Service Department

A “HOLDEN” Product.

BRISBANE SYDNEY MELBOURNE ADELAIDE PERTH

For the latest and/or any missing Techline bulletins,

please refer to Holden Lionheart

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Turn Signal Switch Does Not Cancel

XC BARINA excluding SRi

(Group 12) TL0201-1201

PROBLEM DESCRIPTION

On some vehicles the turn signal switch (non

cruise control type) does not cancel after

turning steering wheel back to straight ahead.

On vehicles with this condition the cancelling

cam loses contact with the flange on the

airbag contact unit.

PRODUCTION RECTIFICATION

Revised turn signal switches p/n 09185413

have been fitted to vehicles from:

ISOVIN: Build Date:

W0L0XCF6824004516 24/08/01

NOTE: Revised switches did not change part

number but can be identified from the date

code as shown in figure 1. Switches

manufactured after “-311-” (week 31, 2001)

have been revised.

Figure 1.

SERVICE RECTIFICATION

On vehicles with the above condition fit a new

turn signal switch manufactured after the date

code shown in Figure 1.

All HSPO stocks of turn signal switches are of

the revised type.

NOTE: DO NOT REPLACE THE DRIVERS

AIRBAG CONTACT UNIT FOR THIS

CONDITION.

PARTS INFORMATION

Part No.: Description: Qty:

09185413 Switch turn signal –

without cruise

control.

Attention Parts Managers. Any switches with

a pre-breakpoint date code should be

returned to HSPO for credit.

WARRANTY CLAIM INFORMATION

Use existing Labour Times information in

Warranty Information section of current SIP

Update

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Boot Carpet Sagging

V2 Monaro

(Group 1) TL0201-0101

PROBLEM DESCRIPTION

Some customers may complain about boot

carpet sagging behind the rear seat.

PRODUCTION RECTIFICATION

Additional fasteners have been added to the

boot carpet to provide more support from:

ISOVIN: Build Date:

6H8V2X37F2L814274 09/01/02

SERVICE RECTIFICATION

Summary: Fit two (2) additional trim retainers

to increase boot carpet retension.

1. Remove the existing trim retainers from the

carpet behind the rear seat.

2. Identify the existing holes in the sheet metal

behind the rear seat as shown in Figure 1.

Figure 1

3. Align the boot carpet and mark the position

of the sheet metal holes on the carpet.

4. CAREFULLY pierce the carpet and fit two

additional trim fasteners. Refit any other

retainers removed during the rework.

PARTS INFORMATION

Part No.: Description: Qty:

92136478 Retainer – Trim 2

WARRANTY CLAIM INFORMATION

Description Carpet – Rear Seat Back

Labour Op. No. C431300

Time 0.3 hr

Failure Code 25

Rear Speaker (RHS) Inoperative

V2 Monaro

(Group 12) TL0201-1206

PROBLEM DESCRIPTION

On some vehicles the right hand side rear

speaker may cease to operate.

This condition could be caused by the

terminals on the rear of the speaker coming

into contact with the rear quarter body panel.

NOTE: This condition is not applicable to the

left hand side speaker.

SERVICE RECTIFICATION

Summary: Rotate speaker in mounting to

provide additional clearance to terminals.

For detailed procedures not supplied refer to

current SIP CD.

1. Remove the speaker.

2. Check speaker terminals. Look for

evidence of terminal touching on body.

3. Rotate speaker clockwise to next

mounting position (120 deg.). In this new

position there is increased clearance

between the speaker terminals and body.

Please submit PIRs for this condition.

WARRANTY CLAIM INFORMATION

Use existing Labour Times information in

Warranty Information section of current SIP

Description Rotate RHS rear

speaker

Labour Op. No. N000366

Time 0.6hr

Failure Code 49

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Throttle Body To Surge Tank Coolant

Hose Damage

TS (X18XE1 & Z18XE Engines)

(Group 12) TL0201-1201

PROBLEM DESCRIPTION

The Throttle Body to Surge Tank Coolant

Hose can foul either the positive battery

terminal protective cap or the positive battery

cable. If undetected this condition could result

in hose failure and coolant loss.

PRODUCTION RECTIFICATION

Clearance between the coolant hose, battery

cable and protective cap has been revised

from model year 2002 vehicles:

ISOVIN:

W0L0TGF4825000001

SERVICE RECTIFICATION

Summary: Adjust clearances by trimming

protective terminal cap and coolant hose, and

orient the battery cable correctly

If this fouling is discovered during service or

battery replacement the technician should

follow these steps to rectify the problem:

1. Trim the cap as shown in Figure 1 in order

to provide 10mm clearance between the

cap and the hose.

2. With engine switched off, disconnect the

coolant hose at the surge tank end.

3. Cut off 15mm of hose and refit the hose.

This will move the bend of the hose away

from the battery cable. See Figure 2.

4. Loosen the battery cable attaching nut, and

rotate the cable anti-clockwise so that there

is 10mm clearance between the cable and

the coolant hose, then tighten cable

attaching nut. See Figure 3.

WARRANTY CLAIM INFORMATION

Description Rework Battery

Cable/Coolant Hose

Labour Op. No. N000363

Time 0.4 hr

Failure Code 26

PARTS INFORMATION

Refer to Partfinder® if parts replacement is

required.

Figure 1

Figure 2.

Figure 3

Update

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Auto Transmission - Harsh Upshifts

VX & VU Series I, WH A8A upgrade,

with Gen 3 Auto

(Group 7B) TL0201-7B01

NOTE: This Techline does not apply to VTII or

WH (pre A8A) models. A service fix for these

models is expected in May 2002.

PROBLEM DESCRIPTION

A typical complaint transmission will exhibit a

harsh 1-2 shift with “end of shift bump” and a

harsh 2-3 shift.

PRODUCTION RECTIFICATION

Revisions to improve the transmission shift

quality were introduced at start of production

of VX,VU & WH, Series 2.

ISOVIN: Build Date:

VXII - 6H8VXK69F2L763647 23/08/01

VUII - 6H8VUK80F2L763676 24/08/01

WHII - 6H8WHY19F2L763313 24/08/01

SERVICE RECTIFICATION

Summary: - Install revised 1-2 accumulator

and reflash PCM with latest software.

Step 1. Replace 1-2 Accumulator

NOTE: For detailed procedures refer SIP CD,

VX, Section 7C5.

1.1 Check ISOVIN to ensure vehicle is Model

Year 2001.

1.2 Place vehicle on hoist.

1.3 Remove Transmission oil pan. Figure 1.

1.4 Remove 1-2 Accumulator. Figure 2.

1.5 Install new 1-2 Accumulator part number

24220143. Ensure that accumulator

piston is in position. Tighten bolts (58

and 59) to 8-14 Nm.

1.6 Reinstall transmission oil pan with new

gasket.

1.7 Lower vehicle and refill transmission with

specified fluid.

Step 2. Reflash PCM

Reflash PCM with the latest software

calibration for VX, VU and WH, Series 2

models from TIS 2000 CD version 28.0.

PARTS INFORMATION

Part No.: Description: Qty:

24220143 1-2 Accumulator 1

24208576 Gasket oil pan 1

WARRANTY CLAIM INFORMATION

For warranty claims use the following:

Description Replace 1-2 Accumulator

& reflash PCM

Labour Op. No. K000276

Time 0.8hr

Failure Code 43 (shifts hard)

Figure 1.

Figure 2. (Number references are from SIP CD)

Update

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

New Control Valve Body, Spacer Plate & Gaskets For 4L60-E Auto. Trans.

All V & W with 4L60-E

(Group 7B) TL0201-7B01

All 4L60-E transmissions built after Julian Date “1 ?? D 002 ? ????????” are fitted with a revised

valve body, spacer plate and valve body gaskets. The old and new design valve bodies, spacer

plates and gaskets are shown in Figures 1 to 5. An explanation of the “Julian Date” is given in

Figure 6.

SERVICE NOTE:

Whenever repairing transmissions it is vital that the correct spacer plates and gaskets are used. Do

not mix plates and gaskets from different kits. Refer to the following table for correct kit usage.

4L60-E built prior to Julian Date 1 002 4L60-E built from Julian Date 1 002

Valve Body Part No. Spacer plate & gasket kit Valve Body Part No. Spacer plate & gasket kit

24210320 - V6

24210321 - V6 S/C

24210317 - Gen3

24221137

24221350

24218187 - V6

24218188 - V6 S/C

24218186 - Gen 3

24221137

Item 1 Previous Design - shows the wide exhaust port on the TCC regulator valve.

Item 2 Later Design - shows the narrow exhaust port on the TCC regulator valve.

Figure 1. Differences between Earlier and Later Design Valve Bodies.

Update

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Figure 2. Pre change gasket identifications – “V” for

valve body gaskets and “C” for case gasket.

Figure 4. Post change identification. – “VB” for

valve body gasket & “CA” for case gasket

Figure 3. Pre change spacer plate identification. 2

letter code

Figure 5. Post change spacer plate identification.

“1” is added to the 2 letter code.

1. Model Year (1= 2001) 4. Julian Date (Day of the year)

5. Shift built (A,B,J=first shift, C,H,W = second shift) 2. Model: V6 3.8 litre……………………….……HF

V6 Supercharged……………………HN

Gen3 V8………………………………HP 6. Individual transmission serial no.

3. Transmission Identifier (D = 4L60E) 7. Location of Transmission Identification No.

Figure 6 JULIAN DATE EXPLANATION

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Body Control Module- Lock Up

VTII, VX (I & II)

(Group 12) TL0201-1202

This Techline supersedes the previous

Techlines on this topic:

Issue 1/2001, page 11 (replace BCM)

Issue 3/2001, page 13 (replace BCM and

install patch harness in key reader circuit )

PROBLEM DESCRIPTION

Symptoms of BCM Lockup condition are loss

of all BCM security related functions resulting

in engine wont start, no central locking, etc.

This is usually accompanied by a ‘buzzing’

noise emitted from the BCM.

When the BCM ‘locks up’ the microprocessor

inside the BCM starts its own self test routine

where part of this test includes switching all

BCM internal relays - hence the ‘buzzing’

sound.

Investigations have found the ‘lock up’

condition is caused by a static voltage

discharge that enters the BCMs’ internal

circuitry which in turn causes the BCM to

malfunction.

PRODUCTION RECTIFICATION

BCMs with revised software to prevent “lock-

up” have been fitted to VX2 vehicles from:

BCM Mid Series (p/n 92109212)

ISOVIN: Build Date:

6H8VXK35A2L811439 12/12/01

BCM Low Series (p/n 92109213)

ISOVIN: Build Date:

6H8VXK69A2L812036 13/12/01

SERVICE RECTIFICATION

When presented with a vehicle that has, or is

reported as having, all of the symptoms

described above (engine no start, central

locking inoperative and a buzzing sound from

BCM), proceed as follows:

1. Request a replacement BCM via a Warranty

Changeover Request Form. Refer to All

Dealer Letter 79/00, or SIP, for a copy of the

form which is to be faxed to Australian

Arrow. The form must be completed with

all detail as requested. Also record the

customer comments prior to the failure (if

applicable).

2. Temporarily return the vehicle to service by

removing Fuse 31 to reset the BCM.

NOTE: Installation of a patch harness as

described in Service Techline Issue 3/2001 is no

longer necessary. Australian Arrow will only

send Retailers (Dealers) a BCM with revised

software.

PARTS INFORMATION

The following BCMs all have the revised

software to prevent lockup.

Part No.: Description: Qty:

92109212 Body Control Module-

VXII Mid Series

92109213 Body Control Module-

VXII Low Series

92145251 Body Control Module-

VTII, VXI Mid Series

92145250 Body Control Module-

VTII, VXI, Low Series

WARRANTY CLAIM INFORMATION

Use existing information in SIP Warranty

Information/Labour Times as shown:

Description Module Body Control Replace

Labour Op. N506600

Time 0.5 hr

Failure Code 50

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Belt “Chirp” Under Hard Acceleration

All V & W with Gen 3 and Auto Trans.

(Group 6A) TL0201-6A01

PROBLEM DESCRIPTION

Under hard acceleration, some vehicles may

experience a momentary chirp or squeal from

the drive belt during the 1-2 shift.

Investigations have shown that increasing the

damping of the belt tensioner reduces this

condition.

NOTE. For complaints of continuous belt

squeal, refer to Techline in Issue 5/2001 that

deals with misalignment of the drive belt

pulleys.

PRODUCTION RECTIFICATION

Revised belt tensioners with increased

damping have been fitted to vehicles from:

ISOVIN: Build Date:

6H8V2X37F2L818822 24/01/02

NOTE: Whilst the above ISOVIN describes a

V2 Monaro, L818822 sets the breakpoint for all

VXII,WHII and V2 vehicles.

SERVICE RECTIFICATION

Where customers complain of the above

symptom fit a new tensioner as listed in Parts

Information.

PARTS INFORMATION

Part No.: Description: Qty:

92111701 Tensioner 1

WARRANTY CLAIM INFORMATION

Use existing Labour Times information in

Warranty Information section of current SIP

CD.

Mirror Switch Replacement

JR & early build JS

(Group 12) TL0201-1205

BACKGROUND

Mirror switch part number 90363312 was

fitted to all JR vehicles and JS vehicles built up

to the following:

ISOVIN: Build Date:

W0L0JBF68X7007783 March/1999

All vehicles built after this breakpoint were

fitted with an improved design switch

09226864.

HSPO has now superceded the earlier switch

90363312 with the later switch 09226864.

SERVICE NOTE

To fit the later switch 09226864 to vehicles

built prior to the above breakpoint, a patch

harness 92112089 must be installed between

the vehicle harness and the new switch .

PARTS INFORMATION

Obtain following parts from HSPO.

Part No.: Description: Qty:

09226864 Switch mirror adjust 1

92112089 Patch harness 1

NOTE: Quantities of the patch harness are

scheduled for delivery into HSPO 3rd week of

Feb.

WARRANTY CLAIM INFORMATION

Use existing Labour Times information in

Warranty Information section of current SIP

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Blaupunkt Audio Units Replaced For

Complaint of Erratic Volume

JS, TS, TT, XC, SB

(Group 12) TL0201-1203

PROBLEM DESCRIPTION

Blaupunkt Audio units 420, 520, and 2020 as

fitted to the above models are being replaced

for complaints of volume increasing or

decreasing automatically. Analysis of these

units by the supplier (Bosch) shows No Fault

Found.

The following feature of these audio units is

the most likely explanation for this

unnecessary replacement.

SPEED CONTROLLED VOLUME

Blaupunkt audio units 420, 520, and 2020

have a vehicle speed controlled volume

function. With this function, as the car

increases in speed, the volume of the radio

increases to compensate for the increase in

driving noise.

Sensitivity Adjustment

NOTE: To cope with all the variable factors

such as road surface, wind noise, engine

speed etc. there are 5 different levels of

compensation available. Customers are then

able to find the level of compensation that best

suits their average driving conditions.

The sensitivity can be set between 0 (off) and

5 (maximum compensation) as per procedure

from Blaupunkt 520 Audio System) Handbook

1. Press LOC button (7) for at least 3 seconds

until you hear a confirmation beep. The display

shows the current setting , eg ‘SD-VOL 2’.

2. Press tuning button within 8 seconds to select

the desired setting between ‘SD-VOL 0’ and

‘SD-VOL 5’.

3. To store the selected setting, press LOC button

(7) again for at least 3 seconds until you hear a

confirmation beep. If you don’t store the new

setting within 8 seconds after the last press of a

button, it will not be stored.

4. To turn this feature off, select and save ‘SD-

VOL 0’.

Please explain this feature to customers who

complain that their radio volume changes

automatically while they are driving.

AM Reception Interference Caused By

Rear Windscreen Tinting

JR, JS Sedan

(Group 12) TL0201-1204

Refer to previous Techlines on AM reception

issues in JR and JS:

Sep 1998 Group 12 & Feb 2000 Group 12.

Further to the above Techlines, investigations

into customer complaints of poor AM radio

reception has highlighted that metallic window

tinting dramatically reduces the AM reception

capability for above models.

Only the sedan body style is affected as this

has the antenna in the rear windscreen.

Holden does not recommend metallic window

tinting of the above models due to the

significantly reduced AM reception

performance. Holden Retailers(Dealers)

should advise customers of this position.

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

LHS O2 Sensor Connector - Water Entry

VTII, VX, VU, WH – All with GEN3 & A/T

(Group 6C) ISSUE 2 TL0201-6C01

This Techline is revised by adding check for correct

sealing of O2 connector. The previous Techline

(Issue 9, 2001 page 16) should be discarded.

Thanks to Steve Tennant of Golden City Motors for a

PIR which initiated this reissue.

PROBLEM DESCRIPTION

The proximity of the left hand side (LHS) oxygen

sensor wiring to the HVAC drain can result in O2

sensor malfunctioning. An oxygen sensor

connector that has had water ingress causing

terminal corrosion may result in the check

engine lamp illuminating while driving &/or a

noticeable loss in performance. Typical

symptoms of a malfunctioning LHS oxygen

sensor will be the logging one of the following

DTCs:

P0131

P0132

P0134

SERVICE RECTIFICATION

On any vehicle where the LHS O2 sensor has

logged the above trouble codes it is

recommended that as well as fitting a new O2

sensor, the sensor harness connector should be

relocated as per the following procedure.

1. Remove old / damaged sensor on the

LHS ONLY. Inspect & verify the condition of the

electrical terminals on the harness. Harness

replacement may be necessary if terminals are

corroded.

2. Carefully slice the spot tape that keeps

the Neutral Start Back Up Switch & the Oxygen

sensor wiring branches together. Ensure not to

slice through the convoluted tubing as wiring

damage may occur. Refer Figure 1.

HINT. Access to the harness to cut the spot

tape is improved by pulling the harness through

the spring clip to take up any slack.

3. Mount the bracket & the bolt from kit

92145044 to the spare threaded boss on the

LHS rear of the transmission (Refer Figure 2).

Bolt torque should be 5 - 12 Nm. The bracket

has an anti-rotation tab.

4. Mount the new O2 sensor into the

exhaust and tighten between 38 - 48 Nm. Route

wiring as illustrated in Figure 2.

5. Check the connector on the vehicle

harness side for the presence of sealing

grommets as shown in Figure 3. To view the

grommets, which are white or green in colour,

first remove the connector cover. To ensure

watertight sealing of the connector add sealer

such as silicone rubber RTV 732 p/n 92140051

around each of the wires in the 4 cavities.

6. Connect the O2 sensor plug to the

connector on the vehicle wiring harness.

7. Mount the sensor connector to the new

bracket via the arrow head clip.

8. Clear fault DTCs & complete testing for

further fault DTCs.

PARTS INFORMATION

Part No.: Description: Qty

92145044 Mounting Kit –

contains bracket & bolt

25326439 O2 sensor asm LHS 1

92140051 Silicone rubber sealer

RTV 732

WARRANTY CLAIM INFORMATION

For vehicles repaired under warranty use:

Description Fit LHS O2 sensor &

relocate harness connector.

Labour Op. No. J000692

Time 0.5 hr

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Figure 1

Figure 2

Figure 3

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Tensioner Rattle/Noise

TR Astra with C16SE, C18SEL, X20XEV

engine

(Group 6Y) TL0201-6Y01

PROBLEM DESCRIPTION

On some vehicles the following symptoms may

be observed:

• Rattle noisy from front of motor at idle.

• Belt tensioner vibrates excessively up &

down.

Investigations show that the alternator induces

a high oscillating load through the accessory

belt and tensioner. This in turn causes the

tensioner damping nylon ring to wear

prematurely thus reducing the damping and

causing the tensioner to oscillate and rattle.

The condition is more noticeable when the

engine is cold.

SERVICE RECTIFICATION

Summary: Remove standard alternator pulley

and replace with “decoupler pulley”.

Procedure:

1. Remove alternator assembly from vehicle

using procedure in TIS CD.

2. Remove alternator pulley nut with an

impact gun.

3. Install decoupler pulley using special tools

A and B as shown in Figure1.

4. Torque pulley attaching nut to 80 – 100

Nm.

5. Press cap plug into decoupler pulley. It is

important this cap is fitted to prevent the

entry of foreign material.

6. Reinstall alternator to vehicle.

SPECIAL TOOLS

Tool A. - Hazet Tool No. 2592 (Adapter)

Tool B. - Hazet Tool No. 2751 (long hexdrive

socket)

NOTE: These tools can be obtained on loan

from your Zone Service office.

For dealerships wishing to purchase their own

tools contact PB Baumann Tools Australia who

will direct you to the closest Hazet tool Agent.

PB Baumann Tools Australia

Telephone: 02 9816 1233.

Email: info@pbtools.com.au

PARTS INFORMATION

Part No.: Description: Qty

92145105 Decoupler pulley 1

92145244 Plug, sealing cap 1

WARRANTY CLAIM INFORMATION

For vehicles outside of warranty use case type

“08”

Description Install Alternator

Decoupler pulley

Labour Op. No. J000698

Time 1.0hr

Failure Code 28 Rattles

Figure 1.

Update

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

DTC P0335 Misfire/Crank Rev. Sensor

Malfunction Diagnosis and Correction

TS with Z18XE Engine

(GROUP 6C) TL0201-6C02

This Techline item is supplied to assist in the

diagnosis of DTC P0335 (crank sensor fault

code) and it’s associated DTC’s – P0700,

P1700 and P1895.

The information is provided so technicians can

carry out diagnosis to determine and correct

the most likely cause of these codes.

PROBLEM DESCRIPTION

Customer complains of engine misfire and

Code P0335 is found during diagnosis of

complaint.

SERVICE RECTIFICATION

Summary: Check for fuel contamination, good

terminal connections, replace Crank Sensor,

Re-flash where required.

1. Check fuel filter for water entry to fuel

system. Replace filter if required.

2. Carry out a terminal security, condition and

retention check on both ECU and Crank

Revolutions Sensor terminals. Correct any

terminal problems that may be found.

NOTE: use Special Tools KM-609-20 and

KM-609-21 for ECU terminals.

3. Carry out a continuity check between the

Crank Revolutions Sensor and ECU, and

correct any problems that are defined by

this check.

4. Replace Crank Revolutions Sensor.

5. If the ECU is not already flash

programmed with ECU Software Version

09 158 670 1280 – re-flash the ECU using

TIS CD 23 or later.

Should DTC P0335 re-occur after the above

process – contact TAS for further instructions.

Additional Diagnosis Hints & Information:

• Misfire codes are also induced by

interruptor ring problems, P0335 will

sometimes log with these codes.

• Special Tools – KM-609-20 & KM-609-21

comprise 3 each terminal test leads for

ECU. It is recommended you order one of

each of these test lead kits for ECU

terminal checking. The complete KM-609

Kit contains a comprehensive range of test

leads for all you dealership’s wiring test

needs.

• Most important terminals to look at for this

condition are 5 & 37 on the X58 connector.

• When checking DTC P0335 with Tech2,

the causes {the “identifiers”(1), (4) or (8) as

shown by Tech2} may be one of the

following:

(1) - ONE of the crank wires is open

circuit.

(4) - No crank signal found (probably both

wires open circuit).

(8) - Number of teeth not plausible (could

be wiring or an engine problem).

• FIP (Fault Isolation Process) C-06 in

TIS2000 – is your normal DTC diagnosis

procedure.

PARTS INFORMATION

Refer to PartFinder for current Crank

Revolutions Sensor part number.

WARRANTY CLAIM INFORMATION

Description Diagnose/Correct P0335

Labour Op. No. J000707

Time 1.0 hr

Failure Code 47

Update

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

HVAC Module Whistle

VT/VX/VU/V2/WH

(GROUP 2) TL0201-0201

PROBLEM DESCRIPTION

A number of PIRs have been submitted to

Holden describing a whistle noise from the

HVAC module

Dealer investigation has revealed the fresh

recirc door has not closed completely,

resulting in the whistle noise.

PRODUCTION RECTIFICATION

Engineering are investigating design changes

to the blower housing to eliminate this

complaint. Breakpoints will be advised once

they have been struck.

SERVICE RECTIFICATION

In the interim, dealers are able to contact the

HVAC supplier for a service fix to address this

complaint in customer’s vehicles. This fix

involves installing a self adhesive foam pad

that seals the fresh recirc door completely.

If a customer presents their vehicle with this

complaint, please contact:

Air International P/L

Phone: 1300 632 316

and request a Service Fix pack for this

complaint.

PARTS INFORMATION

Contact Air International directly on the

number above and refer to Air International

Service Bulletin HMC-92.

WARRANTY CLAIM INFORMATION

Description Fit HVAC Whistle Fix Kit

Labour Op. No. D000330

Time 0.5 hr

Failure Code 40

Cruise Control Inoperative – Incorrect

Software in ECU

TS Astra SRi with Manual Trans.

(Group 6C) TL0201-6C07

PROBLEM DESCRIPTION

Some vehicles may exhibit symptoms of the

cruise control being inoperative.

Investigations have shown that some M/T

vehicle engine ECU’s have been programmed

with A/T engine ECU software.

SERVICE RECTIFICATION

On complaint vehicles the ECU will need to be

reprogrammed with manual transmission

software.

Before proceeding ensure your Tech 2 is

updated with latest software from TIS2000 CD.

Reprogram the vehicles ECU using the TIS

Service Programming System (SPS).

WARRANTY CLAIM INFORMATION

Use existing Labour Times information in

Warranty Information section of current SIP

Update

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Telematics Service Requirements

All Models with Telematics

(GROUP 12) TL0201-1208

The purpose of this Techline item is to remind

Holden Service personnel of the need to

ensure the Telematics System is placed into

“Service Mode” prior to commencing any vehicle

servicing or repairs.

The Holden Assist call centre have received a

number of Unauthorised Entry and Battery

Removal alerts simply because Retailers

(Dealers) have not placed the Telematics

Module into Service Mode.

To prevent alerts of this nature being

transmitted to the Holden Assist call centre,

dealers should:

• Using Tech 2, check the Telematics system

operating mode.

• If not in Service Mode, use Tech 2 to enable

“Service Mode”.

• Carry out vehicle servicing or repairs.

• On completion of servicing or repairs,

use Tech 2 to disable “Service Mode”.

This will automatically place the module

in “Active Mode”.

Failure to disable “Service Mode” will result

in the status light (on rear view mirror)

flashing red and green for 30 seconds plus 5

beeps each time ignition is turned ON.

HOLDEN SERVICE TECHLINE_____________________________________________________________MARCH, 2002

Turn Signal Switch Does Not Cancel

XC BARINA excluding SRi

(GROUP 12) REVISED TL205A-0202

This techline is revised(

♠

) by clarifying how to

interpret the date code. The previous Techline

in Issue 1/2002 should be discarded.

PROBLEM DESCRIPTION

On some vehicles the turn signal switch (non

cruise control type) does not cancel after

turning steering wheel back to straight ahead.

On vehicles with this condition the cancelling

cam loses contact with the flange on the

airbag contact unit.

PRODUCTION RECTIFICATION

Revised turn signal switches p/n 09185413

have been fitted to vehicles from:

ISOVIN: Build Date:

W0L0XCF6824004516 24/08/01

NOTE: Revised switches did not change part

number but can be identified by referring to the

date code as shown in figure 1.

Date Code Interpretation. (♠

♠♠

♠)

Looking at the five digit date code, the 3 digits

after the numeral “5” signify the week and the

year of manufacture.

Some possible date code examples are:

A5311 Worker A week 31 year 2001

5311k Worker K week 31 year 2001

53112 Worker 2 week 31 year 2001

Revised Switches were manufactured from:

“week 31, 2001”

Figure 1.

SERVICE RECTIFICATION

On vehicles with the above condition fit a new

turn signal switch manufactured after the date

code referred to in Figure 1.

All HSPO stocks of turn signal switches are of

the revised type.

NOTE: DO NOT REPLACE THE DRIVERS

AIRBAG CONTACT UNIT FOR THIS

CONDITION.

PARTS INFORMATION

Part No.: Description: Qty:

09185413 Switch turn signal –

without cruise

control.

Attention Parts Managers! Any switches with

a pre-breakpoint date code should be returned

to HSPO for credit.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP.

HOLDEN SERVICE TECHLINE_____________________________________________________________MARCH, 2002

Speedo Drops Out Whilst Driving –

Resumes After Ignition Cycled

TS with ABS

(GROUP 12) TL221-0202

PROBLEM DESCRIPTION

On some vehicles the speedo may cease

operating whilst driving and then resume after

the ignition is cycled.

This condition can result if the vehicle has

mistakenly been fitted with a “Control Unit -

Speed Sensor Signal Convertor” in production.

PRODUCTION RECTIFICATION

100% inspection in assembly plant to ensure

the “Control Unit - Speed Sensor Signal

Convertor” is not fitted from:

ISOVIN: Build Date:

W0L0TGF4825076018 16/11/01

SERVICE RECTIFICATION

Summary: Remove “Control Unit - Speed

Sensor Signal Convertor” if fitted.

1. Confirm the vehicle is fitted with ABS.

These vehicles are identified by the 5

wheel studs. Non ABS have 4 wheel

studs.

2. Check the vehicle build date to confirm

vehicle is pre-breakpoint

3. Inspect the relay box to check if the

“Control Unit - Speed Sensor Signal

Convertor” is fitted. The relay box is

located under the steering column.

Affected part number is 09185826, is

orange in colour, and is located in the top

left hand corner of the relay box.

4. Remove if installed.

5. If not installed, continue with normal

diagnosis applicable to the complaint

condition present.

Please submit a PIR if:-

• Removal of control unit fails to rectify this

condition or

• The control unit is found fitted to a post

breakpoint vehicle.

PARTS INFORMATION

Part No.: Description: Qty:

09185826 Control Unit – Speed

Sensor Signal

Convertor

WARRANTY CLAIM INFORMATION

Description Remove Control Unit –

Speed Sensor Signal

Convertor

Labour Op. No. N000369

Time 0.2 hr

Failure Code 54 (wrong part fitted)

HOLDEN SERVICE TECHLINE_____________________________________________________________MARCH, 2002

Introduction Of Improved Air

Conditioning Compressor

XC Barina, TS Astra except Z22SE

engine

(GROUP 02) TL239-0202

An improved, more durable compressor has

been introduced for the above models. The

main change is the replacement of the bronze

coated steel swashplate with a solid bronze

swashplate.

PRODUCTION RECTIFICATION

Revised compressors have been fitted to

vehicles from start of Model Year 2002:

ISOVIN: Build Date:

W0L0XCF0824002194

27/8/2001

W0L0TGF3522030146

31/8/2001

PARTS INFORMATION

All stocks of HSPO compressors are of the

improved type.

The compressor part number remains

unchanged at 09165714.

Part No.: Description: Qty:

09165714 Compressor air

conditioning

Steering Column Upper Bearing

Excessive Movement

VT, VX, VU, WH

(GROUP 9) TL212-0202

PROBLEM DESCRIPTION

Some customers may complain the steering

wheel has excessive freeplay.

Investigation of complaint vehicles shows balls

from the upper steering column bearing have

dislodged from their cage.

PRODUCTION RECTIFICATION

New steering columns with a double-sided

metal cage (instead of a single sided plastic

cage) are expected to enter vehicle production

in early March.

Production breakpoints will be published in the

Breakpoint Summary in the next issue of

Service Techlines.

SERVICE RECTIFICATION

Order and install a new steering column to the

affected vehicle. These columns are available

from HSPO.

PARTS INFORMATION

Part No.: Description: Qty:

92145394 Column Asm - RHD 1

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP.

Update

HOLDEN SERVICE TECHLINE_____________________________________________________________MARCH, 2002

Auto Transmission - Harsh Upshifts

VX & VU Series I, WH A8A upgrade, with

Gen 3 Auto

(Group 7B) REVISED TL195A-0202

This Techline is revised to correct the oil pan gasket

part number and to expand on step 2. -reflashing

PCM. The previous Techline in Issue 1/2002

should be discarded.

NOTE: This Techline does not apply to VTII or WH

pre A8A models. A service fix for these models is

expected in May 2002.

PROBLEM DESCRIPTION

A typical complaint transmission will exhibit a

harsh 1-2 shift with “end of shift bump” and a

harsh 2-3 shift.

PRODUCTION RECTIFICATION

Revisions to improve the transmission shift

quality were introduced at start of production

of VX,VU & WH, Series 2.

ISOVIN: Build Date:

VXII - 6H8VXK69F2L763647 23/08/01

VUII - 6H8VUK80F2L763676 24/08/01

WHII - 6H8WHY19F2L763313 24/08/01

SERVICE RECTIFICATION

Summary: - Install revised 1-2 accumulator

and reflash PCM with latest software.

Step 1. Replace 1-2 Accumulator

NOTE: For detailed procedures refer to

PV SIP, VX, Section 7C5.

1.1 Check ISOVIN to ensure vehicle Model

Year is 2001.

1.2 Place vehicle on hoist.

1.3 Remove Transmission oil pan. Figure 1.

1.4 Remove 1-2 Accumulator. Figure 2.

1.5 Install new 1-2 Accumulator part number

24220143. Ensure that accumulator

piston is in position. Tighten bolts (58 and

59) to 8-14 Nm.

1.6 Reinstall transmission oil pan with new

gasket.

1.7 Lower vehicle and refill transmission with

specified fluid.

Step 2. Reflash PCM

Reflash PCM with the latest software

calibration for VX, VU and WH, Series 2

models from TIS 2000 version 28.0 or later.

IMPORTANT: Until TIS 2000 version 30.0 is

released it is strongly recommended that the

Gen3 PCM Flash Programming Hint given in

the following Service Techline be applied.

PARTS INFORMATION

Part No.: Description: Qty:

24220143 1-2 Accumulator 1

08654799 Gasket oil pan 1

WARRANTY CLAIM INFORMATION

Description Replace 1-2 Accumulator &

reflash PCM

Labour Op.No. K000276

Time 0.8hr

Failure Code 43 (shifts hard)

Figure 1.

Figure 2. (Number references are from SIP CD)

HOLDEN SERVICE TECHLINE_____________________________________________________________MARCH, 2002

Flash Programming Hint for Gen 3 PCM

VX, VU, V2, WH(A8A)

(GROUP 6C) TL241-0202

PROBLEM DESCRIPTION

When flash programming the PCM in above

models “electrical noise” (generated on the

class 2 communications circuit between Tech

2 and the PCM) may cause the process to

slow or stop altogether.

SERVICE HINT

To avoid the above problem the following

procedure is required:

• Just before the downloading phase (from

Tech 2 to PCM) install a 200 to 250 ohm

resistor into the rear of the Data Link

Connector bridging the terminals 2 (Y-1049)

and 5 (B/Y-155). Refer Figure 1.

• With resistor in place, use multimeter to

check resistance between terminals 2 and 5.

Reading should be somewhere between

170 and 220 ohm.

• Continue with programming.

• Remove resistor on completion.

Notes:

If programming PCM (without resistor) and

process slows or stops, it is possible to

proceed normally once the resistor is installed

provided that Tech 2 has not been

disconnected.

If you still have difficulties with flash

programming even with the resistor installed

as above have a nominated representative

contact TAS.

The use of the resistor for flash programming

Gen 3 in above models will not be required

when TIS 2000 version 30.0 becomes

available.

Figure 1.

Update

HOLDEN SERVICE TECHLINE_____________________________________________________________MARCH, 2002

Tensioner Rattle/Noise

TR Astra with C16SE, C18SEL, X20XEV

engine

(Group 6Y) REVISED TL192A-0202

This techline is revised by changing the case type in

warranty claim information. Please discard

previous bulletin in Issue 1/2002.

PROBLEM DESCRIPTION

On some vehicles the following symptoms may

be observed:

• Rattle noisy from front of motor at idle.

• Belt tensioner vibrates excessively up &

down.

Investigations show that the alternator induces

a high oscillating load through the accessory

belt and tensioner. This in turn causes the

tensioner damping nylon ring to wear

prematurely thus reducing the damping and

causing the tensioner to oscillate and rattle.

The condition is more noticeable when the

engine is cold.

SERVICE RECTIFICATION

Summary: Remove standard alternator pulley

and replace with “decoupler pulley”.

Procedure:

1. Remove alternator assembly from vehicle

using procedure in TIS CD.

2. Remove alternator pulley nut with an impact

gun.

3. Install decoupler pulley using special tools A

and B as shown in Figure1.

4. Torque pulley attaching nut to 80 – 100 Nm.

5. Press cap plug into decoupler pulley. It is

important this cap is fitted to prevent the

entry of foreign material.

6. Reinstall alternator to vehicle.

SPECIAL TOOLS

Tool A. - Hazet Tool No. 2592 (Adapter)

Tool B. - Hazet Tool No. 2751 (long hexdrive

socket)

For dealerships wishing to purchase their own

tools, contact PB Baumann Tools Australia

who will direct you to the closest Hazet tool

Agent.

Telephone: 02 9816 1233.

Email: info@pbtools.com.au

NOTE: These tools can also be obtained on

loan from your Zone Service office.

PARTS INFORMATION

Part No.: Description: Qty

92145105 Decoupler pulley 1

92145244 Plug, sealing cap 1

WARRANTY CLAIM INFORMATION

For vehicles outside of warranty use case type

“07.”

Description Install Alternator

Decoupler pulley

Labour Op. No. J000698

Time 1.0hr

Failure Code 28 Rattles

Figure 1.

HOLDEN SERVICE TECHLINE_____________________________________________________________MARCH, 2002

Noisy Front Bearings – Diagnosis Hints

ALL V & W

(GROUP 3) TL231-0202

PROBLEM DESCRIPTION

Front Hubs returned to REPAC for complaints

of “Noisy” are often No Fault Found by the

supplier.

SERVICE RECTIFICATION

The following information is supplied to assist

in the diagnosis of front bearing noise

complaints:

1. Inspect for signs of impact damage to tyres,

wheels, wheel covers etc. Note: impact

damge is not covered by warranty.

2. Road test the vehicle in an attempt to

reproduce the customer’s complaint:

a) Ensure the complaint is not tyre noise. If

in doubt, compare with a known good

vehicle.

b) Use the smoothest road in your local

area.

c) Reduce cabin noise level as much as

possible (close windows, switch radio

and blower off).

d) Drive at the maximum allowable limit on

the chosen road.

e) Leave the vehicle in Drive (for

automatics) or the current gear (for

manuals) and allow the car to coast

down.

f) Listen for noise from the front of the

vehicle that changes as vehicle speed

decreases.

If the road is not long enough, this may

need to be done in stages (ie starting

speed of second run is the end speed of

the first run)

g) If no noise is apparent try driving

around bends or swerve within the

lane to induce a side load on the

bearing

3. Given that it can be hard to determine which

side the noise is coming from, it may be

necessary to remove the road wheels and

brake discs and rotate the hubs by hand. A

noisy bearing will feel “gritty” or rough when

turned by hand compared to a new bearing

or the hub on the other side of the vehicle.

4. When the failed/noisy bearing has been

identified, replace it only. DO NOT replace

the other hub at the same time! It is very

uncommon for both hubs to fail at the same

time.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP.

HOLDEN SERVICE TECHLINE_____________________________________________________________MARCH, 2002

Door Cladding - Chrome Strip Detaches

At Ends, Material Delaminates

(GROUP 01) TL226-0202

PROBLEM DESCRIPTION

The large door mouldings (cladding) have a

chrome moulding strip adhered in a channel

along the upper edge. On some vehicles this

chrome moulding may experience

delamination of the clear outer layer which

looks unsightly. The ends of the chrome

moulding may also become detached from the

door cladding.

The cause of the delamination is moisture

ingress into the end of the chrome moulding.

This has been been rectified in production by

improving the process which applies sealer to

the ends of the chrome strip

To prevent the chrome strip detaching at the

ends, an additional 5mm material has been

added to the door moulding “end caps”. Refer

Figure 1.

PRODUCTION RECTIFICATION

Revised door mouldings with 5mm longer end

caps have been fitted to vehicles from:

ISOVIN: Build Date:

6H8WHZ19FXL820671 25/01/02

SERVICE RECTIFICATION

Summary:

1. Replace chrome strip if damaged .

2. Re-adhere chrome strip if not damaged but

is detached/curled at ends.

3. Replace door cladding if end caps are

damaged or broken.

Notes on Replacing Chrome strip.

• Peel chrome strip from door cladding

slowly in order to remove as much of the

adhesive as possible.

• Remove any remaining adhesive and wipe

channel with prepsol or similar.

• Install new chrome strip with double sided

tape provided.

• To improve retention of the ends of the

chrome strip, apply a small amount of

urethane p/n 92143609 to adhere the strip

to the door panel. Ensure any excess

urethane is removed with appropriate

solvent.

For all other procedures on removing and

replacing door mouldings refer to PV SIP.

PARTS INFORMATION

Part No.: Description: Qty

92143209 Old

92145245 New

Moulding Asm

Front Door (RH).

92143211 Old

92145247 New

Moulding Asm

Rear Door (RH).

92143210 Old

92145246 New

Moulding Asm

Front Door (LH)

92143212 Old

92145248 New

Moulding Asm

Rear Door (LH)

Parts Notes: Old = pre-breakpoint parts.

New = post-breakpoint parts

When existing HSPO stocks of old level door

cladding are exhausted they will be

superceded by the new design parts (5mm

longer end caps).

The door mouldings (cladding) are primed

only, and will require painting.

The chrome moulding strips must be ordered

separately.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP.

HOLDEN SERVICE TECHLINE_____________________________________________________________MARCH, 2002

Interior Dome Light Stays On or Fuse

Blows

V2 Monaro

(GROUP 12) TL229-0202

PROBLEM DESCRIPTION

Some vehicles may experience the following

symptoms:

• The interior dome light remains on

regardless of switch position.

• Interior light fuse blows when light switched

on.

• Interior lights flash erratically at times.

The above symptoms may be caused by the

wiring harness in the drivers side B pillar being

trapped/damaged by the upper seatbelt anchor

point. Refer Figure 1.

PRODUCTION RECTIFICATION

Production process revised to prevent damage

to B Pillar wiring harness from:

ISOVIN: Build Date:

6H8V2X37F2L819421 25/1/02

SERVICE RECTIFICATION

On complaint vehicles check for trapped wiring

harness under the RHS upper seat belt anchor

point.

Repair any damaged wiring as required.

WARRANTY CLAIM INFORMATION

For wiring and connector warranty claim

submission information refer to current PV SIP.

Figure 1.

Noisy Rear Door Checklinks – Reduced

Service Interval

VT, VX, WH

(GROUP 1) TL233-0202

PROBLEM DESCRIPTION

Some customers may complain of noisy rear

door checklinks.

SERVICE RECTIFICATION

Rear door checklinks should be cleaned of dirt

or debris and lubricated at every service.

Previously the service interval for lubricating

checklinks was every 20,000km.

Apply NLGI No. 2 Polyurea Grease(Mineral Oil

Base) to the checklink arm. Refer to PV SIP-

VTII, Section 0B, group 9 &10 for details.

WARRANTY CLAIM INFORMATION

This is a retail operation and should be

conducted as part of vehicle scheduled

servicing.

HOLDEN SERVICE TECHLINE_____________________________________________________________MARCH, 2002

Gearshift Lever Knob Rattle/Buzz

VTII, VX, VU, V2, Gen 3 Manual Trans.

(GROUP 7A) TL225-0202

PROBLEM DESCRIPTION

The gearshift knob vibrates to the point where

it can generally be heard in 3rd or 4th gear at

wide open throttle between 2500 to 4000 rpm.

This condition is a result of excessive

clearance between the shifter knob and the

shifter lever.

PRODUCTION RECTIFICATION

Transmissions with gearshift knobs glued to

the gearshift lever will be fitted to vehicles in

early March. The breakpoint for this change

will be published in the Breakpoint Summary in

the next issue of Techlines.

SERVICE RECTIFICATION

Summary: Glue gearshift knob to lever.

1. Remove the gearshift knob and gearshift

lever boot. Refer to PV SIP.

2. With the boot inverted back over the knob,

apply one of the following adhesives to the

insert of the shifter knob:

♦ A urethane adhesive such as Holden p/n

92143609 or

♦ A silicone based adhesive/sealer such as

Loctite Black Max 5900 or Dow Corning 7135

The quantity of adhesive should be sufficient

to result in a small excess squeezing out past

the tangs when the knob is refitted to the

shifter lever. This excess should be cleaned

away. Note: The customer should be

advised not to apply excessive force to the

knob until full strength bonding is achieved in

about 24 hours.

3. Reinstall the boot to the console. Refer to

PV SIP.

PARTS INFORMATION

Urethane adhesive p/n 92143609 can be

purchased from HSPO.

Loctite “BlackMax 5900” and Dow Corning

7135 may be purchased from most bearing

suppliers or engineering products retail outlets.

WARRANTY CLAIM INFORMATION

Description Glue gearshift knob to

lever.

Labour Op. No. K000279

Time 0.3 hr

Failure Code 36 (vibrates)

SERVICEABILITY OF THE GEARSHIFT

LEVER BOOT

A Service Techline will be published in the

near future which provides details on

serviceability of the gearshift lever boot when

the knob is glued to the lever.

HOLDEN SERVICE TECHLINE_____________________________________________________________MARCH, 2002

Alloy Wheel Centre Cap Dislodges

Easily

TS - Alloy Wheel 09117922 (6 spoke, 5

bolt holes)

(GROUP 10) TL208-0202

PROBLEM DESCRIPTION

On some vehicles fitted with the alloy wheel

part number 09117922, the centre cap may

dislodge while the vehicle is being driven.

Investigations have traced this problem to a

batch of wheels which were not machined to

specification. The suspect wheels all have the

marking “SM” cast into the wheel centre, and

were manufactured during the period January

to June 2001.

Figure 1 shows the location of the marking

“SM” as well as the date of manufacture on a

small “clockface” cast into one of the spokes

on the inside of the wheel. The two numbers

in the centre represent the year. The small

raised dot appearing in one of the 12

segments represents the month.

Figure 1.

PRODUCTION RECTIFICATION

All Alloy wheels with the supplier marking “SM”

manufactured from July 2001 are ok.

SERVICE RECTIFICATION

On any complaint wheel where the centre cap

falls off, inspect the wheel markings as shown

in Figure 1. Any complaint wheel with the

marking “SM” which was manufactured

between Jan to June 2001 should be replaced.

PARTS INFORMATION

Part No.: Description: Qty:

09117922 Wheel alloy 6Jx15 (5

bolt hole)

90539447 Cap asm wheel

centre

NOTE: Alloy wheels with the supplier marking

“BOH” are not affected.

WARRANTY CLAIM INFORMATION

Description Alloy Wheel - Replace

Labour Op.No. E000358

Time 0.4 hr (add 0.3 for each

extra wheel)

Failure Code 31 (Poor Matching)

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Engine Vibration – Loose Engine Mount

Bolt

(GROUP 6A) TL247-0203

PROBLEM DESCRIPTION

PIR’s have been received that mention

engine/transmission vibration – and diagnosis

has shown that a loose/missing rear powerplant

mounting bolt was the cause.

SERVICE RECTIFICATION

Summary: Refit/Replace bolt and Apply Loctite

243.

Should diagnosis of a “vibration” complaint define

that a rear powerplant mounting bolt is:

a/. Loose – remove the mating nut, apply Loctite

243 (or equivalent) to the bolt threads and refit

the nut, and torque to 55Nm.

b/. Missing – Fit a new bolt and nut (from

HSPO), apply Loctite 243 (or equivalent) before

installation and torque to 55Nm.

Rear Engine Mounting Assembly Precaution.

Note: when attaching the damper block to the

(upper) bracket – ensure the raised “key” section

(3) of the damper is located in the recess (2) in

the bracket, as shown in Figure 1.

Figure 1.

For Reference: The above diagram is taken from

TIS 2000 – Refer to the relevant TIS 2000

section when replacing engine/powertrain

mounts.

PARTS INFORMATION

Use the following parts ONLY when replacement

of missing parts is required:

Part No.: Description: Qty:

11098991 Bolt – Damper to

Bracket.

11098811 Nut – Damper to

Bracket.

WARRANTY CLAIM INFORMATION

Description Engine mount bolt/nut -

Replace

Labour Op. No. J000704

Time 0.3 hr

Failure Code 27 (Loose) or

29 (Part Missing)

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Welch Plug Requirement - During Engine

Block Replacement

All with Gen III Engine

(GROUP 6A) TL248-0203

PROBLEM DESCRIPTION

When replacing a Gen III engine block –

replacement blocks are NOT fitted with three

welch plugs. Refer key nos. 1, 5 and 7 in Figure

The fitting of these welch plugs can easily be

overlooked, and will result in oil leakage or lack

of oil pressure on start-up.

SERVICE RECTIFICATION

The welch plugs should be ordered when

ordering the engine block and fitted during the

replacement.

Order one each of the welch plugs shown in

Parts Information. Locations for fitting the welch

plugs are shown in Figure 1.

Refer to PV SIP, VTII, Section 6A3, Item 3.14

for procedures on removing and installing these

plugs.

PARTS INFORMATION

Part No.: Description: Qty:

12557520 Plug – Oil Level

Indicator Hole

12573460 Plug – Oil Gallery,

Rear

09427693 Plug – Oil Gallery,

Front

Figure 1.

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Steering Knock/Rattle

JS Vectra

(GROUP 9) TL252-0203

Refer to the two previous Techlines on this

subject in PV SIP, Service Techlines, 1998,

Group 9.

Many steering columns, and steering gear

assemblies replaced under warranty for noise

complaints cannot be faulted.

The replacement of steering columns and

steering gears to rectify knock/rattle condition is

not generally recommended as there are no

known problems with these components.

Intermediate shafts however, have had a known

rattle condition and should be replaced to rectify

complaint vehicles. it is important to note that

the new intermediate shaft will still

rattle/knock unless the upper and lower pinch

bolts are tightened to specification.

SERVICE RECTIFICATION

Whenever presented with a customer complaint

of steering knock/rattle we strongly recommend

that only the intermediate shaft be replaced.

For intermediate shaft replacement procedure

refer to previous Techline in PV SIP, Service

Techlines, 1998, Group 9.

IMPORTANT: The “new” upper and lower pinch

bolts must be tightened to:

22Nm(16 lbf.ft) + 45º + 15º

Brake Squeal Rectification

TS – Non-ABS models only

(GROUP 5) REVISED TL259-0203

This Techline which now supercedes the previous

one, is revised by adding a special labour

operation number to Warranty Claim Information.

PROBLEM DESCRIPTION

Some non-ABS equipped TS Astra vehicles may

exhibit a squeal noise under braking.

New front brake pads have been released to

address this squeal.

The new pads have the leading and trailing edges

of the friction material chamfered to move the

squeal frequency outside the audible range.

PRODUCTION RECTIFICATION

The revised brake pads have been fitted in

production from March 2002. When they become

available, breakpoints will be published in the

Service Techline Breakpoint Summary.

SERVICE RECTIFICATION

To address customer complaints, fit the revised

brake pads. These brake pads are available from

HSPO.

PARTS INFORMATION

Part No.: Description: Qty:

93171035 Pad Set-Front Brake 1

WARRANTY CLAIM INFORMATION

Description Pads, disc brake, both

front wheels - replace

Labour Op. No. H000222

Time 0.9 hr

Failure Code 40

Update

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Water Leak Between Top Edge Of Door

Glass and Door Frame Seal

V2 Monaro

(GROUP 1) TL258-0203

PROBLEM DESCRIPTION

Some vehicles may experience water leaking into

the vehicle over the top of the door glass. The

area of concern occurs over a distance of about

100mm forward from the rear vertical edge of the

glass.

SERVICE RECTIFICATION

On any vehicle with the above complaint,

1. Check for correct installation of the door frame

weatherstrip. (Item 1 in Figure 1.)

2. Check window regulator and window

glass adjustment. Refer to PV SIP, V2,

Section 1A5, Item 2.9

3. Confirm if leak is still present.

4. If leak is still present, install a new Weatherstrip

Assembly. Refer to PV SIP, V2,

Section 1A5, Item 2.10 After new

weatherstrip asm. is installed, ensure that the

window glass tucks up under the sealing lip of

the weatherstrip as shown in section AA of

Figure 1.

PARTS INFORMATION

Part No.: Description: Qty:

92092896 Weatherstrip Asm. -

Felt Front Door

Glass (RH)

92092895 Weatherstrip Asm. -

Felt Front Door

Glass (LH)

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

Figure 1

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Wheel Nut Usage - Alloy And Steel Wheels

All V & W

(GROUP 10) TL255-0203

The purpose of this Techline is to highlight the

importance of only using those wheel nuts that

are specified for the type of wheel fitted to the

vehicle.

Originally, alloy wheels had steel nut-seats.

However, in most current design alloy wheels the

steel nut-seats have been deleted and the wheel

nuts now bear directly onto the alloy. The wheel

nuts designed for use on alloy wheels without

steel nut-seats have a much larger taper to

provide increased clamping area.

NOTE :

1. Do not use nuts that are specified for use

with steel wheels to retain alloy wheels.

2. Do not use nuts that are specified for use

with alloy wheels to retain steel wheels.

If wheel nuts designed for use with steel wheels

are used on alloy wheels without steel nut-seats,

there is potential for the following problems to

occur:

1. Lack of sufficient clamp load.

2. Localised nut bite into the alloy nut-seat.

3. Potential fatiguing of the wheel studs.

4. Potential fatigue and/or cracking of the alloy

wheel nut seats.

The following table shows the various nuts

specified in Partfinder with the model usage.

Remember to always refer to Partfinder to

determine which nut is specified for the wheels

concerned.

Part Number

For use on

wheel:

Models

22526184

Alloy wheel

(No steel nut

seat)

V2,VX,WH,VU,

VS,VT

92037665

Alloy wheel

(steel nut seats)

WH, VT, VS

92100089

Alloy wheel

(No steel nut

seats)

92045082

Steel wheel VX,VU,VT,VS,

VP, VR,

92015262

Steel wheel VX,VT,VS,VP,

VR, VQ, VB

Update

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Centre High Mount Stop Light Rattle

V2 Monaro

(GROUP 12) TL240-0203

PROBLEM DESCRIPTION

Some customers may complain of a rattle coming

from the rear parcel shelf area.

On some vehicles the cause of this rattle has

been traced to the Centre High Mount Stop Light

(CHMSL). Under certain driving conditions the

LED assembly vibrates within the CHMSL

housing resulting in a rattle.

PRODUCTION RECTIFICATION

CHMSL’s with the LED/lens assembly glued to

the housing as shown in Figure 1, have been

fitted to vehicles from:

ISOVIN: Build Date:

6H8V2X37F2L827493 12/02/02

SERVICE RECTIFICATION

Summary: Glue LED assembly to CHMSL

housing

To rectify complaint vehicles proceed as follows:

1. Remove CHMSL (refer to PV SIP CD).

2. Glue the LED/lens assembly to the main

housing as shown in Figure 1. Use a

cyanoacrylate adhesive such as Loctite 406.

Ensure that any excess does not show on

external surface of housing.

3. Reinstall CHMSL. (refer to PV SIP CD).

NOTE: On vehicles where the LED assembly has

been glued to the CHMSL housing; it will be

necessary to break the glue bond if the LED

assembly requires replacement. If this cannot be

done successfully then replace the complete

CHMSL assembly.

Figure 1.

PARTS INFORMATION

Part No.: Description: Qty:

92094523 Centre High Mounted

Stop Lamp Assembly

92144531 Bulb, LED, Printed

circuit board & harness

92144530 Lens 1

WARRANTY CLAIM INFORMATION

Description Glue LED/lens assembly

to CHMSL housing

Labour Op. No. N000378

Time 0. 4hr

Failure Code 28 rattles

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Engine Oil Consumption Information

All

(GROUP 6A) TL260-0203

This Techline is provided for general information.

All engines require oil to lubricate and protect the

load bearing and internal moving parts from wear

including cylinder walls, pistons and piston rings.

When a piston moves down its cylinder, a thin film

of oil is left on the cylinder wall. During the power

stroke, part of this oil layer is consumed in the

combustion process. As a result, varying rates of

oil consumption are accepted as normal in all

engines.

Many external factors, such as owner driving habits

and vehicle maintenance, can affect the rate of oil

consumption.

The following are some important items affecting

oil consumption which must be taken into account

when evaluating customer complaint vehicles.

Gasket and External Leaks

Inspect the oil pan and engine covers for leakage

due to over-tightened, damaged, or out of place

gaskets. Inspect oil lines and fittings for signs of

leakage.

Improper Reading of the Oil Level Indicator

(Dipstick)

Verify that the dipstick tube is fully seated in the

block. When checking the oil level, make sure the

dipstick is wiped clean before taking an oil level

reading and fully

depress the dipstick until the shoulder bottoms out

on the dipstick tube. The dipstick should be the

proper part number for the engine/vehicle that is

being checked.

Not Waiting Long Enough After Running Engine

to Check Oil Level

The vehicle should be allowed to sit for at least 10

minutes after the engine has been shut off, before

taking an oil level reading to assure the oil has had

enough time to drain back into the crankcase. In

order to ensure accurate results, the temperature

of the oil should be close to the same temperature

as the last time the oil level was checked.

Improper Oil Fill After an Oil Change

Following an oil change, verify that the proper

amount and type of oil was put in the engine and

that the oil level on the dipstick is not above the full

mark or below the add marks. Refer to the

Owner's Manual or Service Manual for information

on recommended oil quantity, viscosity, and

quality.

