Working on any automobile engine can be intimidating, and that is the very reason why mechanics stay in business, However some tasks that seem intimidating are not actually that difficult if you have the right tools and the right knowledge to complete the task at hand,
The following instructions are on how to remove LB7 Duramax Fuel Injectors. This task is often considered a difficult process to complete, but these instructions will break down the process and make this task seem simple.
GMC or Chevrolet Pick-up Truck
debris,use a bucket and a cloth for a filter.
While the coolant is draining, disconnect the battery. This action will prevent any damage to your ECM of modules.
Using a fan belt tool of 1/2 drive ratchet, remove the tensioner pulley nut on the passenger side of the engine
Then, remove the A/C condenser and fold the condenser by placing it on top of the passenger side battery, There is no need to evacuate the A/C
Next, you will need to remove the water thermostat and coolant neck, We recommend replacing the thermostats at this point. we suggest using OEM thermostats.
You will now need to remove the Fuel injection Control Module (FICM) from the engine so you can easly wor under the valve covers. slide the plastic tabs outwards to remove the FICM. Slide the tabs inward to install it back.
Remove the Glow Plug Harness
With the FICM removed, you should remove the Glow Plug Harness next suing a 8mm Ratchet Wrench. There will be 4 nuts on each side of the heads. Be patient. This part is tedious work.
Remove the Fuel Line
Now, remove the fuel lines with a fuel line disconnect tool, (You can purchase this tool at any automotive or hardware store for around $10 - $15 Dollars)
Tip: Use a pry bar to push the valve cover up of hit it with a rubber hammer to loosen it up.
Caution: Be careful no to lose the 4 bolts of the harness at the bottom of the oil pan.
For this step, remove the lower valve cover with a 5mm Allen Wrench. Be sure to take your time with this removal. Also,clean the outside of the valve cover with a shop vacuum so that you don't get dirt in the heads.
Now that you've removed the lower valve cover, you will need to remove the fuel return line using a 5mm Allen Wrench.
Tip: When reinstalling this item, make sure you only use 10 lb of torque. Also, do not use the old banjo bolts with the reinstallation. By new bolts and don't cheat yourself or the engine.
The fuel line will have a 12 mm bolt o each side of the head, Remove these bolts and be careful, when you find a Banjo washer, don't loose it, but also don't reuse it. Buy a new one for the reinstallation.
In this step, you've finally reach the fuel injector. The fuel injector will have a Injector Hold Down, and you will need to use a 8 mm Allen Wrench to remove the bolt.
Tip: When reinstalling the fuel injector torque to 45 lbs of torque, the injector hold down.
Tip: The small pry bar used in this picture can be purchased from your local parts house or you can obtain this from a automotive or hardware store for a reasonable price.
This is the fuel injector cup. Don't worry if the cup has come out of the head just make sure you replace the injector cup with a new one. The cost of the cup is about $35 and 2 o'rings at $2.50 each.
Tip: Make sure when you install The new injector cup that you used red loctite on the tip of the cup for better sealing.