2003 wont start under 1/4 tank

I cant let my 03 Tahoe go under 1/4 tank. Runs fine but if you shut it off under 1/4 tank of gas it wont start again. If I put 2 gallons of gas in it, it still wont start, but if i put 5 gallons in it it will start right up.

Fuel pump?

I cant let my 03 Tahoe go under 1/4 tank. Runs fine but if you shut it off under 1/4 tank of gas it wont start again. If I put 2 gallons of gas in it, it still wont start, but if i put 5 gallons in it it will start right up.

Fuel pump?

could be the sender reostat in the tank is off..these vehicles are known with defective fuel senders. many have had run out of fuel because the dash guage reads above 1/4 tank.

first measure fuel pressure with a pressure guage. should be 53-62psi. replace fuel filter every 30-40,000mi. never allow fuel to drop below 1/4 tank , this is to prevent excessive condensation and allows for the fuel pump to be properly cooled..

when this occurs again fill tank to max.. if it takes over 20 gallons the in tank sender is n/g..........

make sure the frame rail ground at the fuel tank is clean and secure and not corroded to dust !

If the fuel pump/sender assy is defective use the delphi fuel pump..do not use airtex , unless you want to do this again very soon,..

could be the sender reostat in the tank is off..these vehicles are known with defective fuel senders. many have had run out of fuel because the dash guage reads above 1/4 tank.

first measure fuel pressure with a pressure guage. should be 53-62psi. replace fuel filter every 30-40,000mi. never allow fuel to drop below 1/4 tank , this is to prevent excessive condensation and allows for the fuel pump to be properly cooled..

when this occurs again fill tank to max.. if it takes over 20 gallons the in tank sender is n/g..........

make sure the frame rail ground at the fuel tank is clean and secure and not corroded to dust !

If the fuel pump/sender assy is defective use the delphi fuel pump..do not use airtex , unless you want to do this again very soon,..




my 90 chevy p.u. started the same thing and the plastic dam around the fuel pump was broken

my 90 chevy p.u. started the same thing and the plastic dam around the fuel pump was broken

I'm no 1990 expert on this issue you had . the 2003 vehicle is much different with the inaccurate fuel level indication.

This is so widespread that Gm must of threw money at the right person to kill any recall, to compensate vehicle owners , who suffered losses due to the defective material used in the reostat .

Thanks guys

As a side note...you can NOT just buy the fuel level indicator sending unit...you have to get a complete fuel pump assembly because it is manufactured as a single unit. Definately spend the extra bucks and get the Delphi unit. I've replaced so many of these fuel pumps so many times on so many GM trucks and SUV's. Make sure the replacement pump comes with a new electrical socket. You will have to disconnect the battery and then cut the plug off the Tahoe's wire harness near the pump and then splice on the new plug. Make sure that you don't smash the wire's inbetween the frame and gas tank when you put the tank back in. 2 things I do to make it easier is I will remove the metal shield that protects the tank from road debri and I will jack up the back of the truck just enough to get the tires off the ground. Once the tank retaining straps are removed, the end of the tank CLOSEST to the rear axle will rotate down then you will need to slide the tank as if you were trying to slip it UNDERNEATH the rear axle. There are 3 fuel line connections that you will need to seperate. 2 are located at the front top of the tank these are the feed and return lines. They are right next to each other and have a slightly different design and it is NOT possible to put them back together the wrong way. The 3rd connection is the vapor return hose. It's connector is located at the rear top of the tank. DO NOT KINK THESE HOSES. Obviously you will need to disconnect the gas tank filler hose. The tank strap bolts are 15mm and you will need a ratchet and medium length extension