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GMC Yukon XL 2000–2006

GMC Yukon XLModel years 2000–2006

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1 conditions added

Common on this vehicle:Gauge or instrument faultWarning lightCorrosion or rustNoiseLeakReduced brakingStalls or shuts offLoss of engine power, no acceleration

Record by record

135 records state a cause or a remedy. Each record is shown as short labels in the order fault → finding the cause → correction. Press a label to narrow to the records that state it.

Symptom

Component named as the cause

Work done

How it is said to have ended

  • says it was fixed1
  • says it came back2
  • says it did not fix it1
  • result not stated41

A ribbon is as wide as the records that state both of its ends (only the commonest are drawn). A record that names several symptoms or components runs through each. Orange is records that say the fault came back or was not fixed. Results come from owners’ reports only; one that does not say is “result not stated”. None of this is a likelihood of a cause or a rate at which work succeeds.

Read the records one by one (28)

Known issuesBrake pipe (brake line) corrosion and rupture3

  1. Owner complaint2003 GMC YUKON XL 2500 ・ 2015-01-26

    Brake failure on downhill road in winter conditions

    1. 1Fault

    2. 2Finding the cause

    3. 3CorrectionNot repaired

      I DID NOT YET HAVE THE BRAKES REPAIRED YET BECAUSE THE QUOTES WERE SO HIGH.

      What the documents say to do

      Brake pipe (brake line) corrosion and rupture

      Confirm

      • In the joint inspections, scaling or flaking corrosion was taken as indicating the onset of metal loss and given the second lowest ranking (2); a leaking or previously repaired pipe was the lowest (1).

      Repair

      1. GM recommends replacing the entire set of pipes whenever any pipe leaks or is corroded enough to need replacement.
      2. On June 28, 2013 GM released 66 new part numbers for servicing brake pipes in 1999-2007 GMT800 pickups and utility vehicles.

      Caution

      • Analysis of repair records indicates that consumers often elect to repair only the failed circuit.
    Read the sentences of the record
    Fault
    THE BRAKES FAILED ON ROUTE 26 COMING DOWN THE HILL TOWARDS ROUTE 28. (3 more)
    Remedy
    I DID NOT YET HAVE THE BRAKES REPAIRED YET BECAUSE THE QUOTES WERE SO HIGH.
    Inspection
    2 - A DIFFERENT REPAIR SHOP SAID THAT ALL FIVE OF MY BRAKE LINES HAD FAILED AND WERE LEAKING FLUID DURING A TEST TO LOCATE THE PROBLEM. (1 more)
    Consequence
    WE SLID SIDEWAYS DOWN THE HILL AND ACROSS ROUTE 28. (2 more)

  2. Owner complaint2005 GMC YUKON DENALI XL ・ 2014-12-27

    Brake pedal goes to floor, brake fluid loss, rusted brake line at left rear

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      I IMMEDIATELY ADDED FLUID.

      What the documents say to do

      Brake pipe (brake line) corrosion and rupture

      Confirm

      • In the joint inspections, scaling or flaking corrosion was taken as indicating the onset of metal loss and given the second lowest ranking (2); a leaking or previously repaired pipe was the lowest (1).

      Repair

      1. GM recommends replacing the entire set of pipes whenever any pipe leaks or is corroded enough to need replacement.
      2. On June 28, 2013 GM released 66 new part numbers for servicing brake pipes in 1999-2007 GMT800 pickups and utility vehicles.

      Caution

      • Analysis of repair records indicates that consumers often elect to repair only the failed circuit.
    Read the sentences of the record
    Fault
    I WAS TRAVELING ON A LOCAL HIGHWAY AT THE POSTED SPEED LIMIT WHEN I WAS CAUSED TO SLOW DUE TO TRAFFIC. (3 more)
    Remedy
    I IMMEDIATELY ADDED FLUID.
    Inspection
    I CHECKED THE BRAKE FLUID AND IT WAS MUCH LOWER THAN WHEN WE STARTED OUR TRIP JUST A FEW HOURS PRIOR. (1 more)
    Consequence
    LUCKILY I DID NOT CAUSE AN ACCIDENT BUT EASILY THERE COULD HAVE BEEN ONE.

  3. Owner complaint2003 GMC YUKON XL 2500 ・ 2011-07-20

    Sudden brake failure with ruptured brake line

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

    Read the sentences of the record
    Fault
    2003 GMC YUKON XL 2500 SUDDEN BRAKE FAILURE. (3 more)
    Cause
    CLEARLY THERE IS A MANUFACTURING OR QUALITY DEFECT IN THE LINES INSTALLED ON THIS 2003 YUKON.
    Remedy
    BASED ON THE CONSISTENT AND EXCESSIVE CORROSION THROUGHOUT, I OPTED TO HAVE ALL THE BRAKE LINES AND POWER STEERING LINES REPLACED AT ONCE.
    Inspection
    AFTER STOPPING, I EXAMINED THE VEHICLE AND FOUND THE METAL BRAKE LINE HAD RUPTURED WHERE IT CROSSES OVER THE FRAME RAIL LEADING TO THE FRONT LEFT BRAKE. (1 more)

Known issuesEngine fuel rail crossover tube retainer screws may break (5.3L RPO L59) - recall 04V-3762

  1. Recall2005 GMC YUKON XL ・ 2004-02-08

    Engine Fuel Rail Crossover Tube Retainer Screws

    1. 1Fault

      • The engine fuel rail crossover tube retainer screws were not made to specification and may break; if one breaks, fuel could leak from the crossover joint, the engine may stall, and with an ignition source an engine compartment fire could occur.

    2. 2Finding the cause

      Possible causes

      • The failed screw was harder than specification; the over-hardening came from a conveyor in an induction hardening operation at the fastener plant stopping or slowing excessively, exposing the screws to the hardening for too long.

      Steps to confirm (in the document’s order)

      • Inspect for blue or green paint dots on the fuel rail crossover tube assembly or on the throttle body; if there are any, go to step 13.

    3. 3Correction

      Repair

      1. Hold the fuel crossover tube retainer to the bracket on the fuel rail with locking pliers, using enough force to keep the retainer from moving without damaging any parts.
      2. Remove the fuel rail crossover tube bracket retainer screw on one side and dispose of it properly.
      3. Take the new screws out of the retainer kit (P/N 89017590) and discard the retainer brackets left in the kit.
      4. Start the new screw by hand for at least 3 full turns into the fuel rail crossover tube retainer bracket.
      5. Torque the screw to 4.8Nm (42 lb in).

      Part numbers printed in the document

      The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

      3 more points

      Parts

      • Part number 89017590, RETAINER KIT, F/INJN FUEL RL C/OVR TUBE, quantity 1 per vehicle.

