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2013 Malibu... Much More Than Meets the Eye

1. icelnsi FOR INDEPENDENT SERVICE CENTERS ACDelco oe m Genuine EY Parts 12 ALSO IN THIS ISS gt For routine engine repairs GM OES heads gaskets gt GM responding to increg four and six speed rem gt Look for GM at the ATRA in Las Vegas Event Oct 25 29 gt A primer on GM s No Hassle core return policy The Ecotec 2 4L l 4 DI Direct Injection Engine Powers The eAssist System for Category Leading Fuel Economy CONTENTS GM OE Service 3 Parts Update The latest word on product development and technologies The Technical Fi Side Discover new ways to approach service and repairs Repair Industry News amp Updates Get state of the industry perspectives from GM insiders Genuine ou Parts Business 10 of Repairs New ideas that can benefit how your shop operates and profits GM Servicelnsights Online More Genuine GM Parts resources and links l l l l l l l l l l Download this issue and past issues of GM Servicelnsights magazine at www gmserviceinsights com l I ORs l l l l l l l l l l l l l l l l GM Servicelnsights Headquarters 2604 N E Industrial Dr 230 N Kansas City MO 64117 E mail dealersupport proactgroup com Compliments of your GM dealer We invite your input and suggestions Please address letters to the
2. and improve the performance of the service center ACDelco 360 represents our mission 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 Publisher Rick Balabon ACDelco E mail lt richard balabon gm com Editor Greg St Aubin ACDelco E mail lt gregory staubin gm com Technical Editor Mark Spencer E mail lt mspencer gpworldwide com Production Manager Marie Meredith Desktop Publishing 5byb Design LLC E mail lt gt dkelly 5by5dzign com Write to lt ACDelco TechConnect P O Box 500 Troy MI 48007 0500 On the Web amp To read and search recent issues of TechConnect online www acdelcotechconnect com click the TechConnect Magazine link or Log in to the ACDelco LMS click the Resources link ACDelco service tips are intended for use by professional technicians not a do it yourselfer 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 service of a vehicle Properly trained techni cians have the equipment tools safety instructions and know how to do a job properly and safely If a condition is described it cannot be assumed that the
3. 01 01SIM Features and Benefits Electrical Electronics Stage 1 Hybrid Introduction and Safety Issues with Reprogramming Electrical System Diagnostic Challenge mimi r iA lemm eb IE bmi i oin ha Click the Test Drive link at the top of the page to view various training courses for free Recorded Virtual Classroom Training VCT 1 2 hour courses presented online by an ACDelco S EL06 01 01VCT R S EM01 01 01VCT R instructor Courses are originally presented live and are recorded to be viewed at any time S AC07 01 01VCT R HVAC System Components and Lubricants Recorded Electrical Circuit Function and Diagnosis Recorded Camshaft Position Actuator Systems Recorded The videos available present technical and product related information on a variety of automotive topics and ACDelco products such as serpentine belt diagnostics power steering system bleeding and flushing fuel pump service 4 wheel drive actuator motors brake rotors and drums and remanufactured starters and alternators The videos provide concise information in short snippets and are available to view at any time Thanks to Greg St Aubin 6 TECHCONNECT TechTips The following technical tips provide repair information about specific conditions on a variety of vehicles If you have a tough or unusual service repair the TSS Diagnostic Hotline can help Call 1 800 825 5886 prompt 2 from 8 a m to 8 p m ET Monday F
4. in fuel shut off mode the motor generator unit continues spinning along with the engine to provide immediate and smooth take off power when the driver presses on the accelerator As the vehicle comes to a stop the motor generator unit brings the engine toa controlled stop to position it properly for a smooth restart when the brake is released Ecotec 2 4L l 4 DI Direct Injection Engine found in the 2013 Malibu Eco with eAssist Jul Sep 2012 Servicelnsights Even though the 2013 Chevrolet Malibu is a new vehicle extensive service and repair information resources are a click away at www gmtechinfo com Electronic Service Information Technicians and shop owners can log on 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 subscription to the site Free collision repair procedures are also available by going to www genuinegmparts com Note The 2013 Malibu with the eAssist system utilizes a lithium ion battery pack Any service technician performing work on a vehicle of this type should have acquired the proper skills and training for such work The following are safety requirements to follow when performing any work on the 2013 Malibu with the eAssist system Please reference the Malibu Service Manual for complete information High Voltage Safety for the 2013 Chevrolet Malibu with the eAssist system Danger Always perform th
5. information applies to all vehicles or that all vehicles will have that condition All materials and programs described in this magazine are subject to change Submission of materials implies the right to edit and publish Inclusion in the publication is not necessarily an endorsement of the individual or the company TechConnect is published for ACDelco by Sandy Corporation Troy MI 2012 ACDelco All rights reserved Oxygen Sensor Performance continued from page 1 the sensor element exposed to the exhaust gases forms the negative terminal of the sensor circuit This oxygen sensing cell becomes a galvanic device battery when heated the exhaust gases keep the sensor at about 600 F 315 5 C and it generates an electrical signal as the result of the interaction of outside air the inner sur face of the element the exhaust gases and the outer surface of the element The amount of voltage the O2S gener ates iS proportional to the difference between the amount of oxygen in the outside air and the amount of oxygen in the exhaust gases Using the Data The ECM typically applies a reference voltage also known as bias voltage to the sensor of 450 millivolts some new ECMs use 1 9 volts as its bias voltage The ECM uses this reference voltage with the voltage generated by the O2S A normal oxygen sensor reading varies above and below the bias voltage In a normally operating engine the pre catalyst O
