January–March 2010 - GM Service Insights
Contents
1. on ervice nsigi NDEN T SERVICE CENTERS ACDelco Genuine Ey Parts danuary March 2010 PAGES ALSOINTHI The E ROD from GM Siu Performance Parts m Jay Leno Gamaro squeezes 425 hp out A Revolution in Hot Rodding she 3 LES silverada s Duramax finds new home Tm Tl as An TTT s a Bar F alan yar Y gt CONTENTS GM Parts Product Update The latest word on product development and technologies The Technical Side Discover new ways to approach service and repairs Business of Repairs New ideas that can benefit how your shop operates and profits Repair Industry News amp Updates Get state of the industry perspectives from GM insiders Genuine Eg Parts GM Servicelnsights Online More Genuine GM Parts resources and links Download this issue of GM Servicelnsights and past issues of Movin Parts magazine www gmserviceinsights com GM Servicelnsights Headquarters 2604 N E Industrial Dr 230 N Kansas 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 in2. For additional information on Hybrid Training and other technical training clinics contact your GM Dealer or log on to www gmtechinfo com nature of the safety risks and methods of safely disabling systems Trainer Rick Carroll says one major goal is to dial back some of the confusion and myths that have taken hold want to dispel a lot of the misinformation that techs are getting about safely working on hybrids There are all kinds of rumors and misinformation out there so techs want to know how to work on these vehicles without getting hurt Hybrids do have their quirks however and techs need to understand that the complex technology can produce some surprises Says another trainer Bill Wheaton We discuss some of the unusual occurrences like a car pulled from a lake that started up as it was being towed and an incident in which a collision repairer was tasked to take dents out of a battery box that s a no no There s all C t SEMA Jay Leno Smee But one that stood out from the rest was a race ready twin turbocharged V 6 Camaro concept car built for talk show host and auto enthusiast Jay Leno on display at the GM exhibit Powered by a twin _ turbocharged version of the a 3 6L direct injected V 6 thatis standard in 2010 GM 3 6L V 6 VVT DI LLT for the Camaro LS andr 8 Jan Mar 2010 Servicelnsights Genuine Parts Camaro LS and LT models Leno s Camaro bl
3. e Reinstall the calipers and pads Use a thin film of ACDelco high temperature silicone grease part number 10 4019 on caliper sides rubber components and disc pad shims which will allow the shims to withstand normal brake pad movement without damage and helo dampen vibration e Pump the brakes to pressurize the calipers e Remove the lug nuts conical washers if installed for refinishing the rotors on the vehicle Torque the wheels to specification using a calibrated torque wrench or torque stick e Install and properly torque the wheels It is critical to use the proper tools torque stick or torque wrench to torque the wheels to specification as referenced in the Service Information Thanks to Mike Militello and Mike DeSander Brake Rotor Coating A gray coating may be found on replacement ACDelco brake rotors The rotors are coated with a zinc organic protective spray to prevent the rotors from rusting before they go into service The coating should not be removed and will wear off with normal brake usage The coating does not hinder brake performance 2 TECHCONNECT ACVDelco Volume 17 Number 1 TS PU 0013 10 ACDelco TechConnect is published bi monthly and online for technicians of Total Service Support TSS and Key Fleet accounts to provide timely service information increase knowledge and improve the performance of the service center Publisher Mike DeSander ACDelco E mail lt mike desan
4. from the intake manifold 3 Removal Procedure Remove the intake manifold cover Refer to Intake Manifold Cover Replacement Rear Installation Procedure Install the PCV dirty air tube 1 to the intake Remove the two intake manifold 3 manifold insulator l l retaining pins 1 Install the PCV dirty air tube 1 to the right Remove the intake camshaft cover 2 manifold insulator 2 2 Install the PCV fresh air tube to the air inlet Remove the positive crankcase ventilation Jan Mar 2010 Servicelnsights 9 The Technical Side cont d Install the PCV fresh air tube to the left camshaft cover Install the intake manifold insulator 2 Install the two intake manifold insulator retaining pins 1 Install the intake manifold cover Refer to Intake Manifold Cover Replacement Rear No More Gentle Giant Shop owner gives HUMMER a Diesel makeover When saw it come in knew it was the one he says He didn t have the resources to fix it so offered him 5 000 for the truck and he took it Reed owner of Lafayette Collision Center in Lafayette La was suddenly the proud owner of a five year old truck with a substantially damaged front end But despite his shop s ample collision repair skills he wasn t at all interested in putting it back together Instead he wanted it for what it could do for a close friend that had become too demanding
5. Most terminals in current module connectors ECM BCM EBTCM are small 0 64 mm sq terminals and can be damaged by probing with the wrong tool In many cases once the electrical integrity of the wiring harness is verified the associated module or component becomes suspect However it is possible for a harness that tests as electrically conductive to be the source of an intermittent condition The electrical harness should have the terminal pins re crimped before replacing a module or component that tests OK The correct crimping tool is required to consistently provide secure electrical conditions For additional information on the proper crimping procedure an updated sealed splice installation sheet is available on the TechConnect Magazine website Click the Troubleshooting PDF Job Aids link under Resources on the right side of the page to print out the installation sheet PDF Thanks to Tina Levi and Mike DeSander 4 TECHCONNECT E P a bam nats Fluke 37 5 Multimeter AC and DC Settings Imagine a vehicle with a no start condition and a dead battery Measuring the amperage of a control module using a Fluke DMM digital multimeter in AC mode shows a reading of only 25 mA but in DC mode a reading of 335 mA reveals the continuous draw that would drain the battery This type of scenario shows the importance of checking the multimeter s default settings before testing Fluke 87 multimeter Versions 1 4 of the
