lectric 2011 Chevrolet Volt

December 2010 Volume 12, No.12 The lectric 2011 Chevrolet Volt The all-new 2011 Chevrolet Volt electric vehicle with extended range goes on sale in the U.S. this month. The five-door, four-passenger Volt provides the benefits of an electric vehicle without the range limitations associated with other electric vehicles in the market. The extended-range capability of the Volt enables it to be operated when recharging is not immediately available, such as during a power outage or on a long-distance trip. PROPULSION SYSTEM The Volt is a one-of-a-kind, all-electrically driven vehicle engineered to operate in all climates. GM s revolutionary Voltec propulsion system consists of a 16-kWh lithium-ion battery pack and electric drive unit that provide a pure electric range between 25 and 50 miles Techline News Component Codes Coming to SPS A component code is used to assist in identifying a common part when the part name appears differently depending on publication, such as when the Service Information (SI) is translated into different languages. A component code is not to be confused with an RPO code. Component codes will always be the same once assigned to a unique part name. Until recently, component codes were only found in the SI application for The control module component code will now be listed in SPS. continued on page 2 (40 to 80 km), depending on ambient temperature, terrain and driving technique. When the energy level of the battery drops below the state-of-charge window, the Volt seamlessly transitions to extended-range mode. Power is inverted from a technically advanced, 1.4L 63-kW (84-hp) gasoline-powered onboard engine to the electric drive unit to provide up to 310 additional miles (500 km) of range on a full tank of fuel. When the car is plugged in and recharged, it runs again on a pure electric charge. The Volt reaches a top speed of 100 mph (160 km/h). The electric drive unit s excellent low speed torque of 273 lb.-ft. (368 Nm) takes it from 0 to 60 mph in less than 9.0 seconds and the quarter mile in less than 17.0 seconds. continued on page 2 Contents The Electric 2011 Chevrolet Volt........1 Component Codes Coming to SPS.......1 Module Programming Error E4398......2 Inspection/Maintenance Test DTCs......3 Voltec Electric Drive Unit and High Voltage Battery................4 Volt Engine Operation...............5 GM Technical Assistance Center Offers Dedicated Volt Support..........5 Charging the Volt..................6 Volt Service and Training.............7 Service Know-How.................7 Car Issues Fix It Right the First Time....8 Truck Issues Fix It Right the First Time...9 Customer Care and Aftersales

The Electric 2011 Chevrolet Volt continued from page 1 Volt 1.4L engine and electric drive unit Driver-Selectable Drive Modes The Volt is a one-of-a-kind global electric car designed to perform in all climates, and offers performance modes for varying driving styles and conditions. Using the Drive Mode button on the center stack, the driver can choose Normal, Sport or Mountain Mode: Drivers can select Normal, Sport or Mountain Mode drive modes. Component Codes continued from page 1 Normal Mode: This default setting provides the most efficiency, whether the vehicle is powered by electrical energy that is stored in the propulsion battery or generated by the range-extending gas engine. Sport Mode: Sport Mode automatically reconfigures the accelerator pedal response to provide quicker torque application when desired in various driving situations. While it doesn t provide a higher full power output, it does provide more sensitive feedback to driver inputs. Mountain Mode: Mountain Mode automatically adjusts the system to reserve a sufficient state of charge for driving over mountain passes in extended-range mode. The driver should select this mode at least 20 to 25 minutes before entering mountainous terrain (long grades of 5% or higher), to enable full vehicle capability up sustained grades. If Mountain Mode is selected with a battery charge of four bars or less on the propulsion battery gauge, the engine will run at a higher speed to build the battery buffer. If Mountain Mode is not selected in mountainous terrain, there may be reduced propulsion power and a higher engine speed until a normal battery state of charge can be recovered. HIGH VOLTAGE BATTERY The Volt s high voltage battery consists of a 5.5-foot, 435-pound (198.1 kg) T-shaped, 16-kWh lithium-ion battery pack. It supplies energy to an advanced, 111-kW (149-hp) electric drive unit to propel the vehicle. The battery pack consists of nine modules and 288 prismatic cells. Charging Charging the Volt s battery is simple and intuitive, and can be done through 120V conventional household electrical 240V charging station 120V household outlet schematics, diagnostic procedures and support information. Refer to August 2009 TechLink for additional information related to component codes in SI. Component codes will now be referenced in the Service Programming System (SPS) for Global A models (Camaro, Cruze, Equinox, Terrain, SRX, LaCrosse and Regal) to help provide consistency in identifying programmable control modules with their reference in SI. The component code will be listed along with the global abbreviation and control module long name. Some examples include: K9 BCM Body Control Module K17 EBCM Electronic Brake Control Module K20 ECM Engine Control Module K36 SDM Sensing and Diagnostic Module K71 TCM Transmission Control Module Thanks to Mike Waszczenko and Lisa Scott Charging Times Approximately 4 hours Approximately 10 hours outlets, or through a dedicated 240V charging station. Once the vehicle is plugged in, owners can schedule either immediate or delayed charges, even coordinating charging according to departure time or when electricity rates are lower. Owners also can manage and monitor the Volt remotely via computer on MyVolt.com; or with the OnStar MyLink smart phone application. CHASSIS Volt is equipped with standard chassis control systems such as ABS, traction control and StabiliTrak electronic stability control. An isolated four-mount front cradle contributes to the Volt s overall quietness, outstanding noise and vibration performance, and ride and handling dynamics. Components of the Volt s MacPherson strut-type suspension are constructed of forged aluminum for reduced weight. The compact Volt chassis includes the T-shaped, 16-kWh lithium-ion battery pack between the rear wheels. Cold-formed, high-performance front springs are lighter and use less coiling than conventional springs. A sophisticated compound crank rear axle provides quick reaction, low weight and consistent camber control. The cast iron control arms are attached to the steel cross-car beam with a patented magneticarc welding process. continued on page 3 Module Programming Error E4398 When reprogramming an existing module or programming a new module on 2011 and prior GM passenger cars and lightduty trucks, do not replace the module if an E4398 error code occurs during the programming process. TIP: An E4398 programming error code could occur while programming any module (i.e. BCM, ECM, PCM, TCM, EBCM, etc.) An E4398 programming error is the result of a missing or incomplete data record. This error is not related to the module being programmed or a vehicle issue. It can be repaired by obtaining a Vehicle Configuration Index (VCI) number from the Techline Customer Support Center (TCSC). DO NOT replace the module. Call TCSC at 1-800-828-6860, prompt #2, (English) or 1-800-503-3222 (French) for a VCI number, which will allow the module to be programmed correctly. Thanks to Ray Romeo 2 December 2010

Electric Power Steering The Volt features a ZF variable assist electric power steering system with dual pinions (one is used for steering, the other to add assist). A combined electric motor and sensing unit monitors steering angle, and delivers appropriate assist to the steering gear in all conditions. The system draws its power from a 12V battery in the rear of the vehicle. Regenerative Braking The Volt's fully blended electrohydraulic brake system enables 100% regenerative braking, 100% traditional disc friction braking, or any combination of both. Regenerative braking, which captures energy for transfer back to the battery, can provide up to 0.2g of deceleration (about 94% of braking events). Braking that involves more than 0.2g of deceleration is a combination of regenerative and friction braking. During a panic stop, the system seamlessly transitions to 100% friction. TIP: If the battery is fully charged, the brake controller directs the system to conduct friction braking. The disc brake system uses a highpressure hydraulic accumulator to provide boosted braking. Lightweight aluminum wheels weigh only 17.8 pounds (8.1 kg) each, compared to 24.2 pounds (11 kg) for typical 17-inch wheels. Goodyear Fuel Max all-season low-rolling resistance tires are optimized for electric vehicle range, noise, feel and performance. The Volt is equipped with an electric parking brake, which is applied by pulling the Parking Brake switch next to the shift lever. To release the parking brake, with the ignition ON, press the brake pedal and press the Parking Brake switch. Safety features on the Volt include eight airbags and advanced LED daytime running lamps. The Passenger Presence Volt features lightweight System in the aluminum wheels and lowrolling resistance tires. front passenger seat is a capacitive system and will detect any electronic devices (laptop computer, cell phone, etc.) sitting on the front seat. Remove these items to turn off the PASSENGER AIRBAG ON light when the seat is unoccupied. Volt Technology There is much more technology inside the Volt than its electric propulsion system. Intuitive features high-resolution displays, connectivity and the ability to Volt packs technology in the passenger cabin too. monitor and control vehicle functions remotely redefine how owners will interface with the vehicle. Key technologies include: High-resolution, seven-inch, full-color LCD reconfigurable Driver Information Center display and instrument cluster. The display shows electriconly range, fuel economy, extendedrange, trip information, tire pressure information and a variety of vehicle messages. High-resolution, seven-inch, fullcolor, center stack-mounted touch screen display that serves as the interface for infotainment and cabin climate controls. An Efficiency (Leaf) button accesses power flow, charging, and energy information screens. Touch-control infotainment and climate control systems on the center stack. Charge modes that are customizable according to need and electricity rates for efficient programming and lower costs. Remote Keyless Entry that allows drivers to remotely start the vehicle and precondition the cabin based on outside temperatures while the vehicle is plugged in, enhancing efficiency. An exclusive mobile app, powered by OnStar MyLink, which enables owners to engage with Volt functions such as checking battery charge level, initiate charging, and lock/unlock the doors using a smart phone. Thanks to Keith Newbury and Steve Falko Inspection/Maintenance Test DTCs After repairs on any On-Board Diagnostic (OBD) II-related systems, technicians may find that any Inspection/Maintenance (I/M) Test DTCs that are stored will not clear. I/M Test DTCs are different than traditional current and history DTCs and are used in certain State/Province vehicle emission test programs. The rollout of I/M Test DTCs began in the 2010 model year and will be completed by the 2013 model year. Vehicle implementation is by model and engine, so not all models will be updated at the same time, depending on engine option. I/M Test DTCs cannot be cleared using a scan tool or by disconnecting power to the control module. They will only clear when the control module diagnostic that set the DTC has run and passed, confirming the problem has been repaired. Some diagnostics for I/M Test DTCs will run and pass very quickly (a repaired open circuit DTC will pass in milliseconds), while others may take days depending on vehicle operating conditions (such as a complex diagnostic for an EVAP small leak test).stored I/M Test DTCs discovered during a vehicle emission inspection may cause a vehicle to fail or be rejected. Using a scan tool, technicians can observe I/M System Status. The display provides an indication of when the control module has completed the required tests. This does not necessarily mean that the test has passed, only that a decision was made. If the diagnostic fails, a traditional DTC will indicate the failure. The I/M System Status information may be useful for a technician to determine if diagnostics have run when verifying repairs. The traditional current and history DTCs still exist exactly as before and can be cleared using a scan tool. Every Service Information (SI) diagnostic procedure that indicates to clear codes should be followed, and the Malfunction Indicator Lamp (MIL) should not illuminate if the problem is not present. Thanks to Jack Woodward December 2010 3

Voltec Electric Drive Unit and High Voltage Battery The innovative Voltec electric propulsion system combines a 16-kWh lithium-ion battery pack with a 111-kW (149-hp) electric drive unit. The electric drive unit powers the wheels at all times. DRIVE UNIT Most battery electric vehicles use a single motor with a fixed reduction gear that steps down the motor speed to synchronize with the wheel speed. The Chevrolet Volt uses a unique electric drive unit to boost efficiency. The efficiency of any electric motor always drops off as it approaches its maximum rotational speed. The Volt drive unit consists of two electric motors, three clutches and a planetary gear set that improve overall efficiency by reducing the combined rotational speed of the electric motors. This configuration reduces battery drain at highway speeds, adding up to two miles of additional EV range. Electric drive unit The Volt s motors and gear-set are mounted in-line with the industry s first range-extending internal combustion gasoline engine. Two of the clutches are used to either lock the ring gear of the planetary gear-set or connect it to the generator/motor, depending on the mode. The third clutch connects the gasoline engine to the generator/motor to provide range extension capability. This innovative new drive unit has four distinct operating modes. Electric Vehicle Modes Electric Only, Engine Off (One Motor) The vehicle operates in full-electric mode without starting the engine for approximately 25 to 50 miles (40 to 80 km), depending on ambient temperature, terrain and driving technique. The primary traction motor provides all propulsion, drawing all of its energy from the battery. Electric Only, Engine Off (Two Motors) During highway cruising, if the required torque to propel the vehicle is low, the ring gear is coupled to the generator/motor. This allows the two motors to work in tandem for greater efficiency. Extended-Range Modes Electric Only, Engine On (Series) Once the battery has reached a determined state of charge, the gasoline engine will start. It is coupled to the motor/generator via the third clutch. The engine-driven generator and battery provides electricity to the traction motor via the inverter. The engine will operate at an appropriate speed to optimize fuel consumption while maintaining output power requirements. Because the most efficient way to charge the Volt s battery is to plug it in, the generator is used only to maintain minimum battery state of charge. If the battery is drawn down below the minimum level, the generator will charge the battery up to its minimum state of charge and then maintain it there. Output Split, Engine On (Combined) The blended two motor electric propulsion strategy used at higher speeds in EV driving also has been adapted for extended-range driving. During highway cruising, if the required torque to propel the vehicle is low, the clutches that connect the generator/motor to both the engine and the ring gear are engaged, combining the engine and both motors for efficient operation in an output power split configuration. TIP: Under no circumstances can the Volt be dinghy towed. Towing is to be done by a flatbed carrier only. HIGH VOLTAGE BATTERY The Volt is powered by a lithium-ion high voltage battery pack, which holds its charge efficiently and has no memory effect (so it doesn t have to be run down completely before recharging). The owner should keep the vehicle plugged in, even when fully charged, to keep the battery temperature ready for the next drive. Lithium-ion was chosen over nickel metal hydride for the Volt battery because it packs two to three times the power of a nickel metal hydride battery in a much smaller package. It also is more efficient and suffers little loss of charge when not in use. The battery pack is liquid cooled, T-shaped, and located beneath the vehicle. The 360V direct current battery is formed from 288 cells. Each cell is 5 x 7 x 1/4 inch, and weighs about a pound. Cells are grouped together to form distinct blocks, referred to as sections. The battery is connected to the propulsion circuit or charging circuit using unique pairs of contactors. In general terms, the main contactors will close when the ignition switch is in the ON position, and the charging contactors will close when plugged in with the ignition switch in the OFF position. The high voltage battery is also connected to two distinct low voltage high voltage interlock (HVIL) circuits, one for propulsion, and one for charging. Because batteries can be sensitive to temperature changes, the Volt pack is climate-controlled Lithium-ion high voltage battery pack via an exclusive active liquid control system that continually monitors and maintains the battery pack temperature for optimum performance and durability. Circulating liquid (consisting of coolant and distilled water) passes through a series of internal heat exchangers in the battery modules. It is designed to provide reliable battery operation when plugged in, at temperatures as continued on page 5 4 December 2010

Volt Engine Operation The range-extending Ecotec 1.4L I-4 VVT gasoline engine (RPO LUU) features a number of unique systems that may operate in unfamiliar ways to Volt owners. Conditions that Cause the Gasoline Engine to Start Independent of the vehicle being plugged in or completely charged, when vehicle power is ON, the gasoline engine may start under the following conditions: Propulsion battery charge is low Propulsion battery temperature is Ecotec 1.4L I-4 VVT gasoline engine hot or cold (RPO LUU) Cold ambient temperatures less than approximately 25 F (4 C) Starting the Engine This vehicle does not use a 12V starter motor to crank the gasoline engine. A much more powerful 300V motor/generator located within the transmission is utilized to crank the engine. The 300V drive motor/generator can rotate the engine to operating speed (800 rpm) within just a few hundred milliseconds. The 300V drive motor/generator allows near-instant starting of the engine. Filling the Fuel Tank The Volt is equipped with a pressurized fuel system that is sealed from the atmosphere when the gasoline engine is not operating. Refueling can occur only after the fuel system has been adequately vented to atmosphere through the carbon canister. Premium fuel with an octane rating of 91 or higher is required. Owners who do not understand the fuel door operation may believe the door has malfunctioned. 