6. injectors and the steel CNG fuel tanks which are located in different locations ona vehicle The high pressure system also is equipped with a manually operated isolation valve that is used for some service procedures Check It Out In addition to the online Compressed Natural Gas CNG Fuel Systems course ACDelco offers a variety of instructor led hands on courses To review all the latest training courses available log in to the ACDelco Learning Management System LMS by clicking the Training tab at www acdelcotechconnect com Thanks to Greg St Aubin Take a Test Drive of ACDelco Training Independent Service Centers ISCs can try out some of the training courses ACDelco offers online by clicking the Test Drive menu button at the top of the ACDelco LMS go to www acdelcotechconnect com and click the Training tab Several courses are available in a variety of delivery types including Web Based Training TechAssist Simulations Virtual Classroom Training and Video On Demand Click View and then Launch Course to access the desired course Available online courses include Web Based Training WBT Online courses that cover fundamental information and are typically less than an hour long B SC31 11 01WBT S ELO6 01 03WBT S ELO6 0702WBT TechAssist Very brief web based technical courses S ELO6 18 01 TAS Modules Simulation Web based interactive technical simulation of a specific topic S ELO6
7. replacement warranty batteries will have new part numbers which began being rolled into inventories in March Batteries purchased under the previous part numbers and warranty will still be warranted on the pro rata basis The warranty is what the battery has on it Here s a quick look at the batteries and their new part numbers e Professional 24 5YR 18 month free replacement warranty part number 24P Professional e Professional 24 6YR 30 month free replacement warranty part number 24PS Professional Silver e Professional 24 7YR 42 month free replacement warranty part number 24PG Professional Gold The previous 60 Series battery Is transitioning to the Advantage brand and will also carry a free replacement warranty in the example above it will be part number 24A and have an 18 month free replacement warranty In addition non automotive batteries have been moved to a simplified and improved free replacement warranty New point of sale materials have been developed to support these changes For more information contact your local ACDelco representative Thanks to Dan Carter Updated Wheel Alignment Specifications Before performing a steering wheel angle front toe set or wheel alignment check adjustment be sure to verify the wheel alignment specifications for the vehicle in order to avoid any complica tions from using the incorrect wheel alignment specs This can occur if the wheel alignmen
8. to these other newer designs says Chris Thomas product development manager for transmissions for GM Customer Care and Aftersales Repairers and rebuilders probably won t be seeing many of these newer products for some time but they play into our theme of talking about the latest developments and technologies GM Powertrain also will be emphasizing the value of OE Connection to rebuilders and technicians O0EConnection is the joint effort by OE suppliers to make purchasing OE products for aftermarket applications much Other Fall Automotive Industry Events easier The broader theme for GM Powertrain will be emphasizing the value of staying October 30 November 2 2012 October 30 November 2 2012 with GM products and away from non OE Automotive Aftermarket Product Special Equipment Market in the aftermarket Thomas says Expo AAPEX Las Vegas NV Assoc SEMA Las Vegas NV This year s ATRA show will once again WWW aapexshow com www semashow com be co located with the Automotive Parts Remanufacturers Association s APRA International Big R Show as AUTOMOTIVE AFTERMARKET PRODUCTS EXPO a Jul Sep 2012 Servicelnsights Oxygen sensors have been used in automobiles for over 30 years but are often taken for granted as part of the engine controls system They have progressed from single wire non heated oxygen sensors to heated oxygen sensors and In some vehicles wide band oxygen sensors Prop
9. wg Parts GM is confident that with advance knowledge of the friendly core return policy more ISCs will opt to purchase GM engines transmissions and transfer cases While the No Hassle core return policy is clearly appealing to ISCs it also feeds GM s larger goal of being a leader in remanufactured powertrain components By working to reclaim as many components as possible GM keeps the reman pipeline full and increases its knowledge of real world operation It s also a very green strategy aimed at recycling and reusing when and where possible Jul Sep 2012 Servicelnsights 11 Genuine il 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 Give us a call for all of your Genuine GM Parts needs all at one convenient location Genuine jou i Parts
10. 013 Malibu New Model Provides Advanced Technologies Ride Performance and Fuel Efficient Powertrains In North America the Malibu comes in LS LT and LTZ trim levels along with the Malibu Eco which uses fuel saving eAssist technology to enable EPA estimated fuel economy of 25 city 37 highway for the best fuel economy of any non hybrid midsize sedan An all new fuel efficient and powerful Ecotec 2 5L four cylinder engine and next generation six speed transmission combination leads Malibu s powertrain lineup It s rated at 197 horsepower 147 kW and 191 Ib ft of torque 259 Nm A new Ecotec 2 0L turbo rated at 259 horsepower 193 kW and 260 Ib ft of torque 353 Nm debuts this fall Advanced Fuel Saving Technology With the Malibu Eco eAssist System Malibu Eco s eAssist system uses power stored in an air cooled lithium ion battery to provide needed electrical boost in various driving scenarios optimizing engine and transmission operation An advanced 115V lithium ion battery and 15 kW motor generator unit help increase fuel economy The eAssist is mated to an Ecotec 2 4L direct injection four cylinder engine and next generation six speed automatic transmission The eAssist system captures up to 15kW of power that would be normally lost during braking and uses it to recharge the lithium ion battery The system also shuts down fuel delivery in certain deceleration conditions further improving fuel economy While
