Owners of the 2005 Chevy Silverado report a range of fuel-system failures across multiple components. The most frequent complaint involves fuel injector harness wiring, particularly on cylinders #2 and #7, where the harness shorts or chaffs against factory-installed brackets, causing check-engine lights, rough running, engine misfires, and loss of power that can derate the truck to 25 mph on highways. Several owners report this happened multiple times and costs $370–$504 per repair without warranty coverage.
Fuel gauge failures also appear repeatedly—gauges read empty when tanks are full, fail to transfer fuel between front and rear tanks, or fluctuate wildly, leaving drivers stranded. Multiple owners report running out of fuel despite gauges showing fuel remaining, and dealers have been unable to resolve the issue even after multiple service visits and TSB attempts.
Fuel line and brake line corrosion failures are widespread, with owners reporting premature rust-through of both fuel and brake lines at mileage as low as 58,000 miles. One truck burst into flames while parked. The fuel pump and fuel pump relay also fail prematurely in some cases. The evaporative canister vent solenoid generates repeated check-engine codes across multiple vehicles—owners note Chevy released a retrofit part, suggesting the manufacturer knew of the defect. One owner reports the fuel filler neck allows the pump to shut off mid-fill.
Failure modes owners describe
Fuel Injector Harness Short/Chafe (#2 and #7 cylinders)
Fuel injector wiring harness chaffs against factory-installed brackets or develops internal shorts, primarily on cylinders #2 and #7. This triggers check-engine codes, engine misfires, rough running, and severe loss of power (often derated to 25 mph). Multiple occurrences reported on the same vehicle within months.
When: As early as 7 years of ownership; multiple occurrences within 2–3 months and 2,500 miles on same vehicle
Symptoms owners cite: Check engine light illumination; Engine misfiring and rough running; Severe loss of engine power; Engine vibration; Low-power derate mode (25 mph); Popping and backfiring
Codes mentioned: P2146 (FICM insulate), P1238 (Open circuit injector 6), Various fuel injector module fault codes
Repairs/costs cited: Fuel injector harness replacement; new harness features 90-degree plug and longer wires. Cost $370–$504 per repair; not covered under engine warranty per dealers.
Recalls/TSBs owners mention: GM issued TSB 05-06-04-047C for fuel injector wiring harness; dealers initially did not honor warranty claims; some owners had to inform dealers of the TSB existence.
Fuel Gauge Failure / Inaccurate Fuel Level Indication
Fuel gauge reads incorrectly, often showing empty when fuel tanks are full, or fluctuates wildly and unpredictably. In dual-tank designs, the truck fails to transfer fuel from rear tank to front, leaving owners stranded. Gauge problems persist across multiple dealer service visits and component replacements.
When: As early as 25,000 miles; issues reported throughout ownership
Symptoms owners cite: Gauge reads empty with full tanks; Gauge fluctuates constantly; Failure to transfer fuel between front and rear tanks; Vehicle stalls due to perceived empty condition while fuel remains; Fuel light illuminates despite adequate fuel; Gauge reads over the F mark when tank is full
Codes mentioned: Fuel gauge circuit faults, Fuel tank sending unit faults
Repairs/costs cited: Dealers replaced fuel system components on multiple occasions (4–6 service visits reported) without resolving the issue. One owner pulled PCMB fuse for 30 seconds as a temporary fix. Fuel pump relay replacements attempted. New transfer pump installed in one case without permanent resolution.
Recalls/TSBs owners mention: Manufacturer stated they were investigating the problem; issued service bulletins; one dealer service manager confirmed 'lots of problems with this fuel system'; issue remained unresolved in multiple cases after repair attempts.
Fuel Line Corrosion and Premature Failure
Fuel lines corrode and rust through prematurely, causing fuel leaks. Corrosion occurs on underbody fuel lines and fuel hoses, with the potential for fuel to spill onto hot exhaust components, creating a fire hazard. Failures reported at mileage as low as 58,000.
When: 58,000 miles; also reported on vehicles in 10+ year age range despite regular use
Symptoms owners cite: Fuel leakage from corroded lines; Fuel odor; Fuel spilling onto exhaust system; Risk of fire
Repairs/costs cited: Fuel lines and fuel hoses replaced; one owner paid $2,185 for fuel line and brake line replacement. Owners report similar or worse condition in transmission lines requiring replacement.
Recalls/TSBs owners mention: No manufacturer response reported; one truck burst into flames while parked—owner states no recall notice was ever received.
Brake Line Corrosion and Failure
Brake lines corrode severely, developing leaks and ruptures that cause sudden loss of braking ability. Failures reported at 58,000 miles and correlate with fuel-line corrosion. All brake lines typically affected simultaneously.
