NHTSA Complaint #11321634 — 2012 CHEVROLET MALIBU

CAR WOULD RANDOMLY NOT START UP. STARTER WOULD ENGAGE WITH KEY TURNED, BUT ENGINE WOULD NOT FIRE OFF AND RUN. NO CODES FROM DIAGNOSTICS. NEVER HEARD FUEL PUMP ENERGIZE WITH PROBLEM PRESENT. CAR WOULD EVENTUALLY SUCCESSFULLY START. BENCH TESTED FUEL PUMP RELAY WITH NO ISSUES. DISASSEMBLED FUSE BOX IN TRUNK AND FOUND THE BROWN WIRE CONNECTING THE FUEL PUMP TO ITS RELAY WAS SIGNIFICANTLY HEAT STRESSED. THE BLACK PLASTIC WIRE HARNESS THAT HOUSES THE BROWN FUEL PUMP WIRE WAS ALSO STRESSED AND DEFORMED, AND WAS NO LONGER RETAINING THE CRIMPED CONNECTOR FOR THE BROWN WIRE. I HAD TO CLEAN UP THE METAL CRIMP CONNECTOR AND PINCH DOWN ON THE END SO THAT IT WOULD "GRAB" THE RELAY TERMINAL ONCE REASSEMBLED. CAR HAS YET TO REPEAT THE STARTING PROBLEM A YEAR LATER.