Kappa Performance Forum

Kappa Specific => 2.0L Ecotec Engines => Topic started by: Kuprito on January 22, 2011, 06:17:46 AM

Title: The Intercooler Thread
Post by: Kuprito on January 22, 2011, 06:17:46 AM
Now we have:

RPI
(http://raceprecision.com/products/images/sky_redline_intercoolers/rpi_intercooler_001.jpg)

Dejon New design
(http://solstice.dejonpowerhouse.com/edit/1-02-SS-FIC.jpg)

Hahn
(http://www.turbosystem.com/New_Folder/SolsticeGXPRedline/CIMG0037.JPG)

DDM
(http://www.ddmworks.com/sol_sky_pics/lnf_intercooler/lnf_intercooler_vs.jpg)

Werks Race (The only one with 3" tubes)
(http://www.performanceautowerks.com/catalog/images/Huge.JPG)

Werks Street
(http://www.performanceautowerks.com/catalog/images/DSC03950.JPG)

EDS Technik
(http://eds-motorsport.de/shop/media/images/popup/gt_llkk1.png)
(http://eds-motorsport.de/shop/media/images/popup/opel_gt_llk_eingebaut_ohne_sst.jpg)

Stock
(http://i52.tinypic.com/35n97ac.jpg)


DDM 27" x 8" x 3.375"  895$ -150$ Sale = 745$ right now
Hahn 27" x 8" x 4"  899$
Werks Street 24" x 8" x 3.5"  599$
EDS Motorsport 23.7" x 7.9" x 3.95" 699€
Werks Race 24" x 15" x 3" 1499$
Dejon 24" x 8" x 3.5"  699$
Race Precison ??????  1099$
Title: Re: The Intercooler Thread
Post by: Kelu on January 22, 2011, 06:25:47 AM
Now we have:

EDS Motorsport 23.7" x 7.9" x 3.95" 699€
EDS means $950 but you have lowest shipping tax and no customs issues

I would give up on RPI because I didn't saw them active anymore in Kappa world.
I have Dejon and I tested it in all conditions possible and it was great in last 2 years.
I think it's a personal call between: DDM, Hahn, Werks and EDS
Title: Re: The Intercooler Thread
Post by: kennysabarese on January 22, 2011, 11:27:34 AM
Use the garrett website to determine how large of an IC you need for your desired power level.

http://www.turbobygarrett.com/turbobygarrett/tech_center/turbo_optimization.html (http://www.turbobygarrett.com/turbobygarrett/tech_center/turbo_optimization.html)
Title: Re: The Intercooler Thread
Post by: Arabas on January 22, 2011, 11:32:26 AM
i wouldn't go for EDS...
it takes 3-4 weeks to get it shipped. you know that they are not fabricated by EDS, right? it's an outsourcing product...
i would go for the DDM + pipes.

Title: Re: The Intercooler Thread
Post by: HAMMER DOWN on January 22, 2011, 09:33:22 PM
My Hahn IC was installed with only two minor modification.

1\8" spacer
(http://i99.photobucket.com/albums/l293/HAMMERDOWNGT/GXP/0707081350.jpg)

Elongate holes 3\16" at the top of the bracket.
(http://i99.photobucket.com/albums/l293/HAMMERDOWNGT/GXP/0707081329.jpg)

Pic. after Install.
(http://i99.photobucket.com/albums/l293/HAMMERDOWNGT/GXP/0707081348.jpg)

Mike
Title: Re: The Intercooler Thread
Post by: spider on January 23, 2011, 09:14:00 PM
I wouldn't get the ddm one based soley on their misleading photo sitting below a seemingly tiny hahn one. I have a Hahn it aint small.
Title: Re: The Intercooler Thread
Post by: SKY888 on January 25, 2011, 10:35:28 AM
The Hahn IC is built like a rock!  Very smooth end tanks...which is awesome.  I like it a lot.  Never had any issue with it after 2 years of usage.  

I sold it tho.....since I upgraded to WERKS Race IC which is bigger/better for my build :)



Title: Re: The Intercooler Thread
Post by: Dave@DDMworks on January 25, 2011, 03:14:53 PM
I wouldn't get the ddm one based soley on their misleading photo sitting below a seemingly tiny hahn one. I have a Hahn it aint small.

Wow, thanks for letting us know that. It was not meant to be misleading at all, we just set them both on the ground and took that picture to show the difference between the bar and plate and the extruded core and the number of rows. Sorry if anyone thought it was misleading, I will have them take some new pictures, in the mean time I had Ivy remove that picture from our site.

Thanks,
Dave
Title: Re: The Intercooler Thread
Post by: Go-N Def on January 25, 2011, 03:50:26 PM
I wouldn't get the ddm one based soley on their misleading photo sitting below a seemingly tiny hahn one. I have a Hahn it aint small.
If anything, the DDM is slightly more narrow than the Hahn.  I just installed the DDM and it fit like a glove, a very tight glove, but a glove none the less.  I didn't have to modify anything to make it fit either.
Title: Re: The Intercooler Thread
Post by: spider on January 25, 2011, 07:05:29 PM
Wow, thanks for letting us know that. It was not meant to be misleading at all, we just set them both on the ground and took that picture to show the difference between the bar and plate and the extruded core and the number of rows. Sorry if anyone thought it was misleading, I will have them take some new pictures, in the mean time I had Ivy remove that picture from our site.

Thanks,
Dave


Thanks Dave. Glad to hear it was an oops. I have heard nothing but delight in regard to your products, just thought that photo was...cheers!
Title: Re: The Intercooler Thread
Post by: SKY888 on January 25, 2011, 09:55:21 PM
for more than 3 years that I've been to the three kappa forums, I've never seen any DDM staff talk bad to any other non-ddm products......nor try to  purposely be deceiving.   DDM is one of the most respectable vendors out there that I admire.  Their products are great, and I personally never had any issues with them.

The DDM intercooler is one of the best out there, period! :)

Title: Re: The Intercooler Thread
Post by: Critterman on January 26, 2011, 03:08:30 PM
I have to agree with SKY, a quick look at my signature will show how I feel about their workmanship, quality and customer service. 

Enough said.
Title: Re: The Intercooler Thread
Post by: Graywolf on January 26, 2011, 10:50:58 PM
Nice thread,Ihave had a Hahn IC and it is excellent. I recently ordered some stuff from DDM oil catch can ,excellent quality, prompt shipping. I strongly suggest that you fabricate a piece of angle iron or aluminum to go underneath your intercooler for protection. 
Title: Re: The Intercooler Thread
Post by: DirtyMike on January 27, 2011, 11:32:48 PM
anyone thought of making your own?... buy a core, endtank ect... bolt it on and done
Title: Re: The Intercooler Thread
Post by: joshmass on January 28, 2011, 11:28:23 AM
Here's a shot of the stock intercooler compared to the Werks Street FMIC with black thermal coating.

http://www.flickr.com/photos/43695877@N05/5395281903/ (http://www.flickr.com/photos/43695877@N05/5395281903/)

(http://farm5.static.flickr.com/4145/5395281903_74865f2114_b.jpg)
Title: Re: The Intercooler Thread
Post by: SKY888 on January 28, 2011, 03:53:24 PM
anyone thought of making your own?... buy a core, endtank ect... bolt it on and done

the garrett cores are not bad in prices.

I'm not sure about getting the endtanks and having them fabbed for our application....how much they'll cost?

If you find a great fab guy/welder who'll do it cheap, big garrett core......then you're golden! :)

Title: Re: The Intercooler Thread
Post by: Go-N Def on February 11, 2011, 09:31:01 AM
After the install, did you notice any performance gains?
It's kind of hard to tell for me.  I had not driven the car for 7 months before installing it.
Title: Re: The Intercooler Thread
Post by: snaponbob on February 11, 2011, 10:15:25 AM
In SCCA Solo B/SP, an aftermarket IC is legal. Trimming ANY body panels or interior pieces is NOT legal. Some folks above stated that no modifications were required. So .......... can those that have installed I/Cs verify that no mods were needed (besides those elongated holes in brackets)?

Also, while this next question is not meant to hijack the thread of start any arguments about whose I/C is best (NOT interested in that at this point), who has done before/after dyno tests? I am REALLY interested in the SECOND and THIRD pulls, not the first pull.
Title: Re: The Intercooler Thread
Post by: joshmass on February 11, 2011, 10:38:42 AM
The Werks Street was a straight bolt on.

http://www.flickr.com/photos/43695877@N05/5435777237/ (http://www.flickr.com/photos/43695877@N05/5435777237/)

I don't have enough data on hand to tell you what the HP difference was before and after for the Werks Street FMIC unfortunately.

What I can tell you is that the pulls are ridiculously consistent if we make three consecutive pulls. IAT's are also showing up in the 70's. This is with a Bullseye S256ET turbo @ 28psi.
Title: Re: The Intercooler Thread
Post by: Go-N Def on February 11, 2011, 11:16:30 AM
DDM is bolt-on also. Really tight fit, but no modifications/trimming/shaving/widening/elongating needed...

I haven't done any before or after dyno's though...
Title: Re: The Intercooler Thread
Post by: kennysabarese on February 12, 2011, 09:58:19 AM
The best way to see that your IC is effective is to just log your IATs and KR while driving hard.

You can see on Dejon's site that their IC lowers IATs very effectively.

http://solstice.dejonpowerhouse.com/edit/1-02-SS-Intercoolers-Pipes.htm (http://solstice.dejonpowerhouse.com/edit/1-02-SS-Intercoolers-Pipes.htm)
Title: Re: The Intercooler Thread
Post by: IBDRINKEN on February 12, 2011, 02:51:48 PM
When I installed my Dejon, it was staright bolt on as well.
Title: Re: The Intercooler Thread
Post by: Kelu on February 12, 2011, 02:58:51 PM
When I installed my Dejon, it was staright bolt on as well.
+1
Title: Re: The Intercooler Thread
Post by: baconbits on February 12, 2011, 06:40:17 PM
I wonder just how much airflow is blocked by the ugly license plate install on Ontario solstices..I am thinking of putting in a new IC but will likely send the car to the body shop to fill the plugs the dealer so graciously drilled into the fascia ..tangent question who sells license plate mounts on here..
Title: Re: The Intercooler Thread
Post by: IBDRINKEN on February 12, 2011, 06:54:55 PM
there is one called the Davies Corvette motorized license plate frame. I think spikey has one on his car..
Title: Re: The Intercooler Thread
Post by: Spedee on February 12, 2011, 09:10:27 PM
there is one called the Davies Corvette motorized license plate frame. I think spikey has one on his car..

I have one
(http://www3.sympatico.ca/spedee/Platein.jpg)
(http://www3.sympatico.ca/spedee/Plateout.jpg)
Title: Re: The Intercooler Thread
Post by: DeepBlueGXP on February 12, 2011, 10:57:46 PM
Looks great spedee
Title: Re: The Intercooler Thread
Post by: baconbits on February 13, 2011, 02:18:15 AM
yeah thats the ticket.. will that fit on a stock splitter

Title: Re: The Intercooler Thread
Post by: Kuprito on February 13, 2011, 07:45:51 AM
Hey Speede, where did you get those signal bluish bulbs? Are they 3157 type?
Title: Re: The Intercooler Thread
Post by: Spedee on February 13, 2011, 10:10:41 AM
yeah thats the ticket.. will that fit on a stock splitter


If your referring to the stock GXP nose. It would but the round portion of the bumper will make the plate stand out more.
Title: Re: The Intercooler Thread
Post by: Spedee on February 13, 2011, 10:12:35 AM
Hey Speede, where did you get those signal bluish bulbs? Are they 3157 type?
Those are the chrome style bulbs from ebay.
Title: Re: The Intercooler Thread
Post by: Spedee on February 13, 2011, 10:13:14 AM
Looks great spedee

Thanks all.
Title: Re: The Intercooler Thread
Post by: Spedee on February 13, 2011, 10:21:01 AM
yeah thats the ticket.. will that fit on a stock splitter



(http://www3.sympatico.ca/spedee/GXP.jpg)
Title: Re: The Intercooler Thread
Post by: wspohn on February 13, 2011, 10:39:24 AM
I wonder just how much airflow is blocked by the ugly license plate install on Ontario solstices..I am thinking of putting in a new IC but will likely send the car to the body shop to fill the plugs the dealer so graciously drilled into the fascia ..tangent question who sells license plate mounts on here..


If Ontario mandates a front plate, the best you can do without getting tickets is to move the plate down.  Dejon makes a pretty decent bracket that mounts in the honeycomb grille mesh.  You can see the old holes if you look hard, but because it is gray and I touched up the old rivet holes, they aren't too obvious.

What we in Canada are stuck with:

(http://www.rhodo.citymax.com/i/non-rhodo/sol1.jpg)

With Dejon mount:

(http://www.rhodo.citymax.com/i//solquarterweb.jpg)
Title: Re: The Intercooler Thread
Post by: Spedee on February 13, 2011, 11:02:59 AM
Yes we need the front plate also.
I run with the plate retracted inside so I can get the most air to the intercooler.
So far I haven't been pulled over.
And if I do, hopefully I can explain that I forgot to put it out after the last car show I was at.  ;) ;) ;)
Title: Re: The Intercooler Thread
Post by: Critterman on February 13, 2011, 11:58:43 AM
The grills are not where we get air from.  If you look through them you will see the foam crash protection covering most of the open area.   These cars are bottom breathers they get most of their air from underneath the nose and suck it upward through the radiator.  The GXP has the extra grille down low to direct addtional air to the intercooler.
Title: Re: The Intercooler Thread
Post by: Spedee on February 13, 2011, 12:24:38 PM
The grills are not where we get air from.  If you look through them you will see the foam crash protection covering most of the open area.   These cars are bottom breathers they get most of their air from underneath the nose and suck it upward through the radiator.  The GXP has the extra grille down low to direct addtional air to the intercooler.
Your correct. That's is why I wouldn't put the plate lower.
Also though I have a Stage 2 Supercharger from DDM and the intercooloer gets air from both upper and lower since the rad is in front of the hot water rad and just as big.
I bought the GXP nose from Wade Linger to take advantage of more air as well as Norm's air splitter.
Title: Re: The Intercooler Thread
Post by: Critterman on February 13, 2011, 05:10:34 PM
You know I never thought of getting a nose from him, if you don't mind me asking how much did it run you, and don't you have different braces?
Title: Re: The Intercooler Thread
Post by: Spedee on February 13, 2011, 05:37:02 PM
You know I never thought of getting a nose from him, if you don't mind me asking how much did it run you, and don't you have different braces?

$300 brand new. Grilles, fog lights and side markers all included.
It was a direct bolt on. I just had to order from GM the half moon panel that seals off underneath the intercooler to front nose edge.
Title: Re: The Intercooler Thread
Post by: HAMMER DOWN on February 13, 2011, 06:12:56 PM
Hahn states that there IC gives you up to 27WHP. click on  link for dyno runs.

http://www.turbosystem.com/New_Folder/SolsticeGXPRedline/GXP%20Redline%20Intercooler%20Sell%20Page.htm (http://www.turbosystem.com/New_Folder/SolsticeGXPRedline/GXP%20Redline%20Intercooler%20Sell%20Page.htm)
Title: Re: The Intercooler Thread
Post by: wspohn on February 13, 2011, 06:26:02 PM
Hahn states that there IC gives you up to 27WHP.

They also forget to mention that in fact it will give you exactly zero more power on an 'otherwise untuned car' as soon as the ECM learns down again, some time between 1/2 hour and 1/2 week later.

So to all the guys with stock tunes, fuggedaboutit!
Title: Re: The Intercooler Thread
Post by: Critterman on February 13, 2011, 08:04:44 PM
Thanks speede, they are within driving distance.
Title: Re: The Intercooler Thread
Post by: Spedee on February 13, 2011, 08:58:06 PM
Thanks speede, they are within driving distance.
Your welcome. Ask Wade for a ride in his 427 Solstice. Friggin powerfull.
(http://www3.sympatico.ca/spedee/Wade.jpg)
(http://www3.sympatico.ca/spedee/Wade2.jpg)
Title: Re: The Intercooler Thread
Post by: Graywolf on February 13, 2011, 10:09:10 PM
Intercooler does not start working until your going 60+ MPH
Title: Re: The Intercooler Thread
Post by: elff on February 26, 2011, 07:43:44 PM
I don't have the technical skill, but my daughter makes cool noises that sounds like its running a bigger turbo....does that count?

That's add more HP than a Type R sticker for sure.
Title: Re: The Intercooler Thread
Post by: Gentleman Jack on May 08, 2011, 10:57:52 PM
Anybody have an RPI installed?  Any comments?
Title: Re: The Intercooler Thread
Post by: kennysabarese on May 09, 2011, 10:23:35 AM
I have an RPI sitting in my basement. Haven't had time to install it. Probably won't be done for a long time. I'm going to be away almost every weekend until August :(
Title: Re: The Intercooler Thread
Post by: Sol Asylum on May 09, 2011, 04:40:12 PM
There you go GJ, go get Kenny's he's going to be gone just about every weekend until August.
Title: Re: The Intercooler Thread
Post by: kennysabarese on May 09, 2011, 04:49:21 PM
Ha!

Kelu has just told me that I have to swap it before he arrives so my car is faster at the dragstrip!
Title: Re: The Intercooler Thread
Post by: Kelu on May 09, 2011, 04:51:35 PM
And of course he won't do that cause he is too lazy, GJ you have a go! For the right amount of money I can even do some intel.
Title: Re: The Intercooler Thread
Post by: Getaway on September 06, 2011, 06:19:44 PM
DDM 27" x 8" x 3.375"  895$ -150$ Sale = 745$ right now
Hahn 27" x 8" x 4"  899$
Werks Street 24" x 8" x 3.5"  599$
EDS Motorsport 23.7" x 7.9" x 3.95" 699€
Werks Race 24" x 15" x 3" 1499$
Dejon 24" x 8" x 3.5"  699$
Race Precison ??????  1099$
[/quote]

Hi, Great thread! Thought I would give some additional input to this thread.
I have the HG Motorsport one, which I am very happy with

http://www.hg-motorsport.de/shop/product_info.php/info/p24909_Opel-GT--HFT--intercooler-kit-frontmount.html (http://www.hg-motorsport.de/shop/product_info.php/info/p24909_Opel-GT--HFT--intercooler-kit-frontmount.html)
Looks similar to the EDS one, if not the same.

There is also another IC setup for the kappa platform which is provided by Turbo Zentrum
http://www.turbozentrum.de/ladeluftkuehlung/fahrzeugspezifisch/opel-gt-upgrade-front-llk/a-1837/?plentyID=1 (http://www.turbozentrum.de/ladeluftkuehlung/fahrzeugspezifisch/opel-gt-upgrade-front-llk/a-1837/?plentyID=1)
 

Title: Re: The Intercooler Thread
Post by: elff on September 06, 2011, 08:20:46 PM
Getaway

Do you have the measurements of these 2?
Title: Re: The Intercooler Thread
Post by: Getaway on September 07, 2011, 04:25:28 PM
Sorry, I don't. I never took the measuremets of the HG motorsport one before I installed it. I had the measurements on e-mail from HG motorsport, but must have deleted it  :banghead: Think it is similar to the eds one, quite thick.
Title: Re: The Intercooler Thread
Post by: Kuprito on September 26, 2011, 08:50:15 AM
HG Motorsport Intercooler = EDS Intercooler
Title: Re: The Intercooler Thread
Post by: elff on September 26, 2011, 10:10:48 AM
Cool
So we have a nice international list.

Well done!!
Title: Re: The Intercooler Thread
Post by: reedred on July 03, 2012, 04:26:30 PM
So now that it's out of warranty, my car has apparently decided to start :censor: ing with me.  I noticed over the last week or so that despite the heat wave, the cooling fan always shuts off the second I kill the ignition.  I was walking out of the bank today and noticed this:

(http://i140.photobucket.com/albums/r13/reedred/Mobile%20Uploads/20120703_145408.jpg)

... which presents the following questions:

Title: Re: The Intercooler Thread
Post by: MARVIC 1 on July 03, 2012, 04:36:45 PM
They also forget to mention that in fact it will give you exactly zero more power on an 'otherwise untuned car' as soon as the ECM learns down again, some time between 1/2 hour and 1/2 week later.

So to all the guys with stock tunes, fuggedaboutit!
:huh: But Bill!!!! Who has an untuned Kappa around here these days?  :devil:
Title: Re: The Intercooler Thread
Post by: miller11386 on July 03, 2012, 04:37:21 PM
if it isnt leaking already, it will be soon.

Also the aftermarket coolers work, however there are tons of people with stock IC's laying around. Also the vendors usually have take off coolers as well. The cheapest solution would be to get another OE intercooler, however the aftermarket coolers typically are a bit stronger. Some cool better than others, however all will work on the stock turbo.
Title: Re: The Intercooler Thread
Post by: wspohn on July 03, 2012, 04:41:36 PM
They can fail once they balloon like that - should be a warranty issue unless you are now off warranty for driveline issues.

I'd shop by price - for a stock engine (or close to that) it won't make a heck of a lot of difference, except for bragging rights of the 'mine is bigger than yours' sort.

Several vendors have decent prices (Werks, for one) and some alos have periodic sales that you might be able to wait for.

The fan hasn't got anything to do with this failure as far as I can see.  Sounds like your thermostatic switch sender needs replacement though. Should be cheapish.
Title: Re: The Intercooler Thread
Post by: LatinVenom on July 03, 2012, 06:00:44 PM
You can probably pick an OEM intercooler for the cheap.
DDM, Werks and other members should have some for you to buy.
Title: Re: The Intercooler Thread
Post by: Dave@DDMworks on July 03, 2012, 06:38:22 PM
You can probably pick an OEM intercooler for the cheap.
DDM, Werks and other members should have some for you to buy.

Reed, we have a couple stock intercoolers here and also some used aftermarket intercoolers from RPI here also. Let me know if we can help you out.
Title: Re: The Intercooler Thread
Post by: kennysabarese on July 03, 2012, 07:36:13 PM
I have an RPI IC on my car that I may no longer need. Might put back the stock one.
Title: Re: The Intercooler Thread
Post by: cdflint on July 03, 2012, 08:51:35 PM
That is so strange. I was price searching DDM's, Dejon, Hahn and Werks just yesterday. I forgot about RPI but I'm curious why you would take the RPI off and go back to stock and why they are laying around in the DDM shop? Is somthing wrong with RPI's other than they are no longer in business?

Dave if they are good what price for one?  Dave/Kenny PM me.
Title: Re: The Intercooler Thread
Post by: Dave@DDMworks on July 03, 2012, 08:57:54 PM
That is so strange. I was price searching DDM's, Dejon, Hahn and Werks just yesterday. I forgot about RPI but I'm curious why you would take the RPI off and go back to stock and why they are laying around in the DDM shop? Is somthing wrong with RPI's other than they are no longer in business?

Dave if they are good what price for one?  Dave/Kenny PM me.

There is nothing "wrong" with the RPI intercoolers. We just have loyal customers and when they come in for a complete build they want all of it to be ours. We do like the IAT's we get from our intercooler and also the we ours is built, etc. I just checked and we did sell one of the RPI's we had at nationals, but we have another one here for $450 which is less then half of what they cost new. - http://shoprpi.com/product_info.php?cPath=21_24_33&products_id=65 (http://shoprpi.com/product_info.php?cPath=21_24_33&products_id=65)

I am not sure why Kenny would go back to stock with his, hopefully he will chime in.
Title: Re: The Intercooler Thread
Post by: cdflint on July 03, 2012, 10:02:57 PM
I certainly meant no knock on yours if it came out that way. Everything else I've purchased from you is top notch!  I was just curious. I didn't realize RPI was still around, they are out there in price though. Thanks Dave. I just paid off all my wifes medical bills today. Time to start adding back to the Sol account.
Title: Re: The Intercooler Thread
Post by: Arabas on July 03, 2012, 10:16:07 PM
Reed, get an aftermarket one. An aftermarket ic is not going to fail so easily as the factory one. Better replace that soon, no need to dont have an ic during summer
Title: The Intercooler Thread
Post by: Gentleman Jack on July 03, 2012, 11:04:28 PM
Reed,

Inter cooler may be considered part of the exhaust and covered by longer warranty. Look in to that first.
Title: Re: The Intercooler Thread
Post by: reedred on July 04, 2012, 12:31:55 PM
Thanks, y'all. I'm taking it into the dealer next Saturday for an oil change anyway so I guess I'll start there and see if there's a free option before I start looking at take off parts.
Title: Re: The Intercooler Thread
Post by: Gentleman Jack on July 04, 2012, 05:08:16 PM
Reed,

See here:
http://www.chevrolet.com/owners/warranty/ (http://www.chevrolet.com/owners/warranty/)

What Is Covered
The emission parts listed here are covered under the Emission Control System Limited Warranty. The terms are explained in the "Federal Emission Control System Limited Warranty" and the "California Emission Control System Limited Warranty" below.Important: Certain parts may be covered beyond these warranties if shown with asterisk(s) as follows:* 7 years/70,000 miles, whichever comes first, California Emission Control System Limited Warranty coverage.** 8 years/80,000 miles, whichever comes first, Federal Emission Control System Limited Warranty coverage. (Also applies to California certified light-duty and medium-duty vehicles.)* and ** are 8 years/100,000 miles, whichever comes first, for California LEV2 vehicles equipped with option code NUA.All listed parts are covered for 15 years/150,000 miles, whichever comes first, on California PZEV (NU6) vehicles registered in a PZEV state, except Hybrid batteries and Hybrid A/C compressors, which are covered for 10 years/100,000 miles, whichever comes first.The Emission Control System Limited Warranty obligations do not apply to conditions resulting from tampering, abuse, neglect, or improper maintenance; or any other item listed under "What Is Not Covered" under the New-Vehicle Limited Warranty. The "Other Terms" presented under the New-Vehicle Limited Warranty also apply to the emission-related warranties.Powertrain Control System:
ABS Control Module **
Camshaft Position Actuator *
Camshaft Position Actuator Valve
Coolant Level Sensor
Data Link Connector
Engine Control Module (ECM) **
Engine Coolant Temperature Sensor
Fuel Control Module **
Intake Air Temperature Sensor
Malfunction Indicator Lamp
Manifold Absolute Pressure Sensor
Mass Air Flow Sensor
Oil Pressure Sensor Active Fuel Management (AFM)
Oxygen Sensor(s)
Powertrain Control Module (PCM) **
Throttle Position Sensor
Vehicle Control Module (VCM) **
Vehicle Speed Sensor
Wheel Speed SensorTransmission Controls and Torque Management:
GMLAN (CAN) Communications Circuit
Manual Transmission Clutch Switch
Park/Neutral Switch
Torque Converter Clutch Solenoids
Torque Converter Clutch Switch
Transmission Control Module **
Transmission Fluid Temperature Sensor
Transmission Gear Selection Switch (Diesel)
Transmission Internal Mode Switch *
Transmission Pressure Control Solenoids *
Transmission Pressure Switches *
Transmission Shift Solenoids *
Transmission Speed Sensor (Input) *
Transmission Speed Sensor (Output)Fuel Management System:
Diesel Fuel Injection Pump *
Direct Fuel Injector Assembly (6.6L Duramax Diesel) *
Fuel Injector
Fuel Pressure Regulator
Fuel Pressure Sensor
Fuel Rail Assembly *
Fuel Temperature Sensor
High-Pressure Fuel Pump (SIDI) *Air Management System:
Active Aero Shutters
Air Cleaner
Air Cleaner Resonator
Air Intake Ducts
Charge Air Control Actuator
Charge Air Control Solenoid Valve
Charge Air Control Valve
Charge Air Cooler *Charge Air Cooler Fan
Idle Air Control Valve
Idle Speed Control Motor
Intake Air Heater
Intake Manifold *
Intake Manifold Heater
Intake Manifold Tuning Valve
Supercharger Assembly *
Throttle Body
Throttle Body Heater
Turbocharger Assembly *
Turbocharger Boost Sensor
Turbocharger Oil SeparatorIgnition System:
Camshaft Position Sensor(s)
Crankshaft Position Sensor(s)
Glow Plug(s) (Diesel)
Glow Plug Controller (Diesel)
Ignition Coil(s)
Knock Sensor
Spark Plug Wires
Spark PlugsCatalytic Converter System:
Catalytic Converter(s) and Muffler (if attached as assembly) * **
Diesel Exhaust Temperature and Pressure Sensors
Diesel Exhaust (DPF) Indirect Fuel Injector
Diesel Exhaust Emission Reduction Fluid Injector
Diesel Exhaust Emission Reduction Fluid Tank *
Diesel Exhaust NOx Sensors
Diesel Particulate Filter (DPF) *Exhaust Manifold:
Exhaust Manifold with Catalytic Converter (attached as assembly) * **
Exhaust Manifold Gasket
Exhaust Pipes and/or Mufflers (when located between catalytic converters and exhaust manifold)Positive Crankcase Ventilation (PCV) System:
Oil Filler Cap
PCV Filter
PCV Oil Separator
PCV ValveExhaust Gas Recirculation (EGR) System:
EGR Feed and Delivery Pipes or Cast-in Passages
EGR Valve
EGR Valve Cooler (6.6L Duramax Diesel) *Secondary Air Injection System:
Air Pump
Check ValvesEvaporative Emission Control System (Gasoline Engines):
Canister
Canister Purge Solenoid Valve
Canister Vent Solenoid
Fuel Feed and Return Pipes and Hoses
Fuel Filler Cap
Fuel Level Sensor
Fuel Limiter Vent Valve *
Fuel Tank(s) *
Fuel Tank Filler Pipe (with restrictor)
Fuel Tank Vacuum or Pressure SensorHybrid:
Auxiliary Transmission Fluid Pump
Battery Cooling Fan
Battery Pack Control Module (BPCM) **
Battery Pack Current Sensor
Brake Pedal Travel Sensor
Drive Motors *
Drive Motor Resolvers *
Drive Motor/Generator Control Module **
Electro-Hydraulic Brake Control Module (EBCM) **
Energy Storage Control Module **
Fuel Filler Pipe Adapter Seal
Hybrid Batteries *
Hybrid Battery Temperature Sensors
Hybrid Battery Voltage Sensors
SGCM Coolant Circuit (fan, fan relay, and pump)
Starter Generator *
Starter Generator Control Module (SGCM) **
Starter Generator Drive Belt
Traction Power Inverter Module (TPIM) **
Transmission Substrate Temperature SensorVoltec-Specific Components:
VICM – Vehicle Integration Control Module **
Voltec RESS Battery * **Voltec Rechargeable Energy Storage System Thermal Management:
APM Fan
Battery Coolant Pump
Battery High-Voltage Heater
Battery Inlet Temperature Sensor
Battery Outlet Temperature
E-compressor * **
High Side Refrigerant Pressure Sensor
Low Side Refrigerant Pressure Sensor
Low Side Refrigerant Temperature Sensor
Outside Air Temperature Sensor
PE Coolant Temperature Sensor
Port Valves
Power Electronics Coolant Pump
Radiator FanVoltec OnBoard Charging System:
Charge Port
Charge Port Door Position Sensor
Charge Port Door Release
Charge Port Door Switch
Onboard Charger * **Voltec Refuel Management System:
Fuel Door Lock Assembly
Fuel Door Position Sensor
Refuel Request SwitchVoltec EVAP Emission Control System:
Canister Assembly *Miscellaneous Items Used with Above Components are Covered:
Belts
Boots
Clamps
Connectors
Ducts
Fittings
Gaskets
Grommets
Hoses
Housings
Mounting Hardware
Pipes
Pulleys
Sealing Devices
Springs
Tubes
Wiring and RelaysParts specified in your maintenance schedule that require scheduled replacement are covered up to their first replacement interval or the applicable emission warranty coverage period, whichever comes first. If failure of one of these parts results in failure of another part, both will be covered under the Emission Control System Limited Warranty. For detailed information concerning specific parts covered by these Emission Control System Limited Warranties, ask your dealer.
Title: Re: The Intercooler Thread
Post by: Sky Pilot on July 04, 2012, 06:53:19 PM
So now that it's out of warranty, my car has apparently decided to start :censor: ing with me.  I noticed over the last week or so that despite the heat wave, the cooling fan always shuts off the second I kill the ignition.  I was walking out of the bank today and noticed this:

(http://i140.photobucket.com/albums/r13/reedred/Mobile%20Uploads/20120703_145408.jpg)
...
With the size of that buldge you're not throwing a code? Mine was cracked on the passenger side and was repalced a couple of months ago under the drivetraine warranty.

Title: Re: The Intercooler Thread
Post by: reedred on July 05, 2012, 04:48:50 AM
Thanks, GJ!  I'll march in there with that list.

Nope, SP.  I don't recall this car ever throwing a code.  The bulge wasn't there for NASSM, so for all I know it could've happened while I was inside the bank.  I've only driven it for about 15 minutes since I took that picture.
Title: Re: The Intercooler Thread
Post by: kennysabarese on July 05, 2012, 07:17:51 AM
The only reason I would go back to stock would be if I sell the car.
Title: Re: The Intercooler Thread
Post by: redlinedude on July 05, 2012, 07:30:13 PM
I currently have the BSR tune and hit 22-23 psi under full throttle. The other day I went to give my car gas and no boost. I carefully drove it home a couple of days ago and discovered the rubber hose came off the intercooler on the hot side. This has happened to me on the cold side before so I have replaced all the worm clamps with the spring loaded clamps. I put the hose back on and tightened the clamp and the car drove fine until today. After driving it for a while I went to give it gas and at around 10lbs of boost, the car slowed down, the boost went down, and the CEL started flashing and then went out. I checked all the hoses and let it cool down for a while. I drove the car home and about halfway there, I stepped on the gas and the same sequence of events happened again. This time the CEL stayed on. I pulled the codes and they were P0101, P0300 and P0303. I double checked all the clamps and they are tight. I looked at the front of the intercooler and didn't see any swelling. How can I pressure test my intercooler without taking it out of the car? Could this be something else? Any ideas or suggestions would be appreciated.
Title: Re: The Intercooler Thread
Post by: Dave@DDMworks on July 05, 2012, 07:49:21 PM
The P0101 code is a MAF code
The P0300 code is random cylinder misfires
The P0303 code is random misfires cylinder #3

If the car was here I would be looking for leaks in the system, make sure to check the nipple behind the air flow meter on the intake for cracks or if it has completely come off. Also I would pull the air flow meter on the intake and see if it is dirty and clean it.

