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TSB's: Engine

sperry

Silent Avalanche RIP
SM 2007
SM 2006
SM 2005
Full Member
Joined
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13,160
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These are not sorted by number, as they were posted as needed and are out of sequence to do that.

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03 Reduced Engine Power - DTCs P0120 , P0220 , P1516 and/or P1518 - 03 Model Year Full Size Trucks and Utilities with 4.8 , 5.3 or 6.0 Engines - kw CEL light low LQ4 LQ9 LR4 MIL reducedpwrmde #PIP3042A - (Aug 30, 2004)

The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI.

Condition/Concern:

Service Engine Soon Light and / or Reduced Engine Power Mode due to any of the following DTCs: P0120, P0220, P1516 and/or P1518.

Recommendation/Instructions:

If the SI diagnosis and bulletin 03-06-04-032 did not isolate a concern, the following information may help:

  1.  Inspect the Yellow TAC Motor Control Circuit (581) about 1 inch to 4 inches from the throttle body connector to see if it is broken inside of the insulation.
  2. Inspect S102 if there is a P1518 stored. S102 is in the engine harness and is 5.5 inches from the MAP Sensor.
  3. Install that latest engine diagnostic calibrations in the PCM. Some 2003 model year vehicles have updated engine diagnostic calibrations available to address DTCs P0120, P0220, P1516 and or P1518. The title of the updated engine diagnostic calibration in TIS2000 is "New calibration to eliminate setting of P0120, P0220, or P1516 with the engine not running. Includes diagnostic enhancements for P1518."

If the above did not help, replace the throttle body and retorque it to 45 lb/in on the 1st pass and 89 lb/in on the second and final pass.

Please follow this diagnosis 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. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.

Models:

(03 Cadillac Escalade) and (03 Chevrolet Avalanche) and (03 Chevrolet Silverado)and (03 Chevrolet Suburban) and (03 Chevrolet Tahoe) and (03 GMC Sierra) and (03 GMC Yukon) and (03 Hummer H2)
 
SES Light and Reduced Engine Power with a DTC P1516: DTCs P0120 , P0220 , P1514 , P1515 , P1518 and P2135 May Be Present; 04 Trucks and Utilities with GENIII V-8 Engines - kw 4.8 5.3 6.0 #PIP3089 - (Jul 30, 2004)

The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI.

Condition/Concern:

SES light and reduced engine power with a DTC P1516. DTCS P0120, P0220, P1514, P1515, P1518 and P2135 may also be present.

Recommendation/Instructions:

If the SI diagnostics do not isolate the cause, inspect the Yellow TAC Motor Control Circuit (581) about 1 inch to 4 inches from the throttle body connector to see if it is broken inside of the insulation. Repair as necessary.

Please follow this diagnosis 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. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.

Models:

(03 - 04 Cadillac Escalade C1, C6, K1, K6) and (03 - 04 Chevrolet Avalanche C1, K1, C2, K2) and (03 - 04 Chevrolet Silverado Truck C1, K1, C2, K2, C3, K3 ) and (03 - 04 Chevrolet Tahoe C1, K1 ) and (03 - 04 Chevrolet Suburban C1, K1, C2, K2, C3, K3 ) and (03 - 04 GMC Sierra Truck C1, K1, C2, K2, C3, K3 ) and (03 - 04 GMC Yukon C1, K1 ) and (03 - 04 GMC Yukon XL C1, K1, C2, K2, C3, K3) and (03 - 04 Hummer H2 N2 ) and (03 - 04 Buick Rainier S1, T1 ) and (03 - 04 Chevrolet Trail Blazer EXT S1, T1 ) and (03 - 04 GMC Envoy XL XUV S1, T1)
 
03 8.1 L18 Reduced Engine Power Due to DTCs P0120 , P0220 , P1516 and / or P1518 - kw CEL GMT800 GMT805 GMT830 light low MIL reduced reducedpwrmde #PIP3040 - (Jun 30, 2004)
03 8.1 L18 Reduced Engine Power Due to DTCs P0120 P0220 P1516 and / or P1518


The following diagnosis might be helpful if the vehicle exhibits the described symptoms in the PI.

Condition/Concern:

Service Engine Soon Light and / or Reduced Engine Power Mode due to any of the following DTCs: P0120, P0220, P1516 and/or P1518. This condition is normally very intermittent.

Recommendation/Instructions:

If the published diagnostics did not isolate a concern, the following information may help:

  1. Inspect G104 on the rear of the left cylinder head. See SI document 818627, if necessary.
  2. Install that latest engine diagnostic calibrations in the PCM. Some 2003 model year vehicles have updated engine diagnostic calibrations available to address DTCs P0120, P0220, P1516 and or P1518. The title of the updated engine diagnostic calibration in TIS2000 is "New calibration to eliminate setting of P0120, P0220, or P1516 with the engine not running. Includes diagnostic enhancements for P1518."

Please follow this diagnosis 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. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.

Models:

(03 Chevrolet Avalanche C2, K2) and (03 Chevrolet Silverado C2, C3, K2, K3) and (03 Chevrolet Suburban C2, C3, K2, K3) and (03 GMC Sierra C2, C3, K2, K3) and (03 GMC Yukon XL C2, C3, K2, K3)
 
Info - Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter #04-07-30-013A - (Jan 25, 2005)

2005 and Prior GM Cars and Light Duty Trucks

2005 and Prior Saturn Models

2003-2005 HUMMER H2

This bulletin is being revised to add additional model years and to clarify warranty coverage. Please discard Corporate Bulletin Number 04-07-30-013 (Section 07 -- Transmission/Transaxle).

Engine_MAF_K%26N.gif


The use of an excessively/over-oiled aftermarket, reusable air filter may result in:

  ? Service Engine Soon (SES) Light On
  ? Transmission shift concerns, slipping and damaged clutch(es) or band(s)
  ?    Engine driveability concerns, poor acceleration from a stop, limited engine RPM range

The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur.

When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over- oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern.

The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty.

If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs.


Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items.
 
