Tonyduramax

293
-1

Published on

duramax lb7

Published in: Automotive, Business, Technology
0 Comments
1 Like
Statistics
Notes
  • Be the first to comment

No Downloads
Views
Total Views
293
On Slideshare
0
From Embeds
0
Number of Embeds
0
Actions
Shares
0
Downloads
16
Comments
0
Likes
1
Embeds 0
No embeds

No notes for slide

Tonyduramax

  1. 1. Welcome! GM Duramax 6.6L Diesel Operation and Diagnostics
  2. 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. 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. 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. 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. 6. DURAMAX 6600 DIESEL ENGINE
  7. 7. DURAMAX POWER OUTPUT
  8. 8. 2004 Revised Duramax
  9. 9. EGR
  10. 10. Stainless Steel Cooler
  11. 11. DURAMAX 6600 SPECIFICATIONS
  12. 12. DURAMAX 6600 SPECIFICATIONS
  13. 13. FLUID CAPACITIES/FILTER INFO.
  14. 14. OIL TEMPERATURE RANGE
  15. 15. DEEP SKIRT BLOCK
  16. 16. OIL PANS UPPER OIL PAN LOWER OIL PAN
  17. 17. FRONT ENGINE COVER J 37228 Seal Cutter
  18. 18. FRONT OF ENGINE GEARS FUEL PUMP GEAR CMP GEAR CKP GEAR
  19. 19. FLYWHEEL HOUSING COOLANT PASSAGES ADAPTER
  20. 20. CRANKCASE # 5 THRUST BEARING
  21. 21. MAIN BEARING CAPS CROSS BOLTS
  22. 22. PISTON RINGS COMPRESSION RINGS EMPTY GROOVE OIL RING
  23. 23. PISTON BOWL SHAPE
  24. 24. PISTON COOLING JETS COOLING JETS
  25. 25. COOLING JET OPERATION
  26. 26. FRACTURED ROD END CAP FRACTURE
  27. 27. FOUR VALVES PER CYLINDER
  28. 28. VALVE INSERT VALVE SEAT INSERT
  29. 29. HEAD GASKET SPECIFICATIONS
  30. 30. SERVICE HEAD GASKETS “A” “B” “C”
  31. 31. VALVE BRIDGE VALVE BRIDGE INJECTOR
  32. 32. ROLLER LIFTER
  33. 33. OIL PUMP OIL PUMP
  34. 34. OIL PRESSURE REGULATOR
  35. 35. OIL COOLER ASSEMBLY / OIL FILTER
  36. 36. OIL FLOW
  37. 37. WATER PUMP
  38. 38. THERMOSTAT HOUSING REAR THERMOSTAT FRONT THERMOSTAT
  39. 39. THERMOSTAT
  40. 40. BYPASS COOLANT PORT
  41. 41. TURBOCHARGER BYPASS VALVE BYPASS VALVE
  42. 42. DURAMAX COOLING SYSTEM
  43. 43. DURAMAX COOLING SYSTEM
  44. 44. AIR CLEANER RESTRICTOR INDICATOR
  45. 45. INTAKE AIR HEATER ELEMENT IAH
  46. 46. TURBOCHARGER
  47. 47. Relay Control Coil Low Current Switch
  48. 48. TURBOCHARGER BYPASS VALVE BYPASS VALVE
  49. 49. WASTEGATE CONTROL
  50. 50. TURBOCHARGER AIR FLOW FROM ENGINE EXHAUST TO CHARGE AIR COOLER FILTERED FRESH AIR
  51. 51. WASTEGATE ACTUATOR
  52. 52. TURBOCHARGER OIL RETURN LINE
  53. 53. Variable Nozzle Turbocharger
  54. 54. Rack and Pinion Design
  55. 55. Sensor and Actuator Operation of the vane Control enables the the ECM to monitor postion Of the actuator.
  56. 56. CHARGE AIR COOLER RADIATOR CHARGE AIR COOLER CONDENSER
  57. 57. DURAMAX AIR FLOW EGR Crankcase Vapors
  58. 58. GLOW PLUGS GLOW PLUGS
  59. 59. GLOW PLUG CKT (Federal) 780-875-7925 Alvin
  60. 60. 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
  61. 61. DURAMAX FUEL SYSTEM
  62. 62. LLY Common Fuel Rail
  63. 63. LMM
  64. 64. New Fuel Rail Plumbing
  65. 65. FUEL CAP
  66. 66. FUEL TANK FUEL TANK
  67. 67. FUEL BALANCE PUMP
  68. 68. FUEL PUMP RELAY CIRCUIT
  69. 69. FUEL SENDING UNIT
  70. 70. FUEL LEVEL SENSOR CIRCUIT
  71. 71. FUEL SUPPLY LINE FITTINGS BANJO FITTINGS QUICK-CONNECT FITTING
  72. 72. FICM
  73. 73. FUEL FILTER
  74. 74. FUEL FILTER ASSEMBLY WATER-IN-FUEL SENSOR HAND PUMP HEATER FILTER WATER RESERVOIR PETCOCK
  75. 75. HAND PRIMER AND VENT SCREW
  76. 76. WIF SENSOR REMOVAL
  77. 77. FUEL INJECTION PUMP LOW PRESSURE (SUCTION) FEED HIGH PRESSURE OUTPUT FUEL RAIL PRESSURE REGULATOR (FRPR)
  78. 78. FUEL SUPPLY GEAR PUMP
  79. 79. HIGH PRESSURE PUMP AND FUEL PRESSURE REGULATOR HIGH PRESSURE PUMP FUEL PRESSURE REGULATOR SUPPLY PUMP
