2006 Savana & Express 6.6 L V8 Duramax Tom Sliney Program Engineering Manager

GM ConfidentialLast modified: November 8, 2004

2006 Savana & Express

6.6 L V8 Duramax

Tom Sliney

Program Engineering Manager

2006 Savana & Express

6.6 L V8 Duramax

Tom Sliney

Program Engineering Manager


Discussion Topics

• ChassisChassis• HVAC/PTCHVAC/PTC• Fuel Operated HeaterFuel Operated Heater• Body in WhiteBody in White• Interior/ExteriorInterior/Exterior• ElectricalElectrical• Other new 2006 contentOther new 2006 content


• Dual fuel filters for improved warranty and Dual fuel filters for improved warranty and increased service intervals (20,000 miles for increased service intervals (20,000 miles for normal operation).normal operation).

• HD frames commonized between Gas and HD frames commonized between Gas and Diesel engines to minimize impact to upfitter Diesel engines to minimize impact to upfitter process.process.

• Electronic Throttle Control for Diesel.Electronic Throttle Control for Diesel.• New Air Induction System with Filter Change New Air Induction System with Filter Change

Reminder.Reminder.• Revised Fuel Tanks with 2” Diameter Inlet For Revised Fuel Tanks with 2” Diameter Inlet For

20 Gallon/minute fuel fill. Same fuel tank size 20 Gallon/minute fuel fill. Same fuel tank size as 2005.as 2005.

• Electric Fuel Pump Priming for restart after Fuel Electric Fuel Pump Priming for restart after Fuel filter change.filter change.

Chassis


Chassis/Powertrain Components

TCM KIT

FRAMES

STEERING SYSTEM

Air Cleaner

FRAME CUTAWAY

(139” / 159” / 177”)

CHASSIS HARNESS

FUEL COOLER & FILTER

(FULL BODY)

ENGINE MOUNTS

EXHAUST SYSTEM

FUEL TANKS

Transmission Fill Tube

ELECTRONIC

ACCELERATOR PEDAL


GMT610 Rear Axles.

-Common rear axle to gas with unique gear ratio for diesel (3.73)

Jan 21/03


Math tools utilized to insure proper operation for quality, reliability and durability performance.


• Fuel Operated Heater (FOH) provided as Fuel Operated Heater (FOH) provided as optional equipment. First OEM application on optional equipment. First OEM application on Full size vans.Full size vans.

• Pressurized coolant system with surge tank. Pressurized coolant system with surge tank. • Rear AC interface with Ambulance Package Rear AC interface with Ambulance Package

(Option YF2) on cutaway similar to CK design (Option YF2) on cutaway similar to CK design with ambulancewith ambulance

• Rear heat interface (option ENC) on diesel Rear heat interface (option ENC) on diesel similar to gassimilar to gas

• AC compressor same as the 4.3L V6AC compressor same as the 4.3L V6• Variable Nozzle Turbo Charger (VNT) enables Variable Nozzle Turbo Charger (VNT) enables

improved heater warm- up standard. Same as improved heater warm- up standard. Same as Medium Duty.Medium Duty.

• Optional high idle switch enables sustained Optional high idle switch enables sustained engine idle operation. engine idle operation.

HVAC- PTC


ModelModel GasolineGasoline

(Lts) (Lts)

Diesel Diesel

(Lts)(Lts)

Fr Heater *OnlyFr Heater *Only 12.812.8 19.919.9

Fr Heater with FOHFr Heater with FOH ---- 20.620.6

Rr Heater * OnlyRr Heater * Only 15.615.6 21.621.6

Rr Heater plus FOHRr Heater plus FOH ---- 22.322.3

Coolant Volume Chart for GMT610


C/O BLOWER &

HEATER CORE

MODULE

C/O INT AIR DISTRIBUTION

DUCT

NEW CRFM SYSTEM

(CHARGE AIR COOLER,

RADIATOR, FAN SHROUDS)

HVAC

NEW FUEL OPERATED HEATER


Fuel Operated Heater


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).

GM ConfidentialLast modified: November 8, 2004 G M C o n f i d e n t i a lL a s t m o d i f i e d : N o v e m b e r 5 , 2 0 0 4

C o o l a n t T e m p e r a t u r e C o n t r o lT h e F O H d e fi n e b y i t s e l f t h e l o a d m o d e , d e p e n d i n g o n t h e c o o l a n t

t e m p e r a t u r e . T h e F O H w i l l s t a r t i n h i g h p o w e r a n d w i l l s w i t c h t o l o w p o w e r w h e n t h e c o o l a n t t e m p e r a t u r e r e a c h e s 8 0 ° C . I f t h e c o o l a n t t e m p e r a t u r e

r e a c h e s 8 5 ° C t h e F O H w i l l s w i t c h o ff a n d w i l l r e s t a r t o n c e a g a i n a t 7 5 ° C o r w i l l s w i t c h b a c k t o h i g h i f t h e c o o l a n t r e a c h e s 7 5 ° C i n l o w p o w e r m o d e .

