Fuel System complaints by model year
Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
What owners report
The original fuel tank in this vehicle way rusty and leaking. I replaced the original tank with a Dorman model 576-372 fuel tank. The tank was installed in September 2021. The tank began leaking in February 2022. A repair shop discovered that the tank was defective and had failed. The Tank was discarded and replaced with a new unit. As no OEM parts are available the replacement was also and aftermarket part. That tank also was defective and began leaking within 90 days. A third aftermarket tank was installed and it also began leaking recently. When these leaks occur the tank fails in such a way that a large volume of fuel is spilled collects under the vehicle. As there seems to be only one company manufacturing these parts there seems be be a large potential that the issue will affect many vehicles.
The original fuel tank in this vehicle way rusty and leaking. I replaced the original tank with a Dorman model 576-372 fuel tank. This tank included a new fuel pump lock ring, which was used to secure a new fuel pump in the tank prior to installation in the vehicle. The lock rung failed approximately one week after installation allowing the fuel pump to raise up out of the tank. At the next fuel up a large volume of gasoline escaped form the fuel pump opening and spilled. The defective lock ring was replaced with a OEM part and was subsequently discarded.
Nar 04/28/2003. Mr the consumer experienced problems with his vehicle. The vehicle leaked oil, engine idled roughly, coolant system leaked, there was a problem with the dome light, steering, the rear axle, the left rear glass rattled, the air condition, battery, suspension were all inoperative. The fuel filter, mirror transmission seat, seat belts, wipers, alternator, brakes, fuel pump.
Wiring to the electric fuel pump can over heat (and possibly cause a fire) when the fuel pump fails. This would occur when the fuel pump is in a failed (locked) condition while power is applied to the pump. The electrical current draw is higher than the rating of the wiring.
Tl contact owns a 1997 GMC Suburban. While driving approximately 20 MPH, the vehicle shut off without warning and would not restart. The vehicle was towed to a mechanic and they discovered that the fuel pump sending unit wires were rotted out, which burned out the fuel pump. The fuel pump and sending unit had to be replaced. The VIN was unknown. The current and failure mileages were 151,000.
Parked truck near dealership after having trouble starting it, tried to restart, it didn't. Dealer took it in and called to say that fuel pump is shot and they had one in stock to replace it. Then four hours later they said the wires to it were melted and the sending unit needs to be replaced. This is the 5th time to replace fuel pump for this truck in 264,000 miles. First was at 50,000 miles.
It is a well known fact that there is a defect with the fuel injection pump on the GM 6.5l diesel engines. I have had a number of these pumps replaced by GM at their cost. However, the problem is not getting resolved. These vehicles die intermittently. When they die (stall), you loose your ability to control your vehicle with the loss of steering and braking (for the most part). There have been numerous times when I have almost been involved in an accident because of this issue. It is extremely dangerous when these vehicles die because of the pump problem. I am in hopes that this complaint could possibly turn into some sort of investigation within GM to have them fix the problem. They seem to keep replacing my bad fuel injection pumps with more soon-to-be bad fuel injection pumps....
Dt*: the contact stated while driving various speeds on the highway, the engine stalled without warning. After stalling, the vehicle was not easily restarted. The vehicle was inspected by a dealer who determined the fuel injector pump needed to be replaced. After the initial replacement, the problem persisted. The vehicle was inspected by a dealer who determined the fuel pump needed to be replaced again. The manufacturer was alerted. Updated 12/18/2006 - the injector pump which was replaced under recall failed again. The consumer also wanted to recall fixed, however the dealer refused to honor the recall. Recall numbers 96V057000 and 03V159000. Updated 03/21/07.
Frequently asked questions
Which GMC Suburban years have fuel system problems?
By NHTSA complaints, the 1997 (23), 1999 (19), 1996 (14) and 1998 (5) model years. Fuel System complaints make up 12% of all complaints for the 1997.
Is there a recall for GMC Suburban fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for any GMC Suburban model year. A widespread problem may still be covered by an extended warranty or a manufacturer service bulletin, so ask a dealer.
At what mileage do GMC Suburban fuel system problems start?
Across all years, half of the complaints with a recorded mileage happened before about 87,000 miles; 17% happened before 50,000 miles.
What part fails most often?
Owners most often name the delivery › fuel pump (29 mentions), followed by the fuel injection system (10).
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.