060601007G

File in Section:
Bulletin No.:
Service Bulletin
Date:
06 - Engine
06-06-01-007G
August, 2012
INFORMATION
Subject:
Information On Identifying Duramax™ Diesel Overpower Engine Breakdown or
Non-Function Due to Aftermarket Power-Up Devices vs. Non Overpower Engine
Non-Function of Pistons, Cylinders, Valvetrain Components, DTC P003A or P111D Set
Models:
2001–2013 Chevrolet Silverado
2003–2009 Chevrolet Kodiak
2006–2013 Chevrolet Express
2001–2013 GMC Sierra
2003–2009 GMC TopKick
2006–2013 GMC Savana
Equipped With Duramax™ Turbocharged Diesel Engine RPO LB7, LBZ, LLY, LML, LMM,
or LGH
Attention: Please, always refer to the GM Policy and Procedures Manual — Article: 1.2.2.12 for the
latest GM Policy and Procedures Information.
This bulletin is being revised to add the 2011, 2012 and 2013 Model years, to BOLD the
“Caution” statement, add the LML and LGH engine specifications information to the
Duramax™ Powertrain Horsepower / Torque Ratings section, update the names of the GM
Representatives, add information regarding DTC P111D, and add an Attention statement to
advise the Service Department Personnel that they must always refer to the GM Service
Policy and Procedures Manual Article: 1.2.2.12 for the latest GM Policy and Procedures
Information. Please discard Corporate Bulletin Number 06-06-01-007F
(Section 06 – Engine/Propulsion System).
Caution: Customers should be informed if a hard
part failure is observed in the engine, transmission,
transfer case and/or other driveline components, it
is likely that powertrain components were
weakened to the point of premature failure, while
subjected to the higher stresses from Aftermarket
Power-Up Devices. Failures associated with the
installation of Aftermarket Power-Up Devices,
which have been verified, are not covered under the
terms of the New Vehicle Warranty. In the majority
of these cases, the District Manager Aftersales
(DMA), in Canada, the District Manager Customer
Care and Service Process (DM - CCSP) should be
contacted and the remaining portion of the
powertrain portion of the New Vehicle Warranty
blocked.
GM has adopted a policy that prevents any
UNAUTHORIZED dealer warranty claim
submissions to any remaining warranty coverage.
Copyright 2012 General Motors LLC. All Rights Reserved.
General Motors Position On
Aftermarket Power-Up Devices
Important: General Motors does not support or
endorse the use of devices or modifications that, when
installed, increase the engine horsepower and torque.
Important: For further information on aftermarket
Power-Up Kits, refer to February 2006 Emerging Issues
Course Number 10206.02D. In Canada, information on
aftermarket Power-Up Kits is covered in the April 2006
TAC TALK program.
Aftermarket power-up devices are non-approved by
General Motors. These devices are usually
piggy-backed in the main engine harness or remain
connected to the diagnostic connector to upload the
calibration to the ECM. Recent warranty reviews of
returned engines show engine breakdown or
non-function due to power-up devices that are utilized
for increased horsepower and torque. The following
Page 2
August, 2012
information will assist technicians in identifying
overpower engine breakdown or non-function due to
aftermarket power-up devices vs. non overpower
engine breakdown or non-function.
Non-GM parts can alter the design of the vehicle. GM
dealers need to be aware of the quality of parts being
installed on vehicles. If failure occurs as a result of
installation of sub-par parts, warranty coverage may be
denied.
Installed Power-Up Kit
Aftermarket power-up kits have become a very popular
add on for performance-minded customers. These
devices can add horsepower and torque and can add
additional stress to the engine. These aftermarket
calibrations take the Duramax™ powertrain outside of
its design torque and horsepower rating. They do this
by altering air/fuel ratios and injector timing, resulting in
excessive cylinder pressure and temperature. When
these calibrated parameters are altered, it will upset the
design balance and can lead to a reduction of engine
life expectancy.
Installed Power-Up Kit
• Once installed, the calibration may mask itself with
the factory original calibration ID and may remain
the same. Refer to the latest version of Corporate
Bulletin Number #08-06-04-006 - Information on
Identifying Non-GM Calibration Usage for LMM
Duramax™ Diesel Engine.
• A Tech 2® will not positively enable you to identify
the use of a power-up device.
• Some companies that offer power-up devices
claim increases of 150 or more horsepower and
300 or more lb/ft pounds of torque.
