GM Service Insights
Contents
1. ACHDelco Genuine Parts OCT DEC 2011 ALSO IN THIS ISSUE gt GM s new line of actuator motors compete on price and quality gt RepairLink with MORE eases mechanical parts ordering gt Fall is the time for industry expositions SEMA AAPEX ATRA gt GM Powertrain is the solution for restoration specialist gt TechConnect insert with more valuable service info 2012 SONIC More on the Sonic inside s More resources at including service procedures www 2enuineemparts com CONTENTS GM OE Service The Technical Parts Update Side The latest word on Discover new ways product development e 1 we to approach service and technologies repairlink and repairs with hm ion 14 WF Sed Bireeikal 6h AeA Ei 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 J Parts GM Servicelnsights Online More Genuine GM Parts resources and links Download this issue and past issues of GM Servicelnsights magazine at www gmserviceinsights com GM Servicelnsights Headquarters 2604 N E Industrial Dr 230 N Kansas 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 subm2. Electrical System Diagnostic Challenge o EP08 01 015IM Engine Performance Diagnostic Challenge Choose Wisely Just as in the real world the simulated workstation is dependent on the technician s ability to diagnose the condition and complete the repair The simulation allows the user to freely navigate anywhere on the screen during diagnosis As you progress through the simulation you need to think of the next steps to be taken just as you would when work ing ona vehicle in the shap The virtual tools that are available to help in the diagnostic and repair process are the same as you would find in a shop environment The tabs on the simulation screen provide access to Service Information the work order a variety of tools including a scan tool digital multimeter refrigerant pressure gauge set and others and the parts counter where parts can be ordered for a particular repair Each simulation provides virtual tools to help in diagnosis Just as the appropriate tools and paths are provided within the simulation other tools and paths that are not part of the optimum path for the given scenario also are provided Take the Diagnostic Skills Challenge on the Because the simulations are not training components mini mal or no feedback is given when an incorrect selection is made However if a technician strays too far from the strategy Based Diagnosis path or atternpts to install a replacement part wit
3. has been conceived as a time saving replacement for the standard OE parts ordering process By using a resource laden online system time consuming phone calls faxes and emails can be kept to a minimum Instead of ISCs having to call their dealer to see if they have a part and the dealer faxing parts illustrations back all of it can be done online through RepairLink with MORE says Seth Galvarro OEConnection product manager Mechanical Team Many shops have been ordering non OE aftermarket parts in this fashion so they re accustomed to it Since we re multi OEM shops don t have to learn a separate system for each OE parts supplier With RepairLink with MORE enabled on their shop computer system ISCs gain access to a host of information in participating OEM parts catalogs Once connected an ISC can enter a VIN or YMM and begin searching for parts utilizing a keyword search or a category search When parts are identified detailed illustrations showing parts and complete parts assembly drawings help ensure that orders are correct and complete After determining which parts are needed ISCs can search a dealer s inventory for availability and pricing The parts can be saved to a shopping cart or ordered online directly from the dealer which will invoice and bill accordingly Once the dealer has the information orders are filled and deliveries are scheduled ISCs can monitor the status of their orders after placing them
4. Number Course Name S FNOQ0 01 01VCT R How to Use VCT Recorded S AC07 01 01VCT HVAC System Components and Lubricants S ACO7 02 01VCT HVAC System Operation and Service Hints S AC07 03 01 VCT HVAC System Flushing Recovery and Diagnostics S AC07 04 01 VCT HVAC System Engine Cooling Controls and Communication S EL06 01 01 VCT S EL06 02 01VCT Electrical Circuit Function and Diagnosis Testing Electrical Signal and Control Circuits S EL06 03 01VCT Serial Data Communication Networks S EL06 04 01VCT S EM01 01 01VCT S EM01 02 01VCT Communication Network Diagnosis Camshaft Position Actuator Systems Active Fuel Management Operation S EM01 03 01VCT Active Fuel Management Diagnosis Recorded versions of these courses are also available on the training website New Virtual Classroom Training The following VCT courses are currently being scheduled Course Number Course Name October New Releases S EP08 01 01VCT S EP08 02 01VCT 6 6L Duramax Engine Diagnosis 6 6L Duramax LMM Diesel Engine S EP08 03 01VCT 6 6L Duramax LGH and LML Diesel Engines November New Releases S EL06 06 01VCT GM Hybrid System Safety and Components S EL06 07 01VCT GM Hybrid System Diagnosis and Repair ai Training Spotlight S AC07 01 01VCT HVAC System Components and Lubricants This VCT course emphasizes diagnostic and repair skills for the air conditioning system including the compressor condenser metering de
5. amount of time the engine idles Many vehicles with a start stop system are not full hybrid electric vehicles that have the added cost and complexity of powering a vehicle completely on battery power These fuel saving systems are becom ing more commonplace on new vehicles such as the new 2012 Buick LaCrosse which will have start stop technology as a standard feature on the base model Starter generator New eAssist System In addition to the 2012 Lacrosse the 2012 Buick Regal also will offer a Start stop system The new GM system is called eAssist The 2012 LaCrosse and Regal offer impressive 25 fuel economy gains over the 2011 models without eAssist The start stop feature ACDelco H of the system uses a state of the art lithium ion battery system and an electric induction starter generator eAssist models feature e A 2 4L Ecotec 4 cylinder engine mated to a Hydra Matic 6140 automatic transmission e A starter generator or drive motor mounted to the front of the engine in place of the alternator e An air cooled generator control module comprised of the eAssist powertrain control mod ule 14 volt power module and drive motor control module e A hybrid EV battery pack that stores 115V DC in two lithium ion battery sections e Lightweight 17 inch alloy wheels and tires with lower rolling resistance e Regenerative braking which pro vides up to 15 kW of electricity to charge the high volta
