Mechanics

CHEVY FUEL PUMP

2004 Chevrolet Silverado

Engine Mechanical problem
2004 Chevy Silverado V8 Two Wheel Drive Automatic 68000 miles

I received a recall notice awhile back on the dash gauge cluster saying the speddomoter may go out, by that they are meaning it will fall completely down. This has happened twice in the lat 25K miles, however now the fuwl gauge stays down all the time and the low fuel warning and light stay on. Can this be attrinuted to the gauge cluster? The dealer wants 1K to replce fuel bump and sending assembly. For now I am using the odometer. They said they can tell if the gauge is bad. If it is they will replace under warranty if not I get to pay $68 diagnostic. Seems like a racket.
Avatar
Gifthandler
November 24, 2008.




Ello -

Sorry about the problems. If you do need to get back with us which I believe you will, please let me know if your truck is a 1500, 2500, 2500HD, or 3500 and the exact engine size in liter and the 8th digit of your VIN.

Well, not knowing the above I just "picked" a Silverado to take a quick look at. As for the recall I looked at, one part states the following.
Condition
Some customers of 2003-2004 model year Cadillac Escalade, Escalade ESV, and Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, and Tahoe; and GMC Sierra, Yukon, and Yukon XL vehicles have reported that one or more of the instrument panel (IP) cluster gauges stick, flutter, or become inoperative. This may cause inaccurate readings, including the speedometer and fuel gauge.
Isn't that funny. The fuel gauge is listed also. Isn't that a coincident that your fuel gauge isn't working either.

I am not sure about the fuel warning light etc because I want to makes sure I am looking at the correct vehicle.

So if you want to provide that - then we can look more at your specific vehicle and maybe help you out with more data and then you can see what you think.

Thanks for the donation

Please let us know if what the final fix was for your car so we can better assist others. Thanks!

ImpalaSS
Nov 24, 2008.
1GCHC29U54E144602 It is a 2004 2500HD extended cab with a 6.0 gas guzzler. I called the dealer and he said to bring it in. They would test it (?) And if it is bad, get some numbers and order the part. It takes 3-5 days to arrive, then they will call to replace. I get the truck in the mean time. He asked what it was doing and I told him about the fuel gauge and he said he hadn't seen that before. Funny as it is mentioned in the letter from GM. I also know that for them to change out the fuel pump and sending unit will be approximately $980. They dealer said ( not this inquiry but a couple of weeks ago) that the part cost about $475 which is consistent with after market prices. At that rate the labor works out to be about $126 an hour. If they say the pump or sending unit is bad then i'll take it somewhere else. I'll let you know what they say. BTW, thanks for the really fast response.

Tiny
Gifthandler
Nov 25, 2008.
Hello

I attached the entire recall on the speedometer and as you see, it also says the fuel gauge, just as your letter says. It is possible but at 68000 miles I find it hard to believe the sending unit is bad..especially in light of this recall.

You also have several other recalls.general in nature and numerous safety recalls. I would definitely check them all with the dealer to verify your vehicle is not affected by them or it is and have them fixed.

Next - as you see by the brief info on the fuel sender unit, they have to remove the fuel tank. If it were me, I would mark several items in a way that only you know to verify at a glance that they definitely removed the fuel tank. Also, sometimes it is easier on some models to disconnect the bed and slide it back. So, I would make some bolts or something like that to prove that the bed was moved back.

This way if they say they had to replace the sending unit, you ask them how they did that. If they said we dropped the tank. I would crawl under it and look at the items I had marked to see if the marks moved etc to verify. If they didn't I would ask them about it.

You might also consider telling them you want to be there to watch them plug the new cluster in and see for yourself. They may scream you can not be in the work area due to insurance but you can still ask.

Let me know how it goes.....and please mark things.......

FUEL SENDER ASSEMBLY REPLACEMENT

TOOLS REQUIRED
J 45722 Fuel Sender Lock Ring Wrench

REMOVAL PROCEDURE

Remove the fuel tank.
Disconnect the fuel line from the sending unit.
Disconnect the evaporative emission (EVAP) line from the sending unit.
Using J 45722 remove the sending unit lock ring. CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
Remove the sending unit and seal. Discard the seal.
Clean the sending unit sealing surfaces.

Thanks for the donation

Please let us know if what the final fix was for your car so we can better assist others. Thanks!