R e f e r t o t h e fi g u r e b e l o w f o r a s c h e m a t i c o f t h e c o n t r o l p r o c e s s .

H i g h P o w e r5 K W

L o w P o w e r2 . 5 K W

7 5 ° C 8 0 ° C 8 5 ° C

O F F

C o o l a n t t e m p e r a t u r e ( ° C )

GM ConfidentialLast modified: November 5, 2004 GM ConfidentialLast modified: November 8, 2004

G 300 0305&LLY&YF2.SALES PACKAGE AMBULANCE UPFITTER

2006 Diesel

NPN 10379540AC quick connectFor suction line

Rear heater hookupsNPN 15251105ENC part similar to the GMT 610 Gasoline

NPN 10379540AC quick connectFor liquid line

GM ConfidentialLast modified: November 8, 2004 G M C o n f i d e n t i a lL a s t m o d i f i e d : N o v e m b e r 8 , 2 0 0 4

2 0 0 6 D i e s e lR e a r h e a t e r h o o k u p sN P N 1 5 2 5 1 1 0 5E N C p a r t s i m i l a r t o t h e G M T 6 1 0 G a s o l i n e

G H 1 0 0 2 0 0 3 0 0 0 0& E N C .H V A C P R O V I S I O N S A U X I L L I A R Y H E A T E R P L U M B I N G & W I R I N G


2005 Gasoline

Rear heater hookupsPN 15222929ENC part for GMT 610 Gasoline

GH 100200300 00&ENC.HVAC PROVISIONS AUXILLIARY HEATER PLUMBING & WIRING


• BIW Engine opening designed to accommodate BIW Engine opening designed to accommodate diesel engine. Body is unique for diesel diesel engine. Body is unique for diesel application.application.

• Access plates provided in body for fuel injector Access plates provided in body for fuel injector serviceability. serviceability.

• Stiff body structure maintained for diesel . Stiff body structure maintained for diesel .

BIW StructureBIW Structure


Front-of-DashNEW

NEW LLY ENGINE

RING

C/O LH FRT DASH PNL

NEW RH FRT DASH PNL

C/O LH FRT WHEELHOUSE

C/O RH FRT WHEELHOUSE

NEW LH UNDERBODY

HEATSHIELDS

NEW RH UNDERBODY

HEATSHIELDS

NEW FRT FLR PNL

PLATES FOR INJECTORS SERVICE


PLATES FOR INJECTORS SERVICEPlates seal over the engine ring using snap on features to allow easy service access to the injectors.


• Engine cover size optimized to maximize Engine cover size optimized to maximize passenger foot room and knee room for diesel passenger foot room and knee room for diesel engine. Engine cover unique for diesel.engine. Engine cover unique for diesel.

• Interior designed to minimize road and engine Interior designed to minimize road and engine noise.noise.

• Driver and passenger side knee bolster revised. Driver and passenger side knee bolster revised.

• New switches located on Instrument panel (High New switches located on Instrument panel (High Idle and Export Options)Idle and Export Options)

Interior and Exterior Interior and Exterior ComponentsComponents


NEW ENGINE COVER

NEW PASSENGER

KNEE BOLSTER

C/0 CENTER CONSOLE

NEW DRIVER KNEE

BOLSTER

Interior


15131896

Filler Asm-I/P Cstr Tr Plt (Hi Idle)*Filler

Assemblies Location

HD Passenger Airbag Suppression Cutoff Switch

Hi-Idle switch – optional. Mounted on Instrument panel


• New electrical harness content added for diesel New electrical harness content added for diesel functionality.functionality.

• IP Cluster revised to add diesel telltale IP Cluster revised to add diesel telltale functionality.functionality.

• Class 2 Electrical Architecture from 2003 MY will Class 2 Electrical Architecture from 2003 MY will be maintained except for new Powertrain be maintained except for new Powertrain electrical interface.electrical interface.

• Standard 145 Amp alternator.Standard 145 Amp alternator.• TCM packaged underhood.TCM packaged underhood.• Diesel primary battery underhood and auxiliary Diesel primary battery underhood and auxiliary

battery mounted on LH frame rail.battery mounted on LH frame rail.• New ECM bracket mounted on LH fender inner.New ECM bracket mounted on LH fender inner.• Ambulance package equipped with 50 amp Ambulance package equipped with 50 amp

Maxifuse connector at B Pillar.Maxifuse connector at B Pillar.

