Afternoon, DTR.

One of my fellow Marines needs to change out his injectors. Can anyone help a brother out with some service manual or a good write up? I've checked out a few d-max forums, I have not seen any really good info.


TIA!

mad

 

I found this for an 04 but not too detailed.



1)drain cooling system; and disconnect battery

2)remove charge air cooler pipe and hose from intake and charge air cooler.
3) Remove heater pipe from hose above fuel filter. ( set down beside engine.)
4)Remove crankcase hose from front bracket connection.
5) disconnect FICM connectors, and fuel lines at banjo fittings
6)remove FICM bracket from valve cover.
7) remove fuel filter from valve cover
8) remove injector line locks and injector lines ( clean or replace lines as needed for corrosion)
9) remove glow plug wire from front glow plug only.
10) remove the 5mm allen head bolts from upper valve cover.( be careful not to strip out allen on bolt)
11) pry at edge of cover to break seal ( it is tough , use a long bar to pinch edge to remove)
12) just remove injector wire connections ( do not need to disconnect from harness, just fold back.
13) remove the lower valve cover bolts 5mm allens
Remove lower cover.
14) remove the return line 5m allen bolts and bolt in front to head.
15) remove the injector bolts 8 mm allen head
16) use a rod that will fit in bracket bolt hole to pry back and pop out injector.( there is a special tool to do this)

17)Clean injector bores ( if one of the sleeves pulls out. replace the o-rings at the top and apply red lock tight to the tapered end that seal to the combustion chamber)

18) reinstall injectors( new copper washers and o-rings)
19) Tighten to 36 ft lbs.
20)Install the injector return lines tighten 126 inch lbs ( use new banjo blot seals)
21)reinstall lower valve cover.
22)Reinstall injector wire harness.
23)reinstall upper valve cover.
24)reinstall injector lines ( torque to 30 ft lbs)
25) reinstall locks on injectors
26) reinstall fuel filter assembly
27)reinstall glow plug wire
28) reinstall FICM bracket and FICM, and connections
29 reinstall heater hose/pipe
30) reinstall crankcase vent hose
31) reinstall charge air cooler hose and pipe.
32) fill cooling system ( remove bolt on top of thermostat housing to bleed)
33) bleed fuel system. and reconnect battery.
34 pump primmer till hard, crank till engine starts( 15 min interval, let cool two min)


Read more: Chevy Questions - How to change the passenger side injectors on a 2004 Duramax...step - JustAnswer http://www.justanswer.com/chevy/3nol...#ixzz1KmHb7sPj

 

Check with a dealer before you dive into it. The LB7 had the injectors warrantied to 200k.

 

Eric, I've seen that, thanks.

Tim, we've taken it to different dealers, they agree with the injector service until 200k, but they don't meet the criteria. If you have some solid word on what limits they are checked to... that would be awesome.

 

Why is he changing them out? Does he do UOA on the truck? An oil analysis that shows contaminated oil should be enough for them to warranty the injectors. I will contact a friend and see if he can print me out what they look for.

 

The instructions posted above are pretty complete. draining the coolant is a must because if you pull an injector sleeve out without draining the coolant first, you get a pretty good bath. To reseal the upper valve cover, isuzu makes a really good black silicone ( the factory stuff, and the reason the upper valve covers come off so hard) but it will not leak. Make sure to use new copper washers on all of your return fuel connections. You will probably have to borrow an injector puller from someone. The only one I have ever used is the GM one (I worked on duramax's at a chevy dealer for almost four years, used to be an ASE Master Tech.) Do the passenger side first it is way easier. It is a really easy process once you get all of the things out of the way and can actually see the valve covers. Take your time to know how everything goes back together and I'm sure when your done you will see that it wasn't too bad. But hopefully, they will warranty them for your friend, free is always a good thing.

 

Here is a writeup with pics:

http://www.dieselplace.com/forum/sho...d.php?t=279436

And here is a link to I guess GM's testing policies and procedures:

http://www.dieselplace.com/forum/sho...d.php?t=304674

Hope this helps you/your fellow Marine...

-J

 

is it pretty much the same with the 05 lly?