January/February 2005 Volume 12, No.1

A/C Triage — Ensuring Replacement Compressor Survival In a medical emer- Vacuum and gency, a triage is often pressure leak performed at the hospi- checking will not tal to quickly and accu- locate leaks that rately define the prob- will take out a lem and provide proper compressor in follow-up care. A simi- one-to-three lar situation should months. The loss take place when a cus- of one ounce per tomer arrives with an month may be a A/C refrigeration condi- 20% system loss tion at a service center. Electronic leak detector on some vehicles Procedures enacted during this period. here will pay immedi- This low charge ate as well as long will cause compressor noise, an irate cus- term benefits. These tomer and a NTF compressor return. A/C triage procedures Clean and Contain Internal Debris would include: and Contaminants Over the past several years, ACDelco has 1. Quickly and accurately assess and Prior to as well as after compressor failure, reviewed, inspected and reinstalled hundreds confirm the condition debris particles from the failure flow through- of air conditioning compressors returned under 2. Find and stop refrigerant loss warranty. The failure of these compressors out the refrigerant system — in BOTH direc- 3. Clean and contain internal debris tions. Although a majority of debris travels can be grouped into four basic modes: lubri- and contaminants cation, refrigerant, debris and product defects. downstream from the compressor, upon shut 4. Replace missing fluids down and equalization of remaining refriger- The exact percentage of each mode varies 5. Provide professional follow-up ant, the flow reverses and does flow from slightly among models and manufacturers, but Assess and Confirm the Condition the compressor suction port toward the suc- in general, about 1/3 of the compressors failed tion muffler, hose, A/D and evaporator. These from lubrication problems, approximately 1/3 When inspecting many replaced compres- particles imbed themselves in various internal failed from refrigeration problems, slightly sors, they are deemed NTF (No Trouble components and cannot be 100% flushed less than 1/3 failed from assorted internal Found) because the initial review was inade- out. They will find their way back into the debris, and the 1–2% balance were associat- quate. It failed to verify the root cause. A replacement compressor. ed with various manufacturing defects. quick visual prevents needless replacement caused by low charge, Diagnostic Trouble continued on page 3 Codes (DTC), electrical connections, loose fasteners, etc. Quick checks for proper charge levels and purity as well as electrical IN THIS ISSUE confirmation of clutch engagement will signif- icantly reduce the number of times a good A/C Triage ...... 1 compressor is replaced. Cooling System Seal Tabs ...... 2 Stop Refrigerant Loss Diagnosing European Vehicles ...... 4 (or Stop the Bleeding) Update Your Image with Refrigerant is vital to the short and long New ACDelco Uniforms ...... 5 term operation of a compressor. It is the A Successful 2004 and the refrigerant that is responsible for transporting Countdown to 2005 ...... 6 Causes of compressor failure the lubricant throughout the system. Low or no refrigerant will not provide adequate com- Sports Report ...... 6 Be assured that ACDelco has been actively pressor lubrication. As mentioned earlier, low Tech Tips ...... 7 refrigerant and poor lubrication account for working with the various manufacturers to Diesel Fuel Additives ...... 8 incorporate quality and reliability enhance- nearly two-thirds of the replacement com- Rear Axle Lubricant Level Check ...... 8 ments into the compressors to reduce and pressor warranty returns. eliminate the manufacturing defects. Replacing a compressor WILL NOT ensure Modular Fuel Pump Electrical However, the majority of warranty returns — that the refrigerant leak is fixed. It only takes Connector Terminals ...... 8 many of them repeat compressor replace- a few minutes to check with both a UV light ments — can be attributed to factors all and a quality electronic leak detector to con- acdelcotechconnect.com under the control of the installer. firm that there are NO OTHER leaks.

