2002 GMC Envoy problems

Loss of Headlights

The subject vehicles are model year (MY) 2002-2009 Chevrolet Trailblazer, GMC Envoy, 2004-2007 Buick Rainier, 2003-2008 Isuzu Ascender, 2005-2009 Saab 9-7X, 2002-2004 Oldsmobile Bravada, 2003-2006 Chevrolet SSR, 2005-2009 Buick Lacrosse, and 2006-2008 Pontiac Grand Prix. This scope includes the Trailblazer/Envoy variants: 2002-2006 Envoy XL/Trailblazer EXT and 2004-2005 Envoy XUV. The original scope of this investigation was expanded to include all vehicles equipped with the subject Headlight Driver Module (HDM). The focus of the investigation was to determine whether actions performed by Gene...

HAZARD LIGHT SWITCH FAILURE

ON NOVEMBER 30, 2001, GENERAL MOTORS (GM) CONDUCTED SAFETY RECALL 01V-364 FOR THE SUBJECT VEHICLES BUILT BETWEEN SEPTEMBER 16, 1999 AND AUGUST 28, 2001 TO REMEDY A DEFECTIVE HAZARD SWITCH THAT WOULD CAUSE A LOSS OF HAZARD AND STOP LAMP ILLUMINATION.THE HAZARD SWITCH IS CONTAINED WITHIN THE VEHICLE MULTIFUNCTION SWITCH.ODI OPENED THIS INVESTIGATION BASED ON REPORTS THAT SOME CONSUMERS WERE NOT NOTIFIED OF THE ORIGINAL RECALL OR THAT THEY HAD REPAIRS DONE UNDER 01V-364 BUT EXPERIENCED SUBSEQUENT MULTIFUNCTION SWITCH FAILURES.THE MULTIFUNCTION SWITCH SUPPORTS THE OPERATION OF CRUISE CONTROL, WIND...

FUEL PUMP MODULE LEAKS GASOLINE

DURING THE COURSE OF THIS EA INVESTIGATION, ODI OBSERVED THAT THE MAJORITY OF THE COMPLAINTS (88%) AND WARRANTY CLAIMS (94%) WERE REPORTED FOR VEHICLES THAT ARE REGISTERED FOR USE IN THE SALT BELT REGION OF THE US.THIS AREA INCLUDES 20 STATES IN THE NORTHEAST, MID ATLANTIC AND THE MIDWEST REGIONS AND THE DISTRICT OF COLUMBIA.CONSUMERS IN THE SALT BELT REGION REPORTED TO ODI THAT THEY COULD SMELL FUEL VAPORS IN THEIR VEHICLES WHILE DRIVING.UPON FURTHER EXAMINATION OF THEIR VEHICLES, THEY DISCOVERED THAT FUEL VAPORS WERE COMING OUT OF THE TOP OF THE FUEL TANK. THIS CONDITION IS CAUSED BY CORROSI...

FUEL PUMP MODULE LEAKS GASOLINE

ODI HAS RECEIVED REPORTS THAT THE FUEL PUMP MODULE LEAKS FUEL AND OR VAPOR UNDERNEATH THE VEHICLE.GM STATES, THE FAILURE MECHANISM IS CORROSION OF THE FUEL PUMP MODULE FLANGE WHICH MAY LEAD TO A FUEL LEAK.CORROSION OF THE FUEL PUMP MODULE FLANGE IS THE RESULT OF THE VEHICLE OPERATING IN A CORROSIVE ENVIRONMENT.ODI HAS UPGRADED THIS PE TO ENGINEERING ANALYSIS (EA07-009) TO FURTHER ASSESS THIS ISSUE.

BRAKE LAMP FAILURE

GM STATES THAT SOME BRAKE/TAIL LAMP BULBS CAN PREMATURELY BECOME INOPERATIVE DUE TO MALFUNCTIONING BRAKE/TAIL LAMP SOCKETS.ON MARCH 2, 2004, GM INITIATED A 6-YEAR/72,000 MILE SPECIAL POLICY FOR 989,487 SUBJECT VEHICLES TO INSPECT AND REPLACE THE REAR BRAKE/TAIL LAMP BULB SOCKET ASSEMBLIES.ON APRIL 4, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE04-032) BASED ON CONSUMER COMPLAINTS ALLEGING BRAKE LIGHTS NOT OPERATING WHEN THE BRAKE PEDAL IS DEPRESSED.ON AUGUST 3, 2004 ODI UPGRADED PE04-032 TO AN ENGINEERING ANALYSIS (EA04-021).BY LETTER DATED OCTOBER 27, 20...

