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GMC Yukon XL 2000–2006

GMC Yukon XLModel years 2000–2006

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Common on this vehicle:Smoke or fireStalls or shuts offWarning lightGauge or instrument faultLeakOverheating

issueFuel module reservoir assembly: fuel pump wire connectors may overheat - recall 05V-155Remove

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5 records state a cause or a remedy. Each record is shown as short labels in the order fault → finding the cause → correction. Press a label to narrow to the records that state it.

Symptom

Component named as the cause

Work done

How it is said to have ended

  • says it was fixed1
  • result not stated1

A ribbon is as wide as the records that state both of its ends (only the commonest are drawn). A record that names several symptoms or components runs through each. Orange is records that say the fault came back or was not fixed. Results come from owners’ reports only; one that does not say is “result not stated”. None of this is a likelihood of a cause or a rate at which work succeeds.

Read the records one by one (5)

Known issuesFuel module reservoir assembly: fuel pump wire connectors may overheat - recall 05V-1555

  1. Recall2000–2001 GMC YUKON XL ・ —

    Fuel Module Reservoir Assembly Overheating Recall

    1. 1Fault

      • Some vehicles were built with fuel module reservoir assemblies whose fuel pump wires and/or connectors may overheat under certain operating conditions.
      • If the exposed ignition circuit wire shorts to ground, the fuel pump fuse blows, disabling the fuel pump and causing an engine stall or no-start; if the ignition circuit or ground wire shorts to the fuel level sender card wires, fuel level readings may be inaccurate.
      • If enough heat reaches the pass-through connector, a hole may form in it, which may turn on the Service Engine Soon light during the emission system diagnostics routine; fuel vapor, and in some cases liquid fuel, may leak from the tank through the hole.
      • If enough fuel leaked out and an ignition source were present, a vehicle fire could occur.

    2. 2Finding the cause

      Possible causes

      • Fretting corrosion caused by vibration inside the tank was identified as the cause of high resistance within the fuel pump connector.

    3. 3Correction

      Repair

      1. Dealers remove the fuel tank, remove the fuel module reservoir assembly and install a new service kit, which includes a new pass-through connector and a wiring harness for the fuel pump and fuel sender card.
      2. Start by disconnecting the negative battery cable, then remove and discard the "ECM B" fuse.
      3. In the revised bulletin, the fuel and EVAP pipes are capped with J 41413-300, EVAP Cap/Plug Kit, to prevent fuel system contamination.
      4. Remove the 4 pin Metri Pack 150 electrical connector from the vehicle's body harness.
      5. Connect the new GT280 connector to the vehicle's body harness with the 4 butt splice connectors contained in the kit.
      2 more points

      Parts

      • Part number 15824379, Harness Kit, F/Tnk F/Pmp Mdl Wrg, quantity 1 per vehicle.

      Part numbers printed in the document

      The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

      Caution

      • Do not handle the fuel sender assembly by the fuel pipes; the leverage could damage the joints.
      • Always replace the fuel sender gasket when reinstalling the fuel sender assembly, to reduce the risk of fire and injury from a fuel leak.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：The recall covers certain 2000-2001 Chevrolet 1500 Series Suburban and GMC 1500 Series Yukon XL vehicles built within the listed VIN breakpoints.
    • Condition：Some vehicles were built with fuel module reservoir assemblies whose fuel pump wires and/or connectors may overheat under certain operating conditions.
    • Condition：If the exposed ignition circuit wire shorts to ground, the fuel pump fuse blows, disabling the fuel pump and causing an engine stall or no-start; if the ignition circuit or ground wire shorts to the fuel level sender card wires, fuel level readings may be inaccurate.
    • Condition：If enough heat reaches the pass-through connector, a hole may form in it, which may turn on the Service Engine Soon light during the emission system diagnostics routine; fuel vapor, and in some cases liquid fuel, may leak from the tank through the hole.
    • Condition：If enough fuel leaked out and an ignition source were present, a vehicle fire could occur.
    • Cause：Fretting corrosion caused by vibration inside the tank was identified as the cause of high resistance within the fuel pump connector.
    • Repair：Dealers remove the fuel tank, remove the fuel module reservoir assembly and install a new service kit, which includes a new pass-through connector and a wiring harness for the fuel pump and fuel sender card.
    • Parts：Part number 15824379, Harness Kit, F/Tnk F/Pmp Mdl Wrg, quantity 1 per vehicle.
    • Repair：Start by disconnecting the negative battery cable, then remove and discard the "ECM B" fuse.
    • Repair：In the revised bulletin, the fuel and EVAP pipes are capped with J 41413-300, EVAP Cap/Plug Kit, to prevent fuel system contamination.
    • Caution：Do not handle the fuel sender assembly by the fuel pipes; the leverage could damage the joints.
    • Caution：Always replace the fuel sender gasket when reinstalling the fuel sender assembly, to reduce the risk of fire and injury from a fuel leak.
    • Repair：Remove the 4 pin Metri Pack 150 electrical connector from the vehicle's body harness.
    • Repair：Connect the new GT280 connector to the vehicle's body harness with the 4 butt splice connectors contained in the kit.
    • Repair：Install the fuel tank strap attaching bolts and tighten them to 40 N·m (30 lb ft).
    • Repair：Install the new fuel pump fuse contained in the kit into the vehicle's electrical center (ECM B).
    Cause
    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.
    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.
    Consequence
    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.

