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DuraMax 6.6L V8 Turbo Diesel Engine Manual

2005 duramax 6.6l v8 turbo diesel engine
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2005 DURAMAX™ Diesel Engine
Features and Controls ..................................... 2-1
Starting and Operating Your Vehicle
Instrument Panel ............................................. 3-1
Warning Lights, Gages and Indicators
Service and Appearance Care .......................... 5-1
Diesel Fuel Requirements and Fuel System
Checking Things Under the Hood
Capacities and Specifications
............. 2-2
........... 3-2
... 5-2
............... 5-14
..................... 5-36
Maintenance Schedule ..................................... 6-1
Maintenance Schedule
Index ................................................................ 1
M
................................ 6-2

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  • Page 1 2005 DURAMAX™ Diesel Engine Features and Controls ........2-1 Maintenance Schedule ........6-1 Starting and Operating Your Vehicle Maintenance Schedule ..... 2-2 ........ 6-2 Instrument Panel ..........3-1 Index ..............1 Warning Lights, Gages and Indicators ... 3-2 Service and Appearance Care ......5-1 Diesel Fuel Requirements and Fuel System ...
  • Page 2 General Motors, GM, GMC, CHEVROLET, the GM This manual includes the latest information at the time it Emblem, the GMC Truck Emblem, the CHEVROLET was printed. We reserve the rights to make changes Emblem, and the names SIERRA and SILVERADO are in the product after that time without notice.
  • Page 3 Section 2 Features and Controls Starting and Operating Your Vehicle ....2-2 Starting Your Diesel Engine ......2-2 Winter Cover ..........2-5 Engine Coolant Heater ........2-7...
  • Page 4 Starting and Operating Your Starting Your Engine Vehicle 1. Turn your ignition key to RUN. Observe the wait to start light. See Wait to Start Light on page 3-6. This light may not come on if the Starting Your Diesel Engine engine is hot.
  • Page 5 If Your Diesel Engine Won’t Start When your engine is cold, let it run for a few minutes before you move your vehicle. This lets oil pressure If you’ve run out of fuel, look at Running Out of Fuel on build up.
  • Page 6 Be sure you are using the proper fuel for existing This feature can be turned off and on using the DIC weather conditions. See Diesel Fuel Requirements and steering wheel control buttons. If your vehicle is Fuel System on page 5-2. not equipped with the DIC steering wheel control buttons, doing the following to turn on this feature: If the engine starts, runs a short time, then stops, your...
  • Page 7 Winter Cover The high idle speed will be temporarily interrupted and the engine speed will return to normal if any of the following conditions occur: If your vehicle includes a winter cover, it will enhance heater performance and will reduce the amount of time it •...
  • Page 8 Usage Guidelines • Do not modify the cover. The winter cover does not cover some sections of the front of the vehicle The winter cover should only be used while operating because these openings are needed to provide your vehicle in extremely cold temperatures. In enough airflow to the radiator grille and air cooler in these temperatures, the vehicle does not need a large extremely cold temperatures.
  • Page 9 Installation Instructions Lower Cover Installation 1. Pre-bend all of the small black tabs into the shape The following instructions explain how to install and of a J. remove your vehicle’s winter cover. When installing or removing the cover please refer to the “Usage 2.
  • Page 10 To Use the Engine Coolant Heater How long should you keep the coolant heater plugged in? The answer depends on the outside temperature. 1. Turn off the engine. You may wish to use your coolant heater to improve ease of starting at temperatures between 0°F (−18°C) 2.

  • Page 11: Table Of Contents

    Section 3 Instrument Panel Warning Lights, Gages and Indicators ....3-2 Wait to Start Light ..........3-6 Instrument Panel Cluster .........3-2 Fuel Gage .............3-6 Malfunction Indicator Lamp ......3-3 Driver Information Center (DIC) ......3-7 Oil Pressure Gage ..........3-5...

  • Page 12: Warning Lights, Gages And Indicators

    Warning Lights, Gages and Indicators Instrument Panel Cluster United States Version shown, Canada similar.

  • Page 13: Malfunction Indicator Lamp

    Your instrument cluster is designed to let you know at a Notice: If you keep driving your vehicle with this glance how your vehicle is running. You’ll know how light on, after awhile, your emission controls fast you’re going, about how much fuel you have may not work as well, your fuel economy may not and many other things you’ll need to know to drive safely be as good, and your engine may not run as...
  • Page 14 If the Light Comes On Emissions Inspection and Maintenance Programs This light should come on, as a check to show you it is working, when the ignition is on and the engine is Some state/provincial and local governments have or not running.

  • Page 15: Oil Pressure Gage

    Canadian vehicles indicate pressure in kPa (kilopascals). Oil pressure may vary under different driving conditions and oil types. The DURAMAX™ engine may generate oil pressure in excess of 80 psi (548 kPa) under certain conditions, especially in cold temperatures. This is a...

  • Page 16: Wait To Start Light

    Wait to Start Light Fuel Gage Your diesel engine has a When the ignition is on, glow plug system to aid in the fuel gage shows you starting your vehicle. approximately how much fuel you have left in your tank. An instrument panel wait to start indicator light shows that the system is functioning properly and tells you when the engine is ready to be started.

  • Page 17: Driver Information Center (Dic)

    • The gage doesn’t go back to E (empty) when you Some messages that your DURAMAX™ diesel may turn off the ignition. show are: None of these indicate a problem with the fuel gage.
  • Page 18 ELEVATED IDLE ENABLED WATER IN FUEL On diesel engines, this message will appear when the This message will come on to warn you if there is water elevated idle/exhaust restrictor feature has been in the diesel fuel system. For more information on turned on.
  • Page 19 Section 5 Service and Appearance Care Diesel Fuel Requirements and Fuel System ..5-2 Engine Oil Life System ........5-19 Diesel Engine Fuel .........5-2 Engine Air Cleaner/Filter ........5-20 What Fuel to Use ...........5-2 Automatic Transmission Fluid ......5-22 Very Cold Weather Operation ......5-4 Engine Coolant ..........5-25 Water in Fuel ..........5-5 Coolant Surge Tank Pressure Cap ....5-28...

  • Page 20: Diesel Fuel Requirements And Fuel System

    Diesel Fuel Requirements and • If you ever run out of diesel fuel, it can be difficult to restart your engine. To avoid all this, Fuel System never let your tank get empty. If you run out of fuel, Running Out of Fuel on page 5-9 Some states and provinces have restrictions on the tells you how to restart your engine.
  • Page 21 It is acceptable to use diesel fuel containing up to 5% biodiesel (B5), but the final blended fuel must meet CAUTION: the same specification, ASTM D975-03 (Grade Low Sulfur), as other fuels used in your vehicle, and the biodiesel used for making this fuel must meet the Heat coming from the engine may cause the ASTM D6751-03 specification.

  • Page 22: Very Cold Weather Operation

    It is important that diesel-powered trucks are refueled Higher concentration (i.e., greater than B5) only with low-sulfur fuel. Use of fuels with higher-sulfur biodiesel-containing fuels or the use of unmodified content will affect the function of the emission bio-oils blended into diesel fuel at any concentration is components and may cause reduced performance, not recommended and could damage your fuel excessive smoke and unpleasant odor.

  • Page 23: Water In Fuel

    Water in Fuel If your fuel tank needs to be purged to remove water, see your dealer or a qualified technician. Improper purging can damage your fuel system. Sometimes, water can be pumped into your fuel CAUTION: tank along with your diesel fuel. This can happen if a service station doesn’t regularly inspect and clean Diesel fuel containing water is still flammable.

