08206A - Secondary Air Injection (SAI) System Disabled - Reprogram Powertrain Control Module (08206A)

08206A - Secondary Air Injection (SAI) System Disabled - Reprogram Powertrain Control Module

SERVICE CAMPAIGN BULLETIN

Condition

General Motors has decided to conduct a Voluntary Emission Recall involving certain  2004 model year Cadillac SLS, STS; 2004-05 model year Cadillac DeVille, DHS, DTS; and Pontiac Bonneville vehicles, equipped with a 4.6L V8 (RPO LD8, L37 - VIN Y, 9) engine. The secondary air injection (SAI) system may have been disabled as the result of a previous service procedure that included Powertrain Control Module (PCM) reprogramming or replacement.

Correction

Dealers are to reprogram the Powertrain Control Module (PCM) and verify SAI system operation.

Vehicles Involved

Involved are certain 2004 model year Cadillac SLS, STS; 2004-05 model year Cadillac DeVille, DHS, DTS; and Pontiac Bonneville vehicles, equipped with a 4.6L V8 (RPO LD8, L37 - VIN Y, 9) engine and built within these VIN breakpoints:

Year	Division	Model	From	Through
2004	Cadillac	DeVille, DHS, DTS	4U100001	4U550713
2004	Cadillac	SLS, STS	4U100013	4U176879
2004	Pontiac	Bonneville	4U178557	4U263069
2005	Cadillac	DeVille, DHS, DTS	5U100065	5U550403
2005	Pontiac	Bonneville	5U100023	5U239222

For dealers with involved vehicles, a listing of the 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 and Canadian dealers/retailers - GM GlobalConnect Recall Reports

- Export dealers - sent directly to dealers

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.

Calibration Information

Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) or Tech 2® scan tool and TIS2WEB with the calibration update. Use TIS2WEB  data version on or after 05/26/08  to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided.

Service Procedure

1. Reprogram the PCM controller with the updated calibration files using the TIS2WEB Service Programming System (SPS) application.
   1. Refer to SI and Service Programming System (SPS) documentation for further programming instructions, if required.
   2. Select J2534 MDI or Tech 2® and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen.
   3. Select PCM Powertrain Control Module from the Supported Controllers screen.
   4. Follow the on-screen instructions for programming the PCM.
   5. Using the MDI or Tech 2®, clear all DTCs if required.
2. Verify SAI pump and valve operation.
   1. Start and idle the engine.
   2. Allow the engine to reach Closed Loop.
   3. Command the SAI System ON with a scan tool. The SAI Pump should turn ON and the Shut-Off valve should open.
   4. Observe the HO2S Bank 1 Sensor 1 Voltage parameter while the SAI System is commanded ON. The HO2S Bank 1 Sensor 1 Voltage parameter should decrease below 100mV.
   5. If the HO2S Bank 1 Sensor 1 Voltage parameter does not decrease below 100mV, refer to DTC P0410 to diagnose and repair the SAI system. Refer to SI, for DTC P0410 Secondary Air Injection (SAI) System.
3. CALIFORNIA, MASSACHUSETTS, MAINE, & VERMONT VEHICLES ONLY:  Install a Recall Identification Label. Also, for California vehicles complete a "Proof of Correction" certificate upon recall completion.

Recall Identification Label - California/Massachusetts/Maine/Vermont 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.

Courtesy Transportation - For US and Canada

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 Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program 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. GM dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Saturn Canada retailers should refer to applicable Home Office letter on this subject.

Claim Information

Submit a Product Recall Claim with the information indicated below:

Repair Performed	Part Count	Part No.	Parts Allow	CC-FC	Labor Op	Labor Hours	Net Item
Reprogram PCM.	-	-	-	MA-96	V1999	0.4
Perform SAI Pump, Check Valve function check						Add: 0.3
Replace SAI Check Valve if necessary						Add: 0.4	*
Replace SAI Pump, if necessary						Add: 0.7
Courtesy Transportation for vehicles within the New Vehicle Limited Warranties (US & Canadian GM Dealers)	N/A	N/A	N/A	MA-96	**	N/A	***
* The amount identified in the "Net Item" column should represent the actual sum total of the current GMSPO Dealer net price for SAI system parts needed to perform the required repairs, plus applicable Mark-Up or Landed Cost (for Export). ** Submit courtesy transportation using normal labor operations for courtesy transportation as indicated in the GM Service Policies and Procedures Manual for vehicles within the New Vehicle Limited Warranties. *** The amount identified in the "Net Item" column should represent the actual dollar amount for courtesy transportation.

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

Customer Notification - For US and Canada

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.

Customer Notification - For Export

Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the attached sample letter.

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

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 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.

OWNER LETTER

November 2008

Dear General Motors Customer:

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

Reason For This Recall:  Your 2004 Cadillac SLS, STS; 2004-05 Cadillac DeVille, DHS, DTS; or Pontiac Bonneville vehicle, equipped with a 4.6L V8 engine., may have had the secondary air injection (SAI) system disabled as the result of a previous service procedure that included a Powertrain Control Module (PCM) reprogramming or replacement. Your vehicle has been certified to meet California and Federal emission standards and your engine may be releasing air pollutants which exceed these standards if your SAI system has been disabled.

What Will Be Done:  Your dealer will reprogram the Powertrain Control Module (PCM) and verify proper SAI pump system operation. This service will be performed for you at no charge. 

How Long Will The Repair Take?  Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual service correction time of approximately 30 minutes.

What You Should Do:  Please contact your dealer as soon as possible to arrange a service date. 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.

Division	Number	Text Telephones (TTY)
Cadillac	1-866-982-2339	1-800-833-2622
Pontiac	1-800-620-7668	1-800-833-7668
Guam	1-671-648-8450
Puerto Rico - English	1-800-496-9992
Puerto Rico - Espanol	1-800-496-9993
Virgin Islands	1-800-496-9994

Customer Reply Form:  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.

Courtesy Transportation:  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.

Emission Law Information:  In order to ensure your full protection under the emission warranty made applicable to your Cadillac DeVille, DHS, DTS; or Pontiac Bonneville 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 Cadillac SLS, STS, DeVille, DHS, DTS; or Pontiac Bonneville. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished.

IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS 

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

08206

Dear Division(s) Customer:

Division(s)

General Motors Corporation

Enclosure