Clean Diesel Exhaust Chemistry

May & June 2010

Clean Diesel Exhaust Chemistry In 2010, diesel engines sold in the U.S. are required to meet new Environmental Protection Agency (EPA) emissions requirements. To meet the standards for nitrogen oxide (NOx) reduction, the new Duramax Diesel engines in full-size GM trucks and vans feature a Selective Catalyst Reduction (SCR) system that uses automotive-grade urea — known as Diesel Exhaust Fluid (DEF) — that is mixed in the exhaust stream, causing a chemical reaction that converts the gases into mostly nitrogen and water. The DEF in the vehicle must be refilled periodically, similar to the fuel tank, but not as often.

Diesel Emissions Control The SCR after-treatment system on the new Duramax Diesel engines causes NOx reduction reactions to occur in the exhaust stream. It’s called “selective” because it uses ammonia as a reductant to reduce NOx levels within a catalyst system. The Engine Control Module (ECM) controls the DEF delivery

system. Based on the engine NOx emissions level communicated to the ECM by the NOx sensors, the ECM will send a command to the DEF injector to dose a given quantity of DEF. The injected DEF combines with the exhaust gas with the help of mixers before contacting the SCR. The SCR brick stores the ammonia and through a chemical reaction with the NOx in the exhaust gas produces nitrogen (N2), water (H2O) and small amounts of carbon dioxide (CO2), which are natural elements common in the air.

Diesel Exhaust Fluid DEF is a colorless, clear solution of water and urea that has 32.5% +/- 0.7% of urea by weight. DEF also is referred to by other names such as AdBlue, ClearBlue, Urea, and Aus32 (Aqueous Urea Solution). The recommended temperature for storing DEF is between 12°F – 86°F (-11°C – 30°C). To prevent DEF decomposition, it should not be transported or stored at temperatures above 77°F (25°C). The shelf life of DEF depends on storage continued on page 4

Summer Maintenance Tips

IN THIS ISSUE

Many drivers around the country are in the midst of spring fever, rolling down the windows and turning up the radio, but when it comes to the actual vehicles they’re driving, signs of winter are probably still hanging around. Check the fluids or tires? Change the air filter or wiper blades? Spring is the perfect time for a maintenance check-up of these items and many others. Remind your customers that the following items require regular inspection or maintenance: • Automatic transmission fluid • Battery and cables • Belts • Cabin air filter • Chassis lubrication • Engine air filter • Engine oil and filter • Exhaust • Fuel filter • Hoses • Lights

Clean Diesel Exhaust Chemistry . . . . . . . . .1

• Power steering fluid • Tire inflation and condition • Windshield washer fluid • Wiper blades Include these tips about some items hardest hit by winter weather in your maintenance discussions with customers.

Low Tire Pressure A long, cold winter may have led to a less than diligent check of tire pressures by many customers, resulting in additional tire wear. Point out how to check the tire tread for uneven or irregular wear as well as cuts or bruises along the sidewalls that may have been caused by potholes. Explain that uneven tire wear may be a symptom of worn suspension components.

Worn Belts and Hoses Check belts for looseness and worn conditions. Replace a belt when cracked, frayed, glazed or showing continued on page 5

Summer Maintenance Tips . . . . . . . . . . . . .1 DuraStop Performance Brake Pads and Rotors . . . . . . . . . . . . . . . . .2 New Brake Seminars: Hybrid Technology to Basic Diagnosis . . .3 ACDelco Merchandising Materials Focus on Marketing to Women . . . . . . . . . .4 New ACDelco Belt Wear Tool . . . . . . . . . . .5 TSS Q&A . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Duramax Diesel Water Pump Cover . . . . .6 Tech Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Training Update . . . . . . . . . . . . . . . . . . . . . . .8

ON THE WEB – www.acdelcotechconnect.com, click the TechConnect Magazine link, or – Log in to the ACDelco LMS, click the Resources link

DuraStop Performance Brake Pads and Rotors Aggressive stopping power in a heavy-duty use environment is a requirement for any brake materials used on police and fleet vehicles. However, not all heavy-duty parts can measure up to the demands of daily use in police patrol vehicles.

Volume 17, Number 3 (TS-PU-0015-10) ACDelco TechConnect is published bi-monthly and online for technicians of Total Service Support (TSS) and Key Fleet accounts to provide timely service information, increase knowledge and improve the performance of the service center. ACDelco 360 represents our mission to look at our businesses at every possible angle to provide value and assistance to our distributors and their customers as well as offer a full circle of support with programs, tools, training and marketing focused on enhancing and growing our partnership successfully.

