Welcome!GM Duramax 6.6L

Diesel Operation and Diagnostics

Introduction

Tony Salas- Performance Automotive Techniques Master ASE Certified Home Based: Las Vegas, Nevada Training provider for dealers, independent shops

and fleet shops Other classes instructed are: Electrical,

electronics, A\C, 6.5 L Diesel, Gasoline Fuel Injection, Powerstroke 7.3L & 6.0L, Body, SIR Airbag, transmission control

COURSE OBJECTIVES

Upon completion of the course the student will be able to: Recognize major features and benefits of the Duramax 6600 Diesel

engine Identify important maintenance items Describe the mechanical features of the Duramax 6600 Diesel engine Describe lubrication system components and operation Identify cooling system components and describe their operation Explain turbocharger assembly components and their operation Describe the electric air heater system Explain the charge air cooler purpose Identify fuel system components and their operation Perform a fuel quality test on diesel fuel Perform fuel-related data parameter monitoring with the scan tool Identify injector replacement procedures

Duramax 6.6L

2001 Model Year released New Body Silverado 2004 Chevrolet HD with a 6.5L First Generation LB7 December of 2003 was the last LB7 Sept 2003-Model 2004 January of 2004 the LLY released 2005 LBZ 2006 models 2006 Savanna and the Express Vans LLY later in 07

to LMM

COURSE OBJECTIVES

Upon completion of the course the student will be able to: Perform fuel system diagnosis as it relates to service information Test the glow plug circuit of the Duramax engine Describe the electronic components and operation of the fuel system Perform a fuel pressure regulator control test and an injector balance

test using a scan tool Identify components related to engine management Test inputs and outputs of the engine management system Describe the engine management supporting inputs and outputs,

and explain their function Locate service information related to the Duramax engine Identify elements of Strategy Based Diagnostics (SBD) Use an On-Board Diagnostic System Check to perform diagnostics

DURAMAX 6600 DIESEL ENGINE

DURAMAX POWER OUTPUT

2004 Revised Duramax

EGR

Stainless Steel Cooler

DURAMAX 6600 SPECIFICATIONS

DURAMAX 6600 SPECIFICATIONS

FLUID CAPACITIES/FILTER INFO.

OIL TEMPERATURE RANGE

DEEP SKIRT BLOCK

OIL PANS

UPPER OIL PAN

LOWER OIL PAN

FRONT ENGINE COVER

J 37228Seal Cutter

FRONT OF ENGINE GEARS

FUEL PUMP GEAR

CMP GEAR

CKP GEAR

FLYWHEEL HOUSING

COOLANT PASSAGES ADAPTER

CRANKCASE

# 5 THRUST BEARING

MAIN BEARING CAPS

CROSS BOLTS

PISTON RINGS

COMPRESSION RINGS

EMPTY GROOVE

OIL RING

PISTON

BOWL SHAPE

PISTON COOLING JETS

COOLINGJETS

COOLING JET OPERATION

FRACTURED ROD END CAP

FRACTURE

FOUR VALVES PER CYLINDER

VALVE INSERT

VALVE SEAT INSERT

HEAD GASKET SPECIFICATIONS

SERVICE HEAD GASKETS

“A”“B” “C”

VALVE BRIDGE

VALVE BRIDGE

INJECTOR

ROLLER LIFTER

OIL PUMP

OIL PUMP

OIL PRESSURE REGULATOR

OIL COOLER ASSEMBLY / OIL FILTER

OIL FLOW

WATER PUMP

THERMOSTAT HOUSING

REAR THERMOSTAT

FRONT THERMOSTAT

THERMOSTAT

BYPASS COOLANT PORT

TURBOCHARGER BYPASS VALVE

BYPASS VALVE

DURAMAX COOLING SYSTEM

DURAMAX COOLING SYSTEM

AIR CLEANER RESTRICTOR INDICATOR

INTAKE AIR HEATER ELEMENT

IAH

TURBOCHARGER

Relay

ControlControlCoilCoilLow CurrentLow Current

SwitchSwitch

TURBOCHARGER BYPASS VALVE

BYPASS VALVE

WASTEGATE CONTROL

TURBOCHARGER AIR FLOW

FROM FROM ENGINE ENGINE EXHAUSTEXHAUST TO CHARGE TO CHARGE

AIR COOLERAIR COOLER

FILTEREDFILTEREDFRESH AIRFRESH AIR

WASTEGATE ACTUATOR

TURBOCHARGER OIL RETURN LINE

Variable Nozzle Turbocharger

Rack and Pinion Design

Sensor and Actuator

Operation of the vaneControl enables the theECM to monitor postionOf the actuator.

CHARGE AIR COOLER

RADIATOR

CHARGE AIR COOLER

CONDENSER

DURAMAX AIR FLOW

EGREGR

Crankcase VaporsCrankcase Vapors

GLOW PLUGS

GLOW PLUGS

GLOW PLUG CKT (Federal)

780-875-7925 Alvin780-875-7925 Alvin

CRANKCASE VENTILATION COMPONENTS

SPRING, DIAPHRAGM AND COVERTO VALVE ROCKER ARM COVER

OIL SEPARATOR ASSEMBLYSPRING, DIAPHRAGM AND COVERTO VALVE ROCKER ARM COVER

OIL SEPARATOR ASSEMBLY

DURAMAX FUEL SYSTEM

LLY Common Fuel Rail

LMM

New Fuel Rail Plumbing

FUEL CAP

FUEL TANK

FUEL TANK

FUEL BALANCE PUMP

FUEL PUMP RELAY CIRCUIT

FUEL SENDING UNIT

FUEL LEVEL SENSOR CIRCUIT

FUEL SUPPLY LINE FITTINGS

BANJO FITTINGS

QUICK-CONNECT FITTING

FICM

FUEL FILTER

FUEL FILTER ASSEMBLY

WATER-IN-FUEL SENSOR

HAND PUMP

HEATER

FILTER

WATERRESERVOIR

PETCOCK

HAND PRIMER AND VENT SCREW

WIF SENSOR REMOVAL

FUEL INJECTION PUMPLOW PRESSURE(SUCTION) FEED

HIGHPRESSURE

OUTPUTFUEL RAIL PRESSUREREGULATOR (FRPR)

FUEL SUPPLY GEAR PUMP

HIGH PRESSURE PUMP AND FUEL PRESSURE REGULATOR

HIGH PRESSURE PUMP

FUEL PRESSURE REGULATOR

SUPPLY PUMP

HIGH PRESSURE PUMP

PUMP PLUNGER OPERATION – INTAKE STROKE

INTAKE VALVEINTAKE VALVE

PUMP PLUNGER OPERATION – DELIVERY STAGE

OUTLET VALVEOUTLET VALVE

FRPR

JUNCTION BLOCK

FUEL PRESSURE RELIEF VALVE

FUEL PRESSURE SENSOR

FUEL RAIL PRESSURE SENSOR

FUEL PRESSURE RELIEF VALVE

FUEL RAIL

HIGH PRESSURE LINES

FUEL INJECTOR

FUEL PULSES

INJECTOR INTERNAL VIEW

Coil

Ball and seat

Nozzle

INJECTOR HARNESS

FUEL RETURN LINE REMOVAL

FUEL INJECTOR REMOVAL

J 44639 FUEL INJECTOR REMOVER

RETURN LINES AND BANJO FITTINGS

RETURN LINE

BANJO FITTING

FUEL COOLER

FUEL COOLER

FUEL LINES

SUPPLY LINES

FUEL LINES

FUEL LINES

HIGH PRESSURE LINES

FUEL LINES

RETURN LINES

FUEL LINES

HIGH PRESSURE LINES

SUPPLY LINES

RETURN LINES

ENGINE CONTROLS

14.7 psi at sea level

Baro-KPA (low pressure was measured in inches of mercury (hg)

100 kpa-14.7psias atltitude rises, pressure drops

20psi turbo boost (over atmospheric)34.7psi130kpa

14.7psi14.7psi

hghg

100kpa100kpa

Baro hg/2=psiBaro hg/2=psi

BATBAT

GroundGround

ECMECM

13.4volts13.4voltsdisconnecteddisconnected

BAT=? 13.4 voltsBAT=? 13.4 volts

11.2 volts11.2 voltsconnectedconnected

ECM

Worksheets and Exercises

Exercise #2 Glow Plug Circuit pg 8 Group 1 Exercise #3 Fuel System Diagnosis pg12 Group 2 Exercise #4 Scan tool data pg14 Group 3 Worksheet #4 Scan Data pg17 Group 4 Exercise #6 Injector Replacement pg 22 Group 5 Exercise #7 Special Functions pg 23 Worksheet#9 FRP Sensor Graphing

ECM COMMUNICATION

FICM

FICM CIRCUIT

FICM DRIVERS(one bank shown)

INJECTOR GROUPS

ECT SENSOR

ECT SENSOR

ECT VOLTAGE vs. TEMPERATURE

MAF

MAF/IAT SENSORS

IAT

MAF

MAF/IAT CIRCUITS

BAROMETRIC SENSOR

BARO SENSOR

BARO/BOOST SENSOR CIRCUITS

BOOST SENSOR

BOOST SENSOR

FUEL RAIL PRESSURE SENSOR

FUEL RAIL PRESSURE

SENSOR

FUEL RAIL PRESS. SENSOR CKT.

FUEL TEMPERATURE SENSOR

FUEL TEMP. SENSOR

CKP SENSOR

CKP SENSOR

CKP RELUCTOR

CKP SENSOR CIRCUIT

NN

CMP SENSOR

CMP SENSOR

CMP RELUCTOR

CMP SENSOR CIRCUIT

ACCELERATOR PEDAL POSITION SENSOR

APP SENSOR

APP SENSOR OPERATION

APP SENSOR CIRCUIT

VEHICLE SPEED SENSOR

VSS CIRCUIT

OIL LEVEL SENSOR

OIL LEVEL SENSOR

OIL LEVEL SENSOR CIRCUIT

PASSLOCK CIRCUIT

FUEL RAIL PRESSURE REGULATOR

FRPR

FRPR CIRCUIT

INJECTORS

INJECTOR CIRCUIT

FICM FUNCTION

GLOW PLUGS

GLOW PLUG CKT (Fed.)

GLOW PLUG CKT. (Cal.)

INTAKE AIR HEATER (IAH)

IAH CIRCUIT

COMPRESSOR CONTROLS

DURAMAX DIESEL EGR

POWER TAKEOFF (PTO) CIRCUIT

STRATEGY BASED DIAGNOSTICS

Diagnostic Process

Verify Complaint “Open the hood!” Visual Diagnostic Circuit Check Check Bulletins! And Preliminary Information Check DTC’s? Status? DTC info! Fuel System: AIR, suction, balancing rates (4 idle, 6 in drive) OIL? Check for fuel! Check cylinder power balance test. Return Volume test. Compare one side to the other side Check volume on each injector! Keep in mind at the Pressure limiting valve Pressure Regulator Test

ALLISON 1000 TRANSMISSION

TRANSMISSION POSITON SENSOR

Gear Range C1 C2 C3 C4 C5 TCC

Park/Neutral -- -- -- -- X --

Reverse -- -- X -- X --

First X -- -- -- X --

Second X -- -- X -- X

Third X -- X -- -- X

Fourth X X -- -- -- X

Fifth -- X X -- -- X

RangeLine

Pressure @ 600 RPM

Line Pressure @ 2100 RPM

Forward Converter (Torque Converter Clutch not

applied)

700-1380 kPa

(101-200 PSI)

1515-1795 kPa

(220-260 PSI)

Forward Lockup (Torque Converter Clutch applied)

N/A1000-

1170 kPa (145-170 PSI)

Reverse700-

1380 kPa (101-200 PSI)

1515-1795 kPa

(220-260 PSI)

Neutral/Park800-

1655 kPa (130-240 PSI)

1515-1795 kPa

(220-260 PSI)

If you are experiencing harsh shifts, it is important to verify whether the particular shift is converged. Use the Scan Tool to determine if the problem shift is converged.

•If it is not, the TCM is still learning how to adapt that shift, and simply needs to be driven a bit more with the intention of performing more of the particular type of shift. •If a particular shift is converged, but still objectionable, it's good troubleshooting practice to reset the adaptive values for that shift back to base calibration level. This will automatically reset the TCM to fast adaptive mode. The vehicle should then be driven to allow the TCM to "re-learn" the shift. Many times this will correct the problem. It is possible to reset individual shifts without affecting the other shifts.

Transmission Diagnostics

Check fluid(engine running) Check selector valve and switching (P,R,N,D,L) Turn engine on. Drive vehicle check all gear ratios Check gear ratios under all loads If shift quality issue, clear the TAP If transmission is serviced or changed out, reset

all TAPS.

In general, FastLearn is a procedure for Allison 1000 Series transmissions in which a series of tests are run to allow the Transmission Control Module (TCM) to "learn" individual clutch characteristics. Once the clutch data is learned, FastLearn translates it to the adaptive data cells, which the TCM uses for clutch control during range shifts. FastLearn is used at GM assembly plants and allows the vehicle to be driven out of the assembly plant in a near-fully-adapted state so as to minimize any customer shift complaints. The Scan Tool version of FastLearn is intended to provide the same benefit following transmission repair or replacement at GM Dealerships.

FastLearn must be used when one of the following repairs have been made to the vehicle:

•Transmission replacement or internal service/overhaul. •Valve Body repair or replacement, including replacement of A or B solenoids. •Transmission Control Module replacement. •TCM software/calibration update. •Any service in response to a shift quality complaint.

TECH 2 DATA LIST

TECH 2 DATA LIST

SPECIAL TOOLS —Engine Controls

SPECIAL TOOLS —Engine Controls

SPECIAL TOOLS —Engine Mechanical

SPECIAL TOOLS —Engine Mechanical