LLY DURAMAX TEARDOWN. BAD Silverado 6.6L Turbodiesel V8. Unrebuildable You Say? Yeah, Pretty Much.
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- Опубліковано 27 вер 2024
- Want to see a particular engine torn down? I may have already done one! I've done well over 20 other teardowns from Cummins to an LS7, and from Rotary to Ram Ecodiesels. Check them out here • Blown Up Engine Tear D...
My name is Eric and I own and run a full service auto salvage business called Importapart located in the Saint Louis MO area. Part of our model is dismantling and selling parts from rare and niche market engines. If you're interested in buying parts from this engine or other engines I've torn down, email us at Importapartsales@gmail.com.
In this video I teardown a 6.6L Duramax Turbodiesel, an LLY specifically. This engine is found in 04.5-05 Silverado and Sierra 2500/3500 HD Trucks as well as some medium duty applications. This engine was clearly worked on by people who don't quite have the grasp of what they are doing, which seems to be a trend amongst the bad cores I've torn down lately.
As always, I appreciate all of the comments, feedback and even the criticism, I love it all.
Catch you on the next one!
-Eric
freeze plugs blew out when the motor torched the heads. All that compression went into the cooling system and blew the plugs out of it
I think that is dead right.....blew em.....
Yep, you are absolutely correct, seen it happen before
I've seen damage like that before in a diesel engine. Why I was the one that caused it. April of 97 my mom had a heart issue while in the hospital recovering from surgery. I was in Kentucky at the Tennessee line when I found out. I told my boss that he better let Illinois know that speed limits weren't going to work for me that day. 4 hours later I was home. It was a distance of just over 370 miles. I had burned pistons 2 and 4 and cylinder 1 had swallowed the intake valves. I pegged the pyrometer at 1500 degrees.
Boss all he said was overhaul time and we are going to make her able to take anything thrown at her. Yeah he did took her from a 444 Cummins that was already hopped to around 500 to 850hp. She literally could pick up the right front tire off the ground under heavy loads after the overhaul.
This engine was hopped up by someone who didn't have a clue what they were doing.
I was about to say the same thing
As a further comment on what my boss said when I got to the yard that day. He went nice to know that my 20k in donations to the Illinois state police foundation was good for something besides a tax deduction for all those years. I had 2 escorts in Illinois running in front of me. When I hit the line the first one said we're aware of your problem you set the pace and drop the hammer driver. We will replace ourselves as needed to get you home. So I proceeded to put Rose as that truck was called into 13th gear which was .5 to one in ratio and turned 3.55 rear end gears. Then slammed the throttle to the floorboard jerking out the manual throttle to overfuel her and let her rip. I topped her out at 110 before the police said that was fast enough. Why they were running out of speed. I still had 300 rpm leftover. But running that hard that long literally cooked the entire engine.
I think a lot of us have those days where we feel like "I do not know, I'm just the guy pulling bolts out until stuff falls off" keep up the good work and excellent videos
That’s my specialty lol. If you need something taken apart quickly and half the parts dropped into a different dimension, I’m your guy
Yes excellent
100% About to go do this
If you don’t accidentally blow you tensioner pulley apart mid corner because you forgot a nut are you really doing it right?
"I'm just the guy pulling bolts out 'till stuff falls off."
That'd be my introduction line on my CV... Or maybe his UA-cam tagline... 😁
I've never seen holes like that in a block before. Excellent! This is why i like this channel.
Happens when you have an injector failure. The injector "hangs" (doesn't close) and unmetered fuel pours into the engine and the injector turns into a blow torch. Usually this happens due to bad fuel or water getting into the injector and causing it to stick/fail. Another thing that does this is poor tuning where again, too much timing (fuel) is injected and likewise melts the engine. Of course since the injectors weren't shown its just my best guess based on seeing more than one melted engine. Usually though there's melt damage on the pistons as well. So if it's in the heads only, the initial failure was high EGT (exhaust gas temperature). Just a guess
I had a luck to tear down in line 4 engine, that developed hole in piston, head, head gasket and between cylinder bores. Only after that driver gave up and stopped. We managed to get it running on remaining two pistons and only then we started to believe, that this dude was insane for holding this smoke machine flat out.
