Campaign - Fuel Filler Pipe/Filler Cap Replacement

SERVICE UPDATE

Bulletin No.: 08329B

Date: July 24, 2009

Subject: 08329B - Service Update for Inventory Vehicles Only - Fuel Cap Does Not Seal Properly - Expires December 31, 2009

Models:
2008 Saturn Astra

Supercede:
THIS BULLETIN IS BEING REVISED TO EXTEND THE EXPIRATION DATE TO DECEMBER 31, 2009. PLEASE DISCARD ALL COPIES OF BULLETIN 08329, ISSUED FEBRUARY 2009.

THIS SERVICE UPDATE INVOLVES VEHICLES IN RETAILER INVENTORY ONLY AND WILL EXPIRE DECEMBER 31, 2009.

Purpose

This bulletin provides a service procedure to replace the fuel filler pipe and fuel cap on certain 2008 model year Saturn Astra vehicles. On some of these vehicles, irregularities in the fuel filler pipe surface may prevent the fuel cap from sealing properly.

This service procedure should be completed on involved vehicles currently in retailer inventory as soon as possible but no later than December 31, 2009, at which time this bulletin will expire.

Vehicles Involved

A list of involved vehicles currently in retailer inventory is available on the "Service Update Bulletin Information" link under the "Service" tab in DealerWorld (US), or attached to the Dealer Communication (Canada), used to release this bulletin.

Important
Retailers are to confirm vehicle eligibility prior to beginning repairs by using the system(s) below. Not all vehicles within the above breakpoints may be involved. - Canadian Saturn retailers should use GMVIS. - US Saturn retailers should use the 'Investigate Vehicle History' link on the Global Warranty Management application within DealerWorld.

Parts Information

Canada Only: Parts required to complete this recall are to be obtained from General Motors Service and Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO = Customer Special Order.

US Only: A pre-shipment of the required parts to perform this recall has been sent to involved Saturn US retailers from Saturn Service Parts Operations (SSPO).





Service Procedure

Caution
Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.

Important

- The fuel tank must be drained with a suitable, commercially-available fuel removal unit and suction hose - follow safety regulations and national legislation. The fuel tank is fitted with a refill limit float valve. This is located on the filler neck in the fuel tank. To prevent damaging the refill limit float valve, a suitable suction hose must be used.
- In the presence of fuel vapors or escaping fuel - observe safety regulations and national legislation. Store drained fuel in a suitable, sealable container.

2. Drain the fuel tank.
3. Remove the fuel fill cap.
4. Remove the fuel fill cap retaining strap screw.
5. Raise and support the vehicle.
6. Remove the right rear tire/wheel assembly.
7. Remove the right rear wheelhouse liner.
8. Remove the fuel tank filler pipe seal.
9. Remove the fuel tank filler pipe screw from the fuel tank filler pipe housing.
10. Remove the fuel tank filler pipe bolt from the underbody side rail.
11. Remove the three tie straps securing the wiring harness to the filler pipe.
12. Disconnect the electrical connector from the pressure sensor (atmospheric pressure).
13. Disconnect the fuel tank fill EVAP emission pipe quick connect fitting from the fuel tank vent pipe.
14. Loosen the fuel filler pipe hose clamp at the fuel tank.
15. Separate the fuel filler pipe hose from the fuel tank.
16. Remove the fuel tank filler pipe.
17. Transfer the pressure sensor (atmospheric pressure) to the new fuel filler pipe.
18. Install the fuel tank filler pipe.
19. Install the fuel filler pipe hose to the fuel tank.
20. Connect the fuel tank fill EVAP emission pipe quick connect fitting from the fuel tank vent pipe.
21. Tighten the fuel filler pipe hose clamp at the fuel tank.
22. Install the fuel tank filler pipe bolt to the underbody side rail.
23. Connect the electrical connector to the pressure sensor (atmospheric pressure).
24. Install the three tie straps.
25. Install the fuel tank filler pipe screw to the fuel tank filler pipe housing.
26. Install the fuel tank filler pipe seal.
27. Install the right rear wheelhouse liner.
28. Install the right rear tire/wheel assembly.
29. Lower the vehicle.
30. Install the fuel fill cap retaining strap screw.
31. Install the new fuel fill cap.
32. Fill the fuel tank with the fuel removed in Step 1.
33. Inspect for leaks.
34. Connect the negative battery cable.

Claim Information - Canada Only

For vehicles repaired under this service update, use:





Claim Information - US Only





1. To receive credit, submit a claim with the information shown in the table above.





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