Service Department

A “HOLDEN” Product.

BRISBANE SYDNEY MELBOURNE ADELAIDE PERTH

For the latest and/or any missing Techline bulletins,

please refer to Holden Lionheart

SERVICE TE CHNICIAN REFERENCE INFORMATION

ALL

(GROUP 0B) February 2000

This Techline is published to provide Dealership Service personnel with a list of commonly

requir ed Holden cont act Fax number s and som e helpful additional information.

HOLDEN SERVICE RELATED FAX No’s

HOLDEN TAS 03 9647 2495

HOLDEN SECURITY INFO. 03 9647 2865

IGM TAS/CAS 03 9644 6622

PIR’s (EDAG FUTURE) 03 9552 8104

REPAC 03 9647 1198

TECHNICI AN’s GUILD 03 9876 5797

CENTRAL SERVICE 03 9647 2525

HOLDEN CAS 03 9647 1237

WARRANT Y ADMIN. 03 9647 2525

Other Information:

PIR forms: request a pad ( 100 forms) by q uot ing “SD 28331” on a Merchandising Material

Order For m and fax to Salmat, on ( 03) 9251 6352.

Security Number Request Form: photocopy form attached to All Dealer Letter DL 63/99.

Tech 1 Repairs: Ref er HSPO Parts Techline Bullet in PT31, dated May 5, 1999.

Update

REAR WINDSCREEN MOULDING DISTORTION "HINT"

(GROUP 1) REISSUE/DELETION February 2000

A Service Techline with t he same title as above was issued in Issue 10, Decem ber , 1999 page 6. That

previous Techline should be destroyed.

The previously issued Techline item recommended removal and refit of distorted mouldings without

glass removal.

The earlier information was released to assist technicians in rectifying vehicles quickly in the pre-

Christmas period, where distortion may have occurred to the mouldings on some vehicles at pre-

delivery and very low kilometres. The procedure quoted was viable only for mouldings not correctly

fitted – and an in-plant rework was carried out using the same information.

It is no longer necessary to use this recommendation. Further replacement of mouldings must be

done as per the released Ser vice information (glass must be removed).

REVISED PROCEDURE FOR FITME NT OF

REAR DOOR FIXED WINDOW GLASS

VT (w agon) & WH

(GROUP 1) February 2000

In addition to the rear door fixed window glass

fitment procedure in VT Series Service Manual,

Volume No.1, page 1A5-19, and WH Series

Service Manual Supplement, Volume 1A, page

1A5-24 - when refitting the rear door fixed glass

for any reason, please perform the following

additional procedure.

The removal of the rear door fixed window is the

same as outlined in the service manual. When

reinstalling the window, perform the additional

steps outlined below:

• Using a small br ush, apply primer BETASEAL

43532, or a similar product to the door frame

painted surface "C" as shown in Section A-A

over a minimum length of 250m m as indicat ed

in Figures 1 & 2.

Section A - A

• Ensure the prim er is dr y before proceeding.

• Using a urethane product available from

HSPO P/N VS18319, or alternatively,

BETASEAL 58702, or BETASEAL 15685 -

apply a small, continuous bead in the cavity

between the encapsulated glass and the

primed area of the door frame.

Figure 1. – VT Wagon

Figure 2. - WH

• Reinstall the door frame seal ensuring to

clean up any excess urethane.

Suitable sealants and primers required and

noted in this procedure can be obtained from

windscreen fitment out lets.

Note: for revised procedure for VT sedan rear

door fixed window glass replacement –– Refer to

Techline Bulletin shown on page 93 of 1998

Service Communication Book .

100mm

150mm

REVISED EVAPORATOR THERMISTOR POSITION

TF RODEO V6

(GROUP 2) February 2000

Information from the field has revealed that V6 Rodeo vehicles may experience evaporator ice –

up on 100km+ distance trips. Evaporator ice up is usually described as poor blower fan output

with large quant it ies of water draining from the evaporat or when the vehicle is stationar y.

Air International has developed a revised thermistor position to prevent the evaporator

temperature dropping below zero degrees which causes the condensation on the evaporator to

freeze.

Refer to the diagram below for the revised thermistor position, and disregard any prior bulletins

referring to this subject.

Note- Evaporator viewed from the air

off side. Thermistor tip location

should be 150 mm from the upper

side and 100 mm (10 fins) from the

left side of the core.

The thermistor clip is approx. 20mm

from the plotted sensor tip point.

FRONT BRAKE HOSE RETENTION PRECAUTION

VT, WH

(GROUP 5) February 2000

This Techline item is a precautionary note to ensure correct reinstallation procedures are carried

out whenever front suspension, steering, or front br ake work is carried out on a vehicle.

Whenever front brake hose/s are removed from their retaining clip/s (on front suspension strut

body) during any service work, the br ake hose/s must be refitt ed int o t heir retaining clip/ s .

Refer to the sketch below for brake hose (1) location, showing its method of location in the strut

mounted clip.

Update

ABS WARNING LAMP ILLUMINATES - LHF

ABS SENSOR LEAD RETENTION

VT with ABS, & WH

(GROUP 5) February 2000

PROBLEM DESCRI PTION

On extreme suspension movement during turns,

excess length of the LHF ABS wheel sensor lead

may come into contact with the stabiliser bar

vertical link. The result of this may be an ABS

DTC 25 or 27, because the lead becomes

disconnected or stressed (causing poor terminal

contact) during suspension movement, resulting

in the ABS warning lamp on the instrument panel

illuminating, and ABS function being eff ect ed.

PRODUCTION RECTIFICATION

A retaining clip has been fitted to vehicles from:

PSN No.: Build Date:

L536320 01/12/99

SERVICE ACTIONS:

Where a VT(with ABS) or a WH is presented for

service with an ABS warning lamp illuminated, or

DTCs 25 or 27 stored in the ABS module, the

following procedur e should be car r ied out :

1. Turn vehicle steering to the furthest left

position.

2. Locate the left -hand front ABS sensor lead.

3. Inspect the sensor lead for damage, poor

routing, connector engagement or

disconnection, correct as necessar y.

4. Fit sensor lead retaining clip to brake hose

and sensor lead to ensure routing of lead as

per Figur e 1.

5. Connect Tech 2 and clear any existing ABS

DTCs.

6. Roadtest vehicle to ensure fault has been

rectified. Should any fault reoccur further

diagnosis should be carried out to determine

cause.

NOTE: This condition only affects VT/WH (with

ABS), from: L384387 to L536319, (built 29/09/98

to 01/12/99). An ABS retention clip should NOT

be fitted to vehicles built prior to L384387, as the

ABS lead length on those vehicles is shorter and

does not req uir e r etention.

Figure 1.

PARTS INFORMATION

Part No.: Description: Qty

92057758 Clip – Sensor Lead Retaining 1

WARRANTY CLAIM I NFORMATION:

Description Install re t aining clip to LHF ABS

sensor lead

Labour Op. No. H000216

Time 0.3 hr

Failure Code 51

CRANKSHAFT PULLEY BOLT

RODEO with 4JB1 –T

(GROUP 6A) February 2000

From engine number: 586429 (build - December 99), the crankshaft front pulley bolt tension for

the 4JB1- T engine has been increased to 24+/- .5kg.m (174+/- 4lb.ft, 235+/-5N.m) from 21+/- 2

kg . m (152+/- 14lb.ft, 206+/- 20 N. m).

All relevant workshop manuals should be chang ed accor dingly.

Dealers aware of any failed or loose bolts in engines manufactured after the above breakpoint

should notif y I-GM TAS immediately. (PH: 1800 032 608 )

Modified

insertion

oin

Early insertion

point

TURBOCHARGER FAILURE

JACKAROO with 4JX1 –TC

(GROUP 6A) February 2000

Jackaroo’s fitted with the 4JX1 –TC diesel engine may experience turbocharger failure due to air

leaking int o the suction side of t he primary oil pump at the oil st r ainer o ring.

Isuzu have modified the insertion point of the strainer for improved installation and sealing from

VIN no. JACUBS73GW7101646. Please refer to Diag ram A

All 4JX1 engines with turbocharger f ailure t hat are before the br eak point (JACUBS73G W7101646)

must have the following proceedure carried out t o pr event r epeat failure.

1) Check for two punch marks on the lip of the lower sump, adjacent to the drain plug. (refer

diagram B). If present the seal has already been replaced,do not proceed further,

contact IGM TAS.

Diagram A

Main sump

Lower sump

Front axle

Drain plug

Punch marks

Front of engine

ote – As viewed from underneath of vehicle.

Diagram B

2) Drain engine oil.

3) Remove lower sump

4) Remove primary oil pump str ainer and discar d

Note - There are two strainers visable when the lower sump is removed. The primary oil pump

strainer is fitted into the cylinder block and has a mounting bolt that attaches to main

bearing cap. T he secondar y oil pump st r ainer is fitted t o t he alum inium main sump.

5) Clean strainer inser t ion point

6) Fit new oil strainer ( Par t #. 8971370363) and seal ( Part #. 8971377980)

Note - W hen fitting new strainer and seal apply three bond 1207b ( HSPO part #.0882600080A )

sealant, to the seal.

7) Tension str ainer m ount bolt (20Nm)

8) Refit lower sump ( Use t hr ee bond 1207b on sealing surfaces)

9) Fill engine with oil

10) Test engine oil pressure with master gauge (refer 4JX1 workshop manual, section 6G,

page 3)

11) Center punch two marks into the lip of the lower sump adjacent to the drain plug as depicted

in diagram B.

ENGINE FRONT & REAR SEAL INSTALLATION TOOL CAUTION

VT, WH (GEN III V8)

(GROUP 6A) REISSUED February 2000

This Service Techline supersedes the previous Techline on this topic (Issue 10, December, 1999

page 9). This previous Techline should be dest r oyed.

This Techline item provides a revised service procedure regar ding engine f r ont seal replacement.

REVISED PROCEDURE:

W hen inst alling a f ront seal, or fr ont engine cover - Cent ralising t ool J41476 m ust not be at tached

with bolt/s.

The tool must be installed on the shaft and held in position by hand - using bolt/s to retain the

tool and over-tightening the bolt/s will result in tool breakage.

Please check the updated information in the current VT Service Manual CD. A revised page

6A3-92 copy is included (following this page) to attach over VT Series II Service Manual, Volume

14A, Page 6A3- 92 t o show this revision.

6A3-92 ENGINE MECHANICAL – GEN III V8 ENGINE

5. Install centralising Tool J 41476 as shown and hold

in position by hand.

NOTE: DO NOT install the crankshaft balancer bolt to

retain. If the bolt is installed and over-ti

htened the

alignment tool will be destroyed.

Important: Ali

n the tapered le

s of the tool with the

machined alignment surfaces on the front cover.

6. Ti

hten the two bolts

(

)

securin

Tool J 41480 to

the front cover, to the specified torque.

ALIGNMENT TOOL TO FRONT

COVER BOLT 25 Nm

TORQUE SPECIFICATION

7. Ti

hten the en

ine front cover bolts to the correct

torque specif ic atio n.

ENGINE FRONT COVER BOLT

TORQUE SPECIFICATION 25 Nm

8. Remove the alignment tools.

Figure 6A3-1

9. Measure the oil pan surface to front cover fo

flatness, as follows:

a. Place a strai

ht ed

e across the en

ine bloc

and front cover oil pan sealin

surfaces. Avoid

contact with the portion of the

asket tha

protrudes into the oil pan surface.

b. Insert a feeler

e between the front cove

and the strai

ht ed

e tool. The cover must be

flush with the oil pan surface or no more than

0.25 mm below flush (dimension ‘A’).

c. If the front cover-to-engine block oil pan surface

alignment is not within specifications, repeat the

cover alignment procedure.

10. If the correct front cover to en

ine block ali

nment

cannot be obtained, replace the front cover.

Figure 6A3-2

ENGINE VIBRATION ON ACCELERATION

JS VECTRA with C22SEL (A/T only)

(GROUP 6A) February 2000

PROBLEM DESCRIPTION

Some vehicles fitted with C22SEL engines and automatic transmission, may exhibit an engine

vibration or “boom”, upon medium to heavy acceleration from a stationary position at 1300 –

1700 rpm.

SERVICE RECTIFICATION

When presented with a customer complaint vehicle having the symptoms described above,

technicians should apply the following t hr ee- step procedure.

A. - Replace rear engine mount

Replace the rear eng ine mounting with the revised part detailed below. Follow instr uctions set out

in TIS 2000, Service Information section, Engine and Engine aggregates, Repair (remove, install,

adjust).

B. - De - stress engine and exhaust system

De-stress procedur e m ust be carried out on a 4 post hoist.

1. Drive vehicle onto vehicle hoist and disconnect battery. Select PARK and apply the

HANDBRAKE

2. Loosen the bolts securing the engine tor que rod, located at the RHF strut tower.

3. Raise vehicle on hoist to gain access to the RHF eng ine mount undercover, to g ain access to

engine mount at t achm ents.

4. Remove RHF engine mount under cover.

5. Loosen all engine mount t o sub- frame at t achm ents.

6. Loosen exhaust bolts at the joining interfaces

-Manifold to front pipe

-Front pipe to int ermediate pipe

-Interm ediate pipe to rear muffler

7. Lower vehicle on hoist, re-connect t he vehicle batt er y and star t the engine.

8. With the foot brake depressed, and engine idling repeatedly shift transmission between

reverse and drive a minimum of 10 times.

9. Select PARK, tur n engine off, disconnect t he vehicle batt er y.

10. Re-t or que the engine torque reaction rod bolts to specified torque.

11. Re-t or que the vehicle engine mounts t o the specified tor que.

12. Re-torque the vehicle exhaust system bolts to specified torque. Starting from the front of the

exhaust system through t o t he r ear .

NOTE: Refer TIS 2000, Service Information / Standard Information / ‘Other Information’

section for torque specs.

13. Re-fit RHF engine m ount undercover.

14. Lower hoist, re-connect the vehicle battery and adjust the engine idle speed as defined below.

C. - Adjust engine idle speed

1. With engine at normal operat ing temperat ur e, Connect Tech 2 to t he vehicle.

2. Select – Diagnostics / Model Year / Model type / Engine / Additional Functions / Adjust Idle

Speed.

3. Adjust eng ine idle speed to achieve 896 RPM, press the “confirm” soft key at the base of the

Tech 2 screen to com plet e.

4. With Tech 2 still connected, return to the additional functions menu and select Adjust Idle

Drive.

5. Adjust idle drive setting to achieve 896 RPM press the “confirm” soft key at the base of the

Tech 2 screen to com plet e.

6. Remove Tech 2 fr om the vehicle and road test to confirm success of pr ocedur e.

PARTS INFORMATION

Part No.: Description: Qty

90538303 Damper Block – Rear Mount 1

WARRANTY CLAIM I NFORMATION:

Description Tak e- off Vibr at ion Cor rection

Labour Op. No. J000636

Time 1.5 hr

Failure Code 28

HOLDEN ENGINE OIL AVAILABILITY

VS, VT, WH

(GROUP 6A) February 2000

This Techline bulletin is released to ensure technicians are aware of the following oils that are

available from HSPO:

Part No.: Description: Size

92142396 GF2 10W- 30 OIL 5 Litre

Preferred oil for use in all V6 (normally aspirated) and V6 Supercharged engines and Gen III V8.

Its use provides fuel economy benefits over the originally recommended 20W-50 SG/SH/SJ oil.

Not recommended for use in 5.0 l i t re V8 engine.

Holden recommends the use of 10W/30 GF2 engine oil for all VS & VT V6 engines with the

exception of LPG fuelled engines.

Part No.: Description: Size

92140105 20W-50 SJ/ CF O IL 5 Litre

For use in all V6 (normally aspirated) and V6 Supercharged engines and 5 litre V8 – normal

operating conditions – this oil is still a recommended oil f or V6 engines, but does not allow the f uel

economy benefits of GF2 10W-30 oil (as noted above).

Part No.: Description: Size

92142397 15W-40 SJ/ CF O IL 5 Litre

For use in all V6 (normally aspirated) and V6 Superchar ged engines and 5 lit re V8 – f or prolonged

use in snow areas - is still a recom mended oil f or V6 engines, but does not allow the fuel econom y

benefit s of GF2 10W-30 oil (noted above).

Part No.: Description: Size

92142398 LPG 15W-40 OIL 5 Litre

For use specifical ly in LPG equipped V6 vehicles.

Full HSPO information regarding these oils was published in Parts Bulletin M434, dated

26 October, 1999. Refer to your Parts Department to view HSPO Parts Bulletin M434, which

includes a Product News Brochure regarding these oils.

INTERMITTENT COLD STALL

SB with C14NZ

(GROUP 6A) February 2000

PROBLEM DESCRIPTION

Some vehicles fitted with C14NZ engines may experience an intermittent stall condition on

deceleration, shor tly after cold start. Some reports also suggest that intermitt ent stall may occur if

the engine is left idling for long per iods during engine warm up. Af ter t he stall condition occurs the

engine may appear to cr ank fast, have a lack of compression or be hard to restart. This condition

will be more pronounced in colder climates or during the winter months where ambient

temperat ur es below 10 degr ees exist.

SERVICE RECTIFICATION

1. Service personnel should thoroughly question the customer to ensure that the symptoms of

the stall complaint meet with the symptoms described above.

2. Connect Tech 1 and inspect vehicle for any DTC’s that may exist. Rectify the cause of these

DTC’s prior t o any further diagnosis.

3. Connect Tech 1 and compare engine data list parameters against QUICK CHECK F0: DATA

LIST SB Series, Service Manual, Volume 3, page J226. Any data errors can be further

diagnosed in section 5. 1. 6 of SB Series, Ser vice Manual, Volume 3, pag e J234

4. Install T ech 1, road test vehicle and attempt t o reproduce com plaint. SNAPSHOT engine data

list when stall occurs. Compar e captured data with :

- Q UICK CHECK F0: DATA LIST, SB Series, Ser vice Manual, Volume 3, page J226

- Section 5. 1.6 SB Series, Service Manual, Volume 3, page J234.

5. Install a fuel pressure gauge to the vehicle. Ensure that fuel pressure is within specification

and that no fuel system flow restrict ions exist. Fuel pressure gaug e may be left on the vehicle

while road testing to monitor any immediate loss of pressure when stalling occurs. (When

these actions are carried out – ensure that appropriate safeguards are made so no damage

occurs to any f uel line, and no fuel leak exists before, during or af t er the procedure.)

6. Check for loose connections. Apply a general “wiggle t est” to engine and m ain wiring har ness

connections as a means of fault location.

7. Check base ig nit ion t im ing setting as per SB Series, Service manual, Volume 3, page J-203.

Aft er com pleting the above inspections if no fault can be identified carry out the following:

8. Replace engine hydraulic lifters with revised part number detailed below. Refer SB Series

Service Manual, Volume 3, Page J 117.

9. After fitting revised hydraulic lifters ensure that engine oil fill meets Holden specification

15W-40 or 15W-50 meeting ACEA A2 or A3. Refer 1998 service communication book.

Page 103.

10. Roadtest vehicle and ensure no further st all exists.

11. Should any stall be evident after fitting of revised parts, refer to Service Techline, Issue 1,

February 1999, page 17 for f urther rectification and specific inspections.

PARTS INFORMATION

Part No.: Description: Qty

92065681 Hydraulic Lifter 8

A “H” etched on t he m achined land of the hydraulic lif ter plunger ident ifies the revised type lift er.

WARRANTY CLAIM I NFORMATION:

Where r eplacement of hydraulic lifters is r equired, use Warranty Claim information detailed below.

Description Cold Stall - Lifter Replace

Labour Op. No. J000639

Time 1.3 hr

Failure Code 83

W here a preliminary inspection identifies a fault and requirement for part replacement, other than

hydraulic lifter replacement, claim the relevant part labour operation as per the Labour Time

Manual. Where additional time is required, additional to published time, seek authorisation from

zone service representative.

DTC P0341/ P0342/ P0343 SET - CAM POSITION SENSOR FAULT

VT, WH with GEN III V8

(GROUP 6C) February 2000

PROBLEM DESCRIPTION

Investigation into reports of DTCs P0341, P0342, P0343 have identified a potentially faulty

camshaft position sensor. Separation of the camshaft position sensor internal circuit board can

cause the fault to occur. Customers may report that the check engine lamp is illuminated or that

extended cranking times exist.

SERVICE RECTIFICATION

Should the fault occur, inspect the date code stamped on the camshaft position sensor - Refer

Figure 1.

Replace fault y camshaft position sensor s with date codes numerically lower than t he following:

Camshaf t Position Sensor Date Code - 99246 ( r epr esent s day 246 of 1999)

Clear any existing DTC’s and roadt est the vehicle.

Where the DTC re- occurs af t er r eplacement of a fault y camshaf t sensor , or the sensor fitted t o the

vehicle is post breakpoint of the dates advised above, carry out existing diagnostic procedures in

current ser vice inf ormation relevant to the code/ s st or ed.

PRODUCTION RECTIFICATION

A vehicle ISOVIN or PSN No. is not available. The appr oximate eng ine number, f or int roduction of

post breakpoint camshaft position sensors into engine production is:

Engine No.: Build Date:

VF99263XXXX 20/09/99 (=day 263)

NOTE: this Engine No. defines that any engines built on day 263 of 1999 are “OK”.

W here “99” = 1999, “263” = day 263, and “XXXX” represents the serial number of the engine built

that day.

PARTS INFORMATION

All camshaft position sensors in HSPO stock have been inspected and are post breakpoint of the

dates advised.

Any camshaft position sensors found in dealer parts st ock with date codes earlier than t hat shown

above must not be used, but r eturned to HSPO for credit.

Sensor part num ber ( for reference) is:

Part No.: Description: Qty

12561211 Sensor, Camshaft Position 1

WARRANTY CLAIM I NFORMATION:

Use existing inf or m ation in Labour Time Manual.

Figure 1

1. Camshaft Position Sensor

2. Date Code (Replace if Date Code “XXXXX” is lowe r than 99246)

DTC P0335/ P0336 SET - CRANK POSITION SENSOR FAULT

VT, WH with GEN III V8

(GROUP 6C) February 2000

PROBLEM DESCRIPTION

Investigat ions into reports of DTCs P0335 and P0336 have identif ied a pot entially f aulty crank shaf t

position sensor. Separation of the crankshaft position sensor internal circuit board can cause the

fault to occur. Customers may report that the engine is unable to be started, an engine stall

condition has occurred or that the check engine lamp is illuminated.

SERVICE RECTIFICATION

Should the fault occur, inspect the date code stamped on the, crankshaft position sensor - Refer

Figure 1.

Replace crankshaft position sensor s with date codes numerically lower than t he following:

Crankshaft Position Sensor Dat e Code – 99237

(Represents day 237 of 1999)

Clear any existing DTC’s and roadt est the vehicle.

Where the DTC re-occurs after replacement of a faulty crankshaft position sensor or the sensor

fitted to the vehicle is post breakpoint of the dates advised above. Carry out existing diagnostic

procedures in curr ent Ser vice information relevant t o the code/s stored.

PRODUCTION RECTIFICATION

A vehicle ISOVIN or PSN No. is not available. The appr oximate eng ine number, f or int roduction of

post break point crankshaft position sensors int o engine production is:

Engine No.: Build Date:

VF99263XXXX 20/09/99 (=day 263)

NOTE: this Engine No. defines t hat any eng ines built on day 263 of 1999 are “OK”.

W here “99” = 1999, “263” = day 263, and “XXXX” represents the serial number of the engine built

that day.

PARTS INFORMATION

All crankshaf t position sensor s in HSPO st ock have been inspected and ar e post break point of the

dates advised.

Any crankshaft position sensors found in dealer parts stock with date codes earlier than that

shown above must not be used, but returned to HSPO for cr edit .

Sensor part num ber ( for reference) is:

Part No.: Description: Qty

12560228 Sensor, Crankshaft Posit ion 1

WARRANTY CLAIM I NFORMATION:

Use existing inf or m ation in Labour Time Manual.

Figure 1

1. Crankshaft Position Sensor

2. Date Code (Replace if Date Code “XXXXX” is lowe r than 99237)

M/T OIL SPEC. REVISION

JS, JR, TR, TS, SB

(GROUP 7A) REISSUED February 2000

This Service Techline supersedes the previous Techline on this topic (Issue 10, December, 1999

page 12). This previous Techline should be dest r oyed.

This Techline is to advise technicians of a new manual transmission oil specification for use in

JS Series II, with F23 M/T.

Oil specified for these transmissions is:

CASTROL SMX-O

This oil is also recom m ended for the following models - by transmission type:

Model

Trans. Type

Castrol

SMX-O Current Holden 92140007

and Previously available oils

MTF1067, MTF1067 & MTF0063

SB – All M/T ✔

✔✔

✔✓

TR – All M/T ✔

✔✔

✔✓

TS – All M/T ✔

✔✔

✔✓

JR – All M/T ✔

✔✔

✔✓

JS Series I,

F18 Trans. ✔

✔✔

✔✓

JS Series II,

F23 Trans. ✔

✔✔

✔✖

✔

✔✔

✔ = RECOMMENDED

✓ = MAY BE USED

✖ = DO NO T USE

SERVICE USAGE & PRECAUTION

Castrol SMX-O oil MUST be used at all times in JS Vectra Series II with F23 M/T, and may be

used for ser vice replacem ent or ‘top-up’ of oil in t he above manual t r ansm issions.

Holden oil Part No. 92140007 remains available from HSPO, and can be used as per

recommendat ions in t he chart above.

Castrol SMX-O r eplaces pr eviously released Castrol oils MTF1067, MTF1067 & MTF0063

These previously released oils MUST NOT be used in JS Series II, F23 M/T, for durability

reasons.

At the time of release of this bulletin, there are no commercially available equivalents to Castrol

SMX-O for this JS Series II usage.

PRODUCTION INTRODUCTION

Oil to this specification was introduced at st ar t of JS Vectr a Ser ies I I vehicle production as follows:

ISOVIN: Build Date:

W0L0JBF19YL482379 30/07/99

FUEL TANK/CAP REPLACEMENT REQUIREMENT

JR (All), JS (Hatch)

(GROUP 8) February 2000

SERVICE REQUI REMENT

Whenever a fuel tank is replaced on:

JR - all models

JS - Hatch models only with compliance Plate dated up to and including 31/12/98.

the f uel t ank filler cap should also be r eplaced with a later filler cap.

PRODUCTION RECTIFICATION

The later filler cap (vented type) has been fitted to all JS Sedan and Wagons from start of JS

production, and t o JS Hat c h m odels with Compliance Plat es dat ed after 01/ 01/ 99.

Compliance Plates are locat ed on RHF strut tower.

PARTS INFORMATION

Part No.: Description: Qty

92078849 Cap, Fuel Filler 1

To identify early (non-vented) and later (vented) filler caps fitted to vehicles – the following

sketches ar e pr ovided. Ear lier design f iller caps ar e no longer available from HSPO .

Early Filler Cap

Do NOT re-fit when replacing a fuel tank

Later Filler Cap

Fit when replacing fuel tank (as noted).

POOR AM RADIO RECEPTION

(GROUP 12) February 2000

PROBLEM DESCRIPTION

Some vehicles are reported to have poor radio reception and excessive levels of vehicle induced

interference while listening to “AM” band stations. Investigations have identified ignition noise and

poor antenna connections as the pr im ar y causes.

Various root causes have been identified and f ixes introduced to overcome recept ion problems on

the “AM” band.

PRODUCTION RECTIFICATION

•Ignit ion system ear t h st rap installation for JS:

Introduced Start of Production

•Antenna lead routing on the right hand side of the vehicle:

Introduced 12/11/98, Tag L396309.

•Installation of turn sig nal relay to overcome popping noise:

Introduced 11/ 01/ 99, W1361702.

•Assembly plant test t he r eception signal:

Introduced May 99.

SERVICE RECTIFICATION

•For vehicles built prior to 12/11/98, L396309 refer to the September 98’ Techline (Page 80 of

1998 Service Communicat ion Book) on the same subject and f ollow the procedures to rer oute

the antenna cable. Then continue with the checks out lined below.

•Vehicles built af ter 12/11/98, L396309 will have the antenna cable re r outed. Technicians are

advised to commence with antenna circuit connection and earthing checks.

1. Use the Vectra radio rem oval k eys, to detach the radio from the cr adle.

2. Remove the radio cradle and ensure the antenna connector at the back is inserted correctly

and the centre m etal pin of the ant enna is not broken or bent .

Note: The antenna connection may become dislodged whilst reinstalling the radio. Apply

some tape to the connection preventing the antenna from dislodging during the radio

installation.

3. On sedan models, remove the parcel shelf and ensure that the two antenna amplifier box

attaching nuts are tight (1). Also check that the 2 pin power connector to the amplifier is f ully

home (2). (Refer to Figure “A” following).

Figure “A”

4. On hatch and wagon models, ensure the attaching nut that holds the antenna amplifier to the

roof panel is not loose. This nut and stud is the earth path for the ant enna amplifier so a good

earth is crit ical.

5. Also on hatch and wagon models, check the coaxial cable where it enters the amplifier for

damage such as a f rayed coaxial cable shield or exposed bare copper. To check coaxial cable

integrity at this location, tune the radio to a weak “AM” band station and increase the volume.

Then wrigg le t he ant enna lead and listen for changes in the level of inter ference.

TURN SIGNAL LAMPS INOPERATIVE AT LOW AMBIENT TEMPS.

(GROUP 12) February 2000

PROBLEM DESCRIPTION

Investigation into reports of turn signal lamps inoperative at low ambient temperatures, have

identified the cause as being the hazard warning switch being partially dislodged in the instrument

panel fascia. This is caused by the lower locking tang of the switch distorting the switch case,

which in turn causes an interruption in the turn signal circuitry through the hazard switch.

PRODUCTION RECTIFICATION

Hazard warning switches with revised locking tangs have been fitted to vehicles from:

ISOVIN: Build Date:

6H8VTK69HYL543303 16/12/99

SERVICE RECTIFICATION

If presented with a vehicle that exhibits the symptoms described above, technicians should replace

the switch assembly with a post breakpoint part.

PARTS INFORMATION

Order the new part from HSPO PartFinderTM - all parts at HSPO are of the latest specification.

Revised hazard switches can be identif ied by date code. T he date code is hot st amped, par allel to

the lower edge of the switch body, on the left side of the switch body, when viewing t he switch as it

would be mounted in the instrum ent panel fascia.

OK parts ar e dat e coded: 06M9 and higher.

Where: 06 = Day; M = December; 9 = 1999

WARRANTY CLAIM I NFORMATION:

Use existing inf or m ation in Labour Time Manual.

SPEED SIGNAL CONVERTER MODULE

JS (non-ABS)

(GROUP 12) February 2000

Some technicians have experienced difficulty in locating the speed signal converter module fitted

to JS Vectra vehicles without ABS. The JS series circuit diagrams indicate that the module is

located in the passenger compartment in the vicinity of the instrument panel, this information is

incorrect.

The speed signal converter module is in fact fitted in the relay box mounted in the engine

compartm ent (ref er k ey 1 figur e 1). The speed convert er module can be identif ied by its dist inctive

orange colour. Dealerships should update their copies of the JS Circuit Diagram Manual - Vehicle

Electrical System, “Views of relays and fuses” section, page 31 to reflect the correction in this

Techline issue.

Figure 1

POOR AM RADIO RECEPTION – TURN SIGNAL RELAY INTERFERENCE

(GROUP 12) February 2000

PROBLEM DESCRIPTION

Some customers have complained that when using the turn sig nals with the radio t uned to an AM

radio station, they can hear indicator “popping” noise through t he r adio.

PRODUCTION RECTIFICATION

A revised relay was introduced into production in the impor ted model only.

ISOVIN: Build Date:

W0L0JBF68W1361702 11/01/99

This relay was not introduced into local pr oduction.

SERVICE RECTIFICATION

A revised turn signal relay with a noise filter installed, has been released to suppress the

interference.

Dealers are advised to fit this relay to rectify complaints of turn signal interf erence. The relay can

be distinguished by its yellow colour.

Note: The revised relay combines both left and right side turn signal relays. Technicians only

need to f it one r eplacem ent relay when fitting the r evised type.

PARTS INFORMATION

Part No.: Description: Qty

09134880 Flasher, T ur n Signal 1

WARRANTY CLAIM I NFORMATION:

Use existing inf or m ation in Labour Time Manual.

DOOR SNIB (LOCK) BUTTON BINDING

VT, WH

(GROUP 1) HINT March 2000

PROBLEM DESCRI PTION

On some vehicles, the door snib (lock) button may appear to bind up in its mechanism when it is

operated by remote button or manually. The snib button may also feel ‘notchy’ during manual

operation.

This condition may be caused by excessive friction within the door lock, or incorrect adjustment

(too long) of the exterior door handle rod.

SERVICE RECTIFIC ATION

Before attempting any other rectification, ensure locks have been:

1. Lubricated as per Techline Bulletin June, 1999, Issue 4, page 8, then check for OK snib button

operation,

2. Checking lock rod adjustment as per Techline Bulletin June, 1999, Issue 4, page 8.

NOTE: incor r e ct lock rod adjustment (too long) can result in the lock mechanism binding.

REGISTRATION PLATE RATTLE

(GROUP 1) REISSUED March 2000

This Techline item was previously published in Service Techline Issue 6/99 to advise technicians

and pre-delivery departments of the need to correctly mount registration plates to WH Series

vehicles. Field reports indicate that correct registration mount fixing procedures are not being

adhered to and customers continue to complain about rattles f rom incorrectly mounted registr ation

plates. Please ensure this Techline item is distributed to the correct dealership personnel to

prevent further occurrence of registration plate rattle.

PROBLEM DESCRI PTION

Front and rear registration plates may rattle due to incorrect mounting.

Four screws are required to mount each registration plate securely.

The front r egistration plate must have four fasteners located along the top of the plate, two on the

ends and two slightly inboard (same as VT Series vehicles).

The rear plate also utilises four fasteners. The two top fasteners screw into a boss, while the two

bottom fasteners ‘self -tap’ into the bumper facia. There are no bosses in the facia at the bottom of

the plate, but the screws will hold.

To prevent plate rattles, please use four fasteners to attach each registration plat e.

FRONT SEAT BELT WEBBING CATCHES ON RECLINER/ LUMBAR KNOB/S

VT, WH

(GROUP 1) March 2000

PROBLEM DESCRI PTION

Customer survey results indicate that some customers have experienced a condition where the

front seat belt webbing did not freely slide over t he front seat recliner knob or lumbar knob.

PRODUCTION RECTIFICATION

As a continuous product improvement, the surface finish to both knobs has been revised and

introduced into production. The revised knobs feature a hard surface finish compared to the earlier

“soft feel” knobs. This enables the seat belt webbing to slide more easily over the knob.

Revised knob/s were introduced into VT/WH production as follows:

For Pewter Colour Knobs:

PSN: Build Date:

L521331 25/10/99

For Shale Colour Knobs:

PSN: Build Date:

L527046 07/11/99

Note: Taupe colour trim (and knobs) was not carried into VT Series II (introduction L464495,

31/05/99).

SERVICE RECTIFIC ATION

Where a customer complains of seat belt webbing “catching” on recliner or lumbar knobs, on

vehicles built prior to the above breakpoints, the revised knobs should be installed to both front

seats.

Parts requir ed are detailed in Parts Information below.

Whe n replacing the knobs, refer to the following service information:

Recliner Knob:

VT Service Manual, Volume 12, Page 12M-21,

Ref. 2.3

Lumbar Knob (non- Side Air Bag):

VT Service Manual, Volume 14A, Page 1A7-5,

Ref. 2.2

Lumbar Knob (Side Air Bag):

VT Service Manual, Volume 14A, Page 1A7-6,

Ref. 2.4

Update

PARTS INFORMATION

Part No.: Description: Qty:

92143234 Recliner Knob - Shale 1

92143235 Recliner Knob - Pewter 1

92143238 Recliner Knob - Taupe 1

92143230 Lumbar Knob, (non-SAB)

- Shale 1

92143231 Lumbar Knob, (non-SAB)

- Pewter 1

92143236 Lumbar Knob, (non-SAB)

- Taupe 1

92143232 Lumbar Knob, (SAB)

- Shale 1

92143233 Lumbar Knob, (SAB)

- Pewter 1

92143237 Lumbar Knob, (SAB)

- Taupe 1

* “SAB” – Side Air Bag

WARRANTY CLAIM INFORMATION:

Use the following information:

Description Rod, Selector Control - Replace

Labour Op. No. C000397

Time 0.3 hr

Failure Code 39

FRONT BRAKE SQUEAL NOISE

(GROUP 5) March 2000

PROBLEM DESCRI PTION

Front brakes may exhibit a “squeal” noise during light brake application.

PRODUCTION RECTIFICATION

Revised brake pads installed:

VIN: Build Date:

Y5000001 13/08/99

SERVICE RECTIFIC ATION

1. Test drive vehicle and determine that the squeal is orig inat ing from the front brakes.

2. Replace front brake pads (as per TIS instructions).

IMPORT ANT NOTE: Ensure to clean the brake pad guides in the caliper and the caliper itself with

a soft wire brush. Apply anti-sq ueak paste to the guides as shown in TIS.

PARTS INFORMATION

Part No.: Description: Qty

09195607 Brake Pads, Front Brake

without ABS 1

09192157 Brake Pads, Front Brake

with ABS 1

90166282 Anti-squeak paste 1

WARRANTY CLAIM INFORMATION:

Use existing Labour Time Manual info. as follows:

Description Fr ont disc brake pads - Replace

Labour Op. No. H105000

Time 0.9 hr

Failure Code 90

Update

P0335 - CRANKSHAFT REVOLUTION SENSOR REVISION

TR, JR (4Cyl); JS (4Cyl)

(GROUP 6C) March 2000

PROBLEM DESCRI PTION

Investigation into reports of DTC P0335 (incorrect RPM signal) stored in the Engine Control Unit

(ECU), have been identified as failure of the Crankshaft Revolution Sensor (CRS). In some

instances DTC P0340 may also be stored.

PRODUCTION RECTIFICATION

A revised CRS was introduced into JS production at:

ENGINE No.: Build Date:

C22SEL25014889 Jan. , 2000.

SERVICE RECTIFIC ATION

When presented with a vehicle storing DTC P0335, technicians should follow the relevant

diagnosis for this code - Refer TIS 2000, Checking Procedures. Care should be taken to ensure no

fault exists with the CRS circuit or mounting. Full, correct diagnosis must be carried out to ensure

there is no unnecessary replacement of either the CRS, or an ECU. If no fault is identified on

inspection, the CRS should be replaced with t he revised part detailed below.

PARTS INFORMATION

This revised Crankshaft Revolution Sensor should be used in all cases requiring replacement, on

TR, & JR/JS 4 Cyl. Engine vehicles.

Part No.: Description: Qty

09174621 Crankshaft Rev’n Sensor 1

New Part Identification:

The part number is moulded into the plastic body of the sensor.

Any Crankshaft Revolution Sensors found in dealer parts stock with previous part number

90506103, must not be used, but ret urned to HSPO for credit.

WARRANTY CLAIM INFORMATION:

Use existing information in Labour Time Manual

Update

STEERING COLUMN INSTALLATION PROCEDURE

(GROUP 9) REISSUED March 2000

This Techline is re-published because:

•a number of steering shaft and related parts have been replaced unnecessarily,

•a number of steering shaft lower bearings have been damaged as a result of

technicians NOT following this procedure.

The following information was previously released in Techline Issue 8, October, 1999, page 8.

Whenever reinstalling or replacing the steering column assembly in TS series Astra built prior to

the production breakpoint shown below. It is critical the correct lower steering column mounting

clamp load is achieved. Failure to correctly set this clamp load may result in two separate

conditions. If too loose, a rattle condition at the base of the steering column may be experienced. If

too tight, failure of the lower steering column bearing may result.

PRODUCTION RECTIFICATION

Tighter production tolerances to the lower steering column mounting bracket have eliminated the

requirem ent for this critical clamp load adjustment.

Vehicle breakpoint is as specified below:

ISOVIN: Build Date:

W0L0TGF48X5033674 21/09/98

SERVICE PROCEDURE

Technicians need to ensure that the procedures outlined below are applied at all times when the

steering column is reinstalled or replaced in TS series vehicles built prior to the above mentioned

breakpoint. .

1. Reinstall the steering column assembly as per removal and reinstallation procedures set out

on the TIS CD ROM, Group M – Steering “Remove and reinstall steering column assembly”

(Steering column assembly adjust able).

2. Centralise the steering wheel and engage the steering lock.

3. Move the adjustable steering lever out of the lock position so the steering column can be

moved up or down, in or out.

4. Locate the clamp bolt (1) that houses the lower steering column bearing and loosen to allow

the installation of the first shim package of 4.0mm (bolt (1) threaded end visible with a 7mm

hex on end of bolt) as indicated in Figure A (showing the steering column removed for clarity).

Shim in mm Number of shims

0.4 21-321-321

1.6 2221111- --

Total 4.0 3.6 3.2 2.8 2.4 2.0 1.6 1.2 0.8 0.4

FIGURE A

5. Beginning with an overall thickness of 4.0 mm insert the package of 4 shims, as indicated in

Figure B, between the steering column bracket and the crossmember and tighten the clamp

bolt to 22 Nm/16 ft.lb.

FIGURE B

6. To check if the clamping f orce is correct, grasp the steering shaft at the intermediate shaft end

and push the steering shaft axially with moderate effort (in the direction of the arrow) as

indicated in Figure C.

FIGURE C

7. If the visible grey guide sleeve located in t he clamp on the steering column is moved, release

the clamp bolt and remove one 0.4mm shim.

8. With the reduced shim package of 3.6 mm, tighten the clamp bolt again to 22 Nm/16 ft.lb.

Repeat the checking procedure, observing whether the grey guide sleeve continues to move.

Repeat the procedure of continually reducing the overall thickness of the shims by 0.4 mm

until the guide sleeve ceases to move while applying moderate effort as indicated.

9. Once the correct number of shims has been determined, push the st eering column inwards as

far as it will go and check that the grey sleeve located within the clamp is positioned towards

the front of the vehicle as far as possible. It may be necessary to loosen the clamp bolt and

apply an axial force to the steering shaft towards the front of the vehicle until the grey sleeve

seats on the clamp in it’s forward most position. Ensure to tighten the clamp bolt to

22N m/1 6 ft.lb.

10. Re-inst all all com ponents. Move the steering column adjustment lever into the lock position.

PARTS INFORMATION

Shim kits to adjust clamping load are available via HSPO under the part number supplied below.

Part No.: Description: Qty

09192728 Shim kit 1

SERVICE TE CHNICIAN REFERE NCE INFORMATION

ALL

(GROUP 0B) UPDATED March 2000

This Techline is published to provide Dealership Service personnel with a list of commonly required

Holden contact Fax numbers and some helpful additional information.

HOLDEN SERVICE RELATED FAX No’s

HOLDEN TAS 03 9647 2495

HOLDEN SECURITY INFO. 03 9647 2865

IGM TAS/CAS 03 9644 6622

PIR’s (EDAG FUTURE) 03 9552 8104

REPAC 03 9647 1198

TECHNICIAN’s GUILD QUESTIONNAIRES,

Tech. Guild Issue content,

and Questionnaire queries ONLY: 03 9876 5797

TECHNICIAN’s GUILD ADMINISTRATION

For all other Tech. Guild queries (enrolments,

prizes, dates, exam venues, etc): 03 9647 2525

CENTRAL SERVICE 03 9647 2525

SERVICE ENGI NEERING 03 9647 2525

HOLDEN CAS 03 9647 1237

WARRANTY ADMIN. 03 9647 2525

Othe r In fo rmation :

PIR forms: request a pad (100 forms) by quoting “SD 28331” on a Merchandising Material Order

Form and fax to Salmat, on (03) 9251 6352.

Security Number Request Form: photocopy form attached to All Dealer Letter DL 63/99.

Vehicle Security Info. Change Advice Form: photocopy form attached to All Dealer Letter

DL 63/99.

Tech 1 Repairs: Refer HSPO Parts Techline Bulletin PT31, dated May 5, 1999.

Tech 2 Repairs: Refer All Dealer Letter DL 43/97

Tech 2 Cable Repairs: Refer All Dealer Letter DL 06/00

JS Vectra Circuit Diagram Manual Update Pages: Refer All Dealer Letter DL 58/99

TS Astra Circ uit Di agram Update Pages: Refer All Dealer Letter DL 01/99

INSTRUMENT CLUSTER - TRIPME TER FUNCTION

JR, JS

(GROUP 12) March 2000

Some customers may report that their tripmeter is intermittently resetting to zero without command

- mainly on long distance trips. To reduce the possibility of unnecessary instrument cluster

replacement, this Techline has been issued to define the counting/reset parameters of the

tripmeter fun c tion.

JR & JS SERIES 1

All JR, and JS Series 1 instrument cluster tripmeters are designed to count to 1999 kilometr es and

reset to zero at the 2000 kilometre mark.

JS SERIES 2

JS Series 2 instrument cluster tripmeters are designed to count to 999 kilometres and reset t o zero

at 1000 kilometre mark.

INSTRUMENT PROGRAMMING - TRIPLE WINDOW TYPE

(GROUP 12) March 2000

Included in Tech 2 software version 8.100, TIS 2000 CD 7.0B, is a new function that allows

instrume nt clusters to be configured for vehicles with and without Elect r onic Climate Control (ECC).

This function should be used when fitting or replacing instrument clusters. Failure to correctly

program the instrument configuration may result in an “X” being displayed in the instrument right

side display window, along with instrument DTC 10.

In Particular, this is relevant where triple window display type instruments are fitted to vehicles

without electr onic clim ate control ie. HSV or HBD upgrade.

To correctly configure the instrument clusters ECC option follow the steps detailed below.

1. Select Diagnostics / Model Year / VT Commodore / F3: Body / Instrument / F5: Program / F0:

Instrument Config uration.

2. Press the NEXT soft key at the base of the Tech 2 screen to scroll to the ECC option

configuration.

3. Press the MODIFY soft key at the base of the Tech 2 screen.

4. Select the DISABLE soft key at the base of the Tech 2 screen (for vehicles without ECC).

Select the ENABLE soft key at the base of the Tech 2 screen (for vehicles with ECC).

5. After the configuration has been modified the Tech 2 will display the current configuration.

Select the PROGRAM soft key at the base of the Tech 2 screen to accept the configuration

settings.

POWER STEERING HOSE RETENTION

VT, WH with GEN III V8

(GROUP 9) February 2000

PROBLEM DESCRIPTION

PIR’s have been received, which advise of a power steering (P/S) fluid leak, caused by the P/S

return hose cont acting with the power steering pump pulley.

PRODUCTION RECTIFICATION

A tie strap has been added in pr oduct ion from:

PSN No. : Build Date:

L493683 14/08/99

SERVICE RECOM MENDATION

When fitting or re-fitting a P/S return hose for any reason, carry out the following hose

replacement pr ocedur e:

•On fitting the new P/S return hose, turn the upper (reservoir) end away from the P/S pump

pulley, before tightening the hose clamp.

•Re-f it the existing tie st rap (p/ n 92138212) t o the power steering hoses, 80m m f r om t he power

steering reservoir - as shown in the accompanying sketch. If the vehicle is built before

L493683 – fit a tie strap during this hose replacement. (Refer ‘Warranty Claim Information’).

Addition of this tie strap ensures t hat the hose cannot contact t he P/ S pum p pulley.

When fitting the t ie st r ap, ensur e t he P/S hoses are not compressed by the tie str ap.

PARTS INFORMATION

Part No.: Description: Qty

92138212 Strap –Tie, P/S Retention 1

WARRANTY CLAIM INFORMATION:

The following labour operation number m ay be used ONLY for addition of a tie strap, to vehicles built prior to

L493683, when replacing a damaged P/S return hose, or re-fitting a P/S return hose.

Description Add Strap to P/S Hoses

Labour Op. No. M000172

Time 0.3 hr

Failure Code 25

LOWER RADIATOR HOSE INSTALLATION PRECAUTIONS

JR, JS (4 Cyl. Engines)

(GROUP 6K) March 2000

PROBLEM DESCRI PTION

The following precautions must be observed during lower radiator hose installation, to ensure no

abrasion occurs, that may result in a coolant leak. In addition, a protective cap has been added to

A/T filler tube retaining studs to ensure no abrasion can occur.

PRODUCTION RECTIFICATION

The installation precautions noted below are existing procedures in the vehicle assembly plant.

The protective cap (as mentioned in Figure 3 below) was introduced into production at:

ISOVIN: Build Date:

W0L0JBF19XL430814 01/03/99

SERVICE RECTIFIC ATION

W hen installing a lower radiator hose, ensure correct positioning of the lower radiator hose by:

1. Aligning the white paint mark on the lower end of the hose, with the moulded boss on the

radiator end tank – Refer Figure 1 which shows the correct hose positioning .

Figure 1.

2. Adjusting the position of the hose (by loosening connections and twisting the connections) so

that adequate clearance exists between the electrical harness connector – Refer Figure 2 for

details of clearance and hose positioning.

Figure 2.

3. On A/T equipped vehicles: where the branch of the lower hose runs past the A/T filler tube

retaining bracket nut, add a protective cap – P/N 90539656 – Refer Figure 3.

Figure 3.

View from front of engine compartment towards A/T."

INTERIOR RATTLE NOISE DIAGNOSIS

ALL MODELS (MELBOURNE BASED VEHICLES)

(GROUP 1) April 2000

PROBLEM DESCRIPTION

When investigating instrument panel “rattle” complaints, where a vehicle is fitted with an “e-TAG”

unit ( electronic sig nal transm itter f or use on t he Melbourne CityLink electr onic tollway system), f irst

remove the e-T AG unit.

Any rattle that may emanate from the “e-TAG” unit could lead to misdiagnosis of the noise, in the

belief t hat interior trim or com ponents in the instrument panel may be the cause.

NOTE: “ e-TAG’s” ar e normally attached to the inside of the front windscreen behind the rear view

mirror, via a mounting bracket, and are detachable. The “e-TAG” can be detached from the

bracket by g r ipping the “e-T AG” and rotating the top rearwards and downward.

Should an “e- TAG” be def ined as the cause of a rat t le noise – t he customer should be advised that

the ratt le is em anat ing fr om t he “e-TAG” , not the vehicle.

Update

QUARTER WINDOW GLASS – IMPROVING GLASS FIT

VS Utility

(GROUP 1) April 2000

PROBLEM DESCRI PTION

Poor appearance of utility quarter window fixed glass - a gap at the top of the glass between glass and

rear side window cover - is caused by the locat ion of the glass in the body opening.

PRODUCTION REVI SION

Revised glass and mouldings were fit ted to vehicles in production fr om :

ISOVIN: Build Date:

6H8VSK80HXL454372 30/04/99

SERVICE RECTIFICATION

To improve the fit of the quarter window glass on complaint vehicles, the following procedure should

be carried out.

On vehicles built before L454373 - discard old glass and moulding and use NEW glass and NEW moulding,

fitted as per these instructions:

On v ehicles built after L454373 – glass and moulding (with moulding shape as per Figure 2) m ay be re-used,

and fitted as per these instructions:

IMPO RTANT NOTE: If the procedure below is to be carried out as a sub-let repair, provide a copy of

this Techline t o t he sub-let repairer.

1. Remove quarter window glass, using existing removal procedures in the VR Service Manual,

Volume 1, Pag e 1A7- 11.

2. Remove remnants of old urethane from glass and body aperture flange, then clean the quarter

window glass and body opening with a lint free rag wetted with Prepsol.

3. Apply spacers - p/ n 92039967 – as shown in Section A-A in Figure 1.

NOTE: spacers MUST be applied or poor glass fit t o body and outer cover will result.

Figure 1 –Spacer locati on and uret hane i n ‘fitted’ l ocat i on.

4. Fit moulding to glass, if new glass and moulding are being f itted.

5. Using a hack saw, cut of f any excess moulding protruding above the top of the glass until it is f lush

with the top of the glass, and follow a ‘cut’ line perpendicular (90°) to t he glass. Refer to Figure 2.

NOTE: Take care with these operations, or glass breakag e m ay result .

Figure 2

6. Perform a trial fitment of the glass assembly. Ensure there is no interference between the

moulding and t he dr ip gutter. Refer to figure 3.

NOTE: There must be a small gap between the glass and the drip gutter sheet metal. Refer to

Figure 3.

7. Apply urethane to the body aperture flange. Urethane should be inboard of spacers – Refer to

Figure 1.

8. Install the quarter window glass to the body aperture flange, ensure the top, forward corner

locates as per the trial f it, then press glass firmly into position. Do not f orce the glass to sit flush

with the drip gutter. Refer Figure 3.

9. Insert a locating piece – p/n 92075426 – under the lowest portion of the glass to hold the glass

during t he ur et hane curing process. Refer to figure 2 f or location.

10. Check ef fect iveness of sealing from inside the vehicle. Should any gaps in the sealing exist, apply

additional urethane on t he out side to fill these gaps. Using a flat bladed tool, sm oot h the surface of

the urethane ar ound the edge of the outside of t he glass to ensure ef fective sealing.

11. Reinstall quarter window inner trim moulding (Refer 1A9 HEADLINING AND REAR END TRIM

Section in VR Series Service Manual, Volume 1).

12. Tighten q uar ter window drip moulding attaching screws and refit the rear side window cover (Refer

1A5 LOAD COMPARTMENT AND ENDGATE Section in VR Series Service Manual, Volume 1).

Figure 3

PARTS INFORMATION

The quantities quoted below are for one side only:

Part No.: Description: Qty:

92056371 Glass - Qtr Window (RH) 1

92056372 Glass - Qtr Window (LH) 1

92056373 Moulding - Q t r Window (RH) 1

92056374 Moulding - Q t r Window (LH) 1

92039967 Spacer - Qtr Window 2

92075426 Locating Piece - Qtr Window 1

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time Manual as shown:

Description Glass Asm. Side Panel RH – Repl.

Labour Op. No. C004100

Time 1.1 hr

Failure Code 25

Description Glass Asm. Side Panel LH – Repl.

Labour Op. No. C004200

Time 1.1 hr

Failure Code 25

WATER LEAK INTO HEADLINING

SB CABRIO

(GROUP 1) April 2000

PROBLEM DESCRIPTION

Damp patches in the headlining material around the top of the A pillar may be evident after a

vehicle roof has been soaked for extended periods of time. The water entry that causes this

condition has been found to be via the headlining m aterial extending too far into a wet area along

the roof and door weatherstrip flanges.

SERVICE RECTIFICATION

To rectify this water entry condition, it is necessary to trim excess headlining material from the

upper door weatherstrip flange, and the roof weatherstrip flange, as follows:

Refer to Figure 1 for location of the typical section through both flanges, as noted in the following

Figures and t ext.

Figure 1.

Refer Figure 2 for Secti on A-A.

Figure 2 – Typical sect i on

(door opening shown, roof secti on same)

1 = Edge of headlining exposed to water from outside vehicle.

2 = Excess headlining material extending into wet area.

3 = Weatherstrip.

Update

1. Open doors and roof.

2. Remove roof weatherst r ip and t op por t ion of door weatherstrip.

3. Caref ully remove the portion of the headlining material that is folded over and glued to the r oof

and door weatherstrip flanges (Only remove the material that is glued to the flange ends and

extends into the outside “wet” area). Take care not to tear or stretch the material during this

removal process. Figure 3 shows the headlining material removed from the flanges, and the

areas of excess (5m m appr ox.) m at er ial.

]

Figure 3

Shows excess headlining material on both the door

weatherstrip fl ange ( l ower) and t he roof weatherstr i p f l ange ( upper)

4. Clean any remnants of headlining material or glue from the flanges, so no air or water entry

gaps exist.

5. W ith a sharp k nif e, neatly trim t he excess headlining mater ial flush with the f langes, as shown

in Figure 4, t aking care not to damage paint finish.

Figure 4

“A” Shows tr i mmed headl i ni ng areas

6. If the headlining material separates from the inboard side of the flange during this process,

add glue behind the material to retain it, or use waterproof tape to retain the material to the

flang e edge. Make sure any tape used is not visible when the weatherstrip is ref it t ed.

7. Caref ully refit the weatherstrips t o the roof and door flanges.

WARRANTY CLAIM I NFORMATION:

Description Correct headlining water leaks

Labour Op. No. B000400

Time 0.6 hr

Failure Code 87

ACCESSORY POWER SOCKET LOOSE

VT, WH

(GROUP 12) April 2000

PROBLEM DESCRIPTION

The accessory power socket loosens in console mounting hole, due to insufficient

retention t orque capability of the existing nut and shell.

PRODUCTION RECTIFICATION

A revised (shorter) power accessory sock et shell has been fitted t o vehicles f r om:

ISOVIN: Build Date:

6H8VTK69HYL551551 01/02/00

SERVICE RECTIFICATION

Vehicles presented with a loose power accessory socket should have a new power

accessory socket shell – P/ N 92094030 - fitted.

PARTS INFORMATION

Part No.: Descri pt i on: Qty

92094030 Shell – Accessory Access. 1

WARRANTY CLAIM I NFORMATION:

Use existing inf or m ation in Labour Time Manual as shown:

Description Accessory Power Socket – Repl.

Labour Op. No. N311700

Time 0.5 hr

Failure Code 27

CRUISE CONTROL “DROP-OUT”

VS UTILITY

(GROUP 12) April 2000

PROBLEM DESCRIPTION

Some customers may experience an intermittent disengagement of the cruise control, particularly

when driving for long periods. A change to the speedometer operating mechanism on later built

VS Utility vehicles has raised this concern.

Electrical “noise” generated on the speedometer voltage supply has been identified as the cause.

This inter ference af fects t he vehicle speed signal being supplied to the cruise control module. The

module is sensitive to this int er ference, causing a cruise control dropout condition.

PRODUCTION RECTIFICATION

Revised speedometer assemblies, with increased capacitance to rectify this condition, have been

introduced into pr oduction from:

ISOVIN: Build Date:

6H8VSK80HYL560257 24/02/00

SERVICE RECTIFICATION

The following replacement recomm endation affects vehicles built in the f ollowing ranges:

V6 Utility

From :6H8VSK80HWL345970, 12/6/98

To :6H8VSK80HYL560257, 24/02/00

V8 Utility

From :6H8VSK80UWL346473, 15/6/98

To :6H8VSK80HYL560257, 24/02/00

(This is a V6 Isovin, and is supplied for “limiting” the affected range only)

When presented with a VS Utility from the breakpoint specified above that exhibits intermittent

cruise control dropout, technicians should perf orm a basic inspection of t he cruise control system.

These inspections should include all circuit connections and adjustments of both of the cruise

control stop lamp switches. If no faults are identified replace the speedometer assembly with the

revised part specif ied.

PARTS INFORMATION

Revised speedometer assemblies can be identif ied by locating the VDO date code label, adhered

to the rear f ace of the assem bly. This label shows the date of manuf acture and should have a date

code “210200” or lat er .

NOTE: T here are t wo labels located on the rear of the speedom eter assem bly. The one on t he top

face of the assembly should not be used t o ident ify breakpoint parts.

All parts in stock in HSPO warehouse, at time of publication, are of the latest specification.

Distributor or Dealership parts stock , found t o be date coded prior to the date code shown above,

should be returned t o HSPO for cr edit .

Part No.: Description: Qty

92142867 Speedometer Asm. 1

92142866 Speedomet er Asm . (Police) 1

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time Manual f or removal and replacement of the speedometer

assembly.

CRUISE CONTROL INOPERATIVE - HINT

VR, VS, VT

(GROUP 12) April 2000

When presented with a “cruise control inoperative” condition in any of the above model vehicles,

technicians should inspect the stop lamp circuit for correct oper at ion.

In some instances failed stop lamp globes have been the cause of the cruise control system

becoming inoperative, resulting in unnecessary replacement of parts and unnecessary or

excessive diagnosis times.

A pull up type resistor cir cuit is at tached to t erm inal “G” of the cr uise contr ol module. This monitor s

the stop lamp cir c uit via the stop lamp globes to eart h.

In the event that this circuit becomes int errupted, IE: Poor connections (open circuit) or failed stop

lamp globes, this disables the operation of the cruise contr ol system .

Every eff ort should be made to def ine the cause of t he stop lamp circuit failure, to ensure that this

fault does not r eoccur .

FINAL DRIVE/REAR AXLE OIL - NAME CHANGE

VP, VQ, VR, VS, VT, WH

(GROUP 4) April 2000

OIL NAME CHANGE

Spicer Axle Australia, Holdens final drive unit/rear axle supplier, and Mobil Oil Australia Ltd.,

advise that Mobilube SHC 80W/140 ID oil is now known as:

Mobilube SHC ID

This nam e change was effect ive fr om December 1, 1999, and has tak en place to avoid confusion

with another Mobil product bearing a sim ilar nam e.

USAGE

This oil is recom m ended for use in:

VP/VQ:

All V8

All Utilities

VR/VS:

V6 with LSD

All V8

VT/WH:

All S/C V6 & V8

Wagons with V6 & M/T

The oil is Synthetic Hypoid Gear Oil to Holden’s Specificat ion HN2040. Refer to individual Service

Manuals for equivalents, where available.

Please ensure all Service and Parts personnel are aware of this name change, to ensure the use

of t he cor r ect oil in the above vehicles.

LEAK DETECTION DYE ADDED TO ENGINE OIL

JS, V6

(GROUP 6A) April 2000

PRODUCTION CHANGE:

This T echline bullet in is an inf ormat ion item t o advise that f r om eng ine number 08 480 202 built on

09/03/00, a sm all amount of fluorescent dye has been added to the first fill engine oil.

This dye confor m s t o GM Mat erial Specifications.

It is possible that a small number of engines, built for validation, prior to the breakpoint will also

have dye.

The chang e has been made as a q uality improvement to enable bet ter leak detection capability, in

the engine assem bly plant.

IN SERVICE:

It should be noted that under normal lighting the engine oil with have a red/brown appearance,

somewhat different t o nor mal engine oil.

Please advise all pre-delivery and service technicians of this change, so there is no concern that

oil in these engines is “ contaminated”.

PRODUCTION INTRODUCTION

A small amount of fluor escent dye has been added to t he first fill engine oil from:

Engine No.: Build Date:

08 480 202 09/03/00

DTC P0340 - CAM SENSOR INCORRECT SIGNAL

TR, JR (4 Cyl), JS (4 Cyl)

(GROUP 6C) April 2000

PROBLEM DESCRIPTION

Investigations into unnecessary ECU replacement, where DTC P0340 (camshaft sensor incorrect

signal) is stored, have identified the camshaft posit ion sensor as the cause of the f ailure. In some

instances DTC P0335 m ay also be stor ed.

SERVICE RECTIFICATION

When presented with a vehicle storing DTC P0340, technicians should follow the relevant

diagnosis for this code - Refer TIS 2000, Checking Procedures. Care should be taken to ensure

no fault exists with the Camshaft sensor circuit or mounting. If no fault is identified on inspection,

the Camshaft sensor should be replaced with the revised part detailed below.

PARTS INFORMATION

Revised Camshaft posit ion sensors can be identified by a manufactur ing date code located on the

rear face of the sensor (sensor in position on engine). The date code is stamped in white ink and

should be “2098b” or higher.

Date Code Int er pr e t ation:

“20” = week 20; “98” = 1998; “ b” = disr egard

All part s in stock in the HSPO warehouse at time of publication ar e of the lat est specification. Any

old stock found in Distributor or Dealership parts stock date coded prior to the date code above

should be returned t o HSPO for cr edit .

Any Camshaft Revolution Sensors in Distributor or Dealership parts stock – under previous part

number 90506103, m ust not be used, but ret ur ned t o HSPO for cr edit .

Part No.: Descripti on: Qty

90458252 Camshaft sensor 1

WARRANTY CLAIM I NFORMATION:

Use existing inf or m ation in Labour Time Manual

A/ T COOLER HOSE RETENTION

JS w ith A/T

(GROUP 7B) April 2000

PROBLEM DESCRIPTION

All A/T oil cooler hoses are r etained by a tie str ap (fitt ed in production), located ar ound the hoses,

between the A/T body and the radiator, visible from under the vehicle

If the hose retaining strap is not replaced - after removal for any reason, the A/T oil cooler hoses

may rub on the front engine/ trans. mount, causing hose damage, and pot entially, a leak.

SERVICE RECTIFICATION

The A/T oil cooler hose retaining tie strap must be replaced after removal for any reason. If any

vehicle is found, during servicing, to have the t ie st r ap m issing, a new tie strap should be f it t ed.

The sketch below shows the location of t he tie strap.

Figure 1 – Showing tie st rap location

PARTS INFORMATION

Part No.: Description: Qty

9275610 Strap – Hose Retaining 1

A/T REPLACEMENT REQUIREMENT - COOLER FLUSH & FLOW RATE CHECK

VR, VS, VT, WH

(GROUP 7B) April 2000

Analysis of SRTA returned automatic transmissions, and the incidence of repeat transmission

failure/replacement, highlights the need for technicians to ensure an A/T cooler flush and flow

check is done.

It is recommended that Service Managers, Workshop Controllers or Service Advisors

advise technicians to carry out the procedure – by adding the wording “Cooler Flush &

Flow Rate Check Required” to Repair Orders - w henever:

• a changeover or replacement tr ansmi ssion is installed.

• fluid contaminat i on i s suspected.

The procedure appears in the VT Service Manual, Volume 14C, Page 7C4-5 (last printed version) or in the

latest version of Holden SIP CD, Section 7C4 - 2.3 TRANSMISSION COOLER REVERSE FLUSH AND

FLOW RATE CHECK

STEERING WHINE NOISE

TS (TRW Steering Gear)

(GROUP 9) April 2000

PROBLEM DESCRIPTION

Some cust omers may complain of a light “whine” noise f rom steering , when steering is turned j ust

off-centre, at low speed.

Investigations have revealed that noise can be transferred into the vehicle body, if the P/S pump

body contacts the pump m ount ing bracket (beneath the pump).

PRODUCTION RECTIFICATION

To correct noise complaints as described above, as an interim action, washers were added at

three locations bet ween the P/S pum p and it s mounting bracket f r om :

ISOVIN: Build Date:

Not Available 12/08/99

As a final corr ective action, a r evised power steering pump m ounting brack et, with upward swaged

lower mounting holes, has been int r oduced into vehicle production at:

ISOVIN: Build Date:

Not Available 01/03/00

As the revised bracket is not yet available from HSPO, the following Service Rectification will be

required on complaint vehicles where interference between P/S pump and mounting bracket is

defined.

When parts are available from HSPO, a Techline Bulletin will be released, advising to fit the

revised bracket in lieu of this procedur e.

SERVICE RECTIFICATION

If an abnormal P/S “whine” noise is reported on a vehicle with TRW steering system; where the

noise occurs when steering wheel is turned “just off-centre” at low speed – the following check

must be carried out :

Raise vehicle on a hoist and check that clearance exists between the P/S pump and the pump

mounting bracket, at the inboard (RH) side of the pump. This can be done by raising the vehicle

on a hoist and passing a feeler strip or piece of thin card between the pump and bracket, to

ensure clearance exists. NO CO NTACT SHO ULD BE EVIDENT AT THE INBOARD SIDE OF THE

PUMP/BRACKET.

If clearance exi st s - furt her diagnosis is required to define the cause of the noise.

If no clearance exi st s - carry out the following procedure:

1. Loosen the single upper mounting nut, accessible from engine compartment and located

horizontally on the outboard (LH) side of the pump body. Loosening this mounting nut allows

pump movement lat er .

Refer View A in Figure 1 below.

2. Raise vehicle on a hoist.

3. From under vehicle, loosen and remove the three pump t o mounting bracket mounting nuts –

the third mount is accessible from behind LHF wheel. (rubber mounts above nuts should be

held during loosening, with a 14mm spanner).

4. Have an assistant lif t t he power st eering pump up of f the mount ing bracket , providing enough

clearance to fit a washer – P/N 11035613 – on the mounting bracket at all three lower

mounting holes between the pump and its mounting bracket (glue washers to bracket if

required, to assist assembly).

NOTE: the washers requir ed ar e a specific size – do not use any other washers.

Refer View B in Figure 1 below.

5. Lower the pump onto the washers/mount ing bracket .

6. Reinstall the three lower mounting nut s to the mounting studs, torque to 7Nm (rubber mounts

should be held during t or quing, with a 14mm spanner ) .

7. Torque the upper mounting stud (in engine compartment) to 7Nm (rubber mount should be

held during t or quing, with a 14mm spanner ) .

PARTS INFORMATION

Part No.: Descript i on: Qty:

11035613 Washer – P/ S Spacer 3

WARRANTY CLAIM I NFORMATION:

Description Fit P/S Spacer Washers

Labour Op. No. M000178

Time 0.4 hr

Failure Code 40

Figure 1

INLET MANIFOLD – ALTERNATIVE PART

USAGE

VT & WH with Gen III V8

(GROUP 6A) May 2000

PROBLEM DESCRIPTION

TAS has received calls regarding replacement

engine assemblies ex-HSPO, being fitted with an

alternative inlet manifold that appears different to

the manifold on the original engine.

An alternative inlet manifold (that has a plugged

hole at the top, front of the manifold) has been

fitted to engines in vehicle production, and for

HSPO supply (this plugged hole is used for a

derivative of the Gen III engine used in other

market areas).

This manifold is different only by the addition of a

“plugged hole”, and is totally interchangeable with

the “non-plugged’ manifold.

PRODUCTION RECTIFICATION

No breakpoint information is required for this

alternative manifold, as it is used intermittently.

SERVICE RECTIFICATION

Do not replace the manifold, as both manifolds

are fully interchangeable.

Technicians should not be concerned that there is

any additional component to be fitted at the

plugged hole location.

PARTS INFORMATION

No specific parts information is required – existing

parts and part numbers are unchanged, and

interchangeability is not affected.

ENGINE STALL ON DECELERATION/HIGH

ENGINE IDLE SPEED

JR, JS with C20SEL or C22SEL Engine

(GROUP 6M) May 2000

This Service Techline updates the previous

Techline on this topic (Issue 10, December, 1999

page 15) – by providing new part number

information.

PARTS INFORMATION

Since release of the original Techline item on this

condition, a kit comprising necessary components

has been made available.

For initial fitment of PCV oil separator as per the

previously issued Techline, order:

Part No.: Description: Qty

92065659 Kit, PCV Oil Separator 1

90411546 Valve – Idle Air Control (IAC). 1

09240103 Gasket - IACV 1

For reference, kit 92065659 contains:

1 x Oil Separator

2 x Vent Hose

2 x Hose Clamps

For Service replacement of PCV oil separator

and related components, these individual

parts will be shown in a future issue of

PartFinderTM:

Part No.: Description:

90411546 Valve – Idle Air Control (I AC).

09240103 Gasket - I ACV

09193502 Separator – PCV Oil

24421017 Hose – PCV Vent

90467971 Clam p – Vent Hose

Update

IGNITION KEY REMOVAL DIFFICULTY

JR, JS with A/T May 2000

(GROUP 7B & 12) HINT

PROBLEM DESCRI PTION

Some customers may report that they have

difficulty in removing the ignition key from the

ignition bar r e l.

Investigation into these reports has identified that

the problem r elates to the PBSL ( Park Br ake Shift

Lock) mechanism. Excessive preload/incorrect

adjustment of the automatic transmission selector

cable prevents actuation of the PBSL microswitch,

fur t her preventing rem oval of the ignit ion key.

Other symptoms include the automatic

transmission select or lever release but ton not f ully

returning to the rest position or the selector lever

does not align cor r ect ly in its selected position.

SERVICE RECTIFICATION

1. Shift the automat ic transmission selector lever

into the “P” ( par k) position.

2. Locate the selector lever cable in the engine

bay, refer Figure 1.

Figure 1.

(View of engine compartm ent f r om LH si de)

3. Locate and remove the selector lever cable-

retaining clamp from the cable connector,

refer Figure 2.

Figure 2.

4. Push forward and pull back on the cable to

minimise any preload present in either

direction, r efer Figure 3.

Figure 3.

5. Insert the cable-retaining clamp back into the

cable connector.

6. Move the selector lever to the “D” (drive)

position.

7. To confirm that the correct adjustment has

been achieved, inspect f or t he following:

- The white line on the gear selector

lever should be in line with the “D”

(drive) position;

- It is possible to access all gears with

the selector lever, i.e. P-R-N-D-3-2-1;

- The selector lever release button

travels all the way to its rest position

when “P” (park) is selected, refer

Figure 4;

- The key can be removed from the

ignition bar r e l freely.

Figure 4.

A/ T EXTERNAL OIL COOLER DELETION

VT, WH (with V6 & A/T)

(GROUP 7B) May 2000

PROBLEM DESCRI PTION

TAS calls have been received requesting

information on vehicles being pre-delivered –

where technicians have noted no external A/T oil

cooler is f it t ed.

As from vehicle build of April 10, 2000, the

external A/T oil cooler fitted to V6 (non-S/C)

engined VT and WH vehicles has been replaced

by two “in-tank” oil cooler s located in the RH & LH

radiator end t anks.

Vehicles carrying this r evision are identifiable by:

- NO exter nal A/ T oil cooler;

- Oil cooler connect ions t o bot h ends of the

radiator;

- Crossover pipe on radiator between A/T cooler

connections.

(Supercharged V6 engined vehicles remain

unchanged.)

