duramax lb7

1. Welcome!
GM Duramax 6.6L
Diesel Operation and
Diagnostics

2. 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

3. 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

4. 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

5. 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

6. DURAMAX 6600 DIESEL ENGINE

7. DURAMAX POWER OUTPUT

8. 2004 Revised Duramax

10. EGR

11. Stainless Steel Cooler

12. DURAMAX 6600 SPECIFICATIONS

13. DURAMAX 6600 SPECIFICATIONS

14. FLUID CAPACITIES/FILTER INFO.

15. OIL TEMPERATURE RANGE

16. DEEP SKIRT BLOCK

17. OIL PANS
UPPER
OIL PAN
LOWER
OIL PAN

18. FRONT ENGINE COVER
J 37228
Seal Cutter

19. FRONT OF ENGINE GEARS
FUEL PUMP GEAR
CMP GEAR
CKP GEAR

20. FLYWHEEL HOUSING
COOLANT PASSAGES ADAPTER

21. CRANKCASE
# 5 THRUST BEARING

22. MAIN BEARING CAPS
CROSS BOLTS

23. PISTON RINGS
COMPRESSION
RINGS
EMPTY GROOVE
OIL RING

24. PISTON
BOWL SHAPE

25. PISTON COOLING JETS
COOLING
JETS

26. COOLING JET OPERATION

27. FRACTURED ROD END CAP
FRACTURE

28. FOUR VALVES PER CYLINDER

29. VALVE INSERT
VALVE SEAT INSERT

30. HEAD GASKET SPECIFICATIONS

31. SERVICE HEAD GASKETS
“A”
“B” “C”

32. VALVE BRIDGE
VALVE
BRIDGE
INJECTOR

33. ROLLER LIFTER

34. OIL PUMP
OIL PUMP

35. OIL PRESSURE REGULATOR

36. OIL COOLER ASSEMBLY / OIL FILTER

37. OIL FLOW

38. WATER PUMP

39. THERMOSTAT HOUSING
REAR THERMOSTAT
FRONT THERMOSTAT

40. THERMOSTAT

41. BYPASS COOLANT PORT

42. TURBOCHARGER BYPASS VALVE
BYPASS
VALVE

43. DURAMAX COOLING SYSTEM

44. DURAMAX COOLING SYSTEM

45. AIR CLEANER RESTRICTOR INDICATOR

46. INTAKE AIR HEATER ELEMENT
IAH

47. TURBOCHARGER

48. Relay
Control
Coil
Low Current
Switch

49. TURBOCHARGER BYPASS VALVE
BYPASS
VALVE

50. WASTEGATE CONTROL

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

52. WASTEGATE ACTUATOR

53. TURBOCHARGER OIL RETURN LINE

54. Variable Nozzle Turbocharger

55. Rack and Pinion Design

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

57. CHARGE AIR COOLER
RADIATOR
CHARGE AIR
COOLER
CONDENSER

58. DURAMAX AIR FLOW
EGR
Crankcase Vapors

59. GLOW PLUGS
GLOW PLUGS

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

61. 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

62. DURAMAX FUEL SYSTEM

63. LLY Common Fuel Rail

64. LMM

65. New Fuel Rail Plumbing

67. FUEL CAP

68. FUEL TANK
FUEL TANK

69. FUEL BALANCE PUMP

70. FUEL PUMP RELAY CIRCUIT

71. FUEL SENDING UNIT

72. FUEL LEVEL SENSOR CIRCUIT

73. FUEL SUPPLY LINE FITTINGS
BANJO FITTINGS
QUICK-CONNECT FITTING

74. FICM

75. FUEL FILTER

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

77. HAND PRIMER AND VENT SCREW

78. WIF SENSOR REMOVAL

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

80. FUEL SUPPLY GEAR PUMP

81. HIGH PRESSURE PUMP AND FUEL
PRESSURE REGULATOR
HIGH PRESSURE
PUMP
FUEL PRESSURE
REGULATOR
SUPPLY
PUMP

82. HIGH PRESSURE PUMP

83. PUMP PLUNGER OPERATION –
INTAKE STROKE