He didn't gave a shit about sudden power gains, just kept driving.
Idk about getting those pistons out but I do have one tip on how to get the diesel smell off when you’re done. After you wash your hands in fast orange or whatever, dry them off and put olive oil on them. Work that in for 30 seconds or so and then wash off with soap and water. Thanks for the awesome teardown videos!
That's crazy, I've seen burnt valves and seats but never a torched head.
How does it happen?
@@robertshelton3796 It starts with a tiny leak, and hot combustion gases get to work.
I am guessing this had to be used for pulling and extreme loads.
Aluminum has a low melting point. This design is a total fail. And I used to own the 350 Olds diesel, had 2, and I thought that was the worst diesel made. This one is just as poor of a design. One had a crank snap in half, other had so much blowby, finally it could no longer start reliably. When I got my truck, I knew it had to be a cummins, and I preferred the 5.9 in the 2005 model. Which so far has proven itself to me.
@@robertshelton3796 Think exothermic cutting process in metal fabrication.
DIESELS at one time were such a simple and easy to work on. Not so much now days.
Nowadays they want a sensor on anything they resembles a part lmao
Honestly these duramaxes arent as bad as this video made them look. I can have the heads off of one of these llys in about 6 hours while its in the truck. No cab pulling or anything. But like all things, you learn the fastest ways after a few times
Somewhere under all that shit is a diesel engine!!
You have that right
Yeah, no kidding, that's a LOT of crap up there just to get the valve cover (cover)s off
@@gorak9000It’s the way they seem to shove the truck engines deep into the back of the engine bay that confuses me. Seems inconvenient
The idea of taking the pile of parts and *assembling* a working motor from them-or more, of designing the machine in the first place-shows the ingenuity involved. It’s astounding engineering.
...and it's all for naught with some careless maintainance or usage. Dismayed by all the beautiful machining that ends up on the scrap heap. Killing an engine is like shooting a horse.
I love your humility. Can't wait for part 2.
A lot of times - If you strip an allen head screw head too bad, you can hammer a torx bit into it for a second chance...
Set that tune to race mode and pull your trailer up that mountain!! That must have been one hell of a show when she blew.
That's exactly what I was thinking with the torched head
WOW---I have never seen burn holes in a cylinder head before. And when I saw how rusted those bores were, I cringed. Much respect for selling that turbo as a core---many less respectable yards would claim it's "mint" just because it turns, and try to get as much as they could for it
Ya, me either. I figured they’d just crack or blow apart. Didn’t think they’d actually melt away like that.
@@jspin1103 I've seen it happen to hi horse turbo powered gasoline engines. Happens when the head lifts from too much boost.
Don't stop doing these videos. We love this!
It was probably some high schools kids truck had a “buddy” that knew how to do injectors and put bigger injectors with some sort of tuner and melted holes in the heads due to high exhaust gas temperatures and got that thing super hot to blow freeze plugs and not to mention probably didn’t have the right tools for the job
Came across yer channel recently. For me, totally fun and interesting. I have done 2 Duramax engines for rebuild projects in the misty dim past: an LB7 and a LBZ. Both were serviceable with no blown parts. It was "interesting" seeing a trashed LLY engine. Good job on the teardown! These silly things weigh almost 1/2 ton. I may have done the teardown in a slightly different order, but I think you fundamentally got it. Given you found mismatched bolts/nuts in different locations tells me the person who worked on this engine likely didn't know what they were doing or were rushed for time or both.
I think your best bet is to put penetrating oil in the cylinders and let sit for awhile. You may have to work them "back & forth" a couple of times before they pop loose.
Would like to have met the "mechanic" who left a broken stud in the head just so I can recommend no one ever take their vehicle to him/her to be repaired. Not sure I would even trust this person to do a tire change...
That "gotta get that nut off, that's what she said" took me a minute, then I missed about a minute of content laughing hysterically, had to backup and rewatch. Thanks for that, it was great! Love the surprise, unexpected, deadpan comedy from some others otherwise serious UA-camrs.
I still love the pheew pheew pheew of that impact wrench sped up. :)
12:09 "I'm gonna hoard this part, it will save me money at some point, perhaps...." -- Every Grandpa, ever.
