Information on Low Fuel Lubricity and Fuel System Metal Contamination

This bulletin is being revised to update the parts and warranty information. Please discard Corporate Bulletin Number 99-06-04-047B (Section 06 - Engine/Propulsion System).

Important: Low fuel lubricity may be a concern. Recommend to the customer on a new fuel injection pump break-in period to use Stanadyne lubricity additive for two or three tanks of fuel or 3200 km (2000 mi).

Important: Metal contaminants generated by fuel injection pump internal component degradation are returned to the fuel tank. The in-tank strainer filtering capability is sufficient to prevent the reintroduction of these contaminants into the fuel system. Metal contaminants generated by frame mounted lift pump internal component degradation will be trapped in the fuel filter.

Important: If the repair history shows fuel injection pump replacement with multiple fuel system cleaning, check the fuel filter for metal contamination. If the fuel filter shows minimal metal contamination, replace the fuel filter and follow the Stanadyne Lubricity Additive information in this bulletin. A small amount of metal contamination does not necessitate a fuel system cleaning.

Diagnosis of Fuel Related Concerns

A small amount of metal contamination is normal and not detrimental to the operation of the diesel engine. Do not remove the fuel tank for cleaning unless the in-tank fuel strainer is plugged with sediment or plugged with various metal contaminants. Do not clean the fuel system unless the fuel filter is plugged with sediment or plugged with various metal contaminants. Evidence of some metal contamination does not necessitate fuel system cleaning. In some cases, fuel system degradation over time or fuel contamination by fueling the vehicle may collect large amounts of metal or other types of contamination in the fuel tank and is not covered under warranty. The fuel system cleaning procedure in this bulletin, if needed, is divided into three service categories.

Important: 

Important: Refer to GM Service Bulletin Number 03-06-04-017A or newer for further information on Diesel Fuel Additives.

Important: The 6.5L diesel engine is designed to operate on today’s low sulfur fuel without the use of additives. A fuel additive designed to increase lubricity is not a fix for poor quality or contaminated fuel, but some customers may desire to use a lubricity additive to aid in the longevity of the fuel system components. If such an additive is to be used, it must not contain alcohol or other water emulsifiers.

*Stanadyne Lubricity Additive Information

1. The Stanadyne Lubricity Additive will be suggested for use on any repeat 6.5L fuel injection pump concerns. The additive should also be suggested if the dealer is experiencing repeat 6.5L fuel injection pump concerns on other vehicles in their area.
2. Two pint-size bottles of Stanadyne Lubricity Additive should be used during the break-in period of the repeat 6.5L fuel injection pump. Follow the Stanadyne Lubricity Additive instructions for fuel mixing.
3. The dealer should contact a local Stanadyne Dealer to order the Stanadyne Lubricity Additive. The Stanadyne part number for the Pint size treatment bottle is 32174. The Pint size bottle will treat 454 Liters (120 gallons) of fuel.

*We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such products which may be available from others sources.

Important: Labor Operation Times for the replacement of the fuel filter element (J5420) and fuel system clean and flush (L1000) are maintenance repairs and have been removed from the Labor Time Guide. The replacement of the fuel filter element and fuel system clean and flush outlined in this bulletin may be customer pay.

Repair Procedure Number 1 for Fuel System Cleaning

Caution: Refer to Battery Disconnect Caution in Cautions and Notices in SI.

1. Remove the negative battery cables.
2. Take off the fuel cap to release pressure or vacuum in the tank.
3. Remove the fuel feed hoses from both sides of the fuel lift pump. Refer to Fuel Lift Pump Replacement in SI.
4. Remove the lift pump.
5. Remove the fuel manager/filter. Refer to Fuel Manager/Filter Replacement in SI.
6. Use low pressure air to blow out the fuel feed line, from the fuel filter manager end, toward the rear of the vehicle.
7. Remove the fuel filter from the fuel manager/filter housing. Refer to Fuel Filter Element Replacement in SI.
8. Wipe out the inside of the housing with a clean towel.
9. Remove the heater element from the housing. Refer to Fuel Heater Replacement in SI.
10. Remove the water in fuel sensing element from the housing. Refer to Water in Fuel Sensor Replacement in SI.
11. Clean the inside of the housing with GM Brake Parts Cleaner or equivalent.
12. Dry the housing completely.
13. Install the water in fuel sensor with a new seal. Refer to Water in Fuel Sensor Replacement in SI.

