Good luck Gary. 
Sounds like it isn't to hard to do, just time consuming.
Sounds like it isn't to hard to do, just time consuming.
Wifey's Burb Won't Start
- Thread starter dirtyoldman
- Start date
dirtyoldman
I'm now on Medicare,officially old.
Thanks Nick
Got it Now to install it 
Got it
Now to install it
Last edited:
dirtyoldman
I'm now on Medicare,officially old.
Got it all apart & had a major FAIL.....didn't have my media card in my camera so almost all the pics I took are in the internal memory of the camera...and I can't find the cord to connect it to my pc.I'll buy one soon...but I did get a couple of pics on the card...
Comparing old vs. new
[/IMG]
Removing an old injuctor,just a little squeeze of the tabs
[/IMG]
Done for the day & covered the intake
[/IMG]
Comparing old vs. new
Removing an old injuctor,just a little squeeze of the tabs
Done for the day & covered the intake
Darkanion
The space intentionally left blank.
Progress!
Let's hope that fixes it (once you're through with the repair, that is.. I know it's not fixed now
)! 
Let's hope that fixes it (once you're through with the repair, that is.. I know it's not fixed now
)! 
- Joined
- May 17, 2009
- Posts
- 57,295
- Reaction score
- 36
Very cool! That upper isn't terribly hard to get off... just a lot of connections.
Cool thread so far Gary. Great info.
NWSCREW
Chrome won't get you home!
Here are a few things I'm finding from a shop manual...
#02-06-03-012: Proper Diagnostic Procedures for No
Start, No Crank, Battery, Batteries, Generator,
Gauges, SES, SIR, Brake, Security, Theft, ABS, Hot,
DIC Messages, Lamp, Light, Battery and Generator
Diag. Testing - (Oct 25, 2002)
This bulletin is in response to general inquires:
This bulletin emphasizes two points:
Several bulletins and TechLink articles have been published in recent months regarding:
Subject: Proper Diagnostic Procedures for No Start, No Crank,
Battery, Batteries, Generator, Gauges, SES, SIR, Brake,
Security, Theft, ABS, Hot, DIC Messages, Lamp, Light,
Battery and Generator Diagnostic Testing
Models: 1997--2003 Passenger Cars and Light Duty Trucks (Except
Electric Vehicles)
2003 HUMMER H2
• About batteries and generators
• Requirements for the Battery/Generator Diagnostic Work Sheet
• From National Dealer Council meetings and the Fixed Operations Advisory Board
• Completion of the Electrical System Diagnostic Work Sheet is intended to ensure that only
faulty batteries and generators are replaced and to protect dealers from potential charge
backs for generator or battery replacements where returned parts inspections reveal No
Trouble Found (NTF).
• To emphasize that we will pay for completion of the Electrical System Diagnostic Work
Sheet in the following ways:
-
N0110, Battery R&R, will have the following added to the labor code: ADD -- To
complete Electrical System Diagnostic Worksheet - 0.7 hr.
-
J4100, Generator R&R, will have the following added to the labor code: ADD -- To
complete Electrical System Diagnostic Worksheet - 0.7 hr.
-
N9995, Customer concern not duplicated. This is a straight time labor operation code
and should be used when the Electrical System Diagnostic Work Sheet is completed and
no trouble is found with the electrical system of the vehicle. This labor code has the
following note: "Actual time from 0.1 to 0.3 hours spent to perform the diagnosis is to
be entered as "Labor Hours" for this operation. Any additional diagnosis time greater
than 0.3 hours must be submitted as "Other Labor Hours", and have appropriate Service
Management approval and authorization".
• Charging of Batteries
• TechLink August 2002, Battery Charging Tips, Volume 4, No. 8
• Corporate Bulletin Number 02-06-03-009, Battery Charging Tips, August 2002
• Dealing with Battery Parasitic Drains
• TechLink April 2002, Volume 4, No. 4
• Corporate Bulletin Number 02-06-03-010, Informational -- Battery Parasitic Drain,
October 2002
• Generator Operation and Troubleshooting
• Corporate Bulletin Number 02-06-03-006, No Start, No Crank, Battery, Batteries,
Generator, Gauges, SES, SIR, Brake, Security, Theft, ABS, Hot, DIC Messages, Lamp,
Light, Battery and Generator Diagnostic Testing, and Cadillac Roadside Service,
Warranty Claims Procedure, July 2002
• TechLink May 2002, Generator Operation and Troubleshooting, Volume 4, No. 5
• A separate Electrical System Diagnostic Work Sheet bulletin is in process. The Corporate
Bulletin Number is 02-06-03-011.
