2004 Corvettes with gas tank leaks.

[Tom H.]

Hey all !!

Had a few 04's in the shop lately with some fuel tank leak issues. This is a very expensive repair. GM just stepped up to the plate and is going to fix them for the customers. Finally. Just an FYI for you guys and gals. Here's the letter just released on Friday.




#10150: Special Coverage Adjustment-Fuel Tank Quick Connector Leak - (Aug 13, 2010)

Subject:10150 - Special Coverage Adjustment - Fuel Tank Quick Connector Leak

Models:2004 Cadillac XLR
2004 Chevrolet Corvette

<A href="http://gsi.xw.gm.com/si/showDoc.do?docSyskey=2519705&releaseDate=2010-08-13&name=Special+Coverage+Adjustment-Fuel+Tank+Quick+Connector+Leak&from=ns&bulletinNbr =10150#ss1-2519705">Condition

Some 2004 model year Cadillac XLR and Chevrolet Corvette vehicles may have a fuel tank leak at the quick connectors that are used to link the left and right fuel tanks. The customer may notice a fuel odor while the vehicle is being refueled, driven, or after it is parked. If the leak becomes large enough, a small amount of fuel may be observed dripping on the ground. The leak may also result in a diagnostic code being set and the illumination of the Check Engine light on the instrument cluster.
<A href="http://gsi.xw.gm.com/si/showDoc.do?docSyskey=2519705&releaseDate=2010-08-13&name=Special+Coverage+Adjustment-Fuel+Tank+Quick+Connector+Leak&from=ns&bulletinNbr =10150#ss2-2519705">Special Coverage Adjustment

This special coverage covers the condition described above for a period of 10 years or 100,000 miles (160,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership.
Dealers are to replace the leaking fuel tank. 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 August 16, 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 August 16, 2010, must be submitted to the Service Contract provider.
<A href="http://gsi.xw.gm.com/si/showDoc.do?docSyskey=2519705&releaseDate=2010-08-13&name=Special+Coverage+Adjustment-Fuel+Tank+Quick+Connector+Leak&from=ns&bulletinNbr =10150#ss3-2519705">Vehicles Involved

Involved are certain 2004 model year Cadillac XLR and Chevrolet Corvette vehicles built within the following VIN breakpoints:
Year
Divison
Model
From
Through
2004
Cadillac
XLR
45600796
45602844
2004
Chevrolet
Corvette
45110258
45125500
Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using the Investigate Vehicle History link on the Global Warranty Management application within GlobalConnect. Special Coverage Adjustments are displayed in the Applicable Warranties section.
<A href="http://gsi.xw.gm.com/si/showDoc.do?docSyskey=2519705&releaseDate=2010-08-13&name=Special+Coverage+Adjustment-Fuel+Tank+Quick+Connector+Leak&from=ns&bulletinNbr =10150#ss4-2519705">Parts Information

Parts required to complete this special coverage are to be obtained from General Motors Customer Care and Aftersales (GMCC&A).
Part Number
Description
Qty/ Vehicle
25899601
Tank, Fuel (LH)
1 (If Req'd)
10337582
Tank, Fuel (RH)
1 (If Req'd)
89047640
Insulator, F/Tnk (LH)
1 (Req'd when replacing left fuel tank)
15223882*
Hose, Fuel Feed
1 (If Req'd)
10337583*
Pipe, Aux Fuel Feed & Rtn RR (LH)
1 (If Req'd)
10337581*
Pipe, Aux Fuel Feed & Rtn RR (RH)
I (If Req'd)
21008100**
Gasket, F/Pmp
1 (If Req'd)
* Less than 30% of vehicles requiring tank replacement will require this.
** Less than 25% of vehicles will require this.
<A href="http://gsi.xw.gm.com/si/showDoc.do?docSyskey=2519705&releaseDate=2010-08-13&name=Special+Coverage+Adjustment-Fuel+Tank+Quick+Connector+Leak&from=ns&bulletinNbr =10150#ss5-2519705">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).
<A href="http://gsi.xw.gm.com/si/showDoc.do?docSyskey=2519705&releaseDate=2010-08-13&name=Special+Coverage+Adjustment-Fuel+Tank+Quick+Connector+Leak&from=ns&bulletinNbr =10150#ss6-2519705">Service Procedure

1. <LI type=1>Determine if the left or right fuel tank is leaking. Refer to Fuel Tank Leak Test in SI for diagnostic information.
   If the left or right fuel tank is leaking, proceed to Step 2.
   If the fuel tanks are not leaking, no further action is required.
   <LI type=1>Remove the left or right fuel tank from the vehicle. Refer to Fuel Tank Replacement - Left Side or Fuel Tank Replacement - Right Side in SI.
2. Install the new fuel tank. Refer to Fuel Tank Replacement - Left Side or Fuel Tank Replacement - Right Side in SI.

<A href="http://gsi.xw.gm.com/si/showDoc.do?docSyskey=2519705&releaseDate=2010-08-13&name=Special+Coverage+Adjustment-Fuel+Tank+Quick+Connector+Leak&from=ns&bulletinNbr =10150#ss7-2519705">Claim Information

1. Submit a claim using the table below.
Labor Code
Description
Labor Time
Net Item
T5787
Perform Diagnostics - No Tank Replacement Req'd
0.0-0.3
N/A
T5785
Replace One Fuel Tank
7.5
N/A
Add: Replace Both Fuel Tanks
2.0
Add: Diagnostic Time
0.0-0.3
T5786
Customer Reimbursement (not for use by US GM dealers)
0.2
*
* The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer.
<A href="http://gsi.xw.gm.com/si/showDoc.do?docSyskey=2519705&releaseDate=2010-08-13&name=Special+Coverage+Adjustment-Fuel+Tank+Quick+Connector+Leak&from=ns&bulletinNbr =10150#ss8-2519705">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.
<A href="http://gsi.xw.gm.com/si/showDoc.do?docSyskey=2519705&releaseDate=2010-08-13&name=Special+Coverage+Adjustment-Fuel+Tank+Quick+Connector+Leak&from=ns&bulletinNbr =10150#ss9-2519705">Customer Reimbursement - For Canada and Export

Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to be submitted to the dealer prior to or by August 31, 2011. Repairs must have occurred within the 10 years of the date the vehicle was originally placed in service, or 160,000 kilometers, 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.
August 2010 Dear General Motors Customer:
As the owner of a 2004 Cadillac XLR or Chevrolet Corvette, your satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2004 Cadillac XLR and Chevrolet Corvette vehicles may have a fuel tank leak at the quick connectors that are used to link the left and right fuel tanks. The customer may notice a fuel odor while the vehicle is being refueled, driven, or after it is parked. If the leak becomes large enough, a small amount of fuel may be observed dripping on the ground. The leak may also result in a diagnostic code being set and the illumination of the Check Engine light on the instrument cluster.
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 connectors. If this condition occurs on your 2004 model year Cadillac XLR or Chevrolet Corvette vehicle within 10 years of the date your vehicle was originally placed in service or 100,000 miles (160,000 km), whichever occurs first, 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 GM 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. Your request for reimbursement, including the information and documents mentioned on the enclosed form, must be received by GM by August 31, 2011.

[Clem Z.]

Re: 2004 Corvettes with gas tank leaks.

i don't under stand why this happens as it was not a problem from 1997 to 2003. sounds like GM tried a cheaper way of doing it and it bit them. i see this happen a lot that a later model has a problem that a earlier model of the same car did not.

[Tom H.]

Re: 2004 Corvettes with gas tank leaks.

Different system in 04. We never really had any trouble with them. I had one 5000 mile car with a leak last week and started reading into it a bit. Sounds like there were many more. This service letter was released just last Friday.

[Edward J.]

Re: 2004 Corvettes with gas tank leaks.

Tom, Back in my 97 coupe there was a recall on fuel pumps they replaced both the pumps on my early 97 . I am glad to see that my 2002 Z06 tanks are not on the list.

[Tom H.]

Re: 2004 Corvettes with gas tank leaks.

Tom, Back in my 97 coupe there was a recall on fuel pumps they replaced both the pumps on my early 97 . I am glad to see that my 2002 Z06 tanks are not on the list.

Just 04's ! This is a different problem than we had in the earlier C5's.

[Joe L.]

Re: 2004 Corvettes with gas tank leaks.

All------


Plastic fuel tanks strike again!

[Clem Z.]

Re: 2004 Corvettes with gas tank leaks.

All------


Plastic fuel tanks strike again!

in 04 they had to change the evaporation system because before the fuel return line was in the engine compartment which heated up the gasoline and cause evaporative emissions from the fuel tank to be too high. the return line was built into the fuel tank/fuel pump system all inside the tank so it did not have to go thru the engine compartment

[Edward J.]

Re: 2004 Corvettes with gas tank leaks.

The dealership line mechanics must love to do gas tanks in the newer Corvettes, 7.5 hrs. for one tank and and add another 2.0 for the other plus a little dia. time. this adds up to 10 hrs. x 95-100.00 and hour. not inc. the parts required.

When I was a GM flat rate mechanic GM labor times were way of base. so say GM labor time is 10.0 hrs. that means about 15.0 hrs. would be the flat rate time from the labor guides other than warrenty times. if you had a 2004 corvette go out of warrenty, I would say the parts and labor for the gas tanks replacement would be worth about 2500.00+ bucks or so. I have one word for this- ouchhhh.

[Clem Z.]

Re: 2004 Corvettes with gas tank leaks.

The dealership line mechanics must love to do gas tanks in the newer Corvettes, 7.5 hrs. for one tank and and add another 2.0 for the other plus a little dia. time. this adds up to 10 hrs. x 95-100.00 and hour. not inc. the parts required.

When I was a GM flat rate mechanic GM labor times were way of base. so say GM labor time is 10.0 hrs. that means about 15.0 hrs. would be the flat rate time from the labor guides other than warrenty times. if you had a 2004 corvette go out of warrenty, I would say the parts and labor for the gas tanks replacement would be worth about 2500.00+ bucks or so. I have one word for this- ouchhhh.

i think there are different rates for std trans vs auto trans on fuel tank work

[Edward J.]

Re: 2004 Corvettes with gas tank leaks.

Clem, I have never removed a tank from a C-5 yet, I wonder what the deal is with 7.5 hrs for one tank and another 2.0 for the other? I really never took a close look at my C-5 to see whats required for tank removel. maybe the torque tubes in the way, if so that means the trans, and diff. and craddle sliding back.

[Paul B.]

Re: 2004 Corvettes with gas tank leaks.

Just 04's ! This is a different problem than we had in the earlier C5's.

....supposedly it affected late '03s too. Someone on the Corvette Forum posted a GM Service Bulletin showing the exact VIN # of the 2003 Corvette that this new style of plastic tanks was in effect.

[Tom H.]

Re: 2004 Corvettes with gas tank leaks.

....supposedly it affected late '03s too. Someone on the Corvette Forum posted a GM Service Bulletin showing the exact VIN # of the 2003 Corvette that this new style of plastic tanks was in effect.

Yep, I'm the one who posted the GM letter realeased last Friday.

Here are the vehicles listed in the letter. I'll have to look into the 03's.



Vehicles Involved

Involved are certain 2004 model year Cadillac XLR and Chevrolet Corvette vehicles built within the following VIN breakpoints:
Year
Divison
Model
From
Through
2004
Cadillac
XLR
45600796
45602844
2004
Chevrolet
Corvette
45110258
45125500

[Calvin M.]

Re: 2004 Corvettes with gas tank leaks.

My '04 is 106780, or about 3500 cars before the affected VIN range.

Does anyone know how the tanks (or connectors) differ between the cars before, and those within the range?

Thanks!

[Michael J.]

Re: 2004 Corvettes with gas tank leaks.

My tank started leaking within a month of buying it, in Oct. 2004, a LeMans Commemorative convertible. It leaked for 4 months before they would agree to fix it, March 2005 by now. The service guy said it was covered under warranty, they replaced the fuel tank and it took 2 more months to get the fuel tank for replacement. He told me the reason was that the mounting straps/braces were way overtightened at the factory and it cracked some welds and seams. This poor quality assembly and QC, along with the fact it would eat a battery every year, and the interior panels falling off, lead me to trade this dog in on a better vehicle. I am still afraid of the modern Vettes.

[Terry B.]

Re: 2004 Corvettes with gas tank leaks.

Hi Tom, Good info, do you know when they do the repair if they replace with the same parts or do they have a solution so that it doesn't happen a few years down the road again?

Terry