2004 Pontiac Grand Prix problems

UNSTABLE HEADLAMPS

ODI RECEIVED A PETITION FROM MR. BRAD LAMB OF THE NORTH CAROLINA CONSUMERS COUNCIL, REQUESTING INVESTIGATION OF AN ALLEGED DEFECT EVIDENCED BY SHAKE OR BOUNCE OF THE HEADLAMPS ON MODEL YEAR 2004 PONTIAC GRAND PRIX VEHICLES.ODI'S PREVIOUS REVIEW OF THIS ISSUE IN OCTOBER 2003, DETERMINED THAT IT DID NOT WARRANT INVESTIGATION.ODI'S CURRENT ANALYSIS IDENTIFIED 36 COMPLAINTS IN THE CONSUMER COMPLAINT DATABASE; AND A DECLINING TREND OF REPORTS WAS EVIDENT.A FEW FIELD REPORTS OF SIMILAR NATURE WERE ALSO SUBMITTED BY THE MANUFACTURER IN ITS EARLY WARNING REPORTING DATA.A SERVICE BULLETIN AND A REVISED...

ENGINE AND ENGINE COOLING:ENGINE

General Motors LLC (GM) is recalling certain model year 1998-1999 Chevrolet Lumina and Oldsmobile Intrigue, 1997-2004 Buick Regal and Pontiac Grand Prix, 2000-2004 Chevrolet Impala, and 1998-2004 Chevrolet Monte Carlo vehicles. The affected vehicles were previously repaired under recalls 08V-118, 09V-116, and 15V-201 to address the possibility that engine oil may drip onto the hot exhaust manifold.

Risk: Engine oil that drips onto the hot surface of the exhaust manifold may result in a fire.

ENGINE AND ENGINE COOLING:ENGINE

General Motors LLC (GM) notified the agency on April 2, 2015, that they are is recalling certain model year 2004 Buick Regal vehicles manufactured April 9, 2003, to June 1, 2003, 2004 Chevrolet Impala vehicles manufactured April 8, 2003, to June 23, 2003, and 2004 Chevrolet Monte Carlo vehicles manufactured April 7, 2003, to June 23, 2003. On May 18, 2015, GM expanded the recall to cover an additional 49,751 2004 Pontiac Grand Prix vehicles manufactured January 6, 2003, to June 25, 2004. In the affected vehicles, the valve cover gasket may leak.

Risk: The leaking engine oil can drip onto the hot surface of the exhaust manifold, increasing the risk of a fire.

ELECTRICAL SYSTEM:IGNITION

This defect can affect the safe operation of the airbag system. Until this recall is performed, customers should remove all items from their key rings, leaving only the ignition key. The key fob (if applicable), should also be removed from the key ring. General Motors LLC (GM) notified the agency on July 3, 2014, that they are recalling 5,877,718 model year 2000-2005 Chevrolet Impala and Monte Carlo, 1997-2003 Chevrolet Malibu, 2004-2005 Malibu Classic, 1999-2004 Oldsmobile Alero, 1998-2002 Oldsmobile Intrigue, 1999-2005 Pontiac Grand Am and 2004-2008 Pontiac Grand Prix vehicles. In these models, the weight on the key ring and/or road conditions or some other jarring event may cause the ignition switch to move out of the run position, turning off the engine.

Risk: If the key is not in the run position, the air bags may not deploy if the vehicle is involved in a crash, increasing the risk of injury.

EXTERIOR LIGHTING:HEADLIGHTS

DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.

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

STEERING

DORMAN IS RECALLING 979 STEERING KNUCKLES, DORMAN P/NOS. 697-902 AND 697-903, SOLD UNDER DORMAN'S "OE SOLUTIONS<SUP>TM</SUP>" BRAND NAME, AND NAPA P/NOS. 7-8502 AND 7-8503 WHICH WERE SOLD FOR REPLACEMENT USE ON THE VARIOUS VEHICLES LISTED ABOVE. A POTENTIAL MATERIAL OR DESIGN DEFECT COULD RESULT IN THE STEERING KNUCKLE BREAKING IN THE HUB AREA.

Risk: A BROKEN STEERING KNUCKLE COULD RESULT IN LOSS OF STEERING CONTROL AND A POSSIBLE CRASH WITHOUT WARNING.

VEHICLE SPEED CONTROL:ACCELERATOR PEDAL

CERTAIN PASSENGER VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 124, 'ACCELERATOR CONTROL SYSTEMS.' IF ONE OF THE TWO ACCELERATOR PEDAL RETURN SPRINGS FAILS AND THE TEMPERATURE IS -22 DEGREES F TO -40 DEGREES F, THE ENGINE MAY NOT RETURN TO IDLE WITHIN THREE SECONDS, AS REQUIRED.

Risk: IF THIS WERE TO OCCUR, GREATER BRAKE PEDAL FORCE AND A LONGER DISTANCE MAY BE REQUIRED TO STOP THE VEHICLE.

SERVICE BRAKES, HYDRAULIC

CERTAIN PASSENGER VEHICLES WERE PRODUCED WITH LOWER THAN SPECIFIED TORQUE ON BOTH FRONT BRAKE CALIPER TO STEERING KNUCKLE ATTACHMENT BOLTS. WITH IMPROPER TORQUE, THE CLAMP LOAD AT THE JOINT MAY NOT BE ADEQUATE TO PREVENT MOVEMENT BETWEEN THE CALIPER BRACKET AND KNUCKLE.