The recall we are talking about

Campaign - Instrument Cluster Warranty Extension

Bulletin No.: 07187A

Date: November 08, 2007

SPECIAL COVERAGE

Subject:
07187A - SPECIAL COVERAGE ADJUSTMENT - INSTRUMENT PANEL CLUSTER GAUGE NEEDLE FUNCTION

Models:
2003-2004 CADILLAC ESCALADE, ESCALADE ESV, ESCALADE EXT
2003-2004 CHEVROLET AVALANCHE, SILVERADO, SUBURBAN, TAHOE
2003-2004 GMC SIERRA, YUKON, YUKON XL

Supercede:

THE SERVICE PROCEDURE IN THIS BULLETIN HAS BEEN REVISED. IN A SMALL NUMBER OF VEHICLES, THE GAUGE SWEEP TEST MAY NOT ALWAYS CONFIRM THE CONDITION. PLEASE REVIEW THE SERVICE PROCEDURE IMMEDIATELY.

DUE TO PART AVAILABILITY, THIS SPECIAL COVERAGE IS BEING ADMINISTERED IN PHASES. YOU WILL BE NOTIFIED AS EACH ADDITIONAL PHASE IS RELEASED.

CUSTOMERS ARE BEING INSTRUCTED TO CONTACT THE DEALERSHIP TO ARRANGE AN APPOINTMENT IF THEY BELIEVE THEIR VEHICLE HAS THIS CONDITION. THE CUSTOMER IS BEING ASKED TO PROVIDE THE VIN SO THE IPC CAN BE ORDERED IN ADVANCE OF THE SCHEDULED APPOINTMENT. THIS WILL ELIMINATE THE NEED TO KEEP THE VEHICLE OVERNIGHT. DEALERS ARE TO OBTAIN THE VEHICLE MILEAGE WHEN SCHEDULING A SERVICE APPOINTMENT. THE VEHICLE MILEAGE WILL BE REQUIRED WHEN PLACING AN ORDER FOR THE IPC.

Condition

Some customers of 2003-2004 model year Cadillac Escalade, Escalade ESV, and Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, and Tahoe; and GMC Sierra, Yukon, and Yukon XL vehicles have reported that one or more of the instrument panel (IP) cluster gauges stick, flutter, or become inoperative. This may cause inaccurate readings, including the speedometer and fuel gauge.

Special Coverage Adjustment

This special coverage covers the condition described above for a period of 7 years or 70,000 miles (110,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership.

Dealers are to replace the instrument panel cluster after the condition has been verified. 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 September 28, 2007 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 September 28, 2007, must be submitted to the Service Contract provider.

Involved are certain 2003-2004 model year Cadillac Escalade, Escalade ESV, and Escalade EXT; Chevrolet Avalanche, Silverado, Suburban, and Tahoe; and GMC Sierra, Yukon, and Yukon XL vehicles built within the VIN breakpoints shown.


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ImpalaSS
Nov 25, 2008.
Took the Silverado to the dealer. They replaced the instrument cluster per the warranty. Fuel gauge still inoperative. They did replace the cluster because the trip meter waqs not reset to where I left it when I dropped it off. The meter showed an additional 250 miles. They didn't have the trucklong enough to drive that much. So I guess for awhile I will be using the trip meter. Need to save up for the tank dropping etc.

How big is the oil input in the oil pump? The gauge has been dropping to zero momentarily and the warning buzzer comes on. I take my foot off the gas and evemtaully the pressure come back up. I have only used AMSOIL and change the oil regularily. Could a piece of debris be covering the inlet and then falling off when suction lessens? It looks like that would be fairly easy to check by dropping the oil pan which looks like I wouldn't have to raise the engine your thoughts.

Tiny
Gifthandler
Dec 4, 2008.
Hello -

Well sorry that didn't work out for you on the cluster replacement fixing the fuel gage.

As for the cluster. If the cluster is what I think it is. It would be normal that the odeometer is correct as this comes from the PCM. The trip will be off because it is a different cluster. So it is not that they drove it. Just a different cluster.

As for the dropping the tank. Are you going to try that yourself.I can send you the how-to-do? That way you are just paying for the pump. Well, my suggestion. Though it may just be the sending unit. If it were me.I would replace the entire fuel pump. Your call. My reason.I hate to drop tanks. It is a pain. So I am there. It all gets new goodies. Hoses, clamps, it all. Then I am good (Lord willing) for 100K +.

Have you only got the one tank?

I show a part number of 25315800 for the entire pump. Should be the sending/sock and all. From the dealer it will be about $410.17. It is only about $270.34. If you go this direction I would verify with the Chevy parts department that this part comes with everything. Then get it through the GM parts.

