1 copyright © 2008 general motors corporation. all rights reserved

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Copyright © 2008 General Motors Corporation. All Rights Reserved.

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Duramax 6600: Operations, Service

& DiagnosisCourse #16340.45D2

Welcome to

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The material contained in

this course component

was accurate and current

at the time of course

development

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www.gmtraining.com

Web Site

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Question 1

In which of the following regions is your dealership located?

A. Atlanta

B. Chicago

C. Dallas

D. Los Angeles

E. New York

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Upon successful completion of this course, you will be able to apply concepts and procedures to diagnose concerns associated with the Duramax 6600 LMM Diesel Particulate Filter Exhaust Aftertreatment System.

Course Goal

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¨ Identify Duramax technology changes

¨ Explain the purpose of the Exhaust Aftertreatment System

¨ Describe the function of the Exhaust Aftertreatment System

Session Objectives

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¨ Review procedures for diagnosing & repairing Exhaust Aftertreatment System concerns

¨ Diagnose DPF Exhaust Aftertreatment

¨ Complete Service Regeneration Procedure

Session Objectives cont.

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¨ Differences between RPO Codes

¨ Data parameters, output tests & fuel system tests

¨ Fuel system diagnostic procedures

¨ Engine management control system diagnostic procedures

Session 1 Review

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¨ Identify Duramax technology changes

¨ Explain the purpose of the Exhaust Aftertreatment System

¨ Describe the function of the Exhaust Aftertreatment System

¨ Review procedures for diagnosing & repairing Exhaust Aftertreatment System concerns

Module 3 Objectives

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¨ DPF System Components

¨ Function of DPF System Components

¨ DPF Fuels and Lubricants

¨ Particulate Filter Regeneration

Module 3 Topics

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Diesel Fuel Labels

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Fuel Pump Labels

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Low Ash (CJ-4) Motor Oil

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API Rating

CI-4

1.5% ASHCJ-4

1% ASH

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API Label Description

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DFP Aftertreatment System Components

Intake Air Valve

Diesel Oxidation Catalyst

EGT 1 Sensor / EGT 2 Sensor

Particulate Filter

Differential Pressure Sensor / lines & hoses

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Fill-in-the-Blanks Exercise

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Fill-in-the-Blanks Exercise (completed)

DPS onChassis frame

DPS PressureLines & Hoses

ParticulateFilter

EGT Sensors DOC

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¨ Poisoning– Sulfur content > 15 ppm

– Can occur with 2-3 tanks fuel & sulfur > 500 ppm

¨ Operating temperature– Engine oil/coolant consumption will cause

DOC poisoning

– Insufficient DOC operating temp. is sign of DOC poisoning

Diesel Oxidation Catalyst Concerns

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Question 2

When looking at the various types of diesel fuels available, Low Sulfur Highway Diesel fuel has a maximum sulfur content of ________ ppm.

A. 5

B. 15

C. 50

D. 500

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Exhaust Gas Temperature (EGT) Sensor 1 & Sensor 2

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EGT 1 & 2 (MD)

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Particulate Filter

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Captured Cell Filter

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How the Particulate Filter Works

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What conditions do you think would cause the meltdown of a Particulate Filter?

Question

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Particulate Filter Meltdown

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Particulate Filter Meltdown cont.

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Differential Pressure Sensor

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Differential Pressure Sensor & Lines

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Intake Air Heater

Fuel Injectors

Turbocharger

Intake Air Valve

Exhaust Air Cooler

Engine Components

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Intake Air Valve

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Exhaust Air Cooler / Tailpipe

End View Tailpipe - Sierra / Silverado

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Particulate Filter Regeneration

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Normal Regeneration

– Passive

– Active

Service Regeneration

Types of Regeneration

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¨ Engine run time

¨ Distance traveled

¨ Fuel used

¨ Pressure across Particulate Filter

Particulate Filter Regeneration

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Platforms & Altitudes

Express & Savana

Kodiak & Topkick

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¨ No intervention from driver or ECM

¨ Build-up of particulate matter in DPF

¨ High exhaust temps incinerate soot

¨ ECM determines need for corrective action

Normal DPF Passive Regeneration

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¨ Different engine calibration

¨ Exhaust gas temps > 550ºC (1022ºF)

¨ Engine temp increased by late injections

¨ Engine elevates to 800 RPMs

Normal DPF Active Regeneration

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Silverado / Sierra DIC Messages

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Express / Savana DIC Messages

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Kodiac / Topkick DIC Messages

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¨ Must be performed outdoors

¨ Clean filter lamp illuminated

¨ Is performed due to P2463

¨ Takes approximately 35 minutes

¨ Vehicle must NOT be left unattended

Service Regeneration – Highlights

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¨ Identified Duramax technology changes

¨ Explained the purpose of Exhaust Aftertreatment System

¨ Described the function of Exhaust Aftertreatment System

Module 3 Summary

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Posttest Question 1

The REQUIRED type of fuel for the Duramax LMM is ______________.

A. Low Sulfur Diesel

B. Ultra Low Sulfur Diesel

C. Off-Road Diesel

D. All of the above

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Posttest Question 2

What is the REQUIRED type of engine oil for the Duramax LMM?