PRODUCTION INTRODUCTION

The above revisions were introduced fr om :

VT:

ISOVIN: Build Date:

6H8VTK35HYL579900 10/04/00

WH:

ISOVIN: Build Date:

6H8WHY19HYL580005 10/04/00

SERVICE RECTIFICATION

On vehicles identified as being built after the

breakpoints above, and carrying revisions noted

above:

• An auxiliary (external) A/T oil cooler must not

be fitted.

• NO auxiliary (external) A/T oil cooler is

required when fitting tow bars (ALL tow bars).

All V6 (A/T) vehicles are able to tow 2100kg

without additional A/T cooling hardware.

WARRANTY CLAIM I NFORMATION:

The revisions noted have no effect on warranty

claiming.

HIGH CURRENT DRAW/FLAT BATTERY –

REAR DEMISTER RELAY STICKING

JR, JS

(GROUP 12) May 2000

PROBLEM DESCRI PTION

Investigations into reports of “flat battery” or high

standing current draw, on some vehicles, has

been identified as a sticking Rear Window

Demister Relay. This condition has become more

apparent during colder weather, where there is

increased use of t he r ear demister.

SERVICE RECTIFICATION

If there has been a complaint of a ‘flat batter y’ or,

during diagnosis, a high standing current draw

exists with no identifiable cause:

1. Remove fuse/relay panel cover from the right

hand side, lower instrument panel – Refer to

page 6-20 of Vectra Owner Handbook .

2. Move the fuse panel down by depressing the

lower release lever/handle and pulling towards

rear of vehicle.

3. Locate and remove the Rear Window

Demister Relay. Refer JS Wiring Diagrams,

Views of Relays and Fuses, Page 41 – Key

number 13.

4. With the demister relay removed from the

vehicle and with an Ohmmeter, probe

terminals 87 and 30 of the Rear Window

Demister Relay. If continuity exists, replace

the relay with the revised part specif ied below.

5. Should continuity not exist, further diagnosis

should be carried out to determine the source

of t he excessive current draw.

PARTS INFORMATION

The revised relay is black in colour, which is

distinctively different from the original, which is

blue in colour.

Part No.: Description: Qty

90464760 Rear Window Demister

Relay Asm 1

WARRANTY CLAIM I NFORMATION:

Use existing inf or m ation in Labour Time Manual

HOLDEN SERVICE TECHLINE _______________________________________________________________June 2000

PIR SUBMISSION PRECAUTION

ALL

(GROUP OB)

PROBLEM DESCRI PTION

PIR numbers reported at Foremen’s and Service

Managers Association Meetings do not match the

number believed to have been sent by Service

Managers, Foremen and Technicians.

As a consequence:

• Holden Service Engineering do not receive

vital product information;

• PIR conditions mentioned are not able to be

reported;

• PIR conditions are not able to be addressed

and production action or Techline action

cannot be initiated;

• Majority of PIR’s sent t o “old” fax numbers are

not f or warded to Holden Ser vice Eng ineer ing;

• Complaints are received from people owning

the “old” fax numbers.

Dealership personnel may also suffer reduced

PIR numbers, aff ect ing Zone incentive program s.

PROBLEM CAUSE

Old PIR pads with “old” fax numbers being used.

Incorrect “ old” or wrong f ax numbers programmed

in Dealership f ax machines.

PRODUCTION RECTIFICATION

Service Engineering provided a list of Holden fax

numbers – including t he PI R fax:

SEND PIR’s TO: (EDAG FUTURE)

ON 03 9552 8104

- in Techline Issue 2, 2000, Page 4 for use of all

Dealership Service Personnel.

Method of ordering correct PIR forms was also

supplied in that T echline item:

PIR forms: pads of PIR f orms ar e currently being

reprinted – Dealerships will be advised by All

Dealer Letter when new pads are available.

SERVICE RECTIFICATION

Applying the rectification below will help both

Holden, and Dealers, in the pro-active reporting,

assessment and correction of customer complaint

conditions.

Service Managers and Foremen should:

1. Find all copies of PIR f orms or pads with “old”

fax num bers and chang e the f ax number t o 03

9552 8104;

2. Ensure PIR’s are only sent via the latest fax

number – change all pre-programmed fax

machine numbers t o 03 9552 8104;

3. Make sure all Dealership staff who may write

PIR’s or have blank PIR forms – receive a

copy of this bulletin and change/use the fax

number.

A/C COMPRESSOR LUBRICANT

QUANTITY REVISED

VT & WH; V6 Engines

(GROUP 2)

CURRENT CONDITION

A revised quantity of A/C refrigerant oil is now

installed in compressors used on V6 engines.

These compressors now contain 220cc of oil in

lieu of t he pr evious 265cc.

PRODUCTION REVI SION

Revised V6 A/C compressors with reduced oil

quantit y have been fit t ed to vehicles from:

ISOVIN: Build Date:

6H8VTK69HYL574428 28/03/00

SERVICE RECTIFICATION

When servicing ANY VT or WH, V6 A/C

compressor, the quantity of oil added, or

calculated using existing service instructions,

should be 220cc not 265cc as per Service

Manuals.

NOTE:

For V8 Compressor, the oil quantity remains at

265cc and Service Manual compressor servicing

details remain t he sam e.

HOLDEN SERVICE TECHLINE _______________________________________________________________June 2000

FRONT SEAT BELT WEBBING “CATCHES”

ON RECLINER/LUMBAR KNOB/S

VT, WH

(GROUP 1)

This Service Techline supersedes the pr evious

Techline on this topic (I ssue 2, March, 2000 page

6). Parts Information is revised. The previous

Techline should be destroyed.

PROBLEM DESCRI PTION

Customer survey results indicate that some

customers have experienced a condition where

the front seat belt webbing did not freely slide

over the front seat recliner knob or lumbar knob.

PRODUCTION RECTIFICATION

As a continuous product improvement, the

surface f inish to both knobs has been r evised and

introduced into production. The revised knobs

feature a hard surface finish compared to the

earlier “sof t f eel” k nobs. This enables the seat belt

webbing to slide more easily over the k nob.

Revised knob/s were introduced into VT/WH

production as follows:

For Pewter Colour Knobs:

PSN: Build Date:

L521331 25/10/99

For Shale Colour Knobs:

PSN: Build Date:

L527046 07/11/99

Note: Taupe colour trim (incl. knobs) was not

carried into VT Series II (introduction L464495,

31/05/99).

SERVICE RECTIFICATION

Where a cust omer complains of seat belt webbing

“catching” on recliner or lumbar knobs, on

vehicles built prior to the above breakpoints, the

revised knobs should be installed to both front

seats.

Parts required are detailed in Parts Information

below.

When replacing the knobs, refer to the following

service information:

Recliner Knob:

VT Service Manual, Volume 12, Page 12M-21,

Ref. 2. 3

Lumbar Knob (non- SAB) :

VT Service Manual, Volume 14A, Page 1A7-5,

Ref. 2. 2

Lumbar Knob (SAB) :

VT Service Manual, Volume 14A, Page 1A7-6,

Ref. 2. 4

∗ “SAB” = Side Air Bag

PARTS INFORMATION

Part No.: Description: Qty:

92143234 Recliner Knob - Pewter 1

92143235 Recliner Knob - Shale 1

92143238 Recliner Knob - Taupe 1

92143230 Lumbar Knob, (non-SAB)

- Pewter 1

92143231 Lumbar Knob, (non-SAB)

- Shale 1

92143236 Lumbar Knob, (non-SAB)

- Taupe 1

92143232 Lumbar Knob, (SAB)

- Pewter 1

92143233 Lumbar Knob, (SAB)

- Shale 1

92143237 Lumbar Knob, (SAB)

- Taupe 1

WARRANTY CLAIM I NFORMATION:

Use the follow ing inf or m ation:

Description Replace Recliner & Lumbar

Knobs

Labour Op. No. C000397

Time 0.3 hr

Failure Code 39

HOLDEN SERVICE TECHLINE _______________________________________________________________June 2000

HVAC VACUUM RESERVOIR “BUZZ”

NOISE

JR, JS

(GROUP 2)

PROBLEM DESCRI PTION

PIR’s advising of a “buzz” noise – emanating from

the lef t hand side of the inst rument panel or glove

box area have been received. This noise may be

caused by two possible conditions:

1. Loose mounting of the Vacuum Reservoir

(described as “Recirculating Air Flap Vacuum

Tank” in TIS) – causing vibration of the

reservoir on the vehicle body mountings ;

2. “Shuttling” of the one-way valve inside the

HVAC vacuum reservoir.

PRODUCTION RECTIFICATION

A revised HVAC vacuum reservoir assembly and

Hose Asm. - Elbow have been fitted in JS

production f r om :

ISOVIN: Build Date:

W0L0JBF19YL540148 14/12/99

SERVICE RECTIFICATION

When a vehicle is presented with a complaint of

“buzz” noise from t he HVAC r e ser voir:

On Post-Breakpoi nt vehicles:

1. Open the engine hood and remove the

plenum chamber t o engine hood weatherseal;

2. Lift the LH side of the plenum chamber cover

to gain access to the vacuum reservoir.

3. Check reservoir mount ing nuts for tightness, if

loose, tighten the nuts. If the noise is

corrected after this step, no further work is

required.

4. Reinstall the plenum cover, plenum chamber

to engine hood weatherseal and close engine

hood.

On Pre-Breakpoint vehicl es:

1. Open the engine hood and remove the

plenum chamber t o engine hood weatherseal.

2. Lift the LH side of the plenum chamber cover

to gain access to the vacuum reservoir.

3. Check reservoir mount ing nuts for tightness, if

loose, tighten the nuts and attempt to

reproduce the noise before completing this

procedure. If the noise is corrected after this

step, no further work is required.

4. Diagnose the noise by listening to the HVAC

reservoir while an assistant operates the

Fresh/Recirc. control to reproduce the noise.

If this does not reproduce the noise, remove

both vacuum hoses from the reservoir and

apply vacuum to the LH side vacuum port,

using a “Mityvac” or similar tool. (The “buzz”

noise should now be heard from the

reservoir).

5. On confirmation of the HVAC vacuum

reservoir as the source of the “buzz” noise,

replace the vacuum reservoir and the hose

elbow that connects the vacuum line to the

reservoir – using the parts noted below.

NOTE: Because of the revisions to the

vacuum reservoir and the hose, for any

replacement of either part, both HVAC

vacuum reservoir and hose MUST be

replaced.

6. Reinstall the vacuum hoses, plenum cover,

plenum chamber to engine hood weatherseal

and close engine hood.

If the “buzz” noise persists, additional

diagnosis must be carried out to define

cause.

PARTS INFORMATION

W henever a vacuum reservoir is replaced for any

reason, a specific reser voir and hose combination

must be fitted if the reservoir is replaced for any

reason. Early type reservoirs are no longer

available from HSPO .

The earlier reservoir had an internal one-way

valve that can cause the “buzz” noise, and the

Hose Elbow was a plain rubber 90° elbow.

The later reservoir has NO one- way valve, but the

Hose Asm. - Elbow which MUST be used with the

reservoir has a one-way valve added to it .

To identify an early or late type reservoir, apply

vacuum to the LH side (larger) vacuum port - a

later reservoir will NOT hold vacuum at all – an

early reservoir will hold minimal residual vacuum,

and most lik ely exhibit a “buzz” noise.

If technicians suspect that a later type reservoir is

incorrectly fitted to a vehicle with a plain rubber

90° Hose Elbow, the elbow must be replaced by

HOLDEN SERVICE TECHLINE _______________________________________________________________June 2000

the later Hose Asm. - Elbow noted below, to

ensure correct Recir c . Control/f lap oper at ion.

Part No.: Descripti on: Qty

24412538 Vacuum Reservoir 1

24416795 Hose Asm. - Elbow, Air

Recirc. 1

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time Manual,

as shown:

Description Reservoir Asm. Vacuum -

Replace

Labour Op. No. D907000

Time 0.3 hr

Failure Code 36

REVISED FUEL FILTER ASSEMBLY

JACKAROO 4JX1 DIESEL

(GROUP 6 M)

When used in cold conditions ( Below 0°C) some

4JX1 Jackaroo vehicles may experience fuel flow

difficulties through the filter assembly upon cold

start up.

The rest r ict ion is due t o trapped air f r eezing on

the f ilt er element creating a barrier thr ough which

the f uel is unable t o flow. To overcome this

concern, Isuzu has released a r evised f ilt er

assembly that has impr oved air

breathing / b leeding abilities.

The part num ber for the r evised f ilter assembly is

8972245600.

FRONT END ALIGNMENT SPEC.

HSV VT I, VT II & WH GRANGE

(GROUP 3)

The following information is repeated from HSV

bulletin of Feb. 9, 2000, for use by technicians

when servicing HSV VT Series I, VT Series II,

and WH Grange vehicles.

PLEASE ENSURE ALL TECHNICIANS

INVOLVED IN FRONT END ALIGNMENT

WORK ARE MADE AWARE OF THESE

REVISED HSV SPECIFICATIONS.

FRONT END ALIGNM ENT SPECIF ICATIO N:

The information below supersedes information

provided in SIP CD ROM Version 1.1, relating to

HSV vehicles.

FRONT WHEEL ALIGNMENT AT KERB

WEIGHT

Toe-in Degrees Total 0° 10’ ± 0° 10’

Toe-in Degrees Per Wheel 0° 05’ ± 0° 05’

Camber - 0° 30’ ± 0° 20’

Caster 7° 45’ ± 1° 15’

Note: Front toe and front camber have been

reduced to optim ise front t yre life.

FUEL GAUGE INACCURACY

UES FRONTERA

(GROUP 12)

I-GM is current ly investigat ing fuel gauge

inaccuracy in current model Frontera vehicles.

The fuel gauge will tend to t ravel through its r ange

fr om full to empt y unevenly (i.e. the am ount of

gaug e m ovement for 50k m from full will not be the

same as 50km from ½ full ), also an excessive

amount of usable fuel will remain in t he t ank when

empty is indicated.

If a vehicle is present ed t o your dealer ship with

the above complaint, please advise your customer

that the issue is cur rently being investigated by I –

GM. Do not commence diagnosis of the

system. All developments regarding this issue

will be published through the dealer let ter system.

Update

HOLDEN SERVICE TECHLINE _______________________________________________________________June 2000

BRAKE SQUEAL – ANTI-SQUEAL PASTE

REVISION

(GROUP 5) Info. Update

PROBLEM DESCRI PTION

Previously issued Techlines of Issue 10, 1999,

page 7 and Issue 2, 2000, page 11, on this same

subject, advised use of a specific Anti-Squeal

Paste.

The material recommended has been revised.

The size of t he tube of anti-sq ueal paste has also

been increased from 4ml tube to a 100 gm tube,

to allow for multiple vehicle applications from the

one tube.

A new part number has been assigned to this

anti-squeal paste and is shown in parts

infor m ation below.

Please use only this anti-squeal paste - when

rectifying brake “squeal” - as mentioned in

Techlines noted above.

PARTS INFORMATION

Part No.: Descripti on: Qty

90512280 Anti-Sq ueal Past e - 100gm 1

DTC P0327 SETTING – KNOCK SENSOR

SENSITIVITY REVISION

VT & WH with LS1 (Gen III) V8 engine

(GROUP 6C) Re-Issued

This Service Techline supersedes the pr evious

Techline on this topic (I ssue 10, December, 1999

page 11). Breakpoint info. added. The previous

Techline should be destroyed.

PROBLEM DESCRI PTION

Reports have been received of DTC P0327 being

set repeatedly. This has led, in some cases, to

time consuming diagnosis with no rectification

resulting.

The cause of DTC P0327 setting (when no

definable problem exists with engine, knock

sensor or knock sensor harness) is an over-

sensitive knock sensor diagnostic system.

PRODUCTION RECTIFICATION

Revised PCM calibration was introduced to

vehicle production fr om :

ISOVIN: Build Date:

6H8VTX69FYL523541 02/11/99

SERVICE RECTIFICATION

Revised software has been released in the TIS

2000 CD-ROM Version 54, via DL 68/99 dated

December 6, 1999 which will rectify vehicles in

the field. Use of the software contained in this

new CD, to flash program PCM’s will rectify this

complaint on non-HSV vehicles only.

For HSV vehicles which suffer this complaint – fax

a “Holden Special Vehicles Warranty Request

Form No. 9861” with full details, to HSV

“Attention: John Volarich” (Fax No. (03) 9265

9555), who will supply a change-over PCM.

HOLDEN SERVICE TECHLINE _______________________________________________________________June 2000

PCV SYSTEM REVISION

JS with C22SEL Engine

(GROUP 6M)

PROBLEM DESCRIPTION

Oil separators are no longer fitted to C22SEL

engined JS vehicles. Refer breakpoint information

below.

JS C22SEL engined vehicles are now built with a

revised PCV system that feeds PCV gas into the

lower part of the inlet manifold. This new system

does not require use of an oil separator.

PRODUCTION RECTIFICATION

JS C22SEL engined Vehicles using this new PCV

system were built from:

ISOVIN: Build Date:

WOLOJBF19YL557427 16/02/00

For reference:

Engine No.:

C22SEL25015395

SERVICE RECTIFICATION

Technicians may believe vehicles have been built

incorrectly – “without an oil separator” – several

have called TAS to ask if a plant build error has

occurred, and whether an oil separator should be

installed as per previous Techline bulletins. (EG:

Techlines issued on “Engine Stall on

Decel./High Engine Idle” in Issue 10, December,

1999, page 15 & Issue 4, May, 2000, page 5.

Technicians MUST NOT fit oil separators to post

breakpoint C22SEL engined vehicles.

P/S OIL COOLER INSTALLATION WHEN

FITTING TOW BARS

VT/WH, with V6 ENGINES

(GROUP 9 & OB)

PROBLEM DESCRIPTION

No mountings are provided for the Power

Steering (P/S) oil cooler that is required to be

fitted with 1600Kg & 2100Kg tow bar packages

on:

• Auto. Trans. (A/T) equipped vehicles with V6

engines built after L579900 (VT) & L580005

(WH). (Refer Techline item, Issue 4, May,

2000, page 7 advising of A/T oil cooler

deletion).

This P/S oil cooler mounts on the external A/T oil

cooler mounting brackets on V6, A/T equipped

vehicles built prior to the above breakpoints.

NOTE: S/C V6 equipped vehicles are not

affected, as external A/T oil coolers are retained

on these vehicles.

SERVICE RECTIFICATION

When ordering a tow bar package that requires a

P/S oil cooler addition to the vehicle, assess the

vehicle engine/trans. configuration - where the

vehicle is built after the breakpoints noted above

– order P/S oil cooler mounting brackets and

mounting hardware from HSPO PartFinderTM.

HOLDEN SERVICE TECHLINE ____________________________________________________________________ JUNE 2000

KNOCK/CREAK FROM FOOTWELL OR STEERING GEAR AREA

VT & WH

(GROUPS 1 & 9) HINT

This Service Techline supersedes the previous Techline on this topic (Issue 5, July, 1999 page 6). Text

and torque specificat ions have been revised. This previous Techline should be destroyed.

PROBLEM DESCRI PTION

A knocking or creaking noise maybe heard from around the footwell area, or from the steering gear

assembly or its mount ings, when the vehicle travels over undulating gr ound and t he body flexes.

This knock or creak may be caused by the front longitudinal brace attaching nuts becoming loose,

causing relat ive movement bet ween the body and the braces.

SERVICE RECTIFICATION

NOTE: Because exact location of the noise source may be difficult, carry out the following procedure

befor e consider ing replacement of any steering g ear assembly.

To rect ify, torq ue the longitudinal to front floor brace nuts t o 31 ± 4Nm as indicated in Figure 1.

Figure 1.

PRODUCTION TORQ UE REVISION

Retaining nut t orque was increased from :

ISOVIN: Build Date:

6H8VTK35HYL588344 10/05/00

Torque Nuts to 31±4Nm

HOLDEN SERVICE TECHLINE _____________________________________________________ JUNE 2000

RADIO INOPERATIVE – DIAGNOSIS

PRECAUTION

GMC TC/TK Light Truck (Ambulance)

(GROUP 12) HINT

This Techline bulletin applies only to GMC

TC/TK vehicles imported under the

Holden/JAKAB agreement specified in

Warranty Processing letter WD 06/98, dated

August 28, 1998.

Warr anty Clerks should refer to the above letter

for warrant y claiming details, when required.

The f ollowing informat ion is provided by JAKAB

and has been circulated to Am bulance Services

who operate these vehicles nationwide.

This information is provided to assist Holden

Dealership technicians who work on these

vehicles.

PROBLEM DESCRI PTION

Radio is inoperative, even though no problem

can be found with the radio assembly, IE: fuse

OK, wiring (power and earth) to radio is OK.

SERVICE RECTIFICATION

On presentation of a vehicle with this condition

–– technicians should be aware that if one

speaker is shorted out, the radio will cease to

function.

Fitting a new radio will result in the same

condition.

Trace the radio speaker wiring to define the

location of any short circuit in the wiring, and

repair the shor t circ uit – PRIOR to attempt ing to

replace a radio assembly.

WARRANTY CLAIM I NFORMATION:

When claiming any warranty work on these

vehicles - use existing Labour Operation

numbers and times for Commodore in the

Passenger Labour Time Manual, or contact

JAKAB, as per the information provided in

W ar ranty Processing let ter WD 06/98 regarding

these vehicles.

STEERING TOE CONVERSION FROM

DEGREES/MINUTES TO MILLIMETRES.

ALL

(GROUP 3) Re-Issued

This Techline Bulletin has been re-issued to

ensure all technicians are aware of the

conversion dat a contained in the att ached chart

(ON PAGE 24).

This Service Techline has been issued to aid

dealers in converting wheel alignment toe

figures from degree/minutes to decimal

degrees or t o m illimetres and vice-versa.

The table on the back of this Service Techline

shows toe readings as measured at the rim

edge for 13”, 14”, 15”, 16”, 17” diameter rims.

Also included are toe readings for a 28” tyre.

This is included for those wheel alignment

machines that are calibrated to read toe at the

old convention of 28” diameter.

Most modern wheel alignment equipment,

allows the operator to ‘dial in’ the actual

diameter of the rims of the vehicle being

measured. Some machines which do not allow

the rim diameter to be dialled in, may default to

measuring t oe at a 14” rim diameter .

When reading the output from the wheel

alignment equipment, ensure the operator

knows the difference between a readout in

degrees/minutes (0°00’) format or in decimal

degrees (0. 00°) format.

Since the introduction of VT, all wheel

alignment specifications are given in a

degree/minute format as per the VT Series

Service Manual, Volume No.1.

Note: 1 deg r ee ( 01°00’) = 60 m inutes ( 00°60’) ;

1 minute (0°01’) = 0.0167° decimal

degree.

IF THE MACHINE DOES NOT CALL FOR THE

EXACT RIM DIAMETER OF THE VEHICLE BEING

MEASURED, IT IS ESSENTIAL FOR THE

TECHNICIAN TO KNOW WHICH CALIBRATION

DIAMETER APPLIES TO THEIR MACHINE i.e. 14”

OR 28” DIAMETER SO T HAT T HE CORRECT TOE

SPECIFICATIONS CAN BE ACHIEVED.

HOLDEN SERVICE TECHLINE _____________________________________________________ JUNE 2000

M/T NOISE

HSV VT with GEN III & MM6 M/T

(GROUP 7A)

PROBLEM DESCRI PTION

Some customers may be concerned about the

noise levels from the MM6 6-speed Manual

Transmission (M/T) fitted to Gen III V8

equipped HSV vehicles.

Engine firing pulses input into this high torque

capacity trans., with its low friction design, can

result in a gear “rattle” or “buzz” noise while

driving.

This noise and other normal gear noises can

also be transferred into the gear lever, where

they may be am plified by the gear lever boot or

a loose gear lever k nob.

Holden took steps to reduce these noise levels

as much as possible, by the use of a noise

reduction package, in later built VT MM6 M/T

equipped vehicles – the package consists of :

- Additional 0.5 litre of Dexron III® Automatic

Transmission Fluid (ATF) required as

‘normal fill’. – Provides additional noise

absorption.

- Additional insulator on gearshift control

lever. – Reduces noise transfer into

passenger compartm ent .

- Revised gear lever dimension – Stops loose

gear lever knob vibration and noise transfer

into passenger compar t m ent.

This pack age is now used in ALL VT, MM6 M/T

equipped vehicles.

PRODUCTION INTRODUCTION

The noise reduction package was added to

ALL VT vehicles (including HSV vehicles) fitt ed

with MM6 M/T from:

ISOVIN: Build Date:

6H8VTK69FYL511925 28/09/99

However – to fill HSV orders in a timely

manner, early built HSV MM6 equipped

vehicles were released prior to availability of

the noise reduction package.

The MM6 M/T, in VT Series II HSV

vehicles, was introduced into production at:

ISOVIN: Build Date:

6H8VTK69FXL446731 29/04/99

Additional ATF ( 0. 5 litre) was added at:

ISOVIN: Build Date:

6H8VTK69FYL505387 14/09/99

SERVICE RECTIFICATION

Dealerships may receive complaints regarding

transmission noise levels in early built HSV

MM6 M/T vehicles. Carry out the revisions

requir ed t o affected vehicles, as shown:

Affected Vehicle

Range: Revisions Required:

L446731 to L505386 Trans. & Lever

Revisions and Oil

“Overfill”

L505387 to L511924 Trans. & Lever

Revisions only

NOTE: some vehicles may already have some

of the additional parts fitted through

recommendations from TAS – where partial

application of this package is found – add only

the parts required.

Trans. & Lever Revisions

For vehicles from L446731 to L511925

1. Remove gear lever knob and attached boot

– DO NOT attempt to remove knob by

rotating - Refer VT Service Manual

Volume 14C, page 7B3-15. NOTE: If

difficulty is encountered removing the gear

lever knob, a small flat blade screwdriver

may be inserted inside the lower end of the

knob to detent the retaining lugs, allowing

easier removal.

2. Measure t he top of the gear lever as shown

in Figure 1. Early build levers are

13.30/13.70mm Dia. Later levers are

13.90/14.00m m Dia. . If the lever Dia. is less

than 13.90mm – the lever (P/N 92075003)

must be replaced. (All HSPO stock is of the

later type).

Aft er the g ear lever diamet er is check ed as O K,

or a new lever is installed – fit a G ear

3. Lever Asm. Isolator (P/N 92087709) over

the lever, pressing the isolator onto the

HOLDEN SERVICE TECHLINE _____________________________________________________ JUNE 2000

lever and attaching screws to ensure

maximum noise reduction is achieved.

Refer Figure 1.

Figure 1.

4. Before re-fitting the knob and boot

assembly -–ensure the cable tie retaining

the boot to the knob is as tight as possible,

to ensure no noise “leak paths” remain.

5. Refit the gear lever knob and boot

assembly.

“Oil Overfill”

For vehicles from L446731 to L505386

1. Raise the vehicle on a hoist, ensuring that

the vehicle is level. Refer to

Section 0A GENERAL INFORMATION in

Volume 1 of VT Service Manual, for the

location of jacking point s.

2. Place a drain t ray beneath transmission and

remove transmission filler plug from left

hand side of transmission case, using a

3/8” drive sock et bar .

3. Allow excess fluid to drain until flow stops. If

required, top up fluid level until it reaches

the bottom of the thr eaded filler plug hole.

4. Clean the threads of the f iller plug and hole,

apply thread sealant (GM P/N 12346004),

then reinstall filler plug, torque to 20 – 34

Nm. Do not apply Tef lon thread tape to the

plug thr eads.

5. Remove back-up switch wiring harness

connector (1) from the back-up switch,

located on the right hand side of the

transmission case. Refer Figur e 2.

Figure 2.

6. Remove back-up lamp switch from the

transmission case – shown by arrow in

Figure 3.

7. Add a measured, 0.5 litres of Dexron III®

ATF to the transmission, via the back-up

lamp switch threaded hole in the

transmission case.

8. Apply Sealant (P/N 12346004) to the

cleaned threads of the back- up lam p switch.

6. Install switch to transmission case and

torque to 20 – 34 Nm, then refit electrical

connector.

7. On the left hand side of the trans. at the

“old” filler plug – wipe the existing label

under the plug with a solvent to remove all

traces of dirt and contaminants, then apply

a “DO NOT OPEN….” sticker (P/N

92095432) OVER the existing label. This

ensures the plug is not opened, which

would result in loss of the added ATF, in

future. Refer Figure 4.

HOLDEN SERVICE TECHLINE _____________________________________________________ JUNE 2000

Figure 4.

Full details of lubricant level checking and

addition, removal and replacement of the back-

up lamp switch, gear lever, knob and boot are

contained in VT Series II Service Manual,

Volume 14C, pages 7B3- P8 & P9, and pages

7B3- P15 & P16.

Should the noise described in this bulletin

continue after application of the above

procedure, contact HSV Technical Assistance

Department on telephone number (03) 9265

9500.

NOTE: The gear rattle, or “buzz” noise will not

be reduced by gear or transmission

replacement.

PARTS INFORMATION

Part No.: Description: Qty

92087709 Boot – Shift Asm.

Isolator 1

92095432 Label – Trans. 1

12346004 Sealant ( Rev. Sw.) As

required

M41089 Dexron III® ATF (1 litre) 1

92075003 Lever - Shift 1 - If

required

NOTE: If Sealant 12346004 is not available -

Permatex “Pipe Thread Sealant With Teflon”

P/N 27838 - 50ml t ube size – may be used.

WARRANTY CLAIM I NFORMATION:

NOTE: some vehicles may already have some

of the additional parts fitted through

recommendations from TAS. Where partial

application of this package is found – add the

additional parts required and claim the reduced

amount of time requir ed for those t asks.

Use the f ollowing information to claim the work

defined above.

Description Fit HSV Noise Reduction

Package

Labour Op. No. K000261

Time 0.8 hr

Failure Code 40

HOLDEN SERVICE TECHLINE _____________________________________________________ JUNE 2000

CHECKING M/T LUBRICANT LEVEL

VT w ith LS1 (Gen III) V8 & M/T

(GROUP 7A)

The following manual transmission information

for LS1 (GEN III) manual trans. is repeated

fr om All Dealer Lett er DL 57/99 – for t he benefit

of service technicians. This information

supersedes t he information shown in VT Series

II Service Manual, Volume 14C, pages 7B3- P8

& P9.

Please note the following important point s on

servicing this transmission:

• This transmission is classified as being a

"Fill for Life" transmission and periodic

checking of the lubricant level is not

required. In production, a sticker is placed

next to the normal filler plug on the

transmission advising technicians: - “DO

NOT OPEN THE FILL PLUG – REFER

SERVICE MANUAL”.

• The only time that fluid level checking is

appropriate, is aft er cor r ection of a fluid leak

that does not req uire the transm ission to be

fully drained and/or removed from the

vehicle.

• The VT Series II Owners Handbook Print

No 3 will have the requirement to

periodically check fluid levels in this

transmission delet ed.

• The VT service manual (CD version only)

has also been revised in line with the

above. The CD with these revisions

released via automatic distribution in

December 1999. The attachment to this

letter is an extract from this CD detailing

information on transmission fluid capacity,

checking & filling procedures. The

additional oil level was introduced as a

noise reduction initiat ive.

• Update your VT Series II Service Manual,

Volume 14C – by photocopying the

following two pages and sticking them

over existing pages 7B3-8 & 9.

PRODUCTION BREAKPOINT

Oil level was increased (as noted in revised

Section 2.2 attached) in the transmission

at:

ISOVIN: Build Date:

6H8VTK69FYL505387 14/09/99

HOLDEN SERVICE TECHLINE _____________________________________________________ JUNE 2000

Photocopy this page

– cut of f excess paper above dotted line -

stick over existing infor m ation on VT SERIES II SERVICE MANUAL, VOLUME 14C, PAGE 7B3- 8

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

2.1 RE COMMENDED LUBRICANT

The recommended lubricant for the ‘T56’ manual

transmission is Dexron III® automatic transmission fluid to

Holden’s Specification HN 2126.

The transmission lubricant capacity is approximately 4.4

litres.

2.2 CHECKING TRANSMISSION

LUBRICANT LEVEL

Important: This transmission is classified as being a

“Fill for Life” transmission and checking the lubricant

level is not recommended.

The only time that fluid level checking would be

appropriate, would be after correction of a fluid leak that

did not require the transmission to be fully drained and/or

removed from the vehicle.

1. Raise the vehicle front and rear and support on safety

stands, ensuring that the vehicle is level. Refer to

Section 0A GENERAL INFORMATION in Volume 1 of

this Service Manual, for the location of jacking points.

2. Place a drain tray beneath transmission and remove

transmission filler plug (1) from left hand side of

transmission case (2), using a 3/8” drive socket bar.

NOTE: Depending on the severity of the loss, fluid

will probably flow from the filler plug hole, following

removal.

3. Allow excess fluid to drain until flow stops. If required,

top up fluid level until it does flow out.

4. Clean the threads of the filler plug, apply thread

sealant such as Loctite 565 or equivalent (GM P/N

12346004), then reinstall filler plug, tightening to the

correct torque specification. Do not apply Teflon

thread tape to the plug threads.

TRANSMISSION FILLER PLUG

TORQUE SPECIFICATION 20 - 34 Nm

5. Remove the back-up lamp switch as detailed in 3.1

BACK-UP LAMP SWITCH, Replace in this Section.

6. Using commercially available fluid dispensing

equipment, add a measured, 0.5 litres of the

recommended lubricant to the transmission, via the

back-up lamp switch threaded hole in the

transmission case.

7. Reinstall the back-up lamp switch, as detailed in

3.1 BACK-UP LAMP SWITCH, Replace in this

Section, then lower the vehicle to the ground.

Figure 7B3- 7

HOLDEN SERVICE TECHLINE _____________________________________________________ JUNE 2000

Photocopy this page

– cut of f excess paper above dotted line -

stick over existing infor m ation on VT SERIES II SERVICE MANUAL, VOLUME 14C, PAGE 7B3- 9

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

3.1 BACK-UP LAMP SWITCH

REPLACE

1. Raise front of vehicle and support on safety stands.

Refer to Section 0A GENERAL INFORMATION in

Volume 1 of this Service Manual, for the location of

jacking points.

2. Remove wiring harness connector (1) from switch,

located on the right hand side of the transmission case.

3. Loosen, then remove switch (arrow) from the

transmission case.

4. Apply Loctite 565 or equivalent (GM P/N 12346004), to

the cleaned threads of the back-up lamp switch.

5. Install switch to transmission case and tighten to the

correct torque specification.

BACK-UP LAMP SWITCH

TORQUE SP ECIFICAT I O N 20 - 34 Nm

6. Install wiring harness connector to switch.

7. Remove safety stands and lower vehicle to ground.

8. Check back-up lamp operation.

Figure 7B3- 9

Figure 7B3- 10

HOLDEN SERVICE TECHLINE _____________________________________________________ JUNE 2000

ANTI THEFT/KEYLESS ENTRY DIAGNOSIS

JACKAROO

(GROUP 12)

The chart s below are q uick reference material that is int ended to be used in conjunction with the relevant

workshop manual section ( 8H) and wiring diagrams (8D – 242) in the current Jack ar oo work shop manual.

DOOR SWITCH DIAGNOSIS

Front Door Key Swit ch

Detect Switch Circuit - Open

FUNCTION OPERATION

Anti – Theft LED No effect

Remote Lock ing No effect

Mechanical Locking No effect

Alarm System ( Arming ) Mechanical key will not arm system

Alarm System ( Disarm ) Mechanical key will not arm system

Note Unlocking the door with the mechanical key will activate the alar m system .

