July/September 2011 - GM Service Insights
Contents
1. Exhaust valve materials resist higher temperatures and the corrosive nature of propane and natural gas Intake and exhaust valves feature a special insert that ensures an excellent seal between the valve and valve seat e Dedicated gaseous fuel injection and engine control module e Engine performance designed to meet Environmental Protection Agency EPA and California Air Resources Board CARB emission certification requirements Fuel System The CNG fuel system consists of e Four CNG fuel tanks e CNG fuel tank pressure relief device PRD e CNG fill receptacle and fill line e CNG fuel tank high pressure lock off HPL solenoid valves e CNG fuel tank pressure FTP sensor e CNG fuel lines e CNG 1 4 turn isolation valve e CNG fuel filter e CNG high pressure regulator HPR The CNG fuel system has four tanks with a 23 gasoline gallon equivalent GGE capacity The first tank 6 4 GGE is located under the center of the vehicle in place of the regular fuel tank There are two tanks 4 9 GGE and 4 5 GGE mount ed where the spare tire normally is located at the rear of the vehicle The fourth tank 72 GGE is mounted on the cargo floor in an enclosure inboard of the left rear wheelhouse The fuel storage system provides fuel system corrosion resistance and fuel system integrity that exceed Federal Motor Vehicle Standards Federal regulations require that the fuel tanks and brackets be inspected every three years or2. DEPENDENT SERVICE CENTERS a r o ee ni gt GM powertrain components OE quality valuesis obvious gt Help and resources available for reprogramming TCMs gt Visit ATRA and showcased GM transmissions pa ai _ gt New modular training clinics debut gt E Rod mated to 66 GTO without a rite SIX SPCeCd transmission gt TechConnect insert with more valuable service info More on the inside including powertrain repair procedures CONTENTS GM OE Service Parts Update The latest word on product development and technologies The Technical Side Discover new ways to approach service and repairs Repair Industry Business News amp Updates of Repairs Get state of the New ideas that can industry perspectives benefit how your shop from GM insiders operates and profits Genuine i 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 submitted imply the right to edit and publish Every effort is made to ensure the accuracy of the information in the offers contained in this magazin
3. Tighten the water pump bolts in sequence 6 Tighten the water pump bolts in sequence to 12 N m 106 Ib in 7 Tighten the water pump bolts a second pass in sequence to 12 N m 106 Ib in Rear Leaf Spring Clunk Noise 1999 2011 Chevrolet Silverado and GMC Sierra 1500 2500 2000 2011 Chevrolet Suburban and GMC Yukon XL 2500 2002 2006 Chevrolet Avalanche 2500 2003 2011 Chevrolet Express and GMC Savana 2500 3500 vans with 8500 GVWR 8600 GVWR or 9600 A rear leat spring slap or clunk noise may be heard when the vehicle is oper ated over irregular road surfaces The rear leaf spring tip inserts may have broken apart from wear and fallen out or may be severely worn or damaged Do not disassemble the main pack on the leaf spring or remove the bushing from the spring when diagnosing this condition Verify that the rear leaf spring tip inserts are present on the leading and trailing ends of the overload spring second stage leaf and inspect the condition of the inserts If the inserts 7 TECHCONNECT are either not present or severely worn or damaged install new inserts Light duty rear leaf spring tip inserts On some models the vehicle may have to be raised to allow the springs to separate enough so the insert can be installed Vehicles originally equipped with all plastic or plastic and rubber design tip inserts can be serviced by updated all rubber design inserts A Plastic tip insert B Plast
4. making the convertible a boulevard cruiser said enhance the already stiff body structure to eliminate the Al Oppenheiser Camaro chief engineer Instead we took common convertible maladies of cowl and steering wheel the more difficult but better path of bolstering structure Shake They include rather than softening the suspension We didn t change e A tower to tower brace under the hood a Strut bushing or spring rate from the Camaro coupe e A transmission support reinforcement brace The result is a convertible that preserves nearly all the e Underbody tunnel brace acceleration road holding and performance capabilities e Front and rear underbody V braces of the Camaro coupe Even though the 2011 Chevrolet Camaro 2011 Chevrolet Ca maro is anew vehicle extensive service and repair information resources are a click H a e oa Intake Manifold Replacement Electronic Service Information Technicians Removal Procedure and shop owners can log on to the site to Note 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 1 Remove the engine covers Refer to Engine Cover Replacement Free collision repair procedures are also available by going to 2 Remove the air cleaner resonator and outlet duct Refer to Air Cleaner www genuinegmparts com Resonator and Outlet Duct Replacement Jul Sep 2011 Servicelnsights The
5. the high pressure side of the fuel system for some service procedures If the valve is inadvertently left in the Off posi tion the vehicle will not operate The CNG fuel filter a high pressure coalescing media filter is located forward of the CNG 1 4 turn isolation valve It requires periodic service intervals Fuel flow begins when the ignition is cycled and the high pressure lock off HPL and the high pressure regulator HPR solenoids open The HPR is supplied with fuel at pressures up continued on page 5 4 TECHCONNECT New Compressed Natural Gas Powered Chevy Express and GMC Savana continued from page 4 to 3 600 psig pound force per square inch gauge or 24 821 kPa kilopascal at 70 F 21 C The outlet pressure is regulat ed to 90 110 psig and delivered through the low pressure lines to the fuel rail and CNG injectors The CNG fuel injectors are installed in the base vehicle fuel rail and require spacers between the injector and manifold injector boss The ECM controls fuel delivery in the same manner as a gasoline vehicle The CNG fuel system also features the same powertrain diagnostics and use of the Tech 2 scan tool as a gasoline engine There are not any new Diagnostic Trouble Codes Follow the standard repair protocol as with a gasoline vehicle Refer to the appropriate GM Service Information for specific CNG information B Fuel filter A 1 4 turn isolation valve C High Pressure Regulator When t