• A Technology Close-Up training broadcast which will show and discuss the Electrical
System Diagnostic Work Sheet will take place on December 19, 2002.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that
may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the
equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin
applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.
#02-06-03-012: Proper Diagnostic Procedures for No
Start, No Crank, Battery, Batteries, Generator,
Gauges, SES, SIR, Brake, Security, Theft, ABS, Hot,
DIC Messages, Lamp, Light, Battery and Generator
Diag. Testing - (Oct 25, 2002)
This bulletin is in response to general inquires:
This bulletin emphasizes two points:
Several bulletins and TechLink articles have been published in recent months regarding:
Subject: Proper Diagnostic Procedures for No Start, No Crank,
Battery, Batteries, Generator, Gauges, SES, SIR, Brake,
Security, Theft, ABS, Hot, DIC Messages, Lamp, Light,
Battery and Generator Diagnostic Testing
Models: 1997--2003 Passenger Cars and Light Duty Trucks (Except
Electric Vehicles)
2003 HUMMER H2
• About batteries and generators
• Requirements for the Battery/Generator Diagnostic Work Sheet
• From National Dealer Council meetings and the Fixed Operations Advisory Board
• Completion of the Electrical System Diagnostic Work Sheet is intended to ensure that only
faulty batteries and generators are replaced and to protect dealers from potential charge
backs for generator or battery replacements where returned parts inspections reveal No
Trouble Found (NTF).
• To emphasize that we will pay for completion of the Electrical System Diagnostic Work
Sheet in the following ways:
-
N0110, Battery R&R, will have the following added to the labor code: ADD -- To
complete Electrical System Diagnostic Worksheet - 0.7 hr.
-
J4100, Generator R&R, will have the following added to the labor code: ADD -- To
complete Electrical System Diagnostic Worksheet - 0.7 hr.
-
N9995, Customer concern not duplicated. This is a straight time labor operation code
and should be used when the Electrical System Diagnostic Work Sheet is completed and
no trouble is found with the electrical system of the vehicle. This labor code has the
following note: "Actual time from 0.1 to 0.3 hours spent to perform the diagnosis is to
be entered as "Labor Hours" for this operation. Any additional diagnosis time greater
than 0.3 hours must be submitted as "Other Labor Hours", and have appropriate Service
Management approval and authorization".
• Charging of Batteries
• TechLink August 2002, Battery Charging Tips, Volume 4, No. 8
• Corporate Bulletin Number 02-06-03-009, Battery Charging Tips, August 2002
• Dealing with Battery Parasitic Drains
• TechLink April 2002, Volume 4, No. 4
• Corporate Bulletin Number 02-06-03-010, Informational -- Battery Parasitic Drain,
October 2002
• Generator Operation and Troubleshooting
• Corporate Bulletin Number 02-06-03-006, No Start, No Crank, Battery, Batteries,
Generator, Gauges, SES, SIR, Brake, Security, Theft, ABS, Hot, DIC Messages, Lamp,
Light, Battery and Generator Diagnostic Testing, and Cadillac Roadside Service,
Warranty Claims Procedure, July 2002
• TechLink May 2002, Generator Operation and Troubleshooting, Volume 4, No. 5
• A separate Electrical System Diagnostic Work Sheet bulletin is in process. The Corporate
Bulletin Number is 02-06-03-011.
• A Technology Close-Up training broadcast which will show and discuss the Electrical
System Diagnostic Work Sheet will take place on December 19, 2002.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that
may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the
equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin
applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.
Last edited:
NWSCREW
Chrome won't get you home!
And, here is another one from the manual:
#04-08-49-018E: Cranks But No Start, Stall,
Inaccurate/Incorrect Fuel Gauge Reading, No Fuel,
Vehicle is Out of Fuel and Fuel Gauge Reads Above
Empty (Replace Fuel Level Sensor) - (Jan 5, 2005)
This bulletin is being revised to include information on the Chevrolet Colorado and the
GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018 D (Section 08 -
Body and Accessories).
Condition
Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of
fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge
may read 1/4 tank.
