NHTSA owner reports · September 18, 2026 snapshot.
Electrical System complaints
76 reportsClear category filterMileage unknown · Dec 13, 2005
Electrical SystemFuel System, OtherLatches/locks/linkages
DT: THE CONTACT HAD PROBLEMS WITH THE REAR HATCHBACK OPENING WHILE DRIVING SINCE THE VEHICLE WAS PURCHASED. AFTER MULTIPLE ATTEMPTS TO REPAIR THE DEFECT BY THE DEALERSHIP THE CONTACT WAS ALERTED OF NHTSA RECALL CAMPAIGN 04V150000. THE RECALL NOTICES WERE SENT TO THE DEALERSHIP 15 DAYS BEFORE SHE PURCHASED THE VEHICLE, AN…
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DT: THE CONTACT HAD PROBLEMS WITH THE REAR HATCHBACK OPENING WHILE DRIVING SINCE THE VEHICLE WAS PURCHASED. AFTER MULTIPLE ATTEMPTS TO REPAIR THE DEFECT BY THE DEALERSHIP THE CONTACT WAS ALERTED OF NHTSA RECALL CAMPAIGN 04V150000. THE RECALL NOTICES WERE SENT TO THE DEALERSHIP 15 DAYS BEFORE SHE PURCHASED THE VEHICLE, AND THE RECALL REPAIRS DID NOT SOLVE THE PROBLEM. THE GAS GAUGE ON THE VEHICLE DID NOT WORK ACCURATELY. THE DEALERSHIP REPLACED THE ELECTRONIC CONTROL MODULE (ECM) MULTIPLE TIMES, BUT THE PROBLEM PERSISTED. THEY SUGGESTED THAT SHE DETERMINE THE AMOUNT OF GAS USED BY THE MILES TRAVELED. THE LOCKS DID NOT UNLOCK THE DOOR WHEN THE VEHICLE WAS IN PARK. THE CONTACT HAD TO TURN THE VEHICLE ON AND OFF TO UNLOCK THE DOORS AND THE MANUAL LOCKS DID NOT ALWAYS WORK. THERE HAVE BEEN NO REPAIRS MADE TO THE LOCKS . *AK
NHTSA ODI #10145091
5,545 miles · Nov 22, 2005
Electrical SystemEngine And Engine CoolingService Brakes, Hydraulic
MY 2004 BUICK RENDEZVOUS HAS BEEN IN THE SHOP 8 TIMES IN 10 1/2 MONTHS. CURRENTLY I AM EXPERIENCING A LOUD NOISE (MUCH LIKE AN AIR RAID HORN) WHILE I AM STOPPED IN TRAFFIC AND WHEN I TURN MY VEHICLE OFF. IT STARTED BACK IN APRIL, THE DEALERSHIP COULD NOT RECREATE THE NOISE, IN THE SHOP AGAIN 11/4/05 AND AGAIN 11/11/05. I JUST…
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MY 2004 BUICK RENDEZVOUS HAS BEEN IN THE SHOP 8 TIMES IN 10 1/2 MONTHS. CURRENTLY I AM EXPERIENCING A LOUD NOISE (MUCH LIKE AN AIR RAID HORN) WHILE I AM STOPPED IN TRAFFIC AND WHEN I TURN MY VEHICLE OFF. IT STARTED BACK IN APRIL, THE DEALERSHIP COULD NOT RECREATE THE NOISE, IN THE SHOP AGAIN 11/4/05 AND AGAIN 11/11/05. I JUST DO NOT FEEL SAFE IN THE CAR. I IT IS GETTING PROGRESSIVELY WORSE, LOUDER AND MORE FREQUENT, LASTING LONGER. I PURCHASED MY VEHICLE 17 DEC 04 AND THE VERY NEXT DAY HAD A BREAK PROBLEM. MY SERVICE RECORD IS AS FOLLOWS: 1) 12/20/04- ABS LIGHT ON - ALL WHEEL DRIVE DISABLED 2) 01/27/05 - ABS LIGHT ON - ALL WHEEL DRIVE DISABLED 3) 4/25/05 - ABS LIGHT ON ALL WHEEL DRIVE DISABLED WOULD NOT DRIVE OVER 40 MPH - 3) 4/25/05 - PASSENGER SIDE MIRROR CLICKING WHEN VEHICLE IS PUT INTO REVERSE 3) 4/25/05 VEHICLE MAKES A LOUD AIR HORN NOISE WHEN VEHICLE IS TURNED OFF 4) 5-19/05 - ABS LIGHT ON - ALL WHEEL DRIVE DISABLED 4) 5/19/05 - VEHICLE LOOSES POWER WHEN MAKING LEFT TURNS OR ON INCLINE 4) 5/16/05 INSTALLED REAR LIFT GATE LATCH 5) 7/15/05 DRIVER SIDE MIRROR GLASS CAME LOOSE 6) 9/01/05 - DRIVERS SIDE POWER WINDOW INOPERATIVE- 7) 11/4/05 - VERY LOUD ACCELERATION - EXHAUST MANIFOLD LEAKING RIGHT EXHAUST MANIFOLD 7) 11/4/05 LOUD NOISE WHILE DRIVING VEHICLE, STOPPING IN TRAFFIC AND WHEN VEHICLE IS TURNED OFF 8) 11/11/05 WOBBLE IN LEFT FRONT TIRE- REFACE FRONT ROTORS OUT OF ROUND 8) 11/11/05 TOOK VEHICLE IN FOR THE LOUD AIR HORN NOISE WHILE DRIVING, STOPPING IN TRAFFIC AND TURNING VEHICLE OFF - HAD A 5 MINUTE DISCUSSION WITH SERVICE PERSON ABOUT THIS AND IT DID NOT EVEN MAKE IT ON THE INVOICE. *NM
NHTSA ODI #10143461
63,629 miles · Nov 11, 2005
Electrical SystemEngine And Engine Cooling
SERVICE ENGINE SOON LIGHT CAME ON AND THE SERVICE TECHNICIAN FOUND THE MASS AIR FLOW SENSOR WAS NOT PROPERLY CONNECTED AFTER THE FUEL SYSTEM WAS SERVICED. THE TECHNICIAN SUBSEQUENTLY FOUND THE FUEL TANK HARNESS WAS CORRODED AND NEEDED TO BE REPLACED. THE SERVICE MANAGER ADVISED THAT THIS CONNECTOR WAS EXPOSED TO THE WEATHER EL…
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SERVICE ENGINE SOON LIGHT CAME ON AND THE SERVICE TECHNICIAN FOUND THE MASS AIR FLOW SENSOR WAS NOT PROPERLY CONNECTED AFTER THE FUEL SYSTEM WAS SERVICED. THE TECHNICIAN SUBSEQUENTLY FOUND THE FUEL TANK HARNESS WAS CORRODED AND NEEDED TO BE REPLACED. THE SERVICE MANAGER ADVISED THAT THIS CONNECTOR WAS EXPOSED TO THE WEATHER ELEMENTS AND IF THE CONNECTOR FAILED THE ENGINE WOULD SHUT OFF WHILE DRIVING. THIS IS A SERIOUS SAFETY HAZARD IN MY OPINION. THE CONNECTOR WAS REPLACED AT A COST OF $199.50. *JB
NHTSA ODI #10142452
Mileage unknown · Sep 11, 2005
Electrical SystemFuel System, GasolineSeats
VEHICLE'S MANUAL STATES 18/25 MPG, VEHICLE AVERAGE 13.0 MPG. SERVICE DEPARTMENT AT RYDELL (DEALERSHIP) STATED 18 MPG AFTER 40 MILES TEST DRIVE, SERVICE DEPARTMENT AT VERMONT CHEVY/BUICK (DEALERSHIP) STATED 27 MPG AFTER 25 (FREEWAY) MILES TEST DRIVE. BOTH SERVICE DEPARTMENTS ARE WRONG: VEHICLE AVERAGES 13.0 MPG UNDER NORMAL DRIVI…
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VEHICLE'S MANUAL STATES 18/25 MPG, VEHICLE AVERAGE 13.0 MPG. SERVICE DEPARTMENT AT RYDELL (DEALERSHIP) STATED 18 MPG AFTER 40 MILES TEST DRIVE, SERVICE DEPARTMENT AT VERMONT CHEVY/BUICK (DEALERSHIP) STATED 27 MPG AFTER 25 (FREEWAY) MILES TEST DRIVE. BOTH SERVICE DEPARTMENTS ARE WRONG: VEHICLE AVERAGES 13.0 MPG UNDER NORMAL DRIVING CONDITIONS & NORMAL DRIVING HABITS ON CITY STREETS AND FREEWAY. DEALER COULD NOT DUPLICATE PROBLEM, I WAS ADVISED THAT VEHICLE CHECKED OK AFTER SCAN. PROBLEM PERSISTS. SERVICE ADVISOR/SERVICE MANAGER ADVISED THAT THIS HIGH MPG IS NORMAL FOR