#09-06-04-034: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Cir

[CtChevy427]

#09-06-04-034: Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs and Cylinder Bank Shut Down DTCs, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires) - (Aug 17, 2009)

<table border="0"><tbody><tr><td valign="top" width="100">Subject:</td><td valign="top">Malfunction Indicator Lamp (MIL) Illuminated, Fuel Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208 and Cylinder Bank Shut Down DTCs P2146 or P2149, Reduced Engine Power (Repair Fuel Injector Control Module (FICM) Harness Chafed Wires)</td></tr></tbody></table>
<table border="0"><tbody><tr><td valign="top" width="100">Models:</td><td valign="top">2001-2004 Chevrolet Kodiak C4500/C5500 Series, Silverado Models</td></tr></tbody></table>
<table border="0"><tbody><tr><td valign="top" width="100">
</td><td valign="top">2001-2004 GMC Sierra Models, TopKick C4500/C5500 Series</td></tr></tbody></table>
<table border="0"><tbody><tr><td valign="top" width="100">
</td><td valign="top">Equipped with Duramax™ Diesel Engine RPO LB7</td></tr></tbody></table>
<table border="0"><tbody><tr><td valign="top" width="100">
</td><td valign="top">2004-2005 Chevrolet Kodiak, Silverado Models</td></tr></tbody></table>
<table border="0"><tbody><tr><td valign="top" width="100">
</td><td valign="top">2004-2005 GMC Sierra Models, TopKick</td></tr></tbody></table>
<table border="0"><tbody><tr><td valign="top" width="100">
</td><td valign="top">Equipped with Duramax Diesel Engine RPO LLY</td></tr></tbody></table>
<table border="0"><tbody><tr><td valign="top" width="100">
</td><td valign="top">Please Refer to GMVIS</td></tr></tbody></table>​

<hr> Condition

Some customers may comment that the malfunction indicator lamp (MIL) is illuminated or intermittent and there is a significant reduction in engine power (limp home mode).
The scan tool may display one or more Injector Driver Circuit DTCs P0201, P0202, P0203, P0204, P0205, P0206, P0207 or P0208 and/or Cylinder Bank Shut Down DTCs P2146 or P2149 set as Current or in History.
Cause

This condition may be caused by the fuel injector control module (FICM) wiring harness protective conduit rubbing against the back of the alternator, the alternator bracket or the FICM harness retaining bracket. This may result in the conduit rubbing through, exposing the wires inside and chafing of the wire insulation then occurs.
Correction

1. Turn ON the ignition, with the engine OFF.
2. Observe the DTC information with the scan tool.
3. If any of the above DTCs are set, then proceed to inspect the FICM wiring harness at the locations outlined in the following steps.
4. Turn OFF the ignition and all accessories and allow the control modules to power down.Note: For Silverado and Sierra models only perform Step 5.
5. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI.
   
   
   
   
   Important: DO NOT break off the tab on the electrical connectors.
6. Disconnect the FICM electrical connectors (2) from the FICM (1).
   
   
   
   
7. Carefully bend up and backwards the FICM wiring harness electrical connectors (1) away from the FICM (4).
   
   
   
   
   Note: Some of these chafes are very small, possibly the size of a pen tip, but could still cause injector circuit concerns.
8. Inspect the wiring harness for chafing (3) that may result from rubbing at the back of the alternator (2), the alternator bracket or at the FICM harness retaining bracket.If necessary, peel the tape from the area and look for ANY chafes into the wires.
   
   <table border="0"><tbody><tr><td valign="top">⇒</td><td valign="top">If chafing is observed and the conductive portion of the wire IS NOT damaged, apply electrical tape around the wire.</td></tr></tbody></table>
   <table border="0"><tbody><tr><td valign="top">⇒</td><td valign="top">If chafing is observed and the conductive portion of the wire IS damaged, then refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs in SI.</td></tr></tbody></table>
   <table border="0"><tbody><tr><td valign="top">⇒</td><td valign="top">If chafing IS NOT OBSERVED , then refer to the appropriate DTC Diagnostic procedures in SI. </td></tr></tbody></table>​
9. Connect the electrical connectors to the FICM.
10. Insulate the harness with suitable material such as conduit or heater hose to prevent a reoccurrence.Note: For Silverado and Sierra models only perform Step 11.
11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement in SI.
12. Clear the DTCs with a scan tool.

Warranty Information

For vehicles repaired under warranty, use:
<table border="1" width="95%"> <tbody><tr> <th rowspan="1" align="center" valign="bottom">Labor Operation
</th><th rowspan="1" align="center" valign="bottom">Description
</th><th rowspan="1" align="center" valign="bottom">Labor Time
</th></tr> <tr> <td rowspan="1" align="center" valign="middle">N6606
</td><td rowspan="1" align="center" valign="middle">Wiring and/or Connector-Fuel System - Repair or Replace
</td><td rowspan="1" align="center" valign="middle">Use Published Labor Operation Time
</td></tr> <tr> <td rowspan="1" align="center" valign="middle">J5020*
</td><td rowspan="1" align="center" valign="middle">Duct And / Or Hose, Outside Air - Replace
</td><td rowspan="1" align="center" valign="middle">Use Published Labor Operation Time
</td></tr> <tr> <td rowspan="1" colspan="3" align="center" valign="middle">*Add for GMC Sierra or Chevrolet Silverado only.
</td></tr> </tbody></table> <table width="95%"> <tbody><tr> <td align="LEFT" width="80%"> 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 technicians have the equipment, tools, 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 GM dealer for information on whether your vehicle may benefit from the information.

</td> <td align="CENTER" width="42">

</td> <td align="CENTER" width="167"> WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION
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