6. Readers Rides noone e 5 i After completing the refinish sand Wheel Speed Sensor Diagnosis 6 Check the Minimum both sides of the rotor for approximately ASE Computer Based Testing 6 Thickness specification one minute per side using 130 150 i grit sandpaper to obtain a non directional Tech Tips nannan na a o 7 finish Wash the rotor with mild soap and water or wipe it clean with ACDelco Training Update eee 8 brake parts cleaner part number 10 6012 Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by product of machining to the ON THE WEB pad material reducing the chance for squeaks or other noises to occur Do not clean the rotor with a brake cleaner solvent based product www acdelcotechconnect com click the TechConnect Magazine link or Log in to the ACDelco LMS click the Resources link Preventing Pulsation Any time a brake rotor is refinished measuring lateral runout LRO will help to prevent pulsation and customer come backs Pulsation is caused by brake rotor thickness variation which is usually the result of excessive LRO or brake rotor corrosion 360 Product Offerings Distribution Network Customer Programs Marketing Training E Business Relationships continued on page 2 Brake Rotor Service continued from page 1 Lateral runout is a measurement of the waviness of the rotor face The GM specification for excessive LR
7. because rT PERFORMANCE its engine was the PARTS gee a first generation of a revolutionary new line of E ROD high performance engines engineered by GMPP to slash emissions improve fuel efficiency and become both more environmentally friendly and street legal in the process The classic Chevy on display marked the official unveiling of the E ROD line GMPP s response to the challenge restorers and performance enthusiasts face when they want to take to the road in their creations As more States follow California s lead in blocking the licensing of specially constructed vehicles that are not emissions compliant many restored vehicles can be consigned to the garage All it takes is an E ROD crate engine system which in addition to the base LS engine includes components to make it emissions legal They include catalytic converters an engine wiring harness an engine control module with emissions legal calibration exhaust manifolds oxygen sensors and sensor bosses a fuel tank evaporative emissions canister an air filter mass airflow sensor and sensor boss and an accelerator pedal On top of the kit builders also must source a transmission and other application specific components related to fuel air induction exhaust and front end drive systems Jan Mar 2010 Servicelnsights EJ Product Update cont d Once properly installed an E ROD crate engine system The E ROD line up that is planned includes the will tu
8. to helo TSS accounts build their business with the support of ACDelco such as with the Consumer Assurance Program Customer Satisfaction Index CSI Program and ACDelco advertising In addition there are a variety of money saving discounts available to TSS partici pants including discounts on GM vehicles Bosch diagnostic tools SPX tools and equipment uniforms GM Service Information and ASE certification The changes for 2010 include opening the instructorled training courses to all levels increasing the use of the acdelco com locator service and increasing the payout through the EY Rewards program Here are some of the details Red Level Less than 12 000 in annual purchases Limited access to free instructor led training White Level 12 000 35 999 in annual purchases Expansion to more accounts to provide increased access to the acdelco com locator service and additional free instructorled training New accounts enter the program at the White level Blue Level 36 000 or more in annual purchases Unlimited access to free instructorled training and acdelco com preferred locator listing position The exclusively yours Rewards program also has increased the opportunities for monthly payouts The minimum amount for earning a percentage back based on monthly purchases has been reduced Plus a new level of 5 back for top performers has been added for 2010 Thanks to Steve Sheldon Readers Rides T
9. 09 and Pontiac Torrent built prior to July 2008 2006 2009 Saturn SKY built prior to April 24 2009 with an automatic transmission only Technicians may experience some difficulty installing the new style ignition lock cylinder on these models Before installing the new cylinder carefully inspect the housing for debris or damage from the old lock cylinder No tools are required for installing the new lock cylinder When installing into the housing ensure that the lock cylin der is fully seated to ensure it latches into position Do not use the old style lock cylinder that is still used on a manual transmis sion equipped vehicle on a vehicle with an automatic transmission the original binding condition will likely return Refer to GM bulletin 09 02 35 005A for additional information Aluminum Heater Core and Radiator Replacement 2005 and prior GM passenger cars and light duty trucks It may be necessary to replace an aluminum heater core radiator or water pump due to erosion corrosion or insufficient inhibitor levels in the coolant A coolant check should be performed when replacing these components in order to verify proper coolant effectiveness Verity coolant concentration using a refractometer A 50 coolant water 7 TECHCONNECT solution ensures proper freeze and corrosion protection The refractometer uses a minimal amount of coolant that can be taken from the coolant reservoir radiator or eng
