Recall - Chassis Harness Wired Incorrectly: Overview
PRODUCT EMISSIONBulletin No.: 10402
Date: January 11, 2011
Subject: 10402 - Chassis Harness Wired Incorrectly
Models:
2010-2011 Chevrolet Express
2010-2011 GMC Savana Cutaway Chassis
Equipped with a Duramax Diesel Engine (LGH)
Condition
General Motors has decided to conduct a Voluntary Emission Recall involving certain 2010 and 2011 model year Chevrolet Express and GMC Savana Cutaway vans equipped with a Duramax Diesel Engine (LGH). The vehicle may be releasing air pollutants in excess of the standards due to an incorrectly wired chassis harness. Certain wires in the harness may have been reversed and can affect proper control of the emission control systems and could damage certain emission control components.
Correction
Dealers are to inspect the wire harness connections and, if necessary, reverse the connections.
Vehicles Involved
Involved are 2010 and 2011 model year Chevrolet Express and GMC Savana Cutaway vans equipped with a Duramax Diesel engine (LGH).
All involved vehicles are identified by VIN in the Global Warranty Management System - Investigate Vehicle History (GMVIS2) Application. Dealership technicians should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is essential to routinely verify eligibility because not all similar vehicles may be involved regardless of description or option content.
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 to dealers through the GM GlobalConnect Recall Reports. Dealers will not have a report available if they have no involved vehicles currently assigned.
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 Information
Parts required to complete this recall are to be obtained from General Motors Customer Care and Aftersales (GMCC&A). 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.
Service Procedure
1. Raise and support the vehicle.
Note
The exhaust temperature sensor harness is difficult to see in its installed position on an upfitted vehicle. The above illustration shows the harness out of the vehicle.
2. Determine if there is a blue and light pink marking tape (1) on the exhaust temperature sensor harness. The marking tape (1) is located near the breakout for the sensor leads of the exhaust temperature sensor harness. Refer to illustration.
- If the exhaust temperature sensor harness does NOT have marking tape, proceed to Step 3 and refer to the Harness Without Marking Tape table.
- If the exhaust temperature sensor harness does have marking tape, proceed to Step 3 and refer to the Harness With Marking Tape table.
Note
The exhaust temperature sensor harness is difficult to see in its installed position on an upfitted vehicle. The above illustration shows the harness out of the vehicle.
3. Inspect the wire colors at the chassis harness side connector for position 3 (front) & 5 (rear) exhaust temperature sensors.
Harness Without Marking Tape
- Sensor Position #3 - Wire Color: Light Green & Tan
- Sensor Position #5 - Wire Color: Dark Blue/White & Tan
- If the wire colors match as indicated above, no action is required.
- If the wire colors do not match as indicated above, the chassis harness electrical connectors will need to be swapped. Proceed to Step 4.
Harness With Marking Tape
- Sensor Position #3 - Wire Color: Dark Blue/White & Tan
- Sensor Position #5 - Wire Color: Light Green & Tan
- If the wire colors match as indicated above, no action is required.
- If the wire colors do not match as indicated above, the chassis harness electrical connectors will need to be swapped. Proceed to Step 4.
4. Disconnect the exhaust temperature sensor #3 electrical connector.
5. Detach the exhaust temperature sensor #3 chassis harness electrical connector from the harness support bracket.
6. Disconnect the exhaust temperature sensor #5 electrical connector.
7. Detach the exhaust temperature sensor #5 chassis harness electrical connector from the frame rail.
8. Remove the bolts (1, 2) securing the wiring harness to the frame rail.
9. Allow the wiring harness to drop down.
Note
The lead that was previously connected to sensor #3 (front) will now be connected to sensor #5 (rear). The lead that was previously connected to sensor #5 (rear) will now be connected to sensor #3 (front).
10. Bundle the harness as shown in the illustration below. At the bend, wrap the harness with insulated tape, GM P/N 10184916 to prevent contact with the exhaust.
11. Install the bundled harness back into position and install the bolts securing the harness to the frame rail.
12. Connect the electrical connectors to both sensors.
13. Attach the exhaust temperature sensor #3 chassis harness electrical connector to the harness support bracket.
14. Attach the exhaust temperature sensor #5 chassis harness electrical connector to the frame rail.
15. Lower the vehicle.
16. CALIFORNIA, CONNECTICUT MASSACHUSETTS, MAINE, OREGON, VERMONT, & WASHINGTON VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.
Recall Identification Label - California/Connecticut/Massachusetts/Maine/Oregon/ Vermont/Washington Vehicles Only
Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen.
Put the Recall 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 Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering.
Warranty Transaction Information
Submit a transaction using the table below.
* The amount identified in "Net Item" should represent the actual sum total of the current GMCC&A Dealer net price for the 1' of tape needed to perform the required repairs, not to exceed $3.73 USD, $6.96 CAD, plus applicable Mark-Up or Landed Cost (for Export).
Customer Notification
General Motors will notify customers of this recall on their vehicle (see copy of customer letter included with this bulletin).
In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.
Dealer Recall Responsibility
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.
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA***
When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration.
Additional Certificates can be obtained, at no charge, from Dealer Support Materials by ordering on the web from the DWD Store, www.gmdealerworld.com, and then click on the DWD Store link; request GM Item Number 1825 when ordering.
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