Diesel Fuel System Problems of Chevrolet Silverado 2500 - part 1

The contact owns a 2020 Chevrolet silverado. The contact stated that while attempting to remote start the vehicle, the vehicle failed to start. The contact was able to manually start the vehicle however, the message "service emissions system - speed limited to 65 mph" was displayed. The contact stated while driving approximately 25 mph, the "check engine” and “speed limit 65 mph" messages were displayed. The contact heard an abnormal sound like air coming from the rear of the vehicle. The contact stated there was thick black smoke coming from the exhaust pipe. The contact returned to the residence. The contact had not taken the vehicle to the dealer or independent mechanic. The vehicle was not diagnosed. The contact had used a handheld scanner and became aware that the reductant heater circuits 1, 2, and 3 had short-circuited. The contact checked and observed that the wiring harness located under the vehicle near the fuel tank and the diesel exhaust fluid (def) tank had melted. The vehicle was not repaired. The contact had researched online and related the failure to technical service bulletin number: n202300791 - service update diesel exhaust fluid system (fuel system, diesel). The manufacturer was informed of the failure. The failure mileage was approximately 131,000.

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The contact owns a 2021 Chevrolet Silverado 2500. The contact stated that while driving 70-75 mph, there was an abnormally loud sound coming from the vehicle. The vehicle independently decelerated to approximately 50 mph then down to 40 mph before being able to pull off on a nearby exit. The contact stated that the vehicle then stalled and lost motive power. The vehicle was towed to the dealer who diagnosed that the fuel pump module had failed and needed to be replaced. The vehicle had not been repaired due to the part being on backorder. The manufacturer was made aware of the failure. The failure mileage was 83,000.

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The contact owns a 2019 Chevrolet Silverado 2500. The contact stated while towing an RV and driving approximately 65 mph, the vehicle suddenly lost motive power and stalled. During the failure the message "forward propulsion failure" was displayed. The vehicle was towed to the local dealer who diagnosed that the fuel pump control module had failed. The fuel pump control module was replaced, and the vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 70,000.

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The contact owns a 2016 Chevrolet Silverado 2500. The contact stated that while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The driver was able to coast to the shoulder of the roadway, where the vehicle failed to restart. No warning lights were illuminated. The vehicle was taken to the dealer, who diagnosed failures with the fuel injection pump and diesel particulate filter. The vehicle was repaired, but the failure reoccurred. The vehicle was taken back to the dealer, who diagnosed failures with the catalytic converter and fuel injector sensor. The vehicle was repaired. The manufacturer was notified of the failure, and a case was opened. The failure mileage was 174,000.

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The contact owns a 2015 Chevrolet Silverado 2500. The contact stated while driving approximately 65 mph, the vehicle stalled. The contact stated there was no warning illuminated. The contact had the vehicle towed to a local dealer, where it was diagnosed and determined that the high-pressure diesel fuel pump had failed, and the entire fuel system needed to be replaced. The vehicle was repaired. The manufacturer was informed of the failure and referred the contact to the NHTSA hotline to report the failure. The failure mileage was approximately 190,000.

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The contact owns a 2024 Chevrolet Silverado 2500. The contact stated that while starting the vehicle, the check engine warning light illuminated. The vehicle was taken to the dealer, where the battery was disconnected temporarily to reset the ecm. The check engine warning light was reset; however, the failure reoccurred while driving. Additionally, the contact stated that the vehicle was experiencing abnormal fuel consumption. The contact stated that the fuel economy was 8. 2 - 9 miles per gallon while driving and hauling a trailer. The contact related the failure an unknown gm voluntary recall for faulty fuel injector flow rate. The dealer was notified of the failure. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA hotline for assistance. The failure mileage was approximately 400.

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The contact owns a 2016 Chevrolet Silverado 2500. The contact stated while driving approximately 65 mph, the vehicle lost motive power, stalled, and stopped in the middle of the roadway. The contact stated that there were unknown warning lights illuminated. The contact had the vehicle towed to a local dealer, where it was diagnosed and determined that the high-pressure fuel pump needed to be replaced. The vehicle had not been repaired due to a national backorder on the part. The manufacturer had been informed of the failure. The contact researched online and related the failure to NHTSA campaign number: 21e101000 (fuel system, diesel). The failure mileage was approximately 70,000.

