2006 Savana

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2006 Savana Express 6.6 L V8 Duramax Tom
Sliney Program Engineering Manager
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Discussion Topics

• Chassis
• HVAC/PTC
• Fuel Operated Heater
• Body in White
• Interior/Exterior
• Electrical
• Other new 2006 content

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Chassis

• Dual fuel filters for improved warranty and
  increased service intervals (20,000 miles for
  normal operation).
• HD frames commonized between Gas and Diesel
  engines to minimize impact to upfitter process.
• Electronic Throttle Control for Diesel.
• New Air Induction System with Filter Change
  Reminder.
• Revised Fuel Tanks with 2 Diameter Inlet For 20
  Gallon/minute fuel fill. Same fuel tank size as
  2005.
• Electric Fuel Pump Priming for restart after Fuel
  filter change.

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Chassis/Powertrain Components
FRAMES
FRAME CUTAWAY (139 / 159 / 177)
ENGINE MOUNTS
TCM KIT
FUEL TANKS
FUEL COOLER FILTER (FULL BODY)
Transmission Fill Tube
Air Cleaner
STEERING SYSTEM
EXHAUST SYSTEM
ACCELERATOR PEDAL
CHASSIS HARNESS
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Math tools utilized to insure proper operation
for quality, reliability and durability
performance.
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HVAC- PTC

• Fuel Operated Heater (FOH) provided as optional
  equipment. First OEM application on Full size
  vans.
• Pressurized coolant system with surge tank.
  
• Rear AC interface with Ambulance Package (Option
  YF2) on cutaway similar to CK design with
  ambulance
• Rear heat interface (option ENC) on diesel
  similar to gas
• AC compressor same as the 4.3L V6
• Variable Nozzle Turbo Charger (VNT) enables
  improved heater warm- up standard. Same as
  Medium Duty.
• Optional high idle switch enables sustained
  engine idle operation.

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Coolant Volume Chart for GMT610
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HVAC
C/O INT AIR DISTRIBUTION DUCT
NEW FUEL OPERATED HEATER
NEW CRFM SYSTEM (CHARGE AIR COOLER, RADIATOR, FAN
SHROUDS)
C/O BLOWER HEATER CORE MODULE
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Fuel Operated Heater

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FOH CONTROL The FOH will be operated
automatically. All the conditions listed below
are required to switch-on the FOH Outside
air temperature lt 4C. (via GMLAN) Engine is
running (via GMLAN) . Fuel Level gt12.5 total
volume of fuel tank. ( signal via GMLAN) .
Coolant temperature lt75 C (Internal signal
received from FOH coolant temperature sensor,
which is POA FOH).    Any of the conditions
listed below will switch-off the 5 KW FOH
Outside air temperature gt 4C. Engine is not
running. Fuel Level lt12.5 total volume of
fuel tank Coolant temperature gt85 C
(Internal signal received from FOH coolant
temperature sensor, which is POA FOH).        
 
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2006 Diesel
Rear heater hookups
NPN
15251105
ENC part similar to the
GMT 610 Gasoline
NPN 10379540
AC quick connect
For suction line
NPN 10379540
AC quick connect
For liquid line
G 300 0305
LLYYF2.
SALES PACKAGE
AMBULANCE UPFITTER
GM Confidential
Last modified November 8, 2004
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2005 Gasoline
Rear heater hookups PN 15222929 ENC part for GMT
610 Gasoline
GH 100200300 00 ENC. HVAC PROVISIONS AUXILLIARY
HEATER PLUMBING WIRING
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BIW Structure

• BIW Engine opening designed to accommodate diesel
  engine. Body is unique for diesel application.
• Access plates provided in body for fuel injector
  serviceability.
• Stiff body structure maintained for diesel .
  

