2000 Saturn L-Series Vehicles (All Models)

The Highway Safety Act, as amended, provides that each vehicle which is subject to a recall campaign of this type must be adequately repaired within a reasonable time after the owner has tendered it for repair. A failure to repair within sixty (60) 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 owner may be entitle 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 owner and to repair their vehicle as soon as possible. As you will see in reading the attached copy of the owner letter, the owners are being instructed to contact the Saturn Customer Assistance Center if their Retailer does not remedy the condition within five (5) days of the mutually agreed upon service date. If the condition is not remedied within a reasonable time, owners are instructed on how to contact the national Highway Traffic Safety Administration.

Saturn has decided that certain 2000 L-Series Saturn vehicles may fail to conform to Federal Motor Vehicle safety Standard (FMVSS) 301, "Fuel System Integrity." These vehicles may have been produced with an inoperative valve within the fuel tank assembly. If a vehicle with an inoperable valve were involved in a rollover, fuel spillage could occur. If an ignition source were present, a fire could result. to ensure that the fuel tank assembly valve is operating as intended, Saturn will inspect the fuel tank assembly valve, and replace the fuel tank assembly if necessary.

Only selected 2000 model year LS Saturn vehicles within the following VIN range will require this campaign:

YY600001-YY602473

A VIN listing of the vehicles is included in this bulletin for your reference.

You must verify campaign involvement through your AS400 system or with the listing attached to this bulletin. It is important to note that campaign claims will only be paid on involved vehicles.

Owners of all involved vehicles will be notified of this campaign by Saturn. Refer to the owner letters included in this bulletin.

A list of vehicles assigned to you (Facility VIN Listing), which our records indicate were sold by or shipped to you, or are located in close proximity to your facility, is enclosed.

This listing contains:

The Facility VIN Listing , with owner information, is furnished to involved Retailers with the Product Campaign Bulletin. Although these vehicles are assigned to your facility, it is important to note that owners may elect to have their vehicle serviced at the Saturn Retail Facility of their choice.

Those Retailers not involved initially in this campaign will receive a message at the top of a blank Facility VIN Listing that states: NO VEHICLES ASSIGNED AT THIS TIME FOR CAMPAIGN 00C01.

These listings may contain owner names and addresses obtained from State Motor Vehicle registration Records. The use of such motor vehicle registration data for any other purpose is a violation of the law in several states. Accordingly, you are urged to limit the use of this listing to the follow up necessary to complete this campaign. Those records updated with California DMV registration information will have the following message printed adjacent to the appropriate VIN: "OWNER INFORMATION UPDATED BY CALIFORNIA DMV; PUBLICATION PROHIBITED."

All unsold vehicles in Retailers' possession and subject to this campaign must be held at the retail facility and repaired per the service procedure of this campaign bulletin before owners take possession of these vehicles.

Retailers are to service all vehicles subject to this campaign at no charge to owners, regardless of mileage, age of vehicle, or ownership, from this time forward.

Owners of vehicles recently sold from your vehicle inventory are to be contacted by the Retailer and arrangements made to make the required correction according to the procedure contained in this bulletin.

In summary, whenever a vehicle subject to this campaign enters your vehicle inventory, or is in your retail facility for service in the future, please take the steps necessary to be sure the campaign correction has been made before selling or releasing the vehicle.

Saturn vehicles that have been sold by you, which may be closer in proximity to another Saturn Retailer, may still appear on your Facility VIN Listing. If either you or the vehicle owner determines that it is more desirable for a vehicle on your Facility VIN Listing to be serviced by another Saturn Retailer, or if the customer's address has recently changed, campaign responsibility may be transferred by completing the following:

A copy of the Campaign Vehicle Action Report is included for your reference. Additional copies can be ordered from Saturn Publications, 1-800-828-2112, prompt 3, Item #S0397050. All changes to campaign responsibility will be reflected in your next Unfixed VIN Report.

All other changes in vehicle status (e.g., scrapped, stolen, etc.) are to be made in accordance with section 4.4.3 of the Retailers Service Reference Guide , "Notifying Saturn of Vehicle Status Change."

