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.
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.
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…….

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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.

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…….


J 45722 Fuel Sender Lock Ring Wrench


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.

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The recall we are talking about

Campaign - Instrument Cluster Warranty Extension

Bulletin No.: 07187A

Date: November 08, 2007









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.

Parts Information - U.S. and Canadian Dealers Only

Instrument panel clusters (IPC) required to complete this special coverage are to be obtained from the Electronic Service Centers. The vehicle mileage will be required when placing an order. Refer to GM Service Policies and Procedures Manual, section 1.5.9, for specific procedures. To eliminate keeping the customer's vehicle overnight, customers are being told to contact the dealership to arrange a service appointment and to supply their VIN. Dealers are to pre-order the IPC identifying the part from the Electronic Parts Catalog using the VIN filter so it will be at the dealership on the day of the scheduled appointment.

1. The customer will contact the dealership to arrange an appointment and provide their VIN.

2. Contact a GM Authorized Electronic Service Center to order an exchange and arrange for delivery of the pre-exchange product.

3. All units will be shipped FedEx Ground (US) or Purolator (Canada).

4. After removal of the defective unit, return the defective core to the Electronic Service Center using the supplied pre-paid Automatic Return shipping (ARS) label.

5. Failure to return the product within 30 days to the Electronic Service Center will result in a charge to the Dealer's Open Parts Account.

Parts Information - Export Dealers Only

For Export Dealers Only: Order appropriate instrument panel cluster from General Motors Service and Parts Operation (GMSPO).

Customer Notification

General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly).

Service Procedure

There are pre-programming instructions for 2003 model year instrument panel clusters (IPC). In order for the engine hours to set to their current value when the IPC is replaced, carefully read and follow the instructions below. This information is applicable for 2003 model year IPCs only. An add time of 0.1 for the pre-programming requirement is published in the Claim section of the bulletin.

2003 Model Year Instrument Panel Cluster (IPC) Pre-Programming Instructions

Install the IPC. Ensure everything is connected properly. The replacement IPC requires SPS Programming and IPC Setup procedures to be performed. It does not matter which procedure is performed first.

Start the engine and then select IPC Setup. You must have the engine running before performing the IPC Setup. Select IPC Setup. With the engine running, enter the appropriate mileage and engine hours.

Select OK. Review the pop up asking you to verify the mileage and engine hours. Move the pop up out of the way if necessary to view the verification screen. This may require a click and drag of the dialog box.

Verify that the mileage and engine hours are correct and select "OK". DO NOT turn the ignition OFF until the engine has run for approximately seven (7) minutes. Allowing the engine to idle for this period of time allows the IPC to accumulate 1/10th of an hour and write the correct engine hour value to the permanent memory.

The engine must be running before set up is performed and run for approximately seven minutes after the user selects "OK" confirming their mileage/engine hour inputs. After approximately seven minutes, shut the engine OFF and complete the event. The seven minute clock starts after you select "OK" confirming the entries.

Note: Based on feedback from technicians, we are currently making changes to the "IPC Setup" application which will include several enhancements to the set up screens. These are scheduled to be released and available in TIS2WEB very soon.

Only IPC conditions listed in the Condition section of the bulletin are covered under this special coverage program. In a small number of vehicles, the condition may be intermittent and the gauge sweep test may not always verify the condition.

IPC Performance

IPC performance may be affected by the following conditions:

Cold temperatures

Temperature fluctuations

High humidity

Driving over rough surfaces such as dirt roads or potholes

Customer Comments and Observations

Customers who describe gauge performance as jumpy, sticky, slow or erratic. Gauge performance may also be described as being inoperative or inaccurate. For example, for a period of time the speedometer may appear to move normally but be inaccurate and not return to zero (0) after the vehicle comes to a stop. This inaccurate condition may be more or less pronounced during the drive cycle and may, for a time, return to normal operation. A Tech 2 sweep test may not reveal the condition.

Perform a gauge sweep test to determine/verify that an IPC gauge is sticking, stuck, or inoperative. Using the Tech 2, navigate to the following screens to perform the gauge sweep test: Body -> Instrument Panel Cluster -> Special Functions -> IPC Gauges -> Display(s) Test.

