The Duramax Diesel Engine Repair Manual covers the 6.6 liter (402 cu in) Turbo Diesel for Chevrolet and GMC Trucks and Vans. It is an outstanding first class Haynes technical handbook that provides step wise instructions to repair, maintain or perform a full tear down and rebuild of the 6.6L Duramax Diesel. The techbook includes complimentary illustrations, diagrams, schematics and detailed photos of all service and repair tasks. It is a must have companion for the Duramax diesel owner.
The General Motors Duramax diesel engine was designed by Isuzu for light and medium duty trucks. The Duramax is produced in Moraine, Ohio by DMAX, which is a joint venture between GM and Isuzu. The Duramax engine was introduced in 2001 and continues to be an option for Chevy and GMC pickups, vans and medium-duty trucks. In 2006, the production of the engine at the Moraine plant was limited to 200,000 engines per year. On May 9, 2007, DMAX announced the production of the one millionth Duramax V-8 Diesel at its Moraine facility, courtesy of Wikipedia for the Duramax V8 engine.
Dec 25, 2014 Good manual for maintenance as well as major engine work. Would be nice if Haynes made GMC/Silverado 2500/3500 HD service manual That included maintenance of the Duramax. The vast majority of HD's are diesel and the regular GMC/Silverado repair manual has a large amount of info that does not pertain to the diesel HD models. Jun 11, 2019 This is the most complete Service Repair Manual for the JCB Dieselmax Tier3 SE Engine (SE Build).Service Repair Manual can come in handy especially when you have to do immediate repair to your JCB Dieselmax Tier3 SE Engine (SE Build).Repair Manual comes with comprehensive details regarding technical data. Diagrams a co. Duramax Diesel 6600 was an immediate success, achieving best-in-class honors for operating quietness and smoothness, even getting a favorable comparison with the same size of gasoline engines. As evidence of the overwhelming success of Duramax 6600, GM's market share enjoyed in Heavy Duty Diesel Pickup Truck category jumped 30 percent.
If you are interested in learning more about the DURAMAX Diesel Engine from other Duramax enthusiasts, we recommend that you pay a visit to the DURAMAX GM Diesel FORUM. The discussions on the DURAMAX forum cover a wide range of current topics related to this popular GM Diesel engine.
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Duramax Service Manual Download
DURAMAX Diesel Engine Repair Manual ISBN-10: 1620920433 | ISBN-13: 9781620920435 | Haynes 103316.6L Duramax Maintenance Schedule, Service Intervals
Replace engine oil & oil filter | 10,000 miles or when 'change engine oil' message is displayed by the oil life monitoring system | |
Replace fuel filter | 2001 - 2010 | 15,000 miles |
2011 - 2016 | 22,500 miles or when 'change fuel filter' message is displayed | |
Replace engine air filter | Check filter condition every oil change and replace as necessary; replace at 45,000 miles regardless | |
Flush engine cooling system | 150,000 miles | |
Replace automatic transmission fluid & filters | 2001 - 2011 | 50,000 miles (normal conditions) |
2012 - 2016 | Replace external filter at 45,000 mile intervals and full service at 97,500 miles under normal conditions | |
Replace manual transmission fluid | GM advises that the ZF S6-650 6 speed manual transmission does not require service. To maintain shift quality and promote transmission life, consider replacing fluid at 60,000 mile intervals, especially if usage meets any of the severe duty conditions. | |
Replace transfer case fluid | 2001 - 2011 | 50,000 miles |
2012 - 2016 | 97,500 miles (normal conditions) | |
Replace front differential fluid (4x4) | Service interval not provided by GM, routine service may promote longevity. Fluid level should be checked periodically. Drain and replace differential fluid immediately if the axle is submerged in water. | |
