1996 Chevrolet K1500 Fuel system Problems

“Failing diesel injection pump on 1996 Chevrolet K1500 pickup with 6.5l diesel engine causes engine to stall when approaching a stop, rendering power steering and power brakes inoperable. This is a common problem on 1994 through 1999 GM vehicles equipped with this engine. Dealer diagnosed the problem, but refused to repair under warranty, despite an 11-year, 120,000 mile extended warranty issued by Chevrolet motor division due to numerous problems with this pump.”

“The consumers vehicle would not start. The vehicle was taken to a mechanic who stated the the vehicle fuel sending unit shorted out in the gas tank. The consumer felt if there was any air in tank there would have been an explosion.”

“This letter is to provide information regarding a hazardous and potentially catastrophic materiel defect on the 1996 Chevrolet pickup (model: K1500 1/2 ton 4.3 l f/I v6). The vehicle had 112231 original mi. And was operated consistent with its intended use. The vehicle is production representative with no modifications or history of damage. On 20 apr 04 while driving approximately 25 mi/hr the engine quit running with no impending indications of a failure. Subsequent inspection and repair was conducted by a certified mechanic at ron's firestone, geneva, al. …”

“The contact owns a 1996 Chevrolet K1500. The fuel pump assembly failed. The wires were too small a gauge for the load. The plastic insulation caused the wires to over heat and it burned down to the fuel tank. The contact showed the parts to the dealer and they stated that they have never seen this type of failure. He attempted to reach the manufacturer and was unable to speak with anyone. The contact is aware of the safety risk involved. The vehicle has not been repaired. The failure mileage was 106,000.”

“Oem battery leaks acid from crack around positive terminal post. Acid drips on inner fender paint, A/C electrical connector, battery cables, rubber hoses, airbag sensor mounted in wheel well and on driveway.”