      Part numbers printed in the document

      The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

      Caution

      • Do not remove the crossover tube from the fuel rail or disturb the o-ring seal, because a fuel leak may result.
      • The service procedure in this recall differs from the one in the service manual.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：The recall covers certain 2005 Chevrolet Silverado, Tahoe and Suburban and GMC Sierra, Yukon and Yukon XL vehicles equipped with a 5.3L (RPO L59) E85 V8 engine and built within the listed VIN breakpoints.
    • Condition：The engine fuel rail crossover tube retainer screws were not made to specification and may break; if one breaks, fuel could leak from the crossover joint, the engine may stall, and with an ignition source an engine compartment fire could occur.
    • Cause：The failed screw was harder than specification; the over-hardening came from a conveyor in an induction hardening operation at the fastener plant stopping or slowing excessively, exposing the screws to the hardening for too long.
    • Confirm：Inspect for blue or green paint dots on the fuel rail crossover tube assembly or on the throttle body; if there are any, go to step 13.
    • Caution：Do not remove the crossover tube from the fuel rail or disturb the o-ring seal, because a fuel leak may result.
    • Caution：The service procedure in this recall differs from the one in the service manual.
    • Repair：Hold the fuel crossover tube retainer to the bracket on the fuel rail with locking pliers, using enough force to keep the retainer from moving without damaging any parts.
    • Repair：Remove the fuel rail crossover tube bracket retainer screw on one side and dispose of it properly.
    • Parts：Part number 89017590, RETAINER KIT, F/INJN FUEL RL C/OVR TUBE, quantity 1 per vehicle.
    • Repair：Take the new screws out of the retainer kit (P/N 89017590) and discard the retainer brackets left in the kit.
    • Repair：Start the new screw by hand for at least 3 full turns into the fuel rail crossover tube retainer bracket.
    • Repair：Torque the screw to 4.8Nm (42 lb in).
    • Repair：Check that the retainer is seated and not loose by trying to wiggle it slightly; it should not move. Then re-torque the screw to 4.8Nm (42 lb in).
    • Repair：Repeat steps 5 through 10 on the other side of the crossover tube.
    • Repair：Check for leaks: ignition ON with the engine OFF for 2 seconds, ignition OFF for 10 seconds, ignition ON with the engine OFF, then visually inspect for fuel leaks.
    Cause
    ON CERTAIN SPORT UTILITY VEHICLES AND PICKUP TRUCKS EQUIPPED WITH 5.3L (RPO L59) V8 ENGINES, THE ENGINE FUEL RAIL CROSSOVER TUBE RETAINER SCREWS WERE NOT MANUFACTURED TO SPECIFICATIONS AND MAY BREAK.
    Remedy
    DEALERS WILL INSPECT THE FUEL RAIL CROSSOVER TUBE AND, IF NECESSARY, REPLACE THE RETAINER SCREWS. OWNERS WERE NOTIFIED BY TELEPHONE ON JULY 30, 2004, WITH A FOLLOWUP OWNER LETTER BEGAN AUGUST 5, 2004. OWNERS SHOULD CONTACT CHEVROLET AT 1-800-630-2438 OR GMC AT 1-866-996-9463. NOTE: THE GM BULLETIN LISTS THE TAHOE AND YUKON MODELS BECAUSE CANADIAN VEHICLES ARE INCLUDED IN THE BULLETIN. NO U.S. TAHOE OR YUKON VEHICLES ARE INCLUDED IN THE U.S. CAMPAIGN.
    Consequence
    IF THE TUBE RETAINER SCREW BREAKS, FUEL COULD LEAK FROM THE FUEL RAIL CROSSOVER JOINT, THE ENGINE MAY STALL AND, IF AN IGNITION SOURCE WERE PRESENT, AN ENGINE COMPARTMENT FIRE COULD OCCUR.

  2. Recall2005 GMC YUKON XL ・ 2004-08-05

    Fuel Rail Crossover Tube Retainer Screws Recall

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      Not stated

      What the documents say to do

      Engine fuel rail crossover tube retainer screws may break (5.3L RPO L59) - recall 04V-376

      Confirm

      • Check for leaks: ignition ON with the engine OFF for 2 seconds, ignition OFF for 10 seconds, ignition ON with the engine OFF, then visually inspect for fuel leaks.

      Repair

      1. Dealers inspect the fuel rail crossover tube and replace the retainer screws if necessary.
      2. Hold the fuel crossover tube retainer to the bracket on the fuel rail with locking pliers, using enough force to keep the retainer from moving without damaging any parts.

      Caution

      • The GM bulletin lists Tahoe and Yukon models because Canadian vehicles are included in the bulletin.
    Read the sentences of the record
    Cause
    On certain vehicles, the fuel rail crossover tube retainer screws were not manufactured to specifications and may break. If a tube retainer screw breaks, fuel could leak from the fuel rail crossover joint, the engine may stall and, if an ignition source were present, an engine compartment fire could occur. Correction: Dealers will inspect the fuel rail crossover tube assembly and, if necessary, replace the two tube retainer screws.

Known issuesEngine fuel rail pulse damper retainer clip may fracture (8.1L V8) - recall 06V-289 / Transport Canada 20061952

  1. Recall2004–2006 GMC YUKON XL ・ 2006-03-08

    Fuel Rail Pulse Damper Retainer Clip Fracture Recall

    1. 1Fault

      • The engine fuel rail pulse damper retainer clip may fracture, resulting in inadequate retention of the damper; if the damper comes loose, a fuel leak may result and may cause a fire if an ignition source is present.

    2. 2Finding the cause

      Possible causes

      • Analysis showed some clips were not properly heat treated and were more susceptible to fracture.

      Steps to confirm (in the document’s order)

      • To inspect for leaks, turn the ignition ON with the engine OFF for 2 seconds, turn it OFF for 10 seconds, turn it ON with the engine OFF, and inspect the fuel rail, fuel rail dampener, and fuel rail pressure cap and valve for fuel leaks.

    3. 3Correction

      Repair

      1. Dealers are to replace the engine fuel rail pulse damper retainer clip.
      2. Connect the J 34730-1A fuel pressure gage to the fuel pressure valve, wrapping a shop towel around the fitting while connecting it to avoid spillage.
      3. Open the valve on the J 34730-1A to bleed the system pressure; to help relieve residual pressure in the fuel rail, push down on the fuel rail dampener, which should move inward approximately 2-3 mm (1/8 in) as the pressure releases.
      4. Push down on the fuel dampener and remove the fuel pressure dampener clip; discard the old clip.
      5. Push down on the fuel dampener and install the new fuel pressure dampener clip.
      1 more points

      Parts

      • Part: 12575017 Clamp-Fuel Pulse Dpnr, quantity 1 per vehicle.

