GM Service Manual Online
For 1990-2009 cars only

General Motors of Canada Limited warrants to owners of 2004 Medium Duty Trucks and Chassis sold in Canada, that the engine (1) was designed, built and equipped so as to conform at the time of sale with the Emission Regulations under the Canadian Environmental Protection Act and (2) is free from defects in materials and workmanship which cause the vehicle to fail to conform with those regulations during the warranty period.

    • For heavy duty gasoline engines, the warranty period is 5 years or 80 000 kilometres (whichever first occurs).
    • For heavy duty diesel engines, the warranty period is 5 years, or 160 000 kilometres, or 3,000 hours of operation (whichever first occurs).

Emission-related defects in the genuine GM components listed below including related diagnostic costs, parts, and labour are covered by this warranty. The applicable warranty period shall begin on the date the vehicle is delivered to the first retail purchaser, or, if the vehicle is first placed in service as a demostrator or company vehicle prior to sale at retail, on the date the vehicle is first placed in such service.

Emission Performance

Some provinces and local jurisdictions have established periodic vehicle Inspection and Maintenance (I/M) programs to encourage proper maintenance of your vehicle. If a provincial I/M program is enforced in your area you may also be eligible for Emission Performance coverage when all of the following three conditions are met:

  1. the vehicle has been maintained and operated in accordance with the instructions for proper maintenance and use set forth in the Owner's Manual, New Vehicle Warranty, or Maintenance Schedule supplied with your vehicle;
  2. the vehicle fails a provincial I/M test during the emission warranty period indicated above; and
  3. the failure results, or will result, in the owner of the vehicle having to bear a penalty or other sanctions (including the denial of the right to use the vehicle) under local, provincial, or federal law.

Claims Procedure

Make your vehicle available to any authorized GM dealer as soon as possible after failing a provincial I/M test or at any time you suspect a defect in a part. If all the above conditions are met, GM warrants that your dealer will replace, repair, or adjust to GM specifications, at no charge to you, any of the parts listed which may be necessary to cause your vehicle to conform to the applicable emission standards.

Repairs which do not qualify will be charged to you.

In the event a warranty matter is not handled to your satisfaction, refer to "Customer Satisfaction Procedure" in this booklet under Owner Assistance .

What Is Covered

Listed below are most of the systems that affect emissions of your engine. Emission control components of these systems are covered by the emission warranty as applicable. Items that require scheduled replacement are warranted up to the replacement interval specified in your Maintenance Schedule booklet.

    • Engine Control System
        Powertrain control module, mass air flow sensor, and associated sensor and parts
    • Fuel Management System
        Fuel injection system, fuel rail assembly
    • Air Management System
        Intake manifold, air cleaner assembly, turbocharger assembly, supercharger assembly, throttle body assembly
    • Ignition System
        Ignition parts and associated controls including spark plugs and ignition wires, distributor assembly, electronic ignition control module.
    • Catalytic Converter System
        Catalytic converter, exhaust manifolds, and associated parts
    • Positive Crankcase Ventilation System
        PCV valve and associated parts, oil filler cap
    • Exhaust Gas Recirculation System
        EGR valve and associated parts
    • Secondary Air Injection System
        Air pump
    • Evaporative Emission Control System (Gasoline Engines only)
        Vapour storage canister and associated controls, fuel tank, fuel filler cap, and fuel tank filler pipe
    • Miscellaneous Items Used in Above Systems
        Emission-related actuators, belts, clamps, connectors, ducts, fittings, gaskets, grommets, hoses, housings, mounting hardware, pipes, pulleys, relays, sealing devices, sensor, springs, switches, tubes, valves, and wiring.

If failure of one of the above components results in failure of another part, both will be covered by this warranty. For detailed information concerning specific components covered by the Emission Control Systems Warranty, ask your General Motors Medium Truck dealer.

What Is Not Covered

These Warranty Obligations Do Not Apply To:

    • Conditions resulting from tampering, abuse, neglect or improper maintenance; or
    • Any other item listed under "What Is Not Covered" in the GM Medium Duty Truck Limited Warranty.
    • Parts specified in your maintenance schedule as requiring scheduled replacement are covered up to their first replacement interval or the applicable emission warranty coverage period, whichever comes first. There is no coverage under this warranty for the failure of parts which are not replaced as required. If failure of one of these parts results in failure of another part, both will be covered under the Emission Control System Warranty.
        For detailed information concerning specific parts covered by these emission control systems warranties, ask your dealer.

