DuraMax 6.6L V8 Turbo Diesel Engine Manual Download

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Normal Maintenance Replacement Parts

Replacement parts identified below by name, part number, or specification can be obtained from your dealer.

Part

GM Part Number

ACDelco

Part

Number

Oil Filter

88917036

PF2232

Engine Air Cleaner/Filter

25332443

A1618C

Fuel Filter

97382952

—

Use only the specified filters.

6-16

Summary of Contents for 6.6L V8 Turbo Diesel Engine

Page 1: ...l 3 1 Warning Lights Gages and Indicators 3 2 Service and Appearance Care 5 1 Diesel Fuel Requirements and Fuel System 5 2 Checking Things Under the Hood 5 14 Capacities and Specifications 5 36 Mainte...

Page 2: ...the proper use and maintenance of your vehicle Keep this manual with the owner manual in your vehicle so it will be there if you ever need it while you are on the road If you sell your vehicle leave t...

Page 3: ...Starting and Operating Your Vehicle 2 2 Starting Your Diesel Engine 2 2 Winter Cover 2 5 Engine Coolant Heater 2 7 Section 2 Features and Controls 2 1...

Page 4: ...Start Light on page 3 6 This light may not come on if the engine is hot 2 As soon as the wait to start light goes off immediately turn the ignition key to START When the engine starts let go of the ke...

Page 5: ...r on page 2 7 See Diesel Fuel Requirements and Fuel System on page 5 2 for information on what fuel to use in cold weather If Your Diesel Engine Won t Start If you ve run out of fuel look at Running O...

Page 6: ...nces heater performance by raising the engine coolant temperature faster This feature can be turned off and on using the DIC steering wheel control buttons If your vehicle is not equipped with the DIC...

Page 7: ...uts are removed the engine idle speed will slowly ramp back up to high idle after the normal delay if the conditions for engine coolant temperature and air intake temperature are still met Winter Cove...

Page 8: ...hese conditions could cause your vehicle to overheat If this happens while the cover is being used remove the cover Do not use the winter cover if towing a trailer The added power needed to tow a trai...

Page 9: ...back of the patch Grille Cover Installation 1 Pre bend all the small black tabs into the shape of a J 2 Remove the four push pins and slide them through each of the pre punched tabs 3 Install the fou...

Page 10: ...e starting the engine be sure to unplug and store the cord as it was before to keep it away from moving engine parts If you don t it could be damaged How long should you keep the coolant heater plugge...

Page 11: ...ts Gages and Indicators 3 2 Instrument Panel Cluster 3 2 Malfunction Indicator Lamp 3 3 Oil Pressure Gage 3 5 Wait to Start Light 3 6 Fuel Gage 3 6 Driver Information Center DIC 3 7 Section 3 Instrume...

Page 12: ...Warning Lights Gages and Indicators Instrument Panel Cluster United States Version shown Canada similar 3 2...

Page 13: ...re any problem is apparent This may prevent more serious damage to your vehicle This system is also designed to assist your service technician in correctly diagnosing any malfunction Notice If you kee...

Page 14: ...ler has the proper test equipment and diagnostic tools to fix any mechanical or electrical problems that may have developed Emissions Inspection and Maintenance Programs Some state provincial and loca...

Page 15: ...a under certain conditions especially in cold temperatures This is a normal operating range CAUTION Do not keep driving if the oil pressure is low If you do your engine can become so hot that it catch...

Page 16: ...warm up glow plug system The Wait To Start Light will illuminate for a considerably shorter time than most diesel engines due to the rapid heating of the glow plug system For more information see Sta...

Page 17: ...e vehicle Driver Information Center DIC The Driver Information Center DIC is located on the instrument panel cluster above the steering wheel The DIC comes on when the ignition is on After a short del...

Page 18: ...ENGINE POWER A computer monitors the operation of the electric accelerator If the REDUCED ENGINE POWER message comes on while you are driving the computer is indicating that your vehicle has a proble...