High Speed or High RPM Driving

Continuous driving at high speeds/high RPMs may

increase oil consumption. Because this may not

always be an everyday occurrence, it is hard to

determine exactly how much the oil economy will

be affected.

Towing or Heavy Usage

Towing a trailer will increase oil consumption and

may cause oil consumption to fall below the normal

accepted rate referenced in this bulletin for an

unloaded vehicle in a personal use application.

Large frontal area trailers will further increase the

work required from the engine, especially at

highway speeds, and thus increases the rate of oil

consumption.

Crankcase Ventilation System

Verify that the positive crankcase ventilation (PCV)

system is operating properly. Incorrect PCV

valves, blockages, restrictions, or damage to the

PCV system can result in increased oil use.

Oil Dilution (Fuel and Water)

On vehicles that are usually driven short distances,

less than 8 km, especially in colder weather,

unburned fuel and condensation generated from

cold engine operation may not get hot enough to

evaporate out of the oil. When this occurs, the

dipstick may indicate that the oil level is over-full.

Subsequent driving on a trip where the engine is at

normal operating temperature for 30 minutes or

more, will vaporize excess moisture and fuel, and

may give the customer the impression of excessive

oil consumption if the oil level is checked

immediately after.

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Engine Temperature

If an engine is run at overheated temperatures (see

Owner's Manual or Service Manual) for more than

brief periods, oil will oxidize at a faster than normal

rate. In addition, gaskets may distort, piston rings

may stick, and excessive wear may result. Verify

that all cooling system components are in proper

working order.

Engine Wear

Piston scuffing, excessive piston-to-wall clearance,

tapered or out of round cylinders, worn, damaged

or improperly installed valve guides, seals and

piston rings will all cause an increase in oil

consumption.

Interior Rattle Noise Diagnosis

All Models Fitted With Melbourne CityLink

e-Tag device

(GROUP 1) HINT TL261-0203

This techline was first issued in 2000. It is

reissued due to ongoing cases of noise mis-

diagnosis.

When investigating instrument panel “rattle”

complaints, where a vehicle is fitted with an “e-

TAG” unit (electronic signal transmitter for use on

the Melbourne CityLink electronic tollway system),

first remove the e-TAG unit.

Any rattle that may emanate from the “e-TAG”

unit could lead to misdiagnosis of the noise, in the

belief that interior trim or components in the

instrument panel may be the cause.

NOTE: “e-TAG’s” are 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 gripping the “e-TAG” and rotating

the top rearwards and downward.

Should an “e-TAG” be defined as the cause of a

rattle noise – the customer should be advised that

the rattle is emanating from the “e-TAG”, not the

vehicle.

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Design Changes To Condensor and

Receiver Dryer

TS and TT Model Year 2002

(GROUP 2) TL249-0203

The receiver dryer on the above models is now

integrated into the side tank of the condensor.

This design enables replacement of a cartridge

containing the drying granules instead of

replacing the complete receiver dryer as in

previous models. Figure 1 shows the cartridge

removed from the condensor.

NOTE: The quantity of R134A refrigerant in the

A/C system has been reduced as a result of this

design change. Refer to the label in the engine

compartment or to TIS for specified quantities of

R134A.

Figure 1

PRODUCTION CHANGE INFORMATION

The new design condensor with integral receiver

dryer has been fitted to vehicles from

commencement of Model Year 02:

Model ISOVIN:

TS Hatch W0L0TGF4825003949

TS Sedan W0L0TGF6925010206

Zafira W0L0TGF752H000000

PARTS INFORMATION

Part No.: Description: Qty:

93170609 Receiver Dryer

(cartridge)

93170608 Condener asm. 1

SERVICING THE RECEIVER DRYER

To replace the Drying Agent Cartridge refer to

procedure in TIS 2000 CD. To find procedure in

TIS follow the path as shown in table:

Item Select

Sales Make Opel

Type of Info. Standard Information

Vehicle Data Astra-G or Zafira, 2002

Assembly Group (D) HVAC

Application Repair(Remove,Install,

Adjust)

Document List Document No. 25 of 126

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Excessive Gear or Road Noise from M/T

Shifter Area

VTII, VU, VX,V2 with 6 speed M/T (MM6)

(GROUP 7A) TL227-0203

PROBLEM DESCRIPTION

Some customers may complain of excessive

noise coming from the transmission shifter area.

This condition may be caused by:

a) Inner boot torn or split as a result of

excessive wear, or

b) Retainer plate loose.

Note: A boot collar turned upwards as shown in

Figure 1 can contribute to excessive wear of the

boot convolutions.

Figure 1. Problem of upturned boot collar

PRODUCTION RECTIFICATION

To improve both the product and the assembly

process, the following revisions have been made:

• The boot collar has been revised to fit into a

recessed groove in the remote shifter lever.

Note the new collar is now upturned. These

changes provide positive location for the boot

collar. Refer Figure 2.

• The boot material has been changed for

improved durability. The new boot material is

white in colour.

• The boot asm. attachment method has been

revised. The retainer plate now has 4 welded

on studs. The previous nutserts retained in

the sheetmetal have been replaced with 4

nuts applied from below the vehicle during

assembly.

Transmissions with the above changes have been

fitted to vehicles from:

ISOVIN: Build Date:

6H8VUK80F2L832048 21/02/2002

SERVICE RECTIFICATION

Summary: Check boot for condition and

installation. Install new boot as required.

1. Remove gearshift knob and outer trim boot

assembly. For procedure refer to PV SIP,

VTII, Section 7B3, Item 3.5.

2. Check the inner boot for tears, splits or

excessive wear. If damaged, replace with

new boot asm. If boot is okay, but collar is

upturned as in Figure 1, the boot should be

removed and reinstalled with the collar turned

downwards.

3. Installation of new design boot asm. on

vehicles built prior to breakpoint.

After installing new design boot asm.

92145520(without studs), the collar of the

boot must be glued to the remote shifter lever

4mm below the step as shown in Figure 2.

Use a “super glue” such as Loctite 406.

4. Installation of new design boot asm. on

vehicles built after breakpoint.

When installing new design boot asm.

92065868(with studs) it is not necessary to

glue the boot collar to the remote shifter lever

(refer step 3) as it will be positively retained in

the recessed groove as shown in Figure 3.

The four attaching nuts applied from

underneath the vehicle are to be torqued to 12

–18 Nm.

Figure 2.

Boot colla

upturned

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Figure 3.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP.

PARTS INFORMATION

Part No.: Description: Qty:

92065868

Use From L832048

Boot Asm. M/T Control

Lever (4 studs in retainer

plate)

92145520

Use Prior to L832048

Boot Asm M/T Control

Lever (4 holes in retainer

plate – no studs)

NOTE: When you first receive this Techline the

above parts may not be immediately available.

However, orders may still be placed.

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

Revised TX Valve

SB Barina with A/C

(GROUP 2) TL232-0203

Ongoing product improvement has resulted in an

improved durability, replacement Thermal

Expansion Valve (TXV) becoming available for

the above model.

The new TXV (92144973) is visually the same as

the previous one (52464434).

SERVICE RECTIFICATION

Whenever a TX valve replacement is required, fit

a new part as shown in Parts Information.

PARTS INFORMATION

Part No.: Description: Qty:

92144973 Thermostatic

expansion valve kit.

NOTE: Quantities of 92144973 are not expected to be

available from HSPO until mid May, however orders

may still be placed.

Front Wiper Blades Noisy, Shudders

XC Barina

(GROUP 1) UPDATE TL237-0204

This Techline supersedes the previous Techline

on this topic in Issue 9, Sep 2001, which should

be destroyed.

PROBLEM DESCRIPTION

Windscreen wiper blade operating noise

excessive, as a result of wiper blade judder.

Investigations have shown the wiper blade profile

and material causes an incorrect attack angle and

high noise level as a result of blade deformation.

PRODUCTION BREAKPOINT

Ongoing improvements to the wiper blade design

on this model has resulted in a change of

suppliers. Bosch wiper blades have been fitted to

XC Barina vehicles from:

ISOVIN: Build Date:

W0L0XCF6824071208 07/11/01

SERVICE RECTIFICATION

On vehicles with complaint of noisy front wiper

blades:

1. Clean windscreen glass and rubber wiper blade

to remove all pollution deposits and foreign

material contamination.

2. Operate wipers (with running water) and listen

for wiper blade noise.

3. If this fails to provide satisfactory wiper blade

noise levels, replace blades with new parts.

PARTS INFORMATION

The part number of the new Bosch wiper blades

is:

Part No. Description: Qty:

93171135 Set – Front

windscreen wiper

blades.

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

A/C TX Valve Noise

VTII, VX, VU, V2, WH, with Gen III

(GROUP 2) TL272-0204

PROBLEM DESCRIPTION

Some owners may complain of a rumble type

noise coming from the dash area with the A/C

operating.

Investigations show the TX valve can be the

source of this type of noise.

NOTE: There are reports that some dealers have

replaced compressors for this noise only to find

that the TX valve was actually at fault.

PRODUCTION RECTIFICATION

To reduce A/C noise, revised TX Valves p/n

92116220 (Eaton brand) have been fitted to

vehicles from:

ISOVIN: Build Date:

6H8VXK69F2L813616 09/01/02

A further breakpoint is expected in June for fitting

a new TX Valve, p/n 92117402 (TGK brand)

which is the same valve that was introduced into

V6 models from L854345 on April 11th,2002..

SERVICE RECTIFICATION

If available, use an electronic listening device to

determine where the A/C rumble noise is coming

from. If it is loudest at the low pressure pipe out

of the TX valve, then replace valve with revised

part as shown in Parts Information.

PARTS INFORMATION

Part No.: Description: Qty:

92117402 TX Valve 1

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

Tech 2 DTC Symptom Descriptors

Simtec Engine Management Systems

(GROUP OB) TL271-0204

TAS often receive queries about the number in

brackets appearing in line 3 of the Tech 2 DTC

Display. For Example;

Line 1. - P0115

Line 2. - Coolant Temperature etc.

Line 3. - (0)

The number in line 3, “(0)” represents the specific

symptom descriptor for the DTC displayed.

A list of the most frequently used symptom

descriptors is shown in the following table.

NOTE: Sometimes, symptom descriptors not

listed in the table may appear on Tech 2. These

descriptors will be specific to a particular part

manufacturer and will normally be listed in the

diagnosis chart.

(0) = "No fault symptom available for this

DTC"

Used if the DTC identified does not require any

additional fault symptom (E.g. defective

EEPROM).

(1) = "Above Maximum Threshold"

Could be either "High Input" or "High Voltage"

"Too Rich".

(2) = "Below Minimum Threshold"

Could be either "Low Input" or "Low Voltage" or

"Too Lean".

(4) = "No Signal"

Could be either "Range/Performance" or "No

Activity".

(8) = "Invalid Signal"

Could be either "Incorrect Ratio" or "Number of

Teeth Not Plausible".

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

Some examples of DTC’s with their specific

symptom descriptors are:

DTC 0335 (8)

"Crankshaft Position Sensor Malfunction"

(Number of Teeth Not Plausable).

DTC 0335 (4)

"Crankshaft Position Sensor Malfunction" (No

Signal / Signal Line Open).

Remote Sender Unit (Key Head) Operating

Frequency Revised From 315 to 433 MHz

TS Astra

(GROUP 12) TL269-0204

To improve the operating range of the remote

sender unit (key head), the operating frequency

has been revised from 315 MHz to 433 MHz. The

breakpoint for this change is shown below.

PRODUCTION BREAKPOINTS

Remote sender operating frequency of 433 MHz

fitted to vehicles from:

ISOVIN: Build Date:

Convertible -

W0L0TGF672B009028 30/01/02

All except convertible -

W0L0TGF4825156920 21/02/02

SERVICE NOTE

Whenever replacing senders or modules it is vital

that the same frequency replacement parts are

used. Do not use a 315 MHz sender with a 433

MHz module and vice versa.

Identification of senders.

The frequency of the sender is shown on the

sender as depicted in following figure.

Identification Of Modules.

Module identification can be performed in the

vehicle with a Tech 2.

PARTS INFORMATION

Refer Holden Partfinder for part numbers of all

service replacement senders and modules.

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

Improved Air Conditioning Compressor

XC Barina, TS Astra Z18XE engine only

(GROUP 02) REVISED TL239A-0204

This techline is revised by redefining the TS

models affected. The previous Techline in Issue

2, 2002 should be destroyed.

An improved, more durable compressor has been

introduced for the above models. The main

change is the replacement of the bronze coated

steel swashplate with a solid bronze swashplate.

PRODUCTION RECTIFICATION

Revised compressors have been fitted to vehicles

from start of Model Year 2002:

ISOVIN: Build Date:

W0L0XCF0824002194

27/8/2001

W0L0TGF3522030146

31/8/2001

PARTS INFORMATION

All stocks of HSPO compressors are of the

improved type.

The compressor part number remains unchanged

at 09165714.

Part No.: Description: Qty:

09165714 Compressor air

conditioning

Camshaft Cover Seal Leaks

JR(C20SEL), JS (C22SEL), UES (X22SE)

TR (C18SEL & X20XEV)

(GROUP 6A) TL266-0204

PROBLEM DESCRIPTION

Oil weep from camshaft cover seal area.

SERVICE RECOMMENDATION

Summary: Install a bead of RTV sealant in

addition to a new camcover gasket.

• Remove camshaft cover.

• Clean sealing surfaces before applying the

RTV sealant (P/N: 92144969)

Use a white spirit based cleaning solvent to

clean sealing surface.

Do not use abrasive pad/bristle devices which

will produce fine grit)

Do not gouge or scratch any engine sealing

surface during the cleaning process.

Do not allow any RTV residue to fall in the

engine.

• Apply a constant 2.0 mm bead of RTV sealant

to the cylinder head along the centre of the

cam cover sealing flange. Refer Figure 1 for

routing of bead.

• Reassemble the camshaft cover and new

gasket and torque fasteners within 5-10

minutes after sealant is applied to cylinder

head. Ensure the camshaft cover does not

slide around once in position as the RTV

sealant may be wiped off flange and fall into

engine.

• Allow the sealant to cure for a minimum of 1

Hour before running the engine.

Detailed service procedures:

For UES refer to LCV SIP.

For other models refer to TIS 2000.

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

Figure 1.

PARTS INFORMATION

Part No.: Description: Qty:

92144969 RTV sealant - tube 1

90501944 Gasket – camshaft

cover

NOTE: The sealant 92144969 is not expected to be

available from HSPO until mid May, however orders

may still be placed.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV or LCV SIP CD.

PRODUCTION RECTIFICATION

Bead of sealer added to cam cover gasket in

engines from:

Engine Eng. No. Date

C18SEL C18SEL 039419 March 01

C20SEL C20SEL 25033858 March 01

C22SEL C22SEL 25027168 March 01

X20XEV X20XEV 25038994 March 01

X22SE X22SE 25053552 March 01

Seat Squab Worn By Console Lid

JR & JS Series I Vectra CD models

(GROUP 1) TL251-0204

PROBLEM DESCRIPTION

The piping on the front seat bolsters contacts the

centre console box lid when the lid is

opened/closed. This may result in wearing of the

velour trim as shown in Figure 1.

Figure 1.

SERVICE RECTIFICATION

Summary: Install extra springs to front seat

bolsters to pull bolsters inwards.

Procedure for fitting springs:

1. Cut 15mm lengths of 4mm diameter heat

shrinkable plastic tubing and apply these to

each end of the spring as shown in Figure 2.

This is to prevent any metallic squeaking

noises.

2. Detach upholstery from the front seat back.

(Refer to Figure 3).

3. Carefully detach the foam as shown in Figure 3

to expose the lower horizontal crossmember of

the seat back frame.

4. On each side of the lower horizontal cross

member, drill a 3mm diameter hole 60mm

inwards from the seat cover side edge and

8mm below the top edge (just below the first

rib). Refer Figure 4.

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

5. At each side of seat, attach one end of the

spring to the seat back vertical trimming wire

(located through existing hole in the rubber hair

seat back), then, attach the other end to the

drilled hole in the lower horizontal cross

member. Refer figure 5.

6. Re-adhere foam to frame cross member with a

contact adhesive.

7. Reinstall upholstery to seat back.

8. Above procedure applies to both front seats.

Figure 2.

Figure 3.

Figure 4

Figure 5.

PARTS INFORMATION

Part No.: Description: Qty:

90569760 Spring 4

Obtain 4mm diam. heat shrinkable tubing

from your nearest electrical supplies

retailer.

WARRANTY CLAIM INFORMATION

Description Install extra springs to

bolsters on both front seats

Labour Op.No. C000451

Time 1.5 hr

Failure Code 62

NOTE: For vehicles out of warranty, approval

must be obtained from your Holden Aftersales

Business consultant to perform this work.

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

Backlash “Clunk” Noise - Information

VS with IRS, VT/VU/VX/V2/WH

(GROUP 4) TL277-0204

PROBLEM DESCRIPTION

A significant number of IRS differentials are

being replaced for backlash “clunk” noise

complaints. When tested, these differentials

all meet the suppliers backlash specification.

This Techline is provided to ensure

technicians thoroughly diagnose such

complaints and determine whether any

complaint noises are characteristic, and

exactly which component is the noise source

– before attempting any differential

replacement.

Owners may comment that their vehicle

exhibits a “clunk” noise while driving, when

the accelerator is quickly depressed and then

released, especially during gear changes.

Whenever there are two or more gears interacting

with one another, there must be a certain amount

of clearance between those gears in order for the

gears to operate properly. This clearance or

freeplay (also known as lash) can translate into a

clunk noise whenever the gear is loaded and

unloaded quickly, or whenever the direction of

rotation is reversed. The more gears you have in

a system, the more freeplay the total system will

have.

The clunk noise that owners sometimes hear may

be the result of a buildup of freeplay (lash)

between the components in the driveline.

For example, the potential for a driveline clunk

would be greater in a 4-wheel drive or all-wheel

drive vehicle than a 2-wheel drive vehicle. This is

because, in addition to the freeplay from the rear

axle gears, the universal/constant velocity joints,

and the transmission (common to both types of

vehicles), the 4-wheel drive transfer case gears

(and their associated clearances) provide

additional freeplay to the driveline.

In service, retailers are discouraged from

attempting to repair driveline clunk conditions for

the following reasons:

• Comments of driveline clunk are almost never

the result of one individual component with

excessive lash, but rather the result of the

added affect of freeplay (or lash) present in all

of the driveline components. Because all of the

components in the driveline have a certain

amount of lash by design, changing driveline

components may not result in a satisfactory

lash reduction.

• While some owners may find the clunk noise

objectionable, this will not adversely affect

durability or performance.

SERVICE ACTION

Whenever presented with a customer concern of

driveline “clunk” ensure that the customer is made

aware of the above facts.

Also ensure that before replacing any

components in the vehicle that a full and proper

assessment is made of:

- age of vehicle,

- engine/trans. combination,

- kms travelled,

- customer driving style,

- distance travelled,

- WHERE or WHICH PART the noise generated

from,

Retailers may also wish to allow the customer to

drive a “like” vehicle (same body style, engine,

trans.) to confirm similarity of condition – where

the condition may be characteristic, and not

necessarily complaint level. This can provide an

understanding of the condition, as some

customers may be overly concerned about

‘noises’ that emanate from vehicle components.

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

Blower Fan Motor/Resistor Diagnosis Hint

XC Barina with Air Conditioning

(GROUP 2) HINT TL278-0204

Thanks to Tony Luppino of Parker Brothers

for a PIR describing the cause of this problem.

PROBLEM DESCRIPTION

Customers may complain of partial or no

operation of the airconditioning fan.

Investigations have shown that, in some vehicles,

water may be entering the blower motor via the

filter housing to dash panel seal (item 3) shown in

Figure 1.

Figure 1

Some blower motors returned to REPAC which

show signs of water entry is further evidence of

this condition.

SERVICE RECTIFICATION

If a vehicle is presented with an inoperative

blower motor and water entry is evident (from rust

or moisture in the blower case), check the filter

housing to dash panel seal. Replace seal if

required.

PARTS INFORMATION

Part No.: Description: Qty:

09115349 Seal – Filter Housing

to Dash Panel

90535115 Fan Motor &

Housing asm. (C60)

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD.

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

LSD Additive Availability For Servicing

VS/VT/VX/VU/WH with IRS LSD

(GROUP 04) TL279-0204

PROBLEM DESCRIPTION

Many vehicles have had LSD additive and a

revised seal installed for a “chatter” condition

(Refer to Retailer Letter DL 30/02 which has

superseded Dealer Letter DL 54/01).

Until now, the additive has not been available for

differentials that require oil replenishment or top-

up following a repair.

This additive is now available from HSPO.

Before use of this additive, ALL Service personnel

should familiarise themselves with the guidelines

in below.

PRODUCTION RECTIFICATION

Final drives with the additive and revised seal

included have been fitted to vehicles from:

ISOVIN: Build Date:

6H8VXK69F1L762226 20/08/01

SERVICE ACTIONS

This additive is ONLY for use in replenishment of

oil, following repairs to final drive units that:

(a). are fitted to any vehicle built after breakpoint

L762226;

(b). are built before breakpoint L762226 and have

had the additive and the seal (as per DL 54/01 or

RL 30/02). These vehicles are identified by a

metal ID tag fitted to the rear of the differential,

carrying the words “Field Fix”, as shown here:

LSD “CHATTER”:

LSD “chatter” complaints must still be corrected in

vehicles covered by warranty – Refer to Retailer

Letter DL 30/02 (which supersedes DL 54/01).

PARTS INFORMATION

Part No.: Description: Qty:

92145121 Additive Kit 1

This kit consists of:

- 1 bottle, 100ml LSD Additive,

- Material Safety Data Sheet (for additive),

- ID Tag (in case of original tag damage.

This additive is NOT suitable for use in

differentials not fitted with the revised seal and

additive – as seal degradation and failure will

result.

Update

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Engine Hard To Start (DTC P1615, P1616);

Doors hard to open with Remote Key;

DTC B1485 Set

XC Barina

(GROUP 12) TL222-0205

PROBLEM DESCRIPTION

Vehicle may have one or more of the following

symptoms.

• Engine hard to start. SVS telltale flashes

while starting. DTCs P1615 and/or P1616

are stored.

• Difficulty in unlocking the car doors with the

remote control at first attempt. Several

attempts are usually needed to unlock the

doors. No problems are reported when

locking the car.

• DTC B1485 stored. No symptoms evident.

The above symptoms have been traced to a fault

in the -BCM software.

PRODUCTION RECTIFICATION

BCM’s with revised software to overcome the

above conditions were fitted to vehicles from start

of Model Year ‘02.

ISOVIN: Build Date:

W0L0XCF0824002194 27/08/01

SERVICE RECTIFICATION

On any vehicle with one or more of the above

symptoms built prior to the breakpoint, replace

the BCM with the latest part as shown in Parts

Information.

PARTS INFORMATION

Part No.: Description: Qty:

24467904 Body Control Module -

Australia

24467903 Body Control Module

- New Zealand

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD.

Suspect Quality Oil Filter Elements

Z22SE engine - TT, TS Sri & Convertible

(GROUP 6A) TL287-0205

PROBLEM DESCRIPTION

Suspect quality oil filter elements which

potentially could fail, resulting in particles

blocking oil galleries in the cylinder head, leading

to oil starvation and possible camshaft seizure.

SERVICE RECOMMENDATION

Important!

The following part numbers should not be used

anymore:

oil filter assy. 93 171 211 H

oil filter assy. 09 194 745 H

oil filter assy. 09 198 748 H

oil filter element 09 194 746 H

Parts Managers Note:

The above parts should be returned to HSPO for

credit via the CRRM system.

For all vehicle specified oil changes, ensure that

only the following oil filter elements are used.

oil filter assy. 93 173 660 =

oil filter element 93 171 212 >

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Poor Radio Reception - Roof Mounted

Antenna Base Nut Loose

JR Hatch, JS Wagon/Hatch, TS, TT, TR, SB

(GROUP 12) HINT TL281-0205

PROBLEM DESCRIPTION

Poor Radio reception in many cases is caused by

the roof-mounted antenna-base attaching nut

being loose.

SERVICE RECTIFICATION

Whenever replacing antenna components or

diagnosing poor radio reception on above

models, always ensure the antenna base is

firmly secured to the roof with the latest serrated

nut p/n 24432681. This nut has revised

serrations to resist loosening. Refer photograph

for differences between old and new nuts.

When reinstalling torque nut to 7 – 8 Nm.

NOTE: Good radio reception is dependant on

the serrated nut piercing the paint on the inside

of the roof panel.

PRODUCTION BREAKPOINTS

The new serrated nut 24432681 was fitted to

models as follows:

XC Barina from: Start of Production.

TS Astra from: W0L0TGF4815114312.

PARTS INFORMATION

Part No.: Description: Qty:

24432681 Nut – Antenna Base

to roof

Clutch Fluid Discolouration

VX, VU, V2

(GROUP 7A) TL202-0205

PROBLEM DESCRIPTION

It may be observed on some vehicles that the

clutch fluid darkens in colour after being in

service for a period of time.

Cause

This is a phenomenon that occurs with time due

to the interraction between clutch system rubber

parts with hydraulic fluid. The level of

discolouration will vary with factors such as

driving conditions, underhood temperatures etc.

SERVICE RECOMMENDATION

Laboratory investigations of returned fluid

samples shows that discolouration does not

detrimentally affect performance of the fluid.

Field reports indicate that where clutch system

components and fluid have been replaced for this

condition, the discolouration has reoccurred as

before.

Discoloured clutch fluid should not be replaced in

a normally operating system prior to the interval

specified in the maintenance schedule in the

owners handbook.

Update

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Throttle Body To Surge Tank Coolant

Hose Damage

TS (X18XE1 & Z18XE ENGINES)

(Group 6K) REVISED TL206A-0205

This Techline is revised by restating the

Production Rectification information. The

previous Techline in Issue 1, 2002 should be

destroyed.

PROBLEM DESCRIPTION

The Throttle Body to Surge Tank Coolant Hose

can foul either the positive battery terminal

protective cap or the positive battery cable. If

undetected this condition could result in hose

failure and coolant loss.

PRODUCTION RECTIFICATION

The previous breakpoint published in Issue

1/2002 was ineffective. Production rectification is

still pending.

SERVICE RECTIFICATION

Summary: Adjust clearances by trimming

protective terminal cap and coolant hose, and

orient the battery cable correctly

On any vehicle where fouling is observed

perform steps 1 to 4 to rectify the problem.

1. Trim the cap as shown in Figure 1 in order to

provide 10mm clearance between the cap and

the hose.

2. With engine switched off, disconnect the

coolant hose at the surge tank end.

3. Cut off 15mm of hose and refit the hose. This

will move the bend of the hose away from the

battery cable. See Figure 2.

4. Loosen the battery cable attaching nut, and

rotate the cable anti-clockwise so that there is

10mm clearance between the cable and the

coolant hose, then tighten cable attaching nut.

See Figure 3.

PARTS INFORMATION

Refer to Partfinder if part/s replacement is

required.

WARRANTY CLAIM INFORMATION

Description Rework Battery

Cable/Coolant Hose

Labour Op. No. N000363

Time 0.4 hr

Failure Code 26

Figure 1.

Figure 2.

Figure 3

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Water Leaks Into Decklid via Spoiler

Mounting Holes

VT, VX, WH

(GROUP 1) HINT TL274-0205

PROBLEM DESCRIPTION

Water leaks into the decklid assembly.

Often these leaks are found to be caused by a

defect in the spoiler to decklid mounting gasket.

This allows water to track between the inner and

outer skin of the decklid panel assembly.

Eventually this water will collect and drip into the

boot when the decklid is opened.

SERVICE RECTIFICATION

If water ingress into the decklid/decor is reported

on any vehicle fitted with a decklid spoiler, prior

to removing the décor panel, remove and visually

check the spoiler sealing gaskets and all

attachments. If the gasket on the spoiler has

significantly distorted or is broken, a new gasket

should be fitted. Obtain original equipment

spoiler replacement gaskets from HSPO. The

spoiler should be re-fitted and attaching bolts

torqued to 2-5 Nm.

For genuine accessory dealer fitted spoilers

follow the supplier’s fitting instructions when

installing new gaskets. If not already fitted, it is

recommended that rubber washer part number

92043323 is fitted to all attaching bolts to seal

the bolt head to the decklid inner panel.

Figure 1. Shows typical spoiler mounting to

decklid

PARTS INFORMATION

Part No.: Description: Qty:

92144151 Gasket Spoiler to

decklid – S Pack

92144153 Gasket Spoiler to

decklid - Lumina

92144150 Gasket Spoiler to

decklid – SS Pack

E09-970601 Gasket Spoiler to

decklid - WH

E09-970602 Gasket Spoiler to

decklid – V2

92043323 Seal spoiler to

decklid (rubber

washer)

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Door Checklink Bolts Loose

TS Astra

(GROUP 1) REPEAT TL285-0205

This Techline was first published in Issue

10/2001. It is repeated due to the high number

of PIRs still being received on this problem.

