Archive for June 2015

Rear Axle Damage

A condition where the vehicle will not move when in gear on some 2010-2015 Camaro SS models (equipped with the 218-mm ring gear axle) and 2014-2015 Chevrolet SS models may be due to damage in the differential of the rear drive axle.

 

On the Camaro, the 218-mm ring gear axle can be identified by an aluminum differential carrier housing, not cast iron. (Fig. 1)

 

F01 diff housing

Fig. 1

 

Operation

 

The rear drive axle receives power from the propeller shaft and transfers it to the drive pinion, which in turn transfers power to the ring gear. The ring gear is attached to the differential case. It contains four gears — two side gears and two pinion gears. The pinion gears are mounted on a differential pinion shaft, and the pinion gears are free to rotate on this shaft. The pinion shaft is fitted into a bore in the differential case and is at a right angle to the axle shafts.

 

Components include: (Fig. 2)

Pinion shaft lock bolt (2)

Pinion shaft (1)

Differential case (3)

Pinion gears (8)

Pinion gear thrust washers (7)

Differential side gears (6)

Differential side gear shims (5)

Differential side gear spring washers (4)

 

F02 diff image

Fig. 2

 

Power is transmitted through the differential when the drive pinion rotates the ring gear, causing the ring gear to rotate the differential case. The ring gear, as it rotates with the differential case, forces the pinion gears against the side gears. The side gears rotate the axle shafts.

 

When both wheels have an equal amount of traction, the pinion gears do not rotate on the pinion shaft because the input force on the pinion gears is equally divided between the two side gears. Therefore, the pinion gears revolve with the pinion shaft but do not rotate around the shaft itself.

 

Brake Torquing

 

Damage to the rear axle may occur if there is extended “brake torquing” of the rear axle. (Fig. 3) This action disengages the limited slip clutch and causes one wheel to spin, which drives the rear axle lubricant out of the differential pinion gears and pinion shaft interface. Without the proper lubricant, the pinion shaft will be damaged.

 

TIP: Damage to the rear axle caused by improper operation, such as brake torquing, is not covered by the new vehicle warranty.

 

F03 diff damage

Fig. 3

 

Inspect the pinion and ring gear teeth for cracking, chipping, scoring or excessive wear. Check the pinion gear splines for wear. Also inspect for worn or broken parts. (Fig. 4)

 

F04 diff cross pin damage

Fig. 4

 

– Thanks to Dave MacGillis

Hybrid Emergency First Responder Information

First responder information regarding various hybrid vehicles produced by GM is available online for emergency personnel. (Fig. 5) The information can help first responders in learning about the hybrid vehicles and/or hybrid systems so that they can perform the necessary actions quickly and properly in an emergency situation.

F05 responder spark

Fig. 5

 

First Responder Guides are available for the following GM vehicles:

 

Buick

• 2012-2015 LaCrosse eAssist (RPO HP6)

• 2015-2015 Regal eAssist (RPO HP6)

 

Cadillac

• 2009-2013 Escalade with Two-Mode Hybrid System (RPO HP2)

• 2014-2015 ELR

 

Chevrolet

• 2008-2010 Malibu Hybrid (RPO HP7)

• 2008-2013 Tahoe Hybrid with Two-Mode Hybrid System (RPO HP2)

• 2009-2013 Silverado Hybrid with Two-Mode Hybrid System (RPO HP2)

• 2011-2015 Volt

• 2013-2014 Malibu Eco eAssist (RPO HP6)

• 2014-2015 Spark EV

 

GMC

• 2008-2013 Yukon Hybrid with Two-Mode Hybrid System (RPO HP2)

• 2009-2013 Sierra Hybrid with Two-Mode Hybrid System (RPO HP2)

 

Saturn

• 2007-2009 Saturn Aura Hybrid (RPO HP7)

• 2007-2010 Saturn Vue Hybrid (RPO HP7)

 

Go to www.gmstc.com and select the First Responder link in the lower-left corner of the page. (Fig. 6)

 

F06 responder link

Fig. 6

 

The guides include a variety of useful information, including an overview of hybrid system operation components and their location, high voltage label locations and cable cut label locations, airbag information, and high-strength steel body structure identification. Additional guides on other topics for first responders also are available.

