For 1990-2009 cars

# Special Coverage Adjustment - Fuel Tank Cap

Subject: | 06081 -- Special Coverage Adjustment - Fuel Tank Cap

Models: | 2003-04 SAAB 9-3 SPORTS SEDAN

| 2004 SAAB 9-3 CONVERTIBLE

| 2004 CHEVROLET MALIBU, AVEO

| 2004 CADILLAC XLR, SRX

| 2004 SATURN L-SERIES

### Condition

Some customers of 2003-04 Saab 9-3 Sports Sedan; 2004 Saab 9-3 Convertible; Chevrolet Malibu, Aveo; Cadillac XLR, SRX; and Saturn L-Series model vehicles may experience a condition where the fuel tank gas cap won’t tighten properly or the fuel cap won’t come off, or is broken. These conditions may also cause the illumination of the Malfunction Indicator Light (MIL).

### Special Coverage Adjustment

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 November 2, 2006 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 November 2, 2006 must be submitted to the Service Contract provider.

### Vehicles Involved

Involved are certain 2003-04 Saab 9-3 Sports Sedan; 2004 Saab 9-3 Convertible; Chevrolet Malibu, Aveo; Cadillac XLR, SRX; and Saturn L-Series model vehicles and built within the following VIN breakpoints:

Year | Division | Model | From | Through
--- | --- | --- | --- | ---
2003 | Saab | 9-3 Sports Sedan | 31001238 | 31064389
2004 | Saab | 9-3 Sports Sedan | 41000069 | 41020857
2004 | Saab | 9-3 Convertible | 4600001 | 46020605
2004 | Chevrolet | Malibu | 4F100001 | 4F250545
2004 | Chevrolet | Aveo | 4B092801 | 4B278323
2004 | Cadillac | XLR | 45600001 | 45604352
2004 | Cadillac | SRX | 40100026 | 40192620
2004 | Saturn | L-Series | 4Y500011 | 4Y521322

### Parts Information - GM, Saturn Canada and Saab Canada Only

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

Part Number | Description | Qty/ Vehicle
--- | --- | ---
10372246 | Cap, Fuel Tank (Malibu) | 1
10372246 | Cap, Fuel Tank (Saab 9-3) | 1
10372242 | Cap, Fuel Tank (XLR, SRX) | 1
10372865 | Cap, Fuel Tank (Saturn L-Series) | 1
15258231 | Cap, Fuel Tank (Aveo) | 1

### Parts Information - Saturn US Only

This is a stocked part for Saturn retailers. For additional needs, please adjust your stocking policy or place an emergency order if necessary.

Part Number | Description | Qty/ Vehicle
--- | --- | ---
10372865 | Cap, Fuel Tank (Saturn L-Series) | 1

### Parts Information - Saab US Only

This is a stocked part for Saab retailers. For additional needs, please adjust your stocking policy or place an emergency order if necessary.

Part Number | Description | Qty/ Vehicle
--- | --- | ---
10372246 | Cap, Fuel Tank (9-3) | 1

### Customer Notification

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).

### Service Procedure

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

• | If the SES light is illuminated, record the Diagnostic Trouble Codes (DTC) using the Tech 2.

• | On 2004 Chevrolet Malibu, DTC P0442 or P0455 may be set by a cracked EVAP canister. For EVAP canister concerns, refer to bulletin 05-06-04-004A.

• | If the fuel cap cannot be tightened or removed, proceed to the section below titled, Replacing Broken Fuel Cap.

• | If DTC P0442 - Evaporative Emission (EVAP) System Small Leak Detected is stored in the Engine Control Module (ECM), proceed to section titled DTC P0442.

• | If DTC P0455 - Evaporative Emission (EVAP) System Large Leak Detected is stored in the ECM, proceed to section titled DTC P0455.

• | Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance.

• | Some vehicles may intermittently set a DTC of P0442 or P0455, leak in the evaporative emissions system. In addition to checking the system and performing the diagnostics as described in the Service Information for this DTC, the technician should be aware that some of the fuel caps used on GM vehicles may not seal adequately to the filler neck if pushed down when being tightened. This may occur more often when this cap is used on a vehicle with a steel fuel filler neck. The owner should be instructed not to apply a downward force to the fuel cap when tightening.

#### 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.

### Claim Information - GM, Saturn Canada and Saab Canada Only

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

Repair Performed | Part Count | Part No. | Parts Allow | CC-FC | Labor Op | Labor Hours | Net Item
--- | --- | --- | --- | --- | --- | --- | ---
Check EVAP DTCs, inspect, tighten fuel cap | N/A | N/A | N/A | MK-95 | T5652 | 0.2 | N/A
Check EVAP DTCs, inspect and replace broken fuel cap | 1 | -- | * | MK-95 | T5653 | 0.3 | N/A
Customer Reimbursement (Canadian & Export Dealers/US CAC) | -- | -- | N/A | MK-95 | T5654 | 0.2 | **
* The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price plus applicable Mark-Up for the fuel cap needed to complete the repair. ** The amount identified in the "Net Item" column should represent the customer reimbursement amount.

