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Shipping/Pickup: at many local warehouses in the united States. It is quick and easy; just call our number we set up the order then you can pickup the same day. Our 55 gal drums ship for around onehundred thirty and cases are less then twelve dollars. Please call txt 860 436 7034 for specifics.

CDN customers note:in stock in our Toronto and Edmonton warehourse now. Or choose delivery our delivered price from Toronto or Edmonton is unbeatable. Please call 800 692 7109 to schedule pickup or call/txt 860 436 7034  or add to cart

The best protection for your Duramax ( 2007 and newer ) DME synthetic 15W40

55 Gallon Drum OED synthetic 15W40 Diesel most economical has great fleet and operator pricing.

 Free engine motor maintenance tool.

Yes you can use and should use synthetic oil and filters in your Duramax. They will give you the best performance and value. This table shows what is recomended for your Duramax
Duramax 6.6
recomendations
6.6 duramax
Recomended
Synthetic Oil
6.6 duramax
recomended
Oil filter
6.6 duramax
Bypass Filter
order list
6.6 duramax
recomended
Air Filter
6.6 duramax
recomended
INJEN
induction
system
2007 6.6 duramax and newer 15W40 5W40
click for price
wix 57202 EAO52 610875(PowerCore) PF7076
2006 6.6 duramax and older 15W40 5W30
click for price
57202 EAO52 BMK21 BK1201
BK1202
BP242(qty 2)
EAA123
 
wix 46678
PF7075 install instructions
buy 55 gal drum AME buy 55 gal drum HDD buy 55 gal drum DME buy 55 gal drum DEO

Here is published synthetic diesel motor comparison oil test showing how well Amsoil Premium diesel synthetic 5W40 DEO and synthetic 15W40 DME performed with diesel in oil situation. If you cant see this click the thumbnail lower down on this page.  It can expand quite a bit. This diesel motor oil comparison is using the Kurt Orbahn Shear stability Test. The diesel motor oil comparison compares amsoil Amsoil DEO 5W40 Diesel oil and the Amsoil DME 15W40 diesel oil vs Mobil Delvac 1 ESP vs Shell Rotella T vs Chevron Delo 400 LE vs Valvoline Premium Blue Extreme. The diesel oil comparison test clearly shows that Mobil Delvac 1 ESP, Shell Rotella T, Chevron Delo 400 LE, Valvoline Premium Blue Extreme shear viscosity degrades quickly, The diesel oil comparison test further shows that at 2% diesel in oil shell rotella t falls out of grade, at 4% dilution Mobil Delvac 1 ESP, Shell Rotella T, Chevron Delo 400 LE, Valvoline Premium Blue Extreme fall out of grade.amsoi synthetic diesel oil 5W40 and 15W40 comparion

Diesel in oil is a big issue for 2007-2010 diesel pickups from Dodge, Gm and Ford. We have the solution, but first a quick explanation of how it gets there. Dodge, Gm and Ford have chosen to meet emissions by injecting raw diesel fuel on the exhaust stroke of combustion. This excess fuel can wash past the piston rings and into the crankcase. You can read more about this in the Technical Service Bulletin here.

Diesel in oil can be prevented if you can break in your diesel the following way. To stop fuel form washing past the rings the rings must be kept much tighter so you cannot break the engine the traditional way. You must drain the breakin oil almost immediately and go straight to synthetic 5W40 (DEO) or 15W50 (DME). This is not a radical idea. All European diesels leave the factory with synthetic oil in the crankcase and never run on anything else

Diesel oil comparison testIf you were not able to switch to synthetic diesel oil soon enough and you now are finding diesel in oil you do have another option. Some oils can tolerate up to 4% diesel in oil. Click the chart twice then you will see a published test showing how well Amsoil Premium diesel synthetic 5W40 DEO and synthetic 15W40 DME performed with diesel in oil situation.This diesel motor oil comparison is using the Kurt Orbahn Shear stability Test. The diesel motor oil comparison compares amsoil Amsoil DEO 5W40 Diesel oil and the Amsoil DME 15W40 diesel oil vs Mobil Delvac 1 ESP, Shell Rotella T, Chevron Delo 400 LE, Valvoline Premium Blue Extreme. The diesel oil comparison test clearly shows that Mobil Delvac 1 ESP, Shell Rotella T, Chevron Delo 400 LE, Valvoline Premium Blue Extreme shear viscosity degrades quickly, The diesel oil comparison test further shows that at 2% diesel in oil shell rotella t falls out of grade, at 4% dilution Mobil Delvac 1 ESP, Shell Rotella T, Chevron Delo 400 LE, Valvoline Premium Blue Extreme fall out of grade. Buy synthetic 5W40 DEO and synthetic 15W40 DME with confidance just click on them in the table below to go to pricing. 

