Bulletin No.: PIP5198B
Date: 14-Apr-2016

Subject:

Instrument Panel Cluster (IPC) Warning Lamps And/Or MIL Are Illuminated Diesel Exhaust Fluid (DEF)
Message Displayed Various DTCs Set (Inspect Wiring Harnesses for Chafing)

Models:

2015 Chevrolet Silverado
2015 GMC Sierra
Equipped with 6.6L Duramax™ Diesel Engine RPO LML

This PI was superseded to update Part Information and Recommendation/Instructions. Please discard PIP5198A.
The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern
Some customers may comment on any of the following conditions:
A driver information center (DIC) message is displayed.
Instrument panel cluster (IPC) warning lamps are illuminated.
Erratic or fluctuating engine oil pressure gauge.
One or more diesel exhaust fluid (DEF) warning messages are displayed.
The malfunction indicator lamp (MIL) is illuminated.
The engine may crank but not start.
The engine may run rough or misfire.
The technician may observe on a scan tool one or more of the following DTCs set as Current or in History:
DTC

Description

P00CA

Fuel Pressure Regulator 1 High Control Circuit High Voltage

P00C9

Fuel Pressure Regulator 1 High Control Circuit Low Voltage

P00EA

Intake Air Temperature (IAT) Sensor 3 Circuit Low Voltage

P00EB

Intake Air Temperature (IAT) Sensor 3 Circuit High Voltage

P003A

Turbocharger Vane Position Not Learned

P006E

Turbocharger Boost Control Solenoid High Control Circuit Low Voltage

P006F

Turbocharger Boost Control Solenoid High Control Circuit High Voltage

P008F

Engine Coolant Temperature (ECT) – Fuel Temperature Not Plausible

1

P0045

Turbocharger Boost Control Solenoid Control Circuit

P0047

Turbocharger Boost Control Solenoid Control Circuit Low Voltage

P0048

Turbocharger Boost Control Solenoid Control Circuit High Voltage

P0090

Fuel Pressure Regulator 1 Control Circuit

P0091

Fuel Pressure Regulator 1 Control Circuit Low Voltage

P0092

Fuel Pressure Regulator 1 Control Circuit High Voltage

P0117

Engine Coolant Temperature (ECT) Sensor Circuit Low Voltage

P0118

Engine Coolant Temperature (ECT) Sensor Circuit High Voltage

P0128

Engine Coolant Temperature (ECT) Below Thermostat Temperature

P0182

Fuel Temperature Sensor Circuit Low Voltage

P0183

Fuel Temperature Sensor Circuit High Voltage

P0191

Fuel Rail Pressure Sensor Performance

P0192

Fuel Rail Pressure Sensor Circuit Low Voltage

P0193

Fuel Rail Pressure Sensor Circuit High Voltage

P0202

Cylinder 2 Injector Control Circuit

P0204

Cylinder 4 Injector Control Circuit

P0206

Cylinder 6 Injector Control Circuit

P0208

Cylinder 8 Injector Control Circuit

P0340

Camshaft Position Sensor Circuit

P0403

Exhaust Gas Recirculation (EGR) Motor Control Circuit

P0405

Exhaust Gas Recirculation (EGR) Position Sensor Circuit Low Voltage

P0406

Exhaust Gas Recirculation (EGR) Position Sensor Circuit High Voltage

P046C

Exhaust Gas Recirculation (EGR) Position Sensor Performance

P049D

Exhaust Gas Recirculation (EGR) Position Not Learned

P0489

Exhaust Gas Recirculation (EGR) Motor Control Circuit 1 Low Voltage

P0490

Exhaust Gas Recirculation (EGR) Motor Control Circuit 1 High Voltage

P0522

Engine Oil Pressure Sensor Circuit Low Voltage

2

P0523

Engine Oil Pressure Sensor Circuit High Voltage

P0532

Air Conditioning (A/C) Refrigerant Pressure Sensor Circuit Low Voltage

P0606

Control Module Processor Performance

P0641

5 V Reference 1 Circuit

P0672

Cylinder 2 Glow Plug Control Circuit

P0674

Cylinder 4 Glow Plug Control Circuit

P0676

Cylinder 6 Glow Plug Control Circuit

P0678

Cylinder 8 Glow Plug Control Circuit

P10CF

Charge Air Cooler Temperature - Intake Air Temperature (IAT) Sensor 3 Correlation

