March & April 2009 members: Now is the time to renew your membership. Don't miss out on the great new content coming to The Diesel Page in the months ahead.
This past February 4th, and we learned all about GM's plans for the 2011 model year GM 2500HD/3500 series pickups. Though we're expecting a price increase of $3,000-$5,000, due to the addition of the "Diesel Exhaust Fluid" (urea) system, GM is back with a range of improvements and upgrades that promise to make GM the HD diesel truck leader. Go here for all of the new truck details.
The 2010 emissions regulations are upon us - as well as GM. Here's an indepth look at the new 2011 LML Duramax 6600 and the new emissions equipment. How's it all work? What effect will it have on ownership? What else is new & different about the Duramax? We'll answer all these questions and more.
The roots of the Automotive Engine Rebuilders Association goes all the way back to 1922. With over 3,000 current members worldwide, the AERA has focused on member service through its publications, the web and in meetings and seminars. Networking on a professional level allows its members access to the best and most up-to-date engine service information, which can result in the best overall vehicle owner satisfaction. Diesel engines have always been a part of the AERA's program, and some of the best 6.2/6.5 problem-solving information originated with the large network of AERA member techs. Here's a run-down on a selection of 6.2/6.5 related AERA bulletins that we've referred to here in The Diesel Page quite often.
The chaos in the economy, the uncertain political climate and the trials GM has had these past 12 months have produced a flood of rumors on the Internet and certainly among the GM diesel community of pickup owners. Is the Duramax on borrowed time? Well.... for the time being no, but there have been a number of curious events that could cause one to believe that. This editorial discusses what I've heard, and despite the big hole in production, smart money expects the newest LML urea-equipped Duramax 6600 to appear in the 2011 model lineup. Go here for the details.
Diesel engines are hard on head gaskets. No matter how well the gasket may have been designed, replacing the head gaskets can be an issue a longtime diesel owner may need to deal with. The Duramax was designed to produce a compression ratio (CR) of between 18:1 to 16.8:1, depending on model year. Add the high CR (compared to a gas engine) and the high power/torque output of these engines, and you know cylinder pressures are high. What I hope to do here is describe what symptoms appear when a head gasket or an LB7 injector cup begins leaking, which usually results in excessive cooling system pressure or a loss of coolant. Knowing what to look for can save you a lot of money if the problem is caught early, and taking care of the problem before it becomes worse can reduce both downtime and overall expense.
Here is a story about a Duramax 6600 diesel powered Massey Ferguson tractor owned by Lammert ter Heide, here in Holland. This is not the first GM diesel to power this tractor. Before the Duramax, Lambert powered his Massey with a 6.2L turbo diesel. More is better, so installing a Duramax promised to take the power to a new level, and make it very competitive during the popular tractor pulls now sweeping Europe.
Operating a diesel engine during the cold winter months demands that all diesel fuel and electrical systems operate normally. Included here is list of precautionary measures and cold weather strategies that will help your diesel pickup operate reliably throughout the coming winter. If you're new to the GM diesel, the information found here should help to answer your questions as well as reduce any anxiety you might have about cold weather operation. It's really easier than you think.
We've been discussing the Holset HX35 here at The Diesel Page for quite a while now as a potential improvement in turbochargers over what is possible when using the GM-x series of factory turbos. Member Tyler Nelson has installed an HX-35 on his 6.5L diesel that is currently installed in his 1986 CHevy K10. Tyler's installation broadens the application of this turbo to include all 6.2/6.5 diesel engines in the 1980's body style trucks and Suburbans.
"Lucky Max" Twin 6.2L Diesel Powered - Chris Craft Commander
Lucky Max is a Chris Craft Commander (Sports Cruiser model) built in Michigan in 1972. She is 31' long and approx 10' wide. The hull is fiberglass, constructed before the folks really knew the true strength of fiberglass. This means that the material is thicker that what you might find on a boat built today, but also, I believe it was all "hand-laid" at that time. I have not yet been able to confirm weights, but I've been told that the boat would probably scale around 7 tons.
Member Andrew Prince wrote recently to provide information concerning how he applied some rust prevention to his new truck. As some of you may recall, The Diesel Page produced an article in 2004 entitled, "Room for Improvement", which included some shots beneath the new trucks that showed far too many rusted components. In that 2004 article, we said "A certain segment of the Duramax powered 2500HD/3500 truck buying group is comprised of enthusiasts - those who obsess to some degree over the look, ride, utility or performance of their new truck. Including myself as part of that group, I've winced at certain details of the new trucks. GM could easily rectify the situation, and this article is intended to highlight some of what I feel needs attention." While there have been a few improvements made since 2004, with regard to rust control, more needs to be done. That's what this article is about.
Has the cooling efficiency of your truck's air conditioning system gone down hill in recent years? Does the inside of your truck smell like wet socks when it's damp outside? If so, maybe you need to replace the in-cab "Passenger Compartment Air Filter". One of the least talked about routine maintenance items is the passenger compartment air filter. Factory installed in the 1999-2002 GM full-size pickups, the in-cab air filter(s) was designed to trap dust, pollen, and other debris that might enter through the vehicle's fresh air vent system. In addition to making the in-cab environment a more pleasant place to spend time, filtering the air also helps to keep the A/C evaporator core and heater core functioning normally. We'll show you with large and clear photos how to easily replace the in-cab air filter.
This tech page first appeared here in The Diesel Page in February of 2001. After analyzing the various wiring diagrams and theory of operation for both the 1991-1993 DB2-equipped 6.5 trucks and comparing that information to the 1994+ 6.5TD equipped trucks, an idea was born that I thought might help those truck owners who wished to convert their DS electronic trucks to use a DB2 mechanical fuel injection pump. We knew going in that maintaining shift quality for the 4L80-E would be the biggest challenge following a mechanical fuel injection conversion. This tech page is being re-printed here to show what we did more than 8 years ago, and perhaps spur additional thought. In addition, new and expanded information has been added that outlines what alternatives are available for 4L80-E control.
USDP's third annual Dyno Day was held this past June 6, 2009 here in Missoula Montana, and the crowd just keeps getting bigger each year. From morning till late afternoon, 42 of the Big Three's diesel pickups rolled across the Mustang dyno rollers and kept everyone entertained.
Pickup trucks and large sport utility vehicles have been GM's most profitable automotive segment. Pickup truck sales accounted for just 1% of the total automotive sales volume in 1959, while trucks (pickups & large SUV's) totaled 64% of GM sales in 2005. Due to their enormous popularity, pickups aren't going away anytime soon, and the Duramax Diesel will remain a big factor in driving pickup sales.
MagnaFlow Performance Exhaust Systems
Do you really need to install a performance exhaust system before adding power?
Does an aftermarket exhaust system really make a difference in dyno or towing performance?
Real-life testing is the best way to answer these questions.
Product Review: Factory exhaust systems have improved considerably though the years, with mandrel-bent 3-1/2" or 4" tubing now being the norm. You've probably read quite a few exhaust system reviews through the years, and saw the rear-wheel horsepower improvement following the installation of a performance exhaust system. The installation photos were nice and the dyno numbers usually reinforce the notion that an aftermarket exhaust system allows the engine to make more power and help to provide a safety margin when installing performance products. What's the real story?
As is typical for any production engine, the manufacturer can introduce design changes throughout the production life as experience is gained through warranty repairs. GM recently released the most recent upgrade in cylinder head gasket design as well as new head bolt torque specifications for the LB7, LLY and early LBZ engines. The second-generation head gasket will require a new lower head bolt torque angle specification as well as special cleaning methods for the head/block gasket surfaces. Go here for all of the details.
Product review: Being able to read and erase trouble codes is a basic necessity these days - especially for anyone owning a GM diesel truck that is out of warranty. Even if your truck is still covered by the factory powertrain warranty, knowing what that "service engine soon" light means and how serious the problem might be can help you when scheduling service or can help you gain some insight into what the problem might be. The inexpensive T50e can can help you save money on vehicle maintenance.
To promote goodwill and maintain the reputation of the Duramax 6600, GM offered a generous 7-year or 200,000 mile injector replacement warranty to all LB7 owners. This was good news to those owning 2001-2004.5 Duramax equipped truck, and the extended warranty did save a lot of owners a lot of money on injector replacement. But, all that has already or will soon be coming to an end. The first LB7 Duramax powered trucks are coming up on nine years old. The first two model years for the Duramax are now past the 7-year time limit, and those owners have to bite the bullet and pay for any injector replacement out of their own pocket. For the past thirteen years The Diesel Page has been here to help members save money on engine service, and that's why we're presenting this do-it-yourself fuel injector replacement tech story.
A lot has been said in recent years about using marine fuel injection system components for an on-road 6.5L turbo diesel application. For those who may not know, connecting the word "marine" with the GM 6.5L diesel began with the development efforts at Peninsular Diesel. Specially calibrated marine fuel injectors, marine fuel injection pump calibrations and marine oriented turbochargers all came from the "boat" point of view at Peninsular. A marine 6.5L diesel must be equipped to cruise at approximately 2600-2800 RPM for extended periods of time, and make efficient power at those engine speeds. Not coincidentally, Peninsular's marine 6.5L turbo diesels produce maximum torque and deliver an efficient fuel consumption rate at that same RPM range. It's all about the torque peak... To work with the marine paradigm in engine speeds, the fuel injection system must meet the needs of the engine RPM (and of course, meet the expectations of the boat owners). Here's what we know about marine 6.5L fuel injectors and marine fuel injection pumps.
Brake Specific Fuel Consumption Power, Load & RPM How do these factors affect diesel fuel economy?
We've been telling folks for years that in general, a diesel engine produces its best fuel economy when run at or near the RPM that coincides with its torque peak. Whether you're towing a heavy trailer or simply commuting to work, the torque peak RPM is where you'll find the best fuel economy. In June 2006, we dyno tested a new 6.5L "Fuel Mizer" fuel economy engine using Peninsular Engine's calibrated fuel metering and engine dynamometer system in hopes of confirming that fact.
After a long winter here in the Northwest U.S., most diesel pickup owners are ready for a trip to the Southwest - Southwest Canada to be precise, the home of BD Diesel Performance and their semi-annual Dyno Day. Despite the gray skies, hundreds of diesel enthusiasts made their way to Abbotsford, British Columbia last spring on April 5th, and a total of sixty trucks spun the rollers from early morning through late afternoon. If you like power, this was a great way to spend a day, to both learn more about diesel performance and have an opportunity to see trucks push the Mustang dyno to nearly 1000-hp.
Bringing new life to an older truck is more than just a way to save a ton of money. A surprising number of members keep the same vehicle for decades, and want to do all they can to keep it on the road. Converting the drivetrain to Duramax/Allison power has become a popular upgrade for the GM fans, which increases the vehicle's capability. Member Kean Clark is currently working his way through a 1987 Chevy C30 restoration and Duramax conversion project, and we wanted to share his progress with the GM community.
