GM Service Manual Online
For 1990-2009 cars only

The emission warranty on your vehicle is issued in accordance with the U.S. Federal Clean Air Act. Defects in material or workmanship in Isuzu emission parts may also be covered under the Medium Duty Truck Limited Warranty coverage. There may be additional coverage on GM diesel engine chassis. In any case, the warranty with the broadest coverage applies.

What Is Covered

The parts covered under the emission warranty are listed under the "Emission Warranty Parts List" later in this section.

How to Determine the Applicable Emission Control System Warranty

State and Federal agencies may require a different emission control system warranty for chassis depending on:

    • Whether the vehicle conforms to regulations applicable to light duty or heavy duty emission control systems
    • Whether the vehicle or engine conforms to California regulations in addition to U.S. Environmental Protection Agency (EPA) Federal regulations

To determine eligibility: Light Duty vehicles with a Gross Vehicle Weight Rating (GVWR) of 8,500 lbs. or less; Heavy Duty vehicles with a GVWR of 8,500 lbs. or greater.

All vehicles are eligible for Federal Emissions Control System Warranty Coverage. If the emissions control label contains language stating the vehicle conforms to California regulations, the vehicle is also eligible for California Emissions Control System Warranty Coverage.

Federal Emission Control System Warranty

Federal Warranty Coverage is as follows:

    • Vehicles with a 8,500 GVWR or less equipped with a Light Duty Emission Control System Gasoline Engine
       - 2 years or 24,000 miles, and 8 years or 80,000 miles for the catalytic converter or vehicle, powertrain control module, whichever comes first.
    • Vehicles with a 8,500 GVWR or greater equipped with a Heavy Duty Gasoline Engine
       - 5 years or 50,000 miles, whichever comes first.
    • Vehicles with a 14,000 GVWR or less equipped with a Heavy Duty Diesel Engine
       - 5 years or 50,000 miles, whichever comes first.
    • Vehicles with a 14,000 GVWR or greater equipped with a Heavy Duty Diesel Engine
       - 5 years or 100,000 miles, whichever comes first.

Federal Emission Defect Warranty

GM warrants to the owner the following:

    • The vehicle was designed, equipped, and built so as to conform at the time of sale with applicable regulations of the Federal Environmental Protection Agency (EPA)
    • The vehicle is free from defects in materials and workmanship which cause the chassis to fail to conform with those regulations during the emission warranty period

Emission related defects in the genuine GM parts listed under the Emission Warranty Parts List covered, including related diagnostic costs, parts, and labor are covered by this warranty.

Federal Emission Performance Warranty

Some states and/or local jurisdictions have established periodic Chassis Inspection and Maintenance (I/M) programs to encourage proper maintenance of the chassis. If an EPA approved I/M program is enforced in your area, you may also be eligible for Emission Performance Warranty coverage when all of the following three conditions are met:

    • The chassis has been maintained and operated in accordance with the instructions for proper maintenance and use set forth in the owner manual supplied with the chassis.
    • The chassis fails an EPA approved I/M test during the emission warranty period.
    • The failure results, or will result, in the owner of the chassis having to bear a penalty or other sanctions (including the denial of the right to use the chassis) under local, state, or federal law.

GM warrants that your dealer will replace, repair, or adjust to GM specifications, at no charge to you, any of the parts listed under the "Emission Warranty Parts List" later in this section which may be necessary to conform to the applicable emission standards. Non-GM parts labeled "Certified to EPA Standards" are covered by the Federal Emission Performance Warranty.

California Emission Control System Warranty

This section outlines the emission warranty that GM provides for the chassis in accordance with the California Air Resources Board. Defects in material or workmanship in GM emission parts may also be covered under the Medium Duty Limited Warranty coverage. There may be additional coverage on GM diesel engine chassis. In any case, the warranty with the broadest coverage applies.

This warranty applies if the chassis meets both of the following requirements:

    • The chassis is registered in California or other states adopting California emission and warranty regulations*.
    • The chassis conforms to California regulations as indicated on the chassis emission control label.

Important: *Massachusetts, Maine, and Vermont have California Emissions Control System Warranty coverage. (New York adopted California emission standards, but not the California emissions warranty. The Federal Emissions Control System warranty applies to all vehicles in New York.)

Your Rights and Obligations (For Chassis Subject to California Exhaust Emission Standards)

The Emission Control System Warranty on your vehicle is issued in accordance with the California Air Resources Board and GM. In California, new chassis must be designed, equipped, and built to meet the state's stringent anti-smog standards. GM must warrant the chassis emission control system for the periods of time and mileage listed below provided there has been no abuse, neglect, or improper maintenance of your chassis. The chassis emission control system may include parts such as the fuel injection system, ignition system, catalytic converter, and engine computer. Also included are hoses, belts, connectors, and other emission related assemblies.

Where a warrantable condition exists, GM will repair the chassis at no cost to you including diagnosis, parts, and labor.

