Pontiac SUNFIRE recalls by model year

Reported: 2002-03-06 (March 6, 2002) · Model years: 1995, 1996, 1997

ON CERTAIN PASSENGER VEHICLES. IF THE ENGINE FAILS TO START AND THE DRIVER HOLDS THE KEY IN THE "START" POSITION FOR AN EXTENDED PERIOD, HIGH CURRENT FLOWS THROUGH THE IGNITION SWITCH, AND SOMETIMES PRODUCES ENOUGH HEAT TO MELT INTERNAL SWITCH PARTS.

Consequence: IF THE SWITCH IS DAMAGED, A FIRE COULD OCCUR IN THE STEERING COLUMN, EVEN WITH THE ENGINE OFF AND THE KEY REMOVED.

Remedy: DEALERS WILL INSTALL A RELAY KIT IN THESE VEHICLES TO PREVENT HIGH CURRENT FROM FLOWING THROUGH THE IGNITION SWITCH. OWNER NOTIFICATION BEGAN MARCH 27, 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, PONTIAC AT 1-800-762-2737, BUICK AT 1-800-521-7300, OR OLDSMOBILE AT 1-800-442-6537.

Reported: 1995-02-16 (February 16, 1995) · Model years: 1995

THESE VEHICLES HAVE BEEN BUILT WITH WELDS MISSING FROM THE FRONT SUSPENSION LOWER CONTROL ARM ASSEMBLIES CAUSING EXCESSIVE LOADS ON THE EXISTING WELDS.

Consequence: THIS CONDITION CAN RESULT IN SEPARATION OF THE FRONTBUSHING SLEEVE SUBASSEMBLY FROM THE CONTROL ARM INCREASING THE POTENTIAL FOR A VEHICLE CRASH.

Remedy: DEALERS WILL INSPECT BOTH LEFT-HAND AND RIGHT-HAND FRONT SUSPENSION LOWER CONTROL ARM ASSEMBLIES AND REPLACE ALL CONTROL ARM ASSEMBLIES FOUND WITH OMITTED WELDS.

Reported: 1995-07-26 (July 26, 1995) · Model years: 1995

SOME WELDS WERE OMITTED FROM THE BODY LOCK PILLAR, OR "B" PILLAR. THIS DOES NOT COMPLY WITH FMVSS NO.208, "OCCUPANT CRASH PROTECTION."

Consequence: CONSEQUENCE OF NON-COMPLIANCE: IF A VEHICLE CRASH SHOULD OCCUR, OCCUPANT PROTECTION LEVELS COULD BE REDUCED.

Remedy: ALL VEHICLES IN THIS RECALL CAMPAIGN HAVE BEEN REPURCHASED AND REPLACED WITH A COMPARABLE VEHICLE.

Reported: 1996-01-02 (January 2, 1996) · Model years: 1995

THE INSTRUMENT PANEL CLUSTER TRIM PLATE/BEZEL CAN SAG AND COVER THE LIGHT EMITTING DIODE PORTION (LIGHTED POINTED ABOVE PANEL) OF THE TRANSAXLE SHIFT INDICATOR DISPLAY. THIS DOES NOT COMPLY WITH FMVSS NO. 101, "CONTROL LOCATION, IDENTIFICATION, AND ILLUMINATION."

Consequence: CONSEQUENCE OF NON-COMPLIANCE: THE DRIVER OF THE VEHICLE WOULD NOT BE ABLE TO SEE THE ACTUAL POSITION OF THE TRANSAXLE GEAR SELECTOR RESULTING IN A DRIVER EITHER INADVERTENTLY LEAVING A PARKED OR IDLING VEHICLE IN DRIVE, REVERSE, OR NEUTRAL RATHER THAN PARK, OR SELECTING AN INCORRECT TRANSAXLE SHIFT POSITION WHILE DRIVING THE VEHICLE.

Remedy: DEALERS ARE TO INSTALL A NEW INSTRUMENT PANEL CLUSTER TRIM PLATE/BEZEL ASSEMBLY WHICH IS NOT SUBJECT TO THIS CONDITION.

Reported: 1996-12-17 (December 17, 1996) · Model years: 1995, 1996

THE FRONT AND/OR REAR HAZARD WARNING LAMPS (FOUR-WAY FLASHERS) DO NOT FLASH WHEN THE HAZARD SWITCH IS ACTIVATED. THIS FAILS TO COMPLY WITH FMVSS NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."