THIS TYPE OF VEHICLE: 3.6 L ENGINE. DOOR LOCKS SOMETIMES WORK, SOMETIMES DON'T. DEALER COULD NOT DUPLICATE PROBLEM. SCAN AND CHECK SYSTEM AFTER RECALL. PROBLEM PERSISTING. PASSENGER SIDE MIRROR MOVES INSIDE MIRRORS HOUSING AT HIGHWAY SPEEDS (65 M/H) AND HAVE TO BE RE-SET UPON REACHING DESTINATION. DEALER COULD NOT DUPLICATE PROBLEM. PROBLEM PERSISTING. AUDIO SYSTEM COULD NOT READ ALL CDS. DEALER REPLACED RADIO/CD PLAYER TWICE. PROBLEM PERSISTING. DRIVER'S SEAT MOVES BACK AND FORTH. DEALER REPLACED SEAT ADJUSTER DUE TO EXCESSIVE LOOSENING. REPLACED SEAT TRACK ASSY. VEHICLE WENT TO RYDELL'S SERVICE DEPARTMENT THREE (3) TIMES DUE TO EXCESSIVE ALIGNMENT/STEERING ISSUES: VEHICLE CURRENTLY STILL PULLING TO RIGHT SIDE OF ROAD, STEERING WHEEL OFF CENTER. DEALER DID NOT RESOLVE ISSUES AFTER THREE ATTEMPTS, ALIGNMENT NOW OUT OF WARRANTY (7.5 K MILES ONLY), PROBLEM PERSISTING. *NM
NHTSA ODI #10136131
23,000 miles · Sep 2, 2005
Electrical SystemEngine And Engine CoolingFuel System, Other
DT: THE STARTER AND HORN DID NOT ALWAYS WORK. THERMOSTAT AND FUEL GAUGE WAS NOT ACCURATE. THERE HAD PREVIOUSLY BEEN A PROBLEM WITH THE IGNITION SWITCH AND IT WAS REPAIRED DUE TO A RECALL. THE PROBLEM WITH THE STARTER STARTED IN MARCH OF 2005. THESE PROBLEMS HAVE NOT BEEN REPAIRED AS OF YET. WHEN THE CONSUMER TOOK THE VEHIC…
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DT: THE STARTER AND HORN DID NOT ALWAYS WORK. THERMOSTAT AND FUEL GAUGE WAS NOT ACCURATE. THERE HAD PREVIOUSLY BEEN A PROBLEM WITH THE IGNITION SWITCH AND IT WAS REPAIRED DUE TO A RECALL. THE PROBLEM WITH THE STARTER STARTED IN MARCH OF 2005. THESE PROBLEMS HAVE NOT BEEN REPAIRED AS OF YET. WHEN THE CONSUMER TOOK THE VEHICLE IT TO THE DEALERSHIP THEY TOLD HER IT WAS DESIGNED THAT WAY. *JB
NHTSA ODI #10135186
12,350 miles · Jun 23, 2005
Electrical System
PURCHASED 2004 BUICK RENDEZVOUS 6/22/2005 AND WHILE TRAVELING TO WORK ON BUSY BELT-LINE WAITING IN TRAFFIC, THE VEHICLE JUST SHUT DOWN COMPLETELY AND BATTERY LIGHT CAME ON. PUT VEHCILE IN NEUTRAL AND IT RESTARTED. LATER FOUND THAT PRESETS IN RADIO HAD ALL BEEN ERASED WHICH WOULD INDICATE A COMPLETE LOSS OF ELECTRICAL POWER. THIS…
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PURCHASED 2004 BUICK RENDEZVOUS 6/22/2005 AND WHILE TRAVELING TO WORK ON BUSY BELT-LINE WAITING IN TRAFFIC, THE VEHICLE JUST SHUT DOWN COMPLETELY AND BATTERY LIGHT CAME ON. PUT VEHCILE IN NEUTRAL AND IT RESTARTED. LATER FOUND THAT PRESETS IN RADIO HAD ALL BEEN ERASED WHICH WOULD INDICATE A COMPLETE LOSS OF ELECTRICAL POWER. THIS HAS THE POTENTIAL TO BE A SERIOUS SAFETY CONCERN DUE TO THE POSSIBILTY OF REAR END COLLISIONS. HAVE READ OF SIMILAR COMPLAINTS FROM OTHER OWNERS OF THIS VEHICLE WITH OUT RESOLUTION. WILL CONTACT DEALERSHIP IF PROBLEM CONTINUES TO HAPPEN.
