2002 GMC Envoy problems

What is wrong

Some sport utility vehicles equipped with an electronically controlled air suspension (ecas) have a condition in which the ecas may produce a brief electrical spike while the vehicle is operating. This electrical spike can disrupt the powertrain control module (PCM) causing the vehicle to stall.

Risk

If the spike damages the PCM, the vehicle may not restart. If this happens while the vehicle is moving, a crash could occur without prior warning.

Remedy

Dealers will install a wiring harness. The recall will begin on august 19, 2004. Owners should contact oldsmobile at 1‑800‑630‑6537 or gmc at 1‑866‑996‑9463.

Recall number 04V289000 · Recall details

What is wrong

Certain light duty pickup trucks and sport utility vehicles fail to conform to federal motor vehicle safety standard no. 209, "seat belt assemblies." one of the two sensors in the driver's and front passenger's seat belt retractors could be inoperative. The seat belt retractors will lock when the belt webbing is extracted during a crash; however, the mechanism that locks the seat belt retractor when the vehicle decelerates quickly, such as heavy braking, may not operate as intended.

Risk

If this were to occur, the safety belt may not restrain the occupant as intended during a crash, and could result in injury to the occupant.

Remedy

Dealers will inspect the driver and front passenger safety belt retractors, and replace them if necessary. Owner notification began on june 24, 2004. Owners should contact chevrolet at 1‑800‑630‑2438, gmc at 1‑866‑996‑9463, or oldsmobile at 1‑800‑630‑6537.

Recall number 04V201000 · Recall details

What is wrong

Certain sport utility vehicles have windshield wiper systems that will not turn on, cease operation while in use, fail to turn off/on by themselves (moisture sensitive wiper system), or have continuous windshield washer pump operation because the presence of water within the wiper modules can either cause a short circuit or can lead to the corrosion of components within the module.

Risk

Depending on the occurrence and weather situation, driver visibility could be reduced, which could result in a crash.

Remedy

Dealers will cover the windshield wiper module vent hole with a patch. Also, the wiper motor, circuit board, and electrical connector will be inspected to signs of water intrusion and/or corrosion and be replaced as required. The recall began july 6, 2004. Owners should contact chevrolet at 1‑800‑630‑2438; oldsmobile at 1‑800‑630‑6537; or gmc at 1‑866‑996‑9463.

Recall number 04V046000 · Recall details

What is wrong

Certain minivans, passenger and sport utility vehicles fail to comply with the requirements of federal motor vehicle safety standard no. 225, "child restraint anchorage system." the owner's manual does not explain the meaning of the location symbols for the child restraint lower universal anchorage system.

Risk

This does not meet the requirements of the standard.

Remedy

Owners will be provided with a supplement for their owner's manual. This supplement describes and shows the location symbols for the child restraint anchors that are located in the vehicle and on the child restraint or booster cushion. Owner notification began august 18, 2003. Owners should contact buick at 1‑866‑608‑8080, cadillac at 1‑866‑982‑2339, chevrolet at 1‑800‑630‑2438, gmc at 1‑866‑996‑9463, pontiac at 1‑800‑620‑7668, or oldsmobile at 1‑800‑630‑6537.

Recall number 03V250000 · Recall details

What is wrong

Certain sport utility vehicles fail to comply with the requirements of federal motor vehicle safety standards no. 101, "control location, identification, and illumination" and no. 208, "occupant crash protection." these vehicles have an intermittent condition during vehicle start-up in which the instrument panel cluster may not properly power up, resulting in most of the displays, telltale lights, and functions (except the service engine light, turn signal indicators, and the instrument panel cluster backlighting) being inoperative.

Risk

These vehicles do not comply with the standard.

Remedy

Dealers will reprogram the instrument panel cluster. Owner notification began may 29, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1‑800‑222‑1020, gmc at 1‑800‑462‑8782, or oldsmobile at 1‑800‑442‑6537.