Page 19: ...0 Filling Your Tank 5 11 Filling a Portable Fuel Container 5 13 Checking Things Under the Hood 5 14 Engine Compartment Overview 5 14 Engine Oil 5 16 Engine Oil Life System 5 19 Engine Air Cleaner Filt...

Page 20: ...n out of diesel fuel it can be difficult to restart your engine To avoid all this never let your tank get empty If you run out of fuel Running Out of Fuel on page 5 9 tells you how to restart your eng...

Page 21: ...nk This can cause the automatic pump nozzle to shut off even though your tank is not full If this happens just wait for the foaming to stop and then continue to fill your tank CAUTION Heat coming from...

Page 22: ...other fuels used in your vehicle and the biodiesel used for making this fuel must meet the ASTM D6751 03 specification Biodiesel is produced from vegetable oils or animal fat that have been chemically...

Page 23: ...ur fuel system may still need to be cleaned Your dealer can advise you of the appropriate solution If your fuel tank needs to be purged to remove water see your dealer or a qualified technician Improp...

Page 24: ...ain filter system Water In Fuel Light Chart cont d Problem Recommended Action Immediately after refueling large amount of water possibly pumped into fuel tank Fuel tank purging required See your deale...

Page 25: ...several times 5 Remove the fuel resistant container and properly dispose of the contaminated fuel To find out how to properly dispose of contaminated diesel fuel see What to Do With Used Oil under En...

Page 26: ...me the fuel system before operating the vehicle Air in the fuel lines will not harm the engine or the vehicle However the engine may not be able to start until the fuel system is primed and the air is...

Page 27: ...the vent valve Clean any fuel which accumulated on the fuel filter Start the engine and let idle for a few minutes Check the filter for leaks Running Out of Fuel If the engine stalls and you think th...

Page 28: ...ng the procedure for draining water listed previously Your vehicle s engine should be off until the end of this procedure The fuel filter is located in the engine compartment on the passenger s side o...

Page 29: ...ot smoke if you are near fuel or refueling your vehicle Keep sparks flames and smoking materials away from fuel Do not leave the fuel pump unattended when refueling your vehicle this is against the la...

Page 30: ...reful not to spill diesel fuel Don t top off or overfill your tank and wait a few seconds after you ve finished pumping before you remove the nozzle Clean fuel from painted surfaces as soon as possibl...

Page 31: ...mp on page 3 3 Filling a Portable Fuel Container CAUTION Never fill a portable fuel container while it is in your vehicle Static electricity discharge from the container can ignite the gasoline vapor...

Page 32: ...Checking Things Under the Hood Engine Compartment Overview When you open the hood on the 6 6L DURAMAX Diesel Engine you ll see 5 14...

Page 33: ...ngine Oil Dipstick F Automatic Transmission Dipstick If Equipped G Engine Oil Fill Cap H Engine Fan I Power Steering Fluid Reservoir J Remote Negative Terminal K Remote Positive Terminal L Brake Fluid...

Page 34: ...If you do not do this the oil dipstick might not show the actual level 2 Pull out the dipstick and clean it with a paper towel or a cloth then push it back in all the way Remove it again keeping the...

Page 35: ...CI 4 or CH 4 Oils designated as API CI 4 or CH 4 are recommended for your vehicle The CI 4 or CH 4 designations may appear either alone together or in combination with other API designations such as...

Page 36: ...w its viscosity or thickness Do not use other viscosity oils such as SAE 10W 40 or SAE 20W 50 This doughnut shaped logo symbol is used on most oil containers to help you select the correct oil It mean...

Page 37: ...ry for over a year However your engine oil and filter must be changed at least once a year and at this time the system must be reset Your dealer has GM trained service people who will perform this wor...

Page 38: ...rom the filter before disposal Never dispose of oil by putting it in the trash pouring it on the ground into sewers or into streams or bodies of water Instead recycle it by taking it to a place that c...

Page 39: ...the screws on the cover of the housing and lift up the cover 2 Remove the air cleaner filter from the housing Care should be taken to dislodge as little dirt as possible 3 Clean the filter sealing sur...

