May/June2009 Volume 16, No.

3 (TS-PU-0008-09)

Fuel Pump Service

Ever since it was discovered during WWI that
adding tetraethyl lead to gasoline significantly
increased its octane rating (typical mid-1920s
gasolines had a 40–60 octane rating), more
and more additives have been added to gaso-
line during the refining process to improve the
fuel’s performance, emissions and economy.
Common additives in gasoline today include:
detergents, corrosion inhibitors, anti-icers, de-
mulsifiers (to break up water particles), deposit
controls (to prevent carbon buildup), antioxidants
(to prevent gum formation) and metal deactivators
(to inhibit oxidation and gum formation catalyzed by
certain metals, especially copper).
Fuel changes to meet tighter emission standards have
lead to the use of oxygenated fuels such as ethanol,
methanol, ETBE and MTBE. In the past, alcohols and
ethers were used primarily as octane enhancers. Now,
the focus is on emissions reduction. Gasoline additives are
regulated to ensure that the finished fuel will not contribute
to fuel system failure. Additive breakdown or excessive IN THIS ISSUE
amounts of additives in gasoline can result in fuel system
contamination and lead to pump failure. In fact, fuel contamination is the main cause Fuel Pump Service . . . . . . . . . . . . . . . . . . . .1
of electric fuel pump failure by clogging the pickup strainer or inlet filter as well as Cool Technology Covered
causing internal pump damage. in Latest A/C Seminar . . . . . . . . . . . . . . . . . .3
Diagnosis A/C Compressor Service Tips . . . . . . . . . . .3
Overlooked Maintenance Items:
During fuel pump diagnosis, keep in mind these key items:
Wipers and More . . . . . . . . . . . . . . . . . . . . .4
• Start with the basics Improper Use of Conductance Testing
– Is fuel pressure within specifications? (check the Service Information) on New Batteries . . . . . . . . . . . . . . . . . . . . .4
– Does the fuel pressure hold with the key off? (if applicable) Labor Times Now Available on WIP . . . . .5
– On return systems with a vacuum operated regulator, does the fuel pressure Expanded Wiring Sockets
increase during acceleration? and Pigtails Search Tool . . . . . . . . . . . . . . .5
– Has the in-line fuel filter been changed? (if applicable) GM New Vehicle Supplier Discount . . . . .6
TSS Q&A . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
• Measure amperage
Tech Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
– If amperage is low, it may be due to bad connections
Training Update . . . . . . . . . . . . . . . . . . . . . . .8
– If amperage is high, check for possible restrictions or a bad fuel pump
Readers Show Off Their Rides . . . . . . . . . .8
• If a burned, loose terminal is connected to a new fuel pump connector, the new
fuel pump will be ruined
ON THE WEB
• Use the illustrated pigtail search feature on www.acdelcotechconnect.com when
replacing a fuel pump connector – www.acdelcotechconnect.com, click on
• Low fuel level in the fuel tank can shorten fuel pump life. Inform the customer the TechConnect Magazine link, or
that fuel level affects the life of the fuel pump (gasoline is used for both cooling – Log on to the ACDelco LMS, click on the
and lubrication), and fuel with an octane rating specified in the vehicle owner Resources link
manual should be used.
continued on page 2

