July/September 2010 - GM Service Insights
Contents
1. And since this is new equipment it relieves repairers of having to deal with core charge issues on a remanufactured unit GM Performance Parts GMPP engineers have succeeded in expanding the versatility and appeal of the ground breaking E ROD emissions compliant crate engine package by calibrating it to work with most manual transmissions The LS3 manual E ROD package carries the same list price and comes with the same parts as the automatic LS3 version which is rated at 430 horsepower The difference is the programming of the electronic control module allowing the engine to work with a manual gearbox GMPP recommends pairing the engine with the six speed manual part number 92236241 that comes in the current model year Camaro The manual version allows car builders to go with a wider selection of powertrains according to Dr Jamie Genuine E ROD crate engine Meyer GMPP product marketing manager A stick shift is Ideal for muscle cars sports cars kit car builders and off roaders who may like a manual The engine follows the standard LS bolting pattern and works with a wide selection of clutches and flywheels that can be purchased through any GM dealer Already the manual E ROD has attracted the interest of the off roading community Meyer says Four Wheeler magazine has outfitted a Jeep CJ8 with one Additionally 4Wheel amp Off Road magazine is doing a Jeep CJ8 project vehicle wi2. One available interface device is the Bosch Mastertech Vehicle Communication Interface VCI which is designed to connect the vehicle to a TIS 2 Web PC to transfer data and reprogramming calibrations to the vehicle control module The VCI also offers domestic and Asian OEM scan tool functionality back to the 1996 model year as well as J2534 2 reprogramming Tools for GM reprogramming can be purchased from Bosch Diagnostics OTC or GM Dealer Equipment For more information go to www acdelcotechconnect com click the TSS tab and select the Bosch diagnostics equipment link or go to www gmdesolutions com services To review recommended computer hardware specifications and Internet connection guidelines visit www gmdesolutions com services standards php More Information To learn more about service programming there are several training programs available through the ACDelco Learning Management System including hands on courses seminars and Web based TechAssists Go to www acdeleotechconnect com and click the Training tab The NASTF website www nastf org also has a repro gramming section that lists manufacturers requirements and tool information In addition the ACDelco eBusiness Help Desk can answer questions regarding TIS 2 Web and service programming Call 1 888 212 8959 for more information Thanks to Bob Stewart 5 TecHConnect The following technical tips provide repair information about specific conditions on a va
3. FRPR 2 DEF pump and DEF injector The ECM has more than 160 new DTCs The Glow Plug Control Module GPCM is located on the alternator bracket on the right side of the engine The GPCM also provides regulated B for the NOx sensors and reductant heaters Aftertreatment System The new Duramax diesel engines use an aftertreatment system to reduce oxides of nitrogen NOx by 90 This system mixes automotive grade urea also known as Diesel Exhaust Fluid DEF with NOx to convert the pollu tants into nitrogen water and trace amounts of CO2 The urea is quickly hydrolyzed to produce oxidizing ammo nia Two NOx sensors are used by the ECM to adjust DEF dosing in the exhaust system The Diesel Particulate Filter DPF operates the same as on previous engines to remove diesel particulate matter or soot from the exhaust The Hydrocarbon Injector HCl is located on the right side of the engine with a nozzle located in the exhaust downpipe between the turbo and the Diesel Oxidation Catalyst DOC Diesel fuel is injected into the exhaust system ahead of the DOC to raise the temperature of the exhaust for DPF regeneration The regeneration parameters are still based on time distance fuel and soot loading but the algorithms used to determine regeneration now allow more time between generation events Thanks to Chris Graham Kevin Larson and Bill Carnevale Clean Diesel Exhaust Chemistry In 2010 diesel engin
4. INT LIGHTS is open it will cause the right front turn signal to be inoperative The right rear turn signal will still function and the courtesy lamps will still function If the fuse in the UBEC labeled INT LTS PNL DIM is open the courtesy lamps will be inoperative The instrument panel cluster backlighting will still function Diagnostic Assistance For free technical diagnostic assistance and product information regarding specific ACDelco products contact these toll ree information hotlines staffed by ASE certified technicians Brakes 1 888 701 6169 prompt 1 Chassis 1 888 701 6169 prompt 2 Clutches 1 888 725 8625 Lift Supports 1 800 790 5438 Shocks 1 877 466 7752 Starters and Alternators 1 800 228 9672 Steering 1 866 833 5567 Wiper Blades 1 800 810 7096 Trainin How to Take ACDelco Training Go to wwwaacdeleotechconnect com and click on the Training tab to log on to the ACDelco Leaming Management System LMs New VCT Training The new Virtual Classroom Training VCT courses enable participants to talk directly with instructors and other participants during the live training on the Web The current VCT schedule includes the following courses Click the VCT courses link to view the available courses and enroll Course Number Course Name S ACO7 02 011LT Automotive Air Conditioning Advanced Refrigerant System Diagnostics S ACO7 03 01
5. door lock inoperative no start or no crank One possible cause of these conditions may be the interior wiring at the 361 J361 splice Inspect splice 361 J361 parking lamp circuit located in the body hamess under the driver s seat A Body harness under the driver Remove the driver s seat from the vehicle and the driver s door opening carpet retainer Peel back the carpet to about the B pillar and inspect the wires If there is any damage repair splice 361 J361 and other wires Be sure to shrink wrap any repairs to protect against moisture If there is excessive moisture or water evident watertest the vehicle for any leaks Replacement Rear Leaf Spring 2004 2009 Colorado or Canyon Replacement spring When installing a replacement rear leaf spring technicians may notice a change in the diameter of the center alignment bolt on the replacement spring Inspect the replacement spring center alignment bolt If the head of the bolt measures approximately 15mm it is a new design spring Perform the following modification to allow installation of the replacement spring to the axle 1 Obtain a 19 32 drill bit Do not make a substitution for this drill bit size Failure to use the specified size could alter the alignment of the vehicle and the driveline 2 Carefully center the drill bit on the hole in the mounting plate on the axle and enlarge the hole 3 Install the replacement spring verifying prope
