Duramax injector warning

[S2V6RACER]

Just a heads up. The truck had been getting a little hard to get to fire for about 10k miles. Noticably when HOT and re-start. Last Sat it would not fire for about 10 seconds of cranking. Now at 38k, I took it to the dealer and all 8 injectors are being replaced. I have had the fuel filter changed at EVERY oil change interval. The injectors "were" on national backorder and they just got a new set Friday. I had to call GMC to get the scoop on why the parts were not available to fix thier truck. They said the injectors made by a "outsourced" company were ordered to stop production, that is why the backorder existed and the "new" injectors should have been there Friday ( I called they showed up at 1:30 PM ) and the truck will be done Tues. This makes 1 week 2 days out of service. She was unaware of any problems with the injector failure rate and I told here she had enough evidence in front of her nose. The injector warantee was extended to 7 year 200,000 miles for 01, 02 model years and now a cease of production order on the outsource company???

The new LLY engine has been in the dealer(s) for injector problems and I heard it is possible to strip the threads in the head and this happened at the dealer and they had to replace the head on the new "easier" to change the injectors LLY Duramax.

My conclusion is there are guys out there preaching pre-filters and they too are replacing injectors. Yes, there are 01's out there with in excess of 100,000 miles with no problems. I feel factory filtration is sufficient that is why no change in 4 years of production and the problem lies in "WHO" is making the injectors. Maybe multiple companies and problems from "select" companies, this is why the problem is so hit and miss. I wish they would fess up, but I guess there will never be a "recall" because it is not a saftey issue and warantee is keeping a lid on things for now.

I think is really is unacceptable, that they R&D'd this motor for 2 years and did not know of potential problems. I/we pay extra $$ for the diesel, so just charge a little more and make it more reliable.

Insult to injury is I am not going to make it to the track from lack of tow vehicle.

 

[bruce]

FWIW,

Now that the EPA has turned their attention to Diesels, and Diesel Fuel, I can only see a few years of troubles, as the co.s try to deal with ever changing EPA specs..

There is just no way to forcast what the EPA can mandate, so developement is at times likely to not be in synch with the infinite knowledge bank, that the EPA has.

Not to mention the Fuel suppliers wanting to milk all the profit out of the fuels they sell. So there might be even be problems associated with that.


My neighbor across the street had been told his Powerstroke needed a valve job, and it was going to be like $3,500 or some rediculous amount, and for grins took it to several shops. All agreed, until like the 5th one said, lemme try a crank sensor. $200 problem fixed.....

 

[Chuck Leeper]

ABSURD $$$

I'm really glad they issued the extension on the warranty!!!
Len Freeman had the failure on his way to BG this yr, when hauling John Gallina's car... Dlr told him it was $5400 to replace the injectors....
The "other" problem w/ the failure is it can/does fill the crankcase w/ diesel fuel... Then it's bye bye to the entire engine!!!
Ted, I'd keep a close eye on the oil filters to see if the brgs are going south!!

 

[3TURBOS]

If you want a quick fix, sell those problem Duramax and buy a Dodge Cummins. Injector problems with the Duramax is a given. Also be prepared for a week at the dealership when this happens.

 

[JC Turbo]

Ted A.

Do you have any paperwork for the extended warranty? I have an 01 GMC Duramax with bad injectors. The dealership said it would be from $3,000 to $4,300 to fix it. It currently has 109,000 and this is not the first set of injectors. They started by replacing the injectors one at a time, then they replaced all eight of them. But that was 50,000 miles ago. Any information you have would be great. If you have a service bulletin number or campain number or information that would help me greatly.



TIA
John

 

[Dan Buick Man]

Special Policy #04039. Covers '01 and '02 Duramax injectors for 7 years or 200,000 miles. Every Chevrolet/GMC dealer will be very familiar with it.