1
Fuel Pump Service –
continued from page 1
• Check for fuel contamination. It’s
the number one reason for fuel
pump failure. Dirty fuel, additive
breakdown, rust and fuel tank
delamination all work to
clog the fuel pump strainer and
cause premature pump failure.
Pump Replacement
When proper diagnosis leads to the
need to replace the fuel pump, be sure
to follow these guidelines:
• Check for contamination
and flush the fuel tank
– Clean the top of the
fuel tank before re-
moving the fuel pump
– Use hot water
– Install a new in-line
filter and sock filter
• Always install a new
strainer (never re-use)
• Replace the fuel tank
O-ring when installing a
new fuel pump
Hybrid MRA enhancements:
• Always follow the direc-
tions provided with the
C. Ceramic card sensor
new fuel pump
• Inform the customer about not
using fuel additives, except for
manufacturer-recommended prod-
ucts, such as ACDelco Fuel System
Treatment Plus. Remember that any
additive that is put into the fuel
tank, such as to clean the fuel
injectors, must first go through the
fuel pump.
Corrosion and Contamination
The sulfur contaminants found in
some of today’s gasoline can have
corrosive effects on the fuel system
sending unit, disrupting electrical
continuity and leading to erratic or
false fuel gauge readings.
ACDelco Fuel System Treatment Plus
— 20 ounce bottle part number 10-3003
(88861013); 12 ounce bottle part number
10-3004 (88861262) — has a filmer
additive that, when used regularly, helps
protect the sending unit by cleaning
sulfur corrosion and coating the metallic
surfaces of the fuel system. It’s recom-
mended to use ACDelco Fuel System
Treatment Plus at each oil change.
Hybrid Technology
ACDelco’s Hybrid Modular Reservoir
Assembly (MRA) features new
technology that is designed to increase
fuel pump performance and durability.
During service, technicians will notice ACDelco TechConnect is published bi-monthly
some differences between the MRA and and online for technicians of Total Service
the fuel pump being replaced. Support (TSS) and Key Fleet accounts to
provide timely service information, increase
All hybrid MRAs have the latest fuel knowledge and improve the performance of
level sensor technology to reduce fail- the service center.
ures due to worn fingers on the sensor
Publisher:
wiper arm, sulfur contamination, wire
Mike DeSander
wound sensors and lead sensor kits.
ACDelco
The hybrid MRA also has an enhanced E-mail /
electrical connection to help eliminate mike.desander@gm.com
above- and
below-cover Editor:
burning due to Mike Militello
vehicle vibration. ACDelco
The connector is E-mail /
upgraded from a michael.militello@gm.com
MetriPack 150 to Technical Editors:
GT280.
Mark Spencer
The MRAs E-mail /
have an improved mspencer@gpworldwide.com
pump design to
increase pump Jim Horner
life and reduce E-mail /
pump noise. The jhorner@gpworldwide.com
pump is changed Production Manager:
A. GT280 connector from a roller vane Marie Meredith
B. Gerotor pump design to a gero-
tor design. Desktop Publishing:
5by5 Design
Fuel Pump Control Module E-mail /
dkelly@5by5dzign.com
With electronic returnless fuel
systems, the Fuel Pump Control Module
(FPCM) controls the voltage supplied Write to: *
ACDelco TechConnect
to the fuel pump (located within the
fuel tank) to achieve the desired fuel P.O. Box 500
pressure requested by the Engine Troy, MI 48007-0500
Control Module (ECM). There is also a
fuel line pressure sensor, which sends a On the Web: :
feedback signal to the FPCM, so the To read and search recent issues of
FPCM can determine whether the TechConnect online:
– www.acdelcotechconnect.com,
desired pressure is being achieved.
click on the TechConnect Magazine
Examples of vehicles first equipped with
link, or
the new FPCM include 2008 full-size
– Log on to the ACDelco LMS, click
Chevy and GMC pickups.
on the Resources link
DTCs stored in the FPCM may be
ACDelco service tips are intended for use by
due to issues with the electrical wiring
professional technicians, not a “do-it-yourselfer.”
or connectors in the FPCM circuit; or They are written to inform those technicians of con-
ditions that may occur on some vehicles, or to pro-
due to performance issues within the
vide information that could assist in the proper ser-
FPCM module, the fuel line pressure vice of a vehicle. Properly trained technicians have
sensor, fuel pump MRA, or communica- the equipment, tools, safety instructions and know-
how to do a job properly and safely. If a condition is
tions with the ECM.
described, it cannot be assumed that the informa-
