Product Emission Recall
40240 Fuel Feed Pipe Crimp Out of Specification
Reference Number:
GWM Number:
Make
Chevrolet

Release Date:
Revision:

N162040240
2040240
Model Year
From
To
2016
2016

Model
Volt

RPO

July 2016
00
Description

Involved vehicles are marked “open” on the Investigate Vehicle History screen in GM Global Warranty Management
system. This site should always be checked to confirm vehicle involvement prior to beginning any required inspections
and/or repairs.
Condition

Correction

General Motors has decided to conduct a Voluntary Emission Recall involving certain 2016 model year
Chevrolet Volt vehicles. These vehicles may have out-of-specification crimps on the front under hood
flexible fuel feed pipe. Fuel may weep from these connections and the fuel odor may enter the cabin.
Inspect the fuel feed pipe and manufacture date. If there is indication of weeping or the pipe manufacture
date falls into the suspect date range, replace the fuel feed pipe.

Parts
Quantity
1

Part Name
Fuel Feed Front Pipe

Part No.
23375761

Warranty Information
Labor
Operation
9102388

Description
Inspect Fuel Feed Front Pipe
Add: Replace Fuel Feed Front Pipe

Copyright 2016 General Motors. All Rights Reserved.

Labor
Time
0.2
0.8

Trans.
Type
ZFAT

Net
Item
N/A

Page 1 of 6

Product Emission Recall
40240 Fuel Feed Pipe Crimp Out of Specification
Service Procedure
1.

Open the hood and install fender covers.

2.

Install exhaust ventilation hose.

4549772

3.

Locate the fuel feed front pipe (1).

Note: The internal combustion engine (ICE) MUST be running in order to check for a fuel leak.
4.

Start the vehicle in RUN mode.

5.

Set the parking brake.

Page 2 of 6

Product Emission Recall
40240 Fuel Feed Pipe Crimp Out of Specification

4496917

6.

Inspect both ends of the fuel feed front pipe for any signs of fuel leaks at the elbow (1) or past the metal sleeve (2).


If there are NOT signs of fuel leaks, proceed to the next step.



If there are signs of fuel leaks, turn the ignition OFF and proceed to step 10.

7.

Release the parking brake.

8.

Turn the ignition OFF.

Page 3 of 6

Product Emission Recall
40240 Fuel Feed Pipe Crimp Out of Specification

4496920
Note: An inspection mirror may need to be used in order to read the date code.
9.

Inspect the build date tag located on the fuel feed front pipe.


If the build date is 10/15/15, 10/16/15, 10/17/15, or 10/19/15, proceed to the next step.



If the build date is NOT 10/15/15, 10/16/15, 10/17/15, or 10/19/15, proceed to step 11.

10. Replace the fuel feed front pipe. Refer to Fuel Feed Front Pipe Replacement in SI.
11. Close hood and remove fender covers.
12. Remove exhaust ventilation hose.
13. FOR CALIFORNIA, CONNECTICUT, DELAWARE, MARYLAND, MASSACHUSETTS, MAINE, OREGON,
VERMONT, WASHINGTON VEHICLES ONLY: Install a Recall Identification Label upon recall completion. See
General Motors Service Policies and Procedures Manual, Section 6.1.4 - Recall Identification Label, for details
14. CALIFORNIA VEHICLES ONLY: Complete a “Proof of Correction” certificate and provide to the vehicle owner upon
recall completion.
Dealer Responsibility
All new, used, GM Certified Used, courtesy transportation vehicles, dealer shuttle vehicles, etc. in dealers' possession
and subject to this recall must be held and inspected/repaired per the service procedure of this bulletin before customers
take possession of these vehicles. Involved vehicles must be held and not delivered to customers, dealer-traded,
released to auction, used for demonstration, or any other purpose.
All GM Certified Used vehicles currently in the dealers’ inventory within the Certified Pre-Owned Inventory System
(CPOIS) will be de-certified and must be held and remedied per the service procedure in this bulletin. Upon submitting
an accepted/paid warranty transaction in the Global Warranty Management (GWM) system, the vehicle can be re-certified
for sale within the CPOIS system, or once again be used in the CTP program.
Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle,
or ownership, from this time forward.
Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer
information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the
required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this
bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the
customer may not as yet have received the notification letter.
In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership 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.
Page 4 of 6

