Product Safety - V6 Engine Fuel and Vapor Hose Interference (Export Only). Chevrolet Caprice WM 2008

Subject:

07337 -- V6 Engine Fuel and Vapor Hose Interference

Models:

2007-2008 Chevrolet Caprice, Lumina

Condition

General Motors has decided that a defect, which relates to motor vehicle safety, exists in all 2007 and 2008 model year Chevrolet Lumina and Caprice model vehicles equipped with 3.6 litre V6 engine RPO code LE0 and LY7 Some of these vehicles have a condition in which contact between the fuel pressure hose at the rear of the engine compartment, and a clip retaining the vapor vent hose may result in damage leading to potential perforation of the fuel pressure hose, and consequently, fuel leakage.

If perforation were to occur resulting in fuel leakage, and if an ignition source were present, an engine compartment fire could occur.

Correction

Dealers are to inspect the protective covering on the vapor hose clamp, and if worn exposing the metal edge of the clamp, are to replace the fuel pressure hose. The clamp is to be removed from the vapor hose, and replaced by a strap as detailed in the instructions.

Vehicles Involved

Involved are all 2007 and 2008 model year Lumina, Caprice model vehicles equipped with 3.6 litre V6 engine, RPO code LE0 and LY7 and built within these VIN breakpoints:

Year	Division	Model	From	Through
2007/08	Chevrolet	Lumina/Caprice	6G1ML54B37L814195	6G1EL55788L134681

Important: For dealers with involved vehicles, a listing with involved vehicles has been prepared and will be provided. Dealers will not have a report available if they have no involved vehicles currently assigned.

Parts Information

It is anticipated that approximately 5% of affected vehicles will require replacement of the fuel hose.

All vehicles MUST have the vapor hose clamp removed and replaced with the strap shown below.

Parts required to complete this recall are to be obtained from General Motors Service and Parts Operations (GMSPO)/ MEDC.

Part Number	Description	Qty/ Vehicle
92211878	Hose, Fuel pressure (5% of vehicles)	5%
92138154	Strap, vapor hose retaining	100%

Important: It is estimated that only 5% of involved vehicles will require fuel hose replacement. Please order parts accordingly.

Service Procedure

Important: Please note there Are Two Types Of Evaporative Hose Designs fitted to the vehicle.

08-H-01 VE WM V6 Fuel Feed Hose Technical Instruction

Summary: Potential damage to the Fuel Feed Hose, resulting in fuel leakage, can occur if the Fuel Feed Hose rubs on the Saddle Clamp that retains the (Evaporative Emission) Purge Hose. Refer Figure 1 & 2.

Please read the following instructions very carefully to ensure vehicles are correctly campaigned.

Once it has been confirmed that the vehicle is affected and requires campaign action:

•	The Purge Hose Saddle Clamp and M10 retaining bolt will be required to be removed and the Purge Hose MUST be retained with a cable tie.

•	The removed Purge Hose Saddle Clamp MUST be inspected for damage to the Saddle Clamp rubber sleeve.

•	Evidence of damage to the Saddle Clamp rubber sleeve that has exposed the metal band of the clamp indicates that there will be damage to the Fuel Feed Hose and therefore, the Fuel Feed Hose MUST be removed and replaced.

Figure 1

Figure 2


(1)	Contact Area
(2)	Purge Hose
(3)	Purge Hose Saddle Clamp
(4)	Fuel Feed Hose

Procedure

1. Remove The Evaporative Hose Saddle Clamp And Attaching Bolt. Then Reposition The Evaporative Hose.

1.1 Remove the Saddle Clamp and Attaching Bolt:

With the left hand side engine cover removed, locate the Purge Hose retaining Saddle Clamp. Refer Figure 1 & 2.

To remove the Purge Hose Saddle Clamp: remove the M10 retaining bolt and unclip the Saddle Clamp from around the Purge Hose to remove it from the hose. Both the bolt and clamp must be returned to REPAC.

1.2 Cable Tie The Evaporative Hose Into Position:

Important: Please note there Are Two Types Of Evaporative Hose Designs fitted to the vehicle.

The connector in the hose will either form an elbow (Type A shown in figure 4) or will be a straight through connector (Type B shown in figure 5).

Follow the procedure below which applies to the type of connector fitted in the evaporative hose and then proceed with step 2 "Purge Hose Saddle Clamp Inspection".

Type A - Where the connector is an elbow (90o Angle):

Retain the Purge Hose with a cable tie (p/n 92138154) through the Purge Hose connector ring and to the existing cable tie that retains the wiring harness cover. Refer Figure 3 & 4. Tighten and trim the cable tie end.

