Service Department

A “HOLDEN” Product.

BRISBANE SYDNEY MELBOURNE ADELAIDE PERTH

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Front Trim Height Specifications

Rodeo, Frontera And Jackaroo

(GROUP 3) TL201-0301

This Service Techline supersedes the previous

Techline published in Aug 2000 as inconsistent

results could be obtained when measuring the

front t rim heights via the bum p stop clearance.

SERVICE SPECIFICATION

The following specifications reflect the

information provided in SIP.

Measuring the vehicle “trim height” rather than

“vehicle height” is recommended as there are

fewer variables.

TRIM HEIGHT SPECIFICATIONS

Trim height: Z = A - B

Fig.1 refers to Jackaroo, Frontera, Rodeo 4X4

and Rodeo V6 4X2.

Model Year Trim Height

(Z)mm

Jackaroo 1992- 139 +/- 5

Frontera

(MX)

1999 - 119 +/- 5

Frontera (UT) -1999 139 (Maximum

variance of 5mm)

Rodeo 4X4

and 4X2 V6

or 4JH1-TC

All TF 130

Fig. 2 refers to Rodeo 4X2 only (Exc. V6).

Model Year Trim Height (Z) mm

Rodeo

C22NE and

4JB1-T

All TF 56

Important Points:

• The trim height must be inspected, and

adjusted if necessary, prior to adjusting

the wheel alignment (toe, camber or

caster).

• Trim height inspection and adjustment is

incorporated into the service schedule

and is checked at every service.

• The trim height is adjusted when the

vehicle is at kerb mass.

Locking Hub Grease - Breakpoints

Jackaroo & Rodeo - 4x4 With Manual

Locking Hubs

(GROUP 3) TL0201-0301

The following table provides production

breakpoints for vehicles in which the amount of

grease applied to the locking hub assemblies

has been increased by 3 grams.

ISOVIN: Build Date:

MPATFS55H2T100001

MPATFS25H2T100001 Nov 01

JAATFS55H17103411

JAATFS25H17102863

JACUBS26G27100333

JACUBS73G27100535

July 01

Lower

ball

oint

Crossmember

Fig. 1

Fig. 2

Measuring Point B : Centre of ball joint

Z A

Crossmembe

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

Starting or Runni ng Problems Due To Oil

Pick Up Dama ge

Jackaroo Diesel (4JX1)

(GROUP 6M) TL0201-6M01

PROBLEM DESCRI PTION

Starting or running difficulties such as hunting,

surging or hesitation can occur if the oil pick

up, or pick up seal, for the fuel injection

system is damaged. As a result air could

enter the engine oil supplied to the diesel

injection system.

It is possible that the injection system oil pick

up has been bent to create extra room when

performing the inspection on the engine

lubrication pick up seal as described in DL

01/00 (IGM01/00).

SERVICE RECTIFICATION

When removing the oil pick up for either the

injection or lubrication system do not bend the

pick up tube or its brackets. On reinstallation

the pick up seals should checked for

serviceability and replaced where required.

Hint: Aeration of the engine oil supply to the

diesel injection system can be confirmed by

inspecting the oil exhausted from the injector

while the fault is present. The oil will appear

white or ‘milky’.

Rear Brake Squeal - Update

RODEO (4x4 and V6 4X2)

(GROUP 5) TL201-0501

This ServiceTechline is an updat e of t he article

from 2001, Issue 3, page 12. Only the break

points for Thailand built vehicles have been

added, the art icle is ot herwise identical.

PROBLEM DESCRI PTION

Excessive squeal noise emanating from rear

brakes on application.

PRODUCTION RECTIFICATION

Revised brake shoes fitted in production from:

ISOVIN: Build Date:

JAATFS25HY7103377 25/01/01

JAATFS55HY7120056 25/01/01

JAATFR25HY7108590 25/01/01

MPATFR25H1T100091 31/05/01

MPATFS55H1T100452 07/08/01

MPATFS25H1T100002 21/05/01

Note: VINs beginning with MPA are for

vehicles manufactured in Thailand. VINs

beginning with JAA are for vehicles

manufactur ed in Japan.

SERVICE RECTIFICATION

For pre-breakpoint vehicles the service fix

described below, which is the same as in

Dealer Letter IGM 13/99, can be applied.

I - GM has released a modified rear brake

shoe set (part number 5878317230) to

overcome the above complaint.

Before installation of the modified shoes the

rear brake assemblies should be de-dusted

and inspected for correct operation, if no faults

are observed the drums should be de-glazed

and the new shoes installed.

To effectively monitor the success of the

revised brake components, a PIR should be

submitted for any post-breakpoint vehicles that

exhibit squeal from the rear brakes.

PARTS INFORMATION

Part No.: Description: Qty:

5878317230 Brake Shoe Set 1

WARRANTY CLAIM I NFORMATION

Use existing Warranty Information from SIP as

shown:

Description Shoes and Lining

Labour Op. No. H025700

Time 1.2 Hr

Failure Code 40

HOLDEN SERVICE TECHLINE_________________________________________________________FEBRUARY, 2002

‘MIL’ Illuminated – Wiring Harness

Damage

Frontera 01 MY – 02 MY (32 Bit PCM)

(GROUP 6Y) TL0201-6Y01

PROBLEM DESCRI PTION

When the TAG plate was fitted at Port of Entry

the PCM wiring loom, under the radiator

support panel, may have been damaged.

PRODUCTION RECTIFICATION

The TAG plate will be located on the dash

panel near the compliance plate from

February 2002 (compliance date).

SERVICE RECTIFICATION

Where a vehicle is presented with the Engine

MIL illuminated check the wiring harness at the

radiator support panel, as shown in Fig. 1.

Repair any wiring damage before proceeding

with the diagnostic procedures in SIP.

WARRANTY CLAIM I NFORMATION

Description PCM Harness Repair –

Tag Plate Damage

Labour Op. No. N000704

Time 0.5 hr

Failure Code 48

Fig 1.