6. the electric motor is capable of attaining 60 mph in less than nine seconds and a top speed of 100 mph i Engine Generator _Lithium ton Battery Electric Drive Unit ACBelco a JC e eliConnec July amp August 2010 Internal Combustion Engine Technology Seminars The technology being introduced in the internal combustion engine has delivered a smarter working engine producing fewer emissions resulting in engines that are more efficient yet more powerful than ever before Emissions standards continue to become stricter each year Internal engine design changes and exhaust aftertreatment are some of the ways those new standards are being met The new technology of the modern internal combustion engine is high lighted in four new modular ACDelco seminars Designed to be offered as one hour Lunch and Learn training events they can be delivered as one hour stand alone courses or combined to provide an in depth training program for your service center The new Internal Combustion Engine Technology seminars are Advanced Variable Valve Timing S EM01 01 01SEM Camshaft Variable Lift Systems and Active Fuel Management S EM01 02 01SEM New Duramax Diesel Engines Compared with the emissions of gasoline engines diesels have typically offered benefits particularly in hydro carbons and carbon monoxide But controlling nitrogen oxides NOx and particulate mass PM ha
7. Camaro While each come with their own peculiarities and challenges one theme common to many is the presence of GM Performance Parts GMPP crate engines While the shop does many GM restorations it also handles other makes that make ideal platforms for GMPP crate engines July Sept 2010 Serviceinsights and associated parts The company looks to several Los Angeles area GM dealers for engines and transmissions as the need arises Putting a new GM powertrain in a restoration vehicle is getting a lot easier Erskine says Several companies are making cross members and motor mounts for GM engines and transmissions that allow applications into many different makes You simply weld the mounts into the frame and you re good to go The big emerging trend in restorations Erskine says are projects that retain the look but boost the performance to modern day standards Examples are a 1935 Plymouth that was brought in with an original engine rated at 68 horsepower It left with a 350 cublc inch 290 horespower GM crate engine paired with a GM 700 R4 transmission and a GM positraction rear end assembly We stick with Genuine GM Parts when we can says Erskine The warranty is good and the quality and the pricing are there You can t rebuild for the price of many of the engines they offer And with GM standing behind it we know we ll never have to eat an engine job This 93 Camaro recently ended up wit
8. continue to be severely limited When adding DEF to an empty or very low tank always add at least one gallon 3 78L of fluid to release the vehicle from speed limitation DEF Availability The DEF infra structure is expected to grow over the next few years DEF will be made available at dealer ships fuel stations truckstops pumps as well as small containers and other locations that sell automotive fluids DEF is available from ACDelco in one gallon 10 4022 19286291 and 2 5 gallon 10 4023 19286292 packages Thanks to Mike Militello ACVelco Diese Exhaust Fluid Fluide d chappement au diesel CAUTION AVERTISSEMENT naa pi re ea SN nod rants anw EN WNT TS 4 TecuConnect GM began service programming of Engine Control Modules ECM on some vehicles in the 1993 model year By the 1996 model year nearly 100 of GM vehicles had programmable ECMs Soon after Body Control Modules BCM ABS modules and other controllers were reprogrammable as well Today some GM vehicles such as the 2010 Camaro have as many as 38 reprogrammable controllers That number will only continue to grow as more and more electronic features are added and elec trical and communication systems become more sophisticated Reprogramming can be used by OE manufacturers to update module software to improve or modify operation Most manufac turers now release software revisions regularly to update system operations eng
9. the camshaft By advancing or retarding cam timing the engine can improve low end torque high end horsepower or light oad fuel economy all while reducing emissions The seminar covers the operation of the different types of cam phasing devices spline phaser in overhead cam engines and vane phasers in overhead cam engines and carn in block engines System testing and service precautions are reviewed as well continued on page 2 IN THIS ISSUE Internal Combustion Engine Technology Seminars New Duramax Diesel Engines Clean Diesel Exhaust Chemistry Getting into the Reprogramming Business Tech Tips Training Update New Online Virtual Classroom Training IN THE WEB www acdelcotechconnect com click the TechConnect Magazine link or Log in to the ACDelco LMS Resources link Engine Technology Seminars continued from page 1 Camshaft Variable Lift Systems and Active Fuel Management A camshaft variable lift system is an advanced variable valve actuation technology that changes valve lift duration and timing In this seminar the operation of several different valve lifter systems is covered including a look at the roles of various components such as the valve lifter oil switching valve and engine oil pressure switetvoil temperature sensor In addition the seminar reviews the GM Active Fuel Management system which deactivates four of the eight eng
10. 1LT HVAC Control System Operation and Diagnostics S ACO7 06 011LT Toyota HVAC S ACO7 O7Z01ILT Chrysler HVAC S BKOSOL0IILT Braking Systems S EL06 04 021LT Network Communication Diagnosis SEL06 10 02ILT Electrical Power Management SEL06 11 01ILT Automotive Electrical Circuit Diagnosis and Repair Course Number Course Name SEL06 12 011LT Hybrid Technology and Service Camshaft Position SEMOLOLOIVCT Actuator Systems Engine Performance Computer Controls and Ignition System S EMO1 02 01VCT Operation Active Fuel Management S FNOO OLOIVCT How to Use VCT Current Instructor Led Training ACDelco s Instructor Led Training ILT courses provide hands on instruction on the latest automotive systems The following ILT courses are currently being held at train ing center locations around the country Click the Schedule link on the LMS Menu to search the latest training schedule for courses held in your area S EPOB O2O1ILT Diagnostics Engine Performance Air Induction and Fuel System S EPOB O3 01ILT Diagnostics Engine Performance Fault Monitoring and Emission System S EPOB O4OIILT Diagnostics S EPO8 05 01ILT Engine Performance Advanced Drivability Diagnostics S EP08 20 011LT Toyota Engine Performance S EP08 21 011LT Chrysler Engine Performance S EPO8 81 011LT Duramax 6600 Diesel Engine Performance SS04 01 011LT Vi