1 Cooling System Seal Tabs What’s made of ground-up ginger root, a new vehicle. Both cus- almond shells and binder? And causes tomers and well-intentioned confusion in auto service centers? technicians can be misled by ACDelco TechConnect is published Some people call them coolant pellets, these deposits. bi-monthly for retail technicians to but the proper name is cooling system Another side effect comes from provide timely service information, seal tabs. By forming a permanent seal overuse. When seal tabs are used in the increase knowledge and improve inside the cooling system, ACDelco prescribed amounts, they will not cause the performance of the service Cooling System Seal Tabs, part number restrictions or plugging in an otherwise center. 10-108, can eliminate small leaks as well properly operating cooling system. But, if as prevent many leaks before they occur. a little is good, a lot must be better, Publisher & Editor: How Seal Tabs Work right? Wrong! Overuse can lead to plug- Greg Baker ging, especially in the relatively small ACDelco Cooling system seal tabs are dissolved tubes used in heater cores. in the engine coolant and the resulting E-mail / fibers circulate through the cooling sys- A Little History [email protected] tem. At a microscopic level, the tabs There was a time when seal tabs were Technical Editors: break down into irregular, long, thin installed in every new vehicle at the fac- fibers. When a small leak or seepage tory to account for the inevitable small Mark Spencer occurs, the coolant carries the fibers into leaks that occur in castings, joints, and so E-mail / the opening, where they cluster up and on. By the mid 1990s, manufacturing and [email protected] jam together. (Think of logs and branches machining techniques had improved to Jim Horner in a beaver dam.) This mechanism is very the point where the seal tabs were no effective at stopping leaks. Any fibers longer needed on a universal basis. E-mail / [email protected] that make it to the surface will crust over With the introduction of long-life and enhance the seal. coolant, silicate deposits also were no Desktop Publishing: This sealing method is useful only for longer a concern, so the scrubbing action Greg Szpaichler, MediaWurks small-scale leaks and seepage, and tends from the seal tab fibers was no longer to work best in conditions where the sur- needed. E-mail / [email protected] rounding parts aren’t moving. The seals Occasionally, manufacturers still use tend to break down in areas between seal tabs to address specific concerns. Write to: metals that are expanding and contract- * ing with temperature changes, for Today’s Recommendations ACDelco TechConnect instance. GM no longer endorses the universal P.O. Box 500 Troy, MI 48007-0500 A Secondary Benefit use of seal tabs. However, when a condi- tion appears in which seal tabs may be On the Web: The traditional green-colored coolant, beneficial, a specific bulletin is released, ® : used until DEXCOOL was introduced in describing their proper use. For example, acdelcotechconnect.com 1996, contained silicates that deposit on one such bulletin is Customer cooling system surfaces. The tiny fibers Satisfaction Program 03034, dated ACDelco service tips are intended for from the seal tabs acted as scouring 7/7/03. This applies to specific GM 3.8L use by professional technicians, not a pads, removing silicate deposits from the V6 engines only, and is in effect until July “do-it-yourselfer.” They are written to water pump seal faces, which con- 31, 2005. inform those technicians of condi- tributed to longer water pump seal life. tions that may occur on some vehi- When using seal tabs, the proper cles, or to provide information that Side Effects of Seal Tabs number of cooling system seal tabs could assist in the proper service of a In addition to the benefits of sealing depends on the capacity of the vehicle’s vehicle. Properly trained technicians have the equipment, tools, safety small leaks and scrubbing silicates from cooling system. Use between 1 and 1 1/2 grams of tabs per liter of cooling instructions and know-how to do a water pump seals, seal tabs have some job properly and safely. If a condition side effects. system capacity. is described, it cannot be assumed After awhile, a brown, dirty-looking Cooling system seal tabs are usually that the information applies to all stain may form on translucent coolant packaged with 10 tabs per pack, and vehicles or that all vehicles will have that condition. reservoir containers. Residue may form each tab is 10 grams. Check the packag- on the backside of the radiator cap. And ing for complete information. All materials and programs described in this magazine are subject to deposits that resemble rust may be change. Submission of materials found in the cooling system. implies the right to edit and publish. These are not problems, in Inclusion in the publication is not the sense that they necessarily an endorsement of the cause no physical individual or the company. harm. But their TechConnect is published for appearance ACDelco by Sandy Corporation, Troy, MI. can be alarming, ©2005 ACDelco. All rights reserved. especially on

2 A/C Triage — Ensuring Replacement Compressor Survival — from page 1