10. A E 3 ACDelco Instructor Led Training Locations City State How to Take ACDelco Training Go to www acdelcotechconnect com and click on the Training tab South Central Region Training Locations continued to log on to the ACDelco Learning Management System LMS 2 3 e To enroll in an Instructor Led Training ILT course click on the T ok aD Enrollment link or the Instructor Led Courses link North Harris College Houston TX e To launch a Web Based Training WBT course click on the ee eee a ee Pinge ue Web Based Courses link to view the catalog and select a Pulaski Technical College Little Rock AR specific course San Jacinto College Pasadena TX e To launch a TechAssist TAS course click on the TechAssists link South Texas Community College CAAT Center McAllen TX to view the catalog and select a specific course Southwest Tennessee Community College Memphis TN e To launch a Simulation SIM click on the Simulations link to ha view the catalog and select a diagnostic challenge simulation de a ala sata i St Philips College San Antonio TX Training Locations Tarrant County College Fort Worth TX ACDelco offers numerous hands on Instructor Led Training ILT Tulsa Tech Lemley Campus Tulsa OK courses at many convenient locations around the country Following Wichita Area Technical College Wichita KS are the ACDelco training locations West Texas Training Center San Angelo TX Southeast Region Training Locations ACDelco Instructor Led Trainin
11. Fluke 87 multimeter defaults to reading DC amperage when set on the amperage or milliamp scale The new Fluke 87 5 meter version 5 when set on the amperage or milliamp scale will default to reading AC current If a diagnostic test step is requesting a DC amperage reading to be taken and the meter Is set on the AC amperage setting the meter will display O amperage or close to 0 amperage This will cause an inaccurate test result that can cause the test to pass or fail when it shouldn t To avoid an incorrect test result when testing amperage always check the multimeter s display to make sure It Is either on the AC or DC setting Use the unmarked blue or yellow button depend ing on the version of multimeter being used on the top left of the multimeter to select between the AC and DC readings Thanks to David Nowak The TSS Q amp A provides answers to common questions received by the ACDelco Customer Support Center Q Ar Q How do I download material from ACDelco Advantage that have added to My Cart To download the items in your cart e Complete the order process by clicking Begin Checkout from your Cart e You will see an Order ID number that confirms your request was received e Visit your Order History where you will see your order e After a few minutes a Download link will appear that allows you to download your order or email it to recipients of your choice Where can I order ACD
12. O is more than 0 050 mm 0 002 in Excessive LRO occurs to a rotor when the brakes are not applied When the vehicle is being driven any high spot on the rotor rubs the brake pad once per revolution Eventually the high spot is worn down resulting in a thin spot on the rotor rotor thickness variation and pulsation that is transferred through the brake pedal when the brakes are applied Rotor corrosion is another form of thickness variation In cases where rotor corrosion is cosmetic refinishing the rotor is unnecessary More extensive corrosion may be the result of a build up mostly on the rotor material surface caused by a combination of corrosion pad material and heat In some instances cleaning up this type of corrosion may require more rotor material to be removed than typical refinishing When measuring LRO rotate and locate the point on the rotor where the lowest dial indicator reading Is indicated Set the dial indicator to zero Rotate the rotor from the low point and locate the point with the highest dial indicator reading the high spot In addition index mark the rotor and a wheel stud so that it is in the same position as it was prior to service If LRO is excessive use Brake Align correction plates or refer to the appropriate Service Information to correct the lateral runout Measure LRO using a dial indicator Installation Tips Reinstall the rotors on both sides of the vehicle following these steps
13. a little sluggish and frankly in need of a facelift Yes Reed s stock 2004 10 Jan Mar 2010 Servicelnsights This example of replacement procedures for the Positive Crankcase Ventilation Hose Pipe Tube for the 3 6L V 6 found in the 2010 Chevy Camaro 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 If you re doing a powertrain or other mechanical repair procedure remember that we ve got all the related parts you need alternators starters belts hoses batteries plugs wiring maintenance parts whatever you need Hummer H2 as powerful and imposing as it looked was getting to be a burden What it needed Reed figured was what the Chevy pickup had a Duramax Diesel 6600 V8 with an Allison Heavy Duty 5 speed transmission and selectable 2wd 4wd transfer case Reed had heard about such conversions and had even looked into hiring the project out to conversion Specialists But with pros asking upwards of 40 000 and unwilling to share any information with a Genuine E4 Business of Repairs do it yourselfer on some of the trickier parts of the process Reed knew he d have to find a donor vehicle and do the work himself And that s what he did Six weeks after buying the Chevy pic
