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MODEL SELECTION INDEX
SERVICE TECHLINES - MENU
2002 - SERVICE TECHLINES
BREAKPOINT SUMMARY
SOME MONTHLY HINTS
GROUP 0B - GENERAL
Tech 2 DTC Symptom Descriptors - Simtec Engine Management Systems
GROUP 1 - BODY
Boot Carpet Sagging - V2 Monaro
Door Cladding - Chrome Strip Detaches At Ends, Material Delaminates - WH
Noisy Rear Door Checklinks – Reduced Service Interval - VT, VX, WH
Water Leak Between Top Edge Of Door Glass and Door Frame Seal - V2 Monaro
Interior Rattle Noise Diagnosis - All Models Fitted With Melbourne CityLink e-Tag device
Front Wiper Blades Noisy, Shudders - XC Barina
Seat Squab Worn By Console Lid - JR & JS Series I Vectra CD models
Water Leaks Into Decklid via Spoiler Mounting Holes - VT, VX, WH
Door Checklink Bolts Loose - TS Astra
Door Striker Creak or Rattle - TS
Front Seat Map-Pocket Detaches From Seat- Back - VT, VX, WH
Door Checklink Bolts Loose - TS, TT, JS, XC
Squeaks and Rattles: Instrument Panel Facia; Engine Hood Insulator Fasteners - VT,VX,VU,V2,WH
Rear Facia Loose Left Hand Side - VX Sedan
Stone Entry into Rocker Panel Skirts - Sports Body Kit - VT, VX, “S” and “SS” models
Water Leaks – Rear Wheelhouse Body Seams - WH
Passenger Side Rocker Panel Water Entry - V2 MONARO
Hotmelt Glue Protrudes From Under Rear Windscreen Upper Moulding - VX, WH, V2
Decklid to Hinge Attachment - V2
Front Seat Lumbar Support Replacement Guidelines - VX,VU,V2
Driver’s Seat Belt Length TT ZAFIRA
Wind Noise At Upper Rear Corner Of Drop Window - V2 Monaro
Aftermarket Window Tinting Precautions - All
GROUP 2 - HEATING & A/COND.
HVAC Module Whistle - VT/VX/VU/V2/WH
Introduction Of Improved Air Conditioning Compressor - XC Barina, TS Astra except Z22SE engine
Design Changes To Condensor and Receiver Dryer - TS and TT Model Year 2002
Revised TX Valve - SB Barina with A/C
A/C TX Valve Noise - VTII, VX, VU, V2, WH, with Gen III
Improved Air Conditioning Compressor - XC Barina, TS Astra Z18XE engine only
Blower Fan Motor/Resistor Diagnosis Hint - XC Barina with Air Conditioning
Refrigerant Label Location - All V & W with Gen III Engines
Thump Noise From HVAC Case - (Mode Door Slamming) - VT, WH with 5-Pack Vacuum Solenoid Modules
HVAC Case Whistle - VT/VX/VU/V2/WH
HVAC Manual Control Unit - Parts Serviceability - VT, VX, VU with C60 (HVAC) Option
A/C Condensor Fan Deleted On 2003 Model Year - TS Z18XE with M/T
GROUP 3 - FRONT SUSPENSION
Noisy Front Bearings – Diagnosis Hints - ALL V & W
GROUP 4 - REAR SUSPENSION
Backlash “Clunk” Noise - Information - VS with IRS, VT/VU/VX/V2/WH
LSD Additive Availability For Servicing - VS/VT/VX/VU/WH with IRS LSD
Semi Trailing Arms – Voided Inner Bush Orientation - VXII, WHII, V2 - Multi Link Suspension
“Moan” Noise From Rear Cross Member at 105–110 km/h - VX with Gen III V8 & A/T
“Moan” Noise From Rear Cross Member at 105–110 km/h - WH, VX with Gen III V8 & A/T
Rear Wheel Bearing Failure - SB Barina
LSD Chatter Noise - VX, VU, WH with V6 Engine & LSD
LSD “Chatter” Noise - V6 & LSD in VX, VU, V2, WH
“Moan” Noise From Rear Cross Member at 105–110 km/h - WH, VX with Gen III V8 & A/T
GROUP 5 - BRAKES
Brake Squeal Rectification - TS – Non-ABS models only
Front Brake Hose Retention Precaution - VT, VX, VU, V2, WH
Brake Squeal Rectification - TS – Non-ABS models only
Rear Brake Groan/Graunch Noise - TS & TT Model Year 2002 Fitted with LUCAS Calipers
ABS Modulator Damage When Replacing Brake Pads - All Carlines with ABS
GROUP 6A - ENGINE
Belt “Chirp” Under Hard Acceleration - All V & W with Gen 3 and Auto Trans.
