2003 GMC Envoy Xl

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 NHTSA 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 NHTSA.gov under the identification numbers in the attached document.

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.

IN JUNE 2007, GM WILL EXPAND ITS SPECIAL POLICY TO ADDRESS FUEL TANK INLET CHECK VALVE (ICV) FRACTURES ON CERTAIN MODEL YEAR (MY) TRAILBLAZER EXT AND GMC ENVOY XL VEHICLES.THE EXPANDED POLICY COVERS MY 2002-2004 TRAILBLAZER EXT, GMC ENVOY XL, AND GMC ENVOY XUV VEHICLES AND WILL EXTEND FOR A PERIOD OF 10 YEARS OR 150,000 MILES (WHICHEVER COMES FIRST).GM WILL PROVIDE FREE REPAIR OF THE FUEL TANK. IT IS SENDING LETTERS TO OWNERS BEGINNING IN JUNE OF 2007.THIS ACTION SUPERSEDES GM'S PREVIOUS 7 YEAR/70,000 MILE SPECIAL POLICY FOR MY 2002 TRAILBLAZER EXT AND ENVOY XL VEHICLES.THE CONDITION IS MOST OFTEN REPORTED AS ILLUMINATION OF THE SERVICE ENGINE SOON (SES) LIGHT.THE VEHICLE'S DIAGNOSTIC SYSTEM DETECTS THE PRESENCE OF A FUEL SYSTEM PRESSURE LEAK AND ILLUMINATES THE SES LIGHT.OTHER OWNERS REPORT SMELLING GASOLINE FUMES. THE ACTION TAKEN BY THE MANUFACTURER IS SUFFICIENT TO RESOLVE THE ISSUES RAISED BY THIS INVESTIGATION.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.

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.

WHILE DRIVING THE VEHICLE A STRONG ODOR OF GAS ENTERING THE CABIN. FILL VEHICLE UP AND LARGE AMOUNT OF GAS POURS ON THE GROUND FROM UNDER THE VEHICLE. CLOSER INSPECTION REVEALS THE PART THAT ATTACHES TO THE GAS TANK IS BROKEN OFF CAUSING VAPORS TO ESCAPE AND NOT PROVIDING A SEAL TO CONTAIN THE SMELL. WHILE DRIVING ON THE INTERSTATE AT NORMAL OPERATING SPEED VEHICLE LOSES OIL PRESSURE CAUSING IT TO DROP TO 0 AND MESSAGE APPEARS TO STOP ENGINE. BOTH INCIDENTS ARE SAFETY HAZARDS AND CAN CAUSE SERIOUS LIFE AN DEATH INCIDENTS IF ISSUES ARE NOT ADDRESSED BY THE CORPORATION. THIS OCCUR ON INTERSTATE 66 IN WASHINGTON, DC. IMMEDIATE RECALL OF ALL VEHICLES FROM GMC NEEEDS TO BE INITIATED.

NHTSA ID

11299450

Incident

Jan 10, 2020

I WAS DRIVING DOWN THE ROAD WHEN THE CAR SHUT DOWN EVERYTHING I WAS SCARED BECAUSE I HAD TRAFFIC RIGHT BEHIND ME GOING 45MPH AND THEN THEY CAR WOULD NOT RUN AGAIN. I WAS RIGHT IN THE MIDDLE OF AN INTER SECTION AT HALL ROAD AND 59 IT WAS THE SCARIEST THING THAT HAS HAPPENED TO ME. I BOUGHT THIS VEHICLE AS A USED AUTO AND I'M NOT SURE IF THE EMMISSION SYSTEM EVER GOT CHANGED AND THIS HAPPENED ONCE BEFORE AND THE DEALER SAID NOT TO DRIVE WITH MY HOUSE KEYS ATTACHED. I HAD TO GET THE AUTO TOWED HOME.

NHTSA ID

11193870

Incident

Apr 4, 2019

Mileage

188,000 mi

WHEN IN PARK POSITION HEAVY GAS FUMES COMING FROM A LEAK AT THE TOP OF THE TANK. YOU CAN VISUALLY SEE THE GAS STAINS ON THE SIDES AND BOTTOM OF TANK.WHEN ROLLING TO A STOP THE FUMES RETURN.I'M GETTING HEADACHES AND BURNING OF MY EYES AND THROAT.I CHECKED MY VIN FOR RECALLS, THE PARTS INVOLVED ARE #14423C FUEL TANK INLET CHECK VALVE FRACTURE,AND #07076A FUEL TANK MODULAR RESERVOIR ASSEMBLY CORROSION #12166 FUEL FILLER NECK..I'M AFRAID EVERY TIME I DRIVE IT THAT I COULD BE BODILY HARMED AT ANY GIVEN MOMENT, A SPARK,SOMEONE FLICKING A CIGARETTE,A ACCIDENT, ANYTHING THAT WOULD TRIGGER A SPARK.

