For 1990-2009 cars

# DIESEL ROUGH IDLE MIN-MAX GOV. REPAIR KIT

CONDITION: A ROUGH IDLE CONDITION AND/OR COAST DOWN ROUGHNESS MAY BE CAUSED BY TOO GREAT A SENSITIVITY OF THE MIN-MAX GOVERNOR IN THE INJECTION PUMP. A REPAIR KIT TO REDUCE THIS SENSITIVITY HAS BEEN DEVELOPED. TECHNICIANS ATTENDING THE 1981 NEW PRODUCT SCHOOL HAVE BEEN TRAINED TO REMOVE THE MIN-MAX GOVERNOR ASSEMBLY WHEN REPLACING THE THROTTLE SHAFT SEALS AND SHOULD FIND THE REPAIR KIT EASY TO INSTALL. CORRECTION: ROUGHNESS AT IDLE UP TO 900 RPM MAY BE CORRECTED BY INSTALLING THIS REPAIR KIT. REFER TO BULLETINS 80-T-18 AND 80-T-18A TO CORRECT ROUGHNESS CONDITION OVER 900 RPM. A CONDITION MAY EXIST WHERE A ROUGHNESS IS OBSERVED ON COAST DOWN AT 50 MPH WITH A CLOSED THROTTLE. CONFIRM HOWEVER THAT THE CONDITION IS ENGINE ROUGHNESS RATHER THAN TIRE WADDLE OR A BENT WHEEL. COAST DOWN THROUGH THE ROUGHNESS PERIOD IN NEUTRAL AND WITH THE ENGINE AT 1500 TO 2000 RPM. IF ROUGHNESS IS GONE, INSTALL THE KIT. PROCEDURE: 1.DISCONNECT THE NEGATIVE CABLES FROM BOTH BATTERIES. 2.REMOVE THE AIR CLEANER AND AIR CROSSOVER. INSTALL SCREENS IN THE INTAKE MANIFOLD, AND LOOSELY REINSTALL THROTTLE CABLE BRACKET TO PROVIDE TENSION ON THE THROTTLE RETURN SPRING. 3.DISCONNECT THE INJECTION PUMP ELECTRICAL LEADS AND THE FUEL RETURN PIPE. 4.CLEAN THE INJECTION PUMP COVER, UPPER PORTION OF THE PUMP AND GUIDE STUD AREA. (FIG. 1) PLACE SEVERAL RAGS IN THE ENGINE VALLEY TO CATCH FUEL. 5.REMOVE INJECTION PUMP COVER AND REMOVE SCREWS FROM THE COVER. NOTICE: EXTREME CARE MUST BE EXERCISED TO KEEP FOREIGN MATERIAL OUT OF THE PUMP WHEN THE COVER IS OFF. IF ANY OBJECTS ARE DROPPED INTO THE PUMP, THEY MUST BE REMOVED BEFORE THE ENGINE IS STARTED AS INJECTION PUMP DAMAGE AND/OR ENGINE DAMAGE COULD OCCUR. 6.OBSERVE POSITION OF METERING VALVE SPRING OVER THE TOP OF THE GUIDE STUD. THIS POSITION MUST BE EXACTLY DUPLICATED DURING REASSEMBLY. (FIG. 1) 7.REMOVE THE GUIDE STUD AND WASHER. NOTE LOCATION OF PARTS PRIOR TO REMOVAL. (FIG. 1) 8.ROTATE THE MIN-MAX GOVERNOR ASSEMBLY UP TO PROVIDE CLEARANCE AND REMOVE FROM THE THROTTLE SHAFT. (FIG. 2) 9.ONCE THE MIN-MAX GOVERNOR ASSEMBLY IS REMOVED FROM THE PUMP, THE IDLE GOVERNOR SPRING AND THE GOVERNOR SLEEVE ARE TO BE REMOVED FROM THE MIN-MAX GOVERNOR ASSEMBLY AND BOTH ARE TO BE DISCARDED. (FIG. 3) 10.INSTALL THE PLAIN COLORED IDLE SPRING GUIDE (PIN) THROUGH THE SMALL END OF THE NEW SPRING. (THE RED IDLE SPRING GUIDE (PIN) IS ONLY TO BE USED AS DESCRIBED IN STEP 22A). 11.INSTALL IDLE SPRING GUIDE, IDLE SPRING AND GOVERNOR SLEEVE AS DESCRIBED IN FIG. 4. 12.PIVOT MIN-MAX GOVERNOR ASSEMBLY BACK INTO PUMP. (FIG. 5) 13.REINSTALL THE GUIDE STUD WITH A NEW WASHER, MAKING CERTAIN THAT THE UPPER EXTENSION OF THE METERING VALVE SPRING RIDES ON TOP OF THE GUIDE STUD. TORQUE THE GUIDE STUD TO 9.5 N.M (85 IN.LBS.). OVERTORQUEING THE GUIDE STUD MAY STRIP THE ALUMINUM THREADS IN THE HOUSING (FIG. 1). 14.HOLD THE THROTTLE IN THE IDLE POSITION. 