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EI07238-Fuel Cap May Not Seal, MIL/SES Light Illuminated with DTC P0442-Evaporative Emission (EVAP) System Small Leak Detected and/or P0455-Evaporative Emission (EVAP) System Large Leak Detected

Subject:EI07238 -- Fuel Cap May Not Seal, MIL/SES Light Illuminated with DTC P0442-Evaporative Emission (EVAP) System Small Leak Detected and/or P0455- Evaporative Emission (EVAP) System Large Leak Detected

Models:2005 Buick Rainier
2005 Cadillac STS
2005-2006 Cadillac XLR, XLR-V
2004 Chevrolet Express
2005 Chevrolet TrailBlazer, TrailBlazer EXT
2005-2006 Chevrolet Corvette
2004 GMC Savana
2005 GMC Envoy, Envoy XL, Envoy XUV
2004-2005 Pontiac GTO
2004 Saturn ION
2004-2005 Saturn VUE
with 2.0L, 2.2L, 2.3L, 2.8L, 3.5L, 4.2L, 4.4L, 4.6L, 4.8L, 5.7L, 6.0L or 7.0L Engine (VINs 4, A, D, E, F, G, S, U, V -- RPOs LJ3, LC3, L61, LK9, LP9, L66, LH2, LL8, LR4, LS1, LS2, LS7)

Attention: Proceed with this bulletin ONLY if the customer has commented about this concern AND the EI number is listed in GMVIS. If the customer has not commented about this condition or the EI does not show in GMVIS, disregard the bulletin and proceed with diagnostics found in the published Service Information. THIS IS NOT A RECALL--refer to Service Bulletin 04-00-89-053A for more detail on the use of Engineering Information Bulletins.


This bulletin is being revised to change contact information for Kevin McCollum and add a new contact name for VUE models. Please discard Corporate Bulletin Number 07-06-04-022B (Section 06 -- Engine/Propulsion System).


Condition

Some customers may comment on a Service Engine Soon (SES) Light illuminated on the IP cluster and the fuel cap does not seal or tighten. Technicians may find DTC P0442 and/or P0455 set.

What Action to Take

GM Engineering is attempting to determine the root cause for fuel caps not sealing and/or setting codes P0442 or P0455. GM Engineering has a need to obtain information first hand from the dealer technician during diagnosis and before repair. As a result, this information will be used by engineering to "root cause" the customer's concern and develop/validate a field fix. Please follow the instructions below regarding the requested information.

Instructions

Important: If a vehicle is encountered with the above concern, complete the following steps; making sure all the information is documented on the Repair Order.

  1. Verify that the VIN and mileage is accurate.
  2. Accurately document the customers concern. If the SES light is illuminated, record the Diagnostic Trouble Codes (DTC) using a Tech 2®.
  3. • If DTC P0442 - Evaporative Emission (EVAP) System Small Leak Detected is stored, proceed to diagnosis DTC P0442 in SI.
    • If DTC P0455 - Evaporative Emission (EVAP) System Large Leak Detected is stored, proceed to diagnosis DTC P0455 in SI.
    • If diagnostics lead to repair other components not related to the fuel tank filler pipe neck or fuel cap, repair accordingly and disregard this bulletin.
  4. If the diagnostics lead to a leak at the fuel tank filler pipe neck or the fuel cap area, inspect for the following conditions:
  5. • Inspect the condition of the fuel cap by looking for small cracks or any damaged components.
    • Inspect the fuel cap seal for distortion or cuts.
    • Inspect the fuel filler neck sealing surface for gouges or dents produced accidentally by a fuel nozzle.
  6. Contact the appropriate GM Engineer once the vehicle has been diagnosed and before repairing the vehicle for further instructions.

Engineer Contact Information

Contact the appropriate GM Engineer from the list below before repairing the vehicle. GM Engineer Shannon Fahy may be used as a secondary contact. GM Engineering may visit dealerships near the Southwest Michigan area. In either case, you will receive a response back within 2 hours on what action to take the same day of your call (Eastern Daylight Time).

If you do not receive a response from engineering, then proceed to repair the vehicle.

MAKE

MODEL

YEAR

ENGINE-RPO

PRIMARY CONTACT

PHONE #

Buick

Rainier

2005

LL8

Mark Carson

586-947-7396

Cadillac

STS

2005

LH2

Essy Samimy

586-492-5646

Cadillac

XLR, XLR-V

2005-2006

LC3, LH2

Chevrolet

Corvette

2005-2006

LS2, LS7

Chevrolet

Express

2004

LR4

Shannon Fahy

586-947-7393

Chevrolet

TrailBlazer, TrailBlazer EXT

2005

LL8

Mark Carson

586-947-7396

Pontiac

GTO

2004

LS1

Shannon Fahy

586-947-7393

Pontiac

GTO

2005

LS2

Shannon Fahy

586-947-7393

GMC

Envoy, Envoy XL, Envoy XUV

2005

LL8

Mark Carson

586-947-7396

GMC

Savana

2004

LR4

Shannon Fahy

586-947-7393

Saturn

ION

2004

L61

Shannon Fahy

586-947-7393

Saturn

VUE

2004

L61, L66

Nick Culinescu

905-644-2049

Saturn

VUE

2005

L61

Nick Culinescu

905-644-2049

Saab

9-3, 9-5

2005-2007

LJ3, LK9, LP9

Kevin McCollum

586-575-0257

Warranty Information (excluding Saab U.S. Models)

Important: DO NOT use the labor operation listed below if engineering did not respond.

For vehicles repaired under engineering direction, use:

Labor Operation

Description

Labor Time

L9714*

Engineering Information-Fuel Cap and Filler Pipe - Replace

 

Corvette/XLR

1.8 hrs

Express/Savana

0.8 hr

GTO

0.7 hr

Envoy/Rainier/ TrailBlazer/VUE

1.0 hr

STS/ION

1.4 hrs

*This labor operation number is for bulletin use only. This number will not be published in the Labor Time Guide.

Warranty Information (Saab U.S. Models)

For vehicles repaired under warranty, use:

Labor Operation

Description

Failed Object

Fault/Reason Code

Location Code

Warranty Type

Repair/Action Code

Labor Time

2349010*

Engineering Information-Fuel Cap and Filler Pipe - Replace 9-3/9-5

23490

50

0

01

01

1.4 hrs

*This labor operation number is for bulletin use only. This number will not be published in STM.