Info - Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power Performance, Stall Concerns) #04-06-04-047C - (Dec 14, 2004)

2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only)

2005 and All Prior Saturn Vehicles

2003-2005 HUMMER H2

This bulletin is being revised to include additional gasoline brands that currently meet the Top Tier Detergent Gasoline Standards and add Saturn to the Models section. Please discard Corporate Bulletin Number 04-06-04-047B (Section 06 - Engine/Propulsion System).

A new class of gasoline, called Top Tier Detergent Gasoline, is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section.

Gasoline Brands That Currently Meet Top Tier Detergent Gasoline Standards

As of December 8, 2004, the following gasoline brands meet the Top Tier Detergent Gasoline Standards:
  ? Chevron Chevron has markets in 29 states in the West, Southwest and South, as well as in Alaska and Hawaii. ALL grades of Chevron with Techron gasoline meet Top Tier Detergent Gasoline Standards.
  ? QuikTrip (not to be confused with Kwik Trip) QuikTrip operates convenience stores and travel centers in a number of metropolitan areas:
      - Tulsa, OK
      - Springfield, MO
      - Kansas City, MO and Kansas City, KS
      - Wichita, KS
      - Des Moines, IA
      - Omaha, NE
      - St. Louis, MO and St. Louis, IL
      - Atlanta, GA
      - Dallas-Ft. Worth, TX
      - Phoenix, AZ
      - Bartlesville, OK
      - Miami, OK
      - Vinita, OK
      - Columbia, MO
  ? Conoco has over 4,000 stations located in 33 states.
  ? Phillips 66 has locations in 32 states across the nation.
  ? 76 has over 2,700 stations located throughout the country.
  ? Shell Shell Oil Products has a network of nearly 7,000 branded gasoline stations in the Western United States. Shell Oil Company markets branded products through more than 10,000 stations in the Eastern and Southern United States.
  ? Entec Stations offer gasoline through stations located in the greater Montgomery, Alabama area.

What is Top Tier Detergent Gasoline?

Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA.

Where Can Top Tier Detergent Gasoline Be Purchased?

The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and have introduced Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the Top Tier standards.

Who developed Top Tier Detergent Gasoline standards?

Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota.

Why was Top Tier Detergent Gasoline developed?

Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product.

Why did the four automotive companies join together to develop Top Tier?

All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies.

What are the benefits of Top Tier Detergent Gasoline?

Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns.

Who should use Top Tier Detergent Gasoline?

All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline.
 
Information on Serpentine Belt Wear #04-06-01-013 - (Apr 29, 2004)

2004 and Prior Passenger Cars and Trucks

2003-2004 and Prior HUMMER H2

All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use.

Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life.

A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing.

Any belt that exhibits chunking should be replaced.

 
DEX-COOL Engine Coolant Information #00-06-02-006A
(Feb 13, 2004)

DEX-COOL? Engine Coolant Information

2004 and Prior Passenger Cars and Trucks

2004 and Prior HUMMER H2

This bulletin is being revised to add model years and updated information. Please discard Corporate Bulletin Number 00-06-02-006 (Section 6 -- Engine/Propulsion System).

Licensed Approved DEX-COOL? Providers

Important

USE OF NON APPROVED VIRGIN OR RECYCLED DEX-COOL? OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY, AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY.


Following are the only current licensed and approved providers of virgin DEX-COOL? and DEX-COOL? inhibitor packages used for recycling. Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL? have not been tested or approved by General Motors. Non approved coolants may degrade the coolant system integrity and will no longer be considered a 5yr/150,000 mile (240,000 km) coolant.

Approved providers of DEX-COOL? meeting General Motors GM6277M specifications are as follows:

    ? GM Vehicle Care
    ? AC Delco
    ? ChevronTexaco
    ? Shell
    ? Prestone

Sealing Tablets

Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system.

When a condition appears in which seal tabs may be beneficial, a specific bulletin may be released describing their proper usage. After performing specific procedures outlining seal tab usage, install an appropriate identification label to indicate that the seal tabs have been installed. If seal tabs were installed in the cooling system during assembly, the recommended amount may be added if the cooling system is drained and refilled during a service event. The recommended number of seal tabs depends on the capacity of the cooling system. Use between 1 and 1-1/2 grams of seal tabs per liter of cooling system capacity.

Water Quality

The integrity of the coolant is dependent upon the quality of DEX-COOL? and water. DEX-COOL? is a product which has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL? with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL?.

"Pink" DEX-COOL?

DEX-COOL? is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL?, some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of coolant, and still maintains the 5yr/150,000 mile (240,000 km) service interval. General Motors is currently pursuing a course of action which will stabilize the color of DEX-COOL? in the field.

Back Service

Only use DEX-COOL? if the vehicle was originally equipped with DEX-COOL?.

Contamination

Mixing conventional green coolant with DEX-COOL? will degrade the service interval from 5yrs./150,000 miles to 2yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL? and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL? .

After 5 years/150,000 miles (240,000 km)

After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL? and has not had problems with contamination from non-DEX-COOL? coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km).

Equipment (Coolant Exchangers)

The preferred method of performing coolant service is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform a coolant service without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature that allows easing [lsquo ]burping[rsquo ] (removing trapped air) of the cooling system. This is a substantial time savings over current methods of repeatedly thermocycling the vehicle and toping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program (1-800-GM-TOOLS).

Note: The original document (ID# 1459491) contains dealer recycling methods. This clip is intended for the coolant information only.
 
Info - Misfire DTCs P0300, P1380, P1381 and Catalytic Converter Damage Due to Installation of Alarm Systems #02-06-05-004A - (Jan 9, 2004)

2004 and Prior GM Passenger Cars and Light Duty Trucks

2003-2004 HUMMER H2

2004 and Prior Isuzu Light Duty Trucks

This bulletin is being revised to add the 2004 model year and include specific DTCs in the title line. Please discard Corporate Bulletin Number 02-06-05-004 (Section 06 - Engine/Propulsion System).

General Motors Engineering, in an effort to determine the root cause of catalytic converter damage, has determined that aftermarket alarm systems incorrectly installed in vehicles have the potential to cause misfire codes and damage to the converter. These alarm systems use a circuit interrupt which utilizes the ignition circuit on the vehicles.

