2006 Chevy Duramax Fuel Filter

2006 Chevy Duramax Fuel Filter – The fuel filter and filter head on the 2001-2010 Chevrolet Silverado 2500HD and 3500HD trucks, along with the 2001-2010 GMC Sierra 2500HD and 3500HD, equipped with the Duramax diesel V-8 engine can be a point of concern for all owners. Since the trucks don’t have any sort of lift pump (which helps move fuel from the tank to the high-pressure injection pump), the filter head includes a built-in primer module. This aerator is used to draw fuel to the fuel filter in the event the filter is replaced or the system unexpectedly loses prime. Under normal circumstances this setup works perfectly well. However, as trucks age, the O-rings inside the filter head wear down and eventually leak.

The leak is bad for two reasons. First, fuel can escape and leave a mess to clean up (well, the risk of fire from diesel spills is relatively low). The second, and worse of the two, is that the filter head can draw air into the fuel system, which can cause a variety of problems from a no-start condition to high pressure injection pump (CP3) failure. Fortunately, rebuilding the filter head is relatively easy, and parts are cheap.

2006 Chevy Duramax Fuel Filter

Also, we decided it would be wise to install a fuel filter and CAT adapter from Sinister Diesel as well. The benefit of the CAT fuel filter is simple: Better filtration. While the factory filter is good for particles between 5 and 10 microns (depending on who you ask), the CAT unit cuts down to 2 microns. The CAT filter also works as a water trap, although it doesn’t have an outlet or sensor like the factory filter.

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The entire filter head rebuild process takes about two hours from start to finish. If you’re just installing the Sinister CAT fuel filter adapter, the job takes about 10 minutes. The rebuild kit from Merchant Automotive is about $25, while the Sinister CAT filter adapter will set you back about $150.

The fuel filter on the 2001 through 2016 Duramax engine is located toward the rear of the engine with the passenger side vacuum cover attached. It’s hard to see with the engine fully dressed, but the front button on the top is a dead giveaway of what you’re looking at (along with the big white filter hanging from the bottom). Engines built from 2001 to 2010 used the same filter housing; Minor changes have been made to the 2011, 2016, and 2017 models. However, they all do the same thing in principle.

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When we bought our project, a 2002 Chevrolet Silverado 2500HD, the engine fell apart. Therefore, we found most of the accessory parts on the back, including the filter head. Also, since our truck was originally a “California” LB7, meaning it has exhaust gas recirculation (EGR) and a vacuum pump, our filter head hosted a set of sensors and vacuum tubes.

To clean things up a bit, we removed and replaced all the extra sensors and chips. One wire left on the filter housing goes to the fuel heating element located inside the unit.

Duramax Fuel Filter Head Delete Bypass Tube

To rebuild our filter head, we went to Merchant Automotive and picked up the company’s O-ring kit for 2001-2010 engines. The kit includes everything needed to reseal the filter head, including the primer pump.

Disassembling and re-installing the filter head is very easy. The primer housing is removed with three screws, and the heating element is secured with two. Once disassembled, replace the O-rings and reassemble. Merchant Automotive has an excellent video on their website (and YouTube) that demonstrates this in detail.

While we were working on the filter head, we also changed the other most problematic part, the reader cover. From the factory, this scale is made of plastic. After several years of use, it can become brittle and brittle. We replaced it with a Merchant Automotive aluminum cover.

The Sinister Diesel CAT fuel filter adapter kit is very simple. It uses a billet aluminum adapter, made right here in the USA, to adapt the wires from the factory AC Delco filter to those of the CAT filter. Since the kit is good for 2001-2016 trucks, it also comes with a longer spacer and bolts that move the filter head out of the cylinder head for better cleaning for 2011-2016 trucks.

Duramax Fuel Filter Housing Fuel Filter Replacement For A Duramax For Gmc

Reinstalling the filter head begins by screwing the mounting screw onto the valve cover. You probably had to remove yours to perform the rebuild, so this part is a review (unless yours got a kink in the cable, like ours).

Then, the top of the filter can be attached to the band. To make things easier, we screwed the new Sinister Diesel CAT fuel filter adapter onto the top of the filter before we installed it in the truck. When installing the adapter, a little grease on the O-ring will help keep it out of the connector.

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The CAT Filter Adapter comes anodized in Sinister’s trademark blue color, which adds a nice sheen to the engine bay.

We rebuilt the fuel filter housing by replacing all the fuel feed hoses from the housing to the housing as well. Ignore the road groove on the filter – we’re still not working on internal waveguides. The Duramax is an excellent diesel, but it does have its drawbacks, and a leaking fuel filter assembly is one of them.

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A common problem with 2001-2010 Duramax trucks is that the fuel filter head assembly begins to develop air leaks. The engine’s CP3 high-pressure fuel pump can draw from the tank without the aid of an external lift pump as long as the system remains intact. With age as well as the use of ULSD and bio-diesel fuels, the O-rings in the filter head assembly can begin to allow air to bleed into the system, causing the fuel system to fail. If this is the case for you, it may be time for a fuel adjustment.

Early signs of a leak include prolonged jerking after the truck has been sitting for long periods of time as well as the engine starting and then dying. As the problem worsens, the truck may be unable to restart without manually turning it on when parked on an incline. External fuel leaks can also develop, and will be indicated by fuel puddles on the floor or on the filter assembly.

If you have a high-mileage Duramax powered truck and suspect it’s losing traction, or you’ve seen evidence of fuel leaking from the filter head, you’ll want to address the problem as soon as possible. Your GM dealer will most likely recommend replacing the entire assembly, but the Merchant Automotive team has better (and less expensive) solutions: they’ve developed several repair kits that require only hand tools and basic mechanical skills. Kits start at about $20 for replacement rings and for the Master Filter Head Kit that includes new O-rings, a billet aluminum water-in-fuel (WIF) plug, a billet aluminum filter head replacement kit, includes a billet aluminum filter head, comes to around $100. aluminum intake manifold cover and an OEM replacement fuel filter.

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Remember, this is an overview of the process; if you have any questions about the specifications you can consult the team at Merchant Automotive or your local diesel performance shop. You can also watch a video of the process on the Merchant Automotive website. If you plan to rebuild the filter assembly yourself, set aside a few hours and be sure to practice safe shop techniques. After rebuilding and reinstalling the filter assembly, you will need to flush the fuel system before starting the truck. Prime the system by pumping the primer coat several times until it is dry, and then start the engine. After starting, perform a thorough check for fuel leaks before driving the truck.

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The billet aluminum parts look good in the Master Kit, but they’re not just for looks. A billet aluminum casting cap replaces the factory-installed plastic bleeder cap, which is flimsy and prone to chipping and breaking. The water-in-fuel replacement part replaces the factory part with its easily broken cap, and places the filter assembly an extra 3/8-inch away from the engine to make it easier to replace. All billet aluminum parts are black anodized for durability and good looks, and they feature a laser-etched MA logo. You can rebuild your fuel filter assembly without the billet parts, but we think the complete kit is a wise investment.

We followed along with shop technician Jake Phaff as he rebuilt the filter head on a customer’s LB7 Duramax. Phaff removed the filter assembly, rebuilt it and reinstalled it within an hour, despite our typical photography slowness. Check out the next few pages to see the basics of Phaff rebuilding the filter head assembly. DW

1. The Merchant Automotive Master Filter Kit includes everything seen here as well as a new OEM fuel filter.

2. Meeting the filter on this

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