2015 Chevrolet Silverado 2500 Fuel system Problems

My pickup truck has a Duramax diesel engine with a CP4 diesel injection pump. That pump has not failed yet in my truck. However it has been known to fail in numerous other GM vehicles with Duramax engines and when it does fail the engine comes to a complete stop and cannot be restarted. This is a potentially hazardous even fatal situation. Repair if the pump fails is very expensive - $12,000 to $14,000 in some cases. I would like GM to replace the injection pump at my dealership to ensure this known failure does not occur. My pickup truck is otherwise in excellent condition.

NHTSA ID

11710097

Incident

Jan 10, 2026

The contact owns a 2015 Chevrolet Silverado 2500. The contact stated while driving approximately 65 MPH, the vehicle stalled. The contact stated there was no warning illuminated. The contact had the vehicle towed to a local dealer, where it was diagnosed and determined that the high-pressure diesel fuel pump had failed, and the entire fuel system needed to be replaced. The vehicle was repaired. The manufacturer was informed of the failure and referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 190,000.

NHTSA ID

11664512

Incident

Jul 3, 2023

Mileage

190,000 mi

on [XXX] my 2015 Chevy 2500 crew cab LTZ Duramax with 50,959 miles stopped running going down a large hill, Barely made it off the road coasting into a Fire department parking lot. 2nd failure occurred while driving on a main route in WV. At 66,600 miles [XXX], was almost rear ended because truck again just stopped running going 50 mph around a turn. Diesel fuel was pouring onto the hot engine second occurrence. I don't know how the truck didn't catch on fire. Thank [XXX] I wasn't towing my 14,500 lb fifth wheel either time. Both incidents were because of a CP4 injection Pump Failure completely taking out and polluting the entire fuel system. Per GM service department in Wintersville, Oh. I no longer feel safe driving the truck and wouldn't even consider towing with it again. Too dangerous for me and my family !! I am fearful this could end up causing serious injury or death !! INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11633760

Incident

Dec 6, 2024

CP4 fuel pump caused the vehicle to shut down and stopped running.

NHTSA ID

11625151

Incident

Sep 14, 2024

Vehicle stopped without warning due to the CP4 Pump failure in the diesel truck. This pump has been recalled by other manufacturers but not by GM / Chevrolet which is the maker of my vehicle.

NHTSA ID

11603352

Incident

Aug 1, 2020

I was driving north on Va. 10 in Hopewell when my engine unexpectedly, with no warning, quit. I was in heavy traffic with no power brakes or steering and had to maneuver to the right lane and find an area that was off the road that I could get into. Fortunatley there was a parking lot that I managed to coast into. The truck would not re-fire so I called for a wrecker

NHTSA ID

11555621

Incident

Aug 19, 2023

Per a report from Car Complaints, the lawsuit alleges that 2011- through 2016-model-year Chevy Silverado and GMC Sierra pickups equipped with the 6.6L V8 LML turbodiesel Duramax engine are equipped with defective Bosch CP4 fuel pumps that are more fragile and prone to wear than previous CP3 fuel pumps. According to plaintiffs, the defective CP4 pumps can be destroyed by U.S. diesel fuel, which is allegedly “drier” than diesel fuel in other countries. The lawsuit alleges that U.S. diesel fuel does not provide adequate lubrication for the CP4 fuel pump. The lack of lubrication can lead to internal fuel pump damage and result in metal shavings that damage the pump, the fuel system, and the GM Duramax engine as well. This damage can lead to the truck stalling and losing power, and may require the vehicle to be towed to a shop, leaving customers with big repair bills. The lawsuit goes on to allege that GM was aware that the Duramax engines and related fuel pumps were defective prior to selling affected vehicles, but declined to notify customers. Rather, GM allegedly concealed that the defective CP4 pumps may be destroyed by U.S. diesel fuel.

NHTSA ID

11544209

Incident

Sep 1, 2023

The fuel injection pump malfunctioned causing the truck to shut down going down the highway. It was taken to a professional and was confirmed to be an issue with these vehicles. There was no warnings at all. The cost to repair was $8000.00

NHTSA ID

11538201

Incident

Jun 21, 2021

CP4 failure, caused metal fragments to go throughout fuel system and tank. Entire fuel system had to be replaced and tank cleaned out. CP4 failed in the middle of my drive home, stalling the truck in the middle of an intersection. Luckily had enough momentum to roll and pull over to the side of the road.

