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6.6L Duramax:
Engine Diagnosis
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6.6L Duramax: Engine Diagnosis
Table of Contents
Table of Contents
Introduction .................................................................................... i-1
Module 2: Fuel System Testing (Supply Side) and High Pressure Side . 2-1
Instructor Name:
This manual contains information about service for 6.6L Duramax diesel engines and
their components. Always refer to applicable vehicle service information and
appropriate Dealer Technical Service Bulletins for additional information regarding
system operation and diagnostic/repair procedures. When this manual refers to a brand
name, a number, or a specific tool, you may use an equivalent product in place of the
recommended item.
All information, illustrations and specifications in this manual are based on the latest
product information available at the time of publication approval. General Motors
reserves the right to make changes at any time without notice.
No part of this book may be reproduced, stored in any retrieval system, or transmitted in
any form or by any means (including but not limited to electronic, mechanical,
photocopying, and recording) without prior written permission of General Motors
Company. This applies to all text, illustrations, tables and charts.
© 2011
TC-1
6.6L Duramax: Engine Diagnosis
Introduction
Introduction
i-1
6.6L Duramax: Engine Diagnosis
Introduction
Course Goal
Upon successful completion of this course, you will be able to apply concepts and
procedures to diagnose and service concerns on the 6.6 Liter Duramax Diesel engine
and its components.
Session 1 Objectives
Describe Duramax Fuel System and the Duramax Engine Management Control
System diagnostic procedures
Describe Fuel System (Supply Side) and Fuel System High Pressure Side
diagnostic procedures
Describe Glow Plug diagnostic procedures
Describe Variable Nozzle Turbocharger system diagnostic procedures
Special Instructions
The diagnostic charts in this courseware are for reference only. Refer to Service
Information when servicing the Duramax Fuel System and its components.
i-2
MODULE 1
Fuel System Diagnosis
Module 1 Objective
At the end of this module, you will be able to describe the procedures for diagnosing
concerns on the Duramax fuel system and the Duramax engine management control
system.
1-2
6.6L Duramax: Engine Diagnosis
Module 1: Fuel System Diagnosis
Notes:
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1-3
6.6L Duramax: Engine Diagnosis
Module 1: Fuel System Diagnosis
Notes:
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1-4
6.6L Duramax: Engine Diagnosis
Module 1: Fuel System Diagnosis
Misfire detection will only detect insufficient injector fuel delivery. It will not detect
continuous fuel delivery.
If a misfire DTC is not set and you suspect insufficient injector fuel delivery, you may
perform the Fuel Injector Balance Test, which includes checking the cylinder balance
rates for specific customer concerns. Note that there is a different procedure and
different values for automatic and manual transmission vehicles.
For this automatic transmission-equipped vehicle, begin with the engine running at
an operating temperature of 82°C (180°F). Ensure all accessories are OFF.
Apply the brakes. A noticeable hiss identifies the brakes are fully applied.
Place the transmission in DRIVE and let it idle for more than 30 seconds.
With the conditions met, record the balancing rates.
With the DRIVE balancing rates recorded, test the vehicle again with the
transmission in NEUTRAL and record your results.
1-5
6.6L Duramax: Engine Diagnosis
Module 1: Fuel System Diagnosis
The ECM uses Crankshaft Position (CKP) Sensor and the Camshaft Position (CMP)
Sensor information for:
Start-up
Engine speed
Engine stroke
1-6
6.6L Duramax: Engine Diagnosis
Module 1: Fuel System Diagnosis
Concern Cause
Abnormally loud engine ─ Loss of pilot injection / over-fueling
injector
Due to pilot injection, the engine should be quiet. An abnormally loud engine could
be due to loss of pilot injection or to an injector that’s over fueling.
Excessive black smoke from the exhaust or excessive regenerations could be
caused by a disconnected air duct after the Mass Air Flow (MAF) Sensor or a Charge
Air Cooler leak.
Oil residue in the Charge Air Cooler ducts is a normal condition due to the closed
PCV system.
Check to see if the air filter restriction indicator indicates a restriction and also to see
how much light passes through the filter.
The 6-liter gasoline engine air filter and the Duramax air filter may look similar, but
they are not interchangeable. The Duramax air filter has additional support as
compared to the gasoline engine air filter, so the gasoline engine filter may collapse if
used on a Duramax.
A bent or distorted filter could indicate the filter was probably wet at some time. If so,
it should be replaced.
