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

SEOCONTENT-START
        Service Bulletin Bulletin No.: 16-NA-102 Date: May, 2021 TECHNICAL 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 2010 2016 LML, LGH Silverado 2500/3500 GMC Savana Sierra 2500/3500 Involved Region or Country North America, Israel Condition Some customers may comment on one or more of the following conditions: • Hard start • No start Some technicians may find one or more of the following DTCs set in the Engine Control Module (ECM): • P0087: Fuel Rail Low Pressure • P0088: Fuel Rail High Pressure • P0191: Fuel Rail Pressure Sensor Performance • P128E: Fuel Rail Pressure Performance ⇒ Normal SI Diagnostics may be inconclusive or lead to Fuel Injection Pump replacement. Service Procedure Fuel Injection Pump Diagnosis Procedure Complete the current SI diagnostics for any symptoms or DTCs found. If the current SI diagnostic has led to Fuel Injection Pump replacement, replace the fuel injection pump. Refer to Fuel Injection Pump Replacement in SI. Once the fuel injection pump is removed, remove the Fuel Pressure Regulator 1 and inspect 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. 2698603 Remove the Fuel Injection Pump / Pressure Regulator 1 for inspection. Page 2 May, 2021 Bulletin No.: 16-NA-102 3541158 If Pressure Regulator 1 has no debris that can be picked up with a magnet on the screen, continue with Fuel Injection Pump replacement. 3541164 3541165 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. 3541168 Bulletin No.: 16-NA-102 May, 2021 Page 3 3541159 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 PIP5151 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: Service Procedure For All Vans Cleaning and Flushing Procedure Important: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak or result in a No-Start. 1. Replace all 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. Danger: Verify that there are no fuel leaks in the fuel system. Failure to identify any leaks could result in no start, stall, vehicle damage, or bodily injury.” 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. Service Procedure For All P/U Trucks Important: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak or result in a No-Start. Removal Procedure Warning: The ignition must be in the off position and all electrical loads must be turned off before servicing any electrical component. Failure to do so may result in personal injury or damage to the vehicle. 647997 1. Raise and support the vehicle. 2. Remove the nuts that secure the transmission mount to the transmission support. 3. Using a suitable jack, raise the rear of the transmission and place a block of wood between the transmission mount and the transmission support. 4. Remove the jack. 5. Lower the vehicle. Page 4 May, 2021 Bulletin No.: 16-NA-102 5527220 6. Remove the right exhaust manifold outlet pipe heat shield bolts (3) and heat shield (2). 7. Remove the upper bolt (1) that secures the exhaust gas recirculation coolant feed hose/pipe to the EGR cooler bypass valve. 2409415 8. Remove the 2 exhaust manifold outlet pipe nuts (1, 2) and the exhaust manifold outlet pipe bolt (3). Exhaust Manifold Outlet Pipe Replacement – Right Side. 9. Raise the vehicle. 2495773 10. Loosen the 2 bolts (1) at the rear EGR bracket (2). 11. Lower the vehicle. 5527489 12. Separate the Cooling Feed Hose (1) from the EGR Bypass valve cooler. 13. Separate the Heater Inlet Hose (2) from the EGR cooler. Bulletin No.: 16-NA-102 May, 2021 Page 5 5542942 14. Remove the EGR cooler bracket bolt (1). 5542966 15. Remove the 2 rear EGR mounting bolts (3). 16. Disconnect the EGR bypass valve electrical connector. 17. Disengage the hose clamp (1). 18. Separate the EGR cooler water bypass outlet hose (2) from the EGR cooler bypass valve. 19. Remove the rear EGR cooler and discard the gasket. 1871640 20. Disconnect the water in fuel sensor wiring pigtail (2) from the engine wiring harness electrical connector. 