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Front-of-DashNEW
PLATES FOR INJECTORS SERVICE
NEW LLY ENGINE RING
NEW RH FRT DASH PNL
C/O LH FRT DASH PNL
C/O LH FRT WHEELHOUSE
C/O RH FRT WHEELHOUSE
NEW FRT FLR PNL
NEW RH UNDERBODY HEATSHIELDS
NEW LH UNDERBODY HEATSHIELDS
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PLATES FOR INJECTORS SERVICE Plates seal over the
engine ring using snap on features to allow easy
service access to the injectors.
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Interior and Exterior Components

• Engine cover size optimized to maximize passenger
  foot room and knee room for diesel engine. Engine
  cover unique for diesel.
• Interior designed to minimize road and engine
  noise.
• Driver and passenger side knee bolster revised.
• New switches located on Instrument panel (High
  Idle and Export Options)

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Interior
NEW DRIVER KNEE BOLSTER
NEW PASSENGERKNEE BOLSTER
NEW ENGINE COVER
C/0 CENTER CONSOLE
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HD Passenger Airbag Suppression Cutoff Switch
Hi-Idle switch optional. Mounted on Instrument
panel
15131896
Filler Asm-I/P Cstr Tr Plt (Hi Idle)
Filler Assemblies Location
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Electrical

• New electrical harness content added for diesel
  functionality.
• IP Cluster revised to add diesel telltale
  functionality.
• Class 2 Electrical Architecture from 2003 MY will
  be maintained except for new Powertrain
  electrical interface.
• Standard 145 Amp alternator.
• TCM packaged underhood.
• Diesel primary battery underhood and auxiliary
  battery mounted on LH frame rail.
• New ECM bracket mounted on LH fender inner.
• Ambulance package equipped with 50 amp Maxifuse
  connector at B Pillar.

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Diesel
Domestic
Water in Fuel
Cruise (To be also used for VNT, by blinking the
light)
Export
New Oil Pressure Scale
DRL removed
Wait to start
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Diesel Specific Options

• High Idle Switch
• Fuel Operated Heater
• Export Package for Middle East
• Ambulance Package

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Ambulance Content - YF2

• Full Body Van (Type II)
• 6.6 L Diesel Engine
• Front Air Conditioning
• Dual 145 Amp Alternators
• Rear HVAC Provisions w/Quick Connects
• Vinyl Floor Covering, Front
• Stationary Side and Rear Door Windows
• 9600 GVWR

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Ambulance Content - YF2

• Cutaway Body (Type III)
• 6.6 L Diesel Engine
• Front Air Conditioning
• Dual 145 Amp Alternators
• Rear HVAC Provisions w/Quick Connects
• 12000 GVWR

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School Bus Content - B3D

• Cutaway Body (Type A)
• 6.6 L Diesel Engine
• Passenger Door Delete
• OSRV Mirror Delete or Manual OSRV
• ISRV Mirror
• Brake Warning Indicator Light
• Dual Horns
• GVWR Options, 9600, 10000 or 12000 GVWR
• SRW or DRW (GVWR dependent)

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Mass Analysis

• Comparison of 6.6 L Diesel vs. 6.0 Gasoline
• Total Differential Approximately 450 Pounds
• Complete Mass Data Available Spring 05

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Diesel Engine Program Content Summary

• Best In Class Duramax Diesel Performance and
  Features.
• -Engine Noise/Fuel economy/Loaded performance
• -Build on 2003 JD Power Dependability Award
• Transmission designed for diesel operation.
• Designed for quality, reliability, durability and
  minimize life cycle cost.
• Serviceability considered with oil filter and
  fuel filter locations and air filter change
  reminder.
• New offering minimizes change to upfitters
  currently building on gas cutaway vehicles.
  
• Enhanced heating performance with FOH.

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Other New 2006 MY Content

• Gasoline exhaust for Emissions
• Automatic Occupant Suppression
• Velvac Mirror Option

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Automatic Occupant Suppression

• MVSS 208 requires automatic passenger side airbag
  suppression.
• AOS passenger seat on light duty (lt8500 lb)
  gasoline trucks
• Carryover PSIR cutoff switch will remain on HD
  models with passenger airbags.
• 1500 Series Upfit Vans (RPO YF7) over 5500 lbs.
  curb weight are exempt for MVSS 208.
• 
  

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LD Passenger Airbag Suppression Indicator
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HD Passenger Airbag Suppression Cutoff Switch
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Heavy Duty Full Body Vans Gasoline Federal
Applications
HD Catalytic Converter revisions implemented
2005 design
2006 design

M150 converters Federal Non-MDPV
applications Complete vehicles
M120 converters ALL Federal applications Complete
vehicles
M102 converters Federal MDPV applications Complete
vehicles
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Velvac Mirror- RPO DHC
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Questions or Comments