tonyduramax.ppt

5/18/2018 tonyduramax.ppt

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Welcome!

GM Duramax 6.6LDiesel Operation andDiagnostics


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Introduction

Tony Salas- erormance "utomoti#e Tec$ni%ues

Master "S& 'ertiied

(ome )ased* Las +egas, e#ada

Training pro#ider or dealers, independent s$opsand leet s$ops

Ot$er classes instructed are* &lectrical,electronics, "', 6./ L Diesel, Gasoline 0uel

In1ection, o2erstro3e 4.5L 6.7L, )ody, SI8"ir9ag, transmission control


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'O:8S& O);&'TI+&S

:pon completion o t$e course t$e student 2ill 9e a9le to* 8ecogni


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Duramax 6.6L

=77> Model ?ear released e2 )ody Sil#erado

=77@ '$e#rolet (D 2it$ a 6./L

0irst Generation L)4

Decem9er o =775 2as t$e last L)4

Sept =775-Model =77@

;anuary o =77@ t$e LL? released

=77/ L)A =776 models =776 Sa#anna and t$e &xpress +ans L


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'O:8S& O);&'TI+&S

:pon completion o t$e course t$e student 2ill 9e a9le to*

erorm uel system diagnosis as it relates to ser#ice inormation

Test t$e glo2 plug circuit o t$e Duramax engine

Descri9e t$e electronic components and operation o t$e uel system

erorm a uel pressure regulator control test and an in1ector 9alance

test using a scan tool Identiy components related to engine management

Test inputs and outputs o t$e engine management system

Descri9e t$e engine management supporting inputs and outputs,

and explain t$eir unction

Locate ser#ice inormation related to t$e Duramax engine

Identiy elements o Strategy )ased Diagnostics BS)DC

:se an On-)oard Diagnostic System '$ec3 to perorm diagnostics


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D:8"M" 6677 DI&S&L &GI&


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D:8"M" OW&8 O:T:T


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=77@ 8e#ised Duramax


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&G8


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Stainless Steel 'ooler


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D:8"M" 6677 S&'I0I'"TIOS


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D:8"M" 6677 S&'I0I'"TIOS


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0L:ID '""'ITI&SE0ILT&8 I0O.


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OIL T&M&8"T:8& 8"G&


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D&& SFI8T )LO'F


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OIL "S

:&8

OIL "

LOW&8

OIL "


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08OT &GI& 'O+&8

J 37228Seal Cutter


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08OT O0 &GI& G&"8S

0:&L :M G&"8

'M G&"8

'F G&"8


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0L?W(&&L (O:SIG

'OOL"T "SS"G&S "D"T&8


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'8"F'"S&

/ T(8:ST )&"8IG


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M"I )&"8IG '"S

'8OSS )OLTS


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ISTO 8IGS

'OM8&SSIO

8IGS&MT? G8OO+&

OIL 8IG


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ISTO

)OWL S("&


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ISTO 'OOLIG ;&TS

'OOLIG;&TS


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'OOLIG ;&T O&8"TIO


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08"'T:8&D 8OD &D '"

08"'T:8&


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0O:8 +"L+&S &8 '?LID&8


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+"L+& IS&8T

+"L+& S&"T IS&8T


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(&"D G"SF&T S&'I0I'"TIOS


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S&8+I'& (&"D G"SF&TS

H"

H) H'


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+"L+& )8IDG&

+"L+&)8IDG&

I;&'TO8


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8OLL&8 LI0T&8


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OIL :M

OIL :M


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OIL 8&SS:8& 8&G:L"TO8


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OIL 'OOL&8 "SS&M)L? E OIL 0ILT&8


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OIL 0LOW


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W"T&8 :M


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T(&8MOST"T (O:SIG

8&"8 T(&8MOST"T

08OT T(&8MOST"T


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T(&8MOST"T


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)?"SS 'OOL"T O8T


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T:8)O'("8G&8 )?"SS +"L+&

)?"SS

+"L+&


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D:8"M" 'OOLIG S?ST&M


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D:8"M" 'OOLIG S?ST&M


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"I8 'L&"&8 8&ST8I'TO8 IDI'"TO8