ACDelco’s new DuraStop Performance brake pads and rotors are designed to dissipate heat quickly for excellent braking control while offering durable, long life performance. The DuraStop Performance brake pads are available for 2006-2010 Chevrolet Impala, 20032010 Ford Crown Victoria, 2006-2010 Dodge Charger and 2007-2009 Chevrolet Tahoe models. DuraStop Performance pads will use the new PV suffix, which refers to Performance Vehicle. DuraStop Performance brake rotors are available for 2006-2010 Chevrolet Impala, 2003-2010 Ford Crown Victoria, 2006-2010 Dodge Charger/Challenger, and 20072009 Chevrolet Tahoe models.

D3EA® PPSV® Tested DuraStop Performance brake pads are tested to the rigorous Dual Dynamometer Differential Effectiveness Analysis (D3EA) test criteria for Police and Public Service Vehicles (PPSV). The testing criteria specifically targets police fleets and compares friction results of wear, heat dissipation, effectiveness, brake fade and high-speed performance. The high-speed testing isolates the effects of the driver, road and tires.

Publisher: Mike DeSander ACDelco E-mail / [email protected] Editor: Mike Militello ACDelco E-mail / [email protected] Technical Editor: Mark Spencer E-mail / [email protected] Production Manager: Marie Meredith Desktop Publishing: 5by5 Design LLC E-mail / [email protected]

The DuraStop Performance brake pads, specifically manufactured for police fleet applications, are more durable and quieter than competitive pads and are speed rated to assure confident high-speed braking. In testing, competitive pads had more than twice as much wear at 350 degrees (normal braking temperature) and twice as many stops above 70 decibels than the DuraStop Performance pads. Designed to work with DuraStop Performance brake pads are DuraStop Performance rotors, which will last longer than standard OE rotors in police applications. DuraStop Performance rotors are manufactured using damped iron to resist and dissipate heat better than standard Enhanced vane configuration assures quick heat dissipation G3000 rotor iron. The rotors also use an enhanced vane configuration to assure quick heat dissipation. The rotor also is coated with a material that covers the entire surface of the rotor to help resist corrosion better than standard coatings. For more information about DuraStop Performance brakes and specific applications, contact your local ACDelco distributor or consult the ACDelco parts catalog. – Thanks to Kurt Pursche 2

Write to: * ACDelco TechConnect P.O. Box 500 Troy, MI 48007-0500 On the Web:: To read and search recent issues of TechConnect online: – www.acdelcotechconnect.com, click the TechConnect Magazine link, or – Log in to the ACDelco LMS, click the Resources link ACDelco service tips are intended for use by professional technicians, not a “do-it-yourselfer.” They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, it cannot be assumed that the information applies to all vehicles or that all vehicles will have that condition. All materials and programs described in this magazine are subject to change. Submission of materials implies the right to edit and publish. Inclusion in the publication is not necessarily an endorsement of the individual or the company. TechConnect is published for ACDelco by Sandy Corporation, Troy, MI.

©2010 ACDelco. All rights reserved.

New Brake Seminars: Hybrid Technology to Basic Diagnosis ACDelco’s commitment to providing top quality technical training continues with the release of five all-new modular brakes seminars that cover the newest technologies of automotive braking applications. Designed to be offered as one-hour “Lunch-and-Learn” training events, they can be delivered as one-hour stand-alone courses or combined to provide advanced training for your shop.

with applicable diagnostic procedures are key elements of this seminar. ABS subsystems and their operation, including bi-state engine mount systems, dynamic rear proportioning, engine drag control, variable effort steering and vehicle stability enhancement systems, also are reviewed.

Foundation Brakes S-BK05-05.01SEM

Hybrid Regenerative Brake Systems S-BK05-04.01SEM What exactly is regenerative braking? How does a hybrid vehicle control module determine how much hydraulic brake force and regenerative brake force should be used to slow or stop a vehicle? How different are service procedures for hybrid vehicle braking systems compared to conventional ABS? These questions and others about GM, Ford and Toyota regenerative brake systems are answered. In addition, details are provided about high voltage components, identification labels and Personal Protective Equipment. As an added feature, innovative technology (such as a power generating shock absorber) and other possible future technologies are highlighted.