If one or more of the gauges are sticking, stuck, or inoperative. Replace the IPC. Refer to Step 2.

If the Tech 2 gauge sweep test does NOT verify the condition but a customer's comments and observations include information that it outlined in the IPC Performance and/or Customer Comments and Observations section of the bulletin, replace the IPC. Refer to Step 2.

If the Tech 2 gauge sweep test does NOT verify the condition but a customer's comments and observations include information that is outlined in the IPC Performance or Customer Comments and Observations section of the bulletin, do NOT replace the IPC. Submit a claim for Perform Tech 2 Gauge Sweep Test.

If the IPC is to be replaced, record the vehicle odometer and engine hour (where applicable) value from the original IPC.

Remove the instrument panel cluster. Refer to the appropriate vehicle IPC removal and installation procedure in SI.

Install the new instrument panel cluster. Refer to the appropriate vehicle IPC removal and installation procedure in SI.

J2534 Pass-Thru or Tech 2 Legacy Pass-Thru Programming Method for the IPC

If Pass-Thru programming fails, call Techline Customer Support Center (TCSC). A "Candi" module is necessary.


Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Techline Tech 2(R) scan tool and TIS 2 Web with the calibration update. Use TIS2Web version 8.5 for 2007 (available on 08/20/07). If you cannot access the calibration, call the Techline Customer Support Center and it will be provided.

Before reprogramming, please check the battery condition to prevent a reprogramming error of any of the modules due to battery discharge. Battery voltage must be between 12 and 16 volts during reprogramming. If the vehicle battery is not fully charged, use approved Midtronics PCS charger, a fully charged 12V jumper, or booster pack disconnected from the AC voltage supply. Be sure to turn off or disable any system that may put a load on the battery, such as automatic headlamps, daytime running lights, interior lights, heating, ventilation, and air conditioning (HVAC) system, radio, engine cooling fan, etc. A programming failure or control module damage may occur if battery voltage guidelines are not observed.

The ignition switch must be in the proper position. The Service Programming System (SPS) application prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the ignition switch during the programming procedure, unless instructed to do so.

Make certain all tool connections are secure, including the following components and circuits:

The RS-232 communication cable port

The connection at the data link connector (DLC)

The voltage supply circuits

DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming failure or control module damage may occur.

DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful. Ensure that all control module and DLC connections are secure and the TIS terminal operating software is up to date.

Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use approved Midtronics PCS charger, a fully charged 12V jumper, or booster pack disconnected from the AC voltage supply to maintain proper battery voltage during programming.

IPC Programming and IPC Setup are required after installing the IPC. First select IPC Instrument Panel Cluster from the Supported Controllers screen to perform the first calibration. After completing the first programming event, complete the IPC Setup. Select IPC/IPC Setup from the Supported Controllers screen. The odometer mileage and engine hour information (where applicable) is required to perform the IPC Setup. Follow the TIS2WEB instructions.

For information about odometer mileage and engine hour setup, please refer to Technical Service Bulletin 07-08-49-015.

Reprogram the instrument panel cluster (IPC). Refer to SI and Service Programming System (SPS) documentation for IPC programming instructions, if required.

For vehicles repaired under the terms of this special coverage, submit a claim with the information shown.

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 was sent out with the original letter.

Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

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 within one year. Repairs must have occurred within the 7 years of the date the vehicle was originally placed in service, or 110,000 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.

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.

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…… I am there… 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. If you go to and check it out with shipping 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.

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

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Instruments - High/Low Erratic Oil Pressure Readings

File In Section: 06 - Engine/Propulsion System

Bulletin No.: 04-06-04-065

Date: September, 2004


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

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.


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.


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.


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.

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.

Dec 6, 2008.
Hello –

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

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

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Engine Oil Pressure Sensor and/or Switch Replacement

Tools Required
J 41712 Oil Pressure Switch Socket
Removal Procedure

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

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

Installation Procedure

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.) .

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

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.

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!

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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 for @$300. I had a local mechanic install for @$225. The people at 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 The part was shipped UPS ground and arrived in 2 days. I do appreciate all you help and support.

Dec 17, 2008.
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