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2004 Buick Rendezvous

Owner reports · Recalls · Investigations

Similar to other model years

Owner complaints for the 2004 Buick Rendezvous do not stand out strongly from the model-year median of 138.

About this comparison →
200Owner complaints

Model-year median: 138

4Recall campaigns

View recall details →

3Investigations

View investigation details →

How this year compares

Owner complaints by model year

Other model years Selected year
4
2001486
2002281
2003200
2004138
200589
200643
2007
Compare all Rendezvous years →

Counts vary with age, sales and reporting. They are not failure rates.

What owners reported most

Electrical System
76Fuel System, Gasoline
23Engine And Engine Cooling
21Fuel/propulsion System
20Steering
16
All reported categories
Air Bags
14Power Train
12Service Brakes
11Engine
10Service Brakes, Hydraulic
10Suspension
9Unknown Or Other
9Visibility
9Vehicle Speed Control
8Structure
7Fuel System, Other
6Electronic Stability Control (esc)
5Equipment
4Latches/locks/linkages
4Exterior Lighting
3Seats
3Tires
3Wheels
3Seat Belts
2Child Seat
1Traction Control System
1

Tap a category to read its complaints. One report may name several components.

When problems were reported

Mileage at the reported incident

162 reports with mileage · 38 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.

  • Electrical System. Review the 76 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Fuel System, Gasoline. Review the 23 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
  • Engine And Engine Cooling. Review the 21 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →

NHTSA owner reports · September 18, 2026 snapshot.

14 crash reports2 fire reports13 injury reports

What owners actually said

200 reports
50,100 miles · Nov 2, 2017
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT OBSERVED AN ABNORMAL FUEL ODOR WITHIN THE VEHICLE WITHOUT WARNING. IN ADDITION, A SLOW DRIP FROM THE FUEL TANK WAS OBSERVED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO CONFIRMED THAT THERE WAS A LEAK FROM THE FUEL TANK. THE CONTACT THEN CALLED THE LOCAL DEALER (…

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TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT OBSERVED AN ABNORMAL FUEL ODOR WITHIN THE VEHICLE WITHOUT WARNING. IN ADDITION, A SLOW DRIP FROM THE FUEL TANK WAS OBSERVED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO CONFIRMED THAT THERE WAS A LEAK FROM THE FUEL TANK. THE CONTACT THEN CALLED THE LOCAL DEALER (BUICK GMC OF KIRKLAND, 12335 120TH AVE NE, KIRKLAND, WA, 98034) WHERE AN APPOINTMENT WAS SCHEDULED. THE DEALER DIAGNOSED THAT THERE WAS A FRACTURE WITHIN THE FUEL TANK INLET CHECK VALVE. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBERS: 03V454000 (FUEL SYSTEM) OR 07V349000 (FUEL SYSTEM). THE VEHICLE WAS NOT REPAIRED DUE TO THE COST. THE MANUFACTURER WAS CONTACTED AND PROVIDED CASE NUMBER: 8-34895551467. THE CASE WAS ESCALATED, BUT THE MANUFACTURER DENIED THE CLAIM AND STATED THAT THEY WOULD NOT COVER IT NOR WAS THE VEHICLE INCLUDED IN THE PRIOR RECALLS. THE FAILURE MILEAGE WAS APPROXIMATELY 50,100.

NHTSA ODI #11042687

Mileage unknown · Aug 26, 2017
Steering

HARNESS IN FRONT TOO SHORT CAUSING PROBLEMS WITH ABS /TRACTION SYSTEM TO NOT WORK CORRECTLY

NHTSA ODI #11019832

24,000 miles · Apr 11, 2017
Electrical System

TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT STATED THAT THE VEHICLE EXPERIENCED A COMPLETE LOSS OF POWER WHILE TRAVELING VARIOUS SPEEDS. THE CONTACT STATED THAT THE VEHICLE INTERMITTENTLY RESTARTED AFTER A MANUAL RESTART ATTEMPT WAS MADE. THE FAILURE OCCURRED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER, BU…

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TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT STATED THAT THE VEHICLE EXPERIENCED A COMPLETE LOSS OF POWER WHILE TRAVELING VARIOUS SPEEDS. THE CONTACT STATED THAT THE VEHICLE INTERMITTENTLY RESTARTED AFTER A MANUAL RESTART ATTEMPT WAS MADE. THE FAILURE OCCURRED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER, BUT IT COULD NOT BE REPLICATED. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 14V171000 (AIR BAGS, ELECTRICAL SYSTEM) AS A POSSIBLE SOLUTION; HOWEVER, THE VIN WAS NOT INCLUDED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 24,000.