Recall number 03V096000 · Recall details

What is wrong

Certain sport utility vehicles fail to comply with the requirements of federal motor vehicle safety standard no. 114, "theft protection." these vehicles are equipped with a mechanical override that could allow the ignition key to be removed with the shift lever in a position other than park. In addition, these vehicles have an override that can allow the transmission to be shifted out of park with the ignition in the off position.

Risk

These overrides are not permitted unless the vehicle has a locking steering column.

Remedy

Dealers will eliminate these conditions by disabling the overrides. Owner notification began on may 29, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1‑800‑222‑1020, gmc at 1‑800‑462‑8782, oldsmobile at 1‑800‑442‑6537, or hummer at 1‑866‑486‑6376.

Recall number 03V075000 · Recall details

What is wrong

Certain sport utility vehicles are missing welds on the rear floor plan.

Risk

In a crash, missing welds could degrade performance of the third row seat and safety belt anchorage and occupants could receive greater injuries.

Remedy

Dealers will inspect the vehicle for missing welds. If missing welds are found, gm will exchange the vehicle for an equivalent vehicle or provide a refund of the purchase price. Owner notification began october 4, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1‑800‑222‑1020 or gmc at 1‑800‑462‑8782.

Recall number 02V273000 · Recall details

What is wrong

On certain sport utility vehicles, a fuel filter fitting can become disconnected. If this were to occur while attempting to start the engine, a no-start condition would result and fuel would be pumped out the fuel filter onto the ground.

Risk

If the fitting becomes disconnected while the vehicle is in motion, the engine would stop due to inadequate fuel supply and cause a loss of power steering assist. If an ignition source were present, fuel leakage from a disconnected fuel filter fitting could result in a fire.

Remedy

Dealers will replace the fuel filter quick connect retainers. Owner notification began september 20, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1‑800‑222‑1020. Gmc at 1‑800‑462‑8782, or oldsmobile at 1‑800‑442‑6537.

Recall number 02V121000 · Recall details

What is wrong

Certain passenger, mini vans, and sport utility vehicles have an air bag inflator on the driver's side that could fracture at a weld during a deployment.

Risk

Pieces of the inflator could strike and injure vehicle occupants and the air bag cushion would not inflate fully, reducing the capability of the bag to protect the driver.

Remedy

Dealers will inspect, and replace, if necessary, the air bag module assembly on the driver's side. Owner notification began august 15, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact buick at 1‑800‑521‑7300, cadillac at 1‑800‑458‑8006, chevrolet at 1‑800‑222‑1020, gmc at 1‑800‑462‑8782, oldsmobile at 1‑800‑442‑6537, or pontiac at 1‑800‑762‑2737.

Recall number 02V222000 · Recall details

What is wrong

Vehicle description: sport utility vehicles equipped with 4-wheel drive. The calibration of the transfer case control module could cause insufficient high speed gear engagement.

Risk

If the gear is not engaged, the vehicle can roll when the transmission is in "park" and a crash could result without warning.

Remedy

Dealers will update the transfer case control module calibration to increase gear engagement. Owner notification began november 6, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1‑800‑222‑1020 or gmc at 1‑800‑462‑8782.

Recall number 01V334000 · Recall details

What is wrong

Vehicle description: sport utility vehicles (4 wheel-drive). Some of these vehicles were built with a range shift collar in the transmission transfer case that contains cracks.

Risk

This condition could result in a complete fracture of the range shift collar and subsequent loss of vehicle forward and reverse gears, and the inability to maintain "park" position. This increases the risk of a vehicle crash resulting from unintended movement of a parked vehicle.

Remedy

Dealers will replace the transfer cases and update the control module calibration. Owner notification began september 6, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1‑800‑222‑1020 or gmc at 1‑800‑462‑8782.

Recall number 01V283000 · Recall details

What is wrong

Vehicle description: certain sport utility vehicles fail to comply with requirements of fmvss no. 201, "occupant protection in interior impacts." these vehicles have a console cover/armrest lid latch that could release at less than the 10g vertical load requirement of the standard.

