Special Coverage (Policy) Adjustment - Electronic Diesel-Fuel Injection Pump Failure-Repair/Replace

THIS BULLETIN IS BEING REVISED TO ADD INFORMATION TO THE DIESEL EFI DIAGNOSTIC WORKSHEET FOR THE FUEL TEMPERATURE SENSOR, AND ADD INFORMATION TO THE SERVICE PROCEDURE. PLEASE DISCARD SPECIAL POLICY BULLETIN NUMBER 00064F, DATED SEPTEMBER 2004.

Some customers of 1994-2002 Chevrolet and GMC C/K, G and P model trucks; and 1997-1998 B7 school bus chassis, equipped with a 6.5L diesel engine (RPO L49-VIN Code P; RPO L56-VIN Code S; or RPO L65-VIN Code F), may experience a failure of the electronic diesel fuel injection pump.

This special policy covers the condition described above for a period of eleven (11) years or 120,000 miles (193,000 km), whichever occurs first, from the date the vehicle was originally placed in service, regardless of ownership. Damage from poor quality or incorrect grade diesel fuel, and gasoline or water contamination, is not covered under the terms of the 6.5L diesel warranty.

This special policy applies ONLY to electronic diesel-fuel injection pump repairs and/or replacement as a result of injection pump failure. The pump repair or replacement will be made at no charge to the owner. This Special Coverage does not cover: glow plugs, turbocharger wear, low compression engines or PCM/PCM wiring conditions.

Fuel quality may cause driveability problems such as hesitation, lack of power, stall, no start, etc. For best results, use Number 2-D diesel fuel year-round (above and below freezing conditions) as oil companies blend Number 2-D fuel to address climate differences. Number 1-D diesel fuel may be used in very cold temperatures (when it stays below -18°C (0°F); however, it will produce power and fuel economy loss. The use of Number 1-d fuel in warm or hot climates may result in stalling, poor starting when the engine is hot and may damage the fuel injection system. For further detail related to Fuel System Specifications, refer to SI.

Involved are all 1994-2002 Chevrolet and GMC C/K, G and P model trucks, and 1997-1998 B7 school bus chassis, equipped with 6.5L diesel engine (RPO L49-VIN Code P; RPO L56-VIN Code S or RPO L65-VIN Code F) and built from Start of Production to End of Production, which begins and ends with the following VIN breakpoints:

Support parts required to complete this repair are to be obtained from General Motors Service Parts Operations (GMSPO).

General Motors will notify customers of this special policy on their vehicles (see copy of typical customer letter included with this bulletin - actual divisionsl letter may vary slightly.)

Pump Replacement -- Israel Only

Follow current in-country procedure.

Pump Replacement/Repair -- International Countries (except Israel)

Follow current in-country procedure.

Important: Do NOT order the pump through GMSPO or a Stanadyne dealer.

Important: Replacement gaskets, the engine shut-off solenoid and the pump mounted driver are listed in the Parts Information table of this Special Policy Bulletin.

The following information describes the exchange procedure that should be followed if the electronic diesel fuel injection pump requires removal under this Special Policy. Replacement procedure differs between the electronic and mechanical pump models.

Important: DO NOT REMOVE THE INJECTION PUMP. PROPER DIAGNOSTICS MUST BE PERFORMED PRIOR TO CALLING 1-877-446-8227. THIS INCLUDES VERIFICATION OF THE CUSTOMER CONCERN, PERFORMING SERVICE MANUAL DIAGNOSTICS IN SI, RECORDING THE VALUES, EFI WORKSHEET AND CHECKING FOR FUEL QUALITY.

Electronic Pump (DS Model) Engine VIN Code F, P, S

If diagnostics indicate that the electronic fuel injection pump cannot be repaired by the dealership, call 1-877-446-8227 to request an electronic fuel injection pump. THE INJECTION PUMP IS NOT TO BE OBTAINED FROM A STANADYNE DEALER OR GMSPO, OR ANY OTHER ENTITY. For 1994 L65 vehicles built between SOP (Start of Production) and approximately January 15, 1994, make sure to identify the vehicle's pump model.

Service Procedure -- Israel Only

Follow current in-country procedure.

Service Procedure -- International Countries (Except Israel)

Follow current in-country procedure.