1-7
6.6L Duramax: Engine Diagnosis
Module 1: Fuel System Diagnosis
Notes:
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1-8
6.6L Duramax: Engine Diagnosis
Module 1: Fuel System Diagnosis
Module 1 Summary
Described Duramax Fuel System and the Duramax Engine Management Control
System diagnostic procedures
─ Fuel rail pressure data
─ Engine misfire detection
─ Fuel Injector Balance Test
─ CKP and CMP relationship
─ Duramax diagnostic tips
─ Donaldson air filter
1-9
MODULE 2
Fuel System Testing (Supply Side)
and High Pressure Side
Module 2 Objective
At the end of this module, you will be able to describe how to diagnose Fuel System
(Supply Side) and Fuel System High Pressure Side concerns.
2-2
6.6L Duramax: Engine Diagnosis
Module 2: Fuel System Testing (Supply Side) and High Pressure Side
2-3
6.6L Duramax: Engine Diagnosis
Module 2: Fuel System Testing (Supply Side) and High Pressure Side
2-4
6.6L Duramax: Engine Diagnosis
Module 2: Fuel System Testing (Supply Side) and High Pressure Side
In this case, the vacuum doesn’t drop below 203 millimeters (8 inches of vacuum) in
10 minutes. Therefore, we know a leak is in the supply line from the fuel tank.
Now, we need to determine if an air leak is present in the chassis fuel lines or in the
tank.
We check the fuel lines first. To do this, disconnect the supply line at the tank and
plug it.
Remove the plug from the supply line and install the vacuum pump.
2-5
6.6L Duramax: Engine Diagnosis
Module 2: Fuel System Testing (Supply Side) and High Pressure Side
Apply 635 millimeters (25 inches of vacuum) to the supply line. Wait a minute for the
system to stabilize.
We check to see if vacuum drops to below 203 millimeters (8 inches of vacuum)
within 10 minutes.
In our case, it doesn't drop below 203 millimeters (8 inches of vacuum).
Since most of the vacuum held, reconnect the fuel lines at the tank and the engine.
2-6
6.6L Duramax: Engine Diagnosis
Module 2: Fuel System Testing (Supply Side) and High Pressure Side
NOTES:
Only run this test when directed by Service Information (SI).
IMPORTANT: Start Fuel System testing on the Supply Side. Supply Side
malfunctions can affect the results of the High Pressure test.
With the exception of fuel line routing, procedures for Supply Side testing are the
same for 2001 to present pickup applications.
Duramax equipped vans have an electric prime pump on the Supply Side. Refer to
Service Information for the procedures.
While testing the Supply Side for leaks using the EN-47969 hose, allow the engine
to idle for at least 10 minutes to purge any air and to allow the system to stabilize.
Prime the Fuel System 30 times to remove air from the system after installing
components to get the engine in running order.
The CH 48027 Digital Pressure/Vacuum Gauge has replaced the J 44638 Vacuum
Gauge. The Digital Pressure/Vacuum Gauge can also be used on all Duramax
applications.
2-7
6.6L Duramax: Engine Diagnosis
Module 2: Fuel System Testing (Supply Side) and High Pressure Side
Fuel System High Pressure Side testing will identify an internal high side system
leak.
You will be directed to this procedure from another procedure, such as the Engine
Cranks but Does Not Run Diagnostic.
When performing this test, you will need to know the American Petroleum Institute
(API) fuel rating. The return volumes may vary depending on the API rating.
Notes:
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2-8
6.6L Duramax: Engine Diagnosis
Module 2: Fuel System Testing (Supply Side) and High Pressure Side
The Fuel System Diagnosis High Pressure Side procedure should only be performed
when directed by a published diagnostic. It requires several tools.
You'll need:
Approved containers for diesel
fuel
J 45873
J 44581 Fuel Line Disconnect
Tool
J 45873 Fuel Return Volume
Test Kit that lets you compare
return fuel from the injectors for
J 44581
an entire cylinder bank J 45873-30
Adapters for the test tool’s
yellow hoses to attach them to
the LLY Bosch Generation II
injectors J 45873 Fuel Return Volume Test Kit
J 44581 Fuel Line Disconnect Tool
J 45873-30 Adapters for Test Kit Yellow Hoses
Basically, the Fuel System Diagnosis High Pressure Side procedure directs you to
measure individual injector fuel return volume.
This will identify any leaking injectors.
2-9
6.6L Duramax: Engine Diagnosis
Module 2: Fuel System Testing (Supply Side) and High Pressure Side
2-10
6.6L Duramax: Engine Diagnosis
Module 2: Fuel System Testing (Supply Side) and High Pressure Side
Crank the engine in 15 second intervals, with 1 minute for cooling between the
intervals. Do this until fuel flows into all of the graduated cylinders.