Risk

In the event of a crash, the console cover could open and the cover or items stored under it could injure an occupant.

Remedy

Dealers will replace the console latch mechanism and install a striker plate. Owner notification began july 16, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact gmc at 1‑800‑462‑8782.

Recall number 01V158000 · Recall details

What is wrong

Vehicle description: sport utility vehicles. Under certain circumstances the front lower control arm brackets may fracture. This fracture could result in separation of the front lower control arm from the frame.

Risk

A separation could result in loss of vehicle control, resulting in a crash.

Remedy

Dealers will replace the left and right front lower control arm brackets. Owner notification began by telephone on april 4, 2001. The followup letter to consumers was mailed may 3, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact chevrolet at 1‑800‑222‑1020, oldsmobile at 1‑800‑442‑6537, or gmc at 1‑800‑462‑8782.

Recall number 01V126000 · Recall details

The subject vehicles are model year (MY) 2002-2009 Chevrolet Trailblazer, GMC Envoy, 2004-2007 Buick Rainier, 2003-2008 Isuzu Ascender, 2005-2009 Saab 9-7X, 2002-2004 Oldsmobile Bravada, 2003-2006 Chevrolet SSR, 2005-2009 Buick Lacrosse, and 2006-2008 Pontiac Grand Prix. This scope includes the Trailblazer/Envoy variants: 2002-2006 Envoy XL/Trailblazer EXT and 2004-2005 Envoy XUV. The original scope of this investigation was expanded to include all vehicles equipped with the subject Headlight Driver Module (HDM). The focus of the investigation was to determine whether actions performed by General Motors adequately addressed any unreasonable risk to motor vehicle safety in the subject vehicles concerning the headlights and the HDM that controls them.Under normal electrical load and environmental conditions, the HDM can overheat inside the Underhood Electrical Center (UEC). This can cause the module to fail and result in a simultaneous loss of both low beam headlights and both daytime running lights (DRLs), often with no warning or prior detectability to the driver. This failure can be intermittent or permanent. No other exterior lights are affected. High beams, turn signals, brake lights, and reverse lights are still operational.General Motors addressed this issue with 2 recalls (14V755 & 15V519) and a special coverage program (N172091910). In view of the recalls and special coverage program implemented by GM and the vehicle high beams continuing to operate, ODI has tentatively concluded that the actions taken by GM mitigate any unreasonable risk to safety posed by HDM failure in the subject vehicles.Accordingly, the investigation is closed. The closing of this investigation does not constitute a finding by the federal safety agency that a safety-related defect does not exist. The agency reserves the right to take additional action if warranted by new circumstances.The ODI reports cited above are available for review online at under the identification numbers in the attached document.

RQ17002

On november 30, 2001, general motors (gm) conducted safety recall 01v‑364 for the subject vehicles built between september 16, 1999 and august 28, 2001 to remedy a defective hazard switch that would cause a loss of hazard and stop lamp illumination.the hazard switch is contained within the vehicle multifunction switch.odi opened this investigation based on reports that some consumers were not notified of the original recall or that they had repairs done under 01v‑364 but experienced subsequent multifunction switch failures.the multifunction switch supports the operation of cruise control, windshield wipers, exterior lighting and turn signals in addition to hazard and stop lamps. On may 21, 2008, gm notified the agency that it erroneously missed identifying 5,862 vehicles that should have been included in recall 01v‑364.gm will now notify owners of these vehicles under a new the federal safety agency recall number 08v‑231.owner notification began on june 17.the primary cause of brake lamp failure was a design change from copper to brass contact material in the hazard switch.this change was effective for vehicles built after september 16, 1999.gm changed the material back to copper for vehicles built after august 28, 2001. The remedy part for both 01v‑364 and 08v‑231 contains copper contacts.gm's data shows that less than 1% of vehicles repaired under recall 01v‑364 required additional subsequent repair or replacement of the hazard or multifunction switch.this investigation is closed.