Hey, I resemble that remark!
Not just grandfathers. Lotsa *farmers* seem to have a similar attitude - which makes entire sense to me.
Cheap insurance. As long as you have a spare, a part will never fail!
Randy, That only works if you can find the spare...
@@robertyoung2645Just pour antifreeze into the oil fill and it’ll fix everything.
Use the flat stone bore hone to clean out the rust. Comp air to blow out the crud. Then soak in atf. Let that soak for as long as you can. Then try bfh from the bottom.
If you think this is a smelly job, imagine being a sailor on a diesel electric submarine.
Good point. Those diesels would often burn "Bunker oil" which is one of the most putrid fuels.
@@skylinefever submarines? The big ship diesels often use bunker fuel, but I’m not sure about “smaller” ones, e.g.the several thousand horsepower locomotive diesels use #2 as a rule, supposedly. (Including the Fairbanks-Morse opposed engines - used in both trains and submarines, supposedly.)
At least on the sub the diesel smell is overpowered by sweaty dudes and farts.
@@randymagnum143 Among other things.
Worked on a couple LLY's and am happy they were no where near that thing's shape! When you say an engine is torched... this is forever what I will see.
Yes! I have been curious to see one of these for a while.
We all appreciate your style of thinking out loud -- an honest dialogue of your thoughts and actions!
Thank you for the awesome content. Much appreciated. You are just so down to earth and humble.
Your channel has quickly become one of my favourites.
I know you dont really get much say in the cores that come your way, but I would love to see a chevy 3800 supercharged, a 6.2l ford raptor motor, or a ford 6.8 v10. All are engines that I would love to see more about.
Chevy never had a 3800 Supercharged motor. The Impala and Monte Carlo used the Buick 3800 Series 2 and 3.
i thought that there was a raptor tear down ?
Haven't seen a 6.8 that wasn't running.
@@MikeL-FL the monte carlo ss had a 3800 supercharged . It is a gm motor doesnt matter if buick of whatever no need to get technical
Buick 3800 has never failed
I absolutely love the channel and the way he deliverers the content within it!
Yep, I just commented the exact same thing. It's so so damn good because it's so damn.... _un-American_
As an LLY owner, I have been waiting for this specific video, thank you🙏🏻
I just did a head gasket job on my 05 LLY a few months ago. Looking forward to seeing deeper down inside this beast!
I like the fact that you do all this tearing down without cussing and using foul language. Thanks for that!
I know how ya feel. Respect to diesel techs. I've been restoring a 25 year old 7.3l Powerstroke. It's a pain in the ass.
Like that, pull bolts out until something falls off, my approach to working on things! If it doesn’t move, go find bigger hammer! Love this channel, no fancy music background, just a good mechanics business in action.
It would take me a week to disassemble and label every thing and bolts to that engine...WOW huge puzzle to put back together.
Rewatching an old video because I just purchased my first Duramax and wanted a refresher, but it funny to see your gripes and complaint’s and how you change the way you tear engines down in your current videos
Rocker box and cover are what the two valve covers are actually called. Fun tear down as always!!!
I like to use acetone and atf mixed and fill up the cylinders, works all of the time most of the time lol
25 min. of viewer time just to finally get to the valve covers! My heart goes out to mechanics these days. Do you have employee's? Is there a video that says more about you and your shop? I guess I could look! Do you clean up your own mess or do you have a lackey for that? Questions Questions Questions.....My wife doesnt like them either....Being an old gear head I do love your content, thanks...
I don't know if it has been mentioned in the comments but the butt connectors on the fuel injector connectors is part of a technical service bulletin to replace the injector pigtail. If I remember rightly it was on injectors 2 and 7 and they came with a goofy little tin brackets to hold the wiring in place. The pins would get spread in the connector and would intermittently either cause high resistance or go open circuit and that would cause the ECM to shut down all four injectors on that particular driver in the ECM. They're split in two groups of four.
looks like it was overheated badly at the end, explaining the lack of torque on the head bolts.
frost plugs blew out then too.
if those 2 coolant holes failed at thje same time, imagine the combustion pressure the coolant system was subjected to til the relief valve took over.
i'd bet that engine was under a lot of load when it blew.
i've seen heads with enlarged coolant holes, but it came from not changing coolant out and corroding them.
never sen holes like that from baking.
it's a first.
