Pro-Cut Brake Lathe

January 2004 Volume 6, No.01

A Monthly Publication for GM Dealership Service Professionals

Pro-Cut Brake Lathe GM Dealer Equipment has begun shipping the new essential Pro-Cut PFM 9.2 Auto-Compensating On-Vehicle Brake Lathe to all tier 1-4 dealers (franchise sales greater than 100) who sell Chevrolet Colorado and GMC Canyon trucks. TIP: Tier 5 dealers will be required to sublet rotor turning on these vehicles to a facility equipped with approved equipment. Refer to bulletin 03-05-23-005 for details. The Pro-Cut lathe performs brake rotor turning on-vehicle. It can be used with both hubless and captured rotor configurations. Explanation of Hubless vs. Captured Rotor Until now, the typical GM car or truck has used a “hubless” brake rotor. That is, the rotor is slipped onto the studs on the hub, followed by the wheel. The wheel nuts clamp the rotor between the hub and the wheel. The Colorado/Canyon introduces a new brake design called “captured rotor.” Here, the wheel is mounted to the wheel studs on the front side of the hub, the same as before. But the brake rotor is bolted to the back side of the hub and is retained by separate fasteners. 1. Rotor removal requires removal of not only the wheel, tire, and brake caliper, but also the hub/bearing assembly, which con- This affects rotor service in several ways. tains the ABS sensor and wiring. Then the rotor is removed from the backside of the hub. 2. Once the rotor is removed, it is difficult to chuck onto a lathe due to the large, irregu- larly shaped hole in the center (there is no round center hole, as in hubless rotors). continued on page 4

Contents Pro-Cut Brake Lathe ...... 1 Techline News Reminder ...... 1 GMLAN and Class 2 Difficulties ...... 2 GM TechLink in Sixth Year ...... 2 Typical captured rotor Captured rotor components Service Training Standards Requirements ...... 2 20-Inch Accessory Wheels and Tires ...... 3 Techline News Dinghy Towing Update ...... 3 Winter Cover ...... 5 REMINDER upgrade with a full version of Windows Evaporator Case Water Intrusion ...... 5 2000 Professional or Windows XP Steering Wheel Controls ...... 5 DealerWorld ID and Password – U.S. Professional. Review the hardware spec- service managers and technicians are ifications before buying software to 2004 Chevrolet Aveo ...... 6 reminded to obtain individual ID and pass- ensure the TECHLINE PC meets mini- TAC Corner ...... 7 word from your Partner Security Coor- mum specifications. dinator (PSC) for continued access to SI. Waved Steel Clutch Plate ...... 7 Refer to the December TechLink and End of Support for Windows 98 – Fix It Right the First Time ...... 8 GM Messenger communication for full Effective January 15, 2004, GMSO will details. Know How Broadcasts for February ...... 8 no longer test TECHLINE software appli- cations on Windows 98SE, ME and NT. - Thanks to Mike Waszczenko and Dealers are strongly recommended to Lisa Scott Service and Parts Operations