Elevate the hoses so that they hold the fuel, and empty the graduated cylinders into
a suitable container. Return the hoses to the graduated cylinders.
Again, crank the engine for 15 seconds. Measure the fuel in the graduated
cylinders. Compare the amounts with those listed in the Fuel System Specification.
These are the Fuel Injector Return Flow Values.
If high return flows were recorded, replace those fuel injectors that had high return
flow. Repeat the procedure for the other side of the engine.
After servicing the suspect injectors, re-assemble the components. Start the engine
and let it idle. You may need to prime the fuel system.
Lastly, check the pump. Command the fuel pressure to 160 MPa (23,206 psi) using
the scan tool.
Replace the fuel injection pump if the system cannot produce more than 145 MPa
(21,030 psi).
Notes:
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2-11
6.6L Duramax: Engine Diagnosis
Module 2: Fuel System Testing (Supply Side) and High Pressure Side
NOTES:
Just like fuel system testing on the Supply Side, Fuel System Testing on the High
Pressure Side should not be performed unless directed by Service Information.
Refer to Service Information for API ratings and complete testing procedures.
In order to get an accurate test reading, the fuel must be warmer than 18°C (65°F).
The CH 48027 Digital Pressure/Vacuum Gauge has replaced the J 44638 Vacuum
Gauge. The Digital Pressure/Vacuum Gauge can also be used on previous
Duramax applications.
IMPORTANT: Be sure to use the adapters for the yellow hoses with the J 45873
Fuel Return Volume Test Kit.
If the engine will not start, engine rotation must be higher than 150 RPM.
On 2005 through 2010 engines, this procedure can be performed while the engine is
running. If, during testing, an injector or injectors fails the test, follow Service
Information for the proper procedures.
Typically, on LB7 engines, you will be directed to replace all injectors as a set. On
all other engines, you’ll need to replace the failed injector.
During the injector replacement procedure, inspect the fuel line and fittings for signs
of corrosion and contamination.
IMPORTANT: Follow all safety precautions for Fuel System testing in Service
Information.
2-12
6.6L Duramax: Engine Diagnosis
Module 2: Fuel System Testing (Supply Side) and High Pressure Side
Module 2 Summary
Described:
─ Fuel System (Supply Side) diagnostic procedures
─ Fuel System High Pressure Side diagnostic procedures
2-13
MODULE 3
Glow Plug Diagnosis
Module 3 Objective
At the end of this module, you will be able to describe how to diagnose and service a
Glow Plug concern on the 6.6L Duramax diesel engine.
Notes:
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3-2
6.6L Duramax: Engine Diagnosis
Module 3: Glow Plug Diagnosis
Since the introduction of the LLY in 2004, a Glow Plug Control Module (GPCM) is
used on all Duramax applications.
Power for the GPCM is supplied through the Ignition 1 voltage circuit and the battery
voltage circuit.
There is also an engine ground circuit.
Each Glow Plug is controlled and monitored on its own circuit.
The GPCM communicates through the Controller Area Network (CAN)
communication circuits.
Notes:
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3-3
6.6L Duramax: Engine Diagnosis
Module 3: Glow Plug Diagnosis
CAN communication is bi-directional, meaning communications are over the high and
low circuits.
The GPCM uses the CAN communication circuit to communicate with the Fuel
Injection Control Module (FICM), the Transmission Control Module (TCM) and the
Engine Control Module (ECM) Module.
Since CAN communication is only between modules on this system, the scan tool will
communicate with the ECM through a Class 2 circuit.
3-4
6.6L Duramax: Engine Diagnosis
Module 3: Glow Plug Diagnosis
Starting with the 2006 model year, communications will now be on the High Speed
GM Local Area Network (GMLAN).
This will require using the CANdi module in order for the scan tool to communicate
with the modules on the system.
3-5
6.6L Duramax: Engine Diagnosis
Module 3: Glow Plug Diagnosis
Glow Plugs
Gold LB7
Silver LLY
The Glow Plug for the LB7 is gold in color. A relay supplies 12 volts to the plug.
Starting in 2004 with the LLY and all subsequent model years and RPO codes, the
Glow Plug is silver in color. The glow plugs are controlled by the GPCM through a
pulse width modulated 4.7 volts. This allows the glow plugs to reach 1000°C
(1832°F) in 2 seconds.
The thread position on 2006 and newer vehicles has been moved to the center of the
Glow Plug.