Cause
Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings.
Correction
Follow the service procedure below for diagnosis and repair of this concern.
1. Confirm that the vehicle is actually out of fuel.
Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel
Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel
Gauge Reads Above Empty (Replace Fuel Level Sensor)
Models: 2001-2004 Cadillac Trucks
1999-2004 Chevrolet and GMC Trucks
2004-2005 HUMMER H2
with Gasoline Engine (VINs Z, X, V, T, U, N, G,6, 8 -- RPOs LU3, LR4,
LM7, LQ4, LQ9, L59, L18,LK5 , L52 )
Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z --
RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-
04-012B or newer for Variable Fuel (VIN Z -- RPO L59) vehicles.
• If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the
appropriate Service Information.
• If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge.
Refer to the following information:
- Fuel Gage Inaccurate or Inoperative Single Tank (SI Document ID #850196)
- Fuel Gage Inaccurate or Inoperative Dual Tanks (SI Document ID #850195)
- Fuel Gage Inaccurate or Inoperative HUMMER H2 (SI Document ID #826250)
- Fuel Gage Inaccurate or Inoperative Colorado and Canyon (SI Document ID
2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor
assembly and auxiliary tank fuel level sensor if equipped.
3. Replace the fuel level sensor. Refer to the following appropriate service information:
Parts Information
Parts are in limited quantities. Please DO NOT order parts for stock.
#1292631)
• Fuel Level Sensor Replacement 4.8L and 5.3L Engines (SI Document ID #1332662)
• Fuel Level Sensor Replacement 6.0L Engine - Front Tank (SI Document ID #1333086)
• Fuel Level Sensor Replacement 6.0L Engine - Rear Tank (SI Document ID #1333087)
• Fuel Level Sensor Replacement 8.1L vehicles with Front Tank (SI Document ID
#1333104)
• Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank (SI Document ID
#1333105)
• HUMMER H2 vehicles refer to Fuel Level Sensor Replacement (SI Document ID
#861702)
• Fuel Level Sensor Replacement 2.8L Engine (SI Document ID #1220030)
• Fuel Level Sensor Replacement 3.5 L Engine (SI Document ID #1219948)
Part
Number Description
89060635
Sensor Assembly, Aux Tank, Rear
2001-2003
360364 0353, Cab/Chassis, Reg. and Ext Cab
with LQ4 or L18 and minus NQZ (with aux fuel tank)
89060636
Sensor Assembly, Main Tank, Side
2001-2003
360364 0353, Cab/Chassis, Reg. and Ext Cab
with LQ4 or L18 and without K53 (robust fuel system)
89060637
Sensor Assembly, Main Tank, Side
2000-2003
159259 0636, C/K, Long Wheel Base Utility
with LM7 or LQ4 or LQ9 or L18 and without K53 (robust fuel system)
89060638
Sensor Assembly, Main Tank, Side
2000-2003
157 06, C/K, Short Wheel Base Utility
with LM7 or LQ4 or LQ9 or L18 and without K53 (robust fuel system)
Sensor Assembly, Main Tank, Side
Parts are currently available from GMSPO.
Warranty Information
For vehicles repaired under warranty, use:
89060640
1999-2003
100200300 034353, C/K, 2 Dr, 4 Dr and Ext Cab Pickup
with LU3 or LR4 or LM7 or LQ4 or LQ9 or L18 and -- K53 (without robust
fuel system)
2004
100 0353, C/K, 2 Dr and Ext Cab
with LU3 and without K53 (robust fuel system)
89060642
Sensor Assembly, Main Tank, Rear
2000-2003
259 0636, C/K, Long Wheel Base Utility
with LM7 or LQ4 or LQ9 or L18 and without K53 (robust fuel system)
88965384
Sensor Assembly
2004-2005
HUMMER H2
88965817
Sensor Assembly
2004-2005
Colorado / Canyon
Labor
Operation Description Labor Time
L1197
Sensor, Fuel Level (Tank Unit) -
Replace
Use published labor operation
time
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that
may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the
equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin
applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.
#04-08-49-018E: Cranks But No Start, Stall,
Inaccurate/Incorrect Fuel Gauge Reading, No Fuel,
Vehicle is Out of Fuel and Fuel Gauge Reads Above
Empty (Replace Fuel Level Sensor) - (Jan 5, 2005)
This bulletin is being revised to include information on the Chevrolet Colorado and the
GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018 D (Section 08 -
Body and Accessories).