14. and Terminal Crimping Electrical intermittents can be a source of frustration when repairing a vehicle Some circuits in vehicles are not only susceptible to an intermittent condition but high resistance also may cause erratic operation or set DTCs An often overlooked possi bility in the diag nosis of electrical intermittent condi tions Is the quality of the terminal crimps When diagnos ing any type of electrical condition inspect the integri ty of all related wiring harness connectors and terminals Poor connections may lead to numerous types of intermit tent conditions such as miscellaneous DTCs driveability conditions hard or no start conditions incorrect gauge readings illuminated MILs and inopera tive control module conditions Sealed splice installation sheet is now available on the TechConnect Magazine website Once the circuit that connects the components in question has been isolated perform a visual and physical inspection of the wiring harness connectors for integrity Many times repairs may be made by simply disconnecting and reconnecting the connectors A pull test of the terminals should be performed after any wiring harness connector or terminal repairs Insert only the proper size terminal test tool into the terminal to determine if the terminal is making good contact or whether the terminal has been damaged and needs to be replaced It s critical to use the right tool when testing
15. der gm com Editor Mike Militello ACDelco E mail lt michael militello gm com Technical Editor Mark Spencer E mail lt gt mspencer gpworldwide com Production Manager Marie Meredith Desktop Publishing 5byb Design LLC E mail lt gt dkelly bby5dzign com Write to DX ACDelco TechConnect PO Box 500 Troy MI 48007 0500 On the Web 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 technicians have the equipment tools safety instructions and know how to do a job properly and safely If a con dition is described it cannot be assumed that the 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 2010 ACDelco All rights reserved Details on Die
16. e E ROD was the big story coming out of SEMA Actually neither one is entirely appropriate for the typical Meyer says There were 300 members of the press at the ISC today rollout and we were able to formally introduce this to Hybrids with their complex electrical systems co existing some local classic car clubs We think the E ROD is going with internal combustion engines command respect from to revolutionize how the big custom car builders go to both a personal safety and service and repair integrity market in the future standpoint A good way to begin striking the right balance is to get educated and one great way to do that is via GM Powertrain s Hybrid Technology clinic Sponsored by many GM Powertrain dealers and led by Grand Sport Corvette on display in the GM Exhibit at SEMA seasoned experts the clinic provides an overview of current hybrid vehicle technology with a strong emphasis on the knowledge needed to safely and competently provide basic vehicle service In the clinic which runs two plus hours technicians learn not only the essential basics of the various hybrid technologies but also practical information such as the Jan Mar 2010 Servicelnsights The Technical Side cont d kinds of electricity in there he says While the number of hybrids on U S roads today is pegged at 1 25 million 2 3 percent of all vehicles that number could triple by 2015 by some estimates
17. e globules The growths appear slimy and are usually black green or brown Fungi use the fuel as their main energy supply and need only trace amounts of water and minerals The most common symptom of fuel contamination is fuel filter plugging however various metal fuel system components also can corrode If fungi have caused fuel system contamination flush the fuel system replace the fuel filter and refill the tank with clean diesel fuel If a customer desires to use a biocide after flushing the fuel system it should not contain alcohol or other water emulsifiers Diesel Fuel Additives Customer use of diesel fuel additives are neither required nor recommended for the 6 5L diesel and 6 6L Duramax diesel engines Alcohol based additives permit water to pass the fuel filter and water separator causing damage to the fuel system GM Diesel Fuel Conditioner part number 88861009 is alcohol free and utilizes water demulsifiers to cope with water in the fuel Fuel distributors blend no 1 and no 2 diesel fuels for seasonal requirements in a particular region No other blending of fuels is recommend ed If a customer desires to use a winter fuel additive to prevent fuel waxing or icing during extreme cold snaps the winter fuel additive must not contain alcohol or other water emulsifiers that may compromise the water removal effectiveness of the fuel filtering system The use of additives such as a ceta
18. elco calendars for the new year 2010 ACDelco calendars can be ordered by calling 1 877 845 3773 or online at acdelcomerchandise com To order online 1 Log in to your acdelcomerchandise com account 2 Select 2009 Holiday link on the left side of the page 3 Select from the calendar options If you are a new user and want to create an account on acdelcomerchanside com 1 Click Create an Account 2 Select your Registration Type from the drop down menu 3 Fill out the required information How can I order ACDelco multi point inspection forms To purchase ACDelco multi point inspection forms call the ACDelco estore at 1 866 700 0001 and request item AM FM 0065 09 How do get in touch with my new ACDelco representative ACDelco has enhanced their sales representative positions by ensuring all field representatives have a more technical service background Many field representatives are still servicing TSS accounts and the new ACDelco staff is well equipped to support our TSS customers If you have any ques tions please contact the ACDelco CSC at 1 800 825 5886 prompt 0 2010 TSS Program Enhancements In 2010 the Total Service Support TSS program will feature several enhance ments designed to increase the rewards and benefits of participating in the program including new opportunities in training promotions and exclusively yours EY Rewards points The TSS program continues to offer ways