1. A pre-shipment of fuel tank assemblies required to perform this campaign has been automatically sent to your Retailer from Saturn Service Parts Operations (SSPO). In addition, several incidental parts will be sent to each Retailer. These initial parts shipments are to aid Retailers in campaign preparation and will ensure minimal customer inconvenience. Further shipments will automatically be sent at a later date to fulfill your forecasted parts requirements.
2. There are two types of fuel tank assemblies that SSPO will be sending to Retailers. Both types are under the same part number. The tank assemblies differ in the fact that one tank has a rubber shim on the top of the tank covering the fuel line coming from the fuel pump and going to the fuel filter. The other tank incorporates a design change and does not require the addition of the rubber shim. Both types of tanks are being used to replace suspect fuel tank assemblies.
3. Both types of tank assemblies will have a sticker on front of them identifying whether the rubber shim is required. The first four digits of the code on the sticker will read either "LS31" or "LS32."

•	LS31 indicates that tank DOES require rubber shim.

•	LS32 indicates that tank DOES NOT require rubber shim. Tanks requiring rubber shim will have rubber shim already installed from SSPO.

4. Certain tanks have been inspected that have the suspect Julian date of "1119", "1119A", or "1119B" on the grade vent valve. These tanks will have two white dots on the grade vent valve or the fuel pump module signifying that these tanks have been inspected and meet Saturn's quality standards. Tanks with white dots are acceptable and should be used for servicing vehicles.
5. Should additional parts be required, please contact your Parts Support Analyst (PSA) and SSPO will expedite parts shipment. Please do not enter any orders for any part numbers listed without contacting your PSA first.

6. Required Parts:

7. Incidental Parts: The inspection and replacement of fuel tank assemblies might require replacement of some incidental parts. These parts are as follows:

Retailers will scrap all replaced parts in a manner that ensures that they cannot be reused, remanufactured, or otherwise entered into the stream of commerce in the future.

As you know, Saturn's success hinges upon our ability to execute superior customer support throughout the ownership experience, especially when important corrective actions such as this are required.

It is imperative that every effort is made to accommodate the affected owners. Additionally, priority should be given to customer vehicles over retail inventory vehicles. if you have any questions, please coordinate with the Saturn Customer Assistance Center to help ensure customer satisfaction.

Drain Fuel Tank

Caution: Do not allow smoking or the use of open flames in the area where work on the fuel system is taking place.

Caution: Never drain or store fuel in any open container due to the possibility of fire or explosion.

Caution: Make sure vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which components are being removed.

1. Position vehicle on hoist.

Caution: Fuel supply lines will remain pressurized for long periods of time after the engine is shutdown. This pressure must be relieved before servicing the fuel system.

2. Relieve fuel system pressure.

2.1.	Connect scan tool to vehicle diagnostic connector and start vehicle.

2.2.	Use scan tool to command fuel pump OFF. Refer to Tech 2 User Guide for proper scan tool navigation and setup.

2.3.	Engine will stall in 3-5 seconds.

3. Raise vehicle on hoist to comfortable working height, keeping scan tool outside of vehicle and accessible from under vehicle.




Caution: Whenever fuel line fittings are loosened, wrap a shop cloth around the fitting and have an approved container available to collect any fuel.

4. Disconnect fuel feed line at outlet to fuel filter.
5. Install 3/8X1/4 in quick connect (1) adapter from flow/pressure adapter (SA9127E-7) into fuel feed line.
6. Connect suitable drain hose to other end of adapter, and connect drain hose to certified fuel handling cart.
7. Energize fuel pump using scan tool. Refer to Tech 2 User Guide for proper scan tool navigation and setup.
8. Pump out fuel until no more fuel flows from line.
9. Lower vehicle.

Remove Fuel Tank

Caution: Do not allow smoking or the use of open flame in the area where work on the fuel system is taking place.

Caution: Any time the fuel system is being worked on, disconnect the negative battery cable, except for those tests where battery voltage is required.

1. Disconnect negative battery cable.
2. Raise vehicle to a comfortable working position.

Notice: On vehicles equipped with L81 (V-6) engine, support catalytic converter. If catalytic converter is allowed to hang unsupported, exhaust system damage may occur.




3. remove exhaust system intermediate pipe with muffler.



4. remove rear heat shield retaining bolts.



5. Remove fuel filler pipe lower bracket attachment screw.

Caution: Whenever fuel lines are removed, place fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch fuel.




