page 5. Volt - GM Service Insights
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1. a 1950s era Chevrolet Nomad Genuine Parts The owner found the Nomad stored in a barn and although in pretty good condition it still needed a lot of work Britton says We faced a big challenge in restoring Don t Miss the GM Exhibit at the 2010 SEMA Show the original fit and finish and also in mating current technology to an old body style But thanks to Genuine GM Parts the project wasn t as GM Booth 23743 Central Hall formidable as it could have been Working closely with its longtime local GM dealer Britton was able to work through Tu esday Nov 2 Friday Nov 5 various powertrain options and eventually arrive at a solution that far exceeded original expectations The owner liked the idea of putting modern technology into an old beauty and we originally talked about a 350 290 crate engine but that was going to require some special motor mounts he says What we went with was something even better a LS3 Corvette engine that our dealer was able to arrange to pull right off of the assembly line think at the time it was the first LS3 that didn t go GENERAL MOTORS COMPANY into a Corvette While mating an LS3 and a GM Powertrain 4L65E along with a Currie 12 bolt rear end to a 50 year old vehicle frame was no picnic it was typical of the GM Powertrain solutions that Britton values for their relative ease of installation performance and warranty protection Rather than spen2. a 2 E a a pm i lt m l e ACDelco Oct Dec 2010 Genuine EJ Parts gt Genuine GM Parts good for you and your customers gt GM program offers more affordably priced powertrain components r T Toen gt GM unveils line of remanufactured cylinder heads Extended ra nge C lectric veh i cle gt More GM resources available for first responders gt GM Powertrain talks up technology at rebuilder show ma kes Its de but gt GM Parts Web sites gets upgrade more powertrain resources More on the Volt Inside gt Classic 57 Nomad takes shape in Texas resto shop gt TechConnect insert with valuable repair info Info for first responders page 5 Volt s new Global Compact Vehicle Architecture tt TT W shared with the f Chevrolet Cruze page 8 A CONTENTS The Technical Side Discover new ways to approach service and repairs GM Parts Product Update The latest word on product development and technologies Repair Industry Business News amp Updates of Repairs Get state of the New ideas that can industry perspectives benefit how your shop from GM insiders operates and profits GM Servicelnsights Online More Genuine GM Parts resources and links Download this issue and past issues of GM Servicelnsights magazine at www gmserviceinsights com GM Servicelnsights Headquarters 2604 N E Industrial Dr 230 N Kansas
3. so vehicles can be sold with an added value of warranty INSTALLATION SUPPORT GM Ford and Chrysler makes it 3X easier for you to receive product warranty availability and purchase information as well as technical support 1 866 OE PARTS 1 866 637 2787 NO HASSLE CORE RETURN Whichever comes first from date and mileage of installation by an authorized GM Dealer or qualified service center For over the counter sales warranty begins on the date and mileage of retail sale Labor not covered for powertrain component warranty installation Contact your participating Genuine GM Parts or ACDelco powertrain parts source for details GM Parts Product Update Rounding Out overPOWER Hundreds of Genuine GM Parts now more affordably priced Getting great deals on Genuine GM Parts doesn t mean just having to buy a big ticket engine or transmission They re also available on a growing group of parts used in everyday powertrain repair jobs In addition to making some 200 GM Engine and 400 GM Transmission part numbers purchased through GM dealers more affordable overPOWER is adding more than 500 powertrain component parts to the program These engine and transmission component parts Span four distinct categories selected for their volume and level of aftermarket competition pulleys tensioners balancers intake manifolds and gaskets engine oil cooler lines and 4 wheel drive actuator motors By using th
4. the groundbreaking nature of their rollouts are drawing attention The Volt of course stands out as the first plug in electric vehicle And the 2010 Cruze affirms Chevrolet s commitment to building refined fuel efficient vehicles Less publicized though is the fact that both are the first to be built off of GM s new Global Compact Vehicle Architecture The new design platform was conceived to offer a more flexible globally competitive and cost effective template for making vehicles While the new platform spans a range of critical design elements it incorporates structural features certain to be of interest to collision repairers and service providers Front and center at the GM Collision Parts booth at the International Autobody Congress amp Exposition NACE in Las Vegas in early October the vehicles key structural features revolve around the use of advanced high strength steels HSS and designs that give essential structures the ability to both protect and be easily repaired or replaced In both vehicles variants of ultra high strength steel UHSS and dual phase steel are used in differing amounts and locations in critical center pillars header panels floor reinforcements and structural components to limit the crush zone and protect the passenger compartment in the event of a crash Although the design of the Volt and Cruze structure is Similar the Volt uses different variants of advanced Chevrolet V
5. Brake Systems S BK0O5 04 01SEM What exactly is regenerative braking How does a hybrid vehicle control module determine how much hydraulic brake force and regenerative brake force should be used to slow or stop a vehicle How different are service procedures for hybrid vehicle braking systems compared to conventional ABS These questions and others about GM Ford and Toyota regener ative brake systems are answered In addition details are provided about high volt age components identification labels and Personal Protective Equipment As an added feature innovative technology such as a power generating shock absorber and other possible future technologies are highlighted Traction Control and Stability Enhancement Systems S BK05 02 02SEM Modern traction control systems and the various Strategies used for traction control intervention such as corrective fuel management throt tle closure brake application and Spark table modifi cation are dis cussed as well as the traction control switch the brake tem perature algorithm and brake pedal position sensor inputs Operation and diagnosis of stability enhancement system components including the longitudinal accelerometer steering wheel position sensor yaw rate sensor and lateral accelerom eter sensor also are discussed Specific service procedures highlight the brake pedal position sensor calibration zero point calibration and yaw rate reference table