tion applies to all vehicles or that all vehicles will
Using a scan tool to check the FPCM have that condition.
for DTCs could lead to more accurate All materials and programs described in this
diagnosis of a condition, faster determi- magazine are subject to change. Submission of
nation of root cause, and shorter vehicle materials implies the right to edit and publish.
Inclusion in the publication is not necessarily an
repair times. endorsement of the individual or the company.
– Thanks to Mike Militello, Alan Lustre TechConnect is published for ACDelco by Sandy
Corporation, Troy, MI.
and George Nagrant
©2009 ACDelco. All rights reserved.
2
Cool Technology Covered
in Latest A/C Seminar
ACDelco’s updated air condition-
ing system seminar, Emerging
A/C Technology and Service
(S-AC07-03.01SEM), provides an
overview of the latest issues
affecting current and future A/C
system service.
A/C systems have changed
dramatically over the past years,
becoming smaller, increasingly
efficient and more complex.
Refrigerant capacity, for example,
has dropped from nearly four
pounds of refrigerant in older R-12
systems to 16 ounces or less on
newer R-134a systems. A very
small leak can significantly reduce
performance or cause noise in a
modern A/C system.
In the seminar, technicians will
learn about:
• Various A/C systems and their
operation and service
• Scan tools, Service
Programming and CAN data
and how they involve A/C
diagnostics and repair
• Various service items such as oil
balancing, flushing, filters, line
repair, dyes and leak detection
• Various sealants and their affect
on the A/C system
• New SAE regulations for leak
detection, refrigerant purity and
R/R/R machines
• Clutchless and high voltage
hybrid compressors
• Possible future refrigerants and
their systems, such as R-152a,
R744 (CO2) and HFO-1234YF
Virtual Networks
Vehicle networks and program-
ming have grown to control a
variety of A/C system operation,
taking information sharing of the
climate control system as well as
other vehicle systems to a higher
level of communication. In the
seminar, the use of a virtual
network in modern vehicle com-
munication systems is covered.
A virtual network is supported by
virtual devices, which represents a
collection of signals owned by a
single physical device (control
module). A virtual network is trig-
gered by activated switches, such
as an A/C request or a change in a
sensor. The benefit of a virtual
network is a reduction in power
consumption because control
modules are only powered when a
provided functionality is required.
Virtual network of an A/C system
New Regulations
The seminar also covers a
number of emerging topics that
are making news in the A/C
industry. This includes the follow-
ing new SAE regulations:
• J2788 Standards for
Recovery/Recycle/Recharge
machines
• J2810 Standards for recovery
only machines
• J2670 A/C Additives
• J2791 Enhanced Leak Detection
• J2776 Purity Standards for
R134a
A/C refrigerants discussed in
the seminar include several new
refrigerants that are potential
replacements for R-134a. R-134a
has a Global Warming Potential
(GWP) of 1410. Worldwide efforts
to reduce greenhouse gases have
led to an agreement that any
replacement refrigerant must have
a GWP of 150 or less. Currently,
the EPA does not identify any
replacement refrigerant for R-134a
systems and has not evaluated any
alternative refrigerants.
Learn More
For more information about
ACDelco training courses on A/C
systems and other systems and
components available at training
centers and online, go to
www.acdelcotechconnect.com
and click on the Training tab.
Contact your local ACDelco
distributor to learn when the
Emerging A/C Technology and
Service seminar and other semi-
nars will be held in your area.
– Thanks to Mike Militello
3
A/C Compressor
Service Tips
ACDelco studies have shown replacement air
conditioning compressors fail four times more
often than original compressors because of a fail-
ure to properly restore the system. ACDelco has
disassembled, reviewed, and analyzed hundreds
of air conditioning compressors returned under
warranty. The failure of these compressors can
be grouped into three major categories:
• Lubrication
• Refrigerant
• Debris
When repairing A/C conditions, performing the
necessary service to protect replaced parts is
important to avoid replacement failures and
comebacks. Prior to and after compressor failure,
debris particles from a failure flow throughout
the refrigerant system in both directions. These
particles imbed themselves in various internal
components and cannot be completely flushed
