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Wednesday, June 18, 2014

Duramax Turbocharger Vane Position Sensor Duramax 4094 VGT

                                                    Duramax Power Diesel Turbo Vane 

The Duramax diesel turbocharger increases engine power by pumping compressed air into the combustion chambers, allowing a greater quantity of fuel to com-bust at the optimal air or fuel ratio. The duramax 4094 vvt turbine spins as exhaust gas flows out of the engine and over the exhaust turbine blades, and turns the air intake compressor wheel at the other end of the turbine shaft, pumping more air into the intercooler intake system.

The engine control module controls nine vanes for the turbocharger. The vanes are used to vary the amount of boost pressure and can control the boost pressure independent of engine speed. The vanes mount to a unison ring which are rotated to change the vane angle. The engine computer will vary the vane angle which adjusts the boost depending upon the load that applied when you accelerate the pedal at the require speed of the engine.

The turbocharger vanes are normally open when the engine is not under load. However, the engine main computer will often close the turbocharger vanes to create back pressure to drive exhaust gas through the exhaust gas re circulation recognized as the egr or egr delete valve. Does at extreme cold temperatures, the engine computer may close the vanes at low load conditions in order to accelerate engine coolant heating .temperature and when reach the optimum performance temp the turbo vanes will open as require from the engine computer. The engine computer may also close the turbocharger vanes under exhaust braking conditions, only when is below the command coolant temperature 

During engine diesel regeneration, the engine will vary the turbocharger vanes to assist with the exhaust system warm-up, and to maintain proper engine exhaust temperatures needed to properly regenerate the exhaust particulate filter called the dpf or dpf delete.


Tuesday, June 17, 2014

Duramax Diesel Fuel Pump Flow and Diesel Fuel Injection Cycle

                                              Duramax Diesel Fuel Pump Injection Cycle

Duramax Fuel Flow Diagram 

Diesel Fuel Tank 
Titan Fuel Tanks
This is a aftermarket fuel tank by Titan Fuel Tanks 
Fuel is drawn by the fuel injection pump from the fuel tank to the engine through the fuel supply lines. 

Duramax Engine 
Duramax Engine and Fuel Filter Location  
Fuel flows to the fuel filter heater element housing, which combines a water separator, a prime pump, fuel heater element and a filter element.

Duramax Fuel Pumps  
Duramax Engine and Fuel Filter Location 
A mechanical Cp3 fuel injection pump at the front of the engine valley includes the fuel supply pump and the high-pressure pump.

Duramax Cp3 Bag of Parts 
.Fuel Injection Parts 
The small section of the fuel pump assembly is the supply pump called The Bag of Parts modified by Industrial Injection which creates a vacuum to pull fuel from the fuel tank to the high-pressure pump the vacuum varies with engine load and speed as the engine turners.

Duramax Fuel Injectors 
LB7/LLY/LBZ/LMM/LML Duramax Fuel Injectors 
The small section of the fuel pump assembly is the supply pump called The Bag of Parts modified by Industrial Injection which creates a vacuum to pull fuel from the fuel tank to the high-pressure pump the vacuum varies with engine load and speed as the engine turners.

The fuel rail pressure sensor is mounted in the end of the right fuel rail. Fuel is used to cool and lubricate the fuel injectors and fuel injection pump. Then the fuel return system is designed to return this fuel to the fuel tank. If the high side fuel pressure becomes excessive, then the fuel rail pressure relief valve releases the fuel into the fuel return system. The return fuel travels through the fuel cooler and then to the titan fuel tank.and does repeating the cycle of Diesel Fuel Injection System  



Cummins Dual Fueler Belt System Twin CP3 Fuel Pump

                   Cummins Diesel Truck Can Be Equipped With Two Fuel Injection Pumps 

The drive belt system may use 1 belt or 2 belts. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belts are made of different types of rubbers, chloroprene or EPDM, and have different layers or plays containing either fiber cloth or cords for reinforcement.

Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth.

The drive belt is pulled by the crankshaft balance pulley across the accessory drive component pulleys. The spring loaded drive belt tension-er keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tension-er arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft.

The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the accessory.