11. July Sept 2010 2010 ZR1 is the most powerful pear production Corvette ever built gt New V5 A C Compressors now available WITH 638 HORSES co IT S LIKE A ROCKET l ON ae New Vette s Launch Control feature optimizes traction for greater and more consistent on track performance Details on page 7 GM Parts Product Update The latest word on product development and technologies Repair Industry News amp Updates Get state of the industry perspectives from GM insiders 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 GM Servicelnsights Online More Genuine GM Parts resources and links Download this issue and past issues of GM Servicelnsights magazine at www gmserviceinsights com 0 Serviensights Headquarters 250A NLE Indust De 230 N kansas ny MO a17 Eman bdavideproactroup com Compliments ot your GM dealer We Inte your input and suggestions ace adres letters to the extort the above address Letters submitted imply the right to edit and he responsinarty of GM ay GM dese or he companies or inniauats who create produce and sete this magazine Offers and ping may change at any time without prior natiheation The desciptons and specifications in Inis publikation were yn effect at the Tene of approval for printing General Motors r
12. VTC can be done up to one hour prior to the session start time If you try to enroll in a session that starts within an hour you will 8 TecuConnect receive a Past Cutoff Date message and will need to select another session What s Needed to Participate It is important to make sure that the computers and connections used for VCT training meet the minimum require ments necessary to launch a course To participate in a VCT you will need PC headset with attached microphone Standard Internet broadband connection Windows 2000 Professional Vista or XP Interet Explorer 6 or higher Adobe Flash Player 8 or higher Screen resolution of 1024 x 768 For more information on the require ments for VCT refer to the VCT User Guide located under Menu gt Resources in wwwacdelcotraining com Thanks to Dan Carter Genuine Eq Parts The Technical Side The ZR1 returns for 2010 with new Performance Traction Management PTM technology It is an advanced system that is part of a new Launch Control feature that optimizes traction for greater and more consistent on track performance The Corvette ZR1 is powered by a supercharged and intercooled 6 2L engine that is hand assembled at GM s Performance Build Center It is rated at allow us to compete head to head with more marketplace 638 horsepower 476 kW making it the most powerful competitors while increasing both the production content production car e
13. a chemical reaction with the NOx in the exhaust gas produces nitrogen N2 water H20 and small amounts of carbon dioxide CO2 which are natural elements common in the air Diesel Exhaust Fluid DEF is a colorless clear solution of water and urea that has 32 5 0 7 of urea by weight DEF also is referred to by other names such as AdBlue ClearBlue Urea and Aus32 Aqueous Urea Solution The recommended temperature for storing DEF is between12 F 86 F 11 C 30 C To prevent DEF decompo sition it should not be transported or stored at temperatures above 77 F 25 C The shelf life of DEF depends on storage temperature and exposure to sunlight At a constant ambient storage temperature of 50 DEF may have a minimum shelf life of 36 months But at a constant ambient storage tem perature of 86 F it may have a minimum shelf life of only 12 months DEF also freezes below 12 F but it may be reused once it thaws Before using DEF be sure to check every batch of fluid for potential evaporation Driver Requirements The operation of the aftertreatment system for NOx reduction is transpar ent to the driver There is no change in vehicle performance or driveability The only requirement of the driver is to replenish the DEF when the instrument cluster prompts to do so or at regular oil change intervals whichever comes first DEF usage is heavily dependent on drive cycles and will vary from vehicle to vehicle The DEF f
14. anged to enhance oil film thickness and oil pump flow is increased In the cooling system the thermostat is equipped with bleed holes to improve bleeding air from the system The ther mostat must be positioned with the bleed holes oriented toward the front of the engine Orient the thermostat with t toward the front of the engine An oval air filter is used on vans and a flat panel air filter is used on pickups Also on pickups the charge air cooler system has plastic lock rings on the inlet and outlet ducts Twist the lock ring counterclockwise to release the tabs A single variable nozzle turbocharger VNT is used The oil feed has been relocated from the number 4 cam bear ing to a dedicated supply port at the left rear of the engine valley The EGR valve and stepper motor are contained in one unit The position sensor now reflects the true position of the valve the valve moves when the stepper motor extends or retracts A single EGR cooler is used on the LGH engine for Express and Savana van applications and a dual cooler is used on the LGH engine for Silverado and Sierra truck applications The LML engine for the pickups also uses a dual cooler with an EGR cooler bypass con trolled by the ECM to prevent coking of the EGR cooler during light load and idling Fuel System Features The fuel system supply side is equipped with a fuel filter vacuum switch near the fuel filter The switch opens if there is a res
15. art number 19211051 is for model 2007 2009 vehicles and requires the purchase of a new oll pump and screen Part number 19168066 is model year 2004 2006 applications and requires purchase of an application specific new oil pump assembly and screen Part number 12491673 is for 2001 2003 gasoline applications It includes a high volume oll pump assembly Part number 88984300 is for 2001 2003 applications and comes with a high volume oil pump assembly All engines carry GM s 3 year 100 000 mile Service Replacement Powertrain Limited Warranty The engines are emissions certified for direct replacement in all 50 states Vortec 8 1L V 8 2008 L18 medium duty LRZ option for the GMC Topkick Juy Sept 200 Servceinsignts EN GM Parts Product Update cont d GM s popular front wheel drive transmission the 4T65E controlled transmission Since 1997 more than 8 million Buick Chevrolet Oldsmobile Pontiac and Saturn passenger cars and minivans have been equipped with GM s Hydra Matic 4T65E four speed electronically Now remanufactured versions of the 4T65E are available at new attractive pricing to respond to the growing number of consumers choosing to repair or replace major powertrain components on aging vehicles Always the Right Fit With a remanufactured version of the 4T65E transmission your customers are assured of getting a plug and play transmission that exa