The question of whether we should be using synthetic diesel motor oil in our GM diesel engines has been a popular subject for a long time. Synthetic oil has some definite advantages over the available conventional motor oils, but are there any measurable benefits that justify the added expense? Find out here!
This annotated Diagnostic Trouble Code (DTC) list is specific to the Allison 1000 automatic transmission. Being armed with a good basic knowledge about the Allison trouble codes can help to ensure a better level of service if you have an in-warranty truck or can save you a lot of money if your truck is now out of warranty.
The Holset HX-35W has been discussed here in The Diesel Page as an alternative to the factory GM-series of turbochargers - for the performance oriented 6.5 owner. Member Jerry Giedeman dropped by recently to show me his 1994 light-duty K2500, and discuss a few of his engine modifcations. Included among those modifications was the installation of an HX-35W turbocharger. Follow along as we show you Jerry's turbo setup and explain how it was integrated into his overall 6.5 performance plan.
This annotated Diagnostic Trouble Code (DTC) list contains all of the Duramax diesel engine-specific trouble codes relating to the engine. We've learned through the years that while a typical GM service technician may understand gas engines and their related powertrains quite well, a talented diesel mechanic is much harder to find. Being armed with a good basic knowledge about the diesel systems incorporated into your truck can help to ensure a better level of service if you have an in-warranty truck or can save you a lot of money if your truck is now out of warranty. Want to know what the codes are, what they mean, how to retrieve them and know how to repair the problem?
The Engine Shut-Off (ESO) solenoid has long been thought to be a potential cause for an engine stalling problem or any sort of intermittent engine running condition. While a failing ESO remains a potential cause for these conditions, it is not the most likely. This DTC update will discuss the ESO and we'll explain how to troubleshoot and repair an ESO related failure.
Back about the time the auto makers began using electronic fuel injection, they discovered that for the onboard computer to correctly calculate the fuel/air ratio, they needed to measure the incoming air flow to the engine. Electronic fuel injection not only allowed the engine to run more efficiently and to produce better fuel economy and drive-ability, but MAF sensor data also allowed the computer to help protect the engine if the ratio of fuel to air fell outside of normal. The Duramax diesel also employs a MAF sensor, which is used to measure the grams/second of air entering the engine's intake system.
To take the 6.5L Turbo Diesel to the next level of performance, we have to consider using another turbocharger. The factory GM-series of turbochargers are very good at helping the 6.5L diesel produce excellent low to mid-range performance, but the factory turbocharger becomes a hindrance when adding power. The Diesel Page has been promoting aftermarket turbochargers for the 6.5L diesel since the 90's, and we dug deep into the turbocharger theory last year with a comprehensive article that laid out what these engines require in terms of air flow across the RPM range. Analyzing the compressor maps clearly showed that the factory turbos were a limiting factor in producing power, especially at higher engine RPMs. This article is being presented here to show what commonly available turbocharger would make a great alternative.
The 1994 and newer electronic 6.5L diesel PCM (Powertrain Control Module) has the ability to control fuel injection timing, depending on a variety of conditions and sensor inputs. This DTC discussion will hit the high points for DTC-34/P0216, DTC-88/P1214 and DTC-18/P0251, the titles for which are indicated above. A correct fuel injection timing is critical for performance, drive-ability and fuel economy. These codes do not necessarily mean an expensive repair, if you are equipped to resolve the problem yourself. Knowing what these codes mean and knowing how to effectively diagnose the cause of a fuel injection system generating these codes could save to a lot of time and money.
The new and redesigned AMG P400 6.5L Turbo Diesel first became available this past March 2008. Mike Robertson bought one of first, and has installed this engine in his 1993 Chevy K3500. We'll show you what was involved when installing the engine, how it is equipped and we'll show you the dyno data that demonstrates the performance improvement after some minor tweaking of the factory fuel injection system.
The 2001 model-year and newer GM Duramax diesels were all equipped with the "drive-by-wire" Bosch high-pressure common-rail electronic fuel injection system. While the Accelerator Pedal Position (APP) module has performed reliably through the years, the first Duramax equipped trucks are now more than 8 years old, and knowing how the APP operates and how to troubleshoot a problem could be a huge help in the future. Thirteen diagnostic trouble codes are discussed, and we'll walk you through the troubleshooting process.
Beginning in the 1994 model-year, the GM 6.5L diesels began using the "drive-by-wire" Stanadyne DS4 electronic fuel injection system. While it may appear to be a problematic engine control system component, the Accelerator Pedal Position (APP) module has performed reliably through the years. However, the first electronic 6.5 is now more than 14 years old, and knowing how the APP operates and how to troubleshoot a problem could save you a ton of money. Twenty-four diagnostic trouble codes for the OBD I & II systems are discussed, and we'll walk you through the troubleshooting process.
Those of us who have been following GM's on-again off-again diesel Suburban program over the past eight years were beginning to lose faith whether we would ever see a production version. The wait may be coming to an end as GM unveiled its proposed 4.5L Duramax powered Suburban to an enthusiastic crowd during last fall's annual SEMA show. The most recent news we have is that GM will begin production of the 4.5L V-8 sometime in the second half of 2009 (as a 2010 model year), and will introduce this new engine in a variety of full-size vehicles, including the popular Suburban. Go here for more engine details.
This article was first written in May 2006 when diesel fuel cost just $2.90/gallon. Following hurricane Katrina in 2005, GM diesel owners became increasingly concerned about the $3/gallon diesel fuel we experienced as a result of the storm. In an effort to help owners better understand the 6.2/6.5 engine design and to provide a little insight into how to improve fuel economy, we discussed cylinder head and pre-cup design. Fast forward to mid 2008... Now that diesel fuel has reached $5/gallon in some parts of the country, we've reloaded an expanded version of that 2006 article, to provide even more information that explains how to squeeze more fuel economy from your GM 6.2/6.5 diesel.
Product Review: A dual-bypass oil filtration system and synthetic motor oil can extend drain intervals by at least 8 times when compared to conventional oil and filters, and can extend the life of your engine. Follow along as we show you how to install Amsoil's Dual By-Pass oil filteration system and show you the analytical results of cleaner oil.
All those who haven't been living under a rock have probably noticed that the cost of diesel fuel has risen to the "Arm & Leg" level at your neighborhood fuel station. You have to know that the "five finger discounters" have also noticed. Save money on your fuel costs by buying a genuine diesel locking fuel cap directly from your local GM dealer. Go here for the installation instructions.
This editorial is the result of a conversation we were having in our bulletin board forum about exporting diesel fuel and high diesel fuel prices, which motivated me to dig deeper into our nation's energy policies and use of petroleum. What I learned is that time is running out. Aside from the opinions expressed, this editorial catalogs what conventional and unconventional oil sources currently exist here in the United States. Almost everyone believes that becoming energy independent is vital to the future of the country. How much oil are we using? How much is the world using? How much are we paying for imported oil, and how long can we continue to pay? Do we have the will to become energy independent? Do we actually have a choice?
We've always been concerned about fuel economy. That's why many diesel owners bought a diesel in the first place, and is precisely why I bought a 6.2L diesel powered GMC K1500 in the 1980's. Compared to today, fuel was relatively cheap back in the day, but nearly everyone was still concerned about the cost of fuel. Where we once saw diesel fuel at less than $1.30/gallon in the mid 90's, as of May 2008 we're seeing a painful $4.30 or higher. This upward trend will likely continue. What we hope to do here is illustrate powertrain management strategies and modifications that can help to improve fuel economy and save you money.
Like many of you who use your diesel pickup truck or Suburban to tow trailers or haul heavy loads, I use my Suburban to tow a 30 foot travel trailer that tips the scales at a hefty 8500#. Over time, this has caused the rear springs on my 3/4 ton Suburban to relax so that the rear now sits lower than the front even while unloaded. With models available to fit all 6.5L or Duramax powered pickup trucks and Suburbans, I eventually settled on the AirLift adjustable air springs as being the best solution to this problem. Follow along as we take you through the kit introduction, installation and show how the air springs solved the problem.
The Diagnostic Trouble Code P0093 applies to the 2001 model-year Duramax. This trouble code was updated for the 2002-2004 model year engines, and received a new number - P1093. Each refers to the same problem. P0093 & P1093 are defined as "Fuel System Large Leak Detected", which could mean that one or more injectors are experiencing a high fuel-return flow rate. People usually start looking beneath the truck for signs of fuel, but this isn't that kind of a leak. Let's have a look at these, and other related trouble codes, to provide a little more insight into what they mean and how to deal with them.
This article is both a look back to the introduction of the 6.5, with an analysis of the 1988-1998 GM/Ford/Dodge market share, and a look forward to what should mean a bright future for the 6.5L Turbo Diesel.
Not many "new" 6.5L diesel problems come to light these days. After twelve years, we've seen just about every problem these engines and fuel systems can experience. A few months ago one of our Hawaiian members called to report a problem he was having with his DS4 equipped 6.5 that I had not dealt with before, and I thought it was interesting enough to discuss here in The Diesel Page. That problem is excessive fuel return flow and low fuel pressure developed by the electric fuel lift pump.
For several years now, we've been hearing reports of transfer case fluid leaks due to a wear-through on the rear case half. If not caught before a leak develops, the transfer case could suffer complete failure due to a lack of lubrication. The most reliable solution includes installing an aftermarket part that prevents a case wear-through from happening. Follow along as we show you the problem and describe what it takes to produce a permanent solution.
The Crankcase Depression Regulator (CDR) has been a part of the 6.2/6.5 diesel emissions system since the first 6.2L diesel equipped truck rolled off the assembly lines in the fall of 1981. The CDR's primary purpose is to maintain something less than 5" of water vacuum within the crankcase. We sacrificed a perfectly serviceable CDR by cutting it apart to have a look inside, and to show you how it operates.
Two of the most common trouble codes produced by the DS4 electronic fuel injection pump are a result of either a fuel solenoid response time short or long. While the troublesome electronic Fuel Solenoid Driver module usually winds up being the cause of a short response time, a problem with the mechanical fuel solenoid components inside the injection pump are the usual cause of a long response time. What we'll do here is look at those fuel solenoid components, explain how they operate and describe how to improve reliability.
Everyone can appreciate a good deal, an inexpensive upgrade or a quick fix. Making the factory 1992-93 turbo wastegate actuator adjustable is all these, plus it'll allow your 6.5 to produce more power. The modified factory GM turbocharger wastegate actuator shown here will fit all of the GM factory turbos produced from 1992 to 1995, and its adjustability can be used to produce an increase in boost pressure. Before showing you how to modify the factory actuator, let's look at what the turbocharger wastegate does and how it does it.
