1. 1 Copyright © 2008 General Motors Corporation. All Rights Reserved.

2. 2 Duramax 6600: Operations, Service & Diagnosis Course #16340.45D2 Welcome to

3. 3 The material contained in this course component was accurate and current at the time of course development

4. 4 www.gmtraining.com Web Site

5. 5 Question 1 In which of the following regions is your dealership located? A.Atlanta B.Chicago C.Dallas D.Los Angeles E.New York

6. 6 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

7. 7  Identify Duramax technology changes  Explain the purpose of the Exhaust Aftertreatment System  Describe the function of the Exhaust Aftertreatment System Session Objectives

8. 8  Review procedures for diagnosing & repairing Exhaust Aftertreatment System concerns  Diagnose DPF Exhaust Aftertreatment  Complete Service Regeneration Procedure Session Objectives cont.

9. 9  Differences between RPO Codes  Data parameters, output tests & fuel system tests  Fuel system diagnostic procedures  Engine management control system diagnostic procedures Session 1 Review

10. 10  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

11. 11  DPF System Components  Function of DPF System Components  DPF Fuels and Lubricants  Particulate Filter Regeneration Module 3 Topics

12. 12

13. 13

14. 14 Diesel Fuel Labels

15. 15 Fuel Pump Labels

16. 16 Low Ash (CJ-4) Motor Oil

17. 17 API Rating CI-4 1.5% ASH CJ-4 1% ASH

18. 18 API Label Description

19. 19 DFP Aftertreatment System Components  Intake Air Valve  Diesel Oxidation Catalyst  EGT 1 Sensor / EGT 2 Sensor  Particulate Filter  Differential Pressure Sensor / lines & hoses

20. 20 Fill-in-the-Blanks Exercise

21. 21 Fill-in-the-Blanks Exercise (completed) DPS on Chassis frame DPS Pressure Lines & Hoses Particulate Filter EGT Sensors DOC

22. 22  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

23. 23 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

24. 24

25. 25 Exhaust Gas Temperature (EGT) Sensor 1 & Sensor 2

26. 26 EGT 1 & 2 (MD)

27. 27 Particulate Filter

28. 28 Captured Cell Filter

29. 29 How the Particulate Filter Works

30. 30 What conditions do you think would cause the meltdown of a Particulate Filter? Question

31. 31 Particulate Filter Meltdown

32. 32 Particulate Filter Meltdown cont.

33. 33 Differential Pressure Sensor

34. 34 Differential Pressure Sensor & Lines

35. 35  Intake Air Heater  Fuel Injectors  Turbocharger  Intake Air Valve  Exhaust Air Cooler Engine Components

36. 36 Intake Air Valve

37. 37 Exhaust Air Cooler / Tailpipe End ViewTailpipe - Sierra / Silverado

38. 38 Particulate Filter Regeneration

39. 39  Normal Regeneration – Passive – Active  Service Regeneration Types of Regeneration

40. 40  Engine run time  Distance traveled  Fuel used  Pressure across Particulate Filter Particulate Filter Regeneration

41. 41 Platforms & Altitudes Express & Savana Kodiak & Topkick

42. 42  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

43. 43  Different engine calibration  Exhaust gas temps > 550ºC (1022ºF)  Engine temp increased by late injections  Engine elevates to 800 RPMs Normal DPF Active Regeneration

44. 44 Silverado / Sierra DIC Messages

45. 45 Express / Savana DIC Messages

46. 46 Kodiac / Topkick DIC Messages

47. 47  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

48. 48  Identified Duramax technology changes  Explained the purpose of Exhaust Aftertreatment System  Described the function of Exhaust Aftertreatment System Module 3 Summary

49. 49 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 30 2928272625242322212019181716151413121110 9 8 7 6 5 4 3 2 1 0

50. 50 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 30 2928272625242322212019181716151413121110 9 8 7 6 5 4 3 2 1 0

51. 51 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 30 2928272625242322212019181716151413121110 9 8 7 6 5 4 3 2 1 0

