Tonyduramax

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, AC, 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

OIL PANS
UPPER
OIL PAN
LOWER
OIL PAN

FRONT ENGINE COVER
J 37228
Seal Cutter

FRONT OF ENGINE GEARS
FUEL PUMP GEAR
CMP GEAR
CKP GEAR

FLYWHEEL HOUSING
COOLANT PASSAGES ADAPTER

PISTON RINGS
COMPRESSION
RINGS
EMPTY GROOVE
OIL RING

PISTON COOLING JETS
COOLING
JETS

FRACTURED ROD END CAP
FRACTURE

VALVE INSERT
VALVE SEAT INSERT

SERVICE HEAD GASKETS
“A”
“B” “C”

VALVE BRIDGE
VALVE
BRIDGE
INJECTOR

OIL COOLER ASSEMBLY / OIL FILTER

THERMOSTAT HOUSING
REAR THERMOSTAT
FRONT THERMOSTAT

TURBOCHARGER BYPASS VALVE
BYPASS
VALVE

AIR CLEANER RESTRICTOR INDICATOR

Relay
Control
Coil
Low Current
Switch

TURBOCHARGER AIR FLOW
FROM
ENGINE
EXHAUST TO CHARGE
AIR COOLER
FILTERED
FRESH AIR

Sensor and Actuator
Operation of the vane
Control enables the the
ECM to monitor postion
Of the actuator.

CHARGE AIR COOLER
RADIATOR
CHARGE AIR
COOLER
CONDENSER

DURAMAX AIR FLOW
EGR
Crankcase Vapors

GLOW PLUG CKT (Federal)
780-875-7925 Alvin

CRANKCASE VENTILATION
COMPONENTS
SPRING, DIAPHRAGM AND COVER
TO VALVE ROCKER ARM COVER
OIL SEP ARATOR ASSEMBLYSPRING, DIAPHRAGM AND COVER
TO VALVE ROCKER ARM COVER
OIL SEP ARATOR ASSEMBLY

FUEL SUPPLY LINE FITTINGS
BANJO FITTINGS
QUICK-CONNECT FITTING

FUEL FILTER ASSEMBLY
WATER-IN-FUEL
SENSOR
HAND PUMP
HEATER
FILTER
WATER
RESERVOIR
PETCOCK

FUEL INJECTION PUMP
LOW PRESSURE
(SUCTION) FEED
HIGH
PRESSURE
OUTPUT
FUEL RAIL PRESSURE
REGULATOR (FRPR)

HIGH PRESSURE PUMP AND FUEL
PRESSURE REGULATOR
HIGH PRESSURE
PUMP
FUEL PRESSURE
REGULATOR
SUPPLY
PUMP

PUMP PLUNGER OPERATION –
INTAKE STROKE
INTAKE VALVE

PUMP PLUNGER OPERATION –
DELIVERY STAGE
OUTLET VALVE

JUNCTION BLOCK
FUEL PRESSURE
RELIEF VALVE
FUEL PRESSURE
SENSOR

RETURN LINES AND BANJO FITTINGS
RETURN LINE
BANJO FITTING

FUEL LINES
HIGH PRESSURE
LINES

FUEL LINES
HIGH PRESSURE
LINES
SUPPLY LINES
RETURN LINES

14.7 psi at sea level
Baro-KPA (low pressure was measured
in inches of mercury (hg)
100 kpa-14.7psi
as atltitude rises, pressure drops
20psi turbo boost (over atmospheric)
34.7psi
130kpa

14.7psi
hg
100kpa
Baro hg/2=psi

BAT
Ground
ECM
13.4volts
disconnected
BAT=? 13.4 volts
11.2 volts
connected

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

FUEL RAIL PRESSURE SENSOR
FUEL RAIL
PRESSURE
SENSOR

FUEL TEMPERATURE SENSOR
FUEL TEMP.
SENSOR

ACCELERATOR PEDAL POSITION
SENSOR
APP SENSOR

OIL LEVEL SENSOR
OIL LEVEL
SENSOR

FUEL RAIL PRESSURE REGULATOR
FRPR

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

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

Range
Line 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/A
1000-1170 kPa
(145-170 PSI)
Reverse
700-1380 kPa
(101-200 PSI)
1515-1795 kPa
(220-260 PSI)
Neutral/Park
800-1655 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.

SPECIAL TOOLS —
Engine Controls

SPECIAL TOOLS —
Engine Mechanical

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