Recall SL - Check/Replace Fuel Tank/Vapor Container (SL/SL00)

Publication date: 1997-03-01
Reference number: SL/SL00

RECALL SL - CHECK/REPLACE FUEL TANK/VAPOR CONTAINER

SERVICE CAMPAIGN BULLETIN

Reference Number(s): SL/SL00, Date of Issue: March 1997

VOLKSWAGEN:

1997 Model EuroVan Camper

SUBJECT

1997 Model EuroVan Camper

Check/Replace Fuel Tank/Vapor Container

This is to inform you of the initiation of a voluntary safety recall campaign conducted by Winnebago Industries, Inc. in cooperation with Volkswagen of America, Inc. involving a small number of 1997 model Volkswagen Camper EuroVan vehicles. This recall requires the checking and, if necessary, replacement of the fuel tank vapor container assembly.

DEFECT DESCRIPTION

It is possible that during Winnebago's installation of Camper equipment an improperly adjusted power tool drill bit could have punctured the Fuel tank vapor container.

VEHICLE IDENTIFICATION NUMBER RANGE

The vehicles affected are within the following vehicle identification number range:

WV2__870_VH018002 - WV2__870_VH026157

Due to the very small number of vehicles affected, it is imperative that you always check the V-Crest campaign inquiry system for the "Open" SL recall code prior to starting any work.

NOTE: Some Volkswagen dealers have not sold Camper vehicles and may, therefore not be affected by this recall. As to these dealers, this circular is for information only.

REMEDIAL ACTION

Each affected vehicle requires checking of the vapor container for damage and, if necessary, replacement of the fuel tank/vapor container assembly.

OWNER NOTIFICATION MAILING

Owners of affected vehicles will be notified by Winnebago Industries, inc. on or about March 31, 1997. A copy of the owner letter is enclosed.

IMPORTANT: Please Inform and/or Provide A Copy to All Personnel With Recall-Related Responsibilities.

REPAIR OBLIGATION

IMPORTANT: Please make sure that the fuel tank inspection is scheduled during the early part of the day so that the Parts Department can place an immediate order with the warehouse for overnight shipment of a fuel tank assembly, if needed.

PARTS INFORMATION

The following parts may be required for this action:

PARTS

Qty.	Description	Part Number
1	Fuel Tank Assembly	701 201 075AB
1	Slix (gal.)	D 200 201
1	*Plug (Wellnut) Set	No Part Number

NOTE: The fuel tank assembly requires an "overnight" order. DO NOT stock this part for recall.

*We have enclosed Wellnut sets with this circular for those dealers who sold one of the affected vehicles.

WORK PROCEDURE

A. CHECK FUEL VAPOR CONTAINER FOR DAMAGE

Inspect the evaporative chamber on the side of the filler neck for presence of drill bit damage or a small hole.

If there is no damage to the chamber, the tank is good and replacement is not necessary.
If a hole is present and is open to the chamber or if there is damage, the tank must be replaced. Complete inspection procedure then continue with "Replace Fuel Tank/Vapor Container Assembly" procedure.

Move driver seat forward and swivel toward the center to provide working room to remove the lower transition panel from the wall.
Remove the lower safety belt anchor bolt, the 3 screw covers (buttons) and the screws, then remove the panel from the wall.
NOTE: It may be easier to remove the panel if you also remove the table storage cradle piece from the floor near the wall (2 screws).
Enlarge the lower screw hole in the steel inner wall to make an inspection sight hole. Use a 3/8" drill bit and a depth gauge set to 1/2" max. to avoid contacting the tank filler neck.
Shine a light into the inspection hole and look for a small hole that may be drilled into the filler neck chamber.
- If you see drill bit damage, complete Inspection Procedure, then follow Tank Removal Procedure.
- If you see no damage, no replacement is necessary.
Deburr the inspection hole and apply a metal preservative compound (undercoating, primer, etc.) to the raw edges and allow to dry.
Insert the supplied rubber compression nut (Wellnut) into the inspection hole and reposition the panel onto the wall. The plug will compress and grip the hole as the screw is tightened (Fig 1).
Slip the clear plastic snap washer on the supplied machine screw with the indented side of the washer toward the head of the screw. You may need pliers to squeeze the head of the screw down into the washer until it is nearly flush as shown (Fig 1).

Fig 1: Rubber Compression Nut (Wellnut) Installation
Reposition and fasten panel and all other components in reverse order of removal using existing fasteners, except for machine screw in Wellnut. Be careful not to over-tighten Wellnut. Tighten seat belt anchor bolt to 40 N.m (30 ft.lb). Reinstall screw covers (buttons).

B. REPLACE FUEL TANK/VAPOR CONTAINER ASSEMBLY

Attach memory saver for radio code.
Remove ground strap from battery.
Drain fuel tank - use fuel cart FM3000 (available through Volkswagen) or similar.
Lift vehicle.
Remove fuel tank assembly.
Install new tank assembly, part number 701 201 075AB, transfer tank components as necessary.
Refill tank from cart.
Reconnect battery.
Assure function of fuel gauge and check correct clock time.
Remove radio code saver.
Check radio function.
Start engine and check fuel/vacuum lines.

C. DISPOSAL OF OLD FUEL TANK

Tilt removed fuel tank for removal of remaining fuel by using fuel cart. (Fig 2)
ENSURE MAXIMUM REMOVAL OF FUEL.