If the ECM is not reading the incoming air correctly the boost and fueling will not be correct, which will cause the other codes you are getting.

Hope that helps,
Dave
Title: Re: The Intercooler Thread
Post by: redlinedude on July 05, 2012, 08:30:41 PM
(http://i306.photobucket.com/albums/nn272/s2000dude/airintake-1.jpg)

I checked the nipple and it is fine (A). I took the MAF out and it is squeaky clean (B).
I will make a pressure sensor (someone sent me a video on how-to-do this) and try to test my intercooler. Do I have to plug the other end when I run the test? I was going to put the pressure valve on the hot end since it is easier to access it. BTW Dave, thank you for your help. It is greatly appreciated.  :thumbs:
Title: Re: The Intercooler Thread
Post by: kennysabarese on July 05, 2012, 10:20:31 PM
This will help you.

http://www.kappaperformance.com/forum/index.php?topic=5000.0 (http://www.kappaperformance.com/forum/index.php?topic=5000.0)
Title: Re: The Intercooler Thread
Post by: redlinedude on July 06, 2012, 03:34:05 PM
I did a pressure test up to 23lbs and no leaks??? Now what???
Title: The Intercooler Thread
Post by: Gentleman Jack on July 06, 2012, 05:08:10 PM
Did you only test the IC or all the piping as well?
Title: Re: The Intercooler Thread
Post by: redlinedude on July 06, 2012, 06:52:18 PM
Did you only test the IC or all the piping as well?

I disconnected the hose from the turbo and connected my test plug to the intercooler hose so all piping and hoses have been checked. It held 20+lbs for at least 10 minutes. I spoke to a friend and he told me to put the stock spark plugs back in (I have been running NGK 6509's 1 step cooler). I also cleaned the MAF sensor with MAF sensor cleaner. I drove the car and it still acts the same. I think at this point I have some type of software issue. Is it possible to connect the car to some type of scan tool while I am driving to check ECU functions, O2 sensors, knock sensors, A/F ratios, etc...   :banghead:  :banghead:  :banghead:
Title: The Intercooler Thread
Post by: Gentleman Jack on July 06, 2012, 07:15:21 PM
I disconnected the hose from the turbo and connected my test plug to the intercooler hose so all piping and hoses have been checked. It held 20+lbs for at least 10 minutes. I spoke to a friend and he told me to put the stock spark plugs back in (I have been running NGK 6509's 1 step cooler). I also cleaned the MAF sensor with MAF sensor cleaner. I drove the car and it still acts the same. I think at this point I have some type of software issue. Is it possible to connect the car to some type of scan tool while I am driving to check ECU functions, O2 sensors, knock sensors, A/F ratios, etc...   :banghead:  :banghead:  :banghead:


Dude,

What do you have your spark plus gapped to?  Most of us with a tune have regapped our spark plugs down to .30????  I think.  Someone can step in and clairify.  Don't go on my number, but I know there have been some problems  with tunes blowing out spark. Something to look in to.

GJ
Title: Re: The Intercooler Thread
Post by: redlinedude on July 06, 2012, 07:27:08 PM
I have them gapped to .30. Here is another thread I started a while ago.

http://www.kappaperformance.com/forum/index.php/topic,8711.0.html (http://www.kappaperformance.com/forum/index.php/topic,8711.0.html)
Title: The Intercooler Thread
Post by: Gentleman Jack on July 06, 2012, 11:57:06 PM
hey, at least I gave the same advice both times!

I don't post here very often, so I can't always remember what ive said and not said |)
Title: Re: The Intercooler Thread
Post by: 40rtyp on July 08, 2012, 10:51:25 AM
I disconnected the hose from the turbo and connected my test plug to the intercooler hose so all piping and hoses have been checked. It held 20+lbs for at least 10 minutes. I spoke to a friend and he told me to put the stock spark plugs back in (I have been running NGK 6509's 1 step cooler). I also cleaned the MAF sensor with MAF sensor cleaner. I drove the car and it still acts the same. I think at this point I have some type of software issue. Is it possible to connect the car to some type of scan tool while I am driving to check ECU functions, O2 sensors, knock sensors, A/F ratios, etc...   :banghead:  :banghead:  :banghead:


Do you by chance use an Android phone?????
Title: Re: The Intercooler Thread
Post by: redlinedude on July 08, 2012, 11:36:27 AM

Do you by chance use an Android phone?????

Yes
Title: Re: The Intercooler Thread
Post by: 40rtyp on July 08, 2012, 01:02:03 PM
Yes


Awesome! You know how you were wondering what your Afr is and other parameters to help trouble? Go on Google Play store on your phone and download the app"Torque". There is a free version you can try out and a Pro. It will display on your phone all the information from the ecm. It also has a diagnostics tab that reads for engine codes and you can erase them if need be. It will tell you what the codes mean etc. I use this in my car to monitor multiple sensors. It works via Bluetooth and all you would need is to get a Bluetooth ObdII module that can be had for $15 on eBay.

Here is a link: http://torque-bhp.com/ (http://torque-bhp.com/)

On Google play the program is $5 for the Pro

I use the recommend Kiwi Bluetooth module. Here is a link on eBay to all of them.
http://shop.mobileweb.ebay.com/searchresults?kw=bluetooth+obdII&x=31&y=11&cmd=SKW (http://shop.mobileweb.ebay.com/searchresults?kw=bluetooth+obdII&x=31&y=11&cmd=SKW)

Hope this helps. Great app!!
Title: Re: The Intercooler Thread
Post by: redlinedude on July 13, 2012, 12:58:05 PM
I took my car to my local Chevy dealer today to fix the convertible top. I spoke to my Saturn tech and he went for a test drive with me. The car reached around 10psi boost and the check engine light started flashing. The same cylinder #3 misfire codes (P0303) came up. He pulled the car into the shop and switched the coil packs with cylinder #2. We drove the car again and this time misfire on cylinder #2. I replaced the bad coil pack and now the car runs great !!
Title: Re: The Intercooler Thread
Post by: Critterman on July 13, 2012, 01:09:56 PM
Always good when it is a simple solution.  Glad your car is running right again.
Title: Re: The Intercooler Thread
Post by: kennysabarese on July 13, 2012, 01:28:47 PM
Great news!
Title: Re: The Intercooler Thread
Post by: Sly Bob on July 13, 2012, 04:09:50 PM
I took my car to my local Chevy dealer today to fix the convertible top. I spoke to my Saturn tech and he went for a test drive with me. The car reached around 10psi boost and the check engine light started flashing. The same cylinder #3 misfire codes (P0303) came up. He pulled the car into the shop and switched the coil packs with cylinder #2. We drove the car again and this time misfire on cylinder #2. I replaced the bad coil pack and now the car runs great !!

Smart tech! Glad you got everything sorted out.   :thumbs:
Title: Re: The Intercooler Thread
Post by: redlinedude on July 13, 2012, 04:31:37 PM
My joy is short-lived. I went to re-install my BSR tune and it doesn't recognize my car now. A similar situation happened to me a couple of days ago when I had a tech at a Honda dealer clear the check engine light. At that time, I disconnected the battery for 20 minutes and it was okay. When I went to the dealer today, he used a GM TechII scanner. So today, I disconnected my battery and when I reconnected it and I now still get an error code saying I need to sync my tuner with BSR. They want an extra $80.00 to buy a "tuning warranty" for this process.  :banghead:  :banghead:  :banghead: I guess I have to be thankful that my car is running okay.
Title: Re: The Intercooler Thread
Post by: Bill Hahn Jr on July 13, 2012, 04:32:37 PM
Smart tech! Glad you got everything sorted out.   :thumbs:
Good deal.  Coil issues are unfortunately very common on LNF.  He was on his game for sure!
Title: Re: The Intercooler Thread
Post by: Bill Hahn Jr on July 13, 2012, 04:34:36 PM
My joy is short-lived. I went to re-install my BSR tune and it doesn't recognize my car now. A similar situation happened to me a couple of days ago when I had a tech at a Honda dealer clear the check engine light. At that time, I disconnected the battery for 20 minutes and it was okay. When I went to the dealer today, he used a GM TechII scanner. So today, I disconnected my battery and when I reconnected it and I now get an error code saying I need to sync my tuner with BSR. They want an extra $80.00 to buy a "tuning warranty" for this process.  :banghead:  :banghead:  :banghead:
Ah, the apparently never-ending saga of modern electronic performance.  It would appear your dealer tech may have also flashed in the most recent stock cal for your car, creating sync issues for the BSR tune.

Did you perhaps purchase this BSR unit from us?
Title: Re: The Intercooler Thread
Post by: redlinedude on July 13, 2012, 04:37:00 PM
Good deal.  Coil issues are unfortunately very common on LNF.  He was on his game for sure!

Hi Bill, Thanks for the post. I spoke to Jesse at HahnRacecraft today in regards to any help I can get with the BSR tuner I purchased from your company.  He was going to contact BSR to possibly help me get my PPC tuner to read my car again.
Title: Re: The Intercooler Thread
Post by: Bill Hahn Jr on July 13, 2012, 04:55:28 PM
Hi Bill, Thanks for the post. I spoke to Jesse at Hahn RaceCraft today in regards to any help I can get with the BSR tuner I purchased from your company.  He was going to contact BSR to possibly help me get my PPC tuner to read my car again.
Perfect.  Jesse is one of our very treasured new employees.  He'll involve me as needed.

To all: While we've had a great run with the BSR Tuner, all the way back to pioneering it as the first flash tuning option ever available for LNF, it has been largely supplanted by more affordable options as of late.  Despite our most petulant pleadings, BSR refused to respond to rapidly changing market dynamics here in the USA, and would not budge on pricing.  Additionally, they instituted this "two-year service agreement" along the way. 

The background behind the new policy was easy to understand: with a long, successful history in the tuner game, they'd developed a customer base that was simply overwhelming their Technical Support staff with seemingly perpetual Q&A, in many cases many years past actual point of purchase.  Like any manufacturer, they had to create a cutoff point, lest they be mired in free support forever, which comprises a simply unmanageable business model for a company that's been this successful.  So, they chose two years as the cutoff point. 

While we understand this policy's intentions, at times it's been a sticking point for us, for many of the Tuners were sold by us prior to this policy being instituted, and I don't feel such a policy should be retroactive.  To me, that's disingenuous, and just bad customer service.  We've been working with our customers who find themselves in this wedge point, such as redlinedude here.  In instances where BSR has been uncooperative, we've attempted to help customers out by issuing product vouchers for future Hahn RaceCraft purchases in an amount that's typically 1/2 of BSR's "service contract" charge, effectively meeting our customers in the middle.  In some cases, for our customers who've made and/or are about to make particularly large purchases, we've gone even further.  Most have found this to be an accommodating policy.

As an aside, we are phasing out the BSR Tuner, to be replaced with more contemporary and competitive options to be announced soon.  As noted above, we'll still continue to support our customers who've purchased BSR from us.
Title: Re: The Intercooler Thread
Post by: 40rtyp on July 13, 2012, 08:53:16 PM


 Mr. Hahn, I very much think that Hahn racecraft is making the best decision. I think that offering a HP Tuners package or even Trifecta will better fit what you guys represent. I remember looking at the BSR back in Aug of 2008 when I took delivery of my Cobalt SS/TC and was very close to buying it. I have since moved on from that car and now have a Sky Redline. I have been using HP tuners and couldn't be happier at the simplicity of using it for logging and being able to monitor parameters that normally I wouldn't be able to see. It just feels so reassurring having this software coupled with a reputable tuner.

 Glad to see you coming on our forums a lot lately  :thumbs:
Title: Re: The Intercooler Thread
Post by: Gentleman Jack on July 13, 2012, 10:29:46 PM
Wow.  Hahn Racecraft crawls itself out of the nothing and BAM.  Right back in the thick of it with top notch customer service and helpful advice.

Bill,
I hope for all of us that need help along the way that you continue to be succesful and have the time to hang around these forums helping us where ever you can.  Thank you.

GJ
staff CPA
Title: Re: The Intercooler Thread
Post by: reedred on July 14, 2012, 02:04:45 PM
Reed,

See here:
http://www.chevrolet.com/owners/warranty/ (http://www.chevrolet.com/owners/warranty/)

So that list is the current GM Powertrain warranty, which has changed since 2009.  You did inspire me to look in the glovebox, where it turned out I still had the warranty booklet.  The Charge Air Cooler, its fan, and a whole bunch of other stuff are actually covered under the emissions warranty for some reason. Tony read it and agreed with me, so right now they're looking at it so they can order the parts for my covered repair.  Whew- that was a thousand dollars I wasn't looking to spend right now!  Thanks, GJ!!!
Title: Re: The Intercooler Thread
Post by: elff on July 14, 2012, 02:23:39 PM
If you have $600 I would still recommend getting the Hahn Intercooler and see if you could get your dealer to install it for free.
It seems like the stock intercoolers have a limited life span.
I personally like to upgrade whenever a part fails.   The current deal on the Hahn intercooler is a freaking Steal. 
Title: Re: The Intercooler Thread
Post by: wspohn on July 14, 2012, 02:31:50 PM
It seems like the stock intercoolers have a limited life span.

Not sure we have the evidence to support that.

There have definitely been a few factory coolers that have swollen and had to be replaced, but I haven't seen any evidence that this was other than a bad batch. We'd need evidence that showed a higher incidence of bulged coolers in the older cars to be able to say that age factors into this malady, wouldn't we?

I agree with you  that upgrading to something more robust (the question of whether there is any power benefit on an otherwise stock car aside)  is a good idea, but I have heard of many dealers that will not install non-factory parts. In fact unless they install factory parts supplied by the factory, I don't believe that the warranty covers the labour.

The only way to get a friendly mechanic to do this is have them order the new IC in, have him turn his back, cross his fingers, and replace it with your new IC. That keeps the books straight, you get a spare new stock cooler, and the install can be covered.
Title: Re: The Intercooler Thread
Post by: elff on July 14, 2012, 02:36:32 PM
Reeds car is a 2009 Special edition.

To me, that would mean the bad batch spanned over a year of production, which really makes it a crap shoot and he could just as easily get a replacement from that same batch
or
It's a design flaw.  There have been a fair share of them ballooning.

But that discussion aside

The Hahn intercooler for Mid $500 is a killer deal.   
Yes it's more than a free warranty replacement, but it's $200 - $500 cheaper than all the other LNF intercoolers on the market right now so IMHO if you need a new intercooler, it's a no brainer for me.   
Title: Re: The Intercooler Thread
Post by: wspohn on July 14, 2012, 02:41:01 PM
I agree that $500 is below the others. Next closest would be Werks at $625.
Title: Re: The Intercooler Thread
Post by: Sly Bob on July 14, 2012, 04:32:17 PM
So that list is the current GM Powertrain warranty, which has changed since 2009.  You did inspire me to look in the glovebox, where it turned out I still had the warranty booklet.  The Charge Air Cooler, its fan, and a whole bunch of other stuff are actually covered under the emissions warranty for some reason. Tony read it and agreed with me, so right now they're looking at it so they can order the parts for my covered repair.  Whew- that was a thousand dollars I wasn't looking to spend right now!  Thanks, GJ!!!

I love happy endings.    :cryin:
Title: Re: The Intercooler Thread
Post by: Gentleman Jack on July 14, 2012, 07:20:46 PM
In this case, with all other engine parts on Reed's car stock and no tune, I'm inclined to say getting the free replacement from GM is the way to go.  If Reed had some inclination of building power later on, I can absolutely see the benefits of taking this opportunity, and might then let GM swap the IC, then order a Hahn or similar unit, swap them and then sell off the stock IC.  At minimum, the stock IC would cover the cost of someone swapping the two ICs at the upcoming MMM9. (If GM would just give the replacement part to Reed, I'd say that's even better, but they never do that from my experience.)  From what I know, Reed does not have any plans for Go Faster goodies at this point.  As such, my initial thought that GM takes care of their problem stands.

GJ
painfully well thought out
Title: Re: The Intercooler Thread
Post by: reedred on July 14, 2012, 11:57:19 PM
Enough intercoolers have ballooned up that I'm aware of it and realized what was going on before it completely failed and I found coolant all over the garage.  Given my low level of technical expertise, I'd already come to the same conclusion that elff did about the factory part.  Tony the service writer suspects it failed because of the fan issue not cooling it properly so there is a valid possibility that it's really just a symptom and could've otherwise lasted the life of the car.