16. bration Correction Diagnostics S ST10 01 011LT Supplemental Restraint Systems New Online Virtual Classroom Training Taking an online class with live interaction with an instructor is now a reality with ACDelco s new Virtual Classroom Training VCT sessions VCTs are a new learning technology that enables participants to engage directly with the instructor other participants and subject matter experts along with viewing video and animations in a live classroom setting over the Internet With VCTs technicians who may find it difficult to attend traditional classroom training at a specific location will be Whee tip Posie a Sip VCT participants interact live with an Instructor just as they would In a classroom setting TS PU OO16 10 able to sign up for classes that can be launched directly from their computer Upcoming technical VCTs will cover new repair and diagnostic techniques as well as specific instruction on a variety of service issues How to Enroll Log in to www acdelcotraining com to enroll in a VCT just as you would for any other training program available through the ACDelco Learning Management System Courses can be searched by clicking Menu gt Schedule gt Search Course Sessions Enter the desired criteria and click Submit Select the desired course The system will list all available ses sions of the selected course including dates and times Enrollment in a
17. ct the surge tank inlet hose quick connect fitting 1 from the radiator 8 Disconnect the surge tank inlet hose 2 from the radiator Vehicles equipped with a transmission oil cooler disconnect the upper transmission oil cooler line from the radiator Refer to Transmission Fluid Cooler Hose Pipe Quick Connect Fitting Disconnection and Connection 10 Vehicles equipped with an engine oil cooler disconnect the upper engine oil cooler line from the radiator Refer to Engine Oil Cooler Hose Pipe Replacement 71 Baise and support the vehicle Refer to Lifting and Jacking the Vehicle 12 Disengage tension on the radiator outlet hose clamp 1 at the radiator using the 38185 Hose Clamp Pliers 1 Disconnect the radiator outlet hose 2 from the radiator 14 Vehicles equipped with a transmission oil cooler disconnect the lower transmission oll cooler line from the radiator Refer to Transmission Fluid Cooler Hose Pipe Quick Connect Fitting Disconnection and Connection 15 Venicles equipped a with engine oll cooler disconnect the lower engine oil cooler line from the radiator Refer to Engine Oil Cooler Hose Pipe Replacement 1 6 Remove the radiator from the vehicle Installation Procedure 1 Install the radiator to the vehicle 2 Raise the vehicle J Veiis equipped with an engine all cooler connect the lower engine oil cooler line to the radiator Refer to Engine Oil Cooler Hose Pipe Replacement 4 Veh
18. ctly fits thelr vehicle and is enhanced with the most up to date GM Powertrain transmission technology For more information on pricing and availability of the GM Reman 4T65E transmission call 866 637 2787 or contact your GM dealer NEW V5 COMPRESSORS GM has unveiled a new option for replacing V5 air conditioning compressors in older GM vehicles As of May service providers can now purchase new ACDelco branded V5 compressors that conform to original equipment specifications With these compressors shops now have another choice besides a remanufactured aftermarket V5 or a more expensive GM OES version The new V5 is available in 17 part numbers that cover the most common V5 GM applications The VS compressor was installed E iv sept 2010 servicetnsights in many small and medium sized GM vehicles built from the late 1980s through the mid 2000s The ACDelco product is a 5 cylinder variable displacement wobble plate design that incorporates many of the same features as the OE products With a tin plated forged aluminum swash plate swagged connecting rod joints and a helical upstroke spring the compressor meets OE performance and durability standards Available through GM dealers the compressor gives shops a chance to replace old V5 units with a mid range solution This gives shops an opportunity to offer a less expensive repair option for customers with older vehicles says Ted Brundle GM product specialist
19. deliver a fuel savings of 15 This seminar reviews the operation of HCCI technology as well as the valvetrain and injection strategy used in a HCCI engine Since HCCI combustion is sensitive to a number of factors such as climate humidity and fuel composi tion a variety of injection parameters and valvetrain adjustments are made during operation Learn More In addition to the new engine technology seminars ACDelco offers on demand online Web based courses and a variety of instructorled hands on courses To review the latest training courses available log in to the ACDelco Learning Management System LMS at www acdelcotraining com To learn when ACDelco seminars will be scheduled in your area contact your local ACDelco distributor Thanks to Mike Militello 2 TecHConnect Volume 17 Number 4 TS PU 0016 10 ACDelco TechConnect is published bi monthly and online for technicians af Total Service Support counts to provide timely and improve the performance of the service center ACDelco 380 represents our mission to look at our businesses at every possible angle to provi value and assistance to our distributors and sustomers as well as offer a full circle of support with programs tools training and marketing focused on enhancing and growing our partnership successfully Publisher Mike DeSander ACDelco E mail lt mike desander gm com Editor Mike Militello ACDelco E mail lt a michael m
20. ehicle possibly a CTS V Cadillac coupe It will be good to be back at the show and have the opportunity to meet our customers and share with them what we re doing with the ACDelco line Collins says E uv sept 2010 servicetnsights Volt Countdown Continues Chevrolet Plug In will open new era in powertrain propulsion technology Come November 2010 the world s first commercial plug in hybrid electric vehicle the 2011 Chevrolet Volt will make its debut and usher in a new chapter in automotive technology The essential difference between the Volt and other types of hybrid vehicles Is that propulsion is provided exclusively by its 120 kw electric motor A 16 kw lithium ion battery linked to a plug in charger powers the motor for the first 40 miles after that during extended range mode that adds another 300 miles of reach it comes from an onboard generator powered by a four cylinder 1 4L engine connected to two fuel storage tanks with a combined 12 gallon capacity The engine and generator activate when 70 percent of the battery s charge is depleted In addition to powering the motor during extended range mode the generator returns some energy to the battery Energy also Is captured via regenerative braking in both electric mode and extended range made Although its energy source is electricity not an internal combustion engine the Volt is designed not to skip a beat in performance Rated at 150 horsepower