In my decades of working on gas, diesel, heavy and light equipment never saw a head torched like that one.. that's a first for me.
We have an old 02 workhorse at work with this engine. 500k and still running strong. The truck was bought new. After a few years converted to a dump box, used as a tow rig, sander/plow truck, gets rode hard and put away wet.
"How'd you like that in your spaghetti?"
Thank you for providing me with a new go-to description of something disgusting.
I got pistons like that out of my girlfriends mercedec boatengine.
Lett it set in disel. Maniged to get the crank out. And hammered the pistons back and forth
With 2"×4" and sledgehammer.
Changed pistonrings and headgasket, and it runs like a dream. A two cylinder 850ccm diesel from 58.
Someone did a driveway top on the engine without even a torque wrench. And had it turned way to high destrying a perfectly good engine.
Love how you talk through the video! Not awkward at all
The new engines are pushing almost 500 hp and 1000 ft lb of torque. Very impressive considering that semi tractor trailer trucks are 500 hp and 1200 - 1800 ft lb of torque.
The 06/07 LBZ is the one most looked for. The LLY, while injectors are easier to change then the LB7, was prone to head gasket issues and overheating due to the poor intake system sucking in air from under the hood.
Only issue with the cams is they aren’t keyed and have a tendency to lose timing. Seen a bunch of bent values and pushrods from it.
Aftermarket fixed the issue with a keyway
You can key the factory crank if you break the dowel pin.
Diesel engines deserve significant respect. A fuel/air mixture is being squeezed to such a high pressure that it explodes without any external source of ignition. The valves, pistons, cylinders & heads take a terrific beating and MUST be built very strong. To torch a hole though that head requires one helluva lot of heat & pressure.
That LLY is something like 20k psi fuel pressure the 08-10 LMM is up to like 26k psi and I think higher yet for newer models
I reacon the freeze plugs are missing from compression building up in the cooling system from those 2 holes in the head.
Gotta be. But it takes quite a bit to blow them out. I've seen a few of the Dyno and drag guys just fill the block instead so it holds pressure
The most fun on these motors is the dissimilar metal issue
Injector hold down bolt goes through about 2” inches of aluminum valve cover
When it gets totally gagged up and snaps off the only solution is to air chisel the bolt area till it fractures and then pry the valve covers off
Super fun doing it in chassis
18:38 You can ALWAYS make money off a turbo that still spins freely. A lot of us wierdo gearheadey types will buy turbos like that and build jet engines out of them; this is something I want to do as well.
I was thinking what a nice jet that would make
how do you oil the turbo in that application?
@@ben3989 Usually a power steering pump turned by a drill or just a gravity feed system. They're mostly just workbench ornaments so lubrication isn't the most critical thing, but some people have put them on gokarts and such before.
Hey don't call us out like that lol I have a turbo from a 12v82 Detroit that I wanna make a jet out of
@@leviduff2740 lol I am one of the group! Yours oughtta produce quite a bit of thrust if it runs right, too.
"I don't know what I am doing". That is exactly how I learn.
The injector with the butt connectors is to resolve a well known issue with stock harness plugs being strained on #2 (the one you pointed at with the connectors) and #7, the right rear cylinder. I have the factory GM replacement plug, and it comes with heat shrink butt connectors.
An early Saturday video. Heck yeah.
That turbo has to be tons of fun to work on while the engines in the truck.
They definitely are not. LoL
the injector harnesses go on those LLY motors, which is why someone scabbed a new one onto that harness with butt connectors. My dad had it happen to his '04 duramax
I am so happy you did a teardown on this motor! I have the LBZ and I learned a lot.
At this point the cylinders walls needs an bore job, just send it with the wirewheel and remove as much as you can, then penetrant to free up the rings. Thats what I would do
I would do the same thing, but the rust around the pistons is also a problem at it will need a lot of force to make them move.
The rods and pistons will be junk at this point. But you may be able to save the block (will definitively need an overbore after that) and the crankshaft.
