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.
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.
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.
