Product Safety - Fuel Rail Pulse Damper Retainer Clip

This bulletin is being revised to add new information to the service procedure. Please discard Safety Bulletin Number 06080, dated August, 2006.

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-06 Chevrolet Silverado, Suburban, Avalanche; GMC Sierra, Yukon XL; 2006 Chevrolet Kodiak and GMC TopKick model vehicles equipped with an 8.1L V8 (RPO L18 - VIN G) engine. Some of these vehicles have a condition in which 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 and may cause a fire if an ignition source is present.

Dealers are to replace the engine fuel rail pulse damper retainer clip.

Involved are certain 2004-06 Chevrolet Silverado, Suburban, Avalanche; GMC Sierra, Yukon XL; 2006 Chevrolet Kodiak and GMC TopKick model vehicles equipped with an 8.1L V8 (RPO L18 - VIN G) engine and built within these VIN breakpoints:

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS. Not all vehicles within the above breakpoints may be involved.

For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided through the applicable system listed below. Dealers will not have a report available if they have no involved vehicles currently assigned.

-- US GM dealers - GM DealerWorld Recall Information

--- Canadian GM dealers - GMinfoNet Recall Reports

-- Export dealers - sent directly to dealers

The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any 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 recall.

Parts required to complete this recall are to be obtained from General Motors Service and Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

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.

Service Procedure - Light Duty Trucks (Silverado, Suburban, Avalanche, Sierra, Yukon XL)

1. Unsnap the intake manifold sight shield from the stud.
2. Remove the sight shield from the sight shield bracket.

Caution: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

J 34730-1A Fuel Pressure Gage




3. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI.
4. Loosen the fuel fill cap in order to relieve fuel tank vapor pressure.
5. Remove the fuel rail pressure cap.
6. Connect the J 34730-1A to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gage in order to avoid spillage.
7. Install the bleed hose on J 34730-1A into an approved container.
8. Open the valve on the J 34730-1A in order to bleed the system pressure. To assist in relieving residual pressure in the fuel rail, push down on the fuel rail dampener. The dampener should move inward approximately 2-3 mm (1/8 in) as the pressure releases from the system.
9. Once the system pressure is completely relieved, remove the J 34730-1A.
10. Remove the bleed hose on the J 34730-1A from the approved container.
11. Remove the shop towel from around the fitting and discard into an approved container.
12. Disconnect the J 34730-1A from the fuel pressure valve.
13. Drain any fuel remaining in the gage into an approved container.
14. Install the fuel rail pressure fitting cap.



15. Clean any dirt from the fuel pressure dampener (i.e. damper) retainer (clip) and the surrounding area.

Caution: If the fuel pressure is not relieved as instructed in Step 8, or the dampener is not held in position during the replacement of the dampener clip, the dampener O-ring may not seat or seal properly. A damaged or improperly seated O-ring may result in a fuel leak. A fuel leak in the presence of an ignition source may result in a fire.

Caution: Do not remove the fuel dampener from the fuel rail. If the dampener is removed, a fuel dampener kit with a new O-ring must be installed. If the dampener and O-ring is not replaced, a fuel leak may result. Clean dirt and/or debris from dampener cavity and lubricate the new Opring with clean engine oil prior to installation of the dampener.

Notice: Push down on the fuel dampener until Step 16 and 17 are completed to avoid damaging the dampener O-ring.

16. Push down on the fuel dampener and remove the fuel pressure dampener clip (1). Discard old dampener clip.



17. Push down on the fuel dampener and install the fuel pressure dampener clip (1).
18. Install the fuel fill cap.
19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in SI.
20. Use the following procedure to inspect for leaks:

20.1.

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

20.2.

Turn the ignition OFF for 10 seconds.

20.3.

Turn the ignition ON, with the engine OFF.

20.4.

Inspect tje fuel rail, fuel rail dampener, and fuel rail pressure cap and valve for leaks.

If a leak is present, a dampener kit with new O-ring must be installed. Relieve the system pressure as described in Step 4-14 above. Clean dirt and/or debris from dampener cavity and lubricate the new O-ring with clean engine oil prior to installation of the dampener. When finished, repeat Steps 20.1-20.4.