I did consider asking if they would install the Hahn piece instead, but decided against that for two reasons: it's not a drop in replacement so I'd have to ask them to make modifications, and for $600 I can get a pretty good hooker and a decent amount of blow.  While upgrading would be ideal, their decision to replace the entire cooling system at no cost to me was too good to pass up.  If it only lasts another 40K miles I can always go aftermarket later.  As GJ pointed out I have the stock tune, no go faster mods whatsoever, and no plans for any, so the factory piece should suffice.
Title: Re: The Intercooler Thread
Post by: ihawk95 on July 15, 2012, 12:02:59 AM
Enough intercoolers have ballooned up that I'm aware of it and realized what was going on before it completely failed and I found coolant all over the garage.  Given my low level of technical expertise, I'd already come to the same conclusion that elff did about the factory part.  Tony the service writer suspects it failed because of the fan issue not cooling it properly so there is a valid possibility that it's really just a symptom and could've otherwise lasted the life of the car.

I did consider asking if they would install the Hahn piece instead, but decided against that for two reasons: it's not a drop in replacement so I'd have to ask them to make modifications, and for $600 I can get a pretty good hooker and a decent amount of blow.  While upgrading would be ideal, their decision to replace the entire cooling system at no cost to me was too good to pass up.  If it only lasts another 40K miles I can always go aftermarket later.  As GJ pointed out I have the stock tune, no go faster mods whatsoever, and no plans for any, so the factory piece should suffice.

OMFG that is freaking funny, right there!  :lol: :lol: :lol:

Or you could save some $$$ and get a cheap hooker and a shot of penicillin.  :idk:
Title: Re: The Intercooler Thread
Post by: Bill Hahn Jr on July 15, 2012, 12:07:51 PM

 Mr. Hahn, I very much think that Hahn racecraft is making the best decision. I think that offering a HP Tuners package or even Trifecta will better fit what you guys represent. I remember looking at the BSR back in Aug of 2008 when I took delivery of my Cobalt SS/TC and was very close to buying it. I have since moved on from that car and now have a Sky Redline. I have been using HP tuners and couldn't be happier at the simplicity of using it for logging and being able to monitor parameters that normally I wouldn't be able to see. It just feels so reassuring having this software coupled with a reputable tuner.

 Glad to see you coming on our forums a lot lately  :thumbs:
Thanks for your support!  By the way, you can call me Bill, but I do also enjoy the more formal Mr. Hahn, as respectful behavior is often so lacking in today's world :)

You've hit the nail right on the head.  We've used HPTuners for years in some applications, and will soon offer it as an option on our turbosystems, as well as a stand-alone product.  We are currently involved with Trifecta as well, as they've assisted in developing superb tunes for our new Super 20G Turbo Upgrades for LNF (more on this soon!). 

The BSR Tuner was a strong player for us for many years, and our relationship with them was most fruitful.  However, time marches onward, and few places does it move faster than in modern electronics.

Title: The Intercooler Thread
Post by: Gentleman Jack on July 15, 2012, 12:27:23 PM
(must remember to call him Mr. Hahn if I need help with something.....)

Damn,
Did I say that out loud?
Title: Re: The Intercooler Thread
Post by: Sol Asylum on July 15, 2012, 01:08:03 PM
(must remember to call him Mr. Hahn if I need help with something.....)

Damn,
Did I say that out loud?
Nope you didn't say it at all.

You typed it.
Title: Re: The Intercooler Thread
Post by: Critterman on July 15, 2012, 03:53:27 PM
Don't worry no one heard you.
Title: Re: Re: The Intercooler Thread
Post by: SHiNY on July 15, 2012, 05:22:57 PM
Don't worry no one heard you.


That's because no one actually listens!
Title: Re: The Intercooler Thread
Post by: Bill Hahn Jr on July 16, 2012, 12:24:27 PM
Hahn states that their IC gives you up to 27WHP. click on  link for dyno runs.

http://www.turbosystem.com/New_Folder/SolsticeGXPRedline/GXP%20Redline%20Intercooler%20Sell%20Page.htm (http://www.turbosystem.com/New_Folder/SolsticeGXPRedline/GXP%20Redline%20Intercooler%20Sell%20Page.htm)

They also forget to mention that in fact it will give you exactly zero more power on an 'otherwise untuned car' as soon as the ECM learns down again, some time between 1/2 hour and 1/2 week later.

So to all the guys with stock tunes, fuggedaboutit!
:huh: But Bill!!!! Who has an untuned Kappa around here these days?  :devil:

When I first saw this exchange, I had to chuckle, as we did get a bit caught out on this one.  In revising information for our new website, this page will definitely get some updating.  But allow me to elaborate a bit...and while some of this information is definitely Intercooler 101, I do strive to to write for all possible readers, so you advanced gearheads may have to suffer through some elementaries here.  B-air with me ;)

The dyno results stated were in fact genuine, with back-to-back comparison of OEM intercooler to our Hahn HP Intercooler.  However, this was very early on in our development process, and the full capabilities of the GM/Bosch PCM to "learn down" the airflow improvement of our HP Intercooler were not yet fully understood.  Nonetheless, the difference in power was pretty breathtaking in light of the fact that with no other changes, we did in fact pick up 27 WHP, indicating a substantial improvement in airflow/reduction in restriction, as well as significantly reduced intake air temperatures (IAT's).

Now, while it's undoubtedly true that the maximum airflow achievable would soon be learned back down to stock as wspohn indicates, there is a bit more to the story.  We're confident that even on an untuned car, there will still be more than a zero power and performance improvement.  Turbocharger responsiveness is improved, so more power is available at lower RPM and throttle position; actually, this is one of the most common feedbacks we get on this intercooler.  As a result, more power is available at moderate RPM as compared to stock.  Additionally, lower IAT's lead to more aggressive ignition timing being learned by the PCM, which also adds more power and improved responsiveness across the RPM band.   So, while the maximum HP/airflow may not change much, perhaps just a few HP with a stock tune, there will be other noticeable, seat-of-the-pants perceivable improvements not expressed purely in that aspect of max power alone.  The additional engine longevity afforded by the cooler IAT's is also a nice bonus, especially in hot temperatures where the stock intercooler can be highly taxed, and let's face it: unless one lives in Alaska, one's Kappa sees a LOT of warm-weather operation!

A side note: in hot conditions, many otherwise-stock Kappas do not even achieve the full rated stock power, for there are limits to just how much more boost the system will add to compensate, especially when high IAT's also conspire to further reduce available ignition timing via knock detection.  Under such conditions, Kappas equipped with our HP Intercooler can realize MUCH more power than they would be otherwise be able to with a stock intercooler, even with a stock tune.

As a further side note to MARVIC's comment:  Right you are!  And of course, at such higher power levels, the stock intercooler is even more taxed, with even higher IAT's and more knock detection/timing retard, and significantly holds back a lot of tuned Kappas whose owners mistakenly attribute such greatly reduced power strictly to poor climatic conditions.  No tuned car should ever limit itself to the stock intercooler if the owner is interested in not only the best possible power, but the least amount of duress on his/her engine due to excessive intake heat.
Title: Re: The Intercooler Thread
Post by: redlinedude on July 18, 2012, 07:18:41 PM
Thanks go to Jesse and Bill Hahn Jr. at Hahn Racecraft for the great customer service!! Jesse talked to BSR and I received a one year tuning warranty. This means I can connect my tuner to BSR for and download any updates or fixes I may need for a year. I was able to connect to BSR server today and receive the updates my car needed to work properly. I plugged the PPC Tuner in and now I have about 40 more horses and 23 psi again :yay: I know my BSR tune is outdated but other than a K&N air filter my car is completely stock so for now this tuner suits my needs. In the next 6-8 months I plan on upgrading my turbo, downpipe, intercooler and exhaust. By that time I will need a new tune and lots of parts which i'm sure Hahn Racecraft will be able to assist me with. Thanks again Hahn Racecraft for the great customer service !!
Title: The Intercooler Thread
Post by: Gentleman Jack on July 19, 2012, 01:26:56 AM
Hahn edumacation. I'm learned better more now.


People get caught up in peak HP numbers.  Great explanation on why that can be flawed thinking.  I wonder if Hahn can make a human IC for my long runs on hot days....
Title: Re: The Intercooler Thread
Post by: miller11386 on July 19, 2012, 05:29:52 AM
HP is just a way to quantify it. The key question is, when you put the skinny pedal down, does it make you smile?
Title: Re: The Intercooler Thread
Post by: Arabas on July 31, 2012, 03:19:38 AM
would an ic be more effective if it had a fan mounted on it and staying on all the time?
Title: Re: The Intercooler Thread
Post by: Bill Hahn Jr on July 31, 2012, 07:47:52 AM
would an ic be more effective if it had a fan mounted on it and staying on all the time?
In some cases, yes, but even the strongest electric fans are hard pressed to reproduce the air blast and quantity that the car traveling at, say, 60 MPH can provide on its own.   Electric fans, even on cooling system radiators, are primarily intended to address periods of slow or no car movement.  Once you're up and running, the car's speed takes care of the needed airflow over the radiator and/or intercooler.

This inherently works in our favor in that the more heat one puts into the intercoooler, the faster one tends to be going, and thus the better the cooling effect.  Taken another way...you can't put heat into the intercooler while the car is standing still or moving very slowly.  You have to be working the turbo hard enough to be producing sufficient intake heat  that would then need be dissipated, which typically means 10PSI or more boost.  As such, the only time the intercooler needs cooling effect from ambient air flow over the core is when you are already moving fast enough for it to work efficiently.  :thumbs:
Title: Re: The Intercooler Thread
Post by: Arabas on July 31, 2012, 07:51:30 AM
thx a lot for your reply Bill!!
very reasonable and very easy to understand!!  :thumbs:
Title: Re: The Intercooler Thread
Post by: kennysabarese on July 31, 2012, 09:25:26 AM
Sky888 has (or had at some point) sprayers on his IC to help cool it down even more. So external methods can help. Especially in the case where you don't have enough room in the car to fit an IC large enough for the power you are making.
Title: Re: The Intercooler Thread
Post by: Arabas on July 31, 2012, 09:28:02 AM
thx Kenny, i remember we had this discussion some time ago.
i am not looking for more power at the moment, just trying to find out which are the practical ways to get the coldest air possible into the engine.
Title: Re: The Intercooler Thread
Post by: Critterman on July 31, 2012, 09:28:55 AM
Move to the Artic?
Title: Re: The Intercooler Thread
Post by: Arabas on July 31, 2012, 09:32:04 AM
Move to the Artic?

Greek summer is exactly the opposite of the Arctic, so that's why i am curious about practical ways.
a downside of the arctic is that there are no sand beaches... :)
Title: Re: The Intercooler Thread
Post by: Dave@DDMworks on July 31, 2012, 09:38:17 AM
would an ic be more effective if it had a fan mounted on it and staying on all the time?

FYI - the only time we have seen this as a benefit is on a couple drift cars that we worked on. The reason it worked well on those, is because the cars are sideways for a lot of time, the air entering the front grill is reduced, which reduced the air going through the intercooler, causing IAT's to climb pretty quick. With the fans in place (several pretty large Spal fans) the IAT's could be kept down.

Otherwise, like Bill said, once you are moving, the fans start to become a restriction to the flow of air through the intercooler/radiator.
Title: Re: The Intercooler Thread
Post by: kennysabarese on July 31, 2012, 09:43:31 AM
thx Kenny, i remember we had this discussion some time ago.
i am not looking for more power at the moment, just trying to find out which are the practical ways to get the coldest air possible into the engine.

I didn't mean you put the coolers on to get more power. I meant that if you are making big power with a bigger turbo, you need an IC so large it doesn't fit into the space we have. So by getting additional cooling via water or C02 spray, you can make up for the lack of size.
Title: Re: The Intercooler Thread
Post by: Sly Bob on July 31, 2012, 09:52:31 AM
 Looked at my inter cooler when I had the bumper off the other day and it's getting beat up with rocks. There maybe a new inter cooler in my future sooner rather than later.
Title: Re: The Intercooler Thread
Post by: wspohn on July 31, 2012, 10:02:57 AM
Otherwise, like Bill said, once you are moving, the fans start to become a restriction to the flow of air through the intercooler/radiator.

Yup. I always run a fan on the race cars because we used to get delayed in pregrid and some of them don't like to restart once they are hotter than heck sitting idling in the sun. Always gives you a good feeling to just reach out and flick a switch and sit comfortably while those around you without fans start uttering muted (by the helmets) screams at the track crew to get things on the road.  I gladly sacrifice any small reduction in cooling caused by the fan blocking air at speed for that sense of security in pregrid!
Title: Re: The Intercooler Thread
Post by: Dave@DDMworks on July 31, 2012, 10:10:03 AM
Yup. I always run a fan on the race cars because we used to get delayed in pregrid and some of them don't like to restart once they are hotter than heck sitting idling in the sun. Always gives you a good feeling to just reach out and flick a switch and sit comfortably while those around you without fans start uttering muted (by the helmets) screams at the track crew to get things on the road.  I gladly sacrifice any small reduction in cooling caused by the fan blocking air at speed for that sense of security in pregrid!

I am guessing you are talking about a radiator fan? If so, are you running shrouding on the fan, or is the fan just mounted to the radiator with no shroud?
Title: Re: The Intercooler Thread
Post by: wspohn on July 31, 2012, 10:17:05 AM
Yes, radiator fan, and no, I don't run shrouding - I don't need it at idle and it would just further block the air at speed.  I have the whole nose of the car ducted to the radiator and have no cooling issues once under way.

The IC on the Kappas puts out a fair bit of thermal load, straight into the radiator which must make that component critical as well. Are the racers running upgraded rads as well as ICs?  Kind of compounds the issue.
Title: Re: The Intercooler Thread
Post by: Dave@DDMworks on July 31, 2012, 10:30:27 AM
Yes, radiator fan, and no, I don't run shrouding - I don't need it at idle and it would just further block the air at speed.  I have the whole nose of the car ducted to the radiator and have no cooling issues once under way.

The IC on the Kappas puts out a fair bit of thermal load, straight into the radiator which must make that component critical as well. Are the racers running upgraded rads as well as ICs?  Kind of compounds the issue.

On the shrouding we run the rubber flaps like a lot of OEM's are doing now, it allows you to have shrouding for great cooling with the fan, then at speed the flaps open to allow air to flow out of the shroud easier, works really well. You have done the same as we have done though in the past with the fan direct to the radiator, no shrouding on the race car. Gives it enough to keep from over heating for minimal weight penalty and restriction to flow.
Title: Re: The Intercooler Thread
Post by: tazz on September 08, 2012, 05:31:18 PM
I have a cracked inter cooler :gaah:
Anyone know if it's covered under warranty GMPP?
Don't have the $$ for an aftermarket one right now so suggestions if it's not covered.
Thanks
Title: Re: The Intercooler Thread
Post by: kennysabarese on September 08, 2012, 05:45:38 PM
I think it is covered under drivetrain warranty
Title: Re: The Intercooler Thread
Post by: tazz on September 08, 2012, 06:01:28 PM
I hope so but Im not too sure.  Im looking at my warranty booklet and I don't see air charge cooler or inter cooler listed I might be SOL.
Title: Re: The Intercooler Thread
Post by: kennysabarese on September 08, 2012, 06:02:21 PM
There are definitely some people who have had it replaced out there. I'm sure someone will speak up eventually.
Title: Re: The Intercooler Thread
Post by: elff on September 08, 2012, 06:13:49 PM
Reed just had his repaired under warranty no more than 2 months ago.
Title: The Intercooler Thread
Post by: Gentleman Jack on September 08, 2012, 09:20:10 PM
It is covered by the exhaust warranty. In CA its 80,000 miles or 8 years. Not sure if that translates through. Found the excerpt for Reed two months ago. Search his thread posts as he posted the whole section. How many miles on your car?
Title: Re: The Intercooler Thread
Post by: tazz on September 08, 2012, 09:40:45 PM
Cali warranty as well as a few other states are different than the rest of the US.
Other question is since its past 5yrs in service date by 5 mos if covered by the 5yr 100k warranty will it carry over to the GMPP extended warranty?  I'm thinking probably NOT so either way I'm more than likely screwed or possibly might have to something since its past.  Maybe since i have had issue too many to count they might give me a free courtesy NC repair.
Does anyone know if the split can be TIG welded effectively?
Title: Re: The Intercooler Thread
Post by: tazz on September 08, 2012, 09:51:30 PM
 Did find this though on GM Inside News.
 
