I have a problem with my wife’s ’01 Duramax’s cooling system. You can start out with everything normal with a cool engine – no pressure in the cooling system, coolant level normal. Drive it and get it up to operating temperature. Let it cool down – stone cold, not just cool. The cooling system will still be pressurized. When you take the cap off the bottle you get a surge of coolant and SOMETIMES bubbles. Also, sometimes it will blow coolant out of the overflow tube when you are driving.

All opinions are welcome.

Engine Coolant Loos with No Visible Leaks (Reseal Injector Sleeve) #03-06-02-005B - (Nov 18, 2004)

Engine Coolant Loss with No Visible Leaks (Reseal Injector Sleeve)

2001-2004 Chevrolet Silverado

2001-2004 GMC Sierra

2003-2004 Chevrolet and GMC C4500/5500 Models

with 6.6L Diesel Engine (VIN1 - RPO LB7)

This bulletin is being revised to add technician cautions. Please discard Corporate Bulletin Number 03-06-02-005A (Section 06-Engine).

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1566698&psdid=210&evc=sm#ss1-1566698">Condition

Some owners may comment on engine coolant loss with no visible leaks. Excessive white smoke or a coolant type odor coming from the exhaust pipe, along with low coolant levels, may indicate coolant in the combustion chamber.

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1566698&psdid=210&evc=sm#ss2-1566698">Cause

Condition may be caused by engine coolant entering the cylinder due to a dirty or damaged seal between the fuel injector sleeve and the cylinder head.

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1566698&psdid=210&evc=sm#ss3-1566698">Correction

Perform the following diagnosis to determine the cause of the coolant loss.

<LI type=1>External/Internal Coolant Leaks: <LI type=A>Verify that there are no external coolant leaks. Refer to the Loss of Coolant procedure in the Engine Cooling section of the Service Manual.
If the vehicle is equipped with an Exhaust Gas Recirculation (EGR) system, inspect the EGR valve and intake system for evidence of internal coolant leakage. Replace the EGR cooler if any condition is found. Refer to Exhaust Gas Recirculation (EGR) Valve Cooler Tube Replacement procedure in the Engine Controls -- 6.6L sub-section of the Service Manual.
<LI type=1>Cooling System Pressurization:
http://service.gm.com/engif/000/000/011/11658.gif
http://service.gm.com/tif.gif (http://service.gm.com/servlets/RetrieveTif?pic=11658)
<LI type=A>On a cold engine with the cooling system depressurized, install the J 24460-01 Radiator Pressure Tester. <LI type=A>Start the engine and bring it to operating temperature. <LI type=A>Shut off the engine. <LI type=A>Using the J 24460-01 Radiator Pressure Tester, bring the cooling system pressure to 15 psi (103 kPa). <LI type=A>Allow the engine to cool. Observe for a drop in the cooing system pressure. <LI type=A>Disable the fuel system by removing the IGN 1 relay on C/K trucks or the IGN B relay on C4500/5500 trucks using the J 43244 Relay Puller Pliers. <LI type=A>Disconnect the 4-wire glow plug control circuit connector from the glow plug relay/controller assembly. <LI type=A>Remove the glow plugs. Refer to the Glow Plug Replacement -- Bank 1 and the Glow Plug Replacement -- Bank 2 procedures in the Engine Controls -- 6.6L sub-section of the Service Manual. Inspect for evidence of coolant on the glow plug tips. Note any cylinders that show evidence of coolant leakage. Caution: Keep hands and face clear of glow plug holes while cranking. Hot liquid or gases may be expelled during cranking.

<LI type=A>Place white paper in front of all the glow plug holes and crank the engine over for two compression strokes. <LI type=A>Inspect the paper for evidence of coolant and note the appropriate cylinders.
Release the pressure from the cooling system and remove the J 24460-01 Radiator Pressure Tester.
<LI type=1>Cylinder Leakage Test: <LI type=A>Rotate the engine to bring the cylinder to be tested to Top Dead Center.
http://service.gm.com/engif/000/001/211/1211555.gif
http://service.gm.com/tif.gif (http://service.gm.com/servlets/RetrieveTif?pic=1211555)
<LI type=A>Install the J 35667-9 Cylinder Head Leakdown Adapter and the J 35667-A Cylinder Head Leakdown Tester to the cylinder. <LI type=A>Apply shop air to the J 3566-7 Cylinder Head Leakdown Tester and adjust according to the manufacturer's instructions. <LI type=A>Inspect for excessive cylinder leakage and air bubbles in the cooling system.
Repeat steps 3.1 through 3.4 for each cylinder. Note any cylinders that indicate leakage.
<LI type=1>Inspection and Repair: <LI type=A>Remove the fuel injector sleeves of the cylinders that show evidence of coolant leakage. Refer to the Fuel Injector Sleeve Replacement procedure in the Engine Mechanical -- 6.6L sub-section of the Service Manual. <LI type=A>Inspect the inside of the fuel injector sleeve for damage to the fuel injector sealing surface. Damage to this portion of the fuel injector sleeve may indicate a loose injector caused by improper tightening or a missing copper washer. A loose injector will allow the fuel injector and the fuel injector sleeve to bounce inside the cylinder head, resulting in coolant leakage to the cylinder. If damage is found, replace the affected components.
http://service.gm.com/engif/000/000/840/840193.gif
http://service.gm.com/tif.gif (http://service.gm.com/servlets/RetrieveTif?pic=840193)
Inspect the tapered sealing surface of the cylinder head and the fuel injector sleeve (1) for evidence of machining debris, carbon tracking, improper machining or damage. If improper machining or damage is found, replace the affected component. If there is machining debris found on the fuel injector sleeve or cylinder head sealing surfaces, clean the debris and reinstall the fuel injector sleeve. Refer to Fuel Injector Sleeve Replacement in the Engine Mechanical -- 6.6L sub-section of the Service Manual.
If no debris or damage is found on the fuel injector sleeve or the fuel injector sleeve bore in the cylinder head, remove the cylinder head and inspect the cylinder head and gasket for damage. Replace components as necessary.