The contact owns a 2013 Chevrolet Silverado 2500. The contact stated while driving 80 mph, the vehicle stopped unintentionally without warning. The contact was able to shift the vehicle into neutral(n) and pull over to the side of the road. The vehicle was towed to the dealer to be diagnosed. The contact was informed that the cp4 high-pressure fuel injection pump needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and informed of the failure. The contact was informed that the manufacturer was aware of the failure however, there was no recall for the failure. The failure mileage was 130,000.

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The contact owns a 2015 Chevrolet Silverado 2500. The contact stated that while driving at various speeds, the vehicle entered limp mode with a warning message indicating how many miles before the vehicle would independently turn off. The contact had taken the vehicle to a dealer and was informed that the diesel exhaust fluid (def) tank needed to be replaced; however, the failure returned. Over time, the rear brakes, rotors, calipers, and various other parts had been replaced; however, the repairs failed to fix the vehicle. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 143,000.

The contact owns a 2020 Chevrolet Silverado 2500 hd. The contact stated that while driving at 50 mph, a warning alarm engaged an advised that there was an emission system issue and the vehicle needed to be serviced within 160 miles. The transmission warning light illuminated. The contact stated that she parked the at some point to run an errand and upon restarted the vehicle, a death issue system alarm engaged indicating that the vehicle needed to be repaired within 90 miles. The vehicle was taken to the local dealer where the failure was diagnosed as a death issue and one of the pin on the wiring harness had burnt and was starting to melt. The local dealer informed the contact that the death tank and wiring harness needed to be replaced; however the parts for the repair were not available the vehicle was not drivable. The vehicle was not repaired. The manufacturer was notified of the failure and advised the contact the parts for the repair were not available. The vehicle was not repaired. The failure mileage was approximately 20,000.

The contact owns a 2012 Chevrolet Silverado 2500. The contact while driving at various speeds a message indicating that the def system had failed was displayed. The contact stated that the vehicle was taken to several unknown dealers, where the O2 sensor, a diesel injector and other unknown repairs were performed; however, the failure recurred while driving. The contact stated while driving 65 mph, a message indicating that the def system had failed was displayed. Additionally, the vehicle went into limp mode and gradually decelerated. The contact was able to drive to the nearest independent mechanic, where it was diagnosed that the def system, fuel pump system and oxygen sensor had failed. The vehicle was repaired; however, the contact was concerned that the repair was temporary. The manufacturer was notified of the failure. The failure mileage was approximately 22,000.

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2008 Chevrolet silverado. Consumer writes in regards to rubber portion of the fuel supply line kinks and reduces engine the fuel supply to the engine which causes the computer to reduce the power of the engine. The consumer stated while towing a fifth wheel RV and going up a mountain, the engine went into limp mode, which reduced the engine power. The consumer went from 45 mph to 30 mph almost instantly. The fuel line was replaced.

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2003 Chevrolet silverado. Consumer writes in regards to fuel injectors problem . The consumer stated his vehicle was always mis-diagnosed. The dealer never checked to see if there was a problem with the fuel injectors, in which white some was emitting from the vehicle. The dealer only replaced the glow plugs, which was not the problem.

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The contact owns a 2007 Chevrolet Silverado 2500 hd. The contact stated that while driving approximately 45 mph, the fuel gauge warning light illuminated intermittently. The contact stated that the vehicle would fail to accurately indicate the amount of fuel in the vehicle. The vehicle was not taken to a dealer for a diagnostic. The manufacturer was notified of the failure. The vehicle was not repaired. The approximate failure and current mileage was 60,000. . . . Updated 01/14/14 the consumer stated the fuel gauge malfunctioned on a consistent basis. Update 01/16/14.

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Message came on dic saying low def 727 miles. Did not quite know what that meant. Found out. Gm says it should come on at 1000 miles. Nope. Came on 2 x 727 and 72. There is no way to check the def level. Someone realized this as the newer trucks have gauges or other ways to check. I feel this could become an issue if the vehicle goes into limp mode and no close places to purchase def. I talked to gm. They don't seem to concerned about the whole thing. A simple fix would be to make it like the transmission fluid check. Pull out the dip stick/check the fluid/add fluid if necessary through the same tube that the dipstick came out of. My truck has a tube under the hood where you add def. Again there is no way to see how much you need. You just keep adding till it spits out of the tube. I feel gm should take care of this issue with an update of some sort so a motorist vehicle suddenly starts slowing down on the highway. Thanks for your interest. .