THE "OTHER TERMS" PRESENTED IN THE GM MEDIUM DUTY TRUCK LIMITED WARRANTY ALSO APPLY TO THIS WARRANTY.

General Motors Warranty Coverage

GM warrants to the owner that the vehicle was designed, built, and equipped so as to conform at the time of sale with applicable regulations of the Federal Environmental Protection Agency (EPA), or to the California Air Resources Board stringent anti-smog standards, and is free from defects in materials and workmanship which cause the vehicle to fail to conform with those regulations during the warranty period.

    • For heavy duty gasoline engines, the warranty period is 5 years or 50,000 miles, whichever comes first.
    • For heavy duty diesel engines, the warranty period is 5 years, or 100,000 miles for Federal, and 5 years, or 100,000 miles, or 3,000 hours of operation for California, whichever comes first.

Emission-related defects in the genuine GM components listed below, including related diagnostic costs, parts, and labor, are covered by this warranty.

The applicable warranty period shall begin on the date the vehicle is delivered to the first retail purchaser, or, if the vehicle is first placed in service as a demonstrator or company vehicle prior to sale at retail, on the date the vehicle is first placed in such service.

If your vehicle fails a California emissions inspection during the applicable warranty period, and if the emissions failure is caused by the failure or malfunction of an emissions-warranted part, GM Medium Duty Truck will correct the part failure or malfunction.

Owner's Warranty Responsibilities

As the vehicle owner, you are responsible for the performance of the scheduled maintenance listed in your owner manual. GM recommends that you retain all maintenance receipts for your vehicle, but GM cannot deny warranty coverage solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

You are responsible for presenting your vehicle to a GM dealer selling your vehicle line as soon as a problem exists. The warranted repairs should be completed in a reasonable amount of time, not to exceed 30 days.

As the vehicle owner, you should also be aware that GM may deny warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper or insufficient maintenance, or modifications not approved by GM.

If you have any questions regarding your rights and responsibilities under these warranties, refer to the toll-free telephone number under "Customer Assistance Offices" under Owner Assistance .

How to Determine the Applicable Emission Control System Warranty

State and Federal agencies may require different emission control system warranties for medium duty trucks depending on:

    • Whether the truck is certified with a medium duty or heavy duty emission control system
    • Whether the truck is certified for California emissions in addition to Federal emissions

To determine emissions eligibility: locate the emission control label attached to the engine air cleaner housing or on the engine. The language on the bottom left side of the label will describe the medium duty emissions control system.

All medium duty trucks are eligible for Federal Emissions Control System Warranty Coverage. If the emissions control label contains language stating the vehicle is certified to California emissions standards, the vehicle is also eligible for California Emissions Control System Warranty Coverage.

What Is Covered

Listed below are most of the systems that affect emissions of your vehicle. Emission control components of these systems are covered by the emissions warranties as applicable. Maintenance items that require scheduled replacement are warranted up to the replacement interval specified in your owner manual.

    • Engine Control System
        Powertrain control module, mass air flow sensor and associated sensors and parts
    • Fuel Management System
        Fuel injection system, fuel rail assembly
    • Air Management System
        Intake manifold, air cleaner assembly, turbocharger assembly, supercharger assembly, throttle body assembly
    • Ignition System
        Ignition parts and associated controls including spark plugs and ignition wires, distributor assembly, electronic ignition control module
    • Catalytic Converter System
        Catalytic converter, exhaust manifolds, and associated parts
    • Positive Crankcase Ventilation System
        PCV valve and associated parts, oil filler cap
    • Exhaust Gas Recirculation System
        EGR valve and associated parts
    • Secondary Air Injection System
        Air pump
    • Evaporative Emissions Control System (Gasoline Engines Only)
        Vapor storage canister and associated controls, fuel tank, fuel filler cap, and fuel tank filler pipe
    • Miscellaneous Items Used in Conjunction with the Repair of the Above Components are Covered
        Emission-related actuators, belts, clamps, connectors, ducts, fittings, gaskets, grommets, hoses, housings, mounting hardware, pipes, pulleys, relays, sealing devices, sensors, springs, switches, tubes, valves, and wiring.