11. 2S output voltage fluctuates rapidly between 100 millivolts and 900 millivolts This rapidly changing volt age reflects the changes in the air fuel ratio The ECM adjusts injector pulse width in response to the changing O2S signals to try to keep the correct air fuel ratio This data also is used by the ECM to determine short term and long term fuel trim Here are a couple of examples Rich The Earth s atmosphere contains about 78 nitrogen and 21 oxygen O2 sensor 920 MILLION ohms or more w COLD sensor Wery LOA res tance lt 2 ohms HOT Sanaa The ECM uses the bias voltage and the 02S voltage to adjust the air fuel ratio The exhaust from a rich air fuel ratio will contain almost no oxygen With a large difference between the amounts of oxygen contacting the two sur faces of the sensor the sensor is able to generate more voltage When the exhaust gas indicates It is rich the voltage output Is high above 450 millivolts and the ECM will try to lean the mixture out Lean The exhaust from a lean air fuel ratio has about 2 oxygen With a smaller difference between the amounts of oxygen contacting the two surfaces of the sensor the sensor generates less voltage When the exhaust gas Is lean the sensor s voltage output Is low below 450 millivolts and the ECM will try to enrich the mixture This is where having a good understanding of engine controls and oxygen sensor operation is par
12. aning you re assured of receiving a quality OES product every time Jul Sep 2012 Servicelnsights EJ GM OE Service Parts Update cont d GM is Ready Demand Increases for Four and Six Speed Reman Transmissions As many popular late model GM vehicles near their powertrain warranty expiration dates demand for transmission repair and replacement is likely to grow Demanding drivers looking to repower their older vehicles rather than buying new will be looking to ISCs for options While popular GM six speed replacements are now commonplace in new vehicles still under warranty six speeds unveiled with the 2007 model year in select vehicles are now Starting to come off warranty That means ISCs will be seeing an entirely new wave of demand build over time for repair or replacement of a more complex transmission In turn they ll face more critical decisions on procedures and replacement products These six speeds that began carrying 5 year 100 000 mile powertrain warranties in 2007 have hada great durability history and failures have been very rare 4 Jul Sep 2012 Servicelnsights but because of high mileage some may start to show the strain of heavy usage says Chris Thomas product development manager for transmissions for GM Customer Care and Aftersales One of the important features on these transmissions is the computerization inside which GM fully supports in our new aftermarket remanufactured r
13. arts to ensure that the high est quality products are delivered to ACDelco customers Recently an analysis of an ACDelco fuel pump and a compet itor s fuel pump for 2002 2003 GM full size trucks and SUVs showed some striking differences that can impact durability and performance ACDelco electric fuel pumps are designed to provide outstanding fuel delivery quick engine starts long lasting durability and proper fit Quality testing and tear downs are part of ACDelco s commitment to continuous improvement When comparing the fuel pumps here are some of the built in quality features that were evident on the ACDelco pump The ACDelco pump has 10 motor contact points while the competitor s pump has 8 contact points More contact points makes the spinning of the fuel pump turbine more efficient and quieter The ACDelco fuel pump also has a shorter fuel reservoir reducing the chance to pinch the fuel lines The motor oil category offers a search by weight or by type conventional mineral synthetic blends or full synthetics In addition to chemical type specification information by application is offered with the ability to link to the desired product from the specification area In addition to the WIP chemical catalog there also is a stand alone chemical catalog on acdelcotechconnect com GM Medium Duty Applications GM medium duty applications will be released in all catalogs in June and will include The fuel s
14. clude the Chevrolet Impala Pontiac Grand Prix Buick LeSabre and a range of General Motors built minivans Jul Sep 2012 Servicelnsights 5 ACDelco TECHconnect Repair Industry News amp Updates 4L80E The 2012 model year was the last hurrah for this workhorse transmission used in heavy duty trucks motor homes buses and delivery vehicles Updates have improved the transmission s durability over the years resulting ina new and improved roller clutch five pinion output and reaction gear sets for heavy duty applications and new torque converters that optimize the 6 6L Duramax engine application Upcoming Automotive Industry Events GM Powertrain s ATRA 2012 Booth Will Emphasize Advancements Attendees of the 2012 Automatic Transmission Rebuilder Association Powertrain Expo show in Las Vegas in October www atra com will once again get an inside look at GM Powertrain products At the Oct 25 29 ATRA show at the Bally s Hotel cutaways of the 6L80 4L80 6170 and the Chevrolet a Volt drive unit will be on display at the GM Powertrain booth Powertrain GM Powertrain selected the products for the cutaways based on their ability to support discussion of ex D how the company s transmission technologies have advanced and evolved and how the company keeps its remanufactured offerings fully updated The standard 4L80 will serve as an example of some of our older technology and will stand as a good comparison
15. dition using the appro priate Service Information diagnostics for DTC P20EE NOx Catalyst Efficiency Below Threshold and P2BAD Exhaust NOx Concentration High Unknown Reason After making repairs use the DTC P20EE P2BAD repair verification to evaluate and clear the Exhaust Fluid Quality Poor message inoperative Cruise Control 2007 2012 Chevrolet Avalanche Silverado Suburban Tahoe 2007 2012 GMC Sierra Yukon Yukon Denali Yukon XL Yukon Denali XL equipped with a Trailer Brake Controller RPO JL1 The cruise control may be inoperative and the Trailer Brake Control Module may set Diagnostic Trouble Code DTC B3894 Stop Lamp Switch Circuit Plausibility Failure 7 TECHCONNECT If normal diagnostics do not lead to a correction check the Master Cylinder Pressure Sensor parameter listed in the Trailer Brake Control Module data list It it is displaying pressure with no brake pedal input there may be a concern with the master cylinder pressure sen sor wiring terminals or Electronic Brake Control Module EBCM On models with Stabilitrak RPO JL4 the master cylinder pressure sensor Is internal to the Brake Pressure Modulator Valve BPMV EBCM Power Steering Fluid Contamination 2004 2005 Chrysler Pacifica Sebring PT Cruiser Voyager Town amp Country 2004 2005 Dodge Ram Durango Neon SRT4 Stratus Caravan Viper 2004 2005 Jeep Liberty Wrangler 2005 Chrysler 300 2005 Dodge Magnum Severe damage