California Emission Defect and Emission Performance Warranty Coverage

    • For 3 years or 50,000 miles, whichever comes first, vehicles with a GVWR of 14,000 lbs. or less:
        For 5 years or 50,000 miles, whichever comes first, gasoline vehicles with a GVWR of 14,000 lbs. or more:
        For 5 years or 100,000 miles, whichever comes first, diesel vehicles with a GVWR of 14,000 lbs. or more:
       - If your vehicle fails a smog check inspection, GM will make all necessary repairs and adjustments to ensure that your vehicle passes the inspection. This is your Emission Control System Performance Warranty.
       - If any emission related part on your vehicle is defective, GM will repair or replace it. This is your Short-term Emission Defects Warranty.
    • For 7 years or 70,000 miles, whichever comes first, vehicles with a GVWR of 14,000 lbs. or less:
       - If an emission related part listed in this booklet specially noted with coverage for 7 years or 70,000 miles is defective, GM will repair or replace it. This is your Long-term Emission Control System Defects Warranty.
    • For 8 years or 80,000 miles, whichever comes first, vehicles with a GVWR of 8,500 lbs. or less:
       - If the catalytic converter or vehicle, powertrain, control module is found to be defective, GM will repair or replace it under the Federal Emission Control System Warranty.

Any authorized GM dealer will, as necessary under these warranties, replace, repair, or adjust to GM specifications any genuine GM parts that affect emissions.

The applicable warranty period shall begin on the date the chassis is delivered to the first retail purchaser.

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 the chassis, 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 chassis to a GM dealer 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 chassis 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, you should contact Customer Assistance Center at 1-800-222-1020 or, in California, write to:

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

Emission Warranty Parts List

The emission parts listed here are covered under the Emission Control System Warranty. The terms are explained previously in this section under Federal Emission Control System Warranty and California Emission Control System Warranty.

Important: Certain parts may be covered beyond these warranties if shown with asterisk(s) as follows:

    • (*) 7 years/70,000 miles, whichever comes first, California Emission Control System Warranty coverage.
    • (**) 8 years/80,000 miles, whichever comes first, California Emission Control System Warranty coverage.

The Emission Control Systems Warranties 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 New Vehicle Limited Warranty in the warranty booklet. The "Other Terms" presented in the New Vehicle Limited Warranty also apply to the emission related warranties.

Powertrain Control System

Anti-lock Brake System (ABS) Control Module **

Camshaft Position Actuator *

Camshaft Position Actuator Valve

Coolant Level Sensor

Data Link Connector

Electronic Throttle Control (ETC) Motor

Engine Control Module (ECM) *

Engine Coolant Temperature Sensor

Fast Idle Solenoid

Flexible Fuel Sensor *

Intake Air Temperature Sensor

Intake Manifold Temperature Sensor (7.8L Isuzu Diesel)

Malfunction Indicator Lamp

Manifold Absolute Pressure Sensor

Mass Air Flow Sensor

Oil Pressure Sensor (DODâ„¢)

Oil Pressure Sensor (7.8L Isuzu Diesel)

Oxygen Sensors

Powertrain Control Module (PCM) **

Programmable Read Only Memory (PROM)

Throttle Position Sensor

Throttle Position Switch

Vehicle Control Module (VCM) **

Vehicle Speed Sensor

Wheel Speed Sensor

Transmission Controls and Torque Management

IsuzuLAN (CAN) Communications Circuit

PARK/NEUTRAL Switch

Torque Converter Clutch Solenoids

Transmission Control Module **

Transmission Fluid Temperature Sensor

Transmission Gear Selection Switch (Diesel)

Transmission Internal Mode Switch

Transmission Pressure Control Solenoids 1 & 2

Transmission Pressure Switches

Transmission Shift Solenoids 1, 2 & 3

Transmission Speed Sensors

Fuel Management System

Common Rail Assembly (6.6L DURAMAX® Diesel) *

Common Rail Assembly (7.8L Isuzu Diesel)

Diesel Fuel Injection Pump *

Diesel Fuel Injection Pump Timing Adjust

Diesel Fuel Injector Control Module - EDU (6.6L DURAMAX® Diesel) *

Diesel Fuel Temperature Sensor

Direct Fuel Injector Assembly (6.6L DURAMAX® Diesel) *

Function Block (6.6L DURAMAX® Diesel)

Fuel Injector

Fuel Pressure Regulator

Fuel Rail Assembly *

Fuel Rail Pressure Sensor (6.6L DURAMAX® Diesel)

Fuel Rail Pressure Sensor (7.8L Isuzu Diesel)

