Fuel System - Fuel Injector Service Information
INFORMATIONBulletin No.: 03-06-04-036B
Date: November 10, 2009
Subject: Information on Servicing Duramax(TM) Fuel Injectors to Avoid and Remove Contamination
Models:
2001-2010 Chevrolet Silverado
2003-2009 Chevrolet Kodiak C4500/C5500 Series
2006-2010 Chevrolet Express Vans
2001-2010 GMC Sierra
2003-2009 GMC TopKick C4500/C5500 Series
2006-2010 GMC Savana Vans
Equipped with 6.6L Duramax(TM) Diesel Engine RPOs LB7, LLY, LMM, LBZ
Please Refer to GMVIS
Supercede:
This bulletin is being revised to add model years and update the Parts Information. Please discard Corporate Bulletin Number 03-06-04-036A (Section 06 - Engine/Propulsion System).
Fuel injectors may become contaminated during engine servicing. Debris between the injector line and the injector line nut may fall into the injector fuel inlet upon removal. Refer to the following SI procedures for the appropriate model year, vehicle and engine RPO when performing the following bulletin procedures for servicing the fuel injectors and lines.
- Fuel Injection Fuel Rail Assembly Replacement - Bank 1
- Fuel Injection Fuel Rail Assembly Replacement - Bank 2
- Fuel Injector Replacement (Right)
- Fuel Injector Replacement (Left)
Removal of Fuel Injector Lines
1. Before removing the fuel injector line, use regulated compressed air to blow any debris from between the fuel injector line and the fittings (1, 2). Wipe the fittings (1, 2) clean of debris.
2. Spray Super Lube(R), P/N 12346241 (in Canada, P/N 10953474), or a lithium grease equivalent, between the fuel injector line and fittings (1, 2) to assist in containing any debris during removal.
3. Remove the fuel injector line.
4. Remove the upper valve cover.
5. Remove the lower valve cover.
Notice
After the fuel line is removed and the fuel injector inlet is exposed, DO NOT use compressed air to clean debris. Using compressed air can allow debris to enter the fuel injector inlet and damage the fuel injector.
6. Immediately after removal of the lower valve cover, use a vacuum source to remove any contamination in the fuel injector inlet (1).
Fuel Injector Cleaning and Inspection
Notice
The fuel injector must be cleaned with the proper cleaning equipment. DO NOT use abrasive cleaning methods such as a metallic brush to remove deposits. Cleaning an injector with improper tools may damage the fuel injector.
1. Use a soft bristle non-metallic brush and fuel injector cleaner, P/N 88861802 (in Canada, P/N 88861804), or equivalent, to remove any deposits from the nozzle tip (1) and the copper washer sealing area (2) before reinstallation.
2. Inspect the fuel injector nozzle tip (1) for cracks, dents, or other damage.
3. Inspect the nozzle tip (1) for any signs of discoloration (dark yellow, tan, or blue) due to excessive heat.
Note
For information on injector bore cleaning, refer to Corporate Bulletin Number 05-06-04-067 - Information on New Essential Tool EN-47909 Injector Bore Cleaning Kit for 6.6L Duramax(TM) Diesel Engine.
• If any damage is found replace the fuel injector. Clean the fuel injector bore BEFORE installing the new fuel injector.
4. Clean the fuel injector high-pressure lines by performing the following steps:
5. Inspect the fuel injector high-pressure line for excessive corrosion, scale or rust to the sealing surface as shown.
Notice
Medium size media glass beads have a cleaning and peening action and do not remove metal. They do not have the quick abrasive action of sharp edged media. Glass beads clean rust, scale and corrosion from metal parts without any damage.
6. Use an Abrasive Blasting Cabinet, P/N 624-AST-SBC1, (to order, call GM Dealer Equipment), or equivalent, with a medium size media glass beads to clean the high pressure lines and fittings.
Important
Black plastic electrical tape or equivalent will protect the fittings outside coating from being removed with the media. This must be done to ALL sixteen high pressure fittings.
7. Install black plastic electrical tape or equivalent on both of the fittings (1) as shown.
8. When using an Abrasive Blasting Cabinet or equivalent, make sure you only clean the inside of the fittings (2) and as much of the fitting threads as possible as shown.
9. Use pipe cleaners (1) to block the ends of the high pressure lines so the abrasive blasting glass beads will not contaminate the inside of the pipes. Before removing the pipe cleaners, clean them by using regulated compressed air to blow any debris and/or media glass beads from the pipe cleaners.
10. There may be some area of the fitting or line that the glass beads did not clean very well. Disregard any surface that did not clean up as long as the area of the fitting is clean at the bite edge or sealing surface. Refer to the above illustration (1). Replace any suspect high pressure line if the glass beads cannot remove corrosion, scale or rust from the sealing surfaces and/or pitting or any other damage that is found.
11. After cleaning all of the fuel injector high-pressure line fittings with the glass beads, clean by using compressed air to blow any debris and/or media glass beads from inside and outside of all the fittings and lines. Afterwards, wash thoroughly with All Purpose Parts Cleaner, P/N 88862650 (in Canada, P/N 88901247, Brake Parts Cleaner) or equivalent. Repeat this process until all of the debris and/or media glass beads have been removed from the fittings and lines.
Fuel Injector Installation
Install the fuel injectors and lines using published service procedures in SI.
Notice
Ensure proper torquing of the fuel injector line fittings (1, 2). An under-torqued fuel injector line will not seal properly and an over-torqued fuel injector line may damage the fuel injector fitting. An improperly sealed or damaged fuel injector line or fuel injector fitting may cause a fuel leak.
Inspection For Fuel Leaks Into the Engine After Repair
1. Run the engine at idle for 10 minutes. Inspect for external fuel leaks while the engine is running.
2. Stop the engine and wait 10 minutes, then check the engine oil level. This will be the initial oil level.
3. Run the engine at idle for 5 minutes while commanding the fuel pressure to 160 MPa using a scan tool.
4. Stop the engine and wait 10 minutes, then check the oil level.
• If the engine oil level is more than 4.7 mm (3/16 in) above the initial oil level, refer to Fuel Leak Diagnosis (Inside of Engine), and Fuel in Engine Oil procedures in the Engine Controls and Engine Mechanical sections respectively in SI.
• If the engine oil level is less than 4.7 mm (3/16 in) above the initial oil level, the repair is complete.
Parts Information
Warranty Information
For vehicles repaired under warranty, use the table above.
Disclaimer