 

– Thanks to Paul Radzwilowicz

 

 

Electronic Climate Control Module Heating and Cooling Conditions

On some 2014-2015 Camaros built before February 10, 2015, the following HVAC (Fig. 7) conditions may be present at start-up:

• Blower motor and/or indicators are inoperative

•Blower motor may be blowing, but speed cannot be adjusted

• A/C not blowing cold enough air

 

F07 climate controls

Fig. 7

 

DTC U1510 (HVAC Control Module Lost Communication with HVAC Controls) may be set in the Electronic Climate Control Module (commonly referred to as the HVAC Module).

 

If any of the conditions are present, reprogram the Electronic Climate Control Module. An updated software calibration has been released to address these conditions. If there is still a concern after the Electronic Climate Control Module has been updated, continue with the appropriate diagnostics in the Service Information.

 

Refer to the HVAC System Control Module Programming and Setup procedures in the Service Information for details on programming the Electronic Climate Control Module.

 

The calibration for these conditions will not address or repair a basic HVAC system condition, such as if the system is low on refrigerant or the engine cooling fans are not working correctly.

 

– Thanks to Matt Bierlein

Fuel Injector Conditions

Some 2010-2015 Equinox, Terrain, Captiva and 2012-2015 Verano models equipped with the 2.4L engine (RPO LEA) may have an illuminated Service Engine Soon lamp and DTC P219A (Fuel Trim Cylinder Balance) set. In some instances, a DTC P0300 (Engine Misfire Detected) also may be set.

 

These conditions may be due to a faulty fuel injector in one of the cylinders that a GDS 2 fuel injector balance test may not isolate. If the GDS 2 fuel injector balance test does not isolate a cause for this condition, follow the fuel injector diagnosis procedure in the Service Information using the CH-47976 Active Fuel Injector Tester (AFIT) and CH-47976-500 AFIT SIDI Adapter Kit and evaluate the fuel injector for a rich or lean condition.

 

In some instances, a fuel injector that has a flow rate as little as 5% greater/less than the other three injectors could cause DTC P219A to set. If the misfire current counter or misfire graph shows any misfires, it may be an indicator of the cylinder(s) that is causing the condition.

 

– Thanks to Timothy Lightfoot

Check Loose Grounds for Intermittent No Crank Condition

An intermittent no crank or crank/no start condition with an illuminated Service Engine Soon MIL may be present on some 2015 Colorado and Canyon models equipped with the 2.5L 4-cylinder engine (RPO LCV) or 3.6L V6 engine (RPO LFX).

 

Inspect for a loose G107 connection, located on the engine block behind the generator (Fig. 8, #1) (Fig. 10, #2), or loose G108 connection, which is located on the rear center of the engine block on the 4-cylinder engine (Fig. 9, # 2) and on the right front of the engine block near cylinder #2 on the V6 engine. (Fig. 10, #1) Repair the connections as necessary.

 

F08 g107 lcv

Fig. 8

 

F09 g108 lcv

Fig. 9

 

F10 g107g108 lfx

Fig. 10

 

– Thanks to Ken Cole

Low Engine Power Condition

There may be a low engine power condition along with an illuminated Service Engine Soon lamp on some 2015 City Express models. Any of the following DTCs may be set in the ECM: P0011, P0075, P0300, P0301, P0302, P0303 and/or P0304.

 

These conditions may be caused by splicing together the incorrect wires or by a poor splice connection after performing the repair procedure for CSP 15169A. Verify the correct wires were spliced together during the repair by reviewing step #8 of CSP 15169A. The largest gauge purple wire (Fig. 11, #1) and largest gauge red wire (Fig. 11, #2) are used for this repair.

 

F11 red purple wires

Fig. 11

 

If the incorrect wires were spliced, return the wires to their original routing and perform the splice repair again using the correct wiring. Clear the DTCs and verify the repair.

 

If the correct wires were spliced, evaluate the crimp used at the splice for a poor connection and repair as needed.

 

– Thanks to Timothy Lightfoot

Vibration When Turning at Highway Speeds

A small vibration may be experienced through sweeping turns at highway speeds on some 2015 Colorado and Canyon models. The vibration goes away once the roadway straightens out.

 

This condition is called Smooth Road Shake. The Power Steering Control Module (PSCM) has a calibration to lessen the effects of Smooth Road Shake. However, the calibration is inhibited when the steering wheel is turned beyond a certain degree, at which point the vibration may be felt in the vehicle.

 

Do not replace any parts for this condition. A revised calibration is available that increases the amount of degrees from center that the steering wheel can be turned before inhibiting the Smooth Road Shake correction. Program the Power Steering Control Module with the latest calibration available in TIS2Web and verify the repair.

