Special Policy 04039C - Chevy and GMC Duramax Diesel Forum
01-04.5 LB7 Duramax Powertrain Discussion of components that are directly involved in the power production and all that is needed to get and keep the truck moving . Engine , Transmission Ect

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Old 07-09-2010, 04:36 PM   eBay Motors  #1 (permalink)
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Special Policy 04039C

I just found this on alldatadiy.com:

SPECIAL COVERAGE
Bulletin No.: 04039C
Date: December 08, 2009
Subject: 04039C - Special Policy Adjustment - Injector - Replace
Models:
2001-2004 Chevrolet Silverado
2001-2004 GMC Sierra
2004 Chevrolet Kodiak
2004 GMC TopKick
Equipped with 6.6L Duramax Diesel (RPO LB7 - VIN Code 1) Engine

Supercede:
Technical Service Bulletins 03-06-04-036B and 04-06-04-007I have been incorporated into this bulletin. Please discard all copies of bulletin 04039B, issued November 2007.

Condition
Some customers of 2001-04 model year Chevrolet Silverado; GMC Sierra; 2003 Chevrolet Kodiak and GMC TopKick vehicles, equipped with a 6.6L Duramax Diesel (RPO LB7 - VIN Code 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.
Special Policy Adjustment
This special policy 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.
Important
This special policy only covers the above noted failure modes, which are identified by high fuel return flow.

For 2001-2002 vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after May 25, 2004, are covered by this special policy 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 policy 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.
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.
Vehicles Involved
Involved are all 2001-04 model year Chevrolet Silverado, GMC Sierra; 2003-2004 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:

Parts Information
Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO).

*P/N 97729095 is only available in a merchandising pack quantity of 4.
It is recommended that the customer purchase the latest released fuel filter, P/N 12633243. Refer to Corporate Bulletin Number 04-06-04-070B.
Customer Notification
Customers will be notified of the special policy on their vehicles by General Motors (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly).
Injector Core Return Process - Effective June 2008
Effective June 2008, the handling of 6.6L Duramax Injector (MY01-MY04 LB7) cores for part number 97729095 changed. The majority of injector cores will now be returned using the normal light core return process to UPS-Supply Chain Solutions (UPS-SCS). For these cores, credit will be issued using the normal GMSPO core credit process. However, a sampling of injectors replaced under warranty will continue to be returned to the Warranty Parts Center (WPC) for evaluation. This dual process will simplify the core credit process for dealers and provide more efficient handling of the cores overall.
For injector warranty claims, dealers should continue to hold cores until the warranty claim is paid.
Important
All replaced injectors must be returned to either the WPC or the core return center (UPS-SCS). Approximately 30% of the warranty claims will be requested back to the WPC.

Important
WAIT UNTIL THE WARRANTY CLAIM IS PAID TO DETERMINE THE LOCATION TO WHICH THE INJECTORS MUST BE RETURNED. IF A WPC PART RETURN REQUEST IS RECEIVED, RETURN THE INJECTORS TO THE WPC. IF A WPC PART RETURN REQUEST IS NOT RECEIVED, THEN RETURN THE INJECTORS TO THE CORE RETURN CENTER. Please follow Corporate Bulletin 99-00-89-019E that applies to the WPC return procedures. All injectors of a single engine must arrive at the WPC boxed or bagged together in sets of four or eight injectors. A copy of the part request, repair order with technician comments, snapshot of the preliminary (actual) fuel rail pressure vs. desired as commanded by the Tech 2(R) to 160 MPa, and the completed diagnostic worksheet must be included with the injectors. No snapshot is required for vehicles that do not start. If the WPC does NOT request the injectors, return the cores following the normal light core guidelines (apply through EPIC/RAPID)* to UPS-Supply Chain Solutions (UPS-SCS)*.* In Canada, injector cores are now to be returned using the normal core return process using form PC659C (Application for Authorization to Return Material) unless requested by the WPC. Sets of injectors should be secured with tape or in an overpack container in sets of four or eight for returns to both UPS-SCS and to the WPC. A copy of the repair order and diagnostic worksheet is still requested with the core for both warranty related and regular return.

For returns to UPS-SCS, the core ID label (2) must be visible on the outside end of the package at the opposite end from the part label (1).
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation:
-If using GWM, submit as a Net Item under the appropriate labor code.-If using WINS, submit using normal labor operations for courtesy transportation as indicated in the GM Service Policies and Procedures Manual.
Important
A copy of the completed diagnostic worksheet and other required documentation (e.g. Tech 2(R) snapshots) MUST BE INCLUDED in the box with the returned injectors.

* The amount identified in "Net Item" should represent the actual dollar amount for shop supplies needed to perform the required repairs.
** The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer.
Customer Reimbursement - For US
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 shown in this bulletin.
Important
Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

Customer Reimbursement - Canada
Customer requests for reimbursement for previous 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 dealership.