NHTSA ODI #10971936

115,000 miles · Dec 13, 2016
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT STATED THAT THE VEHICLE FUEL TANK WAS FRACTURED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT …

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TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT STATED THAT THE VEHICLE FUEL TANK WAS FRACTURED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN THE NHTSA CAMPAIGN NUMBER: 07V349000 (FUEL SYSTEM, GASOLINE). THE FAILURE MILEAGE WAS AT 115,000. UPDATED 01/26/2017*CT *CN

NHTSA ODI #10935010

169,000 miles · Nov 30, 2016
Fuel/propulsion System

*VT* - ON TWO DIFFERENT OCCASIONS MY 2004 BUICK RENDEZVOUS HAS CAUSED THE INSIDE OF THE CAR TO FILL UP WITH STRONG GASOLINE SMELL. WHEN CHECKING THE GROUND I DISCOVERED IT WAS LEAKING GASOLINE. I WAS TOLD THAT THERE WAS NO MORE RECALL ON MY VIN# - HOWEVER, I'M DISCOVERING THAT OTHER 2004 BUICK RENDEZVOUSES ARE REPORTING THE S…

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*VT* - ON TWO DIFFERENT OCCASIONS MY 2004 BUICK RENDEZVOUS HAS CAUSED THE INSIDE OF THE CAR TO FILL UP WITH STRONG GASOLINE SMELL. WHEN CHECKING THE GROUND I DISCOVERED IT WAS LEAKING GASOLINE. I WAS TOLD THAT THERE WAS NO MORE RECALL ON MY VIN# - HOWEVER, I'M DISCOVERING THAT OTHER 2004 BUICK RENDEZVOUSES ARE REPORTING THE SAME OF SIMILAR PROBLEM UNDER CAMPAIGN #07V349000. I WAS NEVER NOTIFIED OF A RECALL FOR THIS ISSUE, WHICH COULD BE A VERY SERIOUS SAFETY ISSUE, AS I HAUL AROUND BY VERY YOUNG GRANDCHILDREN. WHAT? DOES SOMEONE HAVE TO DIE BEFORE THIS ISSUE IS ADDRESSED PROPERLY?

NHTSA ODI #10928792

111,710 miles · Sep 13, 2016
Fuel/propulsion System

TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. WHILE THE VEHICLE WAS BEING FUELED, THE FUEL POURED OUT ONTO THE GROUND. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FUEL TANK FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAIL…

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TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. WHILE THE VEHICLE WAS BEING FUELED, THE FUEL POURED OUT ONTO THE GROUND. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FUEL TANK FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 111,710.

NHTSA ODI #10906082

289,640 miles · Aug 30, 2016
Air BagsService Brakes

TRAC LIGHT WOULD COME ON AND OFF A FEW TIMES. EVENTUALLY THE TRAC OFF, AND ABS LIGHT STAY ON. IT OCCURS AT RANDOM MOMENTS WHILE STATIONARY AND IN MOTION. DISABLING THE TRACTION CONTROL. THIS IS HAZARDOUS WHEN IT IS ON AND IN MOTION WITH NOT FAVORABLE WEATHER IE RAIN OR SNOW. I HAVE HAD THIS HAPPEN TO ME, DRIVING IN THE RAIN WITH…