 

If a vibration still exists after the Power Steering Control Module calibration has been updated, continue with the appropriate vibration diagnostics in the Service Information.

 

– Thanks to Ken Cole

Heater Core Water Gurgle Sound

There may be a water rush or gurgle-type sound from the center dash area on some 2015 Colorado and Canyon models. Diagnosis may isolate the sound to the heater core, where it is caused by air in the cooling system.

 

If the sound is isolated to the heater core, check the cooling system for leaks. Repair any leaks before proceeding with any further repairs.

 

If no leaks are found or after all leaks are repaired, add 400 ml of coolant to the surge tank. Next, raise the front of the vehicle 1 ft. off the ground. With the surge tank cap off, run the engine for one hour to reach operating temperature and purge air from the cooling system.

 

The surge tank (Fig. 12) is mounted at a point higher than all other coolant passages and provides a coolant fill point and a central air bleed location. During vehicle use, as the coolant heats and expands, the increased coolant volume flows into the surge tank. As the coolant circulates, any air is allowed to bubble out.

 

After one hour, replace the cap on the surge tank, lower the vehicle and recheck for any sounds from the heater core.

 

F12 surge tank

Fig. 12

 

– Thanks to Ken Cole

Bulletin Review – May 2014

 

Screen Shot 2015-06-23 at 10.31.11 AM

Screen Shot 2015-06-23 at 10.31.28 AM

Service Know-How

10215.06D – Emerging Issues

June 11, 2014

 

To view Emerging Issues seminars:

• Log in to www.centerlearning.com

–   Select Resources > Service Know-How/TECHAssist > Emerging Issues > Searchable Streaming Video; or

–   Select Catalog to search for the course number, and then select View > Take or Continue Course

 

 

 

 

Service Technical College – New Training Courses

 

Following are the latest service technical courses available to technicians through the GM Service Technical College.

 

For more information about available service training courses, log in to the GM Center of Learning at www.centerlearning.com and click the Catalog link. Use the drop-down menus to search for courses by delivery type, audience, and category.

Screen Shot 2015-06-23 at 12.08.58 PM

 

Steering Bind after I-Shaft Removal

The steering may bind when turning the steering wheel after having removed the I-Shaft for a service procedure on some 2015 Colorado and Canyon models. The binding may be caused by the I-Shaft nose plug sliding down the inside of the lower I-Shaft and into the joint when the shafts were separated.

 

TIP: The I-Shaft nose plug is used as an assembly aide for vehicle production only to assist in properly aligning and connecting the upper and lower I-Shaft sections.

 

Remove the lower I-Shaft. Next, inspect the upper I-Shaft to determine if the plug is still installed. (Fig. 11) If still installed, remove the plug, discard it and reinstall the lower shaft.

 F11 4178400

Fig 11

 

If the plug is not present in the upper I-Shaft, check down the inside of the lower I-Shaft and joint for the plug. Invert the shaft and tap the open end on a shop towel on a workbench. If found, remove the plug, discard it and reinstall the lower shaft.

 

– Thanks to Ken Cole

Service Column Lock Message

A Service Column Lock message may be displayed on the instrument cluster of some 2013-2014 ATS; 2013 XTS; and 2014 CTS Sedan (VIN A) models. DTC B2897 SYM05 (steering column lock enable input circuit open or shorted to battery) is set as a history DTC.

 

There are currently three normal operation scenarios in which this code may set:

 

1. Power mode is OFF. Open the driver’s door and then press the ignition switch within 100ms (power mode changes to ACC or RUN)

2. Power mode is in ACC or RUN. With the driver’s door open, change power mode to OFF and close the driver’s door within 300ms

3. Power mode is OFF. Open and close the driver’s door quickly in less than 300ms

 

If these scenarios are ruled out as a possible cause or if the DTC is set as a current DTC, follow normal diagnostics in the appropriate Service Information.

 

– Thanks to David Antal

 

No Start, Loss of Communication Conditions

Some 2015 Colorado and Canyon models may have a condition of no crank/start, loss of communication, engine stall or an illuminated Service Engine Soon lamp with possible Driver Information Center messages. If any of these conditions are present, inspect the engine wiring harness for contact with the water pump pulley (Fig. 9) and the oil filter housing. (Fig. 10)

 

Repair the engine harness as necessary and route it away from these possible contact points.