NHTSA ID

11513821

Incident

Aug 24, 2021

Fuel pump failure while driving highway speed 70mph pulling a trailer. Engine light came on and engine went to limp mode for a few seconds then completely shut down without warning while still going at least 60. Lost power steering and power brakes. Service center confirmed the code for "low fuel rail pressure" and did the repair. I have retained the CP4 pump for analysis. I was very lucky to not crash my truck.

NHTSA ID

11510394

Incident

Aug 7, 2022

The contact owns a 2015 Chevrolet Silverado 2500. The contact stated that while driving at various speeds, the vehicle entered LIMP Mode with a warning message indicating how many miles before the vehicle would independently turn off. The contact had taken the vehicle to a dealer and was informed that the diesel exhaust fluid (DEF) tank needed to be replaced; however, the failure returned. Over time, the rear brakes, rotors, calipers, and various other parts had been replaced; however, the repairs failed to fix the vehicle. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 143,000.

NHTSA ID

11506908

Incident

Feb 1, 2022

Mileage

143,000 mi

CP4 pump failed sending metal through out fuel system. Pump, fuel system flushed, injectors all need replaced. Truck stalled in motion. Thankfully I was able to safely pull over without accident occuring.

NHTSA ID

11502579

Incident

Jan 12, 2023

Fuel pump cracked under normal wear and tear under 60,000 miles leaving me stranded for a week and costing $1600 to replace. Transmission is very unresponsive and soupy, sometimes it kicks in late, other times not at all. Ive read this is a known issue with my vehicle.

NHTSA ID

11472760

Incident

Feb 16, 2022

WHILE DRIVING, THE VEHICLE STUTTERED AND SKIPPED DOWN THE ROAD. WHEN I CAME TO A STOP THE TRUCK IT WOULD NEVER TURN ON AGAIN. THE TRUCK WAS HAVING WHAT'S CALLED A CRANK NO START PROBLEM WHERE IT WOULD CRANK OVER, BUT NOT START. THIS IS A FAILURE OF A CP4 PUMP THAT IS CONSIDERED THE WRONG PART AND COMMON KNOWLEDGE FAILURE TO CHEVORLET AND IS EXTREMELY EXPENSIVE TO FIX. *TR

NHTSA ID

11327750

Incident

May 24, 2020

Mileage

67,000 mi

FUEL GAUGE MEASURES EMPTY CAUSING DANGER OF RUNNING OUT OF DIESEL ON HIGHWAY. EVEN AFTER COMPLETE FUEL UP, THE DASHBOARD NEEDLE AND ELECTRONIC READERS IS STILL MARKING EMPTY. THERE HAS BEEN A PREVIOUS RECALL ON THIS ON PREVIOUS MODELS. MY 2015 ONLY HAS 60K MILES AND IT SENSORS OR FLOATERS ARE NOT WORKING. VERY DANGEROUS TO RUN OUT OF FUEL WHEN TOWING ON HIGHWAY.

NHTSA ID

11228872

Incident

Jun 28, 2019

Mileage

60,000 mi

DEF TANK HEATER FAILURE. RESTRICTING SPEED. DANGEROUS ON HIGHWAY AND TRIPS. DEF FLUID RESTRICTIONS BECAUSE OF SOOT BUILD UP.

NHTSA ID

11196671

Incident

Jan 1, 2019

Mileage

29,000 mi

THE DEF FLUID INDICATER IS STUCK AT 24%, THERE ARE MANY INSTANCES ON THE INTERNET OF THE SAME VEHICLE WITH THE SAME PROBLEM, SOME DEALERS FIX FOR FREE WITH A SIMPLE SOFTWARE UPGRADE, OTHER LIKE MINE WANT TO CHARGE ME DIAGNOSTICS AND MECHANICS TIME RUNNING INTO A COUPLE HUNDRED DOLLARS, WITH SO MANY VEHICLES HAVING THIS AND GM WON'T DO ANYTHING ABOUT IT, BEEN ON THE PHONE TO GM SEVERAL TIME WITH NO HELP. WITH THIS STUCK AT 24% YOU COULD RUN LOW ON DEF FLUID AND NOT KNOW IT AND THE TRUCK WILL LOSE POWER AND NOT LET YOU GO FASTER THAN 5 MILES AN HOUR. WHICH COULD CAUSE MANY SAFETY ISSUES. THERE EVEN IS A TSB ON THIS AND HOW TO FIX, BUT IF YOUR OUT OF WARRANTY IT'S MY COST. 22214 BULLETIN PIP4884Q C/S