NOTE: PIRs are only required on complaint

vehicles built after the published breakpoint.

PROBLEM DESCRIPTION

Door checklink attaching bolts loosen.

Investigations show root causes to be:

• Attaching bolts (item 3 in Figure 1) not to

specification

• Relaxation of clamping torque ex factory.

• Stripped threads caused by overtightening of

bolts (above 6.5Nm)

Figure 1.

PRODUCTION RECTIFICATION

Revised checklink attaching bolts with closer

controls on tightening torque have been fitted to

vehicles from:

ISOVIN: Build Date:

W0L0TGF4815283442 05/06/2001

SERVICE RECTIFICATION

On complaint vehicles fit revised checklink

attaching bolts part number 13104167 and

torque to 4.5 to 5.0 Nm.

PARTS INFORMATION

Obtain following parts from HSPO:

Part No.: Description: Qty:

13104167 Bolt Checklink to

door.

per

door

Note: These same bolts are also now used on

TT, JS and XC models.

WARRANTY CLAIM INFORMATION

Use existing Labour Times information in

Warranty Information section of current PV SIP

Update

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Engine Cover Rattle Noise

VTII, VX, VU, V2 & WH with LS1 (Gen III)

(GROUP 6A) REVISED TL199A-0205

This Techline supersedes the previous Techline on

this topic (Issue 11, Nov.2001) which should be

discarded. This latest update removes the

requirement for spacer nuts when fitting new

support brackets due to the latest brackets being

fitted with a larger bumper.

PROBLEM DESCRIPTION

Engine cover “rattle” 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

Stage 1. Additional engine cover support

brackets 92087580 & 92087581 were fitted to

vehicles from:

ISOVIN: Build Date:

6H8VTL35FYL579679 10/04/00

Stage 2. Spacer nuts added underneath

each support bracket to increase preload on cover.

Fitted to vehicles from:

ISOVIN: Build Date:

6H8VXL69F1L750721 3/7/2001

Stage 3. Support brackets fitted with large

bumpers (92138641) thereby removing need for

spacer nuts. Fitted to vehicles from:

ISOVIN: Build Date:

6H8WHY19F2L863282 11/5/2002

SERVICE RECTIFICATION

Summary: Engine covers must be supported with

the two additional brackets fitted with large

bumpers. Also ensure clearance between cover

and IAC valve.

Scenario (A) For complaints of “engine cover

rattle” noise on any Gen III V8 vehicle built prior to

the Stage 1 breakpoint (L579679 built 10/04/00),

additional support brackets should be added as

per the following 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. Attach with two new nuts P/N

09440004, and torque to 4 – 6 Nm.

3. Fit engine cover support bracket P/N 92087581

to LH front coil mounting studs. Attach with two

new nuts P/N 09440004, and torque to

4 – 6 Nm.

4. Remove four foam pads from RH and LH

underside of engine cover. (Pads are not

required as new brackets have insulating

bumpers).

5. Ensure that foam insulator 92086029 is in place

on the engine cover in the location just above

the IAC valve as shown in Figure 1, view A. If

foam insulator is badly damaged due to contact

with the IAC valve it should be replaced. Prior

to fitting new insulator, remove 2 mm of

material from the cover as shown in Figure 1,

view A.

NOTE: Engine covers (p/n 92091015) with

increased clearance to IAC valve were fitted to

vehicles from: Tag No. L794821 Build Date

8/11/01

6. Re-fit main engine cover. Torque retaining nuts

to 8-12Nm.

7. Ensure that the cover does not contact

surrounding parts such as engine oil level

indicator, engine and power steering filler caps

and clutch master cylinder hose.

Scenario (B) On any complaint vehicle which has

support brackets fitted and no spacer nuts, (build

range L579679 – L750721) replace the support

bracket bumpers with the new bumpers

92138641.

Check engine cover as per step 5

Scenario (C) On any complaint vehicle which has

support brackets and spacer nuts fitted, discard

the spacer nuts and fit the larger bumpers

92138641 to the brackets.

Check engine cover as per step 5.

Update

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

PARTS INFORMATION

Part No.: Description: Qty

92087580 Support Bracket, Engine Cover RH

(includes new bumper 92138641)

92087581 Support Bracket, Engine Cover LH

(includes new bumper 92138641)

92138641 Bumper (15mm high , slotted) 1

09440004 Nut 1

92086029 Insulator-Engine dress cover (front) 1

NOTE: The part numbers of the support brackets

fitted with the latest bumper 92138641 have not

changed. For this reason, always check that new

brackets (obtained from your Parts Store) are

fitted with the new, larger type bumper. The

difference between old and new bumpers is shown

in Figure 1.

WARRANTY CLAIM INFORMATION:

Use the following information, for vehicles built

without additional support brackets; i.e. built prior

to the Stage 1 breakpoint (6H8VTL35FYL579679):

Description Add additional engine cover

support brackets LH & RH

Labour Op. No. J000651

Time 0.3 hr

Failure Code 28 (Rattle)

Use the following for vehicles that already have

brackets fitted where only the bumper is replaced.

Description Replace bumper in existing

support brackets.

Labour Op. No. J000710

Time 0.2 hr

Failure Code 28 (Rattle)

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Front Brake Hose Retention Precaution

VT, VX, VU, V2, WH

(GROUP 5) REPEAT TL288-0205

This Techline was first published in Feb. 2000. It is

repeated here as a reminder to Technicians.

This Techline item is a precautionary note to

ensure correct reinstallation procedures are carried

out whenever front suspension, steering, or front

brake 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 brake hose/s

must be refitted into their retaining clip/s.

Refer to the sketch below for brake hose (1)

location, showing its method of location in the strut

mounted clip.

Door Striker Creak or Rattle

(GROUP 1) TL283-0205

PROBLEM DESCRIPTION

Creaking noise from door(s) when driving on

rough or uneven roads, over driveways, etc.

Cause

This condition can be caused by relative

movement between the plastic coating on the

door lock latch and the plastic sleeve on the

striker.

PRODUCTION RECTIFICATION

Strikers with a revised plastic sleeve have been

fitted to vehicles from:

ISOVIN: Build Date:

W0L0TGF4825152533 18/02/02

SERVICE RECTIFICATION

To rectify vehicles with the above complaint install

revised striker part number 13116662 with new

attaching screws 09175119.

PARTS INFORMATION

Part No.: Description: Qty:

13116662 Striker – Door Lock 1

09175119 Screw 2

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

A/T Shifter Button Removal

WH, VX, VU, V2

(GROUP 7B) TL280-0205

PROBLEM DESCRIPTION

A/T shifter buttons returned via Repac have been

found to be damaged by incorrect removal. Marks

have been found around the shifter button top

edge – indicating that technicians believe the

button may be removed by levering the button

from the top edge of the shifter lever. This is not

possible!

SERVICE REQUIREMENT

When replacing a shifter button for any reason –

the SIP procedure must be adhered to. To

access the procedure in SIP refer following path:

VT Series II Commodore, Calais Service

Information

↓ Clutch, Transmission & Drivetrain

↓ Section7C4 - 4L60E On Vehicle Servicing

Operations

↓ 3. On Vehicle Servicing Operations

↓ 3.1 Selector Control Lever Assembly

The procedure in Section 3.1 is summarised as

follows:

- Remove centre console insert (Section 1A3 in

SIP);

- Disconnect wiring to shifter;

- Disconnect shifter control rod, under vehicle

(Section 7C4 in SIP);

- Remove shifter retaining bolts;

- Remove shifter from console;

- Disassembly of the shifter button from the

shifter is then fully detailed in SIP instructions.

WARRANTY CLAIM INFORMATION

Shifter buttons/levers damaged by attempted

removal via the top of the shifter lever/button will

no longer be accepted by Repac.

Semi Trailing Arms – Voided Inner Bush

Orientation

VXII, WHII, V2 - Multi Link Suspension

(GROUP 4) TL290-0205

With the introduction of multi-link suspension in

the above models the inner bushes of the rear

semi trailing arms were changed to voided type.

The correct orientation of these bushes in the

arms is shown in Figure 1.

Whenever bushes are replaced, ensure to align

the edge of one of the voids (1) in the bush with

the welded seam in the trailing arm (2).

Figure 1

NOTE: The above information will be added to

the Passenger Vehicle SIP CD due in June.

PARTS INFORMATION

Part No.: Description: Qty:

90334925 Bush asm. Control

Arm Mounting - Inner

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Refrigerant Label Location

All V & W with Gen III Engines

(GROUP 2) TL292-0205

SERVICE INFORMATION

Warranty Administration are receiving claims for

missing HVAC decals on the radiator shroud of

Gen III Engines (shown as “1” in the drawing

below).

The radiator shroud contains a recess to suit the

Refrigerant label, however a label is not fitted on

new vehicles.

The Refrigerant label on a current Gen III vehicle

is located UNDERNEATH the radiator shroud.

The recess in the radiator shroud will be fitted

with a Refrigerant label when an engineering

change is made later this year. The label

underneath the shroud will be deleted at this time.

Warranty Administration will not accept claims for

Refrigerant labels fitted to the top of radiator

shrouds of Gen III vehicles.

Brake Squeal Rectification

TS – Non-ABS models only

(GROUP 5) REVISED TL259B-0209

This Techline supercedes the previous one in

Issue 5/2002. It is revised by adding Production

Breakpoint for revised pads.

PROBLEM DESCRIPTION

Some non-ABS equipped TS Astra vehicles may

exhibit a squeal noise under braking.

New front brake pads have been released to

address this squeal.

The new pads have the leading and trailing edges

of the friction material chamfered to move the

squeal frequency outside the audible range.

PRODUCTION RECTIFICATION

Revised brake pads have been fitted in production

from:

ISOVIN Build Date

W0L0TGF482520462 14/6/02

SERVICE RECTIFICATION

To address customer complaints, fit the revised

brake pads. These brake pads are available from

HSPO.

PARTS INFORMATION

Part No.: Description: Qty:

93171035 Pad Set-Front Brake 1

WARRANTY CLAIM INFORMATION

As brake pads are a consumable wear item, and

would normally be charged to the customer, the

following policy applies:

If pad material thickness remaining is greater than

5mm, Holden will accept 100% of the parts and

labour charge for the repair.

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

If pad material thickness remaining is less than

5mm, Holden will accept 100% of the parts only

charge for the repair. The labour is to be

charged to the customer.

NOTE: ZONE APPROVAL IS REQUIRED FOR

CLAIMS TO BE PROCESSED.

Contact your dealer business consultant for

authorisation!

To measure the remaining pad material, simply

place the end of a steel ruler on the backing plate

and read the pad material height to the nearest

millimetre at the area of minimum material

thickness.

Description Pads, disc brake, both front

wheels - replace

Labour Op. No. H000222

Time 0.9 hr

Failure Code 40

Please note that warranty data will be monitored to

ensure this labour operation is only performed once

per vehicle.

Engine Stall At Idle Or High Engine Idle

Speed

JR, JS, C20SEL, C22SEL

(GROUP 6C) REVISED TL293-0205

This Techline supersedes the previous one in Issue

10, October, 2001. It is revised by adding a

checking/cleaning procedure to ensure there are

no idle concerns or DTC P0100 set after IACV

fitment.

PROBLEM DESCRIPTION

Some owners may complain of the following

symptoms:

With vehicle speed less than 3km/hr or vehicle

stationary, the engine idle is too high; e.g. 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

Revised Idle Air Control Valves (IACV’s) have been

fitted to all vehicles despatched from Port Of Entry

facilities commencing 24th Sep. 2001.

GENERAL MAINTENANCE NOTE

The need to carry out careful checks of all engine

compartment hoses at regular maintenance

services is stressed to all Technicians, to ensure

continued, efficient vehicle operation. This

includes checking the engine PCV and air intake

hoses.

SERVICE RECTIFICATION

Summary: Fit revised IACV, Flash Program as

required, check/clean PCV port, check hoses.

On vehicles with the above symptoms perform

diagnosis to determine if the IACV is in fact the

cause of the problem. Refer to previous Techline

item in Issue 10/2001 titled “Engine Stall Diagnosis

Update

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

- Non IACV related causes”. After confirming that

nothing else is causing the stall, proceed to fit the

latest “diaphragm type” IACV using the following

procedure.

1. Remove old IACV and install new diaphragm

type IACV and gasket as per procedures

shown in TIS CD.

2. Fit the patch harness (refer Figure 1) – this is

an interface patch harness to connect the

existing vehicle wiring harness to the new

IACV.

Figure 1.

3. Use a tie strap to firmly bind the wiring harness

connector to the IACV connector as shown in

Figure 1. Cut off any excess strap.

4. Use TIS 2000 CD version 23 or later (and

Tech 2 Software Version 10.300 or later), to

flash program the “New IACV” calibration into

the vehicle via TIS Service Programming

System (SPS). Refer to Flash Programming

Details and Calibration Part Numbers below.

Flash programming Details:

Select the vehicle parameters that apply to the

vehicle being programmed.

For example: Holden; VECTRA-B; 2000;

C22SEL Engine,

THEN, for “Type of Idle Air Control Valve” select

“New IACV (PN.: 92 065 903)”,

THEN, select the “Type of Transmission”.

When type of Trans. is selected, if you are

prompted for either “Short Y” or “Long Y” types

of exhaust system:

“Short Y” exhaust front engine pipe has a “Y” (2

into 1) joint directly below the front of the engine

block; “Long Y” exhausts have the Y joint

further rearward approximately in line with the

sump plug.

NOTE. “Short Y” is used with F18 M/T. “Long

Y” is used with later F23 M/T introduced in JSII

from L482379 22/7/99.

Model: Old

Calibration

New

Calibration

JR & JS C20SEL 90569364.**** 92066071.2657

JS 1, C22SEL

(Short Y front

pipe)

92059405.**** 92066073.2658

JS 2, C22SEL

(Long Y front

pipe)

92085493.2659 92066074.2660

(**** = any Number )

After reprogramming is completed proceed as

follows.

5. CHECK FOR AND REMOVE PREVIOUSLY

SET BASE IDLE AS PER FOLLOWING

STEPS (a) to (d).

Failure to remove any previously set base idle

could affect the operating characteristics of the

new IACV.

(a). With Tech 2 connected select the Data

Display screen, start the vehicle and allow it to

come to operating temperature (greater than 70

deg C coolant and inlet air temp between 20 -

30 deg C) with moderate to high underbonnet

temperatures)

(b). With A/C OFF check "IACV steps" at idle. If

"IACV steps" is less than 20 a base idle was

previously applied. If greater than 20 steps no

adjustment is required.

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

(c). Loosen the idle screw and decrease the

Throttle Position until the IACV steps are

above 20-25 steps with the A/C OFF.

(d). Re-tighten idle screw and conduct a final

check of the IACV steps.

6. Apply a Service History Label (SD-28177) to

the back of the fuse panel cover (lower left

corner) and mark the A-3 co-ordinate on the

label.

7. The following PCV hose/port check and clean

procedure must be carried out to all vehicles up

to WOLOJBF19YL557427, Build Date 16/02/00

(Breakpoint for introduction of a revised PCV

system that feeds PCV gasses into the lower

part of the inlet manifold.). This check and

clean (where required) ensures no poor

idle/stall/DTC P0100 will result due to

blockages, after IACV fitting.

Blockage of the PCV hose/port will cause the

engine to run on IACV air only at times. Engine

system calibration is based on specific air flow

through the PCV port PLUS IACV air at high

vacuum times (idle/decel) and thus, loss of air

flow through the hose/port can result in poor

idle and possibly stall.

Checking for blockages in PVC hose and port:

While engine is idling, remove the PCV hose from

the cam cover and check if there is vacuum at the

free end of the hose.

If vacuum is not present, remove the PCV hose

from the throttle body port connection and check

if there is vacuum at the port.

(A) - If vacuum is present at the port – replace the

PCV hose. No further action required.

(B) – If there is no vacuum at port then proceed to

clean the port as follows.

The port is shown in the cross section diagram

below, looking from rear of throttle body:

Contamination builds

up in PCV connector. Blocks calibrated hole.

This port may become blocked by contaminants

carried in PCV gas and, over time, the build-up

will block the small calibrated hole in the throttle

body.

This hole can be carefully cleaned out as follows:

1. Obtain a 1.5mm Diameter, long drill bit from an

engineering supplies outlet. NOTE: this drill bit

MUST not be larger than 1.5 mm Dia., as the

hole is calibrated. Enlarging the hole will result

in incorrect air flow, and cause driveability or

further code setting problems.

2. Remove the main air intake hose from the

throttle body;

3. Using the 1.5mm Dia. drill bit, carefully insert

the drill into the connection and rotate the drill

bit BY HAND until the deposits in the

connection are dislodged and the drill freely

passes through the calibrated hole into the

throttle body inlet passage.

4. Check this by: removing the drill bit from the

throttle body port completely, then open the

throttle blade fully and hold it fully open, insert

the drill bit until it protrudes from the calibrated

hole – then remove drill bit and then close

throttle blade.

5. Clean the connection with a solvent or spray

cleaner and remove any debris left in the

connection hole and throttle body;

6. Re-check that the hole is clear using the drill

bit, and re-assemble previously removed

components.

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

PARTS INFORMATION

Obtain following IACV kit from HSPO.

Part No.: Description: Qty:

92066066 IACV Kit 1

WARRANTY CLAIM INFORMATION

Use the following information to claim for the

installation of the new IACV and flash

programming the ECU.

Description Replace IACV

Labour Op. No. J000686

Time 0.6 hr

Failure Code 84

Note: this Labour Operation is useable for

vehicles within and outside new vehicle warranty

with the above noted idle/stall conditions.

DTC P0100/Poor Idle/Engine Stall

Diagnosis (Non - IACV Related Causes)

JR, JS, C20SEL, C22SEL

(GROUP 6C) TL289-0205

PROBLEM DESCRIPTION

PIR’s have been received advising that vehicles

have not responded to the fitting of new IAC

Valves – as described in Techline of October,

2001 entitled “Engine Stall at Idle or High Engine

Idle Speed”.

These reports mention that vehicles have a DTC

P0100 (MAF Sensor Voltage Low) set and the

vehicles have unstable idle or may stall at odd

times.

The cause of this condition has been investigated

and a number of possible causes have been

found:

• Blocked PCV hose/port in throttle body;

• Loose elbow in air intake duct (above

throttle body);

• Damaged TPS housing on the throttle body;

• Damage/deterioration to secondary PCV hose;

• Purge valve hoses fitted in reverse.

Most of these component concerns should be

found during general checks at scheduled

maintenance services, as technicians check the

general condition of engine compartment hoses.

The need to carry out careful checks of all engine

compartment hoses is stressed, in the interests of

continued, efficient vehicle operation.

As a general rule, any stall that occurs above

4km/h is not IACV related, and requires diagnosis

to ensure a cause is found and corrected.

SERVICE RECTIFICATION

Summary: Check PCV port and hose for

blockage. Replace hose or clean port as

required.

NOTE: The hose/port recommendations below

apply to JR/JS C22SEL engined vehicles built

prior to introduction of a revised PCV system that

feeds PCV gas into the lower part of the inlet

manifold – these were built from:

WOLOJBF19YL557427, Build Date 16/02/00,

Engine No.: C22SEL25015395.

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Blocked PCV Hose/Port in Throttle Body

Blockage of the PCV hose/port causes the engine

to run on IACV air only. Engine system calibration

is based on specific air flow through the PCV port

PLUS IACV air at high vacuum times (idle/decel)

and thus, loss of air flow through the hose/port

can result in poor idle and possibly stall.

Checking for blockages in PVC hose and port:

While engine is idling, remove the PCV hose from

the cam cover and check if there is vacuum at the

free end of the hose.

If vacuum is not present, remove the PCV hose

from the throttle body port connection and check

if there is vacuum at the port.

(A) If vacuum is present at the port replace the

PCV hose. No further action is required.

(B) If there is no vacuum at port then proceed

to clean the port as follows.

This port is shown in the cross section diagram

below, looking from rear of throttle body:

Contamination builds

up in PCV connector. Blocks calibrated hole.

This port may become blocked by contaminants

carried in PCV gas and over time, the build-up will

block the small calibrated hole in the throttle

body.

This hole can be carefully cleaned out as follows:

1. Obtain a 1.5mm Diameter, long drill bit from an

engineering supplies outlet. NOTE: this drill bit

MUST not be larger than 1.5 mm Dia., as the

hole is calibrated. Enlarging the hole will result

in incorrect air flow, and causing driveability or

further code setting problems.

2. Remove the main air intake hose from the

throttle body;

3. Using the 1.5mm Dia. drill bit, carefully insert

the drill into the connection and rotate the drill

BY HAND until the deposits in the connection

are dislodged and the drill freely passes

through the calibrated hole into the throttle

body inlet passage.

4. Check this by: removing the drill bit from the

throttle body port completely, then open the

throttle blade fully and hold it fully open, insert

the drill bit until it protrudes from the calibrated

hole – then remove drill bit and then close

throttle blade.

5. Clean the connection with a solvent or spray

cleaner and remove any debris left in the

connection hole and throttle body;

6. Re-check that the hole is clear using the drill

bit, and re-assemble previously removed

components.

Loose elbow in air intake duct (above throttle

body

Should this elbow be “loose” in the main air intake

duct, the additional un-metered air entering the

system can cause driveability problems, poor idle,

and a P0100 to set.

If the elbow is loose – replace the inlet duct

(containing the elbow).

Damaged TPS housing on the throttle body

While this should be a rare occurrence - if the

TPS housing has been damaged in some way

that allows air/water/dust, etc to enter the body,

the resulting contamination can cause incorrect

operation/readings. EG: Damage during any

service operations, engine/trans. removal, etc.

Any TPS found with damage to the external body

must be replaced with a new TPS.

Damaged/Degraded Secondary PCV Hose

Stalling may be caused if the secondary PCV

hose (Item 2 shown in the diagram below) is split

or torn, or the inner hose walls deteriorate:

Damage (split or torn):

Allows air to by-pass the mass airflow sensor,

leading to incorrect airflow readings which affect

the engine fuel ratio (runs lean). A DTC P0100

may be set.

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Degraded:

Degradation of the hose can result from age and

exposure to PCV gases, and external

contaminants which affect the hose. The hose

should be carefully examined for physical

degradation, EG: softness, cracking, hardness,

etc, and replaced if necessary. Extreme build-up

of PCV contaminants to the point where the hose

is blocked or cleaning is uneconomical also

dictates that the hose should be replaced.

Deterioration of hose inner walls:

Allows particles of the deteriorated hose material

to separate from the hose, and these may

become lodged in the ‘early design’ or “old” IACV

leading to a stall. This will not occur with the ‘later

design’ or “new” IACV – however, the hose

should be examined and replaced where

necessary.

NOTE: kinking, or clamping any other

components to the secondary PCV hose is NOT

permitted.

Purge valve hoses fitted in reverse

The hoses at the canister purge valve must be

fitted the correct way – with the throttle body hose

at the top purge valve fitting – as shown below:

If these hoses are reversed – damage to the

purge valve may result – if this has occurred it is

recommended that the purge valve be replaced.

MAF SENSOR

The following information is repeated from a

previous Techline on Non-IACV related stall – for

reference, should a cause to P0100 not be found

with the above information.

Stalling associated with the MAF Sensor can

occur either while vehicle is moving or stationary.

Usually a DTC P0100 is set. (this DTC may also

be set by a fluctuating idle, so correct diagnosis

of type of stall is required).

Some findings on failed MAF Sensors have been:

♦ Fretting corrosion of the MAF Sensor

terminals. (Replace suspect terminals.)

♦ Connectors not fully or correctly installed.

(Check connections and re-install if required.)

♦ Incorrect routing or attachment of sensor

wiring. (Check wiring against a known OK

vehicle to ensure the wiring is not run in an

incorrect routing, so it does not pick up any

‘stray’ electrical signals from other wiring or

components.)

RELAY INCORRECT FITMENT

If the “Fuel pump” or “injection valves” relays are

not properly fitted – with their terminals fully

engaged in the mating connector/wiring, a stall

may be caused. Check relays for full and proper

connection, re-install if required. Some relays are

a very tight fit and may not have been fully seated

on fitting or subsequent replacement.

CRANKSHAFT OR CAMSHAFT SENSOR

Refer to Techline bulletins of February and

March, 2000 relating to these sensors – available

on your SIP CD. Replace any pre-breakpoint

parts.

To Canister

To Manifold

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Front Seat Map-Pocket Detaches From

Seat- Back

VT, VX, WH

(GROUP 1) TL273-0206

PROBLEM DESCRIPTION

Map pocket detaches from front seat back due to top

mounting bosses breaking.

PRODUCTION RECTIFICATION

Revised map pockets with larger diameter (9.5mm)

mounting bosses have been fitted to vehicles from:

ISOVIN: Build Date:

6H8VXK69F2L844401 20/03/02

SERVICE RECTIFICATION

Summary: Fit revised map pocket with larger diameter

mounting bosses.

For removal and reinstallation procedures for front seat

back cover refer to Passenger Vehicle SIP CD. Path:-

VT Series 1, Section 1A7, Procedure 2.6

NOTE: When fitting a revised map pocket to a vehicle

built prior to the above breakpoint, a foul condition will

occur between the four bosses on the map pocket and

the corresponding mounting holes in the front seat

back cover. To eliminate this foul condition, use a

10mm drill bit to enlarge the holes in the cover. The

drill should be applied from the vinyl side.

Figure 1.

PARTS INFORMATION

• The part numbers of the revised map pockets (larger

diameter mounting bosses) have not changed.

• For all map pocket part numbers refer to Partfinder.

• All stocks of map pockets in HSPO are now of the

revised type.

• NOTE: To ensure the map pocket you are fitting is

the latest type, check that the diameter of the

mounting bosses is 9.5mm. Refer Figure 2.

Figure 2.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Poor AM Band Radio Reception

TS Astra Hatch & Sedan

(GROUP 12) TL250-0206

PROBLEM DESCRIPTION

Some customers may complain of poor reception on the

AM radio band in certain environments.

SERVICE RECTIFICATION

Summary: Do basic checks listed in A and B. If

unsuccessful, disconnect the original two piece lead and

install new one piece lead.

A. Perform basic continuity checks on major radio

system components as described in SIP 2001

Service Techlines, Group 12, “Radio Problem

Diagnosis Guide”.

B. Check the antenna lead connection in roof cavity

as described in Issue 6/2002, Group 12,

“Poor AM Radio Reception – Loose roof antenna

connector.”. Also, ensure that the antenna mast

base to roof attaching nut (serrated type) is tight.

If the checks in (A) and (B) do not provide any

improvement in AM reception, install a one piece

antenna lead as per the following procedure. Refer to

Parts Information for antenna lead part number.

1. Remove radio and radio cradle from Instrument

panel.

2. Disconnect existing antenna from cradle connection

and tie back to harness with a plastic tie strap. Refer

view A. This prevents the original lead from fouling

when the cradle with re-routed antenna lead is

reinserted.

3. Remove, detach or loosen the following components

to allow installation of the one piece antenna lead.

• Remove the Lower Trim panel below steering

column.

• Remove RH Side Kick panel.

• Fold rear seat base forward.

• Fold down RHS rear seat back.

• Remove rear parcel shelf.

• Remove C pillar trim.

• Remove rear interior light/hand grip fittings from

headlining.

• Lower the head lining at rear edge to allow

access to antenna base connection.

NOTE: Failure to remove the rear light/grip

fittings could result in the headlining being

fractured whilst trying to access the antenna

base connection in the roof cavity.

4. Connect one end of new antenna lead to connection

on radio cradle and feed other end down through

RHS of opening in instrument panel and route

across top of air duct above drivers feet. Refer view

A & B.

5. Continue to feed lead downwards to the right of the

engine hood lever and adjacent to door opening

seal. Refer view C.

6. Tie strap lead to air duct - 2 places. View B.

7. Route the antenna lead along the rocker panel and

up C pillar. Ensure cable is spot taped to sheet

metal every 200mm to avoid rattles. Refer views D,

E & F.

8. Feed lead into the roof cavity and withdraw through

opening immediately below antenna mast. Refer

views G, and H.

9. Remove foam tape from around connector in roof.

Undo the existing antenna lead and tie back on itself

using a tie strap. Refer view H. NOTE: From

Model Year 2002, the antenna lead connector in the

roof is a plug-in type. Prior to MY 2002 this was a

screw fitting.

