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2002 Buick Rendezvous

Owner reports · Recalls · Investigations

More warning signs than most Rendezvous years

Owner complaints for the 2002 Buick Rendezvous are substantially higher than the model-year median of 138.

About this comparison →

When problems were reported

Mileage at the reported incident

378 reports with mileage · 108 unknown

NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.

What to inspect

Issues worth paying extra attention to based on owner reports.

  • Engine And Engine Cooling. Review the 115 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Electrical System. Review the 103 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 65 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

18 crash reports8 fire reports15 injury reports

What owners actually said

486 reports
65,000 miles · Sep 8, 2005
Fuel System, Gasoline

DT: 2002 BUICK RENDEZVOUS - THE PART THAT ATTACHES TO THE GAS TANK OR THE FILLER TUBE BROKE OFF. WHILE DRIVING ON A PAVED ROAD GOING ABOUT 55 MPH THE FILLER TUBE BROKE OFF AND ALL THE GAS SLOWLY LEAKED OUT OF THE CAR IN FIVE MINUTES. THE CONSUMER WAS ABLE TO DRIVE TO A REPAIR SHOP, AND IT IS BEING REPAIRED NOW. THERE WERE …

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DT: 2002 BUICK RENDEZVOUS - THE PART THAT ATTACHES TO THE GAS TANK OR THE FILLER TUBE BROKE OFF. WHILE DRIVING ON A PAVED ROAD GOING ABOUT 55 MPH THE FILLER TUBE BROKE OFF AND ALL THE GAS SLOWLY LEAKED OUT OF THE CAR IN FIVE MINUTES. THE CONSUMER WAS ABLE TO DRIVE TO A REPAIR SHOP, AND IT IS BEING REPAIRED NOW. THERE WERE NO RECALLS ON THE GAS TANK PROBLEM THE REPAIR SHOP COULD NOT GIVE ANY REASON FOR THIS TO HAPPEN. *AK UPDATED 3/3/2006 - *NM

NHTSA ODI #10135877

78,000 miles · Sep 8, 2005
Equipment

THE AIR CONDITIONING STOPPED BLOWING COLD AIR ON OUR 2002 RENDEZVOUS. WHEN WE TOOK IT TO THE DEALER WE WERE TOLD THAT THE CONDENSER NEEDED TO BE REPLACED AT A COST OF OVER $800.00 AND THAT THE INTAKE GASKET ALSO NEEDED TO BE REPLACED. WE ENDED UP HAVING BOTH REPLACED AT A COST OF OVER $1500.00 TO US. WHEN HAVING REPAIRED WE WERE…

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THE AIR CONDITIONING STOPPED BLOWING COLD AIR ON OUR 2002 RENDEZVOUS. WHEN WE TOOK IT TO THE DEALER WE WERE TOLD THAT THE CONDENSER NEEDED TO BE REPLACED AT A COST OF OVER $800.00 AND THAT THE INTAKE GASKET ALSO NEEDED TO BE REPLACED. WE ENDED UP HAVING BOTH REPLACED AT A COST OF OVER $1500.00 TO US. WHEN HAVING REPAIRED WE WERE TOLD THAT BOTH OF THESE PROBLEMS ARE VERY COMMON ON GM VEHICLES. WE WERE PAST WARRANTY SO THE DEALER WAS OF NO HELP WITH THE COST. AFTER REVIEWING OTHER COMPLAINTS ON THE NHTSA WEB SITE, IT APPEARS THAT BOTH OF THESE PARTS ARE FAILING AND GM NEEDS TO TAKE RESPONSIBILITY FOR THE REPAIRS. *JB

NHTSA ODI #10135781

Mileage unknown · Sep 7, 2005
Fuel System, Gasoline

2002 BUICK RENDEZVOUS, FAILURE TO RESTART AFTER FUELING OR OTHER SHORT DURATION SHUT OFFS IN HOT WEATHER. *JB

NHTSA ODI #10135755

45,289 miles · Sep 6, 2005
Structure

I OWN A 2002 BUICK RENDEZVOUS AND THE "CHECK ENGINE SOON" LIGHT CAME ON. THE CAR WAS TAKEN TO A GARAGE ON 8/19/05 AND THEY FIXED WHAT THEY THOUGHT WAS THE PROBLEM (R&R FUEL TANK CONNECTION TO CLEAN AND RE-SECURE, HAD WATER IN CONNECTOR). TOTAL COST OF REPAIR WAS $145.07. ON 8/26/05 THE LIGHT CAME ON AGAIN, WE TOOK THE BACK TO T…