These alarm systems utilize mechanical relays and normal vehicle movement can trigger these relays to engage and disengage the ignition circuit while the vehicle is in motion. These disruptions of the ignition circuit, which occur in milliseconds, may cause more fuel to be commanded. Over time, this dumping of fuel on and off again can cause misfire codes and ultimately damage the converter assembly.

Important

Engineering could not identify any alarms that utilize solid state circuitry that would eliminate this concern. Because of this, it has been determined that all alarm systems must be routed through the starter circuit in order to avoid this condition.


Dealers must be aware of this issue and take note of the wiring on vehicles with alarm systems that come in for repair, particularly for catalytic converter damage that seem to have no known root cause.
 
Info - Starter Cranks After Key Is Released (Normal Condition) #03-06-03-001A - (Sep 29, 2003)

2003-2004 Cadillac Escalade, Escalade ESV, Escalade EXT

2003-2004 Chevrolet Avalanche, Express, SSR, Silverado, Suburban, Tahoe

2003-2004 GMC Savana, Sierra, Yukon, Yukon XL

with 4.8L, 5.3L, 6.0L or 8.1L Gas Engine (VINs V, P, T, Z, N, U, G -- RPOs LR4, LM4, LM7, L59, LQ9, LQ4, L1:cool:

This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-06-03-001 (Section 06 - Engine).

Some customers may comment that the engine starter will continue to run after the key is released.

For the 2003 and 2004 model years, the Powertrain Control Module (PCM) controls the starter relay based on input from the key switch. When the ignition switch is held in the start position for 0.4 seconds, the PCM start timer is activated. Once the start timer is activated, the PCM will continue to crank the starter until either the engine starts or a no start time limit is reached.

Occasionally, the fuel pump module will take one or two seconds to build fuel pressure. Often this will occur after the vehicle sits overnight. During some vehicle starts, the customer may release the ignition switch key before the engine actually starts. When this occurs, the engine will then continue to crank until the engine starts or the no start time limit is reached.

This is a normal condition and no repairs should be attempted for this condition.
 
Information on Engine Oil Consumption Guidelines #01-06-01-011A
(Jul 22, 2003)

All 1996-2004 Passenger Cars and Gasoline Powered Light Duty Trucks Under 8500 LB GVW except Chevrolet Corvette

This bulletin is being revised to update the Model Years. Please discard Corporate Bulletin Number 01-06-01-011 (Section 6 -- Engine).

All engines require oil to lubricate and protect the load bearing and internal moving parts from wear including cylinder walls, pistons and piston rings. When a piston moves down its cylinder, a thin film of oil is left on the cylinder wall. During the power stroke, part of this oil layer is consumed in the combustion process. As a result, varying rates of oil consumption are accepted as normal in all engines.

Oil Consumption

The accepted rate of oil consumption for engines used in the vehicles referenced is 0.946 liter (1 qt) in 3200 km (2000 mi). This rate only applies to personal use vehicles, under warranty, maintained in accordance with the appropriate maintenance schedule, with less than 58,000 km (36,000 mi), or 80,450 km (50,000 mi) for Cadillac, driven at legal speeds in an unloaded (for trucks) condition.

Many factors can affect an owner's concern with oil consumption. Driving habits and vehicle maintenance vary from owner to owner. Thoroughly evaluate each case before deciding whether the vehicle in question has abnormal engine oil consumption.

Gasket and External Leaks

Inspect the oil pan and engine covers for leakage due to over-tightened, damaged, or out of place gaskets. Inspect oil lines and fittings for signs of leakage.

Improper Reading of the Oil Level Indicator (Dipstick)

Verify that the dipstick tube is fully seated in the block. When checking the oil level, make sure the dipstick is wiped clean before taking an oil level reading and fully depress the dipstick until the shoulder bottoms out on the dipstick tube. The dipstick should be the proper part number for the engine/vehicle that is being checked.

Not Waiting Long Enough After Running Engine to Check Oil Level

The vehicle should be allowed to sit for at least 5 minutes (20 minutes for the 3.4 L LQ1), after the engine has been shut off, before taking an oil level reading to assure the oil has had enough time to drain back into the crankcase. In order to ensure accurate results, the temperature of the oil should be close to the same temperature as the last time the oil level was checked.

Improper Oil Fill After an Oil Change

Following an oil change, verify that the proper amount and type of oil was put in the engine and that the oil level on the dipstick is not above the full mark or below the add marks. Refer to the Owner's Manual or Service Manual for information on recommended oil quantity, viscosity, and quality.

High Speed or High RPM Driving

Continuous driving at high speeds/high RPMs may increase oil consumption. Because this may not always be an everyday occurrence, it is hard to determine exactly how much the oil economy will be affected.

Towing or Heavy Usage

Towing a trailer will increase oil consumption and may cause oil consumption to fall below the normal accepted rate referenced in this bulletin for an unloaded vehicle in a personal use application. Large frontal area trailers will further increase the work required from the engine, especially at highway speeds, and thus increases the rate of oil consumption.

Crankcase Ventilation System

Verify that the positive crankcase ventilation (PCV) system is operating properly. Incorrect PCV valves, blockages, restrictions, or damage to the PCV system can result in increased oil use.

Oil Dilution (Fuel and Water)

On vehicles that are usually driven short distances, less than 8 km (5 mi), especially in colder weather, unburned fuel and condensation generated from cold engine operation may not get hot enough to evaporate out of the oil. When this occurs, the dipstick may indicate that the oil level is over-full. Subsequent driving on a trip of sufficient length to enable normal engine operating temperature for 30 minutes or more, in order to vaporize excess moisture and fuel, may give the customer the impression of excessive oil consumption.

Engine Temperature

If an engine is run at overheated temperatures (see Owner's Manual or Service Manual) for more than brief periods, oil will oxidize at a faster than normal rate. In addition, gaskets may distort, piston rings may stick, and excessive wear may result. Verify that all cooling system components are in proper working order.

Engine Wear

Piston scuffing, excessive piston-to-wall clearance, tapered or out of round cylinders, worn, damaged or improperly installed valve guides, seals and piston rings will all cause an increase in oil consumption.

Measurement of Oil Consumption

Engines require a period of time to BREAK IN so that moving parts are properly seated. Therefore, oil economy should not be tested until the vehicle has accumulated at least 6400 km (4000 mi). An exception would be allowed only if an engine is reported to be using more than 0.946 liter (1 qt) in 1600 km (1000 mi).

  1. Verify that the engine has no external leaks. Repair as necessary.
  2. Verify that the engine is at normal operating temperature (see Owner's Manual or Service Manual).
  3. Park the vehicle on a level surface.
  4. Wait at least 5 minutes (20 minutes for the 3.4 L LQ1), after the engine is shut off, before checking the oil level to make sure that most of the oil has had time to drain back into the crankcase.
  5. Verify that the oil level is at, but not above, the full mark on the dipstick, and that the proper viscosity and quality oil are being used as recommended in the Owner's Manual.
  6. Record the vehicle mileage, date, and exact oil level on the form included in this bulletin.
  7. Ask the customer to verify the oil level, each time the vehicle is fueled, following steps 1-6 and return the vehicle to the dealership if the oil level is found at or below the add mark, 0.946 liter (1 qt) low. If the oil level remains above the add mark, the customer should continue to operate the vehicle and verify the engine oil level until 3200 km (2000 mi) has accumulated before returning to the dealership for a final evaluation.
  8. If the final evaluation shows that the engine uses more than 0.946 liter (1 qt) in 3200 km (2000 mi), follow the published symptom diagnostics as described in the appropriate Service Manual. If the oil consumption test shows that the engine uses less than 0.946 liter (1 qt) in 3200 km (2000 mi), explain to the customer that their engine meets the guidelines for oil consumption.

Note: The oil consumption worksheet chart was not included in this clip, due to BB code formatting restrictions. If a chart is necessary, request the dealer to print this document in it's entirety. ( Document ID# 1358091)
 
Adm Msg - Vehicle Will Not Start #vss20020149 - (Nov 26, 2002)

2003 Chevrolet Silverado, Tahoe, Suburban, Avalanche

2003 GMC Sierra, Yukon, Yukon XL

2003 Cadillac Escalade EXT

with RPO JL4 (VSES) or Z55 (Real Time Dampening) or NYS (QUADRASTEER?)

Service Managers and Warranty Administrators

Customers may comment that their vehicles will not start. The technician may find the battery is discharged. The root cause has been identified as an anomaly in the steering wheel position sensor. The condition will be corrected by reprogramming the truck body control module. The new calibration will be available on a special GM Access Broadcast on November 26, 2002. The broadcast number will be labeled higher than the number of the last broadcast, which was 11.75. Please use this calibration to correct any customer concerns that you may have had regarding this issue. The TIS CD will be shipped the week of December 23, 2002. Vehicles build on or after November 21, 2002 from the Arlington and Janesville plants (R or J in the 11th VIN position) have the corrected calibration. The remaining plants will begin building vehicles with the corrected calibration the week of December 2, 2002.
 
Popping/Snapping Noise When Vehicle is Hot, at Idle or Immediately After Vehicle is Shut Off (Replace Muffler Heat Shield) #03-06-05-008B - (Jan 13, 2005)

2002-2005 Cadillac Escalade, Escalade EXT

2003-2005 Cadillac Escalade ESV

2002-2005 Chevrolet Avalanche, Suburban, Tahoe

2002-2005 GMC Yukon, Yukon Denali, Yukon Denali XL

2003-2005 HUMMER H2

with 4.8L, 5.3L or 6.0L Gasoline Engine (VINs N, U, T, V, Z -- RPOs LQ9, LQ4, LM7, LR4, L59)

This Bulletin DOES NOT APPLY 8.1L vehicles at this time.

This bulletin is being revised to include additional models and parts availability. Please discard Advanced Service Information Bulletin Number 03-06-05-008A (Section 06 -- Engine/Propulsion System).

Condition

Some customers may comment on a popping/snapping noise from underneath the vehicle at idle or immediately after the vehicle is shut off. Some popping/snapping noise from the exhaust system during cool down is a normal condition.

The noise may be intermittent depending on the outside temperature and or temperature of the exhaust system at the time of testing.

Cause

As the exhaust system warms and cools, the muffler and the muffler heat shield expand and contract at different rates and may cause a popping and/or snapping noise.

Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down.

Correction

DO THIS: Install a new heat shield and straps on the existing muffler.

DON'T DO THIS: DO NOT replace exhaust system components other than the muffler heat shield.

Follow the service procedure below to correct this condition.

Important: Some popping/snapping noise from the exhaust system during cool down is a normal condition. The customer should be made aware that this service procedure is designed to reduce but not eliminate all exhaust system popping and snapping during cool down.

  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information (SI Document ID #737171).

      Caution:
        ? In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
        ? Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges could result in serious personal injury.


  2. Remove the nuts securing the muffler to the catalytic converter.
  3. On 6.0L equipped vehicles only, loosen the exhaust pipe clamp.

      Important: Do not use oil base lubricants on the rubber exhaust hangers.

  4. Apply a soapy solution to the exhaust pipe hanger rods in order to ease the removal of the exhaust hangers.
  5. Pry the exhaust hangers free from the exhaust pipe hanger rods.

      Important: It is not necessary to remove the muffler from the vehicle to replace the muffler heat shield.

  6. Reposition the muffler to gain access to the muffler heat shield.

normal_1510058.gif


    Notice: Use extreme caution not to damage the muffler when removing the heat shield from the muffler.

  7. Using an air-powered hack saw blade, or equivalent, cut off the existing muffler heat shield just as the heat shield rises off of the muffler. See the illustration above.
  8. Remove the heat shield from the muffler.
  9. Hammer flush the remaining heat shield to the muffler.

normal_1510061.gif


    Important:
        ? The new heat shield should not come in contact with the remaining muffler heat shield.
        ? The new heat shield should not come in contact with the horizontal lock seam on the muffler.


  10. Install the new heat shield, P/N 10393433, onto the muffler as shown above.

normal_1510063.gif

  11. Install three straps, P/N 10391259, so that the strap screw head will be located on top of the muffler.

    Tighten
      Tighten the strap screw to 4 N?m (35 lb in).

normal_1510065.gif


  12. Cut off the excess strap material and bend the strap over the strap screw head as indicated above.
  13. Remove the exhaust pipe clamp.

      Important: ONLY 6.0L equipped vehicles require a new exhaust pipe clamp, P/N 15103174.

  14. On 6.0L equipped vehicles only, install a new exhaust pipe clamp, P/N 15103174, on the exhaust pipe.
  15. Reposition the muffler in the correct position.
  16. Slide the muffler forward into position, aligning the studs with the rear of the catalytic converter.
  17. Install the nuts securing the muffler to the catalytic converter, but DO NOT tighten at this time.
  18. Apply a soapy solution to the following areas in order to ease the installation of the hangers.
        - The inner diameter of the exhaust pipe hanger
        - The exhaust pipe hanger rod
  19. Press the exhaust pipe hangers over the exhaust pipe hanger rods.

      Tighten
        ? Tighten the muffler nuts by hand until each contacts the metal flange.
        ? Tighten the muffler nuts to 45 N?m (33 lb ft).
        ? On 6.0L equipped vehicles only, tighten the exhaust clamp to 50 N?m (36 lb ft).
  20. Lower the vehicle.

Dealer Action

Please contact all customers that were told they would be called when a repair became available.

Parts Information

Part Numbers:

15253526
Shield, Muffler Heat Shield with 4.8L or 5.3L engine
(1 ea)

10393433
Shield, Muffler Heat Shield with 6.0L engine
(1 ea)

15103174
Clamp, Exhaust Pipe with 6.0L engine ONLY
(1 ea)

10391259
Strap, Muffler Heat Shield Strap.
(3 ea)

Parts are currently available from GMSPO.
 
99-05 Full Size Trucks, Utilities and Vans with 4.8 5.3 6.0 V8 Engines That Have a P0300 Due to Fuel Contamination Cylinder 7 Misfire - kw CEL code contaminated DTC fuel gas L59 LM7 LR4 LQ4 LQ9 miss #PIP3055 - (Jul 8, 2004)

The following diagnosis might be helpful if the vehicle exhibits the described symptoms in the PI.

Condition/Concern:

Service Engine Soon Light with a P0300 misfire due to misfires mainly on cylinder 7. A possible cause could be fuel contamination. If present, the contaminated fuel will collect around the #7 fuel injector due to the fuel rail configuration in these vehicles. This issue can also cause some random misfires on cylinder 2 and 8 since they are next to cylinder 7 in the firing order.

Recommendation/Instructions:

If the published misfire diagnostics does not isolate the concern, the following suggestions may help if the misfire is related to fuel contamination:

  1. When the lines are removed, cap the fuel rail off to retain any fuel that might be contaminated. Remove the rail, drain it into a clear container and inspect for contamination.
  2. If contamination is found, follow the Fuel System Cleaning procedure in Service Information.
  3. Once the fuel system is cleaned, refill the fuel system with new gasoline.
  4. Advise the customer that they should only use gasoline from a high quality, high volume filling station.

If this is a 99 - 00 Chevrolet Silverado or GMC Sierra, also review 00-06-04-024. This bulletin relates to an updated EVAP vent valve to prevent water from being drawn in through the EVAP Vent Valve, which may lead to repeat fuel contamination.

Please follow this diagnosis 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. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.

Models:

(01 - 05 Cadillac Escalade C1, C6, K1, K6) and (02 - 05 Chevrolet Avalanche C1, K1, C2, K2) and ((03 - 05 Chevrolet Express G1, G2, G3, H1, H2) and (99 - 05 Chevrolet Silverado Truck C1, K1, C2, K2, C3, K3 ) and (00 - 05 Chevrolet Tahoe C1, K1 ) and (00 - 05 Chevrolet Suburban C1, K1, C2, K2, C3, K3 ) and (03 - 05 GMC Savana G1, G2, G3, H1, H2 ) and (99 - 05 GMC Sierra Truck C1, K1, C2, K2, C3, K3 ) and (00 - 05 GMC Yukon C1, K1 ) and (00 - 05 GMC Yukon XL C1, K2, C2, K2, C3, K3) and (03 - 05 Hummer H2 N2 )
 
Info - Engine Knock on Cold Start #01-06-01-028A - (Mar 18, 2003)


1999-2002 Chevrolet and GMC C/K Pickup and Utility Models

2002 Cadillac Escalade (2WD)

with 4.8L, 5.3L or 6.0L Engine (VINs V, T, Z, U -- RPOs LR4, LM7, L59, LQ4)

This bulletin is being revised to add an additional engine to the models section. Please discard Corporate Bulletin Number 01-06-01-028 (Section 06-Engine).

Some of the above vehicles may exhibit an engine knock noise that begins in the first 19,000-24,000 km (12,000-15,000 mi) of use. The knock noise is most often noticed during initial start-up and typically disappears within the first 5-30 seconds (may last longer in extreme cold temperatures). The noise is usually more noticeable on the initial start-up when the temperature is below 10?C (50?F) and may be more pronounced on the first cold start following a long trip.

This noise may be caused by an interaction between carbon that has formed on the piston, the piston motion and the cylinder wall. GM Powertrain Engineering, and an analysis of engines with this condition, has confirmed that the noise is not detrimental to the performance, reliability or durability of the engine. THIS NOISE DOES NOT HAVE ANY EFFECT ON THE LONGEVITY OF ANY OF THE ENGINE COMPONENTS.

Important

At this time, attempts to repair this condition by replacing the engine assembly or pistons are not recommended.


Please share the information found in this bulletin with customers who inquire about this condition. In the event they have additional questions or concerns, please advise your Area Service Manager.
 
(Dealer service action):

High Oil Consumption (Replace Intake Manifold Bolts) #02-06-01-035 - (Oct 17, 2002)

2002 Chevrolet Avalanche

2001-2002 Chevrolet Silverado, Express, Suburban

2001-2002 GMC Sierra, Savana, Yukon XL

2001-2002 Chevrolet and GMC C6-7 Conventional Cab Medium Duty and B7 School Bus Models

With 8.1L Engine (VINs G, E -- RPO L1:cool:
Condition

Some customers may comment about higher than expected oil consumption. Because this type of engine is used under various load conditions, the dealer should verify that the vehicle is using more than 0.946L (1 quart) of oil for every 379L (100  gallons) of fuel used.

