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_____________________________________________________ __________JANUARY, 2003

Glove Box Light Stays on with Glove Box

Lid Closed

(GROUP 12) TL416-0301

PROBLEM DESCRIPTION

There have been several reports of vehicles in which

the glove box light remains on after the glove box lid

is closed. The customer’s complaint may be that

they are able to see the light on in the glove box at

night while driving.

These vehicles may be affected by a condition where

the wiring harness behind the glove box was

incorrectly installed and subsequently touches the

right hand rear corner of the glove box. This may

cause the glove box to distort and the glove box light

switch to turn on.

This condition will not cause the vehicle battery to be

discharged as the glove box light circuit is controlled

via the BCM battery saver function. The light is

switched off at the time period programmed into the

BCM (default is 65 minutes) or 10 seconds after the

vehicle is locked.

PRODUCTION RECTIFICATION

Vehicles were rectified in production by relocating the

wiring harness and fitting an extra tie strap.

ISOVIN: Build Date:

6G1YL52B53L945885 25/11/02

SERVICE RECTIFICATION

Summary: On complaint vehicles, reposition

glovebox wiring harness and increase length of

glovebox switch plunger.

Procedure.

1. Remove the glove box as per the procedure in PV

SIP VY / Internal Fittings / Section 1A3 –

Instrument Panel & Console / 3. Service

Operations - Instrument Panel / 3.2 Instrument

Panel Compartment Assembly / Remove.

2. Locate the heater fan wiring harness on the right

hand side rear of the glove box opening beside

the HVAC case. Refer Figure 1.

3. Remove, invert, and reinstall the original retaining

tie strap (A) in the HVAC case as shown in

Figure 2.

4. Add a new tie strap (part of kit 92146705) above

the rib in the HVAC case. Refer Figure 2.

Figure 1. Original location of harness and tie strap”A”.

Figure 2. Revised location of harness and tie straps

5. Remove the glove box switch from the glove box

housing.

6. Trim the rubber blanking plug (which is part of the

service kit) to an over all length of 8 - 10 mm.

Refer Figure 3.

7. Place the rubber-blanking plug over the switch

plunger (it may be necessary to hold the switch

plunger with pointy nose pliers to ensure the

blanking plug is pushed all the way on).

8. Refit the switch.

Area of contact with glove box Tie Strap A

Tie Strap A, “Inverted”

New Tie Strap

(Above the casting rib)

HOLDEN SERVICE TECHLINE_____________________________________________________ __________JANUARY, 2003

9. Check for correct operation of glovebox light.

Figure 3. Trim rubber blanking plug length to 8-10mm

prior to installing onto plunger.

PARTS INFORMATION

Part No.: Description: Qty:

92146705 Glovebox light kit 1

The Kit consists of a tie strap and rubber blanking

plug.

WARRANTY CLAIM INFORMATION

Description Fit glove box light kit

Labour Op.

No.

N000414

Time 0.4

Failure Code 80

Horn Intermittently Stays On

(GROUP 12) TL420-0301

This Techline was instigated by TAS calls and PIRs.

Thanks in particular to James Brown of Canobolas

Holden for submitting the first PIR which detailed the

exact cause of the problem.

PROBLEM DESCRIPTION

Some customers may complain that their vehicle’s

horn intermittently sounds on its own.

Investigation of these cases reveals that a metallic

backed barcode label fixed to the steering wheel

directly below the horn bar contact (which is located

on the underside of the airbag) may curl up and earth

the horn bar contact which causes the horn to sound.

This condition may be more common with increased

cabin temperatures.

PRODUCTION RECTIFICATION

Steering wheels with relocated barcode labels were

fitted to vehicles from:

ISOVIN: Build Date:

6G1YK43A23L9648463 30/1/03

SERVICE RECTIFICATION

1. Remove the air bag as per the procedure in PV

SIP VY / Electrical System / Section 12M

Occupant Protection System / 2. Service

Operations / 2.3 Steering Wheel Inflatable

Restraint Module Assembly.

2. Inspect the steering wheel hub for a label as

shown in Figure 1.

3. Remove the label highlighted in Figure 1.

4. Reinstall the air bag as per the SIP procedure.

HOLDEN SERVICE TECHLINE_____________________________________________________ __________JANUARY, 2003

Figure 1. Bar code label on steering wheel.

WARRANTY CLAIM INFORMATION

Description Airbag unit drivers SRS -

Remove and detach barcode

label from steering wheel.

Labour Op. No. M000187

Time 0.3 hr

Failure Code 62 Improper clearance

“ADVANCED SERVICE INFORMATION”

Ignition Key Jams In Off Position Or Is

Difficult To Turn from Off Position

TS Astra

(GROUP 9) TL421-0301

PROBLEM DESCRIPTION

In some vehicles the ignition key may jam in the

“OFF” position or be difficult to turn from the “OFF”

position.

This condition appears only to affect ignition

barrels/keys with “S” profile. It does not affect those

with “D” profile. For profile recognition refer to Part

Finder TS Catalogue, section 06-250A.

The cause of this condition appears to be due to the

hard pin causing excessive wear on the ramp section

of the barrel. Refer Figure 1. Production rectification

of this condition is in progress. Production

breakpoints and service fix information will be

released when available.

