Recalls
| Campaign | Manufacturer | Manufacturing date | Type | # of units affected | Date Owner notified Mfg | Recall Initiated by | Manufacturers of recalled vehicles/products | Report Recieved Date | Record Creation Date | Regulation Part Number | FMVSS Number | |||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| FUEL SYSTEM, GASOLINE - DELIVERY - FUEL PUMP | ||||||||||||||||
| 05V155000 | GENERAL MOTORS CORP. | from 08/01/1999 to 07/31/2000 | V (Vehicle) | 316508 | 10/19/2005 | ODI | GENERAL MOTORS CORP. | 04/14/2005 | 04/19/2005 | |||||||
| Defect Summary | Certain trucks and sport utility vehicles were built with fuel module reservoir assemblies that contain fuel pump wires connectors may overheat under certain operating conditions. | |||||||||||||||
| Consequence Summary | If the ignition circuit wire is exposed, the fuel pump fuse will blow, disabling the fuel pump and causing an engine stall or no-start condition. if sufficient heat is conducted to the pass-through connector, a hole in the connector may result, which may cause a 'service engine soon' light to be illuminated during the emission system diagnostic routine. fuel vapor and in some cases liquid fuel may leak out of the fuel tank through the hole in the connector body. fuel leakage, in the presence of an ignition source, could result in a fire. also if the ignition circuit or ground wire is exposed and shorts to the fuel level sender card wires, inaccurate fuel level readings may result. | |||||||||||||||
| Corrective Summary | Dealers will remove the fuel tank, and remove the module reservoir assemblies from the tank, and install a new service kit free of charge. an interim letter to owners was mailed on may 25, 2005. the owners were re-notified on october 19, 2005, since parts are now availabe. owners may contact chevrolet at 1-800-630-2438 and gmc at 1-866-996-9463. | |||||||||||||||
| Notes | Gm recall no. 05027. customers may also contact the national highway traffic safety administration's vehicle safety hotline at 1-888-327-4236 (tty 1-800-424-9153), or go to http://www.safercar.gov. | |||||||||||||||
Bulletins
| Bulletin | Bulletin date | Replacement Bulletin | Item no. | Summary | Added |
|---|---|---|---|---|---|
| FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY | |||||
| 011200 | 12/01/2000 | 616400 | Subject regarding vehicles exhibiting fuel tank leakage. *tt | 02/25/2001 | |
| FUEL SYSTEM, OTHER - STORAGE - FUEL GAUGE SYSTEM | |||||
| 3046A | 3046B | 10009382 | Fuel gauge fluctuation in park or neutral. *tt | 09/27/2004 | |
Investigations
| NHTSA ID | Manufacturer | Date open | Date close | Subject | Recall campaign | |
|---|---|---|---|---|---|---|
| FUEL SYSTEM, GASOLINE - DELIVERY - FUEL PUMP | ||||||
| PE04042 | GENERAL MOTORS CORP. | 05/03/2004 | 09/09/2004 | OVERHEATED FUEL PUMP WIRING | 05V155000 | |
| The fuel pump wiring and connector may overheat and melt a hole in the top of the fuel pump module.possible consequences include fuel tank leakage and engine stall with no restart.fourteen of the 20 complaints to odi allege fuel tank leakage, including one that reported that a fire department was called to the scene after a pool of gasoline was discovered beneath the vehicle.most of the odi complaints report incidents that occurred within the past year. according to gm, fuel leakage can occur in the subject vehicles if the heat is sufficient to melt a hole in the plastic connector large enough for liquid fuel to flow through.on-board emissions diagnostics may detect holes that are approximately 0.040 inches or more and set a service engine soon warning light.the connector position in the subject vehicles is below the fuel level when the tank is full.while gm does not know how much fuel could leak from a tank with a melted fuel pump connector, several consumers have reported significant leak events.engine stall can occur if:(1) a short occurs in the pump wiring (bare wire exposed by melted insulation shorts against a ground or ground wire) and the fuel pump relay fuse is blown; or (2) the vehicle runs out of fuel due to an inaccurate fuel gauge reading resulting from an electrical short between the fuel pump wiring and the level sensor wiring. gm's analysis of five assemblies returned from incident vehicles determined that the condition is caused by elevated resistance/ arcing at the mra undercover b cavity terminal of the four-way 150 metri-pak connector.gm attributes the high resistance and arcing to a depressed contact arm at the 150 metri-pak b cavity female terminal.gm is continuing its investigation to complete its root cause analysis. modular reservoir assemblies using the 150 metri-pak connectors were used by gm in several million c/k-series sport utility vehicles and pickup trucks from my 1997 through 2002, when gm released a metal mra cover and a 280 metri-pak connector in the subject vehicles.during pe04-042, odi collected information from gm concerning my 2000-2002 c/k suv's and pickup trucks.the subject vehicles comprise approximately 9 percent of production for those vehicles and about 39 percent of complaints to gm. this investigation has been upgraded to an engineering analysis to further assess the scope, frequency, and safety consequences of the alleged defect in gm c/k-series vehicles. | ||||||