Consequence: IF THESE LAMPS WERE NOT FLASHING, OTHER VEHICLES WOULD NOT BE AWARE THAT THIS VEHICLE WAS STOPPED INCREASING THE RISK OF AN ACCIDENT.

Remedy: DEALERS OR VEHICLE OWNERS WILL INSPECT FOR PROPER FUNCTION OF THE HAZARD WARNING LAMPS. IF NECESSARY, DEALERS WILL REPLACE THE HAZARD LAMP SWITCH.

Reported: 2002-11-04 (November 4, 2002) · Model years: 1996, 1997, 1998

CERTAIN PASSENGER VEHICLES AND MINI VANS HAVE LOWER PINION BEARINGS IN THE POWER RACK AND PINION ASSEMBLY IN WHICH THE RETAINER TABS WERE NOT CRIMPED PROPERLY. THESE AND SOME OTHER RETAINERS USED IN VEHICLES ASSEMBLED BETWEEN JANUARY 1, 1996 AND OCTOBER 31, 1997, COULD FAIL AND PERMIT THE BALL BEARINGS TO ESCAPE.

Consequence: 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 EXERT MORE EFFORT TO TURN THE STEERING WHEEL, SIMILAR TO A VEHICLE WITHOUT POWER ASSISTED STEERING. IF THE PINION SHAFT MOVES EVEN FURTHER, THE DRIVER WILL REQUIRE MUCH HIGHER EFFORT TO TURN LEFT AND MAY NOT BE ABLE TO TURN THE WHEEL AS MUCH AS INTENDED. WITH THE MAXIMUM PINION SHAFT MOVEMENT, WHICH REQUIRES INTERNAL GEAR COMPONENT DAMAGE, THE DRIVER CAN ENCOUNTER HIGH RESISTANCE TO TURNING LEFT, FOLLOWED BY UNINTENDED POWER ASSIST TO THE RIGHT. IN ANY OF THESE CONDITIONS, A CRASH COULD OCCUR.

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 JANUARY 24, 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, PONTIAC AT 1-800-762-2737, OR OLDSMOBILE AT 1-800-442-6537.

Reported: 1995-10-23 (October 23, 1995) · Model years: 1996

THE ACCELERATOR CONTROL CABLE COULD HAVE BEEN KINKED DURING ASSEMBLY CAUSING HIGH ACCELERATOR PEDAL EFFORT, STICKING ACCELERATOR CONTROL CABLE, OR A BROKEN ACCELERATOR CONTROL CABLE.

Consequence: IF THE ACCELERATOR CONTROL CABLE STICKS OR BREAKS, UNWANTED ACCELERATION AND/OR LOSS OF THROTTLE CONTROL CAN RESULT INCREASING THE RISK OF A VEHICLE ACCIDENT.

Remedy: DEALERS WILL REPLACE THE ACCELERATOR CONTROL CABLE ASSEMBLY.

Reported: 1998-02-17 (February 17, 1998) · Model years: 1996

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THESE VEHICLES WERE BUILT WITH THE POTENTIAL FOR THE INTERIOR LAMPS TO COME ON UNEXPECTEDLY WHILE THE VEHICLES ARE BEING DRIVEN. THIS DOES NOT MEET THE REQUIREMENTS OF FMVSS NO. 101, "CONTROLS AND DISPLAYS."

Consequence: THE INTERIOR LAMPS COMING ON UNEXPECTEDLY COULD STARTLE A DRIVER CAUSING A MOMENTARY LOSS OF CONTROL INCREASING THE RISK OF A VEHICLE ACCIDENT.

Remedy: DEALERS WILL RUN A DIAGNOSTIC TEST ON THE LAMP CONTROL MODULE AND, IF NECESSARY, REPLACE IT.

Reported: 1998-06-29 (June 29, 1998) · Model years: 1996, 1997

VEHICLE DESCRIPTION: PASSENGER VEHICLES. BECAUSE OF CERTAIN CALIBRATIONS IN THE AIR BAG'S SENSING AND DIAGNOSTIC MODULE, AN INADVERTENT AIR BAG DEPLOYMENT COULD OCCUR IN A LOW SPEED CRASH OR WHEN AN OBJECT STRIKES THE FLOOR PAN.

