I had the TSB for the LLY reflash but have lost it. I went to get my truck in in the next few days to have it done. Does anyone have it? Also is their one for the A/C not cooling well?

Thanks
Greg

2004-2005 LLY 6.6L Diesel EGR DTCs P0401 or P0404 - keywords idle rough smoke #PIP3256B - (Mar 22, 2005)

2004-2005 LLY 6.6L Diesel EGR DTCs P0401 or P0404



The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in the PI.

Condition/Concern:

Vehicle may be brought in for SES or MIL light on. Upon inspection of the vehicle, the technician may find EGR DTCs P0401 or P0404.

Recommendation/Instructions:
<LI type=1>Complete the proper SI diagnostics for the DTCs found. <LI type=1>If normal SI diagnostics have been completed and were inconclusive, inspect for any exhaust, air intake, or wiring harness modifications made to the vehicle. Modifications may induce EGR codes. <LI type=1>There has been a calibration released to address the concern of intermittent DTCs P0401 and P0404.
The new calibration will address DTCs P0401 and P0404 when the codes are set with no engine driveability concerns. If P0401 or P0404 are set and there is a customer concern of low power or black smoke, monitor the EGR valve and MAF sensor readings during the concern. A sticking EGR valve or skewed MAF sensor reading may also cause an intermittent P0401 or P0404 to set.
Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.

Models:

(2004-2005 Chevrolet Silverado) and (2004-2005 GMC Sierra)

04 05 6.6 LLY Smoke , Fuel Knock , Surging and High Injector Balance Rates - kw white black idle surge rough noise accelerate P0300 P0301 P0302 P0303 P0304 P0305 P0306 P0307 P0308 miss misfire SES DTC #PIP3129B - (Oct 21, 2004)

04 05 6.6 LLY Smoke, Fuel Knock, Surging, and High Injector Balance Rates

.

The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI.

Condition/Concern:

Customer concern may be a low speed surge (8 to 10 mph or near 1000 RPM), acceleration fuel knock noise at 1700 to 1800 RPM, rough idle, white smoke at idle, or high positive injector balance rates.

Recommendation/Instructions:

<LI type=1>High positive injector balance rates (over +4.0 in park or +6.0 in drive) may be causing white smoke at idle or while driving. <LI type=1>Document all injector cylinder balance rates at the beginning of the diagnosis. <LI type=1>There is an updated calibration to address the white smoke, high positive balance rates, idle surge, and a fuel knock noise at or near 1700 to 1800 RPM. <LI type=1>Install the updated calibration and evaluate the smoking, high injector balance rates, idle surge, and fuel knock noises.
If there is still a mechanical concern with an injector, and balance rates are still over the SI specification of +4.0 in park or +6.0 in drive, replace only the effected injector.
NOTE: Before any injector replacements, a large fuel sample should be taken from the fuel filter and checked for contaminants or poor quality.

.

Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.

Models:

(04 05 LLY 6.6 C2 C3 K2 K3 Chevrolet Silverado 2500HD,3500) and (04 05 LLY 6.6 C2 C3 K2 K3 GMC Sierra 2500 HD,3500 ) and (04 05 LLY 6.6 C4 C5 D4 D5 E4 E5 Chevrolet Kodiak 04 05 LLY 6.6 C4 C5 D4 D5 E4 E5 GMC Topkick)

