Product Safety - Positive Battery Cable Routing

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2001 GMC Yukon Denalis and Yukon XL Denalis. Some of these vehicles were built with a misrouted positive battery cable assembly that could come in contact with the steering shaft universal joint. Over time this contact would cause a wear-through of the cable assembly convoluted conduit and cable insulation. This could expose the wire core and result in intermittent electrical shorting. If this were to occur, it could result in erratic movement of the voltage gage, total battery discharge in a few hours, or the cable insulation and conduit could ignite if enough current is discharged at the point of contact, which could result in an underhood fire.

Dealers are to inspect the positive battery cable for proper routing, and reroute the cable if necessary. The cable is also to be inspected for wear of the conduit and cable insulation, and replaced if necessary.

Involved are certain 2001 GMC Denalis built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) before beginning campaign repairs. [Not all vehicles within the above breakpoints may be involved.]

Involved vehicles have been identified by Vehicle Identification Number. Computer listings containing the complete Vehicle Identification Number, customer name and address data have been prepared, and are being furnished to involved dealers with the campaign bulletin. The customer name and address data furnished will enable dealers to follow-up with customers involved in this campaign. Any dealer not receiving a computer listing with the campaign bulletin has no involved vehicles currently assigned.

These dealer listings may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other purpose is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this listing to the follow-up necessary to complete this campaign.

Parts required to complete this campaign are to be obtained from General Motors Service 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.

1. Inspect the positive battery cable for proper routing and wear of the conduit and the cable insulation. The cable must be routed on the inboard side of the power steering cooler inlet hose.

-	If the conduit and the cable insulation show signs of wear, proceed to the Positive Cable Replacement Procedure below, and replace the positive battery cable.

-

If the cable is routed properly and shows no signs of wear, using tie strap (P/N 12337820), secure the cable, along with the engine harness, to the power steering gear inlet pipe between the power steering pump reservoir and the steering pump mounted cable bracket. Install the GM Campaign Identification Label.

-	If the cable routes on the outboard side of the power steering cooler inlet hose and shows no signs of wear through, proceed to Step 2 and reroute the cable.

2. Remove the clamp that is retaining the power steering cooler inlet hose to the power steering pump. Disconnect the hose.
3. Reroute the positive battery cable to the inboard side of the power steering cooler inlet hose.
4. Connect the power steering cooler inlet hose to the power steering pump. Install the retaining clamp.
5. Using the tie strap, secure the cable, along with the engine harness, to the power steering gear inlet pipe between the power steering pump reservoir and the steering pump mounted cable bracket.
6. Start the engine and allow the engine to idle.
7. Bleed any air that might be trapped in the power steering system by turning the steering wheel 180-360 degrees in both directions five times.
8. Switch the ignition off.
9. Check the power steering fluid level.
10. Install the GM Campaign Identification Label.

Removal Procedure

1. Disconnect the negative battery cable.
2. Unsnap the positive battery cable cap.
3. Disconnect the positive battery cable.
4. Remove the LH underhood crossbrace.
5. Remove the underhood bussed electrical center (UBEC) cover and housing.

Important: The bolt is integral to the battery cable and is not removable.

6. Loosen the positive cable bolt at the UBEC.
7. Unsnap the junction block cover.
8. Remove the positive battery cable from the junction block.
9. Remove the negative cable clip from the positive cable clip.
10. Raise and suitably support the vehicle.
11. Remove both of the underbody shields.
12. Remove the positive battery cable channel bolt.
13. Slide the channel pin out of the oil pan tab.
14. Remove the positive battery cable from the channel.
15. Remove the starter lead nut.
16. Remove the positive cable from the starter.
17. Remove the positive cable from the clip on the oil pan.
18. Route the positive battery cable out from underneath the vehicle.
19. Lower the vehicle.
20. Remove the positive battery cable from the vehicle.

Installation Procedure

1. Install the new positive battery cable from the top and feed down.
2. Raise and suitably support the vehicle.
3. Route the positive cable to the starter.
4. Install the positive cable to the clip on the oil pan.
5. Install the positive cable to the starter.
6. Install the starter lead nut.

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

7. Install the positive battery cable to the channel.
8. Slide the channel pin into the oil pan tab.
9. Install the positive battery cable channel bolt.

Tighten
Tighten the bolt to 12 N·m (106 lb in).

10. Install both of the underbody shields.
11. Lower the vehicle.
12. Install the negative cable clip to the positive cable clip.
13. Install the positive battery cable into the junction block.
14. Snap the junction block cover closed.
15. Tighten the positive cable bolt at the UBEC.

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

16. Install the UBEC housing and cover.
17. Install the LH underhood crossbrace.
18. Connect the positive battery cable.
19. Tighten the positive battery cable bolt.

Tighten
Tighten the bolt to 17 N·m (13 lb ft).

20. Snap the positive battery cable cap closed.
21. Connect the negative battery cable.
22. Install the GM Campaign Identification Label.

FOR US

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. When installing the Campaign Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Campaign Identification Labels for US dealers can be obtained from Dealer Support Material by calling 1-888-549-6152 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

FOR CANADA

Place a Campaign Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin. Each label provides a space to include the campaign number and the five (5) digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or a ball point pen.

Put the Campaign Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle. Additional Campaign Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number GMP 91 when ordering.

Submit a Product Campaign Claim with the information indicated below:

Refer to the General Motors WINS Claims Processing Manual for details on Product Campaign Claim Submission.

FOR US AND CANADA

Customers will be notified of this campaign on their vehicles by General Motors (see copy of customer letter included with this bulletin).

FOR US (US States, Territories, and Possessions)

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall campaign 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 campaign notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the campaign is not completed within a reasonable time.

FOR ALL

All unsold new vehicles in dealers' possession and subject to this campaign MUST be held and inspected/repaired per the service procedure of this campaign bulletin BEFORE customers take possession of these vehicles.

Dealers are to service all vehicles subject to this campaign 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. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. Campaign 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 campaign enters your vehicle inventory, or is in your dealership for service in the future, please take the steps necessary to be sure the campaign 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 2001 GMC Yukon Denalis and Yukon XL Denalis. Some of these vehicles were built with a misrouted positive battery cable assembly that could come in contact with the steering shaft universal joint. Over time this contact would cause a wear-through of the cable assembly convoluted conduit and cable insulation. This could expose the wire core and result in intermittent electrical shorting. If this were to occur, it could result in erratic movement of the voltage gage, total battery discharge in a few hours, or the cable insulation and conduit could ignite if enough current is discharged at the point of contact, which could result in an underhood fire.

Your GMC dealer will inspect the positive battery cable for proper routing, and reroute the cable if necessary. The cable will also be inspected for wear of the conduit and cable insulation, and replaced if necessary. This service will be performed for you at no charge .

The length of time required to perform this inspection is approximately fifteen minutes, and another forty-five minutes if the positive battery cable requires replacement. Additional time may be required to schedule and process your vehicle. If you dealer has a large number of vehicles awaiting service, this additional time may be significant. Please ask your dealer if you wish to know how much additional time will be needed to schedule, process and repair your vehicle.

Please contact your dealer as soon as possible to arrange a service date. Parts are available and instructions for making this correction have been sent to your dealer.

Your dealer is best equipped to obtain parts and provide services to correct your vehicle as promptly as possible. 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:

If, after contacting the GMC 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 attached customer reply card identifies your vehicle. Presentation of this card 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 attached and mailing it in the postage paid envelope.

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.

Pontiac-GMC Division

General Motors Corporation

Enclosure