6. City MO 64117 E mail bdavid proactgroup com Compliments of your GM dealer We invite your input and suggestions Please address letters to the editor to the above address Letters submitted imply the right to edit and publish Every effort is made to ensure the accuracy of the information in the offers contained in this magazine However printing and typographical errors may occur These are not intentional and are not the responsibility of GM any GM dealer or the companies or individuals who create produce and distribute this magazine Offers and pricing may change at any time without prior notification The descriptions and specifications in this publication were in effect at the time of approval for printing General Motors reserves the right to change specifications without notice and without obligation Published letters do not necessarily reflect the opinions of General Motors General Motors Parts General Motors LLC Detroit MI 48202 2010 General Motors LLC All rights reserved Genuine fal Parts GENUINE GM PARTS Good for you good for your customers ENGINEERING Each GM Powertrain component incorporates the very latest engineering technology POWERFUL WARRANTY 3 years 100 000 miles for GM OE Powertrain 1 year 12 000 miles for Genuine GM Parts and ACDelco Powertrain Components The installing independent service center may perform the warranty repairs Warranties reside with the vehicle not the owner
7. Need for a New Adapter New SIDI engine technology represents a significant departure in the way fuel is controlled and injected into the cylinders of the engine This technology has many benefits in improved performance economy and emissions However diagnosis of the system presents new challenges Fuel pressures are much higher and the components are new and typically less accessible on SIDI systems compared to port injection engines The new systems are dramatically different technician familiarity and experience working on port injection systems does not apply to diagnosing SIDI systems except In a very general way This tool automates the process and provides accu rate reliable information about all the elements of the fuel injection system Current Service Information requires manual calculation and inter pretation of the results to reach a diagnosis The AFIT and DMU perform all the measurements and calcula tions automatically giving an accurate diagnosis The AFIT tool with the DMU Adapter tests all the components of the fuel injection system From start to finish testing on average takes less than 10 minutes The test routine is completely prompted in the same way the AFIT tool does for port injection fuel systems No fuel system disassembly is required A number of diagnostic codes and many symptoms that do not set codes can be caused by a number of engine components One of the values of the tool is to
8. high voltage and a structural steel frame comprised mostly of high strength steel HSS emergency first responders looking to quickly and safely extricate passengers must approach the Volt with far more care precision and knowledge than they do with any other vehicle Failure to follow proper procedures can result in not only a critical loss of time in freeing occupants but possibly injury and even death In late September GM assisted by its training partner Raytheon unveiled a Volt First Responder Guide The com prehensive guide patterned after those that have been pro duced for other GM hybrid vehicles that must also be handled with extreme care in crash situations is now posted on the First Responder Resource page of the GM Service Technical College Web site www gmstc com FirstResponder aspx The guide is a detailed fully illustrated primer covering metal cutting techniques and tools identification of key electrical components and methods of safely disabling the electrical system It is designed not as a training manual but as a ready resource for first responders covering information essential to their Safety and that of vehicle occupants Engine Generator Electric Drive Unit Lithium lon Battery Charge Port Chevrolet Volt As the Volt debuts in select markets this fall GM is bringing those guidelines to life in a series of hands on first responder outreach workshops Patterned after a live Volt extri
9. or booster pack disconnected trom the AC power supply to maintain system voltage Do not connect a standard battery charger e The ignition switch must be in the On position with the engine off Do not change the position of the ignition switch during the program ming procedure unless instructed to Avoid programming interrup tions of any kind such as opening vehicle doors or depressing the brake pedal It is also a good practice to make sure no other applications are active or running on the PC e DTCs may set during programming Clear DTCs after programming is complete If error codes appear during programming do NOT assume that the control module cannot be programmed There are certain events that can interrupt programming In most cases a second attempt at programming will be successful For complete program ming information click the SPS link on the Control Module Reference table in the Service Information Thanks to Bob Stewart and Mike Waszczenko New Brake Seminars Hybrid Technology to Basic Diagnosis ACDelco s commitment to providing top quality technical training continues with the release of five all new modular brakes seminars that cover the newest technologies of automotive braking applications Designed to be offered as one hour Lunch and Learn training events they can be delivered as one hour stand alone courses or combined to provide advanced training for your shop Hybrid Regenerative
10. pleats than other popular aftermarket filters to service of a vehicle Properly trained technicians have the equipment tools safety instructions and provide more capacity know how to do a job properly and safely If a con dition is described it cannot be assumed that the Regular engine oil and filter changes following the vehicle s maintenance information applies to all vehicles ofthat aman schedule or oil life monitoring system using ACDelco filters that meet manu will have that condition facturers specifications will helo protect the engine from premature wear and All materials and programs described in this lity fil f magazine are subject to change Submission of assure quality tiltration performance materials implies the right to edit and publish f Inclusion in the publication is not necessarily an Check the most recent parts information to ensure the correct part number oil endorsement of the individual or the company filter is installed during an oil change Do not rely on physical dimensions Some encon aa pubit jai for ACDelco by Sandy aftermarket oil filters may share the outside dimensions of ACDelco OES filters orporato TM A Though they look the same the filters may not meet the proper specifications and 2010 ACDelco All rights reserved requirements for the engine application 2 TECHCONNECT Electrical Ground Repairs Corroded or stripped electrical ground connections can cause a loss of module communication a
11. seminar Hydraulic circuits and components also are reviewed as well as valuable brake system service tips Brake Noise Diagnosis and Service S BKO5 06 01SEM The first step to customer satisfaction is identifying the customer s concern successfully To assist with this critical process this seminar provides a Brake System Description Questionnaire as an additional support tool enabling a techni cian to ask pertinent questions for effective diagnosis How to perform a thorough pre road test inspection and an effective road test are described in detail Diagnosis informa tion includes checking pedal travel as well as specific disc and drum brake checks In addition diagnostic tips are provided for evaluating brake booster operation and noise concerns Learn More In addition to the new brake system seminars ACDelco offers 24 7 on demand online Web based courses that can be completed at any time These online courses complement the instructor led hands on courses that remain the core of ACDelco training To review the latest training courses available log in to the ACDelco Learning Management System LMS at www acdelcotraining com Take the opportunity to expand your technical knowledge contact your local ACDelco distributor to learn when ACDelco seminars have been scheduled in your area Thanks to Greg St Aubin 6 TECHCONNECT The following technical tips provide repair information about specific conditions on a