 

[disco stu]

This is a well known problem and has bbeen for years. That stock Racor is rated at 2 microns but independant testing shows it fall well short of that . I decided to try to prevent this by installing a Nicktane filter kit as soon as I bought my truck.

 

[S2V6RACER]

Re: ABSURD $$$

Originally posted by Chuck Leeper
I'm really glad they issued the extension on the warranty!!!
Len Freeman had the failure on his way to BG this yr, when hauling John Gallina's car... Dlr told him it was $5400 to replace the injectors....
The "other" problem w/ the failure is it can/does fill the crankcase w/ diesel fuel... Then it's bye bye to the entire engine!!!
Ted, I'd keep a close eye on the oil filters to see if the brgs are going south!!

Hey Chuck, I want some fuel in the pan for reserve if I need it.

Go to Thedieselpage.com message board if you want the latest gossip on GM diesels. This board is very imformative and proffesional.

 

[disco stu]

I like the thedieselplace.com.

It is like the whole TB.com vs ******** BS!

 

[efi-street]

Originally posted by 3TURBOS
If you want a quick fix, sell those problem Duramax and buy a Dodge Cummins. Injector problems with the Duramax is a given. Also be prepared for a week at the dealership when this happens.

Yep, then you just have to deal with the pump failures that the Cummins are prone to.

Knock on wood, my '01 HD has 110k on it with the original injectors.
For those interested, here is the text:
GENERAL MOTORS SPECIAL POLICY #04039

Listed below are some anticipated questions and answers to assist in responding to customer inquires.

Q1: What is the condition that prompted a Special Policy?
**: 2001-2002 model year Chevrolet Silverado and GMC Sierra vehicles, equipped with a 6.6L Duramax diesel (RPO LB7) engine, may experience vehicle service engine soon (SES) light illumination, low engine power, hard start, and/or fuel in crankcase, requiring injector replacement, as a result of high fuel return flow rates due to fuel injector body cracks or ball seat erosion.

Q2: What might occur as a result of this condition?
A2: Cracks to the fuel injector body or ball seat erosion may exist if the fuel return rate is high. Ball seat erosion is the result of small particles of contamination present in some fuels.

Q3: What is a "high fuel return flow?"
A3: The Duramax diesel utilizes a common rail fuel injection system, which incorporates fuel re-circulation provisions. A fuel return system normally returns unused fuel from the injectors to the fuel tank. Dealer technical diagnosis procedures include measuring the flow of fuel through the return system, with a specified maximum acceptable flow rate.

Q4: How would a vehicle owner realize the condition exits?
A4: If a customer experiences this issue, their vehicle would display some of the following symptoms: service engine soon light illumination, low power, hard start, and/or fuel in the crank case.

Q5: What can customers do to prevent this issue?
A5: This issue will not occur on all engines. If they experience the previously mentioned symptoms, they should take their vehicle to the dealership for service.

Q6: How is the issue resolved?
A6: If the customer experiences this issue, the dealership will make all necessary repairs to the engine. Dealers have been advised by a technical service bulletin to replace all eight injectors in the event of high fuel return flow diagnosis. This is being done to assure that all injectors prone to body cracks are replaced.

Q7: What is this special policy or warranty?
A7: The special policy is a 7-year/200,000 mile warranty on 2001 and 2002 MY Chevrolet Silverado and GMC Sierra pickup trucks equipped with Duramax engines, covering the repairs of a high fuel return flow diagnosis.

Q8: Is this special policy related to safety concerns?
A8: This is not a safety issue.

Q9: What is the standard Duramax warranty?
A9: There is a 5-year, 100,000-mile powertrain warranty on Duramax 6.6L V-8 diesel engines.

Q10: Does this policy include 2003 MY vehicles with the Duramax, RPO LB7?
**0: No.

Q11: What happens to a customer with a 2003 vehicle that experiences this problem?
**1: If the customer is within their 5-year/100,000-mile warranty, it will be covered. If the customer is out of warranty, and it is identified as the same issue, we will work with the customer on an individual basis to ensure their satisfaction.

