The Pre-Delivery Inspection (PDI) form has been revised, and so has the process for using it (US only) (fig. 1). In addition to this TechLink article, the new PDI form and process will be introduced and explained through several other media, including:

- A "meeting-in-a-box" that will cover New Vehicle Receiving, Pre-Delivery Inspection, and Completely Satisfied Delivery System (CSDS) processes. The kit will be sent to both wholesale and retail personnel in the near future.

- Edge magazine article

- Service Bulletin

- GM Messenger message

- Emerging Issues IDL

Here are the highlights.

Old Form

For background, here are some facts about the outgoing form and process.

Except for Saab and Medium Duty trucks, one common PDI form covered all makes and models.

The PDI form was shipped in the vehicle with the Owner’s Information Package

The PDI form had a GM part number, so changes required an extensive process

New Form

TIP: The paper form will continue to be shipped with the vehicle for the remainder of the 2007 model year. However, dealers will be expected to use the new electronic version as soon as it becomes available. Area Service Managers will be checking for compliance during their PDI reviews.

The paper PDI form is replaced with an electronic version that is specific for year, make and model. (fig. 2)

The electronic form can be changed readily.

The new form will be delivered through DealerWorld on the Service tab, under Pre-Delivery Inspection Forms. The forms will be listed in alphabetical order by make and model.

The new form will include both base inspection content (common for all vehicles), and Special Inspection Items, which vary by make and model, and will change over time.

TIP: Because the PDI form is specific to each make and model, and is subject to change without notice, do not print out a large quantity of forms in advance. They may become obsolete before you use them up.

Special Inspection Items allow GM to address emerging issues before vehicle delivery to the customer. These items are not intended to add labor time to the PDI process but are meant to emphasize items needing special attention or to inform of a potential quality concern.

TIP: If repairs are required, submit a claim under the normal warranty process per the bulletin number referenced with the Special Inspection Item.

The order of the PDI steps has changed to more closely match the way an actual PDI is performed at the dealership:

Initial Preparation, Interior, Exterior, Under Hood, Under Vehicle, Road Test, Special Inspection Items, Final Inspection and Preparation

Several inspection items were eliminated:

- Check neutral start safety switch

- Check horn

- Check child comfort guide – elastic cord visible

- Check trunk safety release

- Erase all messages on voice recorder

A number of inspection items were re-worded to provide clarification, including:

- OnStar® – verify that the function indicator light is green rather than checking for connectivity by pushing the blue button

- Compass – specifies the need to calibrate after setting the correct zone

- Cleaning glass surfaces – indicates using plain water to clean interior glass

Several items were added to improve vehicle quality at the time of delivery to the customer:

- Check remote start

- Check heated and cooled seats and steering wheel

- Insert Navigation system map disc and set to the correct region

- Recheck tire pressures and battery state of charge just before delivery to the customer

- Check GM Vehicle Information System (VIS) for required field actions (open recall campaigns, product enhancement bulletins, systems software updates)

Key Benefits

Increased attention to potential customer dissatisfiers (the Special Inspection Items) should lead to:

- Improved customer satisfaction with the vehicle at the time of delivery as measured by GM’s Customer Satisfaction Index (CSI) survey.

- Improved customer satisfaction with the vehicle’s initial quality as measured by the J.D. Power Initial Quality Study (IQS) survey 90 days after delivery.

- Thanks to Diana Sancya

When performing Pre-Delivery Inspection (PDI) on a vehicle equipped with OnStar®, the PDI form says to “check OnStar for connectivity.” Typically to do this, the PDI technician presses the blue OnStar button to place a call to OnStar. This results in numerous unnecessary phone calls.

To check for OnStar system function, DO NOT press the blue OnStar button. Instead, turn on the ignition and check the OnStar indicator. If it is illuminated and shows green, this is evidence that the OnStar components are connected and all diagnostics have been passed. If the indicator turns red, or will not illuminate, there is a problem with the OnStar system.

