2004 Chevrolet Impala

On certain vehicles equipped with a 3.8L engine, degradation of the front rocker cover gasket may result in eventual oil seepage.  Under hard braking, drops of engine oil may be deposited on the exhaust manifold.  If the manifold is hot enough and the oil runs below the heat shield, it may ignite into a small flame and, in some instances, the fire may spread to the plastic spark plug wire channel and beyond.  An under-hood fire could result in injury and/or property damage.  Correction: Dealers will replace the engine’s front valve cover and front-valve-cover gasket with new parts. The engine’s plastic “beauty” cover and plastic oil-fill-tube extension will also be removed, if they haven’t been already. Note: This recall supersedes and is an expansion of recalls 2008-081, 2009-105 and 2015-145. All vehicles having been inspected and/or serviced under the previous recall will require re-inspection and repair.

On certain vehicles equipped with a 3.8L engine, degradation of the front rocker cover gasket may result in eventual oil seepage.  Under hard braking, drops of engine oil may be deposited on the exhaust manifold.  If the manifold is hot enough and the oil runs below the heat shield, it may ignite into a small flame and, in some instances, the fire may spread to the plastic spark plug wire channel and beyond.  An under-hood fire could result in injury and/or property damage.  Correction: Dealers will remove the spark plug wire retention channel at the front of the engine and install two new-revised spark plug wire retainers.  For vehicles with the 3.8L V6 Supercharged engine (RPO L67), dealers will also replace the front (left hand) rocker cover gasket. Note:  This recall is an expansion of recalls 2008-081 and 2009-105.

On certain vehicles, a defect in the ignition switch could allow the switch to move out of the "run" position if the key ring is carrying added weight or the vehicle goes off-road or is subjected to some other jarring event.  If this were to occur, engine power, power steering and power braking would be affected, increasing the risk of a crash causing injury and/or damage to property.  The timing of the key movement out of the “run” position, relative to the activation of the sensing algorithm of the crash event, may also result in the airbags not deploying in a subsequent collision, increasing the risk of injury. Correction: For each key, dealers will install two key rings and modify the key ring opening shape. Note: Until the correction is performed, all items should be removed from the key ring.

On certain vehicles, two bolts that attach the front brake caliper to the steering knuckle on the left and right front wheel assemblies were not tightened adequately.  If too much movement occurs between the caliper bracket and knuckle, the bolt(s) may back out or fracture.  Depending on whether one or both bolts back out or fracture, the result can be: 1) locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, 2) reduced braking and noise from the affected wheel, or 3) severing of a brake hose, increased brake pedal travel, and reduced steering control.  If this were to occur, it could result in a vehicle crash without prior warning.  Correction:  Dealers will tighten both bolts to the specified torque.