2002 GMC Envoy

The 4.2L LL8 Atlas inline-6 engine develops severe timing chain stretch and guide failure. The primary and secondary timing chain guides crack, break apart, and send plastic debris into the oil pan. Symptoms include a loud rattling noise on startup that may persist, check engine lights with timing codes, and rough running. Complete guide disintegration can cause the chain to skip teeth, destroying the engine.

Replace all timing chains, tensioners, and guides as a complete set. This is a major repair requiring significant engine disassembly. Use updated GM guide parts with improved materials. Flush the oil pan and pickup tube screen to remove plastic debris. Maintain strict oil change intervals with quality synthetic oil to extend the life of the replacement parts.

The HVAC blend door actuators fail frequently on the GMT360 platform, producing a repetitive clicking or knocking noise from behind the dashboard. The actuator gears strip and the blend door gets stuck, causing the system to blow only hot or only cold air regardless of the temperature setting. The noise is particularly annoying as it occurs every time the ignition is turned on.

Replace the failed HVAC blend door actuator. The Envoy has multiple actuators controlling temperature, mode, and recirculation doors. The driver-side temperature actuator is the most common failure. Accessing the actuators requires partial dashboard disassembly. Use AC Delco replacement actuators for proper fit and function.

The Envoy is plagued by various electrical issues including intermittent gauge failures where the speedometer, tachometer, or fuel gauge stop working or read incorrectly. The instrument cluster stepper motors fail, causing the gauge needles to stick or read zero. Other electrical issues include power window failures, door lock malfunctions, and intermittent no-start conditions.

Replace or rebuild the instrument cluster. Cluster repair services are available that replace all stepper motors and re-solder the circuit board for $100-$200. For power window issues, replace the window regulator and motor assembly. For no-start conditions, inspect and clean the battery cables and ground connections, particularly the engine-to-chassis ground strap.

The engine cooling fan clutch fails, either locking up (causing excessive noise and drag) or freewheeling (causing overheating). A failed fan clutch that does not engage properly allows the engine to overheat in slow traffic and during towing. The 4.2L inline-6 runs hot under load, making a functioning fan clutch critical. Owners report overheating warnings during summer driving.

Replace the fan clutch assembly. A locked-up fan clutch will cause a loud roaring noise and reduced fuel economy. A freewheeling clutch will not cool adequately at idle or low speeds. Also inspect the radiator for clogging or corrosion, the thermostat for proper operation, and the coolant level and condition.

The front differential and transfer case develop fluid leaks from the output shaft seals, pinion seals, and case halves. Low fluid levels in either component can cause gear damage, bearing failure, and eventual loss of four-wheel drive function. Owners notice fluid spots under the front of the vehicle and may hear grinding or whining noises from the drivetrain when 4WD is engaged.

Replace the leaking seals and top off or replace the fluid in the front differential and transfer case. If the components have been run with low fluid, inspect the gears and bearings for damage. The transfer case encoder motor and front axle disconnect actuator should also be inspected, as they are common failure points on the GMT360 platform.

CERTAIN MAXZONE HEADLIGHT ASSEMBLIES, DEPO BRAND, P/NO 335-1120L-AS, SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR THE ABOVE LISTED PASSENGER VEHICLES. DURING PRODUCTION THE LAMP HOUSING SHAPE DEFORMED DISTORTING THE ASSEMBLY ANGLE OF THE REFLECTOR AND INFLUENCED THE AIMING POSITION. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

MAXZONE WILL NOTIFY OWNERS AND OFFER REIMBURSEMENT FOR ANY NONCOMPLIANT HEADLIGHTS. THE RECALL BEGAN ON FEBRUARY 16, 2007. OWNERS MAY CONTACT MAXZONE AT 909-822-3288.

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.

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.

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.

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.

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.

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.

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.

DEPENDING ON THE OCCURRENCE AND WEATHER SITUATION, DRIVER VISIBILITY COULD BE REDUCED, WHICH COULD RESULT IN A CRASH.

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.

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.

THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.

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.

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.

THESE VEHICLES DO NOT COMPLY WITH THE STANDARD.

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.

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.

THESE OVERRIDES ARE NOT PERMITTED UNLESS THE VEHICLE HAS A LOCKING STEERING COLUMN.

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.

CERTAIN SPORT UTILITY VEHICLES ARE MISSING WELDS ON THE REAR FLOOR PLAN.

IN A CRASH, MISSING WELDS COULD DEGRADE PERFORMANCE OF THE THIRD ROW SEAT AND SAFETY BELT ANCHORAGE AND OCCUPANTS COULD RECEIVE GREATER INJURIES.

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.

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.

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.

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.

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.

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.

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.

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.

IF THE GEAR IS NOT ENGAGED, THE VEHICLE CAN ROLL WHEN THE TRANSMISSION IS IN "PARK" AND A CRASH COULD RESULT WITHOUT WARNING.

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.

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.

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.

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.

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.

IN THE EVENT OF A CRASH, THE CONSOLE COVER COULD OPEN AND THE COVER OR ITEMS STORED UNDER IT COULD INJURE AN OCCUPANT.

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.

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.

A SEPARATION COULD RESULT IN LOSS OF VEHICLE CONTROL, RESULTING IN A CRASH.

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.