Well on the oil gauge. This is a new problem. Yes? It looks like there is a TSB on this. It may be the oil pressure sensor, even the wiring. I have attached that for your review.

My suggestion here since there is a TSB.I would replace the sensor first. Not the wiring as it may not be the wiring. See what it does. Then the wiring. Then last resort drop the pan.

For that matter check both parts out on the GM site.I show it about $72 at the dealer and about $45 there. Part number 12573107.

Also, when you read the info on the TSB for the oil pump it may throw some codes. Are you able to run by a Auto Zone (AZ) or O'Reilly's (OR) and for FREE they can pull the codes to the car. Most important: Once they check your codes, if they find something and you don't get it fixed and need to get back with us, please make sure you tell us exactly what the code was, number and all. Example, if the code was E0568 O2 Sensor bad. Then make sure you give us all of that. While there for FREE also they can bring their tester out and check your battery, alternator and starter.

That way we can see if it throws those codes.

Okay review the info and see what you think. We can chat about it a little more if you like.

Let me know.

Thanks for the donation

Please let us know if what the final fix was for your car so we can better assist others. Thanks!

Find a car repair manual for your car repair questions.

Instruments - High/Low Erratic Oil Pressure Readings
Notes

File In Section: 06 - Engine/Propulsion System

Bulletin No: 04-06-04-065

Date: September, 2004

ADVANCED SERVICE INFORMATION

Subject: ENGINEERING INVESTIGATION (EI # 04073) - High, Low or Erratic Oil Pressure Gauge Reading Setting DTCs P0522 and/or P0523

Models: 2004 Chevrolet Avalanche, Express, Silverado, Tahoe, Suburban
2004 GMC Savana, Sierra, Yukon, Yukon XL
2004 Isuzu W4

Equipped with 6.0L Engine ONLY (VIN Code U - RPO L04)

Attention: GM of Canada dealers are not authorized to utilize this service bulletin.

Condition

Important: This bulletin only applies to those vehicles identified in GM VIS by Engineering Investigation number 04073 AND the customer's concern is for an erratic gauge reading and DTC P0522 or P0523 is set. All other vehicles should not use this bulletin. If GM VIS shows an EI 04073 is open for this vehicle but the customer does not comment on an erratic gauge reading, DO NOT perform this bulletin.

The customer may comment about a high, low or erratic oil pressure gauge reading and the engine oil pressure indicator being illuminated. The technician will find DTCs P0522 and/or P0523 stored in the PCM. The PCM displays this information in the "Failure Records" on the scan tool.

Cause

GM Engineering is attempting to determine the root cause of Oil Pressure Sensor replacements. General Motors has a need to obtain technical information first hand from the dealer technician BEFORE and during diagnosis and repair. As a result, this information will be used by Engineering to help "root-cause" the customer's concern and develop/validate a field fix.

Important: By using the Tech 2, obtain the engine oil pressure sensor voltage reading. It is important to have this information PRIOR to contacting the engineer.

All U.S. Dealers, please contact engineer Brian Kozumplik. BEFORE proceeding. If Brian can not be reached immediately, leave a message with the VIN, Dealer Name, Dealer Phone Number, Caller's Name and Voltage Reading. Then proceed with the following corrective action.

Correction

Follow the diagnostic procedures for P0522 and/or P0523, found in SI.

If the SI diagnostics did not isolate the concern, OR if it leads to an oil pressure sensor connection concern, perform the following steps: 1. Cut off the oil pressure sensor wire harness 25.4 mm (1 in) from the connector.

Important: Do NOT disconnect the sensor from the connector.

2. Remove the oil pressure sensor with the 25.4 mm (1 in) of harness and connector still connected.

3. Install a new oil pressure sensor using the one listed in the GMSPO parts catalog.

4. Repair the harness by installing an oil pressure sensor connector harness kit, P/N 12102748. This kit comes with a connector, attached leads and Duraseal splice sleeves. DO NOT solder the circuits when installing this service kit. Soldering the splice can impact the performance of the circuit. Instead, use the included splice sleeves and follow the procedure below: 4.1. Open the harness.

- If the harness is taped, remove the tape.

- To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.

- If the harness has a black plastic conduit, pull out the desired wire.

4.2. Cut the wire.

- Cut as little wire off the harness as possible.

- Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage.

4.3. Select the proper size and type of wire.

- The wire must be of equal or greater size than the original.