Fig 2: Removing Remaining Fuel From Fuel Tank

Continue to pour one (1) pint of emulsifying agent from gallon container, part number D 200 201, into tank opening. (Fig 3)

Fig 3: Adding Emulsifying Agent To Fuel Tank
Add one (1) gallon of water and cap off all openings.
Agitate fuel tank for no less than 30 seconds. (Fig 4)

Fig 4: Agitating Fuel Tank
Mixture will turn to a pale milky white color.
Open tank and drain emulsified fuel into a specially identified waste material container. (Fig 5)

Fig 5: Draining Emulsified Fuel Into Waste Material Container
The container must be labeled HAZARDOUS Waste.
Dispose of waste material through licensed reclaimer in accordance with local, state and federal EPA regulations.
Hold tank for inspection for 30 days before disposing of old fuel tank.

REPLACEMENT TIME/REIMBURSEMENT

To ensure proper payment, be sure to enter the correct reimbursement data into system only for VINs showing an SL code in the V-Crest system.

SL DATA ENTRY PROCEDURE

Damage Code	Time Units	Work Scope
SL 11	50 T.U.	Check vapor container for damage; No replacement required
SL 12	150 T.U.	Check vapor container for damage; Replace fuel tank assembly
		1	Tank	701 201 075AB
		1	Slix (1 pint)	D 700 005

The system automatically enters the labor and part number applicable to the above listed reimbursement codes.

For vehicles which according to your information are unreachable, please enter into the system one of the codes indicated below, as applicable:

SL 20 - Customer Refused Repairs
SL 30 - Total Loss
SL 40 - Vehicle Stolen
SL 50 - Vehicle Left Continental U.S.
SL 60 - Customer Moved - No Forwarding Address
SL 70 - Vehicle Sold - New Owner Unknown

Fig 6: SL Saga Claim Entry Procedure

ADDITIONAL ACTIONS

Most of these affected vehicles are also affected by the Service Actions SJ/SN . In the interest of minimizing customer inconvenience, please ensure that any such additional campaign(s) is performed at the same time. For verification, always check your V-Crest recall system.

PARTS DISPOSAL

Dealers will scrap the removed tanks in accordance with the procedure outlined in the work procedure.

DEALER OBLIGATION

To ensure customer satisfaction, dealers are urged to service each vehicle at the scheduled service appointment time, and make sure that each vehicle is returned to the customer washed and cleaned inside. Also make sure that you have arranged with the customer that at least one day repair is required if a new fuel tank is required. Every effort should be made to reduce any inconvenience to customers.

DEALER PERSONNEL INFORMATION

PLEASE INFORM AND/OR PROVIDE A COPY OF THIS COMMUNICATION TO EVERY PERSON IN YOUR DEALERSHIP WHO HAS CAMPAIGN-RELATED RESPONSIBILITIES, INCLUDING ACCOUNTING PERSONNEL.

CUSTOMER LETTER EXAMPLE

WINNEBAGO INDUSTRIES

March 1997

Subject: Recall Campaign SL

Dear Volkswagen Camper Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

Winnebago industries, Inc., the final stage manufacturer of your Volkswagen EuroVan Camper, has decided that a defect which relates to motor vehicle safety exists in some 1997 model Camper vehicles. Records show that you are the owner of an affected EuroVan Camper.

Defect Description

We have found that during the installation of Camper components by Winnebago an improperly adjusted drill bit of a power tool used in the assembly of a trim panel may have punctured the fuel tank vapor container. Should this have happened, fuel vapors could escape from the tank which could cause a fire.

Remedy

Your Volkswagen dealer has been provided with the necessary information for the inspection and, if necessary, for the replacement of the fuel tank/vapor container. However, replacement parts may not be immediately available. If, therefor, your dealer determines that the fuel tank assembly needs to be replaced, he will order a replacement unit from the nearest Volkswagen parts warehouse. The part will be shipped to the dealer overnight so that it is available the following day. We would like to make you aware that while the inspection may take approximately two hours, installation of a new fuel tank assembly may not be completed until a day or two later.

The inspection and/or replacement of the fuel tank assembly will, of course be free of charge to you.

What You Need To Do

Please contact the Service Department of any authorized Volkswagen dealer and schedule an appointment for the inspection as soon as possible. When you present your Camper for service, please present the enclosed authorization form, identifying your vehicle and this action to your dealer.

Precaution

IF prior to the time that the recall work can be completed, please be alert to any gasoline odor near your vehicle. If you detect a gasoline smell contact your dealer immediately.

Service Problem Help

If your authorized Volkswagen dealer fails or is unable to remedy the defect free of charge within a reasonable time, please call or write to:

Volkswagen of America, Inc.
Attn. Customer Relations - 2F02 (SL)
3800 Hamlin Road
Auburn Hills. MI 48326-2855
Toll-free Telephone: 1 (800) 822-8987

If you still cannot obtain satisfaction, you may file a complaint with: Administrator, National Highway Traffic Safety Administration, U.S. Department of Transportation, 400 Seventh Street SW, Washington DC 20590 - Telephone: (800) 424-9393 (Washington, DC area: 366-0123).

We regret any inconvenience this matter may cause you; however, we have taken this action in the interest of your safety and your continued satisfaction with the EuroVan Camper.

Sincerely,

Winnebago Industries, Inc.