SERVICE RECTIFICATION

Until advised otherwise, complaint vehicles should be

fitted with a new ignition barrel. However, In the

event that new parts are unavailable, the following

procedure can be used to rework existing parts to

eliminate binding.

Rework Procedure For Existing Parts.

1. Disassemble pin and spring from outer barrel

(take care because spring may "eject" pin away).

2. Clean pin wear area with rag - see Figure 1.

3. Inspect outer barrel housing for wear caused by

pin.

4. If pin has excessively worn the barrel, de-burr the

cast barrel material with a sharp blade to allow

smooth pin travel on surface of barrel. Refer

Figure 2.

5. Lubricate with powdered graphite only.

PARTS INFORMATION

Refer to Partfinder for replacement ignition barrel part

numbers.

HOLDEN SERVICE TECHLINE_____________________________________________________ __________JANUARY, 2003

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

Figure 1. Pin wear area on barrel

Figure 2. De-burring pin wear area.

Rocker Arm Bolt Sealing

HSV Gen III V8 – 300Kw Version

(GROUP 6A) TL419-0301

In 300kW Gen III V8 engines, the rocker arm bolts

protrude into the inlet ports because additional

porting has been carried out.

Oil consumption, via oil migrating down the thread/s,

may be possible, if the rocker arm bolt threads are

not sealed.

To ensure this oil migration (and possible oil

consumption) does not occur, the threads are sealed

in production with a Teflon based thread sealant.

NOTE: Standard Gen III V8 engine rocker arm bolts

do NOT protrude into the ports and MUST NOT have

the threads sealed.

SERVICE REC0MMENDATION

Summary: Apply sealant to bolts whenever repairing

a 300kW Gen III V8 engine/cyl. head.

300Kw Engine rocker arm bolts must be sealed

whenever removed for any reason.

This sealing of rocker arm bolts should become a

standard operation whenever rebuilding a 300Kw

Gen III 300kW engine.

The sealant used is a Teflon based thread sealant,

Loctite No. "567", or equivalent, available from

Industrial suppliers such as BSC, CBC, Blackwoods,

etc.).

NOTE: DO NOT CARRY OUT THIS SEALING ON

Standard Gen III V8 engine rocker arm bolts – they

do NOT protrude into the ports and MUST NOT have

the threads sealed. Applying thread sealant to

standard engine rocker arm bolts may stop bolts from

seating correctly or achieving the correct retention

torque.

De-burr

HOLDEN SERVICE TECHLINE_____________________________________________________ __________JANUARY, 2003

Instrument Cluster DTC 8

(New Vehicles Only)

VY Ute without ABS / ETC

(GROUP 12 TL417-0301

DTC 8 (no serial data from ABS / ETC) has been

present on all new VY ute’s without ABS / ETC from

start of VY production.

This DTC will not cause any customer detectable

symptoms, and is only evident when DTC’s are

checked with Tech 2 or using the Instrument cluster

self diagnostic mode.

There is no production/service rectification proposed

therefore technicians should ignore this code.

HOLDEN SERVICE TECHLINE____________________________________________________________FEBRUARY, 2003

Stop / Tail Light Globe Failure

VX / WH / V2 / VY

(GROUP 12) TL395-0302

PROBLEM DESCRIPTION

Warranty data shows that there is an ongoing high

level of replacement of stop/tail light globes.

A large percentage of the globes returned to REPAC

are tested and found to have no fault.

SERVICE RECOMMENDATION

The following procedure is recommended when

rectifying stop/tail light globe not functioning.

Visually inspect the globe filament or use an Ohm

meter to ensure that you have a circuit through the

globe.

• If the globe is blown it should be replaced with a

long life globe from HSPO, ensuring it has a blue

dot at the base, which confirms that it is long life.

• If the globe is not blown check the stop/tail

globe socket contacts and grommet to ensure that

it is not trapping the wire and preventing good

socket to globe contact. This condition can be

rectified by pushing more wire through the

grommet to relieve tension.

PARTS INFORMATION

Part No.: Description: Qty:

92080588 Long life stop/tail light

globe

Power Steering Reservoir Retention

VY with V6

(GROUP 9) TL402-0302

PROBLEM DESCRIPTION

On some vehicles the power steering reservoir may

not be positively retained by the retaining clip on the

fan shroud.

PRODUCTION RECTIFICATION

Vehicles have been checked for correct retention of

power steering reservoir from:

ISOVIN: Build Date:

6G1YK54A63L943179 14/11/02

SERVICE RECTIFICATION

Vehicles found to have loose reservoirs should be re-

installed, taking special note that the retaining clip

(moulded as part of fan shroud) is correctly engaged

in position (see Figure 1 below) to ensure positive

retention of the reservoir.

Figure 1.

HOLDEN SERVICE TECHLINE____________________________________________________________FEBRUARY, 2003

Knock Or Thud Noise Under Heavy

Acceleration From Rest

VY Gen 3 & M/T

(GROUP 4) TL435-0302

PROBLEM DESCRIPTION

Under hard acceleration from a standing start, some

vehicles may experience a loud knock/thud from the

rear underbody area.

Investigation shows that this condition can occur if

the rear crