Recall - ORVR Valve Replacement

VOLUME
3

GROUP
Campaign

NUMBER
040

MODEL
Spectra

DATE
May 2003

SUBJECT
Service Campaign: Spectra ORVR Valve

This bulletin provides information related to a service campaign to replace ORVR (on-board refueling vapor recovery) valve on 2002 and 2003 Spectra models. The ORVR valve on Spectra models produced from 5/4/01 through 7/12/02 may have interference with an underbody reinforcement which could result in cracking of a vapor hose connection on the ORVR valve. If a crack occurs, the MIL will illuminate with evaporative system leak related DTCs.





To eliminate possible ORVR damage from underbody interference, a revised ORVR valve has been developed to service affected vehicles.

*NOTICE
There is no charge to the customer for this repair. Under applicable law, you may not sell or otherwise deliver any affected 2002 or 2003MY Spectra until it has been repaired, pursuant to the procedures set forth in this bulletin.

For California Dealers, this recall is subject to the State of California Registration Renewal/Emission Recall Enforcement Program implemented in 1992. Involved vehicles must have the recall service completed before registration renewal.

INSPECTION:





Open driver's door and check for campaign completion label.

^ If label exists, NO FURTHER ACTION IS REQUIRED.

^ If label DOES NOT EXIST, check vehicle claim history for SC026 completion.

^ If label or 5C026 claim history DOES NOT EXIST, continue on to Repair Procedure.

REPAIR PROCEDURE:

*NOTICE
If fuel tank is more than 1/4 full, it must be drained to avoid possible spillage from fuel filler pipe and to reduce excessive weight while fuel tank is being removed and reinstalled.

WARNING
Fuel vapors are flammable. Death or serious injury could result if they are ignited. Make sure there are no open flames or smoking in the area of the repair. Adequate ventilation is necessary to prevent a buildup of fumes which could ignite, causing fire or explosion.





1. Remove rear seat cushion by pushing release mechanisms located under the front of the seat cushion.





2. Remove three screws securing fuel pump cover. Disconnect electrical connectors from fuel pump and leak detection pump short harness.





3. Raise vehicle on hoist and remove rear exhaust system by removing two nuts at rear of main catalytic converter flange and disconnecting rubber hangers from at front and rear of exhaust system.





4. Remove fuel tank exhaust shield.





5. Disconnect electrical connector from evap leak detection pump.





6. Disconnect hoses from charcoal canister, remove mounting bolts and remove charcoal canister.





7. Loosen fuel filler hose clamp at left rear of fuel tank and disconnect hose.





8. Disconnect fuel lines from fuel tank to fuel filter by pushing line toward filter, squeezing tabs to release and pulling line off from filter.





9. Support fuel tank using a suitable jack or lifting device and remove two bolts securing fuel tank straps to the body.





10. Lower fuel tank a few inches and disconnect vent hose from tee.





11. Lower fuel tank. Disconnect vent hoses from ORVR valve, remove screws securing ORVR valve to fuel tank and remove ORVR valve.





12. Install new ORVR valve in fuel tank, reinstall screws and reconnect hoses.





13. Raise fuel tank high enough to reconnect vent hose, reconnect vent hose.





14. Raise fuel tank the rest of the way. Reconnect fuel filler hose and tighten clamp before reinstalling fuel tank straps.





15. Reinstall fuel tank straps and torque to 40-44 lb-ft (54-59Nm).





16. Reconnect fuel lines at fuel filter by pushing line onto fitting until a click is felt, then pull to test.





17. Reinstall charcoal canister and reconnect hoses.





18. Reconnect electrical connector to evap leak detection pump.





19. Reinstall fuel tank exhaust shield.





20. Install a new gasket on catalytic converter flange. Position exhaust system on converter studs and attach at least one rubber hanger at main silencer to support exhaust, then install catalytic converter flange nuts and attach remaining rubber hangers. Torque flange nuts to 35-38 lb-ft (47-51 Nm).





21. Lower vehicle. Reconnect fuel pump wiring and reinstall cover.

22. Reinstall rear seat cushion.

*NOTICE
If fuel was removed, transfer back into vehicle.





23. Install campaign completion label on driver's doorjam.

FOR CALIFORNIA DEALERS:





For vehicles sold in California, a supplied Vehicle Emission Recall Proof of Correction Form must be completed and given to each owner upon completion of the recall service for owner use as proof during renewal of vehicle registration.

AFFECTED PRODUCTION RANGE:

2002, 2003 Spectra models with production dates from 5/4/01 through 7/12/02.





PART NUMBER INFORMATION:





WARRANTY CLAIM INFORMATION: