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LB7 injector TSB

Discussion in 'GM News and Information' started by malibu795, May 18, 2008.

  1. malibu795

    malibu795 misspleelleer..........

    961
    0
    May 7, 2008
    south charleston ohio
    04 LB7


    File In Section: Special Coverage
    Bulletin No.: 04039B
    Service Bulletin Date: November 2007

    SPECIAL COVERAGE
    SUBJECT: SPECIAL COVERAGE ADJUSTMENT – INJECTORS - REPLACE
    MODELS: 2001-2004 CHEVROLET SILVERADO
    2001-2004 GMC SIERRA
    2003-2004 CHEVROLET KODIAK
    2003-2004 GMC TOPKICK
    EQUIPPED WITH 6.6L DURAMAX DIESEL (RPO LB7 - VIN 1) ENGINE
    THIS BULLETIN IS BEING REVISED TO ADD 2004 MODEL YEAR TRUCKS.
    PLEASE DISCARD SPECIAL POLICY BULLETIN NUMBER 04039A, DATED
    OCTOBER, 2006.
    CONDITION
    Some customers of 2001-04 model year Chevrolet Silverado, GMC Sierra; 2003-04 Chevrolet
    Kodiak and GMC TopKick vehicles, equipped with a 6.6L Duramax Diesel (RPO LB7 - VIN 1)
    engine, may experience vehicle service engine soon (SES) light illumination, low engine power,
    hard start, and/or fuel in crankcase, requiring injector replacement, as a result of high fuel return
    rates due to fuel injector body cracks, ball seat erosion, or high pressure seal extrusion. (refer to
    latest version of Technical Service Bulletin 04-06-04-007 and SI).
    SPECIAL COVERAGE ADJUSTMENT
    This special coverage covers the condition described above for a period of 7 years or 200,000
    miles (320,000 km), whichever occurs first, from the date the vehicle was originally placed in
    service, regardless of ownership. The repairs will be made at no charge to the customer.
    IMPORTANT:
    This special coverage only covers the above noted failure modes, which
    are identified by high fuel return flow rates.
    For 2001-02 vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders
    on or after May 25, 2004 are covered by this special coverage and must be submitted using the
    labor operation codes provided with this bulletin. Claims with repair orders prior to May 25, 2004
    must be submitted to the Service Contract provider.
    For 2003 vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or
    after October 10, 2006 are covered by this special coverage and must be submitted using the
    labor operation codes provided with this bulletin. Claims with repair orders prior to October 10,
    2006 must be submitted to the Service Contract provider.
    Copyright 2004 General Motors Corporation. All Rights Reserved.

    Page 2 November 2007 Bulletin No.: 04039B
    For 2004 vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or
    after November 19, 2007 are covered by this special coverage and must be submitted using the
    labor operation codes provided with this bulletin. Claims with repair orders prior to November 19,
    2007 must be submitted to the Service Contract provider.
    VEHICLES INVOLVED
    Involved are all 2001-04 model year Chevrolet Silverado, GMC Sierra; 2003-04 Chevrolet Kodiak
    and GMC TopKick vehicles, equipped with a 6.6L Duramax Diesel (RPO LB7 - VIN Code 1)
    engine, and built within the following start of production to end of production VIN breakpoints:
    YEAR DIVISION MODEL FROM THROUGH
    2001 Chevrolet Silverado
    1E100028 1E346644
    1F100001 1F213872
    1Z100015 1Z100019
    2001 GMC Sierra 1E100021 1E346642
    1F100010 1F213864
    2002 Chevrolet Silverado 2E100009 2E306435
    2F100004 2F247804
    2002 GMC Sierra 2E100003 2E306345
    2F100011 2F247974
    2003 Chevrolet Silverado 3E100002 3E381007
    3F100003 3F259043
    2003 Chevrolet Kodiak 3F500015 3F522532
    2003 GMC Sierra 3E100003 3E381124
    3F100008 3F259040
    2003 GMC TopKick 3F500001 3F900945
    2004 Chevrolet Silverado 4E100018 4E221395
    4F100004 4F174846
    2004 Chevrolet Kodiak 4F500118 4F510079
    2004 GMC Sierra 4E100002 4E223355
    4F100008 4F174834
    2004 GMC TopKick 4F100126 4F510077
    PARTS INFORMATION
    Parts required to complete this special coverage are to be obtained from General Motors Service
    and Parts Operations (GMSPO).
    Part Number Description Quantity/Vehicle
    97729095* Injector Kit, Dir Fuel (Incls:Injector,Gasket,Seal) 8
    97188896 Gasket, Valve Rocker Arm Cover
    (Reusable Gasket) As Req'd
    97228933 Gasket, F/Injr Fuel Return Pipe 8
    97600925 Gasket, F/Injr Fuel Return Pipe 2
    94011604 Seal, Water outlet 1
    12378521 (US)
    88901148 (CN) Sealant As Req’d
    97188463 Housing, F/Injr Noz As Req'd
    94051259 Seal, F/Injr Noz Hsg (O Ring) As Req'd

    Page 3
    November 2007 Bulletin No.: 04039B
    *P/N 97729095 is only available in a merchandising pack quantity of 4. Current order restriction
    limits orders to CSO and availability to 8 injectors per VIN.
    CUSTOMER NOTIFICATION
    General Motors will notify customers of this special coverage on their vehicles (see copy of typical
    customer letter included with this bulletin - actual divisional letter may vary slightly).
    SERVICE PROCEDURE
    Refer to the latest version of Technical Service Bulletin 04-06-04-007 and Service Information to
    perform diagnostics and fuel injector replacement for high fuel return rates.
    CLAIM INFORMATION
    For vehicles repaired under the terms of this special coverage, submit a claim with the information
    indicated below:
    IMPORTANT:
    A copy of the completed TSB 04-06-04-007 diagnostic worksheet
    and other required documentation (e.g. Tech 2 snapshots) must
    be included in the box with the returned injectors.
    REPAIR PERFORMED
    PART
    COUNT
    PART
    NUMBER
    PARTS
    ALLOW CC-FC
    LABOR
    OP
    LABOR
    HOURS
    NET
    ITEM
    Refer to the latest version
    of TSB 04-06-04-007 to
    diagnose and replace all 8
    fuel injectors.
    Silverado, Sierra
    Kodiak, TopKick
    ----* MK-95 T5603
    8.0
    9.7
    **
    Reimbursement For
    Previous Repairs
    (Canadian & Export
    Dealers/US CAC)
    N/A N/A N/A MK-95 T5604 0.2
    Administrative
    labor hours
    ***
    Courtesy Transportation N/A N/A N/A MK-95 **** N/A *****
    *
    The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price plus
    applicable Mark-Up or Landed Cost Mark-Up (for IPC) for injector parts needed to complete
    the repair.
    **
    The amount identified in the “Net Item” column should represent the sum total of the
    current GMSPO Dealer net price plus applicable Mark-Up or Landed Cost Mark-Up (for
    IPC) for shop supplies needed to perform the required repairs.
    ***
    The amount identified in the “Net Item” column should represent the customer
    reimbursement amount.
    ****
    Submit courtesy transportation using normal labor operations for courtesy transportation as
    indicated in the GM Service Policies and Procedures Manual.
    *****
    The amount identified in the "Net Item" column should represent the actual dollar amount
    for courtesy transportation.

    Page 4
    November 2007 Bulletin No.: 04039B
    CUSTOMER REIMBURSEMENT - For US
    All customer requests for reimbursement for previous repairs for the special coverage condition
    will be handled by the Customer Assistance Center, not by dealers.
    A General Motors Special Coverage Customer Reimbursement Procedure Form is included with
    the customer letter.
    IMPORTANT:
    Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for
    specific procedures regarding customer reimbursement and the form.
    CUSTOMER REIMBURSEMENT - For Canada and Export
    Customer requests for reimbursement of previously paid repairs to correct high fuel return rate by
    replacing fuel injectors in 2004 model year trucks are to be submitted prior to or by November 30,
    2008. Repairs must have occurred within the 7 years of the date the vehicle was originally placed
    in service, or 320,000 km, whichever occurs first.
    When a customer requests reimbursement, they must provide the following:
    -
    Proof of ownership at time of repair.
    -
    Original paid receipt confirming the amount of unreimbursed repair expense(s) (including
    Service Contract deductibles), a description of the repair, and the person or entity
    performing the repair.
    If the work was done by someone other than a GM dealership, the amount of reimbursement will
    be limited to the amount that the repair would have cost GM to have it completed by a GM
    dealership.
    COURTESY TRANSPORTATION
    The General Motors Courtesy Transportation program is intended to minimize customer
    inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
    Warranty. The availability of courtesy transportation to customers whose vehicles are within the
    warranty coverage period and involved in a product program is very important in maintaining
    customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
    or some other form of courtesy transportation is available and will be provided at no charge.
    Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
    Transportation guidelines.
    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

    We Support
    Voluntary Technician technicians have the tools, equipment, 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 dealer/retailer for information
    Certification
    on whether your vehicle may benefit from the information.

    Page 5 November 2007 Bulletin No.: 04039B
    November 2007
    Dear General Motors Customer:
    As the owner of a 2001-04 model year Chevrolet Silverado; GMC Sierra or 2003-04 Chevrolet
    Kodiak; GMC TopKick vehicle, your satisfaction with our product is very important to us.
    This letter is intended to make you aware that some 2001-04 model year Chevrolet Silverado,
    GMC Sierra; 2003-04 Chevrolet Kodiak and GMC TopKick vehicles, equipped with a 6.6L
    Duramax Diesel engine, may have a condition where the engine fuel injectors may require
    replacement because of high fuel return rates due to fuel injector body cracks, or ball seat
    erosion, or high pressure seal extrusion. Symptoms of these conditions include illumination of the
    service engine soon (SES) light, low engine power, hard start, and/or fuel in the crankcase.
    Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
    vehicle has the condition as described above.
    What We Have Done: General Motors is providing owners with additional protection for the fuel
    injectors. If this condition occurs on your 2001-04 model year Chevrolet Silverado, GMC Sierra;
    2003-04 Chevrolet Kodiak or GMC TopKick vehicle within seven (7) years of the date your vehicle
    was originally placed in service or 200,000 miles (320,000 km), whichever occurs first, the
    condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the
    condition described above is not covered under this special coverage program.
    What You Should Do: Repairs and adjustments qualifying under this special coverage must be
    performed by a General Motors dealer. You may want to contact your GM dealer to find out how
    long they will need to have your vehicle so that you may schedule the appointment at a time that
    is convenient for you. This will also allow your dealer to order parts if they are not already in
    stock. Keep this letter with your other important glove box literature for future reference.
    Reimbursement: The enclosed form explains what reimbursement is available and how to
    request reimbursement if you have paid for repairs for this condition. Your request for
    reimbursement, including the information and documents mentioned on the enclosed form, must
    be received by GM by November 30, 2008.
    If you have any questions or need any assistance, just contact your dealer or the appropriate
    Customer Assistance Center at the number listed below. The Customer Assistance Center’s
    hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.
    Division Number Text Telephones (TTY)
    Chevrolet 1-800-630-2438 1-800-833-2438
    GMC 1-866-996-9463 1-800-462-8583
    Puerto Rico – English 1-800-496-9992
    Puerto Rico – Español 1-800-496-9993
    Virgin Islands 1-800-496-9994
    GM Commercial Truck 1-800-862-4389
    We are sorry for any inconvenience you may experience; however we have taken this action in
    the interest of your continued satisfaction with our products.
    General Motors Corporation
     
  2. malibu795

    malibu795 misspleelleer..........