• A vehicle that is used to the power-up device
potential 100% of the time will see earlier engine
wear and breakdown.
• A vehicle that takes advantage of additional
power, but on a less frequent basis, may not see
prema break="2"ture engine wear and breakdown
until later in the engine's life.
• A vehicle not pushed to its limits of the power-up
device often may not encounter premature wear
and breakdown until after the engine is out of
warranty.
Duramax™ Powertrain Horsepower / Torque
Ratings
The following horsepower and torque increase over the
past years required new internal components to
accommodate the increase.
• LB7 — 300 hp with 520 ft/lb of torque for model
years 2000–2004
• LLY — 310 hp with 605 ft/lb of torque for model
years 2004–2008
• LBZ — 360 hp with 650 ft/lb of torque for model
year 2006–2008
• LMM — 365 hp with 660 ft/lb of torque for model
year 2007–2009
•
•
•
Bulletin No.: 06-06-01-007G
LGH — Express and Savana with 260 hp (194 kW)
@ 3100 RPM, 525 lb-ft. (712 Nm ) @ 1600 RPM
LGH — Sierra HD and Silverado HD 335 hp
(250kW) @ 3100 RPM, 685 lb-ft. (929 Nm ) @
1600 RPM
LML — Sierra HD and Silverado HD 397 hp
(294kW) @ 3000 RPM, 765 lb-ft. (1037 Nm ) @
1600 RPM
LBZ Improvements
To reliably achieve an increase in 50 horsepower with
45 ft/lb torque, the Duramax ™ diesel had to be revised
in many areas. A few of the revisions on the 2006
LBZ were:
• New pistons with a revised compression ratio.
• Wrist pins that are larger in diameter.
• Connecting rods with added material to increase
the I section strength.
• Engine block and machining changes
• Cylinder heads
Duramax™ Life Expectancy
The Duramax™ 6.6L V8 Turbo Diesel Engine is sold
with a warranty of 100,000 miles/160,000 kilometers.
The Duramax™ has been tested to survive upwards of
200,000 miles/320,000 kilometers. The Duramax™
powertrain is designed for reliability, peak horsepower
and torque within its design limits. When a customer
installs a power-up device, it drastically reduces the
mileage ratings.
Important: Cylinder Wall Spotting (commonly referred
to leopard spots) is from the induction hardening
process of the top 1/3 of the cylinder wall. This is
normal for the Duramax ™ Diesel.
Identifying Fuel Related Aftermarket Power-Up
Devices
2159724
Bulletin No.: 06-06-01-007G
August, 2012
Aftermarket companies have developed a performance
pressure relief fuel valve for Duramax™ diesel engines.
Refer to above graphic illustration. The performance
pressure relief fuel valve attaches to the fuel rail in
place of the OEM valve and will not allow any fuel
return to the tank, giving 100% of the fuel to be
available for additional engine performance. This may
cause additional fuel related driveability concerns and
may set the following DTCs:
• DTC P1093 Fuel Rail Pressure (FRP) Low During
Power Enrichment
• DTC P0087 Fuel Rail Pressure (FRP) Too Low
Page 3
Identifying Overpower Engine Premature Wear and
Breakdown
When premature wear and breakdown is encountered
due to an aftermarket power-up device, it has some
very specific characteristics to the internal engine
components. The following list will assist in identifying
these characteristics as you tear down the engine.
1771277
•
Pistons will be cracked in the lip area, or a hole in
the pistons.
2160302
Aftermarket companies have developed a replacement
performance/economy fuel injector nozzle. Refer to
above illustration. The performance/economy fuel
injector nozzles replace the OEM fuel injector nozzles.
The aftermarket companies claim increased
horsepower, improved fuel atomization, lower exhaust
gas temperatures and increase fuel economy. This may
cause additional fuel related driveability concerns and
may cause internal engine damage to the pistons and
fuel injector nozzles.
1771279
•
Pistons can also be melted on the lip of the
combustion bowl, or the top of the pistons can be
melted.
Page 4
August, 2012
1771281
•
Crosshatch will be polished off the cylinder wall in
the major thrust face of cylinder below ring belt
travel.
Bulletin No.: 06-06-01-007G
1797823
•
Oil coking on the underside of the piston between
the wrist pin bosses.
1797824
1806909
•
Piston pin bore will show signs of scoring, the
wrist pins will be discolored, and can have oil
coking on them. The connecting rod bushing
surface will have accelerated wear. The above
illustration shows a connecting rod bushing.