16. e amp Aftersales product development manager for transmissions We won t make them go through that menu list and we think that s a big point of differentiation that should work in our favor and more importantly that of the customer Out of a hundred units we may get one or two that fall out and can t be reclaimed Thomas says We think our policy is a selling point for the customer who may look at the core return issue as a make or break one in deciding what to buy Genuine EU Parts Engine Transmission Transfer Case No Hassle Core Return Is return like for like Not eligible for return YES y NO YES y NO Is Engine Transmission or Transfer Case complete 50 deduction Is unit in its original shipping container EE ee 100 deduction YES y Is unit drained of fluids 100 deduction o 1 Engines returned without the engine block and main caps cylinder heads and cam carrier caps crankshaft 100 Yo engine rods and rod caps and camshaft s are considered incomplete Core Credit 2 Transmissions returned without the torque converter valve body and output shaft are considered incomplete 3 Transfer Cases returned without the encoder motor and case housing are considered incomplete GenuineGMParts com Genuine amp Parts The table above outlines the applicable deductions and discounts Genuine
17. e High Voltage Disabling procedure prior to servicing any High Voltage component or connection Personal Protection Equipment PPE and proper procedures must be followed The High Voltage Disabling procedure includes the following steps e Identify how to disable high voltage e Identify how to test for the presence of high voltage ee aa 7A Jul Sep 2012Senvicelnsights h 3 N i s e Identify condition under which high voltage is always present and personal protection equipment PPE and proper procedures must be followed Before working on any high voltage system be sure to wear the following Personal Protection Equipment e Safety glasses with appropriate side shields when within 15 meters 50 feet of the vehicle either indoors or outdoors e Certified and up to date Class 0 Insulation gloves rated at 1000V with leather protectors e Visually and functionally inspect the gloves before use e Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly whether the system is energized or not Failure to follow the procedures may result in serious injury or death Danger High voltage circuits should only be tested using a digital multimeter DMM and test leads with at least a CAT Il rating such as the J 39200 A Digital Multimeter Failure to follow the procedures may result in serious injury or death Danger This vehicle is equipped
18. 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 or General Motors Parts General Motors Detroit MI 48202 2012 General Motors All rights reserved A Jul Sep 2012 Servicelnsights Genuine il Parts GM OE Service Parts Update For Routine Engine Repairs Play it Safe with GM OES Heads Gaskets Manifolds Even for the smallest and most basic components look to Genuine GM Parts for any GM vehicle engine repairs To take just two examples cylinder heads and intake manifolds and gaskets that bear the GM stamp of approval cut the time needed for repairs and ensure the right fit form and function Plus they carry GM s 1 year 12 000 mile warranty The list of available remanufactured cylinder head assemblies spans many high volume eng
19. ender of the ACDelco pump has internal springs in the reservoir which eliminates the potential for pinching wires or rubbing through the fuel line The competitive fuel pump has external springs on the guide rods In addition the ACDelco fuel sender has thicker more robust fuel level sensor wiper contacts and wear pads for enhanced durability aN The ACDelco fuel pump also features a jet pump to pre vent fuel pump starvation when the fuel level is low The competitor s pump doesn t have a jet pump Finally ACDelco uses 100 new parts and the quality testing of those parts is evident when tearing down these fuel pumps The wear marks on the armature of the motor for example indicates the end of the line quality testing all ACDelco fuel pumps go through to ensure full functionality 4 Competitor and proper performance The competitive pump is clean with no marks showing it has not completed the same extent of full functionality testing as the ACDelco part Thanks to Dan Carter e 40 Chevrolet and GMC medium duty models e Over 1 800 part numbers e Over 280 000 applications e Virtually all ACDelco product lines For more information about WIP and the ACDelco specialty catalogs go to acdelcotechconnect com and click the eBusiness tab Thanks to Kelli Abbott 5 TECHCONNECT Compressed Natural Gas Fuel Systems Training Compressed Natural Gas CNG Is an alternative fuel that delivers cleaner emi
20. ent temperature and then the control module can predict sensor element temperature based on heater resistance Measuring Oxygen The switching O2S has a center element made of ceramic material zirconia and two platinum electrodes that make up the inner and outer surfaces of the center element The inner surface of the sensor exposed to outside air through its wire out to the harness connector forms the positive terminal of the O2S circuit The platinum coating on the outer surface of continued on page 3 ECMA LHE Oxygen Sensor Performance IN THIS ISSUE Oxygen Sensor Performance ACDelco Battery Warranty Changes 2 Updated Wheel Alignment Specifications Proper Air Shock Installation to Avoid Clunk Noise Concern Competitive Parts Analysis Helps Ensure ACDelco Quality Compressed Natural Gas Fuel Systems Training Take a Test Drive of ACDelco Training Tech Tips S Training Update ACDelco Battery Warranty Changes ACDelco is transitioning away from a pro rated battery replacement warranty to a new simpler free replacement strategy for ACDelco batteries to help reduce customer confusion and dissatisfaction Here s how it works On a 30 month free replacement battery for example if the battery is up to 30 months old it s replaced for free If it s 31 months old a new battery is sold to the customer It s that simple The new tree
21. eplacements The relative complexity of this generation of six speed transmissions underscores the value of selecting GM remanufactured transmissions for replacements over aftermarket substitutes These and all other GM remanufactured transmissions come completely updated fully matched to the application readily installable with plug and play features eligible for GM s generous no hassle core return policy and backed by GM s 3 year 100 000 mile warranty The importance of the exact match shows up in areas like a mismatched torque converter Thomas says A truck with an aftermarket transmission with one that s not matched for example will experience rollback on a hill With the proper application it will hold Two GM six speeds will be particularly impacted by warranty expiration beginning in 2012 opening the market for GM remanufactured replacements bearing the same names Hydra Matic 6L80 and 6L90 The 6L80 was the first generation of GM electronically yrs controlled rear wheel drive six oe speeds installed beginning with the 2007 model year in trucks like the GMC Yukon Chevrolet Tahoe and Cadillac Escalade and the Cadillac XLR V STS V and Chevrolet Corvette It also has begun replacing many 4L60 applications in trucks like the Chevrolet Silverado and GMC Sierra and is used in newer generation Chevrolet Camaros The 6L90 a replacement beginning in 2007 for the 4L80 in some applications is used