When: 58,000 miles; early in vehicle lifecycle
Symptoms owners cite: Brake pedal goes to the floor; Loss of brake pressure; Brake fluid leaks; Brake warning light illumination; Brakes unresponsive during panic stops
Repairs/costs cited: Complete brake line replacement required; costs $2,185 when bundled with fuel-line replacement. Mechanics noted corrosion severity uncommon in vehicles of other makes under identical conditions.
Recalls/TSBs owners mention: No manufacturer recall or TSB issued; manufacturer not notified in at least one early case.
Diesel Fuel Injection Pump Failure
Diesel fuel injection pump fails unexpectedly and without warning at 110,000 miles on Duramax engines. Failure creates sudden loss of power and engine control, posing hazard when towing or on confined roadways. Owner disputes manufacturer claim that methanol water-injection system caused the failure.
When: 110,000 miles
Symptoms owners cite: Sudden loss of power; Loss of engine control; No warning before failure
Repairs/costs cited: Pump replacement required; owner indicates this should not occur on a Duramax/Allison drivetrain rated for 500,000 miles.
Recalls/TSBs owners mention: Manufacturer blamed methanol water-injection system; owner contests this explanation based on system design (methanol injected on air side, does not mix with fuel until cylinder).
Fuel Filler Nozzle / Fuel Door Issue
Fuel pump shuts off during refueling, making it difficult or impossible to fill the tank. Issue occurs with multiple attempts to hold the nozzle at different positions.
When: Not specified
Symptoms owners cite: Fuel pump nozzle shuts off during fill; Unable to maintain fuel pump engagement; Difficult to fill tank
Repairs/costs cited: No repair documented
Evaporative Canister Vent Solenoid Failure
Canister evaporation vent solenoid fails prematurely, triggering repeated check-engine lights. Owner notes Chevy released a retrofit part, suggesting manufacturer awareness of the defect. Mechanics report this is a common problem and should not normally fail.
When: Not specified; one case at 38,000 miles
Symptoms owners cite: Check engine light illumination (repeated); Check engine light returns after reset; Fuel system unable to vent
Codes mentioned: Evaporative system fault codes
Repairs/costs cited: Solenoid replacement cost $171–$290. Owner notes a retrofit part was available, confirming Chevy's awareness of the defect.
Recalls/TSBs owners mention: Chevy released a retrofit evaporative solenoid part after complaints; no recall issued.
Fuel Pump and Fuel Pump Relay Failure
Fuel pump fails prematurely and fuel pump relay fails repeatedly. One owner replaced the relay four times in six months after pump replacement.
When: Not specified; relay replacement four times in six months
Symptoms owners cite: Engine will not start or turn over; Engine spitting and sputtering; Fuel pump relay cycling intermittently; Engine hard to crank
Repairs/costs cited: Fuel pump replacement; fuel pump relay replacement (repeated). One owner replaced relay four times in six months after initial pump replacement.
Fuel Line Collapse
Fuel lines collapse internally, causing inadequate fuel delivery. Dealer attempted repair by replacing portion of fuel line with hydraulic hose, but failure recurred. Failure occurs sporadically, causing intermittent stalling and speed loss at various driving speeds.
When: 58,000 miles
Symptoms owners cite: Abnormal decrease in speed; Sporadiac engine stalling; Loss of power despite accelerator input
Repairs/costs cited: Dealer replaced portion of fuel line with hydraulic hose; failure recurred. No permanent repair documented.
Fuel Tank Strap Fracture / Fuel Tank Detachment
Fuel tank strap fractures due to rust, causing fuel tank to detach from vehicle while driving. Corrosion is widespread, with rear leaf spring also fractured due to rust and subframe pieces falling off while driving.
When: 58,000 miles
Symptoms owners cite: Fuel tank detachment while driving; Fuel leakage; Pieces of corroded metal falling from frame
Repairs/costs cited: Fuel tank strap replacement, fuel tank replacement, brake lines, fuel lines, and rear leaf shackle replacement.
Recalls/TSBs owners mention: Manufacturer not notified in this case.
Rust in Fuel Rail and Injectors
Rust appears inside the fuel rail and injectors despite no water contamination in fuel tank or lines. Dealer installed stainless steel replacement fuel rail. Dealer and manufacturer refused to discuss root cause and denied warranty coverage.
When: Not specified
Symptoms owners cite: Rust debris in fuel system
Repairs/costs cited: Fuel rail replacement cost $1,145.50 out of warranty; replacement part was stainless steel (suggesting design defect in original part).
Recalls/TSBs owners mention: Warranty denied; dealer and GM refused to discuss how rust entered the system or why replacement part is stainless steel; no root cause analysis provided.
Synthesized from 42 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.