Air Management System

Air Cleaner

Air Cleaner Diaphragm Isuzu Motor

Air Cleaner Resonator

Air Cleaner Temperature Compensator Valve

Air Intake Ducts

Charge Air Control Actuator

Charge Air Control Solenoid Valve

Charge Air Control Valve

Charge Air Cooler (6.6L DURAMAX® Diesel) *

Charge Air Cooler (7.8L Isuzu Diesel) *

Charge Air Cooler Fan

Idle Air Control Valve

Idle Speed Control Motor

Intake Manifold *

Intake Manifold Gasket (7/70 only Terraza, Uplander, Montana SV6, RELAY, & DURAMAX® Diesel) *

Intake Manifold Gasket (7.8L Isuzu Diesel) *

Intake Manifold Heater

Intake Manifold Tuning Valve

Intake Manifold Tuning Valve Relay

Supercharger Assembly *

Throttle Body * (Replacement Only)

Throttle Body Heater

Throttle Closing Dashpot

Turbocharger Assembly *

Turbocharger Boost Sensor (6.6L DURAMAX® Diesel)

Turbocharger Boost Sensor (7.8L Isuzu Diesel)

Turbocharger Oil Separator

Turbocharger Thermo Purge Switch

Vacuum Pump (6.6L DURAMAX® Diesel)

Ignition System

Camshaft Position Sensor(s)

Crankshaft Position Sensor(s)

Distributor

Distributor Cap

Distributor Pick Up Coil

Distributor Rotor

Glow Plug(s) (Diesel)

Glow Plug Controller (Diesel)

Glow Plug Relay (Diesel)

Ignition Coil(s)

Ignition Control Module

Ignition Timing Adjustment

Knock Sensor

Spark Plug Wires

Spark Plugs

Catalytic Converter System

Catalytic Converter(s) and Muffler if attached as assembly **

Diesel Particulate Filter assembly (7.8L Isuzu Diesel)

Exhaust Manifold (C/K Trucks < 14,000 GVWR 8.1L)

Exhaust Manifold (7.8L Isuzu Diesel)

Exhaust Manifold with Catalytic Converter if attached as assembly *

Exhaust Manifold Gasket

Exhaust Pipes and/or Mufflers (when located between catalytic converters and exhaust manifold)

Exhaust Pipes and/or Mufflers (when located between catalytic converters and exhaust manifold - 7.8L Isuzu Diesel)

Exhaust Throttle (7.8L Isuzu Diesel)

Positive Crankcase Ventilation (PCV) System

Oil Filler Cap

PCV Filter

PCV Oil Separator

PCV Valve

Exhaust Gas Recirculation (EGR) System

EGR Feed and Delivery Pipes or Cast-in Passages

EGR Valve

EGR Valve Assembly (7.8L Isuzu Diesel)

EGR Valve Cooler (6.6L DURAMAX® Diesel)

EGR Cooler (7.8L Isuzu Diesel)

EGR Vacuum Pump Assembly (6.6L DURAMAX® Diesel)

Secondary Air Injection System

Air Pump

Check Valves

Evaporative Emission Control System (Gasoline Engines)

Canister

Canister Purge Solenoid Valve

Canister Vent Solenoid

Fuel Feed and Return Pipes and Hoses

Fuel Filler Cap

Fuel Level Sensor

Fuel Limiter Vent Valve *

Fuel Tank Filler Pipe (with restrictor)

Fuel Tank(s) *

Fuel Tank Vacuum or Pressure Sensor

Hybrid

Auxiliary Transmission Pump, Relay, and Circuit

Battery Pack Current Sensor and Circuit

Battery Pack 12V Modules (3)

Brake Pedal Switch (PCM ZAB Switch)

Energy Storage Control Module *

IsuzuLAN (CAN) Communications Circuit

Hood Ajar Switch and Circuit

Hybrid Control Module **

SGCM Coolant Circuit (fan and fan relay and pump)

Starter Generator Control Module *

Wheel Speed Sensor and Circuits (left and right front)

Miscellaneous Items Used with Above Components are Covered

Belts

Boots

Clamps

Connectors

Ducts

Fittings

Gaskets

Grommets

Hoses

Housings

Mounting Hardware

Pipes

Pulleys

Sealing Devices

Springs

Tubes

Wiring

Parts specified in your maintenance schedule that require scheduled replacement are covered up to their first replacement interval or the applicable emission warranty coverage period, whichever comes first. 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.

Replacement Parts

The emission control systems of your chassis were designed, built, and tested using genuine GM parts* and the chassis 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 chassis means parts manufactured by or for GM, designed for use on GM chassis, 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 chassis owner.

In an emergency, where an authorized dealer is not reasonably available, repairs can be performed at any available service establishment or by the owner, using any replacement part. GM 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'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 dealer and you believe the repairs are covered by emission warranties, take the replaced parts and your receipt to a GM 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 the separate warranty booklet, take your chassis to any authorized GM dealer facility to obtain service under the emission warranty. 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 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 chassis 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" in the warranty booklet under "Owner Assistance".

For further information or to report violations of the Emission Control System Warranty, 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 chassis subject to the California Exhaust Emission Standards, contact:

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