1. Press the Fuel door release button, located on the driver s door, for one second. The Wait to Refuel message will display on the instrument cluster. 2. When the Ready to Refuel message displays, the fuel door on the passenger s side of the vehicle will unlock. It will not open automatically. 3. Press the rear edge of the fuel door; it will pop open slightly. Open the door to refuel the vehicle. Maintenance Modes The Engine Maintenance Mode will run the engine to keep it in good working condition after approximately six weeks of no or very limited engine operation. The Fuel Maintenance Mode tracks fuel age and will run the engine to use the fuel if the average fuel age exceeds approximately one year. Thanks to Keith Newbury and Steve Falko Voltec Electric Drive Unit cont. from page 4 low as -13 F (-25 C) and as high as 122 F (+50 C), and can be powered during driving either by the battery or the engine. Fully charging or fully depleting a battery shortens its life. The Volt battery is controlled, or buffered, so it operates within a safe state-of-charge window. In demanding situations (such as driving in Mountain mode), the battery state of charge will raise the lower limit to ensure there is adequate power when needed. The battery s top and bottom buffer zones help ensure long life. Thanks to Keith Newbury and Steve Falko GM Technical Assistance Center Offers Dedicated Volt Support The GM Technical Assistance Center (TAC) in the U.S. is ready to provide outstanding service support to Chevrolet Volt certified service technicians on all Volt issues and repairs. The entire GM team has been working together to ensure that the people, processes, and equipment are in place to deliver exceptional technical support and service. The process begins with you, the Volt certified service technician, working with the GM TAC team to report and solve vehicle concerns. Special Support Model A special team of TAC representatives with a deep understanding of the Chevrolet Volt has been created to allow greater flexibility to serve technicians. Beginning in mid-december, this dedicated team will be available to provide fast, accurate diagnostic and repair direction to TAC callers. Each member of this team has been through extensive training alongside the Field Service Engineers. In addition, a Volt will always be at the TAC so that the dedicated team will have direct handson access to a vehicle when needed. Plus, the team will have direct contact with Volt engineers to verify diagnostic paths, component testing procedures and review other service issues. Extended Hours In order to support Volt service technicians and, in turn, Volt customers the TAC dedicated Volt team will be available on Saturdays to assist with Volt cases beginning December 4, 2010, from 8:00 AM to 8:00 PM Eastern time, in addition to normal TAC business hours. How You Can Help What can you do to support efforts to provide exceptional service? Please call in to report ANY issues on a Chevrolet Volt. All Volt cases will be in the hands of the Volt Engineering Team immediately. Please call early in the diagnostic process in order to receive the necessary service support. The Volt team understands that this vehicle technology is new to everyone and that we need to work together! Our dedicated team is ready to assist you in helping provide Volt customers with an outstanding service experience with their truly exceptional vehicle. Thanks to Steve Oakley December 2010 5

Charging the Volt Once the initial electric charge is depleted, the rangeextending gasoline engine will start to generate enough power to continue driving the vehicle. The engine driven generator will not fully charge the propulsion battery pack in the Volt. The vehicle must be plugged in to recharge. Plug-In Charging The provided 120-volt portable charge cord is located in the storage compartment under the cargo floor. To charge the vehicle: 1. Plug the charge cord into an electrical outlet. All four charge level indicators should be green. TIP: Do not use an extension cord. TIP: A reduced charging level is available on the portable charge cord when the electrical current is limited by pressing the orange charge level button. Only two charge level indicators will illuminate. 2. Press the Charge port door release button, located on the driver s door or RKE transmitter, for one second. 3. Plug the charge cord into the vehicle s charge port located in front of the driver s door. TIP: Squeeze the plug button on the charge cord to use the flashlight to help illuminate the charge port if needed. 