6. Technical Side cont d Disconnect the electrical connector for the fuel injectors Disconnect the electrical connectors from the throttle body 5 Disconnect the fuel feed for the fuel injectors Refer to Fuel Line Replacement Engine G Remove positive crankcase ventilation hose pipe tube Refer to Positive Crankcase Ventilation Hose Pipe Tube Replacement Remove the vacuum hose from the brake booster Disconnect the electrical connector from the manifold absolute pressure MAP sensor 9 Remove the MAP sensor 714 1 0 Remove the grommet 715 from the sensor as required 1 1 Remove the evaporative emission EVAP clip 740 bolt 742 bracket 741 valve 730 and tubes 729 735 1 Remove the intake manifold bolts 512 and the fuel rail stop bracket 712 1 Remove the intake manifold 500 14 Remove the intake manifold gaskets 514 1 5 Discard the intake manifold gaskets 1 If necessary clean and inspect intake manifold Refer to Intake Manifold Cleaning and Inspection 8 Jul Sep 2011 Servicelnsights Installation Procedure Note Note 1 Install NEW intake manifold to cylinder head gaskets 514 2 Install the intake manifold 500 Apply a5 mm 0 20 in band of threadlocker to the threads of the intake manifold bolts 512 Refer to Adhesives Fluids Lubricants and Sealers 4 Install the fuel rail stop bracket 712 D Install the intake mani
7. at the Hilton Hotel in Las Vegas Oct 27 31 It will be staged alongside the Automotive Parts Remanufacturers Association APRA expo 2071 Voltec Drive Unit 4ET50 MKA for Chevrolet Volt gi Jul Sep 2011 Servicelnsights Genuine Parts The Technical Side In order to complete the R amp R Removal amp Replacement process for a transmission that has a programmable Transmission Control Module TCM technicians will need to program the TCM for the specific vehicle being serviced There may also be a need to complete learn functions as well as program other control modules Chris J Thomas product development manager for transmissions GM Customer Care and Aftersales 2007 Hydra Matic 6L80 MYC Six Speed RWD Automatic Transmission GM Service Information SI Online The R amp R service procedure for the specific year make and model detailing necessary calibration programming and setup learn procedures is available through ACDelco Techconnect at www acdelcotechconnect com html tss_tech_esi jsp Various types of subscriptions are available based on individual shop requirements Service Programming System SPS Calibration reprogramming is performed using a combination of the Service Programming Systems SPS application and the MDI vehicle communication interface Tech 2 scan tool or third party J2534 compliant vehicle communication interface SPS is a web based application Tech2 Scan To
8. how long the engine was off and if the outside temperature is lower than the last reading taken during the previous ignition cycle From this information it s determined if a new outside temperature reading should be taken On the Web To read and search recent issues of TechConnect online www acdelcotechconnect com If the engine was off long enough or the current outside air temperature is click the TechConnect Magazine cooler than the stored value a new outside temperature reading is taken and HN l displayed If the engine was not off long enough or the current outside air J noe aaa oe SiS cle temperature is higher than the stored value from the previous ignition cycle the last stored value of outside air temperature taken will be displayed ACDelco service tips are intended for use by professional technicians not a do it yourselfer The outside air temperature will continue to be updated every second as long They are written to inform those technicians of l i conditions that may occur on some vehicles or to as the outside air temperature is the same or cooler than the previous reading provide information that could assist in the proper i service of a vehicle Properly trained technicians Once the new outside air temperature reading exceeds the previous temperature Bayar a E Rae cae and the vehicle is traveling less than 18 mph 29 km h the displayed outside air eae to ab ale grey and ziy k a
9. i at t that t temperature will remain at its last value Once the vehicle speed exceeds 18 mph e agalise ie a a all velniles the displayed outside air temperature will be updated If the soeed drops below will have that condition 18 mph the outside air temperature will freeze at its last value A na o rostral e o tin 1 nls magazine are subject to change Submission of Or materials implies the right to edit and publish When using a scan tool during diagnosis it is possible that the temperature Inclusion in the publication is not necessarily an reading on the scan tool will differ from the temperature displayed on the endorsement of the individual or the company DIC radio without there being a problem with the vehicle The DIC Radio only TA A I A vel AC E oy eisichy i Corporation Troy MI displays the reading being sent from the BCM Thanks to Ernest Haller 2011 ACDelco All rights reserved 2 TECHCONNECT New ACDelco Electrical System Diagnosis Training continued from page 1 Common grounds diagnosis as more and more electrical components share a common ground Statistically ground circuits are the most often overlooked when diagnosing electrical concerns With Electronic Control Unit based electrical systems high resistance in ground wire connections can produce conditions such as cranking difficulties or improper injector triggering Intermittent Conditions Another topic covered in the cou
10. ing mark that aligns with the painted link and the crankshaft has a dot to dot alignment The right intermediate gear has a tri angular mark that aligns with the paint ed link Remove EN 46105 1 or 48383 1 from the left bank 6 TECHCONNECT The engine will need to be rotated 115 degrees clockwise for stage two timing The crankshaft marks should align dot to dot Tool EN 46105 2 or EN 48383 2 should fit easily on the rear of the cams on the left bank of the engine ST X EN 48383 3 should be installed on the right bank or bank 1 The triangular marks should be aligned The painted link on the right interme diate shaft should be aligned with the hole in the rear gear The left camshafts will be aligned as shown when in stage two timing posi tion If there are any concerns in identify ing the correct location for the camshafts check the number stamped in the rear of the camshaft RI is right intake RE is right exhaust LI is left intake and LE is left exhaust Thanks to James Bloss uE Lod sLe a 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 Power Steering Fluid Restrictor 2003 Chevrolet Cavalier and Pontiac Sunfire with the 2 2L