NHTSA ID

11101861

Incident

May 11, 2018

Mileage

75,000 mi

WHILE DRIVING ON THE INTERSTATE, WE CAME TO A STOP AT A GAS STATION. WHEN AT A COMPLETE STOP WE STARTED SMELLING DIESEL FUEL, I ASSESSED THE VEHICLE UNDER THE HOOD AND UNDER THE TRUCK. IT WAS RAINING THAT DAY SO I COULDN'T TELL IF ANYTHING WAS LEAKING FROM THE UNDER CARRIAGE. WHILE DRIVING THE REMAINING TWO HOURS OF OUR TRIP, OFF THE INTERSTATE, WE CAME TO A RED-LIGHT, WHILE MAKING THE RIGHT TURN THE TRUCK GOT SIDEWAYS IN THE INTERSECTION. CONTINUING THE TRIP AND ALMOST HOME WE WERE ON A HIGHWAY GOING 65MPH, THE TRUCK GOT SIDEWAYS AND LOST TRACTION AGAIN. CONCERNED BECAUSE I HAVE MY WIFE AND 15 MONTH OLD IN THE TRUCK, I PULL OVER AGAIN TO ASSESS THE TRUCK. AT THIS POINT FELT OF THE TIRES AND THEY HAD A OILY SUBSTANCE ON THEM, CAUSING THE TRUCK TO NOT HAVE ANY TRACTION IN THE RAIN, I ALSO SEEN A SUBSTANTIAL AMOUNT OF FUEL LEAKING FROM AROUND THE TRANSMISSION. THE NEXT DAY I TOOK IT TO THE DEALERSHIP TO GET LOOKED AT. THEY INFORMED ME THAT THE HIGH PRESSURE FUEL PIPES HAD A SEVERE FUEL LEAK FROM THE CONNECTORS. THEY ALSO INFORMED ME THAT THERE WERE NO RECALLS OPEN ON THE VEHICLE. SO THEY ARE WANTING TO CHARGE ME OVER $1,300 TO REPAIR THIS, WHEN I FEEL LIKE THIS IS A HUGE SAFETY ISSUE CAUSED BY A LACK OF QUALITY ASSURANCE AND CONTROL. ALSO I AM FAIRLY CERTAIN THAT THIS USE TO BE A RECALL, AND THE DEALERSHIP SAID THAT THERE ARE NO OPEN RECALLS ON MY VEHICLE. I FEEL LIKE THERE SHOULD BE A RECALL ON THIS ISSUE ASAP, BEFORE IT KILLS SOMEONE.

NHTSA ID

11091158

Incident

Apr 22, 2018

Mileage

127,000 mi

FUEL LINE LEAK. TWO STEEL FUEL LINES WERE RUBBING AGAINST EACH OTHER CAUSING A FUEL LEAK. THIS IS A DIESEL PICK UP AND THE FUEL SYSTEM IS REPORTED AT 28,000 PSI OPERATION PRESSURE. THIS RESULTED IN A LEAK OF DIESEL FUEL THAT SPRAYED ONTO THE EXHAUST SYSTEM, WHICH CAN REACH TEMPERATURES IN EXCESS OF 1400F CAUSING A FIRE HAZARD. THE PROBLEM MANIFESTED AS A STRONG RAW FUEL SMELL IN THE CAB CAUSING AN INHALATION HAZARD. THIS WAS FOLLOWED BY SMALL STAINS IN MY PARKING SPOT. THE SMELL WAS NOT EVIDENT WHEN IN MOTION ON THE HIGHWAY ONLY WHEN STOPPED AND RUNNING. REPAIRS WERE MADE BY CASPER GMC DEALER IN CASPER, WY REPLACING THE FUEL LINES. THERE IS NO BUFFER (SUCH AS A TEFLON BUSHING) TO INSULATE SUCH EFFECTS.

NHTSA ID

10979021

Incident

Apr 10, 2017

Mileage

74,500 mi