TIP: On vehicles with the OnStar buttons on the rear view mirror (fig. 3), the indicator light is usually to the right of the buttons. On vehicles with OnStar buttons not located on the mirror (fig. 4), the indicator light is usually to the left of the buttons.

TIP: If you are setting up OnStar service for a customer, it is necessary to press the OnStar button as a part of that procedure.

- Thanks to Diana Sancya

This information applies to the 2004-07 Cadillac CTS, SRX, STS, XLR and Buick Allure, LaCrosse and Rendezvous with LY7 3.6L, LP1 2.8L V6, LH2 4.6L V8, or LC3 4.4L V8 engines.

When diagnosing concerns with oxygen sensors on these vehicles, observe these points:

1. Malfunctioning oxygen sensors will set a sensor-related diagnostic trouble code. Do not replace the oxygen sensor unless diagnosis following the appropriate document in SI indicates that the oxygen sensor should be replaced.

For example, do not replace the oxygen sensor if diagnostic trouble codes P0420 or P0430 for catalyst efficiency are present alone.

2. When replacing the catalytic converter, do not replace the oxygen sensor. Transfer the oxygen sensor from the old converter to the new converter.

3. Oxygen sensors that are damaged due to underbody impact are not covered under the new vehicle warranty.

4. DO NOT cut the wires of the oxygen sensor when replacing it.

- Thanks to Dave Dickey

On some 2007 full-size utilities, the driver’s outside mirror (either power fold or manual fold) may vibrate or shake while driving. According to bulletin 06-08-64-027, this may be caused by one of the following:

- Loose glass actuator (motor)

- Power folding mirror (RPO DL3) assembly may have been folded or unfolded manually or the mirror was accidently obstructed while power folding.

Repair

With the power fold option, cycle the mirror three times.

With the manual fold mirror, manually fold/unfold the mirror three times.

With either mirror, check the mirror for stability, performance and vibration. If folding the mirrors three times does not improve stability, remove the glass assembly per document 1694905.

Check tightness of the four glass actuator screws shown in document 1731190. Torque 10-14 in lbs (1.13-1.16 Nm)

Bend the metal spring finger up approximately 1/2 inch (12.7 mm) to increase engagement to the housing.

Install the glass assembly.

TIP: Be careful not to allow the spring finger to unseat from its intended track in the mirror housing.

Check for stability, performance and vibration. If stability is not improved, replace the mirror assembly per document 1740757.

- Thanks to Paul Radzwilowicz

2007 Cadillac Escalade models equipped with a SuperNav Radio (RPO U3R) and the factory video system (RPO U42) have a parental control system. The rating level limits playing DVDs with a certain rating. The rating selections are 1 through 8, with 1 (kid safe) being G rated. To change the rating level, press the Parental Level button, then press the Password button. Type in the password, then change the rating level.

If the password has been forgotten, follow this procedure.

1. Place a store-bought DVD into the SuperNav Radio.

2. When the DVD screen appears, press the Options softkey on the upper left part of the screen. Then select the Setup softkey on the bottom of the screen.

3. Select the Settings box and then the Parental Level box.

4. Press and hold the box labeled Number 8 for 10-15 seconds until a audible beep is heard from the radio.

5. The security code is erased. You now have the option to input a new security code or leave the parental controls unsecured.

- Thanks to Paul Radzwilowicz

Some 2000-05 Cadillac DeVilles may make an audible moan/squawk noise during low speed turning manuevers such as parking lots, driveways, etc. This condition may be due to power steering gear valve instability resulting in a pressure disturbance, which creates the audible noise. The noise is transferred to the vehicle structure through the steering column.

To correct, replace the power steering gear return hose assembly (p/n 15839169). For further details, refer to bulletin 02-02-32-001C (SI document 1846919).

- Thanks to Bill Denton

A 2006 Chevrolet Impala or Monte Carlo with 3.5 LZE engine may exhibit a crank-no-start or a start and stall concern. There may or may not be a DTC.