11. 01 VCT S EM01 03 01VCT R S FNO0 01 01 VCT Course Name How to Use VCT Recorded HVAC System Components and Lubricants HVAC System Components and Lubricants Recorded HVAC System Operation and Service Hints HVAC System Operation and Service Hints Recorded HVAC System Flushing Recovery and Diagnostics HVAC System Flushing Recovery and Diagnostics Recorded HVAC System Engine Cooling Controls and Communication HVAC System Engine Cooling Controls and Communication Recorded Electrical Circuit Function and Diagnosis Electrical Circuit Function and Diagnosis Recorded Testing Electrical Signal and Control Circuits Testing Electrical Signal and Control Circuits Recorded Serial Data Communication Networks Serial Data Communication Networks Recorded Communication Network Diagnosis Communication Network Diagnosis Recorded Camshaft Position Actuator Systems Camshaft Position Actuator Systems Recorded Active Fuel Management Operation Active Fuel Management Operation Recorded Active Fuel Management Diagnosis Active Fuel Management Diagnosis Recorded How to Use VCT Current Instructor Led Training Course Number S ACO7 02 01ILT S AC07 03 01 ILT S BK05 01 01 ILT S BK05 02 01 ILT S ELO6 04 021LT S ELO6 10 021ILT S ELO6 11 01ILT S ELO6 11 02ILT S ELO6 12 01ILT S ELO6 13 01ILT S ELO6 14 01ILT S EP08 02 01ILT S EP08 03 01ILT S EP08 04 01ILT S EP08 05 01ILT S EP08 81 01ILT S EP0
12. 36 000 miles 60 000 km whichever occurs first The ser vice life of the tyoe 1 CNG fuel tanks is 15 years from the date of manufacture after which they must be removed from service There are four externally mounted pressure relief devices PRD Two are equipped with a thermally activated PRD one with a combination temperature and pressure valve and one with a pressure operated burst disc The burst disc activates when CNG tank pressure becomes too high for safe opera tion approximately 5 400 psig All external PRDs are connected to fuel storage pressure and cannot be isolated from the high pressure system Service should not be attempted on these devices or connecting tubing hoses unless It s absolutely certain that the system Is completely empty of CNG fuel Four CNG tanks have a 23 GGE capacity The CNG fuel lines consist of different fuel line types based on the working pressure and vehicle interface requirements The high pressure and low pressure CNG fuel lines and hoses are a combination of stainless steel tubing and stainless steel jacketed PTFE polytetrafluoroethylene All connections between lines and components are sealed by O rings specifically designed tor CNG operation The high pressure CNG fuel system is equipped with a manually operated 1 4 turn isolation valve The valve is located forward of the rear wheel on the driver s side of the vehicle atthe inboard side of the LH frame rail The valve can isolate
13. 4 cylinder engine A rattle or knocking noise noticed when turning the steering wheel while driving slowly over rough roads may be caused by hydraulic noise within the steering rack To correct this condition install a fluid restrictor part number 22592200 in the power steering return line A Power steering pump B Power steering return hose Remove the power steering return hose from the power steering pump Install the fluid restrictor in the power steering fluid reservoir return port The inlet and outlet hoses must not be twisted during Installation Do not bend or distort the inlet or outlet hoses to make installation easier After installation fill and bleed the power steering system New Water Pump Bolt Torque Sequence All 2004 2012 GM vehicles equipped with the High Feature V6 engine 2 8L 3 0L and 3 6L A new water pump bolt torque sequence has been implemented on all High Feature V6 engines to help reduce the potential for water pump gasket leaks When installing a water pump use the following revised water pump bolt torque sequence and procedure 1 Ensure that the engine front cover and water pump are clear of old gasket material 2 Ensure that the water pump mounting bolt holes in the front cover are completely clean and dry 3 Place a new water pump gasket on the water pump 4 Place the water pump in position on the front cover 5 Install the water pump bolts finger tight
14. 8 81 02 LT S SS04 01 01ILT S ST10 01 01ILT Course Name Automotive Air Conditioning Advanced Refrigerant System Diagnostics HVAC Control System Operation and Diagnostics Braking Systems ABS Operation and Diagnosis Network Communication Diagnosis Electrical Power Management Automotive Electrical Circuit Diagnosis and Repair Enhanced Automotive Circuit Diagnosis Hybrid Technology and Service Body Electrical Global Diagnostics Advanced Body Control System Electrical Diagnostics Engine Performance Computer Controls and Ignition System Diagnostics Engine Performance Air Induction and Fuel System Diagnostics Engine Performance Fault Monitoring and Emission System Diagnostics Engine Performance Advanced Drivability Diagnostics Duramax 6600 Diesel Engine Performance Duramax Diesel Operation and Diagnosis Vibration Correction Diagnostics Supplemental Restraint Systems 8 TECHCONNECT Genuine a Parts The Technical Side cont d A telling example of the Camaro convertible s strength Strong structure is evidenced in its Suspension tuning specifically the lack The Camaro s architecture was designed to of changes between the convertible and coupe models accommodate a convertible model which means To compensate for the reduced structure of an customers enjoy the fun of top down cruising with coupe open car engineers often will make the suspension like driving dynamics Four strategic reinforcements softer