6. approximately 1500 rom The noise usually is most notice able at the rear of the driver s side front wheel well A ticking noise also may be heard inside the vehicle at idle such as when sitting at a drive through window All 6600 Duramax diesel engines have this condition however some are 7 TECHCONNECT more audible than others Engine build variation from engine to engine contributes to differences in perceived volume All Duramax engines are manu factured to very close tolerances to meet durability and reliability standards This ticking noise is caused by the relationship of the engine cylinder block crankshaft journals bearing inserts and the oil film This relationship may allow a vibration that resonates through the cylinder block and may be heard as an irregular metallic ticking noise This condition has been present in diesel engines produced by many manufacturers for the last 20 or more years The overall noise reduction in engines produced today makes this noise seem new when in fact it was masked by other noises in the past Testing and engine teardowns with this condition reveal no condition that would affect reliability or durability of this engine This noise is a normal operating characteristic of the engine It has no short or long term effects on the engine Replacing the engine or internal components for this noise will not reduce or eliminate the noise Product Information For free technical
7. assistance and product information regarding specit ic 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 Traininc 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 click the Enrollment link or the Instructor Led Courses link to view the catalog and select a specific course e To enroll in a Virtual Classroom Training VCT course click the Enrollment link or the Virtual Classroom Training Courses link to view the catalog and select a specific course e To launch a Web Based Training WBT course click the Web Based Courses link to view the catalog and select a Specific course e To launch a TechAssist TAS course click the TechAssists link to view the catalog and select a specific course e To launch a Simulation SIM click the Simulations link to view the catalog and select a diagnostic challenge simulation Current Virtual Classroom Training The following VCT courses are currently being scheduled Course
8. card information is available from the current model year back to 1972 ACDelco TechConnect On the web VIN information is avail able without a password account or login requirements via the ACDelco TechConnect website Customers gov emment agencies independent repair facilities and any other outside body that requires GM VIN decoding informa tion should use this method of access To access GM VIN information on the web go to www acdelcotechcon nect com and click the link on the left side of the page labeled GM VIN Information Click the desired model year from the displayed list 4 TECHCONNECT ACDelco LMS The ACDelco Diagnostic Challenge simulations give technicians a chance to prove their skills against one another by putting their ability to diagnose and repair a vehicle to the test The simulations available on the ACDelco Learning Management System LMS go to www acdelcotechconnect com and click the Training tab are designed to duplicate the diagnostic process in the ser yice center testing technicians to use their diagnostic skills to efficiantly diagnose and repair the given condition using all of the provided tools parts and Service Information Technicians compete against one another with the top scores posted online Currently there are four simulations available S AC07 01 01SIM HVAC System Diagnostic Challenge BKO5 01 01SIM Brake System Diagnostic Challenge S ELO6 01 01SIM
9. cleaners may damage the paint on the brake calipers Any wheel cleaner must be thorough ly rinsed off the wheel with clean clear water Special care must be taken ta rinse under the hub cap balance weights wheel nuts lug nut caps between the wheel cladding and off the back side of the wheel Staining or finish disturbance also may result from road chemicals such as calcium chionde used tor dust con trol of unpaved roads The staining will look like small pitting and will usually be on the leading edges of each wheel spoke f a vehicle must be operated under such conditions the chrome wheels should be washed with mild soap and water and thoroughly rinsed as 500n as conveniently possible Contact with applied road chemicals Is Corrosive to the wheel finish and may cause damage if the wheels are not kept clean Another type of finish disturbance results from prolonged exposure to brake dust and the resulting penetration of the dust through the chrome As brakes are applied hot particles of brake maternal are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow These hot particles embed themselves in the chrome layer and create a small pit it the material is allowed to sit on the wheel while it is exposed to mois ture or salt it will corrode the wheel beneath the chrome leaving a pit or small blistar in the chrome Pitted wheel damage from road chemicals Heavy brake ou
10. front suspension with coil springs and stabilizer bar and a semi independent torsion beam axle mount compound link type rear suspension featuring a robust tubular V shape beam with gas charged shocks The front and rear tracks are identical at 59 4 inches 1 509 mm for well planted stability and excellent balance Even though the 2012 Chevrolet Sonic 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 2012 Sonic 1 4L l 4 Ecotec Drive Belt Replacement Special Tools Needed e EN 48488 Holding Wrench e EN 955 Locking Pin Removal Procedure Remove the right front wheelhouse liner extension Refer to Front Wheelhouse Liner Inner Front Extension Replacement Install the engine support fixture Refer to Engine Support Fixture Engine Mount N NE NI ees PAO eae Bracket Replacement ies N A i Right Side BEND EN fe AI Aoi ie am Preliminary Procedures Tis aie SL TEES Fea 1 Remove the engine o gt a mount Refer to Engine Mount Replacement Right Side 2 Remove the front wheelhouse front liner if necessary Refer to
11. on the phone or for faxed parts illustrations For more information Visit MOREOEMPARTS COM Or call 866 401 4610 a Oct Dec 2011 Servicelnsights ATRA October 27 31 The GM Powertrain exhibit at the ATRA Automatic Transmission Rebuilders Association show is in Las Vegas Oct 27 31 The event is staged alongside the Automotive Parts Remanufacturers Association APRA expo For information visit http members atra com SEMA Show November 1 4 GM is exhibiting at booth number 23743 at the 2011 SEMA Specialty Equipment Market Association Show held at the Las Vegas Convention Center Nov 1 4 Visit www semashow com ET ee oT for more information 2017 SD AAPEX November 1 3 ACDelco is exhibiting at NAPE booth number 4838 at the 2011 AAPEX Automotive Aftermarket UAI A Products Expo event held Nov 1 3 at the Sands Expo Center in Las Vegas For information on this event visit www aapexshow com ACDelco Systems Step on the brake pedal come to a complete stop and the engine turns off saving fuel and reducing emissions Release the brake pedal and press the accelerator pedal the engine starts again It all happens seamlessly without interruption of any accessory operations A start stop system that automatically turns off and restarts the engine when the vehicle is stopped can deliver a substantial improvement in fuel econo my by simply reducing the
12. or generating the power electronics convert the hybrid battery DC electrical input to a low voltage electrical output that is used to provide both vehicle accessory power and to keep the 12V battery charged A C Operation The air conditioning controls permit the driver to select between eco and normal operating modes Eco mode allows the engine to enter Auto Stop mode more often and for a longer duration When this happens the A C compressor also stops which may allow cabin temperature to rise but fuel economy is maximized To maintain cabin com fort in the eco mode the recirculation button can be activated First Generation Earlier GM vehicles to use a start stop system to improve tuel economy were the Saturn VUE Green Line Hybrid Saturn AURA Green Line Hybrid and Chevrolet Malibu Hybrid models The Saturn VUE Green Line Hybrid the first to debut the system uses a 27 4 Liter Ecotec engine a modified 4745E automatic transmission and a starter generator assembly The system also provides electric power assist while driving or during acceleration when needed The system automatically maintains accessory functionality and passenger comfort when the engine is stopped The major components of the Saturn VUE Green Line Hybrid include A A starter generator 3 phase 65 Nm stall torque 3kW continuous power hard mounted to the engine with a dual tensioner assembly that combines a hydraulic tensioner and friction based r
13. power electronics provide three basic functions When the system Is in the motoring mode the power electronics invert the hybrid electrical power from direct current DC to 3 phase alternating current AC which is then passed on to run the generator with starter as a motor This provides quick engine auto starts torque smoothing and electric power assist as needed When the system is generating electricity for subsequent high voltage battery storage the power electronics rectify the 3 phase AC electrical power input to a DC electrical power output continued on page 3 2 TECHCONNECT ACVDelco Volume 18 Number 5 TS PU 0005 11 ACDelco TechConnect is published for automotive technicians to provide timely service information increase knowledge 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 2 richard balabon gm com Editor Greg St Aubin ACDelco E mail lt gregory staubin 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 dkelly
14. 5by5dzign com Write to X lt ACDelco TechConnect PO Box 500 Troy MI 48007 0500 On the Web 2 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 2011 ACDelco All rights reserved Start Stop Technology continued from page 2 In this mode the energy required to drive the engine may come from either gasoline when accelerating or the kinetic energy of the moving vehicle when decelerating with the fuel cut off Finally whether motoring
15. Front Wheelhouse Liner Replacement Engine Mount Bracket Fastener Qty 3 Caution Caution Procedure Raise and lower the engine as needed to access the bolts 1 Tighten 62 N m 46 lb ft Engine Mount Bracket 2 Genuine Parts 3 Remove the engine mount bracket Refer to Engine Mount Bracket Replacement Right Side Install EN 48488 holding wrench 2 to the drive belt tensioner 1 Move the drive belt tensioner clockwise until the drive belt tensioner can be fixed with EN 955 locking pin 1 6 Remove the EN 48488 holding wrench qT Remove the drive belt 1 Installation Procedure 1 Install the drive belt 1 Install the EN 48488 holding wrench 2 to the drive belt tensioner 1 3 Move the drive belt tensioner clockwise until EN 955 locking pin 1 can be removed Allow the tensioner to slide back Slowly Remove the EN 48488 holding wrench 6 Install the engine mount bracket Refer to Engine Mount Bracket Replacement Right Side Install the right front wheelhouse liner extension Refer to Front Wheelhouse Liner Inner Front Extension Replacement Remove the engine support fixture Refer to Engine Support Fixture This example of Drive Belt Replacement for the 1 4L l 4 Ecotec Engine in the 2012 Sonic 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