Detect Switch Circuit – Short to Gr ound

FUNCTION OPERATION

Anti – Theft LED No effect

Remote Lock ing No effect

Mechanical Locking No effect

Alarm System ( Arming ) No effect – (see below)

Alarm System ( Disarm ) No effect – (see below)

Note Locking / Unlocking the door with the snib button will arm / disarm the alarm

system

Tamper Switch Cir cuit - Open

FUNCTION OPERATION

Anti – Theft LED No effect

Remote Lock ing No effect

Mechanical Locking No effect

Alarm System ( Arming ) No effect

Alarm System ( Disarm ) No effect

Note Open circ uit is the normal state for this switch. For cing the lock will not activate t he alar m

when this condition exists

Tamper Switch Circuit – Short to G r ound

FUNCTION OPERATION

Anti – Theft LED Flashes at constant 2Hz with doors closed

Remote Lock ing Inoperative

Mechanical Locking No effect

Alarm System ( Arming ) Inoperative

Alarm System ( Disar m ) I noper ative

HOLDEN SERVICE TECHLINE _____________________________________________________ JUNE 2000

Door Lock Key Switch

Door Lock Key Switch - Open

FUNCTION OPERATION

Anti – Theft LED No effect

Remote Lock ing No effect

Mechanical Locking No central lock ing from failed door

Alarm System ( Arming ) No effect

Alarm System ( Disarm ) No effect

Note Central locking is still available from arm – rest master switch

Door Lock Key Switch (Lock ) – Shor t to Ground

FUNCTION OPERATION

Anti – Theft LED No effect

Remote Locking Remote unlock only

Mechanical Locking No central locking from failed door

Alarm System ( Arming ) No effect

Alarm System ( Disarm ) No effect

Note Central locking is still available from arm – rest m aster switch

Door Lock Key Switch (Unlock) – Shor t To Ground

FUNCTION OPERATION

Anti – Theft LED No effect

Remote Lock ing Remote lock only

Mechanical Locking No effect

Alarm System ( Arming ) No effect

Alarm System ( Disarm ) No effect

Hood & Dome Lamp Switches

Hood Switch Circuit - O pen

FUNCTION OPERATION

Anti – Theft LED No effect

Remote Lock ing No effect

Mechanical Locking No effect

Alarm System ( Arming ) No effect

Alarm System ( Disarm ) No effect

Note Open circuit is the normal state for this switch. For c ing the hood will not activate the

alarm when this condition exists

Hood Switch Circuit – Short to Ground

FUNCTION OPERATION

Anti – Theft LED Normal operat ion with doors open, but off when

doors locked

Remote Lock ing No effect

Mechanical Locking No effect

Alarm System ( Arming ) Inoperative

Alarm System ( Disar m ) I noper ative

HOLDEN SERVICE TECHLINE _____________________________________________________ JUNE 2000

Dome Lamp Switch ( Door Sw.) Circuit - Open

FUNCTION OPERATION

Anti – Theft LED No effect

Remote Lock ing No effect

Mechanical Locking No effect

Alarm System ( Arming ) No effect

Alarm System ( Disarm ) No effect

Note Open circuit is the normal state for this switch. The dome lamp will not activate when the

door is opened

Dome Lamp Switch (Door Sw.) Circuit – Short t o G round

FUNCTION OPERATION

Anti – Theft LED See note below

Remote Lock ing Inoperative

Mechanical Locking No effect

Alarm System ( Arming ) Inoperative

Alarm System ( Disar m ) I noper ative

Note The Ant i – t heft LED will flash at 2Hz for 30 secs. After a remot e keypad button is

depressed, then go out. The LED will remain on continuously while the unlock button is

depressed on the k eypad.

HOLDEN SERVICE TECHLINE _____________________________________________________ JUNE 2000

COOLANT SPECIFICATIONS

ALL IGM MODELS

(GROUP 6K)

The att ached t able is a reference guide to coolant specifications for all Isuzu vehicles.

Vehicle Model Factory Fill

Spec Recommended

Change at Alternative

Replacement

Coolant Spec

Recommended

Change at

~1998, R7 Rodeo

~1997, L5 Jackaroo

1996, UT Frontera

~1996, Isuzu Truck

HN2043

2 Years / 40 000

HN2217

GM6277m

5 Years / 100 000

(Max)

5 Years / 100 000

(Min)

1997~, Isuzu Truck

HN2217

2 Years / 40 000

GM6277m

5 Years / 100 000

(Min)

1999~, R9 Rodeo

1998~, U8 Jackaroo

1997, UT Frontera

MX, Frontera

HN2217

5 Years / 100 000

(Max)

GM6277m

5 Years / 100 000

(Min)

Suburban

GM6277m

(Dexcool)

5 Years / 100 000

(Min)

Note – An inspection of cooling system component s for corrosion should be car ried out prior to r efilling with

new coolant. Failure to identify a problem at this point may be a costly experience at a later date. When

using an alternative to the factory fill coolant the cooling system must be thoroughly flushed prior

to refilling.

TOE

(MINUTES)

TOTAL

(DECIMAL

DEGREES) 13"

rim 14"

rim 15"

rim 16"

rim 17"

rim

28"

Normal

Tyre TOE

(MINUTES)

TOTAL

(DECIMAL

DEGREES) 13"

rim 14"

rim 15"

rim 16"

rim 17"

rim

28"

Normal

Tyre

0o01' 0.02o0.10 0.10 0.11 0.12 0.13 0.21 0o31' 0.52o2.98 3.21 3.44 3.66 3.89 6.41

0o02' 0.03o0.19 0.21 0.22 0.24 0.25 0.41 0o32' 0.53o3.07 3.31 3.55 3.78 4.02 6.62

0o03' 0.05o0.29 0.31 0.33 0.35 0.38 0.62 0o33' 0.55o3.17 3.41 3.66 3.90 4.14 6.83

0o04' 0.07o0.38 0.41 0.44 0.47 0.50 0.83 0o34' 0.57o3.27 3.52 3.77 4.02 4.27 7.03

0o05' 0.08o0.48 0.52 0.55 0.59 0.63 1.03 0o35' 0.58o3.36 3.62 3.88 4.14 4.40 7.24

0o06' 0.10o0.58 0.62 0.66 0.71 0.75 1.24 0o36' 0.60o3.46 3.72 3.99 4.26 4.52 7.45

0o07' 0.12o0.67 0.72 0.78 0.83 0.88 1.45 0o37' 0.62o3.55 3.83 4.10 4.37 4.65 7.65

0o08' 0.13o0.77 0.83 0.89 0.95 1.00 1.66 0o38' 0.63o3.65 3.93 4.21 4.49 4.77 7.86

0o09' 0.15o0.86 0.93 1.00 1.06 1.13 1.86 0o39' 0.65o3.75 4.03 4.32 4.61 4.90 8.07

0o10' 0.17o0.96 1.03 1.11 1.18 1.26 2.07 0o40' 0.67o3.84 4.14 4.43 4.73 5.02 8.28

0o11' 0.18o1.06 1.14 1.22 1.30 1.38 2.28 0o41' 0.68o3.94 4.24 4.54 4.85 5.15 8.48

0o12' 0.20o1.15 1.24 1.33 1.42 1.51 2.48 0o42' 0.70o4.03 4.34 4.65 4.97 5.28 8.69

0o13' 0.22o1.25 1.34 1.44 1.54 1.63 2.69 0o43' 0.72o4.13 4.45 4.77 5.08 5.40 8.90

0o14' 0.23o1.34 1.45 1.55 1.66 1.76 2.90 0o44' 0.73o4.23 4.55 4.88 5.20 5.53 9.10

0o15' 0.25o1.44 1.55 1.66 1.77 1.88 3.10 0o45' 0.75o4.32 4.65 4.99 5.32 5.65 9.31

0o16' 0.27o1.54 1.66 1.77 1.89 2.01 3.31 0o46' 0.77o4.42 4.76 5.10 5.44 5.78 9.52

0o17' 0.28o1.63 1.76 1.88 2.01 2.14 3.52 0o47' 0.78o4.51 4.86 5.21 5.56 5.90 9.72

0o18' 0.30o1.73 1.86 1.99 2.13 2.26 3.72 0o48' 0.80o4.61 4.96 5.32 5.67 6.03 9.93

0o19' 0.32o1.82 1.97 2.11 2.25 2.39 3.93 0o49' 0.82o4.71 5.07 5.43 5.79 6.15 10.14

0o20' 0.33o1.92 2.07 2.22 2.36 2.51 4.14 0o50' 0.83o4.80 5.17 5.54 5.91 6.28 10.34

0o21' 0.35o2.02 2.17 2.33 2.48 2.64 4.34 0o51' 0.85o4.90 5.28 5.65 6.03 6.41 10.55

0o22' 0.37o2.11 2.28 2.44 2.60 2.76 4.55 0o52' 0.87o4.99 5.38 5.76 6.15 6.53 10.76

0o23' 0.38o2.21 2.38 2.55 2.72 2.89 4.76 0o53' 0.88o5.09 5.48 5.87 6.27 6.66 10.96

0o24' 0.40o2.31 2.48 2.66 2.84 3.01 4.97 0o54' 0.90o5.19 5.59 5.98 6.38 6.78 11.17

0o25' 0.42o2.40 2.59 2.77 2.96 3.14 5.17 0o55' 0.92o5.28 5.69 6.10 6.50 6.91 11.38

0o26' 0.43o2.50 2.69 2.88 3.07 3.27 5.38 0o56' 0.93o5.38 5.79 6.21 6.62 7.03 11.58

0o27' 0.45o2.59 2.79 2.99 3.19 3.39 5.59 0o57' 0.95o5.47 5.90 6.32 6.74 7.16 11.79

0o28' 0.47o2.69 2.90 3.10 3.31 3.52 5.79 0o58' 0.97o5.57 6.00 6.43 6.86 7.28 12.00

0o29' 0.48o2.79 3.00 3.21 3.43 3.64 6.00 0o59' 0.98o5.67 6.10 6.54 6.97 7.41 12.21

0o30' 0.50o2.88 3.10 3.32 3.55 3.77 6.21 0o60' 1.00o5.76 6.21 6.65 7.09 7.54 12.41

WHEEL ALIGNMENT CONVERSION CHAR

(DEGREE/MINUTES TO DECIMAL DEGREE TO MILLIMETRES)

Millimetres of Toe Millimetres of Toe

HOLDEN SERVICE TECHLINE ____________________________________________________________________ JULY 2000

6 6

M/T REVERSE LAMP SWITCH FAILURE

SB, TR, TS, JR, JS, YE (M/T)

(GROUP 7A)

PROBLEM DESCRI PTION

PIR’s have been received, advising of

inoperative M/T (manual trans.) reverse lamp

switches. Cause of failure is a switch internal

connection fault.

SERVICE RECTIFICATION

Whenever an inoperative M/T reverse lamp

switch is encountered, it should be replaced with

a new switch ex-HSPO.

During any switch replacement, fit a new seal to

the switch.

PARTS INFORMATION

The part number f or the reverse lamp switch has

not been changed, but switches in HSPO stock

at the time of this Techline release are from an

alternative supplier with revised inter nal design.

Any switches, in Dealership parts stock, which

carry a date st amp ear lier than “ 26.05.00” on t he

HSPO box label, should not be used, but be

returned to HSPO for credit.

Part No.: Description: Qty

90482454 Reverse Lamp Switch

(M/T) 1

11015219 Seal - Reverse Lamp

Switch 1

WARRANTY CLAIM I NFORMATION:

Use existing inf or m ation in Labour Time Manual

ALTERED TOOTHED BELT

INSTALLATION PROCEDURE

JR, YE - 1997 MY’ WITH X25XE V6

ENGINE

(GROUP 6A)

This Techline item, replaces the item previously

published in December, 1997 Issue 8, to ensure

technicians are aware of the altered procedure

shown, and that the procedure also applies to

YE Calibra wit h X25XE V6 engine.

Various alterations were introduced to the

toothed belt drive on 1997 MY’ JR Vectra, & YE

Calibra with X25XE (V6) engine. These

alterations involved the introduction of a new

toothed belt t ension roller with an additional fr ont

flanged wheel and a modified toothed belt

tension roller base plate (identified by a letter E

stamping).

These alterations were implemented to reduce

engine noise and increase t he toothed belt lif e to

120,000 km (or 8 years). However, in making

these changes, the procedure for installing the

toothed belt was also altered.

Contrary to the previous installation sequence

instructions, the introduction of these alterations

means that the toothed belt is now installed

clockwise.

This is necessary, as the toothed belt can no

longer be pushed onto the toothed belt tension

roller from the front.

Whenever removing or installing a toothed belt

onto an X25XE engine in JR and YE models,

ref er ence should be m ade to:

Service procedure TIC 54 “Altered Toothed Belt

Assembly Sequence” in TIS 2000 CD.

HOLDEN SERVICE TECHLINE ____________________________________________________________________ JULY 2000

7 7

DECKLID BOUNCES AFTER OPENING

JR, JS (Sedan)

(GROUP 1)

This Service Techline supersedes the previous

Techline on this topic (Issue 8, October, 1999

page 5). This previous Techline should be

destroyed.

PROBLEM DESCRI PTION

Decklid ‘bounces’ or ‘rebounds’ when released

aft er opening.

PRODUCTION RECTIFICATION

JR Model:

No production revisions were introduced for this

condition, so all complaint vehicles must be

corrected as per the procedure below (replace

screws & washers).

JS Model:

Revised collar screws (with 4mm head) were

introduced into vehicle product ion as follows:

PSN: Build Date:

L392114 22/10/98

Spring washers were introduced between the

hinge and the pivot screw, to increase friction to

prevent bouncing, as follows:

PSN: Build Date:

L482379 22/07/99

SERVICE RECTIFICATION

If a complaint of decklid ‘bounce’ or ‘rebound’ is

received, carry out the following procedure:

JR Models – replace both collar screws and fit

spring washers.

JS models – assess parts requirements with

reference to the above breakpoints and this

procedure.

1. Remove C-pillar t r ims

2. Locate the decklid hinge on one side and

remove the collar screw f r om the hinge.

3. Measure screw head thickness – if thick ness is

6mm, replace the collar screw with a new collar

screw P/N 90463254 (of 4mm head thickness) .

NOTE: The screws used in this installation

must have a 4mm head thickness, or

insufficient clamp load will be applied to the

spring washer/s.

4. Install spring washer p/n 11100791 between

hinge and pivot as indicated in Fig ure 1.

5. Repeat Steps 3 & 4 for the remaining hinge.

6. Replace removed components and check the

operation of the decklid.

PARTS INFORMATION

Part

No.: Description: Qty

11100791 Spring Washer – Hinge

to Panel Support 2

90463254 Screw, Hinge to Panel

Support 2 (IF

Req’d)

WARRANTY CLAIM I NFORMATION:

Use the f ollowing information:

Description Washer, Deck lid Hinge -

Install

Labour Op. No. C000391

Time 0.6 hr

Failure Code 26

HOLDEN SERVICE TECHLINE ____________________________________________________________________ JULY 2000

8 8

ENGINE COVER RATTLE NOISE

VT & WH with LS1 (Gen III) V8

(GROUP 6A) Update

This Service Techline supersedes the previous

Techline on this topic (Issue 10, December,

1999 page 10) on adding spacer nuts. This

previous Techline should be destroyed.

PROBLEM DESCRI PTION

Reports have been received of engine cover

“ratt le” at idle, or just above idle speed.

This rattle is caused by the main engine cover

contacting the coil/bracket, at the rear of the

engine.

PRODUCTION RECTIFICATION

Additional engine cover support brackets, to

alleviate this condition, have been fitted to

vehicles from:

ISOVIN: Build Date:

6H8VTL35FYL579679 10/04/00

SERVICE RECTIFICATION

For complaints of “engine cover rattle” noise on

any Gen III V8 engined vehicle built prior to the

above breakpoint, additional support brackets

may be added as per the f ollowing procedure:

1. Remove four engine cover retaining nuts and

remove the engine cover.

2. Fit engine cover support bracket P/N 92087580

to RH front coil mounting studs as shown in

Figure 1.

3. Attach with two new nuts P/N 09440004, and

torq ue t o 4 – 6 Nm .

4. Fit engine cover support bracket P/N 92087581

to LH front coil mounting studs as shown in

Figure 1.

5. Attach with two new nuts P/N 09440004, and

torq ue t o 4 – 6 Nm .

6. Remove foam pads from front RH & LH

underside of engine cover (pads are no longer

necessary, as new support brackets carry

insulating bumper s).

7. Re-fit main engine cover - torque retaining nuts

to 8-12Nm.

PARTS INFORMATION

Part

No.: Description: Qty

92087580 Support Bracket, Engine

Cover RH 1

92087581 Support Bracket, Engine

Cover LH 1

09440004 Nut, Support Br acket

Retaining 4

WARRANTY CLAIM I NFORMATION:

Use the following information, for vehicles built

prior to t he above noted br eakpoint:

Description Add Engine Cover Support

Brackets

Labour Op. No. J000651

Time 0.3 hr

Failure Code 28

Figure 1

Update

HOLDEN SERVICE TECHLINE ____________________________________________________________________ JULY 2000

9 9

POWER STEERING PUMP FRONT DRIVE

SHAFT SEAL LEAKS – SEAL

REPLACEMENT

VS, VT, WH

(GROUP 9)

PROBLEM DESCRI PTION

Power steering fluid leaks from the power

steering pum p front dr ive shaft seal.

PRODUCTION RECTIFICATION

Revised front drive shaft seals with a more

durable material (HNBR) were released into

production f r om :

ISOVIN: Build Date:

6H8WHY19FYL528223 11/11/99

SERVICE RECTIFICATION

When any vehicle is presented with a “power

steering pump leak” – the leak source must be

defined, and appropriate repairs initiated – EG:

hose connections, or pump seal/ s, etc.

If the leak point is defined as being from the

power steering pump dr ive shaft (front) seal, the

following rectification procedure must be carried

out in lieu of Pum p Assembly replacement:

1. Identify the leak is originating from the front

drive shaft seal.

2. Remove power steering pump from vehicle

and remove pulley and pulley hub. Refer to

VT Series Service Manual, Volume 5 Page

9A-63.

3. After removal of the pulley and hub, make

sure the pulley hub bore and the pump drive

shaft are free from burrs. Should any shaft

damage have occurred during the pressing

process - which cannot be corrected, and

may damage the new seal on installation -

the pump should be replaced. Clean all

foreign material from the vicinity of the front

drive shaft seal.

4. Remove the front drive shaft seal by

carefully collapsing the seal, by using a

centre punch or similar to deform the metal

part of the seal. Deform the seal around it’s

entire circum ference.

5. Remove the seal by prying out the seal

between the seal outer diameter and the

pump housing using a flat blade screwdriver

and hammer.

6. Inspect the drive shaft for damag e in the seal

running ar ea. If the shaf t is damaged or worn,

the pump should be replaced.

7. Clean the seal seating ar ea and drive shaft.

8. Lubricate new seal P/N 26089245 using

power steering oil. Using tool number E1460-

1 or similar mandrel to suit the shaft and seal

diameters, install seal until fully seated.

9. Ref it pulley hub and pulley and reinstall pump

to vehicle.

PARTS INFORMATION

Part

No.: Description: Qty

26089245 Seal – Drive Shaft. 1

WARRANTY CLAIM I NFORMATION:

Use the f ollowing information for warranty claims

for seal r eplacem ent, as per the procedur e

above.

This Labour O per at ion Number and times will

appear in future issues of the Labour Times, as

issued via the SIP CD.

Description Pump Asm. P/S R&R,

Replace Front Seal

Labour Op. No. M147100

Time (Gen III) 0.9 hr

Time (a ll ot her ) 1.1 hr

Failure Code 42

HOLDEN SERVICE TECHLINE ____________________________________________________________________ JULY 2000

10 10

ENGINE ROUGH IDLE OR HISS NOISE

VT & WH with V6 Engine

(GROUP 6 M)

PROBLEM DESCRI PTION

Engine rough idle may be experienced, or an

audible “hiss” noise may be heard from the

engine compartment – the purge hose between

thrott le body and pur g e solenoid may disconnect

from the elbow that attaches the hose to the

throttle body. Refer to Figure 1 for location of

disconnection. This is caused by insufficient

temperature tolerance of the adhesive used to

retain the hose t o the elbow.

PRODUCTION RECTIFICATION

A new hose assembly, with improved

temperature tolerance adhesive, is currently

being phased into pr oduct ion.

Breakpoint for this introduction will be supplied

in a fut ure Techline Break point Summary.

SERVICE RECTIFICATION

If a disconnected purge hose is defined on any

vehicle, the purge hose should be replaced with

a new purge hose obtained from HSPO.

This pur ge hose replacem ent is requir ed until an

adhesive of the required temperature tolerance

is readily available nationwide. When this

availability is established, a “Revised” Techline

item will be published.

PARTS INFORMATION

Part No. : Description: Qty

92102345 Purge Hose Asm.

Solenoid to Thr ottle Body 1

Figure 1

(LH Side of Engine Showing Disconnection Point)

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time Manual

as shown:

Description Purge Hose - Replace

Labour Op. No. J589300

Time 0.3 hr

Failure Code 71

WATER LEAK INTO HEADLINING

SB CABRIO

(GROUP 1) UPDATE

This Service Techline provides a correction to

the Warranty Information provided in the

previous Techline on this topic (Issue 3, April,

2000 page 5). Please update your previous

Techline with the corrected Labour Operation

Number as shown below:

WARRANTY CLAIM I NFORMATION:

Description Rectif y headlining water

leaks

Labour Op. No. C000400

Time 0.6 hr

Failure Code 87

HOLDEN SERVICE TECHLINE ____________________________________________________________________ JULY 2000

11 11

FIXED GLASS SEALANT AVAILABILITY

ALL MODELS

(GROUP 1)

CURRENT CONDITION

Urethane for use as a fixed glass sealant is

referred to in various Service Manuals and

Techline Bulletins – most recently:

”Revised Procedure for Fitment of Rear Door

Fixed Window Glass – VT wagon & WH” in

Techline Issue 1, February 2000, page 5,

and

“Quarter Window Glass – Improving Glass Fit –

VS Ute” in Techline Issue 3, April 2000, page

11.

Urethane has also been ref erred to by “VS” part

number and alternative products are sometimes

quoted.

Urethane sealant f or f ixed glass r etention is now

available from HSPO under the following part

number:

Part No.: Description: Qty

92143609 Sealer – Urethane

(300ML Cartridge) 1

HOLDEN SERVICE TECHLINE _________________________________________________________________ AUGUST 2000

6 6

FRONT DOOR BELT REVEAL OUTER

MOULDING REPLACEMENT

(GROUP 1)

PROBLEM DESCRIPTION

Reports have been received that some front

door belt line reveal outer mouldings “split” or

“tear” prematurely – at the rear end of the

moulding. Refer Fig ur e 1 for location.

This is caused by door “overslam” (the

distance the door travels past its normal

stationary, closed posit ion)

“Overslam” is a normal occurrence during door

closing, and depends on door inertia and force

used to close the door.

PRODUCTION RECTIFICATION

Revised front door belt line reveal outer

mouldings have been f it t ed to vehicles from:

ISOVIN: Build Date:

6H8VTK35HYL560628 25/02/00

SERVICE RECTIFICATION

Fit new front door belt line reveal outer

mouldings, following procedure in the SIP CD -

VT Series Service Manual, Volume 1, Page

1A5-24.

Because of specific finish/appearance detaiI, it

is necessary t o select t he appropriat e moulding

fr om t he following usage chart :

Vehicle Detail: Part No.:

Series I 8VK

SEDAN or WAGON up to

L560628

RH, 92093952

LH, 92093953

Series I 8VL

SEDAN or WAGON up to

L464494

RH, 92093952

LH, 92093953

Series II 8VL WAGON

- f r om L464495 to L560628 RH, 92093952

LH, 92093953

Series II 8VL SEDAN

- f r om L464495 to L560628 RH, 92093954

LH, 92093955

Series I 8VX SEDAN

- up to L464494 RH, 92093954

LH, 92093955

Series II 8VX SEDAN

- f r om L464495 to L560628 RH, 92093956

LH, 92093957

NOTE: Only damaged mouldings require

replacement.

PARTS INFORMATION

Order par t s as specified in the chart above.

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time Manual

as shown:

Description Moulding Asm. Door Belt

Reveal Outer Fr ont RH/LH -

Replace

Labour Op. No. C832100 (RH) OR

C832200 (LH)

Time 0.3 hr

Failure Code 05

Figure 1.

HOLDEN SERVICE TECHLINE _________________________________________________________________ AUGUST 2000

7 7

SQUEAK FROM FRONT SUSPENSION

(GROUP 3)

This bulletin supersedes all previous Techline

bulletins released on this t opic.

PROBLEM DESCRIPTION

Squeak or creak noise from front of vehicle

when travelling over low-speed bumps, etc.

The sour ce of this sq ueak /cr eak is f rict ional drag

of the stabiliser bar on the rubber bush and

support piece that clamps it to the suspension

torsion rod.

PRODUCTION RECTIFICATION

Revised supports and inner stabiliser bar bushes

have been fitted t o vehicles from:

ISOVIN: Build Date:

W0L0SBF08X4326084 06/05/99

SERVICE RECTIFICATION

To eliminate this frictional drag, thin wall bushes

are now available which should be fitted to the

stabiliser bar. These bushes reduce the friction

loading between the bush and the bar, and

eliminate the noise. Revised supports (t o suit the

resulting larger diameter) are required when

these bushes are fitted. It is necessary to also

replace the self-locking nuts that retain the

supports.

For vehicles suffering from this noise complaint,

the f ollowing procedur es should be car ried out:

For Vehicles Wit h 18/ 20/ 22mm Di a.

Stabili ser Bars:

Vehicles fitted with 18mm, 20mm, or 22mm

diameter stabiliser bars, may be corrected by

fitting specific parts from the accompanying

“Parts Information” chart, as follows:

1. Unbolt (lower) supports from front right and

left torsion rods. Remove stabiliser bar.

Leave rubber bushes in place on torsion

rod. Inspect rubber bushes for damage,

replace only if necessary.

2. Clean stabiliser bar ends up to the forward

support/rubber bush location – remove all

dirt, scale, etc, which may stop installation of

the new inner bushes.

3. Slide new Stabiliser Bar Inner Bushes (2 per

side) onto the stabiliser bar, using silicone

grease (P/N M40347) to assist assembly.

Refer Figure 1 for illustration. Locate each

bush at the flattened area of the stabiliser

bar.

4. Refit stabiliser bar to original location, using

new supports, and retain with new self-

locking nuts.

5. Maintain a dimension of 121mm between the

centre of the bush support stud and the

centre of the torsion rod to control arm

mounting nut. Refer to SB Series Service

Manual Volume 2, page E-63, or instructions

on TIS CD. Torque nut s t o 20Nm.

For Vehicles Wit h 21 or 24mm Di a.

Stabili ser Bars:

Vehicles with 21mm or 24mm diameter stabiliser

bars have N/A shown in New & Additional parts

columns, in the accompanying Parts Information

chart, as there are no revised parts available for

these size stabiliser bars.

These vehicles should be rectified as follows:

1. Unbolt (lower) supports – one at a time - f rom

front right and left stabiliser bar mounts.

Leave rubber bushes and top mounts in place

on torsion rod. Inspect rubber bushes for

damage, r eplace only if necessary.

2. Apply a coating of grease to the inside

surface of each stabiliser bar (lower) support

(4 places). (The recommended grease is any

Molybdenum Disulphide grease that

conforms to Holden specification HN1271.

Two such greases are: Shell M.L. 10 and

Molybond GA 10. )

3. Re-assemble each support to its original

position on the stabiliser bar, fit eight (8) new

self- locking nuts. T or que nuts to 20Nm.

HOLDEN SERVICE TECHLINE _________________________________________________________________ AUGUST 2000

8 8

PARTS INFORMATION

Select parts and quantities required for the

above service procedure, from the chart below,

using the st abiliser bar diameter as a guide.

NOTE: Silicone Grease noted in the chart below

can be used for several installations of bushes,

but MUST NOT be used as a lubricant in place

of the Molybdenum Disulphide grease

(Holden spec. H1271) noted for 21 & 24mm

stabiliser bars.

N/A = Not Available.

Figure 1

18, 20 & 22mm Dia. St abi l i ser bar – Part s Required:

Stabiliser

Bar

Diameter:

Replace Existing

Parts:

Replace With

New Part No.: Fit Additional Part: Qty:

18 mm Support 90539923 - 4

Self Locking Nut 11094293 - 8

- - 92094620

Stab. Bar Inner Bush 4

- -

M40347 Silicone

Grease (150gm) As Req’d

20 mm Support 90539924 - 4

Self Locking Nut 11094293 - 8

- - 92094621

Stab. Bar Inner Bush 4

- - M40347 Silicone

Grease (150gm) As Req’d

22 mm Support 90447948 - 4

(GSI with

X16XE) Self Locking Nut 11094293 - 8

- - 92094622

Stab. Bar Inner Bush 4

- - M40347 Silicone

Grease (150gm) As Req’d

HOLDEN SERVICE TECHLINE _________________________________________________________________ AUGUST 2000

9 9

WARRANTY CLAIM INFORMATION:

For vehicles with 18/20/22mm dia. stabiliser

bars:

Use the following special Labour Operation

Number for this task:

Description Install Inner Stabiliser Bar

Bushes – to 18, 20 or 22mm

Dia. Stabiliser bar.

Labour Op. No. E000344

Time 0.7 hr

Failure Code 40

For the above Labour Operation – return

removed Supports and Self Locking Nuts when

requested by REPAC.

For vehicles with 21 or 24mm dia. stabiliser

bars:

Use existing information in Labour Time Manual

as follows:

Description Install Inner Stabiliser Bar

Bushes

Labour Op. No. E109100

Time 0.6 hr

Failure Code 40

For the above Labour Operation – return

removed Self Locking Nuts when requested by

REPAC.

WINDSCREEN “DOT FADE” AREA

REVISED

VT, WH

(GROUP 1)

Technicians should be aware of the following

revision – when replacing windscreens:

An increased “dot fade” area has been added to

windscreens, above the interior rear view mirror

and between the sunvisors, to provide additional

central light glare reduction.

PRODUCTION RECTIFICATION

This change took place at:

ISOVIN: Build Date:

6H8VTK69HYL588410 10/05/00

PARTS INFORMATION

Refer to PartFinderTM for parts information.

HOLDEN SERVICE TECHLINE _________________________________________________________________ AUGUST 2000

10 10

DECK LID HEAVY TO LIFT/WILL NOT

STAY OPEN – CAUSED BY POST

PRODUCTION SPOILER FITMENT

(GROUP 1)

PROBLEM DESCRIPTION

Customer com plains t hat the deck lid (boot lid) is

heavy to lift and/or will not stay open.

In majority of these cases the complaint is

caused by adding deck lid spoilers to vehicles

after vehicle production without changing the

decklid struts. NOTE; In vehicle production,

vehicles built with spoilers have different

specification struts to those built without

spoilers.

SERVICE RECTIFICATION

Where a spoiler is fitted to a vehicle after

production, the deck lid struts should be

changed to suit the spoiler t ype. T he chart below

defines the correct struts to use for each spoiler

type available through HSPO .

PARTS INFORMATION

Spoiler Type Strut Part No.

Required Qty

“S” or “SS” type

(weight up to 3 Kg.) 92081251 2

HSV Senator type

(weight above 3 Kg. &

up to 5.4 Kg . )

92047962 2

WARRANTY CLAIM I NFORMATION:

The change of strut s det ailed in this Bulletin, f or

the purpose ment ioned, is NOT claimable under

warranty.

CENTRE HIGH MOUNTED STOP LAMP

WARPAGE

JS Series II, Sedan & Hatch

(GROUP 12)

PROBLEM DESCRIPTION

Significant warpage, causing poor appearance,

can occur to the Centre High Mounted Stop

Lamp (CHMSL) when subjected to continuous

high tem per at ures or sunload.

PRODUCTION RECTIFICATION

A revised CHMSL, manufactured from higher

temperature compliant material, has been

introduced into pr oduction:

ISOVIN: Build Date:

W0L0JBF19YL584953 09/05/00

SERVICE RECTIFICATION

Where a customer reports significant signs of

warpage of a CHMSL – the CHMSL should be

replaced.

Refer ident ification below for latest parts.

PARTS INFORMATION

Part No.: Descri ption: Qty

09192293 Lamp Asm., High Mount

Stop. USAG E: Hatch 1

09192294 Lamp Asm., High Mount

Stop. USAG E: Sedan 1

These new CHMSL’s are made from revised

material and are identified with “ABS/PC” on the

back of the assembly. NOTE: As part numbers

have not been revised, return any parts –

without “ABS/PC” identification – to HSPO for

credit.

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time Manual

as shown:

Description Lamp Asm. St op, High

Mounted - Replace

Labour Op. No. R902400

Time 0.4 hr

Failure Code 11

HOLDEN SERVICE TECHLINE _________________________________________________________________ AUGUST 2000

11 11

OIL LEAK FROM A/T REAR SEAL

VS, VT, WH

(GROUP 7B) HINT

PROBLEM DESCRIPTION

Investigation into complaints of “oil leakage”

from Auto. Trans. (A/T) extension housing seals

has defined that a number of seals are being

replaced unnecessarily.

During vehicle assembly, a small amount of

assembly oil (ATF) is retained in the extension

housing seal between the inner and outer seal

lips. If enoug h ATF is ret ained in the seal, it can

be “pumped” out of the seal, onto the extension

housing, propshaft yoke, and onto the vehicle

floor pan – by the nor mal prop shaf t rotat ion and

stroking movement.

This condition can lead technicians to an

incorrect diagnosis of a “leaking seal” and

unnecessary seal replacement.

SERVICE HINT

On any vehicle inspected during Pre-Delivery

Inspection or at t he 1500km service where there

is minimal oil deposited on the area surrounding

the extension housing seal – do not replace the

extension housing seal:

- W IPE the seal area, pr op. shaft yoke and f loor

(if required) to remove all traces of ATF. Ensure

no dirt, et c is wiped into the seal r unning area.

- Do NOT use a solvent – only a clean, dry rag.

By carrying out this process, and an inspection

of the extension housing seal at the next

service, any leak that warrants replacement will

be defined.

Should any extension housing seal display more

than minimal ATF leakage, EG: If ATF is

dripping from seal area – then seal replacement

is warranted.

FRONT END ALIGNMENT SPEC.

HSV VT I, VT II & WH GRANGE

(GROUP 3) UPDATE

This Service Techline supersedes the previous

Techline on this topic (Issue 5, June, 2000 page

8), by revision of Caster figures. Please revise

your previous Techline and any copies of HSV

bulletin of 9/2/ ’00 you may have.

The following information is repeated from HSV

bulletin of Feb. 9, 2000, for use by technicians

when servicing HSV VT Series I, VT Series II,

and WH Grange vehicles.

PLEASE ENSURE ALL TECHNICIANS

INVOLVED IN FRONT END ALIGNMENT WORK

ARE MADE AWARE OF THESE REVISED HSV

SPECIFICATIONS.

FRONT END ALIGNM ENT SPECIF ICATIO N:

The information below supersedes information

provided in SIP CD ROM Version 1.1, relating to

HSV vehicles.

FRONT WHEEL ALIGNMENT AT KERB

WEIGHT

Toe-in Degrees Total 0° 10’ ± 0° 10’

Toe-in Degrees Per Wheel 0° 05’ ± 0° 05’

Camber - 0° 30’ ± 0° 20’

Caster 7° 45’ ± 1° 15’

Note: Front toe and front camber have been

reduced to optim ise front t yre life.

HOLDEN SERVICE TECHLINE _________________________________________________________________ AUGUST 2000

12 12

RIDE HEIGHT SPECIFICATIONS

RODEO & JACKAROO GROUP 3

Detailed below are the ride height specifications for Jackaroo (UBS) and Rodeo (TF). For details

on adjustment refer to the relevant workshop manual ( section 3 ).

Note- All measurements should be made when the vehicle is at curb weight and with bump stops

in good condition. (Curb weights can be found in the relevant owners handbook)

Current model Rodeo

Front- There are two settings, one for TFS (4x4) and TFR25 (4x2, V6), the other for TFR (4x2).

There is a simpler method that requires the construction of a measuring tool. The tool can then be

placed between the bump stop and the lower control arm to indicate the trim height. The diameter

of the tool for 4x2 excluding V6 is 45mm, for 4x4 and V6 17mm (refer below)

Note- this method can only be used if the vehicles bump stops are in good condition.

Z =56mm

TFR (4x2) EXCLUDING V6

ENGINE

Z=130mm

TFS (4x4) & TFR V6 (4X2 WITH

V6 ENGINE

)

TFS & TFR V6 TFR EXCLUDING V6

17 mm 45mm

HOLDEN SERVICE TECHLINE _________________________________________________________________ AUGUST 2000

13 13

Rear- The ride height is measured as a clearance between the bump stop and the top of the

axle(refer below)

Current model Jackaroo

Jackaroo t r im height is 139 +/- 5m m ( r efer below).

The trim height can also be checked by placing a tool between the bump stop and the lower

control arm. The Jackaroo tool diameter is 24mm.(refer below)

The ride height for TFS (4x4) and TFR25 (4x2 V6) is 95mm, and for

TFR (4x2)is 9 0mm

Z = 139mm +/- 5 mm

T= 24mm

HOLDEN SERVICE TECHLINE _________________________________________________________________ AUGUST 2000

14 14

INTERCOOLER/AIR DUCT OIL CONTAMINATION

DIESEL JACKAROO & RODEO GROUP 6A

I-GM has recently received a large number of inquiries regarding acceptable oil contamination on

4JX1 and 4JB1 engine air intake systems.

It should be noted that crankcase ventilation may cause a light coating of oil throughout the intake

ducting as part of normal engine operation, however it is not normal to have oil collecting or

pooling.

