Product Safety - Fuel Tank Inlet Check Valve (ICV) Insufficient Weld

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2004 model year Buick Rendezvous and Pontiac Aztek vehicles. A weld between the fuel tank inlet check valve (ICV) and the fuel tank was not made to specification and can fail. If these parts separate, the driver may notice an odor of fuel, the Service Engine Soon or Check Engine light may illuminate, and/or fuel may leak onto the ground. If a sufficient amount of fuel leaked and if an ignition source were present, a vehicle fire could occur.

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

There are 89 vehicles involved in this recall. Of those, only 12 vehicles will require fuel tank replacement. To reduce customer inconvenience, dealers are being given the option of sending a technician to the customers' home or workplace for an on-site service visit to complete this inspection.

Involved are the vehicles listed below.

Important: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) or GM Access Screen (Canada only) or DCS Screen 445 (IPC only) before beginning recall repairs.

This recall requires an inspection prior to ordering a fuel tank. If the inspection determines that a replacement is necessary, contact Inergy Automotive Systems at 1-877-946-3749. You will be asked for the VIN and the serial number off of the fuel tank to be replaced. The fuel tank will be shipped overnight. Inergy will also arrange for the pickup of the old fuel tank. DO NOT ORDER FUEL TANKS FROM GMSPO.

The following information provides instructions for inspecting the serial number on the bar code label located on the rear section of the fuel tank.

Fuel Tank Inspection

Read the complete inspection procedure before beginning your first inspection.

The bar code label is located on the rear section of the fuel tank and can be viewed using a flashlight from the rear of ALL vehicles (FWD and AWD) as shown above or on a suitable hoist.

The bar code label (1) is located to the right side of a parts label (2). Directly below the bar code is the 14-character serial number.

From underneath the vehicle, read the LAST FOUR numbers of the serial number and compare them to those listed below. Example: FS2543R2060 .

Fuel Tank Replacement

This procedure should be used only if the inspection indicated that the fuel tank requires replacement. For additional information and illustrations, refer to the Fuel Tank Replacement Procedure in the appropriate Service Manual or SI Document ID 901259. Because the replacement fuel tanks in this recall are complete assemblies (include fuel sender, etc.) the labor time allowance is different than that in the labor time guide.

Caution: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury.

1. Relieve the fuel system pressure. For additional information, refer to the Fuel Pressure Relief Procedure in the appropriate Service Manual or SI Document ID 634625.
2. Drain the fuel tank. For additional information, refer to the Fuel Tank Draining Procedure in the appropriate Service Manual or SI Document ID 634632.

Caution: To avoid any vehicle damage, serious personal injury, or death when major components are removed from the vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being remove.

3. Raise the vehicle on a suitable lift, and support as necessary.
4. Disconnect the fuel tank wiring harness connector (1) at the body pass through.
5. Disconnect the quick-connect fitting at the inlet side of the in-pipe fuel filter. For additional information, refer to the Quick Connect Fitting Service Procedure in the appropriate Service Manual or SI Document ID 634629.
6. Disconnect the quick-connect fitting on the fuel return pipe, near the fuel filter.
7. Disconnect the fuel tank evaporative emission (EVAP) pipe quick-connect fitting near the fuel filter.
8. Remove the fuel feed, the fuel return, and the EVAP lines from the fuel pipe retainer.
9. Remove the retaining nut for the EVAP canister bracket.
10. Loosen the fuel tank filler pipe hose clamp.
11. Disconnect the fuel tank filler pipe from the fuel tank.

Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

12. With the aid of an assistant, support the fuel tank and remove the two fuel tank strap attaching bolts.
13. Remove the fuel tank from the vehicle.
14. With the aid of an assistant, position and support the new fuel tank to the vehicle.

Notice: Do not bend the fuel tank straps. Bending the fuel tank straps may damage the straps.

15. Position the fuel tank straps and install the two fuel tank retaining strap attaching bolts.

Tighten
Tighten the fuel tank retaining strap bolts to 47 N·m (35 lb ft).

16. Install the EVAP canister retaining nut.

Tighten
Tighten the EVAP canister retaining nut to 6 N·m (53 lb in).

17. Connect the fuel tank filler pipe to the fuel tank.

Tighten
Tighten the fuel tank filler pipe hose clamp to 2.5 N·m (22 lb in).

18. Connect the fuel feed pipe quick-connect fitting at the inlet side of the fuel filter.
19. Connect the fuel return pipe quick-connect fitting near the fuel filter.
20. Connect the fuel tank EVAP pipe quick-connect fitting near the fuel filter.
21. Install the fuel feed, fuel return, and the EVAP lines in the fuel pipe retainer.
22. Connect the fuel tank wiring harness connector at the body pass-through.
23. Lower the vehicle.
24. Connect the negative battery cable.
25. Add fuel and reinstall the fuel tank filler pipe cap.
26. Inspect for fuel leaks with the following procedure:

26.1.

Turn ON the ignition for 2 seconds.

26.2.

Turn OFF the ignition for 10 seconds.

26.3.

Turn ON the ignition.

26.4.

Inspect for fuel leaks.

27. Install the GM Recall Identification Label.
28. Prepare the old fuel tank for return to the manufacturer.

28.1.

Remove the fuel sender shield from the OLD fuel tank.

28.2.

Disconnect the fuel feed, fuel return and EVAP pipe quick-connect fittings at the fuel sender.

28.3.

Remove the fuel sender assembly from the old fuel tank.

28.4.

Neutralize and flush the old fuel tank clean.

28.5.

Allow the fuel tank to air dry. Do not reinstall the fuel sender or the shield.

28.6.

Store the fuel tank, the fuel sender and the shield until it is picked up by the manufacturer.

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five (5) digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ball point pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle.

For US and IPC

When installing the Recall Identification Label, be sure to pull the tab to allow the adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by either ordering on the web from DWD Store, gm-dealerworld.com, or calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Ask for Item Number S-1015 when ordering.

Additional Recall Identification Labels for IPC dealers can be obtained from your Regional Marketing Office.

For Canada

Additional Recall Identification Labels for Canadian dealers can be obtained from DGN by calling 1-800-668-5539 (Monday-Friday, 8:00 a.m. to 5:00 p.m. EST). Ask for Item Number GMP 91 when ordering.

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.

Customers will be notified of this recall on their vehicles by General Motors (see copy of customer letter included with this bulletin).

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. This could be done by mailing to such customers a copy of the customer letter accompanying this bulletin. 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.

General Motors has decided that a defect which relates to motor vehicle safety exists in certain 2004 model year Buick Rendezvous and Pontiac Aztek vehicles. On some of these vehicles, a weld between the fuel tank inlet check valve and the fuel tank was not made to specification and can fail. If these parts separate, the driver may notice an odor of fuel, the Service Engine Soon or Check Engine light may illuminate, and/or fuel may leak onto the ground. If a sufficient amount of fuel leaked and if an ignition source were present, a vehicle fire could occur.

Your GM dealer will check to see if the fuel tank on your vehicle has a serial number that is on a list of affected tanks. If the serial number matches, the tank will be replaced. This service will be performed for you at no charge .

This inspection will take approximately 15 minutes. If the fuel tank requires replacement, it will take an additional hour. 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 GM 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:

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 attached customer reply card identifies your vehicle. Presentation of this card 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 attached and mailing it in the postage paid envelope.

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