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).
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.
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.
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).
Start with this SI Diagnostic in the Diagnostic Information and Procedures sub-section of the Engine Controls Section
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
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
Injector - Fuel
Gasket - Valve Rocker Arm Cover
Gasket - Fuel Injection Fuel Return Pipe and Injector
Gasket - Fuel Injection Fuel Return Pipe
Seal - Water outlet
Seal, O-ring - Injector Sleeve
*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:
Injector, Fuel - Diagnose & Replace(2003-2004 Models)
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
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:
<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).
Injector Kit, Dir Fuel (Incls: Injector, Gasket, Seal)
Gasket, Valve Rocker Arm Cover (Reusable Gasket)
Gasket, F/Injr Fuel Return Pipe
Gasket, F/Injr Fuel Return Pipe
Seal, Water Outlet
Housing, F/Injr Noz
Seal, F/Injr Noz Hsg (O-Ring)
*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:
Refer to the latest version of TSB 04-06-04-007 to diagnose and replace all 8 fuel injectors.
Reimbursement for Previous Repairs (Canadian Dealers ONLY)
Administrative labor hours
* -- 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.