Traction Control and Stability Enhancement Systems S-BK05.02.02SEM Modern traction control systems and the various strategies used for traction control intervention, such as corrective fuel management, throttle closure, brake application and spark table modification, are discussed as well as the traction control switch, the brake temperature algorithm and brake pedal position sensor inputs. Operation and diagnosis of stability enhancement system components, including the longitudinal accelerometer, steering wheel position sensor, yaw rate sensor and lateral accelerometer sensor, also are discussed. Specific service procedures highlight the brake pedal position sensor calibration, zero point calibration and yaw rate reference table resetting.

Antilock Brake Systems S-BK05-03.01SEM Antilock brake systems (ABS), both integral and non-integral, and typical components of antilock brake systems are discussed in this seminar. ABS sensor inputs, such as active and passive wheel speed sensors, brake pedal position sensors, steering angle sensors and yaw rate/lateral accelerometer sensors, along 3

This informative seminar begins with the physics of braking and how it applies to replacement component parts along with what D3EA certification means to both the customer and technician installing the parts. A modern braking system is comprised of several subsystems, such as the power assist, apply, hydraulic, warning lamp, balance control and wheel brakes systems, and this seminar provides an in-depth discussion of each of these subsystems. Single and dual-diaphragm power boosters are topics that are also discussed along with hydraulic booster systems that use power steering pump pressure to increase hydraulic pressure within the master cylinder. DOT 3, 4 and 5 hydraulic brake fluid properties and applications are additional elements of this seminar. Hydraulic circuits and components also are reviewed as well as valuable brake system service tips.

Brake Noise Diagnosis and Service S-BK05-06.01SEM The first step to customer satisfaction is identifying the customer’s concern successfully. To assist with this critical process, this seminar provides a Brake System Description Questionnaire as an additional support tool, enabling a technician to ask pertinent questions for effective diagnosis. How to perform a thorough pre-road test inspection and an effective road test are described in detail. Diagnosis information includes checking pedal travel as well as specific disc and drum brake checks. In addition, diagnostic tips are provided for evaluating brake booster operation and noise concerns.

Learn More In addition to the new brake system seminars, ACDelco offers 24/7, on-demand, online, Web-based courses that can be completed at any time. These online courses complement the instructor-led, hands-on courses that remain the core of ACDelco training. To review the latest training courses available, log in to the ACDelco Learning Management System (LMS) at www.acdelcotraining.com. Take the opportunity to expand your technical knowledge, contact your local ACDelco distributor to learn when ACDelco seminars have been scheduled in your area. – Thanks to Greg St. Aubin

Clean Diesel Exhaust Chemistry — continued from page 1 Driver Warnings

After-treatment System A. Diesel Oxidation Catalyst (DOC) B. DEF injection and mixer C. Diesel Exhaust Fluid (DEF) D. Selective Catalyst Reduction (SCR) E. Diesel Particulate Filter (DPF) F. Exhaust cooler

temperature and exposure to sunlight. At a constant ambient storage temperature of 50°F, DEF may have a minimum shelf life of 36 months. But at a constant ambient storage temperature of 86°F, it may have a minimum shelf life of only 12 months. DEF also freezes below 12°F, but it may be reused once it thaws. Before using DEF, be sure to check every batch of fluid for potential evaporation.

Driver Requirements The operation of the after-treatment system for NOx reduction is transparent to the driver. There is no change in vehicle performance or driveability. The only requirement of the driver is to replenish the DEF when the instrument cluster prompts to do so New DEF warning or at regular oil change intervals, symbol whichever comes first. DEF usage is heavily dependent on drive cycles and will vary from vehicle to vehicle. The DEF fill location (identified by a blue cap) on GM fullsize vans is next to the fuel filler and on GM full-size trucks is on the right rear side of the engine compartment. The nozzle diameter is smaller than the diesel fuel nozzle. Use the J23688 refractometer to test for DEF dilution. If DEF is contaminated with diesel fuel, the DEF system must be replaced. If the diesel fuel is contaminated with DEF, the water-in-fuel sensor should detect the contamination. Follow the appropriate diagnosis and repair procedures in the Service Information.

