Duramax LML & LGH Diesel

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ATG-23

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Description

Case Study

Duramax engines are not designed and produced by the manufacturer that sells them. This means that the people who created the engine management and emissions systems and the people who wrote the repair information didn't always understand each other. Repair information is becoming scarce and inconsistent for all vehicles, but is even worse for these Bosch fuel systems, Isuzu-designed engines, and GM vehicles.

This manual and class were designed specifically to give technicians a clear diagnostic path.

ATG spent months collecting and comparing technical information to fill in the holes of the repair information, and then diagnosed and repaired these engine management and emissions systems to validate everything we found.

This 200-page manual is the only place you'll find explanations that not only tell you which tests to run in what order and what the test results should be, but why, and what your options are when a test fails.

Table of Contents	Page

LML & LGH Duramax
Duramax Evolution
Generations	8
Overview	8
Things You Need to Know
Warnings	11
GM Bulletins	12
LML & LGH Differences	12
Crankcase Ventilation	12
Head Gasket Selection	14
Dual Thermostats	15
Warrantying Your Engine Work?	16
Identifying Power Up Software	17
Aftermarket ‘Foolers’	22
Alternative Power Up Identification Strategies	22
TCM Peak Torque – The Secret Power Up Clue	23

Air Intake System
Basic Intake System
Overview	25
Mass Airflow (MAF) Sensor	26
Manifold Absolute Pressure (MAP)/Boost Pressure Sensor	27
Intake Pressure PID Example	28
Intake Air Heater (IAH)	29
IAH PIDs	30
IAH Scan Tool Control	31
Intake Air Temperature (IAT) Sensor	31
Intake Air (IA) Valve	31
Intermittent High Idle Bulletin	31
Turbocharging
Turbocharger Overview	32
Variable Vane Turbo (VVT), Variable Geometry Turbo (VGT)	32
Closed Loop: Vane Position Solenoid & Vane Position Sensor	34
Vane Position Sensor Replacement	35
Vane Position Solenoid Circuits & Activity	35
Closed Loop Boost Control Scan Tool Test	36
Normal Vane Position Solenoid & Sensor Relationships	38
Learned Vane Position	39
Scan Tool Vane Learning	41
P003A – Vane Position Not Learned	41
Other Turbo Controls – Vane Position Solenoid	43
Other Turbo Controls – Vane Position Sensor	43
OEM Scan Tool Turbo Control Variations	44
Turbocharger Coolant Bypass	45
Common Turbocharger Smoking Faults	45
Turbocharger & Intake Noises	46
Turbocharger Mechanical Damage	47
Intake Leak Diagnosis (ALER & ISLI PIDs)	48
Exhaust Brake	51

Glow Plug System
Glow Plugs
Overview	52
Glow Plug Control Module (GPCM)	52
Glow Plug Faults	53
Glow Plug Service	54
Glow Plug Fault Codes	54
Glow Plug PIDs – PCM	55
Glow Plug PIDs – GPCM	55
Scan Tool Glow Plug Controls	58
Glow Plug Lab Scope Test	59

