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2002 and 2003MY Impreza WRX models registered in 16 “cold weather” states located in NOAA Climate Zone 1. The affected states are: Alaska, Colorado, Iowa, Idaho, Maine, Michigan, Minnesota, Montana, North Dakota, Nebraska, New Hampshire, New York, South Dakota, Vermont, Wisconsin, and Wyoming. In extremely cold temperatures, a certain engine fuel line/hose may temporarily seep some fuel during initial cold engine start up. If this condition occurs, vehicle occupants may notice the smell of fuel. To correct this condition, affected vehicles will require replacement of the engine fuel delivery line and hose. A special repair parts kit is available and contains all parts needed to complete this repair.

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ISSUE Some 2003-2007 F-Super Duty vehicles, 2003-2005 Excursions and 2004-2010 E-Series vehicles, equipped with a 6.0L diesel engine may exhibit hard start, no start, white smoke, lack of power, running rough condition after cold engine start up, or diagnostic trouble codes (DTCs) P0404, P0470, P0611, P1260 and/or P1378 issues. Refer to the Calibration Content for information detailing specific vehicle content by vehicle application and model year that is being addressed by this calibration update. This article includes previously released calibration content that improves injector performance in cold engine operation and additional diagnostic capabilities and product protection strategy enhancements. These enhancements provide additional diagnostic capabilities, adds additional new DTCs and engine protection strategies. Refer to the Calibration Content for additional details. See the appropriate Powertrain Control/Emissions Diagnostic (PC/ED) manual for technical descriptions and diagnostic routines associated with new DTCs. ACTION Reprogram the powertrain control module (PCM) using IDS release 63.13 and higher or 64.01 and higher. The transmission control module (TCM) and fuel injector control module (FICM) , will automatically update if they are not at the latest calibration level. This new calibration is not included in the VCM 2009.11 DVD. Calibration files may also be obtained at www.motorcraft.com.

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Model(s): 1994-95 Buick Regal 1994-97 Buick Skylark 1994-98 Buick Century 1994-95 Chevrolet Beretta Corsica, Lumina, Monte Carlo 1996-98 Chevrolet Venture 1997-98 Chevrolet Malibu 1993-97 Oldsmobile Cutlass Supreme 1994-96 Oldsmobile Cutlass Ciera 1994-97 Oldsmobile Achieva 1996-98 Oldsmobile Silhouette 1997-98 Oldsmobile Cutlass 1994-98 Pontiac Grand Am, Grand Prix 1996-98 Pontiac Trans Sport with 3100, 3400 V6 Engine (VINs M, E – RPOs ticking type noise that begins shortly after cold engine start-up and gradually diminishes as the engine warms up. In most cases, the noise is gone after five (5) minutes. In severe cases, the noise may not disappear when lhe engine is hot. Under normal design tolerances when the piston pin bore is produced at the maximum tolerance and the piston pin is produced at the minimum tolerance (min-max tolerance) trace noise levels can occur. This level of noise does not affect the reliability or durability of the product. If piston-to-pin noise is detected and the customer desires the condition to be corrected, replace all six pistons with pin assemblies. The new piston sets have a minimal piston-to-pin clearance. Remember, piston-to-pin noise occurs in both park and drive at engine idle rpm and it varies in intensity depending on the number of pistons involved. A ticking sound means one piston is affected whereas a rattle or diesel type sound indicates more than one piston affected. The following should also be checked: 1. On W-Cars, make sure the right side engine splash shield is not contacting the engine crankshaft balancer. This condition usually happens cold and is caused by the shield curling when cold. 2. Reference Service Bulletin 57-71-06 for transmission rattle noise often confused for engine rattle noise. 3. Reference Service Bulletin 47-61-36 for Accessory Drive Belt Tensioner noise. 4. Check cylinder bore diameter and piston diameter as outlined in the Service Manual.

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IPR% higher than expected. Stall shortly after cold start may also be a symptom. Prior to diagnosing a vehicle with a P1211, fuel pressure should verified. This indicates a smaller leak in the high pressure system. Using the same block off plugs described earlier to block off one bank and observing IPR% when engine is running on each bank at similar rpms. Higher IPR% on one bank compared to the other would indicate a leak on the higher IPR% bank. Example: Repair as needed after locating leak as described in visual inspection in previous routing. 4.) Diagnosing P1211 With IPR% Less That 8 at IdleA worn lube oil pump can negatively affect ICP system’s performance in the following ways. Cold engine, abnormal long crank to start. (Oil pressure gauge in dash moves immediately prior to start.) Cold engine, start then stall – then long crank to restart. (Oil pressure gauge in dash moves immediately prior to start.) These symptoms are often mis-diagnosed as high pressure oil (ICP) concerns. Both symptoms may be caused by wear in lube oil pump or thick oil (poor maintenance). Pump wear causes a decrease in pump efficiency. Cold, thick oil becomes to move. Any lube oil system failure can negatively affect the performance of the ICP system.

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Fig. 2 Balance shaft drive & camshaft drive exploded view. 1. Drain coolant from cold engine by setting heater control lever to warm position and unscrew drain plug 2. Disconnect negative battery cable. 3. Remove air cleaner assembly. 4. Remove lower radiator hose. 5. Remove accessory drive belts. 6. Remove upper and lower front timing belt covers Water Pump Assembly
15. Remove water pump retaining bolts and remove water pump.
16. Exchange parts on water pump as necessary.
NOTE: Check the condition of the balance shaft and the camshaft seals. Replace as necessary.