19. en UT TS PU 0013 10 8 TECHCONNECT Genuine ill Parts The Technical Side continued from Servicelnsights page 6 artistic flair and ready access to GM Parts and accessories f The five Camaros on display were selected from a field of yD rt d vste m S 132 proposals sent in by leading custom vehicle makers The best shops in the world came there with their best blend of redesign and powertrain upgrade ideas says Dr e d U cati O n Jamie Meyer GM Performance Parts marketing manager Joining the Camaros in the lavish GM display at SEMA were a customized 2010 Grand Sport Corvette and an off Techs Get up to speed fast with road ready Raptor Fighter Chevrolet Silverado outfitted GM Powertrain Clinics with an LS7 crate engine Not to be overshadowed GM Performance Parts showed off its two new powerful crate engines the LSX 454 and the LSX 376 both built on the famed LSX Bowtie Block Those are boost ready LSX crate engines that are drawing a lot of interest Meyer says But the biggest GM news to come out of SEMA had to be GMPP s new E ROD crate engine system Showcased there in a classic 1955 Chevy the new emissions friendly yet powerful LS engine is envisioned as the answer to restorers challenge of doing a resto mod project that When a hybrid electric vehicle enters your garage what s can also be Street legal your first reaction Panic Concern Or is it ho hum Th
20. ends high performance with surprising efficiency ina racing ready package A pair of Turbonetics T 3 turbochargers blows through a custom air to air intercooler force feeding the engine about seven pounds of boost and lifting its horsepower level to about 425 That s about 40 percent greater than stock and in normal driving when the turbochargers aren t making boost there s virtually no penalty in fuel economy over the non turbocharged 3 6L engine Jay Leno Camaro Repair Procedure for the 2010 Camaro with the 3 6L V 6 Even though the 2010 Chevy Camaro 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 will soon be available by going to www genuinegmparts com and clicking on GM Technical Repair Information This example of replacement procedures for the Positive PCV fresh air tube from the left camshaft cover Crankcase Ventilation Hose Pipe Tube for the 3 6L V 6 p are shown here 5 Remove the PCV fresh air tube from the air inlet Positive Crankcase Ventilation Remove the PCV dirty air tube 1 from the right Hose Pipe Tube Replacement camshaft cover 2 Remove the PCV dirty air tube 1
21. g Locations City State Albany Technical College Albany GA orth Central Region Meining Locations Central Kentucky Technical College Lexington KY a A E Peden ND Central Piedmont Comm College Matthews NC Cincinnati State Community College Cincinnati OH Florida Comm College at Jacksonville Dai nin Columbus Automotive Distributors Warehouse Columbus OH Forsyth Technical Community College uincton Salen NC Cuyahoga Community College Parma OH GM Training Center Alpharetta GA Delta College Saginaw wt Ivy Tech Community College Evansville IN Des Moines Area Community College Ankeny IA J F Drake State Technical College Huntsville AL Dunwoody College of Technology Minneapolis MN J Sargeant Reynolds Community College Goochland VA Fox Valley Technical College Appleton wI Lawson State Community College Bessemer AL New GM Training Center Glendale Heights IL Nashville State Community College Nashville TN GM Training Center Warren MI Sarasota County Technical Institute Sarasota FL Grand Rapids Community College Grand Rapids MI Seminole Community College Santord FL Ivy Technical State College Indianapolis IN Sheridan Technical College Hollywood FL Michigan Technical Education Center Traverse City MI Trenholm State Technical College Montgomery AL Minnesota State Community amp Technical College Moorhead MN Wayne Community College Goldsboro NC Sinclair Community College Dayton OH Western Region Training Locations South East Technical Institute Sioux Falls SD American River Col
22. ine block If the concentration is below 50 the cooling system should be flushed In addition verify that no electrolysis is present in the cooling system using a digital voltmeter The electrolysis test can be performed before or after system repairs Electrolysis is often an intermittent condition that occurs when a device or accessory that Is mounted to the radiator is energized This type of current could be caused by a poorly grounded cooling fan or other accessory and can be verified by watching the voltmeter while turning on off various accessories or engaging the starter motor Follow the flushing procedures outlined in the Service Information for vehicles using DEX COOL coolant and for vehicles using conventional silicate coolant Do not mix the OEM orange col ored DEX COOL coolant with green colored conventional coolant Some GM vehicles such as the 2004 2005 Chevrolet Aveo use a blue colored conventional coolant Diagnostic Assistance For tree technical diagnostic assistance and product information regarding specific ACDelco products contact these toll free information hotlines staffed by ASE certitied technicians Brakes 1 888 701 6169 prompt 1 Chassis 1 888 701 6169 prompt 2 Clutches 1 888 725 8625 Litt Supports 1 800 790 5438 Shocks 1 877 466 7752 Starters and Alternators 1 800 228 9672 Steering 1 866 833 5567 Wiper Blades 1 800 810 7096 Traininc
23. kup removing its engine transmission and transfer case and painstakingly transplanting it in the Hummer Reed essentially had himself a tank with the personality of a race car and the environmental consciousness of a hybrid I m getting 20 miles per gallon now compared with 13 to 15 before and its diesel engine has a lot more power in comparison to the old Hummer gas engine he says It s not fast from the stop but once you get going it pins you to your seat like a racecar The stock Hummer doesn t have that kind of power It s a good thing that Reed is getting a kick out of his new hot rod Hummer one of a rare breed of conversions he s discovered exists only in certain pockets around the country The conversion job one he tackled after hours and on weekends was a Challenging one though not too daunting for someone who knows the basics Still tasks like making a new transmission and shift cable mount changing out fuel lines making an upper tie bar installing the radiator and fashioning a new harness proved tedious and time consuming The painstaking part was the wiring it makes my head hurt just thinking about it he says Once you start digging into that it took a lot of focus and concentration One mess up with that and you ve got trouble Instead what Reed ended up with is trouble of a different sort A reinvigorated Hummer H2 that stalks the streets of Lafayette itching for an opportuni
