2004 Chevrolet Suburban

On certain vehicles, the interface between the electrical terminals of the Heating, Ventilation, and Air Conditioning (HVAC) blower relay resistor module and the wiring connector (which powers the module) may be incapable of conducting higher current levels for sustained periods of operation.  In addition, moisture and other contaminants (such as road de-icing materials) may enter the fresh air intake plenum and contact the internal circuit of the module or corrode the terminals.  These conditions may cause the relay resistor module or wiring connector to overheat, causing various symptoms such as: the HVAC blower may not function on certain or all blower speed settings; a burning-plastic smell or smoke may be present in the vehicle, or; the HVAC blower may run continually with the ignition in the OFF position.  These warning signs could, in certain instances, be leading indicators of an impending vehicle fire, which could result in property damage and/or personal injury.  Correction: Owners will be provided with additional warranty coverage for the blower motor resistor module/wiring connector overheating condition.  Under this "special warranty coverage", should this condition occur within 10 years or 240,000 km from first vehicle registration, dealers will install a replacement blower motor resistor and resistor module connector.

On certain vehicles, the engine fuel rail pulse damper retainer clip may fracture, resulting in inadequate retention of the damper.  If the damper comes loose, a fuel leak may result.  Fuel leakage in the presence of an ignition source could result in a fire.  Correction: Dealers will replace the engine fuel rail pulse damper retainer clip.

On certain vehicles, the 2nd row centre occupant seat belt routing may make it difficult to position the lap portion of the safety belt low around the hips of occupants.  A lap portion of the seat belt routing that is not low and snug on the hips can allow unfavourable occupant kinetics in the event of a crash.  Moreover, the higher routing allows the lap belt to ride up on an occupant's abdomen instead of fitting low around their hipbones, and therefore, can expose them to more risk of abdominal and internal organ injury.  Correction: Dealers will modify the guide loop.

On certain vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost assembly during normal vehicle operating conditions.  If a separation occurred and the hood of the vehicle was open, fragments from the accumulator could cause injury to people in the immediate area.  In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly.  The loss of fluid would cause increased steering and braking effort.  Correction:  Dealers will test and, if necessary, replace the Hydro-Boost assembly.

On certain vehicles, the relief valve o-ring seal within the brake hydro-boost module could fail.  If this happens during braking applications, the driver may be able to hear an engine compartment noise similar to the sound that occurs when the steering wheel is turned to a full stop position.  The driver could also experience a slight increase in steering efforts while braking and parking.  Under certain driving conditions, a slight increase in the applied brake pedal effort may be required to achieve the same vehicle deceleration rate as prior to the seal failure.  Correction:  Dealers will inspect the hydro-boost module, and replace it, if necessary.