Fuel Systems
The Whole Enchilada
Overview	61
Fuel Supply Suction System
Supply Side Fuel Flow	63
Tank & Fuel Tank Module	64
Van Electric Priming Pump	64
Fuel Filter/Fuel Conditioning Module	65
Fuel Filter Vacuum Switch	67
Fuel Filter Warnings	67
Fuel Filter Replacement	68
Fuel Filter Life Reset	69
Manual Fuel Filter Life Reset	70
Aftermarket Fuel Filters	70
Low Pressure System Faults & Symptoms	71
Supply Side Vacuum Test for Restrictions	71
Fuel Aeration & Leak Test Overview	74
Primer Pump Pressure Test	75
High Pressure Pump Draw Test	77
Interpreting Primer Pump & High Pressure Pump Draw Test Results	78
Filler Neck Pressurization Test	78
Fuel Aeration – Finding Supply Side Leaks	79
Fuel Aeration Clear Line Test	79
Manual Supply Path Vacuum Test	81
Hey, I Can See the OEM Diagnostic Path From Here!	82
Intermittent Faults or a Worn Suction Pump? The Aftermrkt Pump Alternative	83
Fuel Conditioning Module Service	83
High Pressure Fuel System
High Pressure Side Fuel Flow	84
Bosch CP4 High Pressure Pump	84
Pump Timing	85
High Pressure Pump Failures	86
Fuel Pressure Regulators (FPR1 & FPR2)	88
FPR1 & FPR2 PID Activity	89
Fuel Temperature Sensors 1 & 2	90
Fuel Lines	91
Fuel Rails	91
Fuel Rail Pressure (FRP) Sensor	92
Fuel Pressure PIDs	93
No-Start/Hard Start – Checking Cranking Fuel Pressure	94
Scan Tool Fuel Pressure Control	94
Scan Tool High Pressure Pump Peak Output Test	96
FPR2 & High Pressure Pump Output Test	97
Return Line Race Fuel Valves?	98
Direct Fuel Injectors	98
Lab Scope Fuel Injector Testing	100
Injector Hydro-Mechanical Operation	103
Injector Balance Rate PIDs	104
Balance Rate Polarity vs. Likely Faults	105
Misfire Codes vs. Balance Rate Codes	105
Misfire vs. Balance Rate PIDs	106
Scan Tool Fuel Injector/Power Balance Test	108
Scan Tool Injector Adaptive Value Reset	110
Pilot Injection Balance	111
Injector Quantity Adjustment (IQA) Programming	113
Injector Return Rate Testing	116
Injector Replacement	119
High Pressure System Fuel leaks	119
Pressurized Fuel Return System
Constant Pressure Regulator	120
Fuel Return Connections	121
Backfill Valve	121
Constant Pressure Regulator Testing	122

Symptom Testing Strategies - ATG Symptom Tests
Overview	124
GM’s Starting Point: The Diagnostic System Check	125
GM’s Second Step: Review Strategy Based Diagnostics	126
GM’s Third Step: Preliminary Tests	126
How to Use ATG Symptom Tests	127
No-Start	127
Hard Start – Cold Only	128
Hard Start – Hot Only	128
2012 LML No-Start Case Study	129
Hard-Start or Start & Stall	133
Hesitation, Sag, Stumble	134
Misfire or Rough Idle	135
Multiple Misfiring Cylinders	136
Misfiring with White Smoke	137
Stalling	137
Surging	137
Poor Fuel Economy	138
Low Power	139
Black Smoke	140
White Smoke	141
Blue/Gray Smoke	142
Any Color Smoke – Only During Regeneration	142
Knocking/Pinging	142
Comprehensive Fuel System Test	143

