NHTSA Defect Investigations for the 2002 GMC Envoy

The Office of Defects Investigations (ODI) is an office within the NHTSA which investigates serious safety problems in the design, construction or performance of vehicles. The NHTSA is authorized to order manufacturers to recall and repair vehicles, if the ODI finds a safety issue. NHTSA investigations for the 2002 GMC Envoy, both ongoing and closed, are listed below:

  1. ENGINE STALL NHTSA Engineering Analysis #EA03007

    Component(s): Engine And Engine Cooling

    Summary: 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 NHTSA 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA03007 »

  2. ENGINE STALL NHTSA Preliminary Evaluation #PE03001

    • Status:
      CLOSED
    • Date Opened: January 03, 2003
    • Date Closed: May 06, 2003
    • Recall: no recall issued

    Component(s): Engine And Engine Cooling
    Power Train
    Power Train:Automatic Transmission:Control Module (Tcm, Pcm)

    Summary: 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE03001 »

  3. BRAKE LAMP FAILURE NHTSA Engineering Analysis #EA04021

    Component(s): Exterior Lighting:Brake Lights

    Summary: 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 NHTSA that it will conduct a safety recall (NHTSA # 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA04021 »

  4. HAZARD LIGHT SWITCH FAILURE NHTSA Defect Investigation #RQ08001

    Component(s): Exterior Lighting:Hazard Flashing Warning Lights:Switch
    Exterior Lighting:Hazard Flashing Warning Lights:Unit

    Summary: 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 NHTSA 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #RQ08001 »

  5. FUEL PUMP MODULE LEAKS GASOLINE NHTSA Engineering Analysis #EA07009

    • Status:
      CLOSED
    • Date Opened: July 10, 2007
    • Date Closed: August 28, 2008
    • Recall: no recall issued

    Component(s): Fuel System, Gasoline:Delivery:Fuel Pump

    Summary: 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 NHTSA 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA07009 »

  6. FUEL PUMP MODULE LEAKS GASOLINE NHTSA Preliminary Evaluation #PE07013

    • Status:
      CLOSED
    • Date Opened: March 12, 2007
    • Date Closed: July 10, 2007
    • Recall: no recall issued

    Component(s): Fuel System, Gasoline:Delivery:Fuel Pump

    Summary: 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE07013 »

  7. 2002 TRAILBLAZER/ENVOY FUEL TANK LEAKS NHTSA Preliminary Evaluation #PE02093

    • Status:
      CLOSED
    • Date Opened: December 17, 2002
    • Date Closed: April 09, 2003
    • Recall: no recall issued

    Component(s): Fuel System, Gasoline:Storage
    Fuel System, Gasoline:Storage:Tank Assembly

    Summary: See attached report.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE02093 »

  8. PINCHER/CHAFED WIRING NHTSA Preliminary Evaluation #PE02036

    • Status:
      CLOSED
    • Date Opened: March 18, 2002
    • Date Closed: October 03, 2002
    • Recall: no recall issued

    Component(s): Steering

    Summary:

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE02036 »

  9. WINDSHIELD WIPER FAILURE NHTSA Engineering Analysis #EA04002

    Component(s): Visibility:Windshield Wiper/Washer
    Visibility:Windshield Wiper/Washer:Motor

    Summary: 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 (NHTSA recall no. 04V-046).accordingly, this investigation is closed.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #EA04002 »

  10. WINDSHIELD WIPER FAILURE NHTSA Preliminary Evaluation #PE03042

    • Status:
      CLOSED
    • Date Opened: September 17, 2003
    • Date Closed: January 06, 2004
    • Recall: no recall issued

    Component(s): Visibility:Windshield Wiper/Washer
    Visibility:Windshield Wiper/Washer:Motor

    Summary: 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.

    NHTSA: For detailed information & supporting documents, see the official NHTSA page concerning investigation #PE03042 »

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