16. PERCHARGERS gt OE CLUTCH KITS Contact your participating dealer for a competitive quote ty at Competitive Prices VERTRAIN COMPONENTS Genuine gig Parts Symptoms e Often damaged from attempts to remove without the proper puller e Debris can cause the belt to run off the pulley Symptoms e Noise or vibration when out of balance e Debris can cause damage to neoprene or coatings Symptoms e Encoder sensor failure e Wiring Electrical failure Symptoms e Fitting or seal failure e Debris contamination Symptoms e Coolant passage leaks e Warpage loss of seal Symptoms e Coolant leaks e Seal failure More resources at Of z www genuinegmparts com a GM OE Service Parts Update GM DEBUTS NEW LINE OF REMAN ACTUATOR MOTORS The remanufactured units introduced and continuing to roll out this year also offer lower prices We ve benchmarked the competition and determined that we can more than compete with aftermarket units at very competitive prices says Keith Loch GM Engines and Transmissions product specialist with GM Customer Care and Aftersales The actuator line which was launched earlier this year with one application that is being followed by two more are validated by GM engineers and can even be used in vehicles still under warranty These reman units are not reverse engineered and they can come with enhancements that address any failure modes or
17. and can freely communicate with dealers via notes and image attachments through the system To get started on using RepairLink with MORE ISCs can log on to www moreoemparts com A key part of the registration process involves selecting preferred OE dealer partners ee OEConnection ACDelco TECHCONNect SPECIAL INSERT Repair Industry News amp Updates cont d To participate a dealer must be part of the RepairLink with MORE network ISCs then must select a preferred dealer for each OEM they select The online system will be set up to funnel orders to that preferred dealer With the preferred dealer link established ISCs will be able to see pricing and availability their dealers offer By the end of 2011 RepairLink with MORE will be available in all major markets says Galvarro As the only multi makes online ordering solution for OE mechanical parts it offers yet another compelling reason for ISCs to choose OE parts over aftermarket substitutes So far ISCs have shown considerable interest in the service and many have become more firmly convinced of the superiority of OE parts he concluded The feedback has been that many love having immediate access to parts catalogs and dealer pricing so they can do a customer repair quote on the fly he says They re finding OEM parts are more competitively priced than they imagined they just never bothered to quote them because they didn t want to wait
18. ansmissions find their way into the vast majority of a CIE WHICrE AUS ESR Beiiles Suburban s restoration modernization projects says Shelly UIST As an aftermarket installer working with engines you can t stand behind all Plekowski Jim s wife and business partner Popular engines for the company s customers include the Ramjet 350 aoa E the ZZ4 350 and the ZZ 572 all reliably supplied through i ig LEIA Catan ein ITE Ge Plekowski s longtime local GMPP dealer AULD SIAL Boa ENG REL SNCS EU The 350 crate engine is the most popular easiest to E anen AE a retrofit engine that can go into just about any vehicle she as Eee eave ee ie ec ia aeae e easier to install Compared to aftermarket products everything fits and we don t have says But 502 and 572s both carbureted and fuel injected to worry about sending things back are popular choices too GMPP engines and transmissions have gone into all manner of resto mod projects Plekowski has handled since 1998 when Suburban stopped doing collision repair work and Relying almost entirely on GM for core powertrain solutions has given the Plekowskis the leeway to savor the other enjoyable aspects of custom resto mod work Their wide ranging portfolio includes a 1957 Chevy with a ZZ 572 a 1939 Ford Coast to Coast roadster witha Ramjet 350 a 1935 Packard with a 502 and a 1969 Chevelle went full bore into restorations GM Per
19. atalog search function on the ACDelco LMS by selecting Simulation on the Course Delivery Type drop down menu The simulations also can be accessed by clicking the simulations link under Technical Training on the Home page Thanks to Greg St Aubin 5 TECHCONNECT The following technical tips provide repair information about specific conditions an a variety of vehicles If you Nave a tough or unusual service repai the TSS Technical Assistance Hot Line can heip Call 1 800 825 5886 prompt 2 to speak with a technical expen with the latest OEM information Chromed Aluminum Wheel Damage 2012 and earlier GM cars and trucks Chemical staining of chrome wheeals in most cases results from acid based cleaners These stains on chrome wheels frequently milky black or greenish in appearance result fram using cleaning solutians that contain acids Soap and water ls usually suti cient to clean wheels Wheel cleaners that are safe for chromed wheels do NOT contain the following Ammonium Bifluorde fluoride source for dissolution of chrome Hydrofluorc Acid directly dissolves chrome Hydrochloric Acid directly dissolves chrome Sodium Dodecyibenzenesultonic Acid Sulfamic Acid Phosphoric Acid e Hydroxyacetic Acid Also keep in mind that many wheel cleaner instructions advise to take care to avoid contact with painted surfaces Many vehicles have painted brake calipers Acidic wheel
20. bber inside which are rated up to 1000V Know where the components are located in the hybrid system and follow all precautions ACDelco Training ACDelco offers a number of advanced technology training courses including Web based Training WBT Instructorled Training ILT and seminars SEM Available ACDelco hybrid system training courses include High Voltage System Safety S ELO6 47 01VVBT Advanced Technology Vehicle Power Electronics 5 ELO6 55 01WBT Hybrid Technology S ELO6 41 01SEM Hybrid Aftermarket Service S EL06 42 01SEM Hybrid Technology and Service S ELOG 12 01ILT Thanks to Steve Bunce Paul Ghanam Mike Pontello and irina Novikova 3 TECHCONNECT First Responders Information Information on GM vehicles with alternative powertrains including models with the latest eAssist system the Volt and other hybrid models is available to first responders and other emergency res cue personnel through the GM Service Technical College at www gmstc com ACDelco service centers may want to point out how to find this valuable infor mation online which emergency vehicle fleet customers may find helpful in their training efforts The website information provides details about the design and operation of GM vehicles with alternative powertrains which may affect how first responders perform in an emergency situation Each supported vehicle or system on the website includes a First Responder Gui