Dual Thermostats Improving Cooling System Performance for the 6.5L Turbo Diesel
The new 130-GPM water pump increased coolant flow through the block and heads by 74%, and through the radiator by 9%. The motivation for increasing the coolant flow-rate was to help eliminate hot spots within the engine and to reduce cylinder head cracking. Dual thermostats were required to both increase the flow rate capacity and to prevent pressure surges within the cooling system that are possible when running a single thermostat. In this article, we learn more from those at GM about why the 6.5L diesel needs dual thermostats when running the 130-GPM water pump.
For decades, splayed main caps have helped power merchants in the gas engine performance market provide a solution to cylinder block failures. Multiplying the power output of a factory engine can stress the block in ways the original engineers never imagined. Splayed main caps anchor the main webs to the pan rails, which help strengthen the bottom end and allow the engine to safely produce a lot more power. Since 2002, custom engine builders have begun adding them to the 6.5L diesel, not so much to make big power, but to reduce the possibility of main web cracking. Let's have a look at three different aftermarket splayed main cap designs for the 6.5L diesel, and consider what they might do to improve 6.5 reliability.
The 18:1 Peninsular pistons were incorporated into our project 6.5TD engine build in late 1998. The advantages of a lower compression ratio (in the context of the project engine) is, a lower CR allows for more boost, and more boost allows for more fuel, which means the engine will make more power, while maintaining reasonable combustion temperatures & pressures. The folks at Peninsular Diesel told me they use a lower CR for the durability advantage. This is an expanded explanation for why lowering the compression ratio improves durability and what effect lowering compression might have on engine operation.
Knowing what to expect when buying performance products for your 6.5 should be a part of your shopping experience, and advertised power gains should be reflected by those seen during real-world tests. Though individual trucks and powertrains can produce some variability in the power they produce with a particular vendor's performance programming, the averages should reflect reality. This article is presented here to provide a historical perspective on 6.5 power going all the way back to 1997 (yes, we've been doing this a long time), and to provide a reality check for advertised performance gains.
The rising popularity of diesel pickups in recent years has created an uncounted number of new markets and new opportunities for both manufacturers and vendors. Even the 6.5L diesel has seen its popularity increase among both diesel owners and the aftermarket. This rising popularity is mostly positive, but it does have a darker side - counterfeiting... Find out how to identify genuine AM General 6.5L diesel engines.
An opportunity presented itself this past summer to learn more about a mechanical fuel injection conversion in a 1996 6.5TD Chevrolet K3500. A local shop bought a really nice black 1996 crew cab dually, that was already equipped with a cowl induction hood, Alcoa aluminum wheels and a high-end aluminum flat bed. The DS4 electronic fuel injection system had become so unreliable that the original owner sold the truck for an unbelievably low price. Because this truck was equipped with the NV4500 5-speed manual transmission, the new owner wanted to convert the fuel system to mechanical fuel injection. Cooling system and cruise control modifications are covered here, along with lots more discussion and photos.
Seemingly overnight, diesel drag racing has swept the nation, and is becoming more popular as each racing season passes. To help fill the need for speed, more retired Pro-Stock drag race trucks are being brought out of retirement, but not to run blown nitro burning bigblocks. Nope... The trucks are rocketing down the track with the state-of-the-art in diesel performance. Brad Makinen brought new life to a retired gas Pro-Stock truck in the form of "Dirtymax", a Duramax diesel powered Chevy 1500. This truck appeared at a drag race event I attended this past June here in Montana, which provided an opportunity to look beneath the fiberglass skin to see what it takes to make a Pro-Stock diesel run in the 8-9 second range.
Turbochargers are the final frontier for 6.5 performance development. Certainly, there have been aftermarket 6.5L turbo options available for several years now, but a lack of understanding about how turbocharger design contributes to diesel performance has hampered a serious investigation - till now. This article shows what it takes to allow the 6.5 to achieve a level of cool-running, smoke-free and long-term performance no one would have thought possible.
Product Review: Most 6.5L diesel owners don't give a lot of thought to the harmonic damper, but the 6.5 and indeed all diesel engines depend on their harmonic damper to produce a smoother running engine and to reduce the destructive effect of harmonic vibrations in the crankshaft. Whether due to age or accumulated mileage, more 6.5L diesel engines are suffering from crankshaft failure - some of which are due to a deterioration of the factory harmonic damper. Until recently, our only choice was the factory damper. Fluidampr's recent release of their viscous damper for the 6.2/6.5 changes everything.
A Charge Air Cooler (also known as an intercooler) is one of the best performance towing upgrades a 6.5L diesel owner can install. Unfortunately, commercial CAC kits have always been too expensive. Now, you can put a kit together on your own using information in this article for less than $400, which is up to $1000 less expensive than some 6.5 commercial kits. This article will save you a lot of money, yet give you a great looking, highly efficient and proven charge air cooler.
Chevy -Vs- Ford Tow testing the new emissions LMM Duramax and 6.4L Powerstroke
A recent pickup truck ad I saw on television said: "Truck guys will tell you taking off with 10,000-lbs ain't no picnic. Stopping 10,000-lbs ain't no picnic either." We agree. Towing tests are few and far between in the automotive media. Most of what we see are dyno results, 1/4-mile elapsed times, and generalized reports about on-road capability. Those types of tests can provide some clue about what we might expect to see while towing a heavy trailer, but they fall short of a real towing evaluation. Part of what most potential GM & Ford buyers really want to know is how the newest diesel pickups stack up against one another in a real-world towing test on a real hill while towing a trailer that weighs at least 10,000-lbs. That's what this test was all about.