24. l speed sensor increases the signal frequency as the wheel speed increases but does not Increase the signal amplitude Poor connections and broken wires are some of the leading causes of wheel speed sensorrelated failures Other common causes of wheel speed sensor malfunction are water intrusion and corrosion in the connector to the sensor and damage to the tone ring For more information on wheel speed sensor diagnosis visit www acdelcotechconnect com and click the Training tab Log in to the ACDelco Learning Management System to view TechAssist S BKO5 01 01 TAS Active Hall Wheel Speed Sensor Operation Thanks to Mike Militello and Mike DeSander ASE Spring 2010 Testing Registration Deadline March 31 2010 The OFFICIAL PRACTICE TESTS Info at www ase com testprep Test Dates May 6 11 13 2010 Choose from a Wide Range of Test Categories Register Online at www ase com ASE 101 Blue Seal Drive S E Suite 101 Leesburg VA 20175 703 669 6600 e www ase com 6 TECHCONNECT oon on Fs solt LW 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 Technical Assistance Hot Line can help Call 1 800 825 5886 prompt 2 to speak with a technical expert with the latest OEM information Engine Mount Replacement 2004 2007 Cadillac CTS with 3 6L LY7 or 2 8L LP1 engine When rep
25. lacing the engine mounts for any reason follow these steps to prepare and install the new mount The new part does not include the exhaust heat shield which must be re used Original mount A Hole location of alignment pin B Retaining spring nut Follow the appropriate Engine Mount Replacement procedure in SI to remove the old mount from the vehicle Once the mount is removed mark the hole location of the alignment pin on the mount heat shield Using a suitable tool remove the retaining spring nut trom the top of the mount heat shield and discard the old mount Replacement mount A Lower locating pin Prepare B Top alignment pin the replace ment mount by cutting the lower locating pin off using a die grinder and cutting wheel Align the marked hole on the heat shield with the top alignment pin on the replacement mount Follow the appropriate Engine Mount Replacement procedure in the Service Information to install the new mount with heat shield into the vehicle Verity that the heat shield is properly located on the mount A retaining spring nut is not required Ignition Lock Cylinder 2008 2009 Cadillac CTS built prior to VIN breakpoint 90163371 2005 2009 Chevrolet Cobalt built prior to April 14 2009 2006 2009 Chevrolet HHR and Pontiac Solstice built prior to April 14 2009 2007 2009 Chevrolet Equinox built prior to July 2008 2007 2009 Pontiac G5 built prior to April 14 20
26. lege Sacramento CA Stark State College North Canton OH Arapahoe Community College Littleton CO Waukesha County Technical College Pewaukee WI Central New Mexico Community College Albuquerque NM Northeast Region Training Locations College of Southern Idaho Twin Falls ID CNY Autotech Training Center Syracuse NY Community College of Southern Nevada N Las Vegas NV Community College of Allegheny County West Hills Center Oakdale PA Cuyamaca College San Diego CA GM Training Center Ardsley NY Denver Training Center Denver CO Lakes Region Community College Laconia NH Fresno City College Fresno CA Mass Bay Community College Ashland MA Glendale Community College Glendale AZ Monroe Community College Rochester NY GM Training Center Burbank CA Northampton Community College Bethlehem PA Las Positas Community College Livermore CA The Community College of Baltimore County Baltimore MD Leeward Community College Pearl City HI South Central Region Training Locations MSU Billings College of Technology Billings MT Austin Community College Austin TX Portland Community College Portland OR Del Mar College W Campus Corpus Christi TX Renton Technical College Renton WA GM Training Center Garland TX Shoreline Community College Seattle WA Hinds Community College Career Center Raymond MS Truckee Meadows Community College Reno NV lowa Western Community College Council Bluffs IA University of Alaska Anchorage AK Johnson County Community College Overland Park KS Weber State University Ogd
27. mmitment to helping restorers and performance enthusiasts express themselves through their vehicles in new and exciting ways Demonstrating that its new stock Chevrolet Camaro as hot as it is is only a starting point GM paraded five Camaro concept cars Each was lavishly accessorized to the designer s vision with a varied mix of readily available Genuine GM Parts and Powertrain components Vehicles like the twin turbocharged V 6 built for Jay Leno the current stock and future accessory indulgent Camaro Chroma and the sophisticated tailored looking m m mm Camaro Dusk showed just what can be done with an eee ee ee E Nola Actual power chart may vary depending on inducten system used LSX 454 Dyno Chart 5 a T m a re Ld re als continued on page 7 after TECHConnect LSX 376 Dyno Chart Synergy Camaro Jan Mar 2010 Servicelnsights January amp February 2010 ACVelco FE eGR ite Brake Rotor Service The key steps during disc brake service include we determining rotor refinishing or replacement 1T properly cleaning all brake components oe including items such as hub rotor and wheel mating surfaces properly refinishing the rotor if applicable and properly reassembling the brake assembly using the proper tools and torque specification Here are some tips to ensure a successful brake service and prevent vibration and brake noise Always refe