21. ce insights along with helpful information about ACDelco products available Technic Scan the QA code with your smartphone for a list of Service Aids M12 Buick LaC rine and 2012 Bick Regal eAssist Vehicles mye la ny E ad Te eaj E Pe ee TT E Labs pei r ee _ E ae ey ee a gE B J Ee ey yy a a E coed 2 oo oe ead ce a a a ye Eag The information is available free of charge and can be downloaded from the website or printed in order to be displayed in a classroom Thanks to Greg St Aubin New technical product service videos are nvailable on wwwacielcotcchconnccti com al Product To view the videos go to www acdelootachconnect com and click Product Information gt Technical Product Service Aids Thanks to Rick Balaban VIN Cards Available on ACDelcoTechConnect com Service Information To access the VIN decoding informa tion in the GM Service Information build a vehicle with division make and model year information select the Service Manual and then go to General Information gt General Information sub section gt Introduction gt Vehicle Engine and Transmission ID and VIN Location Derivative and Usage Thanks to Mike Golinski GoM Vehicle Identification Number VIN cards for all GM vehicles are available on the ACDelco TechConnect website as well as in the GM Service Information Sl VIN
22. de and or a Quick Reference Sheet This information is intended to help first responders apply existing knowledge of how to remove passengers safely when responding to a GM vehicle involved in an emergency situation Information reviewed may include e Vehicle identification to determine f high voltage circuitry exists in the vehicle High voltage circuit disabling procedures to avoid personal injury in an emergency situation High voltage labels that identify potential electrical hazards Cable cut labels to disable the low voltage system that provides energy to enable the high voltage system High voltage cable location High strength steel location e First responder considerations regard ing fire and water immersion e Vehicle Do Not Cut zones Looking for technical information about the diagnosis and service of brakes drive belts starters alternators and other ACDelco parts Check out the latest technical product service videos available on wvww acdelcotechconnect com Video topics covered include e Brake pads and rotors e Steering system service including pulley removal and installa tion bleeding and flushing as well as steering pump diagnosis e Accessory drive belts including belt slip diagnostics Starters and alternators Powertrain components including 4L60E transmission upgrades and AWD actuator motor service Each of the videos offers a variety of diagnostic tips and servi
23. echnical expert with the latest OEM information Manual Transmission Service Tips When performing service on a manual transmission keep in mind the following tips regarding transmission operation Auxiliary Fluid Cooler When the manual transmission is equipped with an external auxiliary fluid cooler a cooler flushing and flow test should be performed after servicing the transmission for a hard part failure A plugged or restricted cooler can cause a repeat failure as a result of elevated operating temperatures due to insuffi cient flow Also if the transmission flow flush machine has Dexron VI in it remember that Dexron VI is not compatible with manual transmissions It will be neces sary to thoroughly drain the oil cooler and lines before reinstalling them to the transmission Synchronizers When performing synchronizer repairs on a manual transmission the following components associated with the gear being serviced should also be replaced e Synchronizer components e Blocking ring e Speed Gear e Shift Fork Inserts Replacing these components reduces the likelihood of a repeat failure or a future noise issue due to damaged components being returned to service Replacement Oil Filter 2011 Chevrolet Equinox and GM Terrain equipped with 3 0L engine RPO LFVV 2011 Buick Enclave Buick LaCrosse Chevrolet Traverse and GMC Acadia equipped with 3 6L engine RPO LLT GM recommends service replace ment
24. elnsights The Technical Side Sonic s Efficient Powertrains Sonic models are powered by efficient power dense Small displacement engines including the Ecotec 1 4L turbo and the Ecotec 1 8L the same engines used in the new Chevrolet Cruze Three transmissions are available a five Speed manual ora six speed automatic with the 1 8L and a six speed manual with the 1 4L turbo 1 4L 4 Ecotec Turbo delivers 138 HP 8 Oct Dec 2011 Servicelnsights Youthful aggressive design is NES backed by available turbocharged performance and agile ride handling The Ecotec 1 4L turbo s power ratings are estimated at 138 horsepower 103 kW and 148 b ft of torque 200 Nm between 1 850 rpm and 4 900 rpm The wide rpm range for the maximum torque a specific trait of turbocharged engines helps the engine delivera better driving experience and performance Premium design elements give the engine world class smoothness and durability The naturally aspirated Ecotec 1 8L engine has many of the same features of the Ecotec 1 4L turbo Its two stage variable intake manifold allows approximately 90 percent of peak torque to be available from 2 400 rpm to 6 500 rpm It is estimated at 135 horsepower 101 kW along with 123 Ib ft of torque 167 Nm at 3 800 rpm Six speed FWD manual transmission for the turbo charged Sonic Engineered for Agile Athletic Ride and Handling All models feature a MacPherson strut