4. The charging indicator on top of the instrument panel will illuminate green and the horn will chirp when properly connected. If the vehicle is locked with the RKE transmitter, the charge cord theft alert is armed automatically after 30 seconds. TIP: When the theft alert is armed, the alarm will sound when the plug is disconnected from the locked vehicle. Charge Cord Status The charge cord status indicators illuminate green or flashing red to identify the charge cord status. If any indicators are flashing red, the charge cord will not permit vehicle charging. Charge Cord Status Indicator The Volt includes a 120-volt portable charge cord. Flashing red AC PRES- ENT (A) Flashing red AC PRES- ENT (A) and FAULT (B) Flashing red FAULT (B) Condition AC voltage is out of range Charging Status The charging status indicator is located on the instrument panel near the windshield. TIP: Immediately after plugging in, the charging status indicator may be amber for up to five seconds before turning green. The charging system may run fans and pumps when the vehicle is turned off. Charging Status Indicator Solid green with single horn chirp Slow (long pulse) flashing green with double horn chirp Fast (short pulse) flashing green Solid yellow No light Horn chirps and no light Using a standard 120-volt household outlet, it will take approximately 10 hours to charge the Volt, and using a 240-volt charging station will take approximately four hours to charge. Charging Modes Press the Leaf button and then touch the Charging tab on the center stack touch AC outlet does not have a proper safety ground Charge cord fault. The charge cord will attempt to reset automatically. If the fault continues for more than 30 seconds, unplug the charge cord from the wall to reset. If the fault remains, the cord requires service. Condition Vehicle is plugged in; battery is charging Vehicle is plugged in; delayed battery charging Vehicle is plugged in; battery is fully charged Vehicle is plugged in; not charging Vehicle is not plugged in OR there is an issue with the charger or wall outlet Electricity was interrupted before charging was completed When the battery is being charged, the status indicator will be solid green. screen or press the Charge port door release button to view the current charge mode status. lt can be programmed for three charging modes: Immediate: Starts charging as soon as it is connected to an electrical outlet Delayed Departure Time: Calculates the charging start time and completion based on the schedule entered Delayed Rate and Departure Time: Calculates the charging start time based on utility rate schedules, rate preference and the programmed departure time for the current day of the week End Charging 1. Unlock the vehicle with the RKE transmitter to disarm the charge cord theft alert. 2. Unplug the charge cord from the vehicle by squeezing the plug button. 3. Unplug the charge cord from the electrical outlet. 4. Stow the charge cord. Thanks to Keith Newbury and Steve Falko 6 December 2010

Volt Service and Training Working on the electrical systems of the Volt requires following all safety precautions. This means having the proper equipment as well as using it in a safe manner. GM TechLink is a monthly magazine for all GM retail technicians and service consultants providing timely information to help increase know - ledge about GM products and improve the performance of the service department. Publisher: Thomas J. Arnold GM Customer Care and Aftersales /Thomas.Arnold@GM.com Editor: Lisa G. Scott GM Customer Care and Aftersales /Lisa.G.Scott@GM.com Technical Editor: Mark Spencer /mspencer@gpworldwide.com Production Manager: Marie Meredith Desktop Publishing: 5by5 Design LLC /dkelly@5by5dzign.com FAX number: 3 1-248-729-4704 Write to: * TechLink PO Box 500 Troy, MI 48007-0500 GM TechLink on the Web: : GM GlobalConnect General Motors service tips are intended for use by professional technicians, not a do-it-yourselfer. T hey 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, do not assume that the bulletin applies to your vehicle or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information. Inclusion in this publication is not necessarily an endorsement of the individual or the company. Copyright 2010 General Motors Company All rights reserved. Safe Multimeter Practices Multimeter safety standards must be followed to help ensure safe work practices. Make sure your multimeter meets the latest International Electrotechnical Commission (IEC) safety standards for test equipment and that it is in good condition. For more information about safe multimeter practices when working on high voltage electrical systems, refer to the January 2008 edition of TechLink. Hand Tools TIP: Volt training mandates that the high voltage system be disabled BEFORE performing any repairs. Insulated class 0 isolation gloves (leather outside, rubber inside) are required during service. The class 0 gloves are rated up to 1000 volts. Also follow all the appropriate safety precautions outlined in SI. In addition, technicians may choose to purchase insulated hand tools. A variety of tools are available from several tool manufacturers. Training To learn more about the features of the Volt and key safety and service features, refer to the Volt