SB-09275
Service Bulletin Details
Public Details for: SB-09275
Saturn/pontiac/chevrolet: see document search button for owner letter. Special coverage adjustment; fuel odor or spotting on ground; replace fuel pump module. Some vehicles may have a condition in which plastic supply or return port on
Models from 9999
9999 PONTIAC PONTIAC |
Models from 2007
2007 CHEVROLET COBALT |
2007 PONTIAC G5 |
2007 SATURN ION |
Models from 2006
2006 CHEVROLET COBALT |
2006 SATURN ION |
Page 6 July 2015 Bulletin No.: 09275C CSC-10033024-1907 April 2013 Dear General Motors Customer: As the owner of a 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicle or 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicle, your satisfaction with our product is very important to us. Previously, you may have been notified of a special coverage adjustment that General Motors made available to you if your vehicle displayed the symptoms described below. This letter is to inform you that the coverage has been expanded to cover the condition regardless of the mileage or age of your vehicle. Some 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicles, or some 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicles, sold or operated in areas with warm weather, may have a condition in which the plastic supply or return port on the modular reservoir assembly (MRA) may crack. If either of these ports develop a crack, fuel will leak from the area. You may notice a fuel odor while the vehicle is being driven or after it is parked. If the crack becomes large enough, fuel may be observed dripping onto the ground and vehicle performance may be affected. 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 pump module. If this condition occurs on your 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicle or 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicle, regardless of the vehicle's age or mileage, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to contact 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 and have not submitted a reimbursement request. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by April 30, 2014. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. Page 7 July 2015 Division Chevrolet Pontiac Saturn Number 1-800-630-2438 1-800-620-7668 1-800-972-8876 Bulletin No.: 09275C Text Telephones (TTY) 1-800-833-2438 1-800-833-7668 1-800-833-6000 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. Jim Moloney General Director, Customer and Relationship Services Enclosure 09275-2 Page 4 CSC-10033024-1724 April 2013 Bulletin No.: 09275B April 2013 Dear General Motors Customer: As the owner of a 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicle or 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicle, your satisfaction with our product is very important to us. Previously, you may have been notified of a special coverage adjustment that General Motors made available to you if your vehicle displayed the symptoms described below. This letter is to inform you that the coverage has been expanded to cover the condition regardless of the mileage or age of your vehicle. Some 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicles, or some 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicles, sold or operated in areas with warm weather, may have a condition in which the plastic supply or return port on the modular reservoir assembly (MRA) may crack. If either of these ports develop a crack, fuel will leak from the area. You may notice a fuel odor while the vehicle is being driven or after it is parked. If the crack becomes large enough, fuel may be observed dripping onto the ground and vehicle performance may be affected. 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 pump module. If this condition occurs on your 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicle or 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicle, regardless of the vehicle's age or mileage, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to contact 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 and have not submitted a reimbursement request. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by April 30, 2014. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. Page 5 April 2013 Division Number Chevrolet Pontiac Saturn 1-800-630-2438 1-800-620-7668 1-800-972-8876 Bulletin No.: 09275B Text Telephones (TTY) 1-800-833-2438 1-800-833-7668 1-800-833-6000 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. Jim Moloney General Director Customer and Relationship Services Enclosure 09275-2 Service Bulletin Bulletin No.: 09275C Date: July 2015 SB-10033024-1907 SPECIAL COVERAGE SUBJECT: Special Coverage Adjustment – Fuel Odor or Spotting on Ground – Replace Fuel Pump Module MODELS: 2006 Chevrolet Cobalt 2006 Pontiac G4 2006 Saturn ION Originally Sold or Currently Registered in Alabama, Arkansas, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, North Carolina, New Mexico, Oklahoma, South Carolina, Tennessee, Texas 2007 Chevrolet Cobalt 2007 Pontiac G5 2007 Saturn ION Originally Sold or Currently Registered in Alabama, Arkansas, Georgia, Hawaii, Louisiana, Mississippi, North Carolina, New Mexico, Oklahoma, South Carolina, Tennessee The repair for this special coverage has been revised to also include the replacement of the fuel tank and the fuel tank filler pipe or filler hose, if necessary. Please discard all copies of bulletin 09275B. CONDITION Some 2006 model year Chevrolet Cobalt, Pontiac G4, and Saturn ION vehicles originally sold or currently registered in Alabama, Arkansas, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, North Carolina, New Mexico, Oklahoma, South Carolina, Tennessee, and Texas; and some 2007 model year Chevrolet Cobalt, Pontiac G5, and Saturn ION vehicles originally sold or currently registered in Alabama, Arkansas, Georgia, Hawaii, Louisiana, Mississippi, North Carolina, New Mexico, Oklahoma, South Carolina, and Tennessee may have a condition in which the plastic supply or return port on the modular reservoir assembly (MRA) may crack. If either of these ports develop a crack, fuel will leak from the area. The customer may notice a fuel odor while the vehicle is being driven or after it is parked. If the crack becomes large enough, fuel may be observed dripping onto the ground and vehicle performance may be affected. SPECIAL COVERAGE ADJUSTMENT If a vehicle involved in this Special Coverage demonstrates the condition or symptoms described above, dealers are to replace the fuel pump module, and if necessary, the fuel tank and fuel tank filler pipe or filler hose, regardless of the vehicle’s age or mileage. For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after January 28, 2010, 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 January 28, 2010, must be submitted to the Service Contract provider. Copyright 2015 General Motors. All Rights Reserved. Page 2 July 2015 Bulletin No.: 09275C VEHICLES INVOLVED All involved vehicles are identified by Vehicle Identification Number on the Applicable Warranties section in GM Global Warranty Management system. Dealership service personnel should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. PART INFORMATION Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A). Part Number 19257126 19257138 20870462 25947828 20757861 20757866 22682111 15776433 15776431 10325852 Description MODULE KIT, F/TNK F/PMP (W/O FUEL LVL SEN) (LE5/L61) MODULE KIT, F/TNK F/PMP (W/O FUEL LVL SEN) (LSJ) TANK, FUEL (-NU6/LNF) (USE WITH 15776431, 15776433) TANK, FUEL (&LNF) (USE WITH 10325852, 22682111) PIPE, F/TNK FIL (W/FIL HOSE) (CHEVROLET, PONTIAC)) * HOSE ASM-F/TNK FIL * (*SATURN ION ONLY, TRIM HOSE TO FIT) SEAL,F/PMP (O-RING) (&LNF) SEAL-F/PMP FUEL RSVR (O RING) (-NU6/LNF) CAM,FUEL SDR (-NU6/LNF)* CAM,FUEL SDR (&LNF)* Quantity/Vehicle 1 (If Req’d) 1 (If Req’d) 1, (If Req’d) 1, (If Req’d) 1, (If Req’d) 1, (If Req’d) 1, (If Req’d) 1, (If Req’d) 1, (If Req’d) 1, (If Req’d) * required only if the fuel tank requires replacement SERVICE PROCEDURE 1. Remove the fuel tank. Refer to Fuel Tank Replacement in SI. 2. Inspect the fuel tank for the most recent part revision (p/n 20870462 or 25947828). 4093630 Page 3 July 2015 Bulletin No.: 09275C Identifying the 20870462 or 25947828 fuel tank. The fuel tank hose connection (1) will have an index feature (2) at the bottom 6 O’clock position where the hose joins the tank. Older style tanks have this feature on top at the 12 O’clock location. The fuel tank may also have an identifying tag displaying the part number. If the part number is 20870462 or 25947828, and has the bottom index, proceed to Step 5. If the part number is not 20870462 or 25947828, and has the top index, proceed to Steps 3 and 4. 3. Replace the fuel tank with p/n 20870462 or 25947828, as applicable. Refer to Fuel Tank Replacement in SI. 4. For Cobalt, G4, G5: Replace the fuel tank filler pipe. Refer to Fuel Tank Filler Pipe Replacement in SI. Saturn ION only: Trim new fuel tank filler hose to match existing fuel tank filler hose. 4.1 Remove fuel tank filler hose from vehicle mounted fill pipe. 4109439 4.2 Match the new hose (2) to the original (1), aligning side by side. Page 4 July 2015 Bulletin No.: 09275C 4109445 4.3 Using a paint pen or equivalent, mark the new hose to the original, starting with the notched fuel tank ends of the hoses so that both hoses are the same length. Note: When cutting the hose, be sure the cut is as straight as possible. Use a hose clamp or tape as a guide. Failure to cut the hose straight could result in leaks. 4.4 Cut the hose from the fill end opposite of the side with the notch (1) to match the length. 4.5 Transfer the clamp on the newly cut hose. 4.6 Install the new trimmed hose to vehicle mounted fill pipe, and to the tank. 5. Remove the fuel pump module. Refer to Fuel Pump Module Replacement in SI. 6. Install a new fuel pump module. Refer to Fuel Pump Module Replacement in SI. 7. Install the fuel tank filler pipe, if needed. Refer to Fuel Tank Filler Pipe Replacement in SI. 8. Install the fuel tank. Refer to Fuel Tank Replacement in SI. CUSTOMER REIMBURSEMENT 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. Page 5 July 2015 Bulletin No.: 09275C WARRANTY TRANSACTION INFORMATION Submit a transaction using the table below. All transactions should be submitted as a ZREG transaction type, unless noted otherwise. Labor Code T5734 9900163 T5735 Description Install New Fuel Pump Module Only (inc. drain & fill) - Cobalt, G4, G5 - ION Install New Fuel Pump Module, Fuel Tank, Fill Pipe or Hose (inc. tank drain & fill) - Cobalt, G4, G5 - ION Customer Reimbursement (not for use by US GM dealers) Labor Time Net Item N/A 1.5 1.2 N/A 1.9 1.4 0.2 * * The amount identified in “Net Item” should represent the dollar amount reimbursed to the customer. 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). GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the tools, equipment, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your dealer/retailer for information on whether your vehicle may benefit from the information. We Support Voluntary Technician Certification Page 6 July 2015 Bulletin No.: 09275C April 2013 Dear General Motors Customer: As the owner of a 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicle or 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicle, your satisfaction with our product is very important to us. Previously, you may have been notified of a special coverage adjustment that General Motors made available to you if your vehicle displayed the symptoms described below. This letter is to inform you that the coverage has been expanded to cover the condition regardless of the mileage or age of your vehicle. Some 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicles, or some 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicles, sold or operated in areas with warm weather, may have a condition in which the plastic supply or return port on the modular reservoir assembly (MRA) may crack. If either of these ports develop a crack, fuel will leak from the area. You may notice a fuel odor while the vehicle is being driven or after it is parked. If the crack becomes large enough, fuel may be observed dripping onto the ground and vehicle performance may be affected. 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 pump module. If this condition occurs on your 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicle or 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicle, regardless of the vehicle's age or mileage, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to contact 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 and have not submitted a reimbursement request. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by April 30, 2014. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. Page 7 July 2015 Division Chevrolet Pontiac Saturn Number 1-800-630-2438 1-800-620-7668 1-800-972-8876 Bulletin No.: 09275C Text Telephones (TTY) 1-800-833-2438 1-800-833-7668 1-800-833-6000 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. Enclosure 09275-2 Jim Moloney General Director, Customer and Relationship Services SB-10033024-6378 Service Bulletin Bulletin No.: 09275B Date: April 2013 SPECIAL COVERAGE SUBJECT: Special Coverage Adjustment – Fuel Odor or Spotting on Ground – Replace Fuel Pump Module MODELS: 2006 Chevrolet Cobalt 2006 Pontiac G4 2006 Saturn ION Originally Sold or Currently Registered in Alabama, Arkansas, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, North Carolina, New Mexico, Oklahoma, South Carolina, Tennessee, Texas 2007 Chevrolet Cobalt 2007 Pontiac G5 2007 Saturn ION Originally Sold or Currently Registered in Alabama, Arkansas, Georgia, Hawaii, Louisiana, Mississippi, North Carolina, New Mexico, Oklahoma, South Carolina, Tennessee This bulletin is being revised to provide coverage of the condition described in this bulletin regardless of the vehicle's mileage or age. Please discard all copies of bulletin 09275A. CONDITION Some 2006 model year Chevrolet Cobalt, Pontiac G4, and Saturn ION vehicles originally sold or currently registered in Alabama, Arkansas, California, Florida, Georgia, Hawaii, Louisiana, Mississippi, North Carolina, New Mexico, Oklahoma, South Carolina, Tennessee, and Texas; and some 2007 model year Chevrolet Cobalt, Pontiac G5, and Saturn ION vehicles originally sold or currently registered in Alabama, Arkansas, Georgia, Hawaii, Louisiana, Mississippi, North Carolina, New Mexico, Oklahoma, South Carolina, and Tennessee may have a condition in which the plastic supply or return port on the modular reservoir assembly (MRA) may crack. If either of these ports develop a crack, fuel will leak from the