If failure of one of the components listed above results in failure of another part, both will be covered by this warranty. For detailed information concerning specific components covered by these emission control systems warranties, ask your dealer.

What Is Not Covered

These warranty obligations do not apply to:

    • Conditions resulting from tampering, abuse, neglect, or improper maintenance; or
    • any other item listed under "What Is Not Covered" under General Motors Corporation New Vehicle Limited Warranty .

The "Other Terms" presented under General Motors Corporation New Vehicle Limited Warranty , also apply to these warranties.

Replacement Parts

The emission control systems of your vehicle were designed, built, and tested using genuine GM parts* and the vehicle is certified as being in conformity with applicable federal and California emission requirements. Accordingly, it is recommended that any replacement parts used for maintenance or for the repair of emission control systems be new, genuine GM parts.

The warranty obligations are not dependent upon the use of any particular brand of replacement parts. The owner may elect to use non-genuine GM parts for replacement purposes. Use of replacement parts which are not of equivalent quality may impair the effectiveness of emission control systems.

If other than new, genuine GM parts are used for maintenance replacements or for the repair of parts affecting emission control, the owner should assure himself/herself that such parts are warranted by their manufacturer to be equivalent to genuine GM parts in performance and durability.

* "Genuine GM parts," when used in connection with GM vehicles means parts manufactured by or for GM, designed for use on GM vehicles and distributed by any division or subsidiary of GM.

Maintenance and Repairs

Maintenance and repairs can be performed by any qualified service outlet; however, warranty repairs must be performed by an authorized dealer except in an emergency situation when a warranted part or a warranty station is not reasonably available to the vehicle owner.

In an emergency, where an authorized dealer is not reasonably available, repairs may be performed at any available service establishment or by the owner, using any replacement part. GM Medium Duty Truck will consider reimbursement for the expense incurred (including diagnosis), not to exceed the manufacturer's suggested retail price for all warranted parts replaced and labor charges based on GM Medium Duty Truck's recommended time allowance for the warranty repair and the geographically appropriate labor rate. A part not being available within 10 days or a repair not being completed within 30 days constitutes an emergency. Retain receipts and failed parts in order to receive compensation for warranty repairs reimbursable due to an emergency.

If, in an emergency situation, it is necessary to have repairs performed by other than a GM Medium Duty Truck dealer and you believe the repairs are covered by emission warranties, take the replaced parts and your receipt to a GM Medium Duty Truck dealer for reimbursement consideration. This applies to both the Federal Emission Defect Warranty and Federal Emission Performance Warranty.

Receipts and records covering the performance of regular maintenance or emergency repairs should be retained in the event questions arise concerning maintenance. These receipts and records should be transferred to each subsequent owner. GM will not deny warranty coverage solely on the absence of maintenance records. However, GM may deny a warranty claim if a failure to perform scheduled maintenance resulted in the failure of a warranty part.

Claims Procedure

As with the other warranties covered in this booklet, take your vehicle to any authorized GM Medium Duty Truck dealer facility to obtain service under the emission warranties. This should be done as soon as possible after failing an EPA-approved I/M test or a California smog check test, or at any time you suspect a defect in a part.

Those repairs qualifying under the warranty will be performed by any GM Medium Duty Truck dealer at no charge. Repairs which do not qualify will be charged to you. You will be notified as to whether or not the repair qualifies under the warranty within a reasonable time (not to exceed 30 days after receipt of the vehicle by the dealer, or within the time period required by local or state law).

The only exceptions would be if you request or agree to an extension, or if a delay results from events beyond the control of your dealer or GM. If you are not so notified, GM will provide any required repairs at no charge.

In the event a warranty matter is not handled to your satisfaction, refer to the "Customer Satisfaction Procedure" under Owner Assistance .

For further information or to report violations of the Emission Control System Warranty, you may contact the EPA at:

Manager, Certification and Compliance
Division (6405J)
Warranty Claims
Environmental Protection Agency
Ariel Rios Building
1200 Pennsylvania Avenue, N.W.
Washington, DC 20460

For a vehicle subject to the California Exhaust Emission Standards, you may contact the:

State of California Air Resources Board
Mobile Source Operations Division
P.O. Box 8001
El Monte, CA 91731-2990