The Supecar Registry NCRS Historical Document Services
NCRS Historical Document Services link
Topic Options
Rate This Topic
#190148 - 06/19/06 02:32 PM Duramax injector failure: need help
Chevy454 Offline


Carpal Tunnel

Registered: 03/20/00
Posts: 11961
Loc: Alton, MO, USA
Anyone else been through this? Or even better, any GM service techs here? I had to miss the Martin event because our '02 Dmax crapped out the night before I was supposed to leave, and now the dealer is jerking me around...they're only wanting to replace one bank of the injectors?! Does that sound right to anyone else? Best I can tell GM is aware that they have a problem with the injectors, and have since the Dmax's inception, and replacing both banks isn't too far out of line since the top end has to come off anyway...but my dealer is telling me that they won't replace the other bank with the updated injectors *unless* I promise to reimburse them if GM kicks back the warranty claim?

I found a TSB that says replacing all 8 is standard fare for "high fuel return rates"...well, it got the fuel so stinking hot that it was literally BOILING out of the tank vent...I don't have any of the fancy book learnin' that the GM service guys have, but my gut tells me an injector pump trying to keep up with faulty injectors is gonna get hot and then pass the heat on in the fuel, and that explains the boiiling fuel...the dealer didn't believe me that this was happening, even though it literally sprayed diesel fuel all over the rear glass of our dually and was running out the rear of the bed...!

Top
#190149 - 06/19/06 03:23 PM Re: Duramax injector failure: need help [Re: Chevy454]
Donnie Online

old hand

Registered: 04/16/05
Posts: 840
Loc: Indiana
ive got an 04.5 so i cant help but go here http://dieselplace.com/forum/index.php and youll get an answer.
make sure to post in the LB7 section.
_________________________
69 SS L78 Chevelle
70 SS 396 Chevelle

Top
#190150 - 06/19/06 06:13 PM Re: Duramax injector failure: need help [Re: Donnie]
BBIGG BLOCK 396 Offline
old hand

Registered: 01/23/02
Posts: 1058
Loc: Porter Texas USA
You can research the web for duramax recalls.I would speak to a GM represenative about this and explain everything.They are going to tell you that your vin# was not under the recall probably.That doesen't mean crap because they used the same parts at all the plants.With a little encouragement on your part you should be able to coax them in getting your vehicle repaired.I was able to get my 98 1 tone crewcab repaired.It was a 1998 and the door panel caught on fire froma faulty remote mirror switch. This was last year and GM did mak the repairs and rented me a car the whole time it was down.All I did was do a little research and then was a little persuasive on the phone to the GM rep.

Bobby

Top
#190151 - 06/19/06 07:03 PM Re: Duramax injector failure: need help [Re: BBIGG BLOCK 396]
Chevy454 Offline


Carpal Tunnel

Registered: 03/20/00
Posts: 11961
Loc: Alton, MO, USA
Welp, with some help from a couple of members & friends here on Yenko.net I was able to talk to a dealer that knew what he was talking about and actually cared...he fed me a bulletin #, and I was able to research it from there...so just in case any of you '01 or '02 Duramax owners go through this, here are a couple of TSB's (originally posted HERE regarding injector failure:

-------------------------------------
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).

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1715916&evc=numSrch#ss1-1715916">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.

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1715916&evc=numSrch#ss2-1715916">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.

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1715916&evc=numSrch#ss3-1715916">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:

<LI type=1>Replace the fuel filter element. <LI type=1>Install all disconnected and removed components. Refer to the applicable procedures. <LI type=1>Start and idle the engine. You may have to prime the fuel system before the engine will start. <LI type=1>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.
<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1715916&evc=numSrch#ss4-1715916">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.

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1715916&evc=numSrch#ss5-1715916">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.

-------------------------------------
Subject:Special Policy Adjustment - Injectors-Replace #04039 - (05/26/2004)



Models:2001-2002 Chevrolet Silverado

2001-2002 GMC Sierra

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





<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1522387&evc=numSrch#ss1-1522387">Condition



Some customers of 2001-02 model year Chevrolet Silverado and GMC Sierra vehicles, equipped with a 6.6L Duramax Diesel (RPO LB7 - VIN Code 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 or ball seat erosion.

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1522387&evc=numSrch#ss2-1522387">Special Policy Adjustment



This special policy 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 policy only covers the above noted failure modes, which are identified by high fuel return flow.

For vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after May 25, 2004, are covered by this special policy 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.

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1522387&evc=numSrch#ss3-1522387">Vehicles Involved



Involved are certain 2001-02 model year Chevrolet Silverado and GMC Sierra vehicles equipped with a 6.6L Duramax Diesel (RPO LB7 - VIN Code 1) engine and built within the following VIN breakpoints:

Year

Division

Model

From

Through

2001

Chevrolet

Silverado

1E100028

1E346644

1F100001

1F213872

1Z100015

1Z100019

2001

GMC

Sierra

1E100021

1E346642

1F1000101

1F213864

2002

Chevrolet

Silverado

2E100009

2E306435

2F100004

2F247804

2002

GMC

Sierra

2E100003

2E306345

2F100011

2F247974

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1522387&evc=numSrch#ss4-1522387">Parts Information



Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO).

Part Number

Description

Qty/ 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

97720043

Gasket, Silicone

1

97188463

Housing, F/Injr Noz

As Req'd

94051259

Seal, F/Injr Noz Hsg (O-Ring)

As Req'd

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

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1522387&evc=numSrch#ss5-1522387">Customer Notification



Customers will be notified of the special policy on their vehicles by General Motors (see copy of typical customer letter included with this bulletin -- actual divisional letter may vary slightly).

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1522387&evc=numSrch#ss6-1522387">Service Procedure



Refer to the latest version of Technical Service Bulletin 04-06-04-007 to perform diagnostics and fuel injector replacement for high fuel return rates.

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1522387&evc=numSrch#ss7-1522387">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 recall 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.

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1522387&evc=numSrch#ss8-1522387">Claim Information



For vehicles repaired under the terms of this special policy, submit a claim with the information indicated below:

Repair Performed

Part Count

Part No.

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.

--

--

*

MK-95

T5603

8.0

**

Reimbursement for Previous Repairs (Canadian Dealers ONLY)

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 or AIPDN Dealer net price plus applicable Mark-Up or Landed Cost Mark-up (for IPC) for injectors 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.

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1522387&evc=numSrch#ss9-1522387">Customer Reimbursement -- For US



All customer requests for reimbursement for previous repairs for the special policy condition will be handled by the Customer Assistance Center, not by dealers.

A General Motors Special Policy 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.

Top

Today's Birthdays
CamarosRus (2014)
sYc Member Details
Click here to become a full member with classifieds priviledges. To help support the sYc and the Supercar Registry as well as gain *full* access to the classifieds section, or to simply check your subscription status, please click the icon below:


Advertise with Yenko
Newest Members
RAR, BPG777, rts, NJDOTwrench, B1gDaddy
14110 Registered Users
Forum Stats
14110 Members
49 Forums
59282 Topics
571816 Posts

Max Online: 373 @ 11/07/12 10:54 PM
Who's Online
26 registered (69SUPERSPORT396, Donnie, sic427, Ls6 Ragtop, black69, budnate, 68l30, ZAPPER68, RPOLS3, 69 JL-8, 67rs/ss, 69 Post Sedan, 67ssonly, NEW, DannyLCMC, camaromb, Starship, Edgemontvillage, Cworkman2, SS4Real, TimG, GRNDNL, pxtx, 3 invisible), 71 Guests and 3 Spiders online.
Key: Admin, Global Mod, Mod