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duramax lb7

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Tonyduramax Tonyduramax Presentation Transcript

  • 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
  • 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 EMPTY GROOVE OIL RING
  • 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 “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 Control Coil Low Current Switch
  • TURBOCHARGER BYPASS VALVE BYPASS VALVE
  • WASTEGATE CONTROL
  • TURBOCHARGER AIR FLOW FROM ENGINE EXHAUST TO CHARGE AIR COOLER FILTERED FRESH AIR
  • 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 RADIATOR CHARGE AIR COOLER CONDENSER
  • 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 TO VALVE ROCKER ARM COVER OIL SEP ARATOR ASSEMBLYSPRING, DIAPHRAGM AND COVER TO VALVE ROCKER ARM COVER OIL SEP ARATOR 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 WATER RESERVOIR PETCOCK
  • HAND PRIMER AND VENT SCREW
  • WIF SENSOR REMOVAL
  • FUEL INJECTION PUMP LOW PRESSURE (SUCTION) FEED HIGH PRESSURE OUTPUT FUEL RAIL PRESSURE REGULATOR (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 VALVE
  • PUMP PLUNGER OPERATION – DELIVERY STAGE OUTLET 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-14.7psi 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
  • 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
  • N
  • 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
  • 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.
  • TECH 2 DATA LIST
  • TECH 2 DATA LIST
  • SPECIAL TOOLS — Engine Controls
  • SPECIAL TOOLS — Engine Controls
  • SPECIAL TOOLS — Engine Mechanical
  • SPECIAL TOOLS — Engine Mechanical