Chevrolet Lumina Recalls — All NHTSA Recall Campaigns

ENGINE AND ENGINE COOLING

GENERAL MOTORS IS RECALLING 1,497,516 MY 1997-2003 BUICK REGAL, MY 1998-2003 CHEVROLET LUMINA, MONTE CARLO AND IMPALA, MY 1998-1999 OLDSMOBILE INTRIGUE, MY 1997-2003 PONTIAC GRAND PRIX VEHICLES EQUIPPED WITH A 3.8L V6 NATURALLY ASPIRATED ENGINE. SOME OF THESE VEHICLES HAVE A CONDITION IN WHICH DROP…

Risk: IF THE MANIFOLD IS HOT ENOUGH AND THE OIL RUNS BELOW THE HEAT SHIELD, IT MAY IGNITE INTO A SMALL FLAME AND MAY SPREAD TO THE PLASTIC SPARK PLUG WIRE CHANNEL AND BEYOND INCREASING THE RISK OF AN ENGINE…

Remedy: DEALERS WILL REPLACE THE ENGINE’S FRONT VALVE COVER AND FRONT-VALVE-COVER GASKET WITH NEW PARTS OF AN IMPROVED DESIGN AND REMOVE THE ENGINE’S PLASTIC COVER AND PLASTIC OIL-FILL-TUBE EXTENSION, FREE OF…

EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES…

Risk: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.

FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY:PRESSURE RELIEF DEVICES

CERTAIN DELPHI FUEL PRESSURE REGULATORS, P/NOS. FP10020-11B1, FP10026-11B1, AND FP10027-11B1, SOLD AFTER JANUARY 9, 2007, AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES LISTED ABOVE. THE UNIVERSAL PRESSURE REGULATORS (UPR) WERE PRODUCED WITHOUT AN O'RING AND RETAINER.

Risk: FUEL MAY LEAK, POSSIBLY RESULTING IN A FIRE.

Remedy: DELPHI WILL NOTIFY OWNERS AND REPLACE THE UPR FREE OF CHARGE. THE RECALL BEGAN ON APRIL 23, 2007. OWNERS CAN CONTACT DELPHI AT 877-411-8770.

STEERING:RACK AND PINION

CERTAIN PASSENGER VEHICLES HAVE LOWER PINION BEARINGS IN THE POWER RACK AND PINION ASSEMBLY IN WHICH THE RETAINER TABS WERE NOT CRIMPED PROPERLY. THESE RETAINERS COULD FAIL AND PERMIT THE BALL BEARINGS TO ESCAPE.

Risk: IF THIS OCCURS, THE PINION SHAFT CAN BE FORCED UPWARD DURING LEFT TURNS AND BACK DOWN AS THE STEERING WHEEL IS MOVED BACK AND TO THE RIGHT. IF THE PINION SHAFT MOVES FURTHER, THE DRIVER WILL NEED TO …

Remedy: DEALERS WILL INSTALL A NEW LOWER PINION BEARING UNLESS INSPECT OF THE EXISTING BEARING INDICATES THAT REPLACEMENT OF THE GEAR ASSEMBLY IS NECESSARY. OWNER NOTIFICATION BEGAN ON FEBRUARY 5, 2004. …

AIR BAGS:FRONTAL

ON CERTAIN PASSENGER, SPORT UTILITY VEHICLES AND MINI VANS, SOME OF THESE VEHICLES HAVE A PASSENGER AIR BAG THAT WAS MANUFACTURED WITHOUT A CHECK VALVE PIN. AN AIR BAG WITHOUT THE CHECK VALVE PIN COULD PRODUCE INCREASED PRESSURE AT THE ONSET OF THE AIR BAG DEPLOYMENT AND REDUCED PRESSURE AFTERWARD.

Risk: THIS COULD INCREASE THE SEVERITY OF INJURY TO A PERSON WHO WAS NOT PROPERLY RESTRAINED AND WHO WAS CLOSE TO THE PASSENGER AIR BAG AT THE TIME OF DEPLOYMENT. IT COULD ALSO REDUCE THE AB8ILITY OF THE A…

Remedy: DEALERS WILL INSPECT AND, IF NECESSARY, REPLACE THE PASSENGER AIR BAG. OWNER NOTIFICATION BEGAN DECEMBER 16, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DA…

AIR BAGS:FRONTAL

VEHICLE DESCRIPTION: PASSENGER, SPORT UTILITY VEHICLES AND MINIVANS. THE PASSENGER AIR BAG INFLATOR MODULES WERE BUILT WITHOUT THE CORRECT AMOUNT OF GENERANT, WHICH PRODUCES THE GAS THAT FILLS THE AIR BAG. SOME WERE BUILT WITH A DOUBLE LOAD OF GENERANT AND SOME WERE BUILT WITHOUT GENERANT.