10. Connect the new antenna lead to the antenna mast

connector. ENSURE THIS CONNECTION IS

TIGHT. Wrap several turns of foam tape around

connector to prevent rattles in roof.

11. Coil up excess length of lead and tie strap coil firmly

to C pillar to avoid rattles. Refer view G.

12. Reinstall all components.

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

PARTS INFORMATION

Part No.: Description: Qty

90513340 Antenna lead one piece

(Sed/hatch up to end

MY01) –screw connection

93160448 Antenna lead one piece

(sed/hatch from MY02)

– plug in connection

90148142 Foam tape - roll 1

WARRANTY CLAIM INFORMATION

Description Install one piece antenna

lead

Labour Op. No. N000381

Time 1.5 hr

Failure Code 33 weak

DTC P1870 - Trans. Slipping

WH, VX, V2, VU with A/T

(GROUP 7B) TL270-0206

PROBLEM DESCRIPTION

A small number of vehicles have been presented

to Retailers with DTC P1870 (Transmission

slipping) set. These codes are most often set

during lengthy trips.

Retailer diagnosis, without transmission

teardown, has been carried out, but no faults

have been found.

Reports show that after diagnosis is carried out

and the code is cleared, the vehicle may remain

in service without the code re-occuring, or may

return some time later (typically a month or more)

with the same DTC set.

SERVICE RECTIFICATION

Events such as this are likely to be caused by

minor transmission internal problems that lead to

fluid pressure reduction. As the causes of this

pressure reduction will require extensive

investigation and possible teardown, it is

recommended that a SRTA transmission be fitted.

UNTIL FURTHER NOTICE – whenever a vehicle

is presented with DTC P1870 in memory, the

following is recommended:

• Carry out the basic checks in Section 6C1-2A

of VX Series 1 in SIP (without dismantling the

transmission).

• Should no fault be found after basic

diagnosis, transmission replacement is

required.

This course of action is recommended to ensure

minimal disturbance to customers.

From investigations into any returned

transmissions – a future Techline may be

produced to enable Retailer repair if necessary.

WARRANTY CLAIM INFORMATION

Use existing information to claim for diagnosis

and/or replacement of transmissions.

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Door Checklink Bolts Loose

TS, TT, JS, XC

(GROUP 1) REVISED TL285A-0206

This Techline supercedes the previous one in Issue

5/2002. It is revised by:- adding new Labour Op. No.

for replacing checklink bolts on all 4 doors and

expanding vehicle model range.

PROBLEM DESCRIPTION

Door checklink attaching bolts loosen.

Investigations show root causes to be:

• Attaching bolts (item 3 in Figure 1) not to

specification

• Relaxation of clamping torque ex factory.

• Stripped threads caused by over tightening of bolts

(above 6.5Nm)

Figure 1.

PRODUCTION RECTIFICATION

Revised checklink attaching bolts with closer controls

on tightening torque have been fitted to vehicles from:

ISOVIN: Build Date:

W0L0TGF4815283442 05/06/2001

SERVICE RECTIFICATION

On complaint vehicles fit revised checklink attaching

bolts part number 13104167 and torque to 4.5 to 5.0

Nm.

PARTS INFORMATION

Obtain following parts from HSPO:

Part No.: Description: Qty:

13104167 Bolt Checklink to door. 2 per

door

WARRANTY CLAIM INFORMATION

Description Bolt/pin check asm. all four

doors - Replace

Labour Op. No. C634000

Time 0.5 hr

Failure Code 40 (Noisy)

If replacing checklink bolts on individual doors, use

Labour Times information in Warranty Information

section of current PV SIP CD

Update

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

A/T Electrical Connector Removal &

“Limited” Repair Procedure

VR, VS, VT, VX, VU, V2, WH

(GROUP 7B) TL310-0206

The information below on removal of connectors was

previously issued in Service Techline September 2000,

Issue 8. For repair of harness – refer to Service

Techline September 2000, Issue 8, Page 17.

PROBLEM DESCRIPTION

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 REMOVAL:

Should this “hard to remove” situation occur in any

vehicle, the method of removal suggested 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 to soften the “glue-like”

material in the connections – IE: repeatedly heat and

check the connection for looseness, until the

connection loosens and can be removed.

After removal 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 during the above

procedure.

CONNECTOR REPAIR:

In addition to the above removal procedure, for

vehicles that are out of warranty, a repair method is

offered as a cost-effective repair for customers, should

damage occur to the vehicle’s harness connectors

during removal as noted above.

As the above procedure is recognised as being for

higher kilometer and older vehicles, the repair

procedure is not to be used for vehicles in warranty.

Flash Programming - Gen3 PCM

VX, VU, V2, WH(A8A)

(GROUP 6C) TL315-0206

The previous Service Techline on this subject in Issue

2/2002, Group 6C, described the need to use a 200

ohm resistor during the downloading phase from Tech

2 to PCM.

This procedure is no longer required provided you

are using TIS 2000 from version 31.5 onwards.

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Squeaks and Rattles

◆

◆◆

◆ Instrument Panel Facia

◆

◆◆

◆ Engine Hood Insulator Fasteners

VT,VX,VU,V2,WH

(GROUP 1) TL275-0205

PROBLEM DESCRIPTION

Customers may complain of any of the following

conditions:

1. A buzz around the headlight switch or the centre

vents when travelling at 60 km/h or faster on

slightly rough bitumen surface

2. A creak/crack from the HVAC control area when

travelling over road cracks or rough road.

3. A chirping noise when driving over road

imperfections at most speeds and appearing to

come from the dash.

Causes

Condition 1 can be caused by relative movement

between the instrument facia and the instrument panel

pad.

Condition 2 can be caused by relative movement

between the instrument facia and the HVAC controls.

Condition 3 can be caused by the hood insulator

fastener rubbing on the fender catwalk flange.

Typically, a vehicle with this condition will show a

witness mark in the paint on the catwalk flange in the

positions shown in Figure 2. A corresponding witness

mark can also be seen on the hood insulator fastener.

SERVICE RECTIFICATION

Summary: Apply specified anti- squeak tapes to

designated areas.

For vehicles with Condition 1 and 2.

1. Remove the IP facia from the vehicle.

2. Lay the facia (face down) on a soft surface such as

a clean towelling cloth

3. Apply flocked tape (92145740) to the edge of the

facia in the areas shown in Figure 1 ensuring that

the tape is not visible after reassembly of the facia

to the instrument panel (utilise the edge feature line

as an alignment guide).

4. Refit the facia panel to the vehicle.

For vehicles with condition 3.

1. Measure back from the front of the fender and

mark the four locations (2 per side) where the

fastener may contact the flange. Refer Figure 2.

2. Cut a 30 mm length of clear polyurethane tape

(92145618). Clean the area that the tape will

cover. Apply the tape centrally over the marked

area ensuring that the edge of the fender flange is

covered and the tape is wrapped around the edge

of the flange.

3. Repeat the tape application at the other three

locations.

PARTS INFORMATION

Part No.: Description: Qty:

92145740 Anti squeak tape –

flocked (11 metre roll)

92145618 Anti squeak tape –

clear polyurethane (11

metre roll)

Note: At Techline publication some tapes may not be

immediately available however orders may still be

placed.

WARRANTY CLAIM INFORMATION

Description Add anti-squeak tape to

Instrument Panel facia

Labour Op. No. C000457

Time 0.5 hr

Failure Code 90

NOTE: To claim the cost of tape used in this

procedure, claim for the cost of 1.0 metres per car.

(Approx. 10 cars per roll)

Description Add anti-squeak tape to

front fender flange(catwalk)

Labour Op. No. C000460

Time 0.2 hr

Failure Code 90

NOTE: To claim the cost of tape used in this

procedure, claim for the cost of 0.12 metres per car.

(Approx. 80 cars per roll)

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Figure 1.

Figure 2.

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Rear Facia Loose Left Hand Side

VX Sedan

(GROUP 1) REVISED TL302A-0209

This Techline supercedes the previous one in Issue 6,

2002. It is revised by adding Production Rectification

breakpoint information.

PROBLEM DESCRIPTION

Rear bumper facia loose at left hand rear wheelhouse.

This particular condition can affect vehicles built from

October 2001 which is when the method of attaching

the liner to wheelhouse (Left Hand Side) was changed

from a screw to a scrivet. Due to a tolerance stackup

on some vehicles the scrivet may have insufficient

clamping load.

PRODUCTION RECTIFICATION

The LHS scrivet and scrivet hole were revised from:

ISOVIN: Build Date:

6H8VXL69A2L885020 29/06/02

SERVICE RECTIFICATION

Summary: Install self tapping screw to retain liner.

1. Raise vehicle on 2 post hoist so that rear

suspension hangs.

2. Leaving the scrivet in position, install screw part

number 92138310 into existing hole located to left

of the tab when looking into wheelhouse area.

Refer position “2” shown in Figure 1.

PARTS INFORMATION

Part No.: Description: Qty:

92138310 Screw liner to

wheelhouse

WARRANTY CLAIM INFORMATION

Description Whatever Asm - Replace

Labour Op. No. C000470

Time 0.3 hr

Failure Code 27

Figure 1.

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Poor “AM” Radio Reception – Loose Roof

Antenna Connector

TS, TT, JS wagon/hatch, JR Hatch, TR

GSi, SB

(GROUP 12) TL308-0207

PROBLEM DESCRIPTION

Investigation of complaint vehicles has shown that the

primary cause of poor “AM” radio reception on vehicles

with roof mounted antenna is a loose antenna

connection in the roof cavity.

SERVICE RECTIFICATION

Rectification can be achieved by tightening the antenna

connector as per the following procedure.

Although this procedure is for a TS Hatch, it will be

similar for most other models.

1. Access To Antenna Connection

• Remove rear parcel shelf.

• Partially remove the weather seal from the upper

section of the hatch opening. Refer Figure 1.

• Remove rear interior light/hand grip fittings from

headlining both sides.

• Lower the head lining at rear edge to allow access

to antenna base connection. NOTE: Failure

to remove the rear light/grip fittings could result in

the headlining being fractured whilst trying to access

the antenna base connection in the roof cavity.

Figure 1

2. Tightening Connector

• Locate the antenna connector inside the centre slot

of the lower roof skin. Refer Figure 2

• Remove all the foam tape from around the connector

and then tighten threaded type fitting firmly by hand.

Figure 2

3. Re-Assembly And Final Checks

• Start the engine, set radio to the AM band and check

that the reception is clear. Confirm reception is still

clear when wriggling the connector.

• Apply several turns of foam tape to connector prior to

reinstalling in roof cavity.

• Refit all remaining components.

PARTS INFORMATION

Part No.: Description: Qty:

90148142 Foam tape - roll 1

WARRANTY CLAIM INFORMATION:

For vehicles covered by warranty use the following:

Description Roof Antenna Connector -Tighten

Labour Op. No. N000315

Time 0.5 Hrs

Failure Code 27

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Rear Brake Groan/Graunch Noise

TS & TT Model Year 2002 Fitted with

LUCAS Calipers

(GROUP 5) REVISED TL294A-0206

This Techline supercedes the previous one in Issue 6, July,

02. It is revised by adding Production Rectification

information.

PROBLEM DESCRIPTION

A groan/graunch noise coming from rear of vehicle on

brake application or takeoff at carpark speeds: viz;

• in reverse on application of brakes

• in drive on application of brakes

• in drive on release of brakes

This noise should not be confused with a squeal..

Squeal is high frequency, a groan/ graunch is low

frequency.

Cause

Brake caliper excitation at low vehicle speeds.

PRODUCTION RECTIFICATION

Vehicles have been fitted with revised parking brake

cable guides (mass damper type) from ISOVIN:

W0L0TGF3535043736

SERVICE RECTIFICATION

Summary: On complaint vehicles, install revised

parking brake cable guides (with mass damper) onto

rear “LUCAS” brake calipers.

NOTE: This fix is not applicable to the BOSCH

calipers.

Procedure:

Before proceeding, confirm the vehicle has LUCAS

calipers. The name LUCAS is cast into the caliper in

the location shown with arrow in following photograph.

1. Remove parking brake cable retaining clip. Refer

Figure 1.

2. Remove actuating lever return spring. Refer Figure II.

3. Loosen parking brake cable guide attaching screw.

Refer Figure III.

Update

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

4. Release parking brake cable guide with parking

brake cable from caliper. Refer Figure IV.

5. Pull parking brake cable out of parking brake cable

guide.

6. Install parking brake cable into new parking brake

cable guide with mass damper.

7. Install new guide and parking brake cable onto

brake caliper as shown in Figure V.

8. Install new attaching screw to caliper.

Torque - 9-11 Nm. Refer Figure VI.

9. Reinstall return spring of actuating lever.

10. Reinstall securing clip onto parking brake cable.

11. Lower vehicle.

12. Check adjustment of parking brake as per procedure

in TIS. Adjust as required.

PARTS INFORMATION

Part No.: Description: Qty

93174517 Parking brake cable guide

with damper - left side .

93174518 Parking brake cable guide

with damper - right side .

WARRANTY CLAIM INFORMATION

For warranty claims use following:

Description Install Park Brake Cable Guide -

Mass Damper Type – both sides

Labour Op. No. H000237

Time 0.4 hr

Failure Code 40

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

“Moan” Noise From Rear Cross Member

at 105–110 km/h

VX with Gen III V8 & A/T

(GROUP 4) TL311-0206

NOTE: Zone authorisation is required before

replacing a cross member for the condition

described in this bulletin.

PROBLEM DESCRIPTION

Some vehicles may exhibit a “moan” or “drone” noise

at 105-110km/h, which is similar to an exhaust

resonance or “cavity boom”.

This noise may be caused by excitation of the rear

suspension cross member by input of various

drivetrain and tyre related vibrations.

PRODUCTION RECTIFICATION

Revised cross members with vibration dampers are to

be fitted to vehicles (with Gen III V8) in production.

At the time of release of this bulletin, no breakpoint

information was available. Breakpoint advice will be

provided in future Breakpoint Summary.

SERVICE RECTIFICATION

Positive rectification of this condition relies on good

diagnosis.

The “moan” or “drone” noise occurs:

- between 105km/h and 110km/h

- at constant throttle for some distance

- travelling on a straight road.

When the condition occurs, steer the vehicle from side

to side – within the lane the vehicle is travelling in – if

the condition varies significantly, the condition is

confirmed.

The condition should not be confused with any exhaust

or other driveline vibration or resonance that will NOT

be reduced by this steering input!

On confirmation of this condition – contact TAS for

loading of a case, and availability of a revised cross

member (Refer Parts Information for details).

TAS will confirm diagnosis, and if required, arrange the

supply of a revised cross member.

Once TAS have confirmed the need for a cross

member – you MUST contact your Zone Office for

authorisation to carry out this task.

After obtaining Zone authorisation, fitting the cross

member, and road testing to confirm that the condition

is corrected – contact TAS immediately to close the

TAS case.

PARTS INFORMATION

At the time of release of this bulletin, a specially

manufactured cross member (fitted with vibration

dampers) is available only from TAS. This cross

member will only be made available through TAS, after

a TAS case is loaded, and the condition is confirmed.

When production parts are available, an updated

bulletin will be released providing part numbers of the

new cross member assemblies, cross member service

parts, and service information.

When replacing cross members observe the

procedures outlined in the SIP CD.

WARRANTY CLAIM INFORMATION

When fitting the cross member described above

(supplied via TAS) use the following information:

NOTE: ZONE AUTHORISATION IS REQUIRED

Description Cross Member - Replace

Labour Op. No. F000179

Time 3.6 hrs

Failure Code 36

Update

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Spark Plug Lead Revisions

WH, VX, VU, V2 – All with V6 Engine

(GROUP 6Y) TL312-0206

PROBLEM DESCRIPTION

Complaints of misfire have been received. These have

been caused by arcing of the high tension lead to

cylinder head as a result of:

- Grease breaking down boot material, resulting

in lead shorting/arcing to heat shield;

and/or

- Excessive boot distortion from the spark plug

lead heat shield spring retaining tabs and

locating dimples

To overcome these conditions, a new grease and

revised heat shields have been introduced.

The new grease is green in colour, and its composition

will not degrade the boot material as the previous

grease did.

The heat shield has been revised in several areas to

improve performance in:

- fit to the spark plug boot,

- pressure applied to the boot,

- heat shield spring position.

PRODUCTION RECTIFICATION

Spark plug leads with the revised heat shields have

been fitted to vehicles from:

ISOVIN: Build Date:

6H8VXK69R2L851016 05/04/02

For Ref – Engine No.: VR213384

NOTE: The upgraded grease was added earlier at

L700356, 05/03/01 prior to heat shield changes.

SERVICE RECTIFICATION

When investigating misfire complaints, if the cause is

not immediately evident,:

1. Inspect the spark plug boots for holes/cracks inside

the boots ( photos 1 & 2) as well as for “tracking”

inside boot (photo 3).

Photo 1. View of inside

of plug boot, showing

boot pin hole.

Photo 2. View of inside

of heat shield, showing

shield arcing witness

marks

Photo 3. Boot cut open

to show “tracking”

2. When arcing marks, holes in boots and/or boot

“tracking” are found – replace the full set of spark

plug leads.

3. Inspect spark plugs for carbon “tracking” – black lines

etched into the porcelain of the plug If these tracking

marks will not clean off with a clean rag – replace the

spark plugs that are affected.

NOTE: Should any engine be found with a number of

the latest design spark plug leads fitted – replace only

the earlier design leads!

Lead Identification:

For identification of the latest design spark plug leads

(via heat shield revisions) refer to the photographs on

following page.

Earlier design heat shields, Type 1 and Type 2 were

used as an interim “fix” until the latest design heat

shields were available. Spark plug leads only need to

be replaced as described in “Service Rectification”

above.

PARTS INFORMATION

HSPO now carry stock of the revised spark plug leads.

Part numbers of spark plug leads have not changed.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD.

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Engine Improvements

Gen III V8

(GROUP 6A) TL296-0296

This bulletin provides information on the major

improvements and revisions made to Gen III V8

engines.

This information will be found useful during service and

repair of these engines.

Revised Oil Pick-up Tube

M/T engines (only) were fitted with a revised oil pick-up

tube; and a revised low oil pressure warning lamp

calibration was applied to vehicles from:

Engine No.:

VF002021193

For Reference, this engine was used in:

ISOVIN: Build Date:

6H8VXK69F1L656328 02/11/00

These M/T engines (and any M/T engines fitted with

the revised pick-up in service) are identified by the “X”

mark, stamped on the cylinder block, as shown below:

The revised oil pick-up is now the only oil pick-up

available from HSPO.

All engines (IE: M/T & A/T) were fitted with revised oil

pick-up tube, and revised low oil pressure warning

lamp calibration from:

Engine No.:

VF011010001

No ISOVIN is available for this engine.

NOTE: From Engine No. VF011010001 – the “X”

stamp mark identifier was no longer used, as all

engines from that breakpoint contain the revised oil

pick-up.

Revised Oil Dipstick & Oil Volume

M/T 225kW/255kW engines were fitted with an

additional 0.5 litre of oil and a revised oil dipstick from:

Engine No.:

VF002700933

For Reference, this engine was used in:

ISOVIN: Build Date:

6H8VXK69F1L675354 13/12/00

All M/T & A/T 225kW/255kW engines carried these

revisions from:

Engine No.:

VF011080001

No ISOVIN is available for this engine.

All 300kW engine carried these revisions from:

Engine No.:

VF002850599

For Reference, this engine was used in:

ISOVIN: Build Date:

6H8VXL69F1L671675 08/12/00

The revised dipstick can be identified by part number

92065825 stamped on the dipstick.

Revised Pistons & Piston Rings

Engines with M/T were fitted with revised pistons (with

a friction resistant coating) and piston rings with revised

ring tension from:

Engine No.:

VF012350476

For Reference, this engine was used in:

ISOVIN: Build Date:

6H8VUK80F2L785247 15/10/01

These pistons are identified by a plain aluminium piston

finish and two rectangular friction coating patches on

the skirts.

The piston rings are identified by a small groove in the

underside of the second compression ring (earlier rings

were a plain rectangular section).

Note: a small number of engines were built with an

alternative design piston with a grey colour finish all

over, and two rectangular friction coating patches on

the skirts).

If repairing an engine for any reason, it is

recommended that these pistons be replaced with the

latest design pistons ex-HSPO.

Update

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Stone Entry into Rocker Panel Skirts -

Sports Body Kit

VT, VX, “S” and “SS” models

(GROUP 1) TL284-0206

PROBLEM DESCRIPTION

There have been isolated customer complaints of a

“sliding rock” type noise under heavy braking or

acceleration.

The cause of this condition is stones/road debris

thrown up in the rear wheel arch which bypass the

rocker skirt end caps. Once inside the rocker skirts,

they may move about under heavy braking or

acceleration.

SERVICE RECTIFICATION

Summary: Install rubber covers in rear wheel arch.

1. Raise vehicle on hoist.

2. Remove rear wheels.

3. Remove rocker skirt rear endcap.

4. Remove rocker skirt forward end attaching screws

5. Remove all stones /debris from the inside area of the

rocker skirt. This can be done by hosing out with

water or compressed air from the forward end.

Removal of debris could be improved by lowering

the vehicle to the ground and then raising the front

only so that gravity assists.

6. Clean the wheelhouse inner panel in area where

rubber cover will be fitted. Use water and a brush.

Location is shown in Figure 1.

7. Using template provided (refer page 23), cutout two

stone covers from sheets of EPDM rubber as

specified in Parts Information. NOTE, the same

shape is reversed to form the opposite hand

wheelhouse cover.

8. After surface has dried from step 6, wash cleaned

area with Prepwash or equivalent.

9. Place the Left Hand cutout cover into position and

install the end cap and endcap screws to hold

cover in position.

10. Mark outline of cover onto wheelhouse liner with

chalk. Refer Figure 1.

11. Pull back cover and apply a continuous bead of

urethane 20mm in from the chalk outline.

12. Press cover into bead of urethane and apply two

attaching screws 92138399 in two places as shown

in Figure 1. Screw 1 is into body (apply urethane

to screw head to seal). Screw 2 goes through

flange. Apply urethane to head of screw 1. Pilot

holes should carefully be drilled for both screws.

13. Smooth off any urethane that squeezes out.

14. Insert narrow flap into rocker panel cavity as shown

in Figure 2.

15. Align lower edge of end cap to end of rocker skirt

and fix in position (2 places) with self tapper screw

92138399. Refer Figure 2.

16. Repeat process for opposite side wheelhouse.

17. Reinstall all components.

PARTS INFORMATION

Part No.: Description: Qty:

92143609 Urethane – 300ml

tube.

92138399 Screw self tapper 8

EPDM rubber sheets 300 x 210 x 3mm thick can be

obtained from most Blackwood/A.E. Baker & Co.

stores.

WARRANTY CLAIM INFORMATION

Description Fit rocker skirt stone covers

to rear wheelhouse liner.

Labour Op. No. C000467

Time 1.0 hr

Failure Code 28

Figure 1.

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Figure 2.

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Electronic Modules - Resetting Procedure

TS, TT, XC, JS (Y26SE)

(GROUP 6C) TL317-0206

This Service Techline supersedes the previous Techline

on this topic (Issue 10, December, 1999 page 11) with

additional models, procedure application and warranty

caution.

For the attention of Technicians & Warranty

Administrators:

A number of Repac returned ECU’s, BCM’s and

Instruments have not been reset’ as per the reset

procedure below. This makes it impossible for correct

testing to be carried out.

When the need arises to replace an engine control

module in these vehicles, technicians should be aware of

the requirement to reset the security feature of the

module prior to removing it from the vehicle.

If the module is not reset prior to removing it, the module

remains security linked to that specific vehicle and

cannot be reprogrammed until reset accordingly.

This procedure is necessary on warranty replaced

modules – which must be reset to allow Holden to

investigate cause of failure.

Similarly, the same procedure should be followed when

installing a module from another vehicle, or where

dealership stock is used to confirm diagnosis.

This procedure applies to the following engine types:

X18XE1

Z18XE

Z14XE

Y26SE

Z22SE

This resetting requirement must also be applied to XC

Body Control Module (BCM) and Instruments before

return to Repac.

Engine Control Module Resetting Procedure

The engine control unit must always be reset in the

vehicle it was initially programmed to.

1. Connect TECH 2 and select the following.

2. F0: Diagnostics/Model year/✷✷✷✷✷/F3: Body/

Immobiliser

(at “/✷✷✷✷✷/” - select vehicle model)

3. F3: Additional Functions

4. F2: Reset Engine Control Module

5. When security code is requested, enter security

code and press enter.

6. When you have entered the correct security code

press okay to proceed.

7. The following warning will appear, “Warning: Engine

will not start after reset! Do this only before replacing

the Engine Control Module” . Press the CONFIRM

soft key at the base of the TECH 2 screen to

continue.

8. Program Completed, the engine control module is

now reset, press the CONFIRM soft key at the base

of the TECH 2 screen to exit.

WARRANTY CLAIM INFORMATION

ECU’s, BCM’s and Instruments NOT reset using the

above procedure will no longer be accepted by Repac.

HOLDEN SERVICE TECHLINE________________________________________________________________ AUGUST, 2002

Thump Noise From HVAC Case - (Mode

Door Slamming)

VT, WH with 5-Pack Vacuum Solenoid

Modules

(GROUP 2) TL309-0207

This Techline is only for those vehicles fitted with the 5-

pack vacuum solenoid module.

For vehicles fitted with the 6-pack vacuum solenoid

module refer to Techline in Issue 11, November 2001.

PROBLEM DESCRIPTION

A light “thump” or “bang” noise may be heard from the

HVAC case when the ECC system automatically

changes mode or when manually operated , and is

more pronounced in the face to foot mode change. It is

also noticeable when the ignition is turned off.

The cause of this “thump” noise is the rapid closing of

the mode door.

SERVICE RECTIFICATION

Summary: After confirming vehicle is built with 5-pack

solenoid vacuum module, install vacuum delay kit part

number 92144219.

To confirm if vehicle is fitted with 5-pack or 6-pack

solenoid vacuum module, refer to the following

breakpoint information:

NOTE: All vehicles built up to the following breakpoints

were fitted with the 5-pack solenoid vacuum modules.

VT Berlina: (Single zone system)

ISOVIN: Build Date:

6H8VTL69HYL514226 07/10/99

VT Calais & WH (Dual Zone system)

ISOVIN: Build Date:

6H8VTX69HYL513521 06/10/99

All vehicles built after the above breakpoints were fitted

with the 6 solenoid vacuum module.

After confirming vehicle has 5-pack solenoid module

proceed to fit Vacuum delay kit 92144219 as follows.

1. Remove console side covers.

2. Locate the floor vacuum actuator on underside of

HVAC with the orange and red(pink) vacuum

tubes.

3. Cut the red(pink) vacuum tube on an angle. Cut

the supplied rubber vacuum hose into 30mm

lengths and attach to the delay valve ports.

Connect the valve between the cut vacuum tubes

with the white side of the delay valve facing

towards the vacuum actuator. Refer to Figure 1.

4. Locate the Face vacuum actuator on underside of

HVAC with the white and green vacuum tubes.

5. Cut the white vacuum tube on an angle. Install the

delay valve between the cut white tubes as shown

in Figure 1. Ensure the white side of the delay

valve is facing towards the vacuum actuator.

6. Ensure that installed parts do not interfere with any

actuating rods or levers.

7. Refit all removed components and retest.

PARTS INFORMATION

Obtain following parts from HSPO:

Part No.: Description: Qty

92144219 Vacuum delay pack (2 delay

valves, tube & instructions)

WARRANTY CLAIM INFORMATION

Description Install vacuum delay valves

to mode actuators

Labour Op. No. D000333

Time 0.8 hr

Failure Code 40

HOLDEN SERVICE TECHLINE________________________________________________________________ AUGUST, 2002

Figure 1.

Clutch Pedal Squeak

XC Barina

(GROUP 7A) HINT TL304-0207

PROBLEM DESCRIPTION

Clutch pedal squeaks when it is depressed.

Investigation of complaint vehicles has shown the main

causes for this condition are:

A. Lack of lubrication in push-rod/clutch pedal pivot.

B. Loose attaching nuts – clutch pedal support

bracket to bulkhead and/or clutch master cylinder.

SERVICE RECTIFICATION

Summary: Lubricate pivot and check tightness of

attaching nuts.

A. Lubrication of push-rod / pedal pivot.

Use a directional nozzle on a container of lithium spray

grease part number M39760 to apply a liberal amount

of grease to the white nylon pivot which houses the

master cylinder push-rod. Refer arrow in Figure1.

Figure 1.

B. Check attaching nuts (Refer Figure 2)

• clutch pedal support bracket to bulkhead. (Nut # 5

– three places)

• clutch master cylinder to support bracket. (Nut # 6

– two places)

Torque all nuts to 20 Nm.