RQ08001

During the course of this ea investigation, odi observed that the majority of the complaints (88%) and warranty claims (94%) were reported for vehicles that are registered for use in the salt belt region of the us.this area includes 20 states in the northeast, mid atlantic and the midwest regions and the district of columbia.consumers in the salt belt region reported to odi that they could smell fuel vapors in their vehicles while driving.upon further examination of their vehicles, they discovered that fuel vapors were coming out of the top of the fuel tank. This condition is caused by corrosion of the return and sender lines of the fuel pump module.water and road salt collect on top of the fuel pump leading to small pinholes appearing on the fuel lines.fuel may leak and collect on top of the module and/or spill onto the ground.the data evaluated under this investigation reflect a relatively low frequency of occurrence that largely arises in salt belt states.gm has extended the warranty on the subject component to ten years or 120,000 miles.further use of agency resources does not appear to be warranted at this time; accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by the federal safety agency that no safety-related defect exists.the agency reserves the right to take further action if warranted by the circumstances.for additional information select document search.

EA07009

Odi has received reports that the fuel pump module leaks fuel and or vapor underneath the vehicle.gm states, the failure mechanism is corrosion of the fuel pump module flange which may lead to a fuel leak.corrosion of the fuel pump module flange is the result of the vehicle operating in a corrosive environment.odi has upgraded this pe to engineering analysis (ea07-009) to further assess this issue.

PE07013

Gm states that some brake/tail lamp bulbs can prematurely become inoperative due to malfunctioning brake/tail lamp sockets.on march 2, 2004, gm initiated a 6-year/72,000 mile special policy for 989,487 subject vehicles to inspect and replace the rear brake/tail lamp bulb socket assemblies.on april 4, 2004, the office of defects investigation (odi) opened a preliminary evaluation (pe04-032) based on consumer complaints alleging brake lights not operating when the brake pedal is depressed.on august 3, 2004 odi upgraded pe04-032 to an engineering analysis (ea04-021).by letter dated october 27, 2004 gm notified the federal safety agency that it will conduct a safety recall (the federal safety agency # 04v527) covering subject vehicles that were not already repaired under gm's special policy.my 2004 subject vehicles built after august 8, 2003 contain improved brake lamp assemblies and are not included in the recall.gm dealers will install the improved brake lamp assembly on subject vehicles built on august 8, 2003 and earlier.the action taken by gm is sufficient to resolve the issues raised by this investigation.accordingly, this investigation is closed.

EA04021

On september 17, 2003, the office of defects investigation (odi) opened a preliminary evaluation (pe03-042) to investigate alleged windshield wiper failure in certain model year (my) 2002 and 2003 chevrolet trailblazer and trailblazer ext, gmc envoy and envoy xl, and oldsmobile bravada vehicles.the investigation was upgraded to an engineering analysis on january 6, 2004, and the scope was expanded to include certain my 2003 isuzu ascender vehicles.all subject vehicles are built on general motors? Gmt360 and gmt370 platforms and were originally equipped with a windshield wiper assembly referred to as the family design module (p/n 15171306 base, p/n 15171307 for vehicles equipped with rainsense automatic moisture sensitive wipers).water enters the windshield wiper module causing the electrical components on the control circuit board to corrode and short out, thus rendering the wiper motor/module inoperative.in november 2002, gm introduced into vehicle production a redesigned windshield wiper assembly referred to as the ?global? Design module (p/n 15094704 base, p/n 15094705 for vehicles equipped with rainsense) to better control water intrusion.odi has received a total of 1,179 non-duplicative owner and field reports alleging windshield wiper failure on vehicles originally equipped with the ?family? Design module.by letter dated february 2, 2004, gm has notified odi that it will conduct a safety recall (the federal safety agency recall no. 04v‑046).accordingly, this investigation is closed.