A number of driver warnings will display on the Driver Information Center to warn the driver that the DEF level is getting low and should be refilled. Several messages indicate the DEF mileage range that the vehicle will be able to travel before refilling. A new DEF warning symbol also will flash on the instrument cluster to communicate DEF system warnings. The Driver Information Center messages include: • Exhaust Fluid Range: XXX – displays available mileage range when the DEF is getting low • Exhaust Fluid Low Speed Limited Soon – displays when the DEF range falls below a specified range; speed will be limited when the DEF level becomes critical • Exhaust Fluid Empty Refill Now – displays when the DEF is empty; speed will be limited and other messages will display that provide more information. If these warning are ignored, additional warning messages will display and the vehicle speed will continue to be severely limited. When adding DEF to an empty or very low tank, always add at least one gallon (3.78L) of fluid to release the vehicle from speed limitation.

DEF Availability The DEF infrastructure is expected to grow over the next few years. DEF will be made available at dealerships, fuel stations, truck stops (pumps as well as small containers), and other locations that sell automotive fluids. DEF is available from ACDelco in one gallon, 10-4022 (19286291), and 2.5 gallon, 10-4023 (19286292), packages. – Thanks to Mike Militello

ACDelco Merchandising Materials Focus on Marketing to Women

DEF is available from ACDelco

As much as these materials were created with women in mind as the target audience, they also serve as a great education tool for all consumers. Please take advantage of these useful tools to help market the services of your service center to all of your customers. Visit acdelcoadvantage.com to immediately download any electronic items or order any physical items from the eStore. – Thanks to Kelly Grinnell

In 2007, the Knowledge is Power program was launched to support an ACDelco Marketing to Women initiative in the field. The program includes many merchandising items, including a complete animated presentation with presenter notes, a seminar guide with helpful hints on how to run a seminar, newspaper and radio advertising templates, winter and summer survival tips, banners, posters, waiting room informational booklets and post-seminar surveys. 4

Summer Maintenance Tips — continued from page 1 signs of excessive wear. Refer to the ACDelco belt wear inspection tool for more details. Not replacing a belt as required could cause a breakdown or serious engine damage. Also inspect hoses at each oil change and replace when leaking, brittle, cracked, swollen or restricted/collapsed. Use the squeeze test — squeeze the ends (within two inches) of a hose with your finger and thumb — to check for electrochemical degradation.

Wiper Damage

to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. The following noises are characteristics of braking systems: • Squeak/squeal noise – Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal; may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. • Grinding noise – Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. It may be caused by corrosion on the metal surfaces during vehicle non-use.

Windshield wipers should be inspected for cracks, cuts, tears, streaking and chattering. If the blades are not clearing the windshield properly, clean the windshield and the rubber wiper blades. If this does not correct the problem, then replace the rubber elements.

• Groan noise – On vehicles equipped with ABS, a groan or moan noise during hard braking applications or on loose gravel, wet or icy road conditions is a normal function of the ABS activation.

Winter weather can result in the following wiper damage: • Sand and salt used on roads for increasing traction and ice control will cause the wiper blades to wear more quickly.

Battery Life

• Rubber blades can be cut or torn when using ice scrapers or when pulling the blades off a frozen windshield. • Using the wipers to wear through frost and ice, instead of allowing the defroster to melt the ice, can dull, nick or tear the rubber blades. • Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield.

Brake Noise Brake noise is often associated with worn pads or poor performance. Some brake noise is normal and differences in loading, type of driving, driving style and weather conditions can make a difference in brake wear. During brake service, verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature ACDelco Silicone Brake Lubricant, P/N 10-4019. Brake noise is caused by a "slip-stick" vibration of brake components. If the noise persists and is consistently occurring, silicone brake lubricant may be applied

Corroded battery terminals can prevent proper battery operation in all weather. Keep the terminals clean and make sure connections are secure. Even though the cold weather months are hard on the battery, hot summer temperatures can be even tougher. Summer heat can shorten the lifespan of a battery. To ensure proper operation, check that the battery is securely mounted and connections are clean, tight and corrosion free. When talking with customers about regular vehicle maintenance, be complete in your service recommendations. Focus on overlooked but required maintenance that has real benefits to the customer. For example, many vehicles are equipped with cabin air filters. If these filters are used beyond replacement time, they may impede airflow, decreasing A/C and heating performance. Providing responsible services at the proper maintenance intervals will greatly aid your service center in gaining repeat business and additional repair services when required. – Thanks to Mike DeSander and Mike Militello