A. CF-4

B. CG-4

C. CH-4

D. CJ-4

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Posttest Question 3

The Intake Air Valve is used ONLY to ___________.

A. control engine RPM

B. assist with regeneration

C. reduce exhaust temperature

D. create engine vacuum

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Posttest Question 4

The purpose of the Differential Pressure Sensor is to monitor __________.

A. DOC status

B. DOC temperature

C. particulate filter status

D. particulate filter temperature

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Posttest Question 5

Which parameter(s) is/are used for regeneration?

A. Engine run time

B. Distance traveled

C. Fuel used

D. All of the above

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¨ Diagnose DPF System

¨ Identify DPF Service Procedures

¨ Diagnose Engine Management Concerns

Module 4 Objectives

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Diagnostic Scenario #1

Vehicle: 2007 GMC Sierra w/2,600 miles

Customer Concern: DIC is illuminated

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Scenario #1 DIC

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¨ EPA requirement 80K

¨ Life expectancy 120K

¨ NO test equipment for fuel or oil

Additional Particulate Filter Notes

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¨ Customer induced

¨ Engine control malfunction

¨ Excessive ash build-up

¨ Ash model incorrect in the ECM

Likely Causes

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What are we referring to when we say “soot model” or “ash model”?

Question

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Before Cleaning

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Regenerations Completed Parameter

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Diagnostic Scenario #2

Vehicle: 2007 GMC Sierra w/36,000 miles

Customer Concern: MIL is illuminated

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MIL in IPC

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¨ Battery Condition – OK

¨ Electrical Connections – clean & tight

¨ Fuses and grounds – OK

¨ No obvious concerns

Document ID# 1852902 – Steps 1 – 8

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¨ Scan Tool powered up

¨ Control Modules communicated

¨ NO communication DTCs

¨ Power Mode parameters - OK

Document ID# 1852902 – Steps 1 – 8 cont.

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What conditions could be causing our misfire concern?

Question

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¨ Low Compression

• Sticking valves

• Head gasket failure

• Burnt piston

¨ Insufficient Injector Flow

Possible Causes

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¨ Perform under conditions of customer concern

¨ Do not operate cruise control during test

¨ No speed/RPM limitation

Cylinder Power Balance Test Notes

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Which procedure was used to view the actual balance rates?

Question

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ECM replacement

GPCM replacement

Fuel Injector replacement

Fuel Injector Flow Rate Programming

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When installing a new fuel injector, ensure that the IQA data number from the yellow IQA Data Tag, shipped with the new injector, is programmed to the correct cylinder.

Important Statement

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Diagnostic Scenario #3

Vehicle: 2007 GMC Sierra w/22,000 miles

Customer Concern: DIC is illuminated

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Engine Power is Reduced

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Why do you think we didn’t find the leak when we commanded the turbocharger vanes closed during the P244B diagnostics?

Question

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What do you do with the Particulate Filter once it has been removed from the vehicle?

Question

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Diagnostic Scenario #4

Vehicle: 2007 Chevrolet Express w/58,000 miles

Customer Concern: MIL is illuminated

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Diagnostic Scenario #5

Vehicle: 2007 GMC Savana w/8,000 miles

Customer Concern: MIL is illuminated

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Ignition ON / Clear DTCs

Select DPF Regeneration Enable

Select ON

Exit Special Functions Menu

Remove scan tool

DPF Regeneration Enable

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¨ Diagnosed DPF System Concerns

¨ Identified DPF Service Procedures

¨ Diagnosed Engine Management Concerns

Module 4 Summary

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Identified Duramax technology changes

Explained the purpose of the Exhaust Aftertreatment System

Described the function of the Exhaust Aftertreatment System

Diagnosed & Repaired Exhaust Aftertreatment system-related concerns

Course Summary

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Posttest Question 6

During the Service Regeneration procedure you MUST _________.

A. place the vehicle outdoors

B. open the hood

C. connect a scan tool

D. all of the above

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Posttest Question 7

DPF Service Regeneration will take approximately ________ minutes to complete.

A. 15

B. 25

C. 35

D. 45

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Posttest Question 8

Under normal operating conditions the particulate filter has a life expectancy of _____ miles.

A. 70,000

B. 90,000

C. 100,000

D. 120,000

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Posttest Question 9

Fuel injector flow rate programming must be done when any of the following procedures are performed EXCEPT when _____________.

A. the ECM is replaced

B. the fuel pump is replaced

C. the GPCM is replaced

D. any fuel injectors are replaced

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Posttest Question 10

All of the following must be done with ECM replacement EXCEPT ________.

A. Capture & Restore Data

B. Record & Reprogram fuel filter life

C. Record fuel tank level

D. SPS Programming

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To Obtain Posttest ResultsTo Obtain Posttest Results

After 5 Business Days go to:¨ www.gmtraining.com¨ Select “Training Records” from menu¨ Select “View Your Training Records”

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Duramax 6600: Operations, Service

& DiagnosisCourse #16340.45D2

Thank you for attending

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Copyright © 2008 General Motors Corporation. All Rights Reserved.