from the system.
The most cost-effective service method for
protecting the compressor and other new
components is to install a suction screen ahead
of the compressor and an in-line filter ahead of
the control valves. These protection devices have
virtually no effect on overall A/C system perfor-
mance but they greatly improve the protection of
a compressor from any residual failure debris.
A quick visual inspection
may prevent needless
compressor replacement
caused by other conditions,
such as a low charge,
Diagnostic Trouble Codes
(DTC), electrical connec-
tions, or loose fasteners.
Check for proper charge Fragment
levels and purity as well contamination
as confirmation of clutch
engagement. Compressors with a low charge
make noise. A proper charge may silence a noisy
compressor.
Job Aids Online
For more information about A/C compressor
installation, a printable .pdf file is available
on TechConnect Magazine Online. Go to
www.acdelcotechconnect.com and click on the
TechConnect Magazine tab. The A/C compressor
job aid and several other job aids are available
under the Troubleshooting PDF Job Aids link
in the Resources section on the right side of
the page.
The job aid includes a number of tips to follow
when installing an A/C compressor. The job aid
also provides a list of related components that
should be inspected when troubleshooting the
A/C system. The operation of many of these
components will affect the performance of the
compressor. Finally, there are several tips to
verify proper installation and operation to help
ensure customer satisfaction.
Overlooked Maintenance Items: Wipers and More
More than 80 percent of the vehicles
that have been inspected at community
car care events across the country over
the past year were in need of service
or parts, reports the Car Care Council.
This reinforces the need for consumer
education about the benefits of regular
vehicle care and maintenance, especial-
ly as the number of years owners keep
their vehicles continues to increase.
Top problem areas typically found
include the need for oil changes, wind-
shield wipers, air filters, and improperly
inflated or worn tires.
Forgotten Wipers
Wipers appear to be one of those
items that drivers forget about when
they are not in use. However, once the
rain starts to fall, the need to replace
worn wipers becomes evident rather
quickly, and good visibility has a major
impact on driver safety.
The replacement interval of wipers is
based on several factors, including
operating conditions (winter conditions
are tough on wiper blades, yet wiper
blades can deteriorate faster and need
more frequent replacement in sun-
soaked desert states), frequency of use,
and the material and type of wipers.
Wiper blades should be inspected
every six months. Streaking or chatter-
ing blades as well as worn or split
rubber are signs that it’s time to replace
the wiper blades.
ACDelco wiper products feature:
– Beam wiper blades — the latest in
wiper technology
– Performance blades that feature
pre-installed adapters that match
a vehicle’s arm type for quick
installation
– Aerodynamic designs that help
prevent windlift
– Broad range of sizes and types of
blades, including low profile and
hard-to-find applications
– Materials and finishes (polymer or
carbon steel) that are designed to
resist rusting, chipping and bending
– Coatings on rubber parts that help
reduce streaking, friction and noise
– Virtually all-makes and all-models
coverage
Maintenance Recommendations
To help ensure the reliability and
safety of a vehicle, as well as to extend
vehicle life, the Car Care Council
suggests these preventive maintenance
steps — many of which are put off
or overlooked by drivers — be recom-
mended to service customers. Checking
these items is especially timely after a
harsh winter’s worth of driving:
– Change the oil and filter regularly
according to the owner’s manual
maintenance schedule.
– Inspect the tires for proper wear
and check the tire pressure at least
monthly, including the spare.
– Have the alignment checked at
least annually. Potholes and other
road conditions can take their toll
on a vehicle’s steering and suspen-
sion.
– Check the hoses and belts — which
are critical to the proper functioning
of the electrical system, air condi-
tioning, power steering and the
cooling system — for cracks,
brittleness or other signs of
excessive wear.
– Inspect the windshield wipers and
lights on the vehicle.
All of these components are
often neglected wear items that are
needed for safe and reliable vehicle
performance.
– Thanks to Chris Vermette