New ACDelco Belt Wear Tool Automotive belt construction has changed over the years, resulting in longer-lasting belts that don’t show ACDelco belt wear inspection tool their age readily. For many years, belts were made of Neoprene rubber. Since the late 1990s, belts have been constructed of more durable EPDM (Ethylene Propylene Diene M-class) rubber. Neoprene rubber could be inspected visually, with identifiable signs of cracking, chunk-out and rib separation. However, EPDM belts wear out gradually and do not necessarily show the same signs of wear, making inspection and determining when it’s necessary to replace the belt more difficult. EPDM belts wear much like a tire. Material is lost in the belt grooves when a belt comes into contact with pulleys as it moves around the drive system. The weakened belt performance and reduced tension can lead to belt slip. Slipping belts can cause severe vibration and a reduced ability to transmit power, which often leads to inconsistent alternator performance or poor A/C system performance. 5

To assist in identifying when belts should be replaced, ACDelco has developed a belt wear inspection tool. Tools (#35-MI-0149-09A) are available for ordering free of charge through the ACDelco e-store. Maximum order quantity is 25. A. Gauge sits above the Go to TechConnect Magazine ribs on a good belt B. Gauge sinks below the Online for tool instructions. ribs on a worn belt A belt wear sell sheet (#35-SS-0025-10) also is available through the ACDelco e-store. It explains the differences between EPDM vs. Neoprene construction and how to look for material loss on EPDM belts. The belt wear inspection tool is available through your ACDelco distributor or through your local ACDelco representative as well. For additional information about belt wear inspection, check out the video on acdelcotechconnect.com. Go to: Product Information tab > Technical Product Service Aids > Accessories Belt Drive System (ABDS) – Thanks to Chris Vermette

The TSS Q&A provides answers to common questions received by the ACDelco Customer Support Center. Q: How can I log in to the Exclusively Yours website? A: To log in to the Exclusively Yours website: 1. Go to acdelcotechconnect.com 2. Click the “Rewards” link in the left corner in the Incentives box 3. Click the “Click here to login” link 4. Enter your 10 digit User ID. This consists of your EY number (6 digit number that begins with a 6) and, immediately following that, the last 4 digits of the cardholder’s Social Security Number (SSN).

Duramax Diesel Water Pump Cover When changing the water pump on a 2001-2005 Duramax Diesel engine, examine the water pump cover. If it shows signs of cavitation, it should also be replaced. A new ACDelco water pump cover for the 2001–2005 Duramax Diesel is now available, part number 97228188. It does not include an O-ring.

Q: How do I view my ACDelco purchases? A: To view the previous month’s purchases: 1. Follow all the website log in steps 2. Click the Rewards tab located next to the Home tab 3. Select Reports from the drop down menu 4. Click the “ISC Performance” link located in the box Q: How can I view a listing of the retailers that accept my EY card? A: For a complete listing of all of the retailers that accept the EY card: 1. Follow all the website log in steps 2. Click the “Click here to view the complete merchant listing” link in the top right corner 3. Enter your card number in the space provided

New ACDelco water pump cover

Two available ACDelco water pumps include an OE water pump, part number 251-723, or an aftermarket water pump, part number 252-838.

Q: How can I view my EY card balance? A: For your EY card balance: 1. Follow all the website log in steps 2. Click the “How many points do I have now? FIND OUT” in the blue box on the right 3. Enter your card number 4. A pop up window will open. Re-enter your EY card number in the top right corner 5. Enter the random code in the box on the left 6. Enter the security code located on the front or back of the EY card in the box on the right Q: I have never received an Exclusively Yours Rewards card. How can I get my card? A: Call 1-877-227-0956 to request a card. You will be asked a few security questions and your EY card will be mailed to you. If you have any questions about the TSS program or any current ACDelco activities, contact the Customer Support Center at 1-800-825-5886, prompt #0.

Damage from cavitation

Cavitation Damage Cavitation is the process where a bubble in a liquid (usually caused by the pressure of the liquid falling below its vapor pressure) rapidly collapses, producing a shock wave. The shock wave is strong enough to cause damage. Possible cavitation is most likely at the impeller blade of a pump, where flow rates and turbulence may be high. Cavitation can cause vibration and noise as well as pitting erosion and additional wear. The pitting accelerates the erosion because it increases the turbulence of the fluid flow, which creates more cavitation and, eventually, may lead to pump failure. – Thanks to Matt Gibbard 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.

