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09285: Product Emission - Service Engine Soon Light Illuminated - Exhaust Gas Recirculation (EGR) Cooler Plugging Prevention - (Nov 23, 2009)

General Motors has decided to conduct an emission recall involving certain 2007-2009 model year Chevrolet Express and Kodiak; 2008-2009 model year Chevrolet Silverado; and 2007-2009 model year GMC Savana, Sierra, and TopKick vehicles equipped with a Duramax 6.6L diesel engine (LMM). During engine operation, exhaust gases containing particulate matter flow through the exhaust gas recirculation (EGR) cooler and valve into the air intake manifold. Engine operation at idle or vehicle operation at low vehicle speeds/loads create low exhaust gas temperatures and low exhaust gas flow through these components, promoting the formation of wet/sticky particulate matter which can accumulate on the fins of the EGR cooler. If enough particulate matter accumulates on the fins inside the EGR cooler, the Service Engine Soon light will illuminate, diagnostic trouble code (DTC) P0401 may set, and the EGR cooler may require cleaning or replacement. Vehicle drive cycles that include extended idle times and/or slow average vehicle speeds can accelerate this condition.

Dealers are to reprogram the ECM only on TopKick/Kodiak (All), Silverado/Sierra (ambulance applications only), and some Express/Savana (non-ambulance, non-shuttle bus), and are to reprogram the ECM and TCM on some Express/Savana (ambulance and shuttle bus). This reprogramming will reduce the likelihood of particulate matter accumulation in the EGR cooler during prolonged idle operation, and will reduce the incidence of EGR cooler fouling.

Involved are certain 2007-2009 model year Chevrolet Express and Kodiak; 2008-2009 model year Chevrolet Silverado; and 2007-2009 model year GMC Savana, Sierra, and TopKick vehicles equipped with a Duramax 6.6L diesel engine (LMM), and built within these VIN breakpoints:

Important: Dealers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers using WINS) or Investigate Vehicle History (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved.

For dealers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to US and Canadian dealers through the GM GlobalConnect Recall Reports, or sent directly to export dealers. Dealers will not have a report available if they have no involved vehicles currently assigned.

The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall.

No parts are required for this recall.

ECM PROGRAMMING INSTRUCTIONS

A new engine operation calibration titled, Engine Calibration Update to Address Frequent Occurrences of DTC P0401 is available. Programming of the TCM is NOT required unless the vehicle is an Express or Savana van equipped with RPO code ANC or YF2.

Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after 10/28/09 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided.

For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal.

1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming.
2. Reprogram the engine control module (ECM). Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required.

   2.1.	Connect the MDI to the vehicle.

   2.2.	Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen.

   2.3.	Select ECM Engine Control Module - Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required.

   2.4.	Follow the on-screen instructions.

3. Using the MDI, and GDS or Tech 2, clear all DTCs if required.

TCM PROGRAMMING INSTRUCTIONS (Express and Savana Only)

Do not attempt to order the calibration number from GMSPO. The calibration numbers required for this service procedure are programmed into control modules via a Multiple Diagnostic Interface (MDI) and TIS2WEB with the calibration update. Use TIS2WEB on or after 10/28/09 to obtain the calibration. If you cannot access the calibration, call the Techline Customer Support Center and it will be provided.

For step-by-step programming instructions, please refer to SI and the Techline Information System (TIS) terminal.

1. Verify that there is a battery charge of 12 to 16 volts. The battery must be able to maintain a charge during programming. Only use an approved Midtronic 165-PSC charger to maintain proper battery voltage during programming.
2. Reprogram the engine control module (ECM). Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required.

   2.1.	Connect the MDI to the vehicle.

   2.2.	Select J2534 MDI and Reprogram ECU from the Select Diagnostic Tool and Programming Process screen.

   2.3.	Select TCM Transmission Control Module - Programming from the Supported Controllers screen. Refer to SI and Service Programming System (SPS) documentation for programming instructions, if required.

   2.4.	Follow the on-screen instructions. Refer to TCM Calibration Information in this bulletin.

3. Using the MDI, and GDS or Tech 2, clear all DTCs if required.

TCM CALIBRATION INFORMATION (Express and Savana Only)

TCM calibrations on shuttle buses and ambulance packages will also have to be updated when the ECM is updated with the P0401 calibration. NOTE: RPO ANC did not exist on 2007 model year Express or Savana vans, so if the vehicle has been converted to a shuttle you need to refer to the part numbers listed below. If a 2007, 2008, or 2009 model year Express or Savana was not ordered with RPO ANC or YF2 but converted to a shuttle or ambulance after production, you will need to call Techline for assistance. Below is the calibration information for shuttle buses (RPO ANC) and ambulances (RPO YF2). If the calibrations are not found in TIS2WEB, please contact the Techline Customer Support Center.

1. 2007 Model Year

   •	Engine diagnostic calibration part numbers

   -	12632400 for single generator equipped vans

   -	12632401 for dual generator equipped vans

   •	Engine operation calibration part number: 12632399

   •	Transmission calibration part number: 24252538

2. 2008 Model Year

   •	Engine diagnostic calibration part numbers:

   -	12632403 for single generator equipped vans

   -	12632404 for dual generator equipped vans

   •	Engine operation calibration part number: 12632402

   •	Transmission calibration part number: 24252539

3. 2009 Model Year

   •	Engine diagnostic calibration part numbers:

   -	12632386 for single generator (less than 14,000 GVWR Gross Vehicle Weight Rating)

   -	12632387 for single generator (greater than 14,000 GVWR)

   -	12632384 for dual generator (less than 14,000 GVWR)

   -	12632385 for dual generator (greater than 14,000 GVWR)

   •	Engine Operation calibration part number: 12632383

   •	Transmission calibration part number: 24252531

Place a Recall Identification Label on each vehicle corrected in accordance with the instructions outlined in this Product Recall Bulletin. Each label provides a space to include the recall number and the five-digit dealer code of the dealer performing the recall service. This information may be inserted with a typewriter or a ballpoint pen.

Put the Recall Identification Label on a clean and dry surface of the radiator core support in an area that will be visible to people servicing the vehicle.

When installing the Recall Identification Label, be sure to pull the tab to allow adhesion of the clear protective covering. Additional Recall Identification Labels for US dealers can be obtained from Dealer Support Materials by ordering on the web from DWD Store, www.gmdealerworld.com, and then click on the DWD Store link. Request Item Number S-1015 when ordering.

remove the exhaust cooler & clean . You may need to relace it .