NHTSA ODI #10126356
Mileage unknown · Jun 15, 2005
Electrical System
DT: THE PROBLEM WAS IGNITION CONTINUED TO CRANK EVEN AFTER LETTING GO OF KEY. THIS PROBLEM WAS LOOKED AT BY MECHANIC, AND HE FOUND NO REASON. VEHICLE SHUT DOWN WHILE DRIVING, WHEN DRIVING ABOUT 20 MPH THERE WAS A WARNING LIGHT WHICH SHOWED A BATTERY. THEN THE VEHICLE WAS CHECKED, WAS PUT ON A BATTERY TESTER, NO PROBLEM APPEAR…
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DT: THE PROBLEM WAS IGNITION CONTINUED TO CRANK EVEN AFTER LETTING GO OF KEY. THIS PROBLEM WAS LOOKED AT BY MECHANIC, AND HE FOUND NO REASON. VEHICLE SHUT DOWN WHILE DRIVING, WHEN DRIVING ABOUT 20 MPH THERE WAS A WARNING LIGHT WHICH SHOWED A BATTERY. THEN THE VEHICLE WAS CHECKED, WAS PUT ON A BATTERY TESTER, NO PROBLEM APPEARED. DEALER TOLD OWNER THERE WERE NO PROBLEMS. THERE WAS A RECALL ON THE INITIAL RELAY, AND THIS WAS REPAIRED. YESTERDAY THE IGNITION WAS CONTINUING TO CRANK. THIS PROBLEM JUST HAPPENED EVERY DAY, BUT NOT EVERY TIME WHILE DRIVING. . THE VEHICLE WAS REGULARLY SERVICED.*AK
NHTSA ODI #10125344
3,000 miles · Jun 13, 2005
Electrical SystemEngine And Engine CoolingFuel System, Gasoline
I BROUGHT A BUICK RENDEVOUZ ON JULY 17,2004. FROM THE VERY FIRST WEEK I HAD IT I TOLD THE DEALER THE GAS GAGE DOESNOT WORK PROPERLY. THEY CHECKED IT OVER AND STILL CANNOT FIND AHYTHING WRONG WITH IT. AND IT STILL NOT WORKING PROPERPLY NOW BUT THEAT IS NOT THE BIGGEST ISSU WITH THIS VEHICLE. THE FIRST INCIDENT 10.10.04. I WA…
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I BROUGHT A BUICK RENDEVOUZ ON JULY 17,2004. FROM THE VERY FIRST WEEK I HAD IT I TOLD THE DEALER THE GAS GAGE DOESNOT WORK PROPERLY. THEY CHECKED IT OVER AND STILL CANNOT FIND AHYTHING WRONG WITH IT. AND IT STILL NOT WORKING PROPERPLY NOW BUT THEAT IS NOT THE BIGGEST ISSU WITH THIS VEHICLE. THE FIRST INCIDENT 10.10.04. I WAS DRIVING ON THE HIGHWAY TO WORK WHEN THE VEHILCE JUST STALLS OUT. I DIDN'T KNOW WHAT WAS GOING ON. THE CAR GET ROLLING FOR A COUPLE OF SCEONDS AND THEN I APPLIED THE BRAKE PUT THE CAR IN PARK. A COUPLE OF SECONDS LATER I STARTED THE TRUCK UP AND BEGIN DRIVING. I DROPPED THE TRUCK OFF TO THE DEALER AND TOLD THEM WHAT HAD OCCURRED. THEY REPLACED A APART AND SENT ME ON MY WAY. SINCE THEN THE VIDHILCE HASE STALLED OUT OVER 10 TIMES. AND SOMEDAY IT STALLS OUT TWICE A DAY. I HAVE BROUGHT IT BACK TO THE DEALER AND THEY KEEP CHANGEING AND REPLACING PARTS BUT ITS NOT FIXING THE STALLING OUT. I AM SCARED THAT ME AND MY DAUGHTER WILL KILLED FROM IT STALLING OUT. THEY JUST CHANGED SOMETHING WITHT THE TRANSMISSON AND NOW IT BACK IN THE SHOP WITH THE SAME PROBLEM.