  • Page 24: Water In Fuel Light Chart

    Water in Fuel Light Chart Water In Fuel Light Chart (cont’d) Problem Recommended Action If the WATER IN FUEL message comes on, use • Fuel tank purging this chart. Immediately after required. See your dealer Water In Fuel Light Chart refueling, large for assistance.
  • Page 25 To drain water, do the following: 6. Install the fuel cap. 1. Stop and park the vehicle in a safe place. 7. Start the engine and let it run for a few minutes. Turn off the engine and apply the parking brake. If the engine stalls, the fuel system may need to be primed.
  • Page 26 Fuel Priming How do I prime the vehicle? In order for the fuel system to work properly, the fuel Your vehicle is equipped with a priming pump lines must be full of fuel and contain no air. If air which is part of the engine mounted fuel filter. gets into the fuel lines, it will be necessary to prime the The priming pump is hand operated and is designed fuel lines, to eliminate air before operating the vehicle.

  • Page 27: Running Out Of Fuel

    5. Open the fuel filter vent 7. Operate the priming pump until a small amount of valve by turning the fuel seeps from the vent valve. When you see the screw counterclockwise fuel, the filter is now full of fuel and the system several full turns.

  • Page 28: Fuel Filter Replacement

    3. Close the air bleed valve. The fuel filter is located in the engine compartment on the passenger’s side of the vehicle, or on the driver’s 4. Turn the ignition key to START for 10 to 15 seconds side frame rail in front of the fuel tank. at a time until your engine starts.

  • Page 29: Filling Your Tank

    7. Tighten the air bleed valve by turning it clockwise until hand tight. 8. Start your engine and let it idle for five minutes. Check your fuel filter and air bleed valve for leaks. Filling Your Tank CAUTION: Fuel vapor burns violently and a fuel fire can cause bad injuries.
  • Page 30 To remove the fuel cap, turn it slowly to the Be careful not to spill diesel fuel. Don’t top off or overfill left (counterclockwise). 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 possible.

  • Page 31: Filling A Portable Fuel Container

    Filling a Portable Fuel Container CAUTION: CAUTION: If a fire starts while you are refueling, do not remove the nozzle. Shut off the flow of fuel by Never fill a portable fuel container while it is in shutting off the pump or by notifying the your vehicle.

  • Page 32: Checking Things Under The Hood

    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 A. Engine Air Cleaner/Filter I. Power Steering Fluid Reservoir B. Coolant Surge Tank J. Remote Negative (−) Terminal C. Battery K. Remote Positive (+) Terminal D. Engine Air Cleaner/Filter Restriction Indicator L. Brake Fluid Reservoir E. Engine Oil Dipstick M. Clutch Fluid Reservoir (If Equipped) F.

  • Page 34: Engine Oil

    Engine Oil When to Add Engine Oil Checking Engine Oil It is a good idea to check your engine oil level every time you get fuel. The engine oil dipstick handle is a yellow loop. See Engine Compartment Overview on page 5-14 for the location of the engine oil dipstick.
  • Page 35 Notice: Use only engine oils that have one of these the proper operating range. Push the dipstick all the designations CI-4 or CH-4 for the DURAMAX™ diesel way back in when you are through. engine. Failure to use the recommended oils can result in engine damage not covered by your warranty.
  • Page 36 • SAE 15W-40 As shown in the viscosity chart, SAE 15W-40 is best for your vehicle. However, you can use SAE 10W-30 at temperatures above 0°F (−18°C). When it is very cold, below 0°F (−18°C), you should use SAE 5W-40 to improve cold starting. These numbers on the oil container show its viscosity, or thickness.

  • Page 37: Engine Oil Life System

    Engine Oil Additives genuine GM parts and reset the system. It is also important to check your oil regularly and keep it at the Do not add anything to your oil. The recommended oils proper level. with the API service symbol are all you will need for If the system is ever reset accidentally, you must good performance and engine protection.

  • Page 38: Engine Air Cleaner/Filter

    Engine Air Cleaner/Filter If the CHANGE ENGINE OIL message comes back on when you start your vehicle, the engine oil life system has not reset. Repeat the procedure. If it still does The air cleaner/filter not reset, see your dealer for service. assembly may have an air cleaner/filter restriction What to Do with Used Oil...
  • Page 39 To inspect and replace the filter and reset the restriction indicator, do the following: 1. Loosen the screws on the cover of the housing and lift up the cover. The air cleaner/filter assembly is located on the front 2. Remove the air cleaner/filter from the housing. Care corner of the engine compartment on the passenger’s should be taken to dislodge as little dirt as possible.