15. Air Temperature Display Operation The outside air temperature is displayed on the Driver Information Center radio ACDelco TechConnect is published bi monthly or rear view mirror in a number of GM vehicles There may be some confusion e DIA 2 aeee UCT a FE Ri accounts to provide timely service information about the operation of the display and how quickly it updates ambient tempera increase knowledge and improve the ture Depending on several factors the temperature may not be updated immedi performance of the service center ately and owners may feel that the display is inaccurate at times ACDelco 360 represents our mission to look at As an example here s a look at the operation of the outside air temperature our businesses at every possible angle to provide value and assistance to our distributors and display on several GM small cars from recent model years 2004 2010 Chevrolet ee aie E aiRirciicle Malibu 2005 2010 Chevrolet Cobalt and Pontiac G6 2006 2011 Chevrolet HHR of support with programs tools training and and 2007 2010 Saturn AURA marketing focused on enhancing and growing l l our partnership successfully The ambient air temperature sensor is a variable resistor interfaced to the Body Control Module BCM The ambient air temperature sensor is a 2 wire negative nt Publisher temperature coefficient thermistor ean A The BCM applies 5 volts to an internal input resistor connected to the signal ACDelco ci
16. PERFORMANCE PARTS guys out on the road with these engines they can be convinced a 2 was some labor involved in getting transmission and engine packag gether and to get everything hooked up s It took a lot of time to set up asi gu 5 Ss Aa Fy L Araric with Alir fi rot ROD inh VUE VY L U 5 hm g S Lo ris Ly U J s PW s y ea i ifaw bo oS t nit to be able to have the gp Bg al a Trew rc ALA AIQNFT I l Y e a VVI WW Je FG Pe Fett Few GI La E Tien a a fy el He g i Pi PLI A E e Mm amp Ha f N a a Ha La F Be SS py c pees E E e E A a ability to adjust every as pect OT the transmission from our laptop Other notable elements of the project included a Ron Davis custom radiator a Rick s Hot Rod Shop custom gas tank Speed Tech Performance upper and lower control arms a quick ratio steering box anda Vintage Air a c unit The result is a restored GM legend that delivers an amazing combination of classic appearance with an enviable mix of power clean operation and performance Genuine g Genuine Genuine i Parts Give us a call for all of your Genuine GM Parts needs all at one convenient location
17. as product pi development manager for transmissions for GM Customer Care and Aftersales will be that GM transmission solutions are hard to beat We ll be bringing the message to shop owners and techs that we have Sr o a strong nationwide 3 year 100 000 mile warranty on plug and play reman fo st J transmissions and that we have a full range of component parts for rebuilding 7 ia jobs some 300 of which are part of our overPOWER the Competition pricing Cs 1 program Thomas Says Even though reman jobs are growing more popular Thomas says GM continues to support j rebuilders Information on the overPOWER program that prices GM OE Service parts to compete with aftermarket parts will be emphasized he says 2071 Hydra Matic 6L50 GM will also use the ATRA opportunity to talk about the MYB Six Speed RWD future of transmissions and how repair specialists will be ATOMENE PANSIMISZION affected In displaying the drive unit used in the Volt GM will be looking to better acquaint attendees with the drive train technologies they re likely to see more of inthe future ye This is another new age in transmissions coming around HS L n similar to the changes that swept the industry when automatic n Da he transmissions were introduced Thomas says It s important for forward leaning transmission specialists to take advantage of every opportunity to learn more about this new technology The ATRA show will be held
18. e 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 Genuine a Parts GM OE Service Parts Update Getting Specific GM makes a case for the top quality and value of competitively priced OE Service parts Words like better superior and a cut above are typically used to describe original equipment parts And for good reason OE parts are the real thing Engineered for the application by the same company that designed the vehicle they should perform better But exactly why and how are they superior GM has answered those questions directly with documentation on specific advantages that some OE Service parts both GM and ACDelco brands have over aftermarket offerings One quality shared by all GM OE Service parts is a design based on the evaluation of real world product failures by GM Engineering and rigor
19. e You don t lens ot ania 20102011 LGH and LAL Jul Sep 2011 Servicelnsights 9 Business of Repairs realize how much these things interact and overlap In addition to variable valve timing other new topics addressed in the modular format include cooling system service tips hybrid regenerative braking camshaft variable valve lift and advanced fuel management homogenous charge compression ignition The other four topics play off of subject matter covered in the standard clinic format and include Duramax 6600 diesel engine features 2010 2011 LGH and LML Duramax 6600 diesel engine updates fuel system servicing tips and emission control servicing tips Each clinic is structured to give a concise overview of the topic and is aimed at giving attendees the key information they need to put into action With advanced variable valve timing for instance the goal is to give techs the ability to identify and describe the components and functions of VVT in GM vehicles that include the spline phaser vane phaser OHC OHC magnetically controlled and vane phaser cam in block magnetically controlled systems Contact your dealer for additional information on training clinics Facitying the Purists California Restomodder places his first bet on the E ROD Steve Keefer has heard the whispers sensed the Skepticism The talk goes something like this What s a self described muscle car master doing dabbling in gree
20. earn how to use power moding in module diagnostics e Review terminal fretting and Its effect on electrical circuits Circuit Testing One testing procedure highlighted in the course covers testing circuit functions in sequence until a fault is detected Knowing how the testing procedure works enables technicians to apply the same knowledge to any version of a given circuit type There are nine circuit functions to test Ground circuits Low reference circuits Battery positive B circuits Ignition circuits AC voltage circuits O oF WN gt Reference voltage circuits ECMA 7 Input signal circuits 8 Output control circuits 9 Serial data circuits Ground circuits for example are becoming more important to proper continued on page 3 IN THIS ISSUE New ACDelco Electrical System Diagnosis Training 1 Outside Air Temperature Display Operation 922 2 New Compressed Natural Gas Powered Chevy Express and GMC Savana 4 New Heavy Duty Cooling System Cleaner T 5 Timing the High Feature V6 Engine 6 Tech Tips 7 7 Training Update 7 8 ON THE WEB www acdelcotechconnect com click the TechConnect Magazine link or Log in to the ACDelco LMS click the Resources link Product Offerings Distribution Network e Customer Programs Marketing Training E Business e Relationships ACVDelco Outside
