special policy official copy
File In Section: Special Coverage
Bulletin No.: 04039B
Service Bulletin Date: November 2007
SUBJECT: SPECIAL COVERAGE ADJUSTMENT – INJECTORS - REPLACE
MODELS: 2001-2004 CHEVROLET SILVERADO
2001-2004 GMC SIERRA
2003-2004 CHEVROLET KODIAK
2003-2004 GMC TOPKICK
EQUIPPED WITH 6.6L DURAMAX DIESEL (RPO LB7 - VIN 1) ENGINE
THIS BULLETIN IS BEING REVISED TO ADD 2004 MODEL YEAR TRUCKS.
PLEASE DISCARD SPECIAL POLICY BULLETIN NUMBER 04039A, DATED
Some customers of 2001-04 model year Chevrolet Silverado, GMC Sierra; 2003-04 Chevrolet
Kodiak and GMC TopKick vehicles, equipped with a 6.6L Duramax Diesel (RPO LB7 - VIN 1)
engine, may experience vehicle service engine soon (SES) light illumination, low engine power,
hard start, and/or fuel in crankcase, requiring injector replacement, as a result of high fuel return
rates due to fuel injector body cracks, ball seat erosion, or high pressure seal extrusion. (refer to
latest version of Technical Service Bulletin 04-06-04-007 and SI).
SPECIAL COVERAGE ADJUSTMENT
This special coverage covers the condition described above for a period of 7 years or 200,000
miles (320,000 km), whichever occurs first, from the date the vehicle was originally placed in
service, regardless of ownership. The repairs will be made at no charge to the customer.
This special coverage only covers the above noted failure modes, which
are identified by high fuel return flow rates.
For 2001-02 vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders
on or after May 25, 2004 are covered by this special coverage and must be submitted using the
labor operation codes provided with this bulletin. Claims with repair orders prior to May 25, 2004
must be submitted to the Service Contract provider.
For 2003 vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or
after October 10, 2006 are covered by this special coverage and must be submitted using the
labor operation codes provided with this bulletin. Claims with repair orders prior to October 10,
2006 must be submitted to the Service Contract provider.
Copyright 2004 General Motors Corporation. All Rights Reserved.
Page 2 November 2007 Bulletin No.: 04039B
For 2004 vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or
after November 19, 2007 are covered by this special coverage and must be submitted using the
labor operation codes provided with this bulletin. Claims with repair orders prior to November 19,
2007 must be submitted to the Service Contract provider.
Involved are all 2001-04 model year Chevrolet Silverado, GMC Sierra; 2003-04 Chevrolet Kodiak
and GMC TopKick vehicles, equipped with a 6.6L Duramax Diesel (RPO LB7 - VIN Code 1)
engine, and built within the following start of production to end of production VIN breakpoints:
YEAR DIVISION MODEL FROM THROUGH
2001 Chevrolet Silverado
2001 GMC Sierra 1E100021 1E346642
2002 Chevrolet Silverado 2E100009 2E306435
2002 GMC Sierra 2E100003 2E306345
2003 Chevrolet Silverado 3E100002 3E381007
2003 Chevrolet Kodiak 3F500015 3F522532
2003 GMC Sierra 3E100003 3E381124
2003 GMC TopKick 3F500001 3F900945
2004 Chevrolet Silverado 4E100018 4E221395
2004 Chevrolet Kodiak 4F500118 4F510079
2004 GMC Sierra 4E100002 4E223355
2004 GMC TopKick 4F100126 4F510077
Parts required to complete this special coverage are to be obtained from General Motors Service
and Parts Operations (GMSPO).
Part Number Description Quantity/Vehicle
97729095* Injector Kit, Dir Fuel (Incls:Injector,Gasket,Seal) 8
97188896 Gasket, Valve Rocker Arm Cover
(Reusable Gasket) As Req'd
97228933 Gasket, F/Injr Fuel Return Pipe 8
97600925 Gasket, F/Injr Fuel Return Pipe 2
94011604 Seal, Water outlet 1
88901148 (CN) Sealant As Req’d
97188463 Housing, F/Injr Noz As Req'd
94051259 Seal, F/Injr Noz Hsg (O Ring) As Req'd
November 2007 Bulletin No.: 04039B
*P/N 97729095 is only available in a merchandising pack quantity of 4. Current order restriction
limits orders to CSO and availability to 8 injectors per VIN.
General Motors will notify customers of this special coverage on their vehicles (see copy of typical
customer letter included with this bulletin - actual divisional letter may vary slightly).
Refer to the latest version of Technical Service Bulletin 04-06-04-007 and Service Information to
perform diagnostics and fuel injector replacement for high fuel return rates.
For vehicles repaired under the terms of this special coverage, submit a claim with the information
A copy of the completed TSB 04-06-04-007 diagnostic worksheet
and other required documentation (e.g. Tech 2 snapshots) must
be included in the box with the returned injectors.
Refer to the latest version
of TSB 04-06-04-007 to
diagnose and replace all 8
----* MK-95 T5603
(Canadian & Export
N/A N/A N/A MK-95 T5604 0.2
Courtesy Transportation N/A N/A N/A MK-95 **** N/A *****
The "Parts Allowance" should be the sum total of the current GMSPO Dealer net price plus
applicable Mark-Up or Landed Cost Mark-Up (for IPC) for injector parts needed to complete
The amount identified in the “Net Item” column should represent the sum total of the
current GMSPO Dealer net price plus applicable Mark-Up or Landed Cost Mark-Up (for
IPC) for shop supplies needed to perform the required repairs.