  • Page 40: Automatic Transmission Fluid

    Automatic Transmission Fluid See Scheduled Maintenance on page 6-4 to determine when to replace the engine air cleaner/filter. When to Check and Change CAUTION: A good time to check your automatic transmission fluid level is when the engine oil is changed. Change both the fluid and filter every 25,000 miles Operating the engine with the air cleaner/filter (41 500 km) if the vehicle is mainly driven under one or...
  • Page 41 How to Check Checking the Fluid Level Prepare your vehicle as follows: Because this operation can be a little difficult, you may choose to have this done at the dealership service • Park your vehicle on a level place. Keep the engine department.
  • Page 42 3. Check the fluid level reading. Repeat the check 4. Safe operating level is within the HOT RUN band procedure to verify the reading. on the dipstick. The width of the HOT RUN band represents approximately 1.06 quart (1.0 liter) 4.

  • Page 43: Engine Coolant

    How to Add Fluid Engine Coolant Refer to the Maintenance Schedule to determine what The cooling system in your vehicle is filled with kind of transmission fluid to use. See Recommended ® DEX-COOL engine coolant. This coolant is designed Fluids and Lubricants on page 6-13. to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add Add fluid only after checking the transmission fluid while...
  • Page 44 What to Use Notice: If you use an improper coolant mixture, your engine could overheat and be badly damaged. Use a mixture of one-half clean, drinkable water and The repair cost would not be covered by your ® one-half DEX-COOL coolant which won’t damage warranty.
  • Page 45 Checking Coolant The vehicle must be on a level surface. When your engine is cold, the coolant level should be at the FULL COLD mark. The coolant surge tank is located in the engine If your vehicle is equipped with a low coolant sensor, compartment on the and the LOW COOLANT LEVEL message comes passenger’s side of the...

  • Page 46: Coolant Surge Tank Pressure Cap

    Adding Coolant Coolant Surge Tank Pressure Cap ® If you need more coolant, add the proper DEX-COOL The surge tank pressure coolant mixture at the surge tank, but only when the cap must be tightly engine is cool. If the surge tank is empty, see Engine installed.
  • Page 47 If Steam Is Coming From Your Engine If No Steam Is Coming From Your Engine An overheat warning, along with a low coolant condition, CAUTION: or LOW COOLANT LEVEL message, if equipped, can indicate a serious problem. For more information, see Steam from an overheated engine can burn “Driver Information Center (DIC)”...

  • Page 48: Cooling System

    Cooling System If you get the overheat warning with no sign of steam, try this for a minute or so: When you decide it’s safe to lift the hood, here’s what 1. In heavy traffic, let the engine idle in NEUTRAL (N) you’ll see: while stopped.
  • Page 49 The coolant level should If there seems to be no leak, start the engine again. be at or above the FULL If your vehicle is equipped with an engine driven cooling COLD mark. If it isn’t, fan, the engine cooling fan speed should increase you may have a leak at the when idle speed is doubled by pushing the accelerator pressure cap or in the...
  • Page 50 How to Add Coolant to the Coolant If no coolant is visible in the surge tank, add coolant as follows: Surge Tank Notice: The diesel engine has a specific coolant fill CAUTION: procedure. Failure to follow this procedure could cause your engine to overheat and be severely damaged.
  • Page 51 CAUTION: CAUTION: Adding only plain water to your cooling You can be burned if you spill coolant on hot system can be dangerous. Plain water, or engine parts. Coolant contains ethylene glycol some other liquid such as alcohol, can boil and it will burn if the engine parts are hot before the proper coolant mixture will.
  • Page 52 3. After the engine cools, open the air bleed valve on 6. Then fill the coolant surge tank with the proper the thermostat housing. mixture, to slightly above the fill mark. Fill with the proper mixture. Add coolant until you see a steady stream of coolant coming from the bleed valve.
  • Page 53 7. With the coolant surge tank pressure cap off, start the engine and let it run until you can feel the 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.

  • Page 54: Capacities And Specifications

    Capacities and Specifications Engine Specification Engine VIN Code Type 6.6L V8 Turbo Diesel Capacities Capacities Application English Metric Cooling System 24.0 quarts 23.0 L Automatic Transmission 24.0 quarts 23.0 L Manual Transmission Engine Oil With Filter 10.0 quarts 9.5 L 6.6L V8 All quantities are approximate.
  • Page 55 Section 6 Maintenance Schedule Maintenance Schedule ........6-2 Owner Checks and Services ......6-10 Introduction ...........6-2 At Each Fuel Fill ..........6-10 Maintenance Requirements ......6-2 At Least Once a Month .........6-10 Your Vehicle and the Environment ....6-2 At Least Once a Year ........6-11 Using Your Maintenance Schedule ....6-2 Recommended Fluids and Lubricants ....6-13 Scheduled Maintenance ........6-4...

  • Page 56: Maintenance Schedule

    Maintenance Schedule Your Vehicle and the Environment Proper vehicle maintenance not only helps to keep your Introduction vehicle in good working condition, but also helps the environment. All recommended maintenance is Important: Keep engine oil at the proper level and important.
  • Page 57 This schedule is for vehicles that: • carry passengers and cargo within recommended CAUTION: limits. You will find these limits on the tire and loading information label. See “Loading Your Performing maintenance work on a vehicle can Vehicle” in your owner manual. be dangerous.

  • Page 58: Scheduled Maintenance

    Owner Checks and Services on page 6-10 tells you If the engine oil life system is ever reset accidentally, what should be checked, when to check it and what you you must service your vehicle within 3,000 miles can easily do to help keep your vehicle in good (5 000 km) since your last service.
  • Page 59 Scheduled Maintenance Service Maintenance I Maintenance II Change engine oil and filter. See Engine Oil on page 5-16. Reset oil life system. See Engine Oil Life System on page 5-19. An Emission Control • • Service. Allison transmission only: Replace external control-main filter only at the first maintenance service performed on the vehicle.

  • Page 60: Additional Required Services

    Scheduled Maintenance (cont’d) Service Maintenance I Maintenance II • Lubricate body components. See footnote (f). • Check transmission fluid level and add fluid as needed. • Replace fuel filter. An Emission Control Service. See footnote †. • Inspect shields and underhood insulation. See footnote (h). •...
  • Page 61 Additional Required Services (cont’d) 25,000 50,000 75,000 100,000 125,000 150,000 Service and Miles (Kilometers) (41 500) (83 000) (125 000) (166 000) (207 500) (240 000) Change automatic transmission • • • • • • fluid and filter (severe service). See footnote (m).

  • Page 62: Maintenance Footnotes

    Maintenance Footnotes (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 † The U.S. Environmental Protection Agency or the needed. To help ensure proper operation, a pressure test California Air Resources Board has determined that the of the cooling system and pressure cap and cleaning the failure to perform this maintenance item will not nullify...
  • Page 63 (g) Check vent hose at transfer case for kinks and (l) Change clutch fluid (or every 24 months, whichever proper installation. occurs first). (h) Inspect shields and underhood insulation for damage (m) Change automatic transmission fluid and filter if the or looseness.

  • Page 64: Owner Checks And Services

    Owner Checks and Services Engine Coolant Level Check Check the engine coolant level and add These owner checks and services should be performed ® DEX-COOL coolant mixture if necessary. at the intervals specified to help ensure the safety, See Engine Coolant on page 5-25 for further details. dependability and emission control performance of your ®...