25. formance Parts offers the Ram Jet 350 which combines the classic look of the original mechanical type injection system with the dependability and optimized performance of contemporary port fuel injection The GMPP crate engine warranty is 2 years 50 000 miles convertible with a 350 The latter project is a prime example of the satisfaction they get from making dreams come true for customers often with the help of GM products That 1969 Chevelle was turned over to them by the wife of a deployed soldier Looking 10 Oct Dec 2011 Servicelnsights Parts Suburban inflod and Custom Classics frist ks EY ay tna LILLIE sie nema a a Bir ie nae ahead to his return from Afghanistan she wanted to surprise him with some restoration work on the car which he d held onto for 20 years as little more than an undriveable frame We got the car and boxes full of parts did a lot of body work and got it fixed up to where it was a huge surprise for him when he got back Shelly says Then he brought it back to us and we did more work which included putting in aGMPP 350 and transmission Three years after it came to them the car is back in one of Suburban s bays awaiting finishing touches on upholstery and some other odds and ends When complete the project will be another source of great memories not just for the owner but for the Plekowskis It s easy to get caught up in the exc
26. ge battery e A driverselectable fuel economy optimizing eco mode for the air conditioning system which enables more frequent and longerduration engine Auto Stop periods continued on page 2 ECMA Start Stop Technology A we z l a i oy x h v W 5 y a i x oe a p k i P K S j a i 2 k i B Sii IN THIS ISSUE Start Stop Technology Aids New Fuel Saving Systems 1 First Responders Information 4 New Online Technical Product Service Videos 4 VIN Cards Available on ACDelcolechConnect com 4 Take the Diagnostic Skills Challenge onthe ACDelco LMS 5 Tech Tips T 6 7 Training Update ee 8 ON THE WEB www acdelcotechconnect com click the TechConnect Magazine link or Log in to the ACDelco LMS click the Resources link 360 Product Offerings Distribution Network e Customer Programs e Marketing Training E Business Relationships Start Stop Technology continued from page 1 The liquid cooled electric induction starter generator is a three phase AC induction machine that serves as a 115 volt AC generator and is used to provide engine power assist as well as to start the engine when in Auto Stop mode As a generator it provides up to 15 kW of AC power to the drive motor control module As a motor the starter generator provides up to 11 kW of electric power assistance and en
27. gine starting The starter generator is con nected to the crankshaft pulley using a specially designed serpentine belt and drive belt tensioner The eAssist generator control and battery module assembly contains the high voltage lithium ion battery pack the integrated power inverter and 14V power module It is located in the for ward area of the trunk compartment and weighs about 65 pounds 29 kg An electric fan cools the generator control and battery module drawing air from a vent located in the package tray behind the rear seat An auxiliary electric driven transmis sion oil pump has been added to keep the transmission fluid flowing and clutches applied when the engine shuts down during an Auto Stop Auto Stop While driving when the brake is applied and the vehicle comes to a complete stop the engine will turn off depending on operating conditions This is referred to as an Auto Stop the tachometer gauge will read AUTO STOP The engine restarts immediately when the brake pedal is released or the accelerator pedal is applied The maxi mum Auto Stop time is two minutes under ideal conditions There are several conditions that may cause the engine to remain running or restart when the vehicle is stopped These include e The engine transmission or high voltage battery has not reached operating temperature e The outside temperature is less the 4 F 20 C e The shift lever is in any gear other than D
28. hout properly diagnosing the condition a message offering suggestions may appear Scoreboard A technician s overall score 15 based upon the amount of time it takes to complete the simulation while following the optimum path The optimum path is the shortest path to efficiently and quickly diagnose and complete the repair as dictat ed by following the Strategy Based Diagnosis process Technicians can retake the sim ulation as many times as they would like in order to improve their score Top scores are posted on the ACDelco LMS Each simulation begins with one hundred points One point is deducted for each choice or selection that is not part of the optimum path In addition after a predetermined amount of time one point is deducted for each minute that passes At the end of the simulation a series of questions are presented and one point is deducted for each incorrect selection Points are not deducted for using the Help tab or for obtaining infor mation on how to navigate within the simulation or Strategy Based Diagnosis process Upon completing the simulation the overall score will appear Technicians that score in the the top five for each simulation will have their score shop name and location posted to the Simulation Scoreboard on the LMS To view the top scores click on the View the Simulation Scoreboard link on the LMS training Home page Try One The diagnostic simulations are accessible via the c
29. itement of these projects Shelly says We re proud of the work we do and we have fun doing it but the most fun is seeing the Satisfaction on the faces of our customers when they pick up their restored vehicle For more information on GM Performance Parts go to www gmperformanceparts com Genuine E Parts Oct Dec 2011 Servicelnsights 11 Genuine Parts We re one stop For your shop Genuine GM Parts Engines and Transmissions Plus all the associated parts you need CLIP AND PLACE BY YOUR TELEPHONE Genuine fi Parts
30. itted 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 2011 General Motors All rights reserved Zz Oct Dec 2011 Servicelnsights PS PN hy N A OE Service Q Now we re making it easier than ever to get competitive pricing on an expanding list of Genuine GM Parts and ACDelco Powertrain Parts your shop needs for everyday repair jobs OE Service quality at pricing you ll like why trust your business or reputation to anything else Q UALIFYING POV gt PULLEYS TENSIONERS BALANCERS gt 4 WHEEL DRIVE ACTUATOR MOTORS gt ENGINE OIL COOLER LINES gt INTAKE MANIFOLDS amp GASKETS gt GENUINE GM PARTS ENGINE amp TRANSMISSION ASSEMBLIES gt CYLINDER HEADS gt TURBO CHARGERS amp SU