In addition to debris, the refrigerant lubrica- detector prior to running the tion may be burnt or contaminated from recovery equipment is a worth- improper sealant or refrigerant. while investment. As with the medical field, successful treat- Replace Missing Fluids ment requires cleaning the damaged area and providing treatment, which will prevent future There are two important flu- infection. ids that must be replaced in proper quantity and quality. The first step is to inspect and clean or re- These are lubricant and refrig- place the existing system debris containment erant. The compressor manu- components. These include the orifice tube, Redesigned filter components: A. Nut, B. Ferrule, C. Seal, facturer must approve the lubri- TXV screen(s), A/D or R/D and any inline filter. D. Tube adaptor, E. Filter body, F. Orifice retainer clip cant. The use of ACDelco lubri- The A/D or R/D cannot be service cleaned. cant assures warranty cover- The general rule of thumb for A/D or R/D Since contamination is generally spread age and OEM specifications adherence. replacement is: throughout the system after compressor fail- No OEM automotive compressor manufac- • A/D or R/D age over three years ure, not to flush the entire system would be similar to changing just the shirt of a small turer endorses the use of esters. Their use • Sealant inclusion within the system will void the warranty from ACDelco. • Significant debris found within the child who had fallen in the mud. The kid’s still system after compressor failure not clean and neither is the system without The second lubrication issue is to ensure an flushing. adequate amount. A lubrication replacement In addition to reviewing the existing OEM balance guide is included with re-placement filtration devices, it is important to remember In addition, all OEM’s except Ford insist on refrigerant flushing only if flushing is to take compressors. Failure to heed these guidelines that the OEM system was installed with a to lubrication replacement after com-ponent certified clean system. Once a component place. Ford allows solvent flushing, but only using an endorsed flushing material and with replacement or flush can and will cause pre- fails, the only way to ensure the system is mature failure and replacement. completely, 100% clean is by replacing all the approved flushing equipment. As men- A/C components, which is rather impractical. tioned previously, flushing does not 100% Finally, refrigerant quality and quantity is criti- Therefore, it is critical for the service techni- guarantee particle removal, so preventive suc- cal in today’s automotive A/C system. Today’s cian to provide protective devices not original- tion and line filters are highly recommended systems will lose performance and reliability ly included in the OEM system (they were to capture those elusive remaining particles. as well as create noise if the charge is not not needed under factory new conditions) The aftermarket use of sealants has provid- kept within the manufacturer’s specification. to prolong service repair life. ed the service industry a repair dilemma. There The use of 12 ounce cans will not provide ACDelco rec- are currently numerous chemical sealants this accuracy. Current charge equipment, ommends the use employed in the automotive A/C service when maintained, will provide charges within of a suction industry. No OEM currently endorses the use the +/- 1 ounce tolerance often required. In screen on all com- of sealants. However, given the thousands of addition, if a refrigerant identifier is not pressor replace- sales made to the do-it-yourselfer and repair employed after charging, there is no way to ments where the shops, they will be in vehicles you service. ensure that excessive air or alternate refriger- replacement com- Removal is dependent upon the amount ants are present. After charging, both of pressor does not and type of sealant employed. There currently these contaminants will cause noise and pre- come with an inter- Suction screen kit is no method for 100% removal of sealants mature compressor failure. nal suction screen (short of total component replacement). A/D (for example, A-6, V-5 and V-7 models). or R/D replacement will greatly reduce sys- The installation of the low-cost suction tem sealant quantities but not completely screen provides additional protection to the remove it from the system. In addition, the precision replacement compressor installed in refrigerant and associated lubricant removed a compromised environment. by recovery equipment assists to minimize In addition to the suction screen, ACDelco has the level of total system contamination. redesigned the in-line filter employed to prevent Of importance to technicians with this rear TXV’s and orifice tubes from premature recovery is protection of their expensive plugging. This filter offers the additional filter recovery equip-ment from sealant. There are debris capacity to maintain system integrity. no tools to identify all the sealants employed This newly redesigned in-line filter is a uni- in the automotive aftermarket. Therefore, the versal one-size-fits-all part that has a use of a seal-ant protection device or seal-ant Refrigerant identifier significantly increased debris containment screen and a technician-friendly leak-free installation design. In addition, it can be Provide Professional Follow-up employed as The term professional follow-up means a line splice more then being paid to repair an A/C sys- for repairing tem. It means the ability to provide the cus- leaks on A/C tomer with qualified diagnostics and quality lines to rear OEM replacement parts and service materi- systems. Orifice with retainer clip als. Rechecking the details prior to final cus- Flushing is tomer release is very important. The re- mentioned often in the aftermarket as the inspection of the entire system for leaks, panacea to system contamination. Flushing functional testing with a thermometer, check- will remove lubricant from the system and ing gauge pressures and performing purity will remove some, but not all, of the debris tests will ensure customer satisfaction. within the system. However, flushing is an Remember, quality ACDelco parts also re- Sealant detector expensive process. quire quality installation and attention to detail.