Risk: IN THE EVENT OF A CRASH THAT WOULD TRIGGER A PASSENGER AIR BAG DEPLOYMENT, A DOUBLE LOAD OF GENERANT CAN CAUSE THE INFLATOR MODULE TO EXPLODE. IF THE AIR BAG MODULE EXPLODES, METAL AND PLASTIC DEBRIS…

Remedy: DEALERS WILL REPLACE THE PASSENGER AIR BAG MODULE. TELEPHONE CALLS WERE MADE TO OWNERS ON JANUARY 29, 2001. FOLLOW UP OWNER MAILING BEGAN ON APRIL 17, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN A…

SEAT BELTS

VEHICLE DESCRIPTION: PASSENGER VEHICLES, LIGHT DUTY TRUCKS, SPORT UTILITY VEHICLES, AND MINI VANS EQUIPPED WITH TRW SEAT BELT BUCKLE ASSEMBLIES. THE BUCKLE BASE OF THESE SEAT BELT ASSEMBLIES WERE NOT PROPERLY HEAT TREATED AND THEREFORE DO NOT PASS THE LOAD BEARING REQUIREMENT OF FEDERAL MOTOR VEHI…

Risk: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT MAY NOT BE PROPERLY RESTRAINED.

Remedy: DEALERS WILL INSPECT THE VEHICLE'S SAFETY BELT BUCKLE ASSEMBLY DATE CODES AND, IF NECESSARY, WILL REPLACE ANY SAFETY BELT BUCKLE ASSEMBLY.

SEAT BELTS:FRONT:ANCHORAGE

THE CENTER REAR SEAT BELT ANCHOR PLATE EXHIBITS STRESS CRACKS.

Risk: IN THE EVENT OF A VEHICLE CRASH, THE SEAT BELT SYSTEM CAN FRACTURE, INCREASING THE RISK OF INJURY TO THE SEAT OCCUPANT.

Remedy: DEALERS WILL REPLACE THE CENTER REAR SEAT BELT SYSTEM.

VISIBILITY:WINDSHIELD WIPER/WASHER:SWITCH/WIRING

SOME OF THESE VEHICLES HAVE A STRAINED OR SEPARATED WASHER/WIPER SWITCH POWER FEED WIRE.

Risk: THIS CAN CAUSE THE WINDSHIELD WASHER/WIPER TO WORK INTERMITTENTLY AND COULD ULTIMATELY RESULT IN INOPERATIVE WIPERS. IF THIS WERE TO OCCUR IN A SEVERE WEATHER SITUATION, DRIVER VISIBILITY COULD BE RE…

Remedy: DEALERS WILL INSPECT AND REPLACE THE OLD DESIGNED WASHER/WIPER SWITCHES WITH A NEWLY DESIGNED SWITCH.

SERVICE BRAKES, HYDRAULIC:POWER ASSIST:VACUUM

THESE VEHICLES WERE ASSEMBLED WITH ONE OF THE FOUR BRAKE BOOSTER TABS NOT PROPERLY LOCATED IN THE FRONT OF DASH REINFORCEMENT ASSEMBLY.

Risk: IF THIS CONDITION WERE PRESENT IN A SITUATION WHERE STOPPING DISTANCES WERE SMALL, A VEHICLE CRASH COULD OCCUR.

Remedy: DEALERS WILL INSPECT FOR PROPER BOOSTER INSTALLATION. BOOSTERS FOUND TO BE IMPROPERLY LOCATED WILL BE REMOVED AND REINSTALLED PROPERLY.

VEHICLE SPEED CONTROL

THESE VEHICLES WERE ASSEMBLED WITH THROTTLE CABLE SUPPORT BRACKETS THAT COULD CONTACT THE THROTTLE LEVER SYSTEM AND INHIBIT THE THROTTLE RETURN. THIS DOES NOT MEET THE REQUIREMENTS OF FMVSS NO. 124, "ACCELERATOR CONTROL SYSTEMS."

