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Duramax Suburban - IFS Rebuild

Maybe it is me but I never use silicone if there is a gasket of any kind.

It always seems to bite people in the arse. I just did mine, I did a scotch Brite with brake clean both surfaces then used a gm paper gasket with no leaks.
 
Ten_Bucks said:
You're very welcome. Always glad to help.

Scott
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Reached out to Dmax store. Couldn't reach mike, but the guy that helped me said they are booked solid into december. A little nervous about waiting that long, but made an appointment anyways in case i need it.
 
Russell said:
What are your exact codes that are set? And what does he mean by they are not the factory tunes? Is he checking calibration numbers and OS numbers? How would he know which ones are supposed to be in your vehicle when your vehicle has an engine several years newer installed? Your OS number would be different if you are running dual tanks vs single tanks, for example, but the actual engine calibration would not be any different.

Give us all the information you can and maybe we can get you set up straight the first time without any re-work on your re-flash from wherever. I can provide you with factory tunes based on VIN and flash them into your PCM as well. I can also disable any engine MIL enablers or diagnostics codes with EFILive so they'd never show up on his scan tool. We can also modify the emissions test criteria to make them pass as well.
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Appreciate the help Russell.

I have attached the paperwork. I also got a real code reader, which will pull up the fuel level malfunction, so i know if it's still there.

He explained that i failed for 2 reasons
1. computer program didn't match what the 06 diesel VIN report should show. He showed me the 2 sheets mentioning that one was mine and one was correct, but not really sure if he was correct on the meaning of the print outs. When i reviewed the info on the code reader i picked up, some of the numbers matched items on both sheets. Screen shots attached. The other sheet he attached, i have no idea what it was copied from.

2. Last sheet in the report is the P0461 code for fuel level malfunction. Truck occasionally has fuel gauge drop to zero, and then go back to full after a while. So it could be this issue, or a software issue. Ref's boss mentioned, when i called him, that he thought he remembered mine and saw 123456 or something as time since last fault, which he guessed was that it has been disabled or tampered with. Who knows.

On the fuel level sending unit, its worth mentioning that the dmax and suburban ones are opposite: one reads 0-80 ohms or whatever, and hte other runs 80-0. There are 2 ways to fix this. Either program with EFI live to read backwards, or "flip" the float around so it reads the same as the dmax computer wants to see. I THINK my float was flipped.

Its also worth noting that my fuel gauge doesn't work right now, mostly sticks at full, and that my second tank transfer switch isn't hooked up. As much as I want to fix this, first priority is passing with no codes. Then i'll deal with custom programming for the dual tanks and gauge later.


Again, really appreciate the help. I'll shoot you my phone number, and hopefully we can discuss tomorrow. If you are able to get this thing setup right, i'm more than willing to pay you for your time!

CK5 rocks!

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Attachments

  • Smog Ref.pdf
    1.3 MB · Views: 3
dhcomp said:
Reached out to Dmax store. Couldn't reach mike, but the guy that helped me said they are booked solid into december. A little nervous about waiting that long, but made an appointment anyways in case i need it.
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Doesn't surprise me that they are booked that far ahead. They're always busy when I come over to their shop. If you don't get help with your problem before your appointment date, it'll be well worth the wait to get their help.

Scott
 
Ten_Bucks said:
Doesn't surprise me that they are booked that far ahead. They're always busy when I come over to their shop. If you don't get help with your problem before your appointment date, it'll be well worth the wait to get their help.

Scott
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Yep, wanted to have them handle it, but early December makes me nervous approaching my registration date. Plus, i'd have to leave it for a week due to distance and work, then get it down to sac right before christmas. We'll see what happens, it may end up there anyways.
 
If you do bring it to them, it'd be cool to meet up with you since you'll be in my neck of the woods. It's always nice to meet fellow CK5'ers, you know?

Scott
 
Ten_Bucks said:
If you do bring it to them, it'd be cool to meet up with you. It's always nice to meet fell CK5'ers, you know?

Scott
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Didn't notice you were in placerville too. I'll let you know. If it ends up there, it'll be a weekend, so we should meet for a beer!
 
P0461 is set when the fuel level sender is stuck. I think you are going to be dropping your fuel tank to replace the sending unit or get it unstuck.

Here is the DTC information from GM:

CIRCUIT DESCRIPTION
The fuel level sensor changes resistance in response to the fuel level. The PCM monitors the signal circuit of the fuel level sensor in order to determine the fuel level. When the fuel tank is full, the sensor resistance is high and the PCM senses a high signal voltage. When the fuel tank is empty, the sensor resistance is low and the PCM senses a low signal voltage. The PCM uses the signal circuit of the fuel level sensor in order to calculate the percentage of remaining fuel in the tank. The PCM sends the fuel level percentage via the class 2 serial data circuit to the instrument cluster in order to control the fuel gage. The fuel level information is also used for misfire and EVAP diagnostics.

This diagnostic tests for a stuck fuel level sensor signal. The PCM sets this DTC if the fuel level sensor signal appears to be stuck based on a lack of signal variation expected during normal operation.

