2002 Chevrolet Suburban Fuel System Problems

WHILE REPLACING THE RUSTED BRAKE LINES ON MY SUBURBAN (SEE TRACKING NUMBER 11066863), I NOTICED THE FUEL LINES GOING TO THE FUEL FILTER WERE ALSO TERRIBLY RUSTED. IT APPEARS THE RUST EMANATES FROM THE PLASTIC CLAMP THAT SECURES THE FUEL LINE TO THE FRAME. THE TUBE NUT THAT GOES INTO THE FILTER APPEARS TO BE FROZEN WITH RUST. SALT AND DIRT ARE TRAPPED IN THE PLASTIC CLAMP AND NUT, WHICH IS IMPOSSIBLE TO WASH OUT. THE FUEL LINES ON TOP OF THE FUEL TANK ARE LIKELY TO BE RUSTED, TOO.

THE REAR FUEL TANK STRAP BROKE BY THE BOLT. THE STRAP THEN PIVOTED DOWN ONTO THE DRIVE SHAFT. THE ONLY REASON THE TANK DID NOT HIT THE ROAD IS BECAUSE OF THE STRENGTH OF THE FUEL FILLER HOSES FROM THE GAS CAP.

SOME DAYS MY TRUCK WILL NOT START SOME DAYS IT DOES FOR INSTANCE IT WILL START FOR A COUPLE OF DAYS CONSECUTIVELY AND THEN IT WONT START FOR 2-3 DAYS AFTER A COUPLE OF DAYS OF JUST SITTING. I HAVE REPLACED THE BATTERY, THE ALTERNATOR , STARTER , FUEL PUMP AND I'M STILL EXPERIENCING THE SAME PROBLEM.THIS HAPPENS ALL THE TIME HAS BEEN GOING ON FOR THE PAST COUPLE YEARS, LOST MY JOB BECAUSE OF NON RELIABLE TRANSPORTATION.

DRIVING ON RESIDENTIAL ROAD AND VEHICLE SUDDENLY REDUCED SPEED TO 10 MPH. MESSAGE DISPLAYED "REDUCED POWER MODE". NO ONE KNOWS HOW TO DIAGNOSE. ALL REPAIRS I HAVE READ ON THE INTERNET FORUMS ARE EXPENSIVE AND THE PROBLEM EVENTUALLY RETURNS. THIS PROBLEM IS INTERMITTENT AND CAN OCCUR AT ANY TIME. THE MOST CONCERN IS ON THE FREEWAY WHERE YOUR VEHICLE IS REDUCED TO 10-20 MPH AND THE SPEED LIMIT IS 70 MPH. *JS

MY 2002 CHEVROLET SUBURBAN 1500 HAS BEGAN TO STALL UNEXPECTEDLY. IT STALLS WHEN FUEL TANK IS LOW AND WHEN TANK IS FULL. LATELY, ITS BEEN DIFFICULT TO CRANK. I HAVE A NEW BATTERY, THE ALTERNATOR TESTED FINE, I'VE HAD THE FUEL PUMP REPLACED TWICE AND IT STILL STALLS. *TR

VEHICLE WILL STALL ON OCCASION WHILE DRIVING DOWN THE ROAD. ACTS AS IF THE ACCELERATOR IS NOT WORKING CAUSING THE VEHICLE TO COME TO A STOP WHILE TRYING TO APPLY THE ACCELERATOR PEDAL. THIS HAS HAPPENED AT LEAST 3 OTHER TIMES SINCE PURCHASING THE VEHICLE NEW. THE FIRST INCIDENT HAPPENED AT ABOUT 10,000 MILES ON THE VEHICLE AND THE LAST INCIDENT HAPPENED WITH A LITTLE OVER 120,000. *TR