Amsoil is about no compromises and saving you time. On our 6.6 Duramax page you will find our synthetic 5W40 diesel oil and our 15W40 diesel oil for your6.6 duramax. diesel oil for the  2007 and newer, and two weights for your 6.6 duramax diesel oil for 2006 and older. The correct diesel oil will enhance performance improve fuel mileage in your 6.6 duramax. In the table you will find a the best 6.6 duramax oil filter for your  engine . You can click the number to read more or just order. Further in the table there is a listing for the best 6.6 duramax bypass filter  . There is a 6.6 Duramax cold air induction system by injen to improve your power also.We have bulk oil pricing. For the best price for your order now please go here. The 6.6 Duramax works hard so it needs to be kept clean.  We can go 2 micron clean and extended drain.  To acomplish this we have the BMK21 and BMK27 bypass oil filter kit .  bypass filter installation instructions for the best bypass filter for your 6.6 duramax, and we have pictures of actual installs.For more pictures of bypass filter intalls on 6.6 Duramax units please go to our installs table on the bypass filter page. To see an Injen install on a 6.6 Duramax please go here. To get your best prices today please go here.

To look up 6.6 duramax synthetic gear oil, synthetic automatic transmission fluid, fuel filters, capacities, plugs, wires, wipers and finally torque specifications to button it all up when you are done. and torques specifications and recomendations for your 6.6 Duramax now click to link to theapplication guide application guide Below I have built a basic table for quick order of oil and filters. If you have questions please call me (Santana ) call/txt 860 436 7034. If you know your product code ( the three letters )Click the price button next to it, then add to cart. Add prefered customer to cart and get instant savings of 25% -35%. All sizes are available quarts to 55 gallon drums, you can select the size once you go to the price page.. Local pickup is available at many US locations and several Canadian locations. You can call me for the location nearest to you. I would be glad to give you a quote over the phone or walk you through all the options.

Bulk pricing on 30 and 55 gallon barrels Get Bulk oil prices for Totes and 55 gal drums

6.6 Duramax bypass filter install showing optional BK1101 Oil filter cap and BK1102 oil fill cap both with When you click I know that this is not a 6.6 duramax. I included this picture because it shows how an amsOil BMK21 bypass filter kit installed with the optional BK1202 oil return cap replacing the standard oil fill cap might look on a 6.6 duramax. Those anodized caps really dress up your 6.6 Duramax unit. The anodized cap is shown with the optional BP242 swivel fitting. The contents of the BMK21 bypass oil kit are listed here. 

6.6 Duramaxbypass filter install pictures
2008 GMC 2500 HD Duramax BMK27
2008 Chevy Silverado 2500HD Crew Cab BMK27
2006 Chevrolet Silverado 2500HD, Turbo Diesel  BMK27

amsoil 6.6 Duramax bypass filter kit components BP34, bp39 and bp 52 When you click this picture you will see  amsOil bypass filter kit fittings BP34, BP 39, BP52. You would remove your existing pressure transmitter from your 6.0 powerstroke and would thread into the T ( the brass fitting ). The other female fitting would take the line that feeds the bypass filter.The amsOil bypass filter kit BMK 21 includes those three parts I just included this picture to give you a visual of how it goes together.

6.6 Duramax bypass filter install showing BP40 self tapping bolt in oil panWhen you click this picture you will see a bypass filter kit hollow bolt installed in non 6.6 Duramax oil pan. It is the BP40 self tapping hollow bolt which which is item number 15 on the bmk21 PARTS list.

To buy a BASIC bypass filter kit for the 6.6 Duramax order BMK 21 and EaBP110. The preferred customer price for this kit shipped to ct. feb 20, 2011 was about $210.00. Prices are subject to change without notice

To buy our DELUX bypass filter kit for the 6.6 Duramax order the BMK21, EaBP110, BK1201, BK1202, BP242(2). The preferred customer price for this kit shipped to ct. feb 20,2011 was about $ 326.00. Prices are subject to change without notice. To see complete installation instructions for the BMK21 bypass filter kit please go here.