The amount identified in the “Net Item” column should represent the customer
Submit courtesy transportation using normal labor operations for courtesy transportation as
indicated in the GM Service Policies and Procedures Manual.
The amount identified in the "Net Item" column should represent the actual dollar amount
for courtesy transportation.
November 2007 Bulletin No.: 04039B
CUSTOMER REIMBURSEMENT - For US
All customer requests for reimbursement for previous repairs for the special coverage condition
will be handled by the Customer Assistance Center, not by dealers.
A General Motors Special Coverage Customer Reimbursement Procedure Form is included with
the customer letter.
Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for
specific procedures regarding customer reimbursement and the form.
CUSTOMER REIMBURSEMENT - For Canada and Export
Customer requests for reimbursement of previously paid repairs to correct high fuel return rate by
replacing fuel injectors in 2004 model year trucks are to be submitted prior to or by November 30,
2008. Repairs must have occurred within the 7 years of the date the vehicle was originally placed
in service, or 320,000 km, whichever occurs first.
When a customer requests reimbursement, they must provide the following:
Proof of ownership at time of repair.
Original paid receipt confirming the amount of unreimbursed repair expense(s) (including
Service Contract deductibles), a description of the repair, and the person or entity
performing the repair.
If the work was done by someone other than a GM dealership, the amount of reimbursement will
be limited to the amount that the repair would have cost GM to have it completed by a GM
The General Motors Courtesy Transportation program is intended to minimize customer
inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited
Warranty. The availability of courtesy transportation to customers whose vehicles are within the
warranty coverage period and involved in a product program is very important in maintaining
customer satisfaction. Dealers are to ensure that these customers understand that shuttle service
or some other form of courtesy transportation is available and will be provided at no charge.
Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of
conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained
Voluntary Technician technicians have the tools, equipment, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO
NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your dealer/retailer for information
on whether your vehicle may benefit from the information.
Page 5 November 2007 Bulletin No.: 04039B
Dear General Motors Customer:
As the owner of a 2001-04 model year Chevrolet Silverado; GMC Sierra or 2003-04 Chevrolet
Kodiak; GMC TopKick vehicle, your satisfaction with our product is very important to us.
This letter is intended to make you aware that some 2001-04 model year Chevrolet Silverado,
GMC Sierra; 2003-04 Chevrolet Kodiak and GMC TopKick vehicles, equipped with a 6.6L
Duramax Diesel engine, may have a condition where the engine fuel injectors may require
replacement because of high fuel return rates due to fuel injector body cracks, or ball seat
erosion, or high pressure seal extrusion. Symptoms of these conditions include illumination of the
service engine soon (SES) light, low engine power, hard start, and/or fuel in the crankcase.
Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your
vehicle has the condition as described above.
What We Have Done: General Motors is providing owners with additional protection for the fuel
injectors. If this condition occurs on your 2001-04 model year Chevrolet Silverado, GMC Sierra;
2003-04 Chevrolet Kodiak or GMC TopKick vehicle within seven (7) years of the date your vehicle
was originally placed in service or 200,000 miles (320,000 km), whichever occurs first, the
condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the
condition described above is not covered under this special coverage program.
What You Should Do: Repairs and adjustments qualifying under this special coverage must be
performed by a General Motors dealer. You may want to contact your GM dealer to find out how
long they will need to have your vehicle so that you may schedule the appointment at a time that
is convenient for you. This will also allow your dealer to order parts if they are not already in
stock. Keep this letter with your other important glove box literature for future reference.
Reimbursement: The enclosed form explains what reimbursement is available and how to
request reimbursement if you have paid for repairs for this condition. Your request for
reimbursement, including the information and documents mentioned on the enclosed form, must
be received by GM by November 30, 2008.
If you have any questions or need any assistance, just contact your dealer or the appropriate
Customer Assistance Center at the number listed below. The Customer Assistance Center’s
hours of operation are from 8:00 AM to 11:00 PM, EST, Monday through Friday.
Division Number Text Telephones (TTY)
Chevrolet 1-800-630-2438 1-800-833-2438
GMC 1-866-996-9463 1-800-462-8583
Puerto Rico – English 1-800-496-9992
Puerto Rico – Espaņol 1-800-496-9993
Virgin Islands 1-800-496-9994
GM Commercial Truck 1-800-862-4389
We are sorry for any inconvenience you may experience; however we have taken this action in
the interest of your continued satisfaction with our products.
General Motors Corporation
If you read page 4 you will find where he can get reembursed for the work performed on his truck if the dealer will not do it. By now all dealer service shops should know about this, so I am thinking they are trying to pull a fast one on him. Good luck.
2001 GMC 2500HD EC/LB, 4X4. A few go fast goodies. 540hp/1107tq Danville Dyno 11/09, Kennedy 40% injectors.
05 IH 9400i with Cummins ISX pulling a lumber bunk trailer, stuck in a swamp somewhere in Indiana.
Proud Veteran Served 6yrs Active Army From Germany, Kuwait and Bosnia to Ft. Hood and Ft. Knox