Basically its covered but the 5yrs i think is the deciding factor for me since Im over. J5685       Intercooler Assembly -- Replace

2007 to 2009 model year GM 5yr/100k Powertrain Warranty
EDIT: The following items apply to 2007-2009 vehicles only
Here is a list of the items covered by the powertrain warranty, LONG READ!
Obvious stuff, I just copied this from the GM manual, this is not an absolute guarantee, as things like excessive wear or damage may cause part or failure to lose coverage.
Powertrain Coverage
The information contained herein was correct at the time of dissemination. General Motors reserves the right to change it in the future.
Coverage Code P/P1 see following
Applicable To U.S. Powertrain Warranty
P - Passenger Car and LD Truck Powertrain Components- 5 years/100,00 miles
P1 - Passenger Car and LD Truck Powertrain Components that require maintenance
5 years/ 100,000 without interruption if maintenance was performed in accordance with the GM Maintenance Schedule
Canadian Powertrain Warranty
P - Passenger Car and LD Truck Powertrain Components- 5 years/160,000km
P1 - Passenger Car and LD Truck Powertrain Components that require maintenance
5 years/ 160,000km without interruption if maintenance was performed in accordance with the GM Maintenance Schedule
Refer to GM Service Policy and Procedure Manual for further information regarding policies and coverages, including applicable models and years.
Labor Operations E0000 -- E9999               
E0050    Cap, Wheel Nut -- Replace
E0072    Cap, Hub Assembly -- Front -- R&R or Replace
E0073    Cap, Hub Assembly -- Rear -- R&R or Replace
E0077    Cap, Hub Assembly -- All -- R&R or Replace
E2220    Bearing, Front Wheel -- Right -- Adjust
E2221    Bearing, Front Wheel -- Left -- Adjust
E2227    Bearing, Front Wheel -- Both -- Adjust
E2230    Cap, Front Wheel Hub Dust -- Right -- Replace
E2231    Cap, Front Wheel Hub Dust -- Left -- Replace
E2237    Cap, Front Wheel Hub Dust -- Both -- Replace
E2239    Front Wheel Hub, Bearing, and Seal Replacement
E2240    Bearing, Front Wheel -- Inner -- Right -- Replace
E2241    Bearing, Front Wheel -- Inner -- Left -- Replace
E2247    Bearing, Front Wheel -- Inner -- Both -- Replace
E2250    Bearing, Front Wheel -- Outer -- Right -- Replace
E2251    Bearing, Front Wheel -- Outer -- Left -- Replace
E2257    Bearing, Front Wheel -- Outer -- Both -- Replace
E2260    Bearing, Front Wheel -- Inner and Outer -- Right -- Replace
E2261    Bearing, Front Wheel -- Inner and Outer -- Left -- Replace
E2267    Bearing, Front Wheel -- Inner and Outer -- Both -- Replace
E2280    Seal, Front Wheel Bearing -- Right -- Replace
E2281    Seal, Front Wheel Bearing -- Left -- Replace
E2287    Seal, Front Wheel Bearing -- Both -- Replace
E2320    Bearing and Hub Assembly, Front Wheel -- Right -- Replace
E2321    Bearing and Hub Assembly, Front Wheel -- Left -- Replace
E2327    Bearing and Hub Assembly, Front Wheel -- Both -- Replace
E2340    Hub Assembly, Front Wheel -- Right -- Replace
E2341    Hub Assembly, Front Wheel -- Left -- Replace
E2347    Hub Assembly, Front Wheel -- Both -- Replace
E3600    Axle, I-Beam -- Replace
E4230    Bearings, Rear Wheel -- Right -- Adjust
E4231    Bearings, Rear Wheel -- Left -- Adjust
E4237    Bearings, Rear Wheel -- Both -- Adjust
E4240    Bearings, Rear Wheel -- Single or Front Tandem -- Right -- Replace
E4241    Bearings, Rear Wheel -- Single or Front Tandem -- Left -- Replace
E4250    Bearings, Rear Wheel -- Rear Tandem -- Right -- Replace
E4251    Bearings, Rear Wheel -- Rear Tandem -- Left -- Replace
E4260    Bearings, Rear Wheel -- Right -- Replace
E4261    Bearings, Rear Wheel -- Left -- Replace
E4267    Bearings, Rear Wheel -- Both -- Replace
E4270    Seal, Rear Wheel Inner Oil (One Wheel) -- Single or Front Tandem -- Right -- Replace
E4271    Seal, Rear Wheel Inner Oil (One Wheel) -- Single or Front Tandem -- Left -- Replace
E4280    Seal, Rear Wheel Bearing Inner Oil (One Wheel) -- Rear Tandem -- Right -- Replace
E4281    Seal, Rear Wheel Bearing Inner Oil (One Wheel) -- Rear Tandem -- Left -- Replace
E4300    Bearing and Hub Assembly, Rear Wheel -- Right -- Replace
E4301    Bearing and Hub Assembly, Rear Wheel -- Left -- Replace
E4307    Bearing and Hub Assembly, Rear Wheel --Both -- Replace
E4360    Hub Assembly, Rear Wheel -- Right -- Replace
E4361    Hub Assembly, Rear Wheel -- Left -- Replace
E4367    Hub Assembly, Rear Wheel -- Both -- Replace
E4370    Hub Assembly, Rear Wheel -- Single or Front Tandem -- Right -- Replace
E4371    Hub Assembly, Rear Wheel -- Single or Front Tandem -- Left -- Replace
E4380    Hub Assembly, Rear Wheel -- Rear Tandem -- Right -- Replace
E4381    Hub Assembly, Rear Wheel -- Rear Tandem --Left -- Replace
E5603    Rear Axle Bushing Replacement
E5622    Rear Axle Upper Control Arm Replacement
E5629    Rear Axle Lower Control Arm Replacement
E5700    Axle Assembly, Rear -- Replace
 
Labor Operations F0000 -- F9999               F0020    Angularity, Drive Line -- Check and Correct
F0025    Actuator, Front Differential Locking -- Replace
F0028    Seal, Front Differential Shifter -- Replace
F0040    Bearing, Center Support (between Trans and Rear Differential) -- Replace
F0060    Slip Joint, Propeller Shaft (between Trans and Rear Differential) -- Replace
F0092    Universal Joint, Front Propeller Shaft -- Front -- Replace
F0093    Universal Joint, Front Propeller Shaft -- Rear -- Replace
F0097    Universal Joint, Front Propeller Shaft -- Both -- Replace
F1002    Universal Joint, Rear Propeller Shaft -- Front -- Replace
F1003    Universal Joint, Rear Propeller Shaft -- Rear -- Replace
F1006    Universal Joint, Rear Propeller Shaft -- Intermediate -- Replace
F1007    Universal Joint, Rear Propeller Shaft -- Both -- Replace
F1200    Propeller Shaft, Front of Transfer Case -- Replace
F1201    Front Propeller Shaft Replacement
F1220    Propeller Shaft, Intermediate -- Replace
F1240    Propeller Shaft, Rear -- Replace
F1250    Propeller Shaft, Intermediate Axle -- Replace
F1280    Propeller Shaft Assembly (between Trans and Rear Differential) - R&R or Replace
F1295    Bracket, Driveline Support -- Replace
F1298    Support, Driveline -- R&R
F1300    Support, Driveline -- Replace
F1305    Tube, Driveline Torque -- Replace
F1420    Shaft, Front Differential Output -- Front -- Right -- Replace
F1421    Shaft, Front Differential Output -- Front -- Left -- Replace
F1427    Shaft, Front Differential Output -- Front -- Both -- Replace
F1440    Seals, Front Differential Output Shaft -- Front -- Right -- Replace
F1441    Seals, Front Differential Output Shaft -- Front -- Left -- Replace
F1447    Seals, Front Differential Output Shaft -- Front -- Both -- Replace
F1465    Shaft Assembly, Intermediate -- Replace
F1468    Seal, Intermediate Shaft -- Replace
F1469    Bearing, Intermediate Shaft (Front Drive Axle) -- Replace
F1470    Shaft, Inner Axle (Front Drive Axle) -- Replace
F1475    Front Wheel Drive Shaft Replacement -- Right Side
F1476    Front Wheel Drive Shaft Replacement -- Left Side
F1480    Rear Wheel Drive Shaft and Rear Axle Shaft Seal Replacement
F1485    Rear Wheel Drive Shaft Replacement
F1500    Halfshaft, Front Drive -- Front -- Right -- R&R
F1501    Halfshaft, Front Drive -- Front -- Left -- R&R
F1507    Halfshaft, Front Drive -- Front -- Both -- R&R
F1510    Halfshaft, Front Drive -- Front -- Right -- Replace
F1511    Halfshaft, Front Drive -- Front -- Left -- Replace
F1512    Halfshaft, Front Drive -- Front -- Both -- Replace
F1513    Halfshaft, Rear Drive -- Rear -- Right -- Replace
F1514    Halfshaft, Rear Drive -- Rear -- Left -- Replace
F1515    Halfshaft, Rear Drive -- Rear -- Both -- Replace
F1516    Halfshaft, Rear Drive -- Rear -- Right -- R&R
F1517    Halfshaft, Rear Drive -- Rear -- Left -- R&R
F1518    Halfshaft, Rear Drive -- Rear -- Both -- R&R
F1523    Shaft, Axle -- Intermediate -- Replace
F1530    Shaft, Axle -- Rear Axle -- Right -- Replace
F1531    Shaft, Axle -- Rear Axle -- Left -- Replace
F1537    Shaft, Axle -- Rear Axle -- Both -- Replace
F1540    Shaft, Axle -- Single or Front Tandem -- Right -- Replace
F1541    Shaft, Axle -- Single or Front Tandem -- Left -- Replace
F1550    Shaft, Axle -- Rear Tandem -- Right -- Replace
F1551    Shaft, Axle -- Rear Tandem -- Left -- Replace
F1555    Front Wheel Drive Shaft Outer Joint Replacement
F1556    Front Wheel Drive Shaft Inner Joint Replacement
F1566    Front Wheel Drive Shaft Inner Joint Boot Replacement
F1567    Front Wheel Drive Shaft Outer Joint Boot Replacement
F1568    Rear Wheel Drive Shaft Inner Joint Boot Replacement
F1569    Rear Wheel Drive Shaft Outer Joint Boot Replacement
F1575    Boot (Seal), Axle Shaft Joint -- One -- Replace
F1580    Front Wheel Drive Shaft Inner Joint and Boot Replacement
F1581    Front Wheel Drive Shaft Outer Joint and Boot Replacement
F1582    Rear Wheel Drive Shaft Inner Joint and Boot Replacement
F1583    Rear Wheel Drive Shaft Outer Joint and Boot Replacement
F1594    Seal, Axle Shaft Inner -- Rear -- Right -- Replace
F1595    Seal, Axle Shaft Inner -- Rear -- Left -- Replace
F1597    Seal, Axle Shaft Inner -- Rear -- Both -- Replace
F1600    Seal, Axle Shaft Oil -- Front Axle -- Right -- Replace
F1601    Seal, Axle Shaft Oil -- Front Axle -- Left -- Replace
F1607    Seal, Axle Shaft Oil -- Front Axle -- Both -- Replace
F1610    Seal, Axle Shaft Oil -- Rear Axle -- Right -- Replace
F1611    Seal, Axle Shaft Oil -- Rear Axle -- Left -- Replace
F1617    Seal, Axle Shaft Oil -- Rear Axle --Both -- Replace
F1650    Bearing, Axle Shaft -- Rear Axle -- Right -- Replace
F1651    Bearing, Axle Shaft -- Rear Axle -- Left -- Replace
F1657    Bearing, Axle Shaft -- Rear Axle -- Both -- Replace
F1660    Bearing, Rear Wheel -- Right -- Replace
F1661    Bearing, Rear Wheel -- Left -- Replace
F1662    Bearing, Rear Wheel -- Both -- Replace
F1665    Hub Assembly, Rear Wheel -- Right -- Replace
F1666    Hub Assembly, Rear Wheel -- Left -- Replace
F1667    Hub Assembly, Rear Wheel -- Both -- Replace
F1670    Seal, Hub Oil -- Rear Axle -- Right -- Replace
F1671    Seal, Hub Oil -- Rear Axle -- Left -- Replace
F1672    Seal, Hub Oil -- Rear Axle -- Both -- Replace
F1675    Gasket, Axle Oil -- Rear Axle -- Right -- Replace
F1676    Gasket, Axle Oil -- Rear Axle -- Left -- Replace
F1677    Gasket, Axle Oil -- Rear Axle -- Both -- Replace
F1680    Differential Oil Cooler Inlet Hose Replacement
F1681    Differential Oil Pump Inlet Hose Replacement
F1683    Differential Oil Cooler Replacement
F2001    Front Differential Carrier Oil Drain or Filler Plug Replacement
F2002    Cover/Gasket, Differential -- Front -- Replace
F2003    Cover and/or Gasket, Differential -- Rear Differential -- Replace
F2004    Cover and/or Gasket, Differential -- Rear Differential -- Right -- Replace
F2005    Cover and/or Gasket, Differential -- Rear Differential -- Left -- Replace
F2006    Cover and/or Gasket, Differential -- Rear Differential -- Rear -- Replace
F2020    Drive Pinion Flange/Yoke and/or Oil Seal Replacement
F2022    Seal, Pinion Shaft Oil -- Front Differential -- Replace
F2023    Seal, Pinion Shaft Oil -- Rear Differential -- Replace
F2024    Seal, Pinion Shaft Oil -- Single or Front Tandem -- Replace
F2025    Seal, Pinion Shaft Oil -- Rear Tandem -- Replace
F2027    Seal, Differential Carrier Extension Cover -- Replace
F2042    Flange, Pinion Shaft -- Front Differnetial -- Replace
F2043    Flange, Pinion Shaft -- Rear Differnetial -- Replace
F2115    Tube Assembly, Front Differential Output Shaft -- R&R or Replace
F2122    Carrier Assembly -- Front Differential -- R&R
F2123    Carrier Assembly -- Rear Differential -- R&R
F2124    Carrier Assembly -- Single or Front Tandem -- R&R
F2125    Carrier Assembly -- Rear Tandem -- R&R
F2134    Carrier Assembly Complete -- Single or Front Tandem -- Recondition
F2135    Carrier Assembly Complete -- Rear Tandem -- Recondition
F2142    Carrier Assembly Complete -- Front Differential -- Replace
F2143    Carrier Assembly Complete -- Rear Differential -- Replace
F2155    Rear Differential Clutch Control Module Replacement
F2158    Differential Carrier Bushing Replacement -- Front
F2159    Differential Carrier Bushing Replacement -- Rear
F2165    Differential Clutch Drum Assembly Replacement
F2166    Rear Wheel Drive Module Clutch Housing Replacement
F2183    Pinion Shaft, Pinion Gears and/or Side Gears, Differential -- Rear Differential -- Replace
F2185    Gears, Differential Side and Pinion -- Replace
F2186    Electronic Locking Differential Coil Lock Replacement
F2223    Case, Differential -- Rear Differential -- Replace
F2240    Plates, Limited Slip Clutch -- Replace
F2263    Bearings, Side -- Rear Differential -- Replace
F2283    Bearing, Pinion (Front and/or Rear) -- Rear Differential -- Replace
F2382    Ring Gear and Pinion -- Front Differential -- Replace
F2383    Ring Gear and Pinion -- Rear Differential -- Replace
F2620    Pad, Carrier Ring Gear Thrust -- Adjust
F2640    Filter, Carrier Oil -- Replace
F2680    Seal, Thru-Shaft Output -- Replace
F2683    Shaft, Thru-Shaft Output -- Replace
F2684    Bearing and/or Housing, Thru-Shaft -- Replace
F2685    Retainer, Thru-Shaft Output Bearing -- Replace
F2820    Shift Assembly, Axle (Electric) -- R&R or Replace
F2840    Motor, Axle Shift -- Replace
F2880    Block, Axle Shift Sliding -- Replace
F3023    Housing Assembly, Differential -- Rear Differential -- Replace
F3026    Seal, Rear Axle Housing Drain -- Replace
F3030    Bushing, Rear Differential Damping -- Right -- Replace
F3031    Bushing, Rear Differential Damping -- Left -- Replace
F3037    Bushing, Rear Differential Damping -- Both -- Replace
F3062    Housing, Axle -- Single or Front Tandem -- Rear -- Replace
F3063    Housing, Axle -- Rear Tandem -- Replace
F3200    Rear Differential Assembly (Complete) -- Replace
F3201    Rear Wheel Drive Module Replacement
F3262    Axle Assembly, Rear -- Single or Front Tandem -- Replace
F3263    Axle Assembly, Rear Tandem -- Replace
F3269    Ventilator, Axle -- Front -- Replace
F3270    Ventilator, Axle -- Rear -- Replace
F3272    Plug, Differential Carrier Drain -- Replace
F3273    Plug, Differential Carrier Fill -- Replace
 