P1227

Cylinder 2 Injector Control Circuit Shorted

P1233

Cylinder 4 Injector Control Circuit Shorted

P1239

Cylinder 6 Injector Control Circuit Shorted

P1247

Cylinder 8 Injector Control Circuit Shorted

P125A

Fuel Pressure Regulator 2 High Control Circuit Low Voltage

P125B

Fuel Pressure Regulator 2 High Control circuit High Voltage

P140D

Exhaust Gas Recirculation (EGR) Motor Control Circuit 2 Low Voltage

P140E

Exhaust Gas Recirculation (EGR) Motor Control Circuit 2 High Voltage

P140F

Exhaust Gas Recirculation (EGR) Motor Current Performance

P1407

Exhaust Gas Recirculation (EGR) Motor Control Circuit Shorted

P205B

Reductant Tank Temperature Sensor Performance

P2146

Injector High Control Circuit Group 1

P2155

Injector High Control Circuit Group 4

P2295

Fuel Pressure Regulator 2 Control Circuit Low Voltage

P2296

Fuel Pressure Regulator 2 Control Circuit High Voltage

P2453

Diesel Particulate Filter (DPF) Differential Pressure Sensor Performance

P2564

Turbocharger Vane Position Sensor Circuit Low Voltage

P2565

Turbocharger Vane Position Sensor Circuit High Voltage

3

P2598

Turbocharger Boost Control Position Performance – Low Position

P2599

Turbocharger Boost Control Position Performance – High Position

Recommendation/Instructions
If any of the symptoms or DTCs described above are found during diagnosis, complete the current SI diagnostic for any symptoms or DTCs found.
Note: This engine wiring harness contains fuel injector circuits. The fuel injector high voltage supply circuit and the high voltage control circuit are both
controlled by the ECM. The ECM energizes each fuel injector by grounding the control circuit and supplying each fuel injector with up to 250 V and 20 amps on
the voltage supply circuit to activate the Piezo type fuel injectors.
Danger: In order to reduce the risk of personal injury, loss of high voltage isolation to ground and higher system impedance, do not attempt to
repair any HV wiring, connector, or terminal that is damaged. High voltage coaxial type cables are not repairable. Never attempt to repair a coaxial
type cable. The entire cable/harness or component must be replaced. In order to maintain system integrity and personal safety, never attempt to
repair any high voltage wiring, cables, or terminals. Performing this procedure on high voltage circuits may result in serious injury or death.
Danger: Before working on any high voltage fuel injection system, be aware of the following procedures:
–

Do not make contact with the fuel injection harness, engine control module (ECM), or fuel injectors while the ignition is ON or RUN positions.

–

Wait 5 minutes after key OFF to allow the electronic control module (ECM) to discharge before attempting to disconnect or test engine control
components.

–

Do not use the electronic control module (ECM) case as a ground while jump starting.

–

Failure to follow the procedure exactly as written may result in serious injury or death.

If the diagnosis does not lead to a resolution or if the symptoms or DTCs are intermittent and cannot be duplicated, check for chafing of the engine wiring
harness that is routed near the EGR Valve. The wiring harness has been found chafed on a tab of the EGR Valve metal gasket.

4

Repair or replace the wiring harness if it is found chafed on the tab of the EGR Valve metal gasket.
It is critical that the wiring harness retainer is fully seated onto the stud on the driver's side rocker cover. This retainer is tied to the harness and is located
underneath the charged air cooler (CAC) inlet pipe near the #4 fuel injector. Proper routing and securing of the harness ensures there is clearance between the
harness and the EGR valve.

5

1.

Wiring harness retainer fully seated onto the stud on the driver's side rocker cover.

2.

Proper clearance between the harness and the EGR valve.

6

3.

Wiring harness retainer NOT fully seated onto the stud on the driver's side rocker cover.

4.

IMPROPER clearance between the harness and the EGR valve.

Bend the tab of the EGR gasket over to prevent a re-occurrence.
Refer to parts catalog for replacement parts based on VIN and vehicle content.

Warranty Information
For vehicles repaired under warranty use:
Labor Operation

Description

7

Labor Time

5430940

Harness Replacement

Use Published Labor Operation Time

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the
remaining steps do not need to be performed.
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 technicians have the equipment, tools,
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 GM dealer for information on whether your vehicle may benefit from the information.

WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION

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