| EA04026 | GENERAL MOTORS CORP. | 09/09/2004 | 08/02/2005 | OVERHEATED FUEL PUMP WIRING | 05V155000 | |
| In a letter dated april 14, 2005, general motors (gm) notified odi that it had identified a defect related to motor vehicle safety in approximately 316,508 model year (my) 2000-01 1500 series chevrolet suburban and gmc yukon xl vehicles (recall 05v-155).gm determined that some of these vehicles were equipped with fuel module reservoir assemblies (mras) that contain fuel pump wires and/or connectors that may overheat under certain operating conditions.according to gm, fuel pump wires that overheat may result in one or more conditions that present risks to motor vehicle safety:(1) fuel leakage from the mra pass-through connector if the overheating produces a hole in the plastic connector; (2) engine stall if wiring exposed by the overheating shorts to ground and causes the fuel pump fuse to blow; or (3) inaccurate fuel level readings if overheated wiring is shorted to the fuel level sender card.gm's analysis identified the cause of the overheated wiring as a high-resistance condition in the mra connector contacts due to fretting corrosion that may develop over time.gm determined that the corrosion is caused by movement between the contact surfaces and that such movement is primarily influenced by chassis and fuel tank virbration characteristics.gm's testing found that the fuel tank vibration characteristics of the recalled my 2000-01 1500-series vehicles were significantly greater than in other gm vehicles equipped with the same mra connectors.these vehicles had the highest rate of related fuel leak and stall complaints; and a recent survey conducted by gm found evidence of mra wiring over-heating in almost one-third of the 1500-series vehicles inspected. other vehicles equipped with the subject mra connector and evaluated during this investigation include approximately 33,000 my 2000-01 2500-series sububran and yukon xl vehicles, which fall within the scope of ea04-026, and peer populations of short wheelbase yukon and tahoe utility vehicles and full-size silverado and sierra pickup trucks. these vehicles are not included in recall 05v-155 for the following reasons:(1) these vehicles are equipped with fuel tanks with significantly less vibration at the mra interface than the recalled vehicles; (2) the potential for fuel leakage is substantially lower in the pickup trucks and short-wheelbase utility vehicles due to differences in fuel tank configuration and no incidents of fuel leakage due to overheated wiring were verified in these vehicles; (3) there there have been only three potentially related complaints of fuel leakage associated with the overheated wiring condition in the 2500-series long-wheelbase utility vehicles; and (4) no evidence of overheated wiring was found in the 2500-series suburban and yukon xl vehicles and pickup trucks inspected by gm in its vehicle survey efforts and the rate found in the short-wheelbase utilities was lower than the recalled vehicles by an order of magnitude. odi will continue to monitor the experience in the 2500 series my 2000-01 long-wheelbase utility vehicles.the closing of this investigation does not constitute a finding by nhtsa that no safety-related defect exists for the 2500 series vehicles.the agency reserves the right to take further action if warranted by a change in circumstances. | ||||||
Consumer Complaints
| Fail date | miles | occurences | Purchase date |
|---|---|---|---|
| FUEL SYSTEM, GASOLINE | |||
| 05/16/2005 | 45860 | 2 | 04/12/2005 |
| My gmc yukon xl has braking and fuel system problems, i have had 1 accident because of the yukons brakes deactivating while hitting a small bump on the street while trying to avoid the accident. i have contacted gmc and all they said is they would offer me a 1,000 rebate on the next purchase of another vehicle, although they advertised this defective product on (cnn) along with the other defects. there has been other hidden recalls on this vehicle and the manufacturer did not properly tell or notify me. *jb | |||
| FUEL SYSTEM, GASOLINE - DELIVERY - FUEL PUMP | |||
| 04/19/2007 | 190000 | 1 | 04/09/2001 |
| Fuel pump is whistling and fuel leak is apparent when parked overnight in garage. already replaced one pump at 96,000 miles. already had service on the melted wires 2 years ago. can gm provide the cost of the gm brand fuel pump so it can be replaced? *jb | |||
| 07/10/2006 | 83000 | 1 | 07/02/2003 |
| Dt*: the contact stated the fuel gauge readings were inaccurate. the dealer replaced the fuel pump which corrected the problem. there is a nhtsa recall # 05v155000, concerning the fuel pump. the vin was not included in the recall. updated 8/14/2006 - the fuel pump wiring melted inside the fuel tank. *nm | |||
| 05/22/2006 | 115000 | 1 | 05/01/2003 |