1 Programming Corner

GM TechLink is a monthly magazine Tech 2 such as “No Communication” for all GM retail technicians and GMLAN and or “CANdi Module Not Detected”. service consultants providing timely Class 2 Difficulties information to help increase knowl- TIP: You can be confident that all edge about GM products and Here are some ways to avoid trou- modules are awake by the time the IP ble when using the Tech 2 to commu- improve the performance of the warning lamps and chimes stabilize. service department. nicate with the GMLAN. 4. Be sure to use the correct 1. Be sure you have the current soft- adapters. For instance, with the CANdi Manager, Product Readiness: ware installed on your Tech 2. module, you need to use p/n 3000098, R. M. (Bob) Savo which is a 16-pin adapter. 2. Perform the Tech 2 Cable Test GM Service and Parts Operations before using the Tech 2 with the CANdi TIP: Do not make the mistake of [email protected] module for the first time. This has been using the 71419 adapter from the old / discussed several times in TechLink T50, T60, etc. Techline terminals. Publisher & Editor: (March 2003, August 2003 and December Although it also has 16 pins, it is incor- 2003) and also appears on the TechLink rect for this application. Mark Stesney website under the Reference Guide GM Service and Parts Operations 5. Most problems experienced with tab. This test permits you to test the /[email protected] integrity of the Tech 2 and the cables. the CANdi module setup result from the cable or adapter, not the CANdi TIP: Call TCSC for help at module itself. Technical Editor: 800.828.6860. TIP: For further information on Jim Horner 3. Before using the Tech 2 to com- GMLAN, tune in to the IDL broadcast municate with the GMLAN (or Class 2, /[email protected] called GMLAN Electrical Architecture 1-248-816-3641 for that matter), turn the ignition on and Functional Diagnostics 16048.20D. and allow all controllers on the vehicle to wake up (“boot up”). Otherwise, - Thanks to Craig Jones and Production Manager: you may get error messages from the Mark Stesney Marie Meredith Desktop Publishing: GM TechLink in Its Sixth Year Greg Szpaichler, MediaWurks /[email protected] TechLink began in over GM who have contributed story FAX number: September, 1998, as an ideas, provided important data, and 3 occasional publication of the reviewed stories for technical accuracy. 1-248-649-5465 Service Technology Group (which eventu- Some statistics – You are reading the Write to: ally became GM Service and Parts 58th issue of TechLink. Each month, * Operations). During the first year, six 68,000 copies are distributed to GM retail TechLink issues were published. TechLink became technicians, some fleets, and within GM PO Box 500 a monthly in October 1999. wholesale. And we’ve posted 35 issues Troy, MI 48007-0500 TechLink owes much of its technical on the website, beginning in March 2001. GM TechLink on the Web: integrity to a dedicated group known as The website is published in four languages: : the Editorial Advisory Board. At present, English, Spanish, French and German. http://service.gm.com there are 14 members; over the past five Over the past five years, we’ve years, 20 people have served on the received numerous unsolicited comments General Motors service tips are about TechLink from readers (mostly intended for use by professional tech- board. We’ve even welcomed two sum- nicians, not a "do-it-yourselfer." They mer college interns. For a photo of some good!). And we’d like to hear from you. are written to inform those techni- of the present members, check the If you have a comment, suggestion or cians of conditions that may occur on Reference Guide tab of the TechLink even a criticism, send them to: some vehicles, or to provide informa- website at http://service.gm.com. [email protected] tion that could assist in the proper Also too numerous to mention are the [email protected] service of a vehicle. Properly trained technicians have the equipment, tools, many subject matter experts from all - Thanks to Bob Savo safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehi- Service Training Standards Requirements cle or that your vehicle will have that Beginning January 2004, the Emerging Issues seminars become part of the condition. See a General Motors deal- Service Training Standards requirements. Each dealership will be required to er servicing your brand of General Motors vehicle for information on participate in at least 6 of the 12 Emerging Issues seminars broadcast in a given whether your vehicle may benefit from year. Dealers can meet this requirement by having either 6 different service the information. technicians participate in distinct seminars, a single service technician view all 6 Inclusion in this publication is not nec- seminars, or any combination of the two. So long as 6 different broadcasts are essarily an endorsement of the indi- viewed by service technicians at a dealership, the dealership will receive a 100% vidual or the company. toward meeting the requirement. Copyright© 2004 General Motors Corporation - Thanks to Tracy Timmerman All rights reserved.