Allison Transmission Shift Conditions The 2001-2007 Silverado Classic, Sierra Classic; 2007-2010 Silverado, Sierra; and 2003-2010 Kodiak and Topkick, equipped with the Allison LCT1000 transmission (RPO M74, MW7) may have a delayed engagement or no engagement into Drive, a delayed engagement or no engagement into Reverse, or a range inhibit with several possible DTCs. These conditions may be more pronounced in cold climates during a cold start. When DTC P0701, P0751, P0756, P0761, P0843, P0848, P0873, P0877 or P0894 set, it could indicate no or excessively low pump pressure as a result of a no prime or loss of prime condition within the transmission pump. Follow the diagnostic steps outlined in the Service Information. All of these DTCs, excluding P0894 could be set due to a fluid service/filter change, transmission service involving removing the pan, low fluid level caused by a leak, or long periods of storage. Also check the transmission fluid level using the Hot Check Procedure. Low fluid level may cause any of the listed DTCs to set, particularly during a cold ambient and cold vehicle start. In cold climates, ensure the fluid level is at the top of the HOT band. After checking the fluid level using the Hot Check Procedure, if any of the DTCs reset during a cold start, inspect the internal suction filter for possible cracks. Replacing the TCM will not likely correct any of the listed DTCs or low main line pressure.

Inoperative, Intermittent or Noisy A/C Some owners of GM vehicles may comment that their A/C is inoperative, operates intermittently or is noisy. No DTCs are set. After further investigation and diagnosis, it may be determined necessary to replace the Thermal Expansion Valve (TXV). However, before replacing TXVs, always follow the A/C Performance Diagnostic in the Service Information to verify the valve performance and review the diagnostic tips.

Possible causes of A/C noise: • Leaking interfaces (Incorrect fastening at TXV) – Fill system with correct charge. • Incorrect refrigerant charge – Fill system with correct charge. • Non-optimized TXV/ evaporator/plumbing – Verify if noise is being produced by the TXV or other A/C system components. Thermal Expansion Valve

The TXV meters the amount of liquid refrigerant that can flow into the evaporator. Located at the evaporator inlet, the TXV is the dividing point between the high and the low pressure sides of the A/C system. As the refrigerant passes through the TXV, the refrigerant pressure is lowered. Due to the pressure differential, the liquid refrigerant will begin to boil at the TXV outlet before entering the evaporator core. This characteristic is observed as a drop in temperature between the TXV inlet tube and the evaporator inlet tube.

TXV Failure Modes Possible causes of inoperative or intermittent A/C: • Bulb Sensor Temperatures on inlet and outlet tubes – Are the temperatures on both sides (inlet and outlet tubes) of the evaporator thermal expansion valve tube at the expansion device similar? If yes, replace the damaged or faulty thermal expansion valve. Pressures – Are both the low side and high side pressures within the specified values? Refer to the appropriate HVAC zone diagnostic. • Incorrect refrigerant charge – Diagnose and repair potential leak and/or fill A/C system with correct charge. • Leaking interfaces (Incorrect fastening at TXV or seal damage) – Apply correct torque or replace seals if necessary. • System contamination – Is the liquid line extremely cold at the expansion device location and warm beyond the expansion device location? The expansion device is restricted. Inspect for contamination (brown, powdery residue or metal flake) and replace TXV. 7

Brake Pedal Kickback 1997-2007 Ford E-Series; 1999-2008 Ford F-Super Duty; 2000-2005 Ford Excursion Some vehicles equipped with the Hydro-Boost brake booster system may exhibit a brake pedal kickback and/or grabbing condition when applying the brakes that may be caused by contamination within the power steering system. Filter the power steering fluid by installing a temporary filter in the power steering system in line with the power steering hose. The filter needs to go in the low pressure line that goes from gear to cooler to reservoir, where it would be most accessible. After the filtering procedure is completed, if the brake pedal kickback persists, it may be necessary to replace the Hydro-Boost brake booster.

Diagnostic Assistance For free technical diagnostic assistance and product information regarding specific ACDelco products, contact these toll-free information hotlines staffed by ASE-certified technicians: Brakes – 1-888-701-6169 (prompt #1) Chassis – 1-888-701-6169 (prompt #2) Clutches – 1-888-725-8625 Lift Supports – 1-800-790-5438 Shocks – 1-877-466-7752 Starters and Alternators – 1-800-228-9672 Steering – 1-866-833-5567 Wiper Blades – 1-800-810-7096

How to Take ACDelco Training Go to www.acdelcotechconnect.com and click on the Training tab to log on to the ACDelco Learning Management System (LMS).