1871642 21. Remove the fuel filter from the fuel filter adaptor. Caution: Keep the fuel filter covered with a clean cloth while passing it through the wheel well. Failure to do so may introduce debris to the fuel system and cause engine damage. 22. Remove the water-in-fuel sensor from the fuel filter. Page 6 May, 2021 Bulletin No.: 16-NA-102 4258732 23. Remove the Heater Outlet Hose Bracket Bolt (1). 24. Separate the Heater Outlet Pipe (2) and position aside. 4258780 25. Remove the fuel filter assembly (2). Refer to Fuel Filter Assembly Replacement in SI. Bulletin No.: 16-NA-102 May, 2021 Page 7 5334169 26. Remove the fuel filter bracket (5). Refer to Fuel Filter Bracket Replacement in SI. 2408336 27. Disconnect the fuel return hose (1) from the injectors and position aside. 2382530 28. Disengage the fuel return line by pulling upward on the cylindrical locking sleeve (1). 29. Remove the fuel return line (2) from the fuel injectors (3). Page 8 May, 2021 Bulletin No.: 16-NA-102 4228683 30. Disconnect the Fuel Return Hose (1) from the Fuel Feed Pipe (2) 4228685 31. Remove the Fuel Injection Fuel Feed Pipe Bracket Bolt (1). 4228687 32. Remove the indirect injector from the fuel feed pipe retainer (1) using the CH-49736 tool. 33. Remove and discard the Fuel Feed Pipe. 2374328 34. Disconnect the hydrocarbon injector (HCI) electrical connector (1). Bulletin No.: 16-NA-102 May, 2021 Page 9 2394330 35. Remove the indirect fuel injector fasteners (1, 2) and reposition. 36. Disconnect the indirect fuel injector exhaust fitting at the exhaust outlet pipe. 2394333 37. Remove and discard the indirect fuel injector (2). 2407046 38. Remove the two right bank fuel injection fuel feed pipe bracket fasteners (1). 39. Remove and discard the fuel injection fuel feed pipes (2). 2370205 40. Remove the right bank fuel rail fasteners (1). 41. Remove and discard the right bank fuel injection fuel rail assembly (2). Page 10 May, 2021 Bulletin No.: 16-NA-102 2408256 42. If necessary, reposition the engine harness aside. 43. Disconnect the fuel return hose (1) from the injectors and discard. 2407097 44. Remove the two left bank fuel injection fuel feed pipe bracket fasteners (1). 45. Remove and discard the four fuel injection fuel feed pipes (2). 2369972 46. Disconnect the fuel pressure relief valve electrical connector (1). 2369976 47. Collapse the spring clamp and disconnect the fuel return hose (1). Bulletin No.: 16-NA-102 May, 2021 Page 11 2369973 48. Disconnect the fuel pressure sensor electrical connector (1). 2369984 49. Remove the fuel rail heat shield fasteners (1). 2369985 50. Remove the left bank fuel injection rail fasteners (1). 51. Remove the heat shield (2). 52. Remove and discard the left bank fuel injection fuel rail assembly (3). Caution: Label all the injector electrical connectors before the connectors are removed in order to prevent reconnecting to the wrong injector. Failure to properly connect the injectors in the correct sequence will cause severe engine damage. 2408253 53. Disconnect the fuel injector electrical connectors (1). Page 12 May, 2021 Bulletin No.: 16-NA-102 2408258 54. Remove all the fuel injector bracket bolts (1). 4663244 55. Using one of the fuel injector brackets (2), install EN-49774 Fuel Injector Puller (1) into the bolt hole in the fuel injector bracket. 56. Install a suitable wrench onto EN-49774 Fuel Injector Puller and work the tool outward until the fuel injector (3) releases from its seat. 57. Remove the EN-49774 Fuel Injector Puller. 4663305 58. Remove the fuel injector bracket (1) and fuel injector. 59. Discard the diesel fuel injector (2). 60. Repeat steps 56-60 for each injector. Injector Bore Cleaning Procedure Warning: Wear safety glasses to avoid eye damage. Caution: Do not allow excessive amounts of solvent to go into the cylinder during cleaning. Failure to do so may cause engine damage upon startup. 1335621 1. Install the EN – 47909–2 Radial Brush to the EN – 47909–1 T-Handle. Bulletin No.: 16-NA-102 May, 2021 Page 13 2. Insert the EN-47909–2 Radial Brush into the injector bore and rotate the EN-47909–1 T-Handle to break loose any carbon deposits from the injector bore walls and the combustion deck hole. 3. Using compressed air, evacuate any debris from the injector bore. 4. Remove the EN-47909–2 Radial Brush from the EN-47909–1 T-Handle. 