At gmpartsdirect you can get the injectors for $175 a piece....when you buy 4 (1 Kit) it turns out to be $700 for 4 injectors + a $400 core charge. thought everyone would find this useful
Attached Images
File Type: jpg vin breakout.jpg (20.3 KB, 2058 views)
File Type: jpg parts breakout.jpg (21.6 KB, 2054 views)
File Type: gif labor codes.gif (5.1 KB, 2051 views)
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Old 03-22-2011, 04:39 PM   eBay Motors  #2 (permalink)
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So, about $2200 including the core charge, but that's $800 back then. Not horrible, compared to the 4k or more I've been seeing.
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Old 06-20-2011, 04:02 PM   eBay Motors  #3 (permalink)
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Hey guys i just bought a 2004 lb7 and was wondering if there are tell tale signs if the injectors are going bad. The truck is completly stock with 116,000 miles. Any help would be greatly appreciated.
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Old 06-21-2011, 01:38 AM   eBay Motors  #4 (permalink)
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Check your oil for fuel...horrible fuel mileage and tons of smoke while idling are other signs.

Your truck may not be covered...depends on when it was put into service and it has to fail exactly as the special policy states.
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2004 GMC 2500HD D/A CC Carbon Metallic w/ LB7
4" turbo back MBRP exhaust, Cognito UCAs & HD tierods
TST Powermax Programmer, Diablosport Predator
305/70-16 BFG T/A KOs on Eagle Alloys Series 187
Clifford remote start. High Idle, Bilstein 5100s, 1.5" lift blocks
CAT fuel filter w/ nicktane adapter
Magnum Force Stage 2 intake with AMSOIL filter
Racor 2 Micron pre-OEM with heater & water sep
Lightforce 140s from Madjackracing
http://WWW.ATPTRUCKS.COM/
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Old 06-29-2011, 06:14 PM   eBay Motors  #5 (permalink)
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Quote:
Originally Posted by ob_1jr View Post
Check your oil for fuel...horrible fuel mileage and tons of smoke while idling are other signs.

Your truck may not be covered...depends on when it was put into service and it has to fail exactly as the special policy states.
One way to do this is touch your dipstick to a paper towel, oil will stay in center and if contaminated with fuel the diesel will leach out in a larger ring than the oil. Just learned it when working on a 6.4 ford.
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Old 07-11-2011, 06:28 PM   eBay Motors  #6 (permalink)
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Quote:
Originally Posted by ob_1jr View Post
I just found this on alldatadiy.com:

SPECIAL COVERAGE
Bulletin No.: 04039C
Date: December 08, 2009
Subject: 04039C - Special Policy Adjustment - Injector - Replace
Models:
2001-2004 Chevrolet Silverado
2001-2004 GMC Sierra
2004 Chevrolet Kodiak
2004 GMC TopKick
Equipped with 6.6L Duramax Diesel (RPO LB7 - VIN Code 1) Engine

Supercede:
Technical Service Bulletins 03-06-04-036B and 04-06-04-007I have been incorporated into this bulletin. Please discard all copies of bulletin 04039B, issued November 2007.

Condition
Some customers of 2001-04 model year Chevrolet Silverado; GMC Sierra; 2003 Chevrolet Kodiak and GMC TopKick vehicles, equipped with a 6.6L Duramax Diesel (RPO LB7 - VIN Code 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.
Special Policy Adjustment
This special policy 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.
Important
This special policy only covers the above noted failure modes, which are identified by high fuel return flow.

For 2001-2002 vehicles covered by Vehicle Service Contracts, all eligible claims with repair orders on or after May 25, 2004, are covered by this special policy 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 policy 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.
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.
Vehicles Involved
Involved are all 2001-04 model year Chevrolet Silverado, GMC Sierra; 2003-2004 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:

Parts Information
Parts required to complete this special policy are to be obtained from General Motors Service Parts Operations (GMSPO).

*P/N 97729095 is only available in a merchandising pack quantity of 4.
It is recommended that the customer purchase the latest released fuel filter, P/N 12633243. Refer to Corporate Bulletin Number 04-06-04-070B.
Customer Notification
Customers will be notified of the special policy on their vehicles by General Motors (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly).
Injector Core Return Process - Effective June 2008
Effective June 2008, the handling of 6.6L Duramax Injector (MY01-MY04 LB7) cores for part number 97729095 changed. The majority of injector cores will now be returned using the normal light core return process to UPS-Supply Chain Solutions (UPS-SCS). For these cores, credit will be issued using the normal GMSPO core credit process. However, a sampling of injectors replaced under warranty will continue to be returned to the Warranty Parts Center (WPC) for evaluation. This dual process will simplify the core credit process for dealers and provide more efficient handling of the cores overall.
For injector warranty claims, dealers should continue to hold cores until the warranty claim is paid.
Important
All replaced injectors must be returned to either the WPC or the core return center (UPS-SCS). Approximately 30% of the warranty claims will be requested back to the WPC.

