- Staff
- #1
This is from another site(duramaxdiesels), but it is VERY interesting reading describing how GM had the DURAMAX engine designed in partnership with ISUZU in just 90 days.
In 1996, as General Motors was finalizing plans for its next generation of full-size trucks (code named GMT800), the company had only 3% market-share of the diesel-powered heavy-duty pick-up truck segment.
By Roy Berndt
It was really no surprise, since GM had single-handedly alienated the American buying public against the diesel engine beginning back in the late ’70s and early ’80s with the 5.7L V8 and 4.3L V6 diesel engines that were, let’s just say, “less than stellar.” While there’s no point now in rehashing mistakes of the past, the 6.2L and 6.5L diesels had continued on in a similar tradition, even though the 6.5L was used in the HUMVEE for the military.
In order to have a winning truck this time, GM needed to have a winning diesel powertrain. The General already had two strikes and a third may have put GM out of the diesel pick-up market altogether.
A small group of stakeholders led by the Planning Group reviewed proposals from numerous possible diesel engine manufacturers for the all-new truck. The decision was reached to go with a proposal from one of GM’s partners – Isuzu Motors LTD, a company founded in 1916 and, with a long history of successful diesel technology, recognized worldwide as a leader in diesel engines. The proposal was developed as a part of a strategic 90-day study conducted by Isuzu and GM, relative to Isuzu’s role in the GM Global enterprise.
While Isuzu’s plan called for a “Clean Sheet” brand new engine design that would not be ready until 2003, GM’s new HD pickup truck was going into production in late 2000. After high-level executive meetings, Isuzu found a way to pull ahead the timing to meet GM’s needs. In May 1997, the project team was established under the leadership of Jim Hogan, GM Truck Group; Yoshihiro Tadaki, Isuzu; and Jim Kerekes, representing GM Powertrain.
The project was codenamed “B908” (bridge between U.S. and Isuzu, 90-day study and 8-cylinders). This would be the first V8 diesel engine Isuzu ever designed for the U.S. HD pickup market. Isuzu was responsible for the base engine design and GM was responsible for the integration of the engine into the vehicle. The GM Powertrain – Romulus Engineering Lab became the center of activity in the U.S.
The first running B908 engines were available in early 1998 in Japan and soon were installed in mule vehicles in the U.S. to begin the final development. The B908 Team used the 13-hour time difference to their advantage. They would videoconference late in the day U.S. time while Japan would work on the issue during their day and when the U.S. team came in the next morning, have another videoconference to review and the US would work during their day while it was Japan’s night. It was truly 24/7 development.
The GM-Isuzu 90-day study established the plan to manufacture the new engine: a joint venture company named DMAX Ltd. (signifying the diesel engine and maximum power, cleanliness and fuel economy) was established in September, 1998 in Moraine, OH. A new 650,000 sq. ft. engine plant was built near the former 6.5L diesel engine plant, and many of the employees were able to transfer to the new joint venture.
The totally new engine design was a 6.6L, 90-degree, direct-injection, overhead valve, four-valve-per-cylinder, turbo-charged diesel V8 with aluminum high swirl cylinder heads. The electrically controlled common-rail fuel system provided maximum power for each pulse of fuel used and allowed full authority in injection timing and quantity. This combination along with pilot injection provided operating quietness and smoothness typical of similarly sized gasoline engines.
When it came time to decide upon the marketing name for the new B908 engine, GM was already handicapped by its poor diesel reputation. The name itself was critical, as it would compete against Ford’s established “Powerstroke” Diesel engine. Dodge was using the Cummins engine and needed no other name, so after many meetings the engine was named Duramax Diesel 6600. Like the joint venture name, “Duramax” was meant to highlight the durability and reliability of the new engine.
In late 2000 the Duramax Diesel 6600 debuted in the new 2001 HD pickup trucks. Brought to market in only 37 months, it was the fastest new engine developed by GM Powertrain – at that time. The engine was an immediate success, making Ward’s Magazine “10 Best Engines” both in 2001 and 2002, and bringing up GM’s market share from 3 percent to 30 percent in the HD Diesel pick-up truck market.
So now that we know how it got here, let’s take a look at the basic specs of this engine, the RPO designations and how the proliferation of the major engine components has taken place. In addition, we’ll highlight some of what you need to know and watch out for as you go through the remanufacturing of these engines.