Emissions Systems
Exhaust Gas Recirculation (EGR)
Overview	144
EGR Valve & Position Sensor	144
EGR Enabling & Operating Conditions	146
EGR Cooler Bypass Valve	147
EGR Cooler & Bypass Paths	148
EGR Temperature Sensors – EGT1 & EGT2	149
EGR, EGR Cooler, & Bypass Valve Faults	150
EGR System PIDs	152
Scan Tool EGR Valve Control	153
Scan Tool EGR Cooler Bypass Valve Control	154
EGR & Bypass Verification Trick Summary	155
Aftertreatment Systems Overview
DOC, DPF, SCR, DEF – So Many Acronyms!	156
Exhaust Gas Temperature (EGT) Sensors	157
Diesel Oxidation Catalyst (DOC) & Diesel Particulate Filter (DPF)
Overview	158
Diesel Oxidation Catalyst (DOC)	158
DOC Faults	158
DOC Quick Check	159
Diesel Particulate Filter (DPF)	159
DPF Faults	160
Closed Loop: DPF Differential Pressure Sensor	161
Regeneration & DPF Service Life	161
Soot Accumulation Rates & Regeneration Frequency	162
Passive vs. Active Regeneration	162
Active vs. Service (Forced) Regeneration	162
Driver Information Center (DIC) Messages & the P2463	162
HCI: The 9^th Injector	164
HCI Faults	165
The Post-Injection Backup Plan	166
HCI Diagnosis	166
HCI Service & Bleeding (DPF Regeneration Enable)	167
Exhaust Air Cooler (Diffuser)	168
Intake Air (IA) Valve	168
Intake Air (IA) Valve Scan Tool Control	169
Service Regeneration Conditions	169
Service Regeneration Termination Conditions	169
Service Regeneration – What to Expect	170
Warnings & Lawyer-Repellent	170
Service Regeneration Example	171
Regeneration Soot Reduction	173
Codes Set During Regeneration	174
Inhibited Regeneration	174
Scan Tool Regeneration Enable	174
Selective Catalyst Reduction (SCR) & Diesel Exhaust Fluid (DEF)
Systems Overview	175
SCR Operation	175
Refilling the DEF (Reductant) Tank	176
Closed Loop Control – NOX Sensors	177
DEF Tank & Reductant Pump Module	179
Reductant Sensor Module	179
Reductant Level Sensor	180
Frozen DEF & DEF Heaters	181
Scan Tool DEF Heater PIDs & Controls	181
Key-Off Injector & Pump Purging	181
DEF Injector	182
DEF Diffuser	182
DEF Pump Testing	182
DEF Injector Testing	183
SCR/DEF DIC Warning Message Summary	183
SCR/DEF DIC Warning Sub-Messages Summary	185
DEF Level Warning Levels	185
Refill Detection	186
Forced Refill Detection	187
DEF Quality Warning Levels	188
Service DEF System: Fault or Tampering Warning Levels	189
Post-Repair Procedures	191
Scan Tool SCR/DEF Resets	191
Reductant Fluid Quality Test (RFQT) Setup	192
Scan Tool RFQT Test Procedure	193
RFQT Critical PID Review	194
Scan Tool RFQT Test Examples	195
Messages Won’t Clear? Your Therapist Says ‘Read This First’	198
Suggested Order of Repair – TSB 12-06-04-002	199
DEF Warning Messages Won’t Clear – PIP 4864	199
‘Exhaust Fluid Quality Poor’ Message Won’t Clear – PIP 5007	200
‘Exhaust Fluid Quality Poor’ Message Won’t Clear – PI 1214	202
Permanent Codes & Code Buckets – TSB 12-06-04-002	203

Reference Information
Wiring Examples
Note About Examples	206
NOX Sensor Network – Powertrain Expansion Bus	206
Basic Sensors	207
High & Low Pressure Fuel Components	208
[High Pressure Fuel Injectors	209
\\EGT & DPF Sensors	210
EGR & Turbocharger Systems	211
APPS & Engine Position Sensors	212
Startability: Glow Plugs & IAH	213
Aftertreatment: SCR & DEF	214

Duramax Intake/Exhaust Leak Check Shortcut

The manual is over 200 pages long, the case study below is a quick sample to show how we leverage underused PIDs to save hours of testing.

This case study used an aftermarket scan tool example, it shows the air leak PID, which is a built-in leak indicator. The manual includes a table to interpret the values. If the EGR is commanded closed and the value is near '1.0', then you don't have to waste any time looking for a boosted or unboosted intake leak, and exhaust leak, or a poorly seating EGR valve. The PCM already did the work for you!

This simple example is one of dozens that show the fastest methods for eliminating the most possible causes with the least effort. It could be said that the point of the manual is to to take apart as little as possible during diagnosis. Even better, we've woven these tests into decision- making indicators so you don't miss anything.

Air Leak PID Graphing Example

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