2006 Savana & Express 6.6 L V8 Duramax Tom Sliney Program Engineering Manager
Discussion Topics • Chassis • HVAC/PTC • Fuel Operated Heater • Body in White • Interior/Exterior • Electrical • Other new 2006 content
Chassis • Dual fuel filters for improved warranty and increased service intervals (20,000 miles for normal operation). • HD frames commonized between Gas and Diesel engines to minimize impact to upfitter process. • Electronic Throttle Control for Diesel. • New Air Induction System with Filter Change Reminder. • Revised Fuel Tanks with 2” Diameter Inlet For 20 Gallon/minute fuel fill. Same fuel tank size as 2005. • Electric Fuel Pump Priming for restart after Fuel filter change.
Chassis/Powertrain Components FRAMES FRAME CUTAWAY (139” / 159” / 177”) ENGINE MOUNTS TCM KIT FUEL TANKS FUEL COOLER & FILTER (FULL BODY) Transmission Fill Tube Air Cleaner STEERING SYSTEM EXHAUST SYSTEM ACCELERATOR PEDAL CHASSIS HARNESS
Math tools utilized to insure proper operation for quality, reliability and durability performance.
HVAC- PTC • Fuel Operated Heater (FOH) provided as optional equipment. First OEM application on Full size vans. • Pressurized coolant system with surge tank. • Rear AC interface with Ambulance Package (Option YF2) on cutaway similar to CK design with ambulance • Rear heat interface (option ENC) on diesel similar to gas • AC compressor same as the 4.3L V6 • Variable Nozzle Turbo Charger (VNT) enables improved heater warm- up standard. Same as Medium Duty. • Optional high idle switch enables sustained engine idle operation.
HVAC C/O INT AIR DISTRIBUTION DUCT NEW FUEL OPERATED HEATER NEW CRFM SYSTEM (CHARGE AIR COOLER, RADIATOR, FAN SHROUDS) C/O BLOWER & HEATER CORE MODULE
FOH CONTROL • The FOH will be operated automatically. • All the conditions listed below are required to switch-on the FOH: • • Outside air temperature <= 4°C. (via GMLAN) • • Engine is running (via GMLAN) . • • Fuel Level >12.5 % total volume of fuel tank. ( signal via GMLAN) . • • Coolant temperature <=75 °C (Internal signal received from FOH coolant temperature sensor, which is POA FOH). • Any of the conditions listed below will switch-off the 5 KW FOH: • • Outside air temperature > 4°C. • • Engine is not running. • • Fuel Level <12.5 % total volume of fuel tank • • Coolant temperature >=85 °C (Internal signal received from FOH coolant temperature sensor, which is POA FOH).
2006 Diesel Rear heater hookups NPN 15251105 ENC part similar to the GMT 610 Gasoline NPN 10379540 AC quick connect For suction line NPN 10379540 AC quick connect For liquid line G 300 0305 &LLY&YF2. SALES PACKAGE AMBULANCE UPFITTER Last modified: November 8, 2004 GM Confidential
2005 Gasoline Rear heater hookups PN 15222929 ENC part for GMT 610 Gasoline GH 100200300 00 &ENC. HVAC PROVISIONS AUXILLIARY HEATER PLUMBING & WIRING
BIW Structure • BIW Engine opening designed to accommodate diesel engine. Body is unique for diesel application. • Access plates provided in body for fuel injector serviceability. • Stiff body structure maintained for diesel .
Front-of-DashNEW PLATES FOR INJECTORS SERVICE NEW LLY ENGINE RING NEW RH FRT DASH PNL C/O LH FRT DASH PNL C/O LH FRT WHEELHOUSE C/O RH FRT WHEELHOUSE NEW FRT FLR PNL NEW RH UNDERBODY HEATSHIELDS NEW LH UNDERBODY HEATSHIELDS
PLATES FOR INJECTORS SERVICE Plates seal over the engine ring using snap on features to allow easy service access to the injectors.
Interior and Exterior Components • Engine cover size optimized to maximize passenger foot room and knee room for diesel engine. Engine cover unique for diesel. • Interior designed to minimize road and engine noise. • Driver and passenger side knee bolster revised. • New switches located on Instrument panel (High Idle and Export Options)
Interior NEW DRIVER KNEE BOLSTER NEW PASSENGERKNEE BOLSTER NEW ENGINE COVER C/0 CENTER CONSOLE
HD Passenger Airbag Suppression Cutoff Switch Hi-Idle switch – optional. Mounted on Instrument panel 15131896 Filler Asm-I/P Cstr Tr Plt (Hi Idle) *Filler Assemblies Location
Electrical • New electrical harness content added for diesel functionality. • IP Cluster revised to add diesel telltale functionality. • Class 2 Electrical Architecture from 2003 MY will be maintained except for new Powertrain electrical interface. • Standard 145 Amp alternator. • TCM packaged underhood. • Diesel primary battery underhood and auxiliary battery mounted on LH frame rail. • New ECM bracket mounted on LH fender inner. • Ambulance package equipped with 50 amp Maxifuse connector at B Pillar.
Diesel Domestic Water in Fuel Cruise (To be also used for VNT, by blinking the light) Export New Oil Pressure Scale DRLremoved Wait to start
Diesel Specific Options • High Idle Switch • Fuel Operated Heater • Export Package for Middle East • Ambulance Package
Ambulance Content - YF2 • Full Body Van (Type II) • 6.6 L Diesel Engine • Front Air Conditioning • Dual 145 Amp Alternators • Rear HVAC Provisions w/Quick Connects • Vinyl Floor Covering, Front • Stationary Side and Rear Door Windows • 9600 GVWR
Ambulance Content - YF2 • Cutaway Body (Type III) • 6.6 L Diesel Engine • Front Air Conditioning • Dual 145 Amp Alternators • Rear HVAC Provisions w/Quick Connects • 12000 GVWR
School Bus Content - B3D • Cutaway Body (Type A) • 6.6 L Diesel Engine • Passenger Door Delete • OSRV Mirror Delete or Manual OSRV • ISRV Mirror • Brake Warning Indicator Light • Dual Horns • GVWR Options, 9600, 10000 or 12000 GVWR • SRW or DRW (GVWR dependent)
Mass Analysis • Comparison of 6.6 L Diesel vs. 6.0 Gasoline • Total Differential: Approximately 450 Pounds • Complete Mass Data Available Spring ‘05
Diesel Engine Program Content Summary • Best In Class Duramax Diesel Performance and Features. -Engine Noise/Fuel economy/Loaded performance -Build on 2003 JD Power Dependability Award • Transmission designed for diesel operation. • Designed for quality, reliability, durability and minimize life cycle cost. • Serviceability considered with oil filter and fuel filter locations and air filter change reminder. • New offering minimizes change to upfitters currently building on gas cutaway vehicles. • Enhanced heating performance with FOH.
Other New 2006 MY Content • Gasoline exhaust for Emissions • Automatic Occupant Suppression • Velvac Mirror Option
Automatic Occupant Suppression • MVSS 208 requires automatic passenger side airbag suppression. • AOS passenger seat on light duty (<8500 lb) gasoline trucks • Carryover PSIR cutoff switch will remain on HD models with passenger airbags. • 1500 Series Upfit Vans (RPO YF7) over 5500 lbs. curb weight are exempt for MVSS 208.
Heavy Duty Full Body Vans – Gasoline Federal Applications HD Catalytic Converter revisions implemented 2005 design 2006 design M150 converters Federal Non-MDPV applications Complete vehicles M120 converters ALL Federal applications Complete vehicles M102 converters Federal MDPV applications Complete vehicles