I took my 02 in for excessive black smoke and the dealer told me injector 1 is failing but due to milage on my truck(142000...no injectors yet) they had to get "special permission" from GM to replace under the "special policy". Then dealer says gm has refused because the injector is not failing in the way the "special policy" dictates. Just nonsense. So I get to pay for the diagnostic AND drive the truck like a time bomb waiting to self destruct ...probably while towing with my family through the mountains. GM is not dealing in good faith with this issue. Funny thing is they WILL pay eventually when they fail totally (even the dealer acknowleged this...total failure imminent)and probably pay more than if it was done now. Dumb , dumb dumb.

Dump a few quarts of diesel into the crankcase and take it back. That should get it done.

Try another dealer!

Can't afford to pay another diagnostic fee for nothing so I'll just have to wait it out. Certainly feeling ripped off.

Paul, how about a location, someone may be able to help u out.

I'd Go To Another Dealer , They Dont Want To Help You Out Or Go With The Diesel In The Crankcase

If it was me I'd get on the chain (what my wife says when I go into the bulldog tied to my doghouse mood)

When it was in they gave you a service number or get it from the service manager and raise hell with GM, talk to every person and get down there throat!
If it shows #1 isn't with'n specs and it is showing signs (you took it in for a reason) it needs to be taken care of because if I read the other posts right you don't want all that diesel in the crank case ruining the motor in the future when it isn't covered.

The phone is an easy way to get heard and it may be a bit of a pain but keeping on bugging them is worth it. Hell if I get too rieled up I will call on one line and have the wife call with the other at the same time........If you don't like the answer ask to talk to a supervisor if you don't like there answer talk to his supervisor. Keep climbing up the ladder till someone takes care of the customer......also get out your paper they sent on the 200000 warranty and keep referring to it!

I would hate to be in the middle of nowhere this summer pulling and have it go tits up...not that it will but theres a chance!

:grd:

2 quarts of diesel in the crankcase a mile before you get to the dealer lot. Won't hurt the engine in the least and will get your truck fixed. No fuss, no muss. You have already reported the problem, this would just be an extension of it. While your at it, you can raise hell saying if they had fixed it the first time, you wouldn't have driven around with diesel in your crankcase, possibly ruining your engine.

Thanks guys...all very much appreciated. I've started climbing the chain with gm...I'll let you know how it goes.

paul, look around there was a post that listed what dealer needs to hear to cover replacement. when you talk to someone make sure they know you are taking names. i may be wrong but black smoke would be emissions violation, so you might want to add that you'll have to notify state EPA or Air Resource Board. the more ammo the better. hope you get it fixed.

That sounds like a good idea. Play their game. But there are also a lot more semi's putting black smoke out there and they have some stringent rules.

Diesel fuel in the crankcase is not the only prerequisite for injector Special Policy. You must prove high return rates from the injectors. You must ramp up the fuel pressure to 160kpa and see if the actual and desired match. If you have fuel in the crancase there is a leak that won't allow rail pressure to build to 160 kpa to be an injector. If it ramps properly and you have fuel in your crankcase it is an external return line leak.
Gm is on to tactics and all injectors are now scrutinized on EVERY core return to prove high return rates. If high return rate injector is not found,dealers can and have been charged back.Did the dealer actually check return rates or just balance rates.

On another note, These trucks are bought knowing it has a 100k waranty and all is perfect. Now @140k it has a problem and everyone now thinks GM is sticking it to them.Gm steped up to the plate and said they would replace injectors under a Special Policy IF they have a high return rate from an internal defect. These injectors went 140K. No diesel manufacturer waranties injectors over 100K.
If you want to dump diesel in the crankcase don't b--ch about truck prices you helped raise them. Gm did everything that they promised when you bought it. Just remember to pick your fights wisely. If you deseve them then you should get them.:rant:

If the engine was advertised as a 200000 mile engine then thats what it should be. You can bet that GM wouldn't be replacing injectors if they hadn't sold a warehouse full of them with known faults. Is the policy good in principal? certainly. Is gm now splitting hairs with what they consider a failure? It appears so. Diesel users and buyers purchase specifically for reliability and the pickup market is the largest segment for the big 3. If they don't step up they lose thier exec bonuses so there was little choice. I think the current tactic of gm is now backpeddling to the point where the dealers don't want to enforce the "special policy" for fear of not getting paid by gm. I'm going to ride it out untill the imminent failure (dealers words, not mine) and when it happens I'll be looking to gm to make it right. Is that asking too much? I guess my thinking of them being proactive and replacing injectors before they do engine damage and it costs them more is just not good corporate thinking...perhaps what got gm where they are now.