Product Emission Recall
40240 Fuel Feed Pipe Crimp Out of Specification
***THE FOLLOWING 2 PARAGRAPHS ARE NOT FOR CANADA***
When a California emissions recall is completed by a GM dealer, the dealer must provide the vehicle owner a “Proof of
Correction Certificate” which the owner may need to present to the California Department Of Motor Vehicles (DMV) when
renewing their vehicle registration. Without this correction certificate, the owner may be unable to renew their vehicle
registration.
Additional Certificates can be obtained, at no charge, from the 1Store application in GlobalConnect. Request GM Item
Number 1825 when ordering.
Dealer Reports
For dealers with involved vehicles, a listing with involved vehicles has been prepared and will be provided to U.S. and
Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. The listing may
contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor
vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in
several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to
complete this recall.
Courtesy Transportation – For USA & Canada
Courtesy transportation is available for customers whose vehicles are involved in a product program and still within the
warranty coverage period. See General Motors Service Policies and Procedures Manual, Section 6.1.10 – Courtesy
Transportation, for details.
Customer Notification
USA & Canada - General Motors will notify customers of this recall on their vehicle (see copy of customer letter included
with this bulletin).

In order to ensure full protection under the emission warranty, and the right to participate in future recalls, the customer
notification letter recommends that customers have their vehicles serviced as soon as possible. It also advises that failure
to do so could legally be determined to be lack of proper maintenance. The vehicle may fail a state or local emission
inspection test if the recall work is not completed.

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 information on whether your
vehicle may benefit from the information.

We Support
Voluntary Technician
Certification

Page 5 of 6

Product Emission Recall
40240 Fuel Feed Pipe Crimp Out of Specification

August 2016
This notice applies to your vehicle, VIN: _____________________________________
Dear General Motors Customer:
This notice is sent to inform you that General Motors is conducting a voluntary emission recall that includes your
vehicle.
Reason For This Recall: General Motors has decided to conduct a Voluntary Emission Recall involving certain 2016
model year Chevrolet Volt vehicles. These vehicles may have out-of-specification crimps on the front under hood
flexible fuel feed pipe. Fuel may weep from these connections and the fuel odor may enter the cabin.
What Will Be Done: Your GM dealer will inspect the Fuel feed pipe and manufacture date. If there is indication of
weeping or the pipe manufacture date falls into the suspect date range, the fuel feed pipe will be replaced. Inspection
and replacement, if required, will be performed for you at no charge.
What You Should Do: Please contact your GM dealer as soon as possible to arrange a service date and to assure
parts availability. Instructions for making this correction have been sent to your dealer. Please ask your dealer if you
wish to know how much time will be needed to schedule, process, and repair your vehicle.
If you have any questions or need any assistance, just contact your dealer or the appropriate Customer Assistance
Center at the number listed below.
Division
Chevrolet
Puerto Rico – English
Puerto Rico – Español
Virgin Islands

Number
1-800-630-2438
1-800-496-9992
1-800-496-9993
1-800-496-9994

Text Telephones (TTY)
1-800-833-2438

Emission Law Information: In order to ensure your full protection under the emission warranty made applicable to
your vehicle by state and federal law, and your right to participate in future recalls, it is recommended that you have
your vehicle serviced as soon as possible. Failure to do so could legally be determined to be lack of proper
maintenance of your vehicle. Also, your vehicle may fail a state or local emission inspection if this recall is not
accomplished.

IMPORTANT MESSAGE FOR CALIFORNIA RESIDENTS
The California Air Resources Board (CARB) requires vehicle emission recalls be completed prior to California
registration renewal. Uncorrected emission recalls will result in the inability to renew your California vehicle registration.
At the time of emission recall completion, your California dealer will issue a "Proof of Correction Certificate". Keep this
certificate and, if required, present it to the Department of Motor Vehicles when renewing your California registration as
proof of recall completion.

We are sorry to cause you this inconvenience; however, we have taken this action in the interest of your continued
satisfaction with our products.

Jeffrey M. Boyer
Vice President
Global Vehicle Safety
40240

Page 6 of 6

GLOBAL SAFETY FIELD INVESTIGATIONS
DCS4124
URGENT - DISTRIBUTE IMMEDIATELY
Date:

July 28, 2016

Subject: 40240 - Emission Recall
Fuel Feed Pipe Crimp Out of Specification
Models: 2016 Chevrolet Volt
To:

All Chevrolet Dealers

General Motors is releasing Emission Recall 40240 today. The total number
of U.S. vehicles involved is approximately 949. Please see the attached
bulletin for details.
Customer Letter Mailing
The customer letter mailing will begin on August 12, 2016.
Global Warranty Management (GWM)
The Investigate Vehicle History (IVH) screen in the GWM system will be updated July
29, 2016. A list of involved vehicles in dealer new inventory is attached to this
message. Please hold all warranty transactions until the VIN appears in IVH.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS