Engine Controls - Intermittent Driveability Conditions
Bulletin No.: 04-06-04-001CDate: November 28, 2006
TECHNICAL
Subject:
LB7 LBZ LLY LMM - Intermittent Driveability Conditions Such as No Crank, Crank But No Start, Hard to Start, MIL/SES, Hesitation, Lack of Power, Surge, Misfire, Fuel Knock, No Serial Data Communication, IPC Indicates No Oil Pressure, DTCs Set (Inspect Connection/Replace Connector Bodies)
Models:
2001-2007 Chevrolet Silverado Pickups
2006-2007 Chevrolet Express Vans
2003-2007 Chevrolet Kodiak C4500/C5500 Series
2001-2007 GMC Sierra Pickups
2006-2007 GMC Savana Vans
2003-2007 GMC TopKick C4500/C5500 Series
with 6.6L Duramax(TM) Diesel Engine (VINs 1, 2, 6, D - RPOs LB7, LLY, LMM, LBZ)
Supercede:
This bulletin is being revised to update the model years and add Condition and Correction content. Please discard Corporate Bulletin Number 04-06-04-001B (Section 06 - Engine/Propulsion System).
Condition
Some customers may comment on any of the following various intermittent driveability conditions:
No crank
Crank but no start
Hard to start
MIL/SES Illuminated with EGR DTCs, cam sensor DTCs, fuel pressure DTCs, turbocharger DTCs, injection circuit DTCs
Hesitation
Lack of power
Surge
Misfire
Fuel knock
No serial data communication
IPC indicates no oil pressure
Various engine faults or DTCs may occur due to backed out pins in the following main engine harness connectors:
C107 and C118 (38-way) Engine Harness to the Engine Chassis Harness Connector
C108 and C119 (24-way) Engine Harness to the Engine Chassis Harness Connector
Cause
The main engine to chassis connectors utilize a plastic tab formed into the connector body as a terminal lock (5). If a terminal lock (5) is damaged or broken, the terminal (1, 4) will be pushed partially out of the connector body (2, 3) during assembly and will make poor or no contact with its mating terminal. Various and intermittent engine control faults may occur.
Correction
When reconnecting the engine to chassis connectors, slide the Primary Lock Reinforcement partially out of the male side connectors to support the ends of the male pins upon installation. Guide the chassis side connectors straight into the engine connectors when using the lever lock to avoid terminal misalignment. Failure to do so may cause terminal lock breakage.
Inspect the terminals in the male and female sides of the connectors for broken terminal locks by removing the terminal position assurance (TPA) comb at the back of the connector (if equipped) and gently pushing and pulling on the wire in question. If the wire moves within the connector and does not lock into position, the connector body should be replaced.
Connector Location
The following connectors are all located at the engine harness to engine chassis harness that is mounted to the top of the driver side valve cover.
C107 and C118 (38-way) Engine Harness to the Engine Chassis Harness Connector
C108 and C119 (24-way) Engine Harness to the Engine Chassis Harness Connector
If an illustration is needed to locate the connector in question, please refer to SI and build your vehicle publication to view. Then select the following areas:
Body
Wiring Systems
Component Location
Master Electrical Component List
Connector Components
Terminal Position Assurance (TPA) (C107 and C118 only)
Cable Seal
Female Terminal
Lever Lock
Connector Body - Female
Connector Seal
Primary Lock Reinforcement (PLR) - Female (C108 and C119 24-way connectors only)
Primary Lock Reinforcement (PLR) - Male (C108 and C119 24-way connectors only)
Connector Body - Male
Male Terminal
Cable Seal
Terminal Position Assurance (TPA) (If equipped)
The 6.6L diesel engine utilizes a 24-way and a 38-way Packard Lever Lock GT Series sealed connector for the engine to chassis connection. Connector components can be serviced using the J 38125 Terminal Kit. Connector bodies are available through GMSPO.
These components are available from the J 38125 Terminal Kit.
Parts Information
Warranty Information
For vehicles repaired under warranty use the table.
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