6. Disconnect EVAP canister vent hose.
7. Disconnect quick connect at recirc line.
8. Loosen fuel filler pipe hose clamp closest to fuel tank.
9. Disengage fuel filler pipe hose from fuel tank.
10. Remove tank grounding strap attachment nut from stud located near fuel filter.
11. Disconnect fuel tank electrical connection and remove connector from underbody.



12. Remove fuel tank strap bracket protecting fuel line connections between fuel tank and chassis fuel bundle.

Caution: Whenever fuel lines are removed, place fuel in an approved container. Container opening must be a minimum of 300 mm (12 in) diameter to adequately catch fuel.




13. Disconnect fuel feed line behind fuel filter.
14. Disconnect fuel return and EVAP canister purge lines between tank and chassis fuel bundle.



15. Loosen front tank strap bolts, but do not remove.
16. With aid of an assistant, remove the two rear tank retaining strap bolts.

16.1.

Lower rear half of tank and slide the fuel tank down and out rearward.

16.2.

Remove fuel tank from vehicle.

Inspect Grade Vent Valve and Fuel Tank

Important: the date code on grade vent valve is very small and can be difficult to see. Using a flashlight and magnifying glass may aid in date code identification.

1. Inspect top of grade vent valve for a date code of "1119," "1119A," or "1119B."

•	If the date code on grade vent valve is "1119," "1119A", or "1119B," fuel tank assembly must be replaced.

•	If the date code on grade vent vale is NOT "1119," "1119A," or "1119B," fuel tank should be re-installed in vehicle.




2. If date on grade vent valve is not "1119," "1119A," or "1119B" and fuel tank is going to be re-installed in vehicle, inspect fuel tank for fuel tank-to-body insulator pad.

•	If fuel tank-to-body insulator pad is present and properly located, install fuel tank in vehicle.

•	If fuel tank-to-body insulator pad is NOT present and a replacement pad is not available, obtain fuel tank-to-body insulator pad by calling the Saturn Parts Assistance Center at 1-800-828-2112, prompt 2.

Install Fuel Tank

Important: There are two types of fuel tank assemblies that SSPO will be sending to Retailers. Both types are under the same part number. The tank assemblies differ in the fact that one tank has a rubber shim on the top of the tank covering the fuel line coming from the fuel pump and going to the fuel filter. The other tank incorporates a design change and does not require the addition of the rubber shim. Both types of tanks are being used to replace suspect fuel tank assemblies.

Both types of tank assemblies will have a sticker on front of them identifying whether the rubber shim is required. The first four digits of the code on the sticker will read either "LS31" or "LS32."

•	LS31 indicates that tank DOES require rubber shim.

•	LS32 indicates that tank DOES NOT require rubber shim. Tanks requiring rubber shim will have rubber shim already installed from SSPO.




1. When installing a replacement fuel tank, remove plastic fuel line retainers on fuel feed line, fuel return line, and recirc line form old tank and install them into female portions of fuel line connections on vehicle. The replacement tank will come with a new retainer on the EVAP canister purge line.
2. With aid of an assistant, position fuel tank under vehicle.
3. Reposition fuel tank mounting straps and shield around tank and install strap mounting bolts to underbody.

Tighten
Tighten the bolts to 20 N·m (15 lb ft).

4. Connect fuel tank electrical connector.

Notice: Care must be taken to ensure that locking tab is centered in window of female connection. Firmly press male and female portions together until a click is heard, then pull firmly back to confirm engagement.





Important: Lubricate male end of filter with clean engine oil to ease installation.

5. Connect fuel feed, fuel return, and EVAP canister purge lines between tank and chassis fuel bundle.



6. Install fuel tank strap bracket.

Tighten
Tighten the bracket to 10 N·m (89 lb in).

7. Install fuel tank grounding strap attachment nut from stud located near fuel filter.

Tighten
Tighten the nut to 4.5 N·m (40 lb in).





Important: Ensure that EVAP vent solenoid pipe is installed in position on filler pipe bracket.

8. Loosely install filler pipe lower bracket attachment screw but do not tighten.




Important: To ease installation, lightly wipe the outside of the fuel tank inlet connector with water.

9. Install fill neck to fuel tank.

Notice: Ensure that the fuel pipe connecting hose is installed until it touches the fuel tank body. The hose clamp should be located within 6 mm (1/4 in) of the end of the connector hose.