The BMK27 bypass filter kit is specifically made for the 6.6 duramax. The preferred customer price fot the BMK27 bypass filter kit on feb 18, 2011 delivered with tax ( ct.) was $316.42. Prices are subject to change without notice. Please note that the BMK27 bypass filter kit includes both the full flow filter and the bypass filter.  For a full list of all the hardware in the BMK27 bypass kit please go to the second page of the BMK27 bypass kit installation instructions here>

preferred CUSTOMER TRIAL MEMBERSHIP ! please contact me for a 6mo trial membership with your first order of at least 4 quarts and one filter. You must contact me by email Or call call/txt 860 436 7034. I must put in your order by telephone. Offer is valid while this is on display and only if you place your order as stated an take delivery. I am doing this because I am so confident that you will love the results from this oil and will continue using it in the future

Here is a list of the parts contained in the BMK21 bypass filter kit. There are some optional items listed also: You would use the BMK 21 on a 6.6 duramax if you choose to mount the bypass filter somewhere in the engine compartment.  The BMK 27 is usually mounted underneath on the frame.

1. Oil Pressure Sending Unit (existing)
2. Filter Mount Assembly, Spin-On 1 BK-303
 3. Fitting Adapter 4 BP-208
4. 5⁄169 Fender Washer 3 BP-205
5. 5⁄169 Flat Washer 3 BP-120
6. 5⁄169-18 Self Locking Nut 3 BP-121
7. 5⁄169- 18 x 19 Hex Head Bolt 3 BP-122
 8. 1⁄49 I.D. Hose 88 BP-251
9. Hose Fitting 4 BP-261
10. Street “T” (1⁄89 x 1⁄89 x 1⁄89) 1 BP-33
11. Straight “T” (1⁄49 x 1⁄49 x 1⁄49) 1 BP-34
12. 90° Street Elbow, 1⁄89 4 BP-52
13. Bushing 1⁄89 x 1⁄49 1 BP-38
14. Nipple 1⁄49 x 29 1 BP-39
15. Self Tapping Hollow Bolt 1 BP-40
16. Sealing Gasket 1 BP-41 Plastic Tie 2 BP-46 Thread Sealant 1 BP-198 Instruction Sheet 1 BP-83
Optional parts available from AMSOIL INC.
Filter adapter for 6.6 Duramax BK-1201
Oil Fill Cap for 6.6 Duramax BK-1202
 BP-242 Oil Sampling Kit
BP-67 Oil Return Swivel Fitting
BP-89 Deluxe Oil Sampling Valve 1⁄49 NPT G-1570
By-pass filter element (EaBP90, EaBP100, or EaBP110, as space dictates) (all sold separately)

preferred CUSTOMER TRIAL MEMBERSHIP ! please contact me for a 6mo trial membership with your first order of at least 4 quarts and one filter. You must contact me by email Or call call/txt 860 436 7034. I must put in your order by telephone. Offer is valid while this is on display and only if you place your order as stated an take delivery. I am doing this because I am so confident that you will love the results from this oil and will continue using it in the future

Injen air induction system for your diesel hereAir induction system for your diesel here

Injen air induction system for your diesel here donaldson  ngk spark plugs       mann

We call this  diesel oil DEO. Amsoil CJ-4 Synthetic Premium Diesel Engine Oil, SAE 5W40. 
		 If you need CJ-4 this is it .  Please call me for fleet/case/ or barrel pricing and quick ship 800 692 7109. 
		  We have filters and bypass filters for all applications.  Call for same day warehouse pickup and same day quick ship.
		  WE call this synthetic diesel oil DEO. DEO is a synthetic 5w40 specifically designed for 2007 and newer diesels. AMSOIL Synthetic 5W-40 Diesel Oil (DEO) is the premium choice for API CJ-4 emission-quality diesel oil required by model-year 2007 and newer diesel engines. It delivers extraordinary lubrication in diesel engines found in commercial, fleet and personal vehicles. Built with the latest additive and synthetic base oil technology, AMSOIL Premium Synthetic 5W-40 Diesel Oil exceeds the higher performance demands of modern engines. It withstands the stress of heat, soot and acids to help prevent deposits, wear and corrosion. AMSOIL Synthetic 5W-40 is wax-free with a broad viscosity range to provide exceptional cold-weather starting and high temperature protection. It resists breakdown and offers maximum fuel efficiency over extended drain intervals. DEO brochure here.

