fuel Gauge System

    Summary: 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA02028 »

  4. ERRATIC FUEL GAUGE NHTSA Defect Investigation #SQ01002

    • Status:
      CLOSED
    • Date Opened: January 26, 2001
    • Date Closed: September 30, 2002
    • Recall: no recall issued

    Component(s): Vehicle Speed Control:Linkages

    Summary: There is no summary currently available

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #SQ01002 »

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