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I was driving down the road at highway speed (65mph) and the front right steel brake line burst and I lost most of my brake fluid. Upon looking under the truck for the cause of the problem, I noticed that all of the brake lines and two of the fuel lines were badly corroded. I tow trailers often and I'm thankful I wasn't towing our 11,000lb 5th wheen camper when this happened or there would have been a horrific crash! I have done quite a bit of research and noticed that there are quite a few compliants about the same problem for this model year pickup. Is there a recall and how do I go about getting this fixed? I am out of work on medical leave and cannot afford to take the truck to the shop and "wait" for gm to think about re-embursing me.

Fuel lines, sending unit and fuel hoses corrosion causing diesel fuel to leak.

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Fuel lines leaking. All lines need replacing.

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Chronic failure of fuel injectors on 2003 duramax chevy truck, deal has replaced injectors three times, now they are failing again and want 5k to fix them. Last fix was 40,000 miles ago. Here is the short and skinny. I was informed (during an injector swap in my truck) that the different types of injectors that were tested by gm and their partners (isuzu and bosch) provided good data for the ongoing service campaign, but will not be released through gm parts. Gm and partners (bosch) have made 2 modifications (documented) to the injector design from original and has deemed the current incarnation of this injector adequate. That is gm's solution apparently. Will it be a permanent solution? who can say, but it probably will be the only solution we ever see. The production and design cost combined with a "limited" customer base dictates that we will probably not see a complete replacement unit of new design come into the marketplace. Many failure causes have been theorized, two main modes of premature failure have emerged, but I am of the thought that a waveform analysis of the power to the injectors done over long term might yield some interesting results. Having been through the mill on these injectors personally, and having read volumes of information, I feel very strongly that we are loooking at the effect of a problem on a weak point (injector bodies), and not the root cause. So the buy is stuck with a poorly engineered truck. What recourse do we have??? come on gm come clean and do what is right, after all we the people bailed you out!.

2002 Chevrolet Silverado 2500hd. Consumer writes in regards to vehicle blowing out diesel fuel it was determined the injectors were bad and the low side pressure lines were causing fuel to enter to enter the crankcase.

Vehicle exhibited hard starting for a few days, and then was found with a large puddle of fuel under it in the morning, and was continuing to leak. Upon inspection, all steel fuel lines, at every point of connection, and at every brace, have thick, scaly, flaking rust. The corrosion is severe. In most locations, nearing the point of failure, and in at least one spot, resulted in a pin hole leak, with a significant quantity of fuel leaking onto the vehicle and the ground. The steel brake lines were also found to have a similar degree of corrosion, and will probably fail in the near term.

I have a 2002 Chevrolet Silverado 2500hd lt ext. Cab lb7 duramax 5 speed allison transmission, it has 114000 miles on it. This truck has been serviced as directed since new. The truck started using lots of fuel, at an idle it serged between 700 & 900 rpm's, and oil started blowing out the blowby tube. I have just found out that 3 fuel injectors are leaking fuel, with a possible head gasket leak,filling my crankcase with diesel, causing oil to blow out all over the truck, road and whatever else it can land on. While investigating what to do, to fix the truck I've found 3 other people I know that have duramax's, and they are going through the same problems. It's going to take me a year to save the money I need to fix this truck. I'm even going to do the work myself. In my opinion gm should be ashamed. They should at leased pay for the parts. The cheapest injectors I've found are $225. 00 apiece with a $125. 00 core charge. It's recomended that all 8 injectors be replaced at once. I've also been told these engines have defective head gaskets. That will cost another $600. 00 for parts, and $110. 00 for special tools I need to do the job. When I forked over the $40,000 cash inheritince money to buy this truck, I didn't signup for this.

Failing fuel injectors causing smoke out of exhaust on a duramax diesel truck. Gm knew of defect with injectors and only issued an extended warranty for 7 years/200,000 miles which ever occurred first. It was only good if you had an issue with the injectors at the time of warranty. I just found this out from a dealer and other owners of same type vehicle. If gm knowingly knew of these issues why did they not do a recall on said vehicles? I'ts really a matter of principle and moral ethics to do the right thing, rather than have the consumer take the fall for their lack of product design!.