Page 40: ...your engine which will damage it Always have the air cleaner filter in place when you are driving Automatic Transmission Fluid When to Check and Change A good time to check your automatic transmissio...

Page 41: ...ling a trailer Checking the Fluid Level Prepare your vehicle as follows Park your vehicle on a level place Keep the engine running With the parking brake applied place the shift lever in PARK P With y...

Page 42: ...to 200 F 93 C is reached 2 Pull out the dipstick and wipe it with a clean rag or paper towel 3 Push it back in all the way wait three seconds and then pull it back out again Repeat the check procedur...

Page 43: ...push the dipstick back in all the way Engine Coolant The cooling system in your vehicle is filled with DEX COOL engine coolant This coolant is designed to remain in your vehicle for 5 years or 150 000...

Page 44: ...could get too hot but you would not get the overheat warning Your engine could catch fire and you or others could be burned Use a 50 50 mixture of clean drinkable water and DEX COOL coolant Notice If...

Page 45: ...and scalding liquids to blow out and burn you badly Never turn the surge tank pressure cap even a little when the engine and radiator are hot The vehicle must be on a level surface When your engine is...

Page 46: ...ll coolant on a hot engine When replacing the pressure cap make sure it is hand tight Coolant Surge Tank Pressure Cap The surge tank pressure cap must be tightly installed Notice If the pressure cap i...

Page 47: ...fire because you keep driving with no coolant your vehicle can be badly damaged The costly repairs would not be covered by your warranty If No Steam Is Coming From Your Engine An overheat warning alon...

Page 48: ...sign of steam and your vehicle is equipped with an engine driven cooling fan push down the accelerator until the engine speed is about twice as fast as normal idle speed for at least three minutes whi...

Page 49: ...le If there seems to be no leak start the engine again If your vehicle is equipped with an engine driven cooling fan the engine cooling fan speed should increase when idle speed is doubled by pushing...

Page 50: ...tank but be sure the cooling system including the coolant surge tank pressure cap is cool before you do it See Engine Coolant on page 5 25 for more information If no coolant is visible in the surge t...

Page 51: ...re and other parts Use the recommended coolant and the proper coolant mixture CAUTION You can be burned if you spill coolant on hot engine parts Coolant contains ethylene glycol and it will burn if th...

Page 52: ...he proper mixture Add coolant until you see a steady stream of coolant coming from the bleed valve 4 Close the bleed valve 5 Rinse or wipe the spilled coolant from the engine and compartment 6 Then fi...

Page 53: ...upper radiator hose getting hot Watch out for the engine cooling fan By this time the coolant level inside the coolant surge tank may be lower If the level is lower add more of the proper mixture to t...

Page 54: ...tem Automatic Transmission Manual Transmission 24 0 quarts 24 0 quarts 23 0 L 23 0 L Engine Oil With Filter 6 6L V8 10 0 quarts 9 5 L All quantities are approximate When adding be sure to fill to the...

Page 55: ...e 6 2 Scheduled Maintenance 6 4 Additional Required Services 6 6 Maintenance Footnotes 6 8 Owner Checks and Services 6 10 At Each Fuel Fill 6 10 At Least Once a Month 6 10 At Least Once a Year 6 11 Re...

Page 56: ...vehicle maintenance can even affect the quality of the air we breathe Improper fluid levels or the wrong tire inflation can increase the level of emissions from your vehicle To help protect our enviro...

Page 57: ...s on page 6 8 for further information CAUTION Performing maintenance work on a vehicle can be dangerous In trying to do some jobs you can be seriously injured Do your own maintenance work only if you...

Page 58: ...GM trained service technicians who will perform this work using genuine GM parts and reset the system If the engine oil life system is ever reset accidentally you must service your vehicle within 3 0...

Page 59: ...ne air cleaner filter change indicator If necessary replace filter See Engine Air Cleaner Filter on page 5 20 An Emission Control Service See footnotes and n Rotate tires and check inflation pressures...