12. their way to the information they need Additionally there will be direct links to other sites such as ACDelco and GM Performance Parts as well as other resources in the form of newsletters and literature The new site will be unveiled in two stages The first phase a soft launch incorporated a redesigned home page and new site navigation features and coincided with the opening of the NACE International Autobody Kenut o Parts inner mma Collision Regalr Powertrain Pramatlecis Locate a Siapiker Relaisd Links Collision Repair pest Baral aa aii Firat repair infi iy make and mn el telect Meme OB Select tede llo Get genuine peace of mind when you choose Congress amp Exposition in early October Then in December the new GM Powertrain related components of the site will be added as the new site is officially launched We want to be able to better engage with independent shops comprising our wholesale parts channel and give them the ability to find everything they need while at one site We believe our new Web presence for Genuine GM Collision and Powertrain Parts will accomplish that and more Schafer says Oct Dec 2010 Servicelnsights The Technical Side cont d High Strength Steel a Key Component GM s new Global Compact Vehicle Architecture debuts in Volt Cruze With the curtain now rising on two of GM s big bets for the future the Chevrolet Volt and the Chevrolet Cruze
13. variety of vehicles If you have a tough or unusual service repair the TSS Technical Assistance Hot Line can help Call 1 800 825 5886 prompt 2 to speak with a technical expert with the latest OEM information SIDI Fuel Line Service GM Ecotec 4 cylinder engine family 2007 2010 RPO LNF 2009 2011 RPO LDK 2010 2011 RPO LAF and 2011 RPO LHU and GM High Feature V6 engine family 2008 2011 RPO LLT 2010 2011 RPO LF1 and 2011 RPO LFV with a Spark Ignited Direct Injection SIDI fuel system When servicing a fuel line on a Spark Ignited Direct Injection SIDI fuel system on the Ecotec 4 cylinder engine family and High Feature V6 engine family the fuel pipe must always be replaced when it incorporates a tube nut fitting Tube nut fitting If a tube nut fitting is loosened for a fuel system repair the line must be replaced because after the tube nut is torqued the first time the sealing surface on the ball end of the pipe becomes modified in a way that will not seal properly again The ball end of the pipe is a softer material than the mating Surface and once pressure is applied from torquing the tube nut it deforms to form a good seal It can be determined that a fuel pipe has been previously installed by viewing the ball end of the pipe After the tube nut fitting has been torqued once and re installed the sealing surface of the ball end will show dual sealing bands indicating that the pipe has been previ ousl
14. www genuinegmparts com is being repurposed and redesigned to be a more complete resource for those who purchase and install Genuine GM Parts both collision and or powertrain Our goal with the redesign is to improve the user experience for our collision repair target audience and also enhance the site by adding GM Powertrain related information says Cindy Schafer digital marketing mana ger on the GM Parts wholesale marketing team The site has been devoted to collision but we ve now broadened it to entail powertrain and at the same time we ve improved the look the content and navigation tools Virtually anything relating to GM Collision or Powertrain Parts that is of notable interest to Independent Service Centers ISCs and Independent Body Shops IBSs will eventually be available at the improved site The content will be heavily geared toward information that repairers need to help them perform high quality repair jobs on GM vehicles Our aim in providing both product and marketing information will be to help repairers learn more about the GM products they re ordering before they order them Says Schafer New resources and features will encompass everything from specific product technical and warranty information official position statements and product marketing materials to dealer locators training videos and links to other related Web sites A search function will also be added to allow users to quickly find
15. as the cause of a driveability condition Thanks to Mike Cable and Tedd Magana Damil Timid Coake OTC List vebieie b DIC Srapidi Daecopie ii Bed Centa Lih body Limir i Creepe beita Handa Cette Gite brhareptzj GME HAE ee PE UPRA LPS Atte Ai r By APS Trn ppr Cees eA imin Cea Fan umru wini aa upra Asb ere Dao Cona Mii Be A LRE R Prigen hepara Cenia Modua piem boMa ag crear Motyki apiece Lay et ae a Pe eye a eel i eee Vee ae eo Sa LE ET ares Cosina L Cros Madu Epe Lenii Mitchie Daiki rpe ORED Miiat Pyg amne ad hg Gite troonterepe efter vE reptecement Conte Soke yale ani a Cools oui Mji mi Pex F mg _ we Hiba fy ME ETET of Te ee ee An Be oe eg pote Aas fin itt Bemscemenr LA Cun _ ee Lee ole Sete Mice AET Deri Drake a aa Seroce Programe aster OP ter CM a eT ae o eee BE epee eet mE HEGEN LOATH Mocs Tid SR armeng Seiten Lihn pity ERM Mare i Rene enen PRELAT emant Eus Denia Moga Laimani t Tt pm Enga Canpa Mugi y T S ls 2 thee Foe upra a a ia z p bi Hia ee lar iii Check the Service Information before setting up a control module e Repair instructions e Programming and setup information Setup Procedures Once programming is completed successfully it s critical to perform the necessary post programming setup procedures For example when programming the Transfer Case Shift Control Module TCCM it s necessary to perform
16. cation demonstration by the Chicago Fire Department at the 2010 Fire Rescue International Conference in Chicago in August the workshops will show the precise steps techniques and tools required to disable the vehicle s electrical system cut battery cables stabilize the vehicle and efficiently cut through steel Additional local workshops will begin to roll out with the car later this year in Detroit Los Angeles San Francisco and Washington D C Oct Dec 2010 Servicelnsights 5 ACDelco TECHconnect Repair Industry News amp Updates cont d GM Powertrain alks Up Technology support at Rebuilder Show At September s Automatic Transmission Rebuilders Association ATRA show industry members got an inside look literally at what s headed their way in terms of GM Powertrain transmission technology Using real cutaways GM Powertrain Showcased the two mode hybrid transmission for the GMC Yukon Cadillac Escalade and Chevrolet Tahoe and 6 speed rear and front wheel drive transmissions two product lines repairers and rebuilders will see in coming years as more vehicles are paired with 6 speeds GM Two Mode Hybrid Transmission In addition many of the attendees at the show staged at the San Antonio Texas Convention Center learned more about yet another new transmission that makes its debut this fall with the unveiling of the Chevrolet Volt plug in electric vehicle Detailed information about the Vo