If confronted with an engine that has excessive oil contamination in the intake system, it is

suggested that thorough examination be undertaken to determine the origin of the oil, e.g.

crankcase breather or turbo seal. If not immediately obvious, the contaminated parts should be

cleaned and the vehicle monitored at short intervals.

CHECK ENGINE LIGHT ILLUMINATING

V6 LPG RODEO GROUP 6C

Rodeo vehicles fitted with approved LPG kits may experience a situation where the check engine

light is illuminated and DTC P0171 is present in the ECM. When confronted with the above

situation, please refe r to the relevant information below.

PARNELL SUPPLIED KITS.

1) The Parnell system will set a lean code after the vehicle has been operated until the LPG

cylinder is empty. During this running period the engine is operating on vapor only, as the liquid

has been consumed and all that remains is indeed vapor. This scenario is a function of the

ECM performing correctly as the engine has experienced a lean condition (as it would when

running out of petrol) and has recorded the appropriate DTC.

Customers should be informed of the above condition and advised not to run on LPG empty.

2) Parnell systems fitted with the CLS2000 processor (located behind the drivers kick panel) may

need a software upgrade, to version V65 (printed on the processor). The upgraded processor

will be supplied by Parnell on a change over basis.

IMPCO

The impco system sets a lean code as a direct result of set operating parameters. This code is

apparent mainly on automatic TF's, it normally sets during coast or when the system is leaning off.

At this stage there is no repair for this condition, Impco are investigating the concern and IGM will

advise when a field fix is developed.

Dealers are advised to confirm if the code sets on petrol. If the code sets while the vehicle is on

petrol, normal diagnosis should be performed. However if the code does not set on petrol the car

should be released, the owner advised and rebooked when a repair is advised.

HOLDEN SERVICE TECHLINE _________________________________________________________________ AUGUST 2000

15 15

4JX1 DIFFICULT S TART PRE – CHECK

DIESEL JACKAROO GROUP 6C

IDENTIFY OIL

VISCOSIT

GRADE

MANUFACTURER

OPERATE FUEL

PRIMING PLUNGER

UNTIL FIRM.

CRANK VEHICLE

DEFINE CRANK

Time: secs.

Engine crank RPM:

LOCATE SOURCE OF

AIR AND REPAIR AS

PER SHEET No. 2

HIGHER

THAN

10 SECS.

TURN ON IGNITION

WAIT FOR GLOW INDICATOR

TO GO OUT.

STARTS O.K.

O.K.

DRAIN / FILL

WITH CORRECT

SPEC. (2 TIMES)

REPLACE BOTH

OIL FILTERS

VERIFY

CHECK BATTERY

RE-CHARGE

CHECK TERMINALS

REPLACE AS

NECESSARY

O.K.

CONFIRM

START O.K.

NO START

OBD1

SYSTEM CHECK

AS PER MANUAL

BELOW

10 SECS.

MORE THAN

100 RPM

LESS

THAN 100 RPM

INCORRECT

NO START BELOW

5 SECS.

CORRECT

INSTRUCTIONS

COMPLETE

RING - TAS.

Note- Copy this sheet and mark the box in the

top right corner as each step is completed.

4JX1

–

DIFFICULT START PRE - CHEC

HOLDEN SERVICE TECHLINE _________________________________________________________________ AUGUST 2000

16 16

4JX1 - DIFFICULT START

(Sheet 2)

Step 1) Fit clear hose between filter housing outlet and lift pump.

Step 2) Fit clear hose on Tank return at rear of head.

Step 3) Fit clear hose between tank & filter housing inlet.

CONFIRM FILTER SEAL

CONFIRM FUEL FILTER

HOUSING (JUNE T/L )

PRODUCTION CHANGE

VERIFY REPAIR

INSPECT FUEL PIPES

FOR LEAKS AND

REPAIR

INSPECT INLET

FITTING TO HEAD FOR

TIGHTNESS AND

LEAKS.

CONFIRM INJECTOR

"O" RING

REWORK AS PER ADL

AIR OR OIL IN

SYSTEM AT THE

TANK RETURN

AIR IN SYSTEM

BETWEEN TANK AND

FILTER HOUSING

AIR IN SYSTEM

BETWEEN

FILTER HOUSING AND

LIFT PUMP

AIR IN FUEL

VERIFY REPAIR

CHECK INJECTOR

COPPER SEALS,

"O" RINGS AND

RE-TORQUE

VERIFY REPAIR

HOLDEN SERVICE TECHLINE ________________________________________________________ SEPTEMBER 2000

9 9

A/C PIPE RUBBING ON AIR CLEANER

INLET DUCT

JR/JS w ith A/C

(GROUP 2)

PROBLEM DESCRI PTION

A/C pipe may rub on the air cleaner inlet duct at

right hand front of engine compartment. In the

long term, this may result in pipe rub through

and loss of A/ C gas.

PRODUCTION RECTIFICATION

A refrigerant pipe to radiator cowl bracket was

introduced to pr ovide clearance from:

VIN: Build Date:

W7154494 17/08/98

SERVICE RECTIFICATION

For all vehicles built prior to the above

breakpoint , during servicing:

• Inspect A/C pipes f or abrasion damag e at the

air cleaner air inlet duct - replace if damaged,

and:

• Fit Ref rigerant Pipe T o Radiator Cowl Bracket

(p/n 09152421) to the vehicle, using existing

fan cowl bolt, and attach to pipe with new bolt

(p/n 11093973). Refer Figure 1 for det ails.

PARTS INFORMATION

Part No.: Description: Q t y

09152421 Brack et – Refrigerant Pipe

to Radiator Cowl 1

11093973 Bolt - Refriger ant Pipe to

Radiator Cowl 1

WARRANTY CLAIM I NFORMATION:

To claim for the addition of the above bracket and

bolt – use the following inform at ion:

Description Add A/C Pipe Retaining Br acket

Labour Op. No. D000221

Time 0.8 hr

Failure Code 19

Note: For dam aged pipe replacement, use

existing inf or m ation in Labour Time Manual – on

SIP CD.

Figure 1.

HOLDEN SERVICE TECHLINE ________________________________________________________ SEPTEMBER 2000

RECIRC & DEMIST SW ITCH

OPERATION

(GROUP 2)

PROBLEM DESCRI PTION

A number of Heater Control Unit assemblies

(which contain all HVAC controls) returned to

Repac have proven to have “no fault found”

when tested.

Defective Material Tags indicate “Air Intake

Button (Recirc/Fresh switch) will not operate

when the vents dial is rotated to Dem ist m ode.

This is the designed method of operation for

the Air Intake Button and Demist switches, to

ensure ef ficient demisting .

This char acteristic of switch operation was not

explained in the original print of TS Astra

Owner Handbook (Noted as: “Part No.

92077117, June 1998 (Astra, TS print 1)” on

the inside f r ont cover).

This om ission has been cor rected in the lat est

version of the Owner Handbook (Noted as:

“Part No. 92077118, March 2000 (Astra, TS

print 2)” on the inside front cover).

Wording has been added as follows:

“Note: air intake will automatically switch from

recirculation to fresh when vents dial is rotated

to demist mode.”

SERVICE RECTIFICATION

NO service rectification is necessary, should

this condition be queried by a customer.

Please explain the switch operation to the

customer, as per the note above, and if

necessary, supply a copy of page 1-16 of TS

Astra Owner Handbook (part No. 92077118)

containing that note – to ensure they have

knowledge of the correct demist/fresh air

switch operation.

In future, any Heater Control Unit

assemblies returned to Repac for this

condition w ill be subject of debit action.

ENGINE MANAGEMENT SYSTEM -

REVISED CALIBRATION DATA

TS with M/T

(GROUP 6C)

CURRENT CONDITION

Some customers may complain of:

- “jer ky” or “rough” gear changes

- “bump” dur ing tip-in acceleration at gear

changes

- “stum ble” when engine slows down to idle

- poor accelerat ion from a standing start,

especially in high ambient temperatures.

PRODUCTION RECTIFICATION

A revised calibration ECU has been

introduced into pr oduction at:

Engine No.:

X18XE20P68391

SERVICE RECTIFICATION

NOTE: Flash Programming is ONLY to be

carried out to cust omer complaint vehicles.

To impr ove driveability of these vehicles:

Using Tech 2 & TIS 2000 Version 12B (or

later), reprogram the vehicles’ ECU using the

Service Programming System (SPS) with the

latest software version.

WARRANTY CLAIM I NFORMATION:

Flash Programming is ONLY to be carried out

to customer complaint vehicles. Use the

following claim informat ion where this is done:

Description Reprogram ECU

Labour Op. No. J000666

Time 0.4 hr

Failure Code 47

HOLDEN SERVICE TECHLINE ________________________________________________________ SEPTEMBER 2000

HARD STARTING/STALLING – FUEL

PUMP FAILURE

VT/WH with Gen III V8

(GROUP 6 M)

PROBLEM DESCRI PTION

A number of fuel pump failures have been

reported – this has lead to customer

complaints of “hard to st ar t” or “eng ine st all”.

Investigation into these failures shows they

have been caused by dropping or mishandling

of the fuel pumps, prior to assembly into

vehicles.

PRODUCTION RECTIFICATION

Revised fuel pump and sender units, with

more robust internal components, were

introduced into pr oduction as follows:

ISOVIN: Build Date:

6H8VTK69FYL608654 30/06/00

SERVICE RECTIFICATION

Pump and sender assemblies requiring

replacement, should be replaced with the part

noted below.

When diagnosing hard starting – use the

diagnosis procedure that is provided in the

Supplier Prior Approval Process (SPAP)

binder supplied to Dealerships with All Dealer

Letter DL 48/00. This binder carries a section

relating to fuel pump diagnosis.

PARTS INFORMATION

Part No.: Description: Qty:

25337050 Pum p & Sender Asm. 1

NOTE: Any stock of old pump and sender

units – Part No. 25324949 - in dealership

stock must not be used, but be returned to

HSPO for credit.

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time

Manual.

REAR WIPER LINKAGE LOCK-UP

VT Wagon

(GROUP 12)

PROBLEM DESCRI PTION

Rear wiper will not operate because internal

linkag e “lock-up” (may also cause wiper motor

seizure).

PRODUCTION RECTIFICATION

Revised wiper motor and linkage assemblies

with revised linkage geometry have been

fitted to vehicles from :

ISOVIN: Build Date:

6H8VTK35HYL623038 03/08/00

SERVICE RECTIFICATION

If a vehicle is presented with the wiper motor

assembly “locked-up” or the motor is seized,

replace the assembly with a new part as noted

below.

PARTS INFORMATION

Part No.: Description: Qty:

92103204 Rear Wiper Motor Asm. 1

NOTE: Do NOT fit previously released part

92058738 – if any of these parts are held in

Dealership Parts Department stock, they

should be returned t o HSPO for cr edit .

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time

Manual in SIP CD.

Update

HOLDEN SERVICE TECHLINE ________________________________________________________ SEPTEMBER 2000

MAN. TRANS. OIL AVAILABILITY

JS, JR, TR, TS, SB

(GROUP 7A)

PROBLEM DESCRIPTION

Castrol SMX-O has been in short supply since

the issuing of previous Techline Bulletins

advising use of t he oil.

To ensure this does not result in technicians

using non-approved oil in these transmissions,

availability of the oil has been improved.

PARTS INFORMATION

Castrol SMX-O oil is now available from HSPO

as follows:

Part No.: Description:

92143771 O il – M/T ( 1 lit re)

Previously released information from Techline

Issue 1, February, 2000, Page 14 is repeated

here to reinforce the importance of the oil

usage:

Oil specified for these transmissions is:

CASTROL SMX-O

This oil is also recommended for the following

models - by transmission t ype:

Model

Trans.

Type

Castrol

SMX-O Current Holden

92140007 and

Previously available oils

MTF1067, MTF1067 &

MTF0063

SB – All M/T

✔

✔✔

✔

✓

TR – All M/T

✔

✔✔

✔

✓

TS – All M/T

✔

✔✔

✔

✓

JR – All M/T

✔

✔✔

✔

✓

JS Series I,

F18 Trans.

✔

✔✔

✔

✓

JS Series II,

F23 Trans.

✔

✔✔

✔

✖

✔

✔✔

✔

= RECOMMENDED

✓

= MAY BE USED

✖

= DO NOT USE

SERVICE USAGE & PRECAUTION

Castrol SMX-O oil MUST be used at all t imes in

JS Vectra Series II with F23 M/T, and may be

used for service replacement or ‘t op-up’ of oil in

the above manual transmissions.

Holden oil Part No. 92140007 r emains available

from HSPO, and can be used as per

recommendat ions in t he chart above.

Castrol SMX-O replaces previously released

Castrol oils MTF1067, MTF1067 & MTF0063

These previously released oils MUST NOT

be used in JS Series II, F23 M/T, for

durability reasons.

At the time of release of this bulletin, there are

no commercially available equivalents to

Castrol SMX-O for this JS Series II usage.

HOLDEN SERVICE TECHLINE ________________________________________________________ SEPTEMBER 2000

M/T GEARSHIFT ADJUSTMENT

JS with F23 M/T

(GROUP 7A)

PROBLEM DESCRI PTION

The procedure shown in the TIS CD has lead

to confusion when technicians attempt to

adjust the gearshift mechanism on F23

manual transm ission ( introduced at JS SII).

SERVICE RECTIFICATION

To assist technicians in adjusting this

gearshift mechanism – the following

infor mation is provided which must be used in

conjunction with instructions found in the TIS

CD, section headed “Adjust Transmission

Remote Shift Linkage (F23)” - which

provides illustrations for the clarified text

below. NOTE: When accessing this

infor m ation in TIS, specify “X25XE” engine.

1. Place gear lever in neutral (resulting

position of external linkage is shown in

fir st TIS illustration).

2. Carefully unclip gear lever cover and fold

up around gear lever to gain access to

gear shift cables. Refer to View A in

Figure 1 below.

3. Carefully unfasten holding sleeves (clamp

blocks) of the shift cables. Ensure the

cable is free to move in the sleeve, but do

not disconnect the clamp blocks from the

cables. Refer to Figure 1 below showing

how to unfasten the clamp blocks with a

thin, flat bladed screwdriver.

4. Press in the gearshift lever locking clip

(Refer to TIS illustration). This positions

the gear lever in a central (neutral)

location, changing the shift cable

positioning.

5. Lock both the holding sleeves (clamp

blocks) by pressing down HARD on the

tabs on the sleeves (Refer to TIS

illustration).

6. Return gearshift lever locking clip to

original posit ion.

7. Refit gearshift lever cover

Figure 1.

HOLDEN SERVICE TECHLINE ________________________________________________________ SEPTEMBER 2000

6 DISC CHANGER SKIPPING CD’s

(GROUP 12)

The following information is repeated from All

Dealer Letter DL: 32/00, and is repeated in

this Techline only to ensure t hat all Dealer ship

Service personnel are aware of the

procedures noted. Please refer to the Dealer

Letter for original information. Please also

circulate this bulletin to Warranty Claims

personnel.

PROBLEM DESCRI PTION

Field complaints have been received of the

CD player fitted to WH Series vehicles

‘skipping’ tracks when the vehicle is driven

over rough road surfaces. To address this

problem, an alternative CD player with a 10

disc cartridge and triple beam laser has been

released for vehicle production as this unit is

less susceptible to sk ipping CD’s. The existing

6 disc changer features only a single beam

laser.

PRODUCTION RECTIFICATION

The vehicle assembly plant introduced the 10

disc player into production as follows:

ISOVIN: Build Date:

6H8WHZ19FYL592679 23/05/00

SERVICE RECTIFICATION

This information provides service fix

instructions for installation of the 10 Disc

changer to customer complaint vehicles with

the above described condition.

Please follow the instructions below to install

the 10 disc changer.

Installation Instructions:

1. Refer to the WH Service Manual to

remove the existing 6 disc chang er .

2. Take t emplate and lay it down on the floor

pan, ensuring to position it to the

reference points. (ie. LPG dimple and

existing 6 disc changer bracket screw).

See Figure 1 below.

Hint: Use masking tape or equivalent to hold

templat e in position.

Figure 1.

3. Take the changer bracket and position it

on top of t he template, ensuring t he holes

in the bracket line up with the holes

marked on the template and the existing

hole in the side panel.

4. Lift bracket f r om template.

5. Centre punch the two marked hole

positions on the tem plate.

6. Remove template of f floor pan.

7. Drilling instructions & precautionary

notes:

The fuel t ank is directly beneath the

position of t he holes. To protect the tank

fr om dam age, place a piece of rubber

hose over a 5.5mm drill bit so that only

the top 5mm of the drill bit is exposed.

Drill both holes to a depth not exceeding

5 mm. See Figure 1 above.

8. Fit the changer bracket and install pop

rivets in the three locations. See Figure 2

below.

9. Connect the lead to the changer.

10. Secure the excess changer lead with a

cable tie to the body harness. See Figure

2 below.

11. Take the piece of foam block, peel away

the sticky back cover and adhere it in

place of the pr evious 6 disc changer. See

Figure 2 below.

Update

HOLDEN SERVICE TECHLINE ________________________________________________________ SEPTEMBER 2000

Figure 2.

12. Seal the two existing 6 disc changer

mounting holes with butyl patches.

13. I nst all the revised rear compartm ent trim.

PARTS INFORMATION

Dealers should order parts from HSPO, as

there is no change-over program t o cover this

process.

Part No.: Description: Qty

92080354 10 Disc Changer 1

92053301 Br acket- 10 disc

changer 1

92088915 Foam piece, rear

compartment 1

92088903 Car pet, CD cover 1

92088904 Car pet and spare

wheel cover 1

92138380 Rivet- br acket to body 1

92138381 Rivet- br acket to floor 2

92143627 Template 1

92060351 Tie strap 1

92018621 Butyl sealing patch 2

Note: But yl Patch 92018621 supersedes

Patch 92055234 quoted in DL 32/ 00 –

92018621 will need to be trimmed for use as

noted above, and will provide enough material

for several inst allations.

WARRANTY CLAIM I NFORMATION:

Use the following information when claiming

for t he above rect ification procedur e:

Description Install WH 10 Disc Changer

Labour Op. No. R000088

Time 0.8 hr

Failure Code 56

Warranty Personnel Please Note:

The replaced 6 Disc Changer unit is to be

returned to Repac together with other parts

when requested via the Repac report. Please

ensure replaced units are kept in a secure

area and appropriately packaged for return to

Repac. Do not send CD chang er s to Eurovox.

HOLDEN SERVICE TECHLINE ________________________________________________________ SEPTEMBER 2000

CALIBRATION REVISIONS AFFECTING

STARTING & A/T SHIFTS

VT/WH with Gen III V8

(GROUP 6C)

PROBLEM DESCRI PTION

Engine poor or hard starting:

– Manual & Auto vehicles

Customer m ay complain of:

- Engine star t s and r uns r ough for a few

seconds (gener ally 1-3 seconds),

- Engine has excessive crank time after hot

soak (engine stopped) of appr ox. 15- 45

minutes.

A/T shifts:

Customers may also complain of:

- “harsh” 1- 2 and 2- 3 auto shifts on light to

medium throttle,

- Excessive driveline “clunk” noise from rear of

vehicle during a 2-1 shift on closed throt tle

coastdown.

Research into these complaints has proven

that the calibration of the Desired Shift Time

(DST) and Shift Energy Management (SEM)

values are less than optimum for this

powertrain combination.

PRODUCTION RECTIFICATION

A revised calibration has been developed and

was introduced into production as follows:

Auto. Trans. Vehicles:

ISOVIN: Build Date:

6H8VTK69FYL584849 02/05/00

Manual. Trans. Vehicles:

ISOVIN: Build Date:

6H8VTK69FYL584822 02/05/00

SERVICE RECTIFICATION

NOTE: Flash Programming is ONLY to be

carried out to customer complaint vehicles.

Does NOT apply to HSV vehicles.

For customer complaint vehicles i n

service:

Using Tech 2 and TIS2000 Version 12B,

reprogram the vehicle’s PCM using the

Service Programming System (SPS) with

software Part Number:

92100254 for Aut o. Trans. - ( non- HSV):

92100255 for Manual Trans. - (non-HSV):

HSV VEHICLES:

Should you require further information

regarding HSV vehicles affected by this

bulletin, then please call HSV Technical

Assistance Department on telephone number

(03) 9265 9500.

WARRANTY CLAIM I NFORMATION:

Use the following claim information where

Flash Programming is carried out to any

customer complaint vehicle:

Description Reprogram PCM

Labour Op. No. J000669

Time 0.4 hr

Failure Code 47

HOLDEN SERVICE TECHLINE ________________________________________________________ SEPTEMBER 2000

A/T ELECTRICAL CONNECTOR

“LIMITED” REPAIR PROCEDURE

VR, VS, VT

(GROUP 7B)

PROBLEM DESCRI PTION

Some neutral start & back-up switch

connector/s may be “hard to remove”. This

may occur in vehicles that have been in

service for a long time, and subjected to long

periods of idling. Heat build-up causes the

internal heat sink material in the switch to

‘migrate’ into the electrical connectors and to

act like a glue between the switch body and

the connector.

SERVICE RECTIFICATION

CONNECTOR REMO VAL:

Should this “hard t o remove” situation occur in

any vehicle, the method of removal sugg ested

is:

Apply heat (with a commercially available heat

gun) to the connector area of the neutral start

& back-up switch where it mates with the

vehicle harness connector. Only apply

sufficient heat t o soften the “ glue-like” m at erial

in the connections – IE: repeatedly heat and

check the connection for looseness, until the

connection breaks free.

Aft er r emoval of the connector / s:

• Clean terminals in the vehicle harness.

Should the neutral start & back-up switch

connector be heavily contaminated, the

switch should be replaced.

• After switch replacement, check switch

operation in workshop, then road test

vehicle to ensure the switch has not been

damaged dur ing the above procedure.

CONNECTOR REPAI R:

In addition to the above removal procedure,

for vehicles which are out of warranty, the

following repair method is offered as a cost-

eff ective repair for customers, should damage

occur to the vehicle’s harness connectors

during r em oval as noted above.

As the above procedure is recognised as

being for higher kilometer and older vehicles,

the following repair procedure is not to be

used for vehicles in warranty.

Use of this procedure assumes that the vehicle

harness connector/s have been disconnected

from the trans. and are damaged beyond

repair. The procedure applies equally to 7-way

connector and 4-way connectors used on later

transmissions.

1. Cut the wires of the harness in a

stagg ered f ashion, ref er to Fig ure 1, below

– this allows creation of a small diameter

repaired har ness, where the wire joints are

not likely to short/earth. Retain the old

connector – to use as a pattern to ensure

correct wire/terminal location.

2. Bare the cut ends of the harness wires, to

allow joining and soldering to a new

connector assembly (refer Parts Info.

Below for p/n’s) .

3. Define (using t he old connector/wiring as a

pattern) where the replacement wires will

attach to t he vehicle harness.

4. Cut the wires on the new connector to

match the ‘staggered cut’ of the wires on

the vehicle wiring harness.

5. If Connector Pin Assurance (CPA)

securing pins are fitted, attach the ‘ring’

end over t he new connector wires near t he

connector body.

6. Bare the wire ends, join and solder each

wire. DO NOT use the crimp–type

terminals provided with the new connector

assembly.

7. Insulate each wire joint individually with

tape to fully seal out moisture.

8. Tape over the entire repaired section to

fully seal out moisture.

9. Assemble connector to neutral start &

back-up switch connection.

10. Refit Connector Pin Assurance (CPA)

securing pins where f itt ed.

11. Check operat ion of neut ral start & back-up

switch in workshop then road test to

confir m cor r ect operation.

Update

HOLDEN SERVICE TECHLINE ________________________________________________________ SEPTEMBER 2000

PARTS INFORMATION

Part No.: Description: Qty:

15305887 7 Way A/T Conn. Asm. 1

15305925 4 Way A/T Conn. Asm. 1

Figure 1.

Shows repair to one connector – repair i s t ypical for both connect ors shown.

HOLDEN SERVICE TECHLINE ___________________________________________________________ OCTOBER 2000

9 9

HARD STARTING/STALLING - FUEL

PUMP FAILURE

VT/W H w i th Ge n III V8

(GROUP 6M) RE-ISSUED

This Service Techline supersedes the

previous Techline on this topic (Issue 8,

September, 2000 page 11) – by correcting

production breakpoint date. This previous

Techline should be corrected or destroyed.

Index page information will be updated to

show this item only.

PROBLEM DESCRIPTION

A number of fuel pump failures have been

reported – this has lead to customer

complaints of “hard to start” or “engine stall”.

Investigation into these failures shows they

have been caused by dropping or mishandling

of the fuel pumps, prior to assembly into

vehicles.

PRODUCTION RECTIFICATION

Revised fuel pump and sender units, with

more robust internal components, were

introduced into product ion as fo llows:

ISOVIN: Build Date:

6H8VTK69FYL608654 30/06/00

SERVI C E RECTIFICATION

Pump and sender assemblies requiring

replacement, should be replaced with the part

noted below.

When diagnosing hard starting – use the

diagnosis procedure that is provided in the

Supplier Prior Approval Process (SPAP)

binder supplied to Dealerships with All Dealer

Letter DL 48/00. This binder carries a section

relating to fuel pump diagnosis.

PARTS INFORMATION

Part No .: Description: Qty.:

25337050 Pump & Sender Asm. 1

NOTE: Any stock of old pump and sender

units – Part No. 25324949 - in dealership

stock must not be used, but be returned to

HSPO for credit.

WARRANTY CLAIM INFORMATION:

Use existing information in Labour Time

Manual.

BRAKE HOSE/CALIPER SEAL RING

REPLACEMENT PROCEDURE

(GROUP 5)

CURRENT CONDITION

As a standard procedure – quoted in TIS -

when replacing brake hoses or brake calipers

for any reason, it is necessary to replace the

seal rings (copper washers) used at the

caliper and hose interface/s.

SERVICE RECTIFICATION

This bulletin is to draw Technicians attention

to this requirement - to replace the seal rings

(copper washers) used at the caliper and

hose interface/s - whenever a brake hose or

caliper is replaced.

PARTS INFORMATION

Confusion has arisen because the seal rings

(copper washers) for rear brake installations

were not shown in earlier versions of

PartFinder.

The current issue of Par tFinder addr esses this

missing information – the seal rings (copper

washers) for rear brake installations have

been added. The seal rings used in rear brake

installations are in fact the same as those

used in front brak e inst allations.

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

PLATE - REAR BUMPER FACIA TO QTR

PANEL – MODIFIED PART/FITTING

INFO..

VT Sedan

(GROUP 1) Parts Info.

The information in this Techline bulletin is

repeated from HSPO Bulletin PT50, dated 21

August, 2000 – to ensure technicians are

aware of this part supersession and

replacement requirement.

CONDITION

Plate assembly (p/n 92052174/5) – rear facia

to quarter panel for VT, will soon be

superseded in HSPO parts stock, to the VX

plate assembly (p/n 92100200/1), for

commonisation.

Note: Following this supersession, only the

VX part will be available for vehicle repairs.

This part is only req uired if the orig inal plate is

damaged.

Future VT plate replacements will require a

specific plate replacem ent procedure as noted

below.

SERVI C E RECTIFICATION

The following procedure is applicable to VT

vehicles where the Plate Assembly - Rear

Facia requires replacing and a VX part (p/n

92100200/1) is the only part available:

1. Enlarge holes in rear quarter panel in

which Plate Assembly - Rear Facia

mounts. The top hole to 8.2 mm dia. and

the lower slot 8.7 mm wide by 11.0 mm

long. Refer Figure 1.

2. Repeat procedure to opposite side, if that

part is also being replaced.

3. Check fitment and alignment of Plate

Assembly studs.

4. Vacuum up swarf and f ilings.

5. Rustproof modified holes, using Zinc

Chromate or equivalent.

6. Inst all Plate Assem bly - Rear Facia to Rear

Bumper Facia with rivets (p/n 92138058), 4

places each side. Refer Figure 2.

7. Reinstall Rear Bumper Facia. Refer to

Service Manual Section 1D - Bumper Bars.

Note: New nuts 92138597 are also

required for the attaching of the Plate

Assembly-Rear Facia to Quarter Panel.

Refer Figure 2.

Figure 1.

Figure 2.

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

RADIATOR CAP CLEANING & TESTING

VS, VT, VX, WH

(GROUP 6K)

BACKGROUND

The majority of radiator caps returned to

Repac have been replaced unnecessarily.

The supplier of these radiator caps reports

that after cleaning the gasket, these

radiator caps hold pressure. Repac has

also confirmed this to be the case.

If, after carrying out this procedure, the

radiator cap is replaced because it will not

hold pressure, note on the Defective

Material Tag that this procedure has been

carried out, or a charge-back will result.

IMPORTANT Warranty claims will not be

accepted for radiator caps replaced

unnecessarily where the cap can be

successfully cleaned and pass a pressure

test.

SERVICE ACTION:

When investigating a radiator cap that does

not hold pressure, the radiator cap centre

valve gasket must be cleaned, prior to

carrying out a pressure test on the radiator

cap. If the radiator cap holds pressure after

cleaning it should be refitted to the vehicle.

CLEANING PROCEDURE

1. Clean both sides of radiator cap gasket

with a wet cloth (Use water only to wet

the cloth). refer figure 1.

2. Lift centre valve and clean gasket area

under the valve, refer figure 2.

3. Ensure the r adiator filler neck cap seating

surface is clean and free from

obstruction, refer figure 3.

4. Pressure te st radiator cap t o the pressure

marked on cap.

5. If radiator cap holds pressure refit to

vehicle.

6. Replace radiator cap if pressure test fails

after cleaning.

Figure 1

Figu re 2

Figu re 3

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

SPEEDO “PPK” PROGRAMMING

VT, VX, WH

(GROUP 12) UPDATE

This Service Techline supersedes all previous

Techlines on Speedo PPK Programming.

Previous Techlines should not be used for

PPK values, and should be destroyed.

SERVICE INFORMATION

The following information is supplied for

technician reference.

Previous PPK values were based on tyre

sizes only – selection of PPK values based on

tyre size is no longer possible.

This is because PPK values vary according to

trans. type and final drive ratios (which also

change with trans . type) – thus it is necessary

to refer to the following chart to determine

exact PPK values for the body style, engine,

trans type and tyre size being worked on.

PPK values shown must be used whenever

speedo PPK programming is required.

Refer VT Series Service Manual Volume 14C,

Section 12C, 5.15 F5: PROGRAM for

programming basic information.

Body Style Engine Trans. Type PP K Value Tyre Size

Sedan/Wagon V6 Auto/Manual 6272 205/65 R15

Sedan/Wagon V6 Auto/Manual 6238 225/60 R15

Sedan (Police 9C1) V6 Auto 6285 215/60 R15

Sedan/Wagon V6 Auto/Manual 6077 215/60 R16

Sedan/Wagon V6 Auto/Manual 6087 225/55 R16

Sedan/Wagon V6 Auto/Manual 6391 225/50 R16

Sedan/Wagon V6 Auto/Manual 6301 235/45 R17

Sedan/Wagon/Ute V8 Auto/Manual 6272 205/65 R15

Sedan/Wagon/Ute V8 Auto/Manual 6238 225/60 R15

Sedan/Wagon/Ute V8 Auto/Manual 6087 225/55 R16

Sedan/Wagon/Ute V8 Auto/Manual 6301 235/45 R17

HSV All Auto 6355 225/50ZR16

HSV All Auto 6210 235/45ZR17

HSV All Auto 6210 235/40ZR18

HSV All M/T - T56

6300 235/45ZR17

HSV All M/T - T56

6300 235/40ZR18

HSV All M/T - Getrag 6355 225/50ZR16

HSV All M/T - Getrag 6210 235/45ZR17

HSV All M/T - Getrag 6210 235/40ZR18

HSV (GTS) All M/T (3.91 axle) 6180 245/35ZR19

Update

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

CARGO BARRIER ROOF TRIM PLUG

DISLODGES

VT WAG ON

(GROUP 1)

PROBLE M DES CRIP TIO N

The Holden accessory cargo barrier kit includes

four “roof trim plugs” that are used to retain the

two upper mounts of the cargo barrier in either

of two locations - Refer Figure 2 below.

Station wagon owners/operators may complain

of the unused cargo barrier roof trim plugs

dislodging or not retaining in the r oof/headlining

panel. This may occur on vehicles built from

17/05/’00 where a revised roof mounting

bracket (under the headlining) was introduced.

A revised design roof trim plug was released in

the cargo barrier kit at the sam e time.

For this reason, some carg o barrier kits fit ted to

vehicles built after 17/05/’00 may be from

earlier stock and may not have the revised

design roof trim plug.

“Old” design roof trim plugs will not retain

permanently in later build roof brackets.

“New” trim plugs will retain correctly in both old

and new design roof brackets.

Lack of, or loss of these roof trim plugs does

not cause a problem with the security of the

cargo barrier mounting or its retention.

PRODUCTION RECTIFICATION

The revised roof bracket (on the vehicle

roo f panel) w a s fitted to wagons from:

ISOVIN: Build Date:

6H8VTK35HYL590221 17/05/00

SERVICE RECTIFICATION

NOTE: Only vehicles built after

6H8VTK35HYL590221 are affected by this

complaint.

If any vehicle is reported to have trim plugs

which “will not retain in the roof/headlining” - the

trim plugs must be replaced with “new” trim

plugs.

NOTE: “old” design clips that do retain in roof

brackets do not require replacement. Confirm

this with ISOVIN/Build Date info. above and by

checking engagement.

Figure 1 below shows difference between old

and new trim plugs.

“New” trim plugs are identified by the part

number 92088207 moulded into the plug.

“Old” trim plugs have no identification except

shape as shown in Figure 1 below.

Figure 1.

W hen r eplacing trim plug s, fit new trim plugs to

(up to four) lo cations in the roof panel.

Fig ure 2. (showing two possible front/rear

locations, RH Shown, LH Opposite)

PARTS INFORMATION

This plug was previously only available in

the Cargo Barrier Kit and is now available

as a separate part for replacements as

noted, as well as for normal customer

service replacement.

Part No.: Descripti on: Qty

92088207 Roof Trim Plug - Cargo

Barrier Mounting 4

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

WARRANTY CLAIM INF OR M ATION:

Use the following labour operation and time

to claim for “once-only” fitment of four

(max.) roof trim plugs:

New trim plugs with “92088207” moulded into

the rear of the clip must not be replaced under

this Techline instruction.

Description Carg o barrier trim plug -

replace

Labour Op. No. R000091

Time 0.2 hr

Failure Code 37

Return old trim plugs removed from vehicles

when requested by REPAC under this labour

operation number.

RADIATOR SEAL FRAME DELETION

TS with A/C

(GROUP 2)

CURRENT CONDITION

A seal f rame is fitt ed between the radiator and

the A/C condenser, on A/C equipped vehicles

built prior to Model Year 2000 build.

Refer Figure 1 below for exact location.

PRODUCTI O N RECTIFICATION

The seal frame between the radiator and the

A/C condenser is no longer used. The seal

fr ame was deleted f rom product ion with Model

Year 2000 build.

SERVICE RECTIFICATION

When removing this seal frame for any

reason, or dismantling components that allow

access to the seal frame – the seal frame

should be removed and discarded.

After removing the seal frame, fit the A/C

condenser directly to the radiator during re-

assembly.

PARTS INFORMATION

The seal frame i s no longer carried by HSPO.

Figure 1.

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

INSTRUMENT PANEL “CRACK” NOISE

VT, WH

(GROUP 1)

PROBLEM DESCRIPTION

An instrument panel “crack” noise may be

heard during instrument panel expansion or

contraction – IE when cooling down a vehicle

interior after being parked in high sun load or

when heating up a cold vehicle interior.

Investigations have shown the cause of the

noise is the instrument panel thermal

expansion/contraction stress being relieved at

its mount ing points .

PRODUCTION RECTIFICATION

Modified instrument panel retaining

screws/washers have been fitted to vehicles

from:

ISOVIN: Build Date:

6H8VTL69HYL616569 19/07/00

These modified screws carry additional

polypropylene washers that reduce friction, to

allow instrument panel “stress” movement

under high thermal expansion/contraction

loads, and thread sealant to ensure mounting

screw torque is maintained in all conditions.

SERVI C E RECTIFICATION

Complaint vehicles where customers complain

of a “crack” noise during rapid vehicle interior

temperature chang es, can be corr ected by the

replacement of the five (5) instrument panel

retaining screws with the modified screws

ment ioned above.

The procedure below should be used to

replace the screws – the procedure is an

abbreviated version of t he proc edure s hown in

SIP CD/VT Series Service Manual, Volume 1,

Pages 1A3-8 to 1A3-15. Use the SIP

CD/Service Manual as reference while

carrying out the procedure. Some of the

illustrations from these pages are included

here to assist in the procedure.