ElectricalElectrical


Cruise (To be also used for VNT, by blinking the light)

DRL removed

Water in Fuel

Domestic

Export

Diesel

New Oil Pressure Scale

Wait tostart


Diesel Specific Options

• High Idle Switch

• Fuel Operated Heater

• Export Package for Middle East

• Ambulance Package


Ambulance Content - YF2Ambulance Content - YF2

• Full Body Van (Type II)Full Body Van (Type II)• 6.6 L Diesel Engine6.6 L Diesel Engine• Front Air ConditioningFront Air Conditioning• Dual 145 Amp AlternatorsDual 145 Amp Alternators• Rear HVAC Provisions w/Quick ConnectsRear HVAC Provisions w/Quick Connects• Vinyl Floor Covering, FrontVinyl Floor Covering, Front• Stationary Side and Rear Door WindowsStationary Side and Rear Door Windows• 9600 GVWR9600 GVWR


Ambulance Content - YF2Ambulance Content - YF2

• Cutaway Body (Type III)Cutaway Body (Type III)• 6.6 L Diesel Engine6.6 L Diesel Engine• Front Air ConditioningFront Air Conditioning• Dual 145 Amp AlternatorsDual 145 Amp Alternators• Rear HVAC Provisions w/Quick Rear HVAC Provisions w/Quick

ConnectsConnects• 12000 GVWR12000 GVWR


School Bus Content - B3DSchool Bus Content - B3D

• Cutaway Body (Type A)Cutaway Body (Type A)• 6.6 L Diesel Engine6.6 L Diesel Engine• Passenger Door DeletePassenger Door Delete• OSRV Mirror Delete or Manual OSRVOSRV Mirror Delete or Manual OSRV• ISRV MirrorISRV Mirror• Brake Warning Indicator LightBrake Warning Indicator Light• Dual HornsDual Horns• GVWR Options, 9600, 10000 or 12000 GVWR Options, 9600, 10000 or 12000

GVWRGVWR• SRW or DRW (GVWR dependent)SRW or DRW (GVWR dependent)


Mass AnalysisMass Analysis

• Comparison of 6.6 L Diesel vs. 6.0 Comparison of 6.6 L Diesel vs. 6.0 GasolineGasoline• Total Differential: Approximately 450 Total Differential: Approximately 450

PoundsPounds

• Complete Mass Data Available Spring Complete Mass Data Available Spring ‘05‘05


• Best In Class Duramax Diesel Performance and Best In Class Duramax Diesel Performance and Features.Features.

-Engine Noise/Fuel economy/Loaded -Engine Noise/Fuel economy/Loaded performanceperformance-Build on 2003 JD Power Dependability Award -Build on 2003 JD Power Dependability Award

• Transmission designed for diesel operation.Transmission designed for diesel operation.• Designed for quality, reliability, durability and Designed for quality, reliability, durability and

minimize life cycle cost.minimize life cycle cost.• Serviceability considered with oil filter and fuel Serviceability considered with oil filter and fuel

filter locations and air filter change reminder.filter locations and air filter change reminder.• New offering minimizes change to upfitters New offering minimizes change to upfitters

currently building on gas cutaway vehicles. currently building on gas cutaway vehicles.

• Enhanced heating performance with FOHEnhanced heating performance with FOH..

Diesel Engine Program Content Diesel Engine Program Content SummarySummary


Other New 2006 MY Content

• Gasoline exhaust for Emissions

• Automatic Occupant Suppression

• Velvac Mirror Option


• MVSS 208 requires automatic passenger side MVSS 208 requires automatic passenger side airbag suppression. airbag suppression.

• AOS passenger seat on light duty (<8500 lb) AOS passenger seat on light duty (<8500 lb) gasoline trucksgasoline trucks

• Carryover PSIR cutoff switch will remain on HD Carryover PSIR cutoff switch will remain on HD models with passenger airbags. models with passenger airbags.

• 1500 Series Upfit Vans (RPO YF7) over 5500 lbs. 1500 Series Upfit Vans (RPO YF7) over 5500 lbs. curb weight are exempt for MVSS 208. curb weight are exempt for MVSS 208.

Automatic Occupant Automatic Occupant SuppressionSuppression



LD Passenger Airbag Suppression Indicator


HD Passenger Airbag Suppression Cutoff Switch


HD Catalytic Converter revisions implementedHD Catalytic Converter revisions implemented

Heavy Duty Full Body Vans – Gasoline Federal Applications

2005 design 2006 design

M150 convertersFederal Non-MDPV applicationsComplete vehicles

M102 convertersFederal MDPV applicationsComplete vehicles

M120 convertersALL Federal applicationsComplete vehicles


Velvac Mirror- RPO DHCVelvac Mirror- RPO DHC


Questions or Comments

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2006 Savana & Express 6.6 L V8 Duramax Tom Sliney Program Engineering Manager

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