22. er oxygen sensor operation is critical for vehicle emissions fuel economy and engine performance However technicians may misdiagnose the performance of an oxygen sensor if they are not familiar with how one works or are just reading a Diagnostic Trouble Code DTC from a scan tool without properly diagnosing the engine control system Here s a closer look at what an oxygen sensor does and how it works The switching Oxygen Sensor 02S is unique among the engine control system sensors because when hot it acts like a battery and is able to generate its own low voltage signal that is sent to the Engine Control Module ECM to monitor the amount of oxygen in the exhaust The O2S provides feedback to the ECM which uses the information to manage fuel delivery and maintain the stoichiometric air fuel ratio of 14 7 1 for gasoline engines ACVelco H The electrically heated oxygen sensor HO2S is used to reduce the amount of time it takes for the sensing element to become hot and active allowing the fuel control system to go into closed loop more quickly which helps reduce emissions On some vehicles it is also used to help keep the engine control system in closed loop when the engine is at idle and may have a low exhaust flow rate On newer vehicles the ECM determines the heater temperature by measuring the current flow through the heater and calculating the heater resistance which correlates to sens ing the elem
23. erlooked though is GM s unusual commitment to fair play when a major component reaches the end of the line Most notably unlike many competitors GM Customer Care amp Aftersales takes back damaged cores without levying a penalty Other deductions related to intactness may ultimately come into play but major damage such asa broken transfer case or a hole in the engine block isn t a deal breaker for GM Some of our competitors will charge an Independent Service Center ISC a significant core deduction if the core is damaged i e the housing is cracked says Denise Harris manager Reman Core Management amp Advanced Technologies With the No Hassle Policy ISCs can have more confidence they ll receive full core credit if they buy from a GM after dealer Basically all we ask in order for the customer to receive 100 core credit is that a like for like core drained of all fluids is returned as a complete assembly in the original undamaged container 10 Jul Sep 2012 Servicelnsights That clear no nonsense policy often stands in stark contrast to that of other powertrain suppliers As a general rule core damage will trigger a deduction and other fine print can expose those returning cores to a cascade of penalties that end up reducing the credit This can be a big benefit when compared to other manufacturers who often present a long list of qualifications says Chris Thomas Customer Car
24. es sor will only cycle at each ignition cycle or until suffi cient weight is added to the vehicle to lower it against the level position sensor he i ia ae A Good pap will add air B Contaminated dryer the shocks to raise the The Automatic Level Control ALC system available on vehicle up to 1995 1999 Buick Riviera 1997 2005 Buick Park Avenue and a level ride Park Avenue Ultra 2000 2005 Buick LeSabre 1998 2001 height Cadillac Seville SLS 1999 2004 Cadillac Seville 2000 2005 2 Always Cadillac DeVille 1995 2003 confirm the Oldsmobile Aurora and 2000 aM shock 2005 Pontiac Bonneville automat ape a Cans have both ically adjusts the rear height of the vehicle in response to changes in vehicle loading moved to the correct oper ating position a d val 3 If the shock Cana Gahis a The ALC system consists of the Rear Integration Control Module RIM height sensor an Upper alr can air compressor assembly an ALC nol in the compressor relay an intake hose up position and filter an air tube two rear put weight in shock absorbers and an accesso the rear seat ry inflator switch The air com two adults pressor assembly consists of an or 250 400 Ibs in the air Compressor and an air dryer Incorrect operating mounted on a bracket The air position compressor head is a replaceable trunk to cycle the compres part of the air compressor The ae with exhaust solenoid is a non replace h
25. igher able part of the air compressor pressure The head higher pressure will To help reduce a possible clunk seat the J 22124 B Pressure Gauge shock Upper 0 300 psi includes Adapter air can in the J 22124 91 and Adapter Tube correct position noise after installing new rear shock absorbers part number 504 143 19257784 on the sys tem follow these service tips 4 If the shock upper air cans do not move to their raised positions the system may have a mechanical or electrical failure such as a leaking or pinched line defective desic cant dryer or inoperative compressor 1 After shock installation turn the ignition on and listen for the compressor to cycle on one time The air compressor should cycle on after the ignition is turned on and cycle off again within the test time approximately 30 to 45 seconds to turn on and then run for approximately 5 to 10 seconds to pressurize the ALC system with the residual air pressure 7 to 14 psi Follow the appropriate Service Information to diagnose the condition Special tool J 22124 B Pressure Gauge may be needed The desiccant dryer part number 22153443 contains a valve that maintains pressure at 7 14 psi when the vehicle is in a no load condition Check the valve for proper operation Thanks to Jim Carbary and Rick Balabon Correct operating position 4 TECHCONNECT ACDelco routinely performs testing and analysis of products with competitive p
