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2004-2006 Chevrolet Malibu Maxx Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning

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Filed Under (Chevrolet) by admin on 21-01-2011

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Subject: Clunk, Knock or Rattle Noise From Front of Vehicle While Driving or Turning Over Bumps at Low Speeds (Diagnose Noise and Perform Outlined Repair) Models: 2004-2006 Chevrolet Malibu Maxx 2004-2008 Chevrolet Malibu Classic 2008-2010 Chevrolet Malibu 2005-2010 Pontiac G6 2007-2010 Saturn Aura Supercede: This bulletin is being revised to update the models years and revise the information for Correction 2. Please discard Corporate Bulletin Number 06-02-32-007E (Section 02 – Steering). Condition 1 Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel. Cause 1 The clunk noise may be caused by a slip/stick condition between the inner and outer components of the intermediate shaft. Important Revised design intermediate shafts went into production in the 2009 model year and are the only design currently available through GMSPO since approximately September 2008. Since any model year vehicle could have had a second design shaft installed, it is critical to identify it before proceeding. The revised design intermediate shafts will NOT tolerate any type of lubricant per the following instructions. Adding lube to the second design shafts will cause a clunk noise in a very short period of time. Use the following pictures to identify which design of shaft you are servicing. Electric Assist Power Steering

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2006 Dodge RAM 2500 DENSO A/C COMPRESSOR REMOVAL

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Filed Under (Dodge) by admin on 05-07-2010

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NOTE: The compressor clutch assembly can be serviced with the refrigerant system fully-charged. Typical A/C compressor shown in illustrations. 1. Disconnect and isolate the negative battery cable. 2. Remove the accessory drive belt. 3. Disconnect the engine wire harness from the compressor clutch field coil connector (1) located on the top of the A/C compressor (5). 4. Remove the bolts that secure the A/C compressor to the engine and support the A/C compressor. 5. Carefully remove the compressor clutch field coil connector and wire lead from the connector bracket (2). 6. Remove the compressor shaft bolt (3). A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate (4) from rotating during bolt removal. CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as this may damage the clutch plate. NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process. 7. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3). 8. Using snap ring pliers (2), remove the snap ring (1) that secures the pulley and bearing assembly (3) to the front of the A/C compressor and remove the pulley and bearing assembly. 9. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), remove the snap ring (4) that secures the compressor clutch field coil (2) to the front of the A/C compressor (3) and remove the field coil. INSTALLATION NOTE: Typical A/C compressor shown in illustrations.

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2007-2008 Dodge Ram 2500/3500 Cummins 6.7L Diesel Turbocharger – Necessary System Inspections And Tests

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Filed Under (Dodge) by admin on 06-01-2011

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SUBJECT: Cummins 6.7L Diesel Turbocharger – Necessary System Inspections And Tests OVERVIEW: This bulletin involves the inspection and/or test of the Diesel Turbocharger and related emissions system components. The customer may experience a Malfunction Indicator Lamp (MIL) illumination. Additional diagnosis may reveal that the MIL is due to Diagnostic Trouble Code (DTC): P2262 – Turbocharger Boost Pressure Not Detected – Mechanical. DIAGNOSIS: 1. Connect the StarSCAN® to the Diagnostic Link Connector (DLC). 2. Set the parking brake. Start the vehicle engine. 3. From the “Home” screen on the StarSCAN® select: a. “ECU View” button. b. “PCM Powertrain Control Module” button. c. “View DTC’s” button. 4. Record all Diagnostic Trouble Codes (DTC’s) that are present in the PCM. NOTE: It is IMPORTANT to record (capture) all DTC’s present in the PCM prior to proceeding further with this diagnosis. Procedures later may cause all DTC’s to be erased. 5. Is DTC P1451, P2463, or P242F present in the PCM? a. If YES >>> STOP. Refer to Service Bulletin (SB) 11-002-07 (or later bulletin) to address this concern and before proceeding further with this Service Bulletin. In addition to other repairs, SB 11-002-07 may direct the technician to perform a thorough cleaning of Engine and Exhaust Aftertreatment System components. Contact STAR if additional assistance is required. Proceed to the next step ONLY after SB 11-002-07 has been reviewed and/or performed. b. If NO >>> then proceed to the next step. 6. Verify that the PCM is at the latest application software level. 7. Is the PCM at the latest application software level? a. If YES >>> then proceed to the next step. b. If NO >>> then reprogram the PCM to the latest software level. Refer to SB 18-013-08 (or later bulletin). Proceed to the next step ONLY after the PCM has been reprogrammed to the latest software level. 8. Was DTC P2262 present in the PCM?

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2006 Dodge RAM 1500 P2122-ACCELERATOR PEDAL POSITION SENSOR

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Filed Under (Dodge) by admin on 04-05-2011

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brake pedal is pressed or has failed. Acceleration rate and Engine output are limited. One trip fault and the code will set within 5 seconds . ETC light is flashing. POSSIBLE CAUSES (F855) 5-volt supply circuit open (F855) 5-volt supply circuit shorted to ground (K23) APP sensor no.1 signal circuit open (K23) APP sensor no.1 signal circuit shorted to ground (K23) APP sensor no.1 signal circuit shorted to the (K167) APP sensor no.1 return circuit (K23) APP sensor no.1 signal circuit shorted to the (K400) APP sensor no.2 return circuit APP sensor PCM Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. DIAGNOSTIC TEST 1. APP SENSOR BELOW 0.25 OF A VOLT Ignition on, engine not running. With a scan tool, read the APP Sensor No.1 voltage. Q: Is the voltage below 0.25 of a volt? YES: Go To 2 NO: Go To 11 2. (F855) 5-VOLT SUPPLY CIRCUIT WHEN MONITORED: With the ignition on and no other APPS No.1 DTCs present. SET CONDITION: When the APP Sensor No.1 voltage is too low. Engine will additionally idle if the Turn the ignition off. Disconnect the APP Sensor harness connector. Ignition on, engine not running. Measure the voltage on the (F855) 5-volt Supply circuit in the APP Sensor harness connector. Q: Is the voltage between 4.5 and 5.2 volts? YES: Go To 3 NO: Go To 8 3. ACCELERATOR PEDAL POSITION SENSOR

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2002 Dodge RAM 1500 Steering Column REMOVAL

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Filed Under (Dodge) by admin on 10-07-2010

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WARNING: BEFORE SERVICING THE STEERING COLUMN THE AIRBAG SYSTEM MUST BE DISARMED. REFER TO RESTRAINT SYSTEMS FOR SERVICE PROCEDURES. FAILURE TO DO SO MAY RESULT IN ACCIDENTAL DEPLOYMENT OF THE AIRBAG AND POSSIBLE PERSONAL INJURY. CAUTION: All fasteners must be torqued to specification to ensure proper operation of the steering column. 1. Position the front wheels straight ahead. 2. Disconnect the negative (ground) cable from the battery. 3. Remove the two switches from the steering wheel. 4. Remove the airbag. 5. Remove the steering wheel with special tool CJ98-1 or an appropriate steering wheel puller. CAUTION: Ensure the puller bolts are fully engaged into the steering wheel and not into the clockspring, before attempting to remove the wheel. Failure to do so may damage the steering wheel/clockspring. 6. Remove the steering column opening cover. 7. Remove the tilt lever. 8. Remove the column shrouds. 9. Remove the clock spring. 10. Disconnect the wiring harness to the column. 11. Remove the shift cable from the column shift lever actuator.. 12. Release the shift cable from the column bracket and remove it from the bracket. 13. Remove the SKIM module in order to disconnect the electrical connector.

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