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I OWN A 2002 BUICK RENDEZVOUS AND THE "CHECK ENGINE SOON" LIGHT CAME ON. THE CAR WAS TAKEN TO A GARAGE ON 8/19/05 AND THEY FIXED WHAT THEY THOUGHT WAS THE PROBLEM (R&R FUEL TANK CONNECTION TO CLEAN AND RE-SECURE, HAD WATER IN CONNECTOR). TOTAL COST OF REPAIR WAS $145.07. ON 8/26/05 THE LIGHT CAME ON AGAIN, WE TOOK THE BACK TO THE SAME GARAGE AND THEY FOUND WATER AGAIN IN THE CONNECTOR AND DETERMINED THAT THE WATER WAS COMING FROM THE INSIDE OF THE VEHICLE. THEY DISCOVERED THE WATER WAS COMING FROM THE AIR CONDITIONING DRAIN TUBE. AS LONG AS THE CAR WAS SITTING STILL THE A/C WOULD DRAIN PROPERLY, BUT AT SPEED THE FORCE OF AIR WOULD FORCE THE WATER BACK INTO THE INTERIOR UNDERNEATH THE SEATS WHERE MANY OF THE ELECTRICAL CONNECTORS ARE, THEREFORE SHORTING THEM OUT. THE SEATS HAD TO TAKEN OUT, THE CARPET HAD TO BE REMOVED AND DRIED OUT AND A NEW A/C DRAIN TUBE WAS INSTALLED. THE EVAPORATOR CASE WAS ALSO RESEALED. TOTAL FOR THIS REPAIR WAS $276.38 UPON ORDERING AND RECEIVING THE NEW DRAIN, THE MECHANIC WAS TOLD THAT THE PART HAD BEEN "UPDATED". THE UPDATED PART HAD A SLIGHT BEND IN IT NOW, AND THE OLD WAS JUST A STRAIGHT PIECE. MY COMPLAINT IS, IF A PIECE NEEDED TO BE UPDATED OBVIOUSLY SOMETHING WAS WRONG WITH THE ORIGINAL DESIGN AND I THE CONSUMER SHOULD NOT HAVE PAY FOR THE DAMAGES OR REPAIRS DUE TO A FAULTY PART. THANK YOU. *NM

NHTSA ODI #10135488

76,000 miles · Aug 30, 2005
Service Brakes, Hydraulic

ANTI-LOCK BRAKES ACTIVATE AT LOW SPEEDS. BASICALLY THE SAME THING THAT IS STATED WITH THE NEW RECALL FOR GMC! WHEN I UNPLUG THE SENSOR AND PLUG IT BACK IN THE PROBLEM GOES AWAY FOR A DAY, THEN THE PROBLEM LASTS FOR SEVERAL DAYS UNTIL THE SENSOR IS UNPLUGGED AGAIN. *JB

NHTSA ODI #10134808

60,173 miles · Aug 30, 2005
Equipment

THE AIR CONDITIONER ON MY 2002 RENDEZVOUS STOPPED COOLING WHEN THE CAR HAD 60713 MILES. I TOOK THE CAR INTO THE DEALER AND WAS TOLD THAT THE CONDENSER HAD 2 HOLES IN IT AND IT WOULD NEED TO BE REPLACED. THIS REPAIR WAS COMPLETED AT A TOTAL COST OF $910. *NM

NHTSA ODI #10134738

49,500 miles · Aug 26, 2005
Electrical System

WHILE DRIVING ALL ELECTRICS SHUT OFF- ENGINE SEEMS TO KEEP RUNNING. THIS IS ESPECIALLY TROUBLING AT NIGHT. THERE IS A DING-DING BATTERY DISPLAY TURNS ON BRIEFLY THEN ALL INTERIOR LIGHTS, DASHBOARD, AND EXTERIOR LIGHTS SHUT DOWN FOR 2 TO 3 SECONDS. THIS HAS HAPPENED TO MY WIFE 3 OR 4 TIMES AND TO ME ON A VERY DARK ROAD. WE PUR…

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WHILE DRIVING ALL ELECTRICS SHUT OFF- ENGINE SEEMS TO KEEP RUNNING. THIS IS ESPECIALLY TROUBLING AT NIGHT. THERE IS A DING-DING BATTERY DISPLAY TURNS ON BRIEFLY THEN ALL INTERIOR LIGHTS, DASHBOARD, AND EXTERIOR LIGHTS SHUT DOWN FOR 2 TO 3 SECONDS. THIS HAS HAPPENED TO MY WIFE 3 OR 4 TIMES AND TO ME ON A VERY DARK ROAD. WE PURCHASED THE CAR USED AND HAD IT 3 WEEKS -THE DEALER REPLACED BATTERY WHICH TESTED BAD -THE DEALER TOOK CARE OF LABOR BUT WE HAD TO PAY FOR THE BATTERY. 3 DAYS LATER SAME ISSUE OCCURRED. *JB