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IT"F& "I8 (&"T&8 &L&M&T

I"(


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T:8)O'("8G&8


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8elay

ControlControl

CoilCoil

Low CurrentLow Current

SwitchSwitch


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T:8)O'("8G&8 )?"SS +"L+&

)?"SS

+"L+&


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W"ST&G"T& 'OT8OL


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T:8)O'("8G&8 "I8 0LOW

08OM08OM

&GI&&GI&

&(":ST&(":ST TO '("8G&TO '("8G&

"I8 'OOL&8"I8 'OOL&8

0ILT&8&D0ILT&8&D

08&S( "I808&S( "I8


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W"ST&G"T& "'T:"TO8


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T:8)O'("8G&8 OIL 8&T:8 LI&


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+aria9le o


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8ac3 and inion Design


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Sensor and "ctuator

Operation of the vaneControl enables the theECM to monitor postion

Of the actuator.


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'("8G& "I8 'OOL&8

8"DI"TO8

'("8G& "I8

'OOL&8

'OD&S&

8


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D:8"M" "I8 0LOW

EGREGR

Crankcase VaporsCrankcase Vapors


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GLOW L:GS

GLOW L:GS


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GLOW L:G 'FT B0ederalC

780-875-7925 Alin780-875-7925 Alin


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'8"F'"S& +&TIL"TIO

'OMO&TS

SPR!"# $%P&R%"M %!$ CO'ER(O '%)'E ROC*ER %RM CO'ER

O) SEP%R%(OR %SSEM+),


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D:8"M" 0:&L S?ST&M


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LL? 'ommon 0uel 8ail


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LMM


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e2 0uel 8ail lum9ing


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0:&L '"


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0:&L T"F

0:&L T"F


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0:&L )"L"'& :M


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0:&L :M 8&L"? 'I8':IT


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0:&L S&DIG :IT


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0:&L L&+&L S&SO8 'I8':IT


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0:&L S:L? LI& 0ITTIGS

+%!JO -((!"S

./C*0CO!!EC( -((!"


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0I'M


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0:&L 0ILT&8


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0:&L 0ILT&8 "SS&M)L?

1%(ER0!0-/E)SE!SOR

&%!$ P/MP

&E%(ER

-)(ER

1%(ERRESER'OR

PE(COC*


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("D 8IM&8 "D +&T S'8&W


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WI0 S&SO8 8&MO+"L


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0:&L I;&'TIO :M

)O1 PRESS/RES/C(O! -EE$

&"&PRESS/RE

O/(P/(-/E) R%) PRESS/RERE"/)%(OR -RPR


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0:&L S:L? G&"8 :M

(IG( 8&SS:8& :M "D 0:&L


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(IG( 8&SS:8& :M "D 0:&L

8&SS:8& 8&G:L"TO8

(IG( 8&SS:8&

:M

0:&L 8&SS:8&8&G:L"TO8

S:L?

:M


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(IG( 8&SS:8& :M

:M L:G&8 O&8"TIO


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:M L:G&8 O&8"TIO J

IT"F& ST8OF&

IT"F& +"L+&IT"F& +"L+&

:M L:G&8 O&8"TIO


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:M L:G&8 O&8"TIO J

D&LI+&8? ST"G&

O:TL&T +"L+&O:TL&T +"L+&


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088


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;:'TIO )LO'F

0:&L 8&SS:8&8&LI&0 +"L+&

0:&L 8&SS:8&

S&SO8


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0:&L 8"IL 8&SS:8& S&SO8


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0:&L 8&SS:8& 8&LI&0 +"L+&


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0:&L 8"IL


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(IG( 8&SS:8& LI&S

0:& I;&'TO8


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0:&L I;&'TO8

0:&L :LS&S


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0:&L :LS&S

I;&'TO8 IT&8"L +I&W


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I;&'TO8 IT&8"L +I&W

I;&'TO8 ("8&SS


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I;&'TO8 ("8&SS

0:&L 8&T:8 LI& 8&MO+"L


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0:&L 8&T:8 LI& 8&MO+"L

0:&L I;&'TO8 8&MO+"L


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0:&L I;&'TO8 8&MO+"L

; @@65K 0:&L I;&'TO8 8&MO+&8


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; @@65K 0:&L I;&'TO8 8&MO+&8