Engine Vibration – Loose Engine Mount Bolt - TS
Welch Plug Requirement - During Engine Block Replacement - All with Gen III Engine
Engine Oil Consumption Information - All
Camshaft Cover Seal Leaks - JR(C20SEL), JS (C22SEL), UES (X22SE) TR (C18SEL & X20XEV)
Suspect Quality Oil Filter Elements - Z22SE engine - TT, TS Sri & Convertible
Engine Cover Rattle Noise - VTII, VX, VU, V2 & WH with LS1 (Gen III)
Engine Improvements - Gen III V8
Engine Improvements - Gen III V8
Oil Filter Cap – Care During Removal and Replacement (Cartridge Type) - TS & XC (X18XE1 or Z18XE Engines)
Timing Chain Serviceability - TT & TS with Z22SE Engine
GROUP 6C - ENGINE MANAGEMENT
LHS O2 Sensor Connector - Water Entry - VTII, VX, VU, WH – All with GEN3 & A/T
DTC P0335 Misfire/Crank Rev. Sensor Malfunction Diagnosis and Correction - TS with Z18XE Engine
Cruise Control Inoperative – Incorrect Software in ECU - TS Astra SRi with Manual Trans.
Flash Programming Hint for Gen 3 PCM - VX, VU, V2, WH(A8A)
Engine Stall At Idle Or High Engine Idle Speed - JR, JS, C20SEL, C22SEL
DTC P0100/Poor Idle/Engine Stall Diagnosis (Non - IACV Related Causes) - JR, JS, C20SEL, C22SEL
Flash Programming - Gen3 PCM - VX, VU, V2, WH(A8A)
Electronic Modules - Resetting Procedure - TS, TT, XC, JS (Y26SE)
Throttle Control Malfunction – DTC’s P0120, P1500, P1550 - XC, TS, (Z14XE , Z18XE engines)
Revised Cylinder Head - XC with Z14XE
Rough Idle, Loss Of Power, Stall During Idle and Hard To Restart - DTC P0400, P1405 Set - XC with Z14XE engine
Engine Stall At Idle or High Engine Idle Speed - TR Astra C18SEL engine
CAUTION - Do Not Use TIS CD’s 36 or 37 for SPS Programming - VX,VU,V2,VY,WH with Gen III & A/T
Engine Hard To Start After Stop - VS 5.0L V8 Series 3 Statesman, Caprice and Utility
GROUP 6K - ENGINE COOLING
Throttle Body To Surge Tank Coolant Hose Damage - TS (X18XE1 & Z18XE ENGINES)
Dex-Cool® Coolant Name Change - All Models Using Dex-Cool®
Engine Fan Shroud Mounting Revised – HSPO Replacement Radiators - VT, VX, VU
GROUP 6Y - ENGINE ELECTRICAL
Tensioner Rattle/Noise - TR Astra with C16SE, C18SEL, X20XEV engine
Tensioner Rattle/Noise - TR Astra with C16SE, C18SEL, X20XEV engine
Spark Plug Lead Revisions - WH, VX, VU, V2 – All with V6 Engine
GROUP 7A - MANUAL TRANSMISSION AND CLUTCH
Gearshift Lever Knob Rattle/Buzz - VTII, VX, VU, V2, Gen 3 Manual Trans.