Diesel fuel in the crankcase is not the only prerequisite for injector Special Policy. You must prove high return rates from the injectors. You must ramp up the fuel pressure to 160kpa and see if the actual and desired match. If you have fuel in the crancase there is a leak that won't allow rail pressure to build to 160 kpa to be an injector. If it ramps properly and you have fuel in your crankcase it is an external return line leak.
Gm is on to tactics and all injectors are now scrutinized on EVERY core return to prove high return rates. If high return rate injector is not found,dealers can and have been charged back.Did the dealer actually check return rates or just balance rates.

On another note, These trucks are bought knowing it has a 100k waranty and all is perfect. Now @140k it has a problem and everyone now thinks GM is sticking it to them.Gm steped up to the plate and said they would replace injectors under a Special Policy IF they have a high return rate from an internal defect. These injectors went 140K. No diesel manufacturer waranties injectors over 100K.
If you want to dump diesel in the crankcase don't b--ch about truck prices you helped raise them. Gm did everything that they promised when you bought it. Just remember to pick your fights wisely. If you deseve them then you should get them.:rant:


Bull****.

If it was an unusual case I agree but since it's the norm, shame on GM. Add $3500 to the price of a new Dmax if you plan on keeping it past 100,000 miles for injector replacement. Add $5000 for the diesel option, add 20% to your fuel costs. It's just not looking pretty for all brand diesel sales.

Looks like they (GM) are going into belt tightening mode. I wouldn't doubt they are looking at the bottom line in all these injector replacements and a gate keeper has been put into place. Chrysler does that as normal business. It can be a real pain. Unless they get approval, the dealer could be liable for repairs that do not fix the problem. They don't want mechanics throwing parts at the trucks, they want diagnosis.

If the engine was advertised as a 200000 mile engine then thats what it should be. You can bet that GM wouldn't be replacing injectors if they hadn't sold a warehouse full of them with known faults. Is the policy good in principal? certainly. Is gm now splitting hairs with what they consider a failure? It appears so. Diesel users and buyers purchase specifically for reliability and the pickup market is the largest segment for the big 3. If they don't step up they lose thier exec bonuses so there was little choice. I think the current tactic of gm is now backpeddling to the point where the dealers don't want to enforce the "special policy" for fear of not getting paid by gm. I'm going to ride it out untill the imminent failure (dealers words, not mine) and when it happens I'll be looking to gm to make it right. Is that asking too much? I guess my thinking of them being proactive and replacing injectors before they do engine damage and it costs them more is just not good corporate thinking...perhaps what got gm where they are now.If it does damage to the engine, I'm not sure GM will pay for that. The 200,000 mile warranty is on the injectors, not the whole motor right? I have heard of many manufacturer balking at the damage caused by another failure, take a look a the batteries leaking on the windshield washer resevoir on our trucks as an example.

Hoot, didn't we get the same song midwest is singing from another tech about a year ago? What was his username? Is this his clone?

No I'm not the same person.

The truck we are discussing has a fuel delivery issue. If the injector is injecting too much fuel there is likely a fuel knock. If you choose to not repair a fuel knock, piston damage is very possible.I would recommend another diagnosis and have the return rates checked.If there is injector ball/seat errosion,the injector will not control fuel delivery properly. This ball seat erroision RESULTS IN high return rates which is covered. Once again, you need proper diagnosis. Will it ramp up fuel pressure?Is the regualtor return rate higher than 1000?What is the actual return rate in cc's per bank and per cylinder?

Paul
In your original post you stated excessive smoke but no rough idle or fuel knock.If these symptoms DO NOT exist, you most likely have a boost issue. One injector putting in enough fuel to smoke excessively will hammer like mad on accel.Yes you could have an injector balance problem starting on one cylinder but the excessive smoke could be as simple as a charge air leak.
See if you can get me some more info.Remember when taking your truck to another dealer,that there is a TAC case on your truck from the previous dealer. Make shure your honest with them because just playing dumb could come back and bite you.Get me some info first and I'll try to help.

Gm is not back pedaling,they are doing everything they stated they would do in the Special policy. This injector thing is going to haunt all diesels with common rail.Ford and Dodge have allready had as much trouble as GM.
Steel is cut every day in industry with 20kpsi water and we have injectors with 23k .Injectors are probably never going to have a long service life.Don't campare them to old diesels, campare them to new ford and dodge. You'll be thankfull you have a GM .

There is a fuel knock and this was stated in my complaint to the dealership. Shop forman test drove the truck so I'm sure he heard it.

Bummer about your truck........

I can tell you some dealers are IDIOTS!

I asked for my balance rates the last time I was there and I got the pulse width timing numbers.

I would'nt let them touch my motor after that.