Tools needed: fuel line quick disconnect kit, can be the cheap plastic ones sold at the local parts store. Inspect the unit as well as the fuel tank and remove the offending particles or repair the separated pickup tube. The fuel sending/pickup unit will then need to be pulled out. Run the fuel level down as much as possible, then the tank will have to be dropped.
This is not a fun job but is not too difficult. The most common thing we see is the paper seals of diesel fuel additive. The common cause is a foreign object gets down the filler neck of the fuel tank. Remove the fuel line and find a suitable replacement at the local auto parts store, making sure the line is rated for diesel fuel. The fuel line can be replaced if the filter change doesn’t fix the problem. If not cracked, the problem is usually fixed by replacing the filter. This is usually caused from a plugged fuel filter causing a major vacuum between the filter head and the cp3.
#2004 DURAMAX FASS PUMP CRACKED#
Collapsing or cracked fuel line between the filter head and the high pressure fuel injection pump (c p3). You will need an 18mm wrench and a bench vise. sells the shim kit, including the proper parts needed to bring the spring pressure back to acceptable level to stop leaking relief valves. If any fuel is leaking past the fprv, then the internal spring will need to be shimmed. This can be tested by doing the “bottle test” This is an easy, cheap way to see if the fprv is leaking. Weak fuel pressure relief valve (fprv) for 2004.5-2010 model years. Common hand tools are all that is needed. sells an inexpensive rebuild kit complete with filter and instructions to repair this important part.The water separator screws into the bottom of the filter itself and must be replaced if cracked or damaged. Leaking fuel filter head, or cracked water separator.The filter head is the part that the fuel filter screws into and has the primer plunger incorporated into it.There are O-rings and seals that break down with age and use. When in doubt, change the filter! This is about a 30 minute job that can be done without any special tools. The filter should be changed in the 8,000-10,000 mile range if good fuel is being purchased and running mostly low HP tuning, much sooner if running competition/race style tuning. Dirty fuel filter is the most common issue we see when fuel rail pressure is low. May include one or all and not limited to Low power, poor shifting quality, excessive smoke, engine limp mode, reduced mpg. This may only happen in high fuel demand situations like towing or racing but it can also happen with everyday use. 
This is a very common problem that we hear about from our Duramax customers.Īctual fuel rail pressure is not keeping up with desired fuel rail pressure. Low rail pressure may or may not cause an MIL (check engine light). DTC P1093, P0087 causing limp mode is common with this issue.
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