HOLDEN SERVICE TECHLINE________________________________________________________________ AUGUST, 2002

Figure 2.

PARTS INFORMATION

Part No.: Description: Qty

M39760 Spray Grease -350gm can 1

Throttle Control Malfunction – DTC’s

P0120, P1500, P1550

XC, TS, (Z14XE , Z18XE engines)

(GROUP 6C) TL257-0207

PROBLEM DESCRIPTION

Complaints of Engine will not rev, no throttle response,

or engine stalling in conjunction with one or more of

the following trouble codes stored in the ECU:

• P1500: Electronic throttle control motor failure.

• P1550: Electronic throttle control reduced power,

forced idle, power management or engine stop.

• P0120: Throttle position sensor circuit #1 voltage

high/low.

The above conditions may occur in throttle bodies with

a manufacturing date code prior to “354- 01B”.

Where: 354 = day of year

01 = Year

B = shift

Figure 1 shows the position of the date code markings.

NOTE: The 4 digits after the date code are to be

ignored.

Figure 1.

SERVICE RECTIFICATION

On any vehicle with above symptoms proceed as

follows:

1. Check throttle body date code as shown in

Figure 1. If date code is prior to 354-01B, proceed

to step 2.

NOTE: Some examples of date codes prior to 354-

01B are 256-01A, 357-00B etc.

If the date code is later than 354-01B contact TAS

for assistance.

2. Clear all Diagnostic Trouble Codes from ECU.

3. Remove old throttle body as per procedure in TIS.

4. Install new throttle body with production date code

after 354-01B. Ensure new gasket is installed.

5. Reset learnt values in ECU.

6. Ensure no new diagnostic trouble codes are stored

in ECU.

PARTS INFORMATION

Part No. Description Qty

09192122 Throttle body asm. Z14XE 1

09196357 Throttle body asm. Z18XE 1

90572766 Gasket Z14XE 1

90543950 Gasket Z18XE 1

NOTE: All stocks of throttle bodies in HSPO are

manufactured after the breakpoint date code.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

HOLDEN SERVICE TECHLINE________________________________________________________________ AUGUST, 2002

Water Leaks – Rear Wheelhouse Body

Seams

(GROUP 1) “HINT” TL327-0207

PROBLEM DESCRIPTION

Some customers may complain of a damp rear seat

cushion

SERVICE RECTIFICATION

Remove the rear wheel, rear seat cushion and rear

seat back and inspect the following body seams for

possible water entry locations. Add sealer as required.

PRODUCTION RECTIFICATION

Additional spot welds have been added to the seam

from.

TAG: Build Date:

L893835 17/07/02

Please report via PIR any complaints seen after this

breakpoint.

HVAC Case Whistle

VT/VX/VU/V2/WH

(GROUP 2) REVISED TL213A - 0207

This Techline supersedes the previous one in Issue

1/2002. It is revised by correcting the phone number

for Air International.

PROBLEM DESCRIPTION

A number of PIRs have been submitted to Holden

describing a whistle noise from the HVAC case.

Dealer investigation has revealed the fresh recirc door

has not closed completely, resulting in the whistle

noise.

PRODUCTION RECTIFICATION

Engineering are investigating design changes to the

blower housing to eliminate this complaint.

Breakpoints will be advised once they have been

struck.

SERVICE RECTIFICATION

In the interim, dealers are able to contact the HVAC

supplier for a service fix to address this complaint in

customer’s vehicles. This fix involves installing a self

adhesive foam pad that seals the fresh recirc door

completely.

If a customer presents their vehicle with this complaint,

please contact:

Air International Pty Ltd

Phone: 1800 673 716

and request a Service Fix pack for this complaint.

PARTS INFORMATION

Contact Air International directly on the number above

and refer to Air International Service Bulletin HMC-92.

WARRANTY CLAIM INFORMATION

Description Fit HVAC Whistle Fix Kit

Labour Op. No. D000330

Time 0.5 hr

Failure Code 40

HOLDEN SERVICE TECHLINE________________________________________________________________ AUGUST, 2002

Passenger Side Rocker Panel Water Entry

V2 MONARO

(GROUP 1) HINT TL328-0207

PROBLEM DESCRIPTION

Some customers may complain of a “sloshing” sound

from the passenger side rocker panel/sill while

accelerating or braking

Investigation of complaint vehicles showed water entry

to rocker sill via the panel seams as shown in the

following photographs.

If you have a vehicle with the above condition remove

the left-hand guard and inspect for gaps in the seam as

shown in photographs. Fill any gaps with sealer.

PRODUCTION RECTIFICATION

The body sealing process in the area shown above was

modified from:

ISOVIN: Build Date:

6H8V2X37F2L881204 19/06/02

Please report via PIR any complaints seen after this

breakpoint.

Rear Power Windows Malfunction – Water

In Door Connector

TS Astra CD Model

(GROUP 12) TL319-0207

PROBLEM DESCRIPTION

There have been isolated reports of inoperative rear

power windows on the above model which has been

traced to water entry into the rear door connector

located as shown in Figure below.

SERVICE RECTIFICATION

Summary: Remove water from connector and seal

with electrical insulating grease.

1. On complaint vehicles remove water from the

connector halves using compressed air. If

possible, use a hair dryer to remove all traces of

moisture from the connectors. DO NOT USE a

heat gun for this procedure.

2. Apply grease M40347 (No 4 Electrical Insulating

Compound) to both halves of connector.

3. Reconnect connector and check window operation.

If windows fail to operate the connector may be

corroded in which case the harness will require

replacement.

PARTS INFORMATION

Part No.: Description: Qty

M40347 Silicone Grease - 150g tube 1

WARRANTY CLAIM INFORMATION

Description Dry connector and seal with

specified grease – both rear doors

Labour Op. No. N000390

Time 0.3 hr

Failure Code 51 electrical connector problem

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

Engine Improvements

Gen III V8

(GROUP 6A) “REVISED” TL296A-0208

This Techline supercedes the previous one in Issue 6,

2002. It is revised by clarifying the breakpoint for

engines with revised pistons and rings.

____________________________

This bulletin provides information on the major

improvements and revisions made to Gen III V8

engines.

This information will be found useful during service and

repair of these engines.

Revised Oil Pick-up Tube

M/T engines (only) were fitted with a revised oil pick-up

tube; and a revised low oil pressure warning lamp

calibration was applied to vehicles from:

Engine No.:

VF002021193

For Reference, this engine was used in:

ISOVIN: Build Date:

6H8VXK69F1L656328 02/11/00

These M/T engines (and any M/T engines fitted with

the revised pick-up in service) are identified by the “X”

mark, stamped on the cylinder block, as shown below:

The revised oil pick-up is now the only oil pick-up

available from HSPO.

All engines (IE: M/T & A/T) were fitted with revised oil

pick-up tube, and revised low oil pressure warning

lamp calibration from:

Engine No.:

VF011010001

No ISOVIN is available for this engine.

NOTE: From Engine No. VF011010001 – the “X”

stamp mark identifier was no longer used, as all

engines from that breakpoint contain the revised oil

pick-up.

Revised Oil Dipstick & Oil Volume

M/T 225kW/255kW engines were fitted with an

additional 0.5 litre of oil and a revised oil dipstick from:

Engine No.:

VF002700933

For Reference, this engine was used in:

ISOVIN: Build Date:

6H8VXK69F1L675354 13/12/00

All M/T & A/T 225kW/255kW engines carried these

revisions from:

Engine No.:

VF011080001

No ISOVIN is available for this engine.

All 300kW engine carried these revisions from:

Engine No.:

VF002850599

For Reference, this engine was used in:

ISOVIN: Build Date:

6H8VXL69F1L671675 08/12/00

The revised dipstick can be identified by part number

92065825 stamped on the dipstick.

Revised Pistons & Piston Rings

All engines from:

Engine No.:

VF012350476

were fitted with revised pistons (with a friction resistant

coating) and piston rings with revised ring tension.

These pistons are identified by a plain aluminium piston

finish and two rectangular friction coating patches on

the skirts.

The piston rings are identified by a small groove in the

underside of the second compression ring (earlier rings

were a plain rectangular section).

This upgraded engine was introduced in manual trans.

vehicles from 15/10/01 and in all vehicles from

18/12/01.

Note: a small number of engines were built, earlier than

the above breakpoint, with an alternative design piston

with a grey colour finish all over, and two rectangular

friction coating patches on the skirts).

If repairing an engine for any reason, it is

recommended that these pistons be replaced with the

latest design pistons ex-HSPO.

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

“Moan” Noise From Rear Cross Member at

105–110 km/h

WH, VX with Gen III V8 & A/T

(GROUP 4) REVISED TL311A-0208

This Techline supersedes the previous one in Issue

6/2002. It is revised by adding WH model and

production breakpoint.

NOTE: ZONE AUTHORISATION IS REQUIRED

BEFORE REPLACING A CROSS MEMBER FOR THE

CONDITION DESCRIBED IN THIS BULLETIN.

PROBLEM DESCRIPTION

Some vehicles may exhibit a “moan” or “drone” noise at

105-110km/h, which is similar to an exhaust resonance

or “cavity boom”.

This noise may be caused by excitation of the rear

suspension cross member by input of various drivetrain

and tyre related vibrations.

PRODUCTION RECTIFICATION

Revised cross members with vibration dampers have

been fitted to vehicles (with Gen III V8) from:

ISOVIN: Build Date:

6G1HM52FX3L908900 23/08/02

SERVICE RECTIFICATION

Positive rectification of this condition relies on good

diagnosis.

The “moan” or “drone” noise occurs:

- between 105km/h and 110km/h

- at constant throttle for some distance

- travelling on a straight road.

When the condition occurs, steer the vehicle from side

to side – within the lane the vehicle is travelling in – if

the condition varies significantly, the condition is

confirmed.

The condition should not be confused with any exhaust

or other driveline vibration or resonance that will NOT

be reduced by this steering input!

On confirmation of this condition – contact TAS for

loading of a case, and availability of a revised cross

member (Refer Parts Information for details).

TAS will confirm diagnosis, and if required, arrange the

supply of a revised cross member.

Once TAS have confirmed the need for a cross

member – you MUST contact your Zone Office for

authorisation to carry out this task.

After obtaining Zone authorisation, fitting the cross

member, and road testing to confirm that the condition

is corrected – contact TAS immediately to close the

TAS case.

PARTS INFORMATION

At the time of release of this bulletin, a specially

manufactured cross member (fitted with vibration

dampers) is available only from TAS. This cross

member will only be made available through TAS, after

a TAS case is loaded, and the condition is confirmed.

When production parts are available, an updated

bulletin will be released providing part numbers of the

new cross member assemblies, cross member service

parts, and service information.

When replacing cross members observe the

procedures outlined in the SIP CD.

WARRANTY CLAIM INFORMATION

When fitting the cross member described above

(supplied via TAS) use the following information:

NOTE: ZONE AUTHORISATION IS REQUIRED

Description Cross Member - Replace

Labour Op. No. F000179

Time 3.6 hrs

Failure Code 36

Update

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

Rear Wheel Bearing Failure

SB Barina

(GROUP 4) TL337-0208

PROBLEM DESCRIPTION

Some isolated reports of rear wheel bearing failure

after servicing have been received from the field.

SERVICE RECTIFICATION

Ensure the service procedure in TIS2000 is followed

precisely.

The grease packing and adjustment of this wheel

bearing are critical to its performance.

Poor packing or excessive preload on the bearing will

cause bearing failure in service.

To locate the procedure for adjusting the wheel

bearings in TIS2000 follow the path shown in table:

TIS Screen ê

êê

ê Select the following ê

êê

Service Information Standard Information

Model Corsa-B

Year select model year for vehicle concerned

Eng. -

Vehicle

Data

Trans. -

Assembly

Group

+ F Rear axle and rear wheel suspension

+ Rear Axle Front Wheel Drive

✓

Rear wheel hub

Standard

Informati

on.

Application Repair (Remove,Install,Adjust)

Document List Adjustment operations, wheel bearing play,

adjust

ABS Modulator Damage When Replacing

Brake Pads

All Carlines with ABS

(GROUP 5) HINT TL331-0208

PROBLEM DESCRIPTION

Some complaints have been received from retailers

describing ABS Modulators internal seal damage

during replacement of brake pads.

SERVICE RECTIFICATION

When pushing brake pistons back into the caliper,

extreme care must be taken!

Caliper piston diameter is relatively large compared to

master cylinder piston diameter. This means the

caliper piston, when forced back into the caliper, is

pumping a large quantity of brake fluid back through

the system at high velocity and pressure.

In some cases, fluid under these conditions can cause

damage to ABS modulator seals.

It is essential that caliper piston retraction be done

slowly and carefully. It is preferable to use a pad

spreading tool. If using a G-clamp, an example of a

suitable slow speed would be one-quarter turn of the

handle per second.

Service Literature (SIP and TIS2000) for pad

replacement also states fluid reservoir level will

increase when pushing back caliper pistons. It is

important not to allow fluid to overflow and spill onto

paintwork.

It has been suggested that loosening the bleed nipple

on the caliper is one method of avoiding both ABS

Modulator damage and fluid overflow.

Holden does not endorse this practice for the following

reasons:

1. Customers will be charged unnecessarily for fluid

replacement if the reservoir needs to be topped up

2. Attempting to loosen the bleed nipple

unnecessarily exposes Service Departments to

associated costs if, for example, the nipple is

broken due to corrosion.

Remember – paint, caliper or ABS modulator damage

as a result of piston retraction is not a warrantable

defect and repair costs are carried by your Service

Department!

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

AM Radio Reception Interference from

Electronic Power Steering Unit

(GROUP 12) TL207-0208

PROBLEM DESCRIPTION

Some customers may complain of interference on the

AM radio band which is related to steering wheel

operation.

The most likely cause of this condition is “electrical

noise" generated as a result of inadequate earthing of

the Electronic Power Steering (EPS) unit .

SERVICE RECTIFICATION

On complaint vehicles, check if Service Earth Lead p/n

24462766 is fitted. If not, then install as per following

procedure.

NOTE: Please report by PIR all cases after vehicle

W0L0XCF6814141463 which require a Service Earth

Lead to rectify the complaint.

PARTS INFORMATION

Obtain the following part from HSPO.

Part No.: Description: Qty:

24462766 Earth Lead. 1

WARRANTY CLAIM INFORMATION

For vehicles covered by warranty use the following:

Description Replace EPS earth lead.

Labour Op. No. N000384

Time 0.9 hr

Failure Code 33

Procedure For Installation Of EPS Service Earth Lead 24462766

1. Trim Removal at Drivers Side.

Refer Figure 1.

a) Remove storage pocket. Insert a thin blade

screw driver into the front of each of the two

tangs (refer arrows) and lever downwards.

b) Remove RHS lower dash.

c) Remove RHS lower shroud panel.

d) Remove RHS kick panel.

2. Lower HVAC Duct Removal

a) Remove the black plastic fastener using a flat

blade screw driver. Refer Figure 2

b) Push duct slightly forward and at the same time

pull on the right hand side of the duct in a

downwards motion to the rear of the vehicle.

Figure 1– Working Environment

Figure 2 – HVAC Duct

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

3. Revised Earth Lead Fitment To

Electronic Power Steering (EPS)

Module.

a) Remove the blue and white plastic connectors

from the EPS module. This is done by

pressing down on the respective tangs at the

base of each connector.

Figure 3 shows in car position of EPS.

Figure 4 shows connectors detached.

b) Prise open the secondary catch of the blue

connector with a flat head screw driver. Refer

Figure 5A

c) Remove the brown (earth) wire terminal from

the blue connector using a two prong tool to

release the 2 locking tangs. Refer Figure 5B.

A handmade tool made to the following

dimensions can be used for this job. The top

section of an antenna mast is ideal for the

prongs. The prongs can then be mounted in a

piece of wooden dowel 25mm dia. by force

fitting into blind holes a little smaller than the

wire diam.

d) Cut the brown earth wire with suitable wire

cutters, just ahead of the tape.

Refer Figure 6.

Figure 3 Figure 4

Figure 5A – Open Secondary catch

Figure 5B – Releasing terminal with handmade tool

Figure 5C – Earth Wire Removed From EPS Connector

Figure 6 – Cutting earth wire

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

3 continued.

e) Insert the revised earth lead connection, part

number 24462766, into the EPS connector.

Refer Figure 7.

f) Where the original earth lead is fitted to the

EPS module, remove the screw with a 10 mm

socket. Remove the brown earth lead and cut

just prior to tape. Retorque earth lead

attaching screw to 20 Nm.

g) Position the revised earth lead behind cross

beam and fix to existing wiring harness using

one (1) cable tie.

Refer Figure 8.

h) Remove the other EPS module screw and fit

earth ring terminal of revised earth lead.

Torque EPS screw to 20 Nm. Refit blue and

white EPS connectors to EPS module. Refer

Figure 9.

4. Fitment Of Revised Earth Lead To Right

Hand Kick Panel Ground

a) Release the harness connector at the right kick

panel to expose the earth nut behind the hood

release lever.

Refer Figure 10.

Figure 7 – Inserting revised earth into EPS connector

Figure 8 – Revised earth lead positioning

Figure 9 – EPS Module With Revised Earth Connected

Figure 10 – Releasing Harness Connector

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

4 continued.

b) Remove the earth nut and original earth lead

(brown wire) using a 13 mm socket and ¼ inch

drive. Refer Figure 11.

c) Cut the original earth lead with suitable wire

cutters near the junction.

Refer Figure 12.

d) Route revised earth lead along original wiring

harness and loop. Secure earth lead with cable

ties. Four (4) cable ties should be sufficient.

Refer Figure 13.

Position revised earth ring terminal at screw

location and refit nut using a 13 mm socket and

¼ inch drive.

Torque to 15 Nm (range 12 – 20 Nm).

e) Refit the harness connector and lock in position.

5. Reassemble All Trim Components

Figure 11 – Earth Screw/Lead Removal

Figure 12 – Cut Original Earth Lead At RH Kick Panel

Figure 13. Revised Earth Wire Routing

Earth

Revised Earth Lead

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

Oil Filter Cap – Care During Removal and

Replacement (Cartridge Type)

TS & XC (X18XE1 or Z18XE Engines)

(GROUP 6A) TL342-0208

PROBLEM DESCRIPTION

PIR’s have reported damage to the oil filter cap used

on cartridge type oil filters.

Damage (cracking) will occur on oil filter housing caps

during removal if the cap is over-torqued when a filter

cartridge is replaced.

Ensure only 15Nm is applied to the filter cap

when an oil filter cartridge is replaced.

All X18XE engines are fitted with cartridge type oil

filters.

Z18XE1 engines are fitted with two types of oil filters:

• Cartridge type – which requires the removal of the

filter housing cap to remove and replace the filter

element;

• Screw-on type – which requires only the filter

assembly to be removed and replaced.

Screw-on type oil filters were introduced to

Z18XE engines from: engine No

Z18XE20V00605

SERVICE RECTIFICATION

Summary: Adhere to correct torque specification and

ONLY use the tools recommended below.

TORQUE SPEC.:

Do NOT over-torque the oil filter cap when fitting a

new oil filter cartridge.

Ensure only 15Nm is applied to the filter cap

when an oil filter cartridge is replaced.

REMOVAL TOOLS:

When removing filter housing caps on engines with

the cartridge type filter, use ONLY a 24mm ring

spanner or socket. This fully supports the cap

material and allows removal without damage to the

cap.

TIS 2000 drawings showing the use of a ratchet

handle and square drive special tool – these are

shown ONLY for the screw-on type oil filter fitted to

engines after the breakpoint shown above.

Auto Trans Shift Quality

VTII & WH (pre A8A) with Gen III

(GROUP 7B) TL333-0208

This Service Techline only applies to VTII and WH

(pre A8A) vehicles built prior to tag L626038 (start of

VX production).

For complaints on VXI & VUI, & WH with A8A - refer

to Techline in Issue 2, Mar/2002.

PROBLEM DESCRIPTION

A typical complaint transmission will exhibit a long 1-2

and/or 2-3 shift with a harsh engagement “bump” at

end of the shift.

The cause of these conditions has been traced to a

software deficiency with the calibration for the above

models.

SERVICE RECTIFICATION

On complaint vehicles, flash the latest PCM

calibration from TIS CD 32.0B or later.

WARRANTY CLAIM INFORMATION

Description Reflash PCM

Labour Op. No. J000713

Time 0.4 hr

Failure Code 43 (Shifts hard)

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

Hotmelt Glue Protrudes From Under Rear

Windscreen Upper Moulding

VX, WH, V2

(GROUP 1) TL338-0208

PROBLEM DESCRIPTION

There have been isolated reports of small amounts of

hotmelt glue protruding from under the rear screen

upper moulding in high ambient conditions.

Note: This glue is used as a production assembly aid

for upper moulding retention. It is not related to the

sealing of the windscreen, therefore, windscreens

should not be removed to rectify this condition.

SERVICE RECTIFICATION

Remove bulk of glue from glass using a razor blade

mounted in a suitable holder. (e.g. paint scraper).

Take care to avoid contacting the moulding with the

razor blade.

If required, wipe any remaining residue from the

glass with Prepsol.

Dex-Cool® Coolant Name Change

All Models Using Dex-Cool®

(GROUP 6K) TL352-0208

The Dex-Cool® coolant (Holden part number

12377912) referred to in Part Finder, Owner

Handbooks, PV SIP and LCV SIP has been

superseded to the following:

"Extended life anti-freeze coolant".

Part Number 92145527 (5 litre container)

Conforms to GM specification 6277M.

The change has occurred because HSPO now obtain

this product from a local supplier. The colour of the

new coolant may vary slightly from Dex-cool but

essentially remains unchanged i.e. orange/red.

Owner Handbooks and SIP will be revised to reflect

the above change.

LSD Chatter Noise

VX, VU, WH with V6 Engine & LSD

(GROUP 4) TL339-0208

PROBLEM DESCRIPTION

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

tight corners at low speeds and parking manoeuvres

where differential action is initiated. Chatter may also

be experienced by the driver as a “grabbing” feel

during the operation of the LSD.

The chatter noise is caused by reduced sliding

lubrication qualities of the LSD cone friction surfaces

within the final drive unit (using the existing oil).

PRODUCTION RECTIFICATION

Differentials with revised LSD cones are scheduled to

be fitted to vehicles in early September. Vehicle

breakpoint details will be published in a future

Breakpoint Summary.

SERVICE RECTIFICATION

IMPORTANT: Do not attempt to rectify

complaint vehicles by using the V8 LSD

Chatter Kit as described in Retailer Letter

30/02.

On complaint vehicles request a changeover unit

through Spicer Axle Australia (SAA) via the

SAA will provide an exchange axle unit that has

revised LSD cones, Mobilube SHC ID synthetic oil, oil

additive and compatible seals. The supplied unit will

have an identification tag that reads “LSD USE

APPROVED LUBRICANT AND FRICTION

MODIFIER”.

established procedure.

Update

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

HVAC Manual Control Unit - Parts

Serviceability

VT, VX, VU with C60 (HVAC) Option

(GROUP 2) TL343-0208

Complete HVAC manual control units are often

returned to Air International when serviceable

components should have been replaced.

SERVICE RECTIFICATION

Be aware that many components for HVAC manual

control units are serviced separately. The following

diagram is taken from PartFinder and shows the

components available.

Warranty claims for complete manual control units will

not be accepted if a serviceable component is

available and should have been replaced.

Revised Centre High Mounted Stop Lamp

(CHMSL)

VU SS

(GROUP 12) TL276-0208

CHANGE DESCRIPTION

The Centre High Mounted Stop Lamp (CHMSL) on

the above model has been resourced to a new

supplier. Because the new CHMSL is a slightly

different design to the previous part, the rear roof

moulding has been revised to suit.

PRODUCTION BREAKPOINT

The new CHMSL with revised rear roof mouldings is

being introduced progressively into vehicle production

on a colour by colour basis. This process

commenced from tag L899802, build date 2/8/02.

When all colours have been introduced, this techline

will be republished with final breakpoint details.

SERVICE RECTIFICATION

On vehicles where the old design CHMSL (p/n

92082683) has failed, install the new design CHMSL

together with the new revised roof moulding:

The CHMSL replacement procedure in Holden PV

SIP is found by the following path.

Select - VU Series

Select - Section 12B – Lighting System

Select - 2. Service Operations

Select - 2.1 high Level Stop Lamp

NOTE: The new centre rear roof moulding 92120003

will require painting in vehicle body colour.

PARTS INFORMATION

Part No.: Description: Qty:

92120002 Lamp Asm. Stop –

Centre High Mount

92120003 Moulding Asm. roof

rear centre(unpainted)

WARRANTY CLAIM INFORMATION

Description Replace CHMSL & Rear

Centre Roof Moulding

Labour Op. N000399

Time 0.3 hr

Failure Code 50

Claim For Painting Roof Moulding:

If sublet, claim as net items expense as normal.

If painted In-house, add up to 0.7hrs to Time and up

to $25 materials cost in net items.

Update

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

Decklid to Hinge Attachment

(GROUP 1) TL256-0208

PROBLEM DESCRIPTION

There have been reports from retailers that when

attempting to retighten the bolts which attach the

decklid to the hinge, they cannot achieve sufficient

clamp load.

Investigations show this condition is caused by

deformation of the captive washer under the head of

the bolt.

PRODUCTION RECTIFICATION

Revised decklid to hinge bolts (hardened steel captive

washers) have been fitted to vehicles from:

ISOVIN: Build Date:

6H8V2X37F2L905347 15 Aug 2002

SERVICE RECTIFICATION

1. On vehicles with the complaint condition, replace

the four existing decklid to hinge bolts with latest

bolts part number 92138683.

2. Torque bolts to 9 ±

±±

± 1.5 Nm.

PARTS INFORMATION

Part No.: Description: Qty:

92138683 Bolt decklid to hinge 4

Figure 1. Decklid to hinge attaching bolts - item #3.

Instrument Cluster - Intermittent

Operation

(GROUP 12) TL318-0208

PROBLEM DESCRIPTION

Complaints such as dash lights and gauges become

inoperative and Engine Management Light comes on.

When engine is switched off it may not restart. Above

conditions can occur intermittently.

The above conditions can be caused by fretting

corrosion of the instrument cluster connector.

PRODUCTION RECTIFICATION

Stage 1. A tie strap was added to eliminate wiring

harness movement in March 2001.

Stage 2. A new wiring harness connector (grey colour)

with reduced tolerances between male/female

connections was introduced from:

ISOVIN: Build Date:

W0L0XCF6824115006. 07/01/02

Stage 3. Nyogel grease to be added to connector from

Model Year 2003. Breakpoint to be advised.

SERVICE RECTIFICATION

Summary: Add electrical grease to wiring harness

connector and secure harness with cable tie.

Procedure:

1. Remove instrument assembly – Procedure is

found in TIS as follows:

TIS Screen ê

êê

ê Select the following ê

êê

Service Information Standard Information

Model Corsa-C

Year 2002

Eng. -

Vehicle

Data

Trans. -

Assemb.

Group

N (Elect. Eqpt. & Instruments)

➨

Instruments & Telltales

Standard

Information

Applicn. Repair (Remove,Install,Adjust)

Document List Instrument Assembly, Remove & Install

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

2. Remove wiring harness from Instrument panel by

use of a suitable tool (picture I).

3. If the wiring harness is already fixed to the wiring

harness connector with a cable tie, go to step 5. If not,

go to step 4.

4. Attach wiring harness to wiring harness connector

with cable tie (picture II). Suitable dimensions for cable

tie are: length = 142mm, width = 2.5mm, thickness

= 1.1mm.

5. Obtain two 25 mm lengths of double-sided tape from

workshop. An alternative (if available), is to use the

circular push-out section of the “number plate bonding

pad” (in glovebox of new XC, TS, TT vehicles for

attaching the number plates). If you are using the

“number plate bonding pad” cut in half along dashed

line with scissors (picture III).

6. Stick double-sided tape/bonding pads at left and

right side of the instrument cluster where the wiring

harness connector attaches (picture IV).

7. Attach wiring harness to instrument panel with cable

tie (picture V).

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

8. Apply grease p/n 92146329 on wiring harness

connector by pushing grease with thumb into female

connector (picture VI).

9. Apply grease to each individual pin of instrument

assembly (picture VII).

10. Reinstall instrument assembly – refer TIS

procedure.

PARTS INFORMATION

Part No.: Description: Qty:

92146329 Nye Nyogel 760G

Grease - 30cc Syringe

This is the only grease recommended for this

application. Do not use electrical grease containing

silicone.

WARRANTY CLAIM INFORMATION

Description Instrument cluster connector

– add tie strap & grease

Labour Op. No. N000396

Time 0.9 hr

Failure Code 51 Electrical Connector Problem

NOTE: Claim only for the cost of the amount of

grease used and place in net items.