I am concerned about the defective lb7 injectors causing a fire when they leak. Vehicle 2002 Chevrolet silverado hd2500 duramax diesel. Also causing another driver to crash from the puddle of diesel left behind when I have injector failure as has happened and will again since gm has no suitable replacement other than the defective part. Also curious about the total affect on the environment as this seems to be a common occurrence on 2001-2004 duramax diesels. Should I repair and then have concern of a vehicle fire? with my family onboard?.

2004 chevy 2500 hd truck with 6. 6 duramax diesel lose fuel suction. Must manually pump up fuel system to get truck started.

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Engine power reduced to 35 mph without warning. Pulling a trailer merging into heavy traffic on to i75. While merging, the vehicle suddenly dropped to 35 mph nearly causing an accident. The reduction is speed occured without warning. A light on the dash came on that said engine power reduced. This reduction in power was the result of the exhaust filter being full or clogged. Drove to next exit at reduced spped on shoulder and exited the highway. Engine is a duramax diesel 6. 6l.

Started my truck up on may 04 2010 and noticed fuel gauge showed empty. I had just filled it up the night before. Took it to my dealer and he determined it was a bad sending unit. My truck had about 16000 miles on it. Turn the problem over to gm with no satisfaction. I then checked the internet and found several problems of this nature. When the repair people took it in for repair they found extensive corrosion and other parts had to be replaced to the tune of $900. 00. I feel this is defective equipment and gm should be responsible.

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My 2002 chevy silverado with duramax diesel engine broke down while on a trip from michigan to florida. The diesel injector casing failed causing the crankcase to overfill with diesel fuel then caused oil and diesel fuel mix to come out of the engine while traveling down the road covering the underside of the vehicle and roadway as well as vehicles directly behind me. The gm dealer in georgia stated we were in by mileage but out of the extended 7 year 200000 mile injector warranty by 1year and 4 days and the cost would be $6250 to replace 8 injectors. They offered a 10% discount off that repair. Subsequent calls to gm customer assistance were made to no end (they stated the 10% discount was their best offer). I pleaded that the time limit should not be a factor as this should not affect wear (injectors do not fail when they are not operating) my vehicle has 120000 miles on it (well under 200000 warranty as stated by the customer assistance rep). I paid extra for the diesel for longevity and fuel economy as I am on a fixed income but wound up being treated unfairly especially for a known problem and the fact that oil/fuel blowing out on the highway and vehicles is a safety and emissions defect. I would like someone from the NHTSA to consider investigating this aspect (time limit) and safety of drivers and fighting for me to get assistance. Thanks for listening.

Fuel injectors go bad causing engine to stall and lurch forward while idling. The truck has been to the dealer and had this problem repaired 3 times and is doing it again.

When I do a fast stop my truck cab smells like raw diesel. . It should not do that I believe there is some kind of leak or overflow that is not sealed properly. Also my tailgate pin on c/s is not lined up with tailgate I took it in twice and they just bent it back it is not safe to haul cargo in bed because the tailgate may not hold.

No incident yet.

The contact owns a 2004 Chevrolet Silverado 2500 hd. While driving he saw smoke coming from the tail pipe, and then he smelled a burning odor. The vehicle was taken to the dealer for inspection. The technician concluded that the thermostats are not allowing the vehicle to achieve operating temperature and injectors 5, 6, 1 are defective. The repair will be performed at the owners expense. The failure mileage was 102000. The current mileage was 103000.

The contact owns a 2001 Chevrolet Silverado 2500 hd. The contact stated that while driving 45 mph the vehicle stalled while attempting to change lanes. The vehicle was taken to an authorized dealer, who stated that that all eight injectors and the injector pump needed to be replaced. The manufacturer was made aware of the failure and informed the contact that the vehicle was not under warranty and there were no related recalls. No other assistance was provided. The failure mileage was 143,000.

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Fuel injector failure.

My chevy diesel pick-up truck dies for 2-3 seconds when driving at medium speeds (50mph) and I floor the throttle. 2 dealers have told me this is normal, it is a lag due to the turbo. Everyone else I talk to that has this truck tells me they have the same problem. However, Ford and Dodge diesel trucks with turbos do not have this problem unless the turbo is defective. Also I have been told by some people who add a chip and adjusted such things as shift points etc. This problem goes always in 45 years of driving many vehicles I have never encountered such a safety issue. This needs to be corrected.