Poor A/C Performance - A/C Will Not Blow Cold Enough (Perform A/C System Checks, Replace Accumulator, If Necessary) #02-01-38-007C - (Jul 27, 2004)
Poor A/C Performance -- A/C Will Not Blow Cold Enough (Perform A/C System Checks, Replace Accumulator if Necessary)
2002-2004 Chevrolet Silverado
2002-2004 GMC Sierra
with 6.6L Diesel Engine (VINs 1, 2 -- RPOs LB7, LLY)
and Denso A/C Compressor
This bulletin is being revised to add part numbers for the hose, bracket and insulator to the Parts Information. Please discard Corporate Bulletin Number 02-01-38-007B (Section 01 -- HVAC).
Condition
Some customers may comment on less than desirable A/C performance, especially when the ambient temperature is above 32°C (90°F).
Correction
Perform the following A/C system checks and replace the accumulator with P/N 89018601, if necessary. This new accumulator requires the accumulator bracket, the accumulator insulator and the A/C suction hose to be replaced also.
<TABLE border=0><TBODY><TR><TD vAlign=top>• </TD><TD vAlign=top>Check for A/C system leaks. </TD></TR></TBODY></TABLE>
<TABLE border=0><TBODY><TR><TD vAlign=top>• </TD><TD vAlign=top>Check the A/C system for proper refrigerant charge. This requires recovering the refrigerant to determine charge in system. Refer to Refrigerant Recovery and Recharging in the HVAC sub-section of the Service Manual. </TD></TR></TBODY></TABLE>
<TABLE border=0><TBODY><TR><TD vAlign=top>• </TD><TD vAlign=top>If no leaks were found and the A/C system is charged to specification, replace the accumulator using the procedure listed below. </TD></TR></TBODY></TABLE>
If normal diagnostics do not lead to a correction, then perform the following A/C system checks.
<LI type=1>Re-calibrate the actuators. Refer to Recalibrating Actuators in the HVAC System - Manual/Automatic sub-section of the Service Manual (SI Document ID #904666). <LI type=1>Inspect the lower A/C condenser deflector for proper installation. The deflector should be positioned at the lower part of the condenser and extend forward into the top of the front bumper and below the two fresh air intake holes. <LI type=1>Check the engine cooling fan clutch for proper operation. Refer to Fan Clutch Diagnosis in the Engine Cooling sub-section of the Service Manual (SI Document ID #774320). <LI type=1>If the vehicle is equipped with a front license plate, inspect for proper installation. If the license plate bracket is installed upside down, it will block part of the two fresh air intake holes in the bumper. When the license plate bracket is installed correctly, the writing on the back of the bracket will be upside down. Inspect for material between the radiator and condenser. Remove the top plate to confirm that there is no restriction. A radiator front filled with material will decrease condenser performance. <LI type=1>Some improvements have been found by lowering the A/C charge from 0.82 kg (1.8 lbs) to 0.73 kg (1.6 lbs). <LI type=1>Check the low pressure cycling switch for proper operation. The low pressure switch opens at 172-234 kPa (25-34 psi) , which stops compressor operation and closes when the low side pressure reaches 276-310 kPa (40-45 psi). This enables the compressor to turn back on. Important: Compressor clutch engagement cannot be used to determine the status of the low pressure switch. The low pressure switch is one of several inputs to the HVAC control module for A/C request authorization. A/C request is one of several inputs to the powertrain control module (PCM) that control A/C compressor clutch engagement. Using a scan tool to monitor low pressure switch status while monitoring the low side pressure with the ACR 2000 at the service port and watch the pressure at which the switch opens/closes is imperative to successfully diagnosing the switch.
If the A/C performance has not improved after performing the above steps, replace the accumulator with P/N 89018601, using the procedure listed below. This new accumulator also requires the accumulator bracket, accumulator insulator and A/C suction hose to be replaced.
Accumulator Replacement
<LI type=1>Remove the suction hose mounting bolt from the A/C compressor. <LI type=1>Remove the suction hose from the compressor. <LI type=1>Remove the suction hose nut from the accumulator. <LI type=1>Remove the suction hose from the accumulator. <LI type=1>Remove the evaporator tube nut from the evaporator. <LI type=1>Remove the evaporator tube from the evaporator. <LI type=1>Disconnect the electrical connector from the A/C low pressure switch. <LI type=1>Remove the nut from the evaporator fitting. <LI type=1>Remove the accumulator bracket nut from the retaining stud. <LI type=1>Remove the accumulator. <LI type=1>Remove the retaining bracket bolt. This bolt must be reused for the new bracket. <LI type=1>Remove the insulator. One half of the insulator must be reused. <LI type=1>Install the new insulator and one half of the old insulator onto the new accumulator. <LI type=1>Install the new retaining bracket and bolt to the accumulator. Do not tighten at this time. <LI type=1>Add the PAG oil directly into the new accumulator that was removed during the recovery process plus an additional 90 ml (3 oz). <LI type=1>Install the new accumulator. <LI type=1>Install the accumulator bracket nut. Tighten Tighten the nut to 9 N·m (80 lb in). <LI type=1>Tighten the retaining bracket bolt. Tighten Tighten the nut to 10 N·m (89 lb in). <LI type=1>Install the nut to the evaporator fitting. Tighten Tighten the nut to 16 N·m (12 lb ft). <LI type=1>Install the evaporator tube to the evaporator. <LI type=1>Install the evaporator tube nut to the evaporator. Tighten Tighten the nut to 16 N·m (12 lb ft). <LI type=1>Install the new suction hose to the accumulator. <LI type=1>Install the suction hose nut to the accumulator. Tighten Tighten the nut to 16 N·m (12 lb ft). <LI type=1>Connect the electrical connector to the A/C low pressure switch. <LI type=1>Install the new suction hose to the compressor.
Install the suction hose mounting bolt to the A/C compressor.
Tighten
Tighten the bolt to 16 N·m (12 lb ft).
Parts Information