Remove the camshaft position actuator magnet and check for the pin in the center of the actuator being spring loaded. If the pin is not spring loaded, it may not be making contact with the center of the magnet, causing the concern. Replace the cam actuator and retest.

- Thanks to Ron Mitchell

In September 2005, the orifice tube used in AC systems in full-size utilities changed to a design called a porous plastic orifice tube (PPOT) (fig. 6). Pickups adopted the design mid-year 2006. It is quieter than the traditional orifice tube.

The orifice tube separates the high pressure portion of the AC system from the low pressure portion. Refrigerant passing through the orifice tube sometimes causes an audible noise, described as a gurgle or water spattering.

In the porous orifice tube, noise muting is provided by a granular polypropylene plastic filter, which looks somewhat like melted wax. This is normal appearance for the porous orifice tube, and is not a defect.

TIP: The tube may change color after being subjected to oil and refrigerant and used for some time.

TIP: Bulletin 06-01-38-002 explains how to replace the liquid line on certain full-size truck and utility models for noise concerns. The larger tube in the bulletin incorporates the porous orifice tube mentioned above.

- Thanks to Dave Roland and Frank Rogers

When replacing the rear differential clutch packs in a 2006-2007 XLR and Corvette Z06, you may find a 5 plate clutch pack. SI also mentions a 5 plate pack, but service parts come as a 4 plate pack.

A change to carbon fiber clutch plates in these models, which increased overall thickness, makes it necessary to reduce the stack to 4 plates. The correct stack using the new design plates is 4 plates and will not affect performance.

TIP: This change does not apply to the normal Corvette.

- Thanks to Charles Krepp

Some owners of a 2004-05 Chevrolet Silverado or GMC Sierra with 6.6L RPO LLY engine may comment that the SES MIL is on. When DTCs are checked with the Tech 2, a U0100, U0101, U0105, and/or U0106 will be set.

The ECM, TCM, FICM, and Glow Plug Controller communicate among each other on circuits 2361 and 2362 (CAN Bus). The Tech 2 does not communicate on these circuits.

In most cases, if all of the listed DTCs are set, the CAN Bus circuits may be shorted to ground at the FICM/generator bracket. Before replacing any parts, perform a thorough visual inspection of the wiring harness near the FICM/generator bracket and repair as necessary if shorted.

- Thanks to Jim Will

The 2000-2006 full-size utility truck Electronic Suspension Control Module Replacement procedures in SI have been revised. The revisions made were to the programming procedures or links to the programming procedures.

TIP: When replacing the ECU you must reprogram with the latest software.

- Thanks to Dan Stress and Gary G. Clark

Bulletin 06-01-39-007 explains that impurities have been found in new commercially available containers of R134a.

Contaminants may cause decreased performance and be detrimental to some air-conditioning components.

Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance.

The Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. It is recommended to use GM or ACDelco sourced refrigerants for all A/C repair work. These refrigerants meet GM internal standards for quality and purity.

See the bulletin for more details.

- Thanks to Jerry Garfield

This information applies to the 2005-07 Chevrolet Corvette and Cadillac STS and 2004-07 Cadillac XLR.

A no crank, no start condition with a Driver Information Center (DIC) message that displays "No FOB Detected" can be caused by a low battery state of charge (SOC). The Remote Control Door Lock Receiver (RCDLR) will not function if the battery SOC is below 9V.

TIP: To enter the Corvette, use the conventional key in the cylinder above the license plate to open the hatch. On the XLR, the key cylinder is located behind a cover on the lower rear fascia. Then use the door release tab inside the trunk to unlatch the driver’s door. For the STS, just unlock door with key in conventional fashion.

Check the battery state of charge and if low, diagnose the cause of the weak battery before performing any other repairs.