Cause

Oil vapor pulled into combustion chamber through the intake manifold may cause this condition.

Correction

Replace all the intake manifold bolts. Replace one bolt at a time in sequence to keep the intake manifold from shifting.

      Notice

      Ensure the intake manifold does not shift as the intake manifold bolts are tightened in the proper sequence. Failure to follow the entire intake manifold bolt tightening sequence exactly may result in an oil leak and serious engine damage.


  1. In the order shown below, remove each bolt and replace with a new bolt. Insert the new bolt and tighten to 5 N?m (44 lb in). Then move to the next bolt in sequence until all bolts have been replaced.

640010-Manifold_TqSeq1500.gif


  2. After all of the bolts have been replaced, tighten each bolt in sequence to 8 N?m (71 lb in).
  3. Tighten all bolts in sequence to a final torque of 12 N?m (106 lb in).

Parts Information

Part Number        Description        Qty
12561518      Bolt, Intake Manifold      10
 
Higher Than Expected Engine Oil Consumption (Replace PCV Valve) #01-06-01-029B - (Jul 19, 2002)

2002 Chevrolet Avalanche

1999-2002 Chevrolet Silverado, Suburban, Tahoe Models

2002 Cadillac Escalade, Escalade EXT

1999-2002 GMC Denali, Sierra, Suburban, Yukon Models

with 4.8L, 5.3L or 6.0L Engine (VINs V, T, N, U -- RPOs LR4, LM7, LQ9, LQ4)

This bulletin is being revised to clarify the parts information. Please discard Corporate Bulletin Number  01-06-01-029A (Section 06 -- Engine/Propulsion System).

Condition

Some customers may comment on higher than expected engine oil consumption. They may further comment on consumption in the range of 3,200 km (2,000 mi) or less per quart (0.946 liter) of oil under normal driving conditions.

Cause

The condition may be due to the positive crankcase ventilation (PCV) valve flow rate under certain engine operating conditions.

Correction

  1. Verify that the oil consumption is not the result of an oil leak or other engine concern.
  2. The dealer should perform an oil consumption test. The vehicle should have accumulated over 6,450 km (4,000 mi) before establishing the oil consumption rate. Reference Corporate Bulletin Number 01-06-01-011, Information on Engine Oil Consumption Guideline, for details.
  3. Remove the PCV valve and inspect the hose going to the intake manifold for signs of excessive oil being present.
  4. If excessive oil is present in the PCV hose, replace the PCV valve (Type 948C) (2) with a new-style fixed orifice PCV valve, GM P/N 12572717(1). See the illustration below.

    FIGURE PCV Valve Identification(c)

index.php


      (1)  New style fixed orifice PCV Valve
      (2)  Spring and plunger style PCV Valve (Type 948-C)

Important
The new style fixed orifice PCV valve contains no moving parts, and does not rattle when shaken.


If the vehicle has an orifice style PCV valve, investigate other causes for high oil consumption.

Parts Information:

Part Number      Description      Qty
-----------------      -------------      ----
12572717        Valve, PCV        1
 
Check Engine Light On with No Driveability Concerns, DTC P0120, P0220, P1516, P1518 (Clear Code) #03-06-04-032 - (Jun 16, 2003)

2003 Cadillac Escalade, Escalade EXT, Escalade ESV

2003 Chevrolet Avalanche, Silverado, Suburban, Tahoe

2003 GMC Sierra, Yukon, Yukon XL

with 4.8L, 5.3L or 6.0L Engine (VINs V, P, T, Z, N, U - RPOs LR4, LM4, LM7, L59, LQ9, LQ4,)

Condition

Some owners may comment that the Check Engine Light is illuminated and there is no driveability concern. Upon investigation, the technician may find codes P0120, P0220, P1516 or P1518. Also, technicians may note that low voltage codes P0562, P0563, P1637 or P1638 have been set.

Cause

The Tach module may set the code in error if it operates at a battery voltage of 4.5 to 5.0 volts.

Correction

If the vehicle has stored one of the low voltage codes, P0562, P0563, P1637 or P1638, follow the appropriate diagnostics for the low voltage code. In most cases, this will lead to correcting the concern without replacing any Electronic Throttle Control (ETC) components.

If codes P0120, P0220, P1516 or P1518 are present without any of the low voltage codes, the technician should observe the Engine RPM in the fault record.

    * If the Engine RPM in the fault record is zero and the customer indicates that the vehicles has experienced a low voltage condition, the code should be cleared and the low voltage should be diagnosed and corrected.
    * If the Engine RPM is zero and the customer indicates that there have been no low voltage conditions, then the P1516 diagnostic aids for intermittent concerns should be used to diagnose and correct the vehicle
    * If the Engine RPM is greater than zero, then check for an obvious loose ground at G103 located next to the right cylinder head just below the head and mounted into the block. Also, check G104 located behind the left cylinder head. Then verify all electrical connections at the TAC module.

If the concern is still not resolved, contact Technical Assistance.
 
SES Light On with TAC Module Codes P1516 and Possible Codes P1514 P1515 P1518 - 4.8 5.3 6.0 actuator clearance cold contact distort DTC intermittent pedal position power sensor temperature throttle #PI00827C - (Oct 22, 2003)

When servicing the vehicle with the VIN you entered, the following diagnosis might be helpful if the vehicle exhibits the described symptoms.

Condition/Concern:

SES light accompanied by DTC P1516, and / or reduced engine power. ( other DTCs may be present as well )

Recommendation/Instructions:

After following all published diagnostics the following should be performed:

For C/K trucks and utilities: Check for an obvious loose ground at G103 located next to the right cylinder head (passenger side) just below the head and mounted into the block. The ground uses a 13 mm bolt head mounted vertically to the right rear of the engine block just above the bell housing. G104 located behind the left cylinder head has also been found to cause this concern.

