NHTSA Complaint #10170692 — 1996 CHEVROLET IMPALA

FUEL PUMP FUSE BLOW OUT. THE CAR CUTS OFF AND STOPS WHILE DRIVING, BLOWING OUT THE FUSE. WHEN A NEW FUSE IS INSTALLED AND THE ENGINE IS STARTED, IT BLOWS OUT AGAIN. THE PROBLEM IS CAUSED BY A FAULTY WIRING HARNESS TO THE FUEL PUMP ASSEMBLY. THE WIRING ON THE FUEL PUMP SENDER UNIT MELTS AND PEELS BACK THE INSULATION, CAUSING THE BARE WIRES TO TOUCH AND SHORT AGAINST THEMSELVES OR GROUND OUT AGAINST THE CAR. THIS OCCURS RIGHT AT THE TOP OF THE FUEL PUMP TANK ON THE SENDER ASSEMBLY OR JUST INSIDE THE TANK. THE FUEL PUMP WIRING HARNESSES ON THESE VEHICLES ARE PROBLEMATIC AND DEFECTIVE, POTENTIALLY CAUSING A FIRE IN THE FUEL TANK AND EVENTUALLY A CATASTROPHIC EXPLOSION. A NEW FUEL PUMP SENDER (OEM PART NO. 25028955) WAS REPLACED IN ADDITION TO A NEW ELECTRIC FUEL PUMP, AND NEW FUEL FILTER. *JB