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 LNN

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 37228
Seal 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

OIL RING

EMPTY GROOVE

PISTON
BOWL SHAPE

PISTON COOLING JETS

COOLING
JETS

COOLING JET OPERATION

FRACTURED ROD END CAP

FRACTURE

FOUR VALVES PER CYLINDER

VALVE INSERT

VALVE SEAT INSERT

HEAD GASKET SPECIFICATIONS

SERVICE HEAD GASKETS

VALVE BRIDGE
INJECTOR

VALVE
BRIDGE

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

Control
Coil
Low Current

Switch

TURBOCHARGER BYPASS VALVE

BYPASS
VALVE

WASTEGATE CONTROL

TURBOCHARGER AIR FLOW

FILTERED
FRESH AIR

FROM
ENGINE
EXHAUST

TO CHARGE
AIR COOLER

WASTEGATE ACTUATOR

TURBOCHARGER OIL RETURN LINE

Variable Nozzle Turbocharger

Rack and Pinion Design

Sensor and Actuator

Operation of the vane

Control enables the the
ECM to monitor postion
Of the actuator.

CHARGE AIR COOLER

CONDENSE
R

CHARGE AIR
COOLER

RADIATOR

DURAMAX AIR FLOW

EGR

Crankcase Vapors

GLOW PLUGS

GLOW PLUGS

GLOW PLUG CKT (Federal)

780-875-7925 Alvin

CRANKCASE VENTILATION
COMPONENTS

SPRING, DIAPHRAGM AND COVER

SPRING, DIAPHRAGM AND COVER
TO VALVE ROCKER ARM COVER
TO VALVE ROCKER ARM COVER

OIL SEPARATOR ASSEMBLY 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

QUICK-CONNECT FITTING

BANJO FITTINGS

FICM

FUEL FILTER

FUEL FILTER ASSEMBLY

HAND PUMP
HEATER

FILTER

WATER-IN-FUEL
SENSOR

WATER
RESERVOIR

PETCOCK

HAND PRIMER AND VENT SCREW

WIF SENSOR REMOVAL

FUEL INJECTION PUMP

LOW PRESSURE
(SUCTION) FEED

FUEL RAIL PRESSURE

REGULATOR (FRPR)

HIGH
PRESSURE
OUTPUT

FUEL SUPPLY GEAR PUMP

HIGH PRESSURE PUMP AND FUEL

PRESSURE REGULATOR
FUEL PRESSURE
REGULATOR

SUPPLY
PUMP

HIGH PRESSURE
PUMP

HIGH PRESSURE PUMP

PUMP PLUNGER OPERATION

INTAKE STROKE
INTAKE VALVE

PUMP PLUNGER OPERATION

DELIVERY STAGE
OUTLET VALVE

FRPR

JUNCTION BLOCK
FUEL PRESSURE
SENSOR

FUEL PRESSURE
RELIEF VALVE

FUEL RAIL PRESSURE SENSOR

FUEL PRESSURE RELIEF VALVE

FUEL RAIL

HIGH PRESSURE LINES

FUEL INJECTOR

FUEL PULSES

INJECTOR INTERNAL VIEW

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

FUEL LINES

SUPPLY LINES

FUEL LINES

HIGH PRESSURE
LINES

FUEL LINES

RETURN LINES

FUEL LINES

SUPPLY LINES
HIGH PRESSURE
LINES
RETURN LINES

ENGINE CONTROLS

14.7 psi at sea level

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

100kpa

14.7psi

Baro hg/2=psi

hg

BAT=? 13.4 volts

ECM

BAT

11.2 volts
connected

Ground

13.4volts
disconnected

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

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 DTCs? 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
Park/Neutral

C1
--

C2
--

C3
--

C4
--

C5
X

TCC
--

Reverse

--

--

--

--

First

--

--

--

--

Second

--

--

--

Third

--

--

--

Fourth

--

--

--

Fifth

--

--

--

Range

Line
Pressure @
600RPM

Forward Converter (Torque

700-1380kPa
Converter Clutch not
(101-200PSI)
applied)
Forward Lockup (Torque
Converter Clutch applied)

N/A

Reverse

700-1380kPa
(101-200PSI)

Neutral/Park

800-1655kPa
(130-240PSI)

Line
Pressure @
2100RPM
15151795kPa
(220-260PSI)
10001170kPa
(145-170PSI)
15151795kPa
(220-260PSI)
15151795kPa
(220-260PSI)

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 nearfully-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