5. Install the EN – 47909–3 Axial Brush to the EN- 47909–1 T-Handle. 6. Insert the EN-47909–3 Axial Brush into the injector bore and rotate the EN-47909–1 T-Handle while also applying a slight downward pressure to force the brush ends into the bottom corners of the injector bore. 7. Using compressed air, evacuate any debris from the injector bore. 8. Lightly dampen EN – 47909–20 Cotton Swab with Top Engine Cleaner and wipe away any deposits from the injector bore. Refer to Adhesives, Fluids, Lubricants, and Sealers in SI. 9. Inspect the injector bore for any deposits and repeat brushing if necessary. Warning: Keep hands and face clear of glow plug holes while cranking. Hot liquid or gases may be expelled during cranking. 10. If necessary, crank the engine to expel any solvent before starting the engine. 11. Remove the glow plugs; – Refer to Glow Plug Replacement – Bank 1 – Refer to Glow Plug Replacement – Bank 2 12. Disable the fuel system. 13. Disconnect the Crank Shaft Position (CKP) sensor electrical connector. 14. Crank the engine to expel excessive solvent. 15. Using the EN-47909–20 Cotton Swab wipe the injector bore clean of any solvent and/or debris. 16. Connect the CKP sensor electrical connector. 17. Enable the fuel system. 18. Install the glow plugs; – Refer to Glow Plug Replacement – Bank 1 – Refer to Glow Plug Replacement – Bank 2 Installation Procedure Caution: Refer to Component Fastener Tightening Caution in SI.. Note: It may be useful to take a photo of the Fuel Injector Flow Rate value on each injector prior to installation. 4663364 Note: Lubricate the NEW fuel injector O-ring seals with clean engine oil. 1. Install combustion Fuel Injector Seal (1). 2. Install fuel injector seal ring (2). 3. Install fuel injector seal ring (3). 4663305 Note: Ensure the fuel injector valve pivot pin is in place in the lower rocker cover before installing the injector bracket. 4. Install high pressure diesel fuel injector (2) assembly. 5. Repeat steps 1-4 for all of the remaining injectors. Page 14 May, 2021 Bulletin No.: 16-NA-102 2408258 6. Install fuel injector bolts (1) . ⇒ Torque the fuel injector bracket bolts to 30Y (22 ft lbs). 2408253 7. Connect the fuel injector electrical connectors (1). Important: It is recommended to insert the High Pressure Fuel Pipe, Rail to Rail under the turbocharger prior to installing the left fuel rail. Also, leave the line end caps in place while inserting this pipe. 2369985 9. Install the left side fuel injection fuel rail assembly (3) and heat shield (2). 10. Install the left side fuel injection rail bolts (1). ⇒ Torque the fuel injector bracket bolts to 25Y (18 ft lbs). 2369984 11. Install the left side fuel rail heat shield bolts (1). ⇒ Torque the fuel rail heat shield bolts to 25Y (18 ft lbs). Bulletin No.: 16-NA-102 May, 2021 Page 15 2369973 12. Connect the fuel pressure sensor electrical connector (1). 2369976 13. Collapse the spring clamp and disconnect the fuel return hose (1). 2369972 14. Connector the left side fuel pressure relief valve electrical connector (1). 15. Ensure all lines, injectors and rail fittings are clean and dry prior to assembly. 2407097 Caution: Ensure proper torque of the fuel injector lines. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting, will cause a fuel leak. 17. Install the left side fuel injection fuel feed pipes (2). ⇒ Torque the fuel injection fuel feed pipes fittings in alternating increments to 30Y(22 ft lbs). Page 16 May, 2021 Bulletin No.: 16-NA-102 18. Install the left side fuel injection fuel feed pipe bracket bolts (1). ⇒ Torque the fuel injection fuel feed pipes bracket bolts to 10Y(89 in lbs). 2370205 19. Position the right side fuel injection fuel rail assembly (2) and install the fuel rail bolts (1). ⇒ Torque the fuel rail bolts to 25Y(18 ft lbs). 20. Ensure right side lines, injectors and rail fittings are clean and dry prior to assembly. 