 

F09 4164081

Fig 9

 

F10 4176330

Fig 10

 

– Thanks to Ken Cole

Steering Vibration during Parking Lot Maneuvers

On some 2014 CTS Sedan (VIN A) models, there may be a slight vibration in the steering wheel during a parking lot maneuver. DTC C055C sym00 (Steering Gear Performance Malfunction) may be set.

 

This condition typically happens while turning left into a parking spot, with the steering close to the end of travel, at speeds of approximately 3–4 mph.

 

Reprogram the Power Steering Control Module (PSCM) with the latest calibration available through TIS2Web. Refer to the Power Steering Control Module Programming section of the Service Information for programming instructions.

 

TIP: If the vehicle already had updated software programmed to the PSCM prior to the May 9, 2015 release of the latest software, program the PSCM once again with the latest calibration.

 

– Thanks to Christopher Crumb

Diagnostic Assistance for ECM DTCs

DTC P00C6 (Fuel Rail Pressure Low During Engine Cranking) and/or P228C (Fuel Pressure Regulator Control Performance – Low Pressure) may be set on some 2010-2015 LaCrosse, CTS, SRX, Equinox, Terrain; 2012-2015 Camaro, Impala; 2013-2015 ATS and XTS models equipped with the HFV6 engine (RPO LF1, LFW, LFX).

 

If normal diagnostics in the appropriate Service Information do not lead to a repair, before any component are replaced, check the terminals at the ECM for fit and tension as well as the crimp to wire connections.

 

In the ECM, inspect connector X2 terminals 3, 18, and 19 for the fuel rail pressure sensor. (Fig. 8)

 

Also inspect connector X3 terminals 16 and 32 for the high pressure fuel pump. (Fig. 8)

 

As little as 2 ohms on either circuit can cause these DTCs to set.

 

If any concerns are found, replace the affected terminals and verify the repair.

 

F08 ecm x2 x3

Fig 8

 

– Thanks to Aron Wilson

Steering Column Noise Conditions

A grinding or popping noise or a binding feeling in the steering column when turning left or right may be experienced on some 2014 Silverado 1500, Sierra 1500; 2015 Silverado, Tahoe, Suburban, Sierra, Yukon models and Escalade models equipped with a tilt and telescoping steering column (RPOs N38, N37).

 

These conditions may be caused by either of the following:

• The lower column bearing may be out of position. The photos show the lower column bearing in its correct position (Fig. 5, #1) and the lower column bearing out of position. (Fig. 6)

 

F05 column 11

Fig 5

F06 column 12

Fig 6

 

• The upper intermediate steering shaft to the lower column shaft bolt and nut may be contacting the inhibitor/shifter cable bracket. (Fig. 7, #2)

 

F07 column 2

Fig 7

 

Do not replace the steering column assembly to correct either condition. See the updated repair recommendations.

 

– Thanks to David MacGillis

 

Updated September 10, 2015

EL-50332 Hybrid/EV Battery Service Tool Components

The EL-50332 Hybrid/EV Battery Service Tool is used to match the voltage level of a replacement battery section to the existing battery sections following a service event on a 2011-2015 Volt, 2014 ELR and 2014-2015 Spark EV.

 

The EL-50332 tool charges and discharges the replacement battery section through a direct connection to the replacement battery section positive and negative terminals.

 

There following cables and components should be included with the EL-50332 tool.

 

Screen Shot 2015-06-05 at 10.43.52 AMScreen Shot 2015-06-05 at 10.44.03 AM

 

Software Updates

 

The EL-50332 requires periodic software updates. The latest software release is available on the GM Dealer Equipment Website (U.S.), which can be accessed through GM GlobalConnect > Service Workbench > GM Essential Tools – Software Updates. Follow the on-line instructions.

 

In Canada, this site can be accessed through GM GlobalConnect > Service Library > Tools and Processes and Equipment > Dealer Equipment & Services (DES) Canada.

 

To access downloads on this website, you must first register and establish a user name and password. Call 1-800-GM-TOOLS (U.S.) or 1-866-868-3372 (Canada) if assistance is needed.

 

– Thanks to Chuck Berecz

Connecting the EL-50332 Hybrid/EV Battery Service Tool

Dealerships are starting to service more hybrid batteries on 2011-2015 Volt, 2014 ELR and 2014-2015 Spark EV models by replacing hybrid battery sections only. After a battery section has been replaced, the battery section has to be balanced with the rest of the battery pack.