26. in high performance cars like the Cadillac CTS V and full size 2500 and 3500 series trucks like the Chevrolet Express Silverado and Suburban series and GMC Sierra Savana and Yukon Meanwhile demand for many popular GM remanufactured electronically controlled four speed transmissions continues unabated as people hang on to their vehicles longer Four speeds are 70 percent of what GM sells to the transmission aftermarket one GM plans to continue servicing 4L60E GM s workhorse transmission installed in more than 20 million vehicles since 1993 has many high volume applications spanning Corvettes Camaros and Pontiac Firebirds light duty trucks like the Silverado Sierra and Sonoma SUVs like the Tahoe and Yukon and the Hummer H2 and H3 Many updates have been incorporated into remanufactured versions including an 4L60E and the H3 Hummer improved reaction sunshell updated valve lt 4 ATESE andaa RAT body bores and sleeves and internal input i ar i ie speed sensors that allow better communication ff Vs i 5 i with the vehicle computer which aftermarket S 2 ES 2 sf non OE versions can t adequately match oe gt DS 4T65E Used in GM mid size cars built between 1997 and 2012 the remanufactured version has emerged as a popular fix for repowering older vehicles Continuously updated to the latest design specifications the 4T65E can be easily mated with the factory engine High volume applications in
27. ine and late model vehicle applications Whether it s 2 2L Ecotec 3 5L and 3 7L Inline 5 cylinder 4 2L Inline 6 cylinder 3 6L High Feature 6 cylinder or the 3 4L V6 GM has the cylinder head and matching head gasket kit to do the job right By choosing the GM Powertrain component solution technicians are assured of getting design enhanced head assemblies and related parts Each assembly s design and build reflects the latest upgrades updates and technical service bulletins With more than a dozen part numbers spanning specific vehicle applications in the five engine categories GM offers a tailored reman cylinder head that meets and or exceeds OEM specifications for fit durability and reliability Head machining with 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 go into each reman head This product offers a convenient and economical alternative for service repairs requiring cylinder head replacement or valve reconditioning saving your shop valuable time as well as customer vehicle downtime Intake manifolds and gaskets are available for most GM vehicles With GM Powertrain components technicians can complete high labor jobs efficiently and potentially avoid re works Available in both thermoplastic and cast metal the manifolds along with gaskets are validated by GM Engineering me
28. le functionality the sensor tip open ings may have different configurations or the length of the sensor body may cause interference issues ACDelco has learned of one aftermarket supplier that has consolidated several GM ACDelco O2S part numbers and applications into a single aftermarket part number ACDelco 02 sensor tips monitor oxygen content while shielding the sensor from thermal shock GM engineers spend a lot of time designing the OEM sensors to work properly in both fit and function In OEM and ACDelco sensors the open ings in the tip are specifically designed to monitor the oxygen content and the tips are designed to shield the sensor from thermal shock which is caused by condensation in the exhaust system hitting a hot sensor Plus the wire lead lengths are designed to fit not be too short and possibly pull wires out of the connector or too long and rub against a chassis component or melt against the exhaust system and the O2 electrical heater resistance tolerances are set to properly maintain the correct tempera ture of the internal sensing element all ensuring proper operation and perfor mance Finally be sure to follow the appropri ate Service Information when replacing an O2 sensor or making repairs to the wire lead as there are specific repair instructions and torque specifications for this procedure Thanks to Rick Balabon Proper Air Shock Installation to Avoid Clunk Noise Concern The compr
29. logy and Service Body Electrical Global Diagnostics Advanced Body Control System Electrical Diagnostics Engine Performance Computer Controls and Ignition System Diagnostics Engine Performance Air Induction and Fuel System Diagnostics Engine Performance Fault Monitoring and Emission System Diagnostics Engine Performance Advanced Drivability Diagnostics Duramax 6600 Diesel Engine Performance Duramax Diesel Operation and Diagnosis Vibration Correction Diagnostics Supplemental Restraint Systems 8 TECHCONNECT Course Number S ACO7 01 01VCT S AC07 02 01VCT S AC07 03 01VCT S AC07 04 01VCT o EL06 01 01VCT S EL06 02 01VCT S EL06 03 01VCT S EL06 04 01VCT S EM01 01 01VCT S EM01 02 01VCT S EP08 01 01VCT S EP08 02 01VCT S EP08 03 01VCT Course Name HVAC System Components and Lubricants HVAC System Operation and Service Hints HVAC System Flushing Recovery and Diagnostics HVAC System Engine Cooling Controls and Communication Electrical Circuit Function and Diagnosis Testing Electrical Signal and Control Circuits Serial Data Communication Networks Communication Network Diagnosis Camshaft Position Actuator systems Active Fuel Management Operation 6 6L Duramax Engine Diagnosis 6 6L Duramax LMM Diesel Engine 6 6L Duramax LGH and LML Diesel Engines Thanks to Greg St Aubin oN nal n Ber f iy an i q 4 e l i q 5 a _ war Gay zg Genuine faim 2
30. lt system and high voltage battery assembly S EL06 48 01TAS eAssist Safety GM eAssist safety practices such as high voltage service precautions personal safety warning labels and the disabling procedure are high lighted in this course S FN00 20 02WBT Multiple Diagnostic Interface MDI Familiarization This course covers the operation of the MDI required for diagnosis and programming of some GM vehicles MDI Setup Software on vehicle oper ation and the Service Programming system procedure are reviewed Training Schedule To search for currently sched uled courses In your area view the Training in Your Area section on the Home page Select search terms from the dropdown menus and click the Submit button Virtual Classroom Training Courses VCT courses currently being scheduled include Course Number S AC07 02 01ILT S AC07 03 01ILT S BKO5 01 01ILT S BK05 02 01ILT S EL06 04 02ILT S ELO6 10 02ILT S ELO6 11 02ILT S ELO6 12 01ILT 9 EL06 13 01ILT S EL06 14 01ILT S EP08 02 01ILT o EP08 03 01ILT S EP08 04 01ILT o EP08 05 01ILT S EP08 81 01ILT o EP08 81 02ILT S 04 01 01ILT 9 01 10 01 01ILT TS PU 0007 12 Course Name Automotive Air Conditioning Advanced Refrigerant System Diagnostics HVAC Control System Operation and Diagnostics Braking Systems ABS Operation and Diagnosis Network Communication Diagnosis Electrical Power Management Enhanced Automotive Circuit Diagnosis Hybrid Techno