HOLDEN SERVICE TECHLINE________________________________________________________MARCH, 2002

ABS Pump Motor Operates

Continuously

Frontera Model Year 1999 & 2000

(GROUP 5) TL242-0202

PROBLEM DESCRIPTION

The ABS pump can be heard operating even

when the ignition is in the off position.

PRODUCTION RECTIFICATION

As from the following build dates surge

protection has been added to the ABS CIM

(Coil Integrated Module) to protect the Field

Effect Transistor.

ISOVIN: Build Date:

4S2UES25FY4100001 MY 00

4S2UES30EY4100001 MY 00

SERVICE RECTIFICATION

Replace the ABS CIM. Refer to LCV SIP for

the procedure)

PARTS INFORMATION

All HSPO stock has been inspected and is

Post Break Point.

Part No.: Description: Qty:

8972147040 Module Asm (CIM)

< 03/00 (Bld Date)

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current LCV SIP.

Engine Diagnostics

Rodeo 4JH1-TC

(GROUP 6) TL243-0202

SERVICE INFORMATION

The ‘On-Board Diagnostics (OBD) System

Check’ and ‘Engine Cranks, But Does Not Run’

flow charts provided in SIP have been updated

as from March 2002 and reflect the changes

introduced with the 4JH1-TC engine.

The two charts mentioned above are the

starting point for diagnosis on any Driveability

Complaint (OBD System Check) or No Start

Situation (Engine Cranks But Does Not Run).

Although the 4JH1-TC engine contains an

advanced fuel injection system (Bosch VP44

Diesel Injection Pump) Technicians should not

over look the basic requirement for a quality

fuel supply and a common sense approach to

engine diagnostics. For example, a restricted

fuel supply could result in reduced delivery

pressure at the injection pump, reduced

injection pressure and hence a change in

timing. This could result in the engine light

being illuminated due to a timing related DTC.

HOLDEN SERVICE TECHLINE_________________________________________________________MARCH, 2002

Oil Pump Gasket Leak

Rodeo C22NE (2.2lt)

(GROUP 6) TL235-0202

PROBLEM DESCRIPTION

Low oil pump fastener torque and gasket

displacement could cause an engine oil pump

gasket leak.

PRODUCTION RECTIFICATION

The production procedure to torque the oil

pump housing bolts has been revised from the

engine number below.

The revised procedure allows for a consistent

torque setting to be achieved.

Engine Number Build Date:

C22NE 25057516 30/10/01

SERVICE RECTIFICATION

Replace the oil pump gasket. For procedure

refer to LCV SIP.

IMPORTANT

• The torque specification for the oil pump

housing bolts in LCV SIP is incorrect

prior to March 2002 (6 Nm). The correct

torque specification is 8-12 Nm.

• Do not attempt to fit the metal oil pump

gasket used in other Holden 2.2lt engine

models.

PARTS INFORMATION

Part No.: Description: Qty:

92060519 Gasket – Oil Pump

(Paper Gasket)

92065913 Gasket – Crankcase

to Cylinder Block

WARRANTY CLAIM INFORMATION

Description Pump, and/or Gasket,

Engine Oil- Replace

Labour Op. No. J102100

Time 5.9 hr

Failure Code 42

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 Wai t i ng 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.

Towi ng 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 Ventilat ion 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.

HOLDEN SERVICE TECHLINE_____________________________________________________________________APRIL, 2002

Ignition Keys - Immobiliser

Rodeo & Jackaroo

(GROUP 12) TL263-0203

When replacing an ignition key it should be noted

that Rodeo Diesel (4JH1) has a unique key.

Although the keys are almost identical in

appearance a different brand immobiliser is used

in vehicles fitted with the 4JH1 engine.

To differentiate between the two types of keys

inspect for the identifiers as shown below.

Applicable Models Key Part Number

Jackaroo (6VE1 & 4JX1)

Rodeo (Except 4JH1) 8971706800

Applicable Model Key Part Number

Rodeo (4JH1 Only) 8973001640

Key marked with SI

and a dot.

Key marked with SI

only

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

Seat Belts Not Extending

UES Frontera

(GROUP 1) TL253-0204

PROBLEM DESCRI PTION

Numerous Frontera seat belts returned through

the warranty system cannot be faulted. The

reason for replacement of these belts is given as

"seat belt will not extend" or "seat belt jamming".

Customers and Retailer staff may be unaware of

the seat belt “Child Restraint Locking Mechanism”

feature. The rear outer seat belts and front

passenger seat belt have an automatic locking

mechanism designed for securing child restraint

seats. When this locking mechanism is

activated, the seat belt is prevented from being

extended. The mechanism is activated and

deactivated as follows.

To activate the system extend the seat belt to its

full length. Once activated, the seat belt can only

be retracted and a clicking noise will be heard

from the seat belt mechanism when the ratchet

operates on retraction.

To deactivate the system allow the belt to fully

retract. This releases the locking ratchet and the

belt returns to normal operation.

SERVICE RECOM MENDATION

To avoid mis-diagnosis of seat belts, Holden

Retailer frontline staff should familiarise

themselves with the operation of the Child

Restraint Locking Mechanism. They will then be

able to explain this feature to any customers who

complain that their seat belts are “jamming”.

NOTE: The UES Frontera owner's handbook

explains operation of the Child Restraint Locking

Mechanism in the section on “seat belts”. Be

aware that owner handbooks with a print date

prior to November 2001 neglected to mention that

the front passenger seat also had this feature.

NOTE: Seat belts replaced unnecessarily for

complaint of “not extending” will not be accepted

as warranty.

Exhaust Resonance

SWB FRONTERA 2.2lt (X22SE)

(GROUP 8) TL205-0801

PROBLEM DESCRI PTION

Customers may report resonance from the

exhaust under acceleration.

SERVICE RECTIFICATION

NOTE: This fix cannot be applied to the 2.0lt

Frontera manufactured prior t o 1999 M Y.