WINDSHIELD WIPER FAILURE

ON SEPTEMBER 17, 2003, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE03-042) TO INVESTIGATE ALLEGED WINDSHIELD WIPER FAILURE IN CERTAIN MODEL YEAR (MY) 2002 AND 2003 CHEVROLET TRAILBLAZER AND TRAILBLAZER EXT, GMC ENVOY AND ENVOY XL, AND OLDSMOBILE BRAVADA VEHICLES.THE INVESTIGATION WAS UPGRADED TO AN ENGINEERING ANALYSIS ON JANUARY 6, 2004, AND THE SCOPE WAS EXPANDED TO INCLUDE CERTAIN MY 2003 ISUZU ASCENDER VEHICLES.ALL SUBJECT VEHICLES ARE BUILT ON GENERAL MOTORS? GMT360 AND GMT370 PLATFORMS AND WERE ORIGINALLY EQUIPPED WITH A WINDSHIELD WIPER ASSEMBLY REFERRED...

WINDSHIELD WIPER FAILURE

THE SUBJECT VEHICLES (CHEVROLET TRAILBLAZER (EXT), GMC ENVOY (XL), AND OLDSMOBILE BRAVADA) ARE BUILT ON THE GMT360 AND GMT370 PLATFORMS AND WERE ORIGINALLY EQUIPPED WITH A WINDSHIELD WIPER ASSEMBLY REFERRED TO AS THE ?FAMILY? DESIGN MODULE (P/N 15171306 BASE, P/N 15171307 FOR VEHICLES EQUIPPED WITH RAINSENSE AUTOMATIC MOISTURE SENSITIVE WIPERS).THE WINDSHIELD WIPER ASSEMBLY IS LOCATED INSIDE THE PLENUM AT THE BASE OF THE WINDSHIELD AND IS MOUNTED ON AN INCLINE APPROXIMATELY EQUAL TO THE RAKE OF THE WINDSHIELD.GM REPORTS THAT VEHICLES ARE SUBJECT TO A QUALITY ASSURANCE WATER TEST AT THE ASSEMBL...

ENGINE STALL

MODEL YEAR (MY) 2002 BRAVADA AND CERTAIN MY 2002 ENVOY VEHICLES WITH OPTIONAL ELECTRONICALLY CONTROLLED AIR SUSPENSION (ECAS) MAY BE SUBJECT TO ENGINE STALL CAUSED BY AN ERRANT VOLTAGE SPIKE TRANSMITTED TO THE POWERTRAIN CONTROL MODULE (PCM).IN ADDITION TO ENGINE STALL, IF THE SPIKE DAMAGES THE PCM, THE VEHICLE MAY NOT RESTART.ON OCTOBER 31, 2001 GM INTRODUCED INTO PRODUCTION A WIRING HARNESS CONTAINING AN INDUCTOR THAT WAS ADDED TO THE ECAS WIRING TO REDUCE THE MAGNITUDE OF THE VOLTAGE SPIKE.ON DECEMBER 6, 2001 GM INTRODUCED INTO PRODUCTION A MODIFIED PCM WITH PROTECTION FROM ERRANT VOLTAGE S...

EXTERIOR LIGHTING:HEADLIGHTS

CERTAIN MAXZONE HEADLIGHT ASSEMBLIES, DEPO BRAND, P/NO 335-1120L-AS, SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR THE ABOVE LISTED PASSENGER VEHICLES. DURING PRODUCTION THE LAMP HOUSING SHAPE DEFORMED DISTORTING THE ASSEMBLY ANGLE OF THE REFLECTOR AND INFLUENCED THE AIMING POSITION. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

Risk: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

ENGINE AND ENGINE COOLING

SOME SPORT UTILITY VEHICLES EQUIPPED WITH AN ELECTRONICALLY CONTROLLED AIR SUSPENSION (ECAS) HAVE A CONDITION IN WHICH THE ECAS MAY PRODUCE A BRIEF ELECTRICAL SPIKE WHILE THE VEHICLE IS OPERATING. THIS ELECTRICAL SPIKE CAN DISRUPT THE POWERTRAIN CONTROL MODULE (PCM) CAUSING THE VEHICLE TO STALL.