For S/T Utilities equipped with the 5.3 LM4: Check for an obvious loose ground at G108 located on the lower left side of the engine block. Verify all electrical connections especially right at the TAC module. There have been reports of the plastic retaining tab in the connector missing causing poor contact especially on rough roads.

Please be aware that a low battery condition may cause any of these codes to set.

If conditions described above are not observed, replace throttle body assembly P/N 12570800. Torque the throttle body mounting nuts per SI in a two step process: 45 lb / inches on the 1st pass, and then 89 lb / inches on the final pass.

Please follow this diagnosis 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. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. This diagnostic approach was developed for the vehicle with the VIN you entered and should not be automatically be used for other vehicles with similar symptoms.

Models:

(03 GMT 370, Trailblazer/Envoy) and (03 Cadillac, Escalade, C6) and (03 Cadillac, EXT, C1) and (03 Chevrolet, Avalanche, K1, K2) and (03 Chevrolet Silverado Truck C1,C2,C3) and (03 Chevrolet Silverado Truck K1,K2,K3) and (03 GMC Sierra Truck C1,C2,C3) and (03 GMC Sierra Truck K1,K2,K3) and (03 CHEVROLET, TAHOE, C1) and (03 CHEVROLET, TAHOE, K1) and (03 CHEVROLET, SUBURBAN, C1,C2) and (03 CHEVROLET, SUBURBAN, K1,K2) and (03 GMC, YUKON, C1) and (03 GMC, YUKON, K1) and (03 GMC, YUKON XL, C1,C2) and (03 GMC, YUKON XL, K1,K2) and (03 GMC, YUKON DENALI, AWD)
 
Cranks But No Start, Stall, Inaccurate/Incorrect Fuel Gauge Reading, No Fuel, Vehicle is Out of Fuel and Fuel Gauge Reads Above Empty (Replace Fuel Level Sensor) #04-08-49-018E - (Jan 5, 2005)

2001-2004 Cadillac Trucks

1999-2004 Chevrolet and GMC Trucks

2004-2005 HUMMER H2

with Gasoline Engine (VINs Z, X, V, T, U, N, G,6, 8 -- RPOs LU3, LR4, LM7, LQ4, LQ9, L59, L18,LK5 , L52 )

Parts are currently available for vehicles with Variable Fuel (VIN Z -- RPO L59) vehicles. Please refer to Corporate Bulletin Number 04-06-04-012B or newer for Variable Fuel (VIN Z -- RPO L59) vehicles.

This bulletin is being revised to include information on the Chevrolet Colorado and the GMC Canyon. Please discard Corporate Bulletin Number 04-08-49-018 D (Section 08 - Body and Accessories).

Condition

Some customers may comment on the vehicle stalling and will not restart, vehicle ran out of fuel, vehicle appears to be out of fuel but the fuel gauge reads above empty. The fuel gauge may read 1/4 tank.

Cause

Contamination on the fuel sending card may cause inaccurate/incorrect fuel gauge readings.

Correction

Follow the service procedure below for diagnosis and repair of this concern.

  1. Confirm that the vehicle is actually out of fuel.
        - If the vehicle is not out of fuel but Engine Cranks but Does Not Run, refer to the appropriate Service Information.
        - If the vehicle is out of fuel and the gauge does not read empty, test the fuel gauge. Refer to the following information:
              ? Fuel Gage Inaccurate or Inoperative Single Tank (SI Document ID #850196)
              ? Fuel Gage Inaccurate or Inoperative Dual Tanks (SI Document ID #850195)
  2. If testing reveals that the fuel gauge is operating correctly, replace the fuel sensor assembly and auxiliary tank fuel level sensor if equipped.
  3. Replace the fuel level sensor. Refer to the following appropriate service information:
        - Fuel Level Sensor Replacement 4.8L and 5.3L Engines (SI Document ID #1332662)
        - Fuel Level Sensor Replacement 6.0L Engine - Front Tank (SI Document ID #1333086)
        - Fuel Level Sensor Replacement 8.1L vehicles with Front Tank (SI Document ID #1333104)
        - Fuel Level Sensor Replacement 8.1 L vehicles with Rear Tank (SI Document ID #1333105)

Parts Information

Note: Provide the VIN of the vehicle for confirmation of the part number.

89060640,  Sensor Assembly, Main Tank, Side 1999-2003

100200300 034353, C/K, 2 Dr, 4 Dr and Ext Cab Pickup

with LU3 or LR4 or LM7 or LQ4 or LQ9 or L18 and -- K53 (without robust fuel system)
----------------------
2004

100 0353, C/K, 2 Dr and Ext Cab

with LU3 and without K53 (robust fuel system)
 
97-05 Vehicles with 4.8 5.3 5.7 and 6.0 Gen III V8 Engines and Misfires on One Bank - kw CEL diagnostics driveability DTC P0171 P0172 P0174 P0175 P0300 P0301 P0302 P0303 P0304 P0305 P0306 P0307 P0308 #PIP3056 - (Jul 12, 2004)

Condition/Concern:

Check Engine Light with a P0300 due to 2 - 4 cylinders misfiring on the same bank of the engine. DTCs P0171, P0172, P0174 or P0175 may also set for the misfiring bank.

Recommendation/Instructions:

If the published misfire diagnostic does not isolate the cause, perform the following suggestions as necessary:

  1. Perform a fuel injector balance test for all 8 cylinders. If a fuel injector concern exists, it is possible to misfuel an entire bank of the engine, causing multiple cylinders on the same bank to misfire even though the root cause is a single fuel injector.
  2. Inspect O2 sensor connections on the misfiring bank for corrosion or water intrusion. If water intrusion is found on the right bank, it may be due to the AC Evaporator Condensation dripping onto the O2 sensor harness. If this condition is found, reposition and shield the harness to prevent a repeat concern and repair the connections.
  3. Check for excessive exhaust backpressure using the restricted exhaust diagnosis from SI.
  4. Swap the Position 1 O2 sensors side to side to see if the misfires move to the other bank of the engine. If so, replace the O2 sensor.

Please follow this diagnosis 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. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.