3 and more. As powerful as the Diagnosing KTS Series is with ESI[tronic], it is also flexible; users have European the option to utilize the KTS as an integrated solution Vehicles with ESI[tronic] and Service Information The digital revolution in System (SIS) or they the automotive industry may choose to use the hasn’t by-passed the auto- KTS strictly as a diagnostic Wiring diagram motive aftermarket but instead scan tool. hit it head-on. Increasingly more complicated vehicle components and their networking to Scope and Meter systems are turning all vehicles—both domestics and imports— Complementing the other into “mobile computers.” functionalities of the KTS Series The importance of having the right diagnostic equipment is are a 2-channel multimeter vital to a service center’s business. When repairing European and a 2-channel oscilloscope. vehicles, Vetronix offers the new KTS Series of diagnostic sys- The convenient multimeter tems, which uses a combination of hardware and software to provides the ability for rapid tackle complex diagnostic conditions. tracing of faults through simul- taneous measurements on The KTS Series is an Integrated European Diagnostic System, two components. meaning that it seamlessly and intuitively incorporates vehicle Convenient 2-channel oscilloscope diagnostics with vehicle service information for an efficient diag- The oscilloscope enables nostic and repair solution. technicians to make complex measurements on state-of-the- The KTS Series consists of two kits: the KTS 650, which is a art vehicle system components. fully self-contained unit in a ruggedized tablet PC with color touch screen, and the KTS 550, which has all the power and Integrating It All functionality of the KTS 650 but requires an interface with a with CAS shop laptop or PC. Powering both the KTS 650 and the KTS 550 The control-unit diagnosis is robust, modular software known as ESI[tronic] (pronounced: values and the troubleshoot- easy-tronic). ing instructions displayed by KTS as a Scan Tool the KTS Series are seamlessly integrated together in An integral component of ESI[tronic] by an application the KTS is its ability to func- called Computer Aided tion as a diagnostic scan tool Service, or CAS. There is no and communicate with all cur- need to run back and forth rent protocols including CAN, between a scan tool and PC ISO and SAE. Depending on or even toggle between differ- the vehicle system, the KTS ent screens—CAS performs can read codes, clear codes, these functions for the techni- access serial data, access The KTS is CAN ready cian, saving valuable time. actual values, perform actuator tests, variant code, show com- In addition to this unique Computer Aided Service – CAS ponent locations and more; feature, four software updates offering all the basic and delivered on DVD are released advanced scanning functional- per year based on an annual subscription, assuring users of ities required today. dynamic and continuously updated software. Developed and manufactured by Bosch, the KTS Series is ESI[tronic] Information exclusively distributed and supported in North America by System Vetronix. For more information on the KTS Series or to see a With the importance of demonstration, contact Vetronix at 1-800-321-4889, ext. 4 or electronics in the car increas- visit www.vetronix.com. ing exponentially, technical service information is now Component location becoming a decisive factor for KTS Features at a Glance today’s technicians. Coverage for BMW, VW, Audi, Mercedes Benz, Volvo Professional fault diagnosis is a and more the key to completing accurate and profitable vehicle repairs. aSeamless integration of serial data & service information ESI[tronic] starts with sim- aSystem specific fault diagnosis ple vehicle and parts identifi- aExtensive library of detailed wiring schematics cation, including the ability to Component location diagrams cross reference parts via a Actuator control testing ESI[tronic] Module A. Users a also move through the guided aContains all current protocols, including CAN, ISO & SAE diagnostics offered by Module Parts database aDetailed parts database with cross-reference table C. And with Module P, wiring Maintains history of last 30 vehicles tested diagrams for all important convenience electronic system areas a 2-channel multimeter and oscilloscope for rapid tracing are included: air conditioning, anti-theft protection, central lock- a of faults ing, airbags, headlights, seat heating, sunroofs, electric windows

