GM Service Manual Online
For 1990-2009 cars only

Warranty Repairs - Component Exchanges

In the interest of customer satisfaction, GM may offer exchange service on some chassis components. This service is intended to reduce the amount of time your chassis is not available for use due to repairs. Components used in exchange are service replacement parts which may be new, remanufactured, reconditioned, or repaired, depending on the component involved.

All exchange components used meet GM standards and are warranted the same as new components. Examples of the types of components that might be serviced in this fashion include: audio equipment, engine and transmission assemblies, instrument cluster assemblies, radios, compact disc players, batteries, and powertrain control modules.

Warranty Repairs - Recycled Materials

Environmental Protection Agency (EPA) guidelines and GM support the capture, purification, and reuse of automotive air conditioning refrigerant gases and engine coolant. As a result, any repairs GM may make to your chassis may involve the installation of purified reclaimed refrigerant and coolant.

Tire Service

Any Chevrolet or tire dealer for your brand of tires can assist you with tire service. If, after contacting one of these dealers, you need further assistance or you have questions, contact Chevrolet Customer Assistance Center. The toll-free telephone numbers are listed under Owner Assistance .

Delayed Warranty Start

Chassis that were originally sold to a body company for later sale to a retail owner may be eligible for a delayed warranty start. Warranty on chassis which have been approved for a delayed warranty start will commence at the date and mileage the chassis was sold to the first retail owner. The extension is from the original date of delivery to the body company up to:

    • Chassis originally sold as commercial use: maximum extension of 12 months or 4,000 miles, whichever comes first.
    • Chassis originally sold as recreational use: maximum extension of 24 months or 6,000 miles, whichever comes first.

Contact your selling commercial or recreational vehicle dealer to process a Delayed Warranty Start Application.

Important: Chassis put in demonstrator use are not eligible for a Delayed Warranty. The delayed warranty start is not valid unless approved by Chevrolet.

6.6L DURAMAX® Diesel Engine Components

For trucks equipped with a 6.6L Duramax® Diesel Engine, the complete engine assembly, including turbocharger components, is covered for defects in material or workmanship for 3 years or 36,000 miles, whichever comes first. No deductible applies during this coverage period. The engine parts listed next continue to be covered for 5 years or 100,000 miles, whichever comes first.

    • Cylinder block and heads and all internal parts, intake and exhaust manifolds, timing gears, timing gear chain or belt and cover, flywheel, harmonic balancer, valve covers, oil pan, oil pump, water pump, fuel pump, engine mounts, seals, and gaskets
    • Diesel Fuel Metering System: injection pump, nozzles, high pressure lines, and high pressure sealing devices
    • Glow Plug Control System: control/glow plug assembly, glow plugs, cold advance relay, and Engine Control Module (ECM)
    • Fuel injection control module, integral oil cooler, transmission adapter plate, left and right common fuel rails, fuel filter assembly, fuel temperature sensor, and function block

Important: Some of these components may also be covered by the Emission Warranty. See the "Emission Warranty Parts List" under Emission Control Systems Warranty for details.

Aftermarket Engine Performance Enhancement Products and Modifications

Some aftermarket engine performance products and modifications promise a way to increase the horsepower and torque levels of your vehicle’s powertrain. You should be aware that these products may have detrimental effects on the performance and life of the engine, exhaust emission system, transmission, and drivetrain. The Duramax® Diesel Engine, Allison Automatic Transmission®, and drivetrain have been designed and built to offer industry leading durability and performance in the most demanding applications. Engine power enhancement products may enable the engine to operate at horsepower and torque levels that could damage, create failure, or reduce the life of the engine, engine emission system, transmission, and drivetrain. Damage, failure, or reduced life of the engine, transmission, emission system, drivetrain or other vehicle components caused by aftermarket engine performance enhancement products or modifications may not be covered under your vehicle warranty.

After-Manufacture "Rustproofing"

Your chassis was designed and built to resist corrosion. Application of additional rust-inhibiting materials is neither necessary nor required under the Front Cab Sheet Metal Coverage. GM makes no recommendations concerning the usefulness or value of such products.

Application of after-manufacture rustproofing products may create an environment which reduces the corrosion resistance built into your chassis. Repairs to correct damage caused by such applications are not covered under your New Cutaway Chassis Limited Warranty.

