Campaign - Fuel Injector Replacement/Warr. Extension: Overview
SPECIAL COVERAGEBulletin No.: 04039C
Date: December 08, 2009
Subject: 04039C - Special Policy Adjustment - Injector - Replace
Models:
2001-2004 Chevrolet Silverado
2001-2004 GMC Sierra
2004 Chevrolet Kodiak
2004 GMC TopKick
Equipped with 6.6L Duramax Diesel (RPO LB7 - VIN Code 1) Engine
Supercede:
Technical Service Bulletins 03-06-04-036B and 04-06-04-007I have been incorporated into this bulletin. Please discard all copies of bulletin 04039B, issued November 2007.
Condition
Some customers of 2001-04 model year Chevrolet Silverado; GMC Sierra; 2003 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.
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.
Vehicles Involved
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 Information
Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO).
*P/N 97729095 is only available in a merchandising pack quantity of 4.
It is recommended that the customer purchase the latest released fuel filter, P/N 12633243. Refer to Corporate Bulletin Number 04-06-04-070B.
Customer Notification
Customers will be notified of the special policy on their vehicles by General Motors (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly).
Injector Core Return Process - Effective June 2008
Effective June 2008, the handling of 6.6L Duramax Injector (MY01-MY04 LB7) cores for part number 97729095 changed. The majority of injector cores will now be returned using the normal light core return process to UPS-Supply Chain Solutions (UPS-SCS). For these cores, credit will be issued using the normal GMSPO core credit process. However, a sampling of injectors replaced under warranty will continue to be returned to the Warranty Parts Center (WPC) for evaluation. This dual process will simplify the core credit process for dealers and provide more efficient handling of the cores overall.
For injector warranty claims, dealers should continue to hold cores until the warranty claim is paid.
Important
All replaced injectors must be returned to either the WPC or the core return center (UPS-SCS). Approximately 30% of the warranty claims will be requested back to the WPC.
Important
WAIT UNTIL THE WARRANTY CLAIM IS PAID TO DETERMINE THE LOCATION TO WHICH THE INJECTORS MUST BE RETURNED. IF A WPC PART RETURN REQUEST IS RECEIVED, RETURN THE INJECTORS TO THE WPC. IF A WPC PART RETURN REQUEST IS NOT RECEIVED, THEN RETURN THE INJECTORS TO THE CORE RETURN CENTER. Please follow Corporate Bulletin 99-00-89-019E that applies to the WPC return procedures. All injectors of a single engine must arrive at the WPC boxed or bagged together in sets of four or eight injectors. A copy of the part request, repair order with technician comments, snapshot of the preliminary (actual) fuel rail pressure vs. desired as commanded by the Tech 2(R) to 160 MPa, and the completed diagnostic worksheet must be included with the injectors. No snapshot is required for vehicles that do not start. If the WPC does NOT request the injectors, return the cores following the normal light core guidelines (apply through EPIC/RAPID)* to UPS-Supply Chain Solutions (UPS-SCS)*.* In Canada, injector cores are now to be returned using the normal core return process using form PC659C (Application for Authorization to Return Material) unless requested by the WPC. Sets of injectors should be secured with tape or in an overpack container in sets of four or eight for returns to both UPS-SCS and to the WPC. A copy of the repair order and diagnostic worksheet is still requested with the core for both warranty related and regular return.
For returns to UPS-SCS, the core ID label (2) must be visible on the outside end of the package at the opposite end from the part label (1).
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation:
- If using GWM, submit as a Net Item under the appropriate labor code.
- If using WINS, submit using normal labor operations for courtesy transportation as indicated in the GM Service Policies and Procedures Manual.
Important
A copy of the completed diagnostic worksheet and other required documentation (e.g. Tech 2(R) snapshots) MUST BE INCLUDED in the box with the returned injectors.
* The amount identified in "Net Item" should represent the actual dollar amount for shop supplies needed to perform the required repairs.
** The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer.
Customer Reimbursement - For US
All customer requests for reimbursement for previous repairs for the special policy condition will be handled by the Customer Assistance Center, not by dealers.
A General Motors Special Policy Customer Reimbursement Procedure form is shown in this bulletin.
Important
Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.
Customer Reimbursement - Canada
Customer requests for reimbursement for previous repairs to correct high fuel return rate by replacing fuel injectors in 2004 model year trucks are to be submitted prior to or by November 30, 2008. Repairs must have occurred within the 7 years of the date the vehicle was originally placed in service, or 320,000 km, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
- Proof of ownership at time of repair.
- Original paid receipt confirming the amount of unreimbursed repair expense(s) (including Service Contract deductibles), a description of the repair, and the person or entity performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will be limited to the amount that the repair would have cost GM to have it completed by a GM dealership.
Disclaimer