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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 →

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
102,000 miles · Dec 30, 2011
Electrical System

TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 65 MPH, THE ENGINE STALLED WITHOUT PRIOR WARNING. THE VEHICLE WAS COASTED TO A SAFE LOCATION AND THE ENGINE WAS TURNED OFF. AFTER WAITING A FEW MOMENTS, THE ENGINE RESTARTED. THE CONTACT WAS ABLE TO RESUME DRIVING. THERE WAS A RECALL RELAT…

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TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. WHILE THE CONTACT WAS DRIVING APPROXIMATELY 65 MPH, THE ENGINE STALLED WITHOUT PRIOR WARNING. THE VEHICLE WAS COASTED TO A SAFE LOCATION AND THE ENGINE WAS TURNED OFF. AFTER WAITING A FEW MOMENTS, THE ENGINE RESTARTED. THE CONTACT WAS ABLE TO RESUME DRIVING. THERE WAS A RECALL RELATED TO THE SIMILAR DEFECT UNDER NHTSA CAMPAIGN ID NUMBER 05V157000 (ELECTRICAL SYSTEM: IGNITION). THE MANUFACTURER WAS NOTIFIED OF THE MALFUNCTION. THE VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE HAD NOT BEEN REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 102,000.

NHTSA ODI #10441789

90,000 miles · Sep 13, 2011
Fuel System, Gasoline

TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT STATED THAT THERE WAS A STRONG ODOR OF GASOLINE INSIDE THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THEY ADVISED HER THAT THE FUEL LINE WAS CORRODED, CAUSING FUEL TO LEAK. THE VEHICLE WAS REPAIRED FOR THE FUEL LINE. THE MANUFACTURER WAS CONTACTED AN…

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TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT STATED THAT THERE WAS A STRONG ODOR OF GASOLINE INSIDE THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THEY ADVISED HER THAT THE FUEL LINE WAS CORRODED, CAUSING FUEL TO LEAK. THE VEHICLE WAS REPAIRED FOR THE FUEL LINE. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 90,000.

NHTSA ODI #10425166

60,000 miles · Aug 28, 2011
Unknown Or Other

I HAVE A 2004 BUICK RENDEZVOUS AND AFTER RUNNING IT, IT DOES NOT ALWAYS RESTART. IT HAS ALSO STALLED AT INTERSECTIONS WHEN IDLING. NO ONE CAN PIN POINT A SPECIFIC PROBLEM BUT AFTER IT SITS AWHILE IT RESTARTS. SOMETIMES I HAVE TO SIT FOR AN HOUR TO GET MY CAR STARTED. A GM MECHANIC SAID THERE WAS A RECALL ON A FUSE, BUT THERE WAS…

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I HAVE A 2004 BUICK RENDEZVOUS AND AFTER RUNNING IT, IT DOES NOT ALWAYS RESTART. IT HAS ALSO STALLED AT INTERSECTIONS WHEN IDLING. NO ONE CAN PIN POINT A SPECIFIC PROBLEM BUT AFTER IT SITS AWHILE IT RESTARTS. SOMETIMES I HAVE TO SIT FOR AN HOUR TO GET MY CAR STARTED. A GM MECHANIC SAID THERE WAS A RECALL ON A FUSE, BUT THERE WAS NOT CHANGE MADE TO THE FUSES SO THE ISSUE WAS NOT CORRECTED. OTHERS HAVE SAID IT WAS THE FUEL PUMP, BUT THEN OTHERS SAY IF IT IS THE FUEL PUMP IT WOULD HAVE GONE COMPLETELY BAD BY NOW. THIS HAS BEEN GOING ON SINCE 2008 WHEN I BOUGHT THE CAR USED FROM A DEALER. *TT

NHTSA ODI #10422311

57,350 miles · Aug 3, 2011
Unknown Or Other

REAR DIFFERENTIAL /TORQUE TUBE DEFECT. VEHICLE TAKEN TO GM DEALERSHIP TO CHECK WHINING, ROARING AND CLUNKING NOISE. GARAGE INDICATED NO PROBLEM WITH VEHICLE. NOISES CONTINUED AND GOT WORSE. VEHICLE TAKEN BACK TO GARAGE SEVERAL TIMES TO NO AVAIL. FINALLY VEHICLE WAS TAKEN TO ANOTHER GARAGE TO DETERMINE PROBLEM. PROBLEM FOUN…

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REAR DIFFERENTIAL /TORQUE TUBE DEFECT. VEHICLE TAKEN TO GM DEALERSHIP TO CHECK WHINING, ROARING AND CLUNKING NOISE. GARAGE INDICATED NO PROBLEM WITH VEHICLE. NOISES CONTINUED AND GOT WORSE. VEHICLE TAKEN BACK TO GARAGE SEVERAL TIMES TO NO AVAIL. FINALLY VEHICLE WAS TAKEN TO ANOTHER GARAGE TO DETERMINE PROBLEM. PROBLEM FOUND AND BOTH GM DEALERSHIP GARAGE AND THE CERTIFIED GARAGE THAT FIXED THE PROBLEM INDICATED A DEFECT IN THE REAR DIFFERENTIAL WITH POTENTIAL OF LOCKING UP WHEELS WHILE DRIVING, CAUSING THE WHEELS TO SKID WITH THE POTENTIAL OF CAUSING AN ACCIDENT.