Risk: DEPENDING ON WHETHER ONE OR BOTH BOLTS BACKS OUT OR FRACTURES, THE RESULT CAN BE LOCKING OF THE AFFECTED WHEEL DURING BRAKING AND AN ABRUPT STEERING INPUT IN THE DIRECTION OF THE LOCKED WHEEL, REDUCED BRAKING AND NOISE FROM THE AFFECTED WHEEL, OR SEVERING OF A BRAKE HOSE, INCREASED BRAKE PEDAL TRAVEL, AND REDUCED STEERING CONTROL. REDUCED BRAKING OR STEERING CONTROL COULD CAUSE A CRASH.

STRUCTURE:FRAME AND MEMBERS

CERTAIN PASSENGER VEHICLES HAVE A CONDITION WHERE THE FRONT FRAME REAR BODY MOUNT BRACKET MAY FRACTURE.

Risk: IF IGNORED, THE BRACKET WOULD FRACTURE AND DEGRADE TO THE POINT WHERE THE INTERMEDIATE STEERING SHAFT COULD SEPARATE, RESULTING IN LOSS OF STEERING CONTROL AND A CRASH COULD OCCUR.

Engine

On certain vehicles equipped with a 3.8L engine, degradation of the front rocker cover gasket may result in eventual oil seepage. Under hard braking, drops of engine oil may be deposited on the exhaust manifold. If the manifold is hot enough and the oil runs below the heat shield, it may ignite into a small flame and, in some instances, the fire may spread to the plastic spark plug wire channel and beyond. An under-hood fire could result in injury and/or property damage. Correction: Dealers will replace the engine’s front valve cover and front-valve-cover gasket with new parts. The engine’s plastic “beauty” cover and plastic oil-fill-tube extension will also be removed, if they haven’t been already. Note: This recall supersedes and is an expansion of recalls 2008-081, 2009-105 and 2015-145. All vehicles having been inspected and/or serviced under the previous recall will require re-inspection and repair.

Engine

On certain vehicles equipped with a 3.8L engine, degradation of the front rocker cover gasket may result in eventual oil seepage. Under hard braking, drops of engine oil may be deposited on the exhaust manifold. If the manifold is hot enough and the oil runs below the heat shield, it may ignite into a small flame and, in some instances, the fire may spread to the plastic spark plug wire channel and beyond. An under-hood fire could result in injury and/or property damage. Correction: Dealers will remove the spark plug wire retention channel at the front of the engine and install two new-revised spark plug wire retainers. For vehicles with the 3.8L V6 Supercharged engine (RPO L67), dealers will also replace the front (left hand) rocker cover gasket. Note: This recall is an expansion of recalls 2008-081 and 2009-105.

Electrical

On certain vehicles, a defect in the ignition switch could allow the switch to move out of the "run" position if the key ring is carrying added weight or the vehicle goes off-road or is subjected to some other jarring event. If this were to occur, engine power, power steering and power braking would be affected, increasing the risk of a crash causing injury and/or damage to property. The timing of the key movement out of the “run” position, relative to the activation of the sensing algorithm of the crash event, may also result in the airbags not deploying in a subsequent collision, increasing the risk of injury. Correction: For each key, dealers will install two key rings and modify the key ring opening shape. Note: Until the correction is performed, all items should be removed from the key ring.

Other

Certain vehicles do not comply with the requirements of CMVSS 124 - Accelerator Control Systems. The Electronic Throttle Control (ETC) accelerator pedal assembly may not return the engine to idle in three seconds or less at low ambient temperatures if either of the two throttle return springs is broken. Correction: Dealers will replace the ETC pedal assembly.

Steering

Certain vehicles were built with right rear body mounts that contain cracks or voids. A crack could propagate during use of the vehicle, resulting in audible creaking, groaning, or clicking noises. If the driver ignores these warnings, both rear body mounts could eventually become detached from the frame structure. If this occurred, the steering intermediate shaft could become detached from the rack and pinion steering assembly, resulting in a total loss of steering control. Correction: Dealers will inspect the front frame assembly for specific Julian date stamps and replace the engine cradle assembly, if necessary.

Brakes

On certain vehicles, two bolts that attach the front brake caliper to the steering knuckle on the left and right front wheel assemblies were not tightened adequately. If too much movement occurs between the caliper bracket and knuckle, the bolt(s) may back out or fracture. Depending on whether one or both bolts back out or fracture, the result can be: 1) locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, 2) reduced braking and noise from the affected wheel, or 3) severing of a brake hose, increased brake pedal travel, and reduced steering control. If this were to occur, it could result in a vehicle crash without prior warning. Correction: Dealers will tighten both bolts to the specified torque.

Brakes

On certain vehicles, the right rear brake hose fitting may not be tightened properly and a brake fluid leak could occur. If the brake fluid level in the master cylinder reservoir dropped to the indicator limit, the brake system warning light would be activated. If enough fluid leaks, the brake pedal will be lower than normal and stopping distances will be increased. Correction: Dealer will tighten the right rear brake hose fitting.