16-NA-102

File in Section:
Service Bulletin
-
Bulletin No.:
16-NA-102
Date:
May, 2016
TECHNICAL
Subject:
Duramax Diesel Hard Start, No Start, DTCs P0087, P0088, P0191, P128E or Injection
Pump Replacement
Attention: This Bulletin also applies to any of the models that may be Israel Export vehicles.
Brand:
Model:
Chevrolet
Express,
Silverado
2500/3500
GMC
Savana,
Sierra
2500/3500
Model Year:
VIN:
from
to
2010
2016
Condition
from
Engine:
Transmission:
to
Diesel (RPOs
LML or LGH)
A dealer may encounter a customer concern of a hard start or a no start. DTCs P0087,
P0088, P0191 or P128E may also be found.
Normal SI Diagnostics may be inconclusive or lead to Fuel Injection Pump replacement.
Service Procedure
Complete the current SI diagnostics for any symptoms
or DTCs found.
If the current SI diagnostic has led to Fuel Injection
Pump replacement, Fuel Pressure Regulator 1 must be
inspected for magnetic metal debris.
Note: Clean the area around Pressure Regulator 1
before removal. It is possible that road debris could find
its way into the regulator port when it is removed. A
small piece of dirt on Pressure Regulator 1 does not
qualify for the fuel system repairs recommended in this
Bulletin.
2698603
Remove the Fuel Injection Pump / Pressure Regulator
1 for inspection.
Copyright 2016 General Motors LLC. All Rights Reserved.
Page 2
May, 2016
3541158
If Pressure Regulator 1 has no debris on the screen,
complete the SI repair procedure and replace the Fuel
Injection Pump.
Bulletin No.: 16-NA-102
3541165
If there is a questionable amount of magnetic debris
found on Pressure Regulator 1, remove the Fuel Rail
Pressure Sensor and/or Fuel Pressure Regulator 2
(Pressure Relief Valve) for inspection.
3541164
3541168
Bulletin No.: 16-NA-102
May, 2016
Page 3
3. The fuel filter housing must be cleaned with a new
fuel filter installed.
4. The fuel tank and fuel sender must be cleaned and
flushed.
Note: The Indirect Fuel Injector (Hydrocarbon Injector)
and its fuel lines must be purged of air any time it is
removed or replaced. Failure to do so may damage the
injector. Perform the Diesel Particulate Filter (DPF)
Regeneration Enable any time the indirect injector or its
fuel lines are opened/removed or replaced. This will
force regeneration as soon as conditions allow and will
purge any air from the system. Refer to Diesel
Particulate Filter (DPF) Regeneration Enable in SI.
3541159
If additional magnetic debris is found on the Fuel Rail
Pressure Sensor and/or Fuel Pressure Regulator 2
(Pressure Relief Valve), the Fuel Injection Pump is
experiencing the condition described.
Important: If magnetic debris described above is
found, complete the repairs listed below:
1. Replace all of the parts listed in the Parts
Information below.
2. Clean and flush all fuel chassis lines, filter pipes,
and other engine mounted fuel system pipes that
are not being replaced.
TIP:
After repairs, the following may help with fuel system
priming:
• Prime fuel to the fuel filter housing.
• Relieve air by opening the bleed screw at the filter
housing.
• Pump the priming ball again until no more air
escapes and close the bleed screw.
• Prime until the priming ball is hard.
• There should be at least 10 psi fuel pressure on
the fuel system pressure gauge attached to the
fuel system service port (schrader valve).
• Crank the engine for up to 15 seconds.
• Key off for one minute.
Repeat the above steps until the engine starts. It is
normal for the engine to start and then stall when the
fuel system loses prime. Repeated priming will alleviate
this concern.
Parts Information
Silverado /
Sierra (LGH)
Silverado / Sierra (LML)
Part
Number
Description
12664429
FILTER
KIT, FUEL
1
X
X
X
X
X
X
X
X
88917036
FILTER, OIL
1
X
X
X
X
X
X
X
97363570
GASKET, CTR
INT MANIF
1
X
X
X
X
X
X
12635466
GASKET, EGR
VLV (LOCR A)
1
X
X
X
X
X
98062923
GASKET, EGR
VLV (LOCR B)
1
X
X
X
X
97223686
GASKET, ENG
COOL
THERM HSG
2
X
X
X
15126137
GASKET-EXH
MANIF PIPE
1
X
X
97188685
GASKET, EXH
TURBO
INL PIPE
2
X
97192618
GASKET, EXH
TURBO
INL PIPE
2
12627897
GASKETTURBO OIL
FEED PIPE
1
12637218
GASKETTURBO OIL
RTN PIPE
1
HOSE ASMFUEL FEED (RH
SIDE OF PUMP,
W/ BANJ)
1
12639312
12639000
HOSE ASMFUEL RTN
1
Qty.