• Fit a new exhaust muffler and tail pipe.

• Discard the bolts used at the front of the

muffler; use the nuts listed below in this

position.

PARTS INFORMATION

Parts are supplied through HSPO.

Part No.: Description: Qty:

97165240 Muffler - Exhaust 1

97165238 Tail Pipe - Exhaust 1

8971487571 Gasket – Exhaust 2

0911502100 Nut 2

WARRANTY CLAIM I NFORMATION

Description Exhaust Resonance Fix

Labour Op. No. L000208

Time 0.8 hr

Failure Code 40

Update

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

Dust Entry Diagnosis – Luggage Area

Jackaroo

(GROUP 1) TL205-0101

PROBLEM DESCRI PTION

Some customers may report excessive dust entry

into the rear luggage area when a vehicle is

frequently operated in dusty conditions.

Note: Customers should be advised that driving

a vehicle with an open window or the ventilation

system in the re-circulate position can lower the

cabin pressure increasing the likelihood of dust

entering the cabin.

SERVICE RECTIFICATION

Use the following information as a guide for repair

when dust entry into the rear luggage area is

considered excessive:

Note: Complete the following steps for both

sides when the dust entry appears to be

throughout the rear of t he vehicle.

1. Remove the third row seat assembly.

2. Remove the rear end floor trim cover.

3. Remove the rear luggage side trim covers.

4. Remove the luggage area floor fittings ie. tie

down points.

5. Lift the carpet to expose the wheel arch panels

and rear floor panel sealing beads.

6. Remove the jack and jack bracket if dust

appears to be entering from behind the panel.

7. Remove the exterior splashguard from the

wheel arch as shown in Fig 1. The guard flare

does not need to be removed.

Fig. 1

8. Inspect for correct sealing at the panel joins

and for evidence of dust entry. Pay particular

attention to the seams indicated in Fig.2.

Fig. 2

9. Inspect for correct sealing at the panel joins

along the entire length of the wheel arch. Pay

particular attention to the seams indicated in

Fig.3.

Fig. 3

Exterior

Splash Guard

Guard

Flare

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2002

10. Where it is difficult to detect the exact point of

dust entry do the following:

Close all doors and windows with a second

person in the vehicle. From the exterior of the

vehicle move an air blower and a lead light over

all panel seams and other areas of potential

dust entry (e.g. tail lights and door hinges)

while the second person in the vehicle

observes for areas of leakage.

11. Clean dust from any leaking areas and seal all

gaps using Silicone Sealant RTV 732 part

number 92140051.

NOTE 1: For leakage around the door hinge

area refer to Service Techline Group 1,

November 1998.

NOTE 2. Do not seal panel drain holes.

12. Reassemble the vehicle as required.

13. Submit a PIR to Holden indicating the areas

requiring sealing.

HINT: An alternative method of finding air leaks to

that described in step 10 is as follows:

Close all windows and doors. Operate the heater

fan on the highest speed with vents set to fresh air.

Feel around the potential leak areas at the rear of

the vehicle for air leaking from the vehicle.

PARTS INFORMATION

Description Part Number

Silicone Sealant RTV 732 92140051

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Check Strap Noise (Popping)

Frontera (UES)

(GROUP 1) TL206-0205

PROBLEM DESCRI PTION

When opening a front door a loud popping or

clicking noise can be heard from the door check

strap.

PRODUCTION RECTIFICATION

A revised check strap bush has been in

production from the following breakpoint.

ISOVIN: Build Date:

4S2UES25F24100690 Feb. 2002

SERVICE RECTIFICATION

Note: The revised bushings described in this

Techline can be fitted to the rear door check strap

arms if required. However, the rear check arms

should only be repaired if reported as noisy.

Inspect The Check Strap Bush

1. Remove the check strap pin by tapping the

pin upwards using a soft hammer. Take care

not to cause paint damage with the hammer.

2. Inspect the pin for signs of wear and replace

only if necessary.

Fig 1

3. Remove the check strap arm from the body

mount and inspect the bush to confirm wear.

Fig 2.

4. If the check arm is fitted with a plastic or gold

bushing, as shown in Fig. 2, refer to the

following bush replacement procedure.

5. If the check arm has no bush, as shown in

Fig. 2, refer to the following check strap

replacement procedure.

Bush Replacement Procedure

1. Remove the plastic or gold bush from the check

arm.

2. Fit the revised black bush to the check arm in

the same direction as the removed worn bush

(refer Fig. 3). Note: It may be necessary to

use pliers to install the new bush completely. If

so, protect the new bush by wrapping in a cloth

before applying pressure to prevent scratching.

Fig. 3

3. Apply molybdenum grease to the pin hole and

both sides of the new bush. Note: Failure to

apply grease to the check arm bush could

cause premature failure of t he new bush.

4. Fit the check arm into the body mount and align

the pin hole.

5. Fit the pin with the slot facing the door

assembly and tap into place (Refer Fig. 4).

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

Fig. 4

6. Repeat the procedure for the opposite front

door.

Check Strap Replacement Procedure

1. Move the window to the fully up position.

2. Remove the door speaker cover.

3. Remove the 4 speaker screws, disconnect the

speaker harness connector and remove the

speaker (Fig. 5).

Fig. 5

4. Remove the check strap assembly retaining

nuts.

5. Reach through the speaker mount into the door

cavity and remove the check strap assembly

(Fig. 6)

Fig. 6

6. Install the new check arm assembly into place

through the speaker opening.

7. Reinstall the two check arm retaining nuts and

tighten (torque: 5.1 lbs. Ft. (6.9 NM) +/- 1.4 lbs.

Ft. (1.9 NM).

8. Apply molybdenum grease to the pin hole and

both sides of the bush.

Note: Failure to apply grease to the check

arm bush could cause premature failure of

the new bush.

9. Fit the pin with the slot facing the door

assembly and tap into place (Refer fig. 4).

Fig. 7

10. Repeat the procedure for the opposite front

door.