 

The battery balance procedure requires using the EL-50332 Hybrid/EV Battery Service Tool. Some technicians are using this service tool for the very first time, so there may be some concerns about using the right cables to make the proper connections.

 

Occasionally, EL-50332 tool will require software updates. Tool Software Updates can be accessed through GM GlobalConnect or through the GMDE software update webpage.

 

New software updates are now available for the EL-50332 tool that enable Pack Depowering and Battery Section Servicing of the ELR, enable Pack Depowering of the Spark, and enable continuous data monitoring and USB writing for Pack Info Mode for all vehicles. It may take approximately one hour to update the tool software, depending on the download speed of the dealership’s Internet connection.

 

Battery Cell Balancing

 

The EL-50332 Hybrid/EV Battery Service Tool is used to match the voltage level of a replacement battery section to the existing battery sections following a service event. The tool charges or discharges the replacement section, as required, based on measured cell group voltage data.

 

The EL-50332 tool requires feedback from the battery energy control module during the balancing process. Communication is through the A4 Hybrid/EV Battery Pack X357 and X358 connectors and a low voltage interface harness provided with the EL-50332 tool. The charging and discharging is performed by direct connection to the replacement battery section positive and negative terminals.

 

Hybrid/EV Battery Cells

 

Using the Volt as an example, there are 96 cell groups in the hybrid battery assembly. These cell groups are electrically connected in series. The battery cell groups are joined to form three sections.

 

The Battery Energy Control Module monitors the voltage of the 96 battery cell groups through four Hybrid Battery Interface Control Modules and determines when a fault condition is present. The Hybrid Powertrain Control Module 2 is the host controller for DTC information.

 

Battery Balance Procedure

 

TIP: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

 

The EL-50332 tool includes a universal fuse box, an interface module and a number of cables. Before balancing a battery section, make sure all the external EL-50332 components and cables are in good condition and working order.

 

Refer to the Hybrid/EV Battery Cell Balancing procedure in the appropriate Service Information for complete instructions on connecting the EL-50332 tool. Here are a few tips to assist on hooking up the tool to a battery section.

 

• Connect the EL-50332-120 High Voltage Interface Cable to the EL–50332 Hybrid/EV Battery Service Tool (Fig. 1, #1) and to the EL-50332-105 Universal Fuse Box. • Connect the EL-50332-125 Vehicle Interface Module Low Voltage 24-Pin Cable to the EL-50332-110 Vehicle Interface Module (Fig. 1, #3) and to the EL-50332 Hybrid/EV Battery Service Tool. (Fig. 1, #2).

 

F01 battery Fig 1 Fig 1

 

• Connect the EL-50332-135 Hybrid/EV Battery Contactor Assembly Interface Cable to the A4 Hybrid/EV Battery Pack (Fig. 2, #3) and to the EL-50332-110 Vehicle Interface Module.

 

F02 battery Fig 2 Fig 2

 

• Connect the EL-50332-145 Black Banana Jack Cable, EL-50332-150 Red Banana Jack Cable, and EL-50332-155 Green Banana Jack Cable to the EL-50332-105 Universal Fuse Box. (Fig. 3)

 F03 battery Fig 3 Fig  3

 

• Connect the EL-50332-155 Green Banana Jack Cable to the A4 Hybrid/EV Battery Pack ground G340. (Fig. 4) • Connect the EL-50332-145 Black Banana Jack Cable to the appropriate section negative stud to be balanced and the EL-50332-150 Red Banana Jack Cable to the appropriate section positive stud to be balanced. (Fig. 4)

 

F04 battery Fig 4 Fig 4

 

If any codes appear when starting up the tool, check the following:

• Make sure the USB memory stick is fully inserted into the machine. • Do not hook the machine to the battery section until instructed to do so by the machine. • Update the balance machine software to the latest version available.

 

Depending on the charge condition of the battery pack and the section being balanced, the balancing process can take up to four hours to perform.

 

The EL-50332 tool balances the selected section by charging/discharging, as appropriate. Initial balancing will be in a constant current mode (max 5 amp charge, 7.5 amp discharge). The tool will transition to a constant voltage mode (decreasing current) near the end of the event.

 

A warranty code and pack voltage current data will be displayed at the conclusion of the balancing event. An audible tone will sound at the end of balancing or if there is a fault condition.

 

– Thanks to Paul Radzwilowicz

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