    961
    0
    May 7, 2008
    south charleston ohio
    01-03 LB7

    Subject: Service Engine Soon (SES) Light On, DTCs P0087, P0093, P1093, Low Power, No Start, Hard Start, Fuel in Crankcase (Replace All Injectors - New Strategy for High Fuel Return Rates) #04-06-04-007F - (10/21/2005)



    Models: 2001-2004 Chevrolet Silverado

    2003-2004 Chevrolet Kodiak C4500/C5500 Series

    2001-2004 GMC Sierra

    2003-2004 GMC Topkick C4500/C5500 Series

    with 6.6L Duramax™ Diesel Engine (VIN 1 -- RPO LB7)




    --------------------------------------------------------------------------------

    This bulletin is being revised to include additional model years and revised warranty information. Please discard Corporate Bulletin Number 04-06-04-007E (Section 06 -- Engine/Propulsion System).


    --------------------------------------------------------------------------------

    Condition
    Some customers may comment on the Service Engine Soon light becoming illuminated. Upon investigation, the technician will find DTCs P0087, P0093 or P1093. Additional customer comments may include a lack of power, a fuel smell on the oil dipstick, fuel in the engine oil, fuel coming out of the crankcase breather, the engine cranks but does not run, or a hard start condition. This condition will not cause an engine misfire. Do not apply this bulletin to any diagnostic other than what is identified in the chart below.

    Cause
    The fuel injectors have internal conditions that may cause them to return an excessive quantity of fuel to the tank, as well as leak fuel into the crankcase. Due to the return flow and/or leakage, the fuel injection pump may not be able to build up adequate fuel rail pressure.

    Correction
    Important: Before the technician begins diagnostics and repair, be sure to follow the guidelines in Corporate Service Bulletin Number 03-06-04-036 to avoid fuel system contamination.

    Follow current diagnostics for the condition the vehicle is experiencing, then reference the table below. If the diagnostics lead to Fuel System Diagnosis - High Pressure Side, follow the diagnostic until the Fuel Injector Return Flow is measured at each cylinder bank return connection (bank to bank).

    Condition
    Start with this SI Diagnostic in the Diagnostic Information and Procedures sub-section of the Engine Controls Section

    Delayed Start
    Hard Start

    Lack of Power
    Lack of Power, Sluggishness or Sponginess

    Engine Cranks but Does Not Run
    Engine Cranks but Does Not Run

    Fuel in Oil or Fuel leak out of breather
    Fuel In Engine Oil in Engine Mechanical

    DTC P0087
    DTC P0087

    DTC P0093
    DTC P0093

    DTC P1093
    DTC P1093


    Important: If the SES light is illuminated, follow diagnostics for the DTC as indicated with the Tech 2.

    Important: When installing the new fuel injectors, lubricate the inside of the fuel injector sleeve with clean engine oil prior to installing the injector. Do not lubricate the injector or O-ring seal prior to installation.

    If fuel return flow on either the right or left cylinder bank is above the initial fuel injector bank return flow value, then replace all eight (8) fuel injectors using the Fuel Injector Replacement procedure in the Engine Controls section of the appropriate Service Manual.

    Record all diagnostic data as outlined on a copy of the attached diagnostic worksheet. The diagnostic worksheet and a copy of the repair order is to be returned with the removed injectors.

    After replacing injectors, perform the following steps:

    Replace the fuel filter element.
    Install all disconnected and removed components. Refer to the applicable procedures.
    Start and idle the engine. You may have to prime the fuel system before the engine will start.
    Connect a scan tool.
    Command the fuel pressure control to 160 MPa with a scan tool.
    • If the fuel pressure is more than 145 MPa, the system is OK.

    • If the fuel pressure is unable to increase to more than 145 MPa. Refer to System Diagnosis -- High Side Pressure in the appropriate Service Manual.

    • Be sure to record fuel pressure readings on the diagnostic worksheet.