General Motors announces an all-new 4.5-liter V-8 Duramax high-output diesel engine for the Chevrolet Silverado and GMC Sierra light-duty pickup trucks and the HUMMER H2. The engine fuel efficiency offers a 25 percent advantage compared with gasoline engines. Environmental benefits of the new engine include a 13-percent reduction in CO2 versus gasoline engines, and at least a 90-percent reduction in particulates and NOx when compared to diesel vehicles today. GM-Media News Release
Helping owners of these GM vehicles has been our primary focus these past 11+ years, and we've covered a lot of ground during this time. Based on some of the discussion topics appearing in our bulletin board and from reading the email I receive, it appears that some of what we've published about the 6.5L diesel during the early days of The Diesel Page might need to be restated for the benefit of the new 6.5 owners. The 6.5L cooling system upgrades, compression ratios, turbocharger boost pressures and more are what we'll discuss this time.
AM General has a new 6.5L diesel engine. The genesis for the engine modifications we'll discuss here began more than a year ago when I first heard about a series of proposed changes to the 6.5 that would allow for a significant power and durability increase. The HMMWV is getting heavier, with all the armor and military technology being added, and a more capable diesel engine became necessary. The power increases, as well as structural and component changes we'll discuss here will take the 6.5 to the next level in performance.
After six years and nine months of continuous production, DMAX Ltd., the maker of the Duramax 6600, celebrated producing its 1,000,000th engine on April 16, 2007. According to DMAX, they can sell all of the engines they produce and more. Go here to see the story and learn more about what makes the Duramax 6600 so successful.
The new VIN code 6 2007i LMM Duramax equipped trucks have arrived, and along with them the new DOC/DPF (Diesel Oxidation Converter/Diesel Particulate Filter). Changes in the emissions system are the big news, and this article should help to explain what's new & different and shine a light on what LMM owners need to know to have the fewest problems. Go here to see original photos of the new emissions components, and learn how these components function. Do we need to worry about the 2007 emissions systems?
Why do we need an EGT (Exhaust Gas Temperature) gauge? Well, if you're adding power to your 6.5, excessive exhaust temperatures could toast your engine. Having an EGT gauge helps you to protect the engine. This article will show you where and how to properly install the pyrometer used by your EGT gauge.
The 6.2L diesel equipped trucks and SUV's were all equipped with rear drum brakes. Upgrading to rear discs help in two important areas - reduce unsprung weight and improve stopping ability. Demands on the braking system increase as loads or vehicle speeds increase, and stopping can sometimes be more important than going fast.
I recently upgraded the stock mirrors on my 2005 GMC 2500HD to the 2006 model trailer towing mirrors. Although the stock mirrors extended for trailer towing, I was not happy with the narrow field of view the stock mirrors provided. For the 2006 model year, GM released a new style extendable towing mirror, similar to the Ford SD towing mirrors. Go here for a photo illustrated step by step guide to installation.
A variable timer allows you to power the glow plugs automatically, or for as long as the switch is held in the momentary-ON position. Adjustability is a key feature - longer glow times can be dialed-in during the winter months, and then reduced once warmer temperatures arrive - simple to install and easy to use.
Book Review: Drivetrain expert and author Jim Allen has teamed up with a leading drivetrain component supplier, Randy Lyman of Randy's Ring & Pinion, to produce a profusely illustrated and perhaps definitive book on the drive axle and differential.
Here, you'll find 43 of the top GM Technical Service Bulletins pertaining to these trucks and the Duramax/Allison drivetrain. Included are the bulletin number, the title and a summary for all 43 listed bulletins. This compilation contains great information you need to know.
Going all the way back to 2000, GM has admonished technicians and vehicle owners not to allow the metal-cased ECM (Engine Control Module) and TCM (Transmission Control Module) to be used as a grounding location that could subject the electrical system to excessive electrical current. Find out what happens when this occurs.
I've answered a lot of questions through the years concerning the GM diesel engines. The hardest question goes something like this: "I'm considering buying a 199x Chevy with the 6.5L turbo diesel. I've heard some bad things about this engine, and I don't want to buy into more problems. I want a diesel, but is this a good engine?" That's a tough one. Go here for the answers.
The ubiquitous 4L80-E Throttle Position Switch first appeared as part of the GM diesel powertrain in 1991 with the introduction of the then brand new 4L80-E electronically-controlled 4-speed automatic overdrive transmission. Whether either for gas or diesel application, a TPS relayed throttle position information to the transmission control module (TCM), which allowed the TCM to control shift scheduling and shift quality. At the same time, GM designed a new TPS that bolted onto the passenger side of the DB2 fuel injection pump, making for an easy installation. Go here to learn how to adjust the TPS to allow correct 4L80-E shift calibration.
Designed to meet the 2007 emissions regulations, the 2007 LLM & LMM Duramax 6600 diesel engines have met the challenge, and continue to lead in power & torque. More power and torque are the good news. Go here to learn all of the details about the new engine and its application.