Improper Use of Conductance Testing on

New Batteries
A new battery does not develop its
full performance capabilities until it has
been through several discharge/charge
cycles. This means a new battery may
not be capable of producing its optimum
current and cold cranking amps (CCA).
If a new battery that has not gone
through a cycling period is tested using
a conductance-type battery tester,
the resulting CCA may be lower than
indicated on the battery’s rating label.
This could lead to condemning an
otherwise good battery.
Conductance is a measurement of a
battery’s current producing capability.
Conductance testers can accurately
identify batteries that have reduced
performance after being in service, but
should never be used to determine the
state of health, state of charge or CCA
rating of a new, never installed battery.
Also, conductance testing of new
batteries should never be used to
determine the warrantable condition.
To check Battery Testing Procedures
the condition
Follow these tips when using a
of a battery
conductance tester to ensure accurate
prior to instal-
test results. Using non-approved
lation to be
adapters or improper test procedures
sure there
can lead to failing test results for
is adequate
batteries that are not defective.
voltage to
start the vehi- Be sure the battery in the tester is
cle, measure good or you may get inaccurate results.
open circuit To check the conductance tester, be
voltage (OCV) sure OCV on the tester matches the
using a digital OCV measured with a known-good
voltmeter DVOM (may vary slightly due to
(DVOM). different internal resistance).
An OCV of
Be sure to get good connections
12.24V is
Don’t use a between the battery terminals and the
adequate
conductance tester to tester clamps. Each tester clamp has
to provide measure the performance two jaws. Each jaw is wired to a differ-
the power of a new battery.
ent part of the tester, and it is essential
requirements
that both jaws make good contact.
for starting most vehicles under most
conditions. The battery should be in If the connections to the battery
service for several days before perform- terminals in the vehicle are in doubt or
ing a conductance test.
continued on page 5

4
Labor Times Now Available on WIP
Why use two sources to check
mechanical labor times and parts
pricing and availability? ACDelco’s
WISE Internet Parts (WIP) now offers
users the ability to do both in one
application, at no additional charge.
WIP, ACDelco’s Web-based parts
catalog application, provides fast
parts inventory access and compre-
hensive parts ordering. ACDelco
WIP subscribers can check inventory
and order parts online anytime from
WISE-enabled ACDelco Warehouse
Distributors. Now, labor times also
are only one click away. Using the
labor time feature will help subscribing
service centers to quickly create
parts and labor estimates. This new
feature does not apply to TurboPart
WIP users.
To display labor times, users will
identify and search for parts as
they have in WIP previously. Build
the vehicle for which the parts are
needed by selecting the year, make,
model and engine, or enter the VIN.
Next, select the parts group and
subgroup.
Once users have identified the vehicle
and parts they are interested in, click on
the Display Parts & Labor button or the
Display Labor Only button. Labor times
for the selected parts will be displayed
below the parts information.
The labor multiplier value used
to calculate the labor times also can
be changed. Click the Edit Labor
Multiplier button to increase or
decrease the multiplier.
The addition of listing labor times
in WIP is just one of many benefits.
WIP also provides:
– The ability to place parts orders
anytime 24/7 with local warehouse
distributors
– A direct link to local warehouse
distributors using your PC and
Internet connection, no additional
hardware or software is required
– Access to the inventory of local
warehouse distributors to check
parts pricing and availability
To learn more about WIP, visit
www.acdelcotechconnect.com, call
1-800-825-5886, prompt #3, or contact
your local ACDelco representative.
– Thanks to Bob Stewart

Parts and labor or labor only can be displayed in WIP. Labor times for parts searched in WIP.