Modular Reservoir Assembly (MRA)

Replacement and Fuel Gauge Calibration

VXII, WHII, VUII, V2

(GROUP 12) CAUTION TL352-0208

When replacing the Modular Reservoir Assembly

(MRA) in one of the above models, DO NOT

recalibrate the fuel gauge using the function available

in Tech 2.

This calibration function has no effect in these

vehicles, and may introduce other errors which could

lead to unnecessary replacement of the instrument

cluster.

If instrument cluster codes are evident after

replacement of the MRA, have your Nominated

Contact phone Holden Technical Assistance for

further guidance.

CANCELLED

Update

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

Revised Cylinder Head

XC with Z14XE

(GROUP 6C) TL335-0208

A revised cylinder head with modified EGR ports was

fitted to engines from:

Engine No: Build Date:

20Y65461 23 May 02

20 = Manufacturing plant (SZENTGOTTHARD)

Y65461 = serial number. When 99,999 is reached the Y

will change to the next letter of the alphabet.

IMPORTANT SERVICE NOTE:

Whenever the latest revised type cylinder head

(part number 93175328) is fitted to an earlier

engine (prior to eng. no. 20Y65461) the ECU must

be updated with software No. 12223620.1 which

has been available from TIS 32.0 onwards.

Notes On Cylinder Head Identification:

Cylinder heads can be identified by their casting

number which is cast into the head just above where

the exhaust manifold is bolted. Refer photograph

below.

Latest cylinder head casting number “ 13 106 674”

Earlier cylinder head casting number “ 90 400 210”

Note: Photo shows engine cover and exhaust

manifold heat shield removed.

Drive Shaft Seal Installation Precautions

TS with F17 M/T

(GROUP 7A) TL345-0208

PROBLEM DESCRIPTION

Minor oil leaks have been reported from transmission

drive shaft seal area.

The cause has been defined as seal damage during

the vehicle assembly process.

As seal installation is a delicate process, the

possibility of seal damage also exists during seal

replacement in service.

PRODUCTION RECTIFICATION

A revised seal design is under consideration for this

application. Any change in seal design will be advised

in future Breakpoint Summary pages.

SERVICE RECTIFICATION

Summary: Fit a new seal – CAREFULLY - using the

correct tool.

During fitting of a new drive shaft seal,

- the seal recess should be carefully inspected for any

burrs – which should be removed before seal fitting;

- the drive shaft end should be inspected for any

burrs, damage or sharp edges – these should be

corrected before seal fitting - sharp edges on the

drive shaft end can be removed with a fine hone

stone and the shaft end carefully cleaned.

- use only the special tool KM 446 (sourced from SPx

Australia).

HOLDEN SERVICE TECHLINE_____________________________________________________________OCTOBER, 2002

Rough Idle, Loss Of Power, Stall During

Idle and Hard To Restart - DTC P0400,

P1405 Set

XC with Z14XE engine

(GROUP 6C) REVISED TL356-0209

This Techline supercedes the previous techline in Issue

11, Nov, 2001. It is revised by updating the EGR

cleaning procedure.

PROBLEM DESCRIPTION

Some vehicles may experience rough idle, loss of

power, stalling during idle, hard to start after a stall

condition. Tech 2 may also show the following DTC’s

present:

P0400 – EGR Circuit Range/Performance or EGR flow

excessive.

P1405 – Exhaust gas recirculation sensor circuit high/low

Vehicles with these symptoms generally have been

found to have EGR valves contaminated with foreign

particles.

PRODUCTION RECTIFICATION

The ECU software was reprogrammed to provide a

“self cleaning” (low frequency shake) routine to the

EGR valve. Engines with this revised ECU software

(p/n 09353469.9) were produced from:

Engine No: Build Date:

20W68679 15/11/01

Engine Number Identification:

20 = Manufacturing plant (SZENTGOTTHARD)

W68679 = serial number. When 99,999 is reached

the W will change to the next letter of the alphabet.

SERVICE RECTIFICATION

Summary: On complaint vehicles remove and clean

EGR valve and reflash ECU with revised software

(EGR shaking routine).

1. Remove the EGR valve. Procedure is found in TIS

as follows.

TIS Screen Selection

Service Information Standard Information

Model Corsa-C

Year 2001 or 2002

Vehicle

Data

Eng. Z14XE

Assembly

Group

L Fuel and Exhaust System

➨

Exhaust System

➨

EGR system

Standard

Informati

on Application Repair (Remove, Install, Adjust)

Document List EGR valve remove and install

2. Inspect valve for foreign material that may be holding

valve open. Remove any foreign material from

valve/seat area with a brass-brush or similar.

Refer Figure I.

3. To confirm if EGR valve is opening and closing

correctly, reconnect it to the wiring loom and operate

valve with Tech 2.

4. Remove any loose foreign material from ports in

EGR to engine adapter plate with a vacuum cleaner .

Refer Figure III.

NOTE: DO NOT replace EGR valve unless foreign

material cannot be removed or valve has been

damaged. Also, DO NOT replace catalytic converter or

exhaust manifold with new parts for this condition.

5. Reinstall EGR valve with new gasket. Ensure all

sealing surfaces are clean.

6. If engine is prior to Eng. No. 20W68679, reprogram

the vehicle ECU with software part number

09353469.9 which is available from TIS 25.0B

onwards. This software includes an EGR shaking

routine for cleaning purposes.

Note: Engines after Eng. No. 20W68679 will already

have the latest EGR shaking routine software

already installed.

HOLDEN SERVICE TECHLINE_____________________________________________________________OCTOBER, 2002

Programming Note:

When reprogramming the ECU, Tech 2 will ask if

vehicle is fitted with old or new cylinder head ?

For engines prior to Engine No. 20Y65461 the

correct answer is - “Old” cylinder head. The reason

for this is that a revised cylinder head was fitted

in production from Engine No. 20Y65461. For

detailed information on the introduction of

revised cylinder heads on Z14XE engines refer

to Techline in Group 6C, Issue 8/2002.

WARRANTY CLAIM INFORMATION

Description Remove, clean, reinstall EGR

valve & reflash ECU

Labour Op. No. J000701

Time 0.7 hr

Failure Code 12 “Foreign Material”

Front Seat Lumbar Support Replacement

Guidelines

VX,VU,V2

(GROUP 1) TL348-0209

PROBLEM DESCRIPTION

Some retailers are still replacing complete seat back

frames under warranty when only the lumbar support is

faulty.

NOTE: The lumbar support has been available as a

replacement part for the models listed above since mid

2000.

WARRANTY ADMINISTRATORS PLEASE

NOTE

Warranty claims will not be accepted for replacement

of the complete seat back frame when only the lumbar

support is faulty.

For lumbar support replacement procedure refer to

previous Service Techline in Group 1, 2000, titled

“VT,VX,WH – Front Seat Lumbar Support Asm.

Replacement Procedure”

HOLDEN SERVICE TECHLINE_____________________________________________________________OCTOBER, 2002

Intermediate Steering Shaft Knock

JR, JS

(GROUP 9) TL362-0209

This Service Techline supersedes the previous techlines

on this topic; refer PV SIP Group 9, 1998 & 2002.

PROBLEM DESCRIPTION

On some vehicles, a knocking noise can be heard in the

area of the steering column when turning. The knocking

noise is caused by slight play in the securing flanges

(upper and lower) of the steering intermediate shaft.

SERVICE RECTIFICATION

Summary: On complaint vehicles, replace the

intermediate steering shaft with the new revised part as

described below.

Removal And Replacement Of Intermediate

Steering Shaft:

1. IMPORTANT: Disconnect the battery and wait at

least 1 minute for the capacitor in the control unit to

discharge. (Airbag safety precautions as outlined in

service manual Volume 1 must be observed).

2. Centre the steering wheel.

3. Remove foot well panels and air ducting.

4. Loosen the pinch bolts of the steering intermediate

shaft (Nos.1 and 2) and engage the steering lock,

see Figure 1.

5. Compress the steering intermediate shaft and

remove.

6. Fit the new steering intermediate shaft Part

Number - 09119322, release the steering lock,

then secure the shaft using new pinch bolts (Torx

screws) and an appropriate thread locking sealant.

7. Torque the upper and lower pinch bolts to

22 Nm/16 lbf.ft + 45° + 15° Failure to

tighten these bolts correctly may result in not

eliminating the knock condition.

8. Refit air ducting and foot well panels.

9. Mark the steering wheel position and remove

the steering wheel using special tool

Puller KM 210-A.

10. Offset the steering wheel 2 teeth to the right.

11. If necessary, with a screwdriver, depress the clock

spring locking tab and move the clockspring until

the driving lugs on the steering wheel locate

correctly into the clockspring.

12. Refit the steering wheel and secure the fastening

nut with the locking plate supplied. Torque to

25 Nm/18 Ibf.ft.

13. Refit the air ducts and foot well panels.

14. Reconnect the battery.

15. Test drive the vehicle and ensure that the steering

is centered.

Figure 1.

PARTS INFORMATION:

Part No. Description Qty.

09119322 Repair Kit - Steering Coupling

Joint (consists of revised shaft,

2 Torx screws, 1 locking

washer)

SPECIAL TOOL REQUIRED:

KM-210-A Puller

WARRANTY CLAIM INFORMATION

Description Repair Kit - Steering

Coupling Joint Replace

Labour Op. No. E000302

Time 0.8 hr

Failure Code 28 rattle

Update

HOLDEN SERVICE TECHLINE_____________________________________________________________OCTOBER, 2002

Buzzing Noise From Fuel Tank Pressure

Relief Valve

SB with C14SE engine

(GROUP 8) TL363-0209

PROBLEM DESCRIPTION

Some customers may complain of a buzzing noise

heard inside the cabin during conditions of high

ambient temperature (usually above 35 deg C) in

stop/start traffic.

SERVICE RECTIFICATION

On complaint vehicles replace fuel cap with the

lockable vented fuel cap p/n 92117453. Note; this cap

comes with its own set of keys.

PARTS INFORMATION

Part No.: Description: Qty:

92117453 cap – fuel filler 1

Exterior Lamp Lens Care Guidelines

All

(GROUP 12) TL303-0208

Most late model vehicles have polycarbonate lenses in

the exterior lamps. This material has been selected

because of its many positive attributes in this

application. However, it is very sensitive to a wide

range of chemicals, which can cause crazing or

cracking of the lens. In these cases the entire lamp

housing must be replaced.

Whenever treating a vehicle with any type of chemical,

such as those sometimes used for rail dust removal

etc., avoid contact with all exterior lamps.

Also, lamps should never be covered with any material

(rags, guard protectors etc) whilst they are turned on.

The heat build up within the lamp has the potential to

permanently damage the lens and housing.

Driver’s Seat Belt Length

TT ZAFIRA

(GROUP 1) TL361-0209

PROBLEM DESCRIPTION

Some customers may complain the driver’s seat belt is

too short.

PRODUCTION RECTIFICATION

Revised drivers seat belt assemblies with longer

webbing have been fitted to vehicles from:

ISOVIN: Build Date:

W0L0TGF752H031619 03/07/02

SERVICE RECTIFICATION

Summary: If owner complains, fit the longer seat belt

assembly.

Refer to the instructions in TIS2000 to remove and

install the front seat belt. The following table shows the

path in TIS2000 to find the required information.

TIS Screen ê

êê

ê Select the following ê

êê

Service Information Standard Information

Model Zafira

Year 2002

Eng. -

Vehicle

Data

Trans. -

Assembly

Group

+ C Body Equipment

+ Seat, Upholstery, Inner Trim Panels

✓

Seat Belt

Standard

Info.

Application Repair (Remove, Install, Adjust)

Document List Seat Belt - Front, Remove & Install

PARTS INFORMATION

Part No.: Description: Qty:

90560636 Belt-Front Seat RH 1

WARRANTY CLAIM INFORMATION

Description Belt Asm, RH Front, Replace

Labour Op. No. C451100

Time 0.5 hr

Failure Code 55 Poor Fit

HOLDEN SERVICE TECHLINE_____________________________________________________________OCTOBER, 2002

A/T Shifter Base Damaged By Contact

With Prop Shaft Front Coupling

VX, VU, V2, WH (All with V6 & A/T)

(GROUP 7B) TL351-0209

PROBLEM DESCRIPTION

Auto Transmission (A/T) shifter base may be damaged

by the prop shaft front coupling if vehicles are

subjected to extreme rough road usage (possibly in

combination with high torque loading).

PRODUCTION RECTIFICATION

A revised engine/trans. rear mount, that includes a

travel limiting bracket, has been introduced in vehicle

production from:

ISOVIN: Build Date:

6H8VXK69A2L912000 30/08/02

SERVICE RECTIFICATION

Summary: On pre-Breakpoint (V6) vehicles, repair A/T

shifter base with available service part/s and fit revised

engine/trans. rear mount.

On presentation of a V6 A/T equipped vehicle where

the A/T shifter base has been damaged by contact with

the prop shaft front coupling, carry out the following

rectification procedure:

1. Define extent of shifter base damage and replace

parts as required. Refer to Figure 1 for parts

availability – parts shown are as per Partfinder CD.

2. Remove existing eng/trans rear mount, bolts and

spacer plate. (these parts will NOT be re-used).

3. Fit new eng/trans rear mount (p/n 92117399) as

shown in Figure 2 using new bolts (p/n 11082123),

torqued to 50-65Nm.

IMPORTANT:

• DO NOT re-fit the spacer plate originally fitted

between the mount and the trans.

• DO NOT re-use the bolts originally retaining the

original mount to the trans.

PARTS INFORMATION

Part No.: Description: Qty:

92117399 Mount Asm., Trans. 1

11082123 Bolt, Trans. Mount 2

WARRANTY CLAIM INFORMATION

Use information as follows:

Description Repair A/T Shifter, Replace

Trans. Mount.

Labour Op. No. J000716

Time 1.1 hr

Failure Code 62 (Improper Clearance)

Figure 1.

Item #15 - Base assembly – A/T shift control

#16 - Pin, Handle

#17 - Spring-Button

#18 - Attaching Stud

#19 - Split Bush

#20 - Bush

#21 - Cap Lower Base

#22 - Seal O Ring

#23 - Screw Cap Retainer

#24 - Seal

Figure 2.

HOLDEN SERVICE TECHLINE_____________________________________________________________OCTOBER, 2002

Insufficient Engagement Of Reverse Gear

VTII, VX, VU, V2 with Gen III M/T

(GROUP 7A) TL357-0209

PROBLEM DESCRIPTION

A customer may complain that sometimes when

selecting reverse gear, the selector does not go fully

into reverse. When the clutch is released, grinding of

the gears can be heard. Also, the gear selector needs

to be physically held in reverse to use the gear.

Investigation of one transmission with the above

condition has shown the cause was a circlip missing

from the forward pivot of the shifter rail. Refer figure

below. The missing circlip allowed the pin to partially

disengage and become loose.

PRODUCTION RECTIFICATION

Transmission shifters which have been confirmed by

the supplier to have the circlips fitted were installed in

vehicles from:

ISOVIN: Build Date:

6H8VUK80F2L882370 25/6/02

SERVICE RECTIFICATION

On vehicles with above complaint, remove

transmission shift lever cover and confirm that circlips

are fitted.

If circlips are missing, TAS have a limited number

available on request.

Please submit PIR’s on any complaint vehicle built after

vehicle 6H8VUK80F2L882370 (built 25/6/02).

Pivot

Shifter Rail

Circlip missing

from this side

HOLDEN SERVICE TECHLINE_____________________________________________________________OCTOBER, 2002

Wind Noise At Upper Rear Corner Of Drop

Window

V2 Monaro

(GROUP 1) TL350-0209

PROBLEM DESCRIPTION

Some customers may complain of excessive wind

noise (air rush/turbulence) coming from the upper rear

corner of the driver or passenger drop windows.

This condition can be caused by a small gap between

the guide rail and the glass in the area shown in Figure

The gap is caused by a mismatch of contours between

the guide rail and the glass.

Figure 1

PRODUCTION RECTIFICATION

Since just after start of production, a small amount of

urethane has been applied to fill any gap in the area

shown.

Revised parts to eliminate this condition are planned

for introduction in October. Breakpoint details will be

published in a future Breakpoint Summary.

SERVICE RECTIFICATION

On complaint vehicle, check the area concerned and

carefully apply a smear of urethane as required to fill

any gap.

PARTS INFORMATION

Part No.: Description: Qty:

92143609 Sealer Urethane -

300ml cartridge

LSD “Chatter” Noise

V6 & LSD in VX, VU, V2, WH

(GROUP 4) Revised TL339A-0209

This Techline supercedes the previous one in Issue 8,

Sept., 2002. It is revised by addition of breakpoint,

identification, oil usage and replacement information.

PROBLEM DESCRIPTION

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

tight corners at low speeds and parking manoeuvres

where differential action is initiated. Chatter may also

be experienced by the driver as a “grabbing” feel during

the operation of the LSD.

The chatter noise is caused by reduced sliding

lubrication qualities of the LSD cone friction surfaces

within the final drive unit (using the existing oil).

LSD chatter noise complaints have been received,

mainly in vehicles that commonly carry and/or tow

heavy loads, or are subjected to harsh usage.

To correct this condition, LSD axle units have been

revised by the replacement of the previous cast iron

cones with sintered iron cones.

These axle units are filled with synthetic oil and a

friction modifier additive.

PRODUCTION RECTIFICATION

Revised axle units with sintered cones have been fitted

to (VY) vehicles from:

ISOVIN: Build Date:

6G1YK52A73L915667 12/09/02

SERVICE RECTIFICATION

Summary: On complaint vehicles, fit an exchange axle

unit from SAA.

IMPORTANT: Do not attempt to rectify V6 LSD

“Chatter” complaint vehicles by using the V8 LSD

Chatter Kit described in Retailer Letter 30/02. The pre-

Breakpoint V6 LSD axle unit Cast Iron cones are not

compatible with the friction modifier in the kit.

On complaint vehicles, request a changeover unit

through Spicer Axle Australia (SAA) via the established

procedure. (Refer to axle exchange request form in PV

SIP). Only sintered cone type axles will be supplied by

SAA from now on.

SAA will provide an exchange axle unit that has

sintered LSD cones, synthetic oil, friction modifier and

compatible seals.

Update

HOLDEN SERVICE TECHLINE_____________________________________________________________OCTOBER, 2002

IDENTIFICATION OF AXLES

Identification of these axle units is by a tag on the axle

filler plug:

On latest V6 LSD Axles with Sintered Cones the tag

carries the following wording:

“USE APPROVED LUBRICANT AND FRICTION

MODIFIER”

On the previously used V6 LSD axle units with Cast

Iron Cones the tag carries the following wording:

“SPIN RESISTANT – USE APPROVED LUBRICANT

ONLY”

Oil Replenishment:

The new V6 LSD Axles with Sintered Cones use

synthetic oil and friction modifier, and oil replenishment

can be carried out using Additive Kit 92145121 - (Refer

Techline “LSD Additive Avail. for Servicing” in

Techline Issue 4, May, 2002).

Spigot Bearing “Squeal” Noise on Cold

Start

VT, VX, VU, V2, WH

(GROUP 7A) TL245-0209

PROBLEM DESCRIPTION

A “squeal” noise may be heard, from the spigot

bearing, at the first use of the clutch pedal after a cold

start. The noise may repeat several times when the

clutch is disengaged, during engine warm-up.

This noise is caused by a combination of damage to

the spigot bush during initial installation and lubricant

“drying out”.

To address possible installation damage, revised

tooling and installation processes have been

introduced.

To address the lubricant “dry-out”, the bush is now

impregnated with synthetic oil with 10% molybdenum

disulphide.

PRODUCTION RECTIFICATION

Revised installation tooling/assembly processes for

spigot bushes, and revised lubrication have been

introduced in engine production from:

Engine No.:

VA221827

First use of engines with revised bush installation:

ISOVIN (for Reference): Build Date:

6H8VUK80A2L865092 13/05/02

SERVICE RECTIFICATION

Summary: Fit new spigot bush.

To rectify this condition, replace the existing spigot

bush with a new bush, p/n 92116034.

NOTE:

• DO NOT attempt to lubricate a ‘noisy’ spigot bush,

replace it!

• When lubricating a new spigot bush prior to

assembly – use only synthetic oil. Do NOT use

grease.

PARTS INFORMATION

Part No.: Description: Qty:

92116034 Spigot Bush 1

WARRANTY CLAIM INFORMATION

Use existing Labour Time information in Warranty

Information section of current PV SIP CD.

Update

HOLDEN SERVICE TECHLINE_____________________________________________________________OCTOBER, 2002

Engine Fan Shroud Mounting Revised –

HSPO Replacement Radiators

VT, VX, VU

(GROUP 6K) TL366-0209

The original method of mounting the fan shroud to the

radiator on models dating back to VT was bolts in 4

places (2 upper, 2 lower).

In vehicle production approximately Nov. 2000, the 2

lower fan shroud to radiator bolts were deleted and

replaced with 2 slotted mountings. Refer Figure 1.

Many of the HSPO replacement radiators for earlier

models now come with the 2 lower slotted mountings

and the 2 lower bolt holes have been deleted.

The original fan shroud fitted to the vehicle can be used

on radiators with this later style of mounting by simply

locating the lower part of the fan shroud into the

mounting 'Lugs' and use the attaching bolts in the top 2

positions only. The 2 lower bolts can be discarded.

Figure 1.

HOLDEN SERVICE TECHLINE_____________________________________________________________OCTOBER, 2002

VEHICLE IDENTIFICATION NUMBERING SYSTEM

WMI CODE: 6 – Oceania

G – Australia

1 – Holden

CARLINE: Y – VY series

2 – V2

LUXURY LEVEL: K – Level 1

L – Level 2

X – Level 3

BODY STYLE: 1 – 2 door coupe (37)

4 – 2 door utility (80)

5 – 4 door sedan (69)

8 – 5 door station wagon (35)

RESTRAINT CODE: 1 – Active (manual) seat belts

2 – Active (manual) seat belts with driver & passenger inflatable restraint

system – frontal

3 – Active (manual) seat belts with driver inflatable restraint system – frontal

4 – Active (manual) seat belts with driver & passenger inflatable restraint

system – frontal and side

ENGINE TYPE: A – 3.8 litre V6 engine (domestic variant)

R – 3.8 litre V6 engine supercharged

F – 5.7 litre GEN III V8 engine

VIN CHECK DIGIT: Calculated check digit

MO DEL YEAR: 3 – 2003

4 – 2004

PLANT: L – Adelaide (Elizabeth) South Australia

PRODUCTION SEQUENCE NUMBER:

123456 – Sequential Production Serial Number

NOTE: The production sequence number is sequentially allocated to each vehicle,

regardless of vehicle type.

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Horn Bar Activates Radio Remote

Switches

VY All

(GROUP 12) TL369-0210

PROBLEM DESCRIPTION

Horn bar when depressed may activate the top (mode

or mute) radio remote buttons.

Investigations reveal that incorrect assembly of the

radio remote switches to the steering wheel can result

in inadequate clearance between the hornbar and the

switches.

PRODUCTION RECTIFICATION

In addition to a revised assembly procedure for the

switches, the horn bar has also been revised to give

additional clearance. These changes were introduced

from:

ISOVIN: Build Date:

6G1YK52B93L923035 02/10/02

SERVICE RECTIFICATION

Summary: Inspect switches for correct mounting and

rectify if required. If problem persists, trim the sides of

the horn bar to give additional clearance.

Measure the horn bar to switch clearance as shown in

Figure 1.

If the clearance is less than 4.5mm, the switch

assemblies should be checked as follows.

1. Remove the horn bar/air bag assembly as per SIP

procedure observing all precautions when removing

SRS components.

2. Remove both switch assemblies and inspect the

underside of the upper locating bore as shown in

Figure 2.

3. A witness mark in the plastic foot around the

locating bore indicates the switch has been

assembled incorrectly. In severe cases the

locating bore may have a burr built up inside it

which can prevent positive seating of the switch to

the mating boss on the steering wheel.

4. Carefully remove any burrs prior to reassembling.

Re-assemble switches to steering wheel as follows:

5. Locate switch on bosses ensuring both locations

are seated correctly.

6. While supporting switch insert 2 screws into

position.

7. TIGHTEN TOP SCREW FIRST.

8. Tighten bottom screw second.

9. Reassemble horn bar.

10. Activate the horn bar to test for actuation of the

radio remote button.

If the condition still exists, trim 1.5mm off each side of

horn bar to provide additional clearance to switches.

WARRANTY CLAIM INFORMATION

Description Inspect Switches, Trim Horn bar

Labour Op. R000106

Time 0.5 hr

Failure Code 62

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Tail Lamp Overflush To Rear Quarter

Panel

VY Sedan

(GROUP 12) TL372-0210

PROBLEM DESCRIPTION

On some vehicles the lower, forward facing corner of

the tail lamp may be overflush to the body panel. Refer

Figure 1. This condition can occur on either LH or RH

side tail lamp and may be worse in high ambient

temperatures.

The cause of this condition is an inability of this

particular mounting point on the lamp to provide

sufficient retention under all circumstances.

Figure 1.

PRODUCTION RECTIFICATION

Tail lamps with revised attachment at the lower

outboard mounting have been fitted to vehicles from:

ISOVIN: Build Date:

6G1YL54A73L923486 02/10/02

SERVICE RECTIFICATION

Summary: On complaint vehicles, rework tail lamp by

installing a threaded stud to the lower outboard

mounting point.

1. Remove tail lamp.

2. Remove existing stud shown in figure 2. Use

suitable socket or spanner.

3. Install threaded stud 92146445 as shown in

Figure 3. Before installing, apply 2 drops of Loctite

480 Instant Adhesive to the fine screw thread.

Use nut 92138628 as shown to install stud. When

stud is fully screwed home, hold stud flange firmly

with pliers before removing nut.

4. Install sealing washer 92145533 onto stud.

5. Remove plastic nutsert from sheet metal slot .

6. Reinstall tail lamp using nut 92138628 to attach

lamp at new stud location.

PARTS INFORMATION

Part No.: Description: Qty:

92146445 Mounting stud 1

92145533 Mounting seal 1

92138628 Nut – Tail Lamp 1

Note: Loctite 480 adhesive may be purchased from

most bearing or industrial suppliers.

WARRANTY CLAIM INFORMATION

Description Tail lamp mounting stud -

replace

Labour Op. No. N000405

Time 0.4 hr

Failure Code 55 poor fit

Figure 2.

Figure 3.

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Wheel Centre Cap Dislodges

V2 Monaro with 18” Alloy Wheel

(GROUP 10) TL324-0210

PROBLEM DESCRIPTION

Under certain operating conditions the wheel centre

caps on the 18 inch alloy wheels may dislodge.

PRODUCTION RECTIFICATION

Revised centre caps with an added spring clip have

been fitted to vehicles from:

ISOVIN: Build Date:

6H8V2X37F2L924425 03/10/02

SERVICE RECTIFICATION

On vehicles where the cap is dislodged or missing, fit

revised design centre cap part number 92121783

PARTS INFORMATION

Part No.: Description: Qty:

92121783 Cap - wheel centre 1

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

Assembly Instructions for Revised CHMSL

Replacement Parts From HSPO

VU SS

(GROUP 12) TL374-0210

PROBLEM DESCRIPTION

Service Techline Issue 8/2002 contained an item which

recommended the use of new parts as follows:

Part No.: Description: Qty:

92120002 Lamp Asm. Stop –

Centre High Mount

92120003 Moulding Asm. roof

rear centre(unpainted)

Some retailers have experienced difficulty in

assembling these parts.

The following notes and pictures will help to clarify the

assembly procedure.

ASSEMBLY NOTES

1. Remove the end stud and loosen the centre stud as

shown in Figure 1.

2. Install lamp as shown in Figure 2 and 3.

NOTE. The attaching holes in the ends of the lamp

have no use in this application. The lamp is secured by

the plastic clips in the moulding.

Figure1.

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Figure 2.

Figure 3.

Timing Chain Serviceability

TT & TS with Z22SE Engine

(GROUP 6A) TL314-0210

PROBLEM DESCRIPTION

A number of revisions have been carried out to Z22SE

timing chain/drive components to improve quality and

durability.

These revised components have been fitted to engines

from:

Engine No.: Z22SETA099999

(“TA” in number = built at Tonewanda plant)

Engine No.: Z22SE11099999

(“11” in number = built at Kaiserslautern plant)

SERVICE RECOMMENDATION

When servicing timing chain/drive system, use the

following kit:

Part No.: Description: Qty:

12577164 Timing Chain Service Kit 1

FOR REFERENCE ONLY – Kit 12577164 consists of

the following parts:

Part No.: Description: Qty:

24461834 Timing Chain, Camshaft

Drive

12577163 Oil Nozzle (full flow) 1

24448509 Tensioner Asm. (“V”

Groove on end)

24449448 Guide – Chain, Moveable

(Tens. Side).

