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How do I Rebuild a Duramax Injector

The Duramax engines are a series of diesel engines that General Motors has manufactured for its larger trucks since 2001. Several different versions of these engines exist, but they all have a displacement of 6.6 liters. Duramax engines use direct fuel injection, which does not require an electronic controller. The procedure for rebuilding the fuel injector is generally the same as for all vehicles with a Duramax engine.

Instructions

1

Open your hood. Disconnect the cables from the negative terminals of the batteries with a socket wrench. Detach the clips on the fuel lines to the fuel injectors, and disconnect the fuel lines from the injectors. Remove the fuel return lines from the fuel injectors. Plug the open fuel lines with plastic caps to prevent debris from entering the fuel lines.

2

Attach GM special tool J-29873 to a socket wrench, and use this assembly to turn the fuel injector counterclockwise. Make sure you grip the 30 mm hex portion of the fuel injector to avoid damage to the injector. Remove the fuel injector, and cover its ends with plastic caps.

3

Replace the gasket on the fuel injector with a new gasket. Install the new fuel injector to the fuel rail. Fasten the fuel injector into place by turning it clockwise with GM special tool J-29873 and a socket wrench.

4

Attach GM special tool J-29873 to a torque wrench, and torque the fuel injector to 50 foot-pounds. Remove the protective caps from the fuel lines, and connect the fuel lines to the fuel injector. Fasten the retaining nuts for the fuel lines, and tighten them to 20 foot-pounds with a torque wrench.

5

Connect the fuel return line to the fuel injector, and attach the clips to the fuel lines. Connect the cables to the negative terminals of the batteries with a socket wrench.

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