4 Update Your Image with New ACDelco Uniforms Uniformed employees are more trust- Committee to develop a more comfort- worthy and credible, and customers have able ACDelco-branded shirt for technicians more confidence that they are profes- featuring an improved ACDelco water- sionals who can get the job done. Those mark and stronger stitching packaged in ACDelco’s traditional red and blue colors. The sub-committee also identified uniform rental as an attractive benefit for TSS service centers, so it was added to the 2005 program. The new shirts are available now for rental or purchase. In addition, the ACDelco shirts currently being worn by many TSS service center employ- ees will be available for pur- chase until May 1, 2005. Updated service consultant Specifications attire also is available, includ- Good looks, comfort and high ing ACDelco-branded polo quality — that’s what you’ll get shirts and oxford shirts. in the new ACDelco technician The new technician uni- uniforms. forms, which include the Technician shirt new ACDelco-branded shirts • Comfortable 65/35 as well as gray Comfort polyester/cotton poplin Fabric™ work pants, are • Improved ACDelco watermark available for rental through • Traditional ACDelco colors Cintas Corporation — North • Available in long and short America’s largest uniform sleeves supplier — and for purchase through FMR. There are no Work pant minimum quantities to order, • Durable Comfort Fabric™ and various sizes are avail- material able. Costs differ from mar- • Comfortable 65/35 polyester/cotton twill are the findings of a recent Uniform and ket to market, so contact your Cintas rep- • Pleated or straight leg styles Textile Service Association survey. resentative for pricing information. • Choice of colors Compelling reasons to make sure TSS For uniform rentals, call 1-800-795-7368, service center employees look as good and for purchases, call 1-877-750-1054. as they perform. The results also showed that 79% of those surveyed prefer to see uniformed employees in the vehicle repair/service industry and that 61% feel they receive a higher quality of service when they see an employee in uniform. “Using some of the tools from the course, I started coach- ACDelco uniforms clearly identify ing one of my technicians who was working at about 64% employees, promote a consistent brand productivity. By the next week his productivity rose to image and can even convey a high level of service. In addition, proper uniforms 86%, and then to 92% the following week. Since then, can help improve employee morale and he has averaged 80-90% productivity. My only regret is teamwork, which, in turn, could mean that I did not take the Dale Carnegie Course ten years increased productivity. ago! Technology changes in the cars, yet people have These feelings of your customers and been the same for years and we need to invest in them.” employees can translate directly to your bottom line. That’s why ACDelco has — Dave Dainton developed a new uniform program that Owner of Spartan Tire & Service in Lansing, MI will provide a good first impression for and Dale Carnegie Training graduate TSS service center customers. Visit Dale Carnegie Training at www.dalecarnegie.com/acdelco ACDelco worked with the TSS Advisory or call 1-800-393-3253. Council and Dedicated Distribution Group (DDG) Customer Development Sub-

5 A Successful 2004 … and the Countdown to 2005 The 2004 racing season was a success for racing legend Warren Johnson. Tom the ACDelco-sponsored teams running in the Paci, ACDelco assistant motorsports NASCAR Busch Series, NHRA POWERade manager, has indicated that this last Pro Stock Series and the IHRA Pro Modified season for Johnson, known as “The Series with strong showings by Ron Hornaday, Professor,”will be dubbed the “School’s Kurt Johnson and Harold Martin, each of Out Tour.” The senior Johnson’s career whom took the checkered flag. And for 2005, achievements include six NHRA Pro the ACDelco teams promise even more Stock championships, 92 national event excitement every racing weekend. Here’s a wins and 143 final round appearances look back at the accomplishments of 2004. — the most of any driver in Pro Stock Busch Series history. Johnson will remain active in Weekly Racing Series Midwest Region racing with Warren Johnson Enterprises, which The 2004 NASCAR Busch Series season supports the racing efforts of his son Kurt. came down to the wire with Martin Truex Jr. championship with 10 victories in 19 starts. winning his first series championship with The 24th year of the NASCAR Busch Series The 2005 NHRA Pro Stock season kicks- 5,173 points, 230 points more than second- begins at Daytona International Speedway in off in February in Pomona, CA with the CAR- place finisher . ACDelco-spon- mid-February with the Hershey’s TAKE 5 QUEST Auto Parts Winternationals. ACDelco sored Ron Hornaday ran a competitive sea- 300. ACDelco