Paint, Trim, and Appearance Items

Defects in paint, trim, upholstery, or other appearance items are normally corrected during new chassis preparation. If you find any paint or appearance concerns, advise your dealer as soon as possible. Your owner manual has instructions regarding the care of these items.

Chassis Operation and Care

Considering your chassis investment, we know you will want to operate and maintain it properly. We urge you to follow the maintenance instructions contained in your owner manual.

If you have any questions on how to keep your chassis in good working condition, see your Chevrolet dealer, the place many customers choose to have their maintenance work done. You can rely on your Chevrolet dealer to use the proper parts and repair practices.

Maintenance and Warranty Service Records

Retain receipts covering performance of regular maintenance. Receipts can be very important if a question arises as to whether a malfunction is caused by lack of maintenance or a defect in material or workmanship.

A "Maintenance Record" is provided in the maintenance schedule section of the owner manual for recording services performed.

The servicing dealer can provide a copy of any warranty repairs for your records.

Chemical Paint Spotting

Some weather and atmospheric conditions can create a chemical fallout. Airborne pollutants can fall upon and adhere to painted surfaces on your vehicle. This damage can take two forms; blotchy, ring-shaped discolorations, and/or small irregular dark spots etched into the paint surface.

Although no defect in the factory applied paint causes this, Chevrolet will repair, at no charge to the owner, the painted surfaces for the front cab sheet metal only, as included in the "Basic Cutaway Chassis Coverage" under General Motors Corporation Chevrolet New Cutaway Chassis Limited Warranty , of new vehicles damaged by this fallout condition within 12 months or 12,000 miles of purchase, whichever comes first.

Warranty Coverage - Extensions

Time Extensions: The New Cutaway Chassis Limited Warranty will be extended one day for each day beyond the first 24 hour period in which your chassis is at an authorized dealer facility for warranty service. You may be asked to show the repair orders to verify the period of time the warranty is to be extended. Your extension rights may vary depending on state law.

Mileage Extensions: Prior to delivery, some mileage is put on your chassis during testing at the assembly plant, during shipping, and while at the dealer facility. The dealer records this mileage on the first page of this warranty booklet at delivery. For eligible chassis, this mileage will be added to the mileage limits of the warranty ensuring that you receive full benefit of the coverage. Mileage extension eligibility:

    • Applies only to new chassis held exclusively in inventory.
    • Does not apply to used chassis, GM owned chassis, dealer owned used chassis, or dealer demonstrator chassis.
    • Does not apply to chassis with more than 1,000 miles on the odometer even though it may not have been registered for license plates.

Touring Owner Service - Foreign Countries

If you are touring in a foreign country and repairs are needed, take your chassis to a GM dealer facility, preferably one which sells and services Chevrolet vehicles. Once you return to the United States, provide your dealer with a statement of circumstances, the original repair order, proof of ownership, and any paid receipt indicating the work performed and parts replaced for reimbursement consideration.

Important: Repairs made necessary by the use of improper or dirty fuels and lubricants are not covered under the warranty. See your owner manual for additional information on fuel requirements when operating in foreign countries.

Warranty Service - Foreign Countries

This warranty applies to GM vehicles registered in the United States and normally operated in the United States or Canada. If you have permanently relocated and established household residency in another country, GM may authorize the performance of repairs under the warranty authorized for vehicles generally sold by GM in that country. Contact an authorized GM dealer in your country for assistance.

Important: GM warranty coverages may be void on GM vehicles that have been imported/exported for resale.

Original Equipment Alterations

This warranty does not cover any damage or failure resulting from modification or alteration to the vehicle's original equipment as manufactured or assembled by General Motors. Examples of the types of alterations that would not be covered include cutting, welding, or disconnecting of the vehicle's original equipment parts and components.

Additionally, General Motors does not warranty non-GM parts and/or calibrations. The use of parts and/or control module calibrations not issued through General Motors will void the warranty coverage for those components that are damaged or otherwise affected by the installation of the non-GM part and/or control module calibration.

The only exception is that non-GM parts labeled "Certified to EPA Standards" are covered by the Federal Emissions Performance Warranty.