NHTSA ID

11153309

Incident

Nov 12, 2018

Mileage

181,000 mi

TL* THE CONTACT OWNS A 2003 GMC ENVOY XL. THE CONTACT NOTICED A STRONG FUEL ODOR INSIDE THE VEHICLE. THE CONTACT TOOK THE VEHICLE TO MANFREDI CHEVROLET (2519 HYLAN BLVD, STATEN ISLAND, NY 10306, (347) 979-0291) PER AN UNKNOWN RECALL REGARDING THE FUEL TANK. THE CONTACT WAS INFORMED THAT THE FAILURE WAS NOT RELATED TO THE RECALL. THE CONTACT THEN TOOK THE VEHICLE TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FUEL TANK WAS LEAKING AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 110,000.

NHTSA ID

11124365

Incident

Sep 1, 2017

Mileage

110,000 mi

WHILE DRIVING ON THE HIGHWAY AT 65 MPH, THE THIRD ROW FLOOR GOT REALLY HOT AND MY CHILDREN WERE SAYING THEIR FEET WERE REALLY HOT AND WE SMELLED SOMETHING LIKE PLASTIC MELTING AND MY 15 YEAR OLD COUSINS BOOT MELTED AND THE CARPET MELTED AND YOU CAN SEE METAL. ONCE WE ARRIVED HOME THE BLINKER STAYED ON AND DID NOT SHUT OFF UNTIL THE BATTERY DIED. JUST BEFORE THIS HAPPED THE VEHICLE LOST POWER AND MY HUSBAND HAD TO PUT HIS FOOT ON THE GAS ALL THE WAY.

NHTSA ID

11104092

Incident

Jun 24, 2018

Mileage

145,000 mi

WE PURCHASED OUR 2003 GMC ENVOY XL SLE 8 CYLINDER BRAND NEW AT ALDEN BUICK IN FAIRHAVEN, MASS IN JULY 2003; FOR THE PAST 3 YEARS WE HAD IT SERVICED AT ROBERTSSON'S GMC 2680 CRANBERRY HIGHWAY, WAREHAM, MASS.02571,508-291-0044. WE HAD IT RECONDITIONED AT THIS DEALERSHIP LAST YEAR, SPENDING $4000.00; WE HAD IT INSPECTED AT THIS DEALERSHIP WITH THE MASSACHUSETTS VEHICLE CHECK; IT PASSED THE FRONT END CHECK AND FRAME CHECK ON 8/4/17. I WAS DRIVING THE VEHICLE IN LATE DECEMBER, AND HIT SEVERAL DEEP POTHOLES CAUSED BY AN ICE STORM; SHORTLY THEREAFTER I LOST STEERING CONTROL OF THE VEHICLE. I HAD IT TOWED TO ALDEN BUICK/GMC IN FAIRHAVEN, MASS. TO BE TOLD THAT THE ENTIRE FRAME HAD COLLAPSED DUE TO EXTENSIVE CORROSION AND RUST. I HAD IT TOWED TO ROBERTSON'S GMC IN WAREHAM AND FILED A CLAIM WITH COMMERCE INS. CO. TO HOPEFULLY COVER THE DAMAGE TO THE FRAME; COMMERCE DENIED THE CLAIM STATING"THE FRAME ASSEMBLY WAS SEVERELY ROTTED AND THIS EXTENSIVE ROT ALLOWED THE RIGHT FRONT CONTROL ARM TO BREAK AWAYFROM THE MOUNTING POINT ON THE FRAME RAIL. GMC ISSUED A TECHNICAL SERVICE BULLETIN STATING THAT SOME ENVOY MODELS SUFFERED FROM EXTENSIVE FRAME CORROSION. WHY DID ROBERTSON'S GMC PASS THE VEHICLE ON THE SAFETY CHECK, AND WHY WAS I NOT INFORMED OF THE VEHICLE'S FRAME CORROSION BEFORE I SPENT THE $4000.00 RECONDITIONING IT? WHY IS FRAME CHECK AND FRONT END CHECK LISTED AS PASS ON MY VEHICLE WHEN THIS CORROSION AND RUST WAS PRESENT AT TIME OF INSSPECTION? FORTUNATELY NEITHER I NOR ANY OF MY FAMILY MEMBERS WERE INJURED WHILE DRIVING/RIDING IN THIS VEHICLE.

NHTSA ID

11071689

Incident

Jan 8, 2018

Mileage

90,000 mi

TL* THE CONTACT OWNS A 2003 GMC ENVOY XL. THE CONTACT STATED THAT THE FILLER PIPE WAS FRACTURED AND CAUSED THE BLADDER TO LEAK. THE CONTACT TOOK THE VEHICLE TO A CERTIFIED MECHANIC WHO DIAGNOSED THAT THE BLADDER AND FILLER NECK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 90,000.

NHTSA ID

11006421

Incident

Jul 7, 2017

Mileage

90,000 mi

THE REAR PASSENGER DOOR STOP CLOSING ....THE LATCH IS BROKEN ...THEY HAD A RECALL ON THIS IN 2005 BUT CLAIM IT'S CLOSE NOW WHAT CAN I DO?

NHTSA ID

11006030

Incident

Jul 16, 2017

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.

GM is receiving damaged (cracked or broken) transmission cores returned to the reman facilities. The damage is being caused either in the removal process by the technician, or inadequate packaging or shipping. This bulletin advises the dealers to be more careful not to damage the transmissions during removal and to package the core properly for return.

This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.

This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.