<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1566698&psdid=210&evc=sm#ss4-1566698">Warranty Information

For vehicles repaired under warranty, use:

<TABLE width="100%" border=1><TBODY><TR><TH vAlign=bottom align=middle>Labor Operation

</TH><TH vAlign=bottom align=middle>Description

</TH><TH vAlign=bottom align=middle>Labor Time

</TH></TR><TR><TD vAlign=center align=middle>J0497

</TD><TD vAlign=center align=middle>Sleeve, Fuel Injector - Right Bank - Replace

</TD><TD vAlign=center align=middle>3.4 hrs

</TD></TR><TR><TD vAlign=center align=middle>Add:

</TD><TD vAlign=center align=middle>To Replace Each

</TD><TD vAlign=center align=middle>0.1 hr

</TD></TR><TR><TD vAlign=center align=middle>Add:

</TD><TD vAlign=center align=middle>To Replace All

</TD><TD vAlign=center align=middle>0.3 hr

</TD></TR><TR><TD vAlign=center align=middle>J0498

</TD><TD vAlign=center align=middle>Sleeve, Fuel Injector - Left Bank - Replace

</TD><TD vAlign=center align=middle>4.4 hrs

</TD></TR><TR><TD vAlign=center align=middle>Add:

</TD><TD vAlign=center align=middle>To Replace Each

</TD><TD vAlign=center align=middle>0.1 hr

</TD></TR><TR><TD vAlign=center align=middle>Add:

</TD><TD vAlign=center align=middle>To Replace All

</TD><TD vAlign=center align=middle>0.3 hr

</TD></TR><TR><TD vAlign=center align=middle>J0499

</TD><TD vAlign=center align=middle>Sleeve, Fuel Injector - Both Banks - Replace

</TD><TD vAlign=center align=middle>7.5 hrs

</TD></TR><TR><TD vAlign=center align=middle>Add:

</TD><TD vAlign=center align=middle>To Replace Each

</TD><TD vAlign=center align=middle>0.1 hr

</TD></TR><TR><TD vAlign=center align=middle>Add:

</TD><TD vAlign=center align=middle>To Replace All - Both Banks

</TD><TD vAlign=center align=middle>0.6 hr

</TD></TR></TBODY></TABLE>

Usually when we see a loss of coolant and a random-overflowing bottle, this is it...

Ditto, injector sleeves are the culprit

Hmm, Sounds like more likely head gaskets to me...

Everyone I have seen with that symptom has been head gasket.. isnt that right Hootie?

Yeah, them too, I just hate sayin' it though..."Them damn Jap Izuzu aluminum heads is never gonna hold up" (in my best redneck Fordboy voice)

Ditto again, just resealed a set on a buddy's '03...identical symptoms, he runs his pretty hard too, drag racing & pulling, etc. Besides it's just an easy days work to try, not like head gskts.-:t.

Todd.

Fuel rails make nice handles..


http://www.uscom.com/~hoot/cars/duramax/gmc/headgaskets/images/DSCN4565.jpg

Well, I took it into the dealership this morning. The service writer listened very carefully to the symptoms and then said it sounded like injector sleeves. It will be a couple of days before they know for sure. The only thing I am not sure about is the fact that I was not loosing any coolant until if was blown out of the bottle. It was almost like the thing would “burp” once in a while. I will post again when I find out.

That burp is when combustion pressure is introduced into the cooling system through a leaking sleeve/head gasket.

It's not that easy to discern wether it's a sleeve or a head gasket.

looking at what a sleeve pays to reseal and what a head pays to replace the gasket on, I prefer to go straight for the heads. Max Payne knows exactly what I am talking about..wink wink. On Hoots we ended up pullling all the sleeve's and resealed them to be safe.