New Training The following ACDelco training programs have recently been made available via the LMS: S-DS11-04.01WBT – Noise, Vibration and Harshness This WBT course covers the theory of vibration and reviews basic to advanced vibration diagnosis. Topics include usage of the Electronic Vibration Analyzer (EVA), tools used to measure runout and driveline working angles, and other current tools. S-DS11-05.01WBT – Waterleak and Windnoise Management This WBT course covers how to identify and repair vehicle water leaks and wind noise concerns. It covers general leak testing, adjusting leaking components, door adjustments, and roof adjustments. S-EM01-01.01WBT – Engine Mechanical Diagnosis and Measurement 1 Part one of this two-part WBT course covers basic engine mechanical concepts, including inspection, disassembly and assembly of the overhead cam and camshaft, crankshaft, piston and rods, cylinder head, engine block and valve train. S-EM01-02.01WBT – Engine Mechanical Diagnosis and Measurement 2 Part two of this two-part WBT course continues the introduction to basic engine mechanical concepts, disassembly and assembly procedures, component measuring, and engine noise diagnosis. S-EP08-81.03WBT – Duramax 6600 Operation, Service and Diagnosis 1 This WBT course is intended for experienced engine/driveability service technicians, focusing on the Duramax 6600 LB7, LLY-LBZ and LMM diesel engines. It covers engine operation, performance and major subsystem integration, including the fuel system, engine management system, exhaust after-treatment system and electronic engine controls. S-EP08-82.01WBT – Duramax 6600 Operation, Service and Diagnosis 2 This WBT course is intended for experienced engine/driveability service

technicians. The course continues to review Duramax 6600 LB7, LLY-LBZ and LMM engine operation, performance and major subsystem integration. Diagnosis information covers the fuel system, engine management system, and exhaust after-treatment system. S-FN00-20.01WBT – Multiple Diagnostic Interface (MDI) Familiarization This WBT course covers common characteristics of the MDI, including MDI Setup Software, MDI/On Vehicle operation, and the Service Programming System procedure. S-MT03-01.01WBT – All Wheel Drive/Four Wheel Drive Systems Intended for experienced driveline and transmission service technicians, this WBT course covers construction and

operation of All-Wheel Drive, part-time and full-time 4-Wheel Drive, Automatic 4-Wheel Drive, and the propeller shaft and front axle assembly. S-MT03-02.01WBT – Manual Gearbox and Clutch This WBT course reviews the manual gearbox and clutch assembly, including the transverse mounted gearbox, clutch assemblies, clutch control, synchronizers and electrical components. S-SS04-06.01WBT – Steering Systems and Diagnostics This WBT course covers basic steering gear sets as well as manual and hydraulic steering systems. The electronic power steering system is introduced, along with the Hybrid parallel steering system. Steering system service also is covered.

Current Instructor-Led Training ACDelco’s Instructor-Led Training (ILT) courses provide hands-on instruction on the latest automotive systems. The following ILT courses are currently being held at training center locations around the country. Click the Schedule link on the LMS Menu to search the latest training schedule for courses held in your area. Course Number Course Name S-AC07-02.01ILT

Automotive Air Conditioning: Advanced Refrigerant System Diagnostics

S-AC07-03.01ILT

HVAC Control System Operation and Diagnostics

S-AC07-06.01ILT

Toyota HVAC

S-AC07-07.01ILT

Chrysler HVAC

S-BK05-01.01ILT

Braking Systems

S-EL06-04.02ILT

Network Communication Diagnosis

S-EL06-10.02ILT

Electrical Power Management

S-EL06-11.01ILT

Automotive Electrical Circuit Diagnosis and Repair

S-EL06-12.01ILT

Hybrid Technology and Service

S-EP08-02.01ILT

Engine Performance: Computer Controls and Ignition System Diagnostics

S-EP08-03.01ILT

Engine Performance: Air Induction and Fuel System Diagnostics

S-EP08-04.01ILT

Engine Performance: Fault Monitoring and Emission System Diagnostics

S-EP08-05.01ILT

Engine Performance: Advanced Drivability Diagnostics

S-EP08-20.01ILT

Toyota Engine Performance

S-EP08-21.01ILT

Chrysler Engine Performance

S-EP08-81.01ILT

Duramax 6600: Diesel Engine Performance

S-SS04-01.01ILT

Vibration Correction Diagnostics

S-ST10-01.01ILT

Supplemental Restraint Systems

TS-PU-0015-10

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