Need opinions. Truck has 82000 kms (50,000 miles) I have no warranty as to my location.
I have three new injectors with all the bits n bobs together with the Helms so no worries there.
I have a raw fuel smell and fuel in the sump and my injectors rates are 4.8 for No.1 and 3.0 for No.4. The rest are around -1+1 so no worries there.

Strange thing is that fuel consumption has improved over the last few months.

I'm going to attempt it in the morning and am going to tackle No. 1 and then No.4 and see if it goes away, good/bad idea? or just do both with fingers crossed.

Thanks

If you think you are leaking fuel into the crankcase, I would remove the valve covers, reconnect the fuel lines, disconnect the wire to fuel injection pump to make the pump put out max pressure, clean off outsides of injector bodies with brake cleaner and then start and idle engine. Look for fuel coming from cracks in injector bodies or eroded ball seats.

Thanks for that info.
Have no leaks on passenger side, going to change No.1 out now. All good, I'm now inside but if you don't have the injector pulling widget, how do get the darn thing out.

Thanks

Yup got a heafty leak or leaks, had 18 litres of oil drained as well.
Eric's sending 8 newbies out tonight. Doing it once correctly and fingers crossed will last a few more years.

I'm trying to create a sticky for newbie injector replacements. It seems like you know what you are doing. Do you go by a manual or just memory? Have any suggestions?

wouldn't say I knew exactly what I'm doing but I have the helms manuals and tools. I do not have an injection puller just bent a large screw driver and had a spare injector line which I attached to each and they came out real easy.
Had a problem with the rocker cover but removed the plastic side wall an used a screw driver and spanner to pinch open the upper from lower.
I have not worked on an engine for over well lets just say 15 years, but its flooding back to me now. The duramax is very easy to work on. Remember I have no specialist within a couple of thousand miles and parts take a while to get to me.
This morning I was crapping my pants(excuse language) at the thought but now the biggest pain is the time for the new parts to get to me. It helps having this site and having a great supplier like Merchant Auto.

I have stripped the passanger side down now and will do the drivers side in the morning. I will post some pics later if you like

Hope this helps

lets see some pics this could be a start to an awesome write up!

I'll give it a go. Did not take too many photos of passenger side. I'll do my best on the other side tomorrow.

How many litres or gallons of coolant can I expect when I drop the hose in the morning??

let me know if you have any questions as i did a lot of injector replacements while working at merchants. pm me if there is anything i can do to help.

use the drain petcock on the radiator instead of just pulling the hose. i would expect around 2-2.5 gallons give or take.

that's great will do thanks again

use the drain petcock on the radiator instead of just pulling the hose. i would expect around 2-2.5 gallons give or take.


stroke250 any hints or tips or anything would be great for the injector replacement process. I'm sure in the coming weeks I will be pm'ing you for some help if you dont mind. Its nice to have an "expert" on hand for some needed help.


I have started a thread here http://www.dieselplace.com/forum/showthread.php?t=269557 if anyone wants to post any suggestions/pics.

take your time and clean everything. check sealing surfaces for imperfections as return lines are a good spot to leak. also, make sure the injector lines are clean and there is no rust build up on the nut ends. don't overtighten harness nuts as they are delicate.

How do you torque down to spec the fuel lines when you cannot get a normal torque wrench on it. Do you have a special tool for those 19mm nuts?

you can use a 19mm "crows foot". a regular combo wrench will work. as far as spec on injector lines, i wouldn't go by it...

How do you remove the fuel line at drivers side rear. I've got the clip off. do you just yank them off or is there a trick to it??

OK that's the other 4 out. Only real problem was a tough lower rocker allen and just getting all the stuff out of the way. Getting all the allens out round the back was a bit of a squeeze, so took off a heat shield and everything came to bits. Injectors came out really easily, you don't need a special tool at least I didn't. Took a load of pics but will start to compose it all when I get home tomorrow. Another thing is the water ingress from the rubber grommets is appaling from what I've seen. I'm going to think up something that will keep all the water out the time. My No.8 inlet was full of rubbish, in fact 1,2,7 and 8 were all pretty murky.

"Another thing is the water ingress from the rubber grommets is appaling from what I've seen."

Do you mean around where the fuel line goes through the valve cover?

Yes, It's pants as far as I'm concered. There has to be a better way to seal it from the elements. I'm fairly convinced that the first 2 years of my ownership where the truck hardly moved due to registration problems was the downfall of these injectors. I only have 50,000 miles on her.
I think that the fuel here in Europe is possibly cleaner than over in the States. The majority of all car here are diesels and to be honest the major manufacturers would be out of business if they had injector failures.
I also have double filtration as well. This has only been on the truck for about 2 1/2 years.
I had no loss of performance, fuel consumption has improved but my balance rates for No. 1 and 4 were borderline but draining 18 liters of oil is by no mean normal.
I'm doing this on my own and paying for all spares( I have no warranty to speak of).
Am I upset to be polite yes and no. I know that I have the best truck here in Spain and long may it continue. This is the first fault she has had in all this time, and it will cost me a few thousand but thats only 2 days work for me.
I'm going to try and fab up some king of cover that will protect it a bit better from the elements but first gotta wait for the newbies to arrive next week.
Hope this helps

Sorry forgot to add. When I pulled the drivers rocker cover there was a chewed up leaf inside. This is the first time I have had the engine in bits.

How in the Lords beautiful earth did a leaf get inside there?

Must have slid passed the grommet, it surprised me too.

Well today is the day. Doing Drivers side first as its the trickiest in my eye.

Will update later

drivers side done 4 hrs yikes

Done, finished. All in all 8 hours to put it back. Took a while to get her to fire, countless bleeds. Balance rates all hoverineg around 0.00. Only thing left in the parts jar was a small rubber grommet????

I still have 2 litres of coolant. Does a thermostat have to open or? Any tips on that one would be a help.

How a seasoned tech can do it in 8 hours all in with cleaning etc. well hats off to them.

Right then where that Suncoast III. It's got to be a walk in the park compared to what I've just done.

Big thankyou goes out to Eric Merchant AGAIN. Without him over the last 3 years, well he keeps me on the road together with this Forum.
Many thanks to all.

Don't worry about the coolant issue, sussed it out thru search function

tolliwacker started a thread about this. My brother added some pictures of his truck while we had it apart. Its a great thread to read for anyone thats thinking about doing the job themselves. If you do a search im sure im sure youll find it.

Glad she is running again Marek. Got the cores back yesterday

I went and got a passport this week so I dont miss out on a chance to go to Spain again. You can fly me over when we build the trans. LOL!

I may well hold you to that Eric. This has been a very stressful 10 days.
Thanks again
Marek

Another thing is the water ingress from the rubber grommets is appaling from what I've seen. I'm going to think up something that will keep all the water out the time. My No.8 inlet was full of rubbish, in fact 1,2,7 and 8 were all pretty murky.


It may be too late, as it appears you have finished, BUT, my injectors were replaeced by the dealer, and the tech sealed the opening in the valve cover with blue RTV silicone.

When I first saw it, I wondered why he would do that, after reading your comments, I think I see why, now.

Well just made it home 650 miles and 11 hours. Ran like a champ, have a small smell of oil but when I changed the filter it was pitch black so probably spalshback etc. Off to the jet wash today to give it a little tickle. Oil pressure was almost centred all journey apart from the long mountain climbs when it dipped a point. All in all quiet happy with myself to be honest.
I have not done the sealant mod was a bit preoccupied to finish but will do something similar.