Risk: IF THE SPIKE DAMAGES THE PCM, THE VEHICLE MAY NOT RESTART. IF THIS HAPPENS WHILE THE VEHICLE IS MOVING, A CRASH COULD OCCUR WITHOUT PRIOR WARNING.

SEAT BELTS

CERTAIN LIGHT DUTY PICKUP TRUCKS AND SPORT UTILITY VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 209, "SEAT BELT ASSEMBLIES." ONE OF THE TWO SENSORS IN THE DRIVER'S AND FRONT PASSENGER'S SEAT BELT RETRACTORS COULD BE INOPERATIVE. THE SEAT BELT RETRACTORS WILL LOCK WHEN THE BELT WEBBING IS EXTRACTED DURING A CRASH; HOWEVER, THE MECHANISM THAT LOCKS THE SEAT BELT RETRACTOR WHEN THE VEHICLE DECELERATES QUICKLY, SUCH AS HEAVY BRAKING, MAY NOT OPERATE AS INTENDED.

Risk: IF THIS WERE TO OCCUR, THE SAFETY BELT MAY NOT RESTRAIN THE OCCUPANT AS INTENDED DURING A CRASH, AND COULD RESULT IN INJURY TO THE OCCUPANT.

VISIBILITY:WINDSHIELD WIPER/WASHER

CERTAIN SPORT UTILITY VEHICLES HAVE WINDSHIELD WIPER SYSTEMS THAT WILL NOT TURN ON, CEASE OPERATION WHILE IN USE, FAIL TO TURN OFF/ON BY THEMSELVES (MOISTURE SENSITIVE WIPER SYSTEM), OR HAVE CONTINUOUS WINDSHIELD WASHER PUMP OPERATION BECAUSE THE PRESENCE OF WATER WITHIN THE WIPER MODULES CAN EITHER CAUSE A SHORT CIRCUIT OR CAN LEAD TO THE CORROSION OF COMPONENTS WITHIN THE MODULE.

Risk: DEPENDING ON THE OCCURRENCE AND WEATHER SITUATION, DRIVER VISIBILITY COULD BE REDUCED, WHICH COULD RESULT IN A CRASH.

EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL

CERTAIN MINIVANS, PASSENGER AND SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 225, "CHILD RESTRAINT ANCHORAGE SYSTEM." THE OWNER'S MANUAL DOES NOT EXPLAIN THE MEANING OF THE LOCATION SYMBOLS FOR THE CHILD RESTRAINT LOWER UNIVERSAL ANCHORAGE SYSTEM.

Risk: THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.

ELECTRICAL SYSTEM:WIRING:INTERIOR/UNDER DASH

CERTAIN SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARDS NO. 101, "CONTROL LOCATION, IDENTIFICATION, AND ILLUMINATION" AND NO. 208, "OCCUPANT CRASH PROTECTION." THESE VEHICLES HAVE AN INTERMITTENT CONDITION DURING VEHICLE START-UP IN WHICH THE INSTRUMENT PANEL CLUSTER MAY NOT PROPERLY POWER UP, RESULTING IN MOST OF THE DISPLAYS, TELLTALE LIGHTS, AND FUNCTIONS (EXCEPT THE SERVICE ENGINE LIGHT, TURN SIGNAL INDICATORS, AND THE INSTRUMENT PANEL CLUSTER BACKLIGHTING) BEING INOPERATIVE.

Risk: THESE VEHICLES DO NOT COMPLY WITH THE STANDARD.

POWER TRAIN:AUTOMATIC TRANSMISSION

CERTAIN SPORT UTILITY VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 114, "THEFT PROTECTION." THESE VEHICLES ARE EQUIPPED WITH A MECHANICAL OVERRIDE THAT COULD ALLOW THE IGNITION KEY TO BE REMOVED WITH THE SHIFT LEVER IN A POSITION OTHER THAN PARK. IN ADDITION, THESE VEHICLES HAVE AN OVERRIDE THAT CAN ALLOW THE TRANSMISSION TO BE SHIFTED OUT OF PARK WITH THE IGNITION IN THE OFF POSITION.

Risk: THESE OVERRIDES ARE NOT PERMITTED UNLESS THE VEHICLE HAS A LOCKING STEERING COLUMN.