Recreation Vehicle and Special Body or Equipment Alterations

Installations, or alterations to the original equipment cutaway chassis, as manufactured and assembled by GM, are not covered by this warranty. The special body company (assembler) or equipment installer is solely responsible for warranties on the body or equipment and any alterations to any of the parts, components, systems, or assemblies installed by GM. Examples include, but are not limited to, special body installation (such as recreational vehicles), the installation of any non-GM part, cutting, welding, or the disconnecting of original equipment chassis parts and components, extension of wheelbase, suspension and driveline modifications, and axle additions.

Pre-Delivery Service

Defects in the mechanical, electrical, and/or other components of your chassis may occur at the factory or while it is being transported to the dealer facility. Normally, any defects occurring during assembly are identified and corrected at the factory during the inspection process. In addition, dealers inspect each chassis before delivery. They repair any uncorrected factory defects and any transit damage detected before the chassis is delivered to the body builder or customer.

Any defects still present at the time the chassis is delivered to you are covered by the warranty. If you find any defects, advise your dealer without delay. For further details concerning any repairs which the dealer may have made prior to you taking delivery of your chassis, ask your dealer.

Production Changes

GM and GM dealers reserve the right to make changes in cutaway chassis built and/or sold by them at any time without incurring any obligation to make the same or similar changes on cutaway chassis previously built and/or sold by them.

Normal Noise

Some of the components within your Chevrolet Cutaway Chassis will emit sound that may vary depending on final vehicle construction, layout, insulation, etc. Typical sounds may include, but are not limited to, air induction, exhaust system, brake noise, and axle and other driveline components. Sounds that do not affect the durability of your cutaway chassis are not covered under this warranty.

Noise Emissions Warranty Light Duty Trucks Over 10,000 LBS Gross Vehicle Weight Rating (GVWR) Only

GM warrants to the first person who purchases this chassis for purposes other than resale, and to each subsequent purchaser of this chassis that, as manufactured by GM, that this vehicle was designed, built, and equipped to conform at the time it left GM's control with all applicable United States EPA Noise Control Regulations.

This warranty covers this chassis as designed, built, and equipped by GM, and is not limited to any particular part, component, or system of the chassis manufactured by GM. Defects in design, assembly, or in any part, component, or chassis system as manufactured by GM, which, at the time it left GM's control, caused noise emissions to exceed Federal Standards, are covered by this warranty for the life of the chassis.

Warranty Repairs -- Component Exchanges

In the interest of customer satisfaction, General Motors of Canada Limited may offer exchange service on some chassis components. This service is intended to reduce the amount of time your chassis is not available for use due to repairs. Components used in exchange are Service Replacement Parts which may be new, remanufactured, reconditioned or repaired, depending on the component involved.

All exchange components used meet GM standards and are warranted the same as new components. Examples of the types of components that might be serviced in this fashion include: engine and transmission assemblies, instrument cluster assemblies, radios, compact disc players, tape players, batteries and powertrain control modules.

Warranty Repairs -- Recycled Materials

Both Environment Canada guidelines and GM support the capture, purification, and reuse of automotive air conditioning refrigerant gases and engine coolant. As a result, any repairs GM may make to your vehicle may involve the installation of purified reclaimed refrigerant and coolant.

Maintenance and Warranty Service Records

Retain receipts covering performance of regular maintenance. Receipts can be very important if a question arises as to whether a malfunction is caused by lack of maintenance or a defect in material or workmanship.

A "Maintenance Record" is provided in the maintenance schedule section of the Owner's Manual for your convenience in recording services performed.

For your records, the servicing dealer should provide a copy of the warranty repair order listing all warranty repairs performed.

Delayed Warranty Start

Chassis that were originally sold to a body company for later sale to a retail owner may be eligible for a delayed warranty start. Warranty on chassis which have been approved for a delayed warranty start will commence at the date and mileage the chassis was sold to the first retail owner. The extension is from the original date of delivery to the body company up to:

    • Chassis originally sold as commercial use: maximum extension of 12 months or 6 500 kilometres, whichever comes first.
    • Chassis originally sold as recreational use: maximum extension of 24 months or 10 000 kilometres, whichever comes first.

Contact your selling commercial or recreational vehicle dealer to process a Delayed Warranty Start Application.

Important: Chassis put in demonstrator use are not eligible for a delayed warranty. The delayed warranty start is not valid unless approved by General Motors.