8&T:8 LI&S "D )";O 0ITTIGS


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8&T:8 LI&S "D )";O 0ITTIGS

8&T:8 LI&

)";O 0ITTIG

0:&L 'OOL&8


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0:&L 'OOL&8

0:&L 'OOL&8

0:&L LI&S


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0:&L LI&S

0:&L LI&S


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S:L? LI&S

0:&L LI&S

0:&L LI&S


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0:&L LI&S

(IG( 8&SS:8&

LI&S

0:&L LI&S


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0:&L LI&S

8&T:8 LI&S

0:&L LI&S


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0:&L LI&S

(IG( 8&SS:8&

LI&S

S:L? LI&S

8&T:8 LI&S

&GI& 'OT8OLS


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&GI& 'OT8OLS


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>@.4 psi at sea le#el

)aro-F" Blo2 pressure 2as measured

in inc$es o mercury B$gC

>77 3pa->@.4psi

as atltitude rises, pressure drops

=7psi tur9o 9oost Bo#er atmosp$ericC

[email protected]>573pa


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!"#7psi!"#7psi

h$h$

!00kpa!00kpa

%aro h$&2'psi%aro h$&2'psi


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%A(%A(

Groun)Groun)

EC*EC*

!+#"olts!+#"olts

)isconnecte))isconnecte)

%A(', !+#" olts%A(', !+#" olts

!!#2 olts!!#2 olts

connecte)connecte)

&'M


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&'M

Wor3s$eets and &xercises


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Wor3s$eets and &xercises

&xercise = Glo2 lug 'ircuit pg Group >

&xercise 5 0uel System Diagnosis pg>= Group =

&xercise @ Scan tool data pg>@ Group 5

Wor3s$eet @ Scan Data pg>4 Group @

&xercise 6 In1ector 8eplacement pg == Group /

&xercise 4 Special 0unctions pg =5 Wor3s$eetK 08 Sensor Grap$ing

&'M 'OMM:I'"TIO


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&'M 'OMM:I'"TIO

0I'M


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0I'M

0I'M 'I8':IT


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0I'M 'I8':IT

0I'M D8I+&8S


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(one bank shown)

I;&'TO8 G8O:S


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I;&'TO8 G8O:S

&'T S&SO8


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&'T S&SO8

&'T S&SO8

&'T +OLT"G& #s T&M&8"T:8&


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&'T +OLT"G& #s. T&M&8"T:8&

M"0


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M"0

M"0EI"T S&SO8S


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M"0EI"T S&SO8S

I"T

M"0

M"0EI"T 'I8':ITS


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M"0EI"T 'I8':ITS

)"8OM&T8I' S&SO8


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)"8OM&T8I' S&SO8

)"8O S&SO8

)"8OE)OOST S&SO8 'I8':ITS


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)"8OE)OOST S&SO8 'I8':ITS

)OOST S&SO8


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)OOST S&SO8

)OOST S&SO8

0:&L 8"IL 8&SS:8& S&SO8


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: SS: S SO

0:&L 8"IL

8&SS:8&

S&SO8

0:&L 8"IL 8&SS. S&SO8 'FT.


125/1730:&L T&M&8"T:8& S&SO8


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0:&L T&M.

S&SO8

'F S&SO8


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'F S&SO8

'F 8&L:'TO8


128/173'F S&SO8 'I8':IT


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'M S&SO8


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'M S&SO8

'M 8&L:'TO8


132/173'M S&SO8 'I8':IT


133/173"''&L&8"TO8 &D"L OSITIO

S&SO8


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S&SO8

" S&SO8

" S&SO8 O&8"TIO


135/173" S&SO8 'I8':IT


136/173+&(I'L& S&&D S&SO8


137/173+SS 'I8':IT


138/173OIL L&+&L S&SO8


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OIL L&+&L

S&SO8

OIL L&+&L S&SO8 'I8':IT


140/173"SSLO'F 'I8':IT


141/1730:&L 8"IL 8&SS:8& 8&G:L"TO8


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088

088 'I8':IT


143/173I;&'TO8S


144/173I;&'TO8 'I8':IT


145/1730I'M 0:'TIO


146/173GLOW L:GS


147/173GLOW L:G 'FT B0ed.C


148/173GLOW L:G 'FT. B'al.C


149/173IT"F& "I8 (&"T&8 BI"(C


150/173I"( 'I8':IT


151/173'OM8&SSO8 'OT8OLS


152/173D:8"M" DI&S&L &G8


153/173OW&8 T"F&O00 BTOC 'I8':IT


154/173ST8"T&G? )"S&D DI"GOSTI'S


155/173Diagnostic rocess


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+eriy 'omplaint HOpen t$e $ood!