Important
WAIT UNTIL THE WARRANTY CLAIM IS PAID TO DETERMINE THE LOCATION TO WHICH THE INJECTORS MUST BE RETURNED. IF A WPC PART RETURN REQUEST IS RECEIVED, RETURN THE INJECTORS TO THE WPC. IF A WPC PART RETURN REQUEST IS NOT RECEIVED, THEN RETURN THE INJECTORS TO THE CORE RETURN CENTER. Please follow Corporate Bulletin 99-00-89-019E that applies to the WPC return procedures. All injectors of a single engine must arrive at the WPC boxed or bagged together in sets of four or eight injectors. A copy of the part request, repair order with technician comments, snapshot of the preliminary (actual) fuel rail pressure vs. desired as commanded by the Tech 2(R) to 160 MPa, and the completed diagnostic worksheet must be included with the injectors. No snapshot is required for vehicles that do not start. If the WPC does NOT request the injectors, return the cores following the normal light core guidelines (apply through EPIC/RAPID)* to UPS-Supply Chain Solutions (UPS-SCS)*.* In Canada, injector cores are now to be returned using the normal core return process using form PC659C (Application for Authorization to Return Material) unless requested by the WPC. Sets of injectors should be secured with tape or in an overpack container in sets of four or eight for returns to both UPS-SCS and to the WPC. A copy of the repair order and diagnostic worksheet is still requested with the core for both warranty related and regular return.

For returns to UPS-SCS, the core ID label (2) must be visible on the outside end of the package at the opposite end from the part label (1).
Claim Information
1. Submit a claim using the table below.
2. Courtesy Transportation:
-If using GWM, submit as a Net Item under the appropriate labor code.-If using WINS, submit using normal labor operations for courtesy transportation as indicated in the GM Service Policies and Procedures Manual.
Important
A copy of the completed diagnostic worksheet and other required documentation (e.g. Tech 2(R) snapshots) MUST BE INCLUDED in the box with the returned injectors.

* The amount identified in "Net Item" should represent the actual dollar amount for shop supplies needed to perform the required repairs.
** The amount identified in "Net Item" should represent the dollar amount reimbursed to the customer.
Customer Reimbursement - For US
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 shown in this bulletin.
Important
Refer to the GM Service Policies and Procedures Manual, section 6.1.12, for specific procedures regarding customer reimbursement and the form.

Customer Reimbursement - Canada
Customer requests for reimbursement for previous 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 dealership.



At gmpartsdirect you can get the injectors for $175 a piece....when you buy 4 (1 Kit) it turns out to be $700 for 4 injectors + a $400 core charge. thought everyone would find this useful
The price for those injectors is great.. Except when you go to checkout, they nail you with a $342 processing fee and shipping fee.!! that adds about $42 to the price of each injector
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Old 10-18-2011, 04:02 PM   eBay Motors  #7 (permalink)
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I just took my 2004 with 139,000 miles on it to get new injectors. I still had to pay 1700.$ for labor though. But still way better than the alternative.
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Old 10-26-2011, 12:31 PM   eBay Motors  #8 (permalink)
 
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If yours is still covered. . .

If your truck is still covered by the special policy discussed above (7yr/200K miles, WHICHEVER COMES FIRST), run, do not walk, to your nearest GMC/Chevy dealer. Actually, you'll probably need to drive so you can have the fuel rails checked for return rate. Policy has probably expired for everything except a few '03 and most '04s.

We had not had any problems with our '03 until I started seeing smoke at idle. It ran fine, fuel mileage was normal, etc.--103K miles. Took it in and sure enough--6 of 8 injectors were bad. And of course, it was sold in July 2002 so is over a year past the deadline. GM's response--too bad, so sad.

And when I say "stock," I mean everything. No programmer, no tuned exhaust, etc.

If anyone has any tips to prolong injector life, I'd sure like to know them. We do a lot of hauling, either a 10,000# sailboat or 13,000# 5th wheel, but the truck is not used for around town driving.
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Old 10-26-2011, 12:35 PM   eBay Motors  #9 (permalink)
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Have had mine done 3 times under warranty, last time was january 2010 at 199,000 miles haha
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Old 10-26-2011, 12:37 PM   eBay Motors  #10 (permalink)
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oh and i never even took my race tune off or my switch out, had stack and CAI, it takes a good relationship with your dealer and it can be gotten away with.
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EFILIVE by Idahorob, Suncoast Tranny by ME
6'' lift, 6'' stack, 35x12.50x20 Federal MTs
8.11@88mph 1/8th


THE WIFE'S RIDE 2006 lbz CCSB 7'' lift 37s on 22s
Efilive dsp5 by Rob-Transgo jr-ppe shim kit
HID lows and Fogs-billett grill-

"Crime don't pay, but neither does farmin these days"
I.B.E.W Local 702
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