21. es sold in the U S are required to meet new Environmental Protection Agency EPA emissions requirements To meet the standards for nitrogen oxide NOx reduction the new Duramax Diesel engines in full size GM trucks and vans feature a Selective Catalyst Reduction SCR system that uses automotive grade urea known as Diesel Exhaust Fluid DEF that is mixed in the exhaust stream causing a chemical reaction that converts the gases into mostly nitrogen and water The DEF in the vehicle must be refilled periodically similar to the fuel tank but not as often Diesel Emissions Control The SCR aftertreatment system on the new Duramax Diesel engines causes NOx reduction reactions to occur in the exhaust stream It s called selective because it uses ammonia as a reductant to reduce NOx levels within a catalyst system The Engine Control Module ECM controls the DEF delivery system Based on the engine NOx emis sions level communicated to the ECM by the NOx sensors the ECM will send a command to the DEF injector to dose a Aftor treatment System Diesel Oxidation Catalyst DOC DEF injection and mixer Diesel Exhaust Fluid DEF Selective Catalyst Reduction SCR Diesel Particulate Filter DPF Exhaust cooler nmpppp given quantity of DEF The injected DEF combines with the exhaust gas with the help of mixers before contacting the SCR The SCR brick stores the ammonia and through
22. eserves the ight ta change specifications without notice and without obligation Published eter go nat necessary eflect tne opinions of General Motors Genera Motors Parts ene Motors LLE Deto 4202 2010 General Motors LLC AI igts reserved Genuine ou Parts Product Update New GM reman 8 1L V 8 The newly released reman 8 1L 496 cubic inch V 8 engine is designed for GM heavy duty pickups full size vans and light and medium duty trucks in GMC and Chevrolet model years 2001 2009 Models include Kodiak Topkick Suburban Avalanche Yukon Escalade Express Savana and many medium duty applications The long block engines based on the L18 code big block offer an economical alternative to rebullding while duplicating the performance characteristics of the stock engine They re designed to install easily allowing for the simple transfer of accessories and components like the oil pan valve covers and balancer GM followed its standard rebuilding process in designing the new release It comes with remanufactured components including the cylinder block rotating assembly and cylinder heads as well as new bearings seals gaskets intake and exhaust valves hydraulic roller lifters graphite anodized coated hypereutectic pistons premium piston rings and timing chain GM Is offering the engine in multiple configurations All except one part number 12491673 are both gasoline and CNG LPG capable KL5 equipped P
23. f reprogramming jobs that it would take to break even Programming Subscription TIS 2 Web is GM s Web based programming application and software that includes Service Programming Systems SPS for GM vehicles required to reprogram GM vehicle control mod ules Tech 2 scan tool software download and the Tech 2 View and Tech 2 Snap Shot diagnostic applications It can be used with generic J2634 devices Several TIS 2 Web subscriptions are available Option 1 TIS All GM Saturn Saab Option 2 TIS SPS GM Saturn Saab service program ming software only Option 3 TIS All Saab Saab only Option 4 TIS Tech 2 Updates Tech 2 software only For complete details on TIS 2 Web or to subscribe go to www acdelcotechconnect com and click the TIS 2 Web link under GM Service Information on the left side of the page Information about GM vehicles that have had updated calibrations for reprogramming released is available for free online Go to tis2web service gm com tis2web to input a specific vehicle s VIN the site will return the vehicle s calibration history Vehicle calibration information Is available free online Tools and Equipment The equipment needed to perform complete reprogram ming on GM vehicles includes a compliant J2534 interface device or scan tool with programming capability such as the Tech 2 as well as a computer with the appropriate operating system and a high speed Internet connection
24. h this GMPP 223 crate engine under the hood The shop s knowledge base on GM Powertrain based restoration jobs along with its reputation got a big boost from its involvement in Foose s Overhaulin television show Invited to take part by GM which was touting its GM Powertrain warranties as a sponsor Duguid one of his employees and a GM Parts rep pitched in on a 1996 Chevrolet Tahoe customization that spanned seven days and involved 10 people Followed constantly by multiple cameras searching for the hottest project action the team transformed the vehicle from a stock Tahoe into a customizer s wildest dream It incorporated an Escalade front end along with a GM Parts 5 7L 350 cubic inch crate engine paired with a GM 4L60E transmission A big focus of the project was the drivetrain says Duguid The owner had put a lot of aftermarket components on the vehicle that we had to take out and replace with components that would make it look under the hood like it did when it came out of the showroom We didn t know why it had stopped running and we weren t sure if it was an electrical problem he says So we ended up changing everything related to the vehicle start up process At the end of the day the 7 day period when the key was turned it fired right up Genuine E Parts Although the project s scope and pace was unlike anything the shop had faced before or since Erskine says it was i
25. he gloves The ECM supplies high voltage and provides a ground Voltage is supplied up to 160 volts at 20 amps and can peak up to 240 volts This causes the injector to open The capacitor dis charges through an injector for initial opening and holds open with 12 volts The piezoelectric fuel injectors operate at high voltage indicated by the orange injector harness Injectors are grouped into four pairs 1 4 6 7 2 5 and 3 8 If a condition is detected in a group that group is disabled and a DTC is set On the fuel system return side the return lines are now equipped with snap in connections The return side is under pressure A pressure retention valve maintains 0 4 to 1 1 mPa of pres sure within the return lines to provide proper fuel injector operation Improper injector return line pressure may cause a no start or performance concern If the engine runs out of fuel or if the fuel system is serviced the system must be primed After priming a feed 3 TecuConnect Piezoelectric Injector A Nozzle B Control valve C Hydraulic amplifier D Piezo actuator E High pressure supply line from the low pressure side of the pump backfills the injector return lines The feed line will also backfill if pressure falls below 0 3 mPa in the injector return lines Electronic Control Features The larger Bosch E86 ECM has three connectors instead of two It also con trols the HCI Hydrocarbon Injector
26. icles equipped with a transmission oil cooler connect the lower transmission oll cooler line to the radiator Refer to Transmission Fluid Cooler Hose Pipe Quick Connect Fitting Disconnection and Connection 5 Connect the radiator outlet hose 2 to the radiator 6 Engage tension on the radiator outlet hose clamp 2 at the radiator Genuine Parts 7 Lower the vehicle 8 Vehicle equipped with a transmission oil cooler connect the upper transmission oil cooler line to the radiator Refer to Transmission Fluid Cooler Hose Pipe Quick Connect Fitting Disconnection and Connection 9 Vehicles equipped with an engine oil cooler connect the upper engine oil cooler line to the radiator Refer to Engine Oil Cooler Hose Pipe Replacement 10 Connect the surge tank inlet hose 2 to the radiator 11 Connect the surge tank inlet hose quick connect fitting 1 from the radiator Note 1 2 Install the cooling fan and shroud assembly to the radiator Refer to Cooling Fan and Shroud Replacement 1 Connect the radiator inlet hose to the radiator 14 Connect the radiator inlet hose quick connect fitting 1 at the radiator 1 5 Install the condenser Refer to Air Conditioning Condenser Replacement 16 Fill the cooling system Refer to Cooling System Draining and Filling 17 Evacuate and recharge the A C system Refer to Refrigerant Recovery and Recharging 18 Leak test the fittings of the com