2407046 Caution: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak. 22. Install the right side fuel injection fuel feed pipes (2). ⇒ Torque the fuel injection fuel feed pipes bolts in alternating increments to 30Y(22 ft lbs). 23. Install the right side fuel injection fuel feed pipe bracket bolts (1). ⇒ Torque the fuel injection fuel feed pipes bracket bolts to 10Y(89 in lbs). Bulletin No.: 16-NA-102 May, 2021 Page 17 5334311 24. Clean the fuel injection fuel feed pipes and fittings for all 8 cylinders and apply sealant at the fittings (1) to prevent moisture and debris from collecting. Refer to Adhesives, Fluids, Lubricants, and Sealers in SI. 2376586 25. Install the NEW fuel injector fuel return line assembly (1). 2408336 26. Connect and reposition the fuel return hose (1). 27. If necessary, install engine wiring harness. Page 18 May, 2021 Bulletin No.: 16-NA-102 2394333 28. Install the indirect fuel injector (2). ⇒ Torque the indirect fuel injector fittings to 45Y (33 ft lbs). 2394330 29. Install the two indirect fuel injector bolts (1, 2). ⇒ Torque the indirect fuel injector bolts to 25Y (18 ft lbs). 4228687 30. Connect the fuel feed pipe Quick Connect Fitting (1). 31. Connect the indirect injector electrical connector. 4228685 32. Install the fuel feed bracket bolt (1). ⇒ Torque the fuel feed bracket bolt to 25Y (18 ft lbs). Bulletin No.: 16-NA-102 May, 2021 Page 19 4228683 Note: After connecting the fuel return hose to the fuel feed pipe, lock the fuel return line by pushing the cylindrical locking sleeve towards the connection point. 33. Connect the fuel return hose (1) to the fuel feed pipe (2). 5542966 34. Position the rear EGR Cooler and the NEW gasket, on top of the engine. 35. Loosely install the rear EGR mounting bolts (3) to the EGR bracket. 36. Install the EGR Cooler water bypass outlet hose (2) to the EGR cooler bypass valve. 37. Engage the hose clamp (1). 5542942 38. Hand tighten the front EGR Cooler bracket bolt (1). 39. Raise the vehicle. 2495773 40. Tighten the rear EGR Cooler Bypass Valve bracket bolts (1). ⇒ Torque the rear EGR bracket bolts to 25Y (18 ft lbs). 41. Lower the vehicle. 42. Tighten the 2 rear EGR mounting bolts and front cooler bracket bolt. ⇒ Torque the bolts to 25Y(18 ft lbs). Page 20 May, 2021 Bulletin No.: 16-NA-102 5527489 43. Install the EGR Cooling Feed Hose (1) and the Heater Inlet Hose (2). 44. Connect the EGR bypass valve electrical connector. 2409415 45. Install and tighten the exhaust manifold outlet pipe bolt (3) and the 2 exhaust manifold outlet pipe nuts (2,1). Exhaust Manifold Outlet Pipe Replacement – Right Side. ⇒ Torque fasteners to 25Y(18 ft lbs). 5527220 46. Install EGR coolant feed hose/pipe upper bolt (1). ⇒ Torque the bolts to 25Y(18 ft lbs). 47. Install the right exhaust manifold outlet pipe heat shield (2) and tighten the heat shield bolts (3). ⇒ Torque the bolts to 10Y(89 in lbs). 48. Raise the vehicle. 647997 49. Using care, raise the transmission and remove the block of wood. 50. Lower the transmission and install the mount to crossmember nuts. ⇒ Torque the nuts to specification. Refer to Fastener Specifications in SI. 51. Lower the vehicle. Bulletin No.: 16-NA-102 May, 2021 Page 21 5334169 52. Install the fuel filter bracket (5). ⇒ Torque all the bolts to 25Y(18 ft lbs). 53. Install the oil level indicator tube bracket bolt (3). ⇒ Torque the oil level indicator tube bolts to 25Y(18 ft lbs). 54. Verify the fuel filter assembly, hoses and adaptor are clean of debris. 1871645 55. Install the water-in-fuel sensor to the fuel filter. 4258780 56. Install the fuel filter housing assembly. Refer to Fuel Filter Housing Assembly Replacement in SI. 57. Install the fuel filter. 