1. CAUTION – Disable the SRS (Air Bag).

Refer to “DISABLING THE SRS”, Section

12M SRS in Volume 7 of the VT Service

Manual/SIP CD.

2. Remove instrument panel lower cover right

side (under steering column).

3. Remove instrument panel end panel right

side (Refer Figure 1A3-13 below).

Figure 1A3-13

4. Remove demist nozzle grille – right side,

by removing end screw and moving fuse

panel down for access. Caution: Pull grille

rearward only (NOT upward or damage will

occur). Ref er Figure 1A3-19 if req uired).

5. Remove glove compartment (Refer Figure

1A3-2 if required).

6. Remove instrument panel end panel left

side (Refer Figure 1A3-14 below).

Figure 1A3-14

7. Rem ove footwell upper closing panel – left side

(under glove box).

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

8. Refer to Figure 1A3-14 – there are a total of 5

screws down the left hand glove compartment

opening – remove the top screw, third screw

from top, and fifth screw from top.

9. Remove demist nozzle grille – left side, by

removing end screw. Caution: Pull grille

rearward only (NOT upward or damage will

occur). Move solar sensor for access to

instrument panel mounting screw. Refer Figure

1A3-19 if required).

Figure 1A3-19.

10. Access is now gained to the five instrument

panel mounting screws across the front edge

of the instrument panel (near windscreen).

Remove the existing screws one at a tim e and

replace with new mounting screws (p/n

92138601).

11. Refit solar sensor.

12. Refit left side demist nozzle grille – Caution:

Take care not to damage the A pillar trim with

grille retaining lugs/clips when refitting grilles.

Ensure the retaining clips on the grille are

centred on the retaining lugs or dam age to the

grille may result, push down on the grille on a

45° angle, or grille will not ‘sit’ correctly on

instrument panel.

13. Refit instrument panel end panel – left side.

Hint: Align the end panel before fitting screws,

and use a magnetic tip screwdriver to hold

screws until started in threads.

14. Refit glove compartment.

15. Refit right side demist nozzle grille – Caution:

use same care as noted in Step 12 above.

16. Refit instrument panel end cap – right side.

Hint: use a magnetic tip screwdriver to hold

screws until started in threads.

17. Refit instrument pa nel lower cover right side.

18. R econnect SRS ( A ir Ba g) system as r equired.

PARTS INFORMATION

Part No.: Description: Qty.:

92138601 Screw – Instrument

Panel Retaining 5

WARRANTY CLAI M INFO RMATION:

Description Replace Instrument Panel

Retaining Screws

Labour Op. No. A000276

Time 0.4 hr

Failure Code 28

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

WHISTLE NOISE FROM ENGINE BAY

JR C20SEL, JS C22SEL, JS X25XE

(GROUP 6M) RE-ISSUED

This Service Techline supersedes the

previous Techline on this topic (Issue 9,

November, 1999 page 13), by providing

additional info. for V6 engined vehicles. This

previous Techline should be destroyed.

PROBLEM DESCRIPTION

Some customers may report a whistle noise

that can be heard f rom t he engine bay area at

varying speeds with light throttle application.

The noise may emanate from the fuel

evaporative carbon canister purge (transfer)

hose (also called carbon canister to fuel tank

vent valve hose). This hose has a corrugated

section, and when air passes through it, a

whistle type noise is produced. To verify this,

the canister purge hose can be disconnected

from the purge valve (at the valve end), and

on road test the noise should stop.

PRODUCTION RECTIFICATION

Revised canister purge hoses have been

introduced into vehicle production f rom:

ISOVIN: Build Date:

W0L0JBF35YL496571 29/09/99

SERVI C E RECTIFICATION

1. Locate the canister purge hose routed

along the engine firewall - (Canister to fuel

tank vent valve)

2. Disconnect the canister purge hose joint,

located under the brake master cylinder.

3. Turn vehicle steering wheel to the farthest

right hand lock position, to gain access to

the rear end of the front inner wheel arch

cover.

4. Remove the two rearmost front wheel arch

cover plastic retaining nuts, and the two

lower plastic retaining clips.

5. Pull the rear section of inner wheel arch

cover away from its mountings to gain

access to the carbon canister (2) – Refer

Fig u r e 2 .

6. Disconnect canister purge hose (2) - Refer

Figure 3 - f rom carbon canist er and remove

the hose from the vehicle.

7. Connect and r oute the revised type canist er

purge hose as per the previous hose.

8. Refit the inner wheel arch cover.

Figure 2.

Figure 3.

PARTS INFORMATION

Revised canister purge hose can be ordered

from HSPO with the part number specified

below:

Part No.: Description: Qty:

92081590 Hose, Canist er Purge (4 Cyl.) 1

92089339 Hose, Canist er Purge (V6) 1

WARRANTY CLAIM INFORMATION:

Description Canister Purge Hose - Replace

Labour Op. No. L000187

Time 0.6 hr

Failure Code 40

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

WHISTLE NOISE/DRIVEABILITY

COMPLAINTS

JS with X25XE Engine

(GROUP 6M)

PROBLEM DESCRIPTION

Some customers may report a whistle noise

that can be heard f rom t he engine bay area at

varying speeds with light throttle application.

In addit ion to this, t he custom er may comp lain

of poor driveability and hot start complaints.

Both these conditions can be caused by

incorrectly routed and re-assembled purge

valve hoses, following a previous workshop

procedure.

SERVI C E RECTIFICATION

Should a customer complain of an engine bay

whistle noise, or poor driveability, carry out the

following procedure:

Check f or correct routing of the canister purge

valve hoses at the purge valve - to ensure

correct operation of the purge valve and

correct installation of the purge hose, ensure

the existing purge valve hoses are routed as

shown below - Refer Figure 1.

Figure 1.

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

FLUID LEAK DIAGNOSIS

ALL MODELS

(GROUPS OB, 2, 6A, 7A, 7B)

PROBLEM DESCRIPTION

Dealers must assume responsibility for the

completion of thorough and accurate

diagnosis of fluid leaks prior to commencing

any rectification work or removing major

components.

Components must NOT be replaced for

“leaks” without thorough definition of leak

sources.

Use of Black Light Dye and Black Light is

highly recommended to trace leak sources.

For extensive information on the use of Black

Light and Black Light Dye, refer to the

following inf orm ation repeated f rom a previous

All Dealer Letter.

Holden strongly recommends the use of the

black light and dye method to diagnose fluid

leak sources . This meth od of leak detection is

a proven, reliable method that identifies the

specific leak sour ce and/ or location. T he black

light and dye method can be used for various

types of leak detection, when used with the

appropriate tracer dye it can be used for

detecting engine and transmission fluid leaks,

R12 & R134A leaks, fuel leaks, and coolant

leaks.

The following pages provide answers to

technicians’ questions about the various

aspects of black lig ht and tr acer dye, and how

dealerships may use this tool to their

advantage.

Black Light & Tracer Dye and Accessori es

There are different types of tracer dye for different applications, plus for air-conditioning systems

tracer dyes, an injector, used to infuse the dye into the system, is required. The following tracer

dyes and accessories are available direct from SPx Australia.

Contact SPx Australia – Ph.: (03) 9544 5222; Fax: (03) 9544 6222 - for normal dealer pricing.

Application Part Number

R134a Air Conditioning Tracer Dye

(24 X ¼ oz bottles) J41447

R12 Air Conditioning Tracer Dye

(24 X ¼ oz bottles) J39475

R134a Air Conditioning Injector

J41459

R12 Air Conditioning Injector

J41709

Petrol & Diesel Engine Fluid and

Transmission Fluid Tracer Dye

(24 X 1 oz bottles)

J28431-B

Coolant T racer Dye

(24 X 1 oz bottles) J29545

Replacement Black Light Bulb

BSL-752

Black Light Leak Detection Lamp

J42220

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

Basi c Black Light and Dye Leak Diagnosis Method:

The following information pages will answer most questions you may have about Black Light and

Tracer Dye usage:

The fo llowing is a summary of the steps involved i n detecting a fluid lea k using black light and dye:

1. Pour specified amount of dye into the system.

2. Road test the vehicle und er normal oper ating conditions, to allow the dye to mix wit h the host fl uid/gas.

3. Define the leak source by directing the Black Light towards the suspect area. The fluid leak will appear as a

brightly coloured path leading to the source. Note: The colour of the dyed fluid can be checked on the

dipstick, or oth er component dir ectly in contact wit h the host fl uid/gas.

4. Repair f l uid leak caus e and recheck to ensure that leak has been rect ified.

General Information

How much dye do you use?

Engine, Transmission, F u el

J28431-B Engine & Trans. Fluid Dye shou ld be used as f ollows:

Petro l En gine Oil - 7.4 ml per 3.79litres of oil ( ¼oz per 4-5 quarts)

Diesel Engine Oil - 7.4 ml per 3.78litres of oil (¼oz per 4 quarts)

Automati c Trans . Fluid - 14.8ml per 5.68litres of flui d (2x¼oz per 6 quarts)

Manual Trans. Fl uid/Oil - 7.4 ml per 5.68lit res of fluid (¼oz per 6 quarts )

Petrol or Diesel Fuel - 7.4ml per 7.57litres of fuel (¼oz per 2 gallons)

A/C Systems

J41447 R134a A/C Dye should be used as follows :

R134a A/C System - 7.4ml per A/C system (¼oz per system)

J39475 R12 A/C Dye should be us ed as follows:

R12 A/C System - 7.4ml per A/C system (¼oz per system)

Power Steering

J28431-B Engine & Trans. Fluid Dye can be used in Power Steerin g as follows:

Power Ste ering Fluid - 7.4ml per 5.68lit r es of fluid (¼oz per 6 quar ts)

Engine Coolant Systems

J29545 Coolant Dye should be used as follows:

Coolant System Radiator Fluid - 7.4ml per 15.14litres (¼oz per 16 qu ar t s)

Note: These amounts are based on various tests - there may be occasions when good fluorescence

is not obtained with these amounts of dye, due to the condition of the host oil/fluid or the nature of

certain additive packages in the oil/fluid itself. If this occurs, use additional dye.

Black Light & Tracer D ye Usage Information

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

Q A

Do you need to use the

Fluoresce nt Enha ncer Safety

Goggles?

Yes - they not only protect the technician, but also visually optimise the dye

fluorescence for enhanced leak detection. They are scientifically designed

to enhance fluorescence by eliminating light at wave lengths that might

interfere with the eye’s ability to view the dye’s fluorescent light emission.

Once you look at the dye with and without the goggles, you will see the

difference.

What life does the dye have

when lef t in c o o lant , ATF,

R12 and R134a refrigerant ?

Indefinit e - unless t he ATF is burned in an A/T cl utch fail ure or i n an A/C

com pressor failure.

What life does the dye have

when left in engine oil? Depends on how dirty the oil was when the dye was added. In clean petrol

engine oil, it will last 500+km. In diesel engine oil, it will not last as long

because of rapid carb on build-up.

Are there any adverse effects

of leaving dye in systems too

long?

None - and A/C dyes especially are very thermally stable and should last

100,000 km.

Is there a preferred method

of cleaning t he dye from a

vehicle, if spilt?

IMPORTANT - Do NOT get dyes on any painted surfaces - use guard

cover s when pourin g dyes i nto a ny vehic le syst em or inj ect ing A/C dyes. A

good cleaning solvent should clean any dye off any metal surfaces. A/C

dyes cannot be cleaned off hoses or plastic components.

What is the shelf life of the

dyes? Indefinite, but it is r ecommende d they be used within five years.

PETROL & DIESEL ENGINE & TRANSMISSION OIL LEAKS

Use J28431-B dye in quantities as specified in “General Information” section.

Putting dye into oil that is fairly clean will achieve the best fluorescence for leak inspection because the greater

the carbon build-up in the oil, the more difficult to obtain good fluorescence from the dye. Therefore, if the oil

appears to be extremely dirty on the di pstick, additional dye may be required to obtain good fluorescence and

can be added without harm to the e ngi ne.

Q A

How do I know if the

dilution ratio of dye added is

correct?

After addin g dye at th e reco mme nded diluti on rati o, oper ate the en gine 3 to

5 minutes to allow dye to mix with oil. Then check the oil dipstick with

bla ck light for the yellow-gre en fluores cent glow of the oil/dye mix t ure.

What is the proper proc edure

for adding dye to the engine? Wi th the engine OFF. This will prevent possible splashing of the dye over

an area of the engine that may need inspecting.

How long do es it normally

take for the dye to work? Most leaks will ap pear a f ter opera ting the engine 5 to 10 minutes. Howe ver ,

it is r ecommended that the vehicl e be taken for a short roa d test in order to

allow th e dye to penetrat e all lea k s.

How long will it take for the

dye t o penetrat e very small

pinholes or porosity leaks?

To accurate ly detec t leaks of thi s type, the vehicl e should be operated for 1

to 3 hours under normal operating co nditions. Suggestion: If su ch a leak i s

suspected, add dye to the engine oil. Then have the vehicle owner use the

vehicle for the time recommended above. The owner should then return for

leak inspection with the black light.

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

Q A

Do I have to clean engine

surfaces prior to using the

dye?

NO! Under black light, all petroleum-based products such as oil, grease,

and AT F wil l fluo resce blue. The dye will pe netrate surf ace oil , gre ase and

grit to leave a yellow-green fluorescent trace (under black light) at the

source of th e le ak.

Do I have to clean the engine

after repai ring the le ak? YES! But only at the source of the leak in order to allow the technician to

operate the engine and then re-inspect the leak repair to insure the job was

done r ight the first time. Su ggesti on: Th e dye/oil mi xture can be removed

by usin g any engi ne degreaser or solvent-type shop cleaner.

After adding dye to t he

engine oil, is it necessary to

change the oil prior to

retu r n ing the vehicle to the

customer?

NO! The dye is 100% compatible with engine oil and can remain in the

system without harm until the next oil change.

How long will it take for

ATF dye to work? Most l eaks will appear aft er operating the transmission for 5 to 10 minutes.

However, it is recommended that the vehicle be taken for a short road test

in order to allow A T F d y e to pe netrate all leaks. NOTE : All o t her

appl ication and leak-detection procedures remain the same as given under

the Engine Dye Section (above). It is not nece ssary to clean transmissi on

exterior surfaces prior to using ATF dye. To detect small pinhole or

porosity leaks, the vehicl e s hould be operated for 1 to 3 hour s. The AT F

dye mixture should be cleaned fr om the source of the leak, and it is not

necess ary to cha nge ATF after adding dye.

How long will ATF dye be

effective in the transmission? Because the tr an s mission remains fairly clean inte r n ally an d d o e s not hav e

the carbon build-up problem present in petrol and diesel engines, the ATF

dye will be effective as long as the ATF is not changed or the AT F is not

“burnt” or discoloured by a transmission failure. Remember to check the

dipstick with the black light prior to inspecting for leaks to check

fluorescence, and do not forget t o check the AT F cooler line for leaks.

BRAKE SYSTEM LEAKS

Q A

Can I use a fluorescent dye

in a brake sy s t em?

Never use any type of a fluorescent tracer dye in a brake system.

POWER STEERING LEAKS

Q A

How much dye should I use

for finding power steering

leaks?

Check the fluid c apacit y of the power steerin g system. You will pro bably

need to add only a sm all am ount of dye at a diluti o n ra ti o o f 7.4ml (¼ oz) to

5.68l (6 quar ts) of power steer ing fluid. Run the syste m, t hen check the cap

or dipstick for fluorescence with the black light.

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

FUEL SYSTEM LEAKS

When a fuel system leak is suspected, it is recommended that the vehicle being tested have a quarter tank or

less of fuel. Trucks and larger capacity systems should be estimated as close as possible in order to keep the

dye requirement at a minimum and to keep the test procedure as economical as possible. If a difficult leak is

suspected, adding more dye than nor mal ( a higher concentration) will pr oduce the best res ults and will not ha r m

the system.

Q A

How do I know if e n ough

fuel dye has been added? A ny di ps tick device that can be ins erted into the fi ller tube can be use d and

then inspected for fluorescence with the black light.

On a fuel-injected (PFI)

vehicle, can I use the fuel

rail for injecting dye?

NO! The small volume of petrol that will receive the dye is probably

insufficient for the dye to show up a t an “O” ring injecto r leak for example.

COO LANT SYSTEM LEAKS

J295 45 dye is totally compatible wit h anti-freeze.

Q A

What is the proper proc edure

for adding dye to the cooling

system?

Add dye with the engine off a nd radiat or “c old”. Th is will prevent splashing

of dye and possible false readings. Also, add the coolant dye directly into

radiato r and not into the reserve/surge tank found on som e v eh i cl es.

How do I clean the coolant

with dye of f the radiator and

engine surfaces?

Use water with detergent and a small scrub brush.

How can I check for a

suspected coolant leak into

the engine oil?

Perform test as follows:-

Pull the engine oil dipstick and confirm the blue fluorescence of the engine

oil with the black light. (This is oil to which no dye has been added.)

With t he e ngine o ff and t he ra di ator c old , pour co ola nt dye i nto t he r adi at or,

and operate vehicle for at least one day to allow coolant to leak into engine

oil.

With the engine off, pull engine oil dipstick and fluoresce dipstick with

bla ck light.

If coolant is leaking into the engine oil, the dipstick should show some green

fluorescent droplets of coolant. Also, the engine oil might fluoresce a slight

whitis h bl ue col our in ste ad of the normal stron g blue fl uoresc ence of engine

oil.

R134a A/C SY STEMS DYE FOR R12 A/C SYST EMS

When R134a or R12 dye is injected into an A/C system and the system has been operated under full pressure

for 5 to 10 minutes, t he dye wil l remain i n the s ystem even thou gh the R134a or R12 has been evacuated for a

repair. The only time R134a or R12 dye must be put back into the A/C system is when the A/C system is

flus hed of refrigerant oil.

Q A

How do I put R134a or R12

dye into an automotive car or

truck A/ C syst em?

Pu t 7.4ml (¼ oz) of dye in the dye inject or reser voir, and use a r efrigerant

sour ce to injec t th e dye into the A/C system .

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

Q A

How long will it take the

R134a or R12 dy e to

circulate thro ugh the typical

automotive A/C system?

Operating the A/C system under full pressure, it will take the dye

approximately 5 to 10 minutes to circulate through most A/C systems.

However, this does not mean that the A/C leak will show up in that time

period.

How long after putting

R134a or R12 dy e into the

A/C syst em and running th e

system under full pressure

can I begin looking for the

A/C leak with the black

light?

This depends on the size and location of the leak. As the refrigerant escapes

under pressure, it carries with it a very small amount of refrigerant lubricant.

This trace of lubricant is what you are looking for with the black light.

Therefore, the size of the leak will determine how long it takes for the

lubricant dye to appear and fluoresce under the black light. A hose porosity

leak would, therefore, take longer to appear than a fracture/fitting leak.

Example: A high-pressure side leak may take over a week or more to have

enough refrigerant escape to affect the cooling capacity of the A/C system,

return the car to the customer, and tell them to bring it back for leak

inspection when they again notice a lack of cooling by the A/C system.

When this car returns, the refrigerant that has escaped will leave a trace of

refri gerant lubric ant with dye, which is what you will be looking for with the

black light.

How do I know if I have a

leaky service valve on the

low-pressure side if I just

use d that valve to put dye

into the A/C system?

After putting the R134a or R12 dye into the A/C system through the low-

pressure service valve, clean the valve with a solvent if the refrigerant taking

the dye into the A/C system did not clean off the service valve, sufficiently

to remove all trace of dye. Do this before starting the A/C system.

How do I clean the R134a or

R12 d y e off A/C com p onents

and engine surfaces?

Use any sho p degr easer or solvent to cle an dye off A/ C co mponents or

engine s u r face s.

Are these A/C dyes

compatible with my

refrigerant recovery and

recycle equipment?

These dyes have been tested and proven compatible by major manufacturers

of recovery and recycle equipment. When refrigerant is evacuated from an

A/C system, a small amount of compressor lubricant is also removed from

the system. The R134a or R12 dye is in solution with the syst em compressor

lubricant, therefore, is separated in the recovery/recycle unit along with the

compressor lubricant. Because of the small amount of compressor lubricant

removed by the rec over y/ r ecycle unit, there is no need to a dd additional

R-134a or R-12 dye to the A/C system for future l eak detectio n.

How do I know i f a vehicle’s

A/C system co ntain s eith er

R134a or R12 dye?

Remove the low-side service port sealing cap and direct the black lamp into

the valve stem area. If you do not see dye/lubricant in this area, depress the

valve stem only for an instant to help bring out some lubricant with the

refrigerant. Again direct the black light at the valve stem for traces of the

fluoresc en t dye/lubricant. Clean dye off serv i ce p ort .

How do I check for

ref r igeran t leaks in th e

evaporator when I cannot

use the black light to see the

leak?

Use the black light to fluoresce the drain hole and see if a trace of the yellow

green dyes has washed down with the condensation. When the evaporator is

removed from the vehicle, use the black light to determine the exact location

of the le ak on the evap or ato r . Remember t o chec k the fi t ti ngs t o and from the

evaporator to be sure they ar e no t th e cau se o f th e le ak.

HOLDEN SERVICE TE CHLINE ___________________________________________________________ OCTOBER 2000

Q A

How do I check for the

dye/lubricant when I cannot

direct ly shine the blac k light

on all suspected leak areas?

Use a mirror to reflect the black light to the underside of a fitting, hose or

component. Also if a mirror cannot be used, a white cloth can be used to

wipe the suspected area, and then fluoresce the cloth with the black light to

check for traces of the yellow-green dye.

Can the dyes rem ain in the

A/C system after it has been

used for the initial leak

detection?

Dyes can safely and effectively remain in the A/C system after the initial

repair. Dyes can be used to detect future refrigerant leaks and can only be

removed from the A/C system by flushing out the system compressor

lubricant.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

REAR SHOCK ABSORBER “KNOCK”

OR “RATTLE” – UPPER BUSH

PREMATURE WEAR

(GROUP 4)

PROBLEM DESCRIPTION

PIR’s have reported premature wear out of

the rear shock absorber upper rubber

bushes.

SERVI C E RECTIFICATION

Should a vehicle be presented with

premat ure shock absorber upper rubber bush

wear (usually with a knock/rattle noise) the

upper bushes and plates should be replaced

with the parts shown below.

These parts are made from a more durable

rubber compound when subjected to

constant usag e on rough or undulating roads.

The compound may result in a slightly

increased road noise on very smooth roads,

but this will only be noticeable to critical

customers .

Refer to WH Series Service Manual/SIP CD,

pages 4A-9 to 11 for details of shock

absorber top mount rubber bush and plate

replacement.

PARTS INFORMATION

Part No .: Description: Qty.:

92040086 Plate, Shock Abs. to

Underbody (Upper &

Lower).

92040065 Bush, Shock Abs.

(Upper) 2

92040066 Bush, Shock Abs.

(Lower) 2

WARRANTY CLAIM INFORMATION:

Description Replace Rear Shock Abs.

Upper Rubbers/Washers

Labour Op. No. F000168

Time 0.4 hr

Failure Code 28

TIMED OVER-RIDE CORRECTION (SIP

CD INFO. ERROR)

VT II

(GROUP 6C)

PROBLE M DES CRI PTI O N

Current SIP CD – VT Series II, Section 6D1-2

“Starting System”, Part 3. Diagnosis, states:

“Turn ignition switch to the ON position and

security override will occur in two hours.” –

THIS IS INCORRECT!

The information was carried over from

previous model information.

There is no longer any “timed override”.

VT Series II Service Manual on SIP does

carry information regarding timed over-ride

deletion in Sections 12F, 12J-1 & 12J-2.

This deletion occurred in:

July, 1998 – BCM’s;

Oct., 1998 – V6 PCM’s;

Nov., 1998 – V8 PCM’s.

In the event of “no crank” conditions,

remember to refer to Section 12J-1, or

Section 12J-2 (4. Diagnosis/Theft

Deterrent).

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

HSV LEVEL RIDE SUSPENSION –

FUSE LOCATIONS

VT II & WH

(GROUP 12)

The following information is repeated from

HSV bulletin of Feb. 9, 2000, for use by

technicians when servicing HSV - VT Series

II, and WH vehicles.

PROBLEM DESCRIPTION

HSV Fuse locations not shown in published

service manuals.

SERVI C E RECTIFICATION

The HSV Level ride suspension fuse details

are as follows:

Fuse

Position Fuse

Rating Usage

F8 25 Amp Level Ride Relay

(label on fuse cover)

F15 10 Amp Level ride sensor

F6 10 Amp Solenoid power

Should you require further information

regarding this bulletin, then please call HSV

Technical Assistance Department on

telephone number (03) 9265 9500.

FRONT DOOR LOCK ROD DETACHES

FROM LOCK

(GROUP 1)

PROBLE M DES CRI PTI O N

Front door remote lock rod becomes

detached from front door lock mechanism,

resulting in front door not able to be opened

via the remote (interior) handle.

SERVICE RECTIFICATION

If a vehicle is found to have the remote lock

rod detached from the door lock mechanism,

the remote rod retaining clip must be

replaced with a new retaining clip and washer

assembly, as follows:

1. Remove the door window regulator

handle, door pull handle and door inner

trim panel (refer VR Service Manual,

Volume 1, page 1A6-4/5 for procedure).

2. Rem ove existing door remot e rod clip from

the door lock mechanism (by depressing

the retaining barbs).

3. Assemble a new washer (p/n 11011616)

over t he barbed ends of a new remote rod

clip (p/n 90120387).

4. Fit this new clip and washer assembly to

the door lock in place of t he old clip – refer

Figure 1 below.

5. Fit the rod through the centre of the clip

assembly, then rotate the clip end upward

until it “snaps” onto the remote rod.

Note: As the clip can be used on RH or LH

door locks by reversing the orientation of

the clip, both installations are shown in

Figure 1.

6. Re-fit previously removed components

and confir m correc t lock operation.

Refer to further information and

illustrations on following page.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

Figure 1.

PARTS INFORMATION

Part No.: Description: Qty:

90120387 Clip, Linkage to Outer

Handle 1

11011616 Washer, Door Handle

Linkage 1

This clip is made from a harder material than

the original clip, and features a double barb

design to improve retention to the remote rod.

WARRANTY CLAIM INFORMATION:

Use existing “W arranty Information” in SIP as

shown:

Description Rod, Remote Control

Front RH - Replace

Labour Op. No. C622800

Time 0.5 hr

Failure Code 55

Description Rod, Remote Control

Front LH - Replace

Labour Op. No. C622700

Time 0.5 hr

Failure Code 55

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

SAFETY TRIANG LE N OT R E TAINING IN

BOOT LID

(GROUP 1) Pre-Delivery Hint

PROBLEM DESCRIPTION

During pre-delivery, the safety triangle,

mounted on the underside of the rear

compar tment (boot) lid, m ay not retain f ully on

its upper retainer. This can be caused by a

misaligned hole in the boot lid carpet, which

stops the triangle from engaging in the

retainer correctly.

SERVI C E RECTIFICATION

Inspect the clearance hole around safety

triangle upper retainer – Refer Figure 1.

• If any carpet material is located over the

base of the upper retainer, trim the material

away.

• Only trim enough material to ensure the

safety triangle can fully seat on the upper

retainer and the retainer pin locks into

place.

• Trimming off too much material may cause

the underlying painted panel to be visible

and unsightly.

Figu re 1.

COOLANT LEAK FROM CROS S-OV ER

PIPE HOSE CONNECTIONS

VT/WH with Gen III V8

(GROUP 6K)

PROBLE M DES CRIPTIO N

PIR’s have reported coolant leaks from the

ends of the radiator cross-over pipe hose

connections, located below and behind the

radiator. The hoses were connected using

spring band type clamps until VX start of

production (SOP).

PRODUCTI O N RECTIFICATION

Worm drive hose clamps for the cross-over

pipe hose connections (larger radiator hoses)

have been fitted to vehicles from VX start of

production:

ISOVIN: Build Date:

6H8VXK69F1L641840 18/9/00

SERVICE RECTIFICATION

On VT & WH vehicles with spring band

clamps on the crossover pipe end

connections:

Any vehicle with a coolant leak from the

cross-over pipe hose connections, where no

defects in hose, pipe or clamp can be defined

– should have both the existing spring band

clamps on the cross-over pipe ends replaced

with worm drive clamps (p/n 92138604).

PARTS INFORMATION

Part No.: Descr i ption: Qty:

92138604 Clamp, Hose 2

WARRANTY CLAI M INFO RMATION:

Use the following information to claim for the

above replacement:

Description Replace Cross-over Pipe

Hose Clamps (2)

Labour Op. No. J000681

Time 0.3 hr

Failure Code 27

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

CLUTCH FLUID RESERVOIR CAP

REPLACEMENT

VS, VT

(GROUP 7A)

PROBLEM DESCRIPTION

PIR’s have reported clutch master cylinder

caps failing by cracking – with the top of the

cap crack ing where it at tac hes t o t he threaded

section of the cap. Failure is related to the

type of material used, and a new design cap

assembly, is now available.

PRODUCTION RECTIFICATION

Revised clutch master cylinder cap and seal

assemblies have been fitted in production

from:

ISOVIN: Build Date:

6H8VTK69HYL629048 16/08/00

SERVICE RECTIFICATION

Whenever replacing a clutch master cylinder

cap on VS or VT models built prior to the

above breakpoint, fit a new clutch master

cylinder cap – p/n 92144027. Figure 1 below

shows the new (“OK”) cap & seal asm. and

old (“Not OK”) cap.

DO NOT OV ER FILL MASTER CYLINDER S

Note: this new cap assembly “breathes”

through the cap thread (not through a

breather hole as in the previous part) and

because of this it is important not to overfill

the reservoir when adding brake f luid.

PARTS INFORMATION

Part No.: Description: Qty

92144027 Cap & Seal Asm. –

Clutch Master Cylinder 1

The cap and seal that make up this new cap

assembly are not available separately.

Figure 1.

WARRANTY CLAIM INFORMATION:

Use existing “Warranty Information” in SIP as

shown:

Description Cap, Clutch Master

Cylinder – Replace.

Labour Op. No. K013750

Time 0.2 hr

Failure Code 05

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

DOOR CHECK LINK SERVICEABILITY

VT Series I & II

(GROUP 1)

This Service Techline Bulletin carries

information repeated from Parts Techline

PT40, dated 11 Oct., 1999 – so technicians

are aware of changes m ade and the methods

of replacement.

PROBLEM DESCRIPTION

The front door check link assembly and

mounting were changed at start of production

of VT Series II. Subsequently, HSPO has

superseded Series I components with Series

II com ponents .

The information in Parts Techline PT40

provides procedures that are to be performed

to repair the various combinations of

door/bodies and check link s.

The following drawing provides details of the

two different check link installations:

G256-01

SERIES 1

SERIES 2

SERVICE RECTIFICATION

Methods of fitting check links and doors as

per the not es above – are more com plex t han

normal replacements, so if this work is

required – refer to the copy of PT40 held in

your Parts Department - which provides

detailed instructions and illustrations.

PRODUCTI O N RECTIFICATION

Revised check links were fitted to vehicles

(VT Series II intro.) from:

ISOVIN: Build Date:

6H8VTK35HXL464495 31/05/99

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

OIL LEAK FROM ENGINE OIL COOLER

YE, JR, JS – all with V6

(GROUP 6A)

PROBLEM DESCRIPTION

If there is any failure of the engine oil cooler,

(located on the engine, called “heat

exchanger” in TIS) or t he sealant used on the

lower face of the oil cooler - oil and coolant

may be m ixed. Reports have been received of

various parts being replaced, varying

diagnoses being performed, resulting in

confusion regarding the source of the leak

and causing repeat repairs.

Investigations currently show that the main

cause is deterioration of the sealant used on

the underside of the engine oil cooler. This

possibility should be considered before any

major engine dismantling or repairs are

attempted. If leak point/s cannot be

confirm ed, re-seal the oil cooler bef ore further

dismantling/repair. DO NOT assume head

gaskets are the cause!

A reminder of the existing service informat ion:

- DO NOT machine cylinder heads on these

engines!

SERVI C E RECTIFICATION

When replacing or re-installing the engine oil

cooler – use newly released Sealant

09163307 from HSPO.

This part number may not be shown in the

PartFinder issue that is current at the time of

release of this bulletin, but the sealant is in

stock at HSPO.

Previously released sealant (90511124) or

other sealants should NOT be used in this

installation!

PARTS INFORMATION

Part No.: Description: Qty:

09163307 Sealant, Engine Oil

Cooler. 1

FRONT DOOR CHECK LINK NOISE

JR, JS

(GROUP 1)

This Service Techline supersedes the

previous Techline on this topic for JR & JS

models.

PROBLE M DES CRIPTIO N

When opening or closing the front doors, a

clicking noise is heard from the front door

check link area.

PRODUCTI O N RECTIFICATION

Revised check link strap to suppor t nuts have

been fitted to vehicles from:

ISOVIN: Build Date:

W0L0JBF19YL515815 13/10/99

SERVICE RECTIFICATION

Fit new door check link bolts, and revised

check link nuts to both front doors.

Perform the following steps when installing

these check link bolts/nuts:

1. Torque the BOLT first – while holding the

nut - to 14±1Nm,

2. Then Torque the NUT – while holding the

bolt - to a final torque of 16±1Nm .

NOTE: The process of torqueing the bolt

before the nut ensures the bolt is seated

completely prior to final torqueing via the nut.

PARTS INFORMATION

Part No.: Description: Qty:

09116434 Bolt – Door Check

Link to Support 2

92138580 Nut – Door Check

Link to Support 2

WARRANTY CLAI M INFO RMATION:

Description Door Check Strap Bolt

Replace – Both Sides

Labour Op. No. C000358

Time 0.3 hr

Failure Code 27

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

TOW BAR RATTLE (1600 & 2100K g

TOW BARS) – ADD LOCK SCREW

VS, VT, WH

(GROUP 1)

Ensure this bulletin is circulated to Pre-

Delivery personnel and Technicians

involved in accessory fitting.

PROBLEM DESCRIPTION

A rattle noise may be heard from the tow bar

tongue of a Holden Accessory 1600Kg. or

2100Kg. tow bar, when ther e is no towing load

on the tow bar.

This rattle is caused by free-play between the

tow bar tongue and tow bar main tube.

PRODUCTION RECTIFICATION

HSPO accessory 1600Kg. and 2100Kg. tow

bar kits have been upgraded to include an

anti-rattle screw/nut on the underside of the

tow bar.

Note: Some k its in Dealer parts stoc k may not

have this ant-rattle screw/nut included. If one

of these kits is to be fitted, the screw and nut

should be added as described in this bulletin.

SERVI C E RECTIFICATION

In service, if customers complain of a rattle

noise from the tow bar tongue, when there is

no load on the tow bar, the following

procedure can be used to add an anti-rattle

screw/nut to the tow bar:

1. Remove the tongue from the tow bar.

2. On the underside of the central tow bar

tube, mar k and centre punc h a point on the

centre of the tube, 70mm forward of the

rear end of t he tube – Ref er Figure 1, View

A, for exact location.

3. Drill an 8.5mm hole at this point.

4. Tap an M10 x 1.25 thread in the hole.

Clean inside of central tube to remove any

burrs around the new hole, and any swarf

or iron filings remaining from the drilling

and tapping process.

5. Apply an anti-corrosion paint, such as

metallic zinc primer, to the threaded hole –

inside and outside of the tow bar tube.

6. Re-assemble the tongue to the tow bar.

7. Fit lock nut (p/n 92138590) to anti-rattle

screw (p/n 11078491) and run it down the

screw thread for clearance.

8. Assemble anti-rattle screw and nut into the

new threaded hole in tow bar central tube

and torque the screw to 5 - 10Nm.

9. While holding the anti-rattle screw, tighten

the lock nut on t he screw to apply suff icient

torque to lock the screw in place.

Advise the vehicle operator:

• this anti-rattle screw must be torqued to

5 – 10 Nm and t he lock nut torq ued to lock

the screw, when there is no load on the tow

bar tongue.

• this anti-rattle screw and nut must be

removed whenever a load is applied to the

tow bar, and refitted when the load is

removed.

PARTS INFORMATION

Part No.: Description: Qty:

11078491 Screw, Tow Bar Anti-

Rattle 1

92138590 Nut, T ow Bar Anti-

Rattle. 1

WARRANTY CLAI M INFO RMATION:

Description Fit Tow Bar Anti-Rattle

Screw

Labour Op. No. R000094

Time 0.4 hr

Failure Code 28

Update

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

TOW BAR RATTLE (1600 & 2100Kg TOW

BARS) – ADD LOCK SCREW - Continued

Figure 1.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

FUEL ODOUR IN HIGH AMBIENT

TEMPERATURES

SB with C14SE Engine

(GROUP 8)

PROBLEM DESCRIPTION

On high ambient temperature days (EG:

30°C or higher), odour from fuel vapour may

be smelt in the vehicle passenger

compartment, (via the ventilation system)

when insufficient air flows over the vehicle;

IE: when parked with engine idling, or when

stopped or moving slowly in traf fic.