27. ilitello gm com Technical Editor Mark Spencer E mail lt mspencer gpworldwide com Production Manager Marie Meredith Desktop Publishing 5by5 Design LLC E mail lt a dkelly 5by5dzign com Write to 5 ACDelco TechConnect PO Box 500 Troy MI 48007 0500 On the Web To read and search recent issues of TechConnect online www acdelcotechconnect com lick 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 tyourselfer 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 knowhow to do a job propery and safely lf a con dition is described it cannot be assumed that the information applies to all vehicles or that all vehicles will have that condition Al materials and programs described in this magazine are subject to change Submission of materials implies the right to edt and publish Inclusion in the publication is not necessarily an endorsement of the individual or tha company TachConnect is published for ACDelco by Sandy Corporation Trey MI 2010 ACDeloo All rights reserved New Duramax Diesel Engines continued from page 1 unchanged The main bearing has been ch
28. ill location identified by a blue cap on GM full size vans is next to the fuel filler and on GM full size trucks is on the right rear side of the engine compartment The nozzle diameter is smaller than the diesel fuel nozzle Use the J23688 refractometer to test for DEF dilution If DEF is contaminated with diesel fuel the DEF system must be replaced If the diesel fuel is contaminated with DEF the waterin fuel sensor should detect the contamination Follow the appropri ate diagnosis and repair procedures in the Service Information Driver Warnings A number of driver warnings will display on the Driver Information Center to warn the driver that the DEF level is getting low and should be refilled Several messages indicate the DEF mileage range that the vehicle will be able to travel before refilling A new DEF warning symbol also will flash on the instrument cluster to communicate DEF system warnings The Driver Information Center messages include Exhaust Fluid Range XXX displays available mileage range when the DEF is getting low Exhaust Fluid Low Speed Limited Soon displays when the DEF range falls below a specified range speed will be limited when the DEF level becomes critical Exhaust Fluid Empty Refill Now displays when the DEF is empty speed will be limited and other messages will display that provide more informatio If these warnings are ignored additional warning messages will display and the vehicle speed will
29. ine and transmission calibrations and service part changes or replacements For example a simple repair procedure such as replacing a window regulator may require a window motor relearn proce dure in the BCM to be performed using a scan tool Return On Investment Many service centers have taken the first step to reprogram ming by purchasing a J2534 tool for emissions related issues The SAE J2534 standard was designed to provide a low cost reprogramming solution to the aftermarket that covers Powertrain Control Module and Transmission Control Module reprogramming for 2004 and newer vehicles Reprogramming access for non emissions related modules is not mandatory however many manufacturers allow vehicle control modules to be reprogrammed The next move is to determine how many repairs in your shop deal with reprogramming non emissions related compo nents The bottom line will be affected by your shop s ability to sell reprogramming just like any other service To determine how much of an investment would be needed to perform reprogramming first add up the cost of any reprogramming equipment diagnostic tool interface device software subscription Next determine how much the service center would charge the customer for reprogramming services typically this service ranges from 80 to 120 and subtract technician labor time to find your gross profit Divide the investment costs by the gross profit to reveal the number o
30. ine cylinders during certain driving conditions to reduce fuel use It explains for example the operation of the valve lifters eight for deactivation and eight for non deactivation in V8 mode and V4 mode Spark Ignition Direct Injection Mechanical direct fuel injection was first used in passenger cars in 1952 The Spark Ignition Direct Injection SIDI system in today s engines offers the advantages of smaller displacement engines improved efficiency and reduced emissions SIDI delivers fuel directly into the combustion chambers during the intake stroke which is ignited by the spark plug to begin combustion during the power stroke The seminar covers the SIDI operat ing modes and the combustion process It also highlights the operation and components of the fuel system including the fuel rail fuel rail pressure sensor high pressure fuel line high pressure fuel pump low pressure line and high pressure fuel injectors A new fuel injector technology piezoelectric injectors also is covered These high voltage injectors use piezo crystal actuators that switch five times faster than a solenoid operated injector Homogenous Charge Compression Ignition The Homogeneous Charge Compression Ignition HCCI is a combustion system where a homo geneous air fuel mixture is ignited by compression It has the potential to improve efficiency without requiring complex lean exhaust aftertreatment helping to
31. nstructive and has given the company more valuable insight into the ever changing always different world of vehicle restoration We got some very good experience out of participating in that Erskine says It was interesting and of course they fed us well Getting back to the real world was a relief for Erskine and his team where restoration jobs can be done in a normal time frame and not in seven pressure filled days Genuine Genuine J Parts We re one stop For your shop Genuine GM Parts Engines and Transmissions Plus all the associated parts you need Genuine E Parts CLIP AND PLACE BY YOUR TELEPHONE Give us a call for all of your Genuine GM Parts needs all at one convenient location
