Vehicle with Flexible Fuel E85 (RPO L59) Will Not Start, Loss of Power, Poor Performance and/or Fuel Gauge Reads Inaccurate/Incorrect (Replace Fuel Pump Strainers AND/OR Redesigned Fuel Level Sensor)

This bulletin is being revised to announce the availability of a fuel strainer kit. The release of this kit allows the technician to replace the fuel strainers without replacing the entire fuel module. Please discard Corporate Bulletin Number 04-06-04-012B (Section 06 -- Engine/Propulsion System).

Some customers may comment that the vehicle may not start, experience lack of power and/or driveability concerns.

Some customers may comment that the vehicle appears to be out of fuel but the fuel gauge reads above empty.

There are two possible causes for this condition:

Important: 

Follow the service procedure below for diagnosis and correction of these conditions.

Important: The fuel level sensor may be sending the fuel gauge false readings.

1. Confirm that there is actually fuel in the fuel tank. DO NOT use the fuel gauge to confirm fuel tank level.

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If the vehicle has fuel in the fuel tank and the vehicle is experiencing driveability concerns or a no start, refer to Engine Cranks but Does Not Run (SI Document ID #834631). If the above diagnosis procedure leads you to a low fuel pressure condition with a Flexible Fuel (L59) Engine, the most likely cause is a restricted fuel strainer. Continue with step 2.

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If the vehicle does not have fuel in the fuel tank and the fuel gauge reads above empty, refer to Fuel Gage Inaccurate or Inoperative (Single Tank) (SI Document ID #850196). If the diagnosis procedure leads you to a faulty fuel level sensor, the most likely cause is a contaminated fuel level sensor. Continue step 2.

2. Check the vehicle's repair history.

•	If the vehicle has NO history of the fuel sender / module assembly replacement, replace the Fuel Level Sensor Kit AND the Fuel Strainer Kit.

•	If the vehicle is experiencing a fuel level sensor issue ONLY and has had the fuel sender / module assembly replaced with P/N's 10355739 or 10355740 that included a redesigned fuel strainer, replace the fuel level SENSOR only.

3. Replace the fuel level sensor kit and / or the fuel strainer kit (see the Parts Information below) using the above vehicle history information. Refer to the applicable SI procedure below:

•	Fuel Level Sensor Replacement (5.3L (L59) Engine) (SI Document ID# 1314273)

•	Fuel Strainer Replacement (E85) (SI Document ID# 1701019)

Notice: Flush the fuel tank. Failure to flush the fuel tank may result in the fuel strainers becoming restricted again.

4. Flush the fuel tank once the fuel sender / module assembly has been removed. Refer to Fuel System Cleaning (SI Document ID #802838).

Important: Use ONLY the appropriate Labor Operation Code. If replacing both the sensor and strainers, use Labor Operation Code L1198.

For vehicles repaired under warranty, use: