Duramax Diesels Forum Truck of the Week
  #1  
Old 10-03-2007, 10:29 AM
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Default Injector Nozzle R&R:

Put injector in a vise and grip on the .375" wide slots in the injector body. Do not over-tighten, just snug. Use a 6-pt high quality deep socket (15mm) to LOOSEN the retaining cap. It is Mucho Tighto.
Attached Images
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File Type: jpg DSC00013.JPG (61.2 KB, 497 views)
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2005 GMC 2500HD LLY "Casper"- LLY O/S 8758. 10.59 @ 129. EFILive "2CP3" Tuning, Mike L Suncoast Trans. PPE Dual CP3's, GT4202R.
2004.5 GMC 3500 SRW LLY "Big Blue" - LLY O/S 1668. 13.12@103. Powered by PPE/VA with Mike L Suncoast Trans.
2006 GMC 2500HD CC/SB LBZ "Wendy"- LBZ O/S 6128. 12.50 @ 107.x. EFILive tuning, Mike L trans.
Pat and Kat McSwain
"Casper" - Record Holder, Bonneville & El Mirage. Best Clocked Speed 197mph, Bonneville '09.
"World's Fastest Production Diesel Pickup - 174.586mph"

Last edited by McRat; 10-03-2007 at 10:35 AM.
  #2  
Old 10-03-2007, 10:44 AM
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Now you will hold the injector vertical in a clean area and unscrew the retaining cap. The injector nozzle will stay put on the end since it's sitting on two locator pins.

Sometimes the needle will want to stay on the injector body. LET IT. If the injector nozzle and needle do not lift together as a pair without the sleeve coming with it, get tweezers and hold the needle in place while lifting the nozzle body.
Attached Images
File Type: jpg DSC00017.JPG (61.2 KB, 464 views)
File Type: jpg DSC00018.JPG (59.9 KB, 455 views)
File Type: jpg DSC00019.JPG (33.3 KB, 510 views)
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2005 GMC 2500HD LLY "Casper"- LLY O/S 8758. 10.59 @ 129. EFILive "2CP3" Tuning, Mike L Suncoast Trans. PPE Dual CP3's, GT4202R.
2004.5 GMC 3500 SRW LLY "Big Blue" - LLY O/S 1668. 13.12@103. Powered by PPE/VA with Mike L Suncoast Trans.
2006 GMC 2500HD CC/SB LBZ "Wendy"- LBZ O/S 6128. 12.50 @ 107.x. EFILive tuning, Mike L trans.
Pat and Kat McSwain
"Casper" - Record Holder, Bonneville & El Mirage. Best Clocked Speed 197mph, Bonneville '09.
"World's Fastest Production Diesel Pickup - 174.586mph"

Last edited by McRat; 10-03-2007 at 10:47 AM.
  #3  
Old 10-03-2007, 11:04 AM
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Here's the problem, there is a little shim that rides between the actuator shaft in the injector body and the nozzle needle and is captured by a sleeve that rides halfway in the injector body and the nozzle.

Normally this shim just sits on the actuator shaft inside the sleeve and stays with the injector body, then life is simple.

But when the sleeve sticks to the needle or the shim sticks to the needle, you need to be very careful. The goal is to just remove the needle and nozzle ONLY from the top of the injector.
Attached Images
File Type: jpg INJECTassy.JPG (58.1 KB, 561 views)
File Type: jpg INJECTSpacer.JPG (47.0 KB, 411 views)
File Type: jpg INJECTneedle.JPG (44.3 KB, 407 views)
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2005 GMC 2500HD LLY "Casper"- LLY O/S 8758. 10.59 @ 129. EFILive "2CP3" Tuning, Mike L Suncoast Trans. PPE Dual CP3's, GT4202R.
2004.5 GMC 3500 SRW LLY "Big Blue" - LLY O/S 1668. 13.12@103. Powered by PPE/VA with Mike L Suncoast Trans.
2006 GMC 2500HD CC/SB LBZ "Wendy"- LBZ O/S 6128. 12.50 @ 107.x. EFILive tuning, Mike L trans.
Pat and Kat McSwain
"Casper" - Record Holder, Bonneville & El Mirage. Best Clocked Speed 197mph, Bonneville '09.
"World's Fastest Production Diesel Pickup - 174.586mph"
  #4  
Old 10-03-2007, 11:09 AM
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When reassembling, you will notice that the two locating pins are offset. Line up the nozzle/needle to these and put in on. It will "float" about .06" above the body if the shim is in correctly. It will be under spring tension of the actuator for that .06".

Screw cap on finger tight, you should not see threads if done right. Put it back in the vice and grab the .375" flats again. I do not have a torque spec, but they stop rotating at about 50ftlb, which is what I used.
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2005 GMC 2500HD LLY "Casper"- LLY O/S 8758. 10.59 @ 129. EFILive "2CP3" Tuning, Mike L Suncoast Trans. PPE Dual CP3's, GT4202R.
2004.5 GMC 3500 SRW LLY "Big Blue" - LLY O/S 1668. 13.12@103. Powered by PPE/VA with Mike L Suncoast Trans.
2006 GMC 2500HD CC/SB LBZ "Wendy"- LBZ O/S 6128. 12.50 @ 107.x. EFILive tuning, Mike L trans.
Pat and Kat McSwain
"Casper" - Record Holder, Bonneville & El Mirage. Best Clocked Speed 197mph, Bonneville '09.
"World's Fastest Production Diesel Pickup - 174.586mph"
  #5  
Old 10-03-2007, 11:15 AM
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Do not "mix and match" injector needles and nozzles.