I HAVE A 2002 CHEVY SUBURBAN. THE TRUCK STARTED SHUTTING OFF AT ANY SPEED LEAVING ME WITHOUT POWER STEERING OR POWER BRAKES. I CHANGED THE FUEL FILTER THE NEXT DAY BUT PROBLEM STILL OCCURS. THEN CAR STALLED ON HIGHWAY AND WOULD NOT START AGAIN. CAR STARTED ABOUT 2 HOURS LATER AND THEN CUT OUT A BLOCK DOWN THE ROAD. STARTED THE CAR ANOTHER 3 HOURS LATER AND CAR WAS ABLE TO MAKE IT THE 5 MILES HOME. FUEL PUMP WAS REPLACED ABOUT 50K MILES AGO. STALL IS A DANGEROUS SITUATION WITH NO STEERING AND LITTLE BRAKING ISSUE. WITH ALL OF THE INTERNET FEEDBACK, AND THE 2000 AND 2001 FUEL ISSUES WITH THIS MODEL, CHEVY SHOULD DO SOMETHING ABOUT THIS. *TR

DURING NORMAL OPERATIONS UNDER NORMAL DRIVING CONDITIONS THE FOLLOWING OCCURRED. LOSS OF ENGINE AT SPEEDS OF 60+ MPH AFTER DRIVING ONE HOUR. ENGINE RESTARTED WITH IN TWO MINUTES. PROBLEM OCCURRED MULTIPLE TIMES WITH SHORTER RUN TIMES BETWEEN EACH ATTEMPT. OVER A THREE YEAR TIME FRAME VEHICLE HAS REQUIRED FOUR FUEL PUMPS ALL FROM DIFFERENT MANUFACTURES TO ELIMINATE THE POSSIBILITY OF ANY COMPROMISED PRODUCT BATCHES. TOTAL CONSUMER COST. $3000. *TR

I HAVE AJ 2002 CHEVY SUBURBAN W/144K MILES ON IT. THE FUEL PUMP WAS REPLACED WHILE STILL UNDER WARRANTY BECAUSE IF THE FUEL LEVEL GOT TOO LOW IT WOULD NOT START. IN THE LAST 3 MONTHS HAVE HAD THE INTERMITTENT SHUT OFF PROBLEM LISTED ON OTHER COMPLAINTS. I HAVE HAD IT DO IT ON ROUGH ROADS AND INTERSTATE HIGHWAYS. SAME THING, ENGINE STOPS, WAIT 3-5 MINUTES ENGINE STARTS, SEEMS LESS PREVALENT WHEN TANK IS FULL. DEALERSHIP SAYS CHEVY SEES NO OVERALL PROBLEM WITH IT, MY MECHANIC TELLS ME A NEW FUEL PUMP IS NOT TOO EXPENSIVE BUT THE REAL COST IS THE LABOR TO TAKE THE FUEL TAKE OFF AND REPLACE IT. TOTAL $900-1100, THAT IS OUTRAGEOUS ESPECIALLY FOR A PROBLEM GM KNOWS IT HAS. *TR

MY 2002 CHEVROLET 2500 SUBURBAN 8.1L, HAS BEEN STALLING CONTINUOUSLY. IT STALLS WHEN DRIVING, SLOW, FAST OR EVEN AT A RED LIGHT, IT DOESN'T MATTER. I HAVE HAD THE FUEL PUMP, STARTER, ALTERNATOR AND BATTER ALL REPLACED. I HAVE READ ON MANY SITES THAT I AM NOT THE ONLY ONE WITH THE SAME VEHICLE WITH THE SAME PROBLEM. *TR

WHILE DRIVING ON THE HOUSTON TOLLWAY AT 65 MPH, MY 2002 SUBURBAN SUDDENLY AND WITHOUT WARNING LOST POWER AND THE ENGINE SHUTDOWN. I MANAGED TO GET THE VEHICLE ONTO THE SHOULDER WITHOUT INCIDENT AFTER ATTEMPTING TO RESTART THE ENGINE WHILE TRYING TO STEER CLEAR OF TRAFFIC. THE VEHICLE WOULD NOT START AND WAS TOWED TO LONE STAR CHEVROLET IN HOUSTON, TEXAS. THE BILL WAS 1045.10. THEY REPLACED THE FUEL MODULE AND THE FUEL FILTER AND TOLD ME THAT THERE HAD BEEN SOME PROBLEMS WITH GM VEHICLES DATING BACK TO 1999 MODELS ON THE SAME PROBLEM. MINE HAD ONLY 70158 MI. I THINK GM SHOULD REIMBURSE ME FOR THE COST OF REPAIR. I TALKED TO A CUSTOMER WHO HAD A SIMILAR PROBLEM ON HIS 1999 GMC SUBURBAN AND THEY FILED A COMPLAINT WITH GM AND WAS REIMBURSED FOR THE REPAIR. FAIR IS FAIR AND I EXPECT NOTHING LESS FROM THEM. *JB

