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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