Page 60: ...See footnote k Additional Required Services The following services should be performed at the first maintenance service I or II after the indicated miles kilometers shown for each item Additional Req...

Page 61: ...See footnote m Change automatic transmission fluid and filter normal service Four wheel drive with automatic transfer case only Change transfer case fluid See footnote g Engine cooling system service...

Page 62: ...ots and axle seals for leaks c Visually inspect hoses and have them replaced if they are cracked swollen or deteriorated Inspect all pipes fittings and clamps replace with genuine GM parts as needed T...

Page 63: ...ntake system installation to assure that gaskets are properly sealed and that all hose connections fasteners and other components are tight Also check to be sure that the air cleaner housing is proper...

Page 64: ...s Notice It is important to check your oil regularly and keep it at the proper level Failure to keep your engine oil at the proper level can cause damage to your engine not covered by your warranty En...

Page 65: ...position contact your GM Goodwrench dealer for service Automatic Transmission Shift Lock Control System Check CAUTION When you are doing this inspection the vehicle could move suddenly If the vehicle...

Page 66: ...egular brake at once should the vehicle begin to move Park on a fairly steep hill with the vehicle facing downhill Keeping your foot on the regular brake set the parking brake To check the parking bra...

Page 67: ...olant 50 50 mixture of clean drinkable water and use only DEX COOL Coolant See Engine Coolant on page 5 25 Usage Fluid Lubricant Hydraulic Brake System Delco Supreme 11 Brake Fluid or equivalent DOT 3...

Page 68: ...Shift Linkage Lubriplate Lubricant Aerosol GM Part No U S 12346293 in Canada 992723 or lubricant meeting requirements of NLGI 2 Category LB or GC LB Usage Fluid Lubricant Chassis Lubrication Chassis L...

Page 69: ...nges Multi Purpose Lubricant Superlube GM Part No U S 12346241 in Canada 10953474 Usage Fluid Lubricant Body Door Hinge Pins Tailgate Hinge and Linkage Folding Seats and Fuel Door Hinge Multi Purpose...

Page 70: ...identified below by name part number or specification can be obtained from your dealer Part GM Part Number ACDelco Part Number Oil Filter 88917036 PF2232 Engine Air Cleaner Filter 25332443 A1618C Fue...

Page 71: ...ed in the boxes provided See Maintenance Requirements on page 6 2 in this section Any additional information from Owner Checks and Services on page 6 10 can be added on the following record pages Also...

Page 72: ...Maintenance Record cont d Date Odometer Reading Serviced By Maintenance I or Maintenance II Services Performed 6 18...

Page 73: ...Maintenance Record cont d Date Odometer Reading Serviced By Maintenance I or Maintenance II Services Performed 6 19...

Page 74: ...Maintenance Record cont d Date Odometer Reading Serviced By Maintenance I or Maintenance II Services Performed 6 20...

Page 75: ...urge Tank Pressure Cap 5 28 Cooling System 5 30 D Diesel Engine Fuel 5 2 Filling a Portable Fuel Container 5 13 Filling Your Tank 5 11 Fuel Requirements and Fuel System 5 2 Running Out of Fuel 5 9 Ver...

Page 76: ...6 10 Diesel Engine 5 2 Diesel Requirements and Fuel System 5 2 Filling a Portable Fuel Container 5 13 Filling Your Tank 5 11 Filter Replacement 5 10 Gage 3 6 Running Out of 5 9 What to Use 5 2 G Gage...

Page 77: ...Once a Year 6 11 Introduction 6 2 Maintenance Requirements 6 2 Scheduled Maintenance 6 4 Using Your 6 2 Your Vehicle and the Environment 6 2 Malfunction Indicator Lamp 3 3 O Oil Engine 5 16 Oil Pressu...

Page 78: ...4 Specification Charts 5 36 Starting Your Diesel Engine 2 2 Surge Tank Pressure Cap Coolant 5 28 T Transmission Automatic Fluid 5 22 W Wait to Start Light 3 6 Water in Fuel 5 5 Water in Fuel Light Cha...

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