Risk: CONSEQUENCE OF NON-COMPLIANCE: THE THROTTLE MAY FAITL TO RETURN QUICKLY CAUSING THE ENGINE SPEED TO NOT DECREASE TO A LEVEL ANTICIPATED BY THE DRIVER.

Remedy: DEALERS WILL REPLACE THE THROTTLE CABLE SUPPORT BRACKET.

SEATS

THE DRIVER AND PASSENGER FRONT SEAT MANUAL RECLINING MECHANISMS DO NOT COMPLY WITH THE REQUIREMENTS OF FMVSS 207, "SEATING SYSTEMS." THE SEAT BACK MECHANISMS WILL NOT LATCH UNDER CERTAIN CONDITIONS.

Risk: THE SEATS MAY RECLINE WITHOUT PRIOR WARNING, RESULTINGIN A HAZARD TO SEAT OCCUPANTS AND POSSIBLE LOSS OF VEHICLE CONTROL.

Remedy: REPLACE THE MANUAL SEAT RECLINER MECHANISM WITH A MECHANISM THAT COMPLIES WITH FMVSS 207.

FUEL SYSTEM, GASOLINE

THERE IS FUEL LEAKAGE AT THE FUEL TANK FILL AND/OR VENT PIPE EXTENSION SOLDER JOINTS.

Risk: FUEL LEAKS CAN LEAD TO A VEHICLE FIRE IF EXPOSED TO ASOURCE OF IGNITION.

Remedy: REPLACE THE FUEL TANK.

POWER TRAIN:AUTOMATIC TRANSMISSION

THE REVERSE SERVO APPLY PIN MAY BIND IN THE CASE WHICH COULD CAUSE REVERSE BAND DISTRESS (LOSS OR SLIPPING OF REVERSE), REVERSE BAND DRAG IN DRIVE RANGE (POOR PERFORMANCE -- POOR POWER), OR THE TRANSMISSION TO REMAIN IN REVERSE WHILE THE SHIFT INDICATOR SHOWS NEUTRAL GEAR POSITION.

Risk: IF THE TRANSMISSION REMAINS IN REVERSE WHILE THE SHIFTINDICATOR SHOWS NEUTRAL, THE VEHICLE MAY UNEXPECTEDLY MOVE REARWARD AND RESULTIN A VEHICLE ACCIDENT.

Remedy: REPLACE THE TRANSAXLE WHERE REQUIRED.

STEERING: STEERING WHEEL/HANDLE BAR

THE FOUR (4) STEERING COLUMN SUPPORT BRACKET ATTACHING BOLTS WERE UNDER TORQUED DURING ASSEMBLY.

Risk: INADEQUATE TORQUE CAN CAUSE THESE BOLTS TO VIBRATE, LOOSEN, OR FALL OUT RESULTING IN LOSS OF STEERING CONTROL AND INCREASE THE POTENTIAL FOR A VEHICLE CRASH.

Remedy: DEALERS WILL RETORQUE THE STEERING COLUMN SUPPORT BRACKET ATTACHING BOLTS TO THE CORRECT SPECIFICATIONS.

SUSPENSION:FRONT:CONTROL ARM:LOWER BALL JOINT

A RIGHT-HAND LOWER CONTROL ARM TAPERED BALL JOINT MOUNTING HOLE WAS INCORRECTLY MACHINED. MOVEMENT WITHIN THIS ATTACHMENT CAN ALLOW THE BALL JOINT STUD TO FATIGUE AND FRACTURE.

Risk: IF THE BALL JOINT FRACTURED WHILE THE VEHICLE WAS IN MOTION, LOSS OF STEERING CONTROL TO THE VEHICLE CAN OCCUR.

Remedy: DEALERS WILL REPLACE THE RIGHT-HAND LOWER CONTROL ARM AND BALL JOINT STUD ON ALL INVOLVED VEHICLES.

SEAT BELTS:FRONT:ANCHORAGE

THE CENTER REAR SEAT BELT ANCHOR PLATE EXHIBITS STRESS CRACKS.

Risk: IN THE EVENT OF A VEHICLE CRASH, THE SEAT BELT SYSTEM CAN FRACTURE AND INJURY TO THE SEAT OCCUPANT CAN OCCUR.

