16-NA-102: Duramax Diesel Hard Start, No Start, DTCs P0087, P0088, P0191, P128E or Injection Pump Replacement – 2010-2016 Chevrolet & GMC

#16-NA-102: Duramax Diesel Hard Start, No Start, DTCs P0087, P0088, P0191, P128E or Injection Pump Replacement – (Mar 2, 2017)

Subject: Duramax Diesel Hard Start, No Start, DTCs P0087, P0088, P0191, P128E or Injection Pump Replacement

Brand: Model: Model Year: VIN: Engine: Transmission:
from to from to
Chevrolet Express, Silverado 2500/3500 2010 2016 Diesel (RPOs LML or LGH)
GMC Savana, Sierra 2500/3500

 

Involved Region or Country North America, Israel
Condition 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 debris that can be picked up with a magnet.

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.

Fuel Injection Pump / Pressure Regulator 1

Remove the Fuel Injection Pump / Pressure Regulator 1 for inspection.

Pressure Regulator 1 has no debris

If Pressure Regulator 1 has no debris that can be picked up with a magnet on the screen, continue with Fuel Injection Pump replacement.

few pieces of debris that can be picked up with a magnet

few pieces of debris that can be picked up with a magnet

If there are only a few pieces of debris that can be picked up with a magnet found on Pressure Regulator 1, remove the Fuel Rail Pressure Sensor and/or Fuel Pressure Regulator 2 (Pressure Relief Valve) for inspection.

additional debris that can NOT be picked up with a magnet (Contamination)

additional debris that can NOT be picked up with a magnet (Contamination)

If additional debris that can NOT be picked up with a magnet (Contamination) is found on the Fuel Pressure Regulator 1, Fuel Rail Pressure Sensor, and/or Fuel Pressure Regulator 2 (Pressure Relief Valve), refer to PIP5370 and Contaminants-in-Fuel Diagnosis. DO NOT perform the repair listed in this bulletin.

Important: If debris that can be picked up with a magnet as 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.
  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.