NHTSA ODI #10417482

135,000 miles · May 2, 2011
Fuel System, Other

GAS GAUGE GIVES FAULTY READINGS WHETHER IT IS JUST BEING STARTED OR AFTER RUNNING FOR A WHILE. IT ALSO GIVES FAULTY READINGS AFTER FILLUPS. THEY GAUGE READS FULL OR NO GAS AT ALL. HAS BEEN GOING ON FOR ABOUT 6 MONTHS. *TR

NHTSA ODI #10398656

68,000 miles · Feb 25, 2011
Electrical System

TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT WAS TRAVELING 60 MPH WHEN THE SPEEDOMETER DISPLAYED THAT HE WAS TRAVELING 1 MPH. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE CLUSTER BOARD WOULD NEED REPLACING. THE MANUFACTURER WAS CONTACTED BUT OFFERED NO ASSISTANCE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE…

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TL* THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT WAS TRAVELING 60 MPH WHEN THE SPEEDOMETER DISPLAYED THAT HE WAS TRAVELING 1 MPH. THE VEHICLE WAS TAKEN TO THE DEALER WHO STATED THAT THE CLUSTER BOARD WOULD NEED REPLACING. THE MANUFACTURER WAS CONTACTED BUT OFFERED NO ASSISTANCE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 68,000 AND THE CURRENT MILEAGE WAS 100,000.

NHTSA ODI #10384499

90,000 miles · Feb 10, 2011
Engine And Engine CoolingFire

TL*THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. WHILE DRIVING APPROXIMATELY 35 MPH THE CONTACT BEGAN TO SMELL A BURNING ODOR. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS TOLD THAT THE COOLANT BEGAN TO MIX WITH THE OIL AND DESTROYED THE HEAD GASKET. THE ENGINE WAS REPAIRED. THE FAILURE AND CURRENT MILEAGES W…

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TL*THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. WHILE DRIVING APPROXIMATELY 35 MPH THE CONTACT BEGAN TO SMELL A BURNING ODOR. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS TOLD THAT THE COOLANT BEGAN TO MIX WITH THE OIL AND DESTROYED THE HEAD GASKET. THE ENGINE WAS REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 90,000. THE VIN WAS UNAVAILABLE.

NHTSA ODI #10381420

100,000 miles · Jan 18, 2011
Electrical System

SPEEDOMETER ON MY 2004 BUICK RENDEZVOUS CXL SUV HAS NOT BEEN WORKING PROPERLY FOR THE LAST 6 MONTHS. SOME DAYS IT WILL BE ALOT LOWER THAN ACTUAL SPEED OF THE VEHICLE AND OTHER DAYS IT WILL BE ALOT HIGHER, LIKE SHOWING 110 MPH WHILE I'M ACTUALLY DRIVING 45 MPH. SOME DAYS IT DOES NOT REGISTER ANYTHING OTHER THAN 0 MPH. *TR

NHTSA ODI #10377059

90,000 miles · Dec 1, 2010
Fuel System, Gasoline

TL*THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT STATED THAT THE FUEL GAUGE DID NOT DISPLAY THE ACCURATE AMOUNT OF FUEL THAT WAS IN THE VEHICLE. THE DEALER WAS UNABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER WAS NOT NOTIFIED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS UNAVAILABLE. THE CURRENT MILEAGE WAS APPROXIMATE…

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TL*THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT STATED THAT THE FUEL GAUGE DID NOT DISPLAY THE ACCURATE AMOUNT OF FUEL THAT WAS IN THE VEHICLE. THE DEALER WAS UNABLE TO DUPLICATE THE FAILURE. THE MANUFACTURER WAS NOT NOTIFIED. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS UNAVAILABLE. THE CURRENT MILEAGE WAS APPROXIMATELY 100,000. THE FAILURE MILEAGE WAS APPROXIMATELY 90,000.

NHTSA ODI #10368515

89,000 miles · Nov 22, 2010
Electrical System

TL*THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, THE SPEEDOMETER DISPLAYED AN INCORRECT SPEED; IT WOULD INDICATE THAT THE VEHICLE WAS TRAVELING FASTER THAN IT ACTUALLY WAS. THE VEHICLE HAD NOT BEEN INSPECTED OR REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 89,000. UPDA…

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TL*THE CONTACT OWNS A 2004 BUICK RENDEZVOUS. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, THE SPEEDOMETER DISPLAYED AN INCORRECT SPEED; IT WOULD INDICATE THAT THE VEHICLE WAS TRAVELING FASTER THAN IT ACTUALLY WAS. THE VEHICLE HAD NOT BEEN INSPECTED OR REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 89,000. UPDATED 3/11/11 *CN THE CONSUMER STATED THE SPEEDOMETER REGISTERS AT 100- 105 MPH WHEN SHE WAS ACTUALLY DRIVING 45 MPH. UPDATED 03/16/11

NHTSA ODI #10367192

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.