the tester displays REPLACE BATTERY or BAD CELL -

REPLACE, disconnect the battery being tested from the
vehicle. Retest the battery with both of the vehicle’s battery
cables disconnected from the battery.
When using an adapter, be sure the adapter makes good
contact with the lead terminal surface on the battery.
Never use steel bolts, nuts, washers, etc., when testing
a side terminal battery. Only use the adaptors included with
the conductance tester. The coating on other adapters may
affect the tester’s accuracy.
Battery Warranty
ACDelco batteries are covered by a comprehensive
warranty program. Any independent service center can accept
an ACDelco battery that is under warranty and not functioning
properly from a customer for return, even if the battery was
purchased from another retailer or service center. ACDelco
will warrant the battery, and in the process, the service
center may earn some additional service business and
customer loyalty.
– Thanks to Mike DeSander and Brad Busboom
Expanded Wiring
Sockets and Pigtails
Search Tool
The wiring sockets and pigtails search tool on
www.acdelcotechconnect.com has been expanded.
This on-line reference source offers a menu-
driven search feature that can narrow the search accord-
ing to brand, number of cavities and gender. With
photos of each pigtail and wiring socket, you also can
visually match the part you are replacing with the new
part number. All of which makes it easier to identify
wiring sockets and pigtails for GM and non-GM vehicles.
To access the wiring sockets and pigtails search tool,
go to www.acdelcotechconnect.com and click on the
Automotive Systems tab and the Product Information
link.
– Thanks to Bob Stewart

