Product Safety - Fuel Tank Weld

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2004 Chevrolet Classic and Pontiac Grand Am vehicles. Some of these vehicles may have been built with a fuel tank that does not meet specification. A weld on these fuel tanks may be insufficient, resulting in a fuel leak. If this were to occur, the operator may notice a strong fuel smell and may notice some dampness on the ground. If a sufficient amount of fuel were to leak out and if an ignition source were present, a vehicle fire could occur.

Dealers are to inspect the fuel tank, and replace it, if necessary.

Involved are certain 2004 model year Chevrolet Classic and Pontiac Grand Am vehicles built within these VIN breakpoints:

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) before beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.]

For US

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned will not have a report available in GM DealerWorld.

For Canada & IPC

For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned will not receive a report with the recall bulletin.

The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any other 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 program.

Parts required to complete this recall are to be obtained from General Motors Service 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.

The following procedure provides instructions for inspection, and if necessary, the replacement of the fuel tank.

Inspection

1. Raise the vehicle in a suitable hoist and support as necessary.



2. Inspect the bottom side of the fuel tank to determine if the tank requires replacement.

•	If the fuel tank has the name "ABC GROUP" as shown above, then proceed to the next step and continue the inspection.

•	If the fuel tank does NOT have the name 'ABC GROUP", then the fuel tank does NOT need to be replaced and no further action is required.

3. Lower the vehicle.
4. Open the hood.
5. Remove the cover from the underhood electrical center and remove the fuel pump relay.
6. Start the engine on the remaining fuel system pressure and allow it to run until stall.
7. Turn the ignition switch to the OFF position.

Caution: Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these instructions may result in personal injury.

Caution: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion.

8. Remove the fuel filler cap.
9. Use a hand or air operated pump device in order to drain as much fuel as possible through the filler neck. Remove the fuel.
10. Raise the vehicle.



11. Remove the bolt attaching the intermediate exhaust pipe bracket to the underbody.
12. Disconnect the rubber exhaust insulators (hangers) from the rear of the exhaust system and allow the system to rest on the rear axle.
13. Remove the four screws and one push-in retainer and remove the exhaust heat shield for the intermediate pipe.
14. Disconnect the electrical connector for the fuel tank sender.
15. Release the wiring harness from the retainer on the right fuel tank strap.
16. Loosen the clamp for the fuel fill hose and separate the hose from the fuel fill pipe. If necessary, the fuel fill hose connection to the fuel tank will be disconnected later in this procedure.
17. Disconnect the fuel feed quick-connect fitting from the fuel filter.
18. Disconnect the fuel return quick-connect fitting.
19. Disconnect the evaporative emission (EVAP) quick-connect fitting at the EVAP canister.
20. Support the fuel tank with a suitable jack.



21. Remove the bolts that attach the fuel tank straps to the underbody.
22. Unhook the other end of the fuel tank straps from the underbody.
23. With the aid of an assistant, lower and remove the fuel tank assembly.



24. Inspect the label as shown above, located on the top of the fuel tank.

•	If the bar code number on the label matches one of those listed at the end of this service procedure, then the fuel tank must be replaced. Proceed to the FUEL TANK REPLACEMENT procedure.

•	If the bar code number on the label does NOT match any of those listed at the end of this service procedure, then the fuel tank does NOT need to be replaced. Proceed to Step 13 in the FUEL TANK REPLACEMENT procedure to reinstall the tank.

Fuel Tank Replacement

Tools Required

J 39765 Fuel Sender Lock Nut Wrench

Important: Before removing the fuel fill hose from the fuel tank, note the orientation of the hose so that it can be installed on the new fuel tank in the same position.

1. Loosen the clamp attaching the fuel fill hose and remove the hose from the fuel tank.
2. Disconnect the EVAP hose from the valve on the fuel tank.
3. Disconnect the electrical connectors from the fuel sender.




Important: 

•	The modular fuel sender may spring up.

•	When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. The reservoir must be tipped slightly during removal to avoid damage to the float.

•	Carefully discard the reservoir fuel into an approved container.