21. engine metals during the cleaning The heavy duty cooling system cleaner part number is 10 5037 is available in a package of six 16 ounce containers Contact your DDG or local ACDelco representative to order Refer to ACDelco Bulletin 11D 032 for more information Thanks to Mike DeSander 5 TECHCONNECT The following GM models offer the available high feature 3 6L V6 engine RPO LY7 LLT 2 8L V6 engine RPO LP1 or 3 0L V6 engine RPO LF1 LFVV 2007 2011 GMC Acadia Buick Lacrosse Cadillac CTS SRX and STS 2007 2009 Pontiac G6 and Saturn AURA 2007 2010 Saturn OUTLOOK 2008 2009 Pontiac Torrent 2008 2011 Buick Enclave Chevrolet Malibu and Equinox 2008 2010 Saturn VUE 2010 2011 Chevrolet Camaro and 2011 Chevrolet Traverse The high feature V6 engine family features a camshaft drive system that consists of a primary timing drive chain driven by the crankshaft sprocket The primary timing drive chain drives two intermediate drive shaft sprockets Each intermediate drive shaft sprocket drives separate secondary timing drive chains which drive the respective cylinder head s intake and exhaust camshaft position actuators The following supplemental informa tion may be helpful when timing the high feature V6 Refer to the appropri ate Service Information for complete timing procedure information Keep these items in mind before beginning the timing procedure e n a front wheel drive vehicle it may be eas
22. entally conscious guy who never really trusted the car on the free way and thought the E ROD s 430 hp which is probably underrated was more than enough for him I think he was pleasantly surprised with what he ended up with The resto mod project which entailed maintaining the GTO s factory appearance while modernizing its powertrain took four months The engine swap work took about 40 hours and was mostly glitch free Keefer says It involved taking off the entire front end to remove a bulky original A C unit and stripping down the frame rails Oil pan steering rod and exhaust modifications were also needed as well as some tinkering with a transmission wiring harness It s a package that should silence the hard line skeptics but Keefer understands the mindset and its frequent rigidity Through years of doing LS engine upgrades for vintage GM vehicles he s had to soothe qualms with removing original factory powertrains Now after dealing with purists on the vintage side he s facing down those on the power side But Keefer is optimistic that engines like the E ROD will win the day So many people have been used to the old school big blocks but once we start talking to them about the I PERFORMANCE ee PARTS sanaa benefits of LS engines we can usually change their Soa mind pretty quick he says h 4 There s a lot of natural resistance but once get GM
23. fied like aftermarket versions They have proper connections to guard against leaks and corrosion use specified materials for proper shielding and can incorporate updates and upgrades e AWD Actuator Encoder Motors The GM OE Service part is validated to perform with GM 4WD transfer case systems and can be readily updated and upgraded Encoder sensors are available separately on many models Lower priced aftermarket versions have developed a reputation for premature failure according to a recent issue of Transmission Digest magazine Up and down the long list of GM engine and transmission components the Story line is the same GM OE Service parts are designed and built to exacting specifications and tests bear out their superiority Why would you settle for anything less Jul Sep 2011 Servicelnsights EI Repair Industry News amp Updates GM TRANSMISSIONS Present and Future on tap for ATRA show But if you re a shop with a big share of GM business a stop at the GM Powertrain booth could leave you more time to do the fun stuff a show offers In addition to showcasing cutaways of six speed transmissions and drive units used in hybrid vehicles like the Chevrolet Volt GM Powertrain will be talking up its transmission component parts its unbeatable warranty on remanufactured transmissions and the outstanding value that GM original equipment parts offer The overarching message at the show says Chris Thom
24. fold bolts 512 Caution Tighten the intake manifold bolts to the sequence below e First Pass Tighten the intake manifold bolts in sequence to 5 N m 44 Ib in e Second Pass Tighten the intake manifold bolts in sequence to 10 N m 89 Ib in 7 Lubricate the MAP sensor grommet 715 with clean engine oil 8 Install the MAP sensor 714 and grommet 715 Install the EVAP valve 730 bracket 741 and bolt 742 Tighten the bolt to 50 N m 37 Ib ft 1 Install the EVAP tubes 729 735 1 1 Install the fuel rail Refer to Fuel Rail and Injectors Installation 1 2 Connect the electrical connector for the MAP sensor 1 3 Install the vacuum hose for the brake booster 1 Connect the electrical connectors 3 for the throttle body 1 5 Connect the electrical connector 1 for the fuel injectors 1 6 Refill the cooling system Refer to Cooling System Draining and Filling 17 Install the engine covers Refer to Engine Cover Replacement This example of Intake Manifold Replacement for the 2011 Chevrolet Camaro is just one of many found in the Service Repair Manual By following the proper repair procedures technicians can ensure that each vehicle maintains its solid performance and uncompromised Safety features for the life of the vehicle WE VE GOT ALL THE PARTS YOU eeu If you re doing a powertrain repair procedure remember that we ve got all the related parts you need electrical gasket