Remedy: DEALERS WILL REPLACE THE CENTER REAR SEAT BELT SYSTEM.

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

THE LEFT FRONT BRAKE LINE CAN CONTACT THE TRANSAXLE MOUNTING BRACKET OR ATTACHMENT BOLT.

Risk: THIS CONDITION CAN CAUSE THE BRAKE LINE TO WEAR THROUGH, RESULTING IN LOSS OF BRAKE FLUID AND EVENTUAL LOSS OF ONE-HALF OF THE VEHICLE'S BRAKE SYSTEM, INCREASING THE POTENTIAL FOR A VEHICLE ACCIDENT.

Remedy: DEALERS WILL INSPECT THE VEHICLE FOR PROPER BRAKE LINE CLEARANCE AND REPOSITION THOSE BRAKE LINES FOUND TO HAVE LESS THAN MINIMAL CLEARANCE. ADDITIONALLY, THOSE BRAKE LINES FOUND TO HAVE AN INDENTATIO…

ENGINE AND ENGINE COOLING:ENGINE

General Motors LLC (GM) is recalling certain model year 1998-1999 Chevrolet Lumina and Oldsmobile Intrigue, 1997-2004 Buick Regal and Pontiac Grand Prix, 2000-2004 Chevrolet Impala, and 1998-2004 Chevrolet Monte Carlo vehicles. The affected vehicles were previously repaired under recalls 08V-118, …

Risk: Engine oil that drips onto the hot surface of the exhaust manifold may result in a fire.

Remedy: The remedy applied under recalls 08V-118, 09V-116, and 15V-201 did not adequately remove the safety risk. Under the improved remedy, dealers will replace the engine’s front valve cover and gasket. V…

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:HOSES, LINES/PIPING, AND FITTINGS

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE RIGHT FRONT BRAKE HOSE IS INCORRECTLY ROUTED BEHIND THE BRAKE PIPE BRACKET RESTRICTING BRAKE HOSE MOVEMENT THAT COULD CAUSE THE HOSE TO EITHER BE CUT BY THE BRACKET OR SEPARATED AT THE CALIPER.

Risk: IF THE HOSE BECOMES DISCONNECTED OR DAMAGED, THERE CAN BE A LOSS OF PRESSURE IN ONE HALF OF THE BRAKE SYSTEM. THE BRAKE WARNING LAMP MAY BE ON, THE PEDAL WILL BE LOWER THAN NORMAL, AND STOPPING DISTA…

Remedy: DEALERS WILL REPLACE AND CORRECTLY ROUTE THE RIGHT FRONT BRAKE HOSE ASSEMBLY.

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE CLAMP THAT SECURES THE FLEXIBLE FUEL FILL HOSE TO THE METAL FILL TUBE MAY BE LOOSE AND COULD SEPARATE.

Risk: THIS COULD CAUSE FUEL LEAKAGE EXCEEDING THE PERMISSIBLE AMOUNT.

Remedy: DEALERS WILL INSPECT THE FUEL HOSE FILL NECK CLAMP AND, IF NECESSARY, REPOSITION AND TIGHTEN THE CLAMP.

AIR BAGS:FRONTAL

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE PASSENGER SIDE AIR BAG MODULES HAVE AN UNDERSIZED INFLATOR ORIFICE.

Risk: IN THE EVENT OF A CRASH THAT WOULD TRIGGER A PASSENGER SIDE AIR BAG DEPLOYMENT, THIS UNDERSIZED ORIFICE CAN CAUSE THE INFLATOR MODULE TO EXPLODE. IF AN AIR BAG INFLATOR MODULE EXPLODES, METAL AND/OR …

Remedy: DEALERS WILL REPLACE THE PASSENGER SIDE AIR BAG MODULES.

SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM

VEHICLE DESCRIPTION: PASSENGER VEHICLES EQUIPPED WITH REAR DRUM BRAKES. THE BOLT HEAD(S) ON THE REAR SPINDLE ROD CAN SEPARATE.

Risk: THE REAR WHEEL CAN SHIFT, CAUSING REAR STEERING OF THE VEHICLE. THE DRIVER COULD LOSE CONTROL AND A CRASH COULD OCCUR.

Remedy: DEALERS WILL REPLACE THE REAR SPINDLE BOLTS.