NHTSA ODI #10134288

48,000 miles · Aug 12, 2005
Electrical System

RESTARTING AND DELAYED START ON 2002 BUICK RENDEZVOUS. ONLY 7/1/05 STOPPED TO FILL GAS TANK. AFTER REFILL, THE CAR STARTED AND MAY HAVE MOVED NO MORE THAN 2 FEET. SHUT OFF AND WOULDN'T RE-CRANK FOR AT LEAST 15 MINUTES. ON 7/5/05 TOOK THE CAR TO MASTER PONTIAC IN AUGUSTA, GA FOR DIAGNOSTICS AND THEY COULD NOT FIND ANYTHING …

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RESTARTING AND DELAYED START ON 2002 BUICK RENDEZVOUS. ONLY 7/1/05 STOPPED TO FILL GAS TANK. AFTER REFILL, THE CAR STARTED AND MAY HAVE MOVED NO MORE THAN 2 FEET. SHUT OFF AND WOULDN'T RE-CRANK FOR AT LEAST 15 MINUTES. ON 7/5/05 TOOK THE CAR TO MASTER PONTIAC IN AUGUSTA, GA FOR DIAGNOSTICS AND THEY COULD NOT FIND ANYTHING THAT COULD HAVE CAUSED THE PROBLEM. ON 7/17/05, HUSBAND WAS DRIVING THE CAR. TOOK SOME FRIENDS HOME, SHUT THE CAR OFF FOR 5 MINUTES. TRIED TO RESTART AND CAR COULD NOT START. THEY TRIED FOR SEVERAL HOURS BEFORE THEY HAD THE CAR TOWED TO MASTER PONTIAC AUGUSTA GEORGIA. ON 7/18/05 THE CAR WAS STARTED IMMEDIATELY AT THE DEALERSHIP. THEY COULD NOT FIND ANYTHING WRONG WITH IT. ON 7/22/05 AGAIN AT A GAS STATION THE CAR WOULD NOT START AFTER REFILLING. HAD TO PUSH IT OUT OF THE WAY AND WAIT 30 MINUTES BEFORE IT WOULD START AGAIN. ON 7/23/05 (SATURDAY) CALLED MASTER PONTIAC AND TOLD SERVICE MANAGER ABOUT THE NIGHT BEFORE INCIDENT. HE STATED THAT THE NEXT TIME IT HAPPENS TO CALL THEM IMMEDIATELY. THOUGH I TRULY APPRECIATE THE OFFER, I PERSONALLY DON'T SEE HOW THIS WILL HELP, SINCE THEY IMMEDIATELY WILL TRY AND START THE CAR AND SOMETIMES ALL YOU HAVE TO DO IS WAIT 15-30 MINUTES BEFORE IT WILL RESTART. MASTER PONTIAC HAS BEEN VERY HELPFUL, BUT UNFORTUNATELY NOTHING CAN BE FOUND. I SUPPLIED THE SERVICE MANAGER WITH A LISTING OF OTHER COMPLAINTS FROM EDMUNDS FORUM TO SHOW THEM I'M NOT MAKING UP THIS PROBLEM. THIS IS VERY FRUSTRATING ESPECIALLY WHEN YOU DO NOT KNOW WHEN THE PROBLEM IS GOING TO HAPPEN. THIS IS UNSAFE FOR MOTHERS WITH SMALL CHILDREN. IT'S UNSAFE FOR ANYONE. THERE ARE NUMEROUS COMPLAINTS REGARDING THIS ON EDMUNDS FORUM AND SOMETHING MUST BE DONE. IN ADDITION TO THE ABOVE NOT STARTING PROBLEM, THE CAR WILL 80% OF THE TIME HAVE A SLOW START WHEN CRANKING. SOMETHING IS DEFINITELY WRONG. THE QUESTION IS WHAT. *NM

NHTSA ODI #10132590

Mileage unknown · Aug 11, 2005
Equipment

AIR CONDITIONING NOT WORKING-CONDENSER CRACKED BOTTOM RIGHT CORNER. INTAKE MANIFOLD GASKET LEAKING ON 02 BUICK RENDEZVOUS. *JB

NHTSA ODI #10132465

Mileage unknown · Aug 11, 2005
Suspension

LEFT FRONT WHEEL BEARING FAILED....REPLACED. ODOMETER FAILED AT 5000 MILES...REPLACED. ODOMETER FAILED AT 52000 MILES... REPLACED. *JB

NHTSA ODI #10132412

Official recalls

2

07V349000 · Fuel System, Gasoline:storage

Aug 8, 2007

ON CERTAIN VEHICLES, VARIATIONS IN THE MANUFACTURING PROCESS OR EXPOSURE TO HIGH AMBIENT TEMPERATURES MAY LEAD TO FRACTURE OF THE FUEL TANK INLET CHECK VALVE (ICV).