- The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.

Important: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC.

Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact.

4.4. Strip the insulation.

- Select the correct size opening in the wire stripper or work down from the largest size.

- Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).

4.5. Select the proper Duraseal splice sleeve (2) and the required crimp nest tool. Refer to the Crimp and Seal Splice Table.

4.6. Place the Duraseal splice sleeve in the J 38125-8 crimp tool nest so that the crimp falls at point 1 on the splice.

4.7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper crimp tool nest.

4.8. Insert the wires into the Duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3).

4.9. Close the handles of the J 38125-8 until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve.

4.10. Shrink the insulation around the splice.

- Using the heat torch, apply heat to the crimped area of the barrel.

- Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

ImpalaSS
Dec 5, 2008.
The oil pressure gauge is another problem. I am going to tackle that one first as I can get to that. I have a haynes manual for this vehicle and it is calling the oil level sensor located on the passenger side of the oil pan. Is that the oil pressure sensor? I am going to call the dealer on the fuel pump this week. Thanks for all your help.

Tiny
Gifthandler
Dec 6, 2008.
Hello -

This is what I show........hope this helps.........good luck on this and the fuel pump

Thanks for the donation

Please let us know if what the final fix was for your car so we can better assist others. Thanks!

Find a car repair manual for your car repair questions.

Engine Oil Pressure Sensor and/or Switch Replacement

Tools Required
J 41712 Oil Pressure Switch Socket
Removal Procedure


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If necessary, remove the engine sight shield.
Disconnect the oil pressure sensor electrical connector (1).


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Using J 41712 or equivalent, remove the oil pressure sensor.

Installation Procedure


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Apply sealant GM P/N 12346004, (Canadian P/N 10953480), or equivalent, to the threads of the oil pressure sensor. Notice: Refer to Fastener Notice in Service Precautions.
Using J 41712 or equivalent, install the oil pressure sensor.
Tighten the oil pressure sensor to 30 Nm (22 ft. lbs.) .


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Connect the oil pressure sensor electrical connector (1).
If necessary, install the engine sight shield.

ImpalaSS
Dec 6, 2008.
I can get my oil sensor locally, but I am having a hard time with GMPARTS DIRECT. Since you have to have prior approval in case the part is incorrect then they won't let you send it back. I provided the fuel pump part number you gave me and asked for confirmation. They said 25315800 was for a 4.3 " X" engine and that according to my VIN (Which is verified again) 1GCHC29U54E144602 USES A 19167468 FUEL PUMP AND 88965379 FUEL SENSOR. They said GM no longer supplies these assemblies together. Soooooooo. I called my local Chevy dealer and provided them the VIN and he said that the part is 19133449 which is a combined part. I have sent this info back to GMPARTSDIRECT and am awaiting an answer tomorrow. I have a good mechanic lined up who will drop the tank and replace the assembly for $250, just need the part. GMPARTSDIRECT has no other way to contact them except by email.
My oil sensor jhas settled down somewhat but I am going to replace it very soon. Thanks for your help. When the dust settles I will be sending you all more donation.

Tiny
Gifthandler
Dec 10, 2008.
Hello -

We really appreciate the update.

Donate as you can. We understand.

I have ordered many things from the GMdirect. Though cheaper you do have to have the exact info. They use to have better IPBs with it. You are definitely doing the right thing by taking to the dealer, getting part numbers etc.

Thanks again and good luck on the tank drop. Oh, are you going to be there to watch/assist? You might consider it if he allows it. Also, if it were me once the tank is down I would replace any rubber hose back there.

Thanks again for the update

Thanks for the donation

Please let us know if what the final fix was for your car so we can better assist others. Thanks!

Find a car repair manual for your car repair questions.

ImpalaSS
Dec 10, 2008.
I just wanted to report back and closeout these issues. I bought an Oil pressure sensor from Autozone and replaced myself. I had to buy a special tool made for the switch, that repair costs $15 plus the part which was @$40.
The fuel pump and sender is another story. I ended up getting the fuel pump and sender from http://www.rockauto.com for @$300. I had a local mechanic install for @$225. The people at gmpartsdirect.com were pretty much useless. They told me the part was not availble based on my VIN. When I talked to the local dealer he gave me the part number. gmpartsdirect said that was discontinued. I then went on line and found RockAuto.com. The part was shipped UPS ground and arrived in 2 days. I do appreciate all you help and support.
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Tiny
Gifthandler
Dec 17, 2008.

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