Pin slot facin

door

Speaker Screws

Retaining Nuts

t fa

doo

HOLDEN SERVICE TECHLINE____________________________________________________________________ JUNE, 2002

PARTS INFORMATION

Part No.: Description: Qty:

8973247840 Check Strap Arm

Bush (Black). 2

8973253310 Check Strap Ass. 2

8941114680 Check Strap Pin If

required

WARRANTY CLAIM I NFORMATION

SIP has been updated with the following labour

codes and times.

Description Bushing, Check Arm

Front R/H - Replace

Labour Op. No. B407200

Time 0.2 hr

Failure Code 06

Description Bushing, Check Arm

Front L/H - Replace

Labour Op. No. B407300

Time 0.2 hr

Failure Code 06

Description Check Assembly, Front

R/H - Replace

Labour Op. No. B407000

Time 0.6 hr

Failure Code 06

Description Check Assembly, Front

L/H - Replace

Labour Op. No. B407100

Time 0.6 hr

Failure Code 06

HOLDEN SERVICE TECHLINE_______________________________________________________________JULY, 2002

Rear Axle Seal Leak

TF Rodeo

(GROUP 4) TL206-0401

PROBLEM DESCRI PTION

Investigations show the rear axle shaft seal could be

damaged by the axle shaft during assembly.

PRODUCTION RECTIFICATION

An auxiliary jig has been introduced in production to

align the axle shaft and seal/housing assembly from

the following break points.

ISOVIN: Build Date:

JAATFR25H27102440 March 2002

JAATFR55H27100771 March 2002

JAATFR30H27102382 March 2002

JAATFR77H27114200 March 2002

JAATFS25H27101760 March 2002

JAATFS55H27102300 March 2002

JAATFS77H27107780 March2002

MPATFS55HYT100212 Feb 2000

MPATFR25HYT100064 March 2000

MPATFR30HYT100003 March 2000

MPATFS25HYT100003 June 2000

PIR any post break point failures.

SERVICE RECTIFICATION

Replace the axle seal using the axle shaft disassembly

and reassembly procedures in LCRV SIP. Path: TF

➜

Clutch, Trans and Drive Train

➜

Rear Axle

➜

Axle

Shaft.

Note: It is extremely important to apply grease to

the axle seal and adjust the axle shaft end float as

described in the axle shaft re-assembly procedure.

PARTS INFORMATION

Part No.: Description: Qty:

5096250920 Seal - Axle As

required

WARRANTY CLAIM I NFORMATION

Use existing information in LCRV SIP.

A/C Compressor Hose – Servicing

Precaution

Jackaroo w ith Turbo Diesel Engine MY01

onw ards

(GROUP 2 & 12) TL305-0206

PROBLEM DESCRI PTION

When the suction or discharge hoses are removed

from the air conditioning compressor on above models

it is possible for PAG compressor oil to leak into the

alternator which is located directly below the

compressor. This oil has the potential to damage the

alternator and nearby wiring harnesses.

SERVICE RECOM MENDATION

It is recommended that whenever working on the

compressor refrigerant hose connections, a rag is

placed over the alternator and nearby wiring to prevent

any damage from PAG oil.

HOLDEN SERVICE TECHLINE ___________________________________________________________________ AUGUST, 2002

Front Wheel Bearing - Revised Service

Procedure

Frontera (2002 MY)

(GROUP 3) TL298-0207

SERVICE PROCEDURE CHANGE

The 2002 Model Year Frontera has a sealed front

wheel bearing hub assembly that does not require

grease replacement.

The bearing assembly is not meant to be dismantled.

The revised service schedule requires the hub

assembly to be checked for excessive axial play at

100, 000km intervals.

How To Identify A 2002 “Model Year” Vehicle

A 2002 Model Year vehicle can be identified by the 2 in

the ISOVIN as shown below.

ISOVIN: ↓

↓↓

↓

4S2UES25F24100000

Vehicles with later hub assemblies can also be

identified by the exposed drive shaft nut, as seen on

most front wheel drive vehicles.

Fuel Gauge Inaccurate

UES Frontera up to MY02

(GROUP 8) TL299-0207

This Service Techline supersedes previously released

information in Dealer Letters DL 09/00 or IGM 09/00.

IMPORTANT: If an affected vehicle is currently not

covered by new vehicle warranty, please refer to

your District Manager – Aftersales to discuss

warranty approval.

PROBLEM DESCRI PTION

Instability of the fuel pump / gauge assembly in the fuel

tank can result in an incorrect fuel level reading (too

low).

Symptoms:

• Fuel gauge needle does not move past the full

indicator when the fuel tank is filled to capacity.

• The fuel gauge reads ½ when the vehicle has been

driven approx. 130km after filling to capacity.

• Fuel tank can only be replenished with 60 lts when

the fuel gauge needle is directly on the empty

position.

PRODUCTION RECTIFICATION

All MY 02 vehicles and later have the revised fuel

pump / sender assembly fitted.

ISOVIN:

4S2UES25F2100001

SERVICE RECTIFICATION

Check the gauge and circuit for normal operation as

per following procedure.

1. Remove the connector from the fuel pump/sender

assembly without removing the fuel tank as shown in

fig 1.

Bearing Hub Ass.

ABS Sensor Ring

HOLDEN SERVICE TECHLINE ___________________________________________________________________ AUGUST, 2002

2. Install a variable resistor between pins 2 and 3 at the

loom connector (F1) as shown in figure 2. Ensure

the correct resistance scale is selected ie not K

ohms and not M ohms.

3. Check that the gauge performance matches the

figures in the table below. The gauge is slow

moving and could take minutes to stabilise.

Resistance OHMS Gauge Reading +/- 2mm

103 E

45 ½

24 F

4. After confirming the gauge performance is within

specification replace the fuel pump sender assembly

following the procedure described in LCRV SIP.

Location in LCRV SIP

1999 – 2000 Section 6C Fuel Tank

2001 Section 8A Fuel Tank

PARTS INFORMATION

Part No.: Description: Qty:

8253415990 Fuel Pump / Sender

Ass.

WARRANTY CL AIM INFORMATION

Description Gauge Unit Ass. – Fuel

Tank

Labour Op. No. N000393

Time 0.9 hr

Failure Code 57

Injector Harness Connector Locking Tabs

Break – Servicing Caution

UBS Jackaroo Diesel (4JX1)

(GROUP 6Y) TL322-0207

PROBLEM DESCRI PTION

When removing the locking tabs on the injector

harness connector, do not over stress the lock tab

otherwise breakage may result. The locking tab should

only be lifted as far as is required to release the

connector.

Holden is in the process of establishing supply of the

injector harness connectors separately. Current

indications are that only the connectors at the injector

will be established as separate parts. Should the oil

rail pressure or temperature sensor connector fail the

complete harness will need to be replaced.

Retailers will be advised via a Service Techline when

the individual connectors are available.

Acces

Connect

HOLDEN SERVICE TECHLINE________________________________________________________________OCTOBER, 2002

Turbo Coolant and Oil Hose Inspection

Hint

UBS Jackaroo 4JX1 TC

(GROUP 6K) TL347-0209

SERVICE REQUIREMENT

The two coolant hoses and the oil return hose

connected to the turbo charger should be inspected for

deterioration at every service, as outlined in the

maintenance schedule.

As these hoses are subjected to extreme operating

temperatures, and are not located in an immediately

obvious position, particular attention is required to

thoroughly inspect the hoses.

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

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

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!

Clutch Pedal Freeplay Checks

(Change to Maintenance Schedule)

YG Cruze with M/T

(GROUP 7A) TL341-0208

The Owners Handbook Maintenance Schedule

currently states to check the clutch pedal freeplay

initially at 30,000km and then every 15,000km

thereafter.

At the next reprinting of the Owners Handbook the

maintenance schedule will be changed to show the

initial check to be done at 15,000km and then every

15,000km thereafter.

Retailers are requested to immediately commence

clutch pedal freeplay checks at the 15,000km service

and at every 15,000km thereafter.

The procedure for checking clutch pedal freeplay is

found in LCV SIP as follows.

Select – Automatic & Manual Transmissions,

Clutch

Select – Section 7C Clutch

Select – 3 On Vehicle Service

Select – 3.2 Clutch pedal and bracket

Select – Clutch pedal free travel

HOLDEN SERVICE TECHLINE_______________________________________________________________SEPTEMBER, 2002

A/C Pipe Knock

Rodeo 4JH1 TC

(GROUP 2) TL330-0208

PROBLEM DESCRIPTION

A knocking noise heard from the engine bay area

under load could be incorrectly diagnosed as a

mechanical engine knock.

Movement in the air-conditioning suction pipe

mounting bracket at the centre of the dash panel in

the engine bay could be the cause of the noise.

PRODUCTION RECTIFICATION

The revised screw (PN 92146330) will be supplied in

future kits.

Break Point Summary will updated when information

is available.

SERVICE RECTIFICATION

To confirm if the air conditioning pipe bracket is the

cause of the noise, isolate the bracket from the dash

panel by removing the existing mounting screw and

confirm if the noise is eliminated.

Proceed once the bracket mounting is confirmed as

the source of the noise.

1/ Replace the A/C pipe bracket screw at the dash

panel with PN 92146330.

2/ Check that the suction pipe (large diameter) at the

evaporator is at 90o to the dash panel. The pipe may

have been bent during tightening at installation.

If required, gently bend the suction pipe at the

evaporator until it is at 90o to the dash panel. Check

that there is at least 20mm clearance between the

suction pipe and brake hose at the master cylinder.

Figure 1

PARTS INFORMATION

Part Number Description Qty

921463300 Screw- Dash Panel 1

Stock is expected mid Sept 2002; part number

11072643 can be used in the interim.

WARRANTY INFORMATION

Description A/C Pipe Bracket – Replace

Screw

Labour Op. No. D000336

Time 0.3 hr

Failure Code 40 Noisy

Check for bent tube

Replace Screw

Check there is 20mm

clearance to brake pipe.

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Spare Wheel Hard Cover Removal

Procedure

UBS JACKAROO

(GROUP 10) TL371-0210

The spare wheel hard cover on some Jackaroo models

has proven difficult for some customers to remove and

replace.

To assist customers, instructions and illustrations as

shown below, will be included in the Owner’s Handbook

when it is next reprinted.

Removal Procedure.

1. Unlock the latch with its dedicated key then loosen

by lifting up and to left as shown in Figure 1..

Figure 1.

2. Grasp the cover as shown in Figure 2. and tilt

upwards, towards you.

Figure 2.

The cover is designed to be a tight fit and therefore

must be “wriggled” and “eased” over the tyre. Figure 3.

Figure 3.

3. The bottom edge of the cover must be clear of the

tyre before it can be lifted up and off as shown in

Figure 4.

Replacement is the reverse of removal.

It may be necessary to relocate the tab on the locking

latch before tightening the latch

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Roof Rail Trim Cover Dislodges

YG Cruz e

(GROUP 1) TL360-0210

PROBLEM DESCRI PTION

The trim covering the front roof rail mounting fasteners

may dislodge.

PRODUCTION RECTIFICATION

Revised trims with larger retaining tabs have been

fitted to vehicles at Port Of Entry from the beginning of

Sep 2002. As a guide, all reworked vehicles will have a

Compliance plate dated from Sep 2002 onwards.

SERVICE RECTIFICATION

On complaint vehicles install revised trim covers as

shown in Parts Information.

PARTS INFORMATION

Part No.: Description: Qty:

92128866 Cover RHF 1

92128867 Cover LHF 1

All parts in HSPO stock are the revised type.

WARRANTY CLAIM I NFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

Injector Sleeve Replacement

UBS JACKAROO with 4JX1 DIESEL

ENGINE

(Group 6M) TL323-0210

PROBLEM DESCRI PTION

Until recently, the injector sleeve seals in the Jackaroo

4JX1 engine have not been serviceable. They are now

serviceable with the use of a special tool which was

forwarded to every Holden Retailer attached to Retailer

Letter RL72/02.

PRODUCTION RECTIFICATION

Injector sleeves with revised o-ring material were

introduced in production from:

VIN Date

JACUBS73GY7102028 03/11/1999

SERVICE PROCEDURE

Use following procedure to replace injector sleeves.

Figure 1. – Working Environment

In preparation for this repair:

§ Check position C2 on the Vehicle Service History

Label to see if the procedure has been previously

completed.

§ Disconnect the battery negative (-) cable/s.

§ Loosen the radiator drain plug and drain

approximately 5 litres of coolant from the radiator

1. Follow LCV-SIP instructions and remove the

injectors and oil rail assembly. Remove oil rail and

injectors as one assembly while avoiding oil entry

into the combustion chamber.

NOTE: Ensure the injectors are installed in the same

positions on the oil rail from which they were removed.

Otherwise, recalibration of the ECU with Tech 2 will be

necessary.

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

2. Clean and inspect the injectors. Wipe away soot

and deposits from the tip of the nozzle with solvent

and a rag.

3. Discard the injector Back Up O Ring and Sleeve

rework if fitted.

CAUTION: THE USE OF A BRUSH WITH

METAL BRISTLES MAY DAMAGE THE

INJECTOR NOZZLE

Before After

Figure 2 – Inspect and Clean Injectors

4. Remove and replace all injector O-rings. Lubricate

with L2 grease. Refer Figure 3.

Figure 3 – Replace Injector Seals

5. Inspect the injector sleeves in the cylinder head to

locate the fuel gallery holes. Refer Figure 4.

Figure 4 – Injector Sleeve Fuel Gallery Holes

6. Orient the sleeve removal tool so the prongs will

engage the fuel gallery holes when pushed into the

sleeve. Refer Figure 5.

Figure 5 – Orienting Sleeve Removal Tool

7. Push the sleeve removal tool into the sleeve until

the prongs on the tool engage the fuel gallery

holes. Twist the tool to check it is fully engaged.

Fig 7.

8. Install the tool outer sleeve and finger tighten the

nut.

9. Install the pin into the centre of the sleeve removal

tool. This keeps the tool prongs engaged in the

fuel gallery holes. If the pin does not seat fully or

becomes stuck, the sleeve removal tool is not

correctly engaged with the injector sleeve. Refer

Figures 6 and 7.

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Figure 6 – Sleeve Removal Tool Assembled

Figure 7 – Tool Assembly in Cylinder Head

10. Hold the flat on the threaded section of the tool with

a wrench and turn the nut clockwise to pull the

sleeve from the head. Refer Figure 8.

Figure 8 – Extracting the sleeve using the tool

11. Remove the pin from the tool and use large pliers

to compress the body of the tool to release the

prongs from the injector sleeve. Refer Figure 9.

NOTE: DO NOT COMPRESS THE PRONGS AS

DAMAGE TO THE TOOL MAY RESULT!

Figure 9 – Removing the tool from the injector sleeve

12. Repeat this process for the remaining three injector

sleeves in the cylinder head.

13. Clean the injector sleeve bores with a lint-free rag

wrapped around a soft material such as wood.

14. Prepare the new injector sleeves for installation

by applying L2 grease to the O-rings. Refer

Figure 10.

Nut

Sleeve

Prongs

Engaged

15mm –

refer step

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Figure 10 – Greasing new injector sleeve O-rings

15. Thoroughly clean one of the old injector sleeves to

use as an installer. Remove the O-rings in order to

identify it.

16. The old sleeve will be used upside down to install

the new sleeve. Refer Figure 11.

Figure 11 – Using old sleeve as installing tool

17. Sit the new injector sleeve in the cylinder head.

Align the fuel gallery holes in the sleeve with the

ports in the cylinder head (no photo).

18. Locate the clean, used injector sleeve upside down

on the new sleeve. Refer Figure 12.

Figure 12– Locating injector sleeves

19. Carefully install the new injector sleeve, using a

hammer, until it is fully seated in the cylinder head.

Refer Figure 13.

Figure 13 – Installing new injector sleeve

NOTE: Check the injector sleeve is fully seated in

the cylinder head by measuring the depth of the

sleeve in th e head . T he correct depth o f the sleev e

in the cylinder head is 15mm ( refer Figure 7) . Once

the sleeve is in the home position do not continue

to install the sleeve as damage may occur.

20. Repeat this procedure for the remaining three

injector sleeves.

21. Remove any oil or coolant that pooled in the

combustion chamber with a vacuum bleeder or

syringe.

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

22. Insert the copper packing into the injector sleeves.

Use the extraction tool pin to guide the packing into

the sleeve. Refer Figures 14 and 15.

NOTE: Th e surfaces of the copper packing create a

seal and must be clean (no visible sign of carbon

etc).

Figure 14 – Using Extractor Tool pin to guide

copper packing

Figure 15 – Installing the copper packing

23. Inspect the copper packing in the sleeve to ensure

it is installed correctly. Refer Figure 16.

Correct Incorrect (upside down)

Figure 16 – Copper Gasket Inspection

24. Install the oil rail and injectors.

Note: Carefully install the injectors into the

sleeves.

25. Install the injector H-clamp and nut and tighten

temporarily.

26. Tighten injector to oil rail bolts to the specified

torque.

Torque: 6.5 Nm (0.7 kgm / 5.1 ft lb)

27. Tighten injector H-clamp nuts to the specified

torque to seat the injectors:

Torque: 30 Nm (3.1 kgm / 22 ft lb)

28. Loosen the injector H-clamp nuts and retighten to

the specified torque:

Torque: 25 Nm (2.4 kgm / 17.4 ft lb)

29. Torque the oil rail bolts to the specified torque:

Torque: 20 Nm (2.0 kgm / 14.5 ft lb)

30. Reinstall the remaining components in the reverse

order. Refer to LCV SIP for information if required.

Note: Check that the injector electrical connection

packing seals are fitted and there is no oil in the

connection.

31. Mark position C2 on the Vehicle Service History

Label.

PARTS INFORMATION

Part No.: Description: Qty:

8971757830 Gasket – Injector

Nozzle Clamp

8972407980 Gasket – Nozzle

Holder

8971611092 Gasket – Injector

Nozzle Clamp

8971842160 O-Ring 2

8971606721 Gasket – Cover to

Cylinder Head

8972451850 Sleeve – Injector 4

WARRANTY INFORM ATION

Description Injector Sleeve – Replace

Labour Op. J000719

Time 2.2hr

Failure Code 95

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

Steering Rack Graunch Noise

YG Cruz e

(GROUP 9) TL359-0210

PROBLEM DESCRI PTION

A graunch noise from steering rack which usually

occurs when commencing a turn from a standing start.

PRODUCTION RECTIFICATION

Steering racks with revised bushes have been fitted to

vehicles from:

ISOVIN: Build Date:

JSAGHY81S00102263 06/08/02

SERVICE RECTIFICATION

On complaint vehicles, fit a new steering rack assembly

from HSPO, as shown in Parts Information below.

Refer to LCRV SIP for replacement procedure.

PARTS INFORMATION

Part No.: Description: Qty:

92125508 Rack asm. steering 1

WARRANTY CLAIM I NFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

Rear Spring Deflection (Add Additional

Leaf)

TF Rodeo – Except 4X4 V6 (All Models)

and 4X4 Diesel Cab Chassis

(GROUP 4) TL306-0210

This Service Techline supersedes the December 1997

article titled Rear Spring Sag.

PROBLEM DESCRIPTION

Some customers may complain of excessive rear

spring deflection when the vehicle is heavily laden.

SERVICE RECTIFICATION

One additional leaf can be fitted to each rear spring in

the second leaf position (second from the top) on

complaint vehicles.

Zone approval must be obtained before this

modification is carried out.

Note: Additional spring leaves are only

recommended for vehicles that are permanently

loaded such as builder’s or plumber’s vehicles or

vehicles fitted with specialised steel body work.

Additional leaves must not be fitted to 4X4 V6 (all

body models) or 4X4 Diesel Cab Chassis as heavy

duty springs are fitted in production.

When an additional leaf spring is fitted to vehicles that

operate permanently at 80% of GVM or above, an extra

25mm of camber should be applied to each spring to

assist in maintaining ride height.

The spring assembly should be refitted with the

shortest distance (a) towards the front of the vehicle as

shown in Fig 1.

Fig 1.

Adjust the load sensing proportioning valve (LSPV)

after the modified springs have been refitted (SIP –

Section 5 – LSPV – Page 17 of 67).

HOLDEN SERVICE TECHLINE_______________________________________________________________NOVEMBER, 2002

PARTS INFORMATION

Parts for this spring revision are not supplied through

HSPO.

Automotive suspension spring suppliers can perform

the recommended spring modifications.

Additional leaf specification:

1150mm (High Ride Height) Length

1130mm (Low Ride Height)

Thickness 7mm

Width 60mm

Edges Rounded

Steel Type XK 9258 S

WARRANTY CLAIM I NFORMATION

Description Add Leaf to Rear Springs

Labour Op. No. F000182

Time

(Includes LSPV

adjustment)

2.2 hours

Failure Code 62

NOTE: The cost of adding leaves and re-camber of the

spring assembly can be claimed as a sublet repair.

Aftermarket Window Tinting Precautions

All

(GROUP 1) TL379-0210

PROBLEM DESCRI PTION

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 Astr a

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.

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Transmission Noise In Fifth Gear

Jackaroo with AR-5 M/T Model Year 1998

and later

(GROUP 7A) TL300-0211

PROBLEM DESCRI PTION

Some customers may complain of a whining noise

when Transmission is in 5th gear.

SERVICE RECTIFICATION

Summary: On complaint vehicles install noise

insulation between transmission and console cover.

Procedure. Refer Figure 1.

1. Bundle 3 layers of noise insulation together and

secure with 3 tie straps as shown in Figure 1. Part

numbers for these parts are shown below

2. Remove the centre console cover.

3. Place the insulation into position over the shift

levers as shown. The chamfered corner of the

insulation must face to the front of the vehicle.

4. Tuck the edge of the insulation into the gap

between the rear heater duct (#8) and the grommet

cover (#9).

5. Reinstall the centre console cover.

PARTS INFORMATION

Part No.: Description: Qty:

8973560730 Insulator-shift lever 3

5097070301 Clip Cable 3

WARRANTY CLAIM I NFORMATION

Description Insulator floor mounted -install

Labour Op. No. K000285

Time 0.7 hr

Failure Code 40

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Figure 1.

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Evaporator Ice-Up - Incorrectly Positioned

Thermistor Probe

TF Rodeo with A/C from 1996-2002

(GROUP 2) TL390-0211

The following information was provided by Air

International, supplier of A/C kits for TF Rodeo.

PROBLEM DESCRI PTION

Some customers may complain that after driving for

approximately 30 minutes the A/C goes hot and the

airflow coming from the vents reduces dramatically.

Another symptom is large quantities of water draining

from the evaporator when the vehicle is stationary.

This condition results from “icing up” of the evaporator.

One of the causes of icing up can be a Thermistor

probe which is incorrectly positioned on the evaporator

coil. Because of the temperature variation across the

evaporator, it is vital that the Thermistor probe is

located exactly as specified. If it isn’t located correctly,

this can cause the compressor to continue operating

until the evaporator surface temperature drops below

zero degrees C, causing condensate to freeze on the

coil. The further build up of ice will restrict the flow of

air through the coil.

SERVICE RECTIFICATION

Summary: On vehicles with above condition, or

whenever replacing the evaporator coil, ensure the

Thermistor pr obe is loc ated as specified in the following

pages.

----------------------------------------------------------------------

1. To check the Thermistor probe location, the

Evaporator assembly will first have to be removed from

the vehicle. This will involve recovering the Refrigerant

and Re-gassing the A/C system on completion.

2. To confirm that the Thermistor probe is correctly

located on the evaporator, refer to the following 4

pages which show the Thermistor probe coordinates

for the 4 different evaporators fitted to Rodeo Petrol

and Diesel vehicles built between 1996 and 2002.

Technicians should read the comments above each

diagram to determine which evaporator is fitted to the

vehicle. The part numbers of the A/C kits can be found

on the “A/C Part Number label” fitted inside the glove

box when the A/C kit was first installed.

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Evaporator Identification

G A/C Kits 2.6L – M41497, M40731

V6 – M41682, 92143097

Diesel – M41682, 92141532, 92143097

2.2L – 92141750, 92142079

G Introduction – 1996 – 1999.

G Manufacturer – “Showa” Japan.

G Coil Thickness – 75 mm. Note: Measure the thickness of the Coil as there are Tw o (2)

different thickness “Showa” Coils used in the Rodeo.

G Coil Colour – Silver.

G TXV – 90 Degree w ith Equalisation Tube.

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Evaporator Identification

G A/C Kits – V6 – 92143920. 2.2L – 92143922. Diesel – 92143921.

G Introduction – 1999 – 2001.

G

G Manufacturer – “Showa” Japan.

G Coil Thickness – 68 mm. Note: Measure the thickness of the Coil as there are Tw o (2)

different thickness “Showa” Coils used in the Rodeo.

G Coil Colour – Silver.

G TXV – 90 Degree w ith Equalisation Tube.

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Evaporator Identification

G A/C Kit - V6 – 92144363. Petrol 2.2 (used kit 92143922) Diesel – 92144690.

G Introduction – 2001 to July 2002

G Manufacturer – Tripac - Australia.

G Coil Colour – Gold.

G TXV – 90 Degree with Equalisation Tube or Block Valve .

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Evaporator Identification

G A/C Kit - V6 - 92145595. 2.2L - 92145594. Diesel - 92145593

G Introduction – July 2002

G Manufacturer – Tripac - Australia.

G Coil Colour – Gold.

G TXV – 90 Degree w ith Equalisation Tube.

G Vehicle fitted w ith Rubber Bonnet Seal.

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

Poor A/C Performance & Evaporator

Noise

TF Rodeo (Late 2001 AND 2002)

(GROUP 2) TL301-0211

PROBLEM DESCRI PTION

Higher than expected air temperature from the A/C

vents when the A/C system is operating. Customers

may report that the A/C is not as cold as in their

previous Rodeo.

Evaporator hiss or whistle may also be reported.

AFFECTED VEHICLES

Vehicles fitted with the following parts from 2001 –

05/2002 could be affected:

Description Part Number

92144363

A/C Kit 92144690

with

Evap. Asm. (with Block Valve). 92145163

PRODUCTION RECTIFICATION

A bonnet seal to prevent air recirculation and revised

TX valve have been added to the A/C kits from:

Date Kit Number Engine

92145595 6VD1

92145594 C22NE

05/02

92145593 Diesel

SERVICE RECTIFICATION

To establish if the vehicle could be affected:

§ Remove the glove box and inspect the

evaporator case for the white identification label

shown in figure 1.

§ If the label is not fitted or indicates a different

valve part number the vehicle is not affected.

Figure 1

§ For affected vehicles, complete the check sheet

on the follow page and fax to Air International on

(03) 9681 9734.

§ Contact Air International Service on 1800 673716

to review the results

Note: If the vehicle shows similar symptoms and is

not fitted with an affected kit contact Holden TAS.

PARTS INFORMATION

Bonnet seal and evaporators (fitted with the revised

TX valve) and will be dispatched directly from Air

International for approved vehicles.

WARRANTY CLAIM I NFORMATION

*This warranty claim is labour only as parts are

supplied directly through Air International.

Description Poor A/C Performance and

Hiss

Labour Op. No. D000339

Time 1.0 hr

Failure Code 56

HOLDEN SERVICE TECHLINE_______________________________________________________________DECEMBER, 2002

FACSIMILE FORM FOR RODEO A/C PERFORMANCE AND NOISE ISSUE

DATE ……/………/………..

DEALERSHIP ………………………………………………………………………………….……

DEALER CODE…………….………….. CONTACT NAME ………………………….………..

PHONE # …………………………….…. FAX # ………………………………………….……..

VEHICLE TYPE ……………………….… ENGINE……………..BUILD DATE ….…/…../……

VIN # ……………………………………………………………………………………………….…

A/C KIT PART NUMBER FITTED TO VEHICLE ……………………………………………..…

PERFORMANCE

Vehicle Set Up For Test Readings

G Maximum Cold A/C

G Blower Speed 2

G Face / Fresh Mode – Thermometer Probe Placed in the Cent re Vent

G Doors / Windows Closed

G Engine At Idl e, then held at 2, 000 RPM

G Test Duration – 5 Minut es

G Check and adjust (if requi red) the HVAC Temperature Air M i xi ng Door

G Am bient Temperature …………………..C

G High Side Pressure Reading I dl e ……………. .…2000RPM………….…….kPa / PSI

G Low Side Pressure Reading Idl e ……………. . … 2000 RPM………………. kPa / PSI

G Centre Vent Temperature Idle ……………C 2000 RPM ……………C

NOISE ONLY– How would you best describe the noise ………………………………………………..…..

………………………………………………………………………………..………………………………………..

G Does the noise appear when the A/C Compressor cycles IN or OUT or BOTH

(circle answer)

AIR INTERNATIONAL USE ONLY –

AUTHORISED : YES or NO PRO DUCT REQUEST DOCKET # ………………….

DISPATCH METHOD: ……………………………………………….. DATE : / /