Tighten
Tighten the water in fuel sensor mounting screws to 2 N·m (18 lb in).

14. Install the heater element with a new O-ring seal and tighten securely. Refer to Fuel Heater Replacement in SI.
15. Install a new fuel filter in the housing.
16. Install the fuel manager/filter housing to the engine. Refer to Fuel Manager/Filter Replacement in SI.

Tighten
Tighten the fuel manager/filter housing mounting bolts to 25 N·m (18 lb ft).

17. Install a new fuel lift pump. Refer to Fuel Lift Pump Replacement in SI.
18. Install both sides of the fuel feed line at the fuel lift pump. Refer to Fuel Lift Pump Replacement in SI.
19. Install clean diesel fuel into the tank until the tank is at least 1/4 full.
20. Install the fuel tank cap.
21. Install the negative battery cables.

Important: Use a suitable container to catch fuel.

22. Install a hose from the fuel injection pump inlet hose (hose to hose) at the fuel injection pump to a closed metal container with a capacity of at least 8 liters (2 gallons).
23. Using the Scan Tool, command the lift pump ON until clean fuel is seen.
24. Reinstall the inlet hose to the fuel injection pump.
25. Start the engine and check the entire fuel system for leaks while idling for 5 minutes.
26. Clear any DTCs.

Important: Labor Operation Times for the replacement of the fuel filter element (J5420) and fuel system clean and flush (L1000) are maintenance repairs and have been removed from the Labor Time Guide. The replacement of the fuel filter element and fuel system clean and flush outlined in this bulletin may be customer pay.

Repair Procedure Number 2 for Fuel System Cleaning

Caution: Refer to Battery Disconnect Caution in Cautions and Notices in SI.

1. Remove the negative battery cables.
2. Take off the fuel cap to release pressure or vacuum in the tank.
3. Remove the fuel feed hoses from both sides of the fuel lift pump. Refer to Fuel Lift Pump Replacement in SI.
4. Remove the lift pump.
5. Remove the fuel manager/filter. Refer to Fuel Manager/Filter Replacement in SI.
6. Use low pressure air to blow out the fuel feed line, from the fuel filter manager end, toward the rear of the vehicle.
7. Remove the fuel filter from the fuel manager/filter housing. Refer to Fuel Filter Element Replacement in SI.
8. Wipe out the inside of the housing with a clean towel.
9. Remove the heater element from the housing. Refer to Fuel Heater Replacement in SI.
10. Remove the water in fuel sensing element from the housing. Refer to Water in Fuel Sensor Replacement in SI.
11. Clean the inside of the housing with GM Brake Parts Cleaner or equivalent.
12. Dry the housing completely.
13. Install the water in fuel sensor with a new seal. Refer to Water in Fuel Sensor Replacement in SI.

Tighten
Tighten the water in fuel sensor mounting screws to 2 N·m (18 lb in).

14. Install the heater element with a new O-ring seal and tighten securely. Refer to Fuel Heater Replacement in SI.
15. Install a new fuel filter in the housing.
16. Install the fuel manager/filter housing to the engine. Refer to Fuel Manager/Filter Replacement in SI.

Tighten
Tighten the fuel manager/filter housing mounting bolts to 25 N·m (18 lb ft).

17. Install a new fuel lift pump. Refer to Fuel Lift Pump Replacement in SI.
18. Install both sides of the fuel feed line at the fuel lift pump. Refer to Fuel Lift Pump Replacement in SI.
19. Install clean diesel fuel into the tank until it is at least 1/4 full.
20. Install the fuel tank cap.
21. Install the negative battery cables.
22. Remove the ECM 1 fuse from the underhood relay center.

Important: Use a suitable container to catch fuel.