Trucks at SEMA were there to attract attention - and boy did they! Each of the 2100+ Vendors and manufacturers who attend the annual Specialty Equipment Market Association event needed something special to lure some of the 100,000+ passers-by (and the media) into their booth. Having an eye catching truck helps them do just that, and this year was no exception. Here is a collection of GM, Ford & Dodge (and Toyota) trucks I thought stood out in some way from the others at SEMA 2006. Have a look!
Product Review: The Allison 1000-Series 5/6-speed transmissions are simply the best and most durable automatics to ever have been installed in a pickup truck. When using stock power, it's practically impossible to hurt the transmission or exceed its torque handling capability. As good as the Allison is, however, it's still possible to exceed its torque handling capability when using a power adder. Most Allisons will hang onto at least 75 additional horsepower and 200 lb-ft of torque, but living on the ragged edge can take a toll on long-term durability. This is why installing a performance-built Allison can increase the fun!
Reducing emissions components found in diesel exhaust is not without its share of engineering challenges and increased cost. While some fear for the future of the light-truck diesel market, we here at The Diesel Page remain optimistic - in fact, confident that the current trend in light-truck diesel usage will continue. Go here to find out what we'll need to know and how the new fuel and emissions requirements will affect all of us.
GM has a lot riding on the 2007 model year. With nearly 50% of all new vehicles sold in the U.S. being pickup trucks, this market is something General Motors simply has to do well in. Introduced as a 1999 model, the outgoing Silverado is now eight model years old, and has begun losing ground to the fresh faces offered by both foreign and domestic competitors. Enter the GMT-900, a new for 2007 body style that introduces a long list of refinements in addition to all new sheet metal. Included here are new photos and information about the new 1500 series trucks, and we'll discuss how the design features shown here could appear in the upcoming 2500HD/3500.
A looming grade can either induce dread or anticipation; depending on whether you're driving the highest rated diesel pickup the "big three" have to offer. Included here is an accounting of the 12 trucks that pulled the hill this year, which included 4- Duramax's, 4- Powerstrokes, 2- Dodge Cummins, and 2- 6.5TD's. Find out what truck is the King of the Hill.
After considering all the various cold air intakes systems available for my truck, I decided to develop my own, which only cost a few dollars and an hour or so to complete. Keeping the intake air as cool as possible improves power and may improve fuel economy. While inexpensive, this modification retains the excellent filtering ability of the stock air intake system.
Diesel Primer Getting acquainted with your GM 6.5TD & Duramax Diesel.
Ok, you just bought a new (or new to you) GM diesel equipped truck or Suburban. You might be wondering what you need to know about diesel engines to get the fuel economy, power and reliability diesel engines are noted for. What you'll find here is essential information specific to the GM diesel engines that could help eliminate some of the problems experienced by new diesel owners, and help you get more out of your "new" diesel engine.
Since the late 1980's, GM has used a firewall-mounted electronic cruise control module that remained more or less unchanged through 1999. The 6.2L/6.5L diesels used this cruise control module in the 1988-1993 model-year 6.2/6.5 diesel (mechanical fuel injection) equipped GMT-400 trucks and in the gasoline engine equipped C/K trucks & SUV's through the 1999 model year. Millions of these cruise control modules exist, and knowing how to retrofit a gas module into a diesel application can save you a ton of money if you're having a problem with the one you have now. In addition, these cruise control modules can be used when converting an electronically fuel injected 6.5 to mechanical fuel injection. If you fit into either category, or if you need to troubleshoot your existing cruise control system, this article is for you.
In an effort to reduce cold-start induced white smoke, GM has upgraded the glow plugs, the glow plug controller and the ECM programming on a continuing basis since first introducing the first Duramax 6600 in the fall of 2000. The 2006 Duramax, identified as either RPO code LLY (early '06 models) or LBZ (late '06 models), saw another glow system upgrade. Faster-acting glow plugs and shorter cycle times combine to further reduce white smoke after a cold start, while helping to make diesel engine operation more transparent to those more familiar with starting a gas engine. However, there have been a few bumps in the road regarding the 2006 glow system.
In a quest to accessorize our vehicles to our tastes with items such as lights, stereos and so on, we sometimes overlook what gives life to these accessories - the charging system. The original charging system is generally adequate for a factory-equipped vehicle, but increasing the electrical load on your factory alternator could lead to problems. There are two options to alleviate the power shortage: a custom high-output single alternator or dual factory alternators. Dual alternators were optional for the 6.5TD, which makes acquiring the factory brackets and hardware easy to obtain and install. Go here to see how to acquire the parts and make the install.
Member Arjan Kolkman reports on one of the most unique 6.2L diesel conversions we've heard about. The amount of ingenuity and fine workmanship make this worthy of inclusion here in The Diesel Page.
Now more than 5 years old, the Washington, DC based Diesel Technology Forum was created to highlight the economic importance of, and push for, continued development of clean diesel technology. Find out what we learned while attending the 2005 meeting.
Through the years, we've discussed fuel economy many times here at The Diesel Page. Common strategies for maximizing MPG include driving slower, reducing weight, reducing drag, and optimizing both vehicle and engine tune. To one degree or another, all of these areas have an effect on fuel efficiency. We'll include all of the common strategies for increasing fuel economy in our new MPG Project, as well every other component and even including vehicle choice that combine to produce the highest possible fuel economy for a GM V-8 diesel powered vehicle.
As the weather turned cooler in the late fall of 2005, we learned that our 18:1 low compression engine needed more glow cycle time to produce quick and clean cold starts. This article illustrates a simple and inexpensive modification designed to provide manual control for the electronic 6.5 glow system.