Consequence & remedy

Consequence: A FRACTURE MAY ALLOW FUEL VAPORS TO PASS THROUGH AND ALLOW DROPLETS OF FUEL TO ACCUMULATE ON THE SIDE OF THE FUEL TANK. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

Remedy: DEALERS WILL REPLACE THE FUEL TANK. THE RECALL WILL BE MAILED IN TWO PHASES WITH THE FIRST PHASE BEGINNING ON DECEMBER 4, 2007. THE SECOND PHASE WILL BE MAILED ON DECEMBER 13, 2007. OWNERS MAY CONTACT BUICK AT 1-866-608-8080; CHEVROLET AT 1-800-630-2438; OR PONTIAC AT 1-800-620-7668. THE VEHICLE POPULATION INCLUDES BUICK RENDEZVOUS AND PONTIAC AZTEK VEHICLE BUILT IN MAY 2003; CHEVROLET VENTURE AND PONTIAC MONTANA VEHICLES BUILT FROM JUNE THROUGH AUGUST 2002; AND ALL VEHICLES REGISTERED IN NEVADA, ARIZONA, VIRGIN ISLANDS, PUERTO RICO, AND HAWAII.

02V222000 · Air Bags:frontal

Aug 9, 2002

CERTAIN PASSENGER, MINI VANS, AND SPORT UTILITY VEHICLES HAVE AN AIR BAG INFLATOR ON THE DRIVER'S SIDE THAT COULD FRACTURE AT A WELD DURING A DEPLOYMENT.

Consequence & remedy

Consequence: PIECES OF THE INFLATOR COULD STRIKE AND INJURE VEHICLE OCCUPANTS AND THE AIR BAG CUSHION WOULD NOT INFLATE FULLY, REDUCING THE CAPABILITY OF THE BAG TO PROTECT THE DRIVER.

Remedy: DEALERS WILL INSPECT, AND REPLACE, IF NECESSARY, THE AIR BAG MODULE ASSEMBLY ON THE DRIVER'S SIDE. OWNER NOTIFICATION BEGAN AUGUST 15, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT BUICK AT 1-800-521-7300, CADILLAC AT 1-800-458-8006, CHEVROLET AT 1-800-222-1020, GMC AT 1-800-462-8782, OLDSMOBILE AT 1-800-442-6537, OR PONTIAC AT 1-800-762-2737.

Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗

NHTSA investigations

2

EA07006 · Fuel Tank Leakage

Opened Apr 18, 2007 · Closed Sep 13, 2007

Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings; Fuel System, Gasoline:storage; Fuel System, Gasoline:storage:tank Assembly; Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap

GM IS RECALLING (NHTSA RECALL NO. 07V-349) CERTAIN MODEL YEAR (MY) 2002-2004 BUICK RENDEZVOUS, CHEVROLET VENTURE (REGULAR WHEELBASE) AND 2001-2004 PONTIAC AZTEK AND MONTANA (REGULAR WHEELBASE) VEHICLES TO REPLACE FUEL TANKS AND CORRECT A DEFECT THAT MAY ALLOW FUEL LEAKAGE.THE VEHICLE RECALL POPULATION IS RENDEZVOUS AND AZTEK VEHICLES BUILT IN MAY 2003, VENTURE AND MONTANA VEHICLE BUILT IN JUNE THROUGH AUGUST 2002 AND CERTAIN SAME MODEL VEHICLES REGISTERED IN NEVADA, ARIZONA, VIRGIN ISLANDS, PUERTO RICO AND HAWAII THAT WERE BUILT THROUGH NOV/DEC 2003 (DEPENDING ON MODEL).THE TOTAL NUMBER OF VEHICLES RECALLED IS 20,594 (INCLUDES 15,196 SUBJECT AZTEK AND RENDEZVOUS VEHICLES). IN ADDITION TO THE RECALL, GM WILL EXTEND THE WARRANTY ON MY 2002-2004 RENDEZVOUS AND REGULAR WHEEL BASE VENTURE VANS AND MY 2001-2004 AZTEK AND REGULAR WHEELBASE MONTANA VANS NOT INCLUDED IN THE RECALL TO PROVIDE WARRANTY COVERAGE FOR A PERIOD OF 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.GM WILL BEGIN NOTIFYING OWNERS IN DECEMBER 2007.GM REPORTS THAT THE FUEL INLET PIPE CONTAINING THE INLET CHECK VALVE (ICV) MAY FRACTURE AND ALLOW FUEL VAPORS OR FUEL TO LEAK OUT.GM DATA REVEALED THAT ELEVATED AMBIENT TEMPERATURES, HIGHER CARBON CONTENT IN THE ICV AND VARIATION IN THE MANUFACTURING PROCESS WERE THE CONTRIBUTING FACTORS FOR POTENTIAL CRACKS IN THE ICV.BEGINNING DECEMBER 2003, GM BUILT VEHICLES WITH A REDESIGNED FUEL TANK/ICV.SUBJECT VEHICLES NOT INCLUDED IN THE RECALL OR EXTENDED WARRANTY DID NOT SHOW A FAILURE TREND SIMILAR TO THE ABOVE VEHICLES..FOR ADDITIONAL DETAILS, SEE RECALL 07V-349.THIS INVESTIGATION IS CLOSED.