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TRAC LIGHT WOULD COME ON AND OFF A FEW TIMES. EVENTUALLY THE TRAC OFF, AND ABS LIGHT STAY ON. IT OCCURS AT RANDOM MOMENTS WHILE STATIONARY AND IN MOTION. DISABLING THE TRACTION CONTROL. THIS IS HAZARDOUS WHEN IT IS ON AND IN MOTION WITH NOT FAVORABLE WEATHER IE RAIN OR SNOW. I HAVE HAD THIS HAPPEN TO ME, DRIVING IN THE RAIN WITH THE ABS DISABLED, I HAD TO APPLY MY BRAKES HARD TO AVOID REAR ENDING THE CAR IN FRONT OF ME WHO HAD HIT THEIR BRAKES TO AVOID AN ACCIDENT AS WELL. I HAVE REPLACED HUB ASSEMBLY, ROTORS BRAKES, BRAKE CALIPERS, BRAKE HOSES THE WHOLE NINE YARDS. WAS TOLD BY ONE MECHANIC THAT WHEN THE TRACTION SYSTEM LIGHTS ARE ON AND ABS IS DISENGAGED THIS CAUSES HIGHER WEAR AND TEAR ON THE ROTORS AND BRAKE PADS. WAS ALSO TOLD THAT THE ABS WIRING HARNESS IS TOO SHORT, SO IT GETS PULLED WHEN MAKING TURNS. THIS ISSUE WILL ALSO HAPPEN IF I GO OVER BUMPS, LIKE RAILROAD TRACKS, THE SMALL STREET DITCH FOR RAIN AT THE END OF A DRIVEWAY. SOMETIMES I JUST START THE CAR UP AND IT WILL IMMEDIATELY COME ON. I ALSO HAD THE SIDE SEAR FRONT PASSENGER AIRBAG DEPLOY WHEN A FRIEND CLOSED THE SEATBELT IN THE DOOR. THE CAR WAS IN DRIVE, HOWEVER IT WAS NOT IN MOTION. THE BUCKLE GOT STUCK ON THE FRAME AT THE LOCK LATCH. THE DOOR FLEW BACK OPEN, AIR BAG DEPLOYED, AND ALL INTERIOR LIGHTS ON THE CAR AS WELL AS THE DASH LIT UP.

NHTSA ODI #10899395

Mileage unknown · May 18, 2016
Fuel/propulsion System

HELLO I NEED HELP IF POSSIBLE. IM [XXX], MY WIFE AND I ARE BOTH DISABLED & ON SSI DISABILITY, OUR PROBLEM IS SHE WAS GIVEN A CAR FROM A SON IN LAW THAT WAS UNDER A RECALL ( 2004 BUICK RENDEZVOUS ) THE GAS TANK WAS ON A SAFETY RECALL AND I TOOK IT TO WEISNER BUICK AND BECAUSE THE TANK WAS LEAKING AND SHE IS ON OXYGEN…

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HELLO I NEED HELP IF POSSIBLE. IM [XXX], MY WIFE AND I ARE BOTH DISABLED & ON SSI DISABILITY, OUR PROBLEM IS SHE WAS GIVEN A CAR FROM A SON IN LAW THAT WAS UNDER A RECALL ( 2004 BUICK RENDEZVOUS ) THE GAS TANK WAS ON A SAFETY RECALL AND I TOOK IT TO WEISNER BUICK AND BECAUSE THE TANK WAS LEAKING AND SHE IS ON OXYGEN AND WAITING FOR A DOUBLE LUNG TRANSPLANT, [XXX] WOULD NOT HONOR THE RECALL OF OVER $ 900,DOLLARS FOR A PLASTIC TANK ! SO THEY SAID THEY WOULD FINANCE IT FOR ME OK SO I HAD NO CHOICE MY PROBLEM IS I CAN ONLY MAKE THE LEAST PAYMENT THAT THEY WILL TAKE AND IT NEVER PAYS THE PRICE DOWN SO WE WILL BE PAYING ON IT THE REST OF OUR LIFE, THE RECALL WAS FOUND ON A GM WEBSITE AND SAYS THEY WILL REPLACE THE TANK NO MATER THE AGE BECAUSE IT'S A SAFETY HAZARD, IS THERE ANY HOPE OF GETTING HELP WITH THIS MATTER [XXX], HOME # [XXX] EMAIL [XXX] PLEASE CONSIDER HELPING US WITH THIS PROBLEM, INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ODI #10865720

85,000 miles · Apr 22, 2016
Fuel/propulsion System

FUEL TANK LEAK CAMPAIGN #07V349000 I WAS NOT NOTIFIED ABOUT RECALL TANK IS NOW LINKING FUMES AND DEALER AND GM SERVICE CLAIMS PAST THE 10 YEAR REPLACEMENT PERIOD. IS THE 10 YEAR PERIOD FROM TIME OF RECALL START DATE OR AGE OF CAR? MY CAR HAS LESS THAN 100,000 MILES ON IT.

