Product Safety - Fuel Rail Crossover Tube Retainer Screws-Replace

VEHICLES INVOLVED IN THE STOP DELIVERY ISSUED JULY 28, 2004 VIA GM ADMINISTRATIVE MESSAGE WIL20040004 THAT ARE NOT LISTED ON THE RECALL VIN LIST INCLUDED WITH THIS BULLETIN, CAN BE RELEASED FOR DELIVERY IMMEDIATELY. ALL REMAINING VEHICLES ON THE RECALL VIN LIST CAN ONLY BE RELEASED FOR DELIVERY AFTER THE SERVICE PROCEDURE CONTAINED IN THIS BULLETIN IS COMPLETED. PRODUCT RECALL CLAIMS CAN BE SUBMITTED BEGINNING AUGUST 6, 2004.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2005 Chevrolet Silverado, Tahoe and Suburban; GMC Sierra, Yukon and Yukon XL model vehicles equipped with a 5.3L (RPO L59) E85 V8 engine. Some of these vehicles have a condition in which the engine fuel rail crossover tube retainer screws were not manufactured to specifications and may break. If a tube retainer screw breaks, fuel could leak from the fuel rail crossover joint, the engine may stall, an if an ignition source were present, an engine compartment fire could occur.

Dealers are to inspect the fuel crossover tube assembly and, if necessary, replace the two tube retainer screws.

Involved are certain 2005 Chevrolet Silverado, Tahoe and Suburban; GMC Sierra, Yukon and Yukon XL model vehicles equipped with a 5.3L (RPO L59) E85 V8 engine and built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through the Recall 04066 VIN list that is attached to the GM Administrative Message . Vehicle eligibility through GMVIS (GM Vehicle Inquiry System) will be available after August 6, 2004. [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 receive a report with the recall bulletin.

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" before ordering parts. Parts should be ordered on a CSO=Customer Special Order.

Important: Due to limited availability of Retainer Kits, dealers should order parts only after review of the Recall 04066 VIN List that is attached to the GM Administrative Message to determine the number of involved vehicles assigned to the dealership. Please only sufficient quantities to repair vehicles on your list.

Important: The service procedure contained in this recall is different from the service procedure found in the appropriate service manual. As a result, the labor time allowance has been revised to correspond with this new service procedure. In the near future the service manual and labor time guide will be updated with this new information.

2005 L59 FUEL RAIL CROSSOVER ATTACHMENT SCREW REPLACEMENT PROCEDURE

1. Open the hood and install fender covers.
2. Remove the engine sight shield (beauty cover).
3. Inspect for blue or green pain dots on the fuel rail crossover tube assembly or on the throttle body. If there are any paint dots, go to Step 13.




Notice: Do not remove the crossover tube from the fuel rail or disturb the o-ring seal as a fuel leak may be produced.

4. Secure the fuel crossover tube retainer to the bracket on the fuel rail with locking type pliers. Use sufficient force to keep the retainer from moving without damaging any parts.
5. Remove the fuel rail crossover tube bracket retainer screws on one side and properly dispose of the removed screw.
6. Remove the two new screws from the retainer kit (P/N 89017590) and discard the remaining retainer brackets from the kit.
7. Install the new screw by hand for at least 3 full turns into the fuel rail crossover tube retainer bracket.

Tighten
Tighten the screw to 4.8 N·m (42 lb in).

8. Remove the locking pliers.
9. Verify that the retainer is properly seated and not loose trying to slightly wiggle the retainer. The retainer should not move.

Tighten
Retighten the screw to 4.8 N·m (42 lb in).

10. Repeat Steps 5 through 9 on the other side of the crossover tube.
11. Inspect for leaks by doing the following:

•	Turn the ignition ON, with the engine OFF, for 2 seconds.

•	Turn the ignition OFF for 10 seconds.

•	Turn the ignition ON, with the engine OFF.

•	Visually inspect for fuel leaks.

12. Reinstall the engine sight shield.

Tighten
Tighten the bolts to 9 N·m (80 lb in).

13. Remove the fender covers.

Dealers in possession of vehicles included in the Stop Delivery are eligible for reimbursement of floor plan expense upon completion of this recall. This reimbursement is limited to the number of days from the Stop Delivery message to receipt of the recall parts and/or repair procedures. Floor plan reimbursement beyond these dates is not allowed. The amount of reimbursement should be charged as a net amount expense using the recall labor operation provided.

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.

Hold all Product Recall Claims until August 6, 2004 and then submit with the information indicated below:

Refer to the General Motors WINS Claims 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).

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

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. A copy of the customer letter is provided in this bulletin for your use in contacting customers. 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.

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2005 Chevrolet Silverado, Tahoe and Suburban; GMC Sierra, Yukon and Yukon XL model vehicles equipped with a 5.3L (RPO L59) E85 V8 engine. Some of these vehicles have a condition in which the engine fuel rail crossover tube retainer screws were not manufactured to specifications and may break. If a tube retainer screw breaks, fuel could leak from the fuel rail crossover joint, the engine may stall, an if an ignition source were present, an engine compartment fire could occur.

Your Dealer will inspect the fuel rail crossover tube retainer assembly and, if necessary, replace the retainer screws. This service correction will be performed for you at no charge .

This inspection and service correction will take approximately 30 minutes. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

To limit any possible inconvenience, we recommend that you contact your GM dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date.

Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the number listed below. The Customer Assistance Center hours of operation are from 8:00 AM - 11:00 PM eastern standard time Monday through Friday.

If, after contacting the appropriate customer assistance center, you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street SW, Washington, DC 20590 or call 1-888-327-4236.

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 mailing it back to u.

If your vehicle is within the New Vehicle Limited Warranty your dealer may 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.

Information about this recall (including frequently asked questions) is available online at the Owner Center at My GMLink. 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 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 safety and continued satisfaction with our products.

General Motors Corporation

Enclosure

04066