and new driver and Kurt Johnson anticipate a close champi- son and finished fourth with 4,258 points. will be in the action all season long. onship chase with champ Greg Anderson. Truex Jr. led in the 2004 standings from NHRA IHRA mid-June and held on for the championship. The 2004 National Hot Rod Association The 2004 International Hot Rod Associa- He led the series in wins (6), poles (7) and (NHRA) Pro Stock season once again saw tion (IHRA) Pro Modified season was the top-five and top-10 finishes during the 34- Greg Anderson take the series champi- best one ever for ACDelco-sponsored Harold race season. Finishing third in the standings onship. ACDelco-sponsored driver Kurt Martin. He had been steadily moving up the just ahead of Hornaday was . Johnson finished fifth in the standings with standings in previous seasons and the 2004 Hornaday completed the season with 1,245 points. standings had Martin among the top finish- ers throughout the summer. He finished seven top-five finishes and 16 top-10 finish- Johnson was one of only four drivers to es, and was in the top 10 in standings for 29 third with 698 points, behind champion Mike win an event in the 2004 season. He took Janis, who had 885 points. weeks. He took the checkered flag at the the Checker Schuck’s Kragen NHRA Nine different drivers took victories in the Alan Kulwicki 250 under the lights at the Nationals in Phoenix in March, the second 12-event 2004 Pro Modified season, with on June 28, taking the lead event of the season, beating Dave Connolly. with seven laps to go after dropping back Janis winning three events. The only other The win in Phoenix was Johnson’s 28th driver to win more than once was Al Billes, one lap earlier in the race. career victory, placing him sixth all-time who won two races and set an IHRA record Hornaday was one of several drivers who on the Pro Stock career wins list. had good paydays throughout 2004. He was with a best time of 6.102 seconds. one of six Busch drivers who won more than Johnson’s 2004 season also saw him qual- After beginning with a loss in the finals of $1 million in purse money. That’s all the ify for the final round in four events. That the season opener at the Amalie Oil Texas more impressive considering the level of accomplishment moved him up to fourth on Nationals in San Antonio, TX, Martin got his competition in the Busch series. In a prac- the Pro Stock career final round appearance first career win at the Western R.V. Rocky tice known as “Busch-whacking,” a number list with 54. Mountain Nationals in Edmonton, Alberta, of Nextel Cup drivers also ran in Busch races Overall, the 2004 season belonged to Canada. He also held the top spot in the all season long, with wins by Nextel Cup vet- Anderson, who finished with 2,402 points, standings at the beginning of the season. erans such as Jamie McMurray, Matt 742 points ahead of second-place finisher By the end of the year, Martin had made the Kenseth, Dale Earnhardt Jr., , and teammate Jason Line. Anderson won field nine times and had qualified in the top and . a record-setting 15 of the 23 NHRA national four in six races. For the 2005 season, ACDelco will spon- events. He also made it to the final round The 2005 IHRA Pro Modified season sor up-and-coming driver Clint Bowyer in the 19 times. In October, he set Pro Stock begins in March once again at the Amalie Oil #2 Richard Childress Chevy Monte Carlo. records for the top speed at 207.75 mph Texas Nationals in San Antonio, TX, where Bowyer finished second in the 2004 Rookie of and best elapsed time at 6.661 seconds. ACDelco and Harold Martin look to continue the Year voting. He won the 2002 NASCAR 2005 will mark the last full-time season for the climb to a championship season. ACDelco Sports Report

NASCAR Busch IHRA Hooters NHRA CITGO Series Stock Pro Modified POWERade Bassmaster Car Racing Series Drag Drag Racing Tour Racing Driver: Pro Stock Angler: Clint Bowyer Driver: Series Jimmy Houston Harold Martin Car: #2 Chevy Driver: Professional Kurt Johnson Monte Carlo Car: Pontiac Angler Jimmy Grand Am Car: Chevy Cavalier Houston casts off the 2005 CITGO Bassmaster Tour with Clint Bowyer, driving the #2 Harold Martin kicks off Kurt Johnson starts the Stop 1 at Lake Tohopekaliga, ACDelco car in the NASCAR the 2005 IHRA Hooters Pro 2005 NHRA POWERade Pro Kissimmee, FL, January Busch Series, begins the 2005 Modified Series at the Amalie Stock Series at the CAR- 27-30. season at the Hershey’s TAKE Oil Texas Nationals, San QUEST Auto Parts 5 300, Daytona International Antonio Raceway, March Winternationals, Pomona Speedway, February 19. 31-April 2. Raceway, February 10-13.

6 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.