Additional source detail variants (5)

Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings

GM IS RECALLING (NHTSA RECALL NO. 07V-349) CERTAIN MODEL YEAR (MY) 2002-2004 BUICK RENDEZVOUS, CHEVROLET VENTURE (REGULAR WHEELBASE) AND 2001-2004 PONTIAC AZTEK AND MONTANA (REGULAR WHEELBASE) VEHICLES TO REPLACE FUEL TANKS AND CORRECT A DEFECT THAT MAY ALLOW FUEL LEAKAGE.THE VEHICLE RECALL POPULATION IS RENDEZVOUS AND AZTEK VEHICLES BUILT IN MAY 2003, VENTURE AND MONTANA VEHICLE BUILT IN JUNE THROUGH AUGUST 2002 AND CERTAIN SAME MODEL VEHICLES REGISTERED IN NEVADA, ARIZONA, VIRGIN ISLANDS, PUERTO RICO AND HAWAII THAT WERE BUILT THROUGH NOV/DEC 2003 (DEPENDING ON MODEL).THE TOTAL NUMBER OF VEHICLES RECALLED IS 20,594 (INCLUDES 15,196 SUBJECT AZTEK AND RENDEZVOUS VEHICLES). IN ADDITION TO THE RECALL, GM WILL EXTEND THE WARRANTY ON MY 2002-2004 RENDEZVOUS AND REGULAR WHEEL BASE VENTURE VANS AND MY 2001-2004 AZTEK AND REGULAR WHEELBASE MONTANA VANS NOT INCLUDED IN THE RECALL TO PROVIDE WARRANTY COVERAGE FOR A PERIOD OF 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.GM WILL BEGIN NOTIFYING OWNERS IN DECEMBER 2007.GM REPORTS THAT THE FUEL INLET PIPE CONTAINING THE INLET CHECK VALVE (ICV) MAY FRACTURE AND ALLOW FUEL VAPORS OR FUEL TO LEAK OUT.GM DATA REVEALED THAT ELEVATED AMBIENT TEMPERATURES, HIGHER CARBON CONTENT IN THE ICV AND VARIATION IN THE MANUFACTURING PROCESS WERE THE CONTRIBUTING FACTORS FOR POTENTIAL CRACKS IN THE ICV.BEGINNING DECEMBER 2003, GM BUILT VEHICLES WITH A REDESIGNED FUEL TANK/ICV.SUBJECT VEHICLES NOT INCLUDED IN THE RECALL OR EXTENDED WARRANTY DID NOT SHOW A FAILURE TREND SIMILAR TO THE ABOVE VEHICLES..FOR ADDITIONAL DETAILS, SEE RECALL 07V-349.THIS INVESTIGATION IS CLOSED.

Fuel System, Gasoline

GM IS RECALLING (NHTSA RECALL NO. 07V-349) CERTAIN MODEL YEAR (MY) 2002-2004 BUICK RENDEZVOUS, CHEVROLET VENTURE (REGULAR WHEELBASE) AND 2001-2004 PONTIAC AZTEK AND MONTANA (REGULAR WHEELBASE) VEHICLES TO REPLACE FUEL TANKS AND CORRECT A DEFECT THAT MAY ALLOW FUEL LEAKAGE.THE VEHICLE RECALL POPULATION IS RENDEZVOUS AND AZTEK VEHICLES BUILT IN MAY 2003, VENTURE AND MONTANA VEHICLE BUILT IN JUNE THROUGH AUGUST 2002 AND CERTAIN SAME MODEL VEHICLES REGISTERED IN NEVADA, ARIZONA, VIRGIN ISLANDS, PUERTO RICO AND HAWAII THAT WERE BUILT THROUGH NOV/DEC 2003 (DEPENDING ON MODEL).THE TOTAL NUMBER OF VEHICLES RECALLED IS 20,594 (INCLUDES 15,196 SUBJECT AZTEK AND RENDEZVOUS VEHICLES). IN ADDITION TO THE RECALL, GM WILL EXTEND THE WARRANTY ON MY 2002-2004 RENDEZVOUS AND REGULAR WHEEL BASE VENTURE VANS AND MY 2001-2004 AZTEK AND REGULAR WHEELBASE MONTANA VANS NOT INCLUDED IN THE RECALL TO PROVIDE WARRANTY COVERAGE FOR A PERIOD OF 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.GM WILL BEGIN NOTIFYING OWNERS IN DECEMBER 2007.GM REPORTS THAT THE FUEL INLET PIPE CONTAINING THE INLET CHECK VALVE (ICV) MAY FRACTURE AND ALLOW FUEL VAPORS OR FUEL TO LEAK OUT.GM DATA REVEALED THAT ELEVATED AMBIENT TEMPERATURES, HIGHER CARBON CONTENT IN THE ICV AND VARIATION IN THE MANUFACTURING PROCESS WERE THE CONTRIBUTING FACTORS FOR POTENTIAL CRACKS IN THE ICV.BEGINNING DECEMBER 2003, GM BUILT VEHICLES WITH A REDESIGNED FUEL TANK/ICV.SUBJECT VEHICLES NOT INCLUDED IN THE RECALL OR EXTENDED WARRANTY DID NOT SHOW A FAILURE TREND SIMILAR TO THE ABOVE VEHICLES..FOR ADDITIONAL DETAILS, SEE RECALL 07V-349.THIS INVESTIGATION IS CLOSED.

