Service Procedure - U.S. and Canada Only

Check the Vehicle Inquiry System (GMVIS) for in-service date and warranty blocks.

Prior to removal and request of an injection pump, perform diagnostics based on symptom or Diagnostic Trouble codes (DTCs). For 1998 or older vehicles, use the 1998 Service Information. For 1999 and newer vehicles, use the applicable service information for that year. Always utilize the Diesel EFI Diagnostic Worksheet for all involved model years.





Complete the entire Diesel EFI Diagnostic Worksheet shown by recording the values of the diagnostics performed. Photocopy the Diesel EFI Diagnostic Worksheet form and attach the form to the repair order hard copy. When a defective injection pump return is requested, the repair order and Diagnostic Worksheet must be returned with the defective injection pump.

Call 1-877-446-8227 to request an exchange pump. Dealer code, parts dealer code, vehicle information 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. On 1995-02 vehicles, the serial number and model number of the injection pump currently on the truck will be required.

Record the serial number of the removed defective injection pump on the warranty repair order.

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 to GM dealers and are to be used on vehicles within the 11 years/120,000 miles (193,000 km) Special Policy and diesel warranty.

Injection pumps received under this Special Policy have a serial number assigned and tracked to a specific VIN and TAC case. These numbers are printed on the package label or packing slip. Parts numbers for Special Policy pumps are also different than injection pumps purchased from GMSPO. It is imperative that technicians only install Special Policy Injection pumps on the assigned vehicle (registered TAC case). If a Special Policy pump will not be installed in the assigned vehicle, call 1-877-446-8227 for disposition of the injection pump.

Record the serial number of the new injection pump on the warranty repair order.

Hold all defective injection pumps with a copy of the repair order and a copy of the Diagnostic Worksheet form until the Special Policy warranty claim has been paid. A Corporate Parts Return Request will be generated. (Refer to Corporate Parts Return SI Bulletin 99-00-89-019B. All associated failed parts for claims paid under this Special Coverage, including the defective diesel injection pump, will be returned to the Warranty Parts Center (WPC).

Failure to retain the defective pumps as required above violates the General Motors Service Policies and Procedures, Article 1.7, with a minimum of $800 (US) debit. Removed defective injection pumps ARE NOT to be sold by the dealer for remanufacturing, rebuilding or scrap. Under no circumstances are the injection pumps to be installed on any vehicle, sold at retail, or used in any other application.

The defective diesel injection pump metal identification tag must remain attached to the injection pump to avoid a claim debit.

All components must remain on the defective diesel injection pump, including: pump-mounted driver, electric fuel shut-off solenoid, stepper motor, etc. in order to avoid a claim debit.

The servicing dealer is authorized to submit a Special Policy warranty claim for pump replacement labor time, plus 0.2 hour administration, and a $45 handling charge in the net amount column of the warranty claim. (See Claim Table ***)

Damage from poor quality or incorrect diesel fuel, or gasoline or water contamination is not covered under the terms of the 6.5L diesel warranty. For proper diagnostics, refer to SI Bulletin 99-06-04-047A in order to determine if the vehicle fuel system contains metal contamination. Be sure to complete the correction for vehicle fuel system metal contamination before installing the new electronic diesel fuel injection pump.

IF NOT DTC IS STORED, FOLLOW DRIVEABILITY SYMPTOM IN SI.

NOTE:
Remember that Passlock is used on 1998 and newer trucks. Do not replace the Powertrain Control Module (PCM), Fuel Pump, etc. prior to performing appropriate service manual diagnostics.