NHTSA ID Number: 10187743
Manufacturer Communication Number: 16NA102
TSB/Document Date: 2021-03-01
Summary
This technical bulletin provides a procedure to clean and repair the complete fuel system due to dirt getting into the fuel system causing the vehicle to have a hard or no start.
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- Restores fuel economy
- Stabilizes ethanol
- Maximizes horsepower
- Improves responsiveness
- For use in both gasoline and diesel engines
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TSB/Document ID: 16NA102
Replacement Service Bulletin Number:
MFR Communication Date: 2021-01-06
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE
MFR Component System:
MFR Component Subsystem:
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Bulletin No.:
Service Bulletin
Date:
16-NA-102
January, 2021
TECHNICAL
Subject:
Duramax Diesel Hard Start, No Start, DTCs P0087, P0088, P0191, P128E or Injection
Pump Replacement
Model:
Model Year:
from
to
2010
2016
VIN:
from
Engine:
to
Express
Silverado 2500/3500
Savana
LML, LGH
Sierra 2500/3500
Involved Region or Country
Condition
North America, Israel
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.
Copyright 2021 General Motors
LLC. All Rights Reserved.
Page 2
January, 2021
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.
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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.
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Bulletin No.: 16-NA-102
January, 2021
Page 3
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
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.
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.
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."
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.
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January, 2021
Bulletin No.: 16-NA-102
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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.
10. Loosen the 2 bolts (1) at the rear EGR bracket (2).
11. Lower the vehicle.
5527489
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.
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
January, 2021
Page 5
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14. Remove the EGR cooler bracket bolt (1).
20. Disconnect the water in fuel sensor wiring
pigtail (2) from the engine wiring harness electrical
connector.
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.
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.
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January, 2021
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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
Bulletin No.: 16-NA-102
January, 2021
Page 7
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26. Remove the fuel filter bracket (5). Refer to Fuel
Filter Bracket Replacement in SI.
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27. Disconnect the fuel return hose (1) from the
injectors and position aside.
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).
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January, 2021
Bulletin No.: 16-NA-102
4228683
30. Disconnect the Fuel Return Hose (1) from the Fuel
Feed Pipe (2)
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.
4228685
31. Remove the Fuel Injection Fuel Feed Pipe Bracket
Bolt (1).
2374328
34. Disconnect the hydrocarbon injector (HCI)
electrical connector (1).
Bulletin No.: 16-NA-102
January, 2021
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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).
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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).
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January, 2021
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42. If necessary, reposition the engine harness aside.
43. Disconnect the fuel return hose (1) from the
injectors and discard.
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46. Disconnect the fuel pressure relief valve electrical
connector (1).
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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).
47. Collapse the spring clamp and disconnect the fuel
return hose (1).
Bulletin No.: 16-NA-102
January, 2021
2369973
48. Disconnect the fuel pressure sensor electrical
connector (1).
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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.
2369984
49. Remove the fuel rail heat shield fasteners (1).
2408253
53. Disconnect the fuel injector electrical
connectors (1).
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January, 2021
Bulletin No.: 16-NA-102
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.
2408258
54. Remove all the fuel injector bracket bolts (1).
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.
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Bulletin No.: 16-NA-102
January, 2021
Page 13
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
1335621
1. Install the EN - 47909–2 Radial Brush to the EN 47909–1 T-Handle.
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 EN47909–1 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
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).
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January, 2021
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.
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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.
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6. Install fuel injector bolts (1) .
⇒ Torque the fuel injector bracket bolts to 30Y
(22 ft lbs).
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 25 Y
(18 ft lbs).
Bulletin No.: 16-NA-102
January, 2021
2369984
11. Install the left side fuel rail heat shield bolts (1).
⇒ Torque the fuel rail heat shield bolts to 25 Y
(18 ft lbs).
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13. Collapse the spring clamp and disconnect the fuel
return hose (1).
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12. Connect the fuel pressure sensor electrical
connector (1).
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.
Page 16
January, 2021
Bulletin No.: 16-NA-102
19. Position the right side fuel injection fuel rail
assembly (2) and install the fuel rail bolts (1).
⇒ Torque the fuel rail bolts to 25 Y (18 ft lbs).
20. Ensure right side 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
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