Replace rear differential fluid | Service interval not provided by GM, routine service may promote longevity. Fluid level should be checked periodically. Drain and replace differential fluid immediately if the axle is submerged in water. | |
6.6L Duramax Service Part Numbers
Part numbers based on Silverado/Sierra trucks - some parts may not be compatible with Sierra/Express vans
Duramax Service Manual
Engine air filter | 2001 - 2005 | |
2006 - 2010 | ||
2011 - 2016 | ||
Engine oil filter | ||
Oil pan drain plug | ||
Fuel filter | ||
Fuel pump | 2001 - 2014 (inline pump) | ACDelco EP1037, Delphi HFP955 |
2015 - 2016 | ||
2015 - 2016 | ||
Serpentine belt | 2001 (105 amp alt) | ACDelco 6K1114, Gates K061114 |
2001 (130 amp alt) | ACDelco 6K1123, Gates K061123 | |
2002 - 2016 (single alt) | ACDelco 6K1195, Gates K061195 | |
Glow plug[1] | 2001 - 2004 LBZ | |
2004 - 2005 LLY | ||
2006 - 2016 | ACDelco 9G (replaces ACDelco 61G) | |
Thermostat[2] | 2001 - 2014 | ACDelco 12T100D (front), ACDelco 12T99D (rear, alternative p/n 131131) |
2015 - 2016 | ||
Thermostat housing gasket | ||
Coolant reservoir cap | 2001 - 2010 | |
2011 - 2016 | ||
Upper radiator hose | 2001 - 2005 | ACDelco 24485L, Gates 22698 |
2006 - 2008 | ACDelco 24589L, Gates 23227 | |
2009 - 2010 | ACDelco 24655L, Gates 23499 | |
2011 - 2014 | ACDelco 27035X, Gates 23721 | |
2015 -2016 | GM 22884211, Dayco 72554 | |
Lower radiator hose | 2001 - 2005 | ACDelco 26397X, Gates 22650 |
2006 - 2010 | ACDelco 26570X, Gates 23260 | |
2011 - 2014 | ACDelco 27099X, Gates 23962 | |
Camshaft position sensor (CPS) | 2001 - 2004 | GM 2134274 (alternative 2132485) |
2004.5 - 2015 | ||
2016 | GM 1267264 | |
Crankshaft position sensor (CKP) | 2001 - 2004 | GM 2134277 (alternative 2132486) |
2004.5 - 2015 | GM 9765037 | |
2016 | ||
Automatic transmission filter | External filter, 2001 - 2016 | ACDelco TF950, Allison 29539579 |
Internal filter, 2001 - 2005 | ||
Internal filter, 2006 - 2010 | ||
Internal filter, 2011 - 2016 | ||
Transmission pan gasket |
[1]Model years with engine crossovers should have engine model verified by VIN number before ordering glow plugs. Glow plugs are not interchangeable with all model years. See: Duramax engine models by VIN number
[2] 2001 to 2014 model year engines use a dual thermostat system, 1 front and 1 rear mounted thermostat.
6.6L Duramax Fluid Specifications & Capacities
Manual Duramax For Sale
Note - fluid capacities are nominal; always fill to proper level as indicated by dipstick, to the bottom of the fill plug, etc. The fluid capacities listed herein are measured in U.S. quarts ('qts') and/or pints ('pts'), NOT Imperial units. Always verify fluid specifications and capacities in your owners manual, if applicable.
Duramax Service Manual Download Honda
Engine oil | 15W-40 | Preferred viscosity, ambient temp > 0° F | 10 qts w/ filter change |
5W-40 | Preferred viscosity, ambient temp < 0° F, acceptable in all temps | ||
10W-30 | Listed as acceptable for certain model years - not advised | ||
Engine coolant | 50/50 DEX-COOL 12346290 engine coolant , distilled water | 22.0 - 31.4 quarts (5.5 - 7.85 gallons) | |
Automatic transmission fluid | 2001 - 2005 (5 spd) | DEXRON III automatic transmission fluid (replaced by ACDelco 10-9243) | 7.4 qts service refill |
2006 - 2016 (6 spd) | DEXRON VI automatic transmission fluid (ACDelco 10-9243) | ||
Manual transmission fluid | ZF S6-650 (6 spd) | GM TranSynd full synthetic transmission fluid (GM 12378515) | 5.8 qts |
Transfer case fluid | 2001-2007 manual shift | DEXRON III automatic transmission fluid (replaced by ACDelco 10-9243) | 2.0 qts |
2001 - 2007 auto shift | AUTO-TRAK II (GM 12378508) | 2.0 qts | |
2008 - 2016 | DEXRON VI automatic transmission fluid (ACDelco 10-9243) | 1.6 qts | |
Front differential fluid | 2001 - 2010 | SAE 80W-90 synthetic gear oil | 1.8 qts |
2011 - 2016 | SAE 75W-90 synthetic gear oil | 1.8 qts | |
Rear differential fluid | SAE 75W-90 synthetic gear oil | 3.2 - 4.3 qts (varies by MY) | |
DEF tank capacity | 5.3 gallons | ||