  2. Owner complaint2001 GMC YUKON XL ・ 2005-05-25

    Fuel system failure, vehicle stranded three times

    1. 1Fault

      Not stated

    2. 2Finding the cause

      Not stated

    3. 3Correction

    Read the sentences of the record
    Remedy
    THE ONLY SOLUTION THESE "CERTIFIED" MECHANICS COULD THINK TO DO WAS REPLACE THE FUEL PUMP, WHILE I KNEW ALL ALONG THERE HAD TO BE SOME KIND OF SHORT IN THE FUEL SENDING SYSTEM.
    Consequence
    THE SYSTEM HAS FAILED THREE TIMES AND LEFT MY WIFE AND CHILDREN STRANDED ON INTERSTATE 45 AND IN GALVESTON, TX.

  3. Owner complaint2000 GMC YUKON XL ・ 2006-07-24

    Inaccurate fuel gauge readings

    1. 1Fault

    2. 2Finding the cause

    3. 3Correction

    Read the sentences of the record
    Fault
    DT*: THE CONTACT STATED THE FUEL GAUGE READINGS WERE INACCURATE.
    Remedy
    THE DEALER REPLACED THE FUEL PUMP WHICH CORRECTED THE PROBLEM.

  4. Manufacturer communication2000–2001 GMC YUKON XL ・ 2005-12-01

    Recall 05-027: fretting of the 4-wire connector terminals on top of the fuel pump assembly; repair kit installation tips

    1. 1Fault

      Not stated

    2. 2Finding the cause

      Possible causes

      • The terminals in the 4-wire electrical connector at the top of the fuel pump assembly may suffer fretting and high resistance.

    3. 3Correction

      Repair

      1. Installing the replacement connector components in the cover is a new procedure; the fuel level sensor is replaced by the existing SI procedure, but the float assembly is re-used, which is new.
      2. Remove and discard the fuel pump fuse as instructed; a replacement is in the kit, and using a new fuse is a precaution.
      3. Align the connector with the opening in the cover, then press it into place with finger pressure until the tab clicks.
      4. To remove the float arm from the old fuel level sensor, twist a small screwdriver under the float arm to push the arm from the retainers.
      5. Cut the old 4-pin MetriPack 150 connector from the vehicle harness for the new chassis connector, staggering the cuts by 1.5 inches (40 mm) so the splices do not overlap.
      1 more points

      Parts

      • The bulletin explains how to install repair kit 15824379 on the fuel pump assembly; the kit contains replacement electrical connectors, a replacement fuel level sensor, related hardware and instructions.

      Part numbers printed in the document

      The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

      Caution

      • After removing the connector, be sure the O-ring does not remain in the cover.
      • Be sure the O-ring is properly seated on the connector and lubricated with the oil in the kit; an O-ring that is not properly lubricated may be damaged during installation.
      • Be sure the sensor wires are routed through their retainers so that they do not interfere with the float arm.
    Read the sentences of the record