| Dt*: the contact stated the engine stalls at various speeds without warning. the vehicle has not been inspected by a mechanic. a nhtsa recall, #05v155000 was performed on the vehicle concerning, the fuel pump however, the recall did not remedy the problem. the dealership would not offer a second repair without charge under the recall. | |||
| 08/04/2005 | 1 | 04/24/2004 | |
| Our gas gauge on our 2000 gmc yukon completely quit working. took it in thinking it was an electrical problem and found out the fuel pump was broken. the problem that cost us a lot of money was that the fuel pump is located inside the gas tank and they had to replace the whole gas tank to fix the problem. first, why would this happen on a car this new with only around 50,000 miles and second, why put the fuel pump inside the gas tank so that it is so expensive to fix? *jb | |||
| 05/17/2003 | 47000 | 0 | 06/01/2000 |
| Noticed on several occasions that vehicle seemed to be leaking fuel when parked and turned off. most recent case occurred shortly after refueling. dealer diagnosed as a cracked fuel sending unit. apparently this allows fuel to be spewed out of the tank when parked. dealer indicated that it wasn't covered by warranty due to mileage. co-worker discussed almost identical problem with his yukon xl (except his spewed more fuel into his garage and need to be cleaned-up by hazmat team). this appears to be more than a random occurrence of a problem that has significant safety and environmental implications. i believe further investigation (by the nhtsa and general motors) is warranted. *nlm | |||
| 03/12/2003 | 1 | ||
| The vehicle stalled. the dealer diagnosed the problem as bad bare wires inside of fuel pump. the wires shorted which caused vehicle to stall. *jb | |||
| 03/15/2003 | 50000 | 10 | 09/09/2002 |
| I own a 2000 gmc yukon xl. over the past few months, i have had a problem with the vehicle continually blowing a fuse (ecm b fuse). upon my own research into the circuitry, i determined the likely problem was the fuel pump. i replaced the fuel pump and upon removing and inspecting the old component, i discovered the hot wire (gray wire) which operates the pump motor had been hot enough to melt the insulation off the wire. moreover, this hot wire had melted into one of the wires of the fuel level sending unit, which is a ground circuit. the problem i would like to bring to light here is that the fuel pump unit is inside the fuel tank. when this hot wire came into contact with the other wire, i assume there was a spark, or the potential for one. why didn't my vehicle explode? i know there are thousands of these vehicles on the road, but i have not heard of any such explosions. i do know of another gm vehicle that had the same problem of exposed wires in the fuel tank. please advise me of the danger level should this happen again. thank you. *nlm | |||
| FUEL SYSTEM, GASOLINE - DELIVERY - HOSES, LINES/PIPING, AND FITTINGS | |||
| 11/03/2005 | 54000 | 1 | 03/25/2000 |
| Dt*: the contact stated while having recall work completed under recall 05v155000 concerning the fuel system, the evaporative emission hose was broken by the dealership. no repairs were made because the broken part is no longer being manufactured. however, the vehicle is now emitting fumes inside the contact's garage where the vehicle is being stored. the consumer stated the check engine light is on. updated 02/28/06. *jb | |||
| FUEL SYSTEM, GASOLINE - FUEL INJECTION SYSTEM - INJECTORS | |||
| 11/10/2002 | 29797 | 6 | 07/26/2000 |
| The vehicle would stall without warning. typically, the stall would occur while the vehicle was cold, or during turns at intersections-going from one roadway to another.*ak dealers response has been a dirty throttle body, code j5485 | |||
| FUEL SYSTEM, OTHER - DELIVERY - FUEL PUMP | |||
| 03/26/2004 | 72000 | 1 | 09/01/2002 |
| My youkon would not start intermittently. i had it towed to courtesy chevrolet and they gave me an estimate for $1500 to replace the fuel tank and pump module. i could not believe a truck only 4 years old already needed a new fuel tank. so i searched the nhtsa database for similar complaints, and found that other people are having the same issue except it is being caused by shorted pump wires in the gas tank. i was able to drive the truck home and removed the gas tank myself so i could get to the bottom of this. when i removed the pump module from the tank it was just like everyone else had said. the wires were completely melted together. therefore the intermittent issue with the truck not starting was being caused by the wires shorting from time to time inside the gas tank. what is amazing to me is that i am still alive today and my wife and two kids (6 & 8) did not get injured. i believe there is an effort of gm to cover this problem up due to my dealings with gm customer support (or their lack of). reporting this to the nhtsa is just my first step. i will further elevate this to the necessary level to get this problem fixed in all the affected vehicles. i have fully documented this and have taken digital pictures of the pump module shorted wires. if anyone wants to see them email me at kchristopher@cfl.rr.com. *ak | |||