Consequence: AIR BAGS DEPLOY WITH GREAT FORCE AND CAN SERIOUSLY INJURE UNRESTRAINED OCCUPANTS WHO ARE TOO CLOSE TO THEM.

Remedy: DEALERS WILL RECALIBRATE THE AIR BAG SENSING AND DIAGNOSTIC MODULE.

Reported: 1998-12-15 (December 15, 1998) · Model years: 1996, 1997

VEHICLE DESCRIPTION: PASSENGER VEHICLES. ONE OF THE REAR SUSPENSION TRAILING ARM BOLTS CAN FATIGUE AND BREAK.

Consequence: IF THIS WERE TO OCCUR WHILE THE VEHICLE WAS IN MOTION, A LOSS OF VEHICLE CONTROL CAN OCCUR, INCREASING THE RISK OF A CRASH.

Remedy: DEALERS WILL REPLACE THE REAR SUSPENSION TRAILING ARM FASTENERS.

Reported: 1997-06-28 (June 28, 1997) · Model years: 1997

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE COMPACT SPARE TIRE ASSEMBLIES WERE ASSEMBLED WITH INCORRECT RIMS. IF THE SPARE TIRE IS UNDERINFLATED, THE BEAD CAN SEPARATE FROM THE RIM CAUSING A RAPID LOSS OF AIR. THIS DOES NOT COMPLY WITH THE REQUIREMENTS OF FMVSS NO. 110, "TIRE SELECTION AND RIMS."

Consequence: A RAPID LOSS OF AIR CAN INCREASE THE RISK OF A VEHICLE CRASH.

Remedy: DEALERS WILL REPLACE THE RIM ON THE COMPACT SPARE TIRE ASSEMBLY. OWNERS ARE REQUESTED NOT TO USE THE SPARE TIRE UNTIL THE RIM HAS BEEN REPLACED.

Reported: 1998-02-25 (February 25, 1998) · Model years: 1997

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THESE VEHICLES WERE BUILT WITH MIS-LOCATED WELDS AT THE JOINT BETWEEN THE LEFT ROCKER PANEL INNER REINFORCEMENT AND THE BODY SIDE RING. THIS DOES NOT MEET THE REQUIREMENTS OF FMVSS NO. 214, "SIDE DOOR STRENGTH."

Consequence: IN THE EVENT OF A VEHICLE CRASH, THE SHEET METAL STRUCTURE WOULD NOT PERFORM AS DESIRED INCREASING THE RISK OF PERSONAL INJURY.

Remedy: DEALERS WILL INSPECT THE WELDS AND, IF NECESSARY, PLACE FIVE WELDS BETWEEN THE INVOLVED PANELS AND APPLY PRIMER AND TOPCOAT FINISH MATERIALS.

Reported: 2004-01-27 (January 27, 2004) · Model years: 1998, 1999, 2000, 2001

ON CERTAIN PASSENGER VEHICLES. IF THE ENGINE FAILS TO START AND THE DRIVER HOLDS THE KEY IN THE "START" POSITION FOR AN EXTENDED PERIOD, HIGH CURRENT FLOWS THROUGH THE IGNITION SWITCH, AND SOMETIMES PRODUCES ENOUGH HEAT TO MELT INTERNAL SWITCH PARTS.

Consequence: IF THE SWITCH IS DAMAGED, A FIRE COULD OCCUR IN THE STEERING COLUMN, EVEN WITH THE ENGINE OFF AND THE KEY REMOVED. THE FIRE COULD SPREAD TO THE INTERIOR OF THE CAR, WHICH COULD INJURE OCCUPANTS OR CAUSE DAMAGE TO ADJOINING STRUCTURES.

Remedy: DEALERS WILL INSTALL A RELAY KIT IN THESE VEHICLES TO PREVENT HIGH CURRENT FROM FLOWING THROUGH THE IGNITION SWITCH, AND CHECK THAT YOUR CAR WILL START WITH A PROPERLY CHARGED BATTERY AND, IF NECESSARY, REPLACE THE IGNITION SWITCH. OWNER NOTIFICATION WILL BEGIN ON MARCH 1, 2004. 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 1-800-630-2438, PONTIAC AT 1-800-620-7668, BUICK AT 1-866-608-8080, OR OLDSMOBILE AT 1-800-630-6537. CUSTOMERS CAN ALSO CHECK THEIR VEHICLE ONLINE BY GOING TO WWW.MYGMLINK.COM AND ENTERING THE VEHICLE'S IDENTIFICATION NUMBER.