31. oil filter PF63 P N 89017525 in order to provide more filter media for additional filtration and strength This is a new filter replacement for high feature V6 applications changing trom PG48 The replacement oil filter PF63 is longer than the OEM produc tion filter ACDelco oil filters are designed to meet the manufacturer s specifications for modern GM powertrains that have higher engine oil pressures increased oil flow rates and extended oil change intervals in both cold and warm operat ing conditions It may be difficult to remove the longer replacement oil filter PF63 without bottoming the filter end cap wrench on the auxiliary cooling fan housing on Terrain and Equinox models It may be necessary to remove the oil filter end cap wrench after loosening the filter yet prior to un threading the filter from the engine adapter The PF68 filter should be installed and hand tightened Then if additional torque is needed install the filter end cap wrench and torque to specification Diesel Engine Ticking Noise 2001 2011 Chevrolet Silverado and GMC Sierra 2006 2011 Chevrolet Express and GMC Savana 2003 2009 Chevrolet Kodiak C4500 C5500 Series and GMC TopKick C4500 C5500 Series equipped with the Duramax diesel engine RPOs LBZ LBZ LGH LLY LML LMM Some diesel engines may exhibit a random ticking noise that is most audible on an engine with a coolant temperature of 158 F 70 C or higher and from idle to
32. otary tensioner ona common pivoting arm which ensures sufficient tension is available in both motoring and generating modes B Generator control module with an inverter and power converter that controls the generator and provides 12V vehicle accessory power C A 36V advanced nickel metal hydride NIMH hybrid battery pack capable of delivering and receiving more than 10kW of peak power D An engine control module with sophisticated Hybrid Supervisory Software to manage both engine and hybri system operation E An engine accessory drive with dual tensioner assembt and rib Aramid cord belt that enables reliable transfer of torqu for both motoring and generating F 4T45 E electronically controlled transmission that includes an auxiliary oll pump and unique hybrid control to ensure seamless hybrid operation G 2 4L 4 cylinder VVT Ecotec engine Safety Considerations High voltage hybrid systems produce voltages higher than a conventional 12V system and even small currents can be dangerous All intermediate voltage circuits are identified with blue wiring conduits Safety precautions are described in appropriate Service Information Become familiar with these precautions and always observe them Some important safety practices Remove or cover belt buckle a Wear safety glasses Wear rubbersoled shoes Itis recom mended to wear class 0 isolation gloves leather Class 0 isolation gloves outside ru
33. rive D e The high voltage battery state of charge is low e The climate control system requires the engine to run based on the climate control or detog setting Using the eco air condition ing mode will result in more frequent and longer Auto Stops e The Malfunction Indicator Lamp MIL is illuminated To view the parameter for an Auto Start review the scan tool Hybrid Data list available in the engine control module This list contains parameters that are directly related to the Auto Start Stop feature Look for Eng Auto Start Reason This parameter will list the last command that caused the Auto Start feature to engage Electric Boost The eAssist system also uses power stored in the 115V lithium ion battery to provide an electrical boost in various driving scenarios The high voltage battery system is designed to provide power assistance to the internal combustion engine rather than store energy for all electric propulsion While in fuel shut off mode the induction motorgenerator unit continues spinning along with the engine to provide regenerative braking torque smoothing and immediate take off power when the driver presses on the accelerator Then as the vehicle comes to a stop the induction motor generator unit spins the engine bring ing it to a smooth stop properly positioned for an immediate restart when the driver releases the brake pedal or applies the accelerator pedal Power Electronics The
34. ronic device is removed from the front passenger seat the DTC willl go into history If this happens all Sensing and Diagnostic Module SDM and PPS DTCs should be cleared using a scan tool If the DTC ts still current follow the service procedure in tha GM Service Information for that DTC Never rest the diagnostic scan tool or components on the passenger front seat or touch the passenger front seat while the diagnostic scan tool is mi con tact with your body This may cause the SIF lamp to illuminate while holding the diagnostic scan tool because your body can transfer the electronic noise to the sensor mat in the passenger front seat Advise customers to avoid placing the electronic device on the front passer ger seat in the future For tes technical digseta assistance and product information regarding spacific ACDelco products contact these toll free information Brakes 1 888 701 6169 prompt II Chassis 1 888 701 6169 prompt 2 Clutches 1 888 725 8625 Lift Supports 1 900 790 5438 Shocks 1 877 466 7762 Starters and Alternators EEI 1 800 228 9672 Steering bib lege ae Pinion Gears 45567 Wiper Blades 1 800 810 7096 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 to speak with a t
35. st build up should be removed from wheels by using a chrome cleaner and polish After cleaning the wheel should be waxed to help protect it from brake dust and reduce adhesion of any brake dust that gets on the wheel surface It s vital to keep the wheels clean and Tree of prolonged exposure to brake dust build up in order to maintain a quality wheel appearance Passenger Presence System Indicator On Due to Electronic Devices 2009 2017 Cadillac CTS Chevrolet Impala GMC Acadia 2010 2012 Cadillac SRX Chevrolet Equinox GMC Terrain 2009 2010 Chevrolet Cobalt excluding 55 Saturn OUTLOOK 2009 2011 HHA fexcluding 5 2010 Saturn VUE and 2012 Chevrolet Sonic When certain electronic devices such as computers MP3 players cell phones a scan tool etc are placed on the front passenger seat the front pas senger airbag indicator may illuminate The seat belt reminder light chime may also be activated 6 TECHCONNECT This is due to the fact that some elec tronic devices placed on the front pas senger seat may interfere with the elec tric field generated by the Passenger Presence System PPS system caus Ing it to enable turn On the passenger airbag and turn on the safety belt reminder light and chime even though the seat is not occupied The electronic device does not necessarily need to be tumed on to cause this cor dition Several Diagnostic Trouble Codes also may set depending on the vehicle lf the elect