2011
2012
2013
2014
2015
2016
2011
2012
Express / Savana (LGH)
2010
2011
2012
2013
2014
2015
2016
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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Page 4
May, 2016
12661071
INJECTOR
ASMINDIRECT FUEL
1
12656313
PIPE ASMFUEL FEED
1
SEAL, COLD
START FUEL
FEED VLV
(O RING)
1
94011618
SEAL, COLD
START FUEL
FEED VLV
(O RING)
1
12625100
94036238
SEAL, OIL LVL
IND TUBE
(O RING)
1
94011603
SEAL, THERM
BYPASS PIPE
(O RING)
1
12670466
PIPE ASMFUEL HIGH
PRESS
1
12641590
SWITCH ASM,
ENG FUEL VAC
1
X
12631851
SEAL-TURBO
AIR INL ADAP
1
X
97224993
SENSOR ASM,
FUEL TEMP
1
X
12676436
SENSOR ASMWAT IN
FUEL IND
1
98065521
GASKET-EGR
VLV CLR
1
12644913
BRACKET ASMFUEL FEED
PIPE CLIP
1
12624346
TUBE-FUEL
PRESS
REG VAC
1
12636270
HOSE-FUEL
FEED (ON RH
PUMP INLET)
1
HOSE-FUEL
FLTR (ON
FILTER
OUTLET)
1
12636274
HOSE-FUEL
PRESS REG
VAC (PIPE TO
SERVICE FIT)
1
12636275
12646725
MANIFOLD
ASM-F/INJN
FUEL FEED
1
PIPE ASMFUEL FEED
(FILTER OUT
TO PUMP
INLET)
1
12639779
PIPE ASMFUEL HIGH
PRESS (CYL 2
& 7)
2
12670460
PIPE ASMFUEL HIGH
PRESS (CYL 1
& 8)
2
12670468
PIPE ASMFUEL HIGH
PRESS (CYL 3
& 6)
2
12670469
PIPE ASMFUEL HIGH
PRESS (CYL 4
& 5)
2
12670471
PIPE ASMFUEL HIGH
PRESS (LEFT
SIDE OF PUMP)
1
12670474
PIPE ASMFUEL HIGH
PRESS (RIGHT
SIDE OF PUMP)
1
12670475
12629458
SEAL-TURBO
AIR INL ADAP
12627913
12645582
Bulletin No.: 16-NA-102
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X
X
X
X
X
X
X
X
X
X
X
X
1
X
X
X
X
X
X
X
X
SEAL-UPR INT
MANIF
1
X
X
X
X
X
X
X
X
HOSE ASMFUEL RTN
(LEFT RAIL TO
FEED PIPE)
1
X
X
X
X
X
X
Bulletin No.: 16-NA-102
May, 2016
98065519
GASKET-EGR
MANIF
1
X
X
X
X
X
X
98065523
GASKETEGR PIPE
1
X
X
X
X
X
X
98065520
GASKET-EGR
VLV CLR
1
X
X
X
X
X
X
PUMP KIT-FUEL
(CONTAINS
FUEL PUMP,
INJECTORS)
1
12672028
X
X
X
X
X
X
98070023
GASKET-EGR
VLV CLR
1
1
12672027
PUMP KIT-FUEL
(CONTAINS
FUEL PUMP,
INJECTORS)
12636266
HOSEFUEL RTN
12641356
X
Page 5
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1
X
X
X
X
X
X
X
PIPE ASMFUEL FEED
1
X
X
X
X
X
X
X
12670457
PIPE ASMFUEL HIGH
PRESS (CYL 6)
1
X
X
X
X
X
X
X
12670463
PIPE ASMFUEL HIGH
PRESS (CYL 7)
1
X
X
X
X
X
X
X
12670456
PIPE ASMFUEL HIGH
PRESS (CYL 8)
1
X
X
X
X
X
X
X
12670454
PIPE ASMFUEL HIGH
PRESS
1
X
X
X
X
X
X
X
12670465
PIPE ASMFUEL HIGH
PRESS (CYL 1)
1
X
X
X
X
X
X
X
12670460
PIPE ASMFUEL HIGH
PRESS (CYL 2)
1
X
X
X
X
X
X
X
12670464
PIPE ASMFUEL HIGH
PRESS (CYL 3)
1
X
X
X
X
X
X
X
PIPE ASMFUEL HIGH
PRESS (CYL 4
OR 5)
2
12670459
X
X
X
X
X
X
X
12670453
PIPE ASMFUEL HIGH
PRESS
1
X
X
X
X
X
X
X
12639101
PIPE ASMFUEL RTN
1
X
X
X
X
X
X
X
26020642
SEAL, P/S
PUMP RSVR
(O RING)
1
X
X
X
X
X
X
X
97368325
GASKET-CTR
INT MANIF
1
X
X
X
X
X
X
X
X
X
Page 6
May, 2016
Bulletin No.: 16-NA-102
Warranty Information
For vehicles repaired under the Powertrain coverage,
use the following labor operation. Reference the
Applicable Warranties section of Investigate Vehicle
History (IVH) for coverage information.
Labor
Operation
4080558*
Description
Labor Time
Diagnose and Clean/Repair
Complete Fuel System
2010-2016 G
Van 21.0
Hours*
2011-2014 C
Truck (2WD)
18.0 Hours*
2011-2014 K
Truck (4WD)
20.0 Hours*
2015-2016 C
and K Truck
(2WD and
4WD) 21
Hours*
*This is a unique Labor Operation for bulletin use only. It will
not be published in the Labor Time Guide.
Version
3
Modified
April 11, 2016 – Updating the Qty. column of the Parts Information table.
April 29, 2016 – Updating the Parts Information table.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these
technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper
service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a
job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your
vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.
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