•
Signs of bearing fretting will also be noticed on the
connecting rod and main bearing caps. Refer to
the above illustration for fretting of main bearing
cap 1 and back side of connection rod bearing 2.
Bulletin No.: 06-06-01-007G
August, 2012
Page 5
Engine Overspeed Causes
If an engine has been run faster than design capability
(redline), and has caused damage as a result, it may be
a result of one of the following conditions:
• Leaking or failed turbocharger (TC) oil seals.
• Oil evident in the intake runners and compressor
side of the TC.
• Starting fluid use or alternative fuel added to the
engine such as ether.
Engine Overspeed Results
The following are indicators that an overspeed event
took place:
1771284
•
Excessive heat in engine compartment caused by
overpower device. Refer to above illustration (1).
Non Overpower Engine Premature Wear
and Breakdown
The following pictures show results of overheat,
overspeed, low/no oil pressure or injector breakdown
and how they differ from aftermarket power-up device
premature wear and breakdown.
Engine Overheat
Overheat can be caused by a loss of coolant or a
general cooling system failure. Some of the indicators
of overheat are:
1771289
•
•
•
•
Melted pistons.
Head gasket breakdown or non-function.
Warped cylinder heads.
Crankshaft and connecting rod discolored.
1771285
•
•
•
Valve train damage.
Pushrods that are bent (4).
Broken valve bridge buttons after cylinder head
removal (2).
• Rocker arm tip damage (1).
• Dry or rusted cylinders from the use of ether,
propane or nitrous oxide.
Page 6
August, 2012
Bulletin No.: 06-06-01-007G
Turbocharger DTC P003A Set
1771287
•
•
Piston to valve contact.
Cam gear pin shear.
Notice: Any other turbocharger position sensor
DTC may also indicate the presence of a
Power-Up Kit.
General Motors has identified a turbocharger (TC)
failure mode involving Power-Up Kits that causes soot
leakage and DTC P003A to be set. The Power-Up Kits
create an over temperature condition from the
increased exhaust gas temperatures that results in a
permanent and excessive turbine housing distortion at
the TC case halves.
1. A technician may observe one or more of the
following conditions:
• DTC P003A being set as Current or in History.
• An unusual odor emanating from the TC due to
an overtemperature condition.
• Soot leaking and accumulating at the V-band
clamp that secures the TC case halves
together.
• Limited or unresponsive travel when
Commanding the TC Vane Pos. Ctrl. Solenoid
ON and OFF with a scan tool.
Lack of Oil Pressure
Lack of lubrication causes rapid bearing wear or
bearing to seize.
2336334
1771291
Bearing failure. Spun main bearings.
Engine Premature Wear and Breakdown Due to
Improper Function of Fuel Injector
A fuel injector may fracture a piston or melt a piston but
the damage will be limited to that cylinder only and all
other pistons and cylinder walls are OK. In some cases
hydraulic lock will occur on the suspected cylinder with
an over-fueling fuel injector. Hydraulic lock on the
suspected cylinder will cause a bent connecting rod.
This can be verified with piston protrusion
measurements.
2. If DTC P003A is found as Current or in History, OR
there is evidence of soot leakage (1) in the area of
the V-band clamp (1), then technicians MUST
verify if the engine control module (ECM) has a
Power-Up Kit aftermarket calibration installed or an
aftermarket hardware device has been installed.
Refer to the latest version of Corporate Bulletin
Number #08-06-04-006 for the calibration
verification information and procedures.
Bulletin No.: 06-06-01-007G
August, 2012
Page 7
2011-2012 Chevrolet or GMC Trucks
With DTC P111D Set
How to Handle a Suspect Engine
Failure Due to a Power-Up Device
Notice: DO NOT replace the MAF sensor or ECM
when only DTC P111D is found on a 2012 Model
Year Duramax equipped vehicle.
The Service Department Personnel may encounter a
customer concern of the SES light being illuminated,
with a DTC P111D: Intake Air Temperature (IAT)
Sensor 1 – Fuel Temperature Sensor 2 Correlation
found.
DTC P111D is utilized in 2011 for both the GMT600 G
Vans and GMT900 C/K Trucks with RPO codes LGH
and LML.
In the 2012 model year P111D is only valid on the
GMT600 vans.