5
GM New Vehicle
Supplier Discount
plus Other Incentives
Add Up
There are several money-saving regional consumer
incentives available right now on most 2009 GM cars and
trucks. TSS service center owners and employees who add
those to the thousands in savings available through the GM
New Vehicle Supplier Discount will find that the amount of
money off really adds up.
The GM supplier discount is available on most new 2009
GM vehicles at participating GM dealerships. Vehicles may
be taken from dealer stock or ordered. (Eligibility may change
at any time without notice and some models may have
limited availability). All that’s needed to get your supplier
discount savings is a GM New Vehicle Supplier Discount
authorization number.
To get your authorization number, follow these steps:
– Go to www.acdelcotechconnect.com
– Click on the Total Service Support tab, and then the
ACDelco TSS GM Vehicle Supplier Discount button on
the right side of the page. (You will have to log in by
entering your 6-digit TSS code [it begins with a 6] and
your zip code.)
– On the GM Vehicle Supplier Discount page, scroll down
to the bottom of the page and click on the link
www.gmsupplierdiscount.com to access the GM supplier
discount website. Always access the GM supplier dis-
count website through www.acdelcotechconnect.com.
This loads the website with the correct company code
for TSS service centers.
– If you have used this website before, input your user
name and password that you have used in the past. If you
do not have a user name and password, click on New to
Supplier Discount to register on the site.
– Click “yes” when you are asked, “Are you a TSS/ACDelco
account?” This question will only appear if you have
logged in using a previous user name and password.
– If you are asked if you would like to use this new account
number because it has changed, always respond “yes.”
This is part of a recent change to improve the process.
– Begin by selecting GM Supplier Discount on the top left
side of the page. Next, click on Obtain Authorization to
generate your GM Discount Certificate. You will be asked
for your birth date, zip code, and other vehicle purchase
information. Click on Step 2 and Step 3 after verifying the
information.
– You can print out the certificate number, write it down, or
email it to a recipient. It’s that easy!
For additional information about the GM supplier discount
or if you have questions about the authorization number
process, call 1-800-960-3375. When calling, please state
that your company name is TSS/ACDelco, not your individual
service center name.
– Thanks to Staci Shelton
6
The TSS Q&A provides answers
to common questions received
by the ACDelco Customer
Support Center.
Q: How does the web-based ACDelco TSS
Customer Satisfaction Index (CSI) Program
track customer satisfaction?
A: The new TSS CSI Program provides for
immediate feedback from service customers.
The system features hang tags with the service
center’s ACDelco TSS account number that are
given to customers after service has been
performed. Customers can go online to
http://survey.acdelcocrs.com, enter the TSS
account number on the tag, and provide their
comments about their service experience.
Q: How is the customer information delivered to
service centers?
A: The data is compiled
for the service center.
All the service center
has to do is hang the
tag on a customer’s
rearview mirror when
service is finished.
Once a customer
answers the online
survey, a link to where
the survey results can
be accessed is sent via
e-mail to the service
center. The service Customers fill out the
satisfaction comments CSI survey online.
and CSI scores are avail-
able immediately, providing instant feedback.
For more information about the TSS CSI Program,
go to www.acdelcotechconnect.com, select the
Total Service Support tab, and then click on the
Marketplace link. After logging in with your six-
digit TSS account number and zip code, scroll
down and select the Customer Satisfaction Index
Program. You also can call 1-800-825-5886,
prompt 4, for more program details.
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.
Correction
In the last issue of TechConnect, an article about
counterfeit tools stated that authentic CANdi modules
have aluminum terminals. It should have stated that
authentic CANdi module terminals may be either nickel
or gold.
 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.
Intermittent Vehicle No
Crank/Dead Battery
2004 Buick Rainier; 2000-2004
Cadillac Escalade, 2002-2004 Cadillac
Escalade EXT, 2003-2004 Cadillac
Escalade ESV; 1998-2004 Chevrolet
Blazer and S-10 Pickup, 1999-2004
Chevrolet Silverado, 2000-2004
Chevrolet Suburban and Tahoe,
2002-2004 Chevrolet Avalanche,
2002-2004 Chevrolet TrailBlazer and
TrailBlazer EXT, 2003-2004 Chevrolet
Express; 1998-2004 GMC Jimmy and
Sonoma, 1999-2004 GMC Sierra,
2000-2004 GMC Yukon and Yukon XL,
2002-2004 GMC Envoy and Envoy XL,
2003-2004 GMC Savana, 2004 GMC
Envoy XUV; 1998-2004 Oldsmobile
Bravada; 2003-2004 HUMMER H2
When diagnosing an intermittent
vehicle no crank or dead battery
condition, remove and reinstall the
ignition switch following the appropriate
procedure in the Service Information.
The ignition switch may have been
misindexed in the steering column
during a previous replacement.
If the ignition switch is misindexed
in one direction, the ignition switch
circuits will not be completely open
when the ignition switch is in the Off
position with the key removed. This may
result in the lights remaining on and will
drain the battery.
If the ignition switch is misindexed
in the opposite direction, the ignition
circuits will open correctly, but the
ignition switch may not close the crank
circuit properly when the ignition key is
turned to the crank position. This will
result in a no crank condition.