31. nd select a specific course e To launch a Web Based Training WBT course WBTs are 1 4 hour self guided online courses click Take Training gt Web Based Training to view the catalog and select a specific course e To launch a TechAssist TAS course TAS courses are 15 20 minute online presentations on a specific topic click Take Training gt TechAssist to view the catalog and select a specific course Instructor Led Training Courses The following ILT courses are currently being scheduled e To launch a Simulation SIM SIMs require users to complete all repairs for a condition click Take Training gt Simulations to view the catalog and select a diagnostic challenge simulation Training Spotlight S EP08 23 01WBT Compressed Natural Gas CNG Fuel Systems This course covers the laws and regulations component function and operation diagnosis service and inspection and maintenance proce dures for CNG fuel systems S EL06 28 01WBT eAssist Battery Storage Systems The GM eAssist battery storage system including the components and function of the generator battery assembly generator control mod ule and battery cooling system are presented in this course S EL06 27 01WBT eAssist Introduction The GM eAssist system and its impact on the drive cycle are covered in this course Components of the system that are reviewed include the starter generator liquid cooling system accessory drive be
32. ng closed tightly to prevent any air loss 3 Press glove to increase pressure 4 Inspect for any of the following conditions e pin holes e air leaks e wear tears or abrasions e damp or wet material e certified up to date If any of the above conditions exist do not use the gloves This example of High Voltage Safety for the 2013 Chevrolet Malibu with the eAssist system is just one of many found in the Service Repair Manual By following the proper repair procedures technicians can ensure that each vehicle maintains its solid performance and uncompromised Safety features for the life of the vehicle WE VE GOT ALL THE PARTS YOU NEED TO DO IT RIGHT THE FIRST TIME A A A eT If you re doing a powertrain repair procedure Ws remember that we ve got all the parts you need cylinder heads actuator motors electrical pulleys a and tensioners gaskets whatever you need to keep your customers happy and coming back Jul Sep 2012 Servicelnsights E Business of Repairs More For Your Core GM s No Hassle Core Return Policy Clarifies and Simplifies the Process With its now five year old No Hassle core return policy on GM engines transmissions and transfer cases GM Customer Care and Aftersales offers unbeatable terms and the simplest process of returning the core GM stakes its reputation on designing building and Supporting powertrain products during their entire product lifecycle Often ov
33. ostic Trouble Codes DTC An Exhaust Fluid Quality Poor message does not always mean the fluid is contaminated or needs to be changed The J 26568 Coolant and Battery Fluid Tester can be used to test the fluid before deciding to discard It 1 Collect a DEF sample of about 150 ml 50z from the DEF tank in a clear container The DEF sample should be clear with no obvious coloration when held up to a light As clean DEF is clear contamina tion by any common automotive fluids will cause the DEF to exhibit a trace of color associated with a specific contaminate e Windshield washer solvent orange purple or blue e Engine coolant orange or green e Engine oil brown e Transmission fluid red or brown e Diesel fuel clear yellow green red or brown 2 Observe the DEF sample It should have an ammonia smell Clear fluid without the presence of an ammo nia odor may indicate water or DEF diluted with water 3 Measure the refractive index of the DEF sample using the J 26568 Tester The refractive index of pure DEF should be between 1 310 1 3843 at 20 C 68 F If not within the specified range drain the remaining DEF and refill the tank with fresh DEF 4 If the DEF tests normal perform the DEF Quality test with a scan tool The DEF Quality test should pass If the test fails replace the DEF If an Exhaust Fluid Quality Poor mes sage is displayed without any set DTCs diagnose the con
34. riday to speak with a technical expert with the latest OEM information Cooling System Performance 2009 Dodge Journey 2007 2009 Chrysler Sebring 2007 2009 Dodge Avenger 2008 Jeep Wrangler 2008 2010 Jeep Cherokee 2009 Dodge Challenger 2007 2010 Chrysler 300 2007 2010 Dodge Charger Magnum 2008 2009 Chrysler Town amp Country 2007 2009 Jeep Grand Cherokee Commander Diagnostic Trouble Code DTC P2181 Cooling System Performance may be set Use a scan tool to determine that all engine systems are functioning as designed Repair any other DTCs as necessary To address DTC P2181 reprogram the Powertrain Control Module PCM with the latest software After PCM programming clear any DTCs that may have set in other modules due to reprogramming On 62I E equipped vehicles clear the Variable Line Pressure Counters and perform the Quick Learn function for the PCM Refer to Bulletin 18 032 11 for more details Duramax Diesel Exhaust Fluid Quality Poor Message 2012 Chevrolet Express and Silverado 2012 GMC Savana and Sierra equipped with the 6 6L Duramax diesel engine RPOs LGH LML An Exhaust Fluid Quality Poor mes sage may be displayed on the Driver Information Center notifying the driver that the Engine Control Module ECM has detected a drop in the NOx reduction efficiency of the Selective Catalyst Reduction SCR system The Exhaust Fluid Quality Poor message may be displayed without any set Diagn
35. ssions than gasoline The combus tion of natural gas reduces carbon monoxide emissions by 90 With stricter environmental regulations to reduce vehicle emissions and improve air quality being put in place manufac turers are developing many different kinds of alternative fuel vehicles CNG is one of those fuels The operating characteristics servicing and maintenance of CNG fuel systems are covered in the latest ACDelco Web Based Training WBT course Compressed Natural Gas Fuel Systems S EP08 23 01WBT The course presents the latest information about new CNG fuel systems now available on the Chevrolet Express and GMC Savana full size vans It covers e Laws regulations characteristics and safety procedures for CNG fuel sytems e CNG system components and operation e CNG vehicles engines and diagnostic procedures e CNG inspection and maintenance procedures Fuel Characteristics A full CNG fuel tank holds the fuel at approximately 3 000 3 600 pound force per square inch gauge 207 248 bar The course reviews the safety proce dures that must be followed to safely handle the fuel including detecting a fuel leak breathing natural gas and fuel shut off procedures The components of a CNG system also are highlighted In the course These include a high pressure regulator from where fuel flows at a reduced pressure of approximately 90 110 pound force per square inch gauge 6 9 bar to the fuel injector rails and