      Part numbers printed in the document

      The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

      Caution

      • The service procedure in this recall is different from the service procedure in the service manual.
      • If the fuel pressure is not relieved as instructed in step 8, or the dampener is not held in position while the clip is replaced, the dampener O-ring may not seat or seal properly, and a damaged or improperly seated O-ring may result in a fuel leak.
      • Do not remove the fuel dampener from the fuel rail; if it is removed, a fuel dampener kit with a new O-ring must be installed.
      • The bulletin was revised to add new information to the service procedure: warning statements were added along with some other minor changes.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to certain 2004-06 Chevrolet Silverado, Suburban, Avalanche; GMC Sierra, Yukon XL; and 2006 Chevrolet Kodiak and GMC TopKick equipped with an 8.1L V8 (RPO L18 - VIN G) engine.
    • Applies to：The defect notice lists GMC Yukon XL (GMT800): 2004 model year manufactured 03/2003 to 06/2004 (967 vehicles), 2005 manufactured 06/2004 to 06/2005 (658), and 2006 manufactured 07/2005 to 01/2006 (152).
    • Condition：The engine fuel rail pulse damper retainer clip may fracture, resulting in inadequate retention of the damper; if the damper comes loose, a fuel leak may result and may cause a fire if an ignition source is present.
    • Cause：Analysis showed some clips were not properly heat treated and were more susceptible to fracture.
    • Repair：Dealers are to replace the engine fuel rail pulse damper retainer clip.
    • Parts：Part: 12575017 Clamp-Fuel Pulse Dpnr, quantity 1 per vehicle.
    • Caution：The service procedure in this recall is different from the service procedure in the service manual.
    • Repair：Connect the J 34730-1A fuel pressure gage to the fuel pressure valve, wrapping a shop towel around the fitting while connecting it to avoid spillage.
    • Repair：Open the valve on the J 34730-1A to bleed the system pressure; to help relieve residual pressure in the fuel rail, push down on the fuel rail dampener, which should move inward approximately 2-3 mm (1/8 in) as the pressure releases.
    • Caution：If the fuel pressure is not relieved as instructed in step 8, or the dampener is not held in position while the clip is replaced, the dampener O-ring may not seat or seal properly, and a damaged or improperly seated O-ring may result in a fuel leak.
    • Caution：Do not remove the fuel dampener from the fuel rail; if it is removed, a fuel dampener kit with a new O-ring must be installed.
    • Repair：Push down on the fuel dampener and remove the fuel pressure dampener clip; discard the old clip.
    • Repair：Push down on the fuel dampener and install the new fuel pressure dampener clip.
    • Confirm：To inspect for leaks, turn the ignition ON with the engine OFF for 2 seconds, turn it OFF for 10 seconds, turn it ON with the engine OFF, and inspect the fuel rail, fuel rail dampener, and fuel rail pressure cap and valve for fuel leaks.
    • Repair：If a leak is present, a dampener kit with a new O-ring must be installed.
    • Caution：The bulletin was revised to add new information to the service procedure: warning statements were added along with some other minor changes.
    Cause
    ON CERTAIN TRUCKS EQUIPPED WITH AN 8.1L V8 (RPO L8-VIN G) ENGINE HAVE A CONDITION IN WHICH THE ENGINE FUEL RAIL PULSE DAMPER RETAINER CLIP MAY FRACTURE RESULTING IN INADEQUATE RETENTION OF THE DAMPER.
    Remedy
    DEALERS WILL REPLACE THE ENGINE FUEL RAIL PULSE DAMPER RETAINER CLIP FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 31, 2006. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 AND GMC TRUCKS AT 1-866-996-9463.
    Consequence
    IF THE DAMPER COMES LOOSE, A FUEL LEAK MAY RESULT. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

  2. Recall2004–2006 GMC YUKON XL ・ 2006-08-04

    Engine fuel rail pulse damper retainer clip fracture recall

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      Not stated

      What the documents say to do

      Engine fuel rail pulse damper retainer clip may fracture (8.1L V8) - recall 06V-289 / Transport Canada 2006195

      Confirm

      • To inspect for leaks, turn the ignition ON with the engine OFF for 2 seconds, turn it OFF for 10 seconds, turn it ON with the engine OFF, and inspect the fuel rail, fuel rail dampener, and fuel rail pressure cap and valve for fuel leaks.

      Repair

      1. Dealers replace the engine fuel rail pulse damper retainer clip.
      2. Dealers replace the engine fuel rail pulse damper retainer clip.

      Caution

      • The service procedure in this recall is different from the service procedure in the service manual.
    Read the sentences of the record
    Cause
    On certain vehicles, the engine fuel rail pulse damper retainer clip may fracture, resulting in inadequate retention of the damper. If the damper comes loose, a fuel leak may result. Fuel leakage in the presence of an ignition source could result in a fire. Correction: Dealers will replace the engine fuel rail pulse damper retainer clip.

Known issuesMid-frame cross member tear could puncture fuel tank in angled frontal impact - recall 03V-0192

  1. Recall2003 GMC YUKON XL ・ —

    Fuel Tank Shield Installation Recall

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

    Read the sentences of the record
    Cause
    ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES, VEHICLES, DURING A 30 DEGREE LEFT ANGLE FRONTAL IMPACT OF SUFFICIENT SEVERITY, A TEAR COULD DEVELOP IN THE MID-FRAME CROSS MEMBER AT ITS ATTACHMENT TO THE LEFT FRAME RAIL. IF THE MID-FRAME CROSS MEMBER TEARS DURING FRONTAL IMPACT AND PRODUCES A SHARP EDGE, CONTACT OF THE SHARP EDGE WITH THE FUEL TANK COULD RESULT IN A PUNCTURE OF THE FUEL TANK AND POSSIBLE FUEL LEAKAGE.
    Remedy
    DEALERS WILL INSTALL A FUEL TANK SHIELD. OWNER NOTIFICATION BEGAN FEBRUARY 20, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020 OR GMC AT 1-800-462-8782.
    Consequence
    FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.

  2. Recall2003 GMC YUKON XL ・ 2003-01-28

    2500 Series Mid-Frame Cross Member Fuel Tank Puncture Recall

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      Not stated

      What the documents say to do

      Mid-frame cross member tear could puncture fuel tank in angled frontal impact - recall 03V-019

      Repair

      • Dealers install a fuel tank shield.
    Read the sentences of the record
    Cause
    On certain 2500 series vehicles, a tear could develop in the mid-frame cross member at its attachment to the left frame rail during a 30 degree left angle frontal impact of sufficient severity. If the mid-frame cross member tears during frontal impact and produces a sharp edge, contact of the sharp edge with the fuel tank may result in a puncture of the fuel tank and possible fuel leakage. If a sufficient amount of fuel were to leak out and if an ignition source were present, a vehicle fire could occur. Correction: Dealer will install a fuel tank shield.

Known issuesHydro-boost brake assist and power steering share one hydraulic supply (four campaigns)2

  1. Recall2004–2005 GMC YUKON XL ・ 2005-08-02

    Bosch Hydro-Boost Brake Accumulator Crack Recall

    1. 1Fault

      • The hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost assembly in normal operation; if it separates with the hood open, fragments could injure people nearby.
      • The crack or fractured surface could let hydraulic fluid leak from the accumulator circuit of the booster, and the loss of fluid would increase steering and braking effort.

    2. 2Finding the cause

      Possible causes

      • The over-pressurization comes from a two-function valve (TFV) that does not open within its specified limits while the hydraulic fluid in the accumulator circuit expands as the booster is exposed to rising under-hood temperatures.

      Steps to confirm (in the document’s order)

      1. With the engine OFF, make at least five (5) high effort brake applies until the pedal feels hard.
      2. Turn the steering wheel to the steering lock (fully turned) position, hold for 1 to 2 seconds, then release; do this a total of 3 times.
      3. Install the inlet port adapter, CH 47950-2, into the booster supply port and slowly tighten it with a torque wrench to 16 N·m (12 lb ft).
      4. Install the accumulator pressure clamp, CH 47950-1, by sliding it over the accumulator so that it straddles the hydro-boost housing.
      5. If fluid comes out of the inlet port adapter at up to 65 N·m (48 lb ft) maximum torque on the clamp bolt, the hydro-boost booster assembly is OK.

    3. 3Correction

      Repair

      1. If no fluid is seen, complete Steps 19-27 and repeat Steps 1-18; if no fluid is visible in the second evaluation, replace the hydro-boost unit.
      2. After the test, reinstall the supply hose/tube to the booster and tighten to 28 N·m (21 lb ft).
      3. When the booster is replaced, install the 4 booster to bulkhead nuts and tighten them to 36 N·m (26 lb ft).

