Product Emission - Fuel Feed Jumper Pipe Assembly-Replace

General Motors has decided to conduct a Voluntary Emission Recall involving certain 2004-05 Cadillac CTS-V model vehicles equipped with a 5.7L (RPO LS6 - VIN Code S) V8 engine. These vehicles may have been built with a fuel feel jumper pipe assembly that does not meet General Motors specifications. The flexible section in some of the assemblies does not contain the specified barrier layer intended to control evaporative emissions.

Dealers are to replace the fuel feed jumper pipe assembly.

Involved are certain 2004-05 Cadillac CTS-V model vehicles equipped with 5.7L (RPO LS6 - VIN Code S) V8 engine and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved]

For US

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld.

For Canada

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld.

The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program.

Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order.

Important: Due to the small number of vehicles involved, dealers are encouraged not to order recall parts for use as shelf stock.

Fuel Pipe Removal

1. Turn off all lamps and accessories.
2. Turn off the ignition.
3. Disconnect the negative battery cable from the battery.
4. Remove the cross car brace bolts and the cross car brace.



5. Place suitable protective tape on the back edge of the engine cover. This tape is required to prevent damage to the engine cover during the removal and installation process.
6. Lift the engine cover to unsnap and carefully remove the engine cover.
7. Loosen the fuel filter cap to relieve the fuel tank vapor pressure.
8. Connect the J 34730-1A to the fuel pressure connection at the left front of the fuel rail. Wrap a shop towel around the fitting while connecting the gauge in order to avoid spillage.
9. Install the bleed hose of the gage into an approved container.
10. Open the valve on the gage to bleed the system pressure. The fuel connections are now safe for servicing.
11. Drain any fuel remaining in the gage into an approved container.
12. Disconnect the J 34730-1A from the fuel rail and re-install the dust cap.



13. Remove the secondary retention clips at the two quick-connect fittings on the fuel pipe.



14. Open the clip holding the fuel return pipe to the fuel feed bracket near the chassis line connection.
15. Remove the two nuts holding down the fuel pipe.
16. Disconnect the quick-connect fitting at the chassis fuel pipe using the J 44581 fuel line disconnect tools. Rags will be required to catch any residual fuel that may leak when the fuel feed pipe is disconnected.



17. Roll the fuel pipe up about 45° then use the J 44581 fuel line disconnect tool to disconnect the quick-connect at the fuel rail.

Fuel Pipe Installation

1. Holding the new fuel feed pipe at approximately 45°, install the fuel feed pipe into the quick-connect on the fuel rail.
2. Once the fuel feed pipe quick-connect is completely engaged (audible click), roll the fuel feed pipe onto the 6 mm studs located at the fuel mounting bolts.



3. Install the secondary retention clip onto the fuel rail quick-connect at the fuel rail.
4. Install the fuel feed pipe into the quick-connect to the chassis fuel line at the rear of the engine.
5. Install the secondary retention clip at the chassis line quick-connect.
6. Install the fuel feed pipe retaining nuts.

Tighten
Tighten the nuts to 10 N·m (89 lb in).

7. Connect the negative battery cable to the battery.

Tighten
Tighten to 17 N·m (13 lb ft).

8. Pressurize the fuel system:

8.1.	Turn the ignition switch on for 3 seconds.

8.2.	Turn the ignition switch off for 10 seconds.

8.3.	Turn the ignition switch on. This should have pressurized the fuel system to normal operating pressure.

9. Inspect both quick-connect areas for fuel leaks. There is NO need to operate the engine to perform this leak inspection.
10. Turn the ignition switch off.



11. Confirm that the protective tape is still in place on the engine cover prior to installation. Carefully set the engine cover in place and align retaining features to the fuel injector rails.



12. Check the cover for proper fit at the throttle body.
13. Push the sight shield down ensuring that the retaining features engage with the fuel rail.
14. Remove the protective tape from the engine cover.
15. Install the cross car brace.
16. Install the cross car brace bolts.

Tighten
Tighten the bolts to 112 N·m (83 lb ft).

17. Calibrate the power windows.

17.1.

Turn the ignition switch to the RUN position.

17.2.

Press the power window switch to the down position. After the window is in the full down position, press and hold the switch in the down position for 3 seconds.

17.3.

Press the power window switch to the up position. After the window is in the full up position, press and hold the switch in the up position for 3 seconds.

17.4.

Repeat calibration for each window.

18. CALIFORNIA, MASSACHUSETTS, MAINE & VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
19. Close the hood.

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle.

When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or by calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Request Item Number S-1015 when ordering.

The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

Submit a Product Recall Claim with the information indicated below.

Note: Canadian dealers should refer to the Canadian distribution of the bulletin for detailed claim information.

Refer to the General Motors WINS Claim Processing Manual for details on Product Recall Claim Submission.

General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).

In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state of local emission inspection test if the recall work is not completed.

All unsold new vehicles in dealers' possession and subject to this recall MUST be held and inspected/repaired per the service procedure of this recall bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA OR IPC***

When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration.

Additional Certificates can be obtained, at no charge, from Dealer Support Materials by calling 1-866-700-0001 (Monday through Friday, 8:00 am to 5:00 pm EST). Ask for GM Item Number 1825 when ordering.

Dear General Motors Customer:

This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle.

General Motors has decided to conduct a Voluntary Emission Recall involving certain 2004-05 Cadillac CTS-V model vehicles equipped with a 5.7L V8 engine. These vehicles may have been built with a fuel feel jumper pipe assembly that does not meet General Motors specifications. The flexible section in some of the assemblies does not contain the specified barrier layer intended to control evaporative emissions.

Your dealer will replace the fuel feed jumper pipe assembly. This service will be performed for you at no charge .

Please contact your General Motors dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle.

If you have any questions or need assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. The Customer Assistance Center's hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

The enclosed customer reply form identifies your vehicle. Presentation of this form to your dealer will assist in making the necessary correction in the shortest possible time. If you no longer own this vehicle, please let us know by completing the form and returning it to us.

If your vehicle is within the New Vehicle Limited Warranty your dealer will provide you with shuttle service or some other form of courtesy transportation while your vehicle is at the dealership for this repair. Please refer to your Owner's Manual and your dealer for details on Courtesy Transportation.

In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle . Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished.

The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration.

At the time of emission recall completion, your California dealer will issue a "Proof Of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion.

This free online service offers vehicle and ownership related information and tools tailored to your specific vehicle. To join, visit www.mygmlink.com and enter your vehicle's 17-character vehicle identification number (VIN) shown on the enclosed customer reply form to get the most personalized information for your vehicle.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

General Motors Corporation

Enclosure

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