15.INSTALL NEW PUMP COVER GASKET. MAKE SURE THE SCREWS ARE NOT IN THE COVER AND POSITION THE COVER ABOUT 1/4 INCH FORWARD (TOWARD SHAFT END) AND ABOUT 1/8 INCH ABOVE THE PUMP. 16.MOVE THE COVER REARWARD AND DOWNWARD INTO POSITION, BEING CAREFUL NOT TO CUT THE GASKET AND REINSTALL THE COVER SCREWS. BE CAREFUL NOT TO DROP FLAT WASHER AND INTERNAL LOCK WASHER WITH EACH SCREW. FLAT WASHER MUST BE AGAINST PUMP COVER. TORQUE TO 3.7 N.M (33 IN. LBS.). 17.RECONNECT THE NEGATIVE CABLES TO BOTH BATTERIES. 18.TURN THE IGNITION SWITCH TO THE RUN POSITION AND TOUCH THE PINK FUEL SOLENOID WIRE TO THE SOLENOID. (FIG. 1) A CLICKING NOISE SHOULD BE HEARD AS THE WIRE IS CONNECTED AND DISCONNECTED. IF THIS CLICKING IS NOT OBSERVED, THE LINKAGE MAY BE JAMMED IN A WIDE OPEN THROTTLE POSITION AND THE ENGINE MUST NOT BE STARTED. IF CLICKING IS OBSERVED CONNECT THE ELECTRICAL CONNECTOR(S) THEN PROCEED TO STEP 20. 19.IF CLICKING IS NOT OBSERVED REMOVE THE COVER. GROUND THE SOLENOID LEAD (OPPOSITE THE HOT LEAD) AND CONNECT THE PINK WIRE. WITH THE IGNITION SWITCH IN THE RUN POSITION, THE SOLENOID IN THE COVER SHOULD MOVE THE LINKAGE. IF NOT THE SOLENOID MUST BE REPLACED. MINIMUM VOLTAGE ACROSS SOLENOID TERMINALS MUST BE 12.0. 20.START THE ENGINE AND CHECK FOR LEAKS. 21.IDLE ROUGHNESS MAY BE OBSERVED DUE TO THE AIR IN THE PUMP, GIVE IT PLENTY OF TIME TO PURGE WHICH IT WILL DO BY ALLOWING THE ENGINE TO IDLE. IT MAY BE NECESSARY TO SHUT THE ENGINE DOWN FOR SEVERAL MINUTES TO ALLOW AIR BUBBLE TO RISE TO THE TOP OF THE PUMP WHERE THEY WILL BE PURGED. 22.USING A MAGTACH, SET IDLE SPEEDS ACCORDING TO EMISSION LABEL. 22A.IF IDLE SPEEDS CAN NOT BE SET TO SPECIFICATIONS, INSTALL IDLE SPRING GUIDE MARKED WITH RED WHICH HAS THE HEAD GROUND OFF APPROXIMATELY .017 IN. FOLLOW STEPS 5 THROUGH 22, CHANGING ONLY THE IDLE SPRING GUIDE (PIN). IF IDLE SPEEDS STILL CAN NOT BE SET TO SPECIFICATIONS, THE PUMP REQUIRES RECALIBRATION AT A ROOSA MASTER DEALER. 23.REMOVE THE INTAKE MANIFOLD SCREENS AND REINSTALL THE AIR CROSSOVER AND AIR CLEANER. 24.APPLY A DAUB OF BLUE PAINT TO THE PUMP MOUNTING FLANGE NEAR THE TIMING MARK. IN CASE OF FUTURE REPAIRS, THIS WILL ALERT ROOSA MASTER DEALERS THAT A GOVERNER KIT HAS BEEN INSTALLED. PARTS INFORMATION: PARTS WILL BE AVAILABLE FROM G.M. PARTS DIVISION AND THE ROOSA MASTER DEALER. EACH KIT CONTAINS: 1 SLEEVE 2 GUIDES (PIN) 1 SPRING 1 COVER GASKET 1 GUIDE STUD SEAL MIN-MAX GOVERNOR KIT GM NUMBER 22513809 ROOSA MASTER NUMBER 23162 WARRANTY INFORMATION: WHEN PERFORMING THESE REPAIRS UNDER WARRANTY, LIST ONLY THE GM GM NUMBER, REGARDLESS OF WHERE THE KIT WAS PURCHASED. OPERATION NUMBER T0037 P/N 22513809 T.C. 92 TIME .6 IF IT IS NECESSARY TO INSTALL THE RED GUIDE (PIN) ADD .3.

General Motors bulletins are intended for use by professional technicians, not a "do-it-yourselfer". They are written to inform those technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions and know-how to do a job properly and safely. If a condition is described, do not assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See a General Motors dealer servicing your brand of General Motors vehicle for information on whether your vehicle may benefit from the information.