training courses available on www.gmtraining.com. (In Canada, due to the later introduction of the Volt, training will begin in the second quarter of 2011. Visit www.gmprocanada.com for details.) Course Number Course Name Delivery Method Service Consultant Training VPTVT.010W1 Volt Service Overview Web VPTVT.010W2 Volt Maintenance 101 Web VPTVT.010W3 Volt Battery and Charging 101 Web VPTVT.010W4 Volt Service Experience 101 Web Technical Training 18420.01W Volt Introduction and Safety Web 18420.02W High Voltage Energy Storage Systems Web 18420.03W Advanced Technology Vehicle Power Electronics Web 18420.04W Advanced Technology Vehicle Transmission Web 18420.05W Advanced Vehicle Technology Supporting Systems Web 18420.02T1 Volt High Voltage Disable Procedure Web 18420.06D1 Electric Vehicle Systems Diagnosis and Service Session 1 Web 18420.06D2 Electric Vehicle Systems Diagnosis and Service Session 2 Web 18446.01H Two-mode Hybrid Safety and Battery System Service Hands-on Service Know-How 10210.12D Emerging Issues December 9, 2010 To view Emerging Issues seminars: Log in to www.gmtraining.com, select Service Know- How/TECHAssist from the menu, select Emerging Issues, and then Searchable Streaming Video to choose the current Emerging Issues seminar or past programs. December 2010 7

Car Issues Fix It Right the First Time Model Year(s) Vehicle Line(s) / Condition Do This Don t Do This Reference Information / Bulletin 2004-2011 AURA, G6, Malibu, Malibu Maxx Intermittently brake lights (stop lamps) do not function correctly, cruise control inoperative Disconnect the C2 or X2 connector, Add dielectric lubricant and reconnect the connector Replace BCM 08-05-22-009C 2004-2011 CTS, SRX, STS Information to prevent incorrect installation of air cleaner cover to air cleaner housing Always make sure air box is assembled correctly Completely remove from the housing the (outlet side) cover if just replacing the filter element 08-06-01-020A 2009-2011 HHR, Impala Front passenger heated seat insufficient heat and proper system operation Compare performance to the passenger seat in a like car to see if seat heater is normal Replace the heater element 09-08-50-013A 2008-2009 G8 Automatic transmission 6th gear whine Install new transmission mount Replace any other front suspension parts 10-07-30-012 2009-2011 Acadia, AURA, Enclave, Envoy, G5, G6, H2, H3, OUTLOOK, Sierra, SKY, Solstice, Suburban, Tahoe, Terrain, Torrent, VUE, Yukon Buzz noise during call when using Bluetooth Ensure that the customer's phone is an older GSM type, and the noise is heard on the land-line side only before attempting the microphone replacement Perform this microphone replacement for newer phones that do not use GSM 10-08-44-003B 2009-2011 Corvette Visor-mounted garage door opener will not program/universal home remote system does not operate garage door Reset the garage door opener first and then contact the toll-free number for assistance with programming the garage door opener Replace the visor/garage door opener 10-08-97-001 2010-2011 LaCrosse Power steering system moan or metal grind noise when turning steering wheel Replace steering gear and I shaft with new part and install new calibration Replace the power steering pump or hose PI0172A 2010 Malibu Engine surge during high ambient temperatures Install new calibration Replace parts for this issue PI0245 2010 Impala No crank/no start, solenoid clicks Check battery cable ground connection Replace starter PI0249 2007-2011 Impala, Malibu Sunroof sunshade cloth comes loose from sunshade panel Re-glue the sunroof sunshade cloth to the sunshade panel Replace the sunroof sunshade PI0250A 2010 Cobalt, G5 Increased rear compartment lid closing effort, trunk ajar displayed in DIC with trunk closed, poor rear compartment lid fit/alignment Adjust decklid Replace the latch PI0252 2011 Cruze License plate will not fit in front bracket during Pre-Delivery Inspection (PDI) process Inform the customer a fix is under development Replace the radio or faceplate PI0254 2010-2011 Camaro Front seat cushion cover J-channel retainer comes loose from front of seat frame Cut the j-clip on the seat cover and reinstall the cover Replace the seat cover PI0258 2010-2011 Camaro, SKY, Solstice Radio display screen scratches Polish the radio faceplate screen Replace the radio faceplate 09-08-44-015C 2007-2010 AURA, Malibu, VUE Check Engine light illuminated, DTC P0AA1 set Replace battery energy control module wiring harness Replace battery energy control module 10-06-130-002A 2010 Equinox, LaCrosse, SRX, Terrain Engine oil leak from oil pan at mounting area Clean bolt hole with brake cleaner, air dry and apply thread locker to bolt threads Replace oil pan PI0263 2010-2011 SRX MIL-Check Engine light on, DTC P182E Set Make sure to pull back firmly on the shifter when adjusting the shift cable Replace the switch without verifying the cable adjustment PI0231A 8 December 2010