4. Using the J 39765, Fuel Sender Lock Nut Wrench, press down and rotate the retaining ring (1) to release the sender from the tank.
5. Carefully remove the fuel sender assembly (complete with all fuel lines) from the fuel tank and remove the fuel line strap from the fuel tank inlet.
6. Position the fuel line strap around the fuel inlet on the NEW fuel tank.
7. Using a new O-ring seal, install the fuel sender in the fuel tank.
8. Slowly apply pressure to the top of the spring-loaded sender until the sender aligns flush with the retainer on the tank.

Important: Be sure that the retaining ring is fully seated within the tab slots in the next step.

9. Using the J 39765, rotate the retaining ring to engage and fully seat the ring within the tab slots.
10. Connect the electrical connectors to the fuel sender.
11. Connect the EVAP hose to the valve on the fuel tank.
12. Install the fuel fill hose and clamp on the fuel tank in the same orientation that was noted before removal from the old tank.

Tighten
Tighten to 3 N·m (27 lb in).

13. With the aid of an assistant, raise and position the fuel tank assembly to the vehicle.
14. Hook the fuel tank straps to the underbody.
15. Install the bolts in the fuel tank straps.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).

16. Connect the EVAP hose to the canister.
17. Connect the fuel feed and return line quick-connect fittings.
18. Install the fuel fill hose and clamp to the fill pipe.

Tighten
Tighten to 3 N·m (27 lb in).

19. Connect the wiring harness to the retainer on the fuel strap.
20. Connect the electrical connector to the fuel sender.
21. Position the exhaust shield to the underbody and install the screws and push-in fastener.

Tighten
Tighten the screws to 2 N·m (18 lb in).

22. Raise the exhaust system and connect the rubber insulators.
23. Position the intermediate exhaust bracket to the underbody and install the bolt.

Tighten
Tighten to 20 N·m (15 lb ft).

24. Lower the vehicle.
25. Fill the fuel tank and install the filler cap.
26. Install the fuel pump relay and install the cover on the electrical connector.
27. Close the hood.
28. Inspect for leaks using the following procedure:

•	Turn the ignition switch to ON with the engine OFF for 2 seconds.

•	Turn the ignition switch to OFF for 10 seconds.

•	Turn the ignition switch to ON with the engine OFF.

•	Inspect for leaks.

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 Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall 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. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines.

Submit a Product Recall Claim with the information indicated below:

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

Dealers are requested to contact customers via telephone. General Motors will also notify customers of this recall by first class mail (see copy of customer letter included with this bulletin).

Dealers are requested to contact customers via telephone. 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.

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle which is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

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, please take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle.

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Federal regulation requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days.

You may have already been contacted regarding this recall by your GM dealer, but this letter is to inform you to contact your GM dealer immediately if your vehicle has not been serviced for the recall described in this letter.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2004 Chevrolet Classic and Pontiac Grand Am vehicles. Some of these vehicles may have been built with a fuel tank that does not meet specification. A weld on these fuel tanks may be insufficient, resulting in a fuel leak. If this were to occur, the operator may notice a strong fuel smell and may notice some dampness on the ground. If a sufficient amount of fuel were to leak out and if an ignition source were present, a vehicle fire could occur.

To prevent the possibility of this condition occurring, your GM dealer will inspect the fuel tank, and replace it, if necessary. This service will be performed for you at no charge .

This inspection and correction, if necessary, will take approximately 15 minutes to 1 hour and 20 minutes, depending on the results of the inspection. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

To limit any possible inconvenience, we recommend that you contact your dealer as soon as possible to schedule an appointment for this repair. By scheduling an appointment, your dealer can ensure that the necessary parts will be available on your scheduled appointment date.

Should your dealer be unable to schedule a service date within a reasonable time, you should contact the appropriate Customer Assistance Center at the number listed below. The hours of operation are from 8:00 AM - 11:00 PM, EST, Monday through Friday.

If, after contacting the appropriate customer assistance center, you are still not satisfied that we have done our best to remedy this condition without charge and within a reasonable time, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street SW, Washington, DC 20590 or call 1-888-327-4236.

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 form and mailing it back to us.

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.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your safety and continued satisfaction with our products.

General Motors Corporation

Enclosure