The GMT900 C/K trucks no longer have a Fuel
Temperature Sensor 2. P111D should not set on any
2012 GMT900 Trucks.
Dealers should not automatically decline warranty
assistance on engine failures due to the fact that a
power-up device or modification is evident or
suspected. The technician must identify that the failure
is due to a power-up device by teardown analysis and
diagnosis of the engine components. The following
steps should be taken if an engine failure occurs and it
is suspected that the modification or addition of a
power-up device maybe the cause of the engine failure.
If unclear of this process or direction feel free to contact
your District Manager Aftersales (DMA) (in Canada, the
District Manager Customer Care and Service Process
(DM-CCSP)).
1. The technician should use proper engine
diagnostics to lead him/her to the failed engine
components. The Aftermarket Power-Up Kit Check
List should be followed and if it is determined that
at least three of the Aftermarket Power-Up Kit
Check List items match the engine component
failures then it can be decided that the failure is not
a warrantable claim.
2. Engine failures that meet at least three criteria of
the Aftermarket Power-Up Kit Check List are
considered failures that are not manufacturer's
defects in workmanship or materials.
3. The dealership should contact the PQC, open a
case to review the findings and make the final
decision on warranty coverage. The District
Manager Aftersales (DMA), in Canada, the District
Manager - Customer Care and Service Process
(DM - CCSP) should be notified of the PQC
decision.
4. Denied claims should be documented as follows:
4.1. The Aftermarket Power-Up Kit Check List
completed with the technicians detailed
written findings of the diagnosis on the repair
order and retained in the repair order file.
4.2. Photographs of the failed parts should be
retained in the repair order file.
5. The customer should be advised that the failure of
their engine was not due to a manufacturer's defect
in workmanship or materials and therefore the
warranty claim is denied on this failure.
Recommendation/Instructions
Do not attempt repairs for P111D if found on a 2012
GMT900 C/K Truck. The condition may be caused by a
calibration mismatch.
If a dealer encounters a P111D on a 2012 truck,
engineering has requested the ECM calibrations be
sent in for verification using the latest version of
Corporate Bulletin Number #08-06-04-006.
The dealer will receive an e-mail reply to advise if the
calibrations are correct for the vehicle.
1. To evaluate the condition the dealer should follow
the steps below:
1.1. If a calibration mismatch has been found
check GWM to see if the ECM has been
replaced.
1.2. If there has been an ECM replacement
ensure the correct part number was installed.
1.3. Dealers should not exchange or swap an
ECM from a 2011 to a 2012 model year. The
memory will be incorrect and may induce a
P111D to set.
2. If the correct ECM has been installed and there is a
calibration mismatch, reprogram the ECM with the
current (2012 model year) TIS2WEB calibrations.
Page 8
August, 2012
Bulletin No.: 06-06-01-007G
Aftermarket Power-Up Kit Check List
Important: Print and use this aftermarket power-up
kit check list when performing an engine
disassembly investigation of overpower engine
breakdown or non-function. Retain a copy of this
checklist and photographs of the failed parts in the
repair order file.
Engine Component
Inspection Area
1
2
3
4
5
6
Visual Damage
Results “YES”
Visual Damage
Results “NO”
Piston Cracked Parallel to
Wrist Pin
____
____
Engine Component
Piston Cracked in Lip Area
____
____
Hole in Piston Connecting Top
of Piston to Oil Cooling
Channel
____
____
Melted Pistons
____
____
Lip of Combustion Bowl
Melted
____
____
Top of Piston Melted / Missing
____
____
Cross Hatching Polished Off
Cylinder Wall
____
____
Cylinder Wall Missing
Crosshatch on Major Thrust
Face of Cylinder, Below Ring
Belt Travel
____
____
Scoring in Upper Piston Pin
Boss / Black Discoloration /
Oil Coking
____
____
Wrist Pin Wear
____
____
Rod Bushing Surface Worn
and Discolored
____
____
Carbon Coking / Discoloration
to Underside of Piston
____
____
Carbon Coking / Discoloration
to Underside of Piston
Between Piston Pin Bosses
____
____
Accelerated Rod / Main
Bearing Wear
____
____
Fretting on Backside of
Bearing
____
____
Bearing Surface Distressed
____
____
Note: When using this checklist, refer to the graphics in the sections of this bulletin titled: Identifying Overpower Engine
Premature Wear and Breakdown and Non Overpower Engine Premature Wear and Breakdown.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these
technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper
service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a
job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your
vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.
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