NHTSA ODI #10125120
Mileage unknown · Jun 8, 2005
Electrical System
2004 BUICK RENDEZVOUS HAS STALLED TWICE WHILE DRIVING. (CAR IS 10 MONTHS OLD) 1ST INCIDENCE OCCURED WHILE TURNING INTO A PARKING SPACE AT A BUSY MALL PARKING LOT. CAR DID START RIGHT BACK UP. CALLED LOCAL DEALERSHIP TO BRING IN. THEY SAID THERE WAS A BULLENTIN REGARDING THIS ISSUE AND REPLACED THE FUSE BOX. THE 2ND INCIDENCE…
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2004 BUICK RENDEZVOUS HAS STALLED TWICE WHILE DRIVING. (CAR IS 10 MONTHS OLD) 1ST INCIDENCE OCCURED WHILE TURNING INTO A PARKING SPACE AT A BUSY MALL PARKING LOT. CAR DID START RIGHT BACK UP. CALLED LOCAL DEALERSHIP TO BRING IN. THEY SAID THERE WAS A BULLENTIN REGARDING THIS ISSUE AND REPLACED THE FUSE BOX. THE 2ND INCIDENCE AFTER THE FUSE BOX WAS REPLACED HAPPENDED 5/27/05. MY HUSBAND WAS DRIVING THE VEHICLE AND IT STALLED WHILE HE WAS DRIVING IN A PARKING LOT. CAR DID START UP AGAIN. CALLED DEALERSHIP AND BROUGHT CAR IN. THEY CAN NOT LOCATE THE PROBLEM. I ASKED WHAT HAPPENS IF THIS HAPPENS AGAIN AND THEY ADVISED TO JUST KEEP BRINGING IT IN AFTER IT HAPPENS TO EXAMINE CAR. PLEASE NOTE THIS IS MY 3RD RENDEZVOUS AND MY FIRST RENDEZVOUS (2001) THIS EXACT SAME THING HAPPENED EXCEPT I WAS ON THE TURNPIKE DRIVING 55 MPH WHEN IT STALLED AND DIDN'T START RIGHT BACK UP AND HAD TO BE TOWED. (STATE TROOPERS WERE INVOLVED WITH THIS INCIDENCE) THE DEALERSHIP COULD NOT LOCATE THE PROBLEM. NEEDLESS TO SAY SINCE I WAS A GM EMPLOYEE THEY DID A COLLATERAL TRADE SINCE I REFUSED TO DRIVE THE VEHICLE DUE TO THE SAFETY ISSUE.
NHTSA ODI #10124644
6,500 miles · Apr 27, 2005
Electrical System
WHILE VACATIONING VEHICLE STALLED AND THEY COULD NOT RESTART IT. VEHICLE WAS TOWED TO A NEARBY DEALER, AND CONSUMER WAS TOLD AFTER IT WAS STARTED, NOT TO TURN IT OFF UNTIL ARRIVING HOME. CONSUMER MADE IT HOME, AND DEALER COULD FIND NOTHING WRONG WITH THE VEHICLE. *AK
NHTSA ODI #10119232
NHTSA investigations
3EA07006 · 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.