6.6L DURAMAX® Diesel Engine Components

For trucks equipped with a 6.6L Duramax® Diesel Engine, the complete engine assembly, including turbocharger components, is covered for defects in material or workmanship for 3 years or 60 000 kilometres, whichever comes first. No deductible applies during this coverage period. The engine parts listed next continue to be covered, for 5 years or 160 000 kilometres, whichever comes first.

    • Cylinder block and heads and all internal lubricant parts, intake and exhaust manifolds, timing gears, timing gear chain or belt and cover, flywheel, harmonic balancer, valve covers, oil pan, oil pump, water pump, fuel pump, engine mounts, seals, and gaskets
    • Diesel Fuel Metering System: injection pump, nozzles, high pressure lines, and high pressure sealing devices
    • Glow Plug Control System: control/glow plug assembly, glow plugs, cold advance relay, and Engine Control Module (ECM)
    • Fuel injection control module, integral oil cooler, transmission adapter plate, left and right common fuel rails, fuel filter assembly, fuel temperature sensor, and function block

Important: Some of these components may also be covered by the Emission Warranty. See the "Emission Warranty Parts List" under Emission Control Systems Warranty

Normal Noise

Some of the components within your General Motors Chassis will emit sound that may vary depending on final chassis construction, layout, insulation, etc.

Typical sounds may include, but are not limited to, air induction, exhaust system, brake noise, and axle and other driveline components. Sounds that do not affect the durability of your chassis are not covered under this warranty.

After-Manufacture "Rustproofing"

Your chassis was designed and built to resist corrosion. Application of additional rust-inhibiting materials is neither necessary nor required under the Front Cab Sheet Metal Coverage. General Motors of Canada Limited makes no recommendations concerning the usefulness or value of such products. Application of after-manufacture rustproofing products may create an environment which reduces the corrosion resistance built into your chassis. Some products may cause other problems with the operation of vehicle components or affect the cosmetic appearance of the vehicle. Repairs to correct damage caused by such applications are not covered under your GM New Cutaway Chassis Limited Warranty.

Paint, Trim and Appearance Items

Defects in paint, trim, upholstery or other appearance items are normally corrected during new chassis inspection or during pre-delivery inspection. If you find any paint or appearance concerns, advise your dealership as soon as possible. Deterioration due to use and exposure is not covered by the New Cutaway Chassis Limited Warranty. The instructions in the Owner's Manual regarding the care of paint, trim, upholstery, glass and other appearance items should be followed closely.

Chemical Paint Spotting

Some weather and atmospheric conditions can create chemical fallout. These airborne pollutants can fall upon and attack painted surfaces on your vehicle. This damage can take two forms: blotchy, ringlet-shaped discolorations and small irregular dark spots etched into the paint surface.

Although no defect in the factory applied paint causes this, General Motors of Canada Limited will repair, at no charge to the owner, the painted surfaces for the front cab sheet metal only as included in the "Base Cutaway Chassis Coverage" under General Motors of Canada Limited Cutaway Chassis Limited Warranty and Owner Assistance Information of new vehicles damaged by this fallout condition within 12 months or 20 000 kilometres of purchase, whichever comes first.

Warranty Distance Extensions

Prior to delivery, some kilometres are put on your chassis during testing at the assembly plant, during shipping and while at the dealership. The dealership records this odometer reading on the front page of this booklet at delivery. For eligible chassis, this odometer reading is added to the distance limits specified in the New Cutaway Limited Warranty and the Emission Control Systems Warranty ensuring that you receive full benefit of their coverage.

Warranty distance extensions eligibility:

    • Applies only to new chassis held exclusively in inventory.
    • Does not apply to used chassis, GM owned chassis, dealer owned used chassis, or dealer demonstrator chassis.
    • Does not apply to chassis with more than 1 600 kilometres on the odometer even though it may never have been "registered" for license plates.

Warranty Service -- Canada

While any General Motors dealer handling your vehicle line will perform warranty service, we recommend that you return to the dealership that sold you your vehicle because of their continued and personal interest in you. For your records, the servicing dealer will provide a copy of the warranty repair order, listing all warranty repairs performed. In the event of an emergency repair, you may take your vehicle to any authorized GM dealer for warranty repairs. However, certain warranty repairs require special tools or training that only a dealer selling your brand may have. Therefore, not all dealers are able to perform every repair. If a particular dealer cannot assist you, contact the Customer Communication Centre (CCC). Refer to Owner Assistance for CCC information.