Figure 3


(1)	Cable Tie
(2)	Existing Cable Tie That Retains Wiring Harness Cover
(3)	Fuel Feed Hose
(4)	Purge Hose Connector Ring

Figure 4 (shows cable tie after tightening)


(1)	Cable Tie Fitted in this procedure
(2)	Existing Cable Tie that Retains Wiring Harness Cover
(3)	Connector Forms an Elbow (90 degree angle)

Type B - Where the connector is a straight through type:

Retain the Purge Hose with a cable tie (p/n 92138154) to the engine wiring harness just behind the harness connector as shown in figure 5. Position the cable tie so tail is pointing toward the rear of the vehicle and trim as short as possible.

Figure 5


(1)	Pull cable tie tight and trim off excess. Orient the tail of the cable tie towards rear of engine.
(2)	Engine Harness
(3)	Engine Harness Connector
(4)	Straight through connector in evaporative hose is positioned in this area.

Purge Hose Saddle Clamp Inspection

With the Purge Hose Saddle Clamp removed, the Saddle Clamp MUST be inspected for damage.

This is a very important step as it is necessary to determine whether FUEL FEED HOSE replacement is required.

The Saddle Clamp has a rubber sleeve that wraps around the edges of the Saddle Clamp. If the rubber sleeve has worn through at the Saddle Clamp edge and metal is visible (refer Figure 6) the Fuel Feed Hose MUST be replaced - Proceed to step 3.

Figure 6 (REPLACE fuel feed hose with this condition)


(1)	Visible Metal: Replace fuel feel hose with this condition.

If there is no metal visible at the Saddle Clamp edge, the Fuel Feed Hose does not need to be replaced. Refer Figure 7. Proceed to step 4.

Figure 7 (DO NOT replace fuel feed hose with this condition)


(1)	Rubber is worn but no metal is visible, DO NOT replace fuel feed hose

Fuel Feed Hose remove and replace (if needed)

Fuel Feed Hose p/n 92211878

Refer standard Electronic Service Information (ESI) procedure for Remove and Replacement of the Fuel Feed Hose.

Procedure is located in ESI 2007 Omega CD Sedan under sub headings:

Engine, Engine Controls and Fuel 3.6L, Repair Instructions, Fuel Injector and Fuel Rail Replacement.

Caution: Ensure that all safety procedures in relation to Gasoline/Gasoline Vapours are adhered to as outlined in the Service Information.

Note: Verifier Clips at each end of the Fuel Feed Hose must be removed from the original Fuel Feed Hose and re-installed onto the new Fuel Feed Hose after hose connections are made. Refer Figure 8.

Figure 8


(1)	Verifier Clip (one at each end of the fuel feed hose)
(2)	Ensure "verifier clip" is correctly installed at both ends of the fuel feed hose after installation.

Claim Information

Submit a Product Recall Claim with the information indicated below:

Repair Performed	Part Count	Part No.	Parts Allow	CC-FC	Labor Op	Labor Hours
Replace clamp with strap and inspect removed clamp for damage.	1	92138154	*	MA-96	V1781	0.3
Replace clamp with strap and inspect removed clamp for damage. Removed clamp damaged; replace damaged fuel hose.	1	92211878		MA-96	V1782	0.5
* The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price plus applicable Mark-Up or Landed Cost Mark-Up for fuel pressure hose if applicable and tie strap needed to complete the repair.

Dealer Recall Responsibility - All

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

January 2008

Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

General Motors has decided that a defect that relates to motor vehicle safety exists in all 2007 and 2008 Model Year Chevrolet Lumina, and Caprice vehicles equipped with 3.6 Litre V6 engine. As a result, GM is conducting a safety recall. We apologize for this inconvenience. However, we are concerned about your safety and continued satisfaction with our products.

Important:

•	Your vehicle is involved in safety recall 07337.

•	Schedule an appointment with your GM dealer.

•	This service will be performed for you at no charge .

Why is your vehicle being recalled?

It has been found that contact between the underhood fuel hose and other components within the engine compartment may result in damage to the fuel supply hose. This may lead to a fuel leak, and potential for underhood fire.

What will we do?

Your GM dealer will inspect the affected hose, and replace it if it is damaged. He will also make a change to ensure that contact cannot occur in the future. This service will be performed for you at no charge . Because of service scheduling requirements, it is likely that your dealer will need your vehicle longer than the actual time of approximately 30 minutes

What should you do?

You should contact your GM dealer to arrange a service appointment as soon as possible. Bring the enclosed customer reply form with you when you visit your dealer. The form identifies the repairs required. If you no longer own this vehicle, please let us know by completing the form and mailing it back to us.

Scott Lawson

General Director,

Customer and Relationship Services

Enclosure

07337