Special Coverage Adjustment - Fuel Tank Cap

Some customers of 2005 Chevrolet Malibu model vehicles, equipped with a 2.2L (L61) 4 cylinder engine, may experience a condition where the fuel tank cap won’t tighten properly, or the fuel tank cap won’t come off, or is broken. These conditions may also cause the illumination of the Malfunction Indicator Light (MIL).

This special coverage covers the condition described above for a period of 10 years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. The repairs will be made at no charge to the customer.

For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after February 21, 2007 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to February 21, 2007 must be submitted to the Service Contract provider.

Involved are certain 2005 Chevrolet Malibu model vehicles, equipped with 2.2L 4 cylinder engines and built within the following VIN breakpoints:

Parts required to complete this special coverage are to be obtained from General Motors Service and Parts Operations (GMSPO).

General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter included with this bulletin - actual divisional letter may vary slightly).

Customers may inform technicians that the Malfunction Indicator Light (MIL) or Service Engine Soon (SES) light is on and/or the fuel cap cannot be tightened or removed.

Notice: The DTC diagnostic labor time for this Special Coverage covers evaporative code diagnosis related to defective fuel caps. Additional diagnostic time related to other problems (purge valve, fuel tank, etc.) are not covered by this Special Coverage and is the responsibility of the owner.

Replacing Broken Fuel Cap

1. Remove the fuel cap tether from the fuel filler pocket or fuel filler door.
2. Remove the fuel cap from the fuel filler.



3. If the fuel cap cannot be removed, remove the fuel cap ratcheting cover by releasing the four (4) tabs holding the cap cover to the lugged sealing base.



4. Position the radiator hose removal tool or similar type tool between the black cover and white inside body, and pry the cover over the retaining tab by rotating the tool counter clockwise. Repeat, if necessary, on the 3 other locations around the cover.



5. Remove the white fuel cap base from the filler pipe by rotating the fuel cap base counter clockwise.
6. Install the new fuel filler cap and secure the tether to the fuel filler pocket or filler door.

DTC P0455 - (Evaporative Emission (EVAP) System Large Leak Detected)

Diagnostic Aids: P0455 diagnostics is checking for a large leak in the EVAP system. Examples of conditions that may contribute to this code setting are: loose or broken fuel cap, disconnected or cracked EVAP lines, cracked charcoal canister, sticking purge or vent solenoids, inaccurate fuel gauge, etc.

DTC P0442 - (Evaporative Emission (EVAP) System Small Leak Detected)

Diagnostic Aids: P0442 diagnostics is checking for a 0.5mm (0.020 in) sized hole in the EVAP system. Examples of conditions which may cause this type leak could include: cracked EVAP lines, cracked charcoal canister, a cut or dirty fuel cap seal, debris on the purge or vent solenoid internal seals, loose fuel lines, etc. Refer to Fuel Cap Inspection for P0442.

Fuel Cap Inspection for P0442

1. Inspect the green sealing ring (1) on fuel cap for debris or cuts which could cause a small EVAP leak.



2. Inspect filler neck sealing surface (1) for gouges or dents produced by accident or fuel nozzle damage.
3. Diagnose P0442 - Evaporative Emission (EVAP) System Small Leak Detected DTC. Refer to DTC P0442 - Evaporative Emission (EVAP) System Small Leak Detected Diagnostics in the Diagnostics Information and Procedures Section of SI for the appropriate vehicle.

For vehicles repaired under the terms of this special coverage, submit a claim with the information indicated below:

All customer requests for reimbursement for previous repairs for the special coverage condition will be handled by the Customer Assistance Center, not by dealers.

A General Motors Customer Reimbursement Procedure and Claim Form is included with the customer letter.

Important: Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

Customer requests for reimbursement of previously paid repairs to correct broken fuel caps are to be submitted to the dealer prior to or by February 29, 2008. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 193,000 km (120,000 miles), whichever occurs first.

When a customer requests reimbursement, they must provide the following:

If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership.

Dear General Motors Customer:

As the owner of a 2005 Chevrolet Malibu, equipped with a 4 cylinder engine, your satisfaction with our product is very important to us.

This letter is intended to make you aware that some 2005 Chevrolet Malibu vehicles, equipped with a 4 cylinder engine, may have a condition where the fuel tank cap won’t tighten properly, or the fuel tank cap won’t come off, or is broken. These conditions may also cause the illumination of the Malfunction Indicator Light (MIL).

Additionally, please be aware that the fuel cap may not seal adequately to the filler neck if pushed down when being tightened. Do not apply a downward force to the fuel cap when tightening.

This is not a recall. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above.

What We Have Done: General Motors is providing owners with additional protection for the fuel tank cap. If this condition occurs on your 2005 Chevrolet Malibu within 10 years of the date your vehicle was originally placed in service or 120,000 miles (193,000 km), whichever occurs first, the condition will be repaired for you at no charge .

What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to call the service department at your dealer to find out how long they will need to have your vehicle so that you may schedule the appointment at a time that is convenient for you. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glove box literature for future reference.

Reimbursement: The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special coverage condition.

If you have any questions or need any assistance, just contact your 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.

We are sorry for any inconvenience you may experience; however we have taken this action in the interest of your continued satisfaction with our products.

General Motors Corporation

Enclosure

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