28. n an analog voltage like with a passive sensor The sensor is able to detect the first edge of the next tooth on the tone ring immediately after powering on The EBCM uses the frequency of the DC signal to calculate the wheel speed If DTCs or diagnosis procedures indicate a wheel speed sensor failure visually inspect the sensors related wiring and connections for problems A variable reluctance wheel speed sensor can be checked by measuring its resistance with a digital multimeter DMM If the sensor resistance is out of specification it will not produce an accurate signal to the EBCM To verity sensor outputs also compare them using an oscil loscope or AC volt meter To measure the output of the magneto resistive wheel speed sensor start by testing the 12 volt ref erence circuit from the EBCM Also DC amperage can be measured across the wheel speed sensor Slowly turn the wheel and watch the DMM Amperage should fluctuate from high to low Measure WSS amperage output using a DMM The digital signal generated by the magneto resistive sensor also can be viewed using an oscilloscope Connect the leads as you would for a DMM A good wheel speed sensor scope wavetorm should have sharp square corners on the DC signal circuit to the EBCM Remember the EBCM sends a 12 volt reference signal to each wheel speed sensor As the wheel spins the wheel speed sensor produces a square wave DC signal voltage The whee
29. ne improver to enhance engine performance or a lubricity additive to aid in the longevity of fuel system components are not fixes for poor quality or contaminated fuel If such additives are used they must not contain alcohol or other water emulsifiers Biodiesel Diesel fuel containing greater than five percent biodiesel B5 or the use of unmodified bio oils blended into diesel fuel at any concentration may damage the diesel fuel system and engine Waxing Diesel fuel gelling or waxing also called cloud point at low temperatures may result if the fuel is not blended properly for the temperatures being experienced Further biodiesel begins to wax at temperatures of 10 to 20 degrees higher than no 2 winter blend fuel A below freezing hard start no start condition may be caused by fuel waxing or fuel contamination Fuel waxing may also restrict the amount of fuel flow through the fuel filter A high fuel system vacuum reading will be found if the system is checked when the fuel is cold and waxing The use of engine block heaters in extreme cold tempera tures may alleviate some fuel waxing concerns Refer to the appropriate Service Information for additional information about diagnosing the effects of contaminants in diesel fuel and testing for the presence of contaminants including fungi water gasoline and biodiesel in amounts larger than five percent Thanks to Bill Carnevale 3 TECHCONNECT Electrical Intermittents
30. r to the appropriate Service Information or latest bulletins for specific proce dures GM bulletin 00 05 22 002L is a good resource that updates and centralizes all of GM s standard brake service procedures Rotor Refinishing When it s determined that a rotor must be lt refinished use a brake micrometer to measure the rotor Multiple measure points should be taken and the lowest measurement recorded Reference the Minimum Thickness specification stamped on the backside of the rotor and the Discard specification in the Service IN THIS ISSUE Information before refinishing the rotor Do not refinish new rotors or remove any special coating that may be applied on some ACDelco replacement brake rotors Brake Rotor Service 7 1 Clean all of the mating surfaces between Brake R Conn 9 the hub rotor and wheel Cleaning all rake Rotor Coating 2 sue mating surfaces and making them free of Details on Diesel Fuel 3 corrosion burrs and other debris is critical Electrical Intermittents and and must be performed whether using an Terminal Crimping an 4 on car or bencn lathe refinishing procedure Fluke 87 5 Multimeter Prior to making the cut when refinishing AC and DC Settings me 4 install the recommended clip on style disc silencer supplied with the lathe Using the TSS Q amp A 2 r 1 ee 5 silencer will help prevent chatter from 2010 TSS Program Enhancements 5 occurring during the cut
31. rn virtually any classic project into a powerful clean addition of the LS327 5 3L and the Corvette Z06 LS7 car that rivals the modern performance and emissions engine package midyear and finally a 6 2L supercharged profile of contemporary GM muscle cars The kit designed in close cooperation with the California Air Resources Board and SEMA to ensure emissions compliance is easily installed into most applications All of the emissions hardware is included in the LS controller kit that package in 2011 Regardless of the power profile each E ROD crate engine promises to expand the definition of performance to also mean environmental friendliness better gas mileage and true road readiness Whether it s the enthusiast GMPP engineers who wants to live and demonstrate a developed based i greener lifestyle or the one who simply on the LS3 and ka wants to get his car legally titled the adapted to work in a kit i car or truck application says E ROD crate engine system will reduce a vehicle s carbon footprint without Dr Jamie Meyer GMPP product i sacrificing true performance he says marketing manager ISCs and speed shops used To locate price or purchase an E ROD to doing restorations will find the E ROD crate engine contact your GM dealer or call the GM Performance Parts system to be an easy swap in most applications customer assistance center at 1 800 450 4150 Or visit Once ins