Excessive Gear or Road Noise from M/T Shifter Area - VTII, VU, VX,V2 with 6 speed M/T (MM6)
Clutch Fluid Discolouration - VX, VU, V2
Clutch Pedal Squeak - XC Barina
Drive Shaft Seal Installation Precautions - TS with F17 M/T
Insufficient Engagement Of Reverse Gear - VTII, VX, VU, V2 with Gen III M/T
Spigot Bearing “Squeal” Noise on Cold Start - VT, VX, VU, V2, WH
Spigot Bearing “Squeal” Noise on Cold Start - VT, VX, VU, V2
GROUP 7B - AUTOMATIC TRANSMISSION
Auto Transmission - Harsh Upshifts - VX & VU Series I, WH A8A upgrade, with Gen 3 Auto
New Control Valve Body, Spacer Plate & Gaskets For 4l60-E Auto. Trans. - All V & W with 4L60-E
Auto Transmission - Harsh Upshifts - VX & VU Series I, WH A8A upgrade, with Gen 3 Auto
A/T Shifter Button Removal - WH, VX, VU, V2
DTC P1870 - Trans. Slipping - WH, VX, V2, VU with A/T
A/T Electrical Connector Removal & “Limited” Repair Procedure - VR, VS, VT, VX, VU, V2, WH
Auto Trans Shift Quality - VTII & WH (pre A8A) with Gen III
A/T Shifter Base Damaged By Contact With Prop Shaft Front Coupling - VX, VU, V2, WH (All with V6 & A/T)
GROUP 8 - FUEL TANK & EXHAUST
Modular Reservoir Assembly (MRA) Replacement and Fuel Gauge Calibration - VXII, WHII, VUII, V2
Buzzing Noise From Fuel Tank Pressure Relief Valve - SB with C14SE engine
Exhaust Outlet (Chrome) Alignment to Rear Bumper Facia - VY V6 – “S”, Berlina & Calais
Modular Reservoir Assembly (MRA) Replacement and Fuel Gauge Calibration - VXII, WHII, VUII, V2
Fuel Tank Vent Line Routing TS & Z18XE
Fuel Filler Cap Hard To Remove - VU, VY Utility
GROUP 9 - STEERING
Steering Column Upper Bearing Excessive Movement - VT, VX, VU, WH
Steering Knock/Rattle - JS Vectra
Intermediate Steering Shaft Knock - JR, JS
GROUP 10 - WHEELS AND TYRES
Alloy Wheel Centre Cap Dislodges Easily - TS - Alloy Wheel 09117922 (6 spoke, 5 bolt holes)
Wheel Nut Usage - Alloy And Steel Wheels - All V & W
Wheel Centre Cap Dislodges - V2 Monaro with 18” Alloy Wheel
GROUP 12 - CHASSIS ELECTRICAL
Turn Signal Switch Does Not Cancel - XC BARINA excluding SRi
Rear Speaker (RHS) Inoperative - V2 Monaro
Throttle Body To Surge Tank Coolant Hose Damage - TS (X18XE1 & Z18XE Engines)
Body Control Module- Lock Up - VTII, VX (I & II)
Mirror Switch Replacement - JR & early build JS
Blaupunkt Audio Units Replaced For Complaint of Erratic Volume - JS, TS, TT, XC, SB
AM Reception Interference Caused By Rear Windscreen Tinting - JR, JS Sedan
Telematics Service Requirements - All Models with Telematics
Turn Signal Switch Does Not Cancel - XC BARINA excluding SRi
Speedo Drops Out Whilst Driving – Resumes After Ignition Cycled - TS with ABS
Interior Dome Light Stays On or Fuse Blows - V2 Monaro
Centre High Mount Stop Light Rattle - V2 Monaro
Remote Sender Unit (Key Head) Operating Frequency Revised From 315 to 433 MHz - TS Astra
Engine Hard To Start (DTC P1615, P1616); Doors hard to open with Remote Key; DTC B1485 Set - XC Barina
Poor Radio Reception - Roof Mounted Antenna Base Nut Loose - JR Hatch, JS Wagon/Hatch, TS, TT, TR, SB
Poor AM Band Radio Reception - TS Astra Hatch & Sedan
Poor “AM” Radio Reception – Loose Roof Antenna Connector - TS, TT, JS wagon/hatch, JR Hatch, TR GSi, SB
Rear Power Windows Malfunction – Water In Door Connector - TS Astra CD Model
AM Radio Reception Interference from Electronic Power Steering Unit - XC
Revised Centre High Mounted Stop Lamp (CHMSL) - VU SS
Instrument Cluster - Intermittent Operation - XC
Modular Reservoir Assembly (MRA) Replacement and Fuel Gauge Calibration - VXII, WHII, VUII, V2
Exterior Lamp Lens Care Guidelines - All
Horn Bar Activates Radio Remote Switches - VY All
Tail Lamp Overflush To Rear Quarter Panel - VY Sedan
Assembly Instructions for Revised CHMSL Replacement Parts From HSPO - VU SS
Modular Reservoir Assembly (MRA) Replacement and Fuel Gauge Calibration - VXII, WHII, VUII, V2
Customer Complaint - “Scheduled Service Reminder did not display” Service Reminder Due - Resetting Procedure - VY All
Cruise Control Inoperative - XC SRi
Headlamp Range Adjustment - TS Convertible
Instrument Cluster DTC 10 (New Vehicles Only) - VY without Occupant Climate Control