32. o Le Mans in the 21st century The continuous exchange of Information and the constant transfer of technology between the racing and production programs ensure that lessons learned on the track benefit every Corvette on the highway Radiator Replacement LS9 Special Tools Even though the 2010 ZR1 Corvette 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 Special Tools 38185 Hose Clamp Pliers 39400 A Halogen Leak Detector Removal Procedure 1 Recover the refrigerant from the A C system Refer to Refrigerant Recovery and Recharging 2 Drain the cooling system Refer to Cooling System Draining and Filling 3 Remove the condenser Refer to Air Conditioning Condenser Replacement Disconnect the radiator inlet hose quick connect fitting 1 at the radiator E uty sept 2010 serviceinsights 5 Disconnect the radiator inlet hose from the radiator Note 6 Remove the cooling fan and shroud assembly from the radiator Refer to Cooling Fan and Shroud Replacement 7 Disconne
33. ot Check Procedure if any of the DTCs reset during a cold start inspect the internal suction filter for possible cracks Replacing the TCM will not likely correct any of the listed DTCs or low main line pressure Inoperative Intermittent or Noisy A C Some owners of GM vehicles may comment that their A C is inoperative operates intermittently or is noisy No DTCs are set After further investigation and diagnosis it may be determined necessary to replace the Thermal Expansion Valve TXV However before replacing TXVs always follow the A C Performance Diagnostic in the Service Information to verify the valve perfor mance and review the diagnostic tips Thermal Expansion Valve The TXV meters the amount of liquid refrigerant that can flow into the evaporator Located at the evaporator inlet the TXV is the dividing point between the high and the low pressure sides of the A C system As the refrig erant passes through the TXV the refrigerant pressure is lowered Due to the pressure differential the liquid refrigerant will begin to boil at the TXV outlet before entering the evaporator core This characteristic is observed as a drop in temperature between the TXV inlet tube and the evaporator inlet tube TXV Failure Modes Possible causes of inoperative or intermittent A C Bulb Sensor Temperatures on inlet and outlet tubes Are the temperatures on both sides inlet and outlet tubes of the evaporato
34. ponent using J39400 A Halogen Leak Detector 1 9 Inspect the transmission fluid level Refer to Transmission Fluid Check This example of Radiator Replacement LS9 for the 2010 Corvette ZR1 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 Juy Sept 200 Semeensgnts EN LA restorer stays grounded after brush with 15 minutes of fame Serious vehicle restorers in the Los Angeles area can count their blessings that Gary Hill Auto Service hasn t gone Hollywood They might have had cause for worry a while back when the shop pitched in on a restoration project featured on celebrity restorer Chip Foose s Overhaulin Discovery Channel reality show But far from letting that experience go to their heads owners Jeff Erskine and Matt Duguid have kept their heads down concentrating on burnishing the company s 35 year legacy as a provider of top notch classic restoration and restomod vehicle projects to customers in the LA basin Matt Duguid Robert Thomson and Neil Lydon with one of their creations 054 Vette at Gary Hill Auto Service The combination conventional repair restoration business which Erskine and Duguid acquired several years ago has tackled rehab projects as varied as a 1920 Cadillac 1956 Ford pickup and a 1989 IROC Z
35. r fit to the axle Power Steering Hose Retrofit Procedure 2006 Impala or Monte Carlo or 2005 2006 Grand Prix with a V8 engine When replacing the power steering hose it s important to note that the new power steering hose is physically different than the original The newly designed hose has a fin type cooler built onto the hose assembly a ao aS New design power steering hose mounting locations The new design power steering hose should include installation instructions which describe how to install the new design hose on vehicles that did not have this style hose previously Per the installation instructions it is necessary to drill mounting holes in the cradle to attach the new design hose assembly to the vehicle Refer to GM bulletin 06 02 32 014 for more information 7 TecuConnect 2006 2010 Impala and 2006 2007 Monte Carlo When diagnosing a condition with the turn signals trunk actuator courtesy lamps or Brake Transmission Shift Interlock BTS it may be possible to overlook some fuses in the Underhood Bussed Electrical Center UBEC The common architecture Body Control Module BCM uses several fuses for power and the labeling of the fuses may be misread If the fuse in the UBEC labeled RT T SIG is open it will cause the right rear tum signal the trunk actuator and the BTSI to be inoperative The right front turn signal will stil function If the fuse in the UBEC labeled
36. r thermal expan sion valve tube at the expansion device similar If yes replace the damaged or faulty thermal expan sion valve Pressures Are both the low side and high side pressures within the specified values Refer to the appropriate HVAC zone diagnostic incorrect refrigerant charge Diagnose and repair potential leak and or fill A C system with correct charge Leaking interfaces Incorrect fastening at TXV or seal damage Apply correct torque or replace seals if necessary System contamination Is the liquid line extremely cold at the expansion device location and warm beyond the expansion device location The expansion device is restricted Inspect for contamina tion brown powdery residue or metal flake and replace TXV 6 TechConnect Possible causes of A C noise Leaking interfaces Incorrect fastening at TXV Fill system with correct charge Incorrect refrigerant charge Fill system with correct charge Non optimized TXV evaporator plumbing Verify if noise is being produced by the TXV or other A C system components Brake Pedal Kickback 1997 2007 Ford E Series 1999 2008 Ford FSuper Duty 2000 2005 Ford Excursion Some vehicles equipped with the Hydro Boost brake booster system may exhibit a brake pedal kickback and or grabbing condition when applying the brakes that may be caused by contamination within the power steering system Filter the power steering fluid by ins
37. riety 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 Allison Transmission Shift Conditions The 2001 2007 Silverado Classic Sierra Classic 2007 2010 Silverado Sierra and 2003 2010 Kodiak and Topkick equipped with the Allison LCT1000 transmission RPO M74 MW7 may have a delayed engagement or no engagement into Drive a delayed engagement or no engagement into Reverse or a range inhibit with several possible DTCs These conditions may be more pronounced in cold climates during a cold start When DTC P0701 P0751 P0756 P0761 P0843 P0848 P0873 P0877 or P0894 set it could indicate no or excessively low pump pressure as a result of a no prime or loss of prime condition within the transmission pump Follow the diagnostic steps outlined in the Service Information All of these DTCs excluding P0894 could be set due to a fluid service flter change transmission service involving removing the pan low fluid level caused by a leak or long periods of storage Also check the transmission fluid level using the Hot Chack Procedure Low fluid level may cause any of the listed DTCs to set particularly during a cold ambient and cold vehicle start In cold climates ensure the fluid level is at the top of the HOT band After checking the fluid level using the H