10. Tighten the hose clamp on filler pipe to fuel tank connecting hose.

Tighten
Tighten the clamp to 5 N·m (44 lb in).




11. Connect EVAP canister vent pipe to canister vent hose at quick connect and recirc line at quick connect.
12. Tighten lower attachment screw on filler pipe to underbody.

Tighten
Tighten the screw to 13 N·m (9.5 lb ft).

13. Install heat shield.

Tighten
Tighten the heat shield to 7 N·m (62 lb in).




14. Install intermediate pipe with muffler.

Tighten
Tighten to 20 N·m (15 lb ft).

15. Lower vehicle.
16. Add fuel to fuel tank.
17. Connect negative battery cable.

Tighten
Tighten the cable to 17 N·m (13 lb ft).

18. Prime fuel system.

18.1.

Using ignition, cycle switch ON for 5 seconds and the OFF for 10 seconds. Repeat this twice.

18.2.

Examine fuel lines for leaks.

18.3.

Crank engine until it starts, allowing a maximum of 15 seconds of cranking time.

Upon completion of the campaign, a Campaign Completion Label and a Clear Protective Cover should be affixed on a clean, dry surface of the radiator core support in an area visible when the hood is raised. Each label provides a space to print in ink (or type) the campaign number (00C01) and the five (5) digit facility code of the Retailer performing the campaign service.

As a reminder, additional labels may be ordered from Saturn Publications, 1-800-828-2112, prompt 3, Item #S03 00013A for the Campaign Completion Label and Item #S03 00013B for the Clear Protective Cover .

1. To receive credit for inspecting, and if necessary, replacing the fuel tank assembly, submit a claim with the information below:

2. To receive credit for loaner/rental car costs incurred while owner awaits campaign repair or other goodwill expenses, submit a claim with the information below:

3. Retailers are empowered to use good judgement regarding loaner/rental cars or any other goodwill expenses deemed necessary. It will not be necessary to call the Saturn Customer Assistance Center for authorization of goodwill. The Goodwill Worksheet, printed towards the back of this bulletin, must be used to document goodwill expenses. The completed Goodwill Worksheet must be attached to the hard copy of the CSO. Retailers are to make sufficient copies of the blank Goodwill Worksheet to document goodwill expenses.

Check your Saturn SERVICELINE.XL Claim Memorandum daily. Remember to code the claim as a WC sale type and VC case type. Contact your field representative if you need assistance.

Refer to the Customer Service Order Preparation Manual for details on Product Campaign Claim Submission.

As stated in the Credit section of this bulletin, Retailers are empowered to use good judgement regarding loaner/rental cars or other goodwill expenses that might become necessary for customer satisfaction.

Complete this worksheet and attach it to the hard copy of the Customer Service Order (CSO) to document all campaign goodwill claims submitted to Saturn.

VIN #

Dear Saturn Owner:

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

Saturn has decided that certain 2000 L-Series Saturn vehicles fail to conform to Federal Motor Vehicle Safety Standard (FMVSS) 301, "Fuel System Integrity." These vehicles may have been produced with an inoperative valve within the fuel tank assembly. If a vehicle with an inoperable valve were involved in a rollover, fuel spillage could occur. If an ignition source were present, a fire could result.

To ensure that the fuel tank assembly valve is operating as intended, Saturn will inspect it and replace the fuel tank assembly if necessary. This service will be performed at no charge to you. It will take about 1 1/2 hours to make the repairs, although some additional time may be required for paperwork and processing.

Contact your Saturn Retailer to arrange to have this service performed.

Your Retailer is prepared to perform this service promptly and with minimal inconvenience to you. However, if your car is provided to the Retailer on the agreed service date and the condition is not remedied on that date, or within five days, please contact the Saturn Customer Assistance Center at 1-800-553-6000 prompt 3, or for the hearing impaired, 1-800-833-6000. We will assist you and the Retailer in getting your car serviced.

If, after contacting your Saturn Retailer and the Saturn Customer Assistance Center, you are still not satisfied 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 St., S.W., Washington, DC 20590, or call 1-800-424-9393 (Washington, DC residents use 202-366-0123).

Again, we sincerely regret any inconvenience or concern this situation may cause you. We want you to know that we will do our best, throughout your ownership experience, to ensure that your Saturn provides you many miles of enjoyable driving.

Sincerely,

Saturn Corporation

00-C-01