Certain delphi fuel pressure regulators, p/nos
Fuel may leak, possibly resulting in a fire.
Fix: Delphi will notify owners and replace the upr free of charge. The recall began on april 23, 2007. Owners can contact delphi at 877-411-8770.
2005 Chevrolet Impala fuel system problems
severe 21 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
21
Recalls
1
Avg fix
$1,200
1crash
2fires
What stands out
Of the 4 model years of Chevrolet Impala we track for fuel system problems, this one carries the most owner complaints on file — 21.
Related recalls
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and Vehicle Data Recorder tools, giving website address and step by step instructions to complete the update.
full bulletin at NHTSA ↗This service bulletin provides diagnostic tips/steps on testing for possible EVAP leaks in the system to correct a customer concern of an MIL Illuminated with DTCs P0442 and/or P0455 Set.
full bulletin at NHTSA ↗This Preliminary Information communication provides information to the technician about engine block of possible cylinder bore damage, scoring or out of round as the possible cause of engine oil consumption, misfire, cylinder leakage or blow by. Technician will need to inspect the engine for Cylinder damage or scoring, An out of round cylinder bore, Dirt intrusion, and Catalytic Converter failure.
full bulletin at NHTSA ↗This Preliminary information communicates the use of Winter grade fuel during the warm months of 2020 and the potential rivability issues that it can cause. The ongoing Coronavirus (COVID-19) pandemic has caused significant reductions in driving and fuel use. Due to the surplus of winter grade fuel sitting in storage (pipelines/stations) the EPA is waiving the fuel vapor requirement. This will extend the use of winter fuel into the summer months. The drivability concerns should not be single events but should be multiple occurrences associated with hot days.
full bulletin at NHTSA ↗This technical bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2005 Impala fuel systems report persistent gasoline odors both inside and outside the vehicle, often starting in the 60k–115k mile range. The smell typically intensifies during startup or when the A/C is activated and comes through the air vents. Multiple owners describe the odor as nauseating and unbearable, often coupled with excessive fuel consumption—one owner burned 1/8 tank in 14 miles of driving.
Fuel pressure regulator defects are the primary complaint. NHTSA Recall ID#64377 and Campaign ID 07E021000 target this issue, but some vehicles aren't included in the campaign despite exhibiting identical failures. One owner reported the regulator was missing an O-ring and retainer, causing overnight leakage. Dealers are aware of these problems but often charge $500 or more to diagnose and repair.
Engine stalling at normal operating temperature and overheating also appear in the complaint set. One owner reported the vehicle stalls when releasing throttle at stops and runs hot without corresponding gauge readings.
A critical safety issue surfaced: post-collision, a missing fuel return line cap on top of the engine allowed gasoline to spray continuously while the engine remained running (vehicle would not shift to Park or turn off), resulting in fire.
Fuel system design flaws complicate repairs—fuel lines don't match OEM parts catalogs, and fuel filters are non-serviceable except through dealers, forcing owners to purchase complete assemblies at premium cost.
Failure modes owners describe
Fuel pressure regulator failure with fuel odor and leakage
Fuel pressure regulator defects causing gasoline odor inside and outside the vehicle, fuel leakage, and excessive fuel consumption. Owners report strong gasoline smell through air vents, particularly during startup or when A/C is activated. Some report the regulator leaking gas overnight or under normal driving conditions.
When: Typically 62,000–114,742 miles; some onset within 2–24 months of ownership
Symptoms owners cite: Strong gasoline odor inside vehicle vents; Strong gasoline odor outside vehicle; Excessive fuel consumption (e.g., 1/8 tank in 14 miles); Gasoline odor occurring sporadically or intermittently; Gasoline odor during startup or A/C activation; Fuel leakage, especially overnight
Repairs/costs cited: NHTSA Recall ID#64377 (fuel system/fuel pressure regulator) and Campaign ID 07E021000 (fuel system, pressure relief devices) address this issue. Some vehicles not included in campaign despite identical failures. Repairs involve fuel pressure regulator replacement; dealers may charge $500+. One owner noted regulator was produced without O-ring and retainer.
Recalls/TSBs owners mention: NHTSA Recall ID#64377; NHTSA Campaign ID 07E021000. Some vehicle VINs not included in recall despite matching symptoms.
Fuel system fire hazard post-collision
After a moderate front-end collision, vehicle fire occurred with a missing fuel return line cap on top of the engine, allowing gasoline to spray directly into the engine bay while the engine continued running. The vehicle would not shift to Park and ignition would not turn off, keeping fuel flowing to the fire.
When: After collision impact
Symptoms owners cite: Vehicle fire under hood after collision; Vehicle remains in Drive and will not shift to Park; Ignition will not turn off; Missing fuel return line cap allowing gasoline spray
Repairs/costs cited: Fire report documented missing fuel return line cap on top of engine. Fuel continued spraying due to engine remaining running.
Engine stalling and overheating
Engine stalls when releasing throttle during approach to stop; overheating and loss of power reported. Vehicle begins running hot and loses power; thermostat becomes very hot.
When: Around 73,000–75,189 miles
Symptoms owners cite: Engine stalls when foot removed from accelerator at stops; Engine only stalls when at normal operating temperature; Vehicle begins running hot; Loss of power; Thermostat becomes very hot; Gasoline odor while driving at any speed
Fuel line parts mismatch and non-serviceable fuel filter
Fuel line components do not match manufacturer parts catalog, forcing owners to purchase complete fuel line assembly. Fuel filter is non-serviceable without dealer service, restricting repair options and increasing costs.
Symptoms owners cite: Fuel line parts do not match OEM catalog; Parts unavailable except as complete assembly; Fuel filter not independently serviceable
Repairs/costs cited: Two separate dealers confirmed parts do not match. OEM does not make individual replacement parts available; complete fuel line assembly purchase required. Dealers reported major repair bills.
Fuel odor with vehicle surge
Strong fuel odor outside vehicle accompanied by random forward surge while driving.
When: Around 114,742 miles
Symptoms owners cite: Strong fuel odor outside vehicle; Vehicle surges forward randomly
Synthesized from 21 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had fuel system trouble with your 2005 Chevrolet Impala?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2005 Chevrolet Impala?
It's a meaningful issue. 21 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,200.
At what mileage does the fuel system typically fail?
Across the 15 complaints that reported odometer mileage, most fuel system failures cluster between 45,733 and 114,742 miles, with the median around 78,000. A quarter of owners report trouble before 45,733; a quarter make it past 114,742. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
Yes — 1 active recall(s) cover fuel system issues on this vehicle. Recall fixes are always free regardless of mileage or warranty status. Use the VIN decoder at the top of the page to check if your specific vehicle is affected.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2005/Chevrolet/Impala.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.