Loose Crankshaft Reluctor This condition may occur when the bat- For the 2004 model year, rust in the tery has been disconnected, or if the injector filter of replaced injectors 2001-04 and GMC full-size and vehicle has a dead battery and is jump- appears to be coming from several medium-duty trucks equipped with the started. Do not replace the instrument sources: Duramax 6600 diesel engine (LB7) cluster to correct this condition. • chassis fuel line The Duramax 6600 diesel engine may The cluster’s microprocessor resets have a rough, unstable, incorrect idle • crossover pipe on the Gen III before the crystal stabilizes, causing the speed or stall. After completing the fuel rail. processor to lockup when there is a loss Service Information diagnostics for an of power. This lockup condition can be Both pipes are made of low-carbon engine stall or misfire condition with no corrected by removing the fuse marked steel, and the inside of the pipe is not trouble found, and the data indicates CLSTR (circuit 1440), waiting approxi- coated. If water gets into the fuel sys- intermittent high balance rates on ran- mately one second, then reinstalling the tem, it has the potential to rust the line. dom cylinders, check for a loose crank- fuse. The fuse panel access door is on When diagnosing driveability symp- shaft reluctor. the left side of the instrument panel. toms due to clogged fuel injectors, follow To inspect the crank reluctor, remove Once the fuse is reinstalled, the cluster the procedures outlined in bulletin 03-06- the right inner fender, crank sensor and should reset with the gauge needles 04-030A. If the bulletin procedures lead crank sensor spacer. Use a blunt probe vibrating at their zero positions for about to replacing an injector, inspect the and try to move the reluctor clockwise two seconds. The body computer also removed injector for evidence of rust or counter clockwise. If the crankshaft will reset. contamination. If rust is plugging the fuel reluctor is found loose, repair by replac- injector, replace it. A procedure for For the 2001 model year, a power-on- ing the necessary parts, including the removing rust from the injector filter has reset chip was added to the instrument alignment pins. not been developed. cluster to address this condition. Transaxle Shift Conditions If rust remains in the fuel line, there is Returnless Fuel Systems 2002-03 Pontiac Bonneville, Buick LeSabre a chance that the injector filter will plug and Park Avenue Returnless fuel systems have been in up again. Whenever rust is observed in production on some GM models since an injector, flush the fuel lines. If the fuel Drivers may experience no transaxle 1998 (Pontiac Trans Am, Chevrolet Camaro line cannot be completely flushed of rust, upshifts, erratic shifts and/or slipping and Corvette). A significant migration replace it. from the transaxle. Diagnostic trouble toward returnless fuel systems began in A small amount of rust in the fuel tank codes P0753 and P1860 may be set. the 2004 model year. By 2007, the majority These conditions may be caused by a will typically not cause a problem. The of GM models will be converted to the fuel filter will prevent the rust from get- poor electrical connection inside of the returnless design. underhood fuse box or Bussed Electrical ting to the injectors. The capacity of the Center. The terminal that feeds the In a returnless fuel system, which is filter is large enough to keep it from plug- transaxle fuse may be spread too large. designed to meet increasingly stringent ging up. There is also a strainer (“sock”) If a deformed terminal is discovered, evaporative emissions regulations, no at the inlet to the fuel pump. The strainer replace it. fuel is sent back to the fuel tank from the prevents contamination from getting into engine. All fuel leaving the tank flows the fuel pump and causing problems. On the Pontiac Bonneville and Buick through the fuel injectors. However, rust in the fuel tank is a sign LeSabre, the terminal at connector C3, pin E7 is at fault. On the Buick Park Any contamination (including rust) that that water may be in the tank. If rust is Avenue, connector C2, pin E4 is the is built into or forms in the fuel line will observed in the fuel tank, empty it and faulty terminal. find its way flush with hot water, according to Service to the fuel Information procedures. Intermittent Dead Battery injectors. A Speaker Rattle 2002-03 Chevrolet TrailBlazer, GMC Envoy filter at the and Oldsmobile Bravada inlet to the 2000-04 Pontiac Sunfire and Chevrolet fuel injector Cavalier An intermittent dead battery condition filters out may be caused by the IGN 0 circuit turn- A rattle or buzz sound from the right small conta- ing on while the key is removed from the front audio system speaker may be minants, ignition switch. To determine if this con- generated by the door trim panel upper including rust. dition is occurring, wiggle the lock cylin- extension covering the exterior mirror If enough der with the key removed and watch to mount (commonly known as the debris accu- see whether the PRNDL display and bat- shark fin). mulates on tery light illuminate. the injector Before replacing the speaker, verify If the IGN 0 circuit is turning on with filter, it will that the shark fin is not the concern. the key removed, replace the ignition start to Apply pressure to the shark fin at the switch. restrict flow. forward lower corner. If the rattle dimin- Instrument Cluster Lockup This will have ishes, repair the condition by removing a negative the trim panel and adding a foam block 2000 Chevrolet Cavalier and Pontiac Sunfire effect on to the forward lower corner to dampen The instrument cluster may appear to performance the low frequency vibrations. Install the be dead, with no movement from the and drivea- trim panel and tighten the screw to gauges and a nonfunctional odometer. bility. Filter at injector inlet specification.