Service Procedure -- U.S. and Canada Only

1. Check the Vehicle Inquiry System (GMVIS) for in-service date and warranty blocks.
2. 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.
3. Complete the entire Diesel EFI Diagnostic Worksheet 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.
4. 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 andm odel number of the injection pump currently on the truck will be required.
5. Record the serial number of the removed defective injection pump on the warranty repair order.
6. 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.

Important: 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.

7. Record the serial number of the new injection pump on the warranty repair order.
8. Hold all defective injection pumps with a copy of the repair order and a copy of the Diagnostic Worksheet form until the Special Policy warrany 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).

Important: 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.

9. 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 ***)

Important: 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.

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.

Submit a Special Policy Claim with the information indicated below:

All customer requests for reimbursement for previous repairs for the special policy condition will be handled by the Customer Assistance Center, not by dealers.

A General Motors Special Policy Customer Reimbursement Procedure Form is included with the customer letter.

Important: Refer to the GM Service Policies and Procedures Manual, section 1.6.12, for specific procedures regarding customer reimbursement and the form.

Customer requests for 2002 model year reimbursement of previously paid repairs to correct the diesel injection fuel pump are to be submitted prior to or by September 30, 2005 . Repairs must have occurred within the 11 years of the date the vehicle was originally placed in service, or 193,000 km, whichever occurs first.

When a customer requests reimbursement, they must provide the following:

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 dealership.

If you have paid to have this special policy condition corrected prior to this notification, you may be eligible to receive reimbursement.

Requests for reimbursement may include parts, labor, fees and taxes. Reimbursement may be limited to the amount the repair would have cost if completed by an authorized General Motors dealer.

Your claim will be acted upon within 60 days of receipt.

If your claim is:

Please follow the instructions on the Claim Form provided on the reverse side to file a claim for reimbursement. If you have questions about this reimbursement procedure, please call the toll-free telephone number provided at the bottom of the form. If you need assistance with any other concern, please contact the appropriate Customer Assistance Center between the hours of 8:00 AM and 11:00 PM, EST, Monday through Friday. They can be reached at:

Please mail this claim form and the required documents to:

General Motors Corporation

P.O. Box 33170

Detroit, MI 48232-5170

All recall reimbursement questions should be directed to the following number: 1-800-204-0261.

Dear General Motors Customer:

As the owner of a 1994-2002 Chevrolet or GMC C/K, G or P model truck, or 1997-1998 B7 school bus, equipped with a 6.5L diesel engine, your satisfaction with our product is very important to us. Your vehicle was provided with a new vehicle warranty, which covers certain parts of your vehicle for a specified period. These warranties are of considerable value to you if you should experience problems with your vehicle.

Some owners of 1994-2002 Chevrolet and GMC C/K, G or P model trucks, and 1997-1998 B7 school bus chassis, equipped with a 6.5L diesel engine have experienced a failure of the electronic fuel injection pump. Failure of the pump can cause complaints of poor performance or hard/no start, hesitation, as well as illumination of the "Service Engine Soon" light.

This is not a recall. Do not take your vehicle to your General Motors dealer as a result of this letter unless you believe that your vehicle has the condition as described above.

General Motors is providing owners with additional protection for the electronic diesel injection pump. If a pump failure occurs on your 1994-2002 Chevrolet or GMC C/K, G or P model truck, or 1997-1998 B7 school bus chassis within eleven (11) years of the date your vehicle was originally placed in service or 120,000 miles (193,000 km), whichever occurs first, the condition will be repaired for you at no charge . Damage from poor quality or incorrect grade diesel fuel, and gasoline or water contamination is not covered under the terms of the 6.5L diesel warranty or this special policy. This special policy applies ONLY to electronic diesel fuel injection pump repairs and/or replacement as a result of injection pump failure.

Repairs and adjustments qualifying under this special coverage must be performed by a GM dealer. You may want to call the service department at the dealership 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 your. This will also allow your dealer to order parts if they are not already in stock. Keep this letter with your other important glovebox literature for future reference.

The enclosed form explains what reimbursement is available and how to request reimbursement if you have paid for repairs for the special policy condition.

If the work was done by a Stanadyne dealer or other service establishment, other than a GM dealership, you may not be eligible for reimbursement. Your dealer will review the case for reimbursement consideration. The amount of reimbursement will generally be limited to the amount that the repair would have cost GM to have it completed by a GM dealership.

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.

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

Enclosure

00064F