- Thanks to Dino Poulos

This information applies to all 2006-07 passenger vehicles with 4T65E transmissions. The vehicle may exhibit:

- DTC P0742: Torque Converter Clutch (TCC) System - Stuck On

- DTC P2764: Torque Converter Clutch (TCC) Pressure Control (PC) Solenoid Control Circuit Low Voltage.

Perform the diagnosis as indicated by SI. If unable to control TCC with the Tech 2, suspect tan wire (ckt 418) shorted to ground. Follow appropriate SI instructions to access the transmission side cover to allow inspection of the internal wiring harness routing. PWM wiring should not be around the clip (fig. 7) in the valve body. If the PWM wires are routed around the clip, remove and inspect for chafe or pinch. And correct the wire routing (fig. 8).

- Thanks to Ron Mitchell

These part numbers for the recovery loop replace the table in the Recovery Loops article in the September 2006 issue of TechLink.

On 1999-2007 full-size trucks, in order to avoid HVAC actuator damage, DO NOT apply power to the actuator when it’s not installed in the HVAC module.

- Thanks to Robert Tette and Art Krygowski

Removal vs. Replacement

In the Engine Mechanical subsections of SI, and within the Repair category, there are two sets of procedures.

Replacement procedures can be performed on-vehicle.

Removal and Install are off-vehicle procedures.

Note that the off-vehicle procedures usually begin after Engine Oil and Oil Filter Replacement. But many off-vehicle procedures can be performed on vehicle, too; for instance, replacement of a cylinder head.

Some Examples

The procedure titled Crankshaft and Bearings Removal is not a complete procedure. Other procedures must be performed first (engine removal, for instance) but not all those listed before this procedure.

The same is true for Crankshaft and Bearings Install. Other procedures must be performed before and after (engine installation, for instance) but not all that are listed.

The off-vehicle procedures are listed in an order for a complete engine disassembly and assembly. In the case of crankshaft replacement, service engineers assume that a reasonably trained and experienced technician knows the basics of engine service, and therefore knows what is required, beginning with engine removal from the vehicle.

In the near future, engine repair procedures will receive additional titles in SI. Replacement procedures will be titled On-Vehicle. Removal or Install procedures will be titled Off-vehicle, or perhaps Unit Repair.

- Thanks to Jerry Garfield

On some 2003-06 Chevrolet SSRs, aftermarket window tint may tear or have vertical scratches. This is noticed primarily when the window travels full up or down.

Because the upper doors have no A-frame or upper door channel like most vehicles, there are guide pads in the door to support the glass. These guide pads make contact with the glass during the vertical movement of the glass, which may damage aftermarket window tint.

GM does not recommend or support the use of any aftermarket tint in any GM vehicle. The aftermarket tint should be removed to correct this concern.

- Thanks to Ron Erman

Some owners of 2007 full-size utilities with RPO AN3 may comment that they are unable to set a personalized easy exit seat position and the seat will move back only a predetermined amount.

Unlike the previous model years, the new 2007 utilities move the seat rearward approximately 3 inches when the easy exit feature is activated. If the owner wishes to have the seat move back further, the exit button can be pressed and the seat will move back an additional 3 inches for each press until the seat is all the way back. Please advise owners with this concern of the new operating characteristic.

- Thanks to Jim Will

Owners of some 2007 full-size utilities with RPO U3U or UVB may comment that the navigation radio volume control does not function and seems to be stuck at a very loud level. This may occur after the radio has been repaired or replaced in service.

If the incorrect radio calibration is selected in TIS, the navigation radio may experience a loss of volume control. To repair the concern, reprogram the navigation radio referencing the correct RPO options of the vehicle, to verify the radio is programmed correctly.

- Thanks to Paul Radzwilowicz

This information applies to all 2000-07 passenger vehicles with a 4T65E transmission.

The vehicle may exhibit a whine noise in Park or Neutral, which is gone when in Drive when not moving.

