Manufacturer communication — 2000 GMC YUKON XL

• Recall bulletin 05-027 is being prepared to cover the 2000-01 Chevrolet Suburban and GMC Yukon XL (excluding 2500 HD).

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  A recall bulletin 05-027 is being prepared to cover 2000-01 Chevrolet Suburban and GMC Yukon XL (excluding 2500 HD).

Possible causes

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

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

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.

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   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.

2. Remove and discard the fuel pump fuse as instructed; a replacement is in the kit, and using a new fuse is a precaution.

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   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.

3. Align the connector with the opening in the cover, then press it into place with finger pressure until the tab clicks.

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   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.

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.

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   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

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.

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   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

6. 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.

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   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.

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.

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  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.

Caution

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

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  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 lubricated with the oil in the kit; an O-ring that is not properly lubricated may be damaged during installation.

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  - 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.

• Be sure the sensor wires are routed through their retainers so that they do not interfere with the float arm.

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  IMPORTANT: Be sure the sensor wires are properly routed through their retainers so they do not interfere with float arm operation.