Fuel - Injection Pump Exchange Program Expanded
File In Section: O6 - Engine/Propulsion SystemBulletin No.: 99-06-04-041A
Date: August, 2000
EXCHANGE PROGRAM
Subject:
Fuel Injection Pump Exchange Program
Models:
1994-2001 Chevrolet and GMC C/K, P, G, B Models with 6.5 L Diesel Engine
(VINs F, P, S, Y - RPOs L65, L49, L56, L57)
Attention:
IPC Dealers are not authorized to utilize this service bulletin.
This bulletin is being revised to include the core process. Please discard Corporate Bulletin Numbers 87-63-07 and 75-63-03B (Canada),
(Section 6E - Engine Fuel and Emission).
The following information describes the exchange procedure that should be followed if an electronic fuel injection pump requires removal under warranty. Warranty replacement procedure differs between the electronic and mechanical pump models.
Important:
DO NOT REMOVE THE INJECTION PUMP. PROPER DIAGNOSTICS MUST BE PERFORMED PRIOR TO CALLING 1-800-872-0610. THIS INCLUDES VERIFICATION OF THE CUSTOMER CONCERN, PERFORMING SERVICE MANUAL DIAGNOSTICS, RECORDING THE VALUES, AND CHECKING FOR FUEL QUALITY.
Access to all new Electronic Injection Pumps through GMSPO is restricted. GM Dealers must call 1-800-872-0610 when a new Injection Pump is required for warranty or customer pay repairs.
Electronic Pump (DS Model) Engine VIN Code F, P, S
If diagnostics indicate the electronic fuel injection pump repair cannot be done by the dealership, call 1-800-872-0610 to request an electronic fuel injection pump. THE INJECTION PUMP IS NOT TO BE OBTAINED FROM A STANADYNE DEALER OR GMSPO. For 1994 L65 vehicles built between SOP (Start of Production) and approximately January 15, 1994, make sure to identify the vehicle's pump model.
Mechanical Pump (DB Model) Engine VIN Code Y
The pump should be removed from the vehicle and sent to a Stanadyne dealer for repairs. The repair claim should be submitted through the GM WINS warranty system as a sublet repair.
Customer Satisfaction Campaign 94-C-57A (Canada 4N26)
This campaign remains active for all remaining eligible vehicles. GM dealers that determine an eligible vehicle requires a new pump, after following the campaign diagnostic worksheet procedures, should request the pump by calling 1-800-872-0610.
Service Procedure
1. Prior to removal and request of an injection pump, perform diagnostics, based on symptom. Follow the latest version of the Diesel Diagnostic Section in the Service Manual and utilize the Diesel EFI Diagnostic Worksheet (Attachment 1).
2. Complete the entire Diesel EFI Diagnostic Worksheet by recording the values of the diagnostics performed (Attachment 1). Photocopy the Diagnostic Worksheet form and attach to the repair order hard copy. If core return is requested, the repair order and diagnostic sheet must be returned with the core.
3. Call 1-800-872-0610 to request an exchange pump. Dealer code and vehicle information, from the GM Request for Warranty Claim, along with details and results of the diagnostics will be required.
On 1994 vehicles, the model number of the injection pump and PROM identification currently installed on the truck will be required. The model number is located on a tag which is attached to the rear of the pump. If model number 5068 is not available, another pump model will be assigned with a PROM update.
4. Once a request is approved, the injection pump will be shipped to the dealership within 24 hours (the next business day). These pumps will be shipped at NO CHARGE and are to be used on vehicles within the warranty.
Caution:
Eye protections should be worn when preforming the pump scrapping procedure to avoid potential eye injury.
Important:
Failure to retain a core for an indeterminate amount of time until scrapped by a GM representative, violates the General Motors Service Policies and Procedures, Article 1.7, with a minimum of $800 (US) debit. Injection pump cores ARE NOT to be sold by dealer for remanufacturing or rebuilding. Under no circumstances are the parts to be installed on any vehicle, sold at retail, salvage, or used in any other application.
5. Unless requested, return of pump cores to GMPT is no longer required. Hold all Injection pumps with a copy of the repair order and a copy of the diagnostic worksheet form until the warranty claim has been paid to ensure the material is not requested to be returned to the WPC.
6. When directed by the GM Representative all pumps retained by the dealer should be scrapped by the following procedure:
6.1. Render the Optical Sensor Encoder (OSTE) (1) unusable with a hammer blow to the wiring connector.
6.2. Render the Engine Shut Off (ESO) solenoid (2) unusable with a hammer blow.
6.3. Render the injection pump body housing unusable with a series of hammer blows to the mounting flange (3), breaking off all three mounting flanges.
6.4. Render the stepper motor (4) unusable with a hammer blow.
6.5. Render the entire delivery head assembly unusable with a series of hammer blows to the delivery head (5) and to the fuel solenoid (6).
6.6. Remove and destroy (by cutting in pieces) the pump serial plate (7) (located on back of pump body).
6.7. Render the Pump Mounted Driver (PMD) (8) unusable by cracking the PMD body with a hammer blow.
7. Have GM representative sign off repair order so that the dealer has a record of the event.
8. For an electronic pump only, the servicing dealer is authorized to submit a warranty claim for pump replacement labor time, plus 0.2 hour administration, and $45 handling charge in the net amount column of the warranty claim.
Important:
Damage from poor quality or incorrect grade diesel fuel, and gasoline or water contamination, is not covered under the terms of the 6.5 L diesel warranty.
Warranty Information
For vehicles repaired under warranty, use the table.