Surging at hwy speed - Diesel Place : Chevrolet and GMC Diesel Truck Forums
 
Home Forum Market Place Garage Tuning Library DTC Tool Register Vendors
Go Back   Diesel Place : Chevrolet and GMC Diesel Truck Forums > GM Diesel Engines > Duramax Third Generation: 2006-2007.5 (LBZ & LLY)
Register FAQ Forum Rules My Replies My Threads Mark Forums Read Advertise

Duramax Third Generation: 2006-2007.5 (LBZ & LLY) Discuss the third generation (2006-2007.5 LBZ & LLY) of the 6.6L Duramax diesel engine & associated components. 2006 LLY engine discussion also belongs in this forum due to the similarities of the 2006 LBZ and the 2006 LLY. Engine related discussion ONLY.

DieselPlace.com is the premier Duramax Diesel Forum on the internet. Registered Users do not see the above ads.
Like Tree2Likes
  • 1 Post By Ron Nielson
  • 1 Post By rodknocker

Reply
 
LinkBack Thread Tools
Old 12-21-2015, 07:50 PM   #1 (permalink)
rodknocker
Glow Plug
 
Join Date: Aug 2008
Location: Baton Rouge, LA
Posts: 220
iTrader Score: 0 reviews

Surging at hwy speed

Really at wit's end with this one.

Recently replaced turbo with 3794 Stage 1. A couple of weeks prior to the turbo swap, started getting P0402 excessive egr flow code. I found a loose intake clamp, tightened it up, cleaned MAF sensor, got the code again. Suspected resonator may have a leak, installed billet plug.
So, completed turbo swap, no turbo issues test driving around town for 2 weeks except still getting the P0402 occasionally. Hooked up the 5ver for the big Christmas trip, about an hour into the trip, felt like the trans or TC was slipping, rpm's would jump up about 400 rpm; but the IQ did not show any slip. Made it to the campground, drove truck all weekend with zero issues. Headed home on Sunday, at highway speed, the surging started again, only worse. Today, drove the truck to local trans guy (familiar with Allison), had them look for codes or trans issues, found nothing. No stored or pending codes, nada. Had them re-flash the TCM anyway. Came home, hooked up the 5ver and went to the interstate for a test hit. As soon as I got to highway speed, surging started again. BTW; my fuel pressure stays around 21k to 25k under load on the highway.
What I've done before this all started--
New turbo (P0402 before turbo)
3 inch downpipe
Cleaned MAF
New fuel filter
New air filter
Changed oil and filter
new trans filter
new antifreeze

I have no codes other than the P0402, changing EGR valve and motor tomorrow

Owned truck since new, blocked and fingered last six years.

Need suggestions, please

__________________
'06 LBZ CCSB Black and Chrome LT3 trim, rolling on 18 x 9 Fuel Octane chrome with Michelin 275/75/18
Stock intake mods, EGR blocker and finger stick
Upgraded tranny cooler lines, PPE deep pan
MaxBrake elec brake controller
SuperSlide 16k fifth wheel hitch
ViAir 100% duty cycle compressor 2.5 gal air tank
Firestone air bags with auto level valve
1000 watt inverter
Banks IQ, speed brake, 4" Monster exhaust, Kitty no
Kenwood HU, Polk spkrs in doors, Kicker 10"
Alpine amp 300/500 mono
Alpine amp 300 4 ch
Offline  
Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Old 12-22-2015, 12:53 AM   #2 (permalink)
Ron Nielson
Diesel Pro
 
Ron Nielson's Avatar
 
Join Date: Aug 2009
Location: Berryton, KS
Posts: 2,360
iTrader Score: 0 reviews

Maybe Santa will get you a subscription at alldatadiy.com

Possible Stuck EGR Valve Pintle With Or Without Service Engine Soon (SES) DTCs P0101 P0402 - keywords black box diesel DTC engine lamp light MIL mode power reduced smoke - (Mar 31, 2010)


Subject: Possible stuck open EGR valve pintle with or without Service Engine Soon [SES] DTC P0101 P0402 Models: 2004-2009 Chevrolet Express, Kodiak, Silverado
2004-2009 GMC Savana, Sierra, Topkick
Equipped with the 6.6L Duramax Diesel Engine RPO codes LLY , LBZ , LMM (VIN's 2 , D , 6 and 9) The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

Condition/Concern:

Some customers may comment on an illumination of the check engine light.

Upon further investigation, the technician may find the following DTCs stored in the ECM:

DTC P0101: Mass Air Flow (MAF) Sensor Performance

DTC P0402: Exhaust Gas Recirculation (EGR) Flow Excessive

Recommendation/Instructions:

Complete the current SI diagnostic for any codes setting.

If MAF readings are found to be lower than a like truck with the EGR commanded closed, the codes could be setting due to non-sealing, or partially stuck open EGR valve.

Note: The EGR Pos. sensor is in the EGR motor and is not directly connected to the EGR pintle therefore it is possible to see a 0% EGR Pos. sensor reading when the EGR pintle is stuck open and or not seating fully.

If the EGR valve is found stuck open on 2006 and 2007 LLY and LBZ refer to the latest version of bulletin # 06-06-04-066D to check for the latest ECM calibration, and to clean the EGR valve.

If the EGR valve is found stuck open on 2004 and 2005 LLY and 2007 to 2009 LMM , replace the EGR valve Using SI repair document for EGR valve replacement. Verify the latest ECM calibrations.

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.




DTC P0401 or P0402
DTC Descriptors

DTC P0401

  • Exhaust Gas Recirculation (EGR) Flow Insufficient
DTC P0402

  • Exhaust Gas Recirculation (EGR) Flow Excessive
Circuit/System Description

The engine control module (ECM) tests the exhaust gas recirculation (EGR) flow when the EGR is in operation. EGR desired flow is compared to EGR actual flow. If EGR flow is lower or higher than expected DTC P0401 or P0402 will set.

Conditions for Running the DTC


  • DTCs P0101, P0102, P0103, P0403, P0405, P0406, P046C are not set.
  • The engine is running.
  • The EGR valve is actively being controlled.
  • DTCs P0401 and P0402 run continuously when the above conditions are met.
Conditions for Setting the DTC

P0401

The ECM calculated air flow deviation based on the MAF sensor input during EGR operation indicates insufficient EGR flow for 15 seconds.

P0402

The ECM calculated air flow deviation based on the MAF sensor input during EGR operation indicates excessive EGR flow for 15 seconds.

Action Taken When the DTC Sets


  • DTC P0401 is a Type B DTC.
  • DTC P0402 is a Type A DTC.
Conditions for Clearing the DTC


  • DTC P0401 is a Type B DTC.
  • DTC P0402 is a Type A DTC.
Diagnostic Aids

Inspect for the following conditions that may cause this DTC to set:


  • Contamination on the MAF sensor element
  • Restriction before or after the MAF
  • Skewed MAF sensor
Circuit/System Verification


  1. If DTC P003A, P0101, P0403, P0405, P0406, P046C, P0698, or P0699 are set, diagnose these DTCs.
  2. Using the output controls on the scan tool command the EGR solenoid to 10 percent.
    • If the actual EGR position remains stationary, replace the EGR valve.
  1. Inspect the exhaust system for leaks, restrictions, or for modification of the original equipment manufacture (OEM) part.
  2. Visually inspect for leaks between the MAF sensor and the turbocharger.
  3. Visually inspect for a restriction in the air cleaner or the air intake ducts.
  4. Visually inspect for a restriction in the turbocharger charge air cooler.
  5. Visually inspect for a restriction in the intake manifold.
  6. Operate the vehicle within the Conditions for Running the DTC. You may also operate the vehicle within the conditions that you observed from the Freeze Frame/Failure Records data.
Circuit/System Testing

Important: Perform the Circuit System Verification before proceeding with Circuit/System Testing.

Inspect the charge air cooler for leaks.

If no problem is found, perform the component testing.

Component Testing

Important: Perform the Circuit/System Verification before proceeding with the Component Testing.


  1. Using the output controls on the scan tool command the EGR solenoid to 10 percent.
    • If the actual EGR position remains stationary, replace the EGR valve.
  1. Spray the EGR valve gaskets and EGR cooler gaskets with a soap solution. Start the engine. Command the turbocharger vane position control solenoid ON to 100 percent and inspect for leaks around the EGR valve gaskets.
    • If a leak is found replace the EGR valve gasket.
  1. Remove the EGR valve.
    • If the EGR valve is sticking, or is damaged, replace the EGR valve.


__________________
Ron Nielson

2008 2500HD LT CCLB/Ally. Line-X, B&W Companion, MaxLoader Springs, Edge Insight CTS, Kennedy Custom ECM
2009 Arctic Fox 5er, Silver Fox Edition 29-5T, 3.6 Onan LPG, SteadyFast Stabilizers
Offline   Reply With Quote Quick reply to this message
Old 12-22-2015, 05:10 PM   #3 (permalink)
rodknocker
Glow Plug
 
Join Date: Aug 2008
Location: Baton Rouge, LA
Posts: 220
iTrader Score: 0 reviews

File this one under the hard to believe category.

I was planning to replace the EGR anyway. Bought it this morning, pulled into the garage to start the R&R. Opened the air intake, 2/3rds of the filter element was covered by a mouse nest. Filter was new weekend before Thanksgiving, I guess the rodent built a nest while truck was down for turbo change.
Neither the wife nor I have ever seen a mouse, or any signs of a mouse, in the 5 yrs we have lived here.
Damage estimate=
cancelled epic Christmas adventure to Durango, CO
167.50 for TCM reflash
314.33 for EGR (to be returned)
Many hours of frustration (priceless)
BTW; truck runs like a brand new one.
__________________
'06 LBZ CCSB Black and Chrome LT3 trim, rolling on 18 x 9 Fuel Octane chrome with Michelin 275/75/18
Stock intake mods, EGR blocker and finger stick
Upgraded tranny cooler lines, PPE deep pan
MaxBrake elec brake controller
SuperSlide 16k fifth wheel hitch
ViAir 100% duty cycle compressor 2.5 gal air tank
Firestone air bags with auto level valve
1000 watt inverter
Banks IQ, speed brake, 4" Monster exhaust, Kitty no
Kenwood HU, Polk spkrs in doors, Kicker 10"
Alpine amp 300/500 mono
Alpine amp 300 4 ch
Offline   Reply With Quote Quick reply to this message
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Diesel Place : Chevrolet and GMC Diesel Truck Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

PLEASE READ! You must check your email inbox for the confirmation link to complete registration. Please check your spam box if you do not see the email in your inbox.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:
Insurance
Please select your insurance company (Optional)

Log-in


Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
AAAA!!!! turbo surging at mid throttle 94yukon2 6.5L Diesel Engine 34 12-05-2018 02:35 AM
Speedometer off by 15 mph on my 97 Suburban acesneights1 6.5L Diesel Engine 40 12-07-2015 09:24 AM
Cutting back and surging Suburban Alafia 6.5L Diesel Engine 5 12-03-2015 09:43 PM
Surging Icr242005 6.2L Diesel Engine 9 11-12-2015 08:23 AM
Will bigger tires help mpg at 80mph? matt951207 Wheels & Tires 28 09-07-2015 10:40 PM


All times are GMT -4. The time now is 04:22 PM.


Powered by vBulletin® Version 3.8.8
Copyright ©2000 - 2019, vBulletin Solutions, Inc.
SEO by vBSEO 3.6.1
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd.
Shoutbox provided by vBShout v6.2.1 (Lite) - vBulletin Mods & Addons Copyright © 2019 DragonByte Technologies Ltd. Runs best on HiVelocity Hosting.
© AutoGuide