NHTSA ODI #10860976

213,000 miles · Mar 3, 2016
SuspensionCrashInjury

TL* THE CONTACT OWNED A 2004 BUICK RENDEZVOUS. WHILE DRIVING APPROXIMATELY 70 MPH, THE REAR DRIVER SIDE BALL JOINT SEPARATED FROM THE AXLE. THE CONTACT CRASHED INTO A SIGN. THE DRIVER SIDE AIR BAG DEPLOYED. A POLICE REPORT WAS FILED. THE CONTACT SUSTAINED TWO BROKEN RIBS, A LACERATED SPINE, AND INJURIES TO THE LEFT THUMB. MEDICA…

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TL* THE CONTACT OWNED A 2004 BUICK RENDEZVOUS. WHILE DRIVING APPROXIMATELY 70 MPH, THE REAR DRIVER SIDE BALL JOINT SEPARATED FROM THE AXLE. THE CONTACT CRASHED INTO A SIGN. THE DRIVER SIDE AIR BAG DEPLOYED. A POLICE REPORT WAS FILED. THE CONTACT SUSTAINED TWO BROKEN RIBS, A LACERATED SPINE, AND INJURIES TO THE LEFT THUMB. MEDICAL ATTENTION WAS REQUIRED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE IT WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS UNKNOWN. THE APPROXIMATE FAILURE MILEAGE WAS 213,000. THE VEHICLE WAS DESTROYED.

NHTSA ODI #10839761

Official recalls

4

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.

05V157000 · Electrical System:ignition

Apr 20, 2005

ON CERTAIN SPORT UTILITY VEHICLES, CONTAMINATION ON IGNITION RELAY CONTACTS CAN CAUSE HIGH RESISTANCE. THIS CAN AFFECT SIGNALS TO THE POWERTRAIN CONTROL MODULE AND, COULD CAUSE INTERMITTENT VEHICLE STALLS AT ANY TIME.

Consequence & remedy

Consequence: THE VEHICLE CANNOT BE RESTARTED IMMEDIATELY. IF THIS WERE TO OCCUR, IT COULD RESULT IN A VEHICLE CRASH.

Remedy: DEALERS WILL REPLACE THE IGNITION RELAY FREE OF CHARGE. THE RECALL BEGAN ON MAY 4, 2005. OWNERS MAY CONTACT PONTIAC AT 1-800-620-7668 AND BUICK AT 1-866-608-8080.

04V150000 · Latches/locks/linkages:hatchback/liftgate:lock

Mar 29, 2004

ON CERTAIN SPORT UTILITY VEHICLES, A STRUCTURAL SUPPORT AT THE LATCH ATTACHMENT IN THE REAR LIFTGATE MAY BE INADEQUATE TO RETAIN THE LATCH TO THE LIFTGATE IN CERTAIN SEVERE VEHICLE CRASH EVENTS.

Consequence & remedy

Consequence: IF THE LIFTGATE WERE TO OPEN IN A VEHICLE CRASH, AN OCCUPANT COULD BE EJECTED FROM THE VEHICLE RESULTING IN INCREASED RISK OF PERSONAL INJURY.

Remedy: DEALERS WILL ADD STRUCTURAL REINFORCEMENTS TO THE LIFTGATE IN THE AREA ADJOINING THE LATCH ASSEMBLY. OWNER NOTIFICATION SCHEDULE BEGAN ON JUNE 21, 2004. OWNERS SHOULD CONTACT BUICK AT 1-866-608-8080. THIS IS AN EXPANSION TO A PREVIOUS RECALL (03V211).

03V454000 · Fuel System, Gasoline:storage

Nov 10, 2003

ON CERTAIN PASSENGER VEHICLES, A WELD BETWEEN THE FUEL TANK INLET CHECK VALVE AND THE FUEL TANK CAN FAIL.

Consequence & remedy

Consequence: IF THESE PARTS SEPARATE, THE DRIVER MAY NOTICE AN ODOR OF FUEL, THE SERVICE ENGINE SOON OR CHECK ENGINE LIGHT MAY ILLUMINATE, AND/OR FUEL MAY LEAK ONTO THE GROUND. FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.

Remedy: DEALERS WILL INSPECT THE SERIAL NUMBER OF THE FUEL TANK TO SEE IF IT IS ON THE LIST OF AFFECTED TANKS. IF THE SERIAL NUMBER MATCHES, THE FUEL TANK WILL BE REPLACED. OWNER NOTIFICATION BEGAN NOVEMBER 4, 2003. OWNERS SHOULD CONTACT BUICK AT 1-866-608-8080 OR PONTIAC AT 1-800-620-7668.

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

3

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.

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.