52. 52 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 30 2928272625242322212019181716151413121110 9 8 7 6 5 4 3 2 1 0

53. 53 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 30 2928272625242322212019181716151413121110 9 8 7 6 5 4 3 2 1 0

54. 54  Diagnose DPF System  Identify DPF Service Procedures  Diagnose Engine Management Concerns Module 4 Objectives

55. 55 Diagnostic Scenario #1 Vehicle:2007 GMC Sierra w/2,600 miles Customer Concern:DIC is illuminated

56. 56 Scenario #1 DIC

57. 57  EPA requirement 80K  Life expectancy 120K  NO test equipment for fuel or oil Additional Particulate Filter Notes

58. 58  Customer induced  Engine control malfunction  Excessive ash build-up  Ash model incorrect in the ECM Likely Causes

59. 59 What are we referring to when we say “soot model” or “ash model”? Question

60. 60 Before Cleaning

61. 61 Regenerations Completed Parameter

62. 62 Diagnostic Scenario #2 Vehicle:2007 GMC Sierra w/36,000 miles Customer Concern:MIL is illuminated

63. 63 MIL in IPC

64. 64  Battery Condition – OK  Electrical Connections – clean & tight  Fuses and grounds – OK  No obvious concerns Document ID# 1852902 – Steps 1 – 8

65. 65  Scan Tool powered up  Control Modules communicated  NO communication DTCs  Power Mode parameters - OK Document ID# 1852902 – Steps 1 – 8 cont.

66. 66 What conditions could be causing our misfire concern? Question

67. 67  Low Compression Sticking valves Sticking valves Head gasket failure Head gasket failure Burnt piston Burnt piston  Insufficient Injector Flow Possible Causes

68. 68  Perform under conditions of customer concern  Do not operate cruise control during test  No speed/RPM limitation Cylinder Power Balance Test Notes

69. 69 Which procedure was used to view the actual balance rates? Question

70. 70  ECM replacement  GPCM replacement  Fuel Injector replacement Fuel Injector Flow Rate Programming

71. 71 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

72. 72 Diagnostic Scenario #3 Vehicle:2007 GMC Sierra w/22,000 miles Customer Concern:DIC is illuminated

73. 73 Engine Power is Reduced

74. 74 Why do you think we didn’t find the leak when we commanded the turbocharger vanes closed during the P244B diagnostics? Question

75. 75 What do you do with the Particulate Filter once it has been removed from the vehicle? Question

76. 76 Diagnostic Scenario #4 Vehicle:2007 Chevrolet Express w/58,000 miles Customer Concern:MIL is illuminated

77. 77 Diagnostic Scenario #5 Vehicle:2007 GMC Savana w/8,000 miles Customer Concern:MIL is illuminated

78. 78  Ignition ON / Clear DTCs  Select DPF Regeneration Enable  Select ON  Exit Special Functions Menu  Remove scan tool DPF Regeneration Enable

79. 79  Diagnosed DPF System Concerns  Identified DPF Service Procedures  Diagnosed Engine Management Concerns Module 4 Summary

80. 80  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

81. 81 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 30 2928272625242322212019181716151413121110 9 8 7 6 5 4 3 2 1 0

82. 82 Posttest Question 7 DPF Service Regeneration will take approximately ________ minutes to complete. A.15 B.25 C.35 D.45 30 2928272625242322212019181716151413121110 9 8 7 6 5 4 3 2 1 0

83. 83 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 30 2928272625242322212019181716151413121110 9 8 7 6 5 4 3 2 1 0

84. 84 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 30 2928272625242322212019181716151413121110 9 8 7 6 5 4 3 2 1 0

85. 85 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 30 2928272625242322212019181716151413121110 9 8 7 6 5 4 3 2 1 0

86. 86 To Obtain Posttest Results After 5 Business Days go to:  www.gmtraining.com  Select “Training Records” from menu  Select “View Your Training Records”

87. 87 Duramax 6600: Operations, Service & Diagnosis Course #16340.45D2 Thank you for attending

88. 88 Copyright © 2008 General Motors Corporation. All Rights Reserved.