Diesel Master Course 10 July 2017

This course is designed to instruct the technician description and operation of the diesel engines found on Ford, GM and Dodge trucks. The diesel engines which are covered are the Dodge Cummins 5.9L CR and the 6.7L. The GM Duramax 6.6L, Ford Powerstroke 6.0L and the 6.4L. Emphasis will be placed on the use of service information, the

scan tool, programming procedures. The use of SCR (Select Catalyst Reduction on newer trucks brings need to discuss and instruct on operation and repair. Emphasis will be placed on the technician to follow a diagnostic strategy.

Course Objective: Given the training, service information and tools, the technician will repair and diagnose Powerstroke, Duramax and Dodge Cummins diesel drivability complaints. Information provided will aid the technician the ability to follow a diagnostic strategy.

Length of course: Five days

The five day course will start with discussion on networks. Have scan tool communication issues? In this portion of the training, we will discuss CAN network and identifying the 16 pin OBD II connector and PIN checks. Wiring diagrams are analyzed and testing is performed on vehicles.

The Powerstroke 6.0L will be introduced and comparisons from the older 7.3L will be discussed. This section of the course will include teardown and demonstrations.

The topics on the Powerstroke 6.0L are:

*G2 Injector operation, what is stiction? Fuel pressure and aeration checks.

*High pressure oil system, the plumbing, isolating leaks, diagnosing.

*The fuel injection module (FICM), programming and diagnostics using the scan tool and IDS.

*Engine design, heads, head gasket issues, diagnosing, engine lower end components.

*Turbocharger, how the variable vane turbocharger functions, design and teardown. Diagnosis and repair.

*Use of service information

*Demonstrate use of IDS scan tool

*Role play diagnostic techniques and review case studies.

The course will continue discussion on the piezoelectric common rail fuel injection. This common rail system was introduced on the Powerstroke 6.4L. Instruction will cover the components and tests to perform with the scan tool and tools recommended.

The course will continue with the following subsystems of the Powerstroke 6.4L:

*Sequential Turbocharging system. Discuss the differences between the low pressure and the high pressure variable vane turbochargers. Tests and diagnosis will be covered.

*After treatment Systems 101. This portion of the course will cover the emission reduction that takes place in the Diesel Oxidation Catalyst (DOC) and the Diesel Particulate Filter (DPF).There will be extensive discussion on regeneration issues. The instructor will cover the operation of the exhaust temperature sensors and the pressure differential sensor. Diagnostic strategies will be viewed.

*Engine design and repair. We will have an engine on hand to tear down and review all the components.

*Electronic Controls- APP, ECT, and various pressure sensors will be discussed and their diagnostics will be shown using the multimeter and the IDS scan tool. Key on engine off (KOEO) and key on engine running tests (KOER) will be performed on a live vehicle.

The course will move on to the Duramax 6.6L engines. There are several versions of the Duramax starting with the LB7 and the following are LLY, LBZ, LMM and an overview of the newer LGH and the LML.

Instruction on the Duramax families will entail the following:

*Which are the Duramax engines? LB7, LLY, LBZ, LMM, LGL and LML.

*Common rail fuel injection system used, components and diagnosing.

*Engine design and differences, key items to know when repairing this engine, disassembly

*procedures, checks and assembly. Review key components.

*Cooling system issues. Instructor will demonstrate common mistakes technicians make with the cooling system, proper repair and filling.

*Turbocharger operation- Early wastegate Borg-Warner to the variable nozzle Garrett style will be explained and we will review common diagnostic checks.

*Programming and the use of service.gm.com. Confirming the latest updates and learn how to program using the scan tool.

*Service information review. Know how to use the service information from GM and other service information providers. Diagnose diagnostic trouble codes properly.

*Network diagnosis, review the CAN system and the GMLAN how they are set-up.

*Instruct common procedures to follow when diagnosing these diesel engines.

*Review use of Tech 2 and Tech 2WIN scan tools. Discuss aftermarket scan tools such as the Snap On Verus.

The last portion of the course will cover the Dodge Cummins 5.9L and the 6.7L Common rail engines. The Dodge ram equipped with common rail injection on both the 5.9L and the 6.7L have brought issues to technicians. Technical information and procedures are available in this course. The 5.9L with CR (common rail) was introduced in 2003. The use of a high pressure fuel system is diagnosed by system to make an accurate assessment on what failed. The low pressure, and return system are checked and procedures are explained. The Cummins 6.7L is also instructed along with additional emission controls and electronics.

Topics that are also covered are:

*Turbocharger diagnosing, identifying the 5.9L vs 6.7L .Compare the wastgate Holset with the variable nozzle found on the 6.7L. Instruct on procedures to check boost and turbo actuator testing. Discuss common issues found with both systems.

*Cummins 5.9L wiring inspection and PIN checking at the ECM connector are demonstrated.