INTAKE VALVE

84. PUMP PLUNGER OPERATION –
DELIVERY STAGE
OUTLET VALVE

85. FRPR

86. JUNCTION BLOCK
FUEL PRESSURE
RELIEF VALVE
FUEL PRESSURE
SENSOR

87. FUEL RAIL PRESSURE SENSOR

88. FUEL PRESSURE RELIEF VALVE

89. FUEL RAIL

90. HIGH PRESSURE LINES

91. FUEL INJECTOR

92. FUEL PULSES

93. INJECTOR INTERNAL VIEW

94. Coil
Ball and seat
Nozzle

95. INJECTOR HARNESS

96. FUEL RETURN LINE REMOVAL

97. FUEL INJECTOR REMOVAL

98. J 44639 FUEL INJECTOR REMOVER

99. RETURN LINES AND BANJO FITTINGS
RETURN LINE
BANJO FITTING

100. FUEL COOLER
FUEL COOLER

101. FUEL LINES

102. SUPPLY LINES
FUEL LINES

103. FUEL LINES
HIGH PRESSURE
LINES

104. FUEL LINES
RETURN LINES

105. FUEL LINES
HIGH PRESSURE
LINES
SUPPLY LINES
RETURN LINES

106. ENGINE CONTROLS

107. 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

108. 14.7psi
hg
100kpa
Baro hg/2=psi

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

110. ECM

111. 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

112. ECM COMMUNICATION

113. FICM

114. FICM CIRCUIT

115. FICM DRIVERS
(one bank shown)

116. INJECTOR GROUPS

117. ECT SENSOR
ECT SENSOR

118. ECT VOLTAGE vs. TEMPERATURE

119. MAF

120. MAF/IAT SENSORS
IAT
MAF

121. MAF/IAT CIRCUITS

122. BAROMETRIC SENSOR
BARO SENSOR

123. BARO/BOOST SENSOR CIRCUITS

124. BOOST SENSOR
BOOST SENSOR

125. FUEL RAIL PRESSURE SENSOR
FUEL RAIL
PRESSURE
SENSOR

126. FUEL RAIL PRESS. SENSOR CKT.

127. FUEL TEMPERATURE SENSOR
FUEL TEMP.
SENSOR

128. CKP SENSOR
CKP SENSOR

129. CKP RELUCTOR

130. CKP SENSOR CIRCUIT

131. N

132. CMP SENSOR
CMP SENSOR

133. CMP RELUCTOR

134. CMP SENSOR CIRCUIT

135. ACCELERATOR PEDAL POSITION
SENSOR
APP SENSOR

136. APP SENSOR OPERATION

137. APP SENSOR CIRCUIT

138. VEHICLE SPEED SENSOR

139. VSS CIRCUIT

140. OIL LEVEL SENSOR
OIL LEVEL
SENSOR

141. OIL LEVEL SENSOR CIRCUIT

142. PASSLOCK CIRCUIT

143. FUEL RAIL PRESSURE REGULATOR
FRPR

144. FRPR CIRCUIT

145. INJECTORS

146. INJECTOR CIRCUIT

147. FICM FUNCTION

148. GLOW PLUGS

149. GLOW PLUG CKT (Fed.)

150. GLOW PLUG CKT. (Cal.)

151. INTAKE AIR HEATER (IAH)

152. IAH CIRCUIT

153. COMPRESSOR CONTROLS

154. DURAMAX DIESEL EGR

155. POWER TAKEOFF (PTO) CIRCUIT

156. STRATEGY BASED DIAGNOSTICS

157. 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

158. ALLISON 1000 TRANSMISSION

159. TRANSMISSION POSITON SENSOR

160. 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

162. 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)

165. 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.

166. 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.

167. 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.

168. 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.

169. TECH 2 DATA LIST

170. TECH 2 DATA LIST

171. SPECIAL TOOLS —
Engine Controls

172. SPECIAL TOOLS —
Engine Controls

173. SPECIAL TOOLS —
Engine Mechanical

174. SPECIAL TOOLS —
Engine Mechanical