Fuel System, Gasoline:storage

GM IS RECALLING (NHTSA RECALL NO. 07V-349) CERTAIN MODEL YEAR (MY) 2002-2004 BUICK RENDEZVOUS, CHEVROLET VENTURE (REGULAR WHEELBASE) AND 2001-2004 PONTIAC AZTEK AND MONTANA (REGULAR WHEELBASE) VEHICLES TO REPLACE FUEL TANKS AND CORRECT A DEFECT THAT MAY ALLOW FUEL LEAKAGE.THE VEHICLE RECALL POPULATION IS RENDEZVOUS AND AZTEK VEHICLES BUILT IN MAY 2003, VENTURE AND MONTANA VEHICLE BUILT IN JUNE THROUGH AUGUST 2002 AND CERTAIN SAME MODEL VEHICLES REGISTERED IN NEVADA, ARIZONA, VIRGIN ISLANDS, PUERTO RICO AND HAWAII THAT WERE BUILT THROUGH NOV/DEC 2003 (DEPENDING ON MODEL).THE TOTAL NUMBER OF VEHICLES RECALLED IS 20,594 (INCLUDES 15,196 SUBJECT AZTEK AND RENDEZVOUS VEHICLES). IN ADDITION TO THE RECALL, GM WILL EXTEND THE WARRANTY ON MY 2002-2004 RENDEZVOUS AND REGULAR WHEEL BASE VENTURE VANS AND MY 2001-2004 AZTEK AND REGULAR WHEELBASE MONTANA VANS NOT INCLUDED IN THE RECALL TO PROVIDE WARRANTY COVERAGE FOR A PERIOD OF 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.GM WILL BEGIN NOTIFYING OWNERS IN DECEMBER 2007.GM REPORTS THAT THE FUEL INLET PIPE CONTAINING THE INLET CHECK VALVE (ICV) MAY FRACTURE AND ALLOW FUEL VAPORS OR FUEL TO LEAK OUT.GM DATA REVEALED THAT ELEVATED AMBIENT TEMPERATURES, HIGHER CARBON CONTENT IN THE ICV AND VARIATION IN THE MANUFACTURING PROCESS WERE THE CONTRIBUTING FACTORS FOR POTENTIAL CRACKS IN THE ICV.BEGINNING DECEMBER 2003, GM BUILT VEHICLES WITH A REDESIGNED FUEL TANK/ICV.SUBJECT VEHICLES NOT INCLUDED IN THE RECALL OR EXTENDED WARRANTY DID NOT SHOW A FAILURE TREND SIMILAR TO THE ABOVE VEHICLES..FOR ADDITIONAL DETAILS, SEE RECALL 07V-349.THIS INVESTIGATION IS CLOSED.

Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap

GM IS RECALLING (NHTSA RECALL NO. 07V-349) CERTAIN MODEL YEAR (MY) 2002-2004 BUICK RENDEZVOUS, CHEVROLET VENTURE (REGULAR WHEELBASE) AND 2001-2004 PONTIAC AZTEK AND MONTANA (REGULAR WHEELBASE) VEHICLES TO REPLACE FUEL TANKS AND CORRECT A DEFECT THAT MAY ALLOW FUEL LEAKAGE.THE VEHICLE RECALL POPULATION IS RENDEZVOUS AND AZTEK VEHICLES BUILT IN MAY 2003, VENTURE AND MONTANA VEHICLE BUILT IN JUNE THROUGH AUGUST 2002 AND CERTAIN SAME MODEL VEHICLES REGISTERED IN NEVADA, ARIZONA, VIRGIN ISLANDS, PUERTO RICO AND HAWAII THAT WERE BUILT THROUGH NOV/DEC 2003 (DEPENDING ON MODEL).THE TOTAL NUMBER OF VEHICLES RECALLED IS 20,594 (INCLUDES 15,196 SUBJECT AZTEK AND RENDEZVOUS VEHICLES). IN ADDITION TO THE RECALL, GM WILL EXTEND THE WARRANTY ON MY 2002-2004 RENDEZVOUS AND REGULAR WHEEL BASE VENTURE VANS AND MY 2001-2004 AZTEK AND REGULAR WHEELBASE MONTANA VANS NOT INCLUDED IN THE RECALL TO PROVIDE WARRANTY COVERAGE FOR A PERIOD OF 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.GM WILL BEGIN NOTIFYING OWNERS IN DECEMBER 2007.GM REPORTS THAT THE FUEL INLET PIPE CONTAINING THE INLET CHECK VALVE (ICV) MAY FRACTURE AND ALLOW FUEL VAPORS OR FUEL TO LEAK OUT.GM DATA REVEALED THAT ELEVATED AMBIENT TEMPERATURES, HIGHER CARBON CONTENT IN THE ICV AND VARIATION IN THE MANUFACTURING PROCESS WERE THE CONTRIBUTING FACTORS FOR POTENTIAL CRACKS IN THE ICV.BEGINNING DECEMBER 2003, GM BUILT VEHICLES WITH A REDESIGNED FUEL TANK/ICV.SUBJECT VEHICLES NOT INCLUDED IN THE RECALL OR EXTENDED WARRANTY DID NOT SHOW A FAILURE TREND SIMILAR TO THE ABOVE VEHICLES..FOR ADDITIONAL DETAILS, SEE RECALL 07V-349.THIS INVESTIGATION IS CLOSED.