CAUTION
Do not install a LLY Glow Plug into a LB7 engine; severe engine damage could result.
3-6
6.6L Duramax: Engine Diagnosis
Module 3: Glow Plug Diagnosis
Diagnostic Scenario
Notes:
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3-7
6.6L Duramax: Engine Diagnosis
Module 3: Glow Plug Diagnosis
Beginning with the Diagnostic System Check for Engine Controls, everything looks
good during the Power Mode check, and the vehicle starts and idles okay.
When checking for DTCs, we find no
current codes set. However, there is
a U0106 in history. This identifies lost
communications from the Glow Plug
Controller.
Before diving into the U0106
diagnostics to track down this
intermittent MIL On concern, let's see
if there are any applicable bulletins.
3-8
6.6L Duramax: Engine Diagnosis
Module 3: Glow Plug Diagnosis
3-9
6.6L Duramax: Engine Diagnosis
Module 3: Glow Plug Diagnosis
Module 3 Summary
3-10
MODULE 4
Variable Nozzle Turbocharger System
Diagnosis
Module 4 Objective
At the end of this module, you will be able to describe how to diagnose a Variable
Nozzle Turbocharger system concern on the 6.6 Liter Duramax diesel engine.
Notes:
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4-2
6.6L Duramax: Engine Diagnosis
Module 4: Variable Nozzle Turbocharger System Diagnosis
Diagnostic Scenario
Notes:
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4-3
6.6L Duramax: Engine Diagnosis
Module 4: Variable Nozzle Turbocharger System Diagnosis
Beginning with the Diagnostic System Check for Engine Controls, everything is within
specifications.
Then, we attempt to reset the P2563 DTC using the Freeze Frame/Failure Records.
In this case, P2563 sets again.
The diagnostics direct us to install an injector test lamp between the turbocharger
vane position solenoid high and low control circuits.
We continue by commanding the turbocharger vane position solenoid ON and OFF
with the scan tool. The test lamp changes from dim to bright.
Since the test lamp flashed, this indicates that the ECM and the control circuits are
functioning within specification.
4-4
6.6L Duramax: Engine Diagnosis
Module 4: Variable Nozzle Turbocharger System Diagnosis
We check the sensor signal, low reference, and sensor 5 volt reference. All circuits
checked good.
The diagnostics now focus on the turbocharger vane control position sensor.
Next, we remove the turbocharger vane position sensor from the turbocharger. With
the ignition ON, observe the scan tool turbocharger vane position sensor voltage
while slowly depressing the plunger at the end of the turbocharger vane position
sensor. The voltage decreases smoothly from approximately 4.9 to 0.2 volts.
4-5
6.6L Duramax: Engine Diagnosis
Module 4: Variable Nozzle Turbocharger System Diagnosis
4-6
6.6L Duramax: Engine Diagnosis
Module 4: Variable Nozzle Turbocharger System Diagnosis
4-7
6.6L Duramax: Engine Diagnosis
Module 4: Variable Nozzle Turbocharger System Diagnosis
Since there is no power to the control valve, it should be in the At Rest position. In
this case, we see the smooth surface portion of the valve in the slot.
The valve seems to be in the Closed position. Therefore, we test the control valve.
After connecting the ECM and the control valve to its connector, turn the ignition ON,
with the engine OFF.
While depressing the button at the tip of the valve, use the scan tool to command the
valve ON and OFF. As we see at the slot closest to the button, the valve is not
responding.
The turbocharger vane control solenoid valve must be replaced.
Diagnosis is completed after the repair by ensuring the DTC does not return and no
other DTCs have been set during the procedure.
Video Notes:
When diagnosing VNT concerns, follow Strategy Based Diagnosis for the most
efficient service. Use the scan tool and the DMM for diagnosis.
The Engine Control Module (ECM) performs the Turbocharger Learn procedure
automatically during each ignition cycle.
However, after a repair to the turbocharger has been performed, the Turbocharger
Learn procedure must be performed manually using the scan tool.
You will need to turn the ignition OFF for at least 30 seconds after the enable
conditions have been met. If this is not done, the DTC may reset.
4-8
6.6L Duramax: Engine Diagnosis
Module 4: Variable Nozzle Turbocharger System Diagnosis
TECH TIP
It is important to note both sets of slots on the side of the control solenoid valve. If
you can see the serrations on the valve in the slot, then the valve is in the At Rest
position.
TECH TIP
4-9
6.6L Duramax: Engine Diagnosis
Module 4: Variable Nozzle Turbocharger System Diagnosis
Module 4 Summary
4-10