36. stics Engine Performance Air Induction and Fuel S EP08 04 01ILT S EP08 05 01ILT S EP08 81 02ILT S SS04 01 01 ILT S ST10 01 01 ILT 8 TECHCONNECT System Diagnostics Engine Performance Fault Monitoring and Emission System Diagnostics Engine Performance Advanced Driveability Diagnostics Duramax Diesel Operation and Diagnosis Vibration Correction Diagnostics Supplemental Restraint Systems Genuine ul Parts Repair Industry News amp Updates cont d Representatives will be on hand to talk about everything from brakes and shocks to belts and hoses to engine and transmission parts We re looking forward to getting back to AAPEX to spend some great one on one time with our distributors and suppliers says Curt Collins associate marketing manager Our overarching message is going to be that we re more than a parts company that we provide a lot of information training and support beyond the parts in the box and that we re part of something bigger and more powerful In addition to displays of selected parts the booth also offers kiosks where visitors can learn about training eBusiness and the new ACDelco illustrated eCatalog featuring GM applications Indy Pace Car On Hand at AAPEX Visitors to ACDelco s booth at the 2011 AAPEX show in Las Vegas will be able to get up close and personal with the Camaro convertible pace car for the 2011 Indy 500 Oct Dec 2011 Servic
37. technical service bulletins that turn up later Loch says Aftermarket products can t say that Sales typically skyrocket in November as the first snowfalls bring out the plows and commercial applications and owners discover the motors need replacing Loch says Now may be a good time to stock up Three new reman actuator motor applications cover millions of popular 4WD vehicles For Tahoes and Silverados For Tahoes Silverados For mid size pickups and 2003 2007 and Yukons with 4L80 SUVs 1992 2005 Part number 19125571 the first transmissions 2003 2007 Part number 19125573 is designed to be introduced has applications Part number 19125578 is for heavy for mid size pickups and SUVs made in 4 wheel drive full size pickups duty applications in model years from 1992 2005 and SUVs like Chevrolet Tahoes and 2003 2007 Tahoes Silverados and Silverados spanning the 2003 2007 Yukons with 4L80 transmissions are model years typical makes models 4 Oct Dec 2011 Servicelnsights Genuine Parts Repair Industry News amp Updates With A Few Mouse Clicks MORE relief for the daily parts hunt now in sight The RepairLink with MORE Mechanical Original Replacement Equipment web based platform brings OE parts suppliers including Genuine GM Parts their dealer networks and ISCs together in an unprecedented collaborative effort to facilitate parts ordering The service available at no cost to an ISC
38. uncompromised safety features for the life of the vehicle Oct Dec 2011 Servicelnsights 9 Business of Repairs Kansas restorer s projects often share common my PERFORMANCE i PARTS oe e a2 GM Powertrain solutions With years of experience building street rods on the side Jim Plekowski had seen his share of performance engine builders and non OE engines Turning his attention to full service custom restoration and modernization he wanted to focus more on design and custom fabrication and less On core powertrain matters That s where the GM product When virtually every project that comes into the Merriam Kan shop is a prospective adventure owner Jim Plekowski portfolio delivers values the certainty that GM Powertrain products offer We know exactly what we re getting with GM hae ee Performance Parts GMPP engines and it s usually AS Eueu ea seye ADs something that s pretty easy to install says Plekowski BUI oe OU GOERE ae With other aftermarket engines many parts end up not A na ELS HD Sere aona l what they build If you have an issue like overheating problems which are common fitting We have to stand behind everything we install and with the GMPP products and the warranty there are usually i that relate to machine work that may not have been done properly you get into the no big surprises or unknowns Regardless of the make or project scope GMPP engines i and tr
39. vice evaporator accumulator and receiverdrier Various lubricants and electrical components also are reviewed S AC07 02 01VCT HVAC System Operation and Service Hints This VCT course covers air conditioning system operation such as changes to the state of refrigerant pressure and temperature safety procedures and diagnostic procedures Training Schedule To search for currently scheduled courses click the Schedule link Select search terms from the dropdown menus and click the Submit button Current Instructor Led Training ACDelco s ILT courses provide hands on instruction on the latest automotive systems The following ILT courses are currently being held at training center locations around the country Course Number S AC07 02 01 ILT Course Name Automotive Air Conditioning Advanced S AC07 03 01 ILT Refrigerant System Diagnostics HVAC Control System Operation and S BK05 01 01 ILT Diagnostics Braking Systems S BK05 02 01 ILT ABS Operation and Diagnosis S EL06 04 02ILT Network Communication Diagnosis S ELO6 10 02ILT S ELO6 11 02ILT Electrical Power Management Enhanced Automotive Circuit Diagnosis S ELO6 12 01ILT S EL06 13 01 ILT Hybrid Technology and Service Body Electrical Global Diagnostics S EL06 14 01 ILT Advanced Body Control System Electrical S EP08 02 01ILT S EP08 03 01ILT Diagnostics Engine Performance Computer Controls and Ignition System Diagno
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