17. confirm the operation of the fuel system How the AFIT DMU Works on SIDI Fuel Systems Using one of two mating cables the DMU connects to the vehicle battery the AFIT main unit and to the vehicle ECM engine harness connector The tester prompts the technician for the proper cable when the vehicle is selected on the AFIT main unit When prompted the technician cranks the engine on the AFIT The tool stops the cranking and after each crank one of the vehicle s injectors is tested The fuel pumps high and low pressure starting system and regulator also are tested for proper operation When the test is complete the results are displayed on the AFIT main unit in a format that is similar to the result screens for a port injection vehicle SIDI systems use fuel pressures in excess of 1000 PSI provided by the engine driven fuel pump The fuel injectors are mounted so they inject fuel directly into the cylinders Although they look different they still rely on fuel pumps and regulators delivering the right pressures and injectors flowing the proper fuel amounts each cycle While cranking the engine the tool measures battery voltage and cranking RPM and compares those results to specifications for the vehicle The tool determines high pres sure pump characteristics by measuring the fuel pressure developed at various engine speeds during each crank and comparing the results to the expected Pressure vs RPM built into the tool s databa
18. ct group of no more than about a dozen a year lucky enough to get slotted in a Shop that s produced its share of award winners including a 1955 Bel Air Sport Coupe named Best Modern The restored 1957 Chevrolet Nomad used a GM Performance Parts LS3 j crate engine and a 4L65E transmission Restoration and displayed by GM in 2005 To the untrained eye what the 31 year old company does to restore classics and build custom rods in fine detail might indeed look like sleight of hand But it s really just the product of professionals who share owner Stephen Ramsey s passion for automotive classics notably Tri Fives 1955 1957 Chevrolets and have the know how and supplier contacts to execute both true to history restorations and resto mod jobs for demanding customers All of that and more came into play with the 57 Nomad project Representative of many of the projects it takes on limited in number annually because the company refuses to stack up projects like cordwood for quality control purposes says Britton the resto mod job brought a Classic back to life with a modern twist The Nomad job wasn t constrained by price as much as creativity and it demanded patience and painstaking attention to detail to bring it to fruition oe je i i jma Wine Fl i 3 m a a o O gt l i a __ E a 1 b a 2 A Britton left and lead tech Kevin Penhaker with a shop specialty
19. ding tens of thousands of dollars to build custom motors that don t have a good warranty I can go to my GM dealer and get a product that s the right fit for my performance minded application without breaking the customer s budget he says After 11 months of work more than three dozen consultations with GM Powertrain a six figure price tag that encompassed 515 000 in body work and paint 8 000 for an interior and 3 200 just for a custom radiator Ramsey s Rods produced a flawless rendition of a 1957 Nomad Las Vegas Convention Center Las Vegas Nev www semashow com omc Bree SEMA ti Mm Parts Genuine Well nearly flawless Shortly after taking delivery the owner had a problem The transmission was a bit jerky creating shifts that were well sort of rough on the occupants Britton got the car back made a few adjustments to the RPM shift point and the problem was solved He was sure he had really fixed it when he had a later encounter At a car show a few months later happened to run into the owner s girlfriend Britton says She came up to tell me that the car now shifts really nice Mission accomplished Genuine g Parts We re one stop For your shop Genuine GM Parts Engines and Transmissions Plus all the associated parts you need CLIP AND PLACE BY YOUR TELEPHONE Genuine Parts Give us a call for all of your Genuine GM Parts needs all at one co
20. ea using a residue tree solvent The rivet stud forms a collar on the rear side to prevent rotation in the hole After drilling the mounting hole for a new location remove any paint and primer from the area until bare metal is visible Install the appropriate new fastener and check that it is securely fastened without any detectable movement The M6 rivet stud will form a collar on the rear side to prevent rotation in the hole Cover the stud threads with protective material and refinish the repair area using an anti corrosion Installed M6 stud primer washer and nut The surrounding area must be properly finished prior to the installation of the ground wire terminal and conductive nut to maintain a secure stable and corrosion free electrical ground Thoroughly clean the stud threads using a residue free solvent Once dry apply dielectric lubricant to the threads to reduce the possibility of fretting Fretting corrosion is a build up of insulating oxidized wear debris than can form when there is a small motion between electrical con tacts causing electrical resistance across the connection Remove any corrosion or contamination on the electrical ground wire terminal Install the terminal tighten the conductive nut to the proper torque and verify system operation Refer to the bulletin for a list of part numbers for the replacement fasteners and special tools Thanks to Dave Peacy 3 TECHCONNECT Wh
21. eel Changing Procedures One area of concern while removing and installing tire wheel assemblies is corrosion on the mating surfaces of the wheel to the hub on the vehicle Excessive corrosion dirt rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall Once the vehicle is driven the debris may loosen resulting in clearance at the mating surface of the wheel and an undertorqued condition Before installing a wheel remove any buildup on the wheel mounting surface around the base of the studs and the hub and brake drum or brake disc mounting surface If corrosion is found remove the debris with a die grinder equipped with a fine sanding pad wire brush or cleaning disc Just remove enough material to assure a clean smooth mating surface Remove any corrosion from the wheel mounting surface Do not use penetrating oils grease or other lubricants on wheel studs to aid in removal or installation Always use a suitable cleaner solvent to remove these lubricants prior to installing the wheel and tire assemblies Lubricants left on the wheel studs may cause improper readings of wheel nut torque Always install wheels to clean dry wheel studs ONLY Beginning with 2011 model year vehicles GM recommends putting a light coating of grease on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub Refer to Bulletin 06 03 10 010A for more info
22. egulators line Line 18 for GM vehicles The new line includes assemblies motors regulators and other parts and is designed and built to meet or exceed OE performance It s backed by ACDelco s 12 month 12 000 mile warranty All New Motors e Cold testing at 20 degrees and water immersion tests where the motors must continue to run while frozen Easy Installation Smart Numbering System The window regulators line number ing system makes it easy to identify each part 11A1 A identifies an assembly regulator and motor 11R1 R identities a regulator only 11M1 M identifies a motor only 11P1 P identifies the part as The window regulators f re all i ii n P a e tal te not be as easy to install as ACDelco s pa ea ech loka tate motors In addition to extensive testing sow heated sare ber len ee for RPM rotational direction amperage Contact your ACDelco Parts supplier and torque the motors must pass All of the ACDelco window regula to learn more about ACDelco s new line e Durability testing that consists of tors are exact fit components with the of aftermarket window regulators and thousands of up down motions proper mounting holes hardware and other quality door system components mounting brackets Thanks to Kevin Smith TS PU 0017 10 8 TECHCONNECT Genuine Parts The Technical Side www genuinegmparts com GM Parts Web site set for repurposing and expansion The Web site
