Duramax Engine Failure-Engine Filled With Deisel

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Everyone is quick to jump on GM. I have real world experience with diesels as a manufacturers rep. Injectors rarely "fail". They become contaminated with dirt or water or are overstressed by "hot boxes". In either case, the injector overfuels the cylinder causing a meltdown in a cylinder or leaks, allowing fuel into the sump. Neither of these situations should be covered by a warranty as the injector is not defective. This is a passionite issue with owners because it is very expensive to repair/replace a diesel engine. My 2 cents to diesel owners. Do not mess with the operating parameters of your engine. It produces plenty of power in stock form. Regardless of what the hot box manufacturers say, they are the death of injectors. Secondly, be religious in the maintenance of your fuel system. Drain the filter housing regularly, replace your filter regularly, use only clean fuel from reputable sources, do not use fuel from an aux tank, they are nortorious for being full of dirt,rust and water. Last, contrary to popular opinion, do not let your engine for extended periods. If it must idle for more than several minutes, shut it down. Idleing is hard on injectors.
 
Originally Posted By: Raceman
Everyone is quick to jump on GM. I have real world experience with diesels as a manufacturers rep. Injectors rarely "fail". They become contaminated with dirt or water or are overstressed by "hot boxes". In either case, the injector overfuels the cylinder causing a meltdown in a cylinder or leaks, allowing fuel into the sump. Neither of these situations should be covered by a warranty as the injector is not defective. This is a passionite issue with owners because it is very expensive to repair/replace a diesel engine. My 2 cents to diesel owners. Do not mess with the operating parameters of your engine. It produces plenty of power in stock form. Regardless of what the hot box manufacturers say, they are the death of injectors. Secondly, be religious in the maintenance of your fuel system. Drain the filter housing regularly, replace your filter regularly, use only clean fuel from reputable sources, do not use fuel from an aux tank, they are nortorious for being full of dirt,rust and water. Last, contrary to popular opinion, do not let your engine for extended periods. If it must idle for more than several minutes, shut it down. Idleing is hard on injectors.


Raceman,

Good points on diesel power boost risks and the need for proper maintenance … I heartily agree!

However, in the case of the early LB7 Duramax there is a known deficiency in the Bosch HPCR injectors. Due to this flaw GM has extended the warranty to 200Kmi/7yrs. Many Dmax owners who have well-maintained, stock trucks still have problems with injectors. Many of these folks have also added supplemental filtration.

Here’s a snip from the latest customer letter GM is sending out.

“November 2007 Bulletin No.: 04039B
Dear General Motors Customer:
As the owner of a 2001-04 model year Chevrolet Silverado; GMC Sierra or 2003-04 Chevrolet Kodiak; GMC TopKick vehicle, your satisfaction with our product is very important to us.This letter is intended to make you aware that some 2001-04 model year Chevrolet Silverado, GMC Sierra; 2003-04 Chevrolet Kodiak and GMC TopKick vehicles, equipped with a 6.6L Duramax Diesel engine, may have a condition where the engine fuel injectors may require replacement because of high fuel return rates due to fuel injector body cracks, or ball seat erosion, or high pressure seal extrusion. Symptoms of these conditions include illumination of the service engine soon (SES) light, low engine power, hard start, and/or fuel in the crankcase. Do not take your vehicle to your GM dealer as a result of this letter unless you believe that your vehicle has the condition as described above. General Motors is providing owners with additional protection for the fuel injectors. If this condition occurs on your 2001-04 model year Chevrolet Silverado, GMC Sierra; 2003-04 Chevrolet Kodiak or GMC TopKick vehicle within seven (7) years of the date your vehicle was originally placed in service or 200,000 miles (320,000 km), whichever occurs first, the condition will be repaired for you at no charge. Diagnosis or repair for conditions other than the condition described above is not covered under this special coverage program.”
 
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