For 1990-2009 cars

# DIESEL ENG. INJECTION PUMP WARRANTY & SERVICE INFORMATION

This bulletin summarizes warranty and service information for diesel injection pump repairs performed by authorized Cadillac dealers and pump repair agencies. Cadillac recognizes the fact that these administrative details are complex and difficult to remember. We strongly urge you to make sufficient copies of this bulletin for all concerned dealership personnel,

I. WARRANTY INFORMATION

A. 1978-1983 Cadillac Diesel Engine Injection Pump Warranty Coverage

(1) New Car Limited Warranty

1978-1983 diesel-equipped vehicles for 12 mths/12,000 miles.

(2) Power Protection Plus Warranty

1981-1982 diesel-equipped vehicles for 24-mths/24,000 miles. 1983 diesel-equipped vehicles for 36-months/50,000 miles.

External leakage is not considered a cause of an emission related failure; therefore, thess items are covered under the Power Protection Plus Warranty. Internal pump leakage or failure is considered emission related and is included in the broader emissions warranty.

(3) Emission Control Systems Warranty

1978-1979 diesel-equipped Federal and California vehicles for 5-years/50,000 miles. 1980-1983 diesel-equipped Federal vehicles for 6-years/50,000 miles 1980-1983 diesel-equipped California vehicles for 10-years/ 100,000 miles.

To deternine which repairs are covered under each warranty, refer to Chart I in this bulletine. This information is also contained in the Cadillac Service Policies and Procedures Manuals and Labor Time Guides applicable to the specific model year.

B. Repairs Performed by Cadillac Dealers

1. Repairs such as pump timing, external seals, gaskets, and solenoids (refer to Chart I for a complete listing), are to be performed by Cadillac dealers and submitted as a warranty claim and should not be sent to pump repair agencies for repair.

2. Additional repairs performed by qualified Cadillac dealers, covered by the New Car Limited, Power Protection Plus, or the Emissions Control Systems Warranties should also be submitted as a warranty claim to Cadillac. Claims for repairs under the Power Protection Plus Warranty will be subject to the $100 per visit deductible amount after 12-months/12,000 miles.

C. Repairs Performed by Authorized Pump Repair Agencies

1. It is essential that careful and thorough diagnosis of the injection pump be made by the dealer before removal. Accurate diagnosis will prevent tying up the owner's car unnecessarily and eliminate shipping and handling expense of sending the injection pump to a repair agency when no problems are present in the units.

2. If the diesel pump requires a repair which cannot be performed by a Cadillac dealer, the pump is to be removed, properly packaged (refer to Packaging Procedure section of this bulletin), and sent to the nearest authorized pump repair service agency (a directory of these agencies and their locations is included with this bulletin). The agency will then repair the unit or furnish an exchange unit and return it prepaid to the Cadillac dealer.

3. The diesel pump manufacturer has agreed to perform repairs qualified under warranty coverage through authorized pump repair service agencies at no charge during the New Car Limited Warranty period of 12-months/12,000 miles (or limits of the Optional Limited Warranty Extension where applicable). The Cadillac dealer should submit a warranty claim for the labor to remove and reinstall the repaired or exchanged pump plus the normal shipping charges incurred and 0.2 hour administrative allowance.

4. Beyond the New Car Limited Warranty but during the Emission Control Systems or Power Protection Plus Warranties, the dealer is to pay for the repair performed by the authorized pump repair service agency. The dealer should submit a warranty claim to Cadillac for the labor to remove and reinstall the repaired or exchanged pump plus the normal shipping charges incurred, and the sublet repair charge from the pump repair agency. Claims for repairs under the power protection plus warranty will be subject to the $100 per visit deductible amount.

II. Service Information

A. Repairs Performed by Cadillac Dealers

The following charts list the necessary service information required for Cadillac dealers to perform and claim in-house diesel pump repairs.

Chart I Diesel Pump Labor Time Guide and Coded Service Parts Information

Labor Operation Operation Description Number (*) ----------- ----------

Pump-R&R 1980-1983 J5950(E) 1978-1979 J384500(E) Pump Replace J5955(E) Seal, Guide Stud or Governor Support Rod Replace J5938(E) Seal, Pump Cover - Replace J5949(E) Seals, Throttle Shaft - Replace J5948(P) Ring, Governor Weight Retainer - Replace J5957(E) Kit, Min/Max Governor T0037(E) Seals, Drive Shaft - Replace J5959(P) Adapter and/or Seal - Replace J5960(P) Pump, Timing Fuel Injection J5965(E) Connector Assembly, Fuel Return Line - R&R or Replace J5956(P) Seals, Advance Piston Plug - Replace J5951(P) Seals, Head Locating Fitting or Advance Screw Hole Plug Replace J5939(P) Seal, Pump Head - Replace J5958(P) Solenoid, Fuel - Replace J5952(P) Solenoid, Cold Advance - Replace J5953(E)

*Warranty applicable after expiration of 12 month/12,0000 mile New Car Limited Warranty: E = Emission Warranty, P = Power Protection Plus Warranty.