Some of the accessories are driven by two fuel injection pumps called CP3 designed by Bosch 

Cummins Diesel Fuel Lift Pumps modified and manufactured by ats diesel or ppe diesel 


Friday, June 13, 2014

Duramax Diesel 6.6L Tap Shift Control by BD Diesel

                         DIESEL GEAR TOUCH CONTROL FOR 2001-2005 GM/CHEVY DURAMAX
                                                                       TOW/HAUL MODE

-It is important to note that the customer may accidentally engage the tow/haul button and then comment about delayed or harsh shifts when not pulling a trailer or under heavy load. This is a Normal function of tow/haul mode when used in inappropriate conditions That may contribute to complaints that "cannot duplicate/no trouble found."
-Tow /Haul is a mode that will optimize gear selection for operation with heavy loads (such as towing):
1.Optimize acceleration performance for launches and rolling accelerations
2.It reduce shift cycling
3.Optimize braking performance and speed control during engine braking situations
4.Improve vehicle speed control while requiring less throttle pedal activity
-Because tow/haul mode maintains lower gears longer and increases shift pressures, it will degrade fuel economy and generate shift feel concerns if it is used inappropriately in unloaded driving conditions.
-Tow/Haul Tap Shift is selected or de-selected via a switch on the end of the transmission shift lever for all models. A light on the instrument panel will illuminate to indicate that tow/haul has been selected.
-Tow/Haul must be re-selected every time the vehicle is started (if desired).
-Tow/Haul is designed to be most effective when the vehicle and trailer combined weight is at least 75% of the vehicle's Gross Combined Weight Rating.
-Operation of tow/haul in a lightly loaded or non-loaded vehicle will not cause damage. However, there is no benefit to the selection of tow/haul when the vehicle is unloaded. The tow/haul switch is not a performance switch.
-Selection of tow/haul when unloaded may result in unpleasant engine and transmission driving characteristics and reduced fuel economy, since up shifts occur at higher engine speeds. Tow/Haul is recommend only when pulling a heavy trailer or a large or heavy load.
-Automatic downshifting Normal Power-train Braking to assist speed control will activate when Tow/Haul mode is active and the brake pedal is depressed (even lightly). Downshifts are commanded at higher speeds than normal resulting in engine braking that assists with speed control. After a power-train braking situation ends, up-shifts will typically be commanded when the accelerator pedal is pushed down. a quick increase in accelerate pedal may be required.

Tuesday, June 10, 2014

Duramax Glow Plugs Operation Glow Plug Relay

                                                    Cold Weather Starts and Glow Plugs 

Glow Plug System Description
Duramax diesel engine, air alone is compressed in the cylinder. Then, after the air has been compressed, a charge of fuel is sprayed into the cylinder and ignition occurs, due to the heat of compression. Eight glow plugs are used as an aid to starting.

The glow plug initial ON time will vary based on the system voltage and temperature. Lower temperatures cause longer ON times all the times.

The ECM provides glow plug operation after starting a cold engine. This post-start operation is initiated when the ignition switch is returned to Run, from the Start position. This operation helps clean up excessive white smoke or poor idle quality after starting.

Control of the instant start system, glow plugs is determine by an electronic glow plug control unit and 4.7 volt glow plugs, requiring 2 seconds to heat up to 1,000°C (1,832°F) . The temperature and the power consumption is controlled between the engine control module and the controller within a wide range to suit the engine's pre-heating requirements. Each glow plug is energized individually. This capability yields more optimum heat times for the glow plugs, thus pre-glow times can be kept to a minimum for short wait to crank times and maximum glow plug durability.

A normal functioning system operates as follows
 1.Turn the ignition ON with the engine OFF, and at room temperature. 
 2.The glow plugs turn ON and heat up in 2 seconds and then are pulse-width modulated for           another 2 seconds .
 3.The glow plug wait lamp is ON for 1 second 
 4.If the engine is cranked during or after the above sequence, the glow plugs may cycle ON and OFF after the ignition switch is returned from the start position, whether the engine starts or not. The engine does not have to be running to terminate the glow plug cycling.

Glow Plugs 
The glow plugs are 4.7 volt heaters in each of the cylinders that turn ON, then pulse-width modulated when the ignition switch is turned to the RUN position prior to starting the engine. They remain pulsing a short time after starting, then they are turned OFF.

A Wait to Start lamp on the instrument panel provides information on engine starting conditions. The Wait to Start lamp will not illuminate during post-start glow plug operation.

Glow Plug/Controller
The glow plug controller is a solid state device which operates the glow plugs. The glow plug controller is connected to the following circuits:
1. The fuel heater ignition 1 voltage circuit
2. The battery voltage circuit
3. The CAN communication circuit located between the engine control module and the glow plug controller
5. The engine ground circuit
6. The glow plug supply voltage circuits located between the glow plug controller and the glow plugs.
7. The glow plug diagnostic circuits are directly monitored individually by using a separate transistor to control current to each glow plug. Individual diagnosis is thus possible for every glow plug.