90537337 Guide – Upper (Cam to

Cam)

13104978 Guide – Chain, Fixed 1

24424758 Crankshaft Sprocket 1

90537632 Cam Sprocket (Inlet &

Exhaust)

90537451 Bolt – Camshaft Sprocket 2

PARTS WARNING:

The following (superseded design) timing chain

components must NOT be used in repairs:

13104980 Kit – Timing Chain

90537338 Chain – Timing

90537802 Tensioner Asm – Timing Chain

90537842 Guide – Timing Chain

90537476 Jet Asm. (Oil Nozzle)

Parts Managers Note:

The above parts should be returned to HSPO for credit

via the CRRM system.

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Aftermarket Window Tinting Precautions

All

(GROUP 1) TL379-0210

PROBLEM DESCRIPTION

Some of the problems which can be caused by the

installation of aftermarket window tinting films are

detailed below:

Heated Rear Windows.

Some aftermarket window tint installers may scratch

the heating element or etch the glass (crack initiation

point) during installation of film tint material to the

tailgate glass. Because of the scratches made during

installation, the scratched heating element suffers a

semi-disconnected condition and the resistance

increases on the operating demister lines.

Also, aftermarket tint installers may disconnect the

heating terminals while affixing film tint material to the

tailgate glass and reinstall the heating terminals

loosely.

The above actions can lead to a localised overheat

condition and may result in glass breakage.

Telematics.

Aftermarket window tinting may affect the operation of

the antenna on vehicles fitted with Telematics. A

warning to this effect is given in Holden PV SIP in the

section on Telematics.

Remote Key Operation – TS Astra

There have been isolated reports of remote key

operation being adversely affected by window tinting. A

warning to this effect is given in the TS owners

handbook.

IMPORTANT WARRANTY NOTE

Tailgate glass breakage or any other condition

which can be attributed to the installation of

aftermarket film tint material is not covered under

the new vehicle warranty.

Engine Stall At Idle or High Engine Idle

Speed

TR Astra C18SEL engine

(GROUP 6C) TL375-0210

PROBLEM DESCRIPTION

Some owners may complain of the following symptoms:

With vehicle speed less than 3km/h or vehicle stationary,

the engine idle is too high; e.g. 1100 RPM+, and engine

may later stall or the idle may remain high.

This is caused by a build-up of deposits from engine by-

pass gases (IACV solenoid shaft/bearing wear particles

depositing on the IACV solenoid shaft) which may cause

the IACV to stick at any point in its operating range. This

results in either too high or too low IACV air entry to the

throttle body. 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.

This behaviour can be confirmed by using Tech 2 to

monitor the IACV commanded steps compared with any

change in idle speed.

GENERAL MAINTENANCE NOTE

The need to carry out careful checks of all engine

compartment hoses at regular maintenance services is

stressed to all Technicians, to ensure continued, efficient

vehicle operation. This includes checking the engine

PCV and air intake hoses.

SERVICE RECTIFICATION

Summary: Fit revised IACV, Flash Program as required,

check/clean PCV port, check hoses.

On vehicles with the above symptoms perform diagnosis

to determine if the IACV is in fact the cause of the

problem. After confirming that nothing else is causing the

stall, fit the latest “diaphragm type” IACV using the

following procedure.

1. Remove old IACV and install new diaphragm type

IACV and gasket as per procedures shown in TIS

CD.

2. Fit the patch harness (refer Figure 1) – this is an

interface patch harness to connect the existing

vehicle wiring harness to the new IACV.

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Figure 1.

3. Use a tie strap to firmly bind the wiring harness

connector to the IACV connector as shown in Figure

1. Cut off any excess strap.

4. Use TIS 2000 CD version 35 or later to flash

program the “New IACV” calibration into the vehicle

via TIS Service Programming System (SPS).

Refer to Flash Programming Details and Calibration

Part Numbers below.

Flash programming Details:

Select the vehicle parameters that apply to the

vehicle being programmed.

For example: Holden; ASTRA-F; 1997; C18SEL

Engine,

THEN, for “Type of Idle Air Control Valve” select

“New IACV (PN.: 92 065 903)”,

Model: Old

Calibration

New

Calibration

TR C18SEL 90562557.**** 93175681.****

(**** = any Number )

After reprogramming is completed proceed as follows.

5. CHECK FOR AND REMOVE ANY PREVIOUSLY

SET BASE IDLE AS PER STEPS (a) to (d) BELOW:

Failure to remove any previously set base idle will

affect the operating characteristics of the new IACV.

(a). With Tech 2 connected select the Data Display

screen, start the vehicle and allow it to come to

operating temperature (over 70 deg C coolant, and

inlet air temp between 20-30 deg C) with moderate

to high underbonnet temperatures)

(b). With A/C OFF check "IACV steps" at idle.

- If "IACV steps" is less than 20 - a base idle was

previously applied – complete step (c) below;

- If "IACV steps" is more than 20 - no adjustment is

required – go to Step 6 below..

(c). Loosen the idle screw and decrease the Throttle

Position until the IACV steps are within the following

range. A/C must be OFF, and transmission in

neutral:

Automatic: 23 - 27 steps.

Manual: 25 - 29 steps.

Re-tighten idle screw and conduct a final check of

the IACV steps.

6. Check and clean (where required) PCV hose/port on

all vehicles. This check and clean ensures no poor

idle/stall/DTC P0100 will result due to blockages,

after IACV fitting. Blockage of the PCV hose/port will

cause the engine to run on IACV air only at times.

Engine system calibration is based on specific air

flow through the PCV port PLUS IACV air at high

vacuum times (idle/decel) and thus, loss of air flow

through the hose/port can result in poor idle and

possibly stall.

Checking for blockages in PVC hose and port:

With engine idling, remove the PCV hose from the cam

cover (Hose 2 in Figure 3.) and check if there is

vacuum at the free end of the hose.

If vacuum is not present, remove the PCV hose from

the manifold port connection and check if there is

vacuum at the port.

(A) If vacuum is present at the port – replace the PCV

hose. No further action required.

(B) If there is no vacuum at port then proceed to clean

the port as follows.

Due to the location of the port in the manifold, it will be

necessary to remove the fitting from the manifold to

clean it. The fitting is shown in Figure 2.

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Figure 2.

This port may become blocked by contaminants carried

in PCV gas and, over time, the build-up will block the

small calibrated hole in the throttle body.

This hole can be carefully cleaned out as follows:

1. Obtain a 1.5mm Diameter drill bit. NOTE: drill bit

MUST not be larger than 1.5 mm Dia., as the hole

is calibrated. Enlarging the hole will result in incorrect

air flow, and cause driveability or further code setting

problems.

2. Using the 1.5mm Dia. drill bit, carefully insert the drill

into the fitting and rotate the drill bit BY HAND until

the deposits in the connection are dislodged and the

drill freely passes through the calibrated hole.

Ensure that the drill passes through the entire fitting.

3. Clean the connection with a solvent or spray cleaner

and remove any debris left in the connection hole.

4. Re-check that the hole is clear using the drill bit, and

re-assemble previously removed components.

5. Fit the PCV hose to the manifold end ONLY and

confirm that vacuum is present at the free end of the

hose. If not – replace PCV hose.

General Checks

The following checks should be done to prevent stalling

or other running problems caused by faults other than

the IACV.

Loose elbow in air intake duct (above throttle body

Should this elbow be “loose” in the main air intake duct,

the additional un-metered air entering the system can

cause driveability problems, poor idle, and a P0100 to

set.

If the elbow is loose – replace the inlet duct (containing

the elbow).

Damaged TPS housing on the throttle body

If the TPS housing has been damaged in any way that

allows air/water/dust, etc, to enter the TPS body, the

resulting contamination will cause incorrect operation

EG: Damage during any service operation,

engine/trans. removal, etc. Any TPS found with

damage to the external body must be replaced with a

new TPS.

Damaged/Degraded Secondary PCV Hose

Stalling may be caused if the secondary PCV hose

(Hose 1 shown in Figure 3) is split or torn, or the inner

hose walls have deteriorated.

Damage (split or torn)

Allows air to by-pass the mass airflow sensor, leading

to incorrect airflow readings which affect the engine

fuel ratio (runs lean). A DTC P0100 may be set.

Degraded

External degradation of the hose can result from age

and exposure to PCV gases, and external

contaminants that affect the hose. The hose should be

carefully examined for physical degradation, EG:

softness, cracking, hardness, etc, and replaced if

necessary.

Internal degradation allows the hose internal walls to

degrade and material will separate from the hose, and

thus become lodged in an ‘early’ or ‘old’ design IACV.

Replace the PCV hose if there is an extreme build-up

of PCV contaminants in the hose. NOTE: for this

reason, kinking the hose, or clamping any other

components to the secondary PCV hose is NOT

permitted.

Figure 3.

Purge valve hoses fitted in reverse

The hoses at the canister purge valve must be fitted

the correct way – with the throttle body hose at the top

purge valve fitting – as shown below:

To Canister

To Manifold

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

If these hoses are reversed – damage to the purge

valve may result – if this has occurred it is

recommended that the purge valve be replaced.

MAF SENSOR

The following information is repeated from a previous

Techline on Non-IACV related stall – for reference,

should a cause to P0100 not be found with the above

information.

Stalling associated with the MAF Sensor can occur

either while vehicle is moving or stationary. Usually a

DTC P0100 is set. (this DTC may also be set by a

fluctuating idle, so correct diagnosis of the type of stall

is required).

Some findings on failed MAF Sensors have been:

♦ Fretting corrosion of the MAF Sensor terminals.

(Replace suspect terminals.)

♦ Connectors not fully or correctly installed.

(Check connections and re-install if required.)

♦ Incorrect routing or attachment of sensor wiring.

(Check wiring against a known OK vehicle to ensure

the wiring is not run in an incorrect routing, so it

does not pick up any ‘stray’ electrical signals from

other wiring or components.)

PARTS INFORMATION

Use the following kit for replacement of IACV:

Part No.: Description: Qty:

92066066 IAC valve kit 1

Select other part/s for replacement from Partfinder.

Exhaust Outlet (Chrome) Alignment to

Rear Bumper Facia

VY V6 – “S”, Berlina & Calais

(GROUP 8) TL388-0210

PROBLEM DESCRIPTION

PIR’s have been received advising that some vehicles

have the exhaust outlet chrome extension misaligned

in the rear bumper facia opening - placing the exhaust

outlet on an angle or offset to one side.

PRODUCTION RECTIFICATION

Exhaust mufflers have been revised to improve

alignment from:

ISOVIN: Build Date:

6GIYL52B73L933057 25/10/02

SERVICE RECTIFICATION

Summary: Enlarge tailpipe slot for adjustment.

To reposition the exhaust outlet in the bumper facia

opening:

1. Disconnect the rear muffler assembly from the

exhaust system, immediately behind the rear axle.

2. At the front of the rear muffler (pipe) connection

there is a small slot to “key” the muffler to the

exhaust pipe – enlarge this slot by filing the UPPER

EDGE of the slot until the opening is 11.0mm wide.

3. Refit the rear muffler to the exhaust system –

making sure to centralise the exhaust outlet

chrome extension in the rear bumper facia -

and tightening the pipe attaching clamp bolts.

WARRANTY CLAIM INFORMATION

Use the existing Labour Operation Number AS

SHOWN to claim for the above task:

Description Rear Muffler – Re-Align

Labour Op. No. L503500

Time 0.4 hr

Failure Code 25 (misaligned)

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Modular Reservoir Assembly (MRA)

Replacement and Fuel Gauge Calibration

VXII, WHII, VUII, V2

(GROUP 8 & 12) TL352A-0211

The previous Techline on this subject in Issue 8,

Sep/2002 is now cancelled as a result of software

revisions in TIS 36.0B.

All printed versions of that article should be

destroyed.

CAUTION - Do Not Use TIS CD’s 36 or 37

for SPS Programming

VX,VU,V2,VY,WH with Gen III & A/T

(GROUP 6C) TL403-0211

The information in this Service Techline is taken from

Retailer Letter RL84/00, issued on 5 December,

2002.

TIS CD’s 36 & 37

The SPS (flash programming) calibrations for the

above models have errors in the engine torque

management area. This affects the application of

torque during A/T shifts, and may affect A/T durability.

Do NOT use TIS CD’s 36 or 37 to perform SPS

(“flash program”) any VX/VU/V2/WH/VY, Gen III A/T

equipped vehicles.

If SPS programming is necessary on these models,

use only CD 35 or earlier, until CD 38 with corrected

calibrations is available in February, 2003.

VEHICLES NOT AFFECTED:

SPS calibrations are not affected for:

Gen III M/T vehicles,

VT Series II vehicles,

WH built pre-A8A, (before L626038),

and vehicles other than V & W cars

WHEN IS FLASH PROGRAMMING REQUIRED?

Some technicians are flash programming vehicles at

pre-delivery and during maintenance services – this

practice is unnecessary and is to be discouraged.

Flash Programming should only be done in the

following circumstances:

• When recommended in Service Techline/Retailer

letter.

• When recommended by TAS.

• When installing a new PCM

Note: calibrations contained in TIS “lag” behind the

production used calibrations by some months due to

TIS production timing, therefore use of TIS calibrations

without positive advice may be counter-productive.

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Customer Complaint - “Scheduled

Service Reminder did not display”

Service Reminder Due - Resetting

Procedure

VY All

(GROUP 12) TL396-0211

The purpose of this Techline is to clarify the

procedures for resetting the “Service Reminder Due”

function and to outline the possible customer

complaint which can occur if the incorrect method is

used.

Customers may advise that they have passed the

scheduled service without the service reminder being

displayed in the instrument cluster.

The service reminder is designed to display 1000

km’s before the service is due. However if the

previous service was performed when the vehicle

was overdue and the service reminder was reset

using the trip computer buttons the instruments

clusters calculation of the next service due may be

incorrect.

There are 3 different methods available to set the

next service due reminder. The method used will

depend upon whether the vehicle odometer reading

is under or over the specified service interval.

Case A. Odometer reading is LESS THAN the

specified service interval.

Example - Next service due - 15,000km.

If the vehicle odometer reading is below the

scheduled service interval (e.g. 14,700 km) reset with

the trip computer buttons or Tech 2.

The next service due will then display at 30,000km.

Case B. Odometer reading is GREATER THAN

the specified interval.

Example. Next service due - 15,000km.

If the current odometer is over the scheduled service

interval (e.g. 15,300 km) a reset should be done

with Tech 2 by selecting the following:

F0: Diagnostic / (3) 2003 / VY Commodore / F3: Body

/ Instrument / F5: Program / F4: Reset Service

Interval.

DO NOT use the trip computer buttons in this case

otherwise the next service due reminder will first

display at 30,500 km.

Case C. Scheduled Service Reminder did not

display.

Checking for the condition.

The “First / Next Service” can be displayed via Tech

2 by selecting the following:

F0: Diagnostic / (3) 2003 / VY Commodore / F3:

Body / Instrument / F2: Data Display / F2:

Configuration.

Repairing the condition

If service interval has already been reset using the

mode switch and caused an incorrect service interval

it can be rectified by reprogramming the instrument

configuration with Tech 2 as per SIP Section 12C / 3.

By selecting the following:

F0: Diagnostic / (3) 2003 / VY Commodore / F3: Body

/ Instrument / F5: Program / F1: Configuration.

Do not change the configuration settings; press

the “Program” soft key. Tech 2 will then recalculate

the service interval while maintaining the current

instrument configuration settings.

PRODUCTION RECTIFICATION

An instrument software revision which will remove the

requirement to use Tech 2 in case B and C is in

progress. The introduction of this revision will be

advised in a future Techline Breakpoint Summary.

IMPORTANT: Vehicles built prior to the introduction

of this revised software will continue to require Tech

2 to reset the service interval if the service is

overdue.

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

“Moan” Noise From Rear Cross Member

at 105–110 km/h

WH, VX with Gen III V8 & A/T

(GROUP 4) REVISED TL311B-0211

This Techline supersedes the previous one in Issue

8/2002. It is revised by adding Parts Information.

PROBLEM DESCRIPTION

Some vehicles may exhibit a “moan” or “drone” noise

at 105 -110km/h, which is similar to exhaust

resonance or “cavity boom”.

This noise may be caused by excitation of the rear

suspension cross member by input of various

drivetrain and tyre related vibrations.

PRODUCTION RECTIFICATION

Revised cross members with vibration dampers have

been fitted to vehicles with Gen III V8 from:

ISOVIN: Build Date:

6H8VXX69F2L908900 23/08/02

SERVICE RECTIFICATION

Summary: Diagnose for complaint condition. Once

confirmed, obtain zone approval to replace

Xmember.

Rectification of this condition relies on accurate

diagnosis.

The “moan” or “drone” noise occurs:

- between 105km/h and 110km/h

- at constant throttle for some distance

- travelling on a straight road.

When the condition occurs, steer the vehicle from

side to side within the lane the vehicle is travelling in.

If the condition varies significantly, the condition is

confirmed.

The condition should not be confused with any

exhaust or other driveline vibration or resonance that

is NOT reduced by this steering input!

Should you be unsure of correct diagnosis of this

condition – contact TAS for confirmation of your

diagnosis process, as incorrect diagnosis may lead to

replacement of unrelated components, unnecessary

vehicle time off the road, and adverse customer

reaction.

NOTE: ZONE AUTHORISATION IS REQUIRED

BEFORE REPLACING A CROSS MEMBER FOR

THE CONDITION DESCRIBED IN THIS BULLETIN.

After obtaining Zone authorisation:

1. Fit the cross member and parts shown in Figure

1 below.

Note: Vehicles built prior to VX Series II will

require the (unused) LH toe link attaching bracket

to be bent to provide clearance to exhaust

system.

2. Road test to confirm that the condition is

corrected

3. If a TAS case was previously opened,

immediately contact TAS to close the case.

When replacing cross members observe the

procedures outlined in the SIP CD.

Figure 1.

PARTS INFORMATION

Part No.: Description: Qty:

92145688 Cross Member Asm. - RR Susp. 1

92115982 Damper, Rear Susp. C/Member 2

11098391 Bolt – Damper to C/Member 2

11095804 Nut - Damper to C/Member 2

92001572 Washer – Damper to C/Member 2

NOTE: For vehicles built prior to Model Year 2002

that are fitted with Ride Levelling suspension, the

following additional parts are required, for attachment

of ride levelling Height Sensor:

Part No.: Description: Qty:

92102775 Bracket – Height Sensor to

C/Member

11081822 Bolt – Sensor Bracket to

C/Member

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

WARRANTY CLAIM INFORMATION

When fitting the cross member and parts described

above use the following information:

NOTE: ZONE AUTHORISATION IS REQUIRED

BEFORE REPLACING A CROSSMEMBER.

Description Cross Member - Replace

Labour Op. No. F000179

Time 3.6 hrs

Failure Code 36

Cruise Control Inoperative

XC SRi

(GROUP 12) TL370-0211

PROBLEM DESCRIPTION

Cruise control function will not operate. Tech 2

shows DTC B3794 - “Cruise control device circuit

open or voltage high”.

Investigation of vehicle complaints reveals that in

majority of cases the red wire in the rear of the turn

signal switch block is broken at the soldered

connection as shown in the photograph below.

PRODUCTION RECTIFICATION

Turn signal switches with wires rerouted to reduce

tension, have been fitted to vehicles from:

ISOVIN: Build Date:

W0L0XCF0834057879 27/9/2002

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

SERVICE RECTIFICATION

Summary: On complaint vehicles, diagnose cruise

control circuit and install new indicator switch

assembly as necesary.

Step 1. Perform cruise control diagnosis using TIS

procedure. Locate TIS procedure as follows.

Start at TIS main screen then select the following ê

êê

Checking procedures(Tech 2)

Diagnostic mode

Opel

XC Corsa

2002

Z18XE

Body system(double click)

Body control system(double click)

Body control module

Validate vehicle options (skip this screen)

Non guided electronic system diagnosis

B- xx Functional group test

B-02- Data List

T-49 Tester Display Cruise Control Signal

Step 2. If voltages measured in test T-49 are not

within range of listed nominal values then cruise

control circuitry is suspect and indicator switch wiring

should be inspected. If inspection shows that wiring

is okay, then standard diagnosis procedures should

be followed.

PARTS INFORMATION

Part No.: Description: Qty:

09185414 Switch turn signal with

cruise control

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

Fuel Tank Vent Line Routing

TS & Z18XE

(GROUP 8) TL387-0211

PROBLEM DESCRIPTION

On some vehicles the fuel tank vent line may appear

to hang too low underneath the vehicle.

This condition has only arisen since revised fuel

feed, fuel return and fuel vent lines were

introduced on vehicles built from 2/10/2001

(W0L0TGF4825044915).

SERVICE RECTIFICATION

Summary: On any vehicle with above condition,

reposition vent line as per following procedure.

1. Lift vehicle on hoist.

2. Refer figure 1. Move the fuel vent line (#1)

towards rear of vehicle until it is raised nearly

level with the fuel line (#2).

3. Ensure the gap between the vent line and the

heat shield is not reduced to below 10mm as

shown in Figure 2..

4. Ensure vent line is still retained fully within in all

nylon retaining blocks in the underbody.

5. Attach and tighten a nylon tie strap (3mm wide)

to the vent line as shown in Figure 3 just

rearward of the retaining block. This will prevent

the vent line from “creeping” back into its original

position.

6. Procedure is completed.

WARRANTY CLAIM INFORMATION

Description Fuel tank vent line -

reposition

Labour Op. No. L000211

Time 0.3 hr

Failure Code 62 Improper clearance

PRODUCTION RECTIFICATION

A reduced length fuel tank vent pipe is planned for

introduction on December built vehicles. When

breakpoints become available they will be added to a

future Breakpoint Summary.

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Figure 1. Shows vent line in “lifted up” position.

Figure 2 Minimum clearance, vent line to Heat

shield

Figure 3. Tie strap added to prevent movement

Fuel Filler Cap Hard To Remove

VU, VY Utility

(GROUP 8) TL405-0211

PROBLEM DESCRIPTION

Some owners may complain that the fuel filler cap is

difficult to unscrew.

The root cause of this condition has been traced to

the use of incorrect lubricant to install the o-ring seal

onto the cap during manufacture. This has resulted

in a binding up of the o-ring in the fuel filler neck

PRODUCTION RECTIFICATION

Revised caps with correct lubricant used on o-rings

have been fitted to vehicles from:

ISOVIN: Build Date:

6G1YK43A43L937599 4/11/02

SERVICE RECTIFICATION

On complaint vehicles install a new fuel filler cap with

a date code greater than “06 J 2”. (6 Sep 02).

This date code is moulded into the screw section of

the cap.

All HSPO supplied fuel filler caps are manufactured

after this date code

PARTS INFORMATION

Part No.: Description: Qty:

92027613 Cap asm fuel tank filler 1

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Headlamp Range Adjustment

TS Convertible

(GROUP 12) TL384-0211

Some owners may comment that there is no

perceptible change in headlamp angle when moving

headlamp range switch between settings 1 and 2.

This is a design characteristic of this model and is

due to the specific shock absorber/spring system

design for TS convertibles.

SERVICE ADVISERS NOTE

If customers query this condition advise them as

explained above ;

“This is a design characteristic of this model and is

due to the specific shock absorber/spring system

design for TS convertibles.”

NOTE: The owners handbook will be revised at the

next reprint to include reference to the above

condition.

Instrument Cluster DTC 10 (New

Vehicles Only)

VY without Occupant Climate Control

(GROUP 12) TL385-0211

PROBLEM DESCRIPTION

DTC 10 (no serial data from Occupant Climate

Control) has been present on all new vehicles without

OCC from start of VY production due too incorrect

instrument configuration.

This DTC will not cause any symptoms which can be

detected by the customer and is only evident when

DTC’s are checked with Tech 2 or using the

Instrument cluster self diagnostic mode.

PRODUCTION RECTIFICATION

DTC 10 has been corrected in new vehicles

commencing from:

ISOVIN: Build Date:

6G1YK54F63L923932 3/10/02

SERVICE RECTIFICATION

DTC10 can now be rectified using the latest Tech 2

software version 11.6 / TIS 36.0B or later.

It is now possible to re-configure the instrument

cluster for vehicles without OCC by performing the

following steps.

1. Using Tech 2 select the following; F0:

Diagnostics / (3) 2003 / VY Commodore / F3:

Body / Instrument / Program / F1: Configuration

2. Scroll through the configuration menu using the

UP / DOWN arrow keys until the Occupant

Climate Control option is highlighted.

3. Press the ENTER key, this will then allow you to

modify the selection (using the UP / DOWN

arrow keys) from PRESENT to NOT PRESENT.

4. Once the correct selection is highlighted press

the MODIFY soft key, this will then return you to

the selection menu.

5. Press the program soft key to initiate the

programming process.

6. Press the confirm soft key when notified that the

programming has been completed successfully.

7. Turn the ignition off then on again to accept the

programming change.

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Spigot Bearing “Squeal” Noise on Cold

Start

VT, VX, VU, V2

(GROUP 7A) “REVISED” TL245A-0211

This Techline supercedes the previous one in Issue

9, Oct, 2002. Revisions have been made to the

breakpoint information.

PROBLEM DESCRIPTION

A “squeal” noise may be heard, from the spigot

bearing, at the first use of the clutch pedal after a

cold start. The noise may repeat several times when

the clutch is disengaged, during engine warm-up.

This noise is caused by a combination of damage to

the spigot bush during initial installation and lubricant

“drying out”.

To avoid possible installation damage, revised tooling

and installation processes have been introduced.

To eliminate the lubricant “dry-out”, the bush is now

impregnated with synthetic oil with 10%

molybdenumdisulphide.

PRODUCTION RECTIFICATION

First engine produced using revised bush installation

processes:

Engine No.: VA221827

First use of engines with revised bush installation

processes:

ISOVIN (for Reference): Build Date:

6H8VUK80A2L865092 13/05/02

First use of engines with revised lubricant for bushes:

ISOVIN: Build Date:

6G1YK52A73L953884 07/12/02

SERVICE RECTIFICATION

Summary: Fit new spigot bush.

To rectify this condition, replace the existing spigot

bush with a new bush, p/n 92116034.

NOTE:

• Do NOT attempt to lubricate a ‘noisy’ spigot

bush. Replace it!

• When lubricating a new spigot bush prior to

assembly – use only synthetic oil. Do NOT use

grease.

PARTS INFORMATION

Part No.: Description: Qty:

92116034 Spigot Bush 1

WARRANTY CLAIM INFORMATION

Use existing Labour Time information in Warranty

Information section of current PV SIP CD.

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

A/C Condensor Fan Deleted On 2003

Model Year

TS Z18XE with M/T

(GROUP 2) TL404-0211

Some PIRs have been received which report that the

condensor fan is missing from above models.

Please note that this is standard condition for this

new model.

The condensor fan is no longer required because:

• The engine fan motor is replaced by a stronger

one therefore additional fans are not required.

• The engine fan speed is now controlled by three

relays.

• The engine control unit now controls the

operation of the fan motor.

• The MKM Control Unit (cooling system control

module) is no longer required as its functions are

now performed by the engine control unit.

NOTE: The above information can be found in TIS.

as follows.

Start at TIS Main Screen then select the following ê

êê

Service Information

New Technical Features

➞

Model Year 2003

Document List

➞

Contents List New Technical Features for MY 2003

➞

Astra-G

➞

Air Conditioning

➞

Change to cooling module components

Engine Hard To Start After Stop

VS 5.0L V8 Series 3 Statesman, Caprice

and Utility

(GROUP 6C) TL368-0211

PROBLEM DESCRIPTION

Customers may complain of being unable to re-start

the engine after moving the ignition key back to the

‘accessory’ position, EG: For short term stops where

the ignition switch is not turned to the “off” position for

ignition key removal.

Vehicles suffering from this complaint can be started

by fully switching off the ignition, waiting 20 seconds,

and then starting the engine.

The cause of this inability to restart is software

related, whereby the engine “run” injector pulse width

signals are retained in memory when the key is not

cycled to the “Off” position. This minimal pulse width

remains available in memory for re-starting, but will

not provide the “start” injector pulse width (richness)

to allow the engine to re-start.

Memcals with this condition are:

Memcal Code Application

CJYN 175 Kw Auto

CJYM 175 Kw Manual

CNPD 195 Kw Auto

CNPC 195 Kw Manual

SERVICE RECTIFICATION

On complaint vehicles fit revised memcal as shown

below.

PARTS INFORMATION

Revised memcal details:

Part No. Memcal Code Application

12221184 DRRP 175 Kw Auto

12221190 DRRT 175 Kw Manual

12221188 DRRS 195 Kw Auto

12221186 DRRR 195 Kw Manual