Truck Issues Fix It Right the First Time Model Year(s) Vehicle Line(s) / Condition Do This Don t Do This Reference Information / Bulletin 2010-2011 Acadia, Avalanche, CTS, CTS-V, CTS Sport Wagon, CTS-V Sport Wagon, Enclave, Escalade, Escalade ESV, Escalade EXT, Sierra, Silverado, Suburban, Tahoe, Traverse, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali Park Assist blocked, See Owners Manual message repeatedly on DIC Reprogram the rear object sensor control module Replace the rear object sensor control module or rear. PI0267 2008 Acadia, Enclave, OUTLOOK SIR light on, DTC B0014 and B0021 set in SDM Replace connector between seatmounted side impact airbag and body harness, reroute harness Grease the existing connector or replace the harness 08-09-41-011C 2007-2010 Acadia, Enclave, OUTLOOK, Traverse Whine/moan noise from power steering system during low speed maneuver Perform a thorough bleed of the system Replace the power steering pump before performing the bleed procedure in the bulletin 10-02-32-002 2007-2010 Allure, Avalanche, Camaro, Envoy, Escalade, G8, Grand Prix, Impala, LaCrosse, Monte Carlo, Rainier, SAAB 9-7X, Sierra, Silverado, Suburban, Tahoe, TrailBlazer, Yukon AFM engine, valve tick noise at start up when engine has been off for 2 hours or more Check oil level and fill if low before doing any repairs Use this bulletin on NON AFM engines 10-06-01-007A 20087-2011 Avalanche, Escalade, Escalade ESV, Escalade EXT, Sierra, Silhouette, Suburban, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali Passenger-side airbag door not flush with dash pad/warped Reposition the locking tabs Replace the air bag assembly 08-09-41-005A 2000-2010 Avalanche, Blazer, Bravada, Escalade, Escalade ESV, Escalade EXT, Express, H2, Jimmy, Rainier, S-10, Savana, Sierra, Silverado, Sonoma, Suburban, Tahoe, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali Information on pitman arm shaft seal service kit Replace the leaking pitman shaft seal Replace the entire gear 10-02-33-001A 2011 Equinox, Terrain Interior headliner sagging at dome lamp area Re-glue the magnets Replace the headliner PI0253A 2006-2011 Canyon, Colorado Broken front floor console compartment lid/armrest latch Replace only the center console lid latch. Labor operation C9952 Replace the console lid and/or armrest assembly. Labor operations C2740 or C2860 PI0262 2005-2010 All Vehicles Reporting missing or inaccurate navigation radio map disc informationcomplete/submit Ask the customer to report concerns to the GM Navigation Disc Center at: www.gmnavdisc.com Replace parts 10-08-44-006 2011 Sierra, Silverado Fuel tank slow or difficult to fill Check for kinked vent hose Replace fuel filler pipe or tank PI0261 2007-2010 Avalanche, Escalade, Escalade ESV, Escalade EXT, Sierra, Silverado, Suburban, Tahoe, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali Driver or passenger heated seat inoperative, slow to warm Correct terminal tension and reroute harness Replace memory seat module, thermo-electric device (TED), or element 10-08-50-008A 2007-2010 Avalanche, Escalade, Escalade ESV, Escalade EXT, Sierra, Silverado, Suburban, Tahoe, Yukon, Yukon Denali, Yukon XL, Yukon XL Denali Front seat cushion cover becomes detached Install 3M Automotive Acrylic Plus attachment tape to the seat frame Replace the seat cover 08-08-50-001B 2010-2011 Sierra, Silverado Body mount bolt stripped or will not loosen Create access hole to repair Use unapproved running boards that attach to body mounts 10-08-61-001 2011 Sierra, Silverado Squeal noise from front of truck / independent of brake apply Lube front axle seals Replace axle seals PI0257 2007-2011 Sierra, Silverado Mounting points for pickup box accessories Mount accessories in correct location with acceptable loads Overload or use cargo management point for attachment 09-08-66-011A 2011 Sierra, Silverado Diesel Exhaust Fluid (DEF) filling instructions and general information Add only 3.5 gallons of DEF at PDI Overfill 10-06-04-013 2010 Acadia, Enclave, Terrain Whine noise heard when using OnStar or Bluetooth (install noise filter) Verify concern occurs only when using OnStar or Bluetooth feature. Obtain the filter and install per instructions Replace the radio or VCIM for this concern 10-08-44-005 2007-2009 Escalade, Escalade ESV, Escalade EXT Avalanche, Silverado 1500, Suburban, Tahoe Sierra 1500, Sierra Denali, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL, G8 GT Engine oil consumption on aluminum block engines with Active Fuel Management (AFM) Install AFM oil deflector and clean carbon from cylinder Perform repairs without doing an oil consumption test first 10-06-01-008A 2007-2011 Acadia, Enclave, OUTLOOK, Traverse Front driver power seat inoperative, driver seat will not move forward/backward Replace the motor drive cable Replace the seat adjuster assembly 07-08-50-013A December 2010 9 Customer Care and Aftersales