      Caution

      • The inspection uses the Hydro-Boost Checking Tool, CH 47950, shipped to each dealer.
      • After starting the engine, do not depress the brake pedal until instructed.
      • Incorrect installation of the fixture washer will damage the accumulator end.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：The recall covers certain 2004 Chevrolet Kodiak and GMC TopKick; 2004-2005 Chevrolet Avalanche, Express, Silverado, Suburban; GMC Savana, Sierra, Yukon XL; and HUMMER H2 vehicles built within the listed VIN breakpoints.
    • Applies to：GM limited the recall to dealer stock vehicles and sold vehicles with less than 150 days in service.
    • Condition：The hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost assembly in normal operation; if it separates with the hood open, fragments could injure people nearby.
    • Condition：The crack or fractured surface could let hydraulic fluid leak from the accumulator circuit of the booster, and the loss of fluid would increase steering and braking effort.
    • Cause：The over-pressurization comes from a two-function valve (TFV) that does not open within its specified limits while the hydraulic fluid in the accumulator circuit expands as the booster is exposed to rising under-hood temperatures.
    • Caution：The inspection uses the Hydro-Boost Checking Tool, CH 47950, shipped to each dealer.
    • Confirm：With the engine OFF, make at least five (5) high effort brake applies until the pedal feels hard.
    • Caution：After starting the engine, do not depress the brake pedal until instructed.
    • Confirm：Turn the steering wheel to the steering lock (fully turned) position, hold for 1 to 2 seconds, then release; do this a total of 3 times.
    • Confirm：Install the inlet port adapter, CH 47950-2, into the booster supply port and slowly tighten it with a torque wrench to 16 N·m (12 lb ft).
    • Confirm：Install the accumulator pressure clamp, CH 47950-1, by sliding it over the accumulator so that it straddles the hydro-boost housing.
    • Caution：Incorrect installation of the fixture washer will damage the accumulator end.
    • Confirm：If fluid comes out of the inlet port adapter at up to 65 N·m (48 lb ft) maximum torque on the clamp bolt, the hydro-boost booster assembly is OK.
    • Repair：If no fluid is seen, complete Steps 19-27 and repeat Steps 1-18; if no fluid is visible in the second evaluation, replace the hydro-boost unit.
    • Repair：After the test, reinstall the supply hose/tube to the booster and tighten to 28 N·m (21 lb ft).
    • Repair：When the booster is replaced, install the 4 booster to bulkhead nuts and tighten them to 36 N·m (26 lb ft).
    Cause
    CERTAIN TRUCKS, SPORT UTILITY VEHICLES, AND VANS EQUIPPED WITH BOSCH HYDRO-BOOST BRAKE ASSEMBLIES, THE HYDRAULIC BRAKE BOOSTER PRESSURE ACCUMULATOR MAY CRACK AND SEPARATE FROM THE HYDRO-BOOST ASSEMBLY DURING NORMAL OPERATING CONDITIONS.
    Remedy
    DEALERS WILL TEST THE HYDRO-BOOST ASSEMBLY FOR FUNCTIONAL OPERATION OF THE TWO-FUNCTION VALVE. IF THE HYDRO-BOOST ASSEMBLY FAILS THE TEST, DEALERS WILL REPLACE THE ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON MARCH 23, 2005. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438, GMC TRUCKS AT 1-866-996-9463 AND HUMMER AT 1-800-732-5493.
    Consequence
    IF A SEPARATION OCCURRED AND THE HOOD OF THE VEHICLE WERE OPEN, FRAGMENTS FROM THE ACCUMULATOR COULD CAUSE INJURY TO PEOPLE IN THE IMMEDIATE AREA. THE PRESENCE OF THIS CRACK OR FRACTURED SURFACE COULD ALLOW THE HYDRAULIC FLUID TO LEAK FROM THE ACCUMULATOR CIRCUIT OF THE BOOSTER ASSEMBLY. THE LOSS OF FLUID WOULD CAUSE INCREASED STEERING AND BRAKING EFFORT AND A CRASH MAY OCCUR WITHOUT PRIOR WARNING.

  2. Recall2004–2005 GMC YUKON XL ・ 2005-02-15

    Hydraulic Brake Booster Pressure Accumulator Crack Recall

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      Not stated

      What the documents say to do

      Hydro-boost brake assist and power steering share one hydraulic supply (four campaigns)

      Confirm

      • Perform the "Power Steering System Test" found in SI and make any necessary repairs based on system diagnosis.

      Repair

      1. Dealers replace the hydro-boost relief valve.
      2. Dealers test the hydro-boost assembly for functional operation and replace it if it fails.

      Caution

      • An inoperative pump raises steering and braking effort but does not completely remove the ability to steer or slow the vehicle.
    Read the sentences of the record
    Cause
    On certain vehicles, the hydraulic brake booster's pressure accumulator may crack and/or separate from the Hydro-Boost assembly during normal vehicle operating conditions. If a separation occurred and the hood of the vehicle was open, fragments from the accumulator could cause injury to people in the immediate area. In addition, the presence of this crack or fractured surface could allow the hydraulic fluid to leak from the accumulator circuit of the booster assembly. The loss of fluid would cause increased steering and braking effort. Correction: Dealers will test and, if necessary, replace the Hydro-Boost assembly.

Known issuesCastech cylinder head porosity crack (gradual coolant loss)1

  1. Manufacturer communication2001–2006 GMC YUKON XL DENALI ・ 2024-03-19

    Internal Coolant Leak from Cylinder Head Location

    1. 1Fault

      • Some vehicles may experience a gradual coolant loss over time.

    2. 2Finding the cause

      Possible causes

      • A very low percentage of cylinder heads manufactured with an embossed Castech logo may develop a porosity crack in a very specific area.

      Steps to confirm (in the document’s order)

      1. Check whether the head is a Castech casting by looking for the casting logo on top of the intake port, under the rocker arm support rail and in the spring deck cavity portion of the cylinder head.
      2. If the head is a Castech casting, inspect the area around the five oil drain holes for witness marks indicating coolant seepage over time.
      3. The crack can be in any of the five cylinder head oil drains and shows as a clean or shiny area on an otherwise stained surface.
      4. Pressurizing the cooling system at this time may reveal coolant, air, or a combination weeping in the described area.

    3. 3Correction

      Repair

      • If inspection reveals evidence of coolant witness marks, replace the entire cylinder head assembly.

      Caution

      • If the cylinder heads are not a Castech casting, follow normal diagnostic procedures in SI to determine the cause of the coolant loss.
      • If no evidence of coolant loss is found on inspection of Castech casting cylinder heads, follow normal diagnostic procedures in SI to determine the cause of the coolant loss.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to 2001-2006 GMC Envoy, Jimmy, Sierra and Yukon models, among other listed GM models, with the 4.8L, 5.3L or 5.7L VORTEC GEN III, GEN IV V8 engine.
    • Condition：Some vehicles may experience a gradual coolant loss over time.
    • Cause：A very low percentage of cylinder heads manufactured with an embossed Castech logo may develop a porosity crack in a very specific area.
    • Confirm：Check whether the head is a Castech casting by looking for the casting logo on top of the intake port, under the rocker arm support rail and in the spring deck cavity portion of the cylinder head.
    • Confirm：If the head is a Castech casting, inspect the area around the five oil drain holes for witness marks indicating coolant seepage over time.
    • Confirm：The crack can be in any of the five cylinder head oil drains and shows as a clean or shiny area on an otherwise stained surface.
    • Confirm：Pressurizing the cooling system at this time may reveal coolant, air, or a combination weeping in the described area.
    • Repair：If inspection reveals evidence of coolant witness marks, replace the entire cylinder head assembly.
    • Caution：If the cylinder heads are not a Castech casting, follow normal diagnostic procedures in SI to determine the cause of the coolant loss.
    • Caution：If no evidence of coolant loss is found on inspection of Castech casting cylinder heads, follow normal diagnostic procedures in SI to determine the cause of the coolant loss.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This bulletin advises the technician of possible location of an internal coolant leak from a specific cylinder head and location.