Labor Operations J0000 -- J2999 J0100     Manifold, Exhaust -- Right Bank -- Replace
J0101     Manifold, Exhaust -- Left Bank -- Replace
J0102     Manifold Converter Assembly, Exhaust -- Right Bank -- Replace
J0103     Manifold Converter Assembly, Exhaust -- Left Bank -- Replace
J0104     Manifold Converter Assembly, Exhaust -- Single -- Replace
J0106     Manifold and/or Gasket, Exhaust -- Replace
J0108     Manifold, Exhaust -- Replace
J0152     Spacer, Intake -- Replace
J0153     Intake Manifold Tube Replacement
J0194     Cover, Upper Intake Manifold -- Replace
J0207     Cover and/or Gasket, Engine Block Valley -- Replace
J0241     Charge Air Cooler Front Manifold Replacement
J0250     Manifold, Intake -- Replace
J0251     Gasket, Intake Manifold -- Replace
J0254     Manifold, Intake (Upper) -- Replace
J0255     Gasket, Intake Manifold (Upper) -- Replace
J0258     Manifold, Intake (Lower) -- Replace
J0259     Gasket, Intake Manifold (Lower) -- Replace
J0260     Manifold, Intake (Right) -- Replace
J0261     Gasket, Intake Manifold (Right) -- Replace
J0264     Manifold, Intake (Left) -- Replace
J0265     Gasket, Intake Manifold (Left) -- Replace
J0268     Manifold, Intake (Center) -- Replace
J0269     Gasket, Intake Manifold (Center) -- Replace
J0280     Cover, Valve Rocker Arm Upper -- Right -- Replace
J0281     Cover, Valve Rocker Arm Upper -- Left -- Replace
J0282     Cover, Valve Rocker Arm Upper -- Both -- Replace
J0300     Cover and/or Gasket, Rocker -- Right Bank -- Replace
J0301     Cover and/or Gasket, Rocker -- Left Bank -- Replace
J0307     Cover and/or Gasket, Rocker -- Both Banks -- Replace
J0308     Cover and/or Gasket, Rocker -- Replace
J0310     Cover and/or Gasket, Camshaft Housing -- Right -- Replace
J0311     Cover and/or Gasket, Camshaft Housing -- Left -- Replace
J0317     Cover and/or Gasket, Camshaft Housing -- Both -- Replace
J0318     Cover and/or Gasket, Camshaft Housing -- One Piece -- Replace
J0319     Camshaft Housing Replacement
J0336     Rocker Arm, Intake -- One Cyl -- Replace
J0337     Rocker Arm -- One Cylinder, Exhaust -- Replace
J0338     Rocker Arm, Exhaust -- One or All -- Replace
J0340     Rocker Arm, Intake (One or All) -- Right (Rear) Head -- Replace
J0341     Rocker Arm, Intake (One or All) -- Left (Front) Head -- Replace
J0342     Rocker Arm, Exhaust (One or All) -- Right (Rear) Head -- Replace
J0343     Rocker Arm, Exhaust (One or All) -- Left (Front) Head -- Replace
J0350     Rocker Arm - One Cyl -- Right Bank -- Replace
J0351     Rocker Arm - One Cyl -- Left Bank -- Replace
J0357     Rocker Arm - One Cyl -- Both Banks -- Replace
J0358     Rocker Arm - One Cyl -- Replace
J0359     Rocker Arm - One or All -- Replace
J0360     Rocker Arm Shaft and/or Assemblies -- Right Bank -- Replace
J0361     Rocker Arm Shaft and/or Assemblies -- Left Bank -- Replace
J0367     Rocker Arm Shaft and/or Assemblies -- Both Banks -- Replace
J0368     Shaft, Rocker Arm -- One or Both -- Replace
J0370     Arm and/or Pivot, Rocker -- One Cyl -- Right Bank -- Replace
J0371     Arm and/or Pivot, Rocker -- One Cyl -- Left Bank -- Replace
J0377     Arm and/or Pivot, Rocker -- One Cyl -- Both Banks -- Replace
J0380     Stud, Rocker Arm -- One Stud -- Right Bank -- Replace
J0381     Stud, Rocker Arm -- One Stud -- Left Bank -- Replace
J0420     Valve Lash -- Adjust
J0495     Plug, Cylinder Head Oil -- Right Bank -- Replace
J0496     Plug, Cylinder Head Oil -- Left Bank -- Replace
J0500     Gasket, Cylinder Head -- Right Bank -- Replace
J0501     Gasket, Cylinder Head -- Left Bank -- Replace
J0507     Gasket, Cylinder Head -- Both Banks -- Replace
J0508     Gasket, Cylinder Head -- Replace
J0509     Valve, Oil Flow Check -- Replace
J0510     Head, Cylinder -- Right Bank -- Replace
J0511     Head, Cylinder -- Left Bank -- Replace
J0517     Head, Cylinder -- Both Banks -- Replace
J0518     Head, Cylinder -- Replace
J0520     Valve -- One Cyl -- Right Bank -- Recondition or Replace
J0521     Valve -- One Cyl -- Left Bank -- Recondition or Replace
J0527     Valve -- One Cyl -- Both Banks -- Recondition or Replace
J0528     Valve -- One Cyl -- Recondition or Replace
J0529     Valve -- Replace
J0530     Guide, Valve -- One Cyl -- Replace
J0540     Spring, Cap and/or Seal, Valve -- One Cyl -- Right Bank -- Replace
J0541     Spring, Cap and/or Seal, Valve -- One Cyl -- Left Bank -- Replace
J0544     Spring, Cap and/or Seal, Valve -- All Seats -- Intake -- Replace
J0545     Spring, Cap and/or Seal, Valve -- All Seats -- Exhaust -- Replace
J0546     Spring, Cap and/or Seal, Valve -- All Seats -- Both -- Replace
J0547     Spring, Cap and/or Seal, Valve -- One Cyl -- Both Banks -- Replace
J0548     Spring, Cap and/or Seal, Valve -- One Cyl -- Replace
J0550     Spring, Cap and/or Seal, Valve -- Intake -- Replace
J0551     Spring, Cap and/or Seal, Valve -- Exhaust -- Replace
J0556     Spring, Cap and/or Seal, Valve -- Both -- Replace
J0560     Adjuster, Valve -- One Cyl -- Replace
J0565     Adjuster, Hydraulic Valve Lash -- One Cylinder, Intake -- Replace
J0566     Adjuster, Hydraulic Valve Lash -- One Cylinder, Exhaust -- Replace
J0580     Push Rod -- One Cyl -- Right Bank -- Replace
J0581     Push Rod -- One Cyl -- Left Bank -- Replace
J0587     Push Rod -- One Cyl -- Both Banks -- Replace
J0590     Guide, Push Rod -- One Cyl -- Right Bank -- Replace
J0591     Guide, Push Rod -- One Cyl -- Left Bank -- Replace
J0597     Guide, Push Rod -- One Cyl -- Both Banks -- Replace
J0610     Manifold, Valve Lifter Oil -- Replace
J0611     Gasket, Valve Lifter Oil Manifold -- Replace
J0620     Lifter, Valve -- Right Bank -- Replace
J0621     Lifter, Valve -- Left Bank -- Replace
J0627     Lifter, Valve -- Both Banks -- Replace
J0629     Lifter, Valve -- Replace
J0630     Lifter, Valve -- Intake -- Replace
J0631     Lifter, Valve -- Exhaust -- Replace
J0632     Lifter, Valve -- Both -- Replace
J0634     Lifters, Intake (One or All) -- Right Head -- Replace
J0635     Lifters, Intake (One or All) -- Left Head -- Replace
J0636     Lifters, Exhaust (One or All) -- Right Head -- Replace
J0637     Lifters, Exhaust (One or All) -- Left Head -- Replace
J0640     Guide and/or Clamp, Lifter -- One Cyl -- Right Bank -- Replace
J0641     Guide and/or Clamp, Lifter -- One Cyl -- Left Bank -- Replace
J0647     Guide and/or Clamp, Lifter -- One Cyl -- Both Banks -- Replace
J0686     Bracket, Timing Belt Tensioner -- Replace
J0720     Balancer, Harmonic -- Replace
J0736     Timing Belt Rear Cover Replacement
J0737     Timing Belt Upper Front Cover Replacement
J0738     Timing Belt Center Front Cover Replacement
J0739     Timing Belt Lower Front Cover Replacement
J0740     Seal, Crankcase Front Cover -- Replace
J0741     Crankshaft Front Oil Seal Replacement
J0750     Seal, Timing Cover Oil -- Replace
J0770     Cover and/or Gasket, Crankcase Front -- Replace
J0771     Engine Front Cover Replacement
J0772     Engine Front Cover with Oil Pump Replacement
J0778     Secondary Camshaft Intermediate Drive Chain Tensioner Replacement -- Right Side
J0779     Secondary Camshaft Intermediate Drive Chain Tensioner Replacement -- Left Side
J0780     Cover and/or Gasket, Timing -- Replace
J0781     Primary Timing Chain Guide Replacement -- Lower
J0784     Guide, Timing Chain -- Replace
J0785     Guides, Timing Chain -- Replace
J0786     Primary Timing Chain Guide Replacement -- Upper
J0787     Tensioner and/or Shoe, Timing Chain -- Replace
J0788     Tensioner, Secondary Timing Chain - Right Bank -- Replace
J0789     Tensioner, Secondary Timing Chain - Left Bank -- Replace
J0791     Tensioner, Timing Chain -- Replace
J0792     Shoe, Timing Chain -- Replace
J0794     Seal, Front Crankshaft Oil -- Replace
J0795     Dust Cover and/or Gaskets, Camshaft Drive Belt -- Upper -- Replace
J0800     Belt, Camshaft Timing -- Replace
P1           
J0802     Belt, Camshaft Timing -- Adjust
P1           
J0808     Cover, Camshaft Drive Belt -- Front -- Replace
J0810     Pulley, Camshaft Idler -- Replace
J0815     Tensioner, Timing Belt -- Replace
J0816     Pulley, Timing Belt Idler (One or Both) -- Replace
J0818     Camshaft Position Actuator Adjuster Replacement
J0819     Housing Assembly and/or Seal, Camshaft Position Sensor -- R&R or Replace
J0820     Chain, Camshaft Timing -- Replace
J0821     Oil Filter, Camshaft Position Actuator Solenoid Valve -- Replace
J0822     Solenoid Valve, Camshaft Position Actuator -- Replace
J0823     Actuator Sprocket, Camshaft Position -- Replace
J0824     Camshaft Position Actuator Replacement
J0825     Chain, Camshaft Secondary Drive -- Right Bank -- Replace
J0826     Chain, Camshaft Secondary Drive -- Left Bank -- Replace
J0828     Tensioner and/or Guide, Camshaft Primary Chain -- Replace
J0830     Sprocket, Crankshaft Timing -- Replace
J0835     Sprocket, Camshaft Timing -- Right Bank -- Intake -- Replace
J0836     Sprocket, Camshaft Timing -- Right Bank -- Exhaust -- Replace
J0837     Sprocket, Camshaft Timing -- Left Bank -- Intake -- Replace
J0838     Sprocket, Camshaft Timing -- Left Bank -- Exhaust -- Replace
J0839     Camshaft Timing Gear/Chain Set Replacement
J0840     Sprocket, Camshaft Timing -- Replace
J0842     Housing, Timing Cover -- Replace
J0844     Idler Sprocket and/or Bearing, Timing Chain -- Replace
J0846     Bearings, Camshaft -- Replace
J0849     Gear, Injection Pump Driven -- Replace
J0850     Camshaft -- Replace
J0851     Seal, Camshaft Front Oil -- Replace
J0852     Seal, Camshaft -- One Seal -- Right Bank -- Replace
J0853     Seal, Camshaft -- One Seal -- Left Bank -- Replace
J0855     Camshaft -- Intake -- Replace
J0856     Camshaft -- Exhaust -- Replace
J0857     Camshaft -- Both -- Replace
J0858     Housing and/or Gasket, Camshaft Position Actuator -- Replace
J0859     Valve, Camshaft Position Actuator Spool -- Replace
J0861     Magnet, Camshaft Postion Actuator -- Replace
J0862     Camshaft -- Right Bank -- Intake -- Replace
J0863     Camshaft -- Right Bank -- Exhaust -- Replace
J0864     Camshaft -- Left Bank -- Intake -- Replace
J0865     Camshaft -- Left Bank -- Exhaust -- Replace
J0866     Plate and/or Gasket Assembly, Cylinder Head Opening -- Replace
J0867     Plug and/or Seal, Cam Drive Access -- Replace
J0880     Gear(s), Balance Shaft -- Replace
J0885     Shaft, Intermediate -- Replace
J0890     Shaft and Bearing, Balance -- R&R or Replace
J0900     Cap, Oil Filler -- Replace
J0910     Breather, Crankcase Ventilation -- Replace
J0920     Oil Level Indicator Replacement
J0930     Tube, Oil Level Indicator -- Replace
J0932     Tube, Engine Oil Filler Rear -- Replace
J0933     Engine Oil Cooler Replacement
J0934     Pipe, Oil Intake -- Replace
J0935     Engine Oil Cooler Hose Replacement
J0944     Cap and/or Seal, Oil Filter -- Replace
J0960     Adapter and/or Gasket, Oil Filter -- Replace
J0964     Oil Filter Adapter and Oil Cooler Assembly Replacement
J0970     Valve, Oil Filter By-Pass -- Replace
J0971     Oil Pressure Relief Valve Replacement
J0973     Valve, Valve Lifter Oil Solenoid -- Replace
J0974     Module, Engine Oil Flow Control -- Replace
J0975     Switch, Engine Oil Flow Control -- Replace
J0982     Valve, Oil Pressure Relief -- Replace
J0986     Oil Tank Replacement
J0987     Oil Tank Outlet Hose Replacement
J0990     Plug and/or Gasket, Oil Pan Drain -- Replace
J1000     Pan and/or Gasket, Oil -- Replace
J1005     Baffle, Oil Pan -- Replace
J1008     Deflector, Oil Wheel -- Replace
J1010     Crankcase and/or Gasket -- Replace
J1011     Lower Crankcase Replacement
J1018     Gear, Oil Pump Drive -- R&R or Replace
J1020     Pump, Engine Oil -- Replace
J1040     Pump Cover and/or Gears, Oil -- Recondition or Replace
J1050     Drive, Oil Pump -- Replace
J1055     Cap and/or Seal, Oil Pump Drive -- Replace
J1057     Manifold and/or Gasket, Engine Oil -- Replace
J1059     Oil Pump, Screen, and Crankshaft Oil Deflector Replacement
J1060     Tube/Screen and/or Gasket, Oil Pickup -- Replace
J1080     Housing and/or Gasket, Rear Main Seal -- Replace
J1081     Crankshaft Rear Oil Seal Housing Replacement
J1085     Shaft Assemblies, Balance -- Replace
J1086     Bearings, Balance Shaft -- Replace
J1087     Drive Chain, Balance Shaft -- Replace
J1088     Tensioner, Balance Shaft -- Replace
J1089     Drive Sprocket, Balance Shaft -- Replace
J1090     Driven Sprocket, Balance Shaft -- Replace
J1093     Chain Guide, Balance Shaft -- Replace
J1120     Seal, Crankshaft Rear Main -- Replace
J1150     Bearing, Crankshaft Main -- One Bearing -- Replace
J1180     Bearing, Connecting Rod -- One Bearing -- Replace
J1190     Seal, Lower Crankcase -- Replace
J1195     Scraper, Crankshaft Oil -- Replace
J1200     Crankshaft -- Replace
J1300     Piston, Rod and/or Rings -- One Cyl -- Right Bank -- Replace
J1301     Piston, Rod and/or Rings -- One Cyl -- Left Bank -- Replace
J1307     Piston, Rod and/or Rings -- One Cyl -- Both Banks -- Replace
J1308     Piston, Rod and/or Rings -- One Cyl -- Replace
J1335     Sleeve, Cylinder Liner -- Replace
J1400     Flywheel (Automatic Transmission/Transaxle) -- Replace
J1420     Flywheel (Manual Transmission/Transaxle) -- Replace
J1440     Cover, Flywheel -- Replace
J1460     Housing, Flywheel -- Replace
J1500     Mount, Engine -- Front -- Right -- Replace
J1501     Mount, Engine -- Front -- Left -- Replace
J1502     Mount, Engine -- Front -- Replace
J1505     Engine Mount Replacement
J1506     Mount, Engine -- Front of Engine -- Replace
J1507     Mount, Engine -- Front - Both -- Replace
J1508     Engine Mount Replacement -- Right Side
J1509     Engine Mount Replacement -- Left Side
J1510     Mount, Engine -- Rear - Right -- Replace
J1511     Mount, Engine -- Rear - Left -- Replace
J1515     Engine Rear Mount Replacement
J1516     Mount, Engine -- Rear - Center -- Replace
J1517     Mount, Engine -- Rear - Both -- Replace
J1520     Strut, Engine Mounting -- Replace
J1540     Bracket, Engine Torque Strut -- Right -- Replace
J1541     Bracket, Engine Torque Strut -- Left -- Replace
J1600     Plug, Expansion -- Replace
J1640     Plug, Oil Gallery -- Replace
J1660     Plug or Cover and/or Gasket, Camshaft Rear Bearing -- Replace
J1800     Block, Engine Fitted -- Replace
J1810     Block, Engine Cylinder -- Replace
J1820     Engine, Partial -- Replace
J1840     Engine, Universal -- Replace
J1880     Engine Assembly -- Replace
 