STRUCTURE:BODY

CERTAIN SPORT UTILITY VEHICLES ARE MISSING WELDS ON THE REAR FLOOR PLAN.

Risk: IN A CRASH, MISSING WELDS COULD DEGRADE PERFORMANCE OF THE THIRD ROW SEAT AND SAFETY BELT ANCHORAGE AND OCCUPANTS COULD RECEIVE GREATER INJURIES.

Other

Issue: This recall is for aftermarket replacement rear window glass produced by Vitro Automotriz. Certain rear window glass may not have been properly tempered. If the window breaks, the glass may separate into large pieces instead of very small ones. Note: This is a voluntary recall that is not being conducted under the requirements of the Motor Vehicle Safety Act. Safety Risk: Glass that breaks in to large pieces could create a risk of injury. Corrective Actions: The company will notify consumers by mail and instruct them to inspect the designation code marked on the rear window glass. Products affected by this recall have the designation “DOT 287” along with the lettering “VMR” (Replacement Market) and a date code that is before July 2019. This information is printed on the bottom corner of the glass. Consumers should contact Vitro's customer service at 1-412-995-6457 or argbacklites@vitro.com to arrange for replacement of the glass.

Electrical

On certain vehicles, the multifunction switch may develop an open circuit condition with the bottom contact of the hazard switch, causing the stop lamps and the hazard lamps to become inoperable (the center high mounted stop lamp and turn signal functions are not affected). The loss of stop lamp and rear hazard lamp function could fail to warn a following driver that the vehicle is braking and/or is stopped, which could result in a crash causing personal injury or death. Correction: Dealers will inspect and replace either the hazard warning switch, or the multifunction switch assembly. Note: This campaign expands the population of recall 2001285.

Lights And Instruments

On certain vehicles, vibration and heat may cause the tail lamp/stop lamp bulb to loosen in its socket. If this occurs, the bulb may flicker and eventually become inoperative. The loss of one or both of the tail lamps/stop lamps could reduce the vehicle's visibility to following drivers and fail to warn others that the vehicle is braking and/or is stopped, which could lead to a vehicle crash. Correction: Dealers will inspect the tail lamp/stop lamp assemblies and, if necessary, replace them.

Engine

On certain vehicles, the Electronically Controlled Air Suspension (ECAS) may produce a brief electrical spike while the vehicle is operating. This electrical spike can disrupt the Powertrain Control Module (PCM) causing the vehicle to stall. If the spike damages the PCM, the vehicle may not restart. Correction: Problem previously addressed by Technical Service Bulletin A001831 in January 2002.

Seats And Restraints

Certain vehicles fail to conform to CMVSS 209, seat belt assemblies. These vehicles have a condition where one or two sensors in the driver's and front seat passengers seat belt retractors may be inoperative. The seat belt retractors will lock when the belt webbing is extracted during a crash; however the mechanism that locks the seat belt retractor when the vehicle decelerates quickly, such as during heavy braking, may not restrain the occupant as intended during a crash, and could result in injury to the occupant. Correction: Dealers will inspect the seat belt assemblies to determine proper vehicle sensor function, and replace them if necessary.

Brakes

On certain vehicles, the brake hoses are not labelled with a designation that identifies the manufacturer of the assembly as required by CMVSS 106. This non-compliance has no effect on the performance of the involved brake hose assemblies. Correction: Since this does not pose a safety risk, no corrective action is required.

Electrical

On certain vehicles, water may seep into the windshield wiper module. If this were to happen, it could result in windshield wipers that will not turn on, cease operation while driving, fail to turn off, turn on by themselves, and/or continuous windshield washer pump operation. Improper operation of the windshield wiper system in a severe weather situation could reduce the driver's visibility, resulting in a possible vehicle crash without prior warning. Correction: Dealer will install a Gore-Tex patch over the windshield wiper module vent-hole. The wiper motor, circuit board, and electrical connector will be inspected for signs of water intrusion and/or corrosion and replaced as required.

Powertrain

Certain vehicles fail to conform to CMVSS 114 - Theft Protection. These vehicles are equipped with a mechanical override that could allow the ignition key to be removed with the shift lever in a position other than park. In addition, these vehicles have an override that can allow the transmission to be shifted out of park with the ignition in the off position. These overrides are not permitted unless the vehicle has a locking steering column and the overrides have covers that can only be removed with a screwdriver or other tool. Correction: Dealers are to eliminate these conditions by disabling the overrides.