Known issuesFuel module reservoir assembly: fuel pump wire connectors may overheat - recall 05V-1551

  1. Recall2000–2001 GMC YUKON XL ・ —

    Fuel Module Reservoir Assembly Overheating Recall

    1. 1Fault

      • Some vehicles were built with fuel module reservoir assemblies whose fuel pump wires and/or connectors may overheat under certain operating conditions.
      • If the exposed ignition circuit wire shorts to ground, the fuel pump fuse blows, disabling the fuel pump and causing an engine stall or no-start; if the ignition circuit or ground wire shorts to the fuel level sender card wires, fuel level readings may be inaccurate.
      • If enough heat reaches the pass-through connector, a hole may form in it, which may turn on the Service Engine Soon light during the emission system diagnostics routine; fuel vapor, and in some cases liquid fuel, may leak from the tank through the hole.
      • If enough fuel leaked out and an ignition source were present, a vehicle fire could occur.

    2. 2Finding the cause

      Possible causes

      • Fretting corrosion caused by vibration inside the tank was identified as the cause of high resistance within the fuel pump connector.

    3. 3Correction

      Repair

      1. Dealers remove the fuel tank, remove the fuel module reservoir assembly and install a new service kit, which includes a new pass-through connector and a wiring harness for the fuel pump and fuel sender card.
      2. Start by disconnecting the negative battery cable, then remove and discard the "ECM B" fuse.
      3. In the revised bulletin, the fuel and EVAP pipes are capped with J 41413-300, EVAP Cap/Plug Kit, to prevent fuel system contamination.
      4. Remove the 4 pin Metri Pack 150 electrical connector from the vehicle's body harness.
      5. Connect the new GT280 connector to the vehicle's body harness with the 4 butt splice connectors contained in the kit.
      2 more points

      Parts

      • Part number 15824379, Harness Kit, F/Tnk F/Pmp Mdl Wrg, quantity 1 per vehicle.

      Part numbers printed in the document

      The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

      Caution

      • Do not handle the fuel sender assembly by the fuel pipes; the leverage could damage the joints.
      • Always replace the fuel sender gasket when reinstalling the fuel sender assembly, to reduce the risk of fire and injury from a fuel leak.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：The recall covers certain 2000-2001 Chevrolet 1500 Series Suburban and GMC 1500 Series Yukon XL vehicles built within the listed VIN breakpoints.
    • Condition：Some vehicles were built with fuel module reservoir assemblies whose fuel pump wires and/or connectors may overheat under certain operating conditions.
    • Condition：If the exposed ignition circuit wire shorts to ground, the fuel pump fuse blows, disabling the fuel pump and causing an engine stall or no-start; if the ignition circuit or ground wire shorts to the fuel level sender card wires, fuel level readings may be inaccurate.
    • Condition：If enough heat reaches the pass-through connector, a hole may form in it, which may turn on the Service Engine Soon light during the emission system diagnostics routine; fuel vapor, and in some cases liquid fuel, may leak from the tank through the hole.
    • Condition：If enough fuel leaked out and an ignition source were present, a vehicle fire could occur.
    • Cause：Fretting corrosion caused by vibration inside the tank was identified as the cause of high resistance within the fuel pump connector.
    • Repair：Dealers remove the fuel tank, remove the fuel module reservoir assembly and install a new service kit, which includes a new pass-through connector and a wiring harness for the fuel pump and fuel sender card.
    • Parts：Part number 15824379, Harness Kit, F/Tnk F/Pmp Mdl Wrg, quantity 1 per vehicle.
    • Repair：Start by disconnecting the negative battery cable, then remove and discard the "ECM B" fuse.
    • Repair：In the revised bulletin, the fuel and EVAP pipes are capped with J 41413-300, EVAP Cap/Plug Kit, to prevent fuel system contamination.
    • Caution：Do not handle the fuel sender assembly by the fuel pipes; the leverage could damage the joints.
    • Caution：Always replace the fuel sender gasket when reinstalling the fuel sender assembly, to reduce the risk of fire and injury from a fuel leak.
    • Repair：Remove the 4 pin Metri Pack 150 electrical connector from the vehicle's body harness.
    • Repair：Connect the new GT280 connector to the vehicle's body harness with the 4 butt splice connectors contained in the kit.
    • Repair：Install the fuel tank strap attaching bolts and tighten them to 40 N·m (30 lb ft).
    • Repair：Install the new fuel pump fuse contained in the kit into the vehicle's electrical center (ECM B).
    Cause
    CERTAIN TRUCKS AND SPORT UTILITY VEHICLES WERE BUILT WITH FUEL MODULE RESERVOIR ASSEMBLIES THAT CONTAIN FUEL PUMP WIRES CONNECTORS MAY OVERHEAT UNDER CERTAIN OPERATING CONDITIONS.
    Remedy
    DEALERS WILL REMOVE THE FUEL TANK, AND REMOVE THE MODULE RESERVOIR ASSEMBLIES FROM THE TANK, AND INSTALL A NEW SERVICE KIT FREE OF CHARGE. AN INTERIM LETTER TO OWNERS WAS MAILED ON MAY 25, 2005. THE OWNERS WERE RE-NOTIFIED ON OCTOBER 19, 2005, SINCE PARTS ARE NOW AVAILABE. OWNERS MAY CONTACT CHEVROLET AT 1-800-630-2438 AND GMC AT 1-866-996-9463.
    Consequence
    IF THE IGNITION CIRCUIT WIRE IS EXPOSED, THE FUEL PUMP FUSE WILL BLOW, DISABLING THE FUEL PUMP AND CAUSING AN ENGINE STALL OR NO-START CONDITION. IF SUFFICIENT HEAT IS CONDUCTED TO THE PASS-THROUGH CONNECTOR, A HOLE IN THE CONNECTOR MAY RESULT, WHICH MAY CAUSE A 'SERVICE ENGINE SOON' LIGHT TO BE ILLUMINATED DURING THE EMISSION SYSTEM DIAGNOSTIC ROUTINE. FUEL VAPOR AND IN SOME CASES LIQUID FUEL MAY LEAK OUT OF THE FUEL TANK THROUGH THE HOLE IN THE CONNECTOR BODY. FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE. ALSO IF THE IGNITION CIRCUIT OR GROUND WIRE IS EXPOSED AND SHORTS TO THE FUEL LEVEL SENDER CARD WIRES, INACCURATE FUEL LEVEL READINGS MAY RESULT.

ENGINE AND ENGINE COOLING4

  1. Manufacturer communication2000–2006 GMC YUKON XL DENALI ・ 2023-04-12(4 earlier editions of this document folded here)

    ACDelco Spin-On Oil Filter Torque Specification Notification

    1. 1Fault

      • An oil leak from underneath the front of the vehicle after an earlier oil service; the leak can take several thousand miles to appear.

    2. 2Finding the cause

      Possible causes

      • The oil may be leaking from between the oil filter gasket and the mounting surface.

      Steps to confirm (in the document’s order)

      • The filter may be very easy to remove, sometimes by hand.

    3. 3Correction

      Repair

      1. Lubricate the new oil filter gasket with clean engine oil.
      2. Install the oil filter 1 full turn after the gasket contacts the sealing surface on the filter mounting flange.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to all passenger cars and trucks, model years 2000 to 2024.
    • Condition：An oil leak from underneath the front of the vehicle after an earlier oil service; the leak can take several thousand miles to appear.
    • Cause：The oil may be leaking from between the oil filter gasket and the mounting surface.
    • Confirm：The filter may be very easy to remove, sometimes by hand.
    • Repair：Lubricate the new oil filter gasket with clean engine oil.
    • Repair：Install the oil filter 1 full turn after the gasket contacts the sealing surface on the filter mounting flange.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This service bulletin provides service information on new torque specification and installation procedure for ACDelco Spin-On Oil Filters.