### Claim Information - Saturn US Only

1. To receive credit, submit a claim with the information below:

Repair Performed | Parts Allow. | Case Type | Labor Op. | Labor Hrs.
--- | --- | --- | --- | ---
Check EVAP DTCs, inspect, tighten fuel cap | * | SP | T9800 | 0.2
Check EVAP DTCs, inspect and replace broken fuel cap | * | SP | T9801 | 0.3
* The parts allowance should be the sum total of the current SSPO retailer net price plus 40% of all parts required for the repair.

2. Check your Saturn SERVICELINE.XL Claim Memorandum daily. Remember to code the claim as an SP case type. Contact your field representative if you need assistance.

Service Performed | Case Type | Labor Op. | Net Item Amount | Net Item Code
--- | --- | --- | --- | ---
Customer Reimbursement | SP | T9802 | * | R
* Customer requests for reimbursement of previously paid repairs to replace the fuel tank gas cap.

#### Saturn Customer Reimbursement Claims - Special Attention Required

Customer reimbursement claims must have the date of the (service repair) prior replacement entered into the "repair date" field of the CSO in the "Labor Detail/Comments" screen.

Customer reimbursement claims must have the mileage of the prior repair of the (service repair) entered on the "Service Order Hub" screen in the "miles in" field.

Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer.

Customer reimbursement claims must be submitted on a different CSO than the Special Coverage repair. This is because the repair date and mileage differ between the two repairs.

### Claim Information - Saab US Only

1. To receive credit, submit a claim with the information below:

#### Checking and Replacement of Fuel Cap

Labor Operation | Description | Object Code | Reason Code | Location Code | Warranty Type | Repair / Action Code | Labor Hours
--- | --- | --- | --- | --- | --- | --- | ---
2349001 | Replace Fuel Filler Cap | 23490 | 71 | 0 | 01 (New Vehicle Warranty) 22 (Beyond New Vehicle Warranty) | 01 | 0.2
1003001 | Check EVAP DTCs | 23490 | 71 | 0 | 01 (New Vehicle Warranty) 22 (Beyond New Vehicle Warranty) | 01 | 0.3

#### Retrieving and Clearing EVAP DTCs

Labor Operation | Description | Object Code | Reason Code | Location Code | Warranty Type | Repair / Action Code | Labor Hours
--- | --- | --- | --- | --- | --- | --- | ---
1003001 | Check EVAP DTCs | 23490 | 71 | 0 | 01 (New Vehicle Warranty) 22 (Beyond New Vehicle Warranty) | 08 | 0.3

#### Checking EVAP DTCs, Inspection and Tightening Fuel Cap

Labor Operation | Description | Object Code | Reason Code | Location Code | Warranty Type | Repair / Action Code | Labor Hours
--- | --- | --- | --- | --- | --- | --- | ---
2349002 | Inspect & Tighten Fuel Cap | 23490 | 71 | 0 | 01 (New Vehicle Warranty) 22 (Beyond New Vehicle Warranty) | 0.5 | 0.2
1003001 | Check EVAP DTCs | 23490 | 71 | 0 | 01 (New Vehicle Warranty) 22 (Beyond New Vehicle Warranty) | 0.5 | 0.3

### Customer Reimbursement - For US

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 Reimbursement - For Canada and Export

Customer requests for reimbursement of previously paid repairs to correct broken fuel caps are to be submitted to the dealer prior to or by November 30, 2007. 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:

• | Proof of ownership at time of repair.

• | Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair.

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.

### Customer Reimbursement - For Saturn US Only

All customer requests for reimbursement for previous repairs for the Special Coverage condition are handled by submitting a reimbursement claim form directly to Saturn retailers for processing; however, if customers choose, they may file a claim through the Saturn Customer Assistance Center.

A Saturn Customer Reimbursement Procedure and Claim Form are included with the customer letter.

November 2006

Dear General Motors Customer:

As the owner of a 2003-04 Saab 9-3 Sports Sedan; 2004 Saab 9-3 Convertible; Chevrolet Malibu, Aveo; Cadillac XLR, SRX; or Saturn L-Series, your satisfaction with our product is very important to us.

This letter is intended to make you aware that some 2003-04 Saab 9-3 Sports Sedan; 2004 Saab 9-3 Convertible; Chevrolet Malibu, Aveo; Cadillac XLR, SRX; and Saturn L-Series may have a condition where the fuel tank gas cap won’t tighten properly or the fuel 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 2003-04 Saab 9-3 Sports Sedan; 2004 Saab 9-3 Convertible; Chevrolet Malibu, Aveo; Cadillac XLR, SRX; or Saturn L-Series 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 (Chevrolet, Cadillac), 7:00 AM to 7:00 PM EST (Saturn), and 8:00 AM to 8:00 PM EST (Saab) Monday through Friday.

Division | Number | Text Telephones (TTY)
--- | --- | ---
Cadillac | 1-866-982-2339 | 1-800-833-2622
Chevrolet | 1-800-630-2438 | 1-800-833-2438
Saturn | 1-800-972-8876 | 1-800-833-6000
Saab | 1-800-955-9007 |
Guam | 1-671-648-8650 |
Puerto Rico - English | 1-800-496-9992 |
Puerto Rico - Español | 1-800-496-9993 |
Virgin Islands | 1-800-496-9994 |

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

06081