Touring Owner Service -- Canada and United States

If you are touring or have changed your residence, visit any General Motors dealer handling your vehicle line in Canada or the United States for warranty service.

Warrantable repairs will be completed at no charge to you. You may be required to provide proof of residency such as driver's license, or vehicle ownership. For your records, the servicing dealer will provide a copy of the warranty repair order, listing all warranty repairs performed.

Some vehicle lines, which are sold only in Canada, may not be serviced by all General Motors' dealers in the United States. If warranty service is necessary while you are in the United States please contact the Canadian Customer Communication Centre (CCC) for guidance. Refer to Owner Assistance for CCC information. CCC personnel will direct you to a dealership and assist the repairing dealer in obtaining the necessary parts and technical information.

You may be charged for these repairs. For reimbursement consideration by General Motors of Canada Limited upon your return home, provide your dealer with a statement of circumstances, the original repair order, proof of ownership and any "paid" receipts indicating the work performed and parts replaced.

Touring Owner Service -- Countries Other than Canada or the United States

If you are touring in a foreign country and repairs are needed, it is suggested you make your vehicle available to a General Motors dealership, preferably one that handles your vehicle line.

For reimbursement consideration, you should provide your dealer upon your return home with a statement of circumstances, the original repair order, proof of ownership and any "paid" receipt indicating the work performed and parts replaced. Please note that repairs made necessary by the use of improper or dirty fuels and lubricants are not covered under the warranty. See Owner's Manual for additional information on fuel requirements when operating in foreign countries.

Warranty Service -- Canadian Sold Vehicles Registered and Operated Outside Canada

This warranty applies to GM vehicles registered in Canada and normally operated in Canada. If you have permanently relocated and established household residency in another country, GM may authorize the performance of repairs under the warranty authorized for vehicles generally sold by GM in that country. Contact an authorized GM dealer in your country for assistance. GM warranty coverages may be void or subject to restrictions on GM vehicles that have been imported or exported.

Original Equipment Alterations

This warranty does not cover any damage or failure resulting from modification or alteration to the chassis' original equipment as manufactured or assembled by General Motors.

Examples of the types of alterations that would not be covered include, but are not limited to, any non-GM theft alarm, remote starting device or remote locking system, or the cutting, welding or disconnecting of the cutaway chassis' original equipment parts and components. Also, the warranty does not cover a rebuilt chassis after it has suffered such extensive collision damage in an accident that it was written-off or deemed to be written-off, even if the rebuilt chassis uses undamaged parts and components from the written-off chassis.

Additionally, General Motors does not warranty non-GM parts and/or calibrations. The use of parts and/or control module calibrations not issued through General Motors will void the warranty coverage for those components that are damaged or otherwise affected by the installation of the non-GM part and/or control module calibration.

The only exception is that non-GM parts labeled "Certified to EPA Standards" are covered by the Federal Emissions Performance Warranty.

Recreation Vehicle and Special Body or Equipment Alterations

Installations or alterations to the original equipment cutaway chassis as manufactured and assembled by General Motors are not covered by this warranty. The body company (assembler) or equipment installer is solely responsible for warranties on the body or equipment, and any alterations to any of the parts, components, systems, or assemblies installed by GM. Examples include, but are not limited to, special body installation (such as recreational vehicles), the installation of a non-GM part, cutting, welding, or the disconnecting of original equipment chassis parts and components, extension of wheelbase, suspension and driveline modifications, and axle additions.

Pre-Delivery Service

Defects in or damage to the mechanical, electrical, sheet metal, paint, trim and other components of your chassis may occur at the factory or while it is being transported to the body company or the dealership. Normally, any defect or damage occurring during assembly is detected and corrected at the factory during the inspection process. In addition, body companies or dealerships are obligated to inspect each chassis before delivery. They repair any uncorrected factory defects and any transit damage detected before the chassis is delivered to the body company or customer.

Any defects still present at the time the chassis is delivered to you are covered by the New Cutaway Chassis Limited Warranty. If you find any such defects when you take delivery, please advise your dealer without delay.

For further details concerning any repairs which the dealership may have made prior to your taking delivery of your chassis, please ask your dealership or body company representative.

Production Changes

General Motors of Canada and its dealers reserve the right to make changes in chassis built and/or sold by them at any time without incurring any obligation to make the same or similar changes on chassis previously built and/or sold by them.