LLY LOAD OVERHEATING BULLETIN
As many have become aware, the 04.5-05 LLY Duramax has had a lot of controversy surrounding its propensity to overheat with ease under high sustained workloads. The actual cause of this problem, and source of the added heat has been elusive to everyone who focused mainly on the cooling system. ENER-vative made significant progress here, beginning with research started in 2005, giving rise to the principles of “Thermal Feedback”, now considered a relevant case study in systems integration debacles. It showed that the cooling system does not need to be malfunctioning for an overheat scenario to develop.
To get the full explanation how simple production design changes in the turbo-diesel induction (turbo compression process) created a nightmare for this cooling system:
This link contains a short narrative, with additional links that will connect you to full technical articles that are the building blocks behind my findings. Some of these findings have been publicized in MaxxTorque magazine as well. Pg 32 here
Joel Paynton exploits this concept further with his own verification testing.
The articles develop to show the culpability of very specific hardware flaws as well as software flaws in oem tuning, combine to create excessive heat conditions when compressing (turbo charging) air for combustion. Among other things, the true importance of a waste gate is brought to light.
After identifying a serious restriction in the induction tract, I set out to develop replacements parts for fix the problem. The Induction Overhaul Kit that I settled on to answer this problem has been the most popular change for LLY sufferers. I have had only compliments on this kit, for its instant changes to performance as well as fan reducing induction heat reduction, plus spool-up benefits, all with a 15 minute installation time. The benefits have been modeled from actual thermodynamic formulas, and match actual documented results surprisingly well. Actual results have been documented from 15 HP (stock tuning) to 45 HP with augmented boost tuning. EGT and other benefits exist as well. The heat reduction implications are clear, and the spreadsheet helps quantify this.
Finally, to address the problems that are decribed here, use one of my Induction Overhaul Kits, AND a True Cold Air Intake. Every LLY will benefit from the improvment.
- Lower operating temperature
- Reduced head gasket failure
- Extended turbocharger longevity
- Increased Economy
- Increased Power available
You can find these IOH kits here. http://killerbeeperformance.com/induction-overhaul/