Just received a call from the dealership that has my wife’s truck. They are working on it. He said that they have been in contact with GM’s technical help people and doting the “I’s” and crossing the “T’s” to get everything right. They are still in the testing phase. He said that they are going to put some dye in the cooling system (?) and then pressurize the system and let it sit for 18 hours. It sounds like they are doing thing right and are trying to do a good job

Got a call last evening from the service department manager. He said they were putting in a new set of injectors and sleeve seals as soon as they could get the parts. He said they were going to replace all 8 injectors and seals. He didn’t argue or anything, just told me the parts were on order.

This brings up another question. Are the injectors still a back ordered item?

He indicated that he thought that maybe, just maybe I could have the truck back Friday if he could get the parts.

Well I got the truck back Friday (Dec 10). This is a list of “stuff” they replaced:

Injectors
Injector sleeve seals
Coolant (result of contamination while working on it)
Oil and filter (result of contamination while working on it)
Fuel filter (result of contamination while working on it)
Thermostats, 2 each
One battery (I haven’t figured this one out. I think they must have dropped my old one and had to replace it.)

With all this replacement, I am still not sure if the problem has been fixed. After driving the vehicle twice and allowing it to cool down, the radiator is STILL pressurized. I feel sure the dealer is trying to do a good job. They have been nothing but courteous and helpful. I have a feeling however that they have made a misdiagnosis and have not touched the problem, which is pointing at a head gasket.

I asked the service writer if he had any idea about the bill on all of the above plus labor. He indicated that it would have been in excess of $2500. Boy am I glad I got that warranty!

Basically what we were trying to say earlier in this thread. Not saying "I told you so". We know you are at the mercy of your dealership.

Looks like in the end GM gets screwed with another big labor bill.

boy if that dont all sound familier.....head gaskets anyone?

Mine was diagnosed the same as yours. Dealer replaced injectors sleeves. Blew coolant out within 100 miles. dmaxalliTech replaced head gaskets, end of problem.

Well, I took it back to the dealership today. I got a big slug or coolant on the driveway and a big gurgle deep in the engine when I took the radiator cap off Monday. I don’t know what to think. We were scheduled to go on a trip next Tuesday, don’t look like that will happen now, at least not in the D’max. We may go in the old reliable ’84 however. This is the second trip the stupid thing screwed up. I actually walked through the lot looking at trucks while I was at the dealership. I was thinking about buying (cover your eyes) a gas burner. Something like a 1500 about 3 years old, certified, with extended warranty. If I did that, perhaps I would have at least one vehicle up and running when I needed to go somewhere. The only problem was they didn’t have a single extended cab, long bed on the lot. I have a feeling, that the aluminum heads are the problem. You just don’t build machine tools out of aluminum, it crawls around.

Well, I went on my trip in the ’84. We put about 1k miles on it and it never had a single problem. It was not very fast and it didn’t climb hills very well but at least it runs. I got a call from the dealership early this morning, Dec 31. He said the diesel guy had started working on it but had been called away to Florida with a death in his family. He will start working on it again when he gets back. They are doing the head gaskets this time. He said it will be at least Tuesday before the can even order the parts. Said something about having to make some measurements of the head in order to get the correct gasket. I guess I will get a truck back at some point; actually, my wife will get a truck back at some point. I just hope this solves the problem. Perhaps we can take it on a trip then.

I have a feeling, that the aluminum heads are the problem. You just don’t build machine tools out of aluminum, it crawls around.
Yeah, you don't build machine tools out of aluminum because it is not quite as hard as case hardened steel.

I'm not sure I would jump to that conclusion. Lots of gassers have aluminum heads. Doesn't the 5.3 have aluminum heads? I don't remember. Sure lots of Duramax's out there, the big topic of discussion on this board seems to be injectors, not heads.

Jim

they dont need to measure for head gaskets unless a moving part is replace like a piston, rod or bearing. the gasket is idenitifed by the markings on it. there are three sizes a,b,c, left or right.

I areeded with Eric replacement of the head should have been discussed. the seals for the injector could have been done there as well. It is a hard diag.

Eric
I havent seen many small leaking heads. where do you see the gasket failing.

We got the truck back last night, 3 weeks to the day after taking it to the dealer. They did the head gaskets – at least, I have not gotten a list of anything else they did. The mechanic put in 40 hours worth of work on it. I guess time will tell if it is really fixed this time. I need to do a pull with it so I can get a little bit of a load and see if it will hold up.

Everyone is always bashing the dealerships but I have nothing but good to say about mine. I think they did everything they could. The 3 weeks time it took to fix it was partly because of Christmas and New Years and some other things that were beyond their control. If you need a dealership in middle Georgia, I can definitely recommend Jerry Barker in Byron Georgia.

Anyway, time will tell if the problem is solved or not.