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Duramax Second Generation: 2004.5-2005 (LLY) Discuss the second generation (2004.5-2005 LLY) of the 6.6L Duramax diesel engine & associated components. 2006 LLY engine discussion belongs in Third Generation forum due to the differences of the 2006 LLY and the 2004.5-2005 LLY. Engine related discussion ONLY.

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Old 06-04-2017, 10:47 PM   #11 (permalink)
Block Heater
Join Date: Jan 2015
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more thoughts, check that the fuses and relays are all in good working order. i am remembering back several years now, that I had the #5 ecm relay going bad, the engine would randomly die and with a bump would come back alive. I replaced the relay with the AC relay, and had no more problems, then bought a new relay for AC. since you bought this truck in a non running condition and that you found the pump busted up some, is it possible that the fuel rails and injectors may have been contaminated? difficult part is that you may have never head this truck run prior to purchase, and that is hardest part of diagnostics.

the fuel feed line from tank to filter in my trucks have no check valve, so if you remove the suction line and blow it back, you should get no restriction. unless you have a full tank, then your pushing against that volume of fuel. this will hopefully help you from not removing the tank, possibly easier to remove the bed or unbolt it on driver side, loosen up passenger side to create a hinge and lift the drivers side to gain access to the tank, be sure to support the bed so it does not crush you.

did you check the service port on the suction line to make sure thats not leaking as well?

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Old 06-05-2017, 05:19 PM   #12 (permalink)
Join Date: Dec 2011
Location: Edmonton, Alberta, Canada
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Alberta Coal Rollers Member

Thanks for the tips so far.

I have checked fuses and relays, as well as rebuilt the filter head system and dropped the tank to check restrictions. There doesn't seem to be any sort of leak in the supply side.

Based on the return test and the volume of fuel in the return system, I'm at the point where injectors are the most likely cause. I'll be looking to test each injector individually this week, and go from there.

I'll also be shimming the FPRV as a precaution (even though no fuel came from the rail I want to be sure it's not causing any additional problems before buying injectors).

2005 Chevy 2500HD 6.6L LLY Duramax
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