Labor Operations J3000 -- J9999 J3128     Cover and/or Gasket, Oil Pan -- Replace
J3470     Cover and/or Gaskets, Coolant Pump -- Replace
J3475     Housing and/or Gasket, Coolant Pump -- Replace
J3480     Pump and/or Gasket, Coolant -- Replace
J3500     Thermostat, Outlet and/or Gasket -- Replace
J3508     Exhaust Gas Recirculation Cooling Pipe Replacement -- Upper
J3509     Exhaust Gas Recirculation Cooling Pipe Replacement -- Lower
J3512     Oil Pump Screen Replacement
J3514     Engine Coolant Air Bleed Pipe Replacement
J3519     Engine Coolant Thermostat Lower Housing Replacement
J3529     Engine Coolant Crossover Pipe Replacement
J3532     Plug, Water Jacket -- Right -- Replace
J3533     Plug, Water Jacket -- Left -- Replace
J3580     Pump, Electric Auxiliary Coolant -- Replace
J4353     Interrupter, Camshaft -- Replace
J4356     Ring, Crankshaft Position Sensor Reluctor -- Replace
J4620     Motor Assembly, Starter -- R&R
J4640     Starter Replacement
J5185     Regulator (Limiter), Fuel Pressure -- Replace
J5430     Pump and/or Gasket, Fuel -- Replace
J5467     Pump, Auxiliary Fuel Tank Transfer -- Replace
J5475     Fuel Return Hose Replacement -- Fuel Return Pipe to Fuel Injection Pump
J5476     Fuel Hose Replacement -- Fuel Injection Pump to Fuel Feed Block
J5490     Throttle Body Assembly Replacement
J5528     Camshaft Position Actuator Solenoid Valve Solenoid Replacement -- Bank 1 (Right Side) Intake
J5529     Camshaft Position Actuator Solenoid Valve Solenoid Replacement -- Bank 2 (Left Side) Intake
J5550     Injector, Sequential Central Port Fuel -- One -- Replace
J5560     Regulator and/or Gaskets, Fuel Pressure -- Replace
J5561     Fuel Pulse Dampener Replacement
J5590     Pump, Fuel (Engine Mounted) -- R&R or Replace
J5603     Fuel Pressure Sensor Replacement
J5646     Fuel Pressure Service Valve Replacement
J5650     Injector, Fuel -- Replace
J5654     Direct Fuel Injector Replacement
J5660     Rail, Fuel -- Replace
J5661     Fuel Injection Fuel Rail Crossover Tube Replacement
J5662     Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement
J5663     Fuel Pressure Sensor Replacement -- Fuel Feed Pipe
J5664     Fuel Pressure Sensor Replacement -- Fuel Injection Fuel Rail
J5665     Fuel Feed Pipe Replacement
J5666     Fuel Feed Intermediate Pipe Replacement
J5685     Intercooler Assembly -- Replace
J5688     Pipe/Duct, Turbo Outlet (to Change Air Cooler) -- Replace
J5689     Pipe/Duct, Charge Air Cooler Outlet (to Intake Manifold) -- Replace
J5690     Pipe, Inlet (Turbo to Intercooler) -- Replace
J5691     Pipe, Turbo to Intercooler Inlet (Both) -- Replace
J5694     Flexible Hose (Intercooler) (One) -- Replace
J5696     Flexible Hose (Intercooler) (Two) -- Replace
J5697     Inlet Pipe, Turbo to Charge Air Cooler (Intercooler) -- Replace
J5698     Rubber Hose, Turbo to Inlet Pipe (Intercooler) -- Replace
J5773     Charge Air Cooler Replacement
J5776     Pump Assembly, Charge Air Cooler Coolant -- Replace
J5787     Exhaust Turbocharger Inlet Pipe Adapter Replacement
J5788     Exhaust Manifold Outlet Pipe Replacement -- Right Side
J5789     Exhaust Manifold Outlet Pipe Replacement -- Left Side
J5790     Pipe, Turbocharger Outlet -- Replace
J5793     Pipe, Charge Air Cooler Inlet -- Replace
J5794     Pipe, Charge Air Cooler Outlet -- Replace
J5796     Hose, Charge Air Cooler Inlet -- Replace
J5797     Hose, Charge Air Cooler Outlet -- Replace
J5800     Actuator, Turbocharger Waste Gate -- Replace
J5805     Solenoid, Waste Gate -- Replace
J5807     Valve, Turbocharger Vane Position Solenoid -- Replace
J5812     Hose, Turbocharger to Charge Air Cooler -- One -- Replace
J5813     Hose, Turbocharger to Charge Air Cooler -- Both -- Replace
J5858     Turbocharger Assembly -- R&R
J5860     Turbocharger Assembly -- Replace
J5865     Pipe/Hose, Turbocharger Oil -- Replace
J5870     Hose and/or Pipe, Turbocharger Oil Return -- Replace
J5880     Line and/or Pipe, Turbocharger Oil Feed -- R&R or Replace
J5890     Cable, Charge Air Bypass -- Replace
J5891     Actuator, Supercharger Boost Control -- Replace
J5892     Manifold, Vacuum Source Supercharger Boost -- Replace
J5894     Solenoid, Supercharger Boost -- Replace
J5905     Gasket, Supercharger -- Replace
J5908     Supercharger Assembly -- Replace
J5928     Dampener, Fuel Injection Fuel Rail -- Replace
J5929     Rail, Common Fuel (Diesel) -- Replace
J5930     Line, Fuel Injection High Pressure (Diesel) -- Right -- R&R or Replace
J5931     Line, Fuel Injection High Pressure (Diesel) -- Left -- R&R or Replace
J5935     Line, Fuel Injection High Pressure (Diesel) -- One -- R&R or Replace
J5937     Line, Fuel Injection High Pressure (Diesel) -- All -- R&R or Replace
J5940     Nozzle and/or Seal, Fuel Injection (Diesel) -- One Nozzle -- Right -- Clean or Replace
J5941     Nozzle and/or Seal, Fuel Injection (Diesel) -- One Nozzle -- Left -- Clean or Replace
J5947     Nozzle and/or Seal, Fuel Injection (Diesel) -- All Nozzles -- Clean or Replace
J5948     Vacuum Pump Assembly Replacement
J5950     Pump, Fuel Injection (Diesel) -- R&R
J5955     Pump, Fuel Injection (Diesel) -- Replace
J5956     Connector Assembly, Fuel Return Line (Diesel) -- R&R or Replace
J5962     Gear and/or Advance Timing Mechanism, Fuel Injection Pump -- Replace
J5963     Coupling Assembly, Fuel Injection Pump Drive (Diesel) -- Replace
J6000     Valve, PCV -- Replace
J6036     Tank Assembly, Intake Manifold Tuning Valve Actuator Vacuum -- Replace
J6354     Powertrain Control Module Engine Reprogramming with SPS
J6355     Pwertrain Control Module Transmission Reprogramming wiht SPS
J6360     Powertrain Control Module Replacement
 
Labor Operations K0000 -- K4999               K0280    Arm, Clutch -- Replace
K0300    Shaft and/or Bushings, Clutch Fork -- Replace
K0610    Cylinder, Concentric Slave -- Replace
K0620    Cylinder, Clutch Actuator -- R&R or Replace
K0700    Bearing, Clutch Release -- Replace
K0720    Fork and/or Ball Stud, Clutch Release -- Replace
K0850    Housing, Clutch -- Replace
K2150    Plug and/or Washer, Transaxle Fluid Drain -- Replace
K2160    Seal, Transmission Extension Rear Oil -- Replace
K2162    Seal, Main Shaft Rear -- Replace
K2164    Flange, Propeller Shaft Transmission -- Replace
K2200    Gasket, Mainshaft Rear Bearing Retainer -- Replace
K2205    Retainer and/or Gasket, Front Bearing -- Replace
K2240    Cover and/or Gasket, Transmission/Transaxle Shift -- R&R or Replace
K2250    Cover and/or Gasket, Shift Detent -- Replace
K2280    Mount, Transmission/Transaxle -- Right -- Replace
K2281    Mount, Transmission/Transaxle -- Left -- Replace
K2282    Mount, Transmission/Transaxle -- Front -- Replace
K2283    Mount, Transmission/Transaxle -- Rear -- Replace
K2284    Transmission Mount Replacement
K2287    Mount, Transmission/Transaxle -- Both -- Replace
K2290    Bracket, Transmission/Transaxle Mount -- Replace
K2295    Bracket, Transaxle Strut Mount (to Cradle) -- Replace
K2400    Valve, Air Slave -- R&R or Replace
K2420    Valve, Transmission Splitter (Three Position) -- Replace
K2440    Valve, Range Control (Two Position) -- Replace
K2500    Cover and/or Gasket, Reverse Idler -- Replace
K2560    Rear Cover, Transaxle -- R&R or Replace
K2570    Hose and/or Tube, Transaxle Vent -- Replace
K2600    Case Assembly, Auto Transaxle -- Replace
K2700    Transmisson Assembly -- Recondition
K2720    Transmission/Transaxle Assembly -- Replace
K2738    Case -- R&R or Replace
K2739    Input Shaft Bearing Replacement
K2740    Transmission Fluid Pump Replacement
K2744    Cover and/or Gasket, Power Take-Off -- R&R or Replace
K2748    Gear -- 6th Speed Gear -- R&R or Replace
K2749    Gear -- 4th Speed Gear -- R&R or Replace
K2750    Gear -- Reverse Gear -- R&R or Replace
K2751    Gear --5th Speed Gear -- R&R or Replace
K2752    Gear --3rd Speed Gear -- R&R or Replace
K2753    Gear --2nd Speed Gear -- R&R or Replace
K2754    Gear --1st Speed Gear -- R&R or Replace
K2755    Synchronizers -- 1st-2nd -- R&R or Replace
K2756    Synchronizers -- 3rd-4th -- R&R or Replace
K2757    Synchronizers -- 5th-Reverse -- R&R or Replace
K2758    Shaft, Input -- R&R or Replace
K2759    Mainshaft -- R&R or Replace
K2760    Idler Assembly, Reverse -- R&R or Replace
K2761    Countershaft and/or Bearing(s) -- Countershaft -- R&R or Replace
K2762    Countershaft and/or Bearing(s) -- Countershaft Bearing(s) -- R&R or Replace
K2763    Front Housing/Sealer -- R&R or Replace
K2764    Rear Housing/Sealer -- R&R or Replace
K2765    Fork and/or Shaft, Shift -- 1st-2nd -- R&R or Replace
K2766    Fork and/or Shaft, Shift -- 3rd-4th -- R&R or Replace
K2767    Fork and/or Shaft, Shift -- 5th-Reverse -- R&R or Replace
K2768    Socket, Shift -- R&R or Replace
K2769    Tower, Shift -- R&R or Replace
K2773    Gear -- 5th & 6th Driven -- R&R or Replace
K2775    Gear -- 6th Drive -- R&R or Replace
K2778    Synchronizers -- 5th-6th -- R&R or Replace
K2780    Synchronizers -- Reverse -- R&R or Replace
K2785    Fork and/or Shaft, Shift -- 5th-6th -- R&R or Replace
K2788    Fork and/or Shaft, Shift -- Reverse -- R&R or Replace
K2789    Fork and/or Shaft, Shift -- 5th-6th and Reverse Shaft -- R&R or Replace
K2790    Shaft and/or Bearing, Counter Shaft Extension -- Replace
K2792    Plate and/or Sealant, Adapter -- Replace
K2818    Seal, Selector Shaft -- Replace
K2822    Retainer, Main Shaft Bearing -- Replace
K2823    Seal, Input Shaft -- Replace
K2824    Bracket, Shift Control Lever -- Replace
K2826    Shaft, Shift Control Lever -- Replace
K2828    Lever Assembly, Reverse Shift -- Replace
K2830    Shaft Assembly, Shift Control -- Replace
K2832    Synchronizers -- 6th -- R&R or Replace
K2834    Synchronizers -- 4th-6th -- R&R or Replace
K2836    Synchronizers -- 2nd-3rd -- R&R or Replace
K2932    Fork, Shift -- 1st-Reverse -- R&R or Replace
K2934    Fork, Shift -- 2nd-3rd -- R&R or Replace
K2936    Fork, Shift -- 4th-5th -- R&R or Replace
K2938    Fork, Shift -- 6th -- R&R or Replace
K3010    Seals, Axle (Transaxle) -- Right -- Replace
K3011    Seals, Axle (Transaxle) -- Left -- Replace
K3012    Front Wheel Drive Shaft Seal Replacement
K3017    Seals, Axle (Transaxle) -- Both -- Replace
K3120    Transaxle Assembly -- Replace
K3130    Differential Assembly -- R&R or Replace
K3131    Bearings, Differential Gear Assembly Side -- R&R or Replace
K3132    Ring Gear, Differential Gear Assembly -- R&R or Replace
K3133    Pinion and Side Gears, Differential Gear Assembly -- R&R or Replace
K3134    Speedometer Gear, Differential Case Assembly -- R&R or Replace
K3135    Case, Differential -- R&R or Replace
K3137    Shaft and/or Gears, Intermediate -- Shaft -- Replace
K3138    Shaft and/or Gears, Intermediate -- 1st Gear -- Replace
K3139    Shaft and/or Gears, Intermediate -- 2nd Gear -- Replace
K3140    Shaft and/or Gears, Input -- 5th Gear -- R&R or Replace
K3141    Shaft and/or Gears, Input -- 4th Gear -- R&R or Replace
K3142    Shaft and/or Gears, Input -- 3rd Gear -- R&R or Replace
K3145    Shaft and/or Gears, Input -- Input Shaft -- R&R or Replace
K3146    Shaft and/or Gears, Input Cluster -- R&R or Replace
K3150    Shaft and/or Gears, Output - 5th Gear -- R&R or Replace
K3151    Shaft and/or Gears, Output - 4th Gear -- R&R or Replace
K3152    Shaft and/or Gears, Output - 3rd Gear -- R&R or Replace
K3153    Shaft and/or Gears, Output - 2nd Gear -- R&R or Replace
K3154    Shaft and/or Gears, Output - 1st Gear -- R&R or Replace
K3155    Shaft and/or Gears, Output -- Output Shaft -- R&R or Replace
K3157    Shaft and/or Gears, Output -- Reverse -- R&R or Replace
K3158    Housing, Bearing Plate -- Replace
K3160    Synchronizers -- 5th -- R&R or Replace
K3161    Synchronizers -- 3rd-4th -- R&R or Replace
K3162    Synchronizers -- 1st-2nd -- R&R or Replace
K3165    Idler Assembly, Reverse -- R&R or Replace
K3170    Clutch or Differential Housing -- R&R or Replace
K3175    Bearing/Sleeve Assembly, Input Shaft -- R&R or Replace
K3176    Bearing, Input Shaft Roller (Quill) -- Replace
K3178    Bearing/Sleeve Assembly, Output Shaft -- R&R or Replace
K3179    Bearing, Output Shaft Roller -- Replace
K3180    Transaxle Case -- R&R or Replace
K3185    Fork and/or Shaft, Shift -- 1st-2nd -- R&R or Replace
K3186    Fork and/or Shaft, Shift -- 3rd-4th -- R&R or Replace
K3187    Fork and/or Shaft, Shift -- 5th -- R&R or Replace
K3189    Fork and/or Shaft, Shift -- Reverse Enable -- R&R or Replace
K4121    Transfer Case Module Reprogramming wth SPS
K4122    Module, Transfer Case Shift -- Replace
K4126    Actuator Assembly, Transfer Case -- Replace
K4129    Transfer Case Two/Four Wheel Drive Actuator Replacement
K4160    Seal, Transfer Case -- Replace
K4162    Seal, Transfer Case Front Output Shaft -- Replace
K4163    Seal, Transfer Case Rear Output Shaft -- Replace
K4164    Seal, Transfer Case Input Shaft -- Replace
K4165    Input Shaft Seal Replacement -- Right
K4166    Input Shaft Seal Replacement -- Left
K4175    Front Output Shaft Front Bearing Replacement
K4176    Input Shaft Bearing Replacement
K4177    Rear Output Shaft Rear Bearing Replacement
K4182    Gasket, Transfer Case Bearing Retainer -- Front Output Shaft (Front) -- Replace
K4183    Gasket, Transfer Case Bearing Retainer -- Front Output Shaft (Rear) -- Replace
K4188    Shaft, Transfer Case Output -- Replace
K4250    Gasket, Transfer Case to Adapter -- Replace
K4260    Gasket or Sealer, Transfer Case Rear Output Shaft Housing -- Replace
K4265    Bushing, Transfer Case Output -- Replace
K4280    Housing, Rear Output Shaft -- Replace
K4290    Plug, Transfer Case Drain -- Replace
K4291    Plug, Transfer Case Fill -- Replace
K4400    Transfer Case Assembly -- R&R
K4410    Transfer Case Assembly -- Replace
 