The advanced synthetic technology used to engineer AMSOIL DEO Premium 5W-40 Diesel Oil enhances viscosity properties and is proven to deliver better fuel economy. In fact, the Environmental Protection Agency’s (EPA) Federal Test Procedure confi rms that AMSOIL 5W-40 Diesel Oil provides up to 3 percent better fuel economy than conventional 15W-40 diesel oils. At a mix of 55 percent city/45 percent highway driving, the average improvement is 1.6 percent and at straight highway driving the average improvement is 1.25 percent. Fleet Savings vs. conventional 15W-40 1 Truck 50 Trucks Fuel Economy Savings (1.6%) $945 $47,250 Extended Drain Savings $210 $10,500 Total Savings with AMSOIL $1,161 $58,050

We call this  diesel oil DME. Amsoil CJ-4 Synthetic Premium Diesel Engine Oil, SAE 15W40.  If you need CJ-4 this is it .  Please call me for fleet/case/ or barrel pricing and quick ship 800 692 7109.  We have filters and bypass filters for all applications.  Call for same day warehouse pickup and same day quick ship.WE call this synthetic diesel oil DME. DME is a synthetic 15w40 specifically designed for 2007 and newer diesels.AMSOIL Synthetic 15W-40 Diesel Oil (DME) is the premium choice for API CJ-4 emission-quality diesel oil required by model-year 2007 and newer diesel engines. It delivers extraordinary lubrication in diesel engines found in commercial, fleet and personal vehicles. Built with the latest additive and synthetic base oil technology, AMSOIL Premium Synthetic 15W-40 Diesel Oil exceeds the higher performance demands of modern engines. It withstands the stress of heat, soot and acids to help prevent deposits, corrosion and wear. AMSOIL, the leader in automotive synthetic lubrication, produced the world’s first API-qualified synthetic motor oil in 1972. Trust the extensive experience of AMSOIL, The First in Synthetics, to do the best job protecting your engine.DME brochure here.

We call this  diesel oil HDD . This amsoil series 3000 is our toughest 5w30  diesel oil if you are using a bypass oil filter, hauling loads this one is for you.  Call me for more details and best pricing, same day warehouse pickup or same day quick ship 800 692 7109.  This is for pre CJ-4  diesels only We call this HDD, Heavy duty 5w30 fortified for your diesel, bypass filter applications , and towing.AMSOIL Series 3000 100% Synthetic 5W-30 Heavy Duty Diesel Oil (HDD) delivers extraordinary lubrication in both diesel and gasoline engines found in commercial, fleet and personal vehicles. By combining the industry’s premier synthetic technology with AMSOIL premium additives, AMSOIL Series 3000 exceeds the higher performance demands of modern engines. It withstands the stress of higher heat, higher acid levels and excessive soot-loading found in EGR-equipped engines. AMSOIL Series 3000 Synthetic 5W-30 Heavy Duty Diesel Oil consistently outperforms conventional and synthetic diesel oils for long-lasting performance and protection. Read HDD brochure here:

We call this  diesel oil AME. Amsoil synthetic 15w40 please call for our best fleet price and quick ship 800 692 7109.  Ask for SANTANA we have filter and bypass filters for all applications we call this AME.  Pre CJ-4.  Call for same day warehouse pickup and same day quick ship.We call this AME. AME is a synthetic 15W40 for Pre 2007 Diesels.  AME is recomended for diesel and gasolines engines and other applications requiring any of the listed worldwide specifications .AMSOIL Synthetic Heavy Duty Diesel & Marine Motor Oil (AME) is a premium diesel oil providing excellent performance in all types of diesel engines where highly effective control of wear and deposits is vital. Built with heavy-duty dispersant/detergent additives, its 12 TBN chemistry neutralizes acids and controls soot thickening from EGR and blow-by to protect against corrosion, cylinder bore polishing (wear) and varnish/sludge deposits. AMSOIL 15W-40 Diesel Oil resists heat and breakdown better than conventional petroleum oils for long lasting performance and protection.