Refer to GM bulletin 04-06-03-002 for
more information.
Low Voltage Display
1998-2008 GM Passenger Cars
and Light Duty Trucks, including Saturn;
2003-2008 HUMMER H2, H3;
2005-2008 Saab 9-7X
These vehicles may have a low
voltage display, lights that dim at stop
lights, slow cranking, no start, low
generator output at idle or dim lights at
idle when electrical loads are heavy at
idle or under slow driving or infrequent
usage conditions. These characteristics
Low voltage display
may be more noticeable with customer-
added electrical accessories or with a
discharged battery.
These are normal operating char-
acteristics of a vehicle electrical system
unless a proven fault has been
diagnosed.
Non-usage of the vehicle for
extended periods of time and extended
periods of engine idling with high
electrical loads are two factors that
may affect generator and battery perfor-
mance. For complete diagnosis of the
battery and/or generator, refer to the
appropriate Service Information.
Refer to GM bulletin 05-06-03-002B
for more information.
Starter Motor Continues to
Run or Crank
1995 Buick Riveria; 1995 Cadillac
Eldorado, Eldorado Touring Coupe,
Seville; 1995 Chevrolet Camaro; 1995
Oldsmobile Aurora; 1995 Pontiac
Firebird – with 3800, 4.0L, 4.6L, 5.7L
engines (RPOs L47, L36, LT1, LD8, L67,
L37); 1994-95 Chevrolet and GMC Truck
C/K, G, P models – with 5.7L, 7.4L
engines (RPOs L05, L19)
The starter motor may continue to
run or crank after the vehicle is started
or turned off. The starter motor solenoid
will not disengage because of a ground
to the #6 circuit. With the #6 circuit
ground to a resistive ground, current is
fed back through the windings to the
ground, holding in the plunger and
causing the starter to continue to run.
7
Disconnect the #6 circuit lead at the
starter “S” terminal. With the ignition
Off or in Run, use an Ohm meter to
check for any electrical path between
the ring terminal on the #6 circuit lead
and ground.
If found, eliminate the grounding
condition. Reroute any wires as
necessary.
Alternator Bolt Tightening
2001-2004 Honda Civic
Conditions such as an engine
crank/no start, MIL on, immobilizer
blinking, or no communication with the
ECM/PCM may be caused by loose
alternator bolts. If these bolts are loose
for any reason, the alternator can
overcharge and damage the ECM/PCM.
Beginning in 2001, the Civic has a
different style alternator bracket that
makes the bolt tightening sequence and
bolt torque critical. Improper tightening
will cause noise.
Refer to the appropriate Service
Information for the proper bolt tighten-
ing sequence and bolt torque specifica-
tions. A belt tension gauge special tool
also is required.
After tightening the alternator bolts,
restart the engine. If it won’t start,
check the ECM/PCM connector for
battery voltage and ground. If there is
battery voltage and ground at the
connector, replace the ECM/PCM.
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
Current Instructor-Led Course Number Course Name
Training
S-AC07-02.01ILT Automotive Air Conditioning: Advanced Refrigerant System Diagnostics
ACDelco’s Instructor-Led Training
(ILT) courses provide hands-on
S-AC07-03.01ILT HVAC Control System Operation and Diagnostics
instruction on the latest automotive
systems. The following ILT
S-AC07-06.01ILT Toyota HVAC
courses are currently being held
at training center locations around S-AC07-07.01ILT Chrysler HVAC
the country.
How to Take S-BK05-01.01ILT Braking Systems
ACDelco Training S-EL06-04.01ILT Body Control Systems Diagnostics
To log on to the ACDelco Learning
Management System go to S-EL06-10.01ILT Battery, Charging, & Starting
www.acdelcotechconnect.com
and click on the Training tab. S-EL06-11.01ILT Automotive Electrical Circuit Diagnosis and Repair
• To enroll in an Instructor-Led S-EL06-12.01ILT Hybrid Technology and Service
Training (ILT) course, click on
the Enrollment link or the S-EP08-02.01ILT Engine Performance: Computer Controls and Ignition System Diagnostics
Instructor-Led Courses link.
• To launch a Web-Based Training S-EP08-03.01ILT Engine Performance: Air Induction and Fuel System Diagnostics
(WBT) course, click on the
Web-Based Courses link to S-EP08-04.01ILT Engine Performance: Fault Monitoring and Emission System Diagnostics
view the catalog and select a
specific course. S-EP08-05.01ILT Engine Performance: Advanced Drivability Diagnostics
• To launch a TechAssist (TAS) S-EP08-20.01ILT Toyota Engine Performance
course, click on the TechAssists
link to view the catalog and S-EP08-21.01ILT Chrysler Engine Performance
select a specific course.
• To launch a Simulation (SIM), S-EP08-81.01ILT Duramax 6600: Diesel Engine Performance
click on the Simulations link to
view the catalog and select a S-SS04-01.01ILT Vibration Correction Diagnostics
diagnostic challenge simulation.
S-ST10-01.01ILT Supplemental Restraint Systems

Readers Show Off Their Rides

A few American classics are some of the rides TechConnect 1. Go to the TechConnect Magazine Online website
readers have submitted for the Readers’ Rides gallery on by clicking on the TechConnect Magazine tab on
TechConnect Magazine Online. To get the story behind the www.acdelcotechconnect.com
cars of fellow TSS shop owners and technicians and view a
2. Click on the Contact Us link
gallery of the cars, go to www.acdelcotechconnect.com and
click on the TechConnect Magazine tab. 3. Send an email with photos attached to technical
editor Mark Spencer
To submit photos of your car or truck (include your name, TSS
center, location and a few technical details about your vehicle): – Thanks to Mike DeSander

1976 Chevy Chevelle Laguna S-3, 1971 Dodge Dart Swinger, 1970 Chevy Chevelle SS,
Scott Hamilton, Bill Levine, Ricky Stephenson,
Hamilton’s Car Care, Arlington, Texas Hamden Public Works, Hamden, Conn. Car Concepts, Inc., Hurst, Texas

TS-PU-0008-09 8