Fuel System, Gasoline:storage:tank Assembly

GM IS RECALLING (NHTSA RECALL NO. 07V-349) CERTAIN MODEL YEAR (MY) 2002-2004 BUICK RENDEZVOUS, CHEVROLET VENTURE (REGULAR WHEELBASE) AND 2001-2004 PONTIAC AZTEK AND MONTANA (REGULAR WHEELBASE) VEHICLES TO REPLACE FUEL TANKS AND CORRECT A DEFECT THAT MAY ALLOW FUEL LEAKAGE.THE VEHICLE RECALL POPULATION IS RENDEZVOUS AND AZTEK VEHICLES BUILT IN MAY 2003, VENTURE AND MONTANA VEHICLE BUILT IN JUNE THROUGH AUGUST 2002 AND CERTAIN SAME MODEL VEHICLES REGISTERED IN NEVADA, ARIZONA, VIRGIN ISLANDS, PUERTO RICO AND HAWAII THAT WERE BUILT THROUGH NOV/DEC 2003 (DEPENDING ON MODEL).THE TOTAL NUMBER OF VEHICLES RECALLED IS 20,594 (INCLUDES 15,196 SUBJECT AZTEK AND RENDEZVOUS VEHICLES). IN ADDITION TO THE RECALL, GM WILL EXTEND THE WARRANTY ON MY 2002-2004 RENDEZVOUS AND REGULAR WHEEL BASE VENTURE VANS AND MY 2001-2004 AZTEK AND REGULAR WHEELBASE MONTANA VANS NOT INCLUDED IN THE RECALL TO PROVIDE WARRANTY COVERAGE FOR A PERIOD OF 10 YEARS OR 150,000 MILES, WHICHEVER OCCURS FIRST.GM WILL BEGIN NOTIFYING OWNERS IN DECEMBER 2007.GM REPORTS THAT THE FUEL INLET PIPE CONTAINING THE INLET CHECK VALVE (ICV) MAY FRACTURE AND ALLOW FUEL VAPORS OR FUEL TO LEAK OUT.GM DATA REVEALED THAT ELEVATED AMBIENT TEMPERATURES, HIGHER CARBON CONTENT IN THE ICV AND VARIATION IN THE MANUFACTURING PROCESS WERE THE CONTRIBUTING FACTORS FOR POTENTIAL CRACKS IN THE ICV.BEGINNING DECEMBER 2003, GM BUILT VEHICLES WITH A REDESIGNED FUEL TANK/ICV.SUBJECT VEHICLES NOT INCLUDED IN THE RECALL OR EXTENDED WARRANTY DID NOT SHOW A FAILURE TREND SIMILAR TO THE ABOVE VEHICLES..FOR ADDITIONAL DETAILS, SEE RECALL 07V-349.THIS INVESTIGATION IS CLOSED.

RQ06009 · Fuel Tank Leakage

Opened Dec 14, 2006 · Closed Apr 18, 2007

Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:storage; Fuel System, Gasoline:storage:tank Assembly; Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap

CERTAIN SUBJECT VEHICLES MAY EXHIBIT LEAKAGE OF ODOR AND/OR FUELFROM THE LOWER PORTION OF THE FUEL TANK INLET FILLER PIPE (INLET CHECK VALVE).THE INLET CHECK VALVE (ICV) AND THE FUEL TANK ARE JOINED TOGETHER USING A HOT PLATE WELDING PROCESS FOR PLASTIC PARTS.GM REPORTS THAT ITS ANALYSIS OF FIELD RETURNED PARTS SHOW EVIDENCE OF PROCESS VARIATIONS FOR DIFFERENT MANUFACTURING PERIODS.THESE VARIATIONS PRODUCED SOME ICV TO FUEL TANK JOINTS WITH POOR MELT FLOW LINES.ODI'S ANALYSIS OF GM'S WARRANTY CLAIM DATA FINDS MORE FREQUENT FUEL TANK REPLACEMENTS IN THE HOTTER CLIMATE STATES.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-006) TO FURTHER ASSESS THIS MATTER.