<TABLE width="100%" border=1><TBODY><TR><TH vAlign=bottom align=middle>Part Number







</TH><TH vAlign=bottom align=middle>Description







</TH></TR><TR><TD vAlign=center align=middle>89018601







</TD><TD vAlign=center align=middle>Accumulator







</TD></TR><TR><TD vAlign=center align=middle>15136596







</TD><TD vAlign=center align=middle>Hose Assembly







</TD></TR><TR><TD vAlign=center align=middle>15136597







</TD><TD vAlign=center align=middle>Bracket







</TD></TR><TR><TD vAlign=center align=middle>10372792







</TD><TD vAlign=center align=middle>Insulator







</TD></TR></TBODY></TABLE>

Parts are currently available from GMSPO.

Warranty Information

For vehicles repaired under warranty, use:

<TABLE width="100%" border=1><TBODY><TR><TH vAlign=bottom align=middle>Labor Operation







</TH><TH vAlign=bottom align=middle>Description







</TH><TH vAlign=bottom align=middle>Labor Time







</TH></TR><TR><TD vAlign=center align=middle>D4702*







</TD><TD vAlign=center align=middle>HVAC System Check







</TD><TD vAlign=center align=middle>0.6 hr







</TD></TR><TR><TD vAlign=center align=middle>Add:







</TD><TD vAlign=center align=middle>To Replace Accumulator







</TD><TD vAlign=center align=middle>0.4 hr







</TD></TR><TR><TD vAlign=center align=middle>Add:







</TD><TD vAlign=center align=middle>To Recover/Recharge A/C System







</TD><TD vAlign=center align=middle>0.5 hr







</TD></TR></TBODY></TABLE>

*This a unique Labor Operation Number for use only with this bulletin. This number will not be published in the Labor Time Guide.

(edited by jc64 to shorten)
04 05 6.6 LLY Smoke , Fuel Knock , Surging and High Injector Balance Rates.......

04 05 6.6 LLY Smoke, Fuel Knock, Surging, and High Injector Balance Rates


Recommendation/Instructions:
<LI type=1>High positive injector balance rates (over +4.0 in park or +6.0 in drive) may be causing white smoke at idle or while driving. <LI type=1>Document all injector cylinder balance rates at the beginning of the diagnosis. <LI type=1>There is an updated calibration to address the white smoke, high positive balance rates, idle surge, and a fuel knock noise at or near 1700 to 1800 RPM. <LI type=1>Install the updated calibration and evaluate the smoking, high injector balance rates, idle surge, and fuel knock noises.
If there is still a mechanical concern with an injector, and balance rates are still over the SI specification of +4.0 in park or +6.0 in drive, replace only the effected injector.
GMCSID or anyone.....

I have seen this before, injector balance rate SI spec. for Park and Drive.
Why are the injector balance rates diferent for Park and Drive?

How does this work for a Manual transmission?
What is the spec for a ZF-6?

Thanks,
jc64

I would say because of the load on the engine in drive the balance rates need a wider range to keep the engine running smoothly. The spec for manual trans is ±4mm³

GMCSID,
Thanks, that has had me puzzled for a while on how that will work with the ZF-6.

I check the T.S.B. forum often. My 05 has a surge at "very light" to "light throttle" at any RPM, any speed generally under 40mph. Gets annoing when driving through a 30mph speed limit zone with small hills like we have here in MO. If I try, I can get-r to buck real good! Took it in twice for the surge, and they said it has all the updates in it and do not see any problem.:mad:
I'm just wating for GM to come out with a fix, or reflash for it, or for it to get so bad that the dealer will say "Yes, that is a problem, let see if we can fix it.":rolleyes: ):h


Thanls,
jc64

ps: Truck always been stock.

:) Howdy y'all ,just signed up ,lots of good info
I got an 2002 d-max w/170 horse intimidator chip Runs great
Just lately in mornings it cranks fine but no fire . tried pumping the fuel primer
which sometimes works immediately usually have to wait a few minutes
and she'll fire. any ideas if that is fuel drainback
do these have lift pumps in tank?
any help would be great Thanks
02 d-maxer
:help:

02 d-maxer,

First off.....:welcome2:

Second, you may want to start a thread in the Duramax First Generation (LB7) 2001-2004 forum. You may have a better chance to have your question answered there than here in the T.S.B.'s forum.

These guys work on there trucks a lot and know there S Censored T.
If you have a question about something else, do a Search, you just may find an answer.

jc64

jc64

Iwill try that ,thanks for your help

02 d-maxer