Service Engine Soon (SES) Light, P0087, P0093, P1093, Low Power, No Start, Hard Start, Fuel in Crankcase (Replace All Injectors - New Strategy for High Fuel Return Rates) #04-06-04-007C - (Nov 10, 2004)
</TABLE>Service Engine Soon (SES) Light, P0087, P0093, P1093, Low Power, No Start, Hard Start, Fuel in Crankcase (Replace All Injectors -- New Strategy for High Fuel Return Rates)
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 the fuel filter. Please discard Corporate Bulletin Number 04-06-04-007B (Section 06-Engine).
Important: Before the technician begins diagnostics and repair, be sure to follow the guidelines in Corporate Service Bulletin 03-06-04-036 to avoid fuel system contamination.
<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1563951&psdid=297&evc=sm#ss1-1563951">Condition
Some owners 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=1563951&psdid=297&evc=sm#ss2-1563951">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=1563951&psdid=297&evc=sm#ss3-1563951">Correction
Important: Before the technician begins diagnostics and repair, be sure to follow the guidelines in Corporate Service Bulletin 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).
<TABLE width="100%" border=1><TBODY><TR><TH align=middle>Condition
</TH><TH vAlign=bottom align=middle>Start with this SI Diagnostic in the Diagnostic Information and Procedures sub-section of the Engine Controls Section
</TH></TR><TR><TD vAlign=center align=middle>Delayed Start
</TD><TD vAlign=center align=middle>Hard Start
</TD></TR><TR><TD vAlign=center align=middle>Lack of Power
</TD><TD vAlign=center align=middle>Lack of Power, Sluggishness or Sponginess
</TD></TR><TR><TD vAlign=center align=middle>Engine Cranks but Does Not Run
</TD><TD vAlign=center align=middle>Engine Cranks but Does Not Run
</TD></TR><TR><TD vAlign=center align=middle>Fuel in Oil or Fuel leak out of breather
</TD><TD vAlign=center align=middle>Fuel In Engine Oil in Engine Mechanical
</TD></TR><TR><TD vAlign=center align=middle>DTC P0087
</TD><TD vAlign=center align=middle>DTC P0087
</TD></TR><TR><TD vAlign=center align=middle>DTC P0093
</TD><TD vAlign=center align=middle>DTC P0093
</TD></TR><TR><TD vAlign=center align=middle>DTC P1093
</TD><TD vAlign=center align=middle>DTC P1093
</TD></TR></TBODY></TABLE>
Important: If 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. <TABLE border=0><TBODY><TR><TD vAlign=top> - </TD><TD vAlign=top>If the fuel pressure is more than 145 MPa, the system is OK. </TD></TR></TBODY></TABLE>
<TABLE border=0><TBODY><TR><TD vAlign=top> - </TD><TD vAlign=top>If the fuel pressure is unable to increase to more than 145 MPa, replace the fuel injection pump. Refer to Fuel Injection Pump Replacement in the appropriate Service Manual. </TD></TR></TBODY></TABLE>
<TABLE border=0><TBODY><TR><TD vAlign=top> - </TD><TD vAlign=top>Be sure to record fuel pressure readings on the diagnostic worksheet. </TD></TR></TBODY></TABLE>
<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1563951&psdid=297&evc=sm#ss4-1563951">Parts Information
<TABLE width="100%" border=1><TBODY><TR><TH vAlign=bottom align=middle>Part Number
</TH><TH vAlign=bottom align=middle>Description
</TH><TH vAlign=bottom align=middle>Qty
</TH></TR><TR><TD vAlign=center align=middle>97729095*
</TD><TD vAlign=center align=middle>Injector - Fuel
</TD><TD vAlign=center align=middle>8
</TD></TR><TR><TD vAlign=center align=middle>97188896
</TD><TD vAlign=center align=middle>Gasket - Valve Rocker Arm Cover
(Reusable Gasket)
</TD><TD vAlign=center align=middle>As Req'd
</TD></TR><TR><TD vAlign=center align=middle>97228933
</TD><TD vAlign=center align=middle>Gasket - Fuel Injection Fuel Return Pipe and Injector
</TD><TD vAlign=center align=middle>8
</TD></TR><TR><TD vAlign=center align=middle>97600925
</TD><TD vAlign=center align=middle>Gasket - Fuel Injection Fuel Return Pipe
</TD><TD vAlign=center align=middle>2
</TD></TR><TR><TD vAlign=center align=middle>94011604
</TD><TD vAlign=center align=middle>Seal - Water outlet
</TD><TD vAlign=center align=middle>1
</TD></TR><TR><TD vAlign=center align=middle>97720043
</TD><TD vAlign=center align=middle>Sealant
</TD><TD vAlign=center align=middle>1
</TD></TR><TR><TD vAlign=center align=middle>97188463
</TD><TD vAlign=center align=middle>Sleeve, Injector
</TD><TD vAlign=center align=middle>As Req'd
</TD></TR><TR><TD vAlign=center align=middle>94051259
</TD><TD vAlign=center align=middle>Seal, O-ring - Injector Sleeve
</TD><TD vAlign=center align=middle>As Req'd
</TD></TR><TR><TD vAlign=center align=middle>97385488
</TD><TD vAlign=center align=middle>Filter, Fuel
</TD><TD vAlign=center align=middle>1
</TD></TR></TBODY></TABLE>
Parts are currently available from GMSPO.
*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=1563951&psdid=297&evc=sm#ss5-1563951">Warranty Information
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:
<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>J7801
</TD><TD vAlign=center align=middle>Injector, Fuel -- Diagnose & Replace
</TD><TD vAlign=center align=middle>8.0 hrs*
</TD></TR><TR><TD vAlign=center colSpan=3>*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.
</TD></TR></TBODY></TABLE>