Additional source detail variants (4)

Fuel System, Gasoline

CERTAIN SUBJECT VEHICLES MAY EXHIBIT LEAKAGE OF ODOR AND/OR FUELFROM THE LOWER PORTION OF THE FUEL TANK INLET FILLER PIPE (INLET CHECK VALVE).THE INLET CHECK VALVE (ICV) AND THE FUEL TANK ARE JOINED TOGETHER USING A HOT PLATE WELDING PROCESS FOR PLASTIC PARTS.GM REPORTS THAT ITS ANALYSIS OF FIELD RETURNED PARTS SHOW EVIDENCE OF PROCESS VARIATIONS FOR DIFFERENT MANUFACTURING PERIODS.THESE VARIATIONS PRODUCED SOME ICV TO FUEL TANK JOINTS WITH POOR MELT FLOW LINES.ODI'S ANALYSIS OF GM'S WARRANTY CLAIM DATA FINDS MORE FREQUENT FUEL TANK REPLACEMENTS IN THE HOTTER CLIMATE STATES.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-006) TO FURTHER ASSESS THIS MATTER.

Fuel System, Gasoline:storage

CERTAIN SUBJECT VEHICLES MAY EXHIBIT LEAKAGE OF ODOR AND/OR FUELFROM THE LOWER PORTION OF THE FUEL TANK INLET FILLER PIPE (INLET CHECK VALVE).THE INLET CHECK VALVE (ICV) AND THE FUEL TANK ARE JOINED TOGETHER USING A HOT PLATE WELDING PROCESS FOR PLASTIC PARTS.GM REPORTS THAT ITS ANALYSIS OF FIELD RETURNED PARTS SHOW EVIDENCE OF PROCESS VARIATIONS FOR DIFFERENT MANUFACTURING PERIODS.THESE VARIATIONS PRODUCED SOME ICV TO FUEL TANK JOINTS WITH POOR MELT FLOW LINES.ODI'S ANALYSIS OF GM'S WARRANTY CLAIM DATA FINDS MORE FREQUENT FUEL TANK REPLACEMENTS IN THE HOTTER CLIMATE STATES.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-006) TO FURTHER ASSESS THIS MATTER.

Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap

CERTAIN SUBJECT VEHICLES MAY EXHIBIT LEAKAGE OF ODOR AND/OR FUELFROM THE LOWER PORTION OF THE FUEL TANK INLET FILLER PIPE (INLET CHECK VALVE).THE INLET CHECK VALVE (ICV) AND THE FUEL TANK ARE JOINED TOGETHER USING A HOT PLATE WELDING PROCESS FOR PLASTIC PARTS.GM REPORTS THAT ITS ANALYSIS OF FIELD RETURNED PARTS SHOW EVIDENCE OF PROCESS VARIATIONS FOR DIFFERENT MANUFACTURING PERIODS.THESE VARIATIONS PRODUCED SOME ICV TO FUEL TANK JOINTS WITH POOR MELT FLOW LINES.ODI'S ANALYSIS OF GM'S WARRANTY CLAIM DATA FINDS MORE FREQUENT FUEL TANK REPLACEMENTS IN THE HOTTER CLIMATE STATES.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-006) TO FURTHER ASSESS THIS MATTER.

Fuel System, Gasoline:storage:tank Assembly

CERTAIN SUBJECT VEHICLES MAY EXHIBIT LEAKAGE OF ODOR AND/OR FUELFROM THE LOWER PORTION OF THE FUEL TANK INLET FILLER PIPE (INLET CHECK VALVE).THE INLET CHECK VALVE (ICV) AND THE FUEL TANK ARE JOINED TOGETHER USING A HOT PLATE WELDING PROCESS FOR PLASTIC PARTS.GM REPORTS THAT ITS ANALYSIS OF FIELD RETURNED PARTS SHOW EVIDENCE OF PROCESS VARIATIONS FOR DIFFERENT MANUFACTURING PERIODS.THESE VARIATIONS PRODUCED SOME ICV TO FUEL TANK JOINTS WITH POOR MELT FLOW LINES.ODI'S ANALYSIS OF GM'S WARRANTY CLAIM DATA FINDS MORE FREQUENT FUEL TANK REPLACEMENTS IN THE HOTTER CLIMATE STATES.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA07-006) TO FURTHER ASSESS THIS MATTER.