@@Fabien2626 piston dont touch the cylinder walls, rings do. And Im 100% sure the rings are trash, anyway you always put new one when putting a "new" piston in. The piston and rods should be fine if he dont hit them too hard
@@felixrobitaille8170 the pistons made contact with the valves, so the rods and pistons are dubious.
Also the rust is so bad, I'm not that sure about the cylinder walls not touching the pistons...
At least something that might have, at one point, been the cylinder walls is currently holding them in place.
In the AC industry there is an oil called Croyle oil a super penetrant and The stuff is amazing
Kano Kroil
Something I've seen recently was a cylinder liner with bad termite damage. The cylinder had deep little worm holes in it. If you have bad coolant you'll have erosion, and high cylinder heat will make it worse. The early ford/international 7.3's had thinner cylinder walls than the 6.9 and erosion was an issue.
Those cylinders looked tasty
Gotta say, I love the sound of the impact driver sped up. Gun go pew pew. . .
I've used screwdrivers for chisels for years, but your use of some tools blows my mind!! 😅 Hammer Happy!!
the module and sensor wire you questioned at 4 minutes 15 seconds into the video is actually a vane position sensor. I'm sure you most likely know what a VVT turbo is considering I've followed this channel for quite some time and you seem very knowledgeable, but since drama engines are my particular specialty, I felt id share this with you. the purpose of the variable vanes in the turbo is to alter exhaust gas velocity turning the exhaust turbine, at a dead stop if you mash the throttle the vanes will close rapidly increasing exhaust gas velocity improving spool up time and reducing "turbo lag". another great benefit of the vanes is the turbine braking feature the truck has for towing heavy loads, in tow haul mode the truck will slow its self down by closing the vanes to 99 percent closed which slows down the engine and slows down the vehicle. similar to how and exhaust brake works only this is built into the turbo.
Put some marvel mystery oil in each cylinder and let it sit for a day or 2. Then try rotating the crank back and forth a little until it starts to break loose. May take a few days of trying but it should break down the rust bond and free it up.
This!
The Florida pool pump motor bearing repair guy When Service Calls Longwood approved ! that was good info
Isuzu set the world record for the fastest time in bringing a clean sheet of paper engine to production with the D-Max and other than early engines having injector issues it’s been a solid engine.
the injection and fueling system in general was provided by GM LOL. Not isuzu
@@dieselgeezer18 wow. I’m so impressed with GM’s contribution.🤣
One way I've got pistons out of an engine where you can't rotate the crank is to lift the crank, rods & pistons out of the bottom of the bottom of the block in one piece. Admittedly when I did it, it was on an inline six 12.6l Ford truck engine, so might not be possible on a Vee engine. It also was a two-man job, with an overhead crane & couple of tonne solid steel t-slotted dyno bedplate!
Pretty sure that jumper harness and module you questioned was a boost fooler.
No its the vane position sensor on the turbo.
Dude had his tuner cranked up to a million
I have an idea on those Rusty cylinders use a worn out cylinder holder that will knock the rushed down so you can get the Pistons out and also a little squirt of PB blast will help
Haven't read through the comments, but with the damage between the combustion chambers and the coolant passages, I would expect the pressure from combustion pushed out the freeze plugins. What a mess.
On a forum somewhere is a kid bitching or bragging about how he blew his engine. Everything should be sold as a core. It all needs to be tore down and inspected. Injectors, turbo, dip stick.
Factory head bolts are notorious for stretching on the Duramax
I have a legitimate question how do you know that the cores that you're buying are not like stolen from chop shops or something
Love your videos..
request a old Pratt and Whitney radial engine tear down please 😊
The thing with the single white wire at 4:14 in the video was the turbo vane position sensor since the turbo is a variable vane to help spook up faster.
I always run a ball hone down the cylinders, blow the crust out then soak them down with penetrating oil of your choice since its just to assist piston moving at that point. Ive seen a d max come in with “a little skip and overheating” had the same issues that one had....burned heads, not 1 but both and yes a few head bolts were loose on both sides from lack of head gaskets actually. He said his son left the hot tune on when pulling their 50’ enclosed trailer up a mountain lol
LLY engines were known for having head gasket issues just like every diesel of that Era dur to the newer emission regulations at the time
A wise man knows when to stop a tear down - you qualify!