23. en button presses so 7 TECHCONNECT that the receiver can properly process the signal from the transmitter For many 2006 and later GM models the trunk release button requires a press and hold before the trunk lid will release Squeak Noise on Brake Apply 2004 2007 Buick Rainer 2008 Buick Enclave 2004 2010 Chevrolet Colorado Chevrolet TrailBlazer models GMC Canyon GMC Envoy models 2005 2009 Saab 9 7X 2007 2008 GMC Acadia Saturn OUTLOOK 2008 2009 Chevrolet Malibu Saturn AURA Pontiac G6 A squeak noise may be heard when the brake pedal is slowly applied with the engine on or off It also may occur when the brake pedal is released The noise may be isolated to the master cylinder area To correct this condition remove as much of the old brake fluid from the master cylinder as possible and refill with new DOT 3 brake fluid P N 88862806 Start the vehicle and fully cycle the brake pedal until the noise diminishes to allow the new fluid to enter the system Diagnostic Assistance For tree technical diagnostic assistance and product information regarding specific ACDelco products contact these toll free information hotlines staffed by ASE certified technicians Brakes 1 888 701 6169 prompt 1 Chassis 1 888 701 6169 prompt 2 Clutches 1 888 725 8625 Lift Supports 1 800 790 5438 Shocks 1 877 466 7752 Starters and Alternators 1 800 228 9672 Steering 1 866 833 5567 Wiper B
24. ese value priced parts Independent Service Centers ISCs are able to improve the quality of a heavy repair job without breaking the bank This provides an OE option at a price that s competitive with aftermarket parts that are often just reverse engineered says Keith Loch product specialist GM Engines and Transmission Components With gasket and manifold repair jobs for instance where labor is the biggest expense it can pay to go with higher quality parts that may be priced only a few dollars more By positioning these component parts to be in the ballpark with pricing of non OE aftermarket parts GM is hoping to give more ISCs a chance to experience the unique value proposition that Genuine GM Parts can offer easier to install less likely to result in customer returns and now more price competitive We took overPOWER national in January and we now have almost 300 dealers involved Loch says We look for more dealers to join in and for dealer efforts to use the program with ISC customers to continue growing GM Introduces Remanufactured Cylinder Head Assemblies Applications for Ecotec 2 2L 3 5L and 4 2L inlines available GM Parts has unveiled a line of remanufactured cylinder head assemblies for various four five and six cylinder GM engines They will provide Independent Service Centers ISCs an lt gt oe economical alternative to traditional repairs allowing them d to be less cost
25. ion and Fuel System Diagnostics To search for currently scheduled courses click S EP08 04 01ILT Engine Performance Fault Monitoring and Emission System Diagnostics the Schedule link Select search terms from the dropdown menus and click the Submit button S EP08 05 01ILT Engine Performance Advanced Drivability Diagnostics Current Instructor Led Training S EP08 20 01ILT Toyota Engine Performance ACDelco s Instructor Led Training ILT courses S EP08 21 01ILT Chrysler Engine Performance provide hands on Instruction on the latest automo S EP08 81 01ILT Duramax 6600 Diesel Engine Performance tive systems The following ILT courses are current ly being held at training center locations around the S EP08 81 02ILT Duramax Diesel Operation and Diagnosis country Click the Schedule link on the LMS Menu S SS04 01 01 ILT Vibration Correction Diagnostics to search the latest training schedule for courses Sea ya Fearon ACDelco Introduces All Makes Aftermarket Window Regulators Line Currently over five million window e Heat testing at 160 degrees All of the correct connectors also regulators are replaced each year during are provided instead of several service or collision repairs To helo meet multi use connectors so there is no demand in this growing market confusion or modifications necessary ACDelco has introduced a new full line during installation of all makes window regulators Line 11 to complement the Original Equipment OE window r
26. lades 1 800 810 7096 Trainino How to Take ACDelco Training the Training tab to log in to the ACDelco Learning S AC07 02 01 ILT Automotive Air Conditioning Advanced Refrigerant System Diagnostics Management System LMS e To enroll in an Instructor Led Training ILT course S AC07 03 01 ILT HVAC Control System Operation and Diagnostics click the Enrollment link or the Instructor Led S ACO7 06 01ILT Toyota HVAC Courses link S ACO7 O701ILT Chrysler HVAC e To enroll in a Virtual Classroom Training VCT 3 course click the Enrollment link or the Virtual se SUES cus Classroom Training Courses link S EL06 04 02ILT Network Communication Diagnosis e To launch a Web Based Training WBT course S ELO6 10 02ILT Electrical Power Management click the Web Based Courses link to view the eat 7 E TO e To launch a TechAssist TAS course click the S EL06 11 021LT Enhanced Automotive Circuit Diagnosis TechAssists link to view the catalog and select a S ELO6 12 01ILT Hybrid Technology and Service speculates S EL06 13 01ILT Body Electrical Global Di ti EL06 13 ody Electrical Global Diagnostics e To launch a Simulation SIM click the Simulations i link to view the catalog and select a diagnostic S EL06 14 01ILT Advanced Body Control System Electrical Diagnostics challenge simulation S EP08 02 01ILT Engine Performance Computer Controls and Ignition System Diagnostics Training Schedule S EP08 03 01ILT Engine Performance Air Induct
27. lling the belt around the Release tension to the tensioner by rotating counterclockwise 1 Note in our hybrid vehicles The Ecotec 1 4L turbo is standard on Eco LT and LTZ models and helps the Cruze Eco with 2 Remove EN 6349 2 3 Apply tension to the tensioner clockwise 1 a standard 6 speed transmission achieve an expected segment leading estimated 40 mpg 4 Install the front compartment splash shield Refer to the on the highway Front Compartment Splash Shield Replacement in SI Oct Dec 2010 Servicelnsights EJ Texas Restorer uses a Tull toolbox including GM Powertrain to fulfill customer dreams Every so often Adrian Britton of Ramsey s Rods and Restorations in Ft Worth Texas is reminded that the classic vehicle restoration business is about more than powertrains and paint jobs At its deepest level it s really about people their memories dreams and yes fantasies some most personal Restoration work on a jet black 1957 Chevrolet Nomad with an attitude was nearing the stage where it was time to talk about the interior Bucket seats right Britton asked the client in not so many words Well not quite No was the customer s reply Britton says I want bench seats so my lady can sit next to me Britton instinctively knew how important that request was to the customer and making sure customers are happy is always at the top of the list Ramsey s customers are a sele
28. lt s automatic transmission which incorporates revolutionary electric motor based technology was a big point of interest at the GM Powertrain booth The industry won t be seeing these new transmissions for some time but they were a real draw says Chris Thomas product development manager for transmissions GM Customer Care and Aftersales The old three and four speed transmissions are steadily going away and giving way to transmissions that are much more complex and electro mechanical based Just like we ve been there with support for the traditional technology our message is we ll be there with parts and service for factory authorized remanufactured units and component parts for repairs of these new generation products Gi Oct Dec 2010 Servicelnsights But GM Powertrain didn t focus entirely on new technology at ATRA Representatives of Marketing Product Development Product Engineering and Sales also talked up the product technical support pricing and warranty advantages that come with present generation GM remanufactured transmissions and transfer cases and component parts for repairing those units A special emphasis was on GM s overPOWER program which gives GM dealers the ability to sell GM engines and transmissions at prices that are more competitive with aftermarket non QE products As shops move more toward diagnostics and total assembly replacement and away from rebuilding GM Powertrain is orienti
29. ly and more quickly completed Remanufactured cylinder heads and associated parts needed to complete the installation are available for the 2000 2007 Ecotec L61 2 2Lfamily the 2004 2006 L52 3 5L I5 family and the 2002 2009 LL8 4 2L I6 collections 4 Oct Dec 2010 Servicelnsights Remanufactured to meet or exceed OEM specifications for fit durability and reliability the cylinder heads come with matching camshaft retaining caps new intake and exhaust valves new or machined intake and exhaust valve seats standard size valve guides new valve guide oil seals and new valve springs Cylinder head installation kits to complete the repairs are available from your GM Dealer The remanufactured cylinder heads carry GM Parts 12 month 12 000 mile limited warranty Genuine Parts Repair Industry News amp Updates Amidst Volt Excitement GM Trains Eye on Safety Emergency responders targeted with electrical safety extrication guidelines As GM readies its debut of the revolutionary plug in elec tric hybrid Chevrolet Volt this fall the company is focused not only on first adopters but first responders as well The same electric propulsion technology and advanced structural design that places the Volt on the automotive leading edge poses a learning curve challenge to emergency personnel responding to any crash involving the vehicle Because of its complex electrical system capable of generating
30. nd other electrical system malfunctions leading to unnecessary repairs and parts replacement The electrical system relies on a secure corrosion free ground connection in order to function properly so any damaged ground connections must be repaired to provide a good mounting point with a low resistance ground path and prevent future corrosion During diagnosis of an electrical condition lt gt which can have widely varying symptoms test all control module grounds and system ground circuits The control module may have multiple ground circuits Other system components also Welded M6 may have separate grounds stud and nut Inspect the grounds for clean and tight connec tions at the grounding point Also inspect the connections at the components and in splice packs if applicable Ensure that the circuit can carry the current necessary to operate the component If it s determined that the ground connection is at fault a recently released GM bulletin covering electrical ground connection repairs may help Refer to GM bulletin 10 08 45 001 for ground connection repair and installation instructions The bulletin outlines ground repair procedures using one of the following replacement fasteners with a conductive finish e Welded M6 stud and nut e Welded M6 nut and bolt e Welded M8 nut and bolt Before installing a new fastener in the current ground location or at a new mounting location remove any grease from the repair ar
31. nder the filter media and above the continued on page 2 IN THIS ISSUE Engine Protection Depends Many things can cause engine damage but one easy way is dir on the Right Oil Filter 0eeeeeeeees 1 prevent engine damage IS throug Electrical Ground Repairs 3 regular engine oil and filter changes using the right oil and filter specified in Wheel Changing piste eet 3 the latest ACDelco parts information AFIT Adapter for Direct Injection The use of aftermarket oil filters that 7 ae Engines and Duramax Diesels 4 do not meet the manufacturer s per s E r Control Module Programming and Setup formance specifications on vehicles Filter media material may plug the 2 mm Procedures ssn 5 can result in engine damage due to block lubrication passage hole creating a neon Brake Seminars a 6 problems such as oil filter gasket leaks aeration in the exhaust lifter oil galley Tea improperly sealing filter media failed a l l K IDS 2 ne rr anti drainback valves that block oil flow of oil filter quality concerns IS tO use Training Update n r ee 8 and internal filter failure that transfers an ACDelco Original Equipment Service ACDelco Introduces All Makes filter debris throughout the engine OES oil filter ACDelco oil filters are Aftermarket Window Regulator Line 8 designed to meet manufacturers spec some engine damage also may be ificatio
32. ng itself to meet this demand Our general message is hey we re more competitive than ever and we expect to be able to continue to chip away at the aftermarket competition Thomas says GM Two Mode Hybrid Transmission Cutaway Whether it s our 3 year fully transferable 100 000 mile warranty live U S based technical support for installations and repairs 1 866 637 2787 plug and play installation and constant updating of remanufactured products GM Powertrain offers an entire package of products and support services that are unrivaled in our industry Thomas concluded September amp October 2010 ACDelco eee aciConnec Engine Protection Depends on the Right Oil Filter T higher engine oil pressures and increased engine oil flow rates that help to optimize engine performance economy and emissions but also make it critical to have proper oil pressure flow and filtering Insufficient oil flow and a lack of lub rication can result in a ticking noise in the valve train If the noise is in the engine block deck intake or exhaust lifters area engine oil filter media or other foreign material may be obstructing the oil galley lubrication hole Foreign material obstruction also can lead an engine knock condition due to low oil pressure or oil starvation Possible sources for foreign material include silicone rubber from the engine oil filter anti drainback valve assembly located u
33. ns for modern GM powertrains due to an Incorrect or improperly that have higher engine oil pressures ON THE WEB installed oil filter The wrong oil filter increased engine oil flow rates and application may not be able to stand up extended oil change intervals www acdelcotechconnect com click the to the extended oil change intervals of TechConnect Magazine link or modern engines Modern Engines Log in to the ACDelco LMS click the One of the best ways to avoid World class engines like the GM 3 6L Resources link expensive engine damage because VVT direct injected V6 engine use es J oy l Product Offerings Distribution Network e Customer Programs Marketing Training 9 E Business e Relationships Engine Protection ACDelco continued from page 1 WechConnect screw on the filter base Any deteriorated silicone rubber may find its way into the oil lubrication galley in both blocks and crank shaft lubrication holes Volume 17 Number 4 TS PU 0017 10 ACDelco TechConnect is published bi monthly and online for technicians to provide timely service information increase knowledge and Some engines including the improve the performance of the service center GM Ecotec 4 cylinder engine family 2 0L 2 2L and 2 4L use a cartridge oil filter where only the filter element is replaced With a cartridge oil filter the filter cap contains an O ring that does not ACDelco 360 represents our mission
34. nvenient location
35. olt Body Structure 8 Oct Dec 2010 Servicelnsights 2010 Chevrolet Cruze high strength steel in structural components that surround the passenger compartment and the front and rear impact zones The Volt employs steels classified with a different yield strength than the Cruze structure With both vehicles construction the critical implication for body shops is to ensure positive identification of the type of steel being repaired or replaced Extra care should always be taken when repairing and welding advanced high strength steels and that s particularly true when the steel is present in structural components The presence of advanced HSS in impact zones may determine the repair or replacement guidelines utilized Genuine Parts Chevrolet Cruze Accessory Drive l l Belt Replacement Variable Displacement Oil Pump helps Chevrolet Electronic Service Information Technicians and shop owners can log on Cruze conserve fuel to the site to gain access to subscription services for service procedures and repair manuals A complete Service Manual is accessible 24 7 through A standard feature in the new Chevrolet a subscription to the site Free collision repair procedures will soon Cruze s Ecotec 1 4L turbocharged engine is the Even though the 2010 Chevrolet Cruze is a new vehicle extensive service and repair information resources are a click away at www gmtechinfo com be available by going to www genuinegmpart
36. resetting Antilock Brake Systems S BK0O5 03 01SEM Antilock brake systems ABS both integral and non integral and typical components of antilock brake systems are discussed in this seminar ABS sensor inputs such as active and passive wheel speed sensors brake pedal position sensors steering angle sensors and yaw rate lateral accelerometer sensors along with applicable diagnostic procedures are key elements of this seminar ABS subsystems and their operation including bi state engine mount systems dynamic rear proportioning engine drag control variable effort steering and vehicle Stability enhancement systems also are reviewed Foundation Brakes S BKO05 05 01SEM This informa tive seminar begins with the physics of braking and how it applies to replacement component parts along with what D3EA certification means to both the customer and technician installing the parts A modern braking system is comprised of several subsystems such as the power assist apply hydraulic warning lamp balance control and wheel brakes systems and this seminar provides an in depth discussion of each of these subsystems Single and dual diaphragm power boosters are topics that are also discussed along with hydraulic booster systems that use power steering pump pressure to increase hydraulic pressure within the master cylinder DOT 3 4 and 5 hydraulic brake fluid properties and applications are additional elements of this
37. rmation Always inspect the wheel studs and lug nuts for signs of damage from cross threading or abuse Never force wheel nuts down the stud Lug nuts that are damaged may not retain proper ly yet give the impression of fully tightening Always start wheel nuts by hand and be certain that all wheel nut threads have been engaged BEFORE tightening the nut If the vehicle has directional tread tires verity the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation Improper wheel nut tightening can lead to brake pulsation and rotor damage In order to avoid additional brake repairs evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in the appropriate Service Information Always observe the proper wheel nut tightening sequence in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration Thanks to Mike DeSander AFIT Adapter for Direct Injection Engines and Duramax Diesels Two new Active Fuel Injector Tester AFIT adapters have been developed to connect to all current GM Spark Ignited Direct Injection SIDI engines and 2001 2010 Duramax Diesel engines The AFIT adapter called the Drive and Measurement Unit DMU is available for SIDI engines and diesel engines at a discount through the TSS program Visit www gmdesolutions com equipment for more information Adapter se
38. s com and clicking on variable displacement oil pump that reduces GA TECNICO REPE ORRON the displacement during engine warm up and Removal Procedure EEEE high speed conditions As a consequence the Set en engine has to work less versus a conventional Raise and suitably support aT CNR pump and ultimately saves fuel the vehicle Remove the front compartment splash shield Refer to the Front Compartment Splash Shield Replacement in SI Release tension to the drive belt tensioner by rotating counterclockwise 1 and lock with EN 6349 2 4 Remove the drive belt 1 Install Procedure The volume of oil from the pump varies with rpm by changing the pump s displacement through a pivoting control chamber mechanism and sliding vanes A fixed displacement pump would typically bypass the extra oil internally Important Variable Displacement Oil Pump By lowering the volume of oil we reduce crankshaft balancer and A C compressor ensure that the belt the amount of energy or torque required to is installed on the REARMOST grooves leaving the front groove pump the oil without taking necessary exposed shown above lubrication away from the engine said Mike Katerberg assistant chief engineer for the 1 4L Reducing the torque demand reduces fuel consumption It s a simple durable maintenance free design that we have used in our transmissions for years and more recently Install the drive belt 1 When insta
39. se In addition it verifies the low pressure pump Is delivering proper pressure to the high pressure pump The tool also performs a high pressure leak down test to determine if the system can maintain proper pressure and is not leaking When all the injector tests are completed the results are displayed on the AFIT main unit screen in both graphical and continued on page 5 4 TECHCONNECT Control Module Programming and Setup Procedures Every time a control module is programmed or replaced there are different setup procedures to follow to ensure that the control module and related components operate properly All of these setup and initialization procedures as well as critical informa tion to ensure proper programming are covered in the appropriate Service Information for the vehicle being repaired In GM Service Information the Control Module References table includes links to all information related to the programming of a control module including e Control module scan tool information e Schematics AFIT Adapter continued from page 4 The AFIT main unit screen provides test results numeric form along with vehicle specif ic good bad tolerances for the injectors The results can also be uploaded to the AFIT Upload Utility installed on the shop PC The tool can help technicians pinpoint the causal component in the fuel system that requires repair as well as eliminate the fuel system