  2. Manufacturer communication2000–2006 GMC YUKON XL DENALI ・ 2023-01-06(2 earlier editions of this document folded here)

    EVAP Leak Diagnostic Service Bulletin (DTCs P0442/P0455)

    1. 1Fault

      • The MIL is illuminated, and DTC P0442 (EVAP small leak detected) and/or P0455 (EVAP large leak detected) may be set in the ECM.

    2. 2Finding the cause

      Possible causes

      • P0455 sets because of a large leak or a purge blockage: an unseated tube connection, a damaged tube, a canister vent valve stuck open, or a purge valve stuck closed.
      • P0442 sets because of a small leak, which can come from a purge valve stuck open or a canister vent valve stuck open.

      Steps to confirm (in the document’s order)

      1. Inspect every purge connection for proper installation, and look along the lines for damage or wear; if damage is seen, confirm it with the smoke test.
      2. Some leaks show only under pressure and some only under vacuum, so check both ways; cycling the purge and vent solenoids with GDS2 while inspecting may show a sticking valve.
      3. Critical connections to check include: purge tube to purge valve (at the intake manifold), purge tube to chassis EVAP line (rear of the engine, near the transmission), chassis EVAP line to canister, and fuel tank load line to canister.
      4. Also check the vent valve line at the vent valve, the fuel tank load line jumper connection near the fuel tank, and that the fuel tank cap is closed properly.
      5. If all connections are good, check the vent valve for a stuck-open position; if the vent valve works correctly, go on to the purge valve.
      1 more points

    3. 3Correction

      Parts

      • No parts are required for this repair.

      Caution

      • For diagnostic instructions, DTC information and required tools, always follow the service information document for the vehicle and DTC being worked on.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：This bulletin only applies to vehicles with gasoline engines.
    • Condition：The MIL is illuminated, and DTC P0442 (EVAP small leak detected) and/or P0455 (EVAP large leak detected) may be set in the ECM.
    • Cause：P0455 sets because of a large leak or a purge blockage: an unseated tube connection, a damaged tube, a canister vent valve stuck open, or a purge valve stuck closed.
    • Cause：P0442 sets because of a small leak, which can come from a purge valve stuck open or a canister vent valve stuck open.
    • Confirm：Inspect every purge connection for proper installation, and look along the lines for damage or wear; if damage is seen, confirm it with the smoke test.
    • Confirm：Some leaks show only under pressure and some only under vacuum, so check both ways; cycling the purge and vent solenoids with GDS2 while inspecting may show a sticking valve.
    • Confirm：Critical connections to check include: purge tube to purge valve (at the intake manifold), purge tube to chassis EVAP line (rear of the engine, near the transmission), chassis EVAP line to canister, and fuel tank load line to canister.
    • Confirm：Also check the vent valve line at the vent valve, the fuel tank load line jumper connection near the fuel tank, and that the fuel tank cap is closed properly.
    • Confirm：If all connections are good, check the vent valve for a stuck-open position; if the vent valve works correctly, go on to the purge valve.
    • Confirm：Work in this order: EVAP lines properly installed and fully seated; damage on the EVAP lines; vent valve malfunction; purge valve malfunction.
    • Parts：No parts are required for this repair.
    • Caution：For diagnostic instructions, DTC information and required tools, always follow the service information document for the vehicle and DTC being worked on.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This service bulletin provides diagnostic tips/steps on testing for possible EVAP leaks in the system to correct a customer concern of an MIL Illuminated with DTCs P0442 and/or P0455 Set.

  3. Manufacturer communication2000–2006 GMC YUKON XL DENALI ・ 2022-09-07

    MIL Illuminated with Fuel Trim and Oxygen Sensor Codes

    1. 1Fault

      • Customers may comment that the MIL is illuminated.
      • Initial diagnosis may show fuel trim and O2 sensor related codes including P0101, P0137, P0138, P0140, P0141, P0157, P0158, P0160 and P0161.
      • The listed codes also include P0171, P0174, P0420, P0430, P1174 and P1175.

    2. 2Finding the cause

      Possible causes

      • These methods find small leaks around the O2 sensor embossments and slight cracks in an intake plenum or gasket.

      Steps to confirm (in the document’s order)

      1. If normal SI diagnostics do not lead to a resolution and an intake vacuum leak or exhaust leak is suspected, use the GE-52250 Variable Pressure Leak Detector (preferred), the J-41416 ultrasonic leak tester, or possibly soapy water with low pressure air into the tailpipe to find the leak.
      2. For an intake leak, introduce the smoke into the brake booster hose or the oil dipstick tube; soapy water can be sprayed near the gasket, seams and all vacuum nipples.
      3. For an exhaust leak, put the hose with smoke or air into the tailpipe sealed with shop towels, then spray soapy water around seals, seams and bosses.

    3. 3Correction

      Parts

      • No parts are required for this repair.

      Caution

      • All of these tests are much more effective if the throttle body is covered or sealed.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to Buick, Cadillac, Chevrolet and GMC passenger cars and trucks, model years 2000 to 2022, gasoline engines only.
    • Condition：Customers may comment that the MIL is illuminated.
    • Condition：Initial diagnosis may show fuel trim and O2 sensor related codes including P0101, P0137, P0138, P0140, P0141, P0157, P0158, P0160 and P0161.
    • Condition：The listed codes also include P0171, P0174, P0420, P0430, P1174 and P1175.
    • Confirm：If normal SI diagnostics do not lead to a resolution and an intake vacuum leak or exhaust leak is suspected, use the GE-52250 Variable Pressure Leak Detector (preferred), the J-41416 ultrasonic leak tester, or possibly soapy water with low pressure air into the tailpipe to find the leak.
    • Caution：All of these tests are much more effective if the throttle body is covered or sealed.
    • Confirm：For an intake leak, introduce the smoke into the brake booster hose or the oil dipstick tube; soapy water can be sprayed near the gasket, seams and all vacuum nipples.
    • Confirm：For an exhaust leak, put the hose with smoke or air into the tailpipe sealed with shop towels, then spray soapy water around seals, seams and bosses.
    • Cause：These methods find small leaks around the O2 sensor embossments and slight cracks in an intake plenum or gasket.
    • Parts：No parts are required for this repair.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This bulletin provides information on tools available to find an intake vacuum leak or exhaust leak to correct a condition of MIL Illuminated with Multiple Fuel Trim and/or Oxygen Sensor Codes Set.

  4. Manufacturer communication2000–2006 GMC YUKON XL ・ 2019-03-18

    Diagnostic Tip: Using Smoke Machine and Ultrasonic Detector for Air Leaks

    1. 1Fault

      • The SES light is on, and initial diagnosis may show fuel trim and/or O2 sensor related codes such as P0171, P0174, P0420 and P0430.