That Turbo is HUGE!! :)
You could borrow “Big Nasty” from SMA. I think she could get the pistons out.
I have been contemplating buying a one ton with a Duramax or a Cummins. After watching both of your respective videos back to back I have made up my mind. The Duramax engine looks like a nightmare compared to the simplicity of the Cummins and you can definitely see the heavy duty in the Cummins vs the automotive in the Duramax.
I think you should watch Gale Banks' series "killing a duramax". You might be in for a surprise.
It's called a dirty max for a reason.
I don't do Cars or Trucks, I wonder why I find engine forensics so interesting.
Take a cheap or wore out 3/8" extension. Cut off both ends and smooth the edges and rough up or notch one end for your drill chuck to grab, cut a slot down the length on the other end just long enough and wide enough to snugly slot a scotch Brite pad in with just a couple mm worth sticking out to rest on the top of the piston. Throw a full pad in, bottom it to the piston and spin it clear. It's worked pretty good for me and with as many engines as you teardown, it will most likely be your best friend before long. It's scotch Brite, so it won't dig grooves or take away any substantial material. Plus a hell of a lot faster than by hand. The pad even works a little quicker when you don't get it perfectly centered. So don't worry about being perfect, the little bit of wonder is helpful. Added benefit of cleaning up the top of the piston at the same time too.
Great idea!
I couldn't imagine remembering how all the hoses and wires were routed and in what order for reassembly.
Step by step guide
@@jonarmedpiandsecurityoffic9051 Yep, all in the service manual if you forget
Very impressed with how the Duramax is built although it's complexity is intimidating. Cummings is also very impressive and more simple design.
The freeze plugs are gone because the head was torched linking the coolant ducts, and as a result, the compression from the chamber blew those plugs out.
When you were beating on the pipe from the turbo, had I nice beat , but I don’t think I could dance to it
I saw a star-shaped pattern on the No. 7 cylinder crown. It looks like the spray pattern from the injector. I suspect the last owner of this engine had a very aggressive tune in the ECM that stretched the injectors spray time well outside it's normal window. The guy probably treated the truck like something he dug out of his ear. And when the truck broke he band-aided the truck so he could beat on it some more.
Great channel. I love your videos. You are a really good and natural communicator.
In the professional repair world, the ultimate level of being a mechanic is the diesel pickup truck “I did it myself” guys. If you had a shop full of those clowns, you could fix the world in a week!
A workout dingleball hone or a cheep harbour freight one,. Will clean the up enough usually to get them out.. now if they keep driving it till it seezed all bets are off 2" steel bar and a 10lb hammer then... Great video's
no need to hate to say it. torx is better than hex. :)
Wow very complex teardown I've seen. You did the right call.
Interesting to imagine the radiated heat from a Turbo. I would never have an engine with a turbo on it. Also the heat under some of these bonnets with a twin turbo I can understand why nobody would want to lift a bonnet to check the oil when filling up. Anyway if you do check your oil people give you "oh your car is in trouble oh dear look".It seems socially unacceptable to lift your bonnet in public. And of course one would never want to get ones hands dirty at home." I simply don't have the time." Better to pay $2300 for a new engine. As for regular service. "The cost my deer - the cost is way too much." I will never forget your vid of a diesel engine with black pudding in it. This is very entertaining for me, keep up the good work. Cheers From a Kiwi living in the land of the Kangaroo's.
@@user-3tf67bk46u Yes how true I had a small Diesel truck would barely do 100kph. Not much use in Australia. Cheers
i love it when you say " i don't know what I'm doing" so honest & we can see it, you are so much fun to watch, keep up the great work. I would love to hear you say " who the hell designed this engine, what a stupid design if it applies
Hmmm. Yeah, maybe some eye protection. Pirate patches are cool but binocular vision is still preferred.
Use a circular wire brush, available at Harbor Freight for like $4 (pack of 4), to clean the bores. Then soak in penetrating oil. Not cleaning out the rust will only jam the pistons in their more when you try to hammer them out.
Run Away engine.