Fuel in the oil is usually caused from leaking fuel injectors. There is a special warranty extension on the injectors.
THIS BULLETIN IS BEING REVISED TO ADD 2004 MODEL YEAR TRUCKS. PLEASE DISCARD SPECIAL POLICY BULLETIN NUMBER 04039A, DATED OCTOBER, 2006.
Some customers of 2001-04 model year Chevrolet Silverado; GMC Sierra; 2003-04 Chevrolet Kodiak and GMC TopKick 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, ball seat erosion, or high pressure seal extrusion (refer to Corporate Bulletin Number 04-06-04-007G and SI).
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 2001-2002 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.
For 2003 vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after October 10, 2006 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 October 10, 2006 must be submitted to the Service Contract provider.
For 2004 vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after November 19, 2007 are covered by this special coverage and must be submitted using the labor operation codes provided with this bulletin. Claims with repair orders prior to November 19, 2007 must be submitted to the Service Contract provider.
Involved are all 2001-04 model year Chevrolet Silverado, GMC Sierra; 2003-2004 Chevrolet Kodiak and GMC TopKick vehicles equipped with a 6.6L Duramax Diesel (RPO LB7 - VIN Code 1) engine and built within the following start of production to end of production VIN breakpoints:
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
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.
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).
Refer to the latest version of Corporate Bulletin Number 04-06-04-007G and Service Information to perform diagnostics and fuel injector replacement for high fuel return rates.
This bulletin is being revised to advise technicians that 2001-2004 model year vehicles may be covered by Special Policy 04039. Please discard Corporate Bulletin Number 04-06-04-007H (Section 06 -- Engine/Propulsion System).
Some customers may comment on the Service Engine Soon light becoming illuminated. Upon investigation, the technician may find DTCs P0087, P0093 or P1093. Additional customer comments may include a lack of power, a fuel smell on the oil indicator (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 excessive 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 03-06-04-036A to avoid fuel system contamination.
Important: If the technician commands the fuel rail pressure with Tech 2® to 160 MPa at idle and it reaches at least 158 MPa, then this bulletin does not apply. The technician should then follow normal SI diagnostics. If the rail pressure does not reach 158 MPa, snapshot the data, then follow the diagnostics in this bulletin.
Reference the table below in order to follow current diagnostics for the condition that the vehicle is experiencing. 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
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.
Injector sleeves only need to be replaced if there is damage to the tapered sealing surface where it seals against the cylinder head. If an injector sleeve becomes loose or dislodged when replacing injectors, inspect the cylinder head to sleeve mounting surfaces. If there are no witness marks from a combustion leak or coolant leak, reseal the sleeve using SI procedures for Fuel Injector Nozzle Tube Sleeve Replacement.
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 SI.
Record all diagnostic data as outlined on a copy of the attached diagnostic worksheet. The diagnostic worksheet, snap shot of any DTCs, snap shot of the preliminary (actual) fuel rail pressure vs desired as commanded by the Tech 2® and a copy of the repair order with technician comments is to be returned with the removed injectors.
After replacing the injectors, perform the following steps:
Fuel Leak Diagnosis (Inside of Engine)
Important: When the fuel injector pressure lines are removed, debris will fall into the fuel injector inlet fitting. Vacuum the debris from the inlet fitting of the fuel injector before reconnecting fuel lines to the fuel injectors.
Tighten Tighten the bolts to 15 N·m (11 lb ft).
Tighten Tighten the fuel feed pipes to 44 N·m (32 lb ft).
Important: During this test the fuel dye may quickly dilute in the engine oil. Observe the internal fuel components for dye traces immediately after startup.
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