2004 Pontiac Grand Prix

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.

Certain vehicles do not comply with the requirements of CMVSS 124 - Accelerator Control Systems.  The Electronic Throttle Control (ETC) accelerator pedal assembly may not return the engine to idle in three seconds or less at low ambient temperatures if either of the two throttle return springs is broken.  Correction:  Dealers will replace the ETC pedal assembly.

Certain vehicles were built with right rear body mounts that contain cracks or voids.  A crack could propagate during use of the vehicle, resulting in audible creaking, groaning, or clicking noises.  If the driver ignores these warnings, both rear body mounts could eventually become detached from the frame structure.  If this occurred, the steering intermediate shaft could become detached from the rack and pinion steering assembly, resulting in a total loss of steering control.  Correction:  Dealers will inspect the front frame assembly for specific Julian date stamps and replace the engine cradle assembly, if necessary.