Vehicles built with C14NZ engines are NOT

affected by this condition.

SERVI C E RECTIFICATION

Revised Canister Ventilation Pipe Installation

for SB Barina and Combo (A/T & M/T) with

C14SE engine:

1. Remove Right Hand front fender liner. Do

this by removing 4 plastic rivets, 2 screws

and 2 plastic nuts. Refer Figure 1.

Figure 1

2. Detach canister ventilation pipe from metal

clips.

3. Remove carbon canister from vehicle by

the screw that retains the clamp. Refer

Fig u r e 2 .

Figure 2

4. Remove ventilation pipe hose from

canister. Note: Some force is required to

remove the hose, take care t o not dam ag e

the plastic canister fitting. Refer Figure 3.

Figure 3

5. Install new canister ventilation pipe hose

to canister and feed through the hole in

inner guard. Make sure it also feeds

through the inner panel. Refer Figure 4.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

Figure 4

6. Ref it carbon canister and clip canister vent

pipe into the two white clips as shown in

Figure 5 below, ensuring there are no

kinks or twists in the hoses.

Figure 5

7. Push the pipe into the white clip on the

engine compartment side of the inner

guard. Fit the rubber water deflector onto

the end of the pipe approx. 25mm. Ensure

that there is a 5 - 10mm clearance

between the water deflector and body.

Refer Fig ur e 6.

Figure 6

8. Refit the Right Hand f ront fender liner.

PARTS INFORM ATION

Part No.: Description: Qty

92143482 Canister Vent Pipe Kit 1

WARRANTY CLAIM INFORMATION:

Description Fit Revised Canister

Vent Pipe

Labour Op. No. L000190

Time 0.7 hr

Failure Code 74

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

LACK OF POWER/PO OR RESPONSE

FROM ENGINE ON HILLS

VT/WH with V6 (non-S/C) & A/T

(GROUP 6C)

PROBLEM DESCRIPTION

Customers may complain about a “lack of

power”, or “lack of res ponse”, when driving at

approx. 70-85km/h in 4th gear (IE: in

“Economy” mode with TCC applied) –

generally when driving up inclines.

With the existing trans. and memcal

calibration, the transmission holds 4th gear

with TCC applied, and under these driving

conditions, the engine power output is near

its maximum (until a 4-3 downshift is forced

by greater throttle opening, or by manual

gear selection – this is also unacceptable to

some cust om ers).

The existing calibration is designed to

achieve optimum fuel economy at such

driving speeds and conditions, and while

most customers are able to accept the

perceived “lack of power” or “response” that

results, and adjust their driving style to suit,

some customers may complain.

PRODUCTION RECTIFICATION

A revised memcal with revised shift

calibration has been fit ted to vehicles fr om:

ISOVIN: Build Date:

6H8VTK69HYL621245 28/07/00

SERVI C E RECTIFICATION

If a customer complains of this perceived

“lack of power”, or “lack of response” and

does not accept the condition, a DJLX

Memcal may be f itt ed as an improvement.

This memcal disengages TCC in 4th gear

prior to the point at which the engine stops

increasing power.

Please note however:

Using this memcal will only affect driving in

Economy mode, and will not change

perceived power or response in either Power

mode or during Cruise Control use. The

memcal must not be used in vehicles with

S/C V6 engine.

PARTS INFORM ATION

Part No.: Descri ption: Q ty:

12203180 DJLX Memcal 1

WARRANTY CLAIM INFORMATION:

Description Fit Memcal for Lack of

Response Complaint

Labour Op. No. J000678

Time 0.4 hr

Failure Code 47

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

BOOT (DECK LID) HARD TO CLOSE

JS Sedan

(GROUP 1)

PROBLEM DESCRIPTION

Deck lid (boot) is hard to close, requiring

considerably high effort to close.

The cause of this com plaint can be:

- Striker out of alignment/adjustment,

- Weatherseal over-compression –

which can be caused by either the

weatherseal not being seated fully on its

mounting flange; or excess body sealer

under the weatherseal.

If striker adjustment is the cause – the deck

lid will travel freely through its range of

movement until the latch comes in contact

with the striker.

If weatherseal over-compress ion is the cause

– the deck lid will NOT move freely through

some part of its travel. This indicates deck

lid/seal “drag ”. I n the JS deck lid/seal des ign,

the vertical sect ion of the s eal – Ref er Figure

1 below – is susceptible to seal drag when

the deck lid (boot) ‘wipes’ on the seal during

closing.

PRODUCTION RECTIFICATION

Revised (reduced) sealer application and

improved weatherseal fitting occurred to

vehicles from :

ISOVIN: Build Date:

W0L0JBF19YL611000 06/07/00

SERVI C E RECTIFICATION

For vehicles with deck lid (boot) “hard to

close” complaints, car ry out the following:

Move deck lid up and down to determine if

the deck lid is catching (dragging on the

weatherseal) at any point of its travel.

If NOT catching – carry out striker

adjustment. Closing effort should now be

corrected, no further action is necessary.

If catching –

1. Remove deck lid weatherseal from deck

lid opening flange.

2. Clean excess body sealer from the deck

lid opening flange. Note: - Minimal sealer

is required on this flange to stop water

entry and excessive sealer will “pack out”

the weatherseal and apply loading to the

deck lid during closing.

3. Fit a new weatherseal (p/n 90462614) to

the deck lid opening flange (a new

weatherstrip is required as the original

production weatherseal cannot be fitted

using a mallet as noted below, as damage

will occur). Take care to:

- align the butt joint in the weatherseal

100mm to the right of the centre of the

vehicle, nearest the lock striker;

- use a rubber mallet to firmly seat the seal

on the whole perimeter of the deck lid

opening f lang e.

PARTS INFORM ATION

Part No.: Descr i ption: Qty:

90462614 Weatherstrip, Deck

Lid 1

WARRANTY CLAIM INFORMATION:

Use existing “Warranty Information” in SIP –

ONLY when deck lid weatherseal requires

replacement - as follows:

Description Weather strip, Deck Lid

- Replace

Labour Op. No. C125500

Time 0.4 hr

Failure Code 58

Figure 1.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

ACCELERAT OR PEDAL - “NOTCHY”

FEEL

VT (All V6 Engines)

(GROUP 6A)

PROBLEM DESCRIPTION

Accelerator pedal response may be

described as “notchy” by some customers.

Replacement of cable, or attem pts to re-rou te

the cable do not improve the feel.

The cause has been defined as internal

friction between the inner and outer cables,

accentuated by the sharp bends in existing

cable routing.

PRODUCTION RECTIFICATION

A shorter, revised accelerator cable, with

revised cable routing, has been fitted to

vehicles from :

ISOVIN: Build Date:

6H8VTK69HXL487036 28/07/99

SERVICE RECTIFICATION

On vehicles subject of this complaint, carry

out the following procedure:

1. Remove existing accelerator cable from

vehicle.

2. Fit new cable (p/n 92082648) – cable

routing is same as previous, except, as

the cable is shorter, the cable must be

routed inboard of the LH strut tower – Ref.

Figure 1 showing “revised cable routing”.

NOTE: Vehicles without Cruise Control –

remove the (now) unused cable retaining

bracket near the LH engine hood strut -

noted on Figure 1.

Vehicles with Cruise Control – the cable

retaining bracket - Refer Figure 1 - is to be

left in place – it still retains the cruise control

cable as per previous installation.

3. When attaching the new cable to throttle

body – Torq ue the adj ust ment nuts - not ed

on Figure 1. - to 2.0 – 4.0Nm.

Figure 1.

PARTS INFORMATION

Part No.: Description: Qty:

92082648 Accelerator Cable 1

WARRANTY CLAI M INFO RMATION:

Use existing “Warranty Information” in SIP as

shown:

Description Cable Asm., Accel. -

Replace

Labour Op. No. J816900

Time 0.3 hr

Failure Code 39

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

CONDENSATION IN HEADLAMPS –

HEADLAMP CLEARANCE

ADJUSTMENT PROCEDURE

(GROUP 12)

PROBLEM DESCRIPTION

Headlamp glass becomes ‘fogged’ with

condensation, or has visible water droplet s on

the glass from moisture entry. The cause has

been found to be insufficient clearance

between the headlamp and eng ine hood. This

leads to contact between engine hood and

headlamp dur ing closing, and constant engine

hood pressure on the headlamp glass,

resulting in moisture entry through damaged

sealing.

SERVI C E RECTIFICATION

For any vehicle presented with moisture or

condensation in headlamp/s:

BEFORE CLOSING THE ENGINE HOOD

after replacing the affected headlamp

assembly, carry out the following procedure

to ensure adequate clearance exists, to avoid

a repeat failur e:

1. Loosen the engine hood striker bolt lock

nut and measured the existing dimension

(Dimension “X” on Fig ure 1) . Measure fr om

the bonnet plate to the end of the spring

retaining washer – Item 1 on Figure 1.

Figu re 1.

2. Adjust striker bolt until dimension “X” is

1.5mm longer than existing dimension –

lightly tighten lock nut to maintain the

dimension until final tightening (end of

procedure).

3. Turn out the engine hood rubber bumpers

by ¼ turn – refer items 2 on Figure 2.

Figure 2.

4. Lower engine hood carefully and press

down until hood catch eng ag es.

5. Using a 0.5mm feeler gauge, check the

clearance between the engine hood and

the headlamp rubber seal – Refer Figure 3

- the feeler has to pass through without

resistance. If required, adjust clearance by

turning hood catch striker bolt in or out.

Figure 3.

6. When the 0.5mm clearance is achieved,

torque the hood catch striker bolt lock nut

to 22Nm.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

WARRANTY CLAIM INFORMATION:

Use existing “W arranty Information” in SIP for

the above clearance adjustment – during

headlamp replacement - as follows:

NOTE: the labour time has been increased on

these labour operation numbers to allow for

the clearance procedure described above.

SIP will be updated as soon as possible to

ref lect t his revision. The clearance adjustment

procedure MUST be carried out whenever a

headlamp or any front bodywork is disturbed.

Description RH Headl amp Asm. -

Replace

Labour Op. No. N104100

Time 1.4 hr

Failure Code 62

Description LH Headlamp Asm. -

Replace

Labour Op. No. N104200

Time 1.4 hr

Failure Code 62

KNOCK NOISE FROM EXHAUST ON

COLD START

JR, JS, with 4 C yl. Engine

(GROUP 8)

This Service Techline supersedes the

previous Techline on this topic (Issue 1,

February, 1999 page 5) by updating the

silencer date code information. This previous

Techline should be destroyed.

PROBLE M DES CRIPTIO N

Customers complain of a metallic knocking

noise after engine is started from cold. Noise

can be misdiagnosed easily as being an

engine internal or drive belt related noise.

Actual noise cause is a rattle noise from

internal baffles in the intermediate silencer,

which stops when the exhaust system

reaches operating temperature.

PRODUCTI O N RECTIFICATION

The silencer has been revised internally from

late 1998. Silencers are identified by date

code of 99/04 or later (99/04 = April, 1999), -

stamped on the identification/part number

plate on the lower, outside surface of the

silencer. No vehicle breakpoint was set for

this change.

SERVICE RECTIFICATION

Fit a new Silencer – Intermediate & Centre

Pipe.

Order the new part from HSPO - all parts at

HSPO are of the latest specification.

PARTS INFORMATION

Part No.: Description: Qty:

90500030 Silencer – Intermediate

& Centre Pipe 1

WARRANTY CLAI M INFO RMATION:

Use existing “Warranty Information” in SIP.

Update

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

SRS WARNING LAMP ON– DTC’s 36/ 38

– WATER ENTRY AFTER CLEANING

VT, VX, WH

(GROUP 1)

Please ensure this Techline is circulated

to: Service Advisors – For liaison with

customers, and Dealership personnel who

organise detailing or interior cleaning.

PROBLEM DESCRIPTION

This is a prec autionary bulletin to alert service

personnel of the possibility of the SRS

warning lamp illuminating (and thus SRS

DTC’s being set) - if excessive moisture is

allowed to enter SRS system connector s.

Investigations into reports of SRS warning

lamps illuminating intermittently have proved

to be caused by moisture entry to SRS

connectors.

In the cases reported, vehicles had recently

had:

- carpet s and seats st eam cleaned, or

- interiors “detailed”, or

- water entry to seat lower trim/s, or

- liquid spills around seat lower trim/s

(these are examples of moisture entry, and

not the only methods of entry).

These resulted in:

DTC 36 – driver’s pre-tensioner short circuit,

loop capacitance too high or,

DTC 38 – passenger pre-tensioner short

circuit, loop capacitance too high, were found

during diagnosis, however, no faults in the

SRS system or components could be defined.

SERVI C E RECTIFICATION

Interior cleaning using steam or excessive

water can cause moisture entry to the SRS

connectors in the vehicle interior.

Accidental rain water entry through open

windows can also contribute to this.

Water, soapy detergent, other cleaning

agents can enter the SRS connections.

Any of the above will short the circuits, which

will allow the resistance and capacitance

values to fall outside their tolerances, and

illuminate the SRS warning lamp.

In cases caused by this water entry, once the

connections are dried out, the condition does

not re-occur.

If a customer presents a vehicle with SRS

warning lamp illuminated, check with the

customer to define if the vehicle interior was

cleaned just prior to the warning lamp coming

on.

If a vehicle is being serviced and has an SRS

warning lamp come illuminated – check

whether the vehicle (during its time in the

dealership) has been detailed/cleaned - where

water may have entered the interior SRS

connections.

The notes below and illustrations in Figure 1

on the following page provide information on

the most likely moisture entry points to the

SRS connections:

1. SRS warning lamp is illuminated – check

which DTC’s are set. Are they DTC 36 or

DTC 38?

If YES – Go to Step 2

If NO – Go to Service Manual Volume 7

(or SIP CD), Section 12M for SRS

Diagnostics for appropriate DTC/s, as

problem is not related to this information.

2. Remove front seat rail end (rear) cover –

Refer to View A showing the possible

moisture entry point – at the seat rail cover

joints - between the driver and passenger

seats and doors.

3. Check for moisture in and around the

Yellow YB207 connector – Ref er Views B

& C that show connector location on seat

rail, and probable moisture entry “track”. If

moisture is present, disconnect the

connector and blow out connector,

terminals, harness wires with compressed

air or heated air to dry out the moisture.

Ensure the terminals are free from

corrosion. Any corrosion will necessitate

replacement of the com ponent to which the

corroded terminals are attached.

4. Check for moisture in and around the

Green seat belt pre-tensioner connector

– Refer to View D for location (between

seat and console).

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

NOTE: IF the DTC is logged as a HISTORY

code, the moisture that entered to cause the

code may have dried out and will not always

be present. IF the DTC is logged as a

FROZEN code, the moisture may still be

present and will require thorough drying out

and cleaning. Use of warm air will speed up

the drying out process.

5. Clear the DTC/s with Tech 2. Cycle

ignition once to confirm the DTC has been

cleared and does not reset.

IF YES – Go to Step 6

IF NO – Go to Service Manual Volume 7

(or SIP CD), Section 12M for SRS

Diagnostics for appropriate DTC/s, as

problem is not related to this information.

6. With the ignition ON, check for loose

connections, faulty wiring (at connectors

noted above) by wriggling/moving the

connectors.

7. Start and run the engine. Ensure the SRS

warning lamp does not stay illuminated.

8. Re-fit the previously removed trim

covers.

CLEANING PRECAUTIONS

It is suggested that you advise your

customers and your cleaning staff (including

any contracted cleaners) of the following

precautions:

Seat Belt Pre-Tensioner Connector (YB

207) Area: (between seat outer edge and

door, both sides)

• Do NOT use excessively wet cleaning

cloths, sponges or high powered steam

cleaning equipment on or around the seat

rail end covers and cover joints – Refer

View A.

• Clean this same area with a MOIST (not

dripping) cloth and wipe over the area to

remove any excess moisture.

• If steam cleaning, shampooing, etc, the

seats and carpets – place a rag over the

seat rail cover joint area to ensure no

moisture enters the joints and connectors

below them.

Seat Belt Pre-Tensioner Connector Area:

(between seat inner edge and console, both

sides)

• W hen cleaning in this area – place a small

plastic bag, split on one side - over the

Green connector to ensure no moisture

entry.

• If steam cleaning or shampooing the seats

and/or carpets – take extra care not to

allow any moisture near this connector.

WARRANTY CLAI M INFO RMATION:

As the conditions mentioned in this

“precautionary” bulletin are related to care and

cleaning procedures, the procedures advised

cannot be claimed under warranty.

Component replacement caused by care and

cleaning procedures as noted in this bulletin

must not be claimed under warranty.

Refer to f ollowing page f or all illustrations.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

Figure 1.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

WIRING ABRASION – INTERMITTENT

FAULTS

VT, WH

(GROUP 12) HINT

PROBLEM DESCRIPTION

A PIR has repor ted a possible cause of wiring

abrasion and intermitt ent elect rical faults.

The condition report ed is the wiring harness at

the LH rear of the engine compartment

rubbing on the body of the theft deterrent

horn. Refer Figure 1 for exact location.

The condition has the potential to cause

numerous intermittent faults, depending on

which wire is damaged.

This Techline is released to draw technicians’

attention to the possibility that some

intermittent faults may be caused by abraded

wires at the location shown. The harness

shown in Figure 1 should be inspected before

any extensive diagnosis work is undertaken.

SERVICE RECTIFICATION

Should a vehicle be found with the wiring

harness contacting the theft deterrent horn:

- Repair the harness as necessary,

- Move the harness away from the theft

deterrent horn by at least 15mm – Refer

Figure 1. Move the harness in it s retaining

clip if required, to ensure harness is

retained away from the horn.

WARRANTY CLAI M INFO RMATION:

Select appropriate Labour Operation Number

from the Wiring and Connector Warranty

Claim Submission Manuals in SIP, for VT

series, Figur e 7 , and WH series, Figure 7.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

FRONT SEAT INNER REAR RAIL

COVER DISLODGES

VT, WH

(GROUP 1)

PROBLEM DESCRIPTION

Front seat inner rear rail covers may be

dislodged by actions of rear seat passengers,

or items carried in rear footwell areas.

It is possible for the moulded retaining lugs in

the cover to be d amaged, and as a result, not

retain properly on the inner seat rail.

PRODUCTION RECTIFICATION

Revised front seat inner rear rail covers with

revised retention (metal spring clips) have

been fit ted to vehicles fr om:

ISOVIN: Build Date:

6H8VTX69SYL587197 08/05/00

SERVI C E RECTIFICATION

On complaint vehicles (built prior to the above

break point) where the f ront seat inner rear rail

cover/s dislodge - and the dislodged cover/s

do NOT have a metal retaining clip - the

following rectification should be carried out to

both covers:

1. Remove both front seat inner rear rail

covers – Refer Figure 1 for location.

2. Turn covers over, and using a sharp knife,

cut the two retaining lugs from the

underside of both covers – Refer Figure 2,

Diagram A, below.

3. Fit a spring clip (P/N 92144035) to both

covers as shown – Refer Figure 2,

Diagram B.

4. Refit the covers, which now appear as per

Figure 2, Diag ram C, to the seat inner rear

rails.

PARTS INFORMATION

NOTE: All VT & WH front seat inner rear rail

covers at HSPO have been superseded to the

new parts with metal retaining clips. Any parts

in Dealership parts s tock WITHOUT the metal

retaining clip should NOT be used for

repairs/replacement, but may be modified

prior to fitment to vehicles, as per the above

procedure.

Part No.: Descr i ption: Qty:

92144035 Clip, front seat inner

rear rail covers 2 (Per

Car)

WARRANTY CLAI M INFO RMATION:

Description Fit Clips to Both Front Seat

Inner Rear Rail Covers

Labour Op. No. C000415

Time 0.3 hr

Failure Code 55

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

Fig ure 1. Showing RH Front Seat (LH opposite)

Fig ure 2. Showing Revisions to Pre-Breakpoint Cover

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

REAR LICENCE PLATE ATTACHMENT

SCREWS REVISION

VX SEDAN

(GROUP 1)

Please pass this information on to your

Pre-Delivery personnel for action.

PROBLEM DESCRIPTION

Rear licence plate attaching screws provided

in standard licence plate fittings envelopes

(carry-over VT) are not long enough for VX

sedan rear licence plate installation. This is

because the décor panel thickness has been

revised.

In the first 1000 (approx.) VX vehicles

produced, there will be two longer scr ews (p/n

11045121) taped to the clear plastic bag

containing the “glovebox” material. These

screws are to be used for attaching the rear

licence plate on sedans only.

This action is being taken only until the

screws are added to the standard licence

plate attachments env elope.

PRODUCTION RECTIFICATION

The two longer screws (p/n 11045121, 19mm

long) will be included in the brown licence

plate attachments env elope from:

ISOVIN: Build Date:

6H8VXL69A1L639557 12/09/00

AT PREDELIVERY:

VX Sedans up to L639556:

Attach sedan rear licence plates with the two

longer screws (p/n 11045121) taped to the

clear plastic “glovebox” material bag.

VX Sedans from L639557 onward:

Attach sedan rear licence plates with the two

longer screws (p/n 11045121) that are

supplied in the brown licence plate

attachments envelope.

DOOR HANDLE & LOCK ROD – CO-

ORDINATED REPLACEMENTS

(GROUP 1)

The information in this Techline bulletin is

reproduced from HSPO Parts Techline PT47,

dated May 18, 2000. Please refer t o that lett er

(retained by your Parts Department) for full

details.

PROBLE M DES CRIPTIO N

Door handles were revised in production

(refer breakpoint below), and earlier design

parts are no longer available.

W hen later design door handles are fitt ed, the

matching door rod must also be fitted.

PRODUCTI O N RECTIFICATION

Revised and strengthened door handles were

fit ted to vehicles fr om:

ISOVIN: Build Date:

6H8VTK69HYL526300 05/11/99

SERVICE RECTIFICATION

When fitting a new door handle to a vehicle

built prior to L526300 - –fit the door handle/rod

combination as shown below.

PARTS INFORMATION

Vehicles Up to L526299

Handle Rod

Front Door

Outer, RH 92085571 92087513

Rear Door

Outer, RH 92085573 92087515

Front Door

Outer, LH 92085574 92087513

Rear Door

Outer, LH 92085574 92087514

WARRANTY CLAI M INFO RMATION:

Use existing “Warranty Information” in SIP.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

LOW OIL PRESSURE WARNING

(INTERMITTENT)

VT/WH with Gen III V8 Engine

(GROUP 6A)

PROBLEM DESCRIPTION

Customers may complain of oil pressure

warning lamp and audible warning chime

coming on intermittently, or complain of “ noisy

valve train” – EG: during starting, on heavy

acceleration, or even at random times. These

complaints may be intermittent and occur for

variable lengths of time - it may not be

possible f or technicians to diagnose the cause

as the complaints are not easily “repeatable”.

PRODUCTION RECTIFICATION

Oil pumps with verified OK machining have

been used in production from Engine No.:

VF002061072 (for reference) - this engine

was used in:

ISOVIN: Build Date:

6H8VXK35F1L638782 08/09/00

SERVI C E RECTIFICATION:

Caution Notes:

• Diagnosis to define possible causes other

than oil pump (Steps 1 & 2) must be done.

• Where the full procedure is carried out, the

engine must be removed f or this procedure,

to ensure correct oil pan fitting. DO NOT

attempt to carry out this procedure with

engine “in – vehicle”.

• Fit a new O ring on pickup tube to pump

joint.

• Ensure all fasteners on the oil pump,

pickup, oil pan, etc, are torqued as per the

service Manual/SIP CD instructions.

• Clean out the oil pan before re-assembly to

ensure there is no possible contamination.

Any vehicle presented with the any of the

above complaints should have the following

diagnosis and repair procedure carried out:

1. Check engine oil level – correct if

required, or continue to Step 2 if level OK.

2. Check oil pressure with a mechanical oil

pressure gauge and with Tech 2 and

compare results of both checks to confirm

correct oil pressure sender signal. If a

sender fault is defined, replace the sender

unit.

Note: The mechanical gauge can be

connected at one of three possible locations:

- Remove oil filter and use adaptor J42907

as per VT Service Manual, page 6A3-20,

Section 2.4.

- At oil gallery plug at RH rear of engine

block, directly in front of crank angle

sensor.

- At oil gallery plug at LH front of engine

block directly above oil filter.

Following a cold start, with engine running at

idle in Park or Neutr al, the oil pressure should

be in excess of 150 k Pa.

Should Tech 2 AND the mechanical gauge

both indicate that the pressure (150 kPa) is

NOT reached immediately following start-up,

carry out the following procedure:

3. Remove engine and then remove oil pan

– as per VT Series Service Manual/SIP

CD, Volume 14A, Page 6A3-85 (Engine &

Oil Pan), and pages 6A3-101 (Oil Pump).

4. Check for loose retaining bolts - oil

pump to block , and oil pickup tube t o pum p

– looseness indicates possible pressure

loss points.

5. Remove oil pickup tube and ensure O

ring is correctly fitted between pickup tube

and pump – damaged or missing O ring

indicates a leak point.

6. Ensure oil pickup tube is not blocked or

partially blocked by any foreign material –

this would create a pressure reduction in

the oil system.

NOTE: Steps 4, 5, 6 are required to ensure

identification and correction of any conditions

that may contribute to loss of oil pressure.

7. Replace oil pump, regardless of findings

in Steps 4, 5, 6 above - with a new oil

pump assembly.

8. Fit a new O ring – oil pickup tube to pump;

ensure it is pr operly installed and lubricated

with clean engine oil prior to assembly to

ensure no damage occurs during

assembly.

9. Measure oil pressure, after re-assembly

and fitting engine to vehicle, confirm that it

exceeds 150 kPa at idle.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

PARTS INFORMATION

Select parts from PartFinder. All oil pumps in

HSPO stock, and those previously sold to

Distributors/Dealers have verified OK

machining.

WARRANTY CLAIM INFORMATION:

Use existing “W arranty Information” in SIP as

shown:

Description Pump Asm. Engine Oil,

Replace (Gen 3 V8).

Labour Op. No. J316500

Time 6.5 hr

Failure Code 61

HEAT SHIELD FOR DUAL COUPLING

PROPSHAFT - 1600 & 2100KG TOW

BAR PACKAGES

WH, VX & VT

(GROUP 1)

The following information is repeated from All

Dealer Letter: DL 46/00, to ensure all

Dealership Service personnel are aware of the

information noted. Please also circulate this

bulletin to Pre-Delivery personnel and any

technicians involved in accessory fitting (tow

bar heat shield information).

When fitting 1600 kg or 2100 kg HSPO

Accessory Tow Bar Packages to VX vehicles,

or VT vehicles fitted with dual coupling

propshaft (only), a new centre bearing heat

shield (p/n 92143924) must also be fitted as

shown on the instruction drawing shown on

Page 37 of this bulletin.

HSPO tow bar packages are currently being

updated with the new heat shield and revised

instruction drawings.

DOOR LOCK ACTUATOR WIRING

DIAGRAM

VS with VT LOCK ACTUATORS

(GROUP 12)

PROBLE M DES CRIPTIO N

Late build VS Series vehicles were fitted with

VT door lock actuators.

A wiring diagram for this installation has not

previously been published.

PRODUCTI O N RECTIFICATION

VT door lock actuators were fitted to VS

vehicles from:

ISOVIN: Build Date:

6H8VSK80UVL221394 13/03/97

SERVICE RECTIFICATION

During diagnosis – check the type of lock

actuator s fitted to the vehicle – the break point

above will define this.

NOTE: there may be a small number of

vehicles built out of sequence that will still

have VS lock actuators, and thus a visual

check of actuators may be required – to

ensure VS or VT actuators are fitted. In

addition, in this installation, a small “patch”

harness is f itted between the actuator and the

door wiring harness – where VS actuators

connect directly to the wiring harness..

The following page carries a wiring diagram

for diagnosis of VS Series III vehicle lock

circuits.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

DRIVER'S DOOR

JAMB SWITC H

YB175

IGNITION

F14

E20

P/ B (39)P (3)

YB176

YB174

YB173

YB57

YB77

YB90

YB26

YB90

YB25

YB76

YB57

YB76

LOC. E 3

YB57

YB90

YB76

YB57

YB29

YB25

YB26

YB77

YB173

YB174

YB173

YB1

YB173

YR10

YR35

YB176

YB173

BCM

BATTERY

F20

F31

B11

UNLOCK

REQUEST

DO OR LOC K POWER

BATTERY MAIN POWER

VS CENTRAL DOOR LO CKING WITH VT ACTUATORS

DRIVER'S

DOOR

LOCK

SWITCH

UNLOCK

LOCK

O/B (7 4 0 )

BR/O (194)

DRIVER'S

DOOR

LOCK

ACTUATOR

O/V (44 0)

(1040)

R (2 )

REAR

COMPARTMENT

LOCK A CTU ATOR

(WAGON ONLY)

ELECTRONIC

EARTH

T12J2136

B/ Y (155)

LOC. E 3

DRIVER'S

DOOR UNLOCK

RELAY

HIGH

CURRENT

EARTH

DOOR

UNLOCK

DRIVE

DOOR LOCK

DRIVE

C13

C26

B10

B/ Y (295)

B\ BLU

(394)

BR/O

(194)

B/ R (29 4 )

B/ G (151)

UNLOCK RELAY

LOCK RELAY

DRIVER'S

DOOR

REQUEST

UNLOCK

LOCK

REQUEST

LOCK &

DEAD LOCK

REQUEST

DRIVER'S

DOOR OPEN

C22

BR/W ( 197)

GY/W (12 6)

C21

BR/R (1 9 5 )

C20

LG/ Y (193)

DRIVER'S DOOR

UNLOCK DRIVE

BLU/ B (293)

L.H.R.

DOOR

LOCK

ACTUATOR

L.H.F.

DOOR

LOCK

ACTUATOR

FROM

IGNITION

SWITCH

R.H.R.

DOOR

LOCK

ACTUATOR

B/ BLU (156)

C12

DE AD L OCK

RELAY

DEADLOCK

DRIVE

V/W (394)

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

FUEL PUMP ELECTRICAL CIRCUIT

DIA GNOSTIC CHART CORRECTION

VT/VX (non-S/C V6)

(GROUP 6M)

PROBLEM DESCRIPTION

The previously published CHART A4.1 V6

PCM – NON SUPERCHARGE ENGINE

FUEL PUMP ELECTRICAL CIRCUIT,

contained a number of errors regarding fuse

and terminal numbering.

SERVI C E RECTIFICATION

Revised diagnostic chart A4.1, on the

following page, rectifies these errors and

contains additional steps to improve electrical

circuit diagnosis.

Revisions to the c hart are shown in bold text,

and two new steps (16, 17) have been

inserted into the procedur e.

It is recommended that this chart is copied

and pasted over the existing chart in VT

Series Service Manual, Volume 3, Section 6C

POWERTRAIN MANAGEMENT – V6

ENGINE.

As this chart also applies to VX Series

vehicles, refer to this Bulletin for diagnosis

until the Service Information Package (SIP) is

updated to include this revised chart.

DIAGNOSTIC CHARTS - V6 ENGINE 6C1-2A-57

CHART A-4.1 V6 PCM NON-SUPERCHARGED ENGINE

FUEL PUMP ELECTRICAL CIRCUIT

STEP ACTION VALUE YES NO

1. Was the "On-Board Diagnostic" (OBD) System Check

performed? Go to Step 2. Go to OBD

System Check in

this Section.

2. Check Fuel Pump fuse. ("F/PMP" fuse F28 in

engine compartment fuse and relay centre)

Is the Fuel Pump fuse blown ?

Go to step 3 Go to step 8

3. 1. Ignition "OFF".

2. Disconnect Fuel Pump electrical connector to pump.

3. Backprobe Fuel Pump Relay harness connector for

Fuel Pump power feed circuit with a test light

connected to + battery terminal.

Is the test light "ON" ?

Go to Step 15 Go to step 4

4. 1. Ignition "OFF".

2. Reconnect Fuel Pump electrical connector.

3. Replace Fuel Pump fuse F28 ("F/PMP").

4. Ignition "ON".

5. Recheck fuse.

Is Fuel Pump fuse OK ?

Problem was an

intermittent short

to earth.

Go to step 5

5. Check for short to earth in Fuel Pump power feed circuit.

Was a problem found? Verify Repair Go to step 6

6. Check for shorted to earth Fuel Pump .

Was Fuel Pump shorted to earth ? Verify Repair Go to step 7

7. Replace Fuel Pump Relay.

Is action complete? Verify Repair

8. 1. Ignition "OFF" for 10 seconds:

2. Disconnect Fuel Pump Relay connector from relay

housing bracket.

3. With Fuel Pump Relay connected, probe relay

connector terminal "5" with test light connected to

earth.

4. Using TECH 2 scan tool, Select FUEL PUMP .

5. Turn Fuel Pump "ON" and "OFF"

Is test light "ON" and "OFF" when Fuel Pump is

"ON" and "OFF" ?

Go to Step 9 If Test

Light stays

"OFF", Go to

Chart A-4.2 in

this Section

-----------------------

If Test Light

stays "ON", Go

to Step 16

9. 1. Ignition "OFF".

2. Disconnect Fuel Pump Relay.

3. Apply +12 volts to Fuel Pump Relay terminal "5".

4. Check that the Fuel Pump is running, check by

listening for Fuel Pump operation in fuel tank.

Is Fuel Pump running ?

Go to Step 10 Go to Step 11

10. 1. Fuel Pump electrical circuits are OK.

2. Reconnect Fuel Pump Relay.

To complete testing of the fuel delivery pressure

system, continue to Chart A-4.3

Go to Chart

A-4.3 in this

Section

11. Check for faulty connection at Fuel Pump and relay.

Is connection faulty? Verify Repair Go to Step 12

12 Check for open in Fuel Pump power feed circuit.

Was a problem found? Verify Repair Go to Step 13

13. Check for open in Fuel Pump .

Is Fuel Pump open? Verify Repair Go to Step 14

14. If both circuits check OK, replace Fuel Pump .

Is action complete? Verify Repair

15. Check for and repair short to earth in Fuel Pump power

feed circuit.

Is repair complete?

Verify Repair

16. 1. Ignition "OFF".

2. Disconnect Fuel Pump Relay.

Is the test light "OFF"?

Go to Step 17 Go to Step 18

17. Repair short to voltage in circuit 465.

Is action complete ? Verify Repair

18. Repair short to voltage in circuit 120.

Is action complete ? Verify Repair

Page 35 (Nov,. 2000 Techline)

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

WH UPGRADE (OPTION A8A)

(GROUP OB)

The following information is repeated from All

Dealer Letter: DL 46/00, and is repeated in

this Techline only t o ensure that all Dealership

Service personnel are aware of the

information noted. Please also circulate this

bulletin to Pre-Delivery personnel and any

technicians involved in accessory fitting (tow

bar heat shield information).

This is t o advise dealers hips of chang es being

introduced into WH Statesman models with

Gen 3 V8 engines under production option

code A8A. These changes commenced in

vehicle production:

ISOVIN: Build Date:

6H8WHY19FXL626038 09/08/00

Some of the more significant changes are as

follow s :

Upgraded Gen 3 V8 Engine

Includes revised inlet manifold, injec tors , f uel

rail, flexplate, etc.

Powertrain Control Module

The Powertrain Control Module (PCM) and its

calibration are both new and are not

interchangeable with earlier (MY2000) engine.

The new PCM calibration software is in TIS

version 13B.

Dual Coupling propshaft

The propshaft is a new design which helps

reduce driveline disturbances. Holden’s

warranty policy on this new propshaft is the

same as for current model, IE: if a propshaft

develops a fault within warranty it is to be

replaced with a complete new propshaft

assembly ex HSPO. Note that the rubber

couplings are included as part of the

assembly. Replaced propshafts are to be

tagged and held until called back via the

REPAC report.

For retail repairs, a limited range of

component parts are replaceable with parts

obtained from HSPO or if required,

changeover propshaft assemblies may be

obtained from Hardy Spicer outlets - as shown

on page 38 of this Bulletin.

FITMENT OF 1600 & 2100KG TOW BAR

PACKAGES

NOTE: When fitting 1600 kg or 2100 kg tow

bar packag es t o WH with A8A upgrade, a new

centre bear ing heat shield p/ n 92143924 must

also be fitted as shown on the instruction

drawing on the next page of this bulletin.

HSPO tow bar packages are currently being

updated with the new heat shield and revised

instruction drawings. Should you require

further information or clarification on tow bar

packages please call Alan Baker on telephone

number (03) 9797 7094.

NOTE: A further package of changes known

as production option code U4B will be

introduced into WH models at the same time

as VX commences product ion.

