NHTSA ID Number: 10199228
Manufacturer Communication Number: 16NA102
TSB/Document Date: 2021-07-19
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.
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
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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).
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.
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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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6. Install fuel injector bolts (1) .
⇒ Torque the fuel injector bracket bolts to 30Y
(22 ft lbs).
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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).
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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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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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12. Connect the fuel pressure sensor electrical
connector (1).
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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.
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13. Collapse the spring clamp and disconnect the fuel
return hose (1).
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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 30 Y (22 ft lbs).
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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 10 Y (89 in lbs).
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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.
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 30 Y (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 10 Y (89 in lbs).
Bulletin No.: 16-NA-102
May, 2021
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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.
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26. Connect and reposition the fuel return hose (1).
27. If necessary, install engine wiring harness.
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25. Install the NEW fuel injector fuel return line
assembly (1).
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May, 2021
Bulletin No.: 16-NA-102
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28. Install the indirect fuel injector (2).
⇒ Torque the indirect fuel injector fittings to 45 Y
(33 ft lbs).
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30. Connect the fuel feed pipe Quick Connect
Fitting (1).
31. Connect the indirect injector electrical connector.
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29. Install the two indirect fuel injector bolts (1, 2).
⇒ Torque the indirect fuel injector bolts to 25 Y
(18 ft lbs).
32. Install the fuel feed bracket bolt (1).
⇒ Torque the fuel feed bracket bolt to 25 Y
(18 ft lbs).
Bulletin No.: 16-NA-102
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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.
38. Hand tighten the front EGR Cooler bracket bolt (1).
39. Raise the vehicle.
33. Connect the fuel return hose (1) to the fuel feed
pipe (2).
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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).
40. Tighten the rear EGR Cooler Bypass Valve bracket
bolts (1).
⇒ Torque the rear EGR bracket bolts to 25 Y
(18 ft lbs).
41. Lower the vehicle.
42. Tighten the 2 rear EGR mounting bolts and front
cooler bracket bolt.
⇒ Torque the bolts to 25 Y (18 ft lbs).
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43. Install the EGR Cooling Feed Hose (1) and the
Heater Inlet Hose (2).
44. Connect the EGR bypass valve electrical
connector.
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46. Install EGR coolant feed hose/pipe upper bolt (1).
⇒ Torque the bolts to 25 Y (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 10 Y (89 in lbs).
48. Raise the vehicle.
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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 25 Y (18 ft lbs).
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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.
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52. Install the fuel filter bracket (5).
⇒ Torque all the bolts to 25 Y (18 ft lbs).
53. Install the oil level indicator tube bracket bolt (3).
⇒ Torque the oil level indicator tube bolts to
25 Y (18 ft lbs).
54. Verify the fuel filter assembly, hoses and adaptor
are clean of debris.
55. Install the water-in-fuel sensor to the fuel filter.
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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.
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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
Bulletin No.: 16-NA-102
May, 2021
Page 23
Parts Information
Part
Number
Description
12664429
FILTER
KIT, FUEL
88917036
97363570
12635466
Silverado /
Sierra (LGH)
Silverado / Sierra (LML)
Qty.
2011
2012
2013
2014
2015
2016
2011
2012
1
X
X
X
X
X
X
X
X
FILTER, OIL
1
X
X
X
X
X
X
X
X
GASKET, CTR
INT MANIF
2
X
X
X
X
X
X
X
X
GASKET, EGR
VLV (LOCR A)
2
X
X
X
- 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: 2021-05-13
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE
MFR Component System:
MFR Component Subsystem:
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