PE04075 · Ignition Relay Failure
Opened Nov 10, 2004 · Closed Apr 28, 2005
Status: closed (inferred from source dates) · Electrical System:ignition; Electrical System:ignition:module
ON NOVEMBER 10, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE THE FAILURE, MALFUNCTION, OR OTHER UNSATISFACTORY PERFORMANCE OF THE ENGINE CONTROL SYSTEM WHICH MAY RESULT IN ENGINE STALLING IN CERTAIN MODEL YEAR (MY) 2004 BUICK RENDEZVOUS (GMT250) AND PONTIAC AZTEK (GMT250) VEHICLES ALLEGEDLY CAUSED BY IGNITION RELAY FAILURE.ODI IS AWARE OF 68 NON-DUPLICATIVE COMPLAINTS AND 1092 WARRANTY CLAIMS RELATED TO THE SUBJECT ISSUE.THERE ARE NO KNOWN CRASHES RELATED TO IGNITION RELAY FAILURE ON THE SUBJECT VEHICLES.BY LETTER DATED APRIL 19, 2005, GENERAL MOTORS CORP. (GM) HAS NOTIFIED ODI THAT IT WILL CONDUCT A SAFETY RECALL (NTHSA RECALL NO. 05V-157) TO REPLACE DEFECTIVE IGNITION RELAY MODULES IN APPROXIMATELY 34,996 SUBJECT VEHICLES BUILT BETWEEN OCTOBER 13, 2003 AND MARCH 8, 2004.THIS PERIOD OF VEHICLE PRODUCTION IS ASSOCIATED WITH ESCALATED WARRANTY CLAIMS RATES AND COMPLAINTS THAT ALLEGE ENGINE STALL DUE TO IGNITION RELAY FAILURE.GM HAS IDENTIFIED PARTS SUPPLIERS WHO USED MATERIALS CONTAINING SILICONE IN THE MANUFACTURE OF SPECIFIC COMPONENTS FOR THE IGNITION RELAY MODULE.SILICONE CONTAMINATION CAN RESULT IN SILICA DEPOSITS FORMING ON THE CONTACTS AS THE RELAY SWITCHES AND THE HEAT GENERATED BY THE RESULTANT ARC CONVERTS THE SILICONE TO SILICA.SILICA BUILD-UP ON THE CONTACTS IS PROGRESSIVE AND MAY PRODUCE A VOLTAGE DROP ACROSS THE RELAY SUFFICIENT TO CAUSE AN INTERMITTENT NO-START OR ENGINE STALL CONDITION.WARRANTY ANALYSIS INDICATES THE INCIDENCE OF NO/HARD START VERSUS ENGINE STALL TO BE EQUAL.ANALYSIS OF TOWING CLAIMS AND DETAILED SERVICE RECORDS INDICATES THAT VEHICLES MAY EXPERIENCE RESTART DIFFICULTIES AFTER A STALLING INCIDENT APPROXIMATELY 20-30 PERCENT OF THE TIME.THE USE OF SILICONE MATERIALS IN THE MANUFACTURE OF THE SUBJECT IGNITION RELAY HAS BEEN DISCONTINUED.THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Additional source detail variants (2)
Electrical System:ignition
ON NOVEMBER 10, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE THE FAILURE, MALFUNCTION, OR OTHER UNSATISFACTORY PERFORMANCE OF THE ENGINE CONTROL SYSTEM WHICH MAY RESULT IN ENGINE STALLING IN CERTAIN MODEL YEAR (MY) 2004 BUICK RENDEZVOUS (GMT250) AND PONTIAC AZTEK (GMT250) VEHICLES ALLEGEDLY CAUSED BY IGNITION RELAY FAILURE.ODI IS AWARE OF 68 NON-DUPLICATIVE COMPLAINTS AND 1092 WARRANTY CLAIMS RELATED TO THE SUBJECT ISSUE.THERE ARE NO KNOWN CRASHES RELATED TO IGNITION RELAY FAILURE ON THE SUBJECT VEHICLES.BY LETTER DATED APRIL 19, 2005, GENERAL MOTORS CORP. (GM) HAS NOTIFIED ODI THAT IT WILL CONDUCT A SAFETY RECALL (NTHSA RECALL NO. 05V-157) TO REPLACE DEFECTIVE IGNITION RELAY MODULES IN APPROXIMATELY 34,996 SUBJECT VEHICLES BUILT BETWEEN OCTOBER 13, 2003 AND MARCH 8, 2004.THIS PERIOD OF VEHICLE PRODUCTION IS ASSOCIATED WITH ESCALATED WARRANTY