Labor Operations K5000 -- K9999               K5125    Actuator, Automatic Transmission Shift Lock Control -- Replace
K5126    Actuator, Automatic Transmission Shift Lock Control -- Adjust
K5140    Seal, Shift Lever -- Replace
K5364    Transmission Control Module Transmission Reprogramming with SPS
K5365    Module, Transmission Control -- Replace
K6130    Indicator, Transmission/Transaxle Oil Level (Dipstick) -- Replace
K6140    Tube and/or Seal, Transmission/Transaxle Filler -- Replace
K6150    Plug and/or Seal, Transmssion/Transaxle Fluid Drain -- Replace
K6263    Flange, Propeller Shaft Drive -- Replace
K6280    Cover and/or Gasket, Power Take-Off -- Replace
K6295    Transmisson Converter Cover Replacement
K6300    Bolts, Converter to Flywheel -- Replace
K6311    Sensor Assembly, Speed Input -- Replace
K6350    Switch, Automatic Transmission Manual Shift Shaft Position -- Replace
K6351    Switch Assembly, Auto Trans Fluid Pressure -- Replace
K6353    Solenoid, Pressure Control -- Replace
K6360    Seal, Extension Housing Rear -- Replace
K6361    Output Shaft Bearing Replacement -- Case
K6362    Bearing, Extension Housing -- Replace
K6364    Sensor, Input/Output Speed -- Replace
K6365    Flange, Transmission Companion -- Replace
K6367    Plug, Transmission Sealed -- Replace
K6370    Seal, Transmission Rear Oil -- Replace
K6388    Rear Case Replacement
K6390    Housing and/or Housing to Case O-Ring Seal or Gasket, Extension -- Replace
K6391    Scavenger Pipe and/or Seal -- Replace
K6395    Differential Carrier and Differential Final Assembly -- R&R or Replace
K6396    Final Drive Sun Gear -- R&R or Replace
K6397    Parking Gear -- R&R or Replace
K6398    Final Drive Sun Gear Shaft -- R&R or Replace
K6399    Gear, Final Drive Internal -- R&R or Replace
K6425    4th Servo -- R&R or Replace
K6431    Governor Assembly -- Replace
K6485    Timing Solenoid -- Replace
K6486    Lock-Up Solenoid -- Replace
K6491    Clutch, Sprag -- Replace
K6500    Pan and/or Gasket, Transmisison/Transaxle Oil -- Replace
K6501    Shaft Manual -- Replace
K6502    Lever, Detent -- Replace
K6503    Rod, Park Actuator -- Replace
K6504    Screens and/or Seals, Scavenger -- Replace
K6506    Accumulator, 1-2 -- R&R or Replace
K6507    Accumulator Assembly, 1-2, 2-3 -- R&R or Replace
K6508    Servo Assembly, Manual 2-1 -- R&R or Replace
K6509    Tube Assembly or Seals, Oil Feed -- Replace
K6511    Servo, Intermediate/4th -- R&R or Replace
K6512    Servo, Low/Reverse -- R&R or Replace
K6514    Valve, Oil Level Control -- Replace
K6519    Cover, Side or Seals -- Replace
K6520    Solenoid, Check Ball and Wiring Assembly -- Replace
K6523    Solenoids, A/B Shift -- Replace
K6528    Solenoid/Valve, 3-4, 4-5 Shift Control -- Replace
K6529    Seal, Manual Shaft -- Replace
K6533    Solenoid, Transmission Kickdown Shfit -- Replace
K6534    Switch and/or Seal, 3rd Clutch Pressure -- Replace
K6535    Switch and/or Seal, 4th Clutch Pressure -- Replace
K6536    Accumulator, Forward -- R&R or Replace
K6538    Manifold and/or Gasket, Clutch Pressure Control Solenoid -- Replace
K6539    Automatic Transmission Electrical Connector Passage Sleeve Replacement
K6540    Cover and/or Gasket, Valve Body -- Replace
K6543    Pump Assembly, Transaxle Oil -- R&R or Replace
K6550    Valve, Pressure Regulator -- Replace
K6552    Valve Assembly, TCC Apply -- R&R or Replace
K6554    Wiring Harness and/or Solenoid -- Harness Assembly -- Replace
K6555    Wiring Harness and/or Solenoid -- 1-2 Shift Solenoid -- Replace
K6556    Wiring Harness and/or Solenoid -- 2-3 Shift Solenoid -- Replace
K6557    Wiring Harness and/or Solenoid -- TCC PWM Solenoid -- Replace
K6558    Wiring Harness and/or Solenoid -- (On/Off) Solenoid -- Replace
K6559    Solenoid, 3-2 Control -- Replace
K6560    Valve Body, Transmission/Transaxle -- R&R or Replace
K6561    Accumulator, 3-4 -- R&R or Replace
K6562    Control Solenoid Valve and Transmission Control Module Assembly Replacement
K6564    Control Valve Body Replacement
K6567    Wiring Harness ans/or Solenoid, Torque Converter Clutch Solenoid -- Replace
K6569    Solenoid, 1-2, 3-4 Shift -- Replace
K6610    Valve Assembly, Lower Control -- R&R or Replace
K6611    Spacer Plate and Gasket Assembly -- Replace
K6615    Plate, Lower Channel -- Replace
K6620    Servo Assembly, Intermediate -- R&R or Replace
K6623    Servo Assembly, Reverse -- R&R or Replace
K6624    Servo Assembly, Forward -- R&R or Replace
K6626    Servo Assembly, 1-2 -- R&R or Replace
K6630    Servo Assembly, 2-4 -- R&R or Replace
K6640    Pawl, Shaft, Rod or Spring, Parking -- Replace
K6645    Detent Spring and Roller Assembly -- Replace
K6650    Piston and/or Spring, Accumulator -- Replace
K6660    Piston and/or Spring, 1-2 Accumulator -- R&R or Replace
K6675    Accumulator, Reverse -- R&R or Replace
K6685    Servo, Front -- R&R or Replace
K6686    Servo, Rear -- R&R or Replace
K6720    Mount, Transmission/Transaxle -- Right -- Replace
K6721    Mount, Transmission/Transaxle -- Left -- Replace
K6722    Mount, Transaxle -- Front -- Replace
K6723    Mount, Transmission/Transaxle -- Rear -- Replace
K6724    Transmission Mount Replacement
K6726    Mount, Transaxle -- Center -- Replace
K6727    Mount, Tranmission/Transaxle -- Both -- Replace
K6732    Bracket, Transaxle Mount -- Replace
K6733    Bracket, Transaxle Mount -- Right -- R&R or Replace
K6734    Bracket, Transaxle Mount -- Left -- R&R or Replace
K6738    Brace, Transaxle Support -- Replace
K6900    Seal, Transaxle Shaft Oil -- Right -- Replace
K6901    Seal, Transaxle Shaft Oil -- Left -- Replace
K6902    Front Differential Carrier Seal Replacement
K6907    Seal, Transaxle Shaft Oil -- Both -- Replace
K6925    Sleeve and/or Output Stub Shaft (Right) -- Replace
K6930    Gear and/or Output Shaft Bearing, Speedometer Drive -- Replace
K6940    Shaft, Transmission/Transaxle Output -- Replace
K6941    Output Shaft Seal Replacement
K6942    Sleeve, Output Shaft (Left) -- Replace
K7000    Transmission/Transaxle Assembly -- Replace
K7011    Torque Dampener Replacement
K7012    Torque Dampener Housing Replacement
K7020    Converter Assembly, Transmission/Transaxle -- Replace
K7023    Seal, Converter Hub Lip -- Replace
K7024    Shaft Assembly,
 
Title: Re: The Intercooler Thread
Post by: Sol Asylum on September 08, 2012, 10:26:26 PM
Do you think it may have been possible to get the Cliffnotes version of that?
Title: Re: The Intercooler Thread
Post by: tazz on September 08, 2012, 10:29:32 PM
I did in RED but then I just posted everything anyway.
Title: Re: The Intercooler Thread
Post by: reedred on September 08, 2012, 10:39:48 PM
The warranty information booklet that came in the packet with my 2009 manual says the 'Long-Term Emission Control System Defects Warranty' is 7 years/70,000 miles.  You get more time and miles in CA emissions states, which are CT, ME, MA, NJ, OR, PA, RI, VT, and WA (not NY- apparently we adopted the standards but not the warranty).  Specifically listed under the Air Management System subsection are the following: Charge Air Control Actuator, Charge Air Control Solenoid Valve, Charge Air Control Valve, Charge Air Cooler, and Charge Air Cooler Fan.

Good luck!
Title: Re: The Intercooler Thread
Post by: tazz on September 08, 2012, 10:45:46 PM
Mines an 07 GXP with GMPP major guard $0 deductable until 81K or Aug 2014 whichever comes first.
Found this on the GMPP website.
http://www.gmprotectionplan.com/majorguard.html (http://www.gmprotectionplan.com/majorguard.html)

Component Coverage
 Covered Parts
 •It's as simple as this: If it's not on the very short list of what's not covered, it's covered!
•For years, millions of Major Guard customers have known that, "From the engine to the trunk lock, if a part breaks - even if it results from wear and tear *Wear and Tear Coverage: The applicable coverage in the event an orginal or like replacement part is unable to function in normal service. - and it's not on the list of the few items not covered, Major Guard will pay for the repair less any applicable deductible - whatever the part!"
 
 
 Non-Covered Parts 
 •Sheet metal
•Body parts, panels and rails
•Bumpers
•Chassis frame
•Cross members
•Hinges
•Trim, moldings, and bright metal
•Paint
•Rust damage
•Convertible and vinyl tops
•Weather-strips
•Carpet and upholstery
 •Exhaust component and catalytic converter
•Tires
•Glass
•Lenses
•Sealed Beams
•Light Bulbs
•Batteries
•Brake drums
•Shock absorbers
•Squeaks , rattles, wind noise and odors
•Correction of air and water leaks
 
 
 Unless required in connection with a covered part we will not pay for: engine tune-up, suspension alignment, wheel balancing, filters, lubricants, engine coolant, drive belts, radiator hoses, heater and vacuum hoses, windshield wiper blades, air conditioning recharging, fluids, spark/glow plugs and wires, brake pads/linings and brake shoes/rotors, manual clutch disc, vehicle manufacturer recommended maintenance services and parts. 
 
Every other part is covered


Not on the list of NOT covered so I guess GMPP should cover it but we'll see.  I can see them trying to say it's an Exhaust component so as not to cover. 
Title: The Intercooler Thread
Post by: Gentleman Jack on September 09, 2012, 01:32:25 AM
Tazz,

How many miles?  If you posted already, im sorry, i missed it.
Title: Re: The Intercooler Thread
Post by: tazz on September 09, 2012, 07:16:09 AM
51K
I'll findout on Monday but my guess is that it has run out on the 5yr 100K part of the standard warranty since it is whichever comes first but they could decide to honor or at least have me pay a percentage.   The GMPP extended major Guard warranty should kick in but it's all going to hinge on wheather they consider the air charge cooler an exhaust component and if they do it's not covered since exhaust and or cat converter partsare not covered under GMPP major guard.  I think this may be the case because if you do a search via on GM-partsgiant the inter cooler is listed under the exhaust and fuel tab but who knows I still think I have a good shot at getting at least some if not all paid for since Ive had nothing but issues with this vehicle.
Title: The Intercooler Thread
Post by: Gentleman Jack on September 09, 2012, 11:09:05 AM
Tazz,

You're good to go. The IC will be covered under either one of the following (they will only choose one warranty to utilize)

Exhaust covered 7 years or 70 K miles (this is the one that covered Reed's IC i think)

Or

If not covered by the 7 yr 70K exhaust, then GMPP covers it.

You are good to go. If they try not to cover it, go somewhere else or just simply throw the book in their face. I don't even see a minor dispute here.

Title: Re: The Intercooler Thread
Post by: elff on September 09, 2012, 11:30:18 AM
Hey SA
Told Ya
Title: Re: The Intercooler Thread
Post by: Critterman on September 09, 2012, 11:42:18 AM
Okay, here is the deal, forget everything you have read, everything you have been told.  Go to the dealer, you either will have to pay or not.  Don't say anything about the federally mandated emissions coverage which most likely will cover you as it has others.  Just bite the bullet and pay if they ask for it.  Do not ask why it isn't covered.
Title: The Intercooler Thread
Post by: Gentleman Jack on September 09, 2012, 02:27:03 PM
Okay, here is the deal, forget everything you have read, everything you have been told.  Go to the dealer, you either will have to pay or not.  Don't say anything about the federally mandated emissions coverage which most likely will cover you as it has others.  Just bite the bullet and pay if they ask for it.  Do not ask why it isn't covered.

Thats great advice Critter. I should have thought of that.
Title: Re: The Intercooler Thread
Post by: Sol Asylum on September 09, 2012, 02:28:05 PM
Hey SA
Told Ya
:lol: :lol: :lol:
Title: Re: The Intercooler Thread
Post by: tazz on September 09, 2012, 02:42:35 PM
I talked to the asst service manager and he said it was NOT covered but he just did a quick check and they were closing so I really don't know if he actually looked it up.  As far as the 7yr 70K to my knowledge that extended warranty is only available to CA and the handful of other States mentioned if you live in another State then it reverts back to the 5yr 100K WHICHEVER COMES FIRST.   That's the way it have worked for YEARS on all my other vehicles.
I will call GMPP on Monday and ask THEM and then relay the message to the dealership.  As it is now unless I trip a code the dealer will not look at it so I have to diagnose it myself and prove to them it is the cause.  Last two issues Ive diagnosed the issue and had them replace part and guess what it fixed the problem.
Quite frankly they just don't really want to deal with me anymore since I usually tell them whats wrong and it pisses them off.  The next dealer is about 30 miles away then would be KC at 60 miles way so Im seriously thinking about taking my vehicle to KC from now on but who knows.  I don't know I really don't think any dealership unless they are a huge dealer really knows much about our vehicles and how to diagnose the isses.  Seems like there are some issues that are common but others that can vary from car to car.
Title: Re: The Intercooler Thread
Post by: tazz on September 10, 2012, 10:02:02 PM
Covered under the GMPP Major Gaurd warranty.
Not covered under CA and the 5(?) other States more Stringent emissions mandate since I do not live in one of those States.
Not covered under the Revised 7yr 70K emissions warranty for the 2009 like Reed because mine is an 2007.
Not covered under the 5yr 100K warranty for the 2007 model yr since my in service date was in early 2007 so it's past 5yrs.
The dealer tried to say that the inter cooler was part of the exhaust system since when they look it up via parts diagram it's part of the exhaust since the turbo is tied to the exhaust and the inter cooler is tied to the turbo.  Called GMPP and they said It's covered have the dealer call them for the warranty code.  Then the dealer tried to say it was a software glitch that caused the error in saying it was not covered.  Did findout though if a COVERED part breaks because of WEAR and TEAR it's covered but most items that wear out are exempt anyway so im not sure what that would really cover i guess like gears and hinges?
Title: The Intercooler Thread
Post by: Gentleman Jack on September 11, 2012, 02:00:22 AM
Well, that was easy.
Title: Re: The Intercooler Thread
Post by: Critterman on September 11, 2012, 09:52:19 AM
Bottom line it was covered.
Title: Re: The Intercooler Thread
Post by: elff on September 11, 2012, 10:36:46 AM
But since this is a change, the real question is does this boot you out of A Stock.
:D
Title: Re: The Intercooler Thread
Post by: Sol Asylum on September 11, 2012, 11:06:46 AM
Only if the tech doesn't put it back together exactly as it was, which you know they won't do.  Probably should just order the better aftermarket one since he'll be in a different class now. :D
Title: Re: The Intercooler Thread
Post by: elff on September 11, 2012, 11:15:10 AM
 :lol: :lol: :lol: :lol:
Title: Re: The Intercooler Thread
Post by: old goat on September 22, 2012, 12:14:45 PM
I just had some intercooler whoa's and I learned something from them, I have a Dejon IC that was cracked by and asshat hitting my parked car while in Costco. It took a while for it to get bad enough to have to fix it or even be able to figure out what it was.

Here is the bottom line I put my stock IC back, drove it a couple of days until I could get up to see Dejon Dave at the Powerhouse to get it fixed, the stock IC worked fine with my Westers tune car drove better than it did with a cracked intercooler for sure. I then put the Dejon IC back with zero other changes to the car. The difference is very noticeable, car has way more low end torque, and spools up faster as well. I lost a couple of lbs of boost at first dropped from 25-26 to 23-24 now after some miles it is back up to 25. This stuff is not magic or conjecture by Bill Hahn or me it's this thing called physics, the stock intercooler is in simplest terms a 2" pipe that flows air while attempting to cool it. Almost all the aftermarket IC's are at least twice as big in volume, and flow more like a 3" pipe, increased volume means air is in IC longer to get cooled, cooler air denser charge, then add the increased flow and what's not to love. ANY aftermarket IC is better than that piece o' crap GM stuck us with, notice they don't use it on the Cobalt SS. When Lyndon Wester saw his first GXP he told me that stock intercooler is junk, the first add on part I bought way back when their was the Dejon or the RPI, that was it, and mine was the first one Dejon ever shipped. I got it just before the very first Mod Meet.
Title: Re: The Intercooler Thread
Post by: Brazen17 on September 22, 2012, 02:09:07 PM
I have a cracked inter cooler :gaah:
Anyone know if it's covered under warranty GMPP?
Don't have the $$ for an aftermarket one right now so suggestions if it's not covered.
Thanks

I am on my second IC. Just had it replaced yesterday and it was covered under warranty.