2002 CHEVROLET SURBURBAN ENGINE STALLED WHILE BEING DRIVEN AT 70MPH DOWN FREEWAY. WAS ABLE TO GET ENGINE RESTARTED WHILE STILL ROLLING. NO REPAIR MADE YET, SERVICE TECHNICIAN SAID MANY POSSIBLE CAUSES AND WOULD BE EASIER TO DIAGNOSE IF IT WOULD NOT START. WIFE'S 2000 MODEL CHEV SUBURBAN HAD ALMOST IDENTICAL PROBLEM 01/21/2002. *NM

DT*: THE CONTACT STATED WHILE DRIVING ON THE HIGHWAY AT 20 MPH AND PULLING UP TO A TOLL BOOTH, THE VEHICLE STALLED SUDDENLY WITHOUT WARNING. THE VEHICLE WAS TOWED TO A DEALERSHIP WHERE THE DEALERSHIP DETERMINED THE VEHICLE NEEDED A NEW IGNITION SWITCH. WHILE DRIVING BACK HOME THE VEHICLE STALLED AGAIN. THE VEHICLE WAS TOWED 100 MILES TO A DEALERSHIP WHERE THE DEALERSHIP DETERMINED THE VEHICLE HAD A FAULTY FUEL PUMP. THE DEALERSHIP INFORMED THE CONTACT THERE WAS A HISTORY OF FAULTY FUEL PUMPS WITH THIS YEAR, MAKE AND MODEL.

2002 CHEVROLET SUBURBAN THAT STALLS INTERMITTENTLY WHILE DRIVING DOWN THE ROAD. THIS HAS HAPPENED SEVERAL TIMES IN THE PAST TWO WEEKS. WE TOOK IT INTO THE SERVICE CENTER WHERE THEY HAVE TOLD US THAT THE FUEL PUMP WILL NEED TO REPLACED AT A COST OF OVER $700. THERE IS CURRENTLY A RECALL ON 2001 MODELS WITH THE EXACT SAME PROBLEM. *NM

I HAVE A 2002 SUBURBAN THAT HAD A RECALL FOR THE GAS TANK LEAKING WHEN IT IS FILLED PAST 3/4 FULL. THE RECALL WORK WAS DONE IN DECEMBER 2005. THEN IN MARCH I SMELT GAS AGAIN I NOTICED A LARGE PUDDLE WAS UNDER MY VEHICLE AS I PULLED OUT OF THE GARAGE. I CARRIED IT BACK IN AND THEY CHARGED ME $890.00 AND STATED SINCE THE RECALL WORK WAS DONE IN DECEMBER THIS WOULD NOT BE COVERED. I HAVE THE PARTS THEY REPLACED. *JB

DURING EVACUATION FOR HURRICANE RITA AS WE WERE PROCEEDING IN TRAFFIC OUR 2002 CHEVY SUBURBAN JUST DIED. IT WAS AS IF IT WAS GETTING NO FUEL. WE HAD A FULL TANK. THE RPM AND POWER STEERING ALONG WITH THE ENGINE JUST WENT DEAD. SINCE THE HURRICANE I HAVE TALK TO 3 OTHER PEOPLE WITH SUBURBANS OR YUKONS THAT THIS HAPPEN TO. THE DEALERSHIP SAID IT WAS THE FUEL PUMP. I NOW THINK SOMETHING IS WRONG WITH THESE VEHICLES. I HAVE THE FUEL PUMP TAKEN FROM MY SUBURBAN. *NM