Please ensure your pre-delivery and service

staff are made aware of the contents of this

letter.

HOLDEN SERVICE TECHLINE _________________________________________________________ NOVEMBER 2000

HARDY SPICER BRANCHES

Information current as at August 2000

QLD

259 Cullen Avenue

EAGLE FARM 4009

PH: (07) 3868 2344

FAX: (07) 3868 2110

319 Nebo Road,

MACKAY 4740

PH: (07) 4952 3488

FAX: (07) 4952 2048

728 Ingham Ro ad

BOHLE 4818

PH: (07) 4774 5399

FAX: (07) 4774 4200

388 Newbridge Road

MOOREBANK 2170

PH: (02) 9600 6333

FAX: (02) 9602 1947

NSW

METROPOLITAN DRIVESHAFTS

11 Ja me s Ru se Dri ve

GRANVILLE 2142

PH: (02) 9637 7933

FAX: (02) 9682 6105

NEWCASTLE

Lot 30 Rural Drive

SANDGATE 2304

PH: (02) 4968 0400

FAX: (02) 4968 0407

1/9 Monterey Road

DANDENONG STH. 3175

PH: (03) 9792 4744

FAX: (03) 9792 3911

VIC

1488 Hume Highway

CAMPBELLFIELD 3061

PH: (03) 9357 1675

FAX: (03) 9357 2400

TAS

Duncan Street,

MONTROSE 7010

PH: (03) 6272 6907

FAX: (03) 6272 0671

56-58 Churchill Rd. North

DRY CREEK 5094

PH: (08) 8349 6400

FAX: (08) 8349 5264

493 Gr eat Eastern Highway

REDCLIFFE 6104

PH: (08) 9277 2966

FAX: (08) 9478 2945

7 Keogh Way,

KALGOORLIE 6430

PH: (08) 9091 1443

FAX: (08) 9091 1463

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

8 8

FRONT SEAT LUMBAR SUPPORT ASM.

– REPLACEMENT PROCEDURE

VT, VX, WH (with Lumbar Adjuster)

(GROUP 1) TL011-0105

PROBLEM DESCRI PTION

The f ront seat lum bar support has recently been

made available as a replacement part. Prior to

this, the complete front seat back had to be

replaced for any lumbar support failure. Some

common complaint s are:

- Lumbar support does not operate (due to

deformation of the lumbar support upper

bracket).

- An audible “click” noise due to contact

between front seat back cover and lumbar

support assembly.

SERVICE RECTIFICATION

The following procedures describe replacement

of the lumbar support assembly. Removal of

seat f r om vehicle is NOT required.

Removal of lumbar support asm.:

1. Disconnect the battery earth and positive

leads.

NOTE: If the vehicle is equipped with side

impact air bag s (SIAB), wait at least 10 seconds

befor e per forming any work on t he vehicle.

2a. For all VT vehicles without SIAB:

Remove the lumbar support knob by pushing

seat back cover in far enough to expose circlip,

remove circlip and remove lumbar support

adjusting knob - Refer Figure 1a.

Figure 1a.

2a. For all VT with SIAB, all WH and all VX

vehicles

Pull the seat side cover away from seat cushion,

forward of the lumbar support adjuster knob - the

lumbar support adjuster knob is part of the side

cover assembly and will come off with the seat

back cover when the sides are pulled apart. Ref er

Figure 1b (without deflector ring) or Figure 1c

(with deflect or r ing).

T12M137

Figure 1b.

Figure 1c

3. Insert a screwdriver between the front seat

back cover and seat back and push up on the

retaining clip (2 places) while pulling the

bottom of the back cover out, away from seat,

to release lower retaining clips, and then pull

back cover down to release top retainers.

Remove front seat back cover. Refer Figure 2

below.

Update

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

9 9

Figure 2.

4. While holding head restraint height adjuster

lock in, pull head restraint completely out of

guide. Refer Fig ur e 3 below.

5. From the back of the seat, squeeze the

locking prongs of head restraint guide together

while pulling top of guide out of seat back

assembly. Ref er Figure 3 below.

T12M110

Figure 3.

6. Pull the four ‘J’ strips away from the seat

frame, then move cover and pad assembly

forward, well clear of seat back frame. Refer

Figure 4 below.

Figure 4.

7. Release the tie strap on the lumbar support

actuator cable by squeezing the tangs on the

cable tie retaining clip (“3” in Figure 5 below)

together and pushing tie strap retaining clip

throug h seat back fr am e hole.

8. Push down the top of the lumbar support to

disengage the two friction guides/retainers (“2”

in Figure 5 below) from the guide rails (“4” in

Figure 5 below) on the seat back, allowing

lumbar support t o swing freely.

9. Move the lumbar support forward and push

the lumbar support downward on each side, in

turn, to release the bottom hooks from the seat

frame.

10. While slightly compressing lumbar support

assembly by hand to release cable (“5” in Fig ure

5 below) tension, disengage cable from the top

of t he lum bar support.

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

10 10

T21A7004

Figure 5.

11. Remove adjusting cable (1) f rom adjust er (2)

by unclipping outer casing (3) of cable from

adjuster and removing cable assembly. Refer

Figure 6 below.

Figure 6.

12. Remove lumbar support unit fr om seat.

Replacing lumbar support asm.:

1. Attach new lumbar support (p/n 92143625) to

the lumbar support actuator (knob end) and

lumbar adjusting cable (Refer to Figure 5 above

for locations).

2. Locate the bottom hooks of the lumbar

support to the bar on the seat frame. Pull each

side upwards, in turn, to “click” into the position

on the bar.

3. Ensure plastic friction guide/retainers are

installed (supplied with new lumbar support) at

the two points (“2” in figure 5) at the top of the

lumbar support assembly. Push the top of the

lumbar support to engage the two retainers with

the guide r ails ( “4” in figure 5)

4. Locate cable tie (supplied with new lumbar

support assembly) t o the hole in the brace panel

(“3” in figure 5) and close the tie around the

actuator cable, tighten strap to secure, and cut

off excess length of t he strap. (Ref er to Figure 5

for locations).

5. Reinstall the seat back foam to the seat

frame, and attach with the four “J” strips. (Refer

to Figur e 4 above.)

6. Replace the two head restraint guides by

pushing t hem throug h the holes in the t op of the

(refer to figure 3 above) and reinstall the head

retraint.

7. Replace the seat back cover to the seat frame

using the or iginal seat back cover clips. I f these

clips are damaged replace with new clips

92140918. (Ref er to fig ure 2 above)

8a. For all VT vehicles without SIAB:

Reinstall the lumbar support spacer and adjuster

knob to the splined shaft and refit circlip. Refer

Figure 1a.

8b. For all VT with SIAB, all WH and all VX

vehicles. Carefully align and reinstall the

lumbar adjusting knob (part of seat back

cover/side cover assembly) back onto the

splined adjuster shaft. Refer Figur es 1b or 1c.

Reinstall ation Precautions:

1. Ensure the head r estraint g uide with adjusting

lock is installed on the correct side, ie. side with

notches on the head rest r aint .

2. Reconnect battery earth and positive leads,

switch ignition on, and obser ve the SRS warning

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

11 11

lamp in the instrument cluster. The warning

lamp should be illuminated for approximately

five seconds. During this period the SDM

perfor m s a wiring and system self check.

PARTS INFORMATION

Part No.: Description: Qty

92143625 Lum bar Support Asm. 1

WARRANTY CLAIM I NFORMATION:

Description Lumbar Support - Replace

Labour Op. No. C502750

Time 0.6 hr

Failure Code As applicable

INSTRUMENT CLUSTER LENS

REPLACEMENT

(GROUP 12) TL011-1207

PROBLEM DESCRIPTION

Some technicians are not aware that the

instrument cluster lens is replaceable, as TIS

instructions and a Warranty Labour Operation

Number have not been available – to date.

SERVICE RECTIFICATION

If an instrument cluster requires a lens

replacement:

- Remove the instrument cluster as per TIS

2000 instructions,

- Depress the nine retaining lugs around the

outside of the lens and remove the lens fr om

the cluster,

- Fit a new lens – taking care to insert the

odometer reset button through the hole in

the lens, then evenly push the lens lugs into

the cluster receptacles until they “snap” into

place.

- Refit the cluster t o the vehicle.

PARTS INFORMATION

The instrument cluster lens is available from

HSPO – refer PartFinder for part num ber .

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time Manual

as follows – this new labour time for TS will be

added to a f uture SIP CD release:

Description Lens, Inst. Clust er -

Replace

Labour Op. No. N300600

Time 0.7 hr

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

12 12

ELECTRONIC CLIMATE CONTROL

ILLUMINATION GLOBE REPLACEMENT

VT, VX, WH

(GROUP 2 & 12) TL011-0203

PROBLEM DESCRI PTION

There have been instances where ECC module

assemblies have been replaced for complaint of

“poor illumination”. In all these cases the

assemblies were fixed by replacement of faulty

globes.

All six globes in the ECC control module are

serviceable and may be obtained through

HSPO. The replacement procedure is

described below.

SERVICE RECTIFICATION

1. Remove the ECC module as per procedure

in SIP CD.

2. Place the ECC module onto a clean rag or

cardboard (t o avoid scratching) face down.

3. Remove the 5 screws retaining the rear

housing. Detach the rear housing carefully.

NOTE: Do not lift the facia panel, turn

upside down or remove the circuit board

as damage may occur.

4. Identify where the suspect faulty globes are

located (There are four, clear globes for

buttons and two, green globes for LCD

screen.)

5. Insert a small flat blade screwdriver into the

slot provided at the rear of the globe holder

then twist anticlockwise until the holder

stops. Gently lift out t he globe holder.

6. Measure the resistance across the globe. A

correctly operating globe should be in the

range of 10 to 13 ohms. I f outside this r ange

replace the globe. If globe resistance is

within 10-13 ohms then the globe circuit is

suspect. First try another known good g lobe

befor e r eplacing module.

7. After globe replacement, reassemble the

rear housing to the front facia with the 5

screws, reconnect the 2 ECC electrical

connectors and reinstall module into

instrument panel.

PARTS INFORMATION

Part No.: Description: Qty:

92140515 Globe and holder

illumination - clear . As

reqd

92140514 Globe and holder

illumination – g r een. As

reqd

WARRANTY CLAIM I NFORMATION:

Use infor m at ion as shown:

Description Globe Heater & A/C

Control - Replace 1 or all

Labour Op. No. N221990

Time 0.4 hr

Failure Code 50

Update

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

13 13

LOWER DÉCOR PANEL CONTACTS

REAR BUMPER FASCIA

VT SEDAN

(GROUP 1) TL011-0103

PROBLEM DESCRI PTION

The lower décor panel contacts t he rear bumper

fascia when the decklid is closed which can

result in damage to the paint finish. Damage

usually occurs at corners.

This condition can be caused by a number of

factors: e.g. Slamming the decklid shut

(overtravel); incorrectly adjusted striker;

incorrectly adjusted decklid bumpers; or

clearance between décor panel and rear fascia

is below assembly specification.

PRODUCTION RECTIFICATION

Revised lower décor panels which provide

increased clearance have been fitted to vehicles

from:

ISOVIN: Build Date:

6H8VTK69FYL620686 28/07/00

SERVICE RECTIFICATION

On complaint vehicles do the following. Adjust

decklid striker and bumpers up as high as

possible whilst ensuring that decklid is not

overflush to r ear quarter panels. Now recheck if

décor panel still contact s r ear fascia on closure:

• If not contacting: check that decklid still

seals okay. Repair any paint damage¯ on

fascia prior to return to customer.

• If still contacting: fit a new lower décor

panel. Revised lower décor panels are

identif iable by their chamf ered corners. Repair

any paint damage¯ on fascia prior to return to

customer.

¯Obtain zone approval prior t o paint r epair.

PARTS INFORMATION

Part No.: Description: Qty:

92094365 Panel asm lower

decor 1

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time Manual

in SIP, as shown. Claim for paint repairs in

usual manner.

Description Lower décor panel asm

Replace

Labour Op. No. C896950

Time 0.3 hr

Failure Code 62

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

14 14

FRONT CUP HOLDER LATCH

REPLACEMENT

WH, VX

(GROUP 1) TL011-0106

PROBLEM DESCRI PTION

The front (console mounted) cup holder cover

latch mechanism may fail to latch properly

(cover may not ‘latch’ open or ‘lat c h’ closed) .

Technicians are replacing the whole cup holder

assembly – when only the latch requires

replacement.

SERVICE RECTIFICATION

If you have a cup holder where the latch only

has failed (it does not open properly, or will not

hold the cup holder closed, et c,) fit ONLY a new

latch assembly – DO NOT replace the whole

cup holder!

The following advance copy of cup holder/latch

removal and installation procedures should be

used for replacements. This information will be

added to f uture versions of SIP.

1.4 CUP HOLDER

Remove

1. Open the cupholder lid ( 2) .

2. Grasp the rear of the cupholder assembly (1)

and press forward to disengage the rear

retaining t ang (3) from the centr e console.

3. Withdraw the cup holder from the centre

console, taking care not to damage the front

locating tab (4). (Refer to Figur e 1A3- 5)

Figure 1A3-5

LATCH REPLACE

1. With the cup holder removed from the centre

console and the lid (2) open, grasp with both

hands and press the latch ( 1) f ir mly up out of

cup holder with thumb.

2. Carefully press replacement latch into place

by hand, ensuring the latch locking tabs are

correctly engaged.

CAUTION: Do not press directly on the latch

jaws.

Reinstall

1. Engage the cup holder front locating tab in

the slot in the centre console and press the

rear edge firmly into place until rear locking

tab is correctly engaged.

NOTE: If the rear locking tab on the cup

holder does not correctly engage, open the

cup holder lid to gain access. (Refer to

Figure 1A3- 6 below)

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

15 15

Figure 1A3-6

PARTS INFORMATION

Order a new latch from HSPO using the

following part number (which will be added to

fut ure Part Finder information) .

Part No.: Descri pt i on: Qty:

92103515 Latch Asm . – Cup

Holder 1

WARRANTY CLAIM I NFORMATION

Use existing Labour Time information in SIP

“Warranty Information” as follows:

Description Cup Holder - Replace

Labour Op. No. C457300

Time 0.2 hr

Failure Code 37

Note: Replacement of cup holder assemblies

where only the latch is at fault will not be

accepted under warranty.

INTERIOR REAR VIEW MIRROR LOOSE OR

DISLODG ES FROM PIVOT

JS, TS

(GRO UP 1) TL011-0101

PROBLEM DESCRIPTION

Interior rear view mirror becomes loose (will not

retain adjustment) in its m ounting ball socket .

PRODUCTION RECTIFICATION

Revised rear vision mirror assemblies with

revised mounting ball sock et material have been

fitted to vehicles from :

For JS 5-Door Hatch Model s:

ISOVIN: Build Date:

W0L0JBF68Y7097903 22/06/00

For JS Sedan/Wagon (Local Built):

ISOVIN: Build Date:

WOLOJBF19YL633325 07/09/00

TS Model: No breakpoint information is

available.

SERVICE RECTIFICATION

If a rear vision mirror is presented which will not

hold its adj usted position, r eplace the mirror with

a new part fr om HSPO .

PARTS INFORMATION

Part No.: Description: Qty:

90541140 Rear View Mirror Asm . . 1

All parts in stock at HSPO, at time of bulletin

printing, have been manufactured after a

“revised material” breakpoint date as advised by

our supplier (not visible on part) .

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time Manual

in SIP.

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

16 16

CRUISE CONTROL “CLUNK” NO ISE ON

ENGAGE/DISENGAGE

WH, VT, VX

(GROUP 12) TL011-1209

PROBLEM DESCRI PTION

Some critical customers may be concerned

about a very light “clunk” noise when cruise

control is engaged or disengaged.

Disengagement noise is generally louder than

engagement noise.

SERVICE RECTIFICATION

When customers complain of a “clunk” noise on

cruise control engagement or disengagement,

carry out the following procedure:

1. Remove the three cruise control module

mounting grommets and screws (located on

the RHF fender skirt in the engine

compartment).

2. Fit three new mounting grommets (p/n

25074502) and screws (p/n 92138227).

3. Torque scr ews to 2-5Nm O NLY.

Note: over-torque of the screws will result in

great er noise t ransfer.

4. Road test to confirm reduced

engagement/disengagement clunk noise.

Aft er application of this procedure, t here may be

a minimal engage/disengage noise that may be

noticed by very critical customers only.

Should this occur – please advise by PIR.

PARTS INFORMATION

Part No.: Description: Qty:

25074502 Grommet, Cruise

Control Mounting 3

92138227 Screw, Cruise

Control Mounting 3

WARRANTY CLAIM I NFORMATION:

Use the f ollowing information to claim for the

above procedure:

Description Fit Revised Cruise Control

Module Mountings

Labour Op. No. N000327

Time 0.3 hr

Failure Code 40

BLAUPUNKT SECURITY CARD –

REPLACEMENT CARDS

JS, TS, SB

(GROUP 12) TL011-1202

PROBLEM DESCRIPTION

Until release of this Techline bulletin,

replacement Blaupunkt audio unit security cards

have not been available. No replacement card

could be supplied to owners who lost cards.

SERVICE RECTIFICATION

Replacement Blaupunkt audio unit security

cards are now available from HSPO .

PARTS INFORMATION

Part No.: Descri ption: Qty:

92057960 Security Card 1

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

17 17

ENGINE STALL ON DECELERATION OR

HIGH ENGINE IDLE

JR, JS, with C20SEL or C22SEL Engine

(GROUP 6 M) T011-6M01

This Service Techline must be used in conjunction

with the previous Techline on this same subject,

in Issue 10/99, page 15. This Techline provides

an additional procedur e (Base idle adjustment) as

an interim action prior to availability of a revised

IACV and software, planned for introduction in

2001.

PROBLEM DESCRI PTION

With vehicle stationary, the engine idle is too

high; EG: 1000 RPM+, and engine may later stall

or the idle may remain high.

This is caused by a build-up of engine by-pass

gases and IACV solenoid shaft/bearing wear

particles on the IACV solenoid shaft, which

causes the IACV to stick at any point in its

operating range. This will result in either too high

or too low IACV air entry to the throttle body and

engine.

When the IACV subsequently “unsticks” and

returns to normal operation, the result may be

a stall or higher than normal idle RPM. It is

not possible to effectively clean the IACV to

correct this condition.

PRODUCTION RECTIFICATION

PCV oil separators have been fitted to vehicles

fr om t he following breakpoint s:

JS:

Engine Number: C22SEL25013594

ISOVIN: W0L0JBF19YL518348

Build date: 30/08/99

C20SEL Engines:

Engine Number: C20SEL25031355

Engine build date. 15/ 09/ 99

SERVICE RECTIFICATION Part 1:

FOR COMPLAINT VEHICLES WITH C20SEL &

C22SEL ENGINES BUILT PRIOR TO THE

ABOVE BREAKPOI NTS,

These vehicles should have an oil separator f itted

as per the instructions provided in Techline Issue

10, 1999, Page 15 (same title) which is readily

available on the SIP CD.

NOTE: A revised PCV system routing that

enabled deletion of the PCV oil separator was

introduced from the following breakpoint: (For

more details refer Issue 5/2000, page 10)

ISOVIN: W0L0JBF19YL557427

Build date: 16/02/00

SERVICE RECTIFICATION Part 2:

BASE IDLE SETTING FOR ALL VEHICLES:

Before carrying out the following procedure, with

engine stopped and ignition ON, connect Tech 2

and check for DTC’s. I f any are stored, correct the

fault defined before progressing. This procedure

provides a “base idle” to prevent stalling in case

of a sticking IACV, however, the potential exists

for other idle quality problems – EG: “hunting”

high idle speed, etc, but these generally will be

‘transparent’ to the customer. If complaints arise

regarding hunting or high idle speed, the above

(complete) procedure can be repeated. DO NOT

clean the throttle blade or throttle body internally

during t his pr ocedur e!

Aft er a PCV oil separator has been f it ted:

1. Inst all a new IACV and gask et . I f gask et has a

“vee” notch on outer edge, it must f ace the top

of t he I ACV flange on assembly.

2. Start engine and warm up to operating

temperature.

3. With Tech 2 connected, engine running

(coolant temp. gr eater than 85°), A/C (if fitted)

ON and active – loosen the idle stop screw

lock nut and wind up the idle screw (throttle

stop) until the engine idles at approx.

1400RPM.

4. With one hand on the throttle cable,

disconnect the IACV connector and modulate

the engine RPM with the cable so that the

engine does not st all.

5. With the IACV now disconnected, and the

throttle resting against the stop, the engine

should idle at approx. 500-600RPM. Fine tune

the idle speed using the throttle stop screw –

to 512RPM (as near as possible), make sure

the A/C is active to allow f or maximum load.

6. Tighten throttle stop screw lock nut and

confirm that idle RPM is still 512RPM. Re-

adjust if required to maintain 512RPM.

7. Apply a spot of yellow paint on interface of

throttle stop screw/lock nut/throttle body (as

per original seal) for identification of retention

of adj ust m ent.

8. Turn the engine OFF. Reinstall IACV

connector then turn the ignition ON & OFF

(removing the key from ignition) – seven

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

18 18

times with a five second pause after removing

the key from the ignition. This teaches the

engine management system its new idle

software switch position.

9. Start the engine and check, using Tech 2,

scroll through the Engine Data List to

Simulated Idle Switch. Ensure that this

parameter reads “Active” and that the IAC

integrator steps are no less than 25, once idle

has been established. (Note: A/C OFF, no

load on engine, and in Neut r a l) .

10. Check with Tech 2 that idle speed is correct,

IE: engine idle speed is within ± 80RPM of

“Desired Idle Speed” .

11. Using Tech 2 – still in the Engine Diagnostics

area, select Programming/Reset init. ECU

Code - this will reset t he I ACV lear nt values.

12. Road test vehicle and confirm original

complaint does not exist.

PARTS INFORMATION

For Part 2, Base Idle Procedure ONLY:

Part No.: Description: Qty

90411546 Valve – Idle Air Control (IAC). 1

90466220 Gasket - IACV 1

For Procedure I Part 1 & 2: where PCV Oil

Separator is r equired:

Part No.: Description: Qty

90411546 Valve – Idle Air Control (IAC). 1

90466220 Gasket - IACV 1

09193502 Separator – PCV Oil 1

24421017 Hose – PCV Vent 2

90467971 Clamp – Vent Hose 2

WARRANTY CLAIM I NFORMATION:

Claiming for correction of any DTC’s that may

be found on initial checks – refer to the relevant

section of the Labour Time Manual that carries

DTC claiming information at the end of the

relevant section. Use the relevant Labour

Operation Num ber for the DTC found.

Claiming for replacement of any component

found faulty during that DTC diagnosis – use the

relevant Labour Operation for remove and replace

of t he faulty part.

For all Warranty Information, Labour Times in

your latest version of the SIP CD.

To claim for the rectification procedures detailed

above, use the f ollowing information:

Part 2 – Base Idle O NLY:

Description Reset Engine Idle

Labour Op. No. J000610

Time 0.6 hr

Failure Code 84

Part 1 & Part 2:

Description Fit PCV Oil Separator

Labour Op. No. J000631

Time 0.9 hr

Failure Code 84

NOTE: the time allowance for this Labour

Operation No. has been increased t o allow for the

additional Part 2: Base I dle Pr ocedure.

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

19 19

REAR WIPER INOPERATIVE

TS Hatch

(GROUP 12) TL011-1203

PROBLEM DESCRI PTION

Rear wiper may fail to operate when the wiper

switch is operated, or may stop during operation

for no appar ent r eason.

The cause has been defined as poor adhesive

bonding of the wiper motor cover (carrying the

electrical contact s ) to the wiper motor housing.

No damage is suffered to the contacts or motor

assembly, and it can be reassem bled.

PRODUCTION RECTIFICATION

Rear wiper motors, with improved adhesive

bonding, were intr oduced from:

ISOVIN: Build Date:

W0L0TGF4815059976 18/10/00

SERVICE RECTIFICATION

To rectify cases of “wiper inoperative” where no

electrical wiring fault is found, the wiper motor

can be r emoved and the motor cover can be re-

adhered to the wiper motor body as follows:

1. Remove wiper motor assembly from tailgate

as per TIS 2000 instructions in TS Astra

Electrical Equipment and Instruments,

section: “Rear Screen W iper Motor, Remove

and Install”.

2. Remove the wiper motor cover (black plastic)

by carefully prising it off with a flat bladed

screwdriver – Refer Figure 1 below - do not

damage the cover, as it is to be re-fitted to

the wiper motor.

Figure 1

3. Remove all traces of oil/grease from the

attaching surfaces of the cover and motor

using an organic solvent such as Acetone or

MEK (Methyl Ethyl Ketone). NOTE: As a

standard procedure, use these solvents only

in a well ventilated area: it is recommended to

keep skin contact to a minimum, or use

impervious gloves when using such solvents.

4. Apply adhesive (either “Loctite 480 Instant

Adhesive”, or “Permabond C737 Black

Magic”) to the wiper motor surface previously

cleaned – Refer Figure 2 below - and quickly

fit the cover to the motor, ensuring it is

correctly aligned. Hold the two parts together

for one minute and apply enough pressure to

ensure the adhesive spreads evenly over the

mating surfaces.

Figure 2

5. After the one minute curing time, the wiper

motor assem bly can be re- fitted t o t he vehicle.

PARTS INFORMATION

Solvents and adhesives mentioned are available

from commercial suppliers, they are not stocked

by HSPO.

A rear wiper motor assembly should only be

replaced if t he pr ocedure above is unsuccessful.

WARRANTY CLAIM I NFORMATION:

Description Re-Adhere Rear Wiper

Cover to Motor

Labour Op. No. N000324

Time 0.9 hr

Failure Code 58

Update

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

20 20

LSD CHATTER NOISE

VT, VX, WH (V8 Engines only)

(GRO UP 4) TL011-0401

The following information is repeated from All

Dealer Letter: DL 65/00, and is repeated in this

Techline only to ensure that all Dealership

Service personnel are aware of the information

noted. Refer to DL 65/00 for all actions.

PROBLEM DESCRI PTION

This letter is to advise Holden Dealerships of a

corrective fix for LSD (Limited Slip Differential)

final drive units that exhibit a “chatter” noise

when turning. This noise may be present in

some VT, VX and WH vehicles with V8 engine.

LSD chatter may be heard when the vehicle is

turning left or right when travelling in a forward

or reverse direction, and is most pronounced

when negotiating sharp bends at low speeds

and parking manoeuvres where differential

action is initiated. The occupants of the vehicle

typically hear a noise originating from the LSD

drive unit (axle). Chatter can also be

experienced by the driver as a “grabbing” feel

during the operation of the LSD. The chatter

noise is caused by diminished sliding lubrication

qualities (using the existing oil) of the LSD cone

fr ict ion sur faces within the final dr ive unit.

Holdens supplier of LSD final drive units, Spicer

Axle Australia (SAA) - previously named BTRE,

has assisted in the definition of the cause of

LSD chatter, and provided a rectification

process, described below, for application to

complaint vehicles.

Affected Vehicles

For reference, V8 LSD final drive units with the

following codes/part numbers are af fected:

VT: EB 92053537, EH 92053542, EM

92078300, EP 92078301, ET 92082622.

VX: FA 92085123, FC 92085125, FE

92085127, FH 92085129, FF 92085136.

WH: EH 92053542, FH 92085129

(Refer to SIP Service Information, Group 0A for

location of final drive unit identification label).

Dealership Action

A rectification procedure is to be carried out to

add an approved friction modifier (supplied by

SAA) to improve lubrication. As the friction

modifier required is not compatible with the

currently f itted Viton material pinion seal, a new,

high performance, Polyacrylic material pinion

seal must be fitted to prevent possible future

leaks through seal degradation. Both friction

modif ier and new seal will be supplied in a “Field

Fix Kit” supplied by SAA.

On examination of a customer complaint vehicle,

and confirming LSD Chatter is evident – fill out

all requested details on a photocopy of the SAA

Rear Axle Assembly Diagnosis & Changeover

Request For m (Attached t o DL 65/00) and f ax to

SAA on Fax Number: (02) 9754 9310.

On receipt of a fully completed SAA Rear Axle

Assembly Diagnosis & Changeover Request

Form, SAA will contact your Dealership by

telephone to confirm acceptance of the request,

advise that a “Field Fix Kit” is being sent by

courier to your dealership, and the approximate

delivery date/time.

If diagnosis to confirm LSD chatter noise has not

been carr ied out, a simple Diag nosis Procedure,

provided below, must be carried out to confirm

the noise cause, and ensure that the rectif ication

procedure will correct t he com plaint.

If any complaint vehicle is presented which

carries a filler plug I.D. tag containing the words

“FIELD FIX” or “& FRICTION MODIFIER” – the

procedure has already been carried out to the

unit and it must NOT have the procedure carried

out again. In a case such as this, a fully

completed SAA Rear Axle Assembly Diagnosis

& Changeover Req uest For m should be f axed to

SAA to req uest a replacement final drive unit.

Parts Information

To carry out the rectification procedure – the

following parts are requ ir ed:

“Mobilube SHC ID” oil. Quantity: 1.5 litres –

Dealership to procur e.

A Field Fix Kit - Supplied by SAA, which

contains the following items:

1. One new Polyacrylic pinion seal.

2. One bottle (100 ml) of friction modifier.

3. A replacement I.D. tag .

4. An extract from the VX and VT SIP Service

Information, referring to seal replacement.

(Also applies to WH. Copies are included as

Attachment s to DL 65/00).

5. T he Material Saf et y Data Sheet f or t he f rict ion

modifier.

6. The diagnostic and rectification procedures

detailed below.

Diagnosis Procedure to define LSD Chatter

(if pr eviously not able to confirm):

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

21 21

LSD chatter can be temperature dependent, so,

prior to the following diagnosis, customer help

should be sought to determine if the chatter

occurs when the final drive is hot or cold, so the

vehicle can be tested for confirmation in the

same temper at ur e range.

Find a driving area large enough to allow the

vehicle to be oper ated, in a safe m anner , at near

full lock, up to a speed of 20km/h in both

forward and reverse direction. The driving

surface of the area should be in good condition

i.e.: free from dips, loose g r avel, et c.

Apply foot brak e and place t he vehicle on full lef t

lock - without activating the power steering

pump pressure r elief valve.

For A/T equipped vehicles, select “D”; for M/T

equipped vehicles - select 1st gear.

Release the foot brake and allow the vehicle to

slowly roll forward/release the clutch. Increase

the speed of the vehicle gradually up to 20km/h

approx..

Listen for an audible rumble sound emanating

from the final drive unit, as the vehicle starts to

roll forward, this noise may change f requency to

a chatter as t he vehicle speed increases.

When the vehicle reaches 20km/h put the A/T

selector or M/T gear lever into neutral and allow

the vehicle to coast down to a stop.

LSD chatter, if present, will be noticed as the

vehicle rolls to a stop.

Other sources of driveline noise such as clutch

shudder are isolated when using t his m et hod.

Repeat the above procedure for full left lock in

reverse, full right lock forward and full right lock

in reverse.

When chatt er noise is confirm ed:

Fill out all requested details on a photocopy of

the SAA Rear Axle Assembly Diagnosis &

Changeover Request Form and fax to SAA on

Fax Number: (02) 9754 9310. SAA will contact

your Dealership by telephone to confirm

acceptance of the request, advise that a “Field

Fix Kit” is being sent by courier to your

dealership, and the approximate delivery

date/time.

Rectifi cat ion Procedure

On receipt of a Field Fix Kit from SAA:

1. Remove the final drive unit drain plug and

drain the oil from the final drive unit.

2. Change the pinion oil seal as per the

instructions provided. CAUTION: The pinion

shaft, pinion flange and pinion nut MUST be

marked prior to removal, and realigned to

these marks on re-assembly, as per Step 3 &

Figure 4B-1, in each of the instructions

provided, and as shown in SIP. It is

recommended that Loctite 243 Nut Lock be

used on re-assembly of pinion nut to pinion.

3. Reinstall the drain plug.

4. Remove the filler plug and add 1.5 litres of

“Mobilube SHC ID” oil. NOTE: this is the only

oil validated through exhaustive testing, as

compatible with the friction modifier required

in this procedure – do NO T use any other oil.

5. Add the contents of bottle of friction modifier

to the axle unit via the filler plug hole.

6. Fit the supplied I.D. tag to the filler plug and

reinstall t he filler plug.

7. Road test to confirm complaint is corrected.

NOTE: The friction modifier requires a run-in

to become effective. The friction modifier

should reduce chatter severity significantly

within a few kilometers of driving. Some

vehicles may require at least 100 km of

driving for the friction modifier to have

maximum effect.

Warranty Claim Information

Use the following information to claim for the

above rectification procedure:

Labour Operat ion No.: F000171

Description: Fit V8 LSD Chatter

Fix Kit

Time: 0.7 Hour

Add For Dual Exhaust: 0.5 Hour

Trouble Code: 41

SAA “Rear Axle Assembly Diagnosis &

Changeover Request Form”

A new copy of the SAA (previously BTRE) Rear

Axle Assembly Diagnosis & Changeover

Request Form is att ached to DL 65/00 f or use in

request ing the Fix kit mentioned above.

The form is also provided for future changeover

final drive unit requests. Please retain a copy of

this form in your files. The new form will be

included in fut ure SIP releases.

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

22 22

FUEL TANK/CAP REPLACEMENT

REQUIREMENT

(GROUP 8) TL011-0804

SERVICE REQUI REMENT

W henever a fuel tank is replaced on a TR Astra

- the fuel tank filler cap should also be replaced

with a revised design filler cap, as noted below

in Parts Information.

PARTS INFORMATION

Part No.: Description: Qty

92088959 Cap, Fuel Filler 1

To identify early and later filler caps fitted to

vehicles – the following sketches are provided.

Early Filler Cap

Do NOT re-fit when replacing a fuel tank

Later Filler Cap

Fit when replacing fuel tank.

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

23 23

COOLING FAN FUSIBLE LINK HOLDER –

REMOVAL OF ASSEMBLY TAPE

VT VX WH

(GROUP 12) TL011-1208

PROBLEM DESCRI PTION

Assembly aid t ape may be left on the cooling f an

fusible link holder cover. As well as obscuring

the wording on the cover, the tape looks

unsightly af ter a period of time.

The location of the tape is shown in Figure 1

below.

SERVICE RECTIFICATION

Remove tape. Also ensure that the cover is

secure.

Figure 1.

HOLDEN SERVICE TECHLINE ___________________________________________________________DECEMBER 1, 2000

24 24

KNOCK NOISE FROM EXHAUST ON COLD

START

JR, JS

(GROUP 8) TL011-0802

This Service Techline supersedes the previous

Techlines on this topic (Issue 1, February, 1999

page 5, and Issue 10, November, 2000, page 23)

by correcting the model/engine usage details.

These previous Techlines should be destroyed.

PROBLEM DESCRI PTION

NOTE: The condition described below only

affects:

JR vehicles with C20SEL engine;

JS vehicles with C20SEL engine up to

breakpoint Y7054589 as noted in Part Fi nder.

Customers may complain of a metallic knocking

noise after engine is started from cold. Noise can

be misdiagnosed easily as being an engine

internal or dr ive belt r elated noise.

Actual noise cause is a rattle noise from internal

baffles in the intermediate silencer, which stops

when the exhaust system reaches operating

temperat ur e.

PRODUCTION RECTIFICATION

The silencer has been revised internally from late

1998. Silencers are identified by date code of

99/04 or later (99/04 = Apr il, 1999), - st amped on

the identification/part number plate on the lower

surface of the silencer body. No vehicle

breakpoint was set for this change.

SERVICE RECTIFICATION

Fit a new Silencer – Intermediate & Centre Pipe.

As part numbers and breakpoint information may

be revised, always refer to current PartFinder

information.

Order the new part from HSPO - all parts at

HSPO are of the latest specification.

PARTS INFORMATION

Part No.: Descripti on: Qty:

90500030 Silencer – Int er mediate

& Centre Pipe 1

WARRANTY CLAIM I NFORMATION:

Use existing information in Labour Time Manual

on SIP CD.

TECH 2 COMMUNICATION

SB w i th C14NZ Engine

(GROUP 6C) TL011-6C01

Previously there were some Tech 2

communication difficulties with early ’96 SB,

C14NZ engine vehicles.

To communicate with the engine ECU, Tech 1

and the mass storage cartridge from the Zone

office was required.

As f rom TIS 2000, CD 12b, the T ech 2 software

version 9.400 is able to communicate with the

engine ECU in these vehicles.

PLEASE NOTE: This Tech 2 software is unable

to communicat e wit h 96 Model Year GSI X16XE

vehicles. These vehicles will still require the

Tech 1 mass storage cartridge available from

individual Zone off ices.