*EGR system on the 6.7L is viewed. This includes the issues such as carbon sticking and use of scan tool data are taught and demonstrated.

*After treatment system , the diesel oxidation catalyst (DOC) and the diesel particulate filter operation and regeneration strategies will be instructed.

*Cooling system refill procedures and tests to perform when coolant consumption is an issue.

*How to program and ensure a correct diagnosis for ECM replacement.

*Review Injector wiring and tests to perform when a short or open diagnostic trouble code is set.

*How to retrieve SKIM codes and explain the role they play when you program an ECM.


*****Technicians attending need to bring a laptop or tablet which has access to Internet Explorer********

Tools and scan tools will be on hand to use on vehicles and engines. You are welcome to bring your scan tool should you have any questions. The course will have technicians using the service information and completing worksheets and discussions which will cover various case studies that will aid in refining the diagnostic process.

Course fee: $1850.00

This fee includes all materials, continental breakfast and lunch for all 5 days of training, Dinner is on your own. Hotel is not included. We will provide pickup and drop off to and from the Cannery Hotel and the airport which has a special rate for all attendees.

About the instructor:

Tony Salas is an Automotive and Diesel Specialist with more than 20 years of experience teaching diesel diagnostics and repair. He has provided contract training for General Motors Fleet and Commercial as well as AC Delco. His training experience includes GM 6.5 and Duramax 6.6L, Ford Powerstroke and various other topics. His experience includes instruction in the post-secondary level where he developed curriculum and taught for the community college in Las Vegas, NV. He also taught classes at the Toyota Urban League Automotive Training Center. Tony holds an associate degree in Automotive and Diesel technology. He is an ASE master technician and holds a teaching credential from Cal State Long Beach. He currently operates Powertrain Performance LLC as a service and repair facility as well as a training provider and training consultant.

Powertrain Performance
576 E Cheyenne Ave 89030
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Ford PowerStroke Diesel 6.7 (2011+) 25 July 2017

This class covers the 2011 up 6.7 PowerStroke engine, which is completely designed and built by Ford Motor
Company. This engine utilizes many unique new systems including a single sequential turbocharger, as well as
dual EGR coolers, SCR (Selective Catalytic Reduction or Urea Injection), Bosch HPCR (High Pressure Common
Rail) fuel injection, aluminum cylinder heads, dual cooling systems, and exhaust aftertreatment system. This
unique engine is covered in detail, covering all operating systems: glow plug circuits, fuel supply and delivery,
complete theory and application, EGR system and twin coolers, dual impeller turbocharger including variable
vanes, computer and injector control systems, diagnostic procedures, computer strategies, common problems and
pattern failures. A wide variety of 6.7 PowerStroke parts are provided for demonstration purposes: cutaway high pressure
fuel pump, cylinder head, variable turbocharger, fuel injectors, sensors, pumps, a complete fuel system, and more.
The class expands on diagnostics with time spent in the shop doing live tests on running PowerStroke equipped
trucks with the factory Ford IDS software. System operation, service, pattern failures, and maintenance
peculiarities will be covered in the class, focusing on Aftertreatment/Regen problems, clogged DPFs, what causes
them and system diagnostics. A “Regen” will be performed during shop time to evaluate the temperatures of the
EGT sensors and DPF pressures. A full-color training manual is provided. 16 hours

Diesel Forward Inc.
6167 Pepsi Way 53598
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DURAMAX TRAINING – Special One Day Training included in registration for the 2017 ADS International Convention & Tradeshow. You will need to let us know if you are coming to this training in the questions asked at the time you register for the Convention.

Duramax Diesel Training 2017

Tony Salas, Powertrain Performance LLC

Designed to update the diesel technician on the changes made

with the newer Duramax Diesels used on the Silverado, GMC Sierra and the Top- Kick and Kodiak GM trucks. The course will have a brief review of the Duramax Diesel 6.6L, from the LB7 to the LLY and the LBZ. Instruction will focus on the LMM, LML and the LGH.

The topics covered are:

  • Turbocharger
  • Common Rail Fuel Injection System
  • DOC/DPF 101
  • DEF Fluid 101
  • EGR
  • Engine and Electronics
  • A review of engine service issues, what to look for in service of the engine, head gasket replacement, lower engine rebuilding and cooling system service procedures.

Service Information from GM will be used to demonstrate information that is available for diagnosing and check-up date programming information.

Tony Salas, a former GM AC Delco instructor has a history for a logical basic approach to issues with Diesel and Gasoline vehicles. He currently owns Pow- ertrain Performance LLC in Las Vegas and provides training under Powertrain Training.  He deals with these vehicles daily and instructs with real case studies   to help you the technician with information to aid you in repairing these trucks the very next day.

Wynn Las Vegas
3131 Las Vegas Blvd. South 89109
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