Recomendations for the 6.6 duramax on how to deal with diesel in oil is written up in this technical service bulletin

More detailed information can be found here

preferred CUSTOMER TRIAL MEMBERSHIP ! please contact me for a 6mo trial membership with your first order of at least 4 quarts and one filter. You must contact me by email Or call call/txt 860 436 7034. I must put in your order by telephone. Offer is valid while this is on display and only if you place your order as stated an take delivery. I am doing this because I am so confident that you will love the results from this oil and will continue using it in the future

donaldsonInjen air induction system for your diesel here   ngk spark plugs     mann

Some History of the 6.6 duramax:General Motors launched the Duramax Diesel 6.6L V8 engine in the Chevrolet Silverado and GMC Sierra 2500HD and 3500 Series trucks with Allison automatic transmissions in 2001. The application expanded to the Chevrolet Kodiak and GMC Topkick medium-duty trucks for 2003, with 16,000-, 18,000- and 19,500-lb. gross vehicle weight ratings (GVWR). According to its engineers, the Duramax Diesel 6.6L V8 features two key characteristics: incredible torque to tow or haul loads, and higher-rev horsepower for smooth, flexible over-highway travel. Turbo Improvements Refinements in 2005 included an overall reduction in exhaust emissions and an increase in torque output, which was enabled by significant hardware changes in 2004. Those changes included a new variable-geometry turbocharger. Self-adjusting turbine vanes and sophisticated electronic controls automatically adjust boost pressure and exhaust backpressure. The vanes direct exhaust gas at the turbocharger’s turbine blades. These vanes can be opened or closed to vary the amount of boost pressure. An electro-hydraulic device operated with engine oil, similar in concept to a camshaft phaser, adjusts the turbine vane angle. The variable-geometry turbo has its own sensors managed by the engine control module (ECM). A solenoid controls oil pressure against a piston that operates a small cam, which works on a unison ring that moves the turbine vanes simultaneously. As the cam turns, it varies the angle of the blades relative to the turbine wheel. The crucial advantage: With the moveable blades, boost pressure can be controlled independent of engine speed. The variable-geometry turbo presents a number of benefits over the conventional fixed-geometry type. Boost can be controlled more precisely, with a greater range of modulation, than with a fixed-blade turbine. The Duramax 6.6L’s turbo eliminates the need for a wastegate, which is often the first turbocharger component to fail as mileage accumulates. Because the variable-geometry turbo can essentially change resistance and adjust the amount of exhaust backpressure, it also eliminates a separate exhaust pressure regulator, which was previously used to manage engine or compression braking. Maximum boost in the Duramax 6.6L remains 20 psi. Yet boost pressure can be varied more subtly over the engine’s rpm range. This presents itself to the customer as more immediate engine response, with virtually no turbo “lag.” Equally important, the ECM measures a number of parameters, from operating temperature to engine speed to fuel injection timing to load demands, when managing the turbine vanes and controlling boost, so the turbocharger operates more efficiently in all conditions. 2006 Improvements Late in the 2006 model year, structural changes to the block and connecting rods increased the strength of the engine, which allowed calibration changes that increased output for the applications in the Chevrolet Silverado and GMC Sierra pickups. For the 2006 model year, a new fuel pump increased fuel pressure from 23,000 psi (roughly 300 times greater pressure than the typical gasoline injection system) to 26,000 psi, and the fuel lines and rails have been strengthened for the higher pressure. Also in 2006, the compression ratio was lowered from 17.5:1 to 16.8:1 to improve the operating smoothness of the engine. As continuing development aimed at lowering diesel emissions progressed, the exhaust gas recirculation (EGR) system was enlarged for the 2006 model year and installed in all Duramax 6.6Ls. The EGR system recycles some exhaust gas back into the intake stream to cool combustion and reduce oxides of nitrogen (NOx) emissions. The Duramax Diesel 6.6L V8 system features a unique cooling process that increases its effectiveness. Hardware required includes: plumbing that carries some exhaust gas from the turbocharger to the intake, an EGR control valve and a stainless steel cooling element. The EGR valve is managed by the E35 ECM. The EGR cooling element bolts to the right side of the engine, on the inboard side of the cylinder head, with jackets fed by engine coolant. Returned exhaust gas passes through a spiraled passage in the element, and the temperature of the gas is lowered before it returns to the combustion chamber. Latest Engine Designs For 2007, the latest version of the Duramax 6.6L is equipped with two-piece rocker covers that accommodate external connections for the fuel lines and new fuel injectors. These resemble conventional rocker covers, but they