PURCHASED A NEW 2002 SUBURBAN K2500 IN AUG OF 2002. AT 17,000 MILES, THE AIR CONDITIONING WENT OUT. DEALER REPLACED THE COMPRESSOR. AT 27,000 MILES, THE FUEL GAUGE SHOWED EMPTY WHEN THE TANK WAS FULL. DEALER REPLACED REAR FUEL TANK SENDING UNIT. AT 55,000 MILES, THE FUEL TANK AGAIN SHOWED EMPTY WITH A FULL TANK AND THE ENGINE SURGED. THE DEALER (BOB STEELE IN COCOA FL) REPLACED THE FUEL PUMP IN THE REAR TANK AND THE SENDING UNIT IN THE FRONT TANK UNDER MY EXTENDED WARRANTY WITH A DEDUCTIBLE. DEALER STATED THIS WAS NOT A RECURRENCE OF THE PROBLEM BEFORE. AT 58,000 MILES THE CAR STALLED WHILE CROSSING OVER A BUSY BRIDGE/CAUSWAY AT APPROX. 60 MPH. "REDUCED ENGINE POWER" GLARED ON THE WARNING INDICATOR, POWER STEERING WAS LOST AND LIGHTS ON THE DASH WERE FLASHING ERRATICALLY. LUCKILY, I HAD CRESTED THE TOP OF THE CAUSWAY AND MANAGED TO STEER TO THE TINY SHOULDER WITHOUT CRASHING INTO ANYBODY. THE CAR WOULD NOT START IMMEDIATELY, BUT AFTER TRYING FOR FIFTEEN MINUTES I WAS ABLE TO GET IT STARTED AND DRIVE HOME. I CALLED THE DEALER (IT WAS FIVE MINUTES TO CLOSING TIME) AND WAS TOLD TO BRING IT IN THE NEXT DAY. IT STALLED AGAIN AT A TRAFFIC LIGHT ON THE WAY TO THE DEALER BUT STARTED IMMEDIATELY. THE DEALER REPLACED THE THROTTLE POSITION SENSOR UNDER MY EXTENDED WARRANTY WITH DEDUCTIBLE AND AGAIN STATED THAT NONE OF THESE FUEL/STALLING PROBLEMS WERE RELATED. THE CAR STALLED AGAIN RECENTLY AND THE DEALER SAID TO BRING IT IN IF IT HAPPENS AGAIN. THIS IS STARTING TO BECOME A VERY DANGEROUS SITUATION THAT THE DEALER SEEMS TO BE VERY UNCONCERNED ABOUT. *NM

MY WIFE AND I HAVE BEEN VERY HAPPY WITH THE VEHICLE UNTIL A SITUATION LAST YEAR. SPECIFICALLY, THERE IS A KNOWN PROBLEM WITH THE GAS TANK AND GAUGE. THE GAS TANK WILL BE A 1/4 FULL BUT THE CAR WILL NOT START BECAUSE IT THINKS THE GAS TANK IS EMPTY. MY LOCAL GM DEALER SERVICE CENTER QUOTED ME OVER $800 TO FIX THIS PROBLEM. IT IS A KNOWN GM DEFECT. GM'S TECHNICAL SOLUTION IS DOCUMENT ID # 1575648. IT READS: VEHICLE WITH FLEXIBLE FULE (RPO L59) WILL NOT START, STALLS AND WILL NOT RESTART, LOSS OF POWER, POOR PERFORMANCE, AND /OR FUEL GUAGE READS INACCURATE/INCORRECT (REPLACE FUEL SENDER/MODULE ASSEMBLY) #04-06-04-012B - (DEC 6, 2004) * REPLACE FUEL SENDER /MODULE ASSEMBLY WITH REDESIGNED FUEL STRAINER AND /OR REDSIGNED FUEL LEVEL SENOR CAN YOU PLEASE HELP ? THANKS, BRENDAN AND LISA O'REILLY. *NM

2 SECONDS AFTER STARTING THE VEHICLE IT STALLED. THEN, CONSUMER RESTARTED THE VEHICLE, AND THE FAILURE RECURRED WITHIN 2 SECONDS. DEALERSHIP INDICATED THAT THEY HAD A LOT OF COMPLAINTS ON THIS ISSUE, AND IT COULD BE DUE TO FUEL INJECTION OR FUEL PUMP PROBLEMS. DEALERSHIP PERFORMED A DIAGNOSTIC TEST, BUT NOT FAILURE WAS FOUND. *AK

DURING COLD WEATHER SEASONS, AFTER STARTING THE VEHICLE, THE CONSUMER SMELLED GAS FUMES INSIDE THE VEHICLE. THE CAUSE HAS YET TO BE DETERMINE. THE DEALERSHIP WAS NOTIFIED BUT DID NOT RESOLVE THE PROBLEM. *NM