The defect
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.
The risk
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.
The remedy
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.
NHTSA's own wording · initiated by ODI
Vehicles covered
| Model | Model years |
|---|---|
| Chevrolet Suburban | 2000, 2001 |
| GMC Yukon XL | 2000, 2001 |
Components: FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP
Model years in this recall
NHTSA complaints and the number of recall campaigns for each model year this recall covers.
| Model | Year | Complaints | Recalls |
|---|---|---|---|
| Chevrolet Suburban | 2000 | 282 | 8 |
| Chevrolet Suburban | 2001 | 440 | 6 |
| GMC Yukon XL | 2000 | 69 | 6 |
| GMC Yukon XL | 2001 | 120 | 4 |
Other fuel system, gasoline recalls in 2005
26 of the 562 recall campaigns reported to NHTSA in 2005 concerned the fuel system, gasoline; GENERAL MOTORS CORP. filed 1,195 campaigns in all.
| 05V555000 13 Dec 2005 | NISSAN NORTH AMERICA, INC. |
| 05V515000 9 Nov 2005 | FORD MOTOR COMPANY |
| 05V497000 1 Nov 2005 | AMERICAN SUZUKI MOTOR CORP. |
| 05V506000 1 Nov 2005 | APRILIA USA, INC. |
| 05V475000 13 Oct 2005 | WINNEBAGO INDUSTRIES, INC. |
| 05V466000 7 Oct 2005 | ISUZU MANUFACTURING SERVICES OF AMERICA |
| 05V453000 5 Oct 2005 | FREIGHTLINER LLC |
| 05V378000 29 Aug 2005 | MERCEDES-BENZ USA, LLC. |
NHTSA recalls (public domain) · all recalls of 2005