    2. 2Finding the cause

      Steps to confirm (in the document’s order)

      1. If normal SI diagnostics do not resolve it and an intake vacuum leak or exhaust leak is suspected, the J41413-200 Evaporative System Tester smoke machine, the J-41416 ultrasonic leak tester, or soapy water with low pressure air into the tailpipe may help find the leak.
      2. For an intake leak, the smoke can be introduced into the brake booster hose or the oil dipstick tube.
      3. Soapy water can be sprayed near the gasket and seams and on all vacuum nipples.
      4. For an exhaust leak, a hose into the tailpipe carrying smoke or air, sealed with shop towels, is effective.
      5. Then spray soapy water around the seals, seams and bosses.
      1 more points

    3. 3Correction

      Caution

      • All of these tests are much more effective if the throttle body is covered/sealed.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to all 2000 - 2019 models with gasoline engines.
    • Condition：The SES light is on, and initial diagnosis may show fuel trim and/or O2 sensor related codes such as P0171, P0174, P0420 and P0430.
    • Confirm：If normal SI diagnostics do not resolve it and an intake vacuum leak or exhaust leak is suspected, the J41413-200 Evaporative System Tester smoke machine, the J-41416 ultrasonic leak tester, or soapy water with low pressure air into the tailpipe may help find the leak.
    • Caution：All of these tests are much more effective if the throttle body is covered/sealed.
    • Confirm：For an intake leak, the smoke can be introduced into the brake booster hose or the oil dipstick tube.
    • Confirm：Soapy water can be sprayed near the gasket and seams and on all vacuum nipples.
    • Confirm：For an exhaust leak, a hose into the tailpipe carrying smoke or air, sealed with shop towels, is effective.
    • Confirm：Then spray soapy water around the seals, seams and bosses.
    • Confirm：These methods are very good for finding small leaks around the O2 sensor bosses and slight cracks in an intake plenum or gasket.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This preliminary information document communicates a tip on the way to diagnose possible induction or exhaust air leaks using the evaporative emission cart smoke machine and ultrasonic leak detector tools.

FUEL SYSTEM, GASOLINE2

  1. Owner complaint2002 GMC YUKON XL ・ 2003-11-19

    Fuel tank leaks when filled beyond 2/3-3/4 full

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

    Read the sentences of the record
    Fault
    FUEL TANK LEAKS WHEN FILLED BEYOND 2/3-3/4 FULL.
    Remedy
    MY DEALER HAS REPLACED "SEVERAL" OF THESE TANKS. (1 more)
    Inspection
    VEHICLE WAS TAKEN TO DEALER AND I WAS ADVISED THAT IN FACT THE PROBLEM WAS A FAULTY GAS TANK.

  2. Manufacturer communication2000–2006 GMC YUKON XL ・ 2021-04-19

    Engine Block Cylinder Bore Damage Information

    1. 1Fault

      • The block is suspected of cylinder bore damage, scoring or out of round as the cause of oil consumption, misfire, cylinder leakage or blow by.

    2. 2Finding the cause

      Possible causes

      • If a catalytic converter fails and the brick breaks, its dust can be drawn back into the engine.

      Steps to confirm (in the document’s order)

      1. The peak to valley spec for crosshatch is .65-2.8 microns; any deviation and the crosshatch will be gone.
      2. Cylinder damage or scoring: the walls have grooves deep enough to catch with a finger nail.
      3. If there is crosshatch all the way around the bore from top to bottom, the bore is not out of round.
      4. Dirt intrusion: with a compromised filtering system the bores look lightly sand blasted, and the crosshatch is faint with no sharpness.
      5. A block with this converter-dust failure has bores that look sand blasted.

    3. 3Correction

      Repair

      • If not caught early there will be no crosshatch and the engine will need to be replaced.

      Caution

      • GM has not had an issue with cylinders being machined out of round for any engine family in recent history.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to all brands and models, model years 2000 - 2021.
    • Condition：The block is suspected of cylinder bore damage, scoring or out of round as the cause of oil consumption, misfire, cylinder leakage or blow by.
    • Caution：GM has not had an issue with cylinders being machined out of round for any engine family in recent history.
    • Confirm：The peak to valley spec for crosshatch is .65-2.8 microns; any deviation and the crosshatch will be gone.
    • Confirm：Cylinder damage or scoring: the walls have grooves deep enough to catch with a finger nail.
    • Confirm：If there is crosshatch all the way around the bore from top to bottom, the bore is not out of round.
    • Confirm：Dirt intrusion: with a compromised filtering system the bores look lightly sand blasted, and the crosshatch is faint with no sharpness.
    • Cause：If a catalytic converter fails and the brick breaks, its dust can be drawn back into the engine.
    • Confirm：A block with this converter-dust failure has bores that look sand blasted.
    • Repair：If not caught early there will be no crosshatch and the engine will need to be replaced.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This Preliminary Information communication provides information to the technician about engine block of possible cylinder bore damage, scoring or out of round as the possible cause of engine oil consumption, misfire, cylinder leakage or blow by. Technician will need to inspect the engine for Cylinder damage or scoring, An out of round cylinder bore, Dirt intrusion, and Catalytic Converter failure.

BRAKES1

  1. Recall2000 GMC YUKON XL ・ 2000-11-17

    Brake pipe wear contact recall

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      Not stated

    Read the sentences of the record
    Cause
    On certain vehicles, the body cross sill may contact the front, right-hand brake pipe. This could eventually wear a hole in the brake pipe over the normal life of the vehicle and result in a brake fluid leak. This could ultimately result in a partial brake system failure and increased stopping distances. Correction: Dealers will inspect for brake pipe wear and replace worn section if necessary. A spacer clip will be installed to ensure adequate clearance.

ELECTRICAL1

  1. Recall2000–2001 GMC YUKON XL ・ 2005-04-15

    Fuel Module Reservoir Assembly Overheating Recall

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      Not stated

    Read the sentences of the record
    Cause
    Certain vehicles were built with fuel module reservoir assemblies that contain fuel pump wires and/or connectors that may overheat under certain operating conditions. Fuel pump wires that overheat may become exposed and result in one or more conditions; 1) If the ignition circuit wire is exposed and shorts to ground, the fuel pump fuse will blow, disabling the fuel pump and causing an engine stall or no-start condition. 2) If sufficient heat is conducted to the pass-through connector, a hole in the connector may result, which may cause the Service Engine Soon light to be illuminated during the emission system diagnostics routine. Fuel vapour (and in some limited cases liquid fuel) may leak out of the fuel tank through the hole in the connector body. 3) If the ignition circuit or ground wire is exposed and shorts to the fuel level sender card wires, inaccurate fuel level readings may result. Correction: Dealers will affect repairs.

EXTERIOR LIGHTING1

  1. Manufacturer communication2000–2006 GMC YUKON XL DENALI ・ 2023-02-28(1 earlier editions of this document folded here)

    Exterior Lamp Condensation and Water Leaks Service Bulletin

    1. 1Fault

      • Exterior lamps such as cornering, turn signal, backup, head or tail lamps may show very small water droplets, a fine mist or white fog (condensation) on the inside of the lens.

    2. 2Finding the cause

      Possible causes

      • Condensation occurs when the air inside the lamp assembly reaches the dew point through atmospheric changes.
      • Non-OE lamps are most often presented as holding moisture or with inoperative bulbs from corroded electrical connections; they appear to be installed as part of a collision repair.

      Steps to confirm (in the document’s order)

      1. Normal: the mist is located mainly in the lens corners near the vents and does not cover more than half the lens surface.
      2. Normal: the moisture clears when the vehicle is parked in a dry environment or driven with the lights on.
      3. Leak: water has accumulated in the bottom of the lamp assembly.
      4. Leak: the condition will not clear when the vehicle is parked in a dry environment or driven with the lights on.

    3. 3Correction

      Repair

      • A condition covering more than half the surface of the lamp lens indicates the need to service the lens or lamp assembly.

      Caution

      • Depending on the lamp and the atmospheric conditions, the time needed to clear the lamp may vary from 2 to 6 hours.
      • If the normal conditions are noted, advise the customer that replacing the lamp assembly may not correct the condition.
      • Moisture that "comes and goes" is considered a normal condition.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to 2023 and prior GM passenger cars and trucks, including medium duty trucks and excluding LCF medium duty trucks.
    • Condition：Exterior lamps such as cornering, turn signal, backup, head or tail lamps may show very small water droplets, a fine mist or white fog (condensation) on the inside of the lens.
    • Cause：Condensation occurs when the air inside the lamp assembly reaches the dew point through atmospheric changes.
    • Caution：Depending on the lamp and the atmospheric conditions, the time needed to clear the lamp may vary from 2 to 6 hours.
    • Confirm：Normal: the mist is located mainly in the lens corners near the vents and does not cover more than half the lens surface.
    • Confirm：Normal: the moisture clears when the vehicle is parked in a dry environment or driven with the lights on.
    • Caution：If the normal conditions are noted, advise the customer that replacing the lamp assembly may not correct the condition.
    • Repair：A condition covering more than half the surface of the lamp lens indicates the need to service the lens or lamp assembly.
    • Confirm：Leak: water has accumulated in the bottom of the lamp assembly.
    • Confirm：Leak: the condition will not clear when the vehicle is parked in a dry environment or driven with the lights on.
    • Caution：Moisture that "comes and goes" is considered a normal condition.
    • Cause：Non-OE lamps are most often presented as holding moisture or with inoperative bulbs from corroded electrical connections; they appear to be installed as part of a collision repair.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This service bulletin provides information for dealers/technicians on Exterior Lamp Condensation and Water Leaks and Replacement Guidelines.

FUEL SYSTEM, OTHER1

  1. Owner complaint2001 GMC YUKON XL 2500 ・ 2009-10-08

    Gas leaking from underneath vehicle, fuel pump assembly fuel nipple

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

    Read the sentences of the record
    Fault
    WAS DRIVING VEHICLE, STOPPED VEHICLE, NOTICED THAT GAS WAS LEAKING FROM UNDERNEATH THE VEHICLE.
    Cause
    THIS WAS NOT DUE TO WEAR AND TEAR. (1 more)
    Remedy
    ENTIRE ASSEMBLY HAD TO BE REPLACED.

STEERING1

  1. Manufacturer communication2006 GMC YUKON XL ・ 2020-08-10

    Power Steering Noise at Low Temperatures - Technical Bulletin

    1. 1Fault

      • Noise or a fluid leak from the power steering pump, gear or high pressure side hose during extreme low outdoor temperature operation.

    2. 2Finding the cause

      Possible causes

      • At -30°C (-22°F) or lower the power steering fluid may thicken and system pressures may rise, potentially causing noise or damage to components.

    3. 3Correction

      Repair

      • Replace any damaged power steering components, flush the system and refill with Cold Climate power steering fluid.

      Parts

      • P/N 12345866 (in Canada 10953484): 16 oz. bottle Power Steering Fluid - Cold Climate.
      • P/N 12345867 (in Canada 10953471): 32 oz. bottle Power Steering Fluid - Cold Climate.

      Part numbers printed in the document

      The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

      Caution

      • In some extreme operating conditions this fluid may not correct the condition.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Applies to 2014 and prior GM passenger cars and light duty trucks.
    • Condition：Noise or a fluid leak from the power steering pump, gear or high pressure side hose during extreme low outdoor temperature operation.
    • Cause：At -30°C (-22°F) or lower the power steering fluid may thicken and system pressures may rise, potentially causing noise or damage to components.
    • Repair：Replace any damaged power steering components, flush the system and refill with Cold Climate power steering fluid.
    • Caution：In some extreme operating conditions this fluid may not correct the condition.
    • Parts：P/N 12345866 (in Canada 10953484): 16 oz. bottle Power Steering Fluid - Cold Climate.
    • Parts：P/N 12345867 (in Canada 10953471): 32 oz. bottle Power Steering Fluid - Cold Climate.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This technical bulletin provides a procedure to eliminate a power steering noise due to extremely low temperatures.

STRUCTURE1

  1. Owner complaint2001 GMC YUKON XL 1500 ・ 2009-06-02

    Roof leaks when raining

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

      Not stated

    Read the sentences of the record
    Fault
    THE CONTACT STATED THAT THE ROOF OF THE VEHICLE LEAKS WHENEVER IT RAINS.
    Cause
    THE ROOF IS LEAKING FROM THE FACTORY MADE ROOF RACK BECAUSE IT IS CORRODED AND CREATED A HOLE.
    Consequence
    AS A RESULT, HIS FAMILY BECOMES ILL WHEN THE FAILURE OCCURS.

SUSPENSION1

  1. Manufacturer communication2003–2006 GMC YUKON XL DENALI ・ 2021-04-16

    Fluid Leakage vs. Seepage Identification Guide

    1. 1Fault

    2. 2Finding the cause

      Not stated

    3. 3Correction

      Information Regarding the Differences Between Fluid Leakage and Seepage This bulletin is intended to help identify the differences between what is considered a fluid leak and what is considered seepage. Improper diagnosis may lead to unnecessary component replacement. Use the following information to determine if the condition is normal acceptable seepage or a defective component

    Read the sentences of the record
    Remedy
    Information Regarding the Differences Between Fluid Leakage and Seepage This bulletin is intended to help identify the differences between what is considered a fluid leak and what is considered seepage. Improper diagnosis may lead to unnecessary component replacement. Use the following information to determine if the condition is normal acceptable seepage or a defective component

TIRES1

  1. Owner complaint2003 GMC YUKON XL ・ 2009-05-29

    Defective tire valve stems; multiple tire failures at highway speed

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

    Read the sentences of the record
    Cause
    CAUSE OF DAMAGE WAS VALVE STEM, TR 413. (1 more)
    Inspection
    AT MY REQUEST INSPECTED 4TH TIRE AND IT HAD A BAD STEM AND WAS LEAKING.
    Consequence
    LUCKILY NO ONE WAS INJURED.

VISIBILITY1

  1. Manufacturer communication2005–2006 GMC YUKON XL ・ 2021-04-19(1 earlier editions of this document folded here)

    Sunroof Operation Issues - Preliminary Information

    1. 1Fault

      • Intermittent sunroof operation, bind, noise, auto-reverse and/or water leaks.

    2. 2Finding the cause

      Possible causes

      • Dirt and debris collect on the sunroof seal or in the tracks, affecting operation, causing noise or plugging the water drainage system.

      Steps to confirm (in the document’s order)

      • Verify that the module drain holes are not plugged.

    3. 3Correction

      Repair

      1. Open the sunroof and remove any obstacles or loose debris.
      2. Wipe the sunroof seal and the roof sealing area with a clean cloth, mild soap and water.

      Caution

      • Do not remove grease from the sunroof.
      • Some replaced sunroof module assemblies returned to the warranty parts center were found to need only cleaning of these areas.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：All models, model years 2005 - 2021.
    • Condition：Intermittent sunroof operation, bind, noise, auto-reverse and/or water leaks.
    • Cause：Dirt and debris collect on the sunroof seal or in the tracks, affecting operation, causing noise or plugging the water drainage system.
    • Repair：Open the sunroof and remove any obstacles or loose debris.
    • Confirm：Verify that the module drain holes are not plugged.
    • Repair：Wipe the sunroof seal and the roof sealing area with a clean cloth, mild soap and water.
    • Caution：Do not remove grease from the sunroof.
    • Caution：Some replaced sunroof module assemblies returned to the warranty parts center were found to need only cleaning of these areas.

    Open the manufacturer’s document (PDF) ↗ The points above were read from this document.

    Remedy
    This Preliminary Information communication advises the technician the steps on diagnosing the concern. Customer's sunroof operation intermittent, bind, noise, auto-reverse, and/or water leaks.

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