CLAIMS RATES AND COMPLAINTS THAT ALLEGE ENGINE STALL DUE TO IGNITION RELAY FAILURE.GM HAS IDENTIFIED PARTS SUPPLIERS WHO USED MATERIALS CONTAINING SILICONE IN THE MANUFACTURE OF SPECIFIC COMPONENTS FOR THE IGNITION RELAY MODULE.SILICONE CONTAMINATION CAN RESULT IN SILICA DEPOSITS FORMING ON THE CONTACTS AS THE RELAY SWITCHES AND THE HEAT GENERATED BY THE RESULTANT ARC CONVERTS THE SILICONE TO SILICA.SILICA BUILD-UP ON THE CONTACTS IS PROGRESSIVE AND MAY PRODUCE A VOLTAGE DROP ACROSS THE RELAY SUFFICIENT TO CAUSE AN INTERMITTENT NO-START OR ENGINE STALL CONDITION.WARRANTY ANALYSIS INDICATES THE INCIDENCE OF NO/HARD START VERSUS ENGINE STALL TO BE EQUAL.ANALYSIS OF TOWING CLAIMS AND DETAILED SERVICE RECORDS INDICATES THAT VEHICLES MAY EXPERIENCE RESTART DIFFICULTIES AFTER A STALLING INCIDENT APPROXIMATELY 20-30 PERCENT OF THE TIME.THE USE OF SILICONE MATERIALS IN THE MANUFACTURE OF THE SUBJECT IGNITION RELAY HAS BEEN DISCONTINUED.THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
Electrical System:ignition:module
ON NOVEMBER 10, 2004, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE THE FAILURE, MALFUNCTION, OR OTHER UNSATISFACTORY PERFORMANCE OF THE ENGINE CONTROL SYSTEM WHICH MAY RESULT IN ENGINE STALLING IN CERTAIN MODEL YEAR (MY) 2004 BUICK RENDEZVOUS (GMT250) AND PONTIAC AZTEK (GMT250) VEHICLES ALLEGEDLY CAUSED BY IGNITION RELAY FAILURE.ODI IS AWARE OF 68 NON-DUPLICATIVE COMPLAINTS AND 1092 WARRANTY CLAIMS RELATED TO THE SUBJECT ISSUE.THERE ARE NO KNOWN CRASHES RELATED TO IGNITION RELAY FAILURE ON THE SUBJECT VEHICLES.BY LETTER DATED APRIL 19, 2005, GENERAL MOTORS CORP. (GM) HAS NOTIFIED ODI THAT IT WILL CONDUCT A SAFETY RECALL (NTHSA RECALL NO. 05V-157) TO REPLACE DEFECTIVE IGNITION RELAY MODULES IN APPROXIMATELY 34,996 SUBJECT VEHICLES BUILT BETWEEN OCTOBER 13, 2003 AND MARCH 8, 2004.THIS PERIOD OF VEHICLE PRODUCTION IS ASSOCIATED WITH ESCALATED WARRANTY CLAIMS RATES AND COMPLAINTS THAT ALLEGE ENGINE STALL DUE TO IGNITION RELAY FAILURE.GM HAS IDENTIFIED PARTS SUPPLIERS WHO USED MATERIALS CONTAINING SILICONE IN THE MANUFACTURE OF SPECIFIC COMPONENTS FOR THE IGNITION RELAY MODULE.SILICONE CONTAMINATION CAN RESULT IN SILICA DEPOSITS FORMING ON THE CONTACTS AS THE RELAY SWITCHES AND THE HEAT GENERATED BY THE RESULTANT ARC CONVERTS THE SILICONE TO SILICA.SILICA BUILD-UP ON THE CONTACTS IS PROGRESSIVE AND MAY PRODUCE A VOLTAGE DROP ACROSS THE RELAY SUFFICIENT TO CAUSE AN INTERMITTENT NO-START OR ENGINE STALL CONDITION.WARRANTY ANALYSIS INDICATES THE INCIDENCE OF NO/HARD START VERSUS ENGINE STALL TO BE EQUAL.ANALYSIS OF TOWING CLAIMS AND DETAILED SERVICE RECORDS INDICATES THAT VEHICLES MAY EXPERIENCE RESTART DIFFICULTIES AFTER A STALLING INCIDENT APPROXIMATELY 20-30 PERCENT OF THE TIME.THE USE OF SILICONE MATERIALS IN THE MANUFACTURE OF THE SUBJECT IGNITION RELAY HAS BEEN DISCONTINUED.THE ACTION TAKEN BY GM IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.
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