36. t could fall and cause a short circuit e After removing any high voltage wires protect and insulate the terminal ends immediately with UL Listed or equivalent insulation tape rated ata minimum of 600V e Always tighten the high voltage terminal fasteners to the specified torque Insufficient or excessive torque will cause malfunctions or damage e After finishing work on the high voltage systems and before closing the manual service disconnect lever inspect for the following Verify high voltage system integrity and that all connectors are installed Verify that all tools or loose components have been removed Genuine Parts Labels for Components Wire Harness and Connectors The wire harnesses and cables for high voltage circuits are encased in an orange colored covering In addition the high voltage energy storage device battery is affixed with a RED DANGER label and other high voltage components e g starter generator are affixed with ORANGE WARNING labels High Voltage Insulation Glove Inspection Procedure TE gt The following procedure visually and functionally inspects the insulation gloves to be used while sy performing service on high voltage systems This inspection procedure should be performed prior to any procedure that requires the use of class 0 insulation gloves rated at 1000V 1 Remove glove from leather protector 2 Inflate glove and seal opening Pinch the openi
37. t rack specifications are not updated regularly In addition the vast variation in specifications depending on the type of vehicle and tire suspension and engine options make it easier to use the wrong wheel alignment specs The only recommended source of current accurate wheel alignment specifications both targets and toler ances is the Service Information for the particular vehicle make model The specifications indicated on the wheel alignment rack should always be verified with the appropriate Service Information In the first quarter of 2012 the following GM models had updated changed wheel alignment specifications e 2007 2012 Acadia e 2007 2012 Enclave e 2009 2012 Traverse e 2010 2012 Corvette e 2010 2012 LaCrosse e 2011 2012 Regal Check the alignment specifications for these models in the appropriate Service Information against the alignment machine specifications before perform ing an alignment Be sure to take into account all related option content on the vehicle including optional tire and Suspension packages These updated specifications most likely will not be included in the latest specifications from alignment machine manufacturers Thanks to David MacGillis 2 TECHCONNECT ACVDelco Volume 19 Number 3 TS PU 0007 12 ACDelco TechConnect is published bi monthly and online for Independent Service Centers and Key Fleet accounts to provide timely service information increase knowledge
38. ticularly important For example when a mis fire occurs incomplete combustion leaves an abundance of oxygen in the exhaust which passes the O2S and is interpreted by the ECM as a lean lots of oxygen vs fuel condition The ECM responds by increasing the fuel deliv ery This condition is very hazardous to the catalytic converter Catalyst Efficiency In addition to fuel control the ECM uses 02S information to perform diagnostics and monitor catalyst efficiency A post cat O2S will not vary the voltage reading as quickly as a pre cat O2 sensor if the catalytic convertor Is operating properly A leak in the exhaust system can lead to misdiagnosis of the pre or post cat O2 sensor if proper diag nosis is not followed Anything that will allow extra oxygen into the exhaust stream can change the amount of oxygen the O2S mea sures and may set a DTC Just because an O2S DTC is set does not mean it is caused by a bad sensor it may just be that the sensor is seeing Information outside of the expected range This would be similar to blaming the engine coolant gauge 3 TECHCONNECT because it indicates a hot engine The coolant gauge is only an indicator of the condition The engine is overheating not the gauge OEM Sensors If proper diagnosis leads to replacing a malfunctioning oxygen sensor what are you going to replace it with There are instances of aftermarket oxygen sensors that may fit but have question ab
39. to the steering system may result from the use of any fluids or supplements that contain Teflon which will cause a restriction at the filter in the power steering fluid reservoir Use only approved fluids in the power steering system The addition of any unapproved fluids or supplements can interfere with the proper function of the fluid Refer to Bulletin 19 010 04 for additional information Product Information For free technical 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 Pumps Rack and Pinion Gears 1 866 833 5567 Wiper Blades 1 800 810 7096 Training Update How to Take ACDelco Training Go to www acdelcotechconnect com and click the Training tab to log in to the ACDelco Learning Management System LMS e To enroll in an Instructor Led Training ILT course ILTs are full day hands on classroom courses click Take Training gt Instructor Led Training to view the catalog and select a specific course e To enroll in a Virtual Classroom Training VCT course VCTs are 1 2 hour live online courses click Take Training gt Virtual Classroon Training to view the catalog a
40. with a high voltage battery that is completely isolated from the chassis ground Never utilize AC powered test equipment to probe the high voltage system Serious injury death and component damage could occur if the high voltage system is grounded through the electric utility Failure to follow the procedure exactly as written may result in serious injury or death Special Tools EL 48900 HEV Safety Kit Precautions when Performing Service or Inspections e Always verify that the high voltage has been disabled before working on or around high voltage components wires cables or harnesses e Remove all metal objects such as rings and watches e The EL 48900 HEV safety kit contains safety cones Place the safety cones around the vehicle to alert other technicians that you are working on the high voltage system e Remove all vehicle keys and secure in a location outside the vehicle If the vehicle is equipped with push button start the keys must remain at least 3 meters 15 feet from the vehicle e Ensure that the manual service disconnect lever is secured in the open position with a zip tie e Always wear certified and tested high voltage insulation gloves when inspecting or testing any high voltage wires and components e Use the One Hand rule Work with only one hand whenever possible Keep the other hand behind your back e DO NOT carry any metal objects such asa mechanical pencil or a measuring tape tha

2013 Malibu... Much More Than Meets the Eye

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