Katerina Swanson
Replacing Duramax fuel injectors can be a costly endeavour, with the total cost of replacing eight injectors on an LLY Duramax ranging from $3500 to $4500 CAD. However, the good news is that LLY injectors are located outside the valve covers, making the task considerably easier and cheaper than on prior LB7 models. Before removing the fuel injector pipes, it is important to use compressed air to blow any debris from between the injector line and fittings. This guide will take you through the steps to replace your Duramax LLY fuel injectors, including removing the fuel injector bracket bolts and pins, disconnecting the negative battery cable, and removing the fuel return hose clips and hose.
| Characteristics | Values |
|---|---|
| Typical LLY Duramax injector failure | High fuel return rates |
| Symptoms of injector failure | Hard starting and rough running, especially noticeable at idle |
| Fuel injector bracket bolts | Remove |
| Fuel injector bracket pins | Remove if necessary |
| Copper washer from the fuel injector bore | Remove and discard |
| O-ring from the fuel injector | Remove and discard |
| WD-40 or penetrating oil | Spray around where the return line goes into the injector |
| Return fitting | Twist back and forth as you pull out |
| Injector bore | Rustes above the O-ring on the return line |
| Injectors | Use a small pry bar to remove |
| Plastic "T"s and clips | Do not break or lose |
| Replacement injectors | Incorporate several updates to help prevent repeat failures |
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What You'll Learn
Disconnecting the negative battery cable and removing the fuel injector pipes
Before disconnecting the negative battery cable and removing the fuel injector pipes, it is important to note that typical LLY Duramax injector failure is caused by high fuel return rates, which cause hard starting and rough running, especially noticeable at idle. Poor quality fuel will also cause premature injector failure.
To disconnect the negative battery cable and remove the fuel injector pipes, first, use compressed air to blow any debris from between the injector line and fittings. Then, wipe the fittings clean of debris. Disconnect the negative battery cable. Remove the fuel injector pipes. Remove the fuel return hose clips. Remove the fuel return hose from the injectors. Disconnect the fuel injector electrical connectors.
To remove the fuel injectors, take a small pry bar underneath the hold-down bracket and use that to pry up on the injector. Remove the fuel injector bracket bolts. Remove the fuel injectors with brackets. If necessary, remove the fuel injector bracket pins. Remove and discard the copper washer from the fuel injector bore. Remove and discard the O-ring from the fuel injector.
Spray WD-40 or the penetrating oil of your choice around where the return line goes into the injector. After that sits for a while, twist the return fitting back and forth as you pull out on them. The bore of the injector rusts above where the O-ring is on the return line and makes them difficult to remove.
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Removing the fuel injector bracket bolts
To remove the fuel injector bracket bolts, you will need to hold down the fuel injectors with brackets. If necessary, remove the fuel injector bracket pins. You should then remove and discard the copper washer from the fuel injector bore, as well as the O-ring from the fuel injector.
Before removing the fuel injector pipes, it is important to use compressed air to blow any debris from between the injector line and fittings. You should then wipe the fittings clean. Disconnect the negative battery cable, remove the fuel injector pipes, and then remove the fuel return hose clips.
Next, remove the fuel return hose from the injectors and disconnect the fuel injector electrical connectors. Take a small pry bar and place it underneath the hold-down bracket. Use this to pry up on the injector. Be careful not to break the plastic "T"s or lose any of the clips.
The LLY Duramax injectors are located outside the valve covers, so the task of replacing them is considerably easier and cheaper than on prior LB7 models. Typical LLY Duramax injector failure is high fuel return rates, which cause hard starting and rough running, especially noticeable at idle.
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Removing the fuel return hose clips
Before removing the fuel return hose clips, it is important to disconnect the negative battery cable and remove the fuel injector pipes. You should also use compressed air to blow any debris from between the injector line and fittings, and wipe the fittings clean.
To remove the fuel return hose clips, you will need to use a small pry bar to gently pry them up and off the fuel return hose. Be careful not to break the plastic "T"s or lose any of the clips, as these can be difficult and expensive to replace.
Once the clips are removed, you can then remove the fuel return hose from the injectors. This may require some force, as the bore of the injector can rust above where the O-ring is on the return line, making it difficult to remove. Spraying WD-40 or penetrating oil around the return line fitting before removal can help to loosen it.
After the fuel return hose is removed, you can then disconnect the fuel injector electrical connectors. Typical LLY Duramax injector failure is high fuel return rates, which cause hard starting and rough running, especially noticeable at idle. Poor quality fuel will also cause premature injector failure.
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Using compressed air to blow any debris from between the injector line and fittings
Before you begin the process of replacing your Duramax LLY fuel injectors, it's important to understand the common causes of injector failure. Typically, LLY Duramax injector failure is caused by high fuel return rates, which can lead to hard starting and rough running, especially when the engine is idling. Poor quality fuel can also contribute to premature injector failure.
Now, let's focus on the specific step of using compressed air to clear debris. Prior to removing the fuel injector pipes, it's crucial to ensure that the area between the injector line and fittings is free of any debris. To achieve this, use compressed air to blow away any dirt or residue. Once you've done this, wipe the fittings clean to ensure that all debris has been removed.
This step is important as it helps prevent any foreign objects or residue from entering the fuel system, which could potentially cause further issues or damage.
After completing this step, you can proceed to disconnect the negative battery cable and remove the fuel injector pipes, following the subsequent steps outlined in other guides or resources.
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Using a small pry bar to get the injectors out
Before you start, make sure you have the right tools for the job. You'll need a small pry bar, and it's also recommended to have compressed air, WD-40 or penetrating oil, and a clean cloth.
If the injector is difficult to remove, it may be due to rust above the O-ring on the return line. In this case, spray WD-40 or penetrating oil around the return line and allow it to sit for a while. Twist the return fitting back and forth as you pull out on it.
Before removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Wipe the fittings clean to ensure no debris gets into the fuel system.
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Frequently asked questions
Typical LLY Duramax injector failure is high fuel return rates, which cause hard starting and rough running, especially noticeable at idle.
The total cost to have a mechanic replace 8 injectors on an LLY Duramax can range from $3500 – $4500 CAD, depending on what other work is performed at the same time.
Prior to removing the fuel injector pipes, use compressed air to blow any debris from between the injector line and fittings. Then, disconnect the negative battery cable and remove the fuel injector pipes.
First, remove the fuel injector bracket bolts. Then, remove the fuel injectors with brackets. If necessary, remove the fuel injector bracket pins.
Poor quality fuel will cause premature injector failure. LLY injectors are located outside the valve covers so the task is considerably easier and cheaper than on prior LB7 models. The LB7 Duramax built from 2001 – 2004.5 is known for injector failure.