    From the manufacturer’s document

    • Applies to：Recall bulletin 05-027 is being prepared to cover the 2000-01 Chevrolet Suburban and GMC Yukon XL (excluding 2500 HD).
    • Cause：The terminals in the 4-wire electrical connector at the top of the fuel pump assembly may suffer fretting and high resistance.
    • Parts：The bulletin explains how to install repair kit 15824379 on the fuel pump assembly; the kit contains replacement electrical connectors, a replacement fuel level sensor, related hardware and instructions.
    • Repair：Installing the replacement connector components in the cover is a new procedure; the fuel level sensor is replaced by the existing SI procedure, but the float assembly is re-used, which is new.
    • Repair：Remove and discard the fuel pump fuse as instructed; a replacement is in the kit, and using a new fuse is a precaution.
    • Caution：After removing the connector, be sure the O-ring does not remain in the cover.
    • Caution：Be sure the O-ring is properly seated on the connector and lubricated with the oil in the kit; an O-ring that is not properly lubricated may be damaged during installation.
    • Repair：Align the connector with the opening in the cover, then press it into place with finger pressure until the tab clicks.
    • Repair：To remove the float arm from the old fuel level sensor, twist a small screwdriver under the float arm to push the arm from the retainers.
    • Caution：Be sure the sensor wires are routed through their retainers so that they do not interfere with the float arm.
    • Repair：Cut the old 4-pin MetriPack 150 connector from the vehicle harness for the new chassis connector, staggering the cuts by 1.5 inches (40 mm) so the splices do not overlap.
    • Repair：Match the wire colors and splice the new 4-pin GT 280 connector to the vehicle harness; the blue splices are for the black and grey wires and the red splices for the purple and orange/black wires.

    Open this issue of GM TechLink ↗ The points above are read from an article of TechLink, GM’s monthly publication for dealership technicians. The article itself is not reproduced here.

    Remedy
    Fuel Pump Modular Reservoir Assembly A recall bulletin 05-027 is being prepared to cover 2000-01 Chevrolet Suburban and GMC Yukon XL (excluding 2500 HD). The terminals in the 4-wire electrical connector at the top of the fuel pump assembly may experience fretting and high resistance. The bulletin explains how to install a repair kit 15824379 to the fuel pump assembly. It contains replacement electrical connectors, a replacement fuel level sensor, related hardware and instructions. Installing replacement connector components in the cover is a new procedure. The kit installation also requires replacing the fuel level sensor, which is an existing SI procedure. However, in this repair, you will re-use the float assembly, which is a new procedure. TIP: You are instructed to remove and discard the fuel pump fuse. A replacement is included in the kit. Using a new fuse is a precaution. TIP: After removing the connector, be sure the O-ring does not remain in the cover - Be sure the O-ring is properly seated on the connector and properly lubricated using the oil in the kit (fig. 6) . IMPORTANT: The O-ring may be damaged during installation if it is not properly lubricated. IMPORTANT: Be sure the connector is properly aligned with the opening in the cover, then use finger pressure to install the connector into place until the tab clicks. TIP: When removing the float arm from the old fuel level sensor, twist a small screwdriver under the float arm, which will push the arm from the retainers IMPORTANT: Be sure the sensor wires are properly routed through their retainers so they do not interfere with float arm operation. You need to cut the old 4-pin MetriPack 150 connector from the harness to prepare the vehicle harness for the new chassis electrical connector. IMPORTANT: Stagger the cuts by 1.5 inches (40 mm) so the splices will not overlap Match the wire colors and splice the new 4-pin GT 280 connector to the vehicle harness. TIP: There are two colors of splices in the kit. The blue splices are for the black and grey wires, and the red splices are for the purple and orange/black wires.

  5. Owner complaint2001 GMC YUKON XL ・ 2005-08-12

    Fuel tank problems; fuel sender failed

    1. 1Fault

      Not stated

    2. 2Finding the cause

    3. 3Correction

      Not stated

      What the documents say to do

      Fuel module reservoir assembly: fuel pump wire connectors may overheat - recall 05V-155

      Confirm

      • On-board emissions diagnostics may detect holes of approximately 0.040 inches (= 1.02 mm) or more and set a service engine soon warning light. The connector sits below the fuel level when the tank is full.

      Repair

      1. Dealers remove the fuel tank and the module reservoir assemblies and install a new service kit.
      2. The bulletin explains how to install repair kit 15824379 on the fuel pump assembly; the kit contains replacement electrical connectors, a replacement fuel level sensor, related hardware and instructions.

      Caution

      • After removing the connector, be sure the O-ring does not remain in the cover.