Campaign - Fuel Filler Cap Warranty Extension: Overview
Subject:Special Coverage Adjustment - fuel Tank Caps
# 07012 - (07/31/2007)
Models:
2004 Chevrolet Colorado
2004 GMC Canyon
Condition
Some customers of 2004 Chevrolet Colorado and GMC Canyon model vehicles may experience a condition where the fuel tank cap won't tighten properly, or the fuel tank cap won't come off or is broken. These conditions may also cause the illumination of the Malfunction Indicator Light (MIL).
Special Coverage Adjustment
This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the customer.
For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or afier August 1, 2007 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to August 1, 2007 must be submitted to the Service Contract provider.
Vehicles Involved
Involved are all 2004 Chevrolet Colorado and GMC Canyon vehicles and built within the VIN breakpoints shown.
Parts Information
Parts required to complete this special coverage are to be obtained from General Motors Service and Parts Operations (GMSPO).
Customer Notification
General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly).
Service Procedure
Customers may inform technicians that the Malfunction Indicator Light (MIL) or Service Engine Soon (SES) light is on and/or the fuel cap cannot be tightened or removed.
^ If the SES light is illuminated, record the Diagnostic Trouble Codes (DTC) using the Tech 2.
^ If the fuel cap cannot be tightened or removed, proceed to the section below titled, Replacing Broken Fuel Cap.
^ If DTC P0442 - Evaporative Emission (EVAP) System Small Leak Detected is stored in the Engine Control Module (ECM), proceed to section titled DTC P0442.
^ If DTC P0455 - Evaporative Emission (EVAP) System Large Leak Detected is stored in the ECM, proceed to section titled DTC P0455.
^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance.
^ Some vehicles may intermittently set a DTC of P0442 or P0455, leak in the evaporative emissions system. In addition to checking the system and performing the diagnostics as described in the Service Information for this DTC, the technician should be aware that some of the fuel caps used on GM vehicles may not seal adequately to the filler neck if pushed down when being tightened. This may occur more often when this cap is used on a vehicle with a steel fuel filler neck. The owner should be instructed not to apply a downward force to the fuel cap when tightening.
Replacing Broken Fuel Cap
1. Remove the fuel cap tether from the fuel filler pocket or fuel filler door.
2. Remove the fuel cap from the fuel filler.
3. If the fuel cap cannot be removed, remove the fuel cap ratcheting cover by releasing the four (4) tabs holding the cap cover to the lugged sealing base.
4. Position the radiator hose removal tool or similar type tool between the black cover and white inside body, and pry the cover over the retaining tab by rotating the tool counter clockwise. Repeat, if necessary, on the 3 other locations around the cover.
5. Remove the white fuel cap base from the filler pipe by rotating the fuel cap base counter clockwise.
6. Install the new fuel filler cap and secure the tether to the fuel filler pocket or filler door.
DTC P0455 - (Evaporative Emission (EVAP) System Large Leak Detected)
Diagnostic Aids: P0455 diagnostics is checking for a large leak in the EVAP system. Examples of conditions that may contribute to this code setting are: loose or broken fuel cap, disconnected or cracked EVAP lines, cracked charcoal canister, sticking purge or vent solenoids, inaccurate fuel gauge, etc.
DTC P0442 - (Evaporative Emission (EVAP) System Small Leak Detected)
Diagnostic Aids: P0442 diagnostics is checking for a 0.5 mm (0.020 in) sized hole in the EVAP system. Examples of conditions which may cause this type leak could include: cracked EVAP lines, cracked charcoal canister, a cut or dirty fuel cap seal, debris on the purge or vent solenoid internal seals, loose fuel lines, etc. Refer to Fuel Cap Inspection for P0442.
Fuel Cap Inspection for P0042
1. Inspect the green sealing ring (1) on fuel cap for debris or cuts which could cause a small EVAP leak.
2. Inspect filler neck sealing surface (1) for gouges or dents produced by accident or fuel nozzle damage.
3. Diagnose P0442 - Evaporative Emission (EVAP) System Small Leak Detected DTC. Refer to DTC P0442 - Evaporative Emission (EVAP) System Small Leak Detected Diagnostics in the Diagnostics Information and Procedures Section of SI for the appropriate vehicle.
Claim Information
For vehicles repaired under the terms of this special coverage, submit a claim with the information shown.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers.
Customer requests for reimbursement of previously paid repairs to correct the special coverage condition are to be submitted prior to or by August 3 1, 2008.
Important:
Refer to GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures reguarding customer reimbursement and the form.
Customer Reimbursement For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct the special coverage condition are to be submitted to the dealer prior to or by August 31, 2008. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km (120,000 miles), whichever occurs first.
When a customer requests reimbursement, they must provide the following:
^ Proof of ownership at time of repair.
^ Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair.
^ If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership.
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