25. he fuel supply system needs to be opened the pressure in the lines must be relieved before attempting repairs Refer to the Service Information for the low pressure side and high pressure side relief procedures Refueling With an estimated mpg of 11 city 16 highway the four tank design with a 23 GGE capacity provides a range of approximately 250 to 360 miles The system is designed to be filled at a 3 600 psi 24 800 kPa station yellow handle on fill nozzle It can be filled at a 3 000 psi 20 684 kPa station blue handle on fill nozzle but this will result in a reduced range and a fuel gauge reading of approximately 7 8 full The CNG fill receptacle is a NGV1 profile and mates to any NGV1 fill dispenser valve The Till dispenser seals to the receptacle with an O ring Replace the O ring in the Till receptacle before refueling if it is damaged or missing otherwise natural gas can leak while refueling The vehicle is shipped with three replacement O rings in the storage bin on the engine cover It should take about 6 8 minutes to fill the fuel tanks at a fuel station for natural gas vehicles Refueling will stop automatically when the tanks are full CNG quantity Is affected by changes In fuel tempera ture and fuel pressure When refuel ing in cold ambient con ditions the fuel gauge may not display FULL even though the tempera ture compen sated refueling event produces a temperature compensated FULL condit
26. ic and rubber tip insert C All rubber tip insert 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 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 challe
27. ier to remove the engine before beginning e When removing the front cover be sure to remove the belt tensioner and all the bolts Damage may occur to the block if this procedure is not followed e When removing the front cover do not pry against or strike the cam actuators This will cause damage to the reluctor or actuator e Intake cam actuators have marks on them for the Right Bank R and the Left Bank L They must be positioned respectively e Be sure to note the orientation of the injector wiring harness The harness with connector should come out on the front side of the engine If installed backwards it will cause misfires and or fuel trim DTCs e 4 screw Delphi and 5 screw Aisin cam actuators are interchangeable but will require the correct shim behind them when applicable 4 screw Delphi actuators use a 0 043 in shim and the 5 screw Aisin actuators use a 0 063 in shim To set the timing on a high feature V6 engine start with the engine in stage one position with tool EN 46105 1 Camshaft Locking Tool or EN 48383 1 Camshaft Retaining Tool on the left bank or bank 2 The circular timing marks on the camshafts should be aligned as shown The painted link should be visible through the hole of the intermediate gear for the left secondary chain Stage one primary chain alignment for the crankshaft and the left interme diate gear is shown below The interme diate gear has a triangular shaped tim
28. in the appropriate direction Learn More In addition to the new electrical system diagnosis courses ACDelco offers on demand online Web based courses instructorled Virtual Classroom Training courses and a variety of other instructor led hands on courses at training centers around the country To review the latest training courses available log in to the ACDelco Learning Management System LMS at www acdelcotraining com Thanks to Rick Balabon 3 TECHCONNECT New Compressed Natural Gas Powered Chevy Express and GMC Savana GM is introducing a dedicated compressed natural gas CNG system available on full size Express and Savana cargo vans for fleet use The CNG option will be available on 3 4 ton 135 inch wheelbase and 1 ton 135 inch wheelbase models This new CNG option adds to GM s position as an alterna tive fuels leader From 1997 to 2007 GM built more than 23 800 CNG or liquefied petroleum gas LPG vehicles Chevrolet and GMC are the only brands to offer a one source CNG option on vans for fleet customers CNG 6 0L V3 Engine The CNG vans are equipped with a Vortec 6 0L V8 RPO LC8 It maintains the same horsepower 323 ho 4 600 rom and torque 373 b ft 4 400 rom rating as the 6 0L V8 gaso line engine Vortec 6 0L V8 Enhancements made to the engine to run on CNG include e Hardened engine components for higher wear resistance and durability required in the gaseous fuel system
29. ion This is due to commercial refueling station output regulated by a temperature vs pressure strategy to prevent the vehicle from becoming overpressurized if relocated to a warmer ambient location after refueling CNG fill receptacle sealing O ring Operating Tips The extra hardware needed for the CNG system adds approximately 800 Ibs to the weight of the vehicle This additional mass reduces the payload capacity This should be noted when loading the vehicle The G23405 model 3 4 ton has a payload capacity of 2 409 lbs and the G33405 model 1 ton has a payload capacity of 3 374 Ibs Extreme cold weather below 4 F 20 C may make it harder to start the engine If the vehicle will be driven regular ly in cold temperatures it will be necessary to use the standard engine block heater Routine maintenance schedules fluids filters etc for the CNG vans are designed to follow the original specifications for the gasoline fueled vans The Owner Manual lists the recommended maintenance service intervals and fluid specifications Thanks to Chris Graham New Heavy Duty Cooling System Cleaner A new heavy duty cooling system cleaner is now available from ACDelco that is safe for removing rust scale and deposits including silicate gel trom the cooling system quickly and effectively This product contains a detergent that removes oil and grease along with a Process corrosion inhibitor to reduce corrosion of
30. n engines sullying his reputation and the nobility of vintage classics in the process Keefer has a ready answer For one he says this is the future Two don t be too hasty in passing judgment That s how the owner of East Bay Muscle Cars a Brentwood Calif resto mod shop defends his developing interest in GM Performance Parts emissions compliant E ROD LS3 crate engine To Keefer the new engine line that marries clean performance with high performance is going to be the right prescription for many of his more discerning and knowledgeable customers It s the future of hot rodding these environmentally conscious engine swaps he says There are a lot of dirty vintage cars out there with original motors and more regulations on cleaner engines and more emissions testing requirements are coming down the pike A lot of people balk at smog equipment on these engines but there s nothing wrong with it That explanation played well recently with a 1966 10 Jul Sep 2011 Servicelnsights Pontiac GTO owner who became Keefer s first ever E ROD installation customer Keefer and his five employees swapped the GTO s original 389 cubic inch V 8 engine for an E ROD 6 2L LS3 engine paired with GM s 4L65E four speed automatic transmission The installation coincided closely with an E ROD event at our shop where we had the E ROD equipped 1955 Chevy on display Keefer says The owner is an environm
