LBZ, LLY, Engine with Rough Idle, Poor Performance, Black, White Exhaust Smoke, MIL/SES Light On, DTCs Set (Reprogram ECM and Replace EGR Motor or EGR Valve, If Necessary)
| Subject: | LBZ, LLY, Engine with Rough Idle, Poor Performance, Black, White Exhaust Smoke, MIL/SES Light On and One or More of the Following DTCs P003A, P060B, P0230, P0403, P0401, P0606, P2146, P2149, P2152, P2155 (Reprogram ECM and Replace EGR Motor or EGR Valve, If Necessary) |
| Models: | 2006-2007 Chevrolet Express, Kodiak C4500/C5500 Series, Silverado, Silverado Classic |
| 2006-2007 GMC Savana, Sierra, Sierra Classic, TopKick C4500/C5500 Series |
| with 6.6L Duramax ™ Diesel Engine (VINs D, 2 -- RPOs LBZ, LLY) |
| Attention: | This bulletin contains separate service procedures for the Van and the Truck Models regarding information on DTC P0403-EGR Solenoid Control Circuit if set. |
This bulletin is being revised to add part information, change warranty information and add procedures for replacing the EGR Valve Motor or EGR Valve Assembly. Please discard Corporate Bulletin Number 06-06-04-066A (Section 06 -- Engine/Propulsion System).
Condition
Some customers may comment on an illumination of the MIL/SES with one or more of the following symptoms:
| • | Rough Idle |
| • | Poor Performance |
| • | Black or White Exhaust Smoke |
Upon further investigation, the technician may find one or more of the following DTCs stored in the ECM:
| • | P003A: Turbocharger Boost Control Position Not Learned |
| • | P060B: Control Module Analog To Digital Performance |
| • | P0230: Fuel Pump Relay Control Circuit |
| • | P0403: EGR Solenoid Control Circuit |
| • | P0401: Exhaust Gas Recirculation Flow Is Insufficient |
| • | P0606: Control Module Internal Performance |
| • | P2146, P2149, P2152, P2155: Injector Positive Voltage Control Circuit Group 1-4 |
Cause
This condition may be caused by the calibration and carbon build up under the brushes of the EGR motor.
Correction
Important: If DTC P0403 was set, replace the EGR motor or EGR valve assembly depending on the vehicle application.
Check the ECM for the latest calibration.
| • | If the ECM does not have the latest calibrations, reprogram the ECM. A revised calibration has been developed to address these conditions. Technicians are to reprogram the ECM using SPS with the latest software available on TIS2WEB. Refer to the Engine Control Module Programming and Setup procedure in SI. As always make sure your Tech 2® is updated with the latest software version. |
| • | If the ECM has the latest calibration and DTC P0403 was set, replace the EGR motor or EGR valve assembly depending on your vehicle. Refer to the appropriate list below. |
LIGHT AND MEDIUM DUTY TRUCK-EGR VALVE MOTOR REPAIR PROCEDURE FOR DTC P0403
Important: Replace the EGR valve motor Only. Some vehicles may have a thin metal spacer between the motor and the valve that appears to be a gasket. The spacer is used to correct for production variances in some valves and should be reinstalled with the new motor.
Replace the EGR motor (1). Refer to Exhaust Gas Recirculation Valve Motor Replacement in SI.
Truck Part Information
Part Number | Description | Qty |
|---|---|---|
98063338 | Motor, EGR Valve | 1 |
VAN-EGR VALVE ASSEMBLY MOTOR REPAIR PROCEDURE FOR DTC P0403
Important: Replace the EGR valve assembly with motor.
Replace the EGR valve assembly (1). Refer to Exhaust Gas Recirculation Valve Replacement in SI.
Van Part Information
Part Number | Description | Qty |
|---|---|---|
97379347 | Valve, EGR Assembly (includes EGR motor) | 1 |
97372002 | Gasket, EGR Valve Cooler | 1 |
97368325 | Gasket, Center Intake Manifold (round gasket) | 1 |
97367014 | Gasket, EGR Valve (rectangular type to intake pipe) | 1 |
97367013 | Gasket, EGR Valve (elongate gasket located towards the middle of EGR valve) | 1 |
97303655 | Gasket, EGR Valve (bottom EGR valve to top EGR cooler) | 1 |
97192618 | Gasket, Exhaust Turbo Inlet Pipe | 1 |
97188685 | Gasket, Exhaust Manifold Outlet Pipe | 1 |
94011605 | Seal, Heater Outlet Pipe (O-ring) | 1 |
Warranty Information
Important: For additional information on warranty coverage for emission related reprogramming for Medium Duty trucks, refer to Corporate Bulletin Number 04-06-04-036C.
For vehicles repaired under the 8 year/80,000 mile (130,000 km) emission controller warranty, use:
Labor Operation | Description | Labor Time |
|---|---|---|
J6353* | Module, Powertrain Control - Engine Reprogramming with SPS | 0.4 hr |
Add: | Motor, Exhaust Gas Recirculation (EGR) Valve - Replace (Truck Only) | 0.5 hr |
Add: | Valve, Exhaust Gas Recirculation (EGR) Complete Assembly - Replace (Van Only) | 4.0 hrs |
*This labor operation number is for bulletin use only. This number will not be published in the Labor Time Guide. | ||