Shift to Drive, apply the brakes and raise the engine rpm. The noise should diminish (may not go away). If the noise is diminished or eliminated, suspect the drive or driven sprocket support bearings, or gear bearing. The most common cause is the drive sprocket support bearing.

Visually inspect the drive sprocket support needle bearing for spalled needle rollers (fig. 9).

Replace the drive sprocket support item 522 (includes 521/523).

Follow appropriate SI repair steps to access the drive and driven sprocket supports for inspection and if the condition is found, replace the appropriate parts.

- Thanks to Ron Mitchell

Owners of some 2007 full-size utilities with manual HVAC controls (RPO CJ3) may experience a low coolant level message on the DIC at times. These vehicles are not equipped with a low coolant level sensor. The low coolant level message may appear due to a software anomaly with the manual HVAC control head (RPO CJ3).

Do not replace the instrument panel cluster or HVAC control head to resolve this concern. Reprogram the HVAC control head with updated calibrations. This new service calibration was released with TIS satellite data update version 6.0, available May 30, 2006.

As always, make sure your Tech 2 is updated with the latest software version.

- Thanks to Paul Radzwilowicz

This information applies to the 2007 full-size utilities and the 2005-07 Chevrolet Silverado Classic and GMC Sierra Classic (1500 models).

Some owners may comment on a scored appearance of the front brake rotors. Scoring could be caused by the formula of the front brake lining, which has ingredients to clean rust from the rotor braking surface. This cleaning feature of the rotor braking surface may have a side effect of scoring.

This scored appearance is normal as long as no other symptoms are experienced, such as pulsation, roughness, or noise, and the scoring does not exceed the specification in SI document 1476240.

- Thanks to Jim Will

There are times when being able to quickly obtain a needed service part is critical -- a customer’s vehicle is down -- and the normal order/supply process has to be expedited. This is a task for the Service Parts Assistance Center (SPAC).

TIP: It’s a good idea to try to obtain the part locally before contacting SPAC.

When a part is needed on an urgent basis, your dealership Parts Manager or other representative will upgrade the order to a SPAC Case using RAPID (EPIC in Canada), TRACS or EPIC (VIN is required).

SPAC Parts Escalation

When a parts situation is extremely urgent, Bulletin GMP05-135 explains how to follow up on a SPAC case. Your inquiry will be escalated through a defined process. Here are some highlights. Refer to the bulletin for details.

The dealership representative should initially call TRACS or access RAPID or EPIC for an update. If no information is available, the dealership representative should choose to speak to a Dealer Call Center agent. The agent will access the SPAC case database and provide the caller with the latest information.

If the information is not adequate, the dealership representative may ask that an inquiry be sent to the Service With Action Team (SWAT) for further investigation.

SWAT will respond to the dealership within 48 hours, based on SPAC's past history for case resolution. Approximately 68% of all SPAC cases are resolved within 48 hours.

TIP: Parts Managers may inquire and escalate their concerns immediately, based on the urgency of their situation.

Under normal circumstances, 48 hours gives adequate time for the case to navigate through the D2D Express process as well as allow for the expedition and processing of any in-transit inventory to an SPO facility.

- Thanks to Dave Gibson

This information applies to the 2005-06 Chevrolet Express, Silverado, Suburban, Tahoe, GMC Savana, Sierra, Yukon equipped with a 4.8, 5.3 or 6.0 engine.

The engine may intermittently stall, misfire, or crank without starting. There may be no trouble codes set.

Complete the SI diagnostics for any symptoms or trouble codes found. If diagnostics are inconclusive, and an intermittent stall, misfire, or a crank no start can be duplicated, inspect for a loss of Ignition 1 voltage to the ignition coils.

Wiggle test the ignition coil harnesses to see if the concern can be duplicated. Inspect splices S160 and S159 for loose connections. Also inspect connectors C148 and C149 for wires breaking near the connector. The pink Ignition 1 power feed wire may break inside the insulation near connector C148/C149.

- Thanks to Don Langer