40. the Transter Case High Low Clutch Reset procedure From the Control Module References table there is a link to the setup procedures and the Transfer Case High Low Clutch Reset procedure which lists the steps to perform the reset procedure using a scan tool or the transfer case shift control switch For some control modules there may be only one opportunity to set up the module correctly Be sure that all cor rect vehicle options are selected during module setup Some options only appear during the initial module setup procedure If the control module is set up Incorrectly it may be necessary to replace the module To ensure proper programming here are just a few of the Items that should be checked before beginning the pro gramming procedure e Always verity a valid reason for reprogramming For GM vehicles available calibrations can be viewed online at tis2web service gm com tis2web A control module should not be reprogrammed simply because there are updated calibrations available 5 TECHCONNECT e Nominal battery voltage should be 12 5 to 13 5 volts This can be checked in most vehicles by connecting a scan tool and viewing the data display for the module Look for the battery voltage or ignition 1 signal to verify good voltage levels e Due to the time requirements of programming a control module connect an approved charger such as the Midtronics PSC 550 or PSC 330 or a fully charged 12V jumper
41. to look at our businesses at every possible angle to provide value and assistance to our distributors and their customers as well as offer a full circle of support with programs tools training and marketing focused on enhancing and growing our partnership successfully require replacement A possible oil Foreign material blocking oil flow to leak may result if an aftermarket the main and rod bearings Publisher oil filter is installed with the new Mike DeSander O ring that comes with the filter In some cases the new O ring is not an OES a design and may develop a flat side leading to a potential oil leak mike desande e Aa Neni The ACDelco OES oil filter cap O ring is designed for Editor the life of the engine and will not develop a flat side Mike Militello because of normal compression during sealing ACDelco A part number PF458G includes a cap and cartridge filter During installation insert the filter in the cap before installing in the engine michael militello gm com Technical Editor Mark Spencer E mail lt mspencer gpworldwide com For more information about how some non OES oil filters can fail and lead to engine damage refer to GM bulletin 10 06 01 003 and ACDelco bulletin 10D 121 f Production Manager If engine damage is suspected and the vehicle is still Marie Meredith covered under the manufacturer s warranty the owner should return to a dealership for further diagnosis Desktop Publishing 5b
42. ts have been put together for service centers that repair mainly gasoline engines or diesel engines Both SIDI adapter and diesel adapter sets are available sepa rately along with SIDI and diesel adapter cable sets A shop that repairs mostly gasoline engines for example could purchase the SIDI adapter first and then purchase the diesel cable later to also have diesel coverage 642 CH 47976 Active Fuel Injector Tester 642 CH 479 76 500 SIDI Diagnostic Adapter Set Diesel Cable Adapter Set used with 642 CH 47976 500 to cover SIDI and diesel engines AFIT SIDI adapter kit 642 CH 47976 505 642 CH 49796 510 Diesel Diagnostic Adapter Set SIDI Cable Adapter Set used with 642 CH 47976 510 to cover diesel and SIDI engines 642 CH 47976 508 All adapters require the use of the AFIT unit The AFIT DMU can be used to diagnose essentially all fuel system related conditions but is especially useful for concerns such as crank no start hard start mistire codes injector wiring codes bank lean rich codes and power loss The AFIT can perform multiple fuel system tests such as an injector coil test fuel pump pressure leak down test and injector balance test without removing the injectors helping to reduce diagnostic time It uses a microprocessor and soft ware program to completely automate testing procedures and eliminates variations in test results due to individual testing methods or changing fuel properties The
43. y installed If a pipe has been removed only once it will only show one sealing band Because of the deformation that takes place on the first tightening the material may not seal properly the sec ond time which is why the fuel pipe must be replaced New fuel pipes are ready to use right out of the package A blue or transpar ent dry lube may be noticed on the ball Dual sealing bands indicate the fuel line has been torqued once and re installed ends of the pipe Do not wipe off this lube It aids in achieving proper torque and sealing at the ball end fitting of the pipe Any time the fuel system Is serviced be sure to properly inspect clean and torque the fuel pipe mating surfaces Also some fuel pipes have specific torque sequences that must be followed to ensure a good seal Remote Keyless Entry Operation 1997 2010 GM passenger cars and trucks To prevent battery drain the Remote Keyless Entry RKE transmitter will lock up if any button or buttons are depressed longer than 30 seconds The transmitter will unlock if another button is depressed When unlocking the vehicle if all doors are not unlocked after the second press of the unlock button it may be due to the time delay needed by the system to recognize the second press of the unlock button In order to unlock all doors press the unlock button once pause 1 2 seconds and press the unlock button the second time There needs to be a pause betwe
44. y5 Design LLC Designed in Qualit E mail lt gt z s r dkelly 5by5dzign com Engine oil must withstand extreme punishment The proper oil filter efficiently filters particles out of the oil to Write to gt lt keep it clean and flowing through the engine ACDelco ACDelco TechConnect oil filters meet or exceed GM specifications using The O ring on an PO Box 500 patented cellulose media that traps particles below ee Troy MIREC O i filter cap will 10 microns one third the width of a human hair not compress On the Web 2 In addition to excellent filter capacity efficiency flow Paar a a E To read and search recent issues of management and durability ACDelco oil filters provide the filter in the cap before TechConnect online installing in the engine www acdelcotechconnect com e Tight seals that prevent unfiltered oil from entering click the TechConnect Magazine the engine link or e Anti drainback valves that retain oil in the filter to helo reduce prime times and nag in to a LMS deii quickly lubricate the engine during start up i i ACDelco service tips are intended for use by e By pass valves that help keep the engine from becoming oil starved during cold professional technicians not a do it yourselfer weather starts They are written to inform those technicians of conditions that may occur on some vehicles or to provide information that could assist in the proper e Filtration media with more paper
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