CONDITIONS FOR RUNNING THE DTC
The ignition is ON.

CONDITIONS FOR SETTING THE DTC
The PCM does not detect a change in fuel level of at least 3.0 L (0.79 gal) over a distance of 320 km (200 miles) .

ACTION TAKEN WHEN THE DTC SETS

  • The fuel gage defaults to empty.
  • The low fuel indicator illuminates.
  • The PCM records the operating conditions at the time that the diagnostic test fails. The PCM displays the failure information in the Failure Records on the scan tool.
CONDITIONS FOR CLEARING THE DTC

  • The DTC becomes history when the conditions for setting the DTC are no longer present.
  • The history DTC clears after 40 malfunction free warm-up cycles.
  • The PCM receives the clear code command from the scan tool.
DIAGNOSTIC AIDS

  • Use the Freeze Frame/Failure Records data in order to locate an intermittent condition. If you cannot duplicate the DTC, the information included in the Freeze Frame/Failure Records data may help in determining the number of miles since the DTC set. The Fail Counter and Pass Counter can also help in determining the number of ignition cycles that the diagnostic test reported a pass and/or fail. Operate the vehicle within the same freeze frame conditions, including those for RPM, for engine load, for vehicle speed, for temperature, and for others. This will isolate at what point the DTC failed.
  • Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures.

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Now, as far as your tune numbers go, it looks like your fuel system calibration ID isn't correct for your VIN. You may want to get into touch with the guys that built your rig and ask if there is a specific reason why you have an alternate calibration ID loaded up instead. If there is no particular reason, it should just be a matter of re-flashing the fuel system calibration with the 12632666 cal from GM and you should be good to go.
 
Huge help.

Fuel level definitely drops to zero occasionally. I'm all for fixing this issue physically, but also sounds like something I can clear and sneak by. The Innova scan tool I just got picks up And clears this code.

In terms of fueling programming, my builder uses Efi live to get by as needed, and will admit that his techs only really know enough about it to be dangerous. He had issues with the ECM that came with this motor, so I'd guess he pulled another out out of the pile, flashed my vin on it, and rolled with it. I really doubt it was intentionally setup non-stock.
 
Well, sounds like we should just get the stock fuel system for that VIN flashed in and you should be able to pass your inspection by clearing the code just before you roll in.
 
Russell said:
Well, sounds like we should just get the stock fuel system for that VIN flashed in and you should be able to pass your inspection by clearing the code just before you roll in.
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I'm not sure how it works exactly but you can't clear a code and drive into a smog station. The car has to go through a certain amount of heat cycles/miles to then qualify for a test. I had to change out my knock sensors on the tahoe a few months back, cleared the codes and drove it for a couple days and it failed at the station because they knew the ECU was cleared recently. Went back a couple days later and it passed.
 
skunked said:
I'm not sure how it works exactly but you can't clear a code and drive into a smog station. The car has to go through a certain amount of heat cycles/miles to then qualify for a test. I had to change out my knock sensors on the tahoe a few months back, cleared the codes and drove it for a couple days and it failed at the station because they knew the ECU was cleared recently. Went back a couple days later and it passed.
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Not surprising! No emissions testing around here, so I've never actually had to pass a test before... I did get crap from an oil change place in Reno when I took my Tahoe in before a drive to Vegas though! haha!

I imagine you could simply disable the DTC so it doesn't pop up on their scan tool as well.
 
Russell said:
Not surprising! No emissions testing around here, so I've never actually had to pass a test before... I did get crap from an oil change place in Reno when I took my Tahoe in before a drive to Vegas though! haha!

I imagine you could simply disable the DTC so it doesn't pop up on their scan tool as well.
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Disabling it is risky. I don't actually know how deep they look, but they mentioned that they check for all "self diagnostic" type items that are supposed to pop up still pop up. Kind of like making sure the check engine light turns on at startup, and that the bulb wasn't removed. I don't know enough to say we could hide it well enough to pass.
 
Russell said:
Well, sounds like we should just get the stock fuel system for that VIN flashed in and you should be able to pass your inspection by clearing the code just before you roll in.
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Stock fuel map plus fixing the fuel sending unit should get us there. Debating if I should fix with a Dmax or Burb sending unit to make dual tank programming in the future easier.

Also not sure how to swap, as it's part of the fuel pump assembly, and mine has been modified to basically be a passive pickup (no fuel pump on the diesel)
 
Was thinking about the stuck float idea, and dual tanks. Was going downhill on 80 the last time it triggered. Wonder if the gravity flow from the rear tank to the front primary tank would cause the computer to think the float is stuck? Truck continues to burn fuel, but fuel level stays even while it refills itself.
 
dhcomp said:
Was thinking about the stuck float idea, and dual tanks. Was going downhill on 80 the last time it triggered. Wonder if the gravity flow from the rear tank to the front primary tank would cause the computer to think the float is stuck? Truck continues to burn fuel, but fuel level stays even while it refills itself.
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If the front tank is all the computer sees, that's probably the issue.
 
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