38. talling a temporary filter in the power steering system in line with the power steering hose The filter needs to go in the low pressure line that goes from gear to cooler to reservoir where it would be most accessible After the filtering procedure is completed if the brake pedal kickback persists it may be necessary to replace the Hydro Boost brake booster Diagnostic Assistance For free technical diagnostic assistance and product information regarding specific ACDelco products contact these toll free information hotlines staffed by ASE certified technicians Brakes 1 888 701 6169 prompt 1 Chassis 1 888 701 6169 prompt 2 Clutches 1 888 725 8625 Lift Supports 1 800 790 5438 Shocks 1 877 466 7752 Starters and Alternators 1 800 228 9672 Steering 1 866 833 5567 Wiper 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 Technical Assistance Hot Line can help Call 1 800 825 5886 prompt 2 to speak with a technical expert with the latest OEM information Various Electrical Conditions 2005 2008 Cobalt 2007 2008 G5 The following electrical issues may be evident on some models SIR warning lamp illuminated instrument panel lights flicker inoperative parking lamps flicker inoperative tail lamps dim inoperative trunk open lamp illuminated radio inoperative
39. th an E ROD paired with a 4L85E automatic The LS platform Is very popular in off road circles and they think that the E ROD could have a huge impact in off road truck applications because off roaders are very sensitive to the environment as well as performance Meyer noted For additional information on the E ROD go to www gmperformanceparts com The new E ROD LS3 crate engine is efficient environmentally conscious and emnission compliant Juy Sept 2010 Seresnsgnts EN ACDelco TECHconnect Repair Industry News amp Updates GM at AAPEX 2010 GM Customer Care and Aftersales is planning to have a high profile at the 2010 Automotive Aftermarket Products Expo AAPEX scheduled for this November at the Sands Expo Center in Las Vegas ACDelco will be carrying the GM banner at the Nov 2 4 event touting its new branding and market penetration strategy designed to appeal to multiple sectors of the automotive aftermarket Spokesperson Curt Collins says GM will emphasize ACDelco s renewed commitment to providing the products training and e business marketing services Independent service centers value We re introducing a tiered branding strategy for the ACDelco brand and we ll be showing off some of the new parts lines we ll be offering like ACDelco Advantage Friction brake products as well as Professional and OE service Collins says GM s display area also will likely feature a buzz worthy new v
40. triction on the supply side indicated by a vacuum of 13 6 15 Hg The fuel system high pressure side uses a two chamber pump that generates 200 megaPascals mPa of pressure 29 000 psi Two high pressure lines feed the right fuel rail A transfer tube carries fuel to the left fuel rail A Fuel Rail Pressure sensor FRP is locat ed on the rear of the left fuel rail The high pressure pump is timed so the peak pressure pulses match the injection events Matching the pressure pulses results in a more constant pres sure within the fuel rails If the pump is removed it must be retimed when it is installed There are timing marks on the pump gear and camshaft gear that must be aligned Two Fuel Rail Pressure Regulators FRPR are used FRPR 1 is still located on the injection pump as on previous Duramax engines FRPR 2 is located on the front of the left fuel rail This sole noid is normally open The ECM supplies pulse width modulation to change the duty cycle of FRPR 2 to control the amount of fuel returned to the fuel tank The new Duramax engines are equipped with Bosch piezoelectric fuel Injectors These injectors operate at high voltage indicated by the orange color of the injector harness Do not make contact with the fuel injector harness ECM or fuel injectors while the ignition is in the On or Run position Use certified insulated Class 0 gloves rated at 1000 volts Remember to check the expiration date of t
41. ve been challenging New emission regulation changes in the U S Canada and Europe require substantial NOx reduction Meeting these new requirements by engine hardware changes alone has proven to be extremely dif ficult However the advanced aftertreatment technologies of the new Duramax diesel engines have shown great effectiveness in dealing with these emissions Two new Duramax diesel engines were developed to meet the 2010 Federal emission standards for oxides of nitrogen NOx and particulate matter PM They reduce NOx to 0 2 grams per brake horsepower per hour g bhp hr The 2007 standard was 1 2 g bhp hr Engine Applications The 6 6L Duramax diesel engine RPO LGH VIN code L is used on 2010 interim and 2011 Chevrolet Express and GMC Savana vans and 2011 Chevrolet Silverado and GMC Sierra trucks with RPO ZW9 chassis cabs or trucks with pickup box delete The 6 6L Duramax diesel engine RPO LML VIN code 8 is used on 2011 Chevrolet Silverado and GMC Sierra pickup models Mechanical Features These engines use an iron A 2 A and aluminum cylinder heads The bore and stroke are continued on page 3 Spark Ignition Direct Injection S EM01 03 01SEM e Homogenous Charge Compression Ignition S EMOT 04 01SEM Advanced Variable Valve Timing Variable Valve Timing VVT also known as cam phasing dynamically changes valve timing events relative to piston timing by controlling
42. ver offered by Chevrolet and GM of the Corvette C6 R race cars and the relevance of racing Based on the Corvette ZR1 supercar the GT2 Corvette to our customers This is a step that positions Corvette for C6 R has strong links to the production version of America s performance icon The GT rules require the use of many production based components expanding the opportunities for the two way transfer of technology between the race track and the showroom The Corvette C6 R utilizes the ZR1 s body design aerodynamic package aluminum frame and chassis structure steering system windshield and other components The race team has prepared the cars for the rigors of endurance racing with safety and performance modifications as permitted by the rulebook One of the many benefits of the Corvette Racing program has been the opportunity to demonstrate the technology transfer between the race car and the production car said Mark Kent GM Racing manager The global movement toward a single GT class will The Technical Side cont d From page 7 Corvette the future of production based sports car racing worldwide and a move that is perfectly aligned with GM s marketing and business objectives in racing The Corvette C6 R race program continues Chevrolet s tradition of racing production based vehicles to improve the breed It is a commitment that has taken Chevy s two seater from the runways of Sebring in the 50s t
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