58. Connect the water-in-fuel sensor electrical connector. Page 22 May, 2021 Bulletin No.: 16-NA-102 59. Prior to installing fuel injection pump replace the Fuel Feed hose on the back of the injection pump. Refer to Fuel Feed Hose Replacement in SI. 60. Install the fuel injection pump. Refer to Fuel Injection Pump Replacement in SI. Danger: Verify that there are no fuel leaks in the fuel system. Failure to identify any leaks could result in no start, stall, vehicle damage, or bodily injury.” Important: Ensure proper torquing of the fuel injector line. An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting will cause a fuel leak or result in a No-Start. Cleaning and Flushing Procedure 1. Clean and flush all fuel chassis lines, filter pipes, and other engine mounted fuel system pipes that are not being replaced. 2. The fuel filter housing must be cleaned with a new fuel filter installed. 3. 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. Important: If the vehicle does not start after the priming procedure has been performed, the most likely cause is that a high pressure line is improperly torqued. Please review each high pressure joint to make sure that they are torqued properly. Bulletin No.: 16-NA-102 May, 2021 Page 23 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 97188685 GASKET, EXH TURBO INL PIPE 2 X X X X X X X 97192618 GASKET, EXH TURBO INL PIPE 2 X X X X X X X 12627897 GASKETTURBO OIL FEED PIPE 1 X X X X X X X 12637218 GASKETTURBO OIL RTN PIPE 1 X X X X X X X 12639312 HOSE ASMFUEL 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 ASMFUEL RTN 1 X X X X X X X X X X X X X X X 12661071 INJECTOR ASMINDIRECT FUEL 1 X X X X X X X X X X X X X X X 12656313 PIPE ASMFUEL 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 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 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 ASMFUEL 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 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 12676436 SENSOR ASMWAT IN FUEL IND 1 X X X X X 98065521 GASKET-EGR VLV CLR 1 X X X X X X X X 12670460 PIPE ASMFUEL HIGH PRESS (CYL 2 & 7) 2 X X X X X X X X 12670468 PIPE ASMFUEL HIGH PRESS (CYL 1 & 8) 2 X X X X X X X X 12670469 PIPE ASMFUEL HIGH PRESS (CYL 3 & 6) 2 X X X X X X X X 12670471 PIPE ASMFUEL HIGH PRESS (CYL 4 & 5) 2 X X X X X X X X Page 24 May, 2021 Bulletin No.: 16-NA-102 12670474 PIPE ASMFUEL HIGH PRESS (LEFT SIDE OF PUMP) 1 X X X X X X X X 12670475 PIPE ASMFUEL 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 ASMFUEL RTN (LEFT RAIL TO FEED PIPE) 1 X X X X X X 98065523 GASKETEGR PIPE 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 HOSEFUEL RTN 1 X X X X X X X 12641356 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 12670459 PIPE ASMFUEL HIGH PRESS (CYL 4 OR 5) 2 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 97373522 GASKET, TURBO COOL FEED & RTN PIPE 2 X X X X X X X X X X X X X X X 98065519 GASKET, EGR MANIF 1 X X X X X X X X X X X X X X X Bulletin No.: 16-NA-102 May, 2021 Page 25 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. • Select California Emission Related Components – 2 years/24,000 miles Federal warranty and 3 years/50,000 miles in California and states that have adopted the CA regulations • Select California Emission Related Components – 7 years/70,000 miles in California and states that have adopted the CA regulations Labor Operation Description Model Labor Time 4080558* Diagnose and Clean/ Repair Complete Fuel System For all P/U Trucks 15.5 hrs For all Vans 21.0 hrs *This is a unique Labor Operation for bulletin use only. Version 9 Modified Released March 31, 2016 Revised April 11, 2016 – Updating the Qty. column of the Parts Information table. Revised April 29, 2016 – Updating the Parts Information table. Revised October 26, 2016 – Updating the Parts Information table. Revised February 03, 2017 – Updating the Service Procedure. Revised March 2, 2017 – Updating the Service Procedure. Revised August 19, 2019 – Removed information in regard to turbocharger removal and installation for the p/u trucks, update the labor time for p/u trucks in the Warranty Information section and update the Parts Information section. Revised January 06, 2021 – Updated Service Procedure section and increased Labor Operation Time to 15.5 hrs, Added Danger, Important Statements and Right Side Cooler removal/install to Service procedure. Revised May 13, 2021 – Update Warranty Information section to add Emission Coverage.