area. The customer may notice a fuel odor while the vehicle is being driven or after it is parked. If the crack becomes large enough, fuel may be observed dripping onto the ground and vehicle performance may be affected. SPECIAL COVERAGE ADJUSTMENT If a vehicle involved in this Special Coverage demonstrates the condition or symptoms described above, dealers are to replace the fuel pump module, regardless of the vehicle's age or mileage. Copyright 2013 General Motors. All Rights Reserved. Page 2 April 2013 Bulletin No.: 09275B For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after January 28, 2010, 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 January 28, 2010, must be submitted to the Service Contract provider. VEHICLES INVOLVED All involved vehicles are identified by Vehicle Identification Number on the Applicable Warranties section in GM Global Warranty Management system. Dealership service personnel should always check this site to confirm vehicle involvement prior to beginning any required inspections and/or repairs. It is important to routinely use this tool to verify eligibility because not all similar vehicles may be involved regardless of description or option content. PART INFORMATION Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A). Part Number 19257126 19257138 Description Module Kit, F/Tnk F/Pmp (w/o Fuel Lvl Sen) (LE5/L61) Module Kit, F/Tnk F/Pmp (w/o Fuel Lvl Sen) (LSJ) Quantity/Vehicle 1 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 1. Remove the fuel pump module. Refer to Fuel Pump Module Replacement in SI. 2. Install a new fuel pump module. Refer to Fuel Pump Module Replacement in SI. WARRANTY TRANSACTION INFORMATION Submit a transaction using the table below. All transactions should be submitted as a ZREG transaction type, unless noted otherwise. Labor Code T5734 T5735 Description Install New Fuel Pump Module Cobalt, G5 ION Customer Reimbursement (not for use by US GM dealers) Labor Time Net Item N/A 1.5 1.2 0.2 * * The amount identified in “Net Item” should represent the dollar amount reimbursed to the customer. Page 3 April 2013 Bulletin No.: 09275B CUSTOMER REIMBURSEMENT 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. GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the tools, equipment, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your dealer for informa tion on whether your vehicle may benefit from the information. We Support Voluntary Technician Certification Page 4 April 2013 Bulletin No.: 09275B April 2013 Dear General Motors Customer: As the owner of a 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicle or 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicle, your satisfaction with our product is very important to us. Previously, you may have been notified of a special coverage adjustment that General Motors made available to you if your vehicle displayed the symptoms described below. This letter is to inform you that the coverage has been expanded to cover the condition regardless of the mileage or age of your vehicle. Some 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicles, or some 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicles, sold or operated in areas with warm weather, may have a condition in which the plastic supply or return port on the modular reservoir assembly (MRA) may crack. If either of these ports develop a crack, fuel will leak from the area. You may notice a fuel odor while the vehicle is being driven or after it is parked. If the crack becomes large enough, fuel may be observed dripping onto the ground and vehicle performance may be affected. 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 pump module. If this condition occurs on your 2006 model year Chevrolet Cobalt, Pontiac G4, or Saturn ION vehicle or 2007 model year Chevrolet Cobalt, Pontiac G5, or Saturn ION vehicle, regardless of the vehicle's age or mileage, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program. What You Should Do: Repairs and adjustments qualifying under this special coverage must be performed by a General Motors dealer. You may want to contact 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 and have not submitted a reimbursement request. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by April 30, 2014. If you have any questions or need any assistance to better understand related repairs, please contact your dealer. If you have questions related to a potential reimbursement, please contact the appropriate Customer Assistance Center at the number listed below. Page 5 April 2013 Division Number Chevrolet Pontiac Saturn 1-800-630-2438 1-800-620-7668 1-800-972-8876 Bulletin No.: 09275B Text Telephones (TTY) 1-800-833-2438 1-800-833-7668 1-800-833-6000 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. Jim Moloney General Director Customer and Relationship Services Enclosure 09275-2 SB-10033024-9715 SB-10033024-9642