No Start, Inaccurate Fuel Gauge (Replace Sender Fuel Feed (Transfer) Pipe and Inspect Primary Module Transfer (Jet) Pump)

This bulletin is being revised to add VIN Breakpoints for each model. Please discard Corporate Bulletin Number 04-06-04-077 (Section 06 -- Engine/Propulsion System).

Built Prior to the following VIN Breakpoints:

Some customers may comment on an inaccurate fuel level gauge reading. In a small number of cases, the vehicle ran out of fuel when the gauge still indicated 1/8 tank.

The cause of this condition may be insufficient fuel transfer from the left fuel reservoir to the right fuel reservoir. The poor fuel transfer may be the result of one or a combination of both of the following:

Important: DO NOT replace the instrument panel cluster (IPC) or the engine control module (ECM) unless diagnosis has determined them to be at fault.

Follow published diagnostics for any stored diagnostic trouble codes (DTC) or use the diagnosis information for fuel gauge inaccuracy (SI Document ID 762180). If the diagnosis leads you inside the fuel tank, determine if the vehicle came in an as-failed condition; pay particular attention to the quantity of fuel in the left and right reservoirs as the tank is lowered from the vehicle. Fuel remaining in the left reservoir and no fuel in the right reservoir is a good indication of poor fuel transfer. If the vehicle is not in a failed condition, it may be necessary to run the vehicle out of fuel to duplicate the concern.

Replace the sender fuel feed (transfer) pipe with P/N 10388380. This new pipe has one anti-siphon hole. Also, inspect the RH primary fuel tank module for a clogged/restricted transfer (jet) pump. Use the procedure listed below:

1. Remove the RH primary fuel tank module from the fuel tank. Refer to the Primary Fuel Tank Module Replacement procedure in the Engine Controls sub-section of the Service Manual.
2. Disconnect the electrical connector from the LH secondary fuel tank module.
3. Rotate the cam lock ring counter-clockwise using the J 45747.
4. Remove the cam lock ring from the fuel tank.
5. Carefully lift the LH secondary fuel tank module from the fuel tank only enough to access the transfer pipe.
6. Disconnect the transfer pipe from the LH secondary fuel tank module by pulling the locking mechanism down and away from the module.
7. Remove the transfer pipe from the fuel tank.
8. Install the new transfer pipe into the fuel tank.
9. Connect the transfer pipe to the LH secondary fuel tank module.
10. Install the cam lock to the fuel tank and rotate clockwise using the J 45747 until fully seated.
11. Connect the electrical connector to the LH secondary fuel module.





12. On the RH primary fuel tank module, inspect the jet pump by releasing the tab (1) securing the pump to the module. Position the jet pump with light at the rear and look through the tube. The hole should be clear from debris and not black in color. If the jet pump shows signs of being plugged, replace the RH primary fuel tank module.
13. Install the RH primary fuel tank module into the fuel tank. Refer to the Primary Fuel Tank Module Replacement procedure in the Engine Controls sub-section of the Service Manual.

For vehicles repaired under warranty, use: