2004 Pontiac Aztek problems

What is wrong

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).

Risk

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.

Recall number 07V349000 · Recall details

What is wrong

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.

Risk

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.

Recall number 05V157000 · Recall details

What is wrong

On certain passenger vehicles, a weld between the fuel tank inlet check valve and the fuel tank can fail.

Risk

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.

Recall number 03V454000 · Recall details

Gm is recalling (the federal safety agency 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.

EA07006

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.

RQ06009

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.

PE04075