Condition
Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of
fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge
may read 1/4 tank.
Cause
Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings.
Correction
Follow the service procedure below for diagnosis and repair of this concern.
1. Confirm that the vehicle is actually out of fuel.
Subject: Cranks But No Start, Stall, Inaccurate/Incorrect Fuel
Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel
Gauge Reads Above Empty (Replace Fuel Level Sensor)
Models: 2001-2004 Cadillac Trucks
1999-2004 Chevrolet and GMC Trucks
2004-2005 HUMMER H2
with Gasoline Engine (VINs Z, X, V, T, U, N, G,6, 8 -- RPOs LU3, LR4,
LM7, LQ4, LQ9, L59, L18,LK5 , L52 )
Attention: Parts are currently available for vehicles with Variable Fuel (VIN Z --
RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-
04-012B or newer for Variable Fuel (VIN Z -- RPO L59) vehicles.
• If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the
appropriate Service Information.
• If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge.
Refer to the following information:
- Fuel Gage Inaccurate or Inoperative Single Tank (SI Document ID #850196)
- Fuel Gage Inaccurate or Inoperative Dual Tanks (SI Document ID #850195)
- Fuel Gage Inaccurate or Inoperative HUMMER H2 (SI Document ID #826250)
- Fuel Gage Inaccurate or Inoperative Colorado and Canyon (SI Document ID
2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor
assembly and auxiliary tank fuel level sensor if equipped.
3. Replace the fuel level sensor. Refer to the following appropriate service information:
Parts Information
Parts are in limited quantities. Please DO NOT order parts for stock.
#1292631)
• Fuel Level Sensor Replacement 4.8L and 5.3L Engines (SI Document ID #1332662)
• Fuel Level Sensor Replacement 6.0L Engine - Front Tank (SI Document ID #1333086)
• Fuel Level Sensor Replacement 6.0L Engine - Rear Tank (SI Document ID #1333087)
• Fuel Level Sensor Replacement 8.1L vehicles with Front Tank (SI Document ID
#1333104)
• Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank (SI Document ID
#1333105)
• HUMMER H2 vehicles refer to Fuel Level Sensor Replacement (SI Document ID
#861702)
• Fuel Level Sensor Replacement 2.8L Engine (SI Document ID #1220030)
• Fuel Level Sensor Replacement 3.5 L Engine (SI Document ID #1219948)
Part
Number Description
89060635
Sensor Assembly, Aux Tank, Rear
2001-2003
360364 0353, Cab/Chassis, Reg. and Ext Cab
with LQ4 or L18 and minus NQZ (with aux fuel tank)
89060636
Sensor Assembly, Main Tank, Side
2001-2003
360364 0353, Cab/Chassis, Reg. and Ext Cab
with LQ4 or L18 and without K53 (robust fuel system)
89060637
Sensor Assembly, Main Tank, Side
2000-2003
159259 0636, C/K, Long Wheel Base Utility
with LM7 or LQ4 or LQ9 or L18 and without K53 (robust fuel system)
89060638
Sensor Assembly, Main Tank, Side
2000-2003
157 06, C/K, Short Wheel Base Utility
with LM7 or LQ4 or LQ9 or L18 and without K53 (robust fuel system)
Sensor Assembly, Main Tank, Side
Parts are currently available from GMSPO.
Warranty Information
For vehicles repaired under warranty, use:
89060640
1999-2003
100200300 034353, C/K, 2 Dr, 4 Dr and Ext Cab Pickup
with LU3 or LR4 or LM7 or LQ4 or LQ9 or L18 and -- K53 (without robust
fuel system)
2004
100 0353, C/K, 2 Dr and Ext Cab
with LU3 and without K53 (robust fuel system)
89060642
Sensor Assembly, Main Tank, Rear
2000-2003
259 0636, C/K, Long Wheel Base Utility
with LM7 or LQ4 or LQ9 or L18 and without K53 (robust fuel system)
88965384
Sensor Assembly
2004-2005
HUMMER H2
88965817
Sensor Assembly
2004-2005
Colorado / Canyon
Labor
Operation Description Labor Time
L1197
Sensor, Fuel Level (Tank Unit) -
Replace
Use published labor operation
time
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that
may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the
equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin
applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.