+isual

Diagnostic 'ircuit '$ec3

'$ec3 )ulletins! "nd reliminary Inormation

'$ec3 DT'sN StatusN DT' ino!

0uel System* "I8, suction, 9alancing rates B@ idle, 6 in dri#eC

OILN '$ec3 or uel!

'$ec3 cylinder po2er 9alance test.

8eturn +olume test. 'ompare one side to t$e ot$er side

'$ec3 #olume on eac$ in1ector!

Feep in mind at t$e ressure limiting #al#e ressure 8egulator Test

"LLISO >777 T8"SMISSIO


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T8"SMISSIO OSITO S&SO8


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Gear Range C1 C2 C3 C4 C5 TCC

Par45!eutral 00 00 00 00 6 00


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Par45!eutral 00 00 00 00 6 00

Reverse 00 00 6 00 6 00

-irst 6 00 00 00 6 00

Secon 6 00 00 6 00 6

(hir 6 00 6 00 00 6

-ourth 6 6 00 00 00 6

-ifth 00 6 6 00 00 6


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RangeLine

Pressure @600 RPM

LinePressure @2100 RPM


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-orar Converter (or9ueConverter Clutch not

applie

7::0;38: 4Pa;:;02:: PS

;=;=0;7>= 4Pa

22:02?: PS

-orar )oc4up (or9ue

Converter Clutch applie

!5%;:::0

;;7: 4Pa

;@=0;7: PS

Reverse7::0;38: 4Pa;:;02:: PS

;=;=0;7>= 4Pa

22:02?: PS

!eutral5Par48::0;?== 4Pa;3:02@: PS

;=;=0;7>= 4Pa

22:02?: PS


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f Aou are eBperiencin harsh shifts# it is important toverifA hether the particular shift is convere. /se the


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Scan (oolto etermine if the problem shift is convere.

Df it is not# the (CM is still learnin ho to aapt thatshift# an simplA nees to be riven a bit more ith theintention of performin more of the particular tApe ofshift.

Df a particular shift is convere# but stillobectionable# itFs oo troubleshootin practice toreset the aaptive values for that shift bac4 to basecalibration level. (his ill automaticallA reset the (CMto fast aaptive moe. (he vehicle shoul then be

riven to allo the (CM to Gre0learnG the shift. ManAtimes this ill correct the problem. t is possible toreset iniviual shifts ithout aHectin the other shifts.

Transmission Diagnostics
http://service.gm.com/servlets/RetrieveTif?pic=59260http://service.gm.com/servlets/RetrieveTif?pic=59260


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'$ec3 luidBengine runningC '$ec3 selector #al#e and s2itc$ing B,8,,D,LC

Turn engine on. Dri#e #e$icle c$ec3 all gear ratios

'$ec3 gear ratios under all loads

I s$it %uality issue, clear t$e T"

I transmission is ser#iced or c$anged out, reset

all T"S.

n eneral -ast)earn is a proceure for %llison ;:::


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n eneral# -ast)earn is a proceure for %llison ;:::

Series transmissions in hich a series of tests are run toallo the (ransmission Control Moule (CM to GlearnGiniviual clutch characteristics. Once the clutch ata islearne# -ast)earn translates it to the aaptive ata cells#hich the (CM uses for clutch control urin rane shifts.

-ast)earn is use at "M assemblA plants an allos thevehicle to be riven out of the assemblA plant in a near0fullA0aapte state so as to minimiIe anA customer shiftcomplaints. (he Scan (ool version of -ast)earn is intene

to provie the same benet folloin transmission repairor replacement at "M $ealerships.


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-ast)earn must be use hen one of the folloin repairshave been mae to the vehicleK

D(ransmission replacement or internalservice5overhaul.

D'alve +oA repair or replacement# incluinreplacement of % or + solenois.D(ransmission Control Moule replacement.D(CM softare5calibration upate.D%nA service in response to a shift 9ualitA complaint.

T&'( = D"T" LIST


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T&'( = D"T" LIST


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S&'I"L TOOLS

&ngine 'ontrols


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g

S&'I"L TOOLS

&ngine 'ontrols


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S&'I"L TOOLS

&ngine Mec$anical


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S&'I"L TOOLS

&ngine Mec$anical


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