23. Install a hose from the fuel injection pump inlet hose (hose to hose) at the fuel injection pump to a closed metal container with a capacity of at least 8 liters (2 gallons).
24. Crank the engine for 15 seconds with one minute cooling periods until clean fuel is pumped out.
25. Reinstall the inlet hose to the fuel injection pump.
26. Install the ECM 1 fuse in the underhood relay center.
27. Start the engine and check the entire fuel system for leaks while idling for 5 minutes.
28. Clear any DTCs.

Important: Labor Operation Times for the replacement of the fuel filter element (J5420) and fuel system clean and flush (L1000) are maintenance repairs and have been removed from the Labor Time Guide. The replacement of the fuel filter element and fuel system clean and flush outlined in this bulletin may be customer pay.

Repair Procedure Number 3 for Fuel System Cleaning

Caution: Refer to Battery Disconnect Caution in Cautions and Notices in SI.

1. Remove the negative battery cables.
2. Take off the fuel cap to release pressure or vacuum in the tank.
3. Remove the fuel feed hoses from both sides of the fuel lift pump. Refer to Fuel Lift Pump Replacement in SI.
4. Remove the lift pump.
5. Remove the fuel manager/filter. Refer to Fuel Manager/Filter Replacement in SI.
6. Use low pressure air to blow out the fuel feed line, from the fuel filter manager end, toward the rear of the vehicle.
7. Remove the fuel filter from the fuel manager/filter housing. Refer to Fuel Filter Element Replacement in SI.
8. Wipe out the inside of the housing with a clean towel.
9. Remove the heater element from the housing. Refer to Fuel Heater Replacement in SI.
10. Remove the water in fuel sensing element from the housing. Refer to Water in Fuel Sensor Replacement in SI.
11. Clean the inside of the housing with GM Brake Parts Cleaner or equivalent.
12. Dry the housing completely.
13. Install the water in fuel sensor with a new seal. Refer to Water in Fuel Sensor Replacement in SI.

Tighten
Tighten the water in fuel sensor mounting screws to 2 N·m (18 lb in).

14. Install the heater element with a new O-ring seal and tighten securely. Refer to Fuel Heater Replacement in SI.
15. Install a new fuel filter in the housing.
16. Install the fuel manager/filter housing to the engine. Refer to Fuel Manager/Filter Replacement in SI.

Tighten
Tighten the fuel manager/filter housing mounting bolts to 25 N·m (18 lb ft).

Important: If the reference table below indicates that the vehicle fuel injection pump has been updated with a ceramic roller-type pump, do not replace the pump. Go to step 19.

17. Identify the fuel injection pump roller type by checking the nameplate and referencing the table below (see Figures 1, 2, and 3).
18. Replace the fuel injection pump. Refer to Fuel Injection Pump Replacement in SI. Call GM Technical Assistance to order a fuel injection pump.
19. Remove the fuel from the tank. Refer to Fuel Tank Draining Procedure in SI.
20. Remove the fuel sender. Refer to Fuel Sender Assembly Replacement in SI.

Important: The fuel tank should be replaced if the tank is rusted internally.

21. Clean the fuel tank.
22. Remove the fuel strainer and replace if necessary. Refer to Fuel Sender Assembly Service in SI.
23. Install the fuel sender. Refer to Fuel Sender Assembly Replacement in SI.
24. Install the fuel tank. Refer to Fuel Tank Replacement in SI.
25. Install a new fuel lift pump. Refer to Fuel Lift Pump Replacement in SI.
26. Install both sides of the fuel feed line at the fuel lift pump. Refer to Fuel Lift Pump Replacement in SI.
27. Install clean diesel fuel into the tank until it is at least 1/4 full.
28. Install the fuel tank cap.
29. Install the negative battery cables.
30. Remove the ECM 1 fuse from the underhood relay center.

Important: Use a suitable container to catch fuel.

31. Install a hose from the fuel injection pump inlet hose (hose to hose) at the fuel injection pump to a closed metal container with a capacity of at least 8 liters (2 gallons).
32. Crank the engine for 15 seconds with one minute cooling periods until clean fuel is pumped out.
33. Reinstall the inlet hose to the fuel injection pump.
34. Install the ECM 1 fuse in the underhood relay center.
35. Start the engine and check the entire fuel system for leaks while idling for 5 minutes.
36. Clear any DTCs.

(1)	Nameplate

Figure 2 -- Nameplate