Product Safety - Fuel Feed Pipe Assembly Replacement

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall 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 entitled 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 customer and to repair their vehicle as soon as possible. In the recall notification letter, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time.

Saturn has decided that a defect relating to motor vehicle safety exists in 2004 Saturn ION vehicles equipped with the supercharged 2.0L 4-cylinder (LSJ) engine. These vehicles were built with a fuel feed pipe that may leak fuel near the fuel rail due to cracks in the fuel feed pipe. If fuel leaks from the fuel feed pipe, there would be a noticeable fuel odor around the vehicle. If an ignition source is present, a fire could result.

Retailers will replace the fuel feed pipe assembly on all affected vehicles.

2004 Saturn ION Red Line coupe vehicles equipped with the supercharged 2.0L 4-cylinder engine (LSJ) within the following VIN range will require this recall:

4Z185538 - 4Z210265

You must verify recall involvement through your AS400 system. It is important to note that recall claims will only be paid on involved vehicles.

Owners of all involved vehicles will be notified of this recall by Saturn. (Refer to the owner letter included in this bulletin.)

All unsold vehicles in Retailers’ possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before owners take possession of these vehicles.

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

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

1. All of the required parts to perform this recall will be automatically sent to involved Retailers from Saturn Service Parts Operations (SSPO). These shipments are to aid Retailers in recall preparation and ensure minimal customer inconvenience.

2. Should you require any additional parts, please contact your Parts Support Analyst (PSA), and we will expedite the shipment.

* No part number change at this time.

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.

Fuel Hose/Pipes Replacement Procedure

CAUTION: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

CAUTION: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.

CAUTION: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

1. Relieve the fuel system pressure.

1.1.	Turn ignition OFF.





CAUTION: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1.2.	Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine.

1.2.1.

Turn OFF all the lamps and the accessories.

1.2.2.

Make sure the ignition switch is in the OFF position.

1.2.3.

Disconnect the battery negative cable from the battery (2).

1.3.	Loosen the fuel filler cap to relieve the fuel tank vapor pressure.

1.4.	Remove the cap from the fuel pressure service port.





CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete.

NOTICE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:    •  The fuel pipe connections    •  The hose connections    •  The areas surrounding the connections

1.5.	Connect the SA9127E Gage Bar Set to the fuel pressure service port connection.

1.5.1.

Connect Gage Bar (53476) to Fuel Gage Pressure Adapter (309725) using a flexible hose from Gage Bar Set (SA9127E).

1.5.2.

Make sure needle valve on Fuel Gage Pressure Adapter (309725) is closed (OFF).

NOTICE: Do not use any tools to tighten the adapter to the fuel pressure service port. If the adapter will not seal with finger tightening, then the seal is defective or damaged and needs to be replaced. Excessive torque on the adapter will damage the fuel pressure service port.

1.5.3.

Connect Fuel Gage Pressure Adapter (309725) to fuel pressure service port connection. Wrap a shop towel around the fitting while connecting the gage to avoid spillage.

CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion.

1.6.	Place the bleed hose of the SA9127E into an approved fuel container.

1.7.	Open the bleed valve on the SA9127E in order to bleed the fuel system pressure. The fuel connections are now safe for servicing.

1.8.	Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage.

1.9.	Disconnect the SA9127E from the fuel pressure service port connection.

1.10.

Drain any fuel remaining in the gage into an approved fuel container.

1.11.

Install the cap to the fuel pressure service port.

2. Remove Powertrain Control Module (PCM) from bracket and set aside. (Do not disconnect electrical connectors.)
3. Remove Underhood Bussed Electrical Center (UBEC).
4. Remove UBEC plastic base.
5. Disconnect the engine fuel feed pipe from the chassis fuel flex hose. Refer to Steps 5.1 - 5.6 for instructions for disconnecting quick connect fittings (metal collar).

CAUTION: Wear safety goggles when using compressed air, as flying dirt particles may cause eye injury.

5.1.	Remove the retainer from the quick-connect fitting.

5.2.	Blow dirt out of the fitting using compressed air.





5.3.	Choose the correct tool from J 37088-A or J41769-1 (blue). Insert the tool into the female connector, then push inward to release the locking tabs.





5.4.	Pull the connection apart.

NOTICE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required.

5.5.	Using a clean shop towel, wipe off the male pipe end.

5.6.	Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.




6. Use two open-end wrenches to disconnect the fuel feed pipe.



7. Remove the fuel feed pipe fasteners located on the engine.
8. Disconnect brake vacuum booster line at throttle body.
9. Disconnect canister purge pipe.
10. Disconnect both vacuum lines from supercharger boost solenoid.
11. Remove the engine fuel feed pipe.

Installation Procedure

NOTICE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

1. Install the new fuel feed pipe to the fuel rail.

Tighten
Tighten the fuel rail to the fuel feed pipe to 14 N·m (10 lb-ft).

2. Install the engine fuel feed pipe fasteners located on the engine.

Tighten
Tighten the fuel feed pipe fastener to 10 N·m (89 lb-in).

3. Connect the engine fuel feed pipe to the chassis fuel flex hose. Refer to Steps 3.1 - 3.4 for instructions for connecting quick connect fittings (metal collar).




CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

3.1.	Apply a few drops of clean engine oil to the male pipe end.





3.2.	Push both sides of the fitting together to cause the retaining tabs to snap into place.





3.3.	Once installed, pull on both sides of the fitting to make sure the connection is secure.

3.4.	Install the retainer to the quick-connect fitting.

4. Install canister purge pipe.
5. Install brake booster line to throttle body.
6. Install both supercharger boost control vacuum lines to solenoid.
7. Install UBEC plastic base and UBEC.
8. Position PCM to bracket and install PCM.



9. Connect the negative battery cable.

Important: Clean any existing oxidation from the contact face of the battery terminal and battery cable using a wire brush before installing the battery cable to the battery terminal.

9.1.	Connect the battery negative cable to the battery (2).

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

9.2.	Reset the clock.

10. Inspect for leaks using the following procedure:

10.1.

With the engine OFF, turn ON the ignition for 2 seconds.

10.2.

Inspect for fuel leaks.

10.3.

Turn the ignition OFF.

10.4.

With the engine OFF, turn ON the ignition for 2 seconds.

10.5.

Inspect for fuel leaks.

10.6.

Turn the ignition OFF.

1. To receive credit for installing a fuel feed pipe assembly, submit a claim with the information below:

2. To receive credit for loaner/rental car cost 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 toward 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.

4. 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.

5. All labor operations claimed in this bulletin must be submitted on individual (unrelated) CSO lines. Refer to the Customer Service Order Preparation Manual for details on Product Recall Claim Submission.

* The parts allowance should be the sum total of the current SSPO retailer net price plus 40% of all parts required for the repair.

** Recall administration allowance.

*** Net amount must be submitted as a miscellaneous sale...Loaner reimbursement not to exceed $30/day.

**** Enter number of days vehicle was rented...Not to exceed 1 day.

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 a defect relating to motor vehicle safety exists in 2004 Saturn ION vehicles equipped with the supercharged 2.0L 4-cylinder (LSJ) engine. These vehicles were built with a fuel feed pipe that may leak fuel near the fuel rail due to cracks in the fuel feed pipe. If fuel leaks from the fuel feed pipe, there would be a noticeable fuel odor around the vehicle. If an ignition source is present, a fire could result.

What Saturn will do:

Retailers will replace the fuel feed pipe assembly on all affected vehicles. This service will be performed at no charge to you.

What you should do:

Contact your Saturn Retailer as soon as possible to arrange for the repair. Repairs will take about 30 minutes although some additional time may be required for paperwork and processing.

The enclosed reply card identifies your vehicle and will facilitate completion of the repairs when presented to your Saturn retail facility. If your address has changed, please provide the new information in the space provided. This will assist us in ensuring that all affected vehicles are corrected.

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 a reasonable time, please contact the Saturn Customer Assistance Center at 1-800-972-8876, 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, you may wish to write the Administrator, National Highway Traffic Safety Administration, 400 7th St., SW, Washington, DC 20590, or call 1-888-327-4236.

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

04053