are split lengthwise along the plane of the top surface of the cylinder head. The lower, rectangular piece of the rocker cover rings the perimeter of the cylinder head and bolts to the head like a conventional cover. The upper portion of the rocker cover attaches to the lower piece. The new two-piece rocker covers ease access to the fuel rails and injectors. Previously, the rocker covers and then the fuel lines had to be removed in order to reach the fuel injectors. The top piece of the new rocker cover is scalloped on its lower edge, around the point where the injectors fit into the cylinder heads. The injectors are now exposed on the engine, and can be removed with no other disassembly required. Such serviceability considerations are particularly significant in an engine like the Duramax 6.6L, with an anticipated useful life beyond 200,000 miles. Fast-heating glow plugs reduce pre-start heating time without increasing draw on the battery. The engine’s glow plugs draw 6.6 watts of electricity, as before, but the element has been redesigned to more efficiently convert electricity to heat. Moreover, the glow-plug controller is specifically calibrated for the Duramax 6.6L’s new engine control module and allows pulse width modulation, which manages current more like a rheostat than an on-off switch. INTERNAL AFFAIRS The 90° turbodiesel V8 utilizes a compact, rigid cast-iron engine block that features induction-hardened cylinder bores — a technique borrowed from larger diesel engines and exclusive in the pickup class — and four-bolt, crossed-drilled bearing caps. A die-cast aluminum lower crankcase strengthens the engine block and serves as the lower engine cover, keeping weight down. The forged steel crankshaft is surface-hardened by nitriding, and aluminum pistons minimize reciprocating mass and improve efficiency. Each has a small hole cast in its skirt, allowing jets to spray cooling oil through a cast channel and up toward the bottom of the piston bowl, where most heat is generated. Aluminum cylinder heads deliver strength greater than or equal to cast iron with considerably less weight. The Duramax also has four valves per cylinder — the standard for contemporary luxury-car diesels — and an integrated oil cooler. Several features make it easier to service, which is good news for technicians. Its compact size leaves more space around the engine when it’s installed in the vehicle. The timing gears are at the front of the engine for easy access, and in heavy-duty pickups, technicians can remove the fuel filter simply by leaning into the engine compartment. The Duramax 6.6L operates on the direct injection principle which, other things equal, allows more complete combustion than the older style indirect injection and decreases specific fuel consumption as much as 20%. Each high-pressure injector has its own solenoid to manage fuel spray. The latest injectors feature six spray points in each injector tip for better fuel vaporization. The solenoid-type injectors reduce the amount of fuel leakage between pulses. They allow more precise fuel control, with more consistent performance under hot-fuel conditions, and greatly reduce the potential for clogging due to fuel contamination. The injectors are installed directly into the head and are coded so that the E35 ECM can precisely match the flow characteristics of each injector on a particular engine to compensate for small variations, ensuring exact fuel delivery. Service Solutions for the 6.6L Q: The GM 6.6L Duramax has different thickness head gaskets. Which one should I use? A: In 2003, the AERA Technical Committee offered the following information regarding cylinder head gasket selection on 2001-’03 GM 6.6L VIN 1 Duramax diesel engines. Using the wrong head gasket on this engine could cause engine damage. GM offers three different thickness head gaskets depending on the amount of piston protrusion the engine has. When measuring piston protrusion, make sure that you measure all pistons on each bank. Notice: The left and right cylinder head gaskets are not interchangeable. Improper placement of the cylinder head gasket will block coolant and oil passages and will cause severe engine damage. The gasket markings face up when correctly installed. In late 2006, the AERA Technical Committee offered additional information regarding a head gasket design change on 2001-’06 GM 6.6L Duramax engines. Special surface cleaning procedures must be followed to allow a proper seal when using the new design head gaskets along with a change in the torque angle specification. A mid-year design change was made to the head gasket of the 2006 Duramax diesel engine. This second-generation head gasket will service all 2001-’06 vehicles, including those that were built with the first generation head gaskets. The second generation head gasket does require a lower head bolt torque angle specification as well as special cleaning methods of the gasket surface. The second generation gasket can be visually identified by its riveted construction as opposed to the crimped design of the first generation gasket (see Figure 1). For vehicles that were equipped with the first generation head gasket, special attention must be given to the cleaning of the engine block and head gasket surfaces when the second generation head gasket is to be used. Over time, the crimped areas of the first generation gasket may allow corrosion buildup where they contact the block and head surface areas. Inspect the gasket sealing surface for corrosion, especially in the areas that were in contact with the crimped tabs of the first generation head gasket. For surfaces that have corrosion or pitting in them, wrap a piece of flat steel with #600 grit wet grade sandpaper. Use a moisture-displacing lubricant (P/N 1052864) or equivalent to wet sand the block surface to remove any remaining gasket material or corrosion. Do not use any paper coarser than #600 grit. Take care to keep the sanding block parallel to the block surface and evenly sand the sealing surface. Some areas of corrosion will still show a stain. Do not attempt to wet sand these areas down to a shiny metal surface. Change sandpaper as necessary, and clean surface with brake parts cleaner along with the head bolt holes and cylinder bores. The second generation head gasket requires a lower torque angle specification for the M12 bolts. The M8 bolt torque remains the same. M12 bolts should be torqued to the following specifications: 1) 37 ft.-lbs. 2) 59 ft.-lbs. 3) 60° 3) 60° M8 bolts should be torqued to 18 ft.-lbs. Q: Some engine technicians have reported an oil cooler leak on 2001-’04 GM 6.6L VIN 1 and 2 diesel engines. What could be causing this? A: Minor imperfections in the engine block’s machine surface at the oil cooler interface may allow engine oil seepage past the oil cooler O-rings. To cure this problem, GM offers the following information: Inspect for other oil leaks, which may be perceived as an oil cooler leak. An oil leak from one of the main bearing cap side bolts may appear to be coming from the oil cooler. If the oil cooler is leaking, remove the oil cooler from the engine. Use care to remove only the five bolts that hold the oil cooler to the engine block. Remove the O-rings from the oil cooler and discard them. Clean the mating surfaces of the engine block and the oil cooler. Install new O-rings (2) to the oil cooler (see Figure 2). Apply sealant (1) P/N 97720043 to the oil cooler as shown in Figure 2. Do not apply sealant to the O-ring grooves on the oil cooler. Install the oil cooler to the engine block. Torque the five oil cooler assembly bolts to 18 ft.-lbs. Allow the vehicle to sit for eight hours at room temperature for the sealant to fully cure before initial startup. Q: I’ve had some 2001-’04 GM 6.6L diesel VIN 1 engines owners comment on engine coolant loss with no visible leaks. They also complain of extreme white smoking. Is this common? A: Excessive white smoke or a coolant-type odor coming from the exhaust pipe, along with low coolant levels, may indicate coolant entering the combustion chamber. This condition may be caused by engine coolant entering the cylinder due to a dirty or damaged seal between the fuel injector sleeve and the cylinder head. Not all fuel injector sleeves may be leaking. A proper pressure test of the cylinder head will reveal any leaking fuel injector sleeves. Once the leaking injector sleeves have been found, remove the sleeve from the cylinder head using a fuel injector sleeve remover/ installer tool, P/N J45910. After the sleeve has been removed, inspect the inside of the fuel injector sleeve for damage to the injector sealing surface. Damage to this portion of the fuel injector sleeve may indicate a loose injector caused by improper installation or a missing copper washer (see Figure 3). A loose injector will allow the fuel injector and the injector sleeve to bounce inside of the cylinder head, resulting in coolant leaking into the cylinder. If damage is found, replace the damaged components Q: I’ve had a few injector sleeves come out when trying to remove an injector on some Duramax engines. Any tips on how to repair these? A: The AERA Technical Committee offers the following information regarding injector tube installation for 2001-’06 GM 6.6L Duramax diesel engines. This information should be considered anytime the cylinder heads are being serviced. This engine uses a removable sleeve to locate and house the injectors for this engine. These sleeves are in direct contact with the engine coolant, which allows the injector to be a constant temperature. On occasion, the sleeve may come out with the injector when it is being removed from the cylinder head. It is important to replace any injector sleeve with scoring or other damage. Clean the fuel injector sleeve lower sealing area and the sleeve bore with GM P/N 12377981 or equivalent. When installing injector sleeves, always use new sealing “O” rings. Lubricate the new injector “O” rings (1) and place in the injector sleeve (2) grooves as shown in Figure 4. Apply sealant to the lower sealing area of the injector sleeve. Place the sleeve in its respective bore and use the sleeve remover/installer tool P/N J45910 to install the sleeve. Lightly tap on J45910 with a hammer to install and seat the fuel injector sleeve as shown in Figure 5. Remove J45910 from the fuel injector sleeve. Install the fuel injector(s). Sources: GM Powertrain and AERA

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