2 Re-Programming – Reprogram the 20-Inch Accessory Wheels and Tires PCM for speedometer accuracy. Contact General Motors has launched its collec- assembly is installed onto the vehicle. Techline to obtain a VCI number tion of all-new 20-inch wheels, available Push the cap in by hand. Alternately, use (1.800.828.6860 English or in forged or chrome finishes to reflect a nonmetallic object to push the cap 1.800.503.3222 French). consumers’ personal styles. The wheels into place. Hammering may result in Then refer to the table were designed with a specific tire as part damage to the cap. in the bulletin for the of the GM tire and wheel system. Tire Pressure Monitoring appropriate calibra- The accessory wheels and (TPM) – If the vehicle tion part number, tires are suitable for installa- was originally based on the tion on certain 1999-2004 equipped with TPM model year and Chevrolet Silverado and sensors, transfer axle ratio. GMC Sierra pickups. the original sen- TIP: Because Refer to bulletin 03-03- sors to the new this is not a war- 10-006 for specific wheels. Note the ranty repair, dealers details and exceptions. wheel location that will incur a charge to Here are the highlights. the TPM sensor came obtain a VCI number. TIP: Initially the from. Install the new Update the tire size value Wheel Launch Kit and tire/wheel/TPM sensor in the ABS module, using the Tech 2. required parts will be assembly in the same wheel Follow this path: Diagnostics > Model available in the USA only. location that the TPM sensor Year > Vehicle Type > Chassis > Product This program will be extended was originally. If the TPM sen- Line > GVW > ABS > Special Functions to Canada in 2004. Canadian deal- sors are not in the original positions, > Tire Size Calibration > Verify VIN > ers must confirm availability of parts you must reprogram the sensors. Select New Tire Size. before utilizing this bulletin. Air Valve (Valve Stem) – For vehicles TIP: If original equipment tires/wheels Designed with a Specific GM Vehicle without TPM, use GM p/n 9593595. are later reinstalled, it will be necessary in Mind – Accessory wheels from GM Wheel (Lug) Nuts – to reset the programming of the PCM offer the best fit and function, and most TIP: Aluminum wheels and the ABS module to the original tailored appearance because they were require special wheel specifications. designed to be an integral part of the nuts. Use GM p/n Labels – After installing the recom- vehicle architecture. The new 20-inch tire 9591772 mended P275/55R20 tires, place the pro- and wheel assembly has been tested at Torque each vided tire inflation pressure and occu- GM’s proving grounds in Michigan and pant/cargo capacities label on the door Arizona. wheel nut in the appropriate sequence jamb, near the original tire label. Do not Tires – GM has created 20-inch wheels to 190 Nm (140 lb ft). cover up the original tire label. based on the Goodyear Eagle LS P275/ Re-check the torque after Warranty Information – USA dealers 55R20 tire. This tire was designed to the first 160 km (100 mi). should refer to GM Warranty GM's Tire Performance Criteria (TPC A wheel lock kit GM p/n 12497479 is also specification 1235 ms). GM's TPC Administration Bulletin 00-03-10-003E available. specifications meet or exceed all Federal and GM Parts Process / Policy Bulletin safety guidelines. Wheel Nut Caps – After tightening the IB03-001 for more information. Spare Tire – Use a P265/75R16 or wheel nuts, install the wheel nut caps Canadian dealers should refer to P265/70R17 tire mounted on the vehi- finger tight, plus 1/2 turn. Black cap GM GM Warranty Administration Bulletin cle's original spare wheel as a spare. The p/n 15646250, bright cap GM p/n 01-03-10-003A. spare tire is not intended for extended 88963146. Important: Installation of these acces- driving conditions. Jounce Bumper – For 2WD vehicles, sory wheels, tires and additional parts Tire Changers – Dealers must have the replace the existing front suspension and related procedures are entirely at correct level of tire changing equipment spring/jounce bumper with Jounce customer expense. to perform tire changing services. GM Bumper kit, GM p/n 12499481. Follow - Thanks to Mikael Hassler, requirements and recommendations for the procedure in the bulletin. Ann Briedis and Nina Price servicing glamour wheels are in the bulletin. For further information regarding equipment meeting the requirements for this program, call 1-800-GM-TOOLS. Dinghy Towing remove the Ignition A and Ignition Balancing – MC style coated weights B fuses from the engine compartment are recommended. If stick-on weights Update fuse block. are used, follow the manufacturer's pro- This information pertains to 2002-04 These vehicles do not have a LOCK cedure (SI Document 664222). Envoy, TrailBlazer and Bravada. position. The ignition should be turned The tire and wheel assembly must be The owner’s manual is being revised to OFF. There is no need to remove balanced on a computerized balancer, regarding dinghy towing (towing the the ignition fuses because there is no capable of static and dynamic balance vehicle with all four wheels on the current draw in the OFF position. modes. Assemblies should be balanced ground). Refer to the appropriate owner’s to within 1/4 ounce on either rim flange. manual for complete procedures. Center Cap – Install the center cap Early versions of the owner’s manual onto the wheel after the tire has been said to turn the ignition to LOCK and - Thanks to Al Ferry mounted and balanced, but BEFORE the

3 Pro-Cut Brake Lathe — from page 1

Bench machining may induce lateral run- Rotor Turning – Take three scratch cuts out, which requires replacement of the to determine the required depth of cut. The rotor. Pro-Cut is equipped with micrometer con- 3. Brake Align Correction Plates will not trols. Once the cutters have been set, run work with captured rotors. the Pro-Cut to automatically turn the rotor. For these reasons, captured brake rotors must be turned on-vehicle. Brake Rotor Lateral Run Out (LRO) TIP: Refer to bulletin 01-05-23-001 and TechLink April 2001 for an explanation of brake rotor lateral run out.

Cleaning mounting surfaces

Tool Installation – Select the proper direct-fit adapter from the four that are included with the Pro-Cut, attach to the vehicle using the lug nuts, and torque prop- Micrometer adjusters erly. Attach the Pro-Cut to the adapter and tighten the retaining knob.

Turning the rotor automatically

Excessive LRO results in intermittent Direct Fit Adapter TIP: On vehicles with rear disc brakes contact between the brake pads and rotor. and limited slip differential, consult SI for Intermittent contact causes uneven rotor TIP: When the Pro-Cut is attached to the special instructions. wear (thickness variation), which causes vehicle, it is supported by the vehicle’s TIP: Non-directional sanding is not the piston to pump in and out of caliper wheel hub. The Pro-Cut carriage is used required due to lathe performance. when the brakes are applied. The customer only to hold the lathe when not in use, and senses this as brake pulsation through the Inspection – Follow standard GM prac- to assist in positioning the lathe to the tices for measuring LRO, using a dial indi- brake pedal. For this reason, GM has wheel hub. established a total indicated run-out spec cator. The specification is 0.002-inch (0.050 of 0.002-inch (0.050 mm) or less for all Auto-Compensation – Run the built-in mm) or less for all vehicles. auto-compensation routine. This aligns the vehicles. Wheel Torque – Improper, uneven lathe to the hub centerline, to ensure an Using the Pro-Cut PFM 9.2 accurate cut. An indicator lamp tells when wheel lug nut torque can cause rotor dis- TIP: Purchase of the Pro-Cut lathe this has been accomplished. tortion, which undoes the careful work includes set-up and training, plus a training you’ve done in finishing the brake rotor. CD. The following is a summary only. (This is not a significant factor of the cap- When performing on-car rotor turning, it tured rotor.) Follow standard GM practices is essential that the cutting tools be proper- for installing wheel lug nuts. This requires a ly oriented to the wheel hub centerline, to torque wrench or an impact wrench ensure that LRO of the finished brake rotor equipped with J-39544 Torque Sockets. is within specifications. The Pro-Cut PFM TIP: Be sure to index-mark the rotor and 9.2 is auto-compensating, which means a wheel stud so the the rotor can be put that the user does not have to perform any back in the same orientation, if it is critical set-up to ensure a high quality job. removed for any reason. Cleaning – As with any brake job, on-car For more information, be sure to watch turning requires that all mating surfaces be the 10280.13D Technology Close-Up -- clean and free of corrosion. Use J-42450A Brakes Town Hall broadcast on January 29. to clean the hub flange around the wheel studs, and use J-41013 to clean the - Thanks to Dave Roland, Jeff Hastings hub/rotor mating surfaces. Indicator lights and Derek Trimble

4 Winter Cover Overheating Guidelines The following guidelines apply, to avoid Evaporator Case This information applies to trucks with overheating the engine: the LB7 and LLY Duramax diesel engine. - Do not use when temperatures are Water Intrusion A winter cover is included for use in cold expected to be above 32°F (0°C). A potential water leak path from weather states. - Do not use when towing a trailer. the evaporator case drain provision Installing the winter cover enhances - Do not modify the cover. has been identified on all 2001-04 heater performance and reduces the Buick Rendezvous and Pontiac Aztek amount of time it takes to warm the Installation Tips models. Under certain high humidity inside of the vehicle when the tempera- The vinyl cover may appear undersized and high ambient temperature condi- ture is below 0°F (-18°C). before being fitted for the first time. This tions, when the vehicle is driven for The cover installs over the front is normal. It’s best to install for the first extended periods with low blower bumper and restricts airflow to the engine time when the cover is warm. motor speed, condensation moisture compartment. The cover is retained by push-pins can reach the vehicle interior under in the grille area, snaps, and black tabs, the carpeting. If an owner encoun- which must be bent into a ters this condition and water testing J-shape. shows no other cause for the water Cut the black stitches provid- leak, install an extension elbow to ed if a front license plate is reduce the likelihood of reoccur- required. rences. The part number recom- More information can be mended is 22542866, which is used found in the owners manual on on other General Motors products. SI (document 837330). Follow The current plan is to utilize this this path: part in production as soon as possi- Build vehicle > Features and ble and a bulletin will contain the Controls > Starting and breakpoints when the production Operating > Description and change occurs. Operation > Winter Cover. - Thanks to Tom Russell - Thanks to Steve Love

Steering Wheel Controls Some 2003 and 2004 GM vehicles 2. On the following vehicles, 3. For the final group of equipped with the OnStar system have the push-to-talk button invokes vehicles, the mute button Steering Wheel Controls (SWC) that voice recognition. A invokes voice recognition. can be used in conjunction with subsequent press A subsequent press will the OnStar Personal Calling Voice will re-invoke re-invoke voice recogni- Recognition system. voice recognition for use with a voice Here is how the Steering tion for use mail system, or other system which may require Wheel Controls function on with a voice tones to be transmitted, vehicles with OnStar voice mail system, such as dialing an extension recognition and Steering or other system after reaching an office phone Wheel Controls. which may require system. Saying the word “dial” will 1. On the following vehicles, tones to be transmitted, transmit the tone(s) associated with the the push-to-talk button invokes such as dialing an exten- digits entered. Subsequent presses of the voice recognition feature. A sion after reaching an office the button will re-invoke the voice recog- subsequent press will re-invoke voice phone system. Saying the word nition system and the process repeats. recognition for use with a voice mail sys- “dial” will transmit the tone(s) associated Pressing the white dot button will exit tem, or other system which may require with the digits entered. voice mode if a call has not been placed. tones to be transmitted, such as dialing Subsequent presses of the The user must use the white dot but- an extension after reaching an office button will re-invoke the ton to end a call. phone system. Saying the word “dial” voice recognition sys- Aztek, Rendezvous, Century, will transmit the tone(s) associated with tem and the process Regal, LeSabre, Bonneville, the digits entered. Subsequent presses repeats. Pressing the Grand Prix, Montana, Venture of the button will re-invoke the voice white dot button will 4. The following OnStar recognition system and the process exit voice mode if a equipped vehicles do not have repeats. Pressing the white dot button call has not been steering wheel controls for use will exit voice mode if a call has not been placed. The user must with the voice recognition func- placed. To disconnect from the call, press use the white dot but- tion. The voice recognition func- the white dot button or the "end" button ton to end a call. tion used for dialing an OnStar on the steering wheel. Escalade, Escalade EXT, Personal Call is accessed using the NOTE: If the vehicle has NAV or the Escalade ESV, Denali, Denali XL, white dot button. UV8 cell phone, these buttons function Yukon, Yukon XL, Tahoe, Suburban, Cavalier, Sunfire, Colorado, Canyon, differently and/or are disabled for OnStar Avalanche, Sierra Crew, Sierra Ext, Venture, Silhouette, Impala, Monte functions. Consult the specific vehicle Silverado Crew, Silverado Ext, Hummer Carlo, Aurora, Ion, LS/LW, Malibu, Park owner manual for proper operation. H2, TrailBlazer, TrailBlazer EXT, Envoy, Avenue, Express, Savana, VUE Seville, DeVille, Cadillac CTS, Cadillac Envoy XL, Bravada, Envoy XUV, - Thanks to Steve Love and XLR, Cadillac SRX Rainier, Ascender Jim Mikolaizik

member, to improve shock When the HOLD button is depressed, Announcing the absorption for more precise and the Hold indicator located in the stable handling. Secondary Information Center will light. 2004 Chevrolet Aveo The torsion beam axle mount There are two Hold mode features: compound link-type rear suspen- Winter Function – When the vehicle sion is designed to optimize dri- is at a stop, depress the hold button. The ving performance when cornering. transmission will start off in third gear. All Aveos are equipped with This will reduce the torque to the front a power-assisted dual diagonal wheels and will help the vehicle maintain brake system, with discs in front traction on slippery road surfaces. and drums in the rear. A Delphi Manually Controlling Shift – When four-channel, four-sensor ABS the vehicle is in motion, depressing the system (DBC-7) with Electronic Hold button will make the transmission Brake force Distribution (EBD) operate like a three speed transmission. is available. You will be able to downshift the trans- Some Service and mission manually. The transmission will Pre-Delivery Tips not shift into forth gear when the Hold Aveo PDI feature is activated. service bulletin 03-00-89-040 The automatic transmission uses T-IV explains sever- fluid GM P/N 88900925 al unique prod- (1 qt). In Canada, use P/N uct features. 22689186 (1L). The information TIP: Do not intermix is useful for all DEXRON® III fluid with technicians, not the T-IV fluid. just the PDI Radio Code – Each Chevrolet has just introduced the entry- technician. Here are radio has a four-digit level Aveo (T200) subcompact four-door some highlights. and five-door sedan. Priced below the unlock code that must be Cavalier, the Aveo provides Chevrolet Coolant – The Aveo entered before the radio dealers with a tremendous opportunity to cooling system is facto- will operate. The code is ry filled with blue sili- attract younger, first-time buyers. located on a paper card cate/hybrid coolant and Factory-fill blue coolant All Aveo models feature Chevrolet's will be serviced with tra- inside the glove box. Be identifiable grille, with trademark horizon- sure the owner is aware tal chrome mid-grille band and gold ditional green coolant. This type of coolant of this code and remind Chevy bowtie emblem. Additional brand them to keep the code is cues include a silver outlined bowtie on must be drained, flushed and refilled a safe place. Any time the center caps of the standard steel the battery is disconnect- wheels and a gold bowtie on the center every 30,000 miles (48,000 km). Use P/N ed, COD will appear in caps of optional alloy wheels, offered on the display, and the code LS models. The bowtie is also featured 12378560 (1 gal). In must be entered into the on center pad of the steering wheel. Canada, use P/N 993088 (1L) or P/N 993089 (4L). radio. Fuse in shipping position Power Steering License Plates – Aveos Fluid – The power built before December 3, steering system uses 2003 will not have the DEXRON® III fluid. license plate fasteners Check the fluid level and placed in the glove box. adjust as necessary. Use Use p/n 9423101 to fas- P/N 12378470 (1 qt). In ten the license plate. Canada, use P/N TIP: The cost of the 10952621 (500 ml) or fasteners should be P/N 10952622 (1L). included in the net item TIP: The use of con- Fuse engaged column for the PDI claim. ventional power steering Aveo Instrument Panel fluid in the system may The Aveo doesn't use lead to leaks. a front license plate bracket. There are four The Aveo is equipped with highly dis- Fuse – The radio/clock tinctive standard aerodynamic halogen fuse is installed in a fuse dimples in the front fas- headlamps and amber side turn signal holder for shipping. The cia. The inboard dimples lamps. Fog lamps are also available. fuse holder must be are the ones that should P185/60R14 all-season steel-belted fully depressed toward be used to fasten the radials are mounted on either steel or the fuse panel and the license plate. The out- alloy 14-inch wheels. fuse will slide into place. board dimples are used The Aveo features a 1.6-liter dual over- This must be done to for European countries. head cam 16-valve inline 4-cylinder ensure proper operation Tire Pressure – The engine that delivers 105 horsepower at of the radio and clock. vehicle’s tires are shipped 5800 rpm and 107 lb-ft of torque at 3600 Automatic inflated to 40 psi (276 rpm. It’s teamed with either a manual 5- Transmission – To kPa) and the pressure speed or automatic 4-speed transaxle. move the automatic must be reduced to 30 psi The front suspension consists of transmission shift lever (207 kPa). The tire pres- McPherson struts with offset coil springs out of Park or Neutral, sure label can be found at and a stabilizer bar. The steering gear is push down on the the bottom of the driver’s mounted on a front suspension cross shifter knob. Press knob down to shift B-pillar.

6 GMDAT Key Cutting Equipment Key Cutting Kaba Ilco Computerized Code Cutting The accompanying chart out- Function Standard Steel Standard All Transponder Part Number Description lines available key cutting equip- Blank Brass Blank or RKE Keys ment. Original equipment key Computerized Duplicating and Highly Highly Highly 74-ULTRACODE Ultracode Code Cutter & blanks for the Chevrolet Aveo are Code Cutting Recommended Recommended Recommended Duplicator steel and are difficult to accurate- Kaba Ilco Machine Duplicating and Code Cutting ly cut with hand-held key cutting Function Standard Steel Standard All Transponder Part Number Description Kit (Required) equipment. Due to the risk of Blank Brass Blank or RKE Keys mis-cutting high-cost Transponder Machine Duplicating and Available* Available* Available* 74-029A-GM Combo Key Duplicator & 74-029A-GMDAT Code Cutting Key Code Cutter and RKE key blanks with hand- held key cutters, GM recom- Kaba Ilco Machine Duplicating mends using computerized dupli- Function Standard Steel Standard All Transponder Part Number Description Blank Brass Blank or RKE Keys cating/code cutting equipment. Machine Duplicating Not Available* Not 74-045-110VAC Heavy Duty Duplicator In addition, RKE and Recommended Recommended Immobilizer (Transponder) Keys Kaba Ilco Hand Held Code Cutting require reprogramming with Tech Function Standard Steel Standard All Transponder Part Number Description Kit (Required) 2 after cutting. Refer to SI for Blank Brass Blank or RKE Keys detailed procedures. Hand Operated Code Cutting Available* Available* Available* 74-MK1-P26 Exacta Cutter & Case 74-MK1-GMDAT - Thanks to Jeff Strausser Curtis Computerized Code Cutting * Original equipment key blanks for these Function Standard Steel Standard All Transponder Part Number Description vehicles are steel and are difficult to Blank Brass Blank or RKE Keys accurately cut with hand held key cutting Computerized Duplicating Highly Highly Highly C9100021 PC+ Computerized equipment. and Code Cutting All Models Recommended Recommended Recommended Code Cutter Due to the the risk of "mis-cutting" high Curtis Hand Held Code Cutting cost Transponder and RKE key blanks with Function Standard Steel Standard All Transponder Part Number Description Cam Set Carriage Code Book the hand held cutter, computerized dupli- Blank Brass Blank or RKE Keys (Required) (Required) (Required) cating/code cutting equipment is highly Chevy Aveo - Hand Available* Available* Available* C-20791 (15XL-45) 45 Degree or 47 C21222 C21223 C21403 recommended. Current computerized Operated Code Cutting C-20792 (15XL-47) Degree Code cutter equipment will require software updates Chevy Optra - Hand Available* Available* Available* C20791 (15XL-45) 45 Degree or 47 C21222 C21223 C21403 for GMDAT vehicles. Operated Code Cutting C20792 (15XL-47) Degree Code cutter Contact 1-800-GM-TOOLS (1-800-468-6657) Chevy Epica - Hand Available* Available* Available* C20791 (15XL-45) 45 Degree or 47 C21222 C21225 C21403 for Ilco products or Barnes Distribution Operated Code Cutting C20792 (15XL-47) Degree Code cutter (Curtis) 1-800-555-2878.

TACCorner TACTips Beginning with this issue, the Technical Strategy Based Assistance Center (TAC) will be providing Diagnosis (SBD): Waved Steel Clutch Plate administrative and Technical tips in the The goal of SBD is to provide guidance This information applies to 4L60E/ TAC Corner. when you create a plan of action for each 4L65E automatic transmissions. Access the most current specific diagnostic situation. By following On approximately November 1, information in SI: a similar plan for each diagnostic situation, 2003, a new heat treating process is used for some transmission clutches. SI on the web is more current than you will achieve maximum efficiency when you diagnose and repair vehicles. The Forward Clutch waved steel clutch using SI via the CDs. The SI web is plate (648) appears dark in color, as if updated weekly on Thursday. Although each of the SBD boxes is num- bered, you are not required to complete it were overheated at one time. The The CD version is updated through GM Low/Reverse Clutch waved steel clutch every box in order to successfully diag- Access every second week, and requires plate (682A) has a similar appearance nose a customer concern. The first step the technician to process the update, at on the inner and outer edges. of your diagnostic process should always start up. Only the appearance has changed; be the Verify the Customer Concern box. the functionality of the clutches is no The stand-alone CD is updated once a The final step of your diagnostic process month. different. These waved clutch plates will should be the Repair and Verify the Fix be used for both production and service. Be Prepared: box. Refer to the Strategy Based - Thanks to GM Technical Assistance We have verified that some recent Diagnostics chart in SI. Use the keyword callers do not represent GM dealerships. “strategy”. We need your assistance to help us con- The guidelines for using Technical firm that the caller is a GM Technician or Assistance are in the P&P Manual, Shop Foreman using GM supplied Service Section 5.3.1. The sections cover: Information and is thus an authorized 1. Being Prepared – follow SBD caller. To accomplish this, we are asking 2. Logging Calls that callers be prepared with an SI docu- 3. Closing a TAC Case ment ID number that relates to the prima- 4. Returning a Survey Request Forward Clutch ry vehicle concern of the call. This request The forms for Technical Assistance applies to all vehicles produced from 1998 are also available in this section. to present. This will also help us more quickly assist in diagnosis and assure that - GM-TAF TAC Form the caller has properly researched the - TAC Case Call Log Sheet issue before calling GM TAC. - Diagnostic Worksheet Please perform all the necessary diag- The worksheets help organize nostics and informational searches before the call. calling TAC. This allows us to serve you - Thanks to GM Technical Assistance Low/Reverse Clutch better.

7 Car Issues -- Fix It Right the First Time

Model Year(s) Vehicle Line(s) - Condition Do This Don’t Do This Reference Information / Bulletin 2003-2004 Cavalier/Sunfire – Grinding Noise Replace clutch hydraulic line. Don’t replace clutch/bearing. 02-07-31-003A on Clutch Apply (very low mileage) 2002-2004 All cars with 4T40/4T45E and 4T65E Disconnect, inspect and reconnect Don’t replace the input speed 02-07-30-022B – DTC P0716/P0717 and other codes transaxle wiring harness at transaxle. sensor. September 2003 TechLink 2001-2003 Venture/Montana/Silhouette/ Install clamp. Don’t replace the catalytic 03-06-05-003 Rendezvous/Aztek – Rattle/ converter. Buzz from Exhaust System 2004 Grand Prix with Monsoon Audio Re-pin speaker wires in I/P fuse Don’t replace speaker, amplifier 03-08-44-015 System – Speaker Buzz panel connector. or radio. 2000-2004 Impala/Monte Carlo – Normal condition when limited to Don’t replace headlamp assembly 01-08-42-001 Condensation in Headlamp fog or fine mist appearance in high when no water droplets are September 2000 TechLink humidity conditions. evident. 2003-2004 CTS – Variable Effort Steering Replace the only the VES Don’t replace the entire 03-02-36-001 (VES) “Service Steering solenoid. steering gear. Message,” DTC C1241 or C0450 2003-2004 Vibe – Normal Exhaust Odor Provide copy of service Don’t replace catalytic 03-06-05-006 bulletin to customer. converter. 1997-2004 Grand Am/Alero/Malibu – Turn rotor and brake align Don’t replace brake rotor for 00-05-23-002, 01-05-23-001 Brake Pulsation procedure pulsation (Know How Video #15040.01B) 2003 All cars with 4T40/45E, 4T65E and Replace TCC PWM Solenoid Don’t replace transmission or 02-07-30-039B 4T80E – Code P0742 valve body assembly 2004 L61 EcoTech 4 Cylinder-2.2L Replace spark plug sets Don’t replace PCM or ignition Recall 03042 Engine – Misfire, DTC P0300 cassettes

Truck Issues -- Fix It Right the First Time

Model Year(s) Vehicle Line(s) - Condition Do This Don’t Do This Reference Information / Bulletin 1993-2004 All Passenger Cars and Trucks – Follow SI and Bulletin for Don’t replace A/C compressor. Service VME, 10/31/03 A/C Compressor diagnostic information before 01-01-38-013A replacing A/C compressor. 1999-2003 Fullsize Pickups – Replace inserts and rubber Don’t replace leaf spring. Service VME, 11/17/03 Rear Spring Slap Noise washers. 1999-2004 GM Car and Trucks models with Use J-41540 HomeLink Tester. Don’t replace HomeLink 01-08-97-001B (models with HomeLink Universal Transmitter – Follow SI and refer customers to Transceiver without validating HomeLink option) Programming Diagnosis Owner’s Manual. internal fault recognized by J-41540. 2002-2003 All TrailBlazers, All Envoys, Lubricate and remove material, Don’t replace upper or lower 02-02-35-006A Bravada – Squeak/Rub/Scrub Type per bulletin. intermediate shaft. Noise in Steering Column 2002-2004 All TrailBlazers, All Envoys, Replace both tail lamp circuit Don’t replace complete tail lamp Service VME, 9/22/03 Bravada, Rainier – Tail Lamp boards assembly. 03-08-42-006A Socket Circuit Board 2003-2004 Fullsize Pickups and Utilities – Replace individual parts as Don’t replace complete mirror 03-08-64-028 Servicing Wide Load Mirrors needed. assembly. (RPO DPF) 2003 Fullsize Pickups and Utilities – Replace encoder motor sensor Don’t replace module, encoder 03-04-21-001B Transfer Case Service Light and reprogram TCCM motor or transfer case for DTCs C0327, P0836, P0500 2003 Fullsize Pickups – 6.6L Diesel Follow SI and bulletins for proper Don’t replace ECM (DTCs P0540 02-06-04-048, 03-06-04-021, Engine ECM diagnostics for P0181. Refer to the and P0181) unless diagnostics 02-06-04-058 Owner’s Manual (block heater confirm need to replace and front cover) 2002-2004 TrailBlazer, TrailBlazer EXT – Repair fascia with Dual Lock Don’t replace front fascia 02-08-62-004 Wavy Front Fascia 2002-2004 All TrailBlazers, All Envoys, Replace mirror actuator and Don’t replace outside mirror 02-08-64-008 Bravada – Mirror Erratic Return reprogram module assembly 02-08-64-021

10280.02D February 12, 9:00 AM, 12:30 PM, Know-How Emerging Issues 2004 3:30 PM Eastern Time Broadcasts 10280.14D February 26, 9:00 AM, 12:30 PM, for February 2005 Chevrolet Equinox 2004 3:30 PM Eastern Time

– Thanks to Tracy Timmerman 8