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Thread: Duramax fuel sender/pump issues

  1. #1
    Registered Member chevynut's Avatar
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    Duramax fuel sender/pump issues

    I have a 2003 2500HD with the Duramax diesel. I've had the instrument cluster repaired twice now and I'm pretty sure my gauges are good. My fuel gauge works fine until I get down to under 1/4 tank. Below that, when I put on the brakes the gauge drops to empty, the light comes on, and it stays that was until I stop or accelerate again. Then it jumps back up, sometimes to 1/2 tank or so. It becomes more erratic as the fuel level drops.

    I think the problem is the sending unit. I have been living with it and just fill up when it starts to happen but it makes me nervous because I don't know how much fuel I have. Is there anything else that it could be?

    I have been investigating this and I thought the sender and pump were the same unit, but apparently that is not the case on the diesels. I have found a replacement EXTERNAL fuel pump and a separate sender unit for sale. Is there actually a pump in the tank?

    Here's the pump I found, which it says is OEM P/N 23484681 or EP1020:



    This is the sending unit, Delphi P/N FG0166


    Summit Racing says it doesn't include the pump, so what are the lines and fittings for?

    http://www.summitracing.com/parts/df...make/chevrolet

    Is there yet another pump in this module? I know there is an injection pump on the engine but I don't see why there would have to be two pumps before it.

    I know it's a royal PITA to change these things, and you can either remove the bed or drop the tank. I would like to fix it but it's not something I'm looking forward to doing.
    56 Nomad, Ramjet 502, Viper 6-speed T56, C4 Corvette front and rear suspension


    Other vehicles:

    56 Chevy 2-door BelAir sedan
    56 Chevy 210 4-door sedan
    57 Chevy 210 4-door sedan
    1962 327/340HP Corvette
    1961 Willys CJ3B Jeep
    2001 Porsche Boxster S
    2003 Chevy Silverado 2500 HD Duramax
    2019 GMC Sierra Denali Duramax

  2. #2
    Registered Member chevynut's Avatar
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    Member #:115
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    This one says it's a "pump module" so it must be included. So what is the EP1020 for? It says it's a frame-mounted OEM pump.

    http://www.ebay.com/itm/Fuel-Pump-Mo...c5fa5b&vxp=mtr
    Last edited by chevynut; 06-12-2015 at 10:45 AM.
    56 Nomad, Ramjet 502, Viper 6-speed T56, C4 Corvette front and rear suspension


    Other vehicles:

    56 Chevy 2-door BelAir sedan
    56 Chevy 210 4-door sedan
    57 Chevy 210 4-door sedan
    1962 327/340HP Corvette
    1961 Willys CJ3B Jeep
    2001 Porsche Boxster S
    2003 Chevy Silverado 2500 HD Duramax
    2019 GMC Sierra Denali Duramax

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