EA04002

The subject vehicles (chevrolet trailblazer (ext), gmc envoy (xl), and oldsmobile bravada) are built on the gmt360 and gmt370 platforms and were originally equipped with a windshield wiper assembly referred to as the ?family? Design module (p/n 15171306 base, p/n 15171307 for vehicles equipped with rainsense automatic moisture sensitive wipers).the windshield wiper assembly is located inside the plenum at the base of the windshield and is mounted on an incline approximately equal to the rake of the windshield.gm reports that vehicles are subject to a quality assurance water test at the assembly plant.the test exposes the vehicles to an amount of water that exceeds the plenum?s capability to divert water away from the wiper module, allowing water to rise to a level that exceeds the height of the windshield wiper motor cover vent hole.water enters through the vent hole then flows down to the bottom of the module and pools causing the electrical components on the control circuit board to corrode and short out, thus rendering the wiper motor/module inoperative.on november 2, 2002 gm introduced into vehicle production a redesigned windshield wiper assembly referred to as the ?global? Design module (p/n 15094704 base, p/n 15094705 for vehicles equipped with rainsense) that uses a polytetrafluoroethylene membrane covered vent hole to control water intrusion.there are a total of 1,172 non-duplicative owner and field reports alleging windshield wiper failure, two vehicle crashes allegedly caused by windshield wiper failure, and 43,219 warranty claims for windshield wiper assembly or wiper control module replacement on vehicles originally equipped with the ?family? Design module.this preliminary evaluation has been upgraded to an engineering analysis (ea04-002) to further study the scope and safety consequences of this issue.

PE03042

Model year (my) 2002 bravada and certain my 2002 envoy vehicles with optional electronically controlled air suspension (ecas) may be subject to engine stall caused by an errant voltage spike transmitted to the powertrain control module (PCM).in addition to engine stall, if the spike damages the PCM, the vehicle may not restart.on october 31, 2001 gm introduced into production a wiring harness containing an inductor that was added to the ecas wiring to reduce the magnitude of the voltage spike.on december 6, 2001 gm introduced into production a modified PCM with protection from errant voltage spikes and also ceased use of the wiring harness with the inductor.the office of defects investigation's (odi) analysis verified that vehicles built on or before october 31, 2001, had the highest rate of engine stalling.odi is aware of 1,132 complaints and field reports on the 37,746 subject vehicles built prior to october 31, 2001 (2,999 reports/100,000 vehicles). There is one crash and one injury resulting from a stalling incident.gm reported 7,859 warranty claims with build dates before october 31, 2001 (20,820 claims/100,000 vehicles).by way of letter dated june 4, 2004, gm notified odi that it had determined that the subject vehicles built on or before october 31, 2001 contained a safety-related defect and that gm will be conducting a safety recall of those vehicles.gm will recall 18,455 my 2002 oldsmobile bravada's and 11,496 my 2002 gmc envoy's (total: 29,951).the recall is identified by the federal safety agency number 04v‑289.not included in this recall are subject vehicles built after october 31, 2001, and subject vehicles built on or before october 31, 2001 that were serviced with the jumper cable or the revised PCM.given that the vehicles outside the recall have remedied, either in production or in service,for the stalling condition, odi has concluded that further expenditure of agency resources in pursuing a safety recall of those vehicles is not warranted.this conclusion does not constitute a finding that no safety-related defect exists in those vehicles.the agency reserves the right to take further action if warranted by the circumstances.

EA03007

Of the 697 total complaints, 240 were received for theenvoy and 457 for the bravada.gm has identified about 5,000 warranty claims related to stalling in the subject vehicles.gm reports that a transient voltage spike generated in the ecas degrades the performance of the PCM resulting in engine stall.gm modified the ecas wiring bundle and the PCM for vehicles built after december 6, 2001 to address the stalling problem.

PE03001

See attached report.

PE02093

PE02036