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Makes 🢒 Chevrolet 🢒 2005 🢒 Express 🢒 Bulletins 🢒 Crank and No Start, Reduced Power, Intermittent Hesitation, Hesitates in High Altitude/High Ambient Temperatures (Replace with Newly Designed Fuel Pump Module without Fuel Level Sensor)

Crank and No Start, Reduced Power, Intermittent Hesitation, Hesitates in High Altitude/High Ambient Temperatures (Replace with Newly Designed Fuel Pump Module without Fuel Level Sensor)

Subject:Crank and No Start, Reduced Power, Intermittent Hesitation, Hesitates in High Altitude/High Ambient Temperatures (Replace with Newly Designed Fuel Pump Module Without Fuel Level Sensor)

Models:2004-2005 Chevrolet Express Van
2004-2005 GMC Savana Van
with 4.8L, 5.3L or 6.0L Gasoline Engine (VINs V, T, U -- RPOs LR4, LM7, LQ4)


This bulletin is being revised to update part information and add additional diagnostics. Please discard Corporate Bulletin Number 05-06-04-046 (Section 06 -- Engine/Propulsion System ).

Condition

Some customers may comment on a driveability condition while driving in high ambient temperatures, usually above 26.6°C (80°F) or while driving in high altitude conditions, usually above 1524 m (5000 ft) above sea level.

Diagnostic Aids

If a lack of fuel pressure is verified during the condition and no fuel pump wiring concerns are found, replace the fuel pump module. If this only occurs at the above conditions, the fuel pressure loss may be due to a fuel system vapor lock.

It is possible that the fuel system may test OK in cooler ambient temperatures or low altitude and fail under high temperatures and high altitude conditions. Refer to the following Diagnostic Information in SI:

    • Symptoms - Engine Controls.
    • Intermittent Conditions.
    • Cuts Out, Misses.
    • Fuel System Diagnosis.

Correction

DO THIS

DON'T DO THIS

Replace the newly designed fuel module WITHOUT the fuel level sensor.

DO NOT replace the complete fuel module with the fuel level sensor.

    Important: When removing the fuel tank strap bolts, DO NOT use air tools. Using air tools may cause the retaining clip nut to spin preventing removal of strap bolt.

  1. Remove the fuel sender assembly from the vehicle. Refer to Fuel Sender Assembly Replacement in SI.

    2. Notice: Use extreme caution when removing the fuel level sensor from the fuel sender assembly. Failure to do so may damage the fuel sender assembly.

  2. Remove the two wire fuel level sensor connector from the fuel sender assembly.

    3. Object Number: 1546848 Size: SH

    Important: The fuel level sensor retaining tab located at the center top of the level sensor has a DUAL sided retaining tab. The fuel level sensor is retained on both the front side and the rear side of the retaining tab.

  3. Using one of two pocket screwdrivers, pull the front retaining tab away from the front of the fuel level sensor while, with the second pocket screwdriver, push the fuel level sensor away and down from the fuel sender assembly.
  4. Remove the fuel level sensor from the fuel sender assembly.
  5. Install the old fuel level sensor by sliding the sensor up into the new fuel sender assembly (refer to Parts Information below).
  6. Plug in the two wire fuel level sensor electrical connector into the fuel sender assembly.
  7. Install the new fuel sender assembly with the old fuel level sensor in the fuel tank. Refer to Fuel Sender Assembly Replacement in SI.

Parts Information

Part Number

Description

19133502

Module Kit, W/O Fuel Level Sensor

2004-2005 G 300 03 LQ4 NC8 NE7

19133508

Module Kit, W/O Fuel Level Sensor

2004-2005 G 300 03 LQ4 LR4 NC8 (Exc NE7)

19133511

Module Kit, W/O Level Sensor

2004-2005 G 300 03 LQ4 LR4 NF4 NF9 NT9 (Exc NE7)

19133516

Module Kit, W/O Level Sensor

2005 G 100/200/300 05/06 E26

2005 H 100 05/06 E26

2005 H 200 05 E26

2005 G 100/200/300 05/06 E26

2005 H 100 05/06 E26

2005 H 200 05

2004 G 100/200/300 05/06 LM7 LQ4 LR4 E26

2004 G 200/300 05 LQ4 LR4 7T6

2004 H 100 05/06 LM7 LQ4 LR4 E26

2004 H 200 05 LM7 LQ4 LR4 E26

2004 G100/200/300 05/06 LM7 LQ4 LR4 E26

2004 G 200/300 05 LQ4 LR4 7T6

2004 H 100 05/06 LM7 LQ4 LR4 E26

2004 H 200 05 LM7 LQ4 LR4 E26

19133519

Module Kit, W/O Level Sensor

2005 G 100/200/300 05/06 (Exc E26 7T6)

2005 G 200/300 05 LQ4 LR4 7T6

2005 H 100 05/06 (Exc E26 7T6)

2005 H 200 05 (Exc E26 7T6)

2005 G 100/200/300 05/06 (Exc E26 7T6)

2005 G 200/300 05 LQ4 LR4 7T6

2005 H 100 05/06 (Exc E26 7T6)

2005 H 200 05 (Exc E26 7T6)

2004 G 100/200/300 05/06 LM7 LQ4 LR4 (Exc E26 7T6)

2004 G 200/300 05 LQ4 LR4 (Exc E26 7T6)

2004 H 100 05/06 LM7 LQ4 LR4 (Exc E26 7T6)

2004 H 200 05 LM7 LQ4 LR4 (Exc E26 7T6)

2004 G 100/200/300 LM7 LQ4 LR4 (Exc E26 7T6)

2004 G 200/300 05 LQ4 LR4 7T6

2004 H 100 05/06 LM7 LQ4 LR4 (Exc E26 7T6)

2004 H 200 05 LM7 LQ4 LR4 (Exc E26 7T6)

Warranty Information

For vehicles repaired under warranty, use:

Labor Operation

Description

Labor Time

L1225

Sender/Pump Assembly, Fuel (Tank Unit) - Left Tank - Replace

Use published labor operation time