In 1996, as General Motors was finalizing plans for its next generation of full-size trucks (code named GMT800), the company had only 3% market-share of the diesel-powered heavy-duty pick-up truck segment.
By Roy Berndt
It was really no surprise, since GM had single-handedly alienated the American buying public against the diesel engine beginning back in the late ’70s and early ’80s with the 5.7L V8 and 4.3L V6 diesel engines that were, let’s just say, “less than stellar.” While there’s no point now in rehashing mistakes of the past, the 6.2L and 6.5L diesels had continued on in a similar tradition, even though the 6.5L was used in the HUMVEE for the military.
In order to have a winning truck this time, GM needed to have a winning diesel powertrain. The General already had two strikes and a third may have put GM out of the diesel pick-up market altogether.
A small group of stakeholders led by the Planning Group reviewed proposals from numerous possible diesel engine manufacturers for the all-new truck. The decision was reached to go with a proposal from one of GM’s partners – Isuzu Motors LTD, a company founded in 1916 and, with a long history of successful diesel technology, recognized worldwide as a leader in diesel engines. The proposal was developed as a part of a strategic 90-day study conducted by Isuzu and GM, relative to Isuzu’s role in the GM Global enterprise.
While Isuzu’s plan called for a “Clean Sheet” brand new engine design that would not be ready until 2003, GM’s new HD pickup truck was going into production in late 2000. After high-level executive meetings, Isuzu found a way to pull ahead the timing to meet GM’s needs. In May 1997, the project team was established under the leadership of Jim Hogan, GM Truck Group; Yoshihiro Tadaki, Isuzu; and Jim Kerekes, representing GM Powertrain.
The project was codenamed “B908” (bridge between U.S. and Isuzu, 90-day study and 8-cylinders). This would be the first V8 diesel engine Isuzu ever designed for the U.S. HD pickup market. Isuzu was responsible for the base engine design and GM was responsible for the integration of the engine into the vehicle. The GM Powertrain – Romulus Engineering Lab became the center of activity in the U.S.
The first running B908 engines were available in early 1998 in Japan and soon were installed in mule vehicles in the U.S. to begin the final development. The B908 Team used the 13-hour time difference to their advantage. They would videoconference late in the day U.S. time while Japan would work on the issue during their day and when the U.S. team came in the next morning, have another videoconference to review and the US would work during their day while it was Japan’s night. It was truly 24/7 development.
The GM-Isuzu 90-day study established the plan to manufacture the new engine: a joint venture company named DMAX Ltd. (signifying the diesel engine and maximum power, cleanliness and fuel economy) was established in September, 1998 in Moraine, OH. A new 650,000 sq. ft. engine plant was built near the former 6.5L diesel engine plant, and many of the employees were able to transfer to the new joint venture.
The totally new engine design was a 6.6L, 90-degree, direct-injection, overhead valve, four-valve-per-cylinder, turbo-charged diesel V8 with aluminum high swirl cylinder heads. The electrically controlled common-rail fuel system provided maximum power for each pulse of fuel used and allowed full authority in injection timing and quantity. This combination along with pilot injection provided operating quietness and smoothness typical of similarly sized gasoline engines.
When it came time to decide upon the marketing name for the new B908 engine, GM was already handicapped by its poor diesel reputation. The name itself was critical, as it would compete against Ford’s established “Powerstroke” Diesel engine. Dodge was using the Cummins engine and needed no other name, so after many meetings the engine was named Duramax Diesel 6600. Like the joint venture name, “Duramax” was meant to highlight the durability and reliability of the new engine.
In late 2000 the Duramax Diesel 6600 debuted in the new 2001 HD pickup trucks. Brought to market in only 37 months, it was the fastest new engine developed by GM Powertrain – at that time. The engine was an immediate success, making Ward’s Magazine “10 Best Engines” both in 2001 and 2002, and bringing up GM’s market share from 3 percent to 30 percent in the HD Diesel pick-up truck market.
So now that we know how it got here, let’s take a look at the basic specs of this engine, the RPO designations and how the proliferation of the major engine components has taken place. In addition, we’ll highlight some of what you need to know and watch out for as you go through the remanufacturing of these engines.