32. sel Fuel Water in diesel fuel is a contami nant that can cause damage to the fuel system Water in fuel can take two forms coarse water droplets that drop out of suspension and can be filtered out or emulsified water particles Suspended in the fuel which can pass through some filters Proper fuel filter servicing and the use of clean diesel fuel that is free of water or contaminants are critical for the longevity of fuel system compo nents of a modern direct injected diesel engine Adherence to the fuel filter change interval will help to ensure that the diesel fuel system will be protected from contami nants and that the engine will continue to operate as designed Purchasing fuel from a high volume fuel retailer increases the chances that the fuel is fresh and of good quality The Water in Fuel Sensor on the GM Duramax diesel engine can be tested after removing it from the fuel filter assembly A good sensor will have continuity when the float is manually raised Use a DVOM to check for continuity The float can be tested by placing it in water and in clean diesel fuel A good float will float in water and sink in diesel fuel arg Ke Se S re J Water in Fuel Sensor Contaminants If water is present in diesel fuel fungi and other microorganisms can survive and multiply especially in warmer climates The fungi can be present in any part of the fuel handling system These fungi grow into long strings and will form larg
33. sure monitoring and other vehicle systems While the appearance of active and passive wheel speed sensors is similar operation is not The operation of the variable reluctance sensor uses a small internal magnet and coil of wire to generate a signal to the Electronic Brake Control Module EBCM Operation involves a gearshaped tone wheel that rotates near the sensor on each wheel As the tone wheel rotates a magnetic field fluctuates around the sensor and induces AC voltage into the internal coil windings AC voltage is sent to the EBCM which interprets the voltage and frequency as a wheel speed signal input This type of sensor requires that the tone wheel rotate fast enough in order to generate a usable signal As wheel rotation slows the signal strength decreas es resulting in a weak signal at very low speeds Magneto resistive wheel speed sensor To combat this weakness in signal strength at low speeds the magneto resistive wheel speed sensor was designed It uses a tone wheel and a permanent magnet like the variable reluctance sensor along with a two wire connection that consists of a supply circuit and signal circuit connected to the wheel speed sensor To power the sensor the EBCM provides 12 volts on the supply circuit As a toothed ring passes by the wheel speed sensor changes in the electromagnetic field cause the wheel speed sensor to produce a DC voltage signal It is a digital high low toggle rather tha
34. talled Meyer says an E ROD crate engine will www gmperformanceparts com deliver significantly more power than the vehicle s original engine without anywhere near the emissions In the 55 on display for instance the E ROD LS3 s 430 horsepower rating is 160 percent over this model s original stock small block V 8 power Dr Jamie Meyer GMPP product marketing manager with the E ROD at SEMA 4 Jan Mar 2010 Servicelnsights Genuine amp Parts Why install aftermarket when you can get OE quality at the same price Simply give us your aftermarket supplier quote and we ll match or beat it on select GM Engines and Transaxles Call your GM Dealer for details Genuine GM Advantages e GREAT PRICING e POWERFUL WARRANTY 3 years 100 000 miles for GM OE Powertrain e NO HASSLE CORE RETURN Contact your GM Dealer for details e INSTALLATION SUPPORT Call 1 866 OE PARTS 1 866 637 2787 Whichever comes first from date and mileage of installation by an authorized GM Dealer or a qualified service center For over the counter sales warranty begins on the date and mileage of retail sale Contact your GM Dealer for details ACDelco TECHCONNect Repair Industry News amp Updates HORSEPOWER TOROQUE From souped up GM classics to new perform ance Horsepower 620 6200 rpm Torque lb ft 590 4800 mam engines to environmentally friendly powertrain solutions GM demonstrated a clear co
35. tentional 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 Company Detroit MI 48202 E l l l l l l l l I l l l l l i I I l l l i 1 I l l l I l l 2010 GM Company All rights reserved Genuine jou Parts Product Update GOING FAST GOING GREEN On the outside the 55 Chevy looked little different from all the other painstakingly restored classics of the Same iconic vintage Even under the hood the LS3 6 2L V 8 engine resembled the kind that restorers commonly use to bring vehicle performance into the modern era But this Chevy on display in the GM Performance Parts GMPP booth at last November s SEMA Specialty Equipment Manufacturers Association show in Las Vegas actually represented the next frontier in resto modding the wedding of modern engine technology to classic vehicle restoration GM Performance Parts E ROD emissions compliant engines deliver speed and power with reduced emissions That s
36. ty to show that there s power and performance under a veneer of toughness Genuine E 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 I l Genuine Parts
37. wo of the latest additions to the TechConnect Readers Rides gallery are built for soeed Read all about the transformations and view more photos at TechConnect Magazine Online To get a closer look at the cars of fellow TSS shop owners and technicians go to www acdelcotechconnect com and click the TechConnect Magazine a Online tab 2007 Chevy SSR Top Sportsman Drag Truck Mark Hicks Maas Radiator Inc To submit photos of your car or Bloomington Ind truck include your name TSS service center location and a few technical details about your vehicle 1 Go to the TechConnect Magazine Online website by clicking the TechConnect Magazine tab on www acdelcotechconnect com 2 Click the Contact Us link 3 Send an email with photos attached to technical editor Mark Spencer Thanks to Mike DeSander Dan Pedroza JC Automotive Specialist Round Rock Texas 5 TECHCONNECT Wheel Speed Sensor Diagnosis When anti lock brakes ABS first became common equipment on new vehicles well over two decades ago it featured a passive variable reluctance wheel speed sensor Later the active magneto resistive sensor was introduced which improved performance by providing a more precise wheel speed reading at very low speeds The role and importance of an accurate wheel speed reading has continued to grow with the increased popularity of electronic controls for automatic transmissions traction control tire pres
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