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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 02-02-2018, 01:16 PM   #1 (permalink)
Freeze Plug
Join Date: Jan 2004
Location: New York
Posts: 20
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P0305 and injector replacement

Figured I would share my experience. I have owned this truck since new in 2004. 220k miles, and started getting code p0305, then blue smoke out exhaust at idle and idle was rough. Since I could not check balance rates, I ordered one injector for #5 cylinder. Never changed an injector, but I did and the truck idles smooth and runs great, no more CEL light! Now just to let others that never changed an injector. When you order your injector order the return line repair kit, its good for the hole bank (4 injectors).
I had a hard time removing the plastic tee return line fitting from the top of the injector. I tried to be real careful, but after installing everything I had a bad diesel leak at this fitting. Turns out the o-ring and the end of the fitting was still in the old injector. So I had to buy the return line kit. Everything else was plain and simple unbolt and bolt back together.

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