PN for the Bosch nozzle/needle assy is:

0 433 171 860 -0B0

DLLA 158 P 1385


This is for LLY, NOT LBZ.
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2005 GMC 2500HD LLY "Casper"- LLY O/S 8758. 10.59 @ 129. EFILive "2CP3" Tuning, Mike L Suncoast Trans. PPE Dual CP3's, GT4202R.
2004.5 GMC 3500 SRW LLY "Big Blue" - LLY O/S 1668. 13.12@103. Powered by PPE/VA with Mike L Suncoast Trans.
2006 GMC 2500HD CC/SB LBZ "Wendy"- LBZ O/S 6128. 12.50 @ 107.x. EFILive tuning, Mike L trans.
Pat and Kat McSwain
"Casper" - Record Holder, Bonneville & El Mirage. Best Clocked Speed 197mph, Bonneville '09.
"World's Fastest Production Diesel Pickup - 174.586mph"
  #6  
Old 10-03-2007, 11:37 AM
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MAXLLY MAXLLY is offline
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Smile

Very Cool, I just went to school. I love information.

Thanks Pat.
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Still tuned by a REDNECK TEXAN
  #7  
Old 10-03-2007, 01:13 PM
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Thank u pat.
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  #8  
Old 02-06-2009, 02:52 PM
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ttt...
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2005 GMC 2500HD LLY "Casper"- LLY O/S 8758. 10.59 @ 129. EFILive "2CP3" Tuning, Mike L Suncoast Trans. PPE Dual CP3's, GT4202R.
2004.5 GMC 3500 SRW LLY "Big Blue" - LLY O/S 1668. 13.12@103. Powered by PPE/VA with Mike L Suncoast Trans.
2006 GMC 2500HD CC/SB LBZ "Wendy"- LBZ O/S 6128. 12.50 @ 107.x. EFILive tuning, Mike L trans.
Pat and Kat McSwain
"Casper" - Record Holder, Bonneville & El Mirage. Best Clocked Speed 197mph, Bonneville '09.
"World's Fastest Production Diesel Pickup - 174.586mph"
  #9  
Old 02-06-2009, 04:09 PM
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Is this just for injector maintanence?
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  #10  
Old 02-06-2009, 04:12 PM
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No, for those who want to put in different/bigger nozzles.
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2005 GMC 2500HD LLY "Casper"- LLY O/S 8758. 10.59 @ 129. EFILive "2CP3" Tuning, Mike L Suncoast Trans. PPE Dual CP3's, GT4202R.
2004.5 GMC 3500 SRW LLY "Big Blue" - LLY O/S 1668. 13.12@103. Powered by PPE/VA with Mike L Suncoast Trans.
2006 GMC 2500HD CC/SB LBZ "Wendy"- LBZ O/S 6128. 12.50 @ 107.x. EFILive tuning, Mike L trans.
Pat and Kat McSwain
"Casper" - Record Holder, Bonneville & El Mirage. Best Clocked Speed 197mph, Bonneville '09.
"World's Fastest Production Diesel Pickup - 174.586mph"
  #11  
Old 02-06-2009, 06:05 PM
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What ever you do, do not lose that shim... All in all, swapping tips is a easy job, 5 out of 10 job for skill level. Make sure you have a super clean work area, a good can of carb cleaner to clean out the tip nut and do not have any distractions while you are exchanging them. We also torque to 50 ft/lbs.

We use a Dynomite Diesel tool to hold the injector body in place. If you order from Dynomite or a Dynomite Dealer, they will send this tool with the nozzels.
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  #12  
Old 02-06-2009, 07:20 PM
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Nice use for a set of parallels Pat!
  #13  
Old 02-06-2009, 07:40 PM
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a couple years ago, i took some LBZ injectors..and lost that stupid shim, BUT the good news, the injectors where screwed and going in for cores anyhow! LOL
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Last edited by turbo-max; 02-06-2009 at 07:40 PM.
  #14  
Old 02-06-2009, 07:53 PM
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Timely resurrection for this thread. I need to disassemble mine to fix the leaks.


  #15  
Old 02-07-2009, 12:40 PM
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Quote:
Originally Posted by Alligator View Post
What ever you do, do not lose that shim... All in all, swapping tips is a easy job, 5 out of 10 job for skill level. Make sure you have a super clean work area, a good can of carb cleaner to clean out the tip nut and do not have any distractions while you are exchanging them. We also torque to 50 ft/lbs.

We use a Dynomite Diesel tool to hold the injector body in place. If you order from Dynomite or a Dynomite Dealer, they will send this tool with the nozzels.
Why not
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