Chart II - Diesel Pump Repair Service Parts

#### Model R-M Year Description Part No. (*) ---- ----------- ------------- 78-83 Pump Cover Seal 12054 78-83 Guide Stud Washer 13556 78-79 Throttle Shaft Retaining Ring 21285 78-83 Throttle Shaft Seals 17438(2) 78-83 Throttle Shaft Fiberwasher 14408 78-83 Min-Max Gov. Kit (GMWDO P/N 22513809) 23162 78-83 Driveshaft Seals 10453(2) 78-83 Driveshaft Seal 21860 78-79 Timing Line Cover Gasket 10574 80-83 Timing Line Cover Gasket 22503 78-83 Advance Cam Plug Seal 12764 78-79 Advance Piston Plug Seal 20113(2) 78-79 Advance Piston Plug Seal 12764 80-83 Advance Piston Plug Seal 22399(2) 78-83 Head Seal 11304 78-83 Fuel Solenoid 21323 80-83 Cold Adv.Solenoid 22840 78-80 Conn. Fuel Return Line 22109 81-83 Conn. Fuel Return Line 23530 78-83 Governor Weight Ret. Ring Kit 22963

*Quantity required per repair is one (1) except as noted.

Chart III - Diesel Pump Service Tool Information

Tool Description Kent Moore P/N Roosa-Master P/N ---------------- --------------- -----------------

Automatic Advance Plug Wrench 14490 Bristol Socket Cam Advance 15499 Screw Wrench Cam Advance Screw Removal 15500 Bushing *Carbon Stop Seal Installer J-28475 *Carburetor Choke Angle J-26701-A Gage (BT7704) Vacuum Regulator Valve Angle Adapter (BT-7944) J-26701-15 Drive Shaft Seal Installer 22727 Throttle Shaft Cam Timing J-29601 Adapter *Hand Operated Vacuum Pump J-23738 *Injection Pump Housing J-28552 Pressure Gauge *Injection Pump Intake J-26987 Manifold Wrench *Injection Pump Pressure J-28526, J-29382 Test Adapter *Magnetic Pick-Up Tachometer J-26925 *Manifold Covers and Screens J-26996, 996-1 996-10, J-29657

Mounting Fixture (see Campaign Bulletin 82-C-2-Template) J-29692 22998 *Plastic Plugs - Pump J-28438 Lines and Nozzles Snap Ring Pliers (or Tru-Arc #22) 13337 *Static Injector Pump Timing Tool J-26896 *Timing Meter J-33075

*Cadillac Essential Tools

B. Repairs Performed by Pump Repair Service Agencies

1. Warranty Claim Form

A special diesel warranty repair claim (S-1019) must be completed and submitted with the inoperative unit to the authorized pump repair service agency. An example of this form is shown on page 6. The form is available at no charge from Cadillac Stationery Control, Lansing, Michigan.

INSTRUCTIONS FOR COMPLETING FORM S1019 FOR INJECTION PUMP AND/OR NOZZLE

All entries made on this form (except the dealer signature) must be typed.

ITEM 1 Vehicle Identification Number - The complete VIN must be in this

ITEM 2 Dealer Firm Name and Dealer Sales Code - Complete dealer firm name and address including zip code, plus the five-digit dealer code.

ITEM 3 Complete Owner Information.

ITEM 4 Delivery Date and Mileage - Vehicle delivery date and mileage at time of repair.

ITEM 5 Extended Warranty - If the vehicle is covered under the optional warranty extension, type an "X" in this box. Include time limit and mileage limit. A copy of the approved warranty extension application must accompany this form when submitted to the Roosa Master Agency.

ITEM 6 Injection Pump Model and Serial Numbers - This information is found on the pump data plate. (Examle Model #DB-2825 PL 3059, Serial #2189785).

ITEM 7 Nozzle Part Number and Date Code - Locate this information on the nozzle. Chalk may be used to help make the numbers clear. Place the part number of the nozzle adjacent to the number representing the cylinder from which it was removed. (Example - Nozzle Part Number 216011, Nozzle Date Code-D7).

ITEM 8 Troubleshooting Guide and Dealer Comments - Indicate the condition and explain in the comments section.

ITEM 9 R.O. Number and r.O. Date.

ITEM 10 Dealer Signature - The signature of the dealer's authorized representative is required.

ITEM 11 Distribution: Yellow - Dealer copy White and Pink - Send with part to Roosa- Master Agency. The pink copy will be comple by Roosa-Master Agency and returned to dealer for attachment to the GM Division scrap copy.

2. Packaging Procedure

Special shipping cartons which will protect the injection pump from shipping damage are available from Roosa-Master Service Agencies. Follow packaging instructions on the shipping carton carefully.

Make sure that all remaining fuel is drained from the units before packaging. After draining thoroughly, install caps to prevent foreign material from entering the parts. The pump must then be placed in the plastic bag contained in the carton for additional protection against fuel spillage. Secure the plastic bag opening tightly. Damage to other freight in the carrier's possession, caused by improperly draining the pump, coulbe considered the responsibility of the shipper (dealer). Place the pink and white copies of Form S1019 in the carton and ship the unit PRE-PAID to the nearest pump repair agency.

The shipping charges are to be submitted to Cadillac on the warranty claim invoice in the "Sublet/Dealer/Material/Towing" column. The repaired or exchange unit will be shipped to the dealer "pre-paid" by the pump repair agency.

III. PUMP DAMAGE OR THEFT IN TRANSIT

Injection pumps which are damaged or stolen from the car during new car transit must be handled on a Transportation Claim. New injection pumps, nozzles and lines are available through GmWDD for this purpose.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.