7 that is free of water. There are diesel fuel Diesel Fuel Additives biocides available to kill bacterial growth The use of diesel fuel additives is not required or in the fuel system. However, the dead recomended for the 6.5L diesel or the 6.6L Duramax® bacteria can cause blockages throughout Diesel engine under normal conditions. The filtering the fuel system. system is designed to block water and contami- If bacterial growth is found in the fuel nants without the use of additives. However, system, the proper method of removal is some customers may desire to use fuel additives to to flush the fuel system using Service improve the characteristics of available diesel fuels. Information procedures, replace the fuel Water Demulsifiers and Emulsifiers filter element and refill the tank with clean diesel fuel. If a customer desires to Fuel additives must be selected carefully. There use a biocide after flushing the fuel sys- are two common methods that fuel additives use to tem, it should not contain alcohol or other cope with water in the fuel. water emulsifiers. Demulsification causes water particles to com- There are many indicators of overall bine together to form larger particles, which drop out of suspen- fuel quality such as cleanliness, specific gravity, volatility, viscosity, sion. This allows the fuel filter/water separator to separate the detergency, corrosion inhibiting abilities, and lubricity. The cetane water from the fuel as it is designed to. number is one indicator of a diesel fuel's ability to ignite. Increasing Emulsification keeps water particles suspended in the fuel. the cetane number alone is not a fix for poor quality fuel. Alcohol is frequently used as the emulsifier. Emulsification can Additionally, increasing the cetane number beyond the engine's allow water to get past the fuel filter/water separator, in most requirements will not increase performance. However, the cetane cases causing damage to the fuel system. number of diesel fuel is not always consistent and some cus- Only alcohol-free water demulsifiers should be used in GM tomers may desire to use a cetane improver to ensure full perfor- diesel engines. mance of their engine. If such an additive is to be used, it must not contain alcohol or other water emulsifiers. Common Diesel Fuel Concerns The 6.5L diesel and the 6.6L Duramax® Diesel engines are Fuel distributors blend number 1 and number 2 diesel fuels for designed to operate on today's low sulfur fuel without the use of seasonal requirements in a particular region. No other blending of additives. A fuel additive designed to increase lubricity is not a fix fuels is recommended. However, a customer may desire to use a for poor quality or contaminated fuel, but some customers may winter fuel additive to prevent fuel waxing or icing during extreme desire to use a lubricity additive to aid in the longevity of their fuel cold snaps. If a winter fuel additive is used, it should not contain system components. If such an additive is to be used, it must not alcohol or other water emulsifiers that may compromise the water contain alcohol or other water emulsifiers. removal effectiveness of the fuel filtering system. If a vehicle is properly maintained but has fuel contamination Bacteria and fungi growth also can occur in diesel fuel when issues, consider obtaining fuel from a different source. Purchasing there is water present, especially during warmer weather. The best fuel from a high volume fuel retailer increases the likelihood that prevention against bacteria and fungi growth is to use clean fuel the fuel is fresh and of good quality.

Rear Axle Modular Fuel Pump Lubricant 15mm (0.6") Electrical Connector Level Check 40mm (1.6") Terminals Checking the lubricant level in Before condemning a fuel pump on a Chevrolet or GMC C/K the rear axle of Chevrolet and truck or G van, check the terminal in the wiring harness connec- GMC full-size pickups and SUVs tor and in the connector on the pump module. If a harness is in the past involved removing the rear axle fill plug and spread apart, it will cause excessive resistance, which leads to seeing if the fluid was level with the fill plug opening. overheating of the terminal. The electrical connector terminal The lubricant check procedure has changed for 1999-2005 should also be inspected with every fuel pump replacement. Chevrolet and GMC full-size pickups and SUVs with the When inspecting the modular fuel pump chassis connector, 8.6-inch axle. use PT818 (4-way female w/leads, black) for replacement. After removing the rear axle fill plug, technicians should fab- The following quick reference chart is provided below with the ricate a dipstick from a pipe cleaner or similar item. Form the C/K truck, G van and S Truck applications and proper connector. pipe cleaner into an “L” shape and insert it into the fill plug opening with the stem facing down. Application ACDelco Modular Connector Part # Fuel Pump Part # Next, remove the pipe cleaner and measure the distance from the bend in the pipe cleaner to the lubricant 1999-03 C/K Pickup Truck MU1089 PT818 level. Specification: the distance should be 1997-00 C/K Pickup Truck MU146 PT818 15-40 mm (0.6-1.6 in.) 1998-00 C/K Pickup Truck MU145 PT818 If the measurement is greater than 40 mm (1.6 in.), add lubricant until the 1998-00 C/K Pickup Truck, MU149 PT818 level is within 15-40 mm Escalade, Tahoe and Yukon (0.6-16. in.) from the bottom 1996-97 C/K Pickup Truck, MU138 PT818 edge of the fill plug hole. Tahoe and Yukon In addition, the recom- 1998-99 C/K Pickup Truck MU152 PT818 mended fluid is now a and Suburban synthetic fluid, SAE 75W-90 1997-02 G Van MU158 PT818 Synthetic Axle Lubricant, GM part number 12378261. 2000-02 S Pickup Truck MU1048 PT1402

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