  • Page 65: At Least Once A Year

    At Least Once a Year Automatic Transmission Shift Lock Control System Check Starter Switch Check CAUTION: CAUTION: When you are doing this inspection, the When you are doing this inspection, the vehicle could move suddenly. If the vehicle vehicle could move suddenly. If the vehicle moves, you or others could be injured.
  • Page 66 Ignition Transmission Lock Check Park on a fairly steep hill, with the vehicle facing downhill. Keeping your foot on the regular brake, While parked, and with the parking brake set, try to set the parking brake. turn the ignition to LOCK in each shift lever position. •...

  • Page 67: Recommended Fluids And Lubricants

    Recommended Fluids and Usage Fluid/Lubricant Lubricants Hydraulic Brake Delco Supreme 11 Brake Fluid or System equivalent DOT-3 brake fluid. Fluids and lubricants identified below by name, part Windshield ® Washer Solvent GM Optikleen Washer Solvent. number or specification may be obtained from your dealer.
  • Page 68 Usage Fluid/Lubricant Usage Fluid/Lubricant Manual Chassis Lubricant Transmission (GM Part No. U.S. 12377985, in Synchromesh Transmission Fluid Chassis (5-Speed Canada 88901242) or lubricant (GM Part No. U.S. 12345349, in Lubrication without Low meeting requirements of NLGI #2, Canada 10953465). Gear, Category LB or GC-LB.
  • Page 69 Usage Fluid/Lubricant Usage Fluid/Lubricant Front Axle Body Door Propshaft Hinge Pins, Spline or Spline Lubricant, Special Lubricant Tailgate Hinge Multi-Purpose Lubricant, Superlube One-Piece (GM Part No. U.S. 12345879, in and Linkage, (GM Part No. U.S. 12346241, in Propshaft Canada 10953511) or lubricant Folding Seats Canada 10953474).

  • Page 70: Normal Maintenance Replacement Parts

    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 —...

  • Page 71: Maintenance Record

    Maintenance Record After the scheduled services are performed, record the date, odometer reading, who performed the service and the type of services performed 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.
  • Page 72 Maintenance Record (cont’d) Odometer Maintenance I or Date Serviced By Services Performed Reading Maintenance II 6-18...
  • Page 73 Maintenance Record (cont’d) Odometer Maintenance I or Date Serviced By Services Performed Reading Maintenance II 6-19...
  • Page 74 Maintenance Record (cont’d) Odometer Maintenance I or Date Serviced By Services Performed Reading Maintenance II 6-20...
  • Page 75 Automatic Transmission, Fluid ......5-22 Diesel Engine Fuel ..........5-2 Filling a Portable Fuel Container ....5-13 Filling Your Tank .......... 5-11 Fuel Requirements and Fuel System ....5-2 Canadian Owners ..........ii Running Out of Fuel ........5-9 Capacities and Specifications Very Cold Weather Operation ......
  • Page 76 Engine Gage Air Cleaner/Filter ......... 5-20 Fuel ............3-6 Compartment Overview ........ 5-14 Oil Pressure ..........3-5 Coolant ............5-25 Oil ............. 5-16 Overheating ..........5-28 Engine Coolant Heater ........2-7 Instrument Panel Cluster ........3-2 Fuel Lights At Each Fuel Fill ......... 6-10 Malfunction Indicator Lamp ......
  • Page 77 Maintenance Schedule Oil, Engine ............. 5-16 At Each Fuel Fill ......... 6-10 Oil Pressure Gage ..........3-5 At Least Once a Month ........ 6-10 Overheating, Engine ........5-28 At Least Once a Year ........6-11 Owners, Canadian ..........ii Introduction ..........6-2 Maintenance Requirements ......

  • Page 78: Starting Your Diesel Engine

    Scheduled Maintenance ........6-4 Wait to Start Light ..........3-6 Specification Charts ......... 5-36 Water in Fuel ........... 5-5 Starting Your Diesel Engine ........ 2-2 Water in Fuel Light Chart ........5-6 Surge Tank Pressure Cap, Coolant ....5-28 Winter Cover ........... 2-5 Transmission, Automatic Fluid ......

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