Duramax Diesel leaks Oil and Oil Consumption

My Duramax Diesel Leaks Oil 

Measurement of Oil Consumption
Engines require a period of time to BREAK IN so that moving parts are properly seated. Therefore, oil economy should not be tested until the vehicle has accumulated at least 6400 km (4000 mi). An exception would be allowed only if an engine is reported to be using more than 0.946 liter (1 qt) in 1600 km (1000 mi).
1.Verify that the engine has no external leaks. Repair as necessary.
2.Verify that the engine is at normal operating temperature (see Owner's Manual or Service Manual).
3.Park the vehicle on a level surface.
4.Wait at least 15 minutes, after the engine is shut off, before checking the oil level to make sure that the oil has had time to drain back into the crankcase.
5.Verify that the oil level is at, but not above, the full mark on the dipstick, and that the proper viscosity and quality oil are being used as recommended in the Owner's Manual.
6.Record the vehicle mileage, date, and exact oil level on the form Vehicle
7.Ask the customer or yourself to verify the oil level, each time the vehicle is fueled, following steps 1-6 and return the vehicle to the dealership or private shop owner if the oil level is found at or below the add mark, 0.946 liter (1 qt) low. If the oil level remains above the add mark, the customer or yourself should continue to operate the vehicle and verify the engine oil level until 3200 km (2000 mi) has accumulated before returning to the shop for a final evaluation on your diesel vehicle.
8.If the final evaluation shows that the engine uses more than 0.946 liter (1 qt) in 3200 km (2000 mi), follow the published symptom diagnostics as described in the appropriate Service Manual or relate the information to your mechanic. If the oil consumption test shows that the engine uses less than 0.946 liter (1 qt) in 3200 km (2000 mi), explain to the customer that their engine meets the guidelines for oil consumption.

Aggressive Driving, High Speed or High RPM Driving
Aggressive driving and/or continuous driving at high speeds/high RPMs will increase oil consumption. Because this may not always be an everyday occurrence, it is hard to determine exactly how much the oil economy will be affected.
A higher rate of oil consumption is normal for vehicles equipped with manual transmissions that are driven aggressively. By "aggressive," we mean operation at high RPM (3,000 RPM to redline), with frequent use of engine braking (using the engine to slow the vehicle). Vehicles that are driven aggressively may consume engine oil at a rate of up to 0.946 L (1 quart) every 805 km (500 mi). This is normal for a vehicle that is driven aggressively. No repair is necessary. This characteristic does, however, require the owner to check the engine oil level at sufficiently frequent intervals, especially when driving aggressively, to assure the oil level remains within the recommended operating range, you should check the oil level every time you get fuel.

                                                        Diesel Consumption Card 
Toxic Diesel 866-488-6942

Duramax Diesel Head Gasket Assembly Cleaning

                              Duramax Diesel New Cylinder Head Gasket Assembly Cleaning 

Special Cleaning Requirements
For 2001-2006 vehicles produced with the first generation head gasket, special attention must be given to the cleaning of the engine block and cylinder head surfaces when servicing with a second generation gasket. The crimped areas (1) on the first generation gasket may, over time, allow corrosion buildup where they contact the block and cylinder head surfaces. The second generation gasket has raised ribs that seal at these crimped areas (1). A special cleaning procedure is required to ensure proper sealing.

Cleaning Procedure
1.Remove the old head gasket using service manual procedures. Save the gasket for reference until the repair is completed.
2.Place clean rags in the cylinder bores and push-rod openings in order to keep out debris.
3.Carefully clean the gasket sealing surface of large sealing or corrosion matter. When scraping, take care not to scratch or gouge the metal surfaces. Do not push the debris into oil, coolant, and combustion openings or bolt holes.
4.Inspect the gasket sealing surfaces for corrosion, especially in the areas that were in contact with the crimped tabs of the first generation head gasket. If corrosion is present, continue with the rest of the steps in this procedure for proper cleaning. If the sealing surface is sufficiently clean and smooth, use the revised torque specification listed towards the end of this bulletin and continue with published service manual procedures to complete the repair.
5.For surfaces that have corrosion or pitting, wrap a piece of flat steel (4"x 2" or larger) with 600 grit wet grade sand paper. Using Moisture Displacing Lubricant, wet sand the block surface to remove any remaining gasket material or corrosion. Do not use any paper coarser than 600 grit.
-Do not use any power type sanding devices.
-Do not use a wire brush or wheel to clean gasket surfaces.
-Do not use chemical cleaning agents on gasket surfaces.
6.Take care to keep the sanding block parallel to the block surface and evenly sand the sealing surface. Some areas of corrosion will still show a stain. Do not attempt to wet sand these areas down to a shiny metal surface.
7.Change the sanding paper when it becomes clogged. Carefully and frequently wipe the surface, using a clean cloth each time, to prevent sanding debris from building up and contaminating the oil and coolant cavities.
8.Clean the bolt threads and holes and remove the rags from the bore cavities and push-rod openings.
9.Repeat the above cleaning procedure on the Cylinder Head Gasket surface.
10.Clean the engine block and cylinder head gasket  surfaces with Brake Parts Cleaner, to remove any traces of oil or debris.
11.Using the revised head bolt torque specification below, reassemble the engine with NEW M-12 cylinder head gasket according to service manual procedures.