21. Install the intake manifold sight shield to the bracket.
22. Snap the intake manifold sight shield onto the stud.
23. Close the hood.

Service Procedure - Medium Duty Trucks (Chevrolet Kodiak and GMC TopKick)

1. Turn the wheels to the left.
2. Tilt the hood open.
3. Remove the clip retaining the wheel housing panel to the radiator support bracket.
4. Remove the clip retaining the wheel housing panel to the rear cowl panel.
5. Remove the wheel housing panel, from the retainer tabs.
6. Remove the wheel house panel from the vehicle.



7. Remove the Under Hood Fuse Block Cover.
8. Remove the 20A/25A ECM-B/FUEL PUMP fuse.
9. Start the engine to relieve fuel rail pressure. (Engine should start and stall.) To assist in relieving residual pressure in the fuel rail, push down on the fuel rail dampener. The dampener should move inward approximately 2-3 mm (1/8 in) as the pressure releases from the system.



10. Clean any dirt from the fuel pressure dampener (i.e. damper) retainer (clip) and the surrounding area.




Caution: If the fuel pressure is not relieved as instructed in Steps 7-9, or the dampener is not held in position during the replacement of the dampener clip, the dampener O-ring may not seat or seal properly. A damaged or improperly seated O-ring may result in a fuel leak. A fuel leak in the presence of an ignition source may result in a fire.

Caution: Do not remove the fuel dampener from the fuel rail. If the dampener is removed, a fuel dampener kit with a new O-ring must be installed. If the dampener and O-ring is not replaced, a fuel leak may result. Clean dirt and/or debris from dampener cavity and lubricate the new Opring with clean engine oil prior to installation of the dampener.

Notice: Push down on the fuel dampener until Step 11 and 12 are completed to avoid damaging the dampener O-ring.

11. Push down on the fuel dampener and remove the fuel pressure dampener retainer (1). Discard old dampener retainer.
12. Push down on the fuel dampener and install a new fuel pressure dampener retainer (1).
13. Install the 20A/25A ECM-B/FUEL PUMP fuse.

13.1.

Turn ON the ignition for 2 seconds.

13.2.

Turn OFF the ignition for 10 seconds.

13.3.

Turn ON the ignition.

13.4.

Inspect the fuel rail dampener for leaks. If a leak is present, a dampener kit with new O-ring must be installed. Relieve the system pressure as described in Step 7-9 above. Clean dirt and/or debris from dampener cavity and lubricate the new O-ring with clean engine oil prior to installation of the dampener. When finished, repeat Steps 13-13.4.

14. Install the Under Hood Fuse Block Cover.



15. Install the wheel housing panel to the retainer tabs.
16. Install the clip retaining the front of the panel to the radiator support bracket.
17. Install the clip retaining the wheel housing panel to the rear cowl panel.
18. Tilt the hood closed.

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:

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).

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that 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, you must 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.

General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004-06 Chevrolet Silverado, Suburban, Avalanche; GMC Sierra, Yukon XL; 2006 Chevrolet Kodiak and GMC TopKick model vehicles equipped with an 8.1L V8 engine. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we have taken this action for your safety and continued satisfaction with our products.

Some of these vehicles have a condition in which 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 and may cause a fire if an ignition source is present.

Your GM dealer will replace the engine fuel rail pulse damper retainer clip. This service will be performed for you at no charge . It is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 35 minutes because of service scheduling requirements.

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.

You should contact your GM dealer to arrange a service appointment as soon as possible. Bring the enclosed customer reply form with you when you visit your dealer. The form identifies the repairs required. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

If you have questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer Assistance Center at the number listed below. More information about this recall can be found at the Owner Center at MyGMLink, http://www.gm.com/recall.

If, after contacting your dealer and the Customer Assistance Center, you are still not satisfied 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 St., SW, Washington DC 20590, or call the toll-free Vehicle Safety Hotline at 1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

Scott Lawson

General Director,

Customer and Relationship Services

Enclosure

06080