31. nd torque is 410 Ib ft 556 Nm The LS3 develops 426 horsepower 318 kW and 420 Ib ft 569 Nm All Camaro models can be equipped with either a six Speed manual or six speed automatic transmission The Aisin AY6 six speed manual is Standard with the 3 6L engine and a Hydra Matic 6L50 six speed RWD Automatic Transmission 6L80 for the Chevrolet Camaro 6 Jul Sep 2011 Servicelnsights SPECIAL INSERT TECHconnect nt d i CONVERTIBLE automatic is optional A Tremec TR 6060 six speed manual is standard on the SS and the Hydra Matic 6L80 six speed automatic is optional The Camaro convertible s enhanced body structure helps prevent cowl or steering wheel shake for a strong confident feel in all driving conditions The top has a smooth tailored fit with acoustical foam in the headliner that helps deliver a quiet ride with the top up SPECIAL EDITION 2011 marks the 100th anniversary of both Chevrolet and the Indianapolis 500 and it s fitting that a special edition Chevrolet Camaro Convertible was the official pace car at the 5 event Chevrolet is producing 500 matching i replicas of this special Indianapolis 500 Pace Car enthusiasts can purchase their own piece of history All the Indy Pace Car convertibles are Camaro SS models equipped with the 6 2L V 8 engine and the choice of a six speed manual or six speed automatic transmission The electrification of the autom
32. nge simulation Training Spotlight The following new or updated ACDelco training programs have recently been made available S EL06 11 02ILT Enhanced Automotive Circuit Diagnosis This ILT course emphasizes diagnos tic skills that are applicable to the complex electrical systems on newer vehicles It includes a review of GM North American wiring diagrams and the new global format S EP08 81 02ILT Duramax Diesel Operation and Diagnosis This ILT course covers the Duramax diesel engine evolution from 2001 to 2011 including an overview of the Duramax features and design changes for all engine applications The course also covers the engine control manage ment system the fuel delivery system and the variable geometry turbocharger as well as the features of the aftertreat ment system of the new Duramax engines Training Schedule To search for currently scheduled courses click the Schedule link Select search terms from the dropdown menus and click the Submit button TS PU 0003 11 Current Virtual Classroom Training Course Number FVCT1 09V S ACO7 01 01 VCT S ACO7 01 01VCT R S ACO7 02 01VCT S AC07 02 01VCT R S AC07 03 01VCT S AC07 03 01VCT R S ACO07 04 01VCT S ACO07 04 01VCT R S EL06 01 01VCT S EL06 01 01VCT R S EL06 02 01VCT S ELO6 02 01VCT R S EL06 03 01VCT S EL06 03 01VCT R S EL06 04 01VCT S EL06 04 01VCT R S EM01 01 01 VCT S EM01 01 01 VCT R S EM01 02 01VCT S EM01 02 01VCT R S EM01 03
33. obile has been taking place for years well before today s hybrid vehicles More and more electronic systems are becoming commonplace and as a result more complicated when it comes to electrical system diagnosis Did you know that the Adaptive Forward Lighting system on some GM vehicles automatically changes light direction and intensity based on speed vehicle direction and weather conditions Understanding the latest electrical systems and how to diagnose them is the focus of two new ACDelco Instructor Led Training ILT courses that are available at local training centers The two new courses are Body Electrical Global Diagnostics S ELO6 13 01ILT and Advanced Body Electrical System Diagnosis S ELO6 14 01ILT Body Electrical Global Diagnostics S ELO6 13 01ILT Body Electrical Global Diagnostics covers various electrical faults found on electronic module networking intermittent electrical faults and the proper meter use all designed to help technicians improve their diagnostics Skills In addition it reviews the serial data architecture of the new GM Global Architecture Global A system D ACDelco Electrical System Diagnosis Trainin In the course technicians will e Diagnose electrical circuits using a Digital Multimeter DMM e Review AC voltage circuits in hybrid vehicles e Perform the ground credibility test and other electrical tests e Identify serial data circuits e L
34. ol Diagnostics Setup DTCs Depending on the vehicle diagnostic procedures and setup procedures are performed with one of two solutions Global Diagnostic Systems 2 GDS2 and Multiple Diagnostic Interface MDI are used for diagnostic and setup procedures of the following vehicles Multiple Diagnostic Interface MDI e GDS2 is a web based application 2010 Forward Chevrolet Camaro Chevrolet Equinox Chevrolet Cruze Chevrolet Volt Buick LaCrosse e Tech 2 supports 1992 to 2012 All other GM makes models Note Third party aftermarket diagnostic tools may support certain diagnostic and setup procedures Contact your tool manufacturer for details and support The Tech 2 scan tool and MDI vehicle communication interface can be Cadillac SRX purchased through approved resellers GMC Terrain such as www boschdiagnostics com or Buick Regal www gmdesolutions com Courtesy of Mike Waszczenko brand quality manager GM Customer Care and Aftersales Jul Sep 2011 Servicelnsights ACDelco The Technical Side co CHEVROLET L99 6 2L V 8 VVT for the Two 6 2L V 8 engines are Chevrolet Camaro SS offered in Camaro SS models including the L99 on automatic equipped vehicles and the LS3 on manual equipped models Both engines are derived from the LS3 that debuted on the 2008 Corvette with an aluminum block with cast iron cylinder liners and aluminum cylinder heads Horsepower for the L99 is 400 298 kW a