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

Part Number Description Qty. Silverado / Sierra (LML) Silverado / Sierra (LGH) Express / Savana (LGH)
2011 2012 2013 2014 2015 2016 2011 2012 2010 2011 2012 2013 2014 2015 2016
12664429 FILTER KIT, FUEL 1 X X X X X X X X X X X X X X
88917036 FILTER, OIL 1 X X X X X X X X X X X X X X X
97363570 GASKET, CTR INT MANIF 2 X X X X X X X X X X X X X X X
12635466 GASKET, EGR VLV (LOCR A) 2 X X X X X X X X X X X X X X X
98062923 GASKET, EGR VLV (LOCR B) 2 X X X X X X X X X X X X X X X
97223686 GASKET, ENG COOL THERM HSG 2 X X X X X X X X X X X X X X X
15126137 GASKET-EXH MANIF PIPE 1 X X X X X X X X X X X X X X X
97188685 GASKET, EXH TURBO INL PIPE 2 X X X X X X X X X X X X X X X
97192618 GASKET, EXH TURBO INL PIPE 2 X X X X X X X X X X X X X X X
12627897 GASKET-TURBO OIL FEED PIPE 1 X X X X X X X X X X X X X X X
12637218 GASKET-TURBO OIL RTN PIPE 1 X X X X X X X X X X X X X X X
12639312 HOSE ASM-FUEL FEED (RH SIDE OF PUMP, W/ BANJ) 1 X X X X X X X X X X X X X X X
12639000 HOSE ASM-FUEL RTN 1 X X X X X X X X X X X X X X X
12661071 INJECTOR ASM-INDIRECT FUEL 1 X X X X X X X X X X X X X X X
12656313 PIPE ASM-FUEL FEED 1 X X X X X X X X X X X X X X X
94011618 SEAL, COLD START FUEL FEED VLV (O RING) 1 X X X X X X X X X X X X X X X
12625100 SEAL, COLD START FUEL FEED VLV (O RING) 1 X X X X X X X X X X X X X X X
94036238 SEAL, OIL LVL IND TUBE (O RING) 1 X X X X X X X X X X X X X X X
94011603 SEAL, THERM BYPASS PIPE (O RING) 1 X X X X X X X X X X X X X X X
12670466 PIPE ASM-FUEL HIGH PRESS 1 X X X X X X X X X X X X X X X
12641590 SWITCH ASM, ENG FUEL VAC 1 X X X X X X X X X X X X X X
12631851 SEAL-TURBO AIR INL ADAP 1 X X X X X X X X X X X X X X X
97224993 SENSOR ASM, FUEL TEMP 1 X X X X X X X X X
12676436 SENSOR ASM-WAT IN FUEL IND 1 X X X X X
98065521 GASKET-EGR VLV CLR 1 X X X X X X X X
12644913 BRACKET ASM-FUEL FEED PIPE CLIP 1 X X X X X X X X
12624346 TUBE-FUEL PRESS REG VAC 1 X X X X X X X X
12636270 HOSE-FUEL FEED (ON RH PUMP INLET) 1 X X X X X X X X
12636274 HOSE-FUEL FLTR (ON FILTER OUTLET) 1 X X X X X X X X
12636275 HOSE-FUEL PRESS REG VAC (PIPE TO SERVICE FIT) 1 X X X X X X X X
12646725 MANIFOLD ASM-F/INJN FUEL FEED 1 X X X X X X X X
12639779 PIPE ASM-FUEL FEED (FILTER OUT TO PUMP INLET) 1 X X X X X X X X
12670460 PIPE ASM-FUEL HIGH PRESS (CYL 2 & 7) 2 X X X X X X X X
12670468 PIPE ASM-FUEL HIGH PRESS (CYL 1 & 8) 2 X X X X X X X X
12670469 PIPE ASM-FUEL HIGH PRESS (CYL 3 & 6) 2 X X X X X X X X
12670471 PIPE ASM-FUEL HIGH PRESS (CYL 4 & 5) 2 X X X X X X X X
12670474 PIPE ASM-FUEL HIGH PRESS (LEFT SIDE OF PUMP) 1 X X X X X X X X
12670475 PIPE ASM-FUEL HIGH PRESS (RIGHT SIDE OF PUMP) 1 X X X X X X X X
12629458 SEAL-TURBO AIR INL ADAP 1 X X X X X X X X
12627913 SEAL-UPR INT MANIF 1 X X X X X X X X
12645582 HOSE ASM-FUEL RTN (LEFT RAIL TO FEED PIPE) 1 X X X X X X
98065519 GASKET-EGR MANIF 1 X X X X X X
98065523 GASKET-EGR PIPE 1 X X X X X X
98065520 GASKET-EGR VLV CLR 1 X X X X X X
12672028 PUMP KIT-FUEL (CONTAINS FUEL PUMP, INJECTORS & RAILS) 1 X X X X X X
98070023 GASKET-EGR VLV CLR 1 X X X X X X X X X
12672027 PUMP KIT-FUEL (CONTAINS FUEL PUMP, INJECTORS & RAILS) 1 X X X X X X X X X
12636266 HOSE-FUEL RTN 1 X X X X X X X
12641356 PIPE ASM-FUEL FEED 1 X X X X X X X
12670457 PIPE ASM-FUEL HIGH PRESS (CYL 6) 1 X X X X X X X
12670463 PIPE ASM-FUEL HIGH PRESS (CYL 7) 1 X X X X X X X
12670456 PIPE ASM-FUEL HIGH PRESS (CYL 8) 1 X X X X X X X
12670454 PIPE ASM-FUEL HIGH PRESS 1 X X X X X X X
12670465 PIPE ASM-FUEL HIGH PRESS (CYL 1) 1 X X X X X X X
12670460 PIPE ASM-FUEL HIGH PRESS (CYL 2) 1 X X X X X X X
12670464 PIPE ASM-FUEL HIGH PRESS (CYL 3) 1 X X X X X X X
12670459 PIPE ASM-FUEL HIGH PRESS (CYL 4 OR 5) 2 X X X X X X X
12670453 PIPE ASM-FUEL HIGH PRESS 1 X X X X X X X
12639101 PIPE ASM-FUEL 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

 

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 Description Labor Time
4080558* 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.

 

Version 6
Modified April 11, 2016 – Updating the Qty. column of the Parts Information table.

April 29, 2016 – Updating the Parts Information table.

Oct. 26, 2016 – Updating the Parts Information table.

Feb. 03, 2017 – Updating the Service Procedure.

March 2, 2017 – Updating the Service Procedure.


16-NA-102

https://www.nhtsa.gov/recalls?nhtsaId=10116595

 


PIP4949E

https://www.nhtsa.gov/recalls?nhtsaId=10115024


PIP4949D

https://www.nhtsa.gov/recalls?nhtsaId=10044240

https://static.nhtsa.gov/odi/tsbs/2014/SB-10044240-3551.pdf

Download (PDF, 481KB)

PIP4949B

https://static.nhtsa.gov/odi/tsbs/2014/SB-10044240-2749.pdf

Download (PDF, 274KB)


 

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Last update on 2019-05-09 / Affiliate links / Images from Amazon Product Advertising API

Last update on 2019-05-09 / Affiliate links / Images from Amazon Product Advertising API

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