    Parts Information
    Part Number
    Description
    Qty

    97729095*
    Injector - Fuel
    8

    97188896
    Gasket - Valve Rocker Arm Cover

    (Reusable Gasket)
    As Req'd

    97228933
    Gasket - Fuel Injection Fuel Return Pipe and Injector
    8

    97600925
    Gasket - Fuel Injection Fuel Return Pipe
    2

    94011604
    Seal - Water outlet
    1

    12378521 (U.S.)

    88901148 (Canada)
    Sealant
    1

    97188463
    Sleeve, Injector
    As Req'd

    94051259
    Seal, O-ring - Injector Sleeve
    As Req'd

    98017645
    Filter, Fuel
    1


    *P/N 97729095 is only available in a merchandising pack quantity of 4. Current order restriction limits availability to 8 per VIN.

    Warranty Information
    Important: This labor operation listed below is covered by emissions and is not subject to the $100.00 deductible. Dealer’s will need to use the following information when submitting claims on vehicles still covered under that warranty:

    2001-2002 Model Year vehicles may be covered by Special Policy Number 04039. Please refer to Special Policy Number 04039 before submitting any warranty claims.

    For vehicles repaired under warranty, use:

    Labor Operation
    Description
    Labor Time

    J7801
    Injector, Fuel - Diagnose & Replace(2003-2004 Models)
    *8.0 hrs

    T5603
    See Special Policy Number 04039 for published times(2001-2002 Models)

    *Note: The labor time represents a reduction over the previously published time due to unnecessary steps in the repair procedure being eliminated, such as removing the radiator shroud and accessory drive belt. Also, the original add time to replace all injectors was overstated, Finally, the number of diagnostic steps have been adjusted because individual injectors are not being diagnosed. The labor time guide will be revised in the near future.


    Important: All replaced injectors must be returned to the WPC. IMPORTANT: WAIT TO RECEIVE THE WPC PART RETURN REQUEST PRIOR TO RETURNING THE INJECTORS. Please follow Corporate Bulletin Number 99-00-89-019C that applies to the WPC return procedures. All eight (8) injectors of a single engine must arrive at the WPC boxed or bagged together. A copy of the part request, repair order with technician comments and the completed diagnostic worksheet should be included with the injectors. The tags found in the replacement injector box must be completed and attached to each injector. The WPC will be verifying sets of injectors for high flow rates.
    ************************************************** ************************************************** ************************************************** ***************************************AND ALSO********************************************** *******************************

    Subject: 04039B – Special Coverage Adjustment
    Injectors – Replace
    Message #: WIR20070463


    GM SERVICE AND PARTS OPERATIONS
    DCS1911
    URGENT - DISTRIBUTE IMMEDIATELY

    DATE: November 19, 2007

    SUBJECT: 04039B – Special Coverage Adjustment
    Injectors – Replace

    MODELS: 2001-2004 Chevrolet Silverado
    2001-2004 GMC Sierra
    2003-2004 Chevrolet Kodiak
    2003-2004 GMC Topkick
    Equipped with 6.6L Duramax Diesel (RPO LB7 –
    VIN 1) Engine

    TO: All Chevrolet and GMC Dealers

    ATTENTION: Service Manager, Parts Manager and
    Warranty Administrator

    PRODUCT FIELD ACTION ANNOUNCEMENT

    General Motors is announcing Special Coverage Adjustment 04039B today. The total number of VINS involved is 68,183. This bulletin is being revised to add 2004 Model Year trucks. Please discard Special Policy Bulletin Number 04039A, dated October 2006.

    Customer Letter Mailing
    Customer letter mailing will begin on November 26, 2007.

    GMVIS Information
    GMVIS information is not loaded for Special Coverages.

    Service Information System (SI)
    Bulletin 04039B will be available in SI on November 20, 2007.

    Campaign Initiation Detail Report (CIDR)
    The CIDR is not available for Special Coverages.

    PLEASE DOUBLE CLICK ON THE ICON BELOW
    THEN SINGLE CLICK ON THE LAUNCH BUTTON
    TO VIEW OR PRINT THE BULLETIN




    END OF MESSAGE
    GM SERVICE AND PARTS OPERATIONS
     

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