Q12: Are you doing anything for customers who experienced this issue out of warranty?
**2: As part of this policy, GM will offer repair reimbursements to customers who believe they have experienced and repaired this issue on their own. GM's goal is a satisfied customer.

Q13: Does the new Duramax use the same fuel injectors?
**3: No. A new injector is used in the LLY engine.

Q14: How will GM Notify owners of the Special Policy of their vehicles?
**4: GM will send a letter to customers on June 1, 2004.

Q15: Are parts at the dealers, and can owners bring in their vehicles for repair right away?
**5: Yes. Parts are available on a limited basis at dealers.

Q16: What should a customer do if they suspect their vehicle has these fuel injector problems?
**6: If a customer experiences the described performance issue with their vehicle, they should immediately take it to their GM dealer to have the issue diagnosed.

Please contact the GM Dealer Business Center at 1-888-414-6322 (Prompt
#3) if you have questions about this message.

 

[WE4]

What about?

The 04 Duramax's.? Do they have the same issues?
I got a Sept of 04 Duramax Dually 3500 Chevy. Any problems there?
Bruce
WE4

 

[efi-street]

'04's should have the new LLY engine with the injectors external of the valve covers. I haven't heard of any problems with them yet. Should have LLY versus LB7 on your option sheet.

 

[S2V6RACER]

Truck still at dealer this morning. That makes 1 week 2 days. Injectors can only be ordered with corresponding VIN # of vehicle, at least that is what the service tech told me when I asked him why parts are not on the shelf.

 

[ronbuick]

early 04's will have the LB7 motor, later models will come with
LLY.

Ron

 

[LV GN]

Originally posted by Ted A.
Truck still at dealer this morning. That makes 1 week 2 days. Injectors can only be ordered with corresponding VIN # of vehicle, at least that is what the service tech told me when I asked him why parts are not on the shelf.

when i took john gallina's truck to dealer in bowling green. the service manager said he was sorry. but the truck would not be finshed till the next day. and it was. that was some good customer service! here in vegas the same injector swap would take at least 3 weeks

 

[Mease Performance]

damn

Yeah, got rid of my '03 because of this, had it for 2 months, F*(^%* ing injector pump went and pumped the motor full of diesel, back to GM it went they REPLACED THE (^^*(^*(^)*(&_*() pump....I told them they could keep the ^&^% truck, cause I wanted a motor...sold it shortly thereafter and bought a 97 vortec (which is now gettin ready to get a DFI cause ITS freakin injector went LOL) I cant win....BUY A POWERSTROKE, and dont get STROKED!!!

 

[LV GN]

Re: damn

Originally posted by Mease Performance
Yeah, got rid of my '03 because of this, had it for 2 months, F*(^%* ing injector pump went and pumped the motor full of diesel, back to GM it went they REPLACED THE (^^*(^*(^)*(&_*() pump....I told them they could keep the ^&^% truck, cause I wanted a motor...sold it shortly thereafter and bought a 97 vortec (which is now gettin ready to get a DFI cause ITS freakin injector went LOL) I cant win....BUY A POWERSTROKE, and dont get STROKED!!!

ford diesel's are junk and thank god for their transmission's! they keep my business going

 

[S2V6RACER]

Well, I got it back last night. The thing starts so fast now it scares me how fast it comes to life. I do have a slight idle surge that it did at 7k miles and went away. I think that was the time the injector $hit started.

I heard it is probably the regulator and in any case I can't imagine it taking to long to diagnose and repair.

 

[LV GN]

i had the idle surge in my 01 and it turned out to be the valve in the fuel regulator.

 

[S2V6RACER]

Originally posted by LV GN
i had the idle surge in my 01 and it turned out to be the valve in the fuel regulator.

Good news. Hopfully they don't have to order that part with the VIN# assigned to it also.