Product Emission - Engine Fuel Injectors-Replace

THIS BULLETIN IS BEING REVISED TO ADD DETAILED STEPS TO THE SERVICE PROCEDURE IN ORDER TO AVOID INJECTOR INSULATOR REMOVAL. PLEASE DISCARD ALL COPIES OF 06090, ISSUED JANUARY 2007.

General Motors has decided to conduct a Voluntary Emission Recall involving certain 2006 Chevrolet Cobalt and Pontiac Pursuit model vehicles, equipped with a 2.2L 4 cylinder (RPO L61 - VIN F) engine. Very small cracks may develop inside the fuel injectors. A crack could allow fuel to seep through into the injector connector pocket, resulting in a fuel odor. If the wiring connector becomes separated from the injector, resulting in an open injector circuit, symptoms could include engine misfire, illumination of the check engine light, and a fuel odor.

Dealers are to replace all four engine fuel injectors.

Involved are certain 2006 Chevrolet Cobalt and Pontiac Pursuit model vehicles equipped with a 2.2L 4 cylinder (RPO L61 - VIN F) engine and built within these VIN breakpoints:

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the GM Vehicle Inquiry System (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 - GM DealerWorld Recall Information

-- Canadian GM - GMinfoNet Recall Reports

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 campaign are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order.

Important: It may be necessary to rock the injectors (3) and rail (8) to aid injector and rail removal in order to avoid removing the injector insulator (5). If the injector insulator is removed from the cylinder head during injector removal, it will be necessary to replace the injector insulator and insulator O-ring assembly, GM P/N 12571864, which are not included in the injector kit.

1. Remove the fuel rail (8) from the cylinder head. Refer to Fuel Rail Assembly Replacement in SI.
2. Remove the fuel injector retainer clip (2).
3. Remove the fuel injectors (3) from the fuel rail (8).




Important: If the upper O-rings (1) remain in the fuel rail, remove the O-rings from the fuel rail assembly while taking care not to damage the sealing surface in the fuel rail.

4. Visually inspect the removed fuel injectors to make sure the upper O-rings (1) were removed from the fuel rail.

Notice: Always install new injector O-rings, which are included in the injector kit, when servicing the fuel injectors. Lubricate the new injector O-rings with clean engine oil. Ensure that the injector bores are free of debris that may cause vacuum leaks or damaged seals.

5. Install the O-rings (1, 4) on the new fuel injector (3) if not already installed.
6. Install the fuel injector clip (2) on the new fuel injector (3) if not already installed.

Important: The fuel injector clip (2) will click when the injector is installed correctly into the fuel rail.

7. Install the fuel injector in the fuel rail with the connector facing away from the cylinder into the fuel rail.

Notice: Care should be used when installing injectors or new injector insulators. If the insulator O-rings are damaged when installing, a vacuum leak may result and a lean condition trouble code may set.

8. If the fuel injector insulator and O-ring assembly (5, 6) were removed or are damaged, ensure that the fuel injector bore in the cylinder head is clean and free from debris and install a new insulator with O-ring, GM P/N 12571864. It is not necessary to replace fuel injector insulators if they were not removed from the cylinder head.
9. CALIFORNIA, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY: Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.

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 either ordering on the web from DWD Store, gm dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Request Item Number S-1015 when ordering.

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).

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.

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 OR EXPORT***

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 calling 1-866-700-0001 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for GM Item Number 1825 when ordering.

Dear General Motors Customer:

This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle.

Your 2006 model year Chevrolet Cobalt or Pontiac Pursuit vehicle may have been built with engine fuel injectors that do not meet GM’s specifications. Very small cracks may develop that fuel can seep through. If this occurs, you may notice a fuel odor. If the wiring connector separates from the injector, you may notice engine misfire, illumination of the check engine light, and a fuel odor.

Your dealer will replace all four engine fuel injectors. 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 40 minutes, because of service scheduling requirements.

Please contact your dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle.

If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance Center at the number listed below. The Customer Assistance Center’s hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

The enclosed customer reply form identifies your vehicle. Presentation of this form 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 card and mailing it back to us.

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.

In order to ensure your full protection under the emission warranty made applicable to your vehicle by State or Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished.

The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration.

At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued satisfaction with our products.

Scott Lawson

General Director,

Customer and Relationship Services

Enclosure

06090