35. ous durability testing In addition to the distinct design and durability advantages of GM OE Service parts GM has also made the parts price competitive Dealer led competitive initiatives and programs such as overPOWER the Competition are convincing Independent Service Centers ISCs and vehicle owners that they are better served by sticking with OE Service parts For hard evidence take a look at what GM is saying about the specific comparative value of a few engine and transmission components e Heat Treated Sun Shell Kit for 4L60E 4L65E and 4L70E transmissions Side by side spline wear durability tests showed the OE Service part remained functional after 6 million cycles while the aftermarket product failed after about 700 000 cycles The reason the heat treated teeth on the OE Service collar stood up to wear because an induction hardening process is used The aftermarket collar failed much quicker because the teeth became worn and non functional OE Service Heat Treated Sun Shell part number 24228345 before and after the durability test The OES Service part remained functional after 6 million cycles After 6 million Before the durability test cycles Teeth on _ the heat treated collar are still intact and the part remains functional e Engine Oil Cooler Lines With pressurized lines form fit and function are key GM OE Service parts are pre bent to OE specifications and thus don t have to be modi
36. rcuit of the ambient air temperature sensor The BCM also provides the ground E mail lt to the ambient air temperature sensor through the low reference circuit When u erseln cher 2 G rm CEI the ambient air temperature is cold the sensor resistance is high and the signal Editor voltage is high When the ambient air temperature is hot the sensor resistance A a is low and the voltage signal is low The BCM provides the logic for reading the E mail lt ambient air temperature sensor filtering the data and transmitting the information michael militello gm com via the serial data circuit to the outside temperature display The outside air i i i l i Technical Editor temperature algorithm uses three pieces of information outside air temperature Mark Spencer data vehicle speed and the time E mail lt the engine was turned off mspencer gpworldwide com The main source of variation Production Manager between actual outside temperature Marie Meredith and the reading inside the vehicle is Desktop Publishing the variable airflow across the sensor T R 5byb Design LLC at low vehicle speed and stopped E mail lt 2 conditions At higher speeds when dkelly 5by5dzign com more airflow is moving through the front of the vehicle a more accurate Write to gt lt indication of actual air temperature ACDelco TechConnect POTEO 500 is provided Troy MI 48007 0500 When the engine is first started the algorithm looks at
37. rse intermittent diag nosis examines the different types of intermittent fault conditions These can include terminal fretting and deforma tion bussed electrical center terminal contact and hot and cold temperature sensitivity Terminal deformation can occur when probing the mating side of the connector terminal without the proper adapter which results in poor terminal contact and causes an open or intermittently open circuit Use the proper terminal probe adapter from a terminal probe test kit when checking terminals Advanced Body Electrical System Diagnosis S ELOG 14 01ILT Advanced Body Electrical System Diagnosis focuses on various procedures and diagnostics for Body Control Module BCM and non BCM body electrical systems such as power windows power locks and lighting as well as keyless entry RainSense wipers and Ultrasonic Rear Parking Assist Participants in the course will cover e Various communication networks e Electrical grounds and voltage circuits e Communication networks e Global Service Information e Power window and sunroof circuits e Keyless entry systems and locking functions e Lighting operation e Identify BCM starting system circuitry e Review the radio theft lock system and active noise cancellation Networks The communication networks highlighted in the course include GMLAN local interconnect network CAN graphical interface class 2 UART and the new Global Architecture Taking a clo
38. s motor mounts belts hoses whatever you need to complete the job right the first time Genuine E Parts Business of Repairs New modular d training clinics for Independent Service Centers ISCs aim for speedier learning As valuable as ongoing education can be it s sometimes hard not to see it as costly downtime Dealers recognize that and some are beginning to roll out a new training clinic format designed to help ISCs use their training time more productively The new quick delivery format which also incorporates some new topics not included in the standard training clinic format lets dealers stage clinics on hini two distinct topics in one session The result is two clinics in roughly two hours allowing ISCs to get in and out quickly with a sense of having spent their time wisely One who did was Leland Prewitt owner of Prewitt s Automotive in Savannah Ga Prewitt recently attended one of the new modular clinics on advanced variable valve timing one of several new topics covered in the new modular format Joined by two of his techs Prewitt got a better feel for the subject and came away feeling more confident to work on GM vehicles so equipped Many import lines have had that feature and now GM seems to be taking it a step further he says We found the clinic very informative The instructor did a good job of covering related issues on emissions and fuel pressur
39. ser look at the Local Interconnect Network LIN technicians will learn that this network bus transmits serial data over a single wire network circuit bus between a primary control module and other control modules within a particular subsystem The LIN bus is not exposed t the rest of the vehicle s main communication bus LIN slaves commu nicate only to the master module for the network not to other control modules on the vehicle Local Interconnect Network The course also covers the operation of a number of circuits for various body components One example reviews the power door lock circuits including the master slave data transmission and free flow data transmission Free Flow Communication On some vehicles the power door lock system may include the Driver Door Switch Passenger Door Switch Body Control Module Driver Information Center Rear Door Lock Unlock Relay and the reversible door lock actuators in each door The modules that activate the power lock motors are the driver door lock actuator passenger door lock actua tor and the Body Control Module rear door lock actuators Operation can be controlled by several actions which the modules are looking for at all times If the front door lock switch provides direct input to the driver door lock actuator a LAN message is sent that Indicates the door lock switch position The module that activates the power door lock motor receives the LAN message and activates the motor
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