Models:

(00 - 05 Cadillac Escalade - C6 and K6) and (02 - 05 Chevrolet Avalanche - C1, C2 K1 and K2) and (99 - 05 Chevrolet Silverado - C1, C2 K1 and K2) and (00 - 05 Chevrolet Suburban - C1, C2, K1 and K2) and (00 - 05 Chevrolet Tahoe - C1 and K1) and (99 - 05 GMC Sierra C1, C2 K1 and K2) and (00 - 05 GMC Yukon - C1, C2, K1 and K2) and (03 - 05 Chevrolet Express G1, G2, G3, H1, H2 ) and (03 - 05 GMC Savana G1, G2, G3, H1, H2 ) and (04 - 05 Buick Rainier S1, T1 ) and (03 - 05 Chevrolet Trail Blazer EXT S1, T1 ) and (03 - 05 GMC Envoy XL XUV S1, T1 ) and (03 - 05 Hummer H2) and (04 - 05 Cadillac CTS-V DB) and (98 - 02 Chevrolet Camaro FB) and (97 - 04 Chevrolet Corvette YB) and (98 - 02 Pontiac Firebird FB) and (04 - 05 Pontiac GTO VB)

.
 
Document ID# 1538353
2004 Chevrolet Avalanche​

04 Full Size Trucks and Utilities with VIN G , N , T, V and U Engines May Have a High Altitude, High Ambient Temperature Stall - kw L18 LM7 LQ4 LQ9 LR4 crank DTC fuel hard Hesitate idle #PIP3022A - (Jul 19, 2004)

The following diagnosis might be helpful if the vehicle exhibits the symptom described in the PI.

Condition/Concern:

Some 2004 Full Size Trucks and Utilities with VIN G, N, T, V and U engines that were built prior to May 1st, 2004, may stall while driving. Typically, this will occur when the altitude exceeds approximently 5,000 feet above sea level with an ambient temperature of 80 degrees F or greater. The vehicle may set DTCs P0171 and P0174 and exhibit a crank no start, hard start, lack of power or rough running concern until the vehicle cools down.

Recommendation/Instructions:

This PI does not apply to vehicles with the L59 (Vin Z) 5.3L engine. Monitor the fuel pressure during the concern. If this PI applies, the fuel pressure will be lower than specification during the concern. If the fuel pressure is low, perform the SI fuel system diagnosis during the concern. If the SI diagnostics isolate a fuel pump module concern, there is an updated fuel pump module available to address this concern. Specific part numbers may be assigned to these updated fuel pump modules in the future. For right now, if the current part number from the parts catalog has a date code of 0834 or newer, it is the updated fuel pump module and should be installed. It may be necessary to open a SPAC case to obtain one of these fuel pump modules.

Note: The Fuel Pump Module Date Code will be on top of the fuel pump module, just below the bar code and production part number. The date code will be a 4 digit number with the first 3 digits being the day of the year and the 4th digit being the year. So a date code of 0834 would translate to the 83rd day of 2004.

Please follow this diagnosis 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. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance.

Models:

(04 Chevrolet Silverado C1, C2, C3, K1, K2 and K3 ) and (04 Chevrolet Suburban C1, C2, C3, K1, K2 and K3) and (04 Chevrolet Tahoe C1 and K1) and (04 Chevrolet Avalanche C1, C2, K1 and K2) and (04 GMC Yukon C1, C2, C3, K1, K2 and K3 ) and (04 GMC Sierra C1, C2, C3, K1, K2 and K3) and ( 04 Cadillac EXT C6 and K6) and ( 04 Cadillac Escalade C6 and K6) and ( 04 Hummer H2)

----------------------------------------

So, unless it was built after the above date, they should honor this bulletin.
After, well, they may have a "policy" in place where they need the DTC.

 
TSB #06-06-01-019B June 2007
Information on Gradual Coolant Loss Over Time With No Evidence of Leak Found


2004-2006 Buick Rainier
2001-2006 Cadillac Escalade Models
2001-2006 Chevrolet Avalanche, Blazer, Silverado, Suburban, Tahoe,
TrailBlazer Models
2001-2006 GMC Envoy, Jimmy, Sierra, Yukon Models
2001-2004 Oldsmobile Bravada
2005-2006 Saab 9-7X
with 4.8L or 5.3L VORTEC? GEN III, GEN IV V8 Engine
(VINs V, T, M, B, Z - RPOs LR4, LM7, LH6, L33, L59)

This bulletin is being revised to include engine RPO L59. Please discard Corporate
Bulletin Number 06-06-01-019A


Some vehicles may experience a gradual coolant loss
over time. A very low percentage of cylinder head(s)
manufactured with an embossed Castech logo may
develop a porosity crack in a very specific area.
Inspect the cylinder head assembly to determine if the
casting was manufactured by Castech. This can be
accomplished by inspecting for their casting logo located
on top of the intake port, under the rocker arm support
rail and in the spring deck cavity portion of the
cylinder head.

Important: If the cylinder head(s) are Not a Castech
casting, follow normal diagnostic procedures in 51 to
determine the cause of the coolant loss.
Refer to the following illustrations on how to identify
Castech casting and/or the very specific areas of the
cylinder head(s) for a coolant leak from porosity.

cylhead1.JPG

(sorry for the crappy pics, when I find better ones they will be replaced)

Cylinder head(s) location of the Castech manufacturing
casting logo (1).

cylhead2.JPG


Close up view of the cylinder head(s) showing the
Castech manufacturing casting logo (1).

cylhead3.JPG


If the cylinder head(s) is a Castech casting (1), inspect
the area around the five oil drain holes for witness
marks indicating coolant seepage over time (2).


Important: If No evidence of coolant loss is found on
inspection of Castech casting cylinder head(s), follow
normal diagnostic procedures in 81 to determine the
cause of the coolant loss.

cylhead4.JPG


The crack location can be found in any of the five
cylinder headis) oil drains. This can be seen as a clean
or shiny area, on an otherwise stained surface (1).
Pressurizing the cooling system at this time may reveal
coolant, air, or a combination, weeping in the described
area. If inspection reveals evidence of coolant witness
marks (1), replace the entire cylinder head(s) assembly.



 
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