Product Emission - Fuel Tank Sender O-Ring Seal

General Motors has decided to conduct a Voluntary Emission Recall involving certain 2003-2004 model year Chevrolet and GMC C Series vehicles equipped with a motor home body and a gasoline engine. These vehicles may have been built with an incorrect O-ring installed between the fuel sender assembly and the fuel tank. This O-ring may degrade over time. A degraded O-ring may compromise the evaporative emissions system and lead to an increase in evaporative emissions.

Dealers are to install a new O-ring.

Involved are certain 2003-2004 model year Chevrolet and GMC C Series vehicles equipped with a motor home body and a gasoline engine and built within these VIN breakpoints:

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

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.

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" prior to ordering requirements. Normal orders should be placed on a DRO = Daily Replenishment Order. An emergency requirement should be ordered on a CSO = Customer Special Order.

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 of an explosion.

Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. For vehicles equipped with a bottom fuel tank drain plug, remove the drain plug.
3. For vehicles not equipped with a bottom fuel tank drain plug, use a hand operated pump, drain as much fuel as possible through the filler neck. Remove the fuel.
4. Reinstall the filler cap.
5. Raise the vehicle on a suitable hoist.
6. If equipped with a fuel tank shield, support the fuel tank shield.
7. If equipped with a fuel tank shield, remove the 16 bolts and the fuel tank shield from the frame.

Important: Clean all of the fuel pipe and hose connections as well as the surrounding areas before disconnecting the fuel pipes and hoses.

8. Disconnect the vent hose at the fuel tank.
9. Disconnect the filler tube at the fuel tank.
10. Support the fuel tank.

Notice: To avoid installing the fuel tank straps incorrectly (backwards) later in this procedure, make a mark or place a piece of masking tape on ONE end of BOTH straps.

11. With the aid of an assistance, remove the fuel tank strap attaching bolts and the fuel tank attaching bolts.
12. Lower the fuel tank enough to disconnect the fuel sender electrical connector and the retaining clips.
13. Remove the nut and ground strap from the fuel sender assembly.
14. Disconnect the hoses from the fuel sender assembly.
15. Remove the fuel tank from the vehicle and place the tank in a suitable work area.
16. Remove the 6 nuts and washers from the fuel sender assembly retaining ring.
17. Remove the fuel sender assembly retaining ring.
18. Remove the fuel sender assembly.

Important: Depending on the condition of the O-ring in the next step, it may be removable in one piece or many smaller pieces. Regardless of its condition, use care when removing it to ensure that no pieces fall into the fuel tank opening. If the O-ring has deteriorated to the point where pieces have fallen into the fuel tank during the removal of the fuel sender, then it will be necessary to flush the tank assembly clean.

19. Remove the fuel sender assembly O-ring from the fuel tank.
20. Install the new fuel sender assembly O-ring to the fuel tank.

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

21. Care should be taken not to fold over or twist the strainer when installing the sender assembly, as this will restrict fuel flow.
22. Install the fuel sender assembly in the fuel tank.
23. Install the fuel sender assembly lock ring to the fuel tank; make sure the lock ring alignment holes fit over the tabs on the tank.
24. Install the 6 washers and nuts retaining the fuel sender assembly lock ring.

Tighten
Tighten the lock ring nuts to 11.5 N·m (102 lb in).

25. Install the fuel sender assembly with the new O-rings on the fuel pipes.
26. Position and support the fuel tank.

Notice: When installing the straps in the next step, use the mark or tape applied before they were removed to correctly position the straps in relation to the frame rail.

27. Position the fuel tank straps and connect the fuel feed and return hoses to the fuel sender fittings.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings may affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

28. Install the ground strap to the fuel sender assembly with the nut.

Tighten
Tighten the nut to 9 N·m (80 lb in).

29. Connect the electrical connector to the fuel sender assembly.
30. Install the retaining clips.
31. Install the fuel filler vent hose to the vent pipe.
32. Install the fuel filler neck connecting tube to the fuel tank.
33. Apply threadlocker, GM P/N 89021297 (Canadian P/N 10953488) or equivalent, to the threads of the fuel tank strap bolts and install.

Tighten

•	Tighten the RH fuel tank strap bolt (the side that has the straps tight to the frame rail) to 20.5 N·m (15 lb ft).

•	Tighten the LH fuel tank strap bolt (the side that has a gap between the strap and the frame rail) to 60 N·m (44 lb ft).

34. Install the fuel tank attaching bolts.

Tighten
Tighten the fuel tank attaching bolts to 85 N·m (63 lb ft).

35. If equipped with a fuel tank shield, install the fuel tank shield to the frame with the 16 bolts.

Tighten
Tighten the fuel tank shield bolts to 175 N·m (129 lb ft).

36. Lower the vehicle.
37. Refill the fuel tank with the fuel removed earlier and install the fuel cap.
38. Connect the negative battery cable.
39. Start the engine and check for leaks.
40. CALIFORNIA VEHICLES ONLY : Install a Recall Identification Label and complete a "Proof of Correction" certificate upon recall completion.

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-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.

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 by calling 1-866-700-0001 (Monday-Friday, 8:00 am to 5:00 pm EST). Request Item Number S-1015 when ordering.

Submit a Product Recall Claim with the information indicated below.

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

General Motors will notify customers of this recall on their vehicle (see copy customer letter included with this bulletin).

In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission inspection test if the recall work is not completed.

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.

When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a "Proof Of Correction Certificate" which the owner may need to present to the California Department Of Motor Vehicles (DMV) when renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle registration.

Additional Certificates can be obtained, at no charge, from Dealer Support Materials by calling 1-866-700-0001 (Monday through Friday, 8:00 am to 5:00 pm EST). Ask for GM Item Number 1825 when ordering.

Dear General Motors Customer:

This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your vehicle.

General Motors has decided to conduct a Voluntary Emission Recall involving certain 2003-2004 model year Chevrolet and GMC C Series vehicles equipped with a motor home body and a gasoline engine. These vehicles may have been built with an incorrect O-ring installed between the fuel sender assembly and the fuel tank. This O-ring may degrade over time. A degraded O-ring may compromise the evaporative emissions system and lead to an increase in evaporative emissions.

Your GM medium duty dealer will install a new O-ring. This service will be performed for you at no charge .

This service correction will take approximately 3 hours. However, due to service scheduling requirements, your dealer may need your vehicle for a longer period of time.

Please contact your GM medium duty dealer as soon as possible to arrange a service date and to assure parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you wish to know how much time will be needed to schedule, process and repair your vehicle.

If you have any questions or need assistance, just contact your medium duty dealer or the appropriate Customer Assistance Center at the number listed below. The Customer Assistance Center's hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.

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 returning it to us in the postage paid envelope.

In order to ensure your full protection under the emission warranty made applicable to your vehicle by Federal Law, and your right to participate in future recalls, it is recommended that you have your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not accomplished.

The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration.

At the time of emission recall completion, your California dealer will issue a "Proof Of Correction Certificate". Keep this certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as proof of recall completion.

More information about this recall (including answers to frequently asked questions) is available online at the Owner Center at My GMLink. This free online service offers vehicle and ownership related information and tools tailored to your specific vehicle. To join, visit www.mygmlink.com, and enter your vehicle's 17-character vehicle identification number (VIN) shown on the enclosed form to get the most personalized information for your vehicle.

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

General Motors Corporation

Enclosure

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