Fuel Quality can determine whether your diesel fuel injection system provides typical service or whether you are plagued with frequent visits to the dealership. GM recently upgraded the factory fuel filter element in an effort to help protect the Bosch high-pressure common-rail fuel injection system used by the Duramax 6600. Trapping more and smaller particles in the fuel can improve both fuel quality and injection system longevity. Lubrication Specialist Greg Landuyt has developed an easy to install and cost effective auxiliary fuel filter kit that can add a significant safety margin to the diesel fuel you're using.
As diesel fuel injection systems become more complex and more sensitive to fuel quality, owners have become more tuned-in to the nature of diesel fuel systems. Being able to check fuel pressure (vacuum) can help an owner diagnose a future problem or allow him to monitor the condition of the fuel filter in an on-going basis. This not only can save you a lot of frustration in the high-stakes game of vehicle service, but can save you money on fuel filters by not replacing them till the fuel restriction gauge tells you it's time.
Got Boost? KD Boost Valve for the 2001-2004 LB7 Duramax 6600
There's an old saying that says "offer a great $5 part that installs in 5 minutes, and you'll sell a million of them." Well, the KD boost valve might be a little more than $5, but it is still inexpensive, installs in minutes, and offers a lot of bang for the buck. This simple device increases maximum boost pressure about ~5-8 psi, and makes the factory LB7 turbo a lot more responsive under all operating conditions. Combine this with any one of a variety of Duramax power mods, and you'll see an even bigger improvement in power than what a power mod by itself delivers.
The third annual Edge Products' "Weekend on the Edge" event was held near Salt Lake City, Utah this past September. For anyone who loves diesel engines, fast trucks and big-big power, this was a weekend you didn't want to miss. Click the above link to read more about it.
We hear of Allison fluid leaks every once in a while, and have recently experienced one ourselves. Most of these leaks result in automatic transmission fluid dripping off the bellhousing area of the transmission. An input shaft seal problem probably comes to mind first, but as we've learned, these seals are rarely the cause. Follow along we show you what to look for and how to repair a leaky Allison.
The 2006 model-year Chevy & GMC diesel pickups began arriving on dealer lots in August of this year. While not much has been added or changed to the pickup styling or option list, the big news is the new RPO code LBZ Duramax 6600 diesel engine. Go here for a look at the new trucks and to learn more about the new uprated Duramax diesel engine.
Making big power these days requires help to burn all of the fuel provided by the power modules and programs used in competition, and nitrous helps burn that fuel and make more power. If you're after the most Duramax diesel performance, all roads lead to nitrous oxide.
The number of different gauges and gauge accessories has grown considerably since our 2002 gauge install piece. I recently stopped by to see the folks at USDieselParts.com, and got acquainted with what's new for those looking for gauges and gauge accessories. Let's have a look.
TheDieselPage.com Editorial LT265/75R16
What you need to know before upsizing tires on your Chevy/GMC 2500HD
An important ingredient in truck appearance is one of proportions. Design engineers consider cab height, cab length, box length, fender well openings and many other appearance details for proper proportions. Tire size is another proportional feature that plays into how we perceive the appearance of a pickup truck. Most agree the factory tire size of 245/75R16 has always appeared to be too small. Nearly all agree - except that is, for GM.
A bright yellow Service Engine Soon or Message Center warning usually means trouble. Luckily, this "Service 4WD" Message Center warning light often means you'll just need to replace the pushbutton switch panel that controls the NV-263 selectable-shift transfer case (RPO code NP1). Go here to find out how.
Performance tuning/flash programmers appear to be carving out a market with the Duramax performance crowd - and for good reason. Programmers offer a number of unique features that make them a "must have" for any Duramax owner. Here is a brief summary of five Duramax power programmers, and a list of features available for your Duramax.
The exterior of the truck was finally completed on the evening of May 13th. That week was rather hectic as we pushed to make the truck ready for a local auto show held in Missoula, Montana on the 15th. We were able to attend, and had a great time, even though there were just 38 miles on the drivetrain upon arriving at the show. The photos shown here were taken that morning. Go here to see the completed exterior truck photos.
For the first time in the history of warfare, troops can communicate via the Internet with the home folks, and can access important online resources. This article was made possible by members serving with the 101st Airborne, currently positioned near Mosul, Iraq. We thought our readers might be interested to learn more about the 6.2/6.5 powered HMMWV and the diesel maintenance challenges encountered in the desert.
Chevrolet's flagship SUV just got a significant boost in power and capability. Effortless towing and the potential for 20+ miles per gallon make this arguably the best Suburban ever...
Note:The Diesel Page is a subscriber supported web magazine. Feature articles are part of the Electronic Magazine (E-Zine) format here in The Diesel Page. Articles appearing in "This Month's Features" section will run for a preiod of time before being removed from the web site (new material is added on about the 15th of each month). Once leaving here, feature articles, product reviews and tech pages will only be available as part of a bound volume specific to each engine.
Solutions for 1994 or newer 6.5TD Stalling This is a comprehensive illustrated checklist for discovering the cause of a stalling problem in a 1994 or newer 6.5L diesel equipped vehicle. Nearly every step can be performed by an owner.
DS4 Electronic Fuel Injection Pump Warranty Replacement Policy #00064D. GM's new 1994-01 electronic fuel injection pump warranty has been extended to 11 years from the date the vehicle first went into service or 120,000 miles (193,000 Kms), whichever comes first.