  80. 80. HIGH PRESSURE PUMP
  81. 81. PUMP PLUNGER OPERATION – INTAKE STROKE INTAKE VALVE
  82. 82. PUMP PLUNGER OPERATION – DELIVERY STAGE OUTLET VALVE
  83. 83. FRPR
  84. 84. JUNCTION BLOCK FUEL PRESSURE RELIEF VALVE FUEL PRESSURE SENSOR
  85. 85. FUEL RAIL PRESSURE SENSOR
  86. 86. FUEL PRESSURE RELIEF VALVE
  87. 87. FUEL RAIL
  88. 88. HIGH PRESSURE LINES
  89. 89. FUEL INJECTOR
  90. 90. FUEL PULSES
  91. 91. INJECTOR INTERNAL VIEW
  92. 92. Coil Ball and seat Nozzle
  93. 93. INJECTOR HARNESS
  94. 94. FUEL RETURN LINE REMOVAL
  95. 95. FUEL INJECTOR REMOVAL
  96. 96. J 44639 FUEL INJECTOR REMOVER
  97. 97. RETURN LINES AND BANJO FITTINGS RETURN LINE BANJO FITTING
  98. 98. FUEL COOLER FUEL COOLER
  99. 99. FUEL LINES
  100. 100. SUPPLY LINES FUEL LINES
  101. 101. FUEL LINES HIGH PRESSURE LINES
  102. 102. FUEL LINES RETURN LINES
  103. 103. FUEL LINES HIGH PRESSURE LINES SUPPLY LINES RETURN LINES
  104. 104. ENGINE CONTROLS
  105. 105. 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
  106. 106. 14.7psi hg 100kpa Baro hg/2=psi
  107. 107. BAT Ground ECM 13.4volts disconnected BAT=? 13.4 volts 11.2 volts connected
  108. 108. ECM
  109. 109. 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
  110. 110. ECM COMMUNICATION
  111. 111. FICM
  112. 112. FICM CIRCUIT
  113. 113. FICM DRIVERS (one bank shown)
  114. 114. INJECTOR GROUPS
  115. 115. ECT SENSOR ECT SENSOR
  116. 116. ECT VOLTAGE vs. TEMPERATURE
  117. 117. MAF
  118. 118. MAF/IAT SENSORS IAT MAF
  119. 119. MAF/IAT CIRCUITS
  120. 120. BAROMETRIC SENSOR BARO SENSOR
  121. 121. BARO/BOOST SENSOR CIRCUITS
  122. 122. BOOST SENSOR BOOST SENSOR
  123. 123. FUEL RAIL PRESSURE SENSOR FUEL RAIL PRESSURE SENSOR
  124. 124. FUEL RAIL PRESS. SENSOR CKT.
  125. 125. FUEL TEMPERATURE SENSOR FUEL TEMP. SENSOR
  126. 126. CKP SENSOR CKP SENSOR
  127. 127. CKP RELUCTOR
  128. 128. CKP SENSOR CIRCUIT
  129. 129. N
  130. 130. CMP SENSOR CMP SENSOR
  131. 131. CMP RELUCTOR
  132. 132. CMP SENSOR CIRCUIT
  133. 133. ACCELERATOR PEDAL POSITION SENSOR APP SENSOR
  134. 134. APP SENSOR OPERATION
  135. 135. APP SENSOR CIRCUIT
  136. 136. VEHICLE SPEED SENSOR
  137. 137. VSS CIRCUIT
  138. 138. OIL LEVEL SENSOR OIL LEVEL SENSOR
  139. 139. OIL LEVEL SENSOR CIRCUIT
  140. 140. PASSLOCK CIRCUIT
  141. 141. FUEL RAIL PRESSURE REGULATOR FRPR
  142. 142. FRPR CIRCUIT
  143. 143. INJECTORS
  144. 144. INJECTOR CIRCUIT
  145. 145. FICM FUNCTION
  146. 146. GLOW PLUGS
  147. 147. GLOW PLUG CKT (Fed.)
  148. 148. GLOW PLUG CKT. (Cal.)
  149. 149. INTAKE AIR HEATER (IAH)
  150. 150. IAH CIRCUIT
  151. 151. COMPRESSOR CONTROLS
  152. 152. DURAMAX DIESEL EGR
  153. 153. POWER TAKEOFF (PTO) CIRCUIT
  154. 154. STRATEGY BASED DIAGNOSTICS
  155. 155. 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
  156. 156. ALLISON 1000 TRANSMISSION
  157. 157. TRANSMISSION POSITON SENSOR
  158. 158. 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
  159. 159. 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)
  160. 160. 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.
  161. 161. 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.
  162. 162. 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.
  163. 163. 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.
  164. 164. TECH 2 DATA LIST
  165. 165. TECH 2 DATA LIST
  166. 166. SPECIAL TOOLS — Engine Controls
  167. 167. SPECIAL TOOLS — Engine Controls
  168. 168. SPECIAL TOOLS — Engine Mechanical
  169. 169. SPECIAL TOOLS — Engine Mechanical
  1. A particular slide catching your eye?

    Clipping is a handy way to collect important slides you want to go back to later.

×