Reported: 1997-11-24 (November 24, 1997) · Model years: 1998

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THE WHEEL LUG NUTS WERE NOT TIGHTENED SECURELY RESULTING IN A FRACTURE OF THE WHEEL STUDS.

Consequence: THE WHEEL COULD SEPARATE FROM THE VEHICLE. IF THE VEHICLE WERE IN MOTION, A VEHICLE CRASH COULD RESULT.

Remedy: DEALERS WILL INSPECT THE TORQUE OF ALL WHEEL NUTS AND, IF NECESSARY, TIGHTEN ANY THAT MAY BE BELOW REQUIRED TORQUE.

Reported: 1999-08-11 (August 11, 1999) · Model years: 1999

VEHICLE DESCRIPTION: PASSENGER VEHICLES. THESE VEHICLES DO NOT COMPLY WITH REQUIREMENTS OF FMVSS NO. 101, "CONTROL LOCATION, IDENTIFICATION, AND ILLUMINATION." THE INSTRUMENT PANEL BACKLIGHTING MAY NOT FUNCTION AFTER ADJUSTING THE INTERIOR LIGHT INTENSITY.

Consequence: IF THE INSTRUMENT PANEL IS NOT LIT AT NIGHT, THE DRIVER MAY NOT BE ABLE TO SEE THE CONTROLS AND DISPLAYS.

Remedy: DEALERS WILL TEST THE BODY CONTROL MODULE, AND IF NECESSARY, REPLACE IT.

Reported: 2004-11-01 (November 1, 2004) · Model years: 2003

ON CERTAIN PASSENGER VEHICLES, THE REAR LAMPS THAT PROVIDE STOP AND TURN SIGNALS AND TAIL LAMP FUNCTIONS STOP WORKING BECAUSE OF INADEQUATE CONTACT BETWEEN THE BULB AND SOCKET. IN ADDITION, IF ONE BULBS WERE TO BECOME INOPERATIVE WHILE THE VEHICLE WAS OPERATING IN CRUISE CONTROL, THE CRUISE CONTROL WOULD DISENGAGE WHEN THE REMAINING BULB WAS ACTIVATED. IF BOTH LAMPS WERE TO BECOME INOPERATIVE, THE CRUISE CONTROL WOULD NOT ENGAGE.

Consequence: AN INOPERATIVE BRAKE LAMP WILL NOT CONVEY THE DRIVER'S INTENTION OF STOPPING TO DRIVERS IN FOLLOWING VEHICLES, AND AN INOPERATIVE REAR TURN SIGNAL LAMP WILL NOT CONVEY THE DRIVER'S INTENTION TO TURN TO DRIVERS IN FOLLOWING VEHICLES. BOTH OF THESE FAILURES CAN INCREASE THE RISK OF A CRASH.

Remedy: DEALERS WILL INSPECT THE REAR LAMP BULB SOCKET ASSEMBLIES AND APPLY GREASE OR REPLACE THEM IF NECESSARY. THE RECALL BEGAN ON JANUARY 18, 2005. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR PONTIAC AT 1-800-620-7668.

Reported: 2004-06-23 (June 23, 2004) · Model years: 2004

CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 210, 'SEAT BELT ASSEMBLY ANCHORAGES.' THE PASSENGER-SIDE REAR SAFETY BELT MAY HAVE BEEN INSTALLED WITH AN INCORRECT NUT AND BOLT.

Consequence: IN A SEVERE CRASH, THE UPPER SEAT BELT ANCHORAGE MAY SEPARATE. THE EFFECTIVENESS OF THE SEAT BELT COULD THEN BE REDUCED AND THE OCCUPANT COULD RECEIVE GREATER INJURIES.

Remedy: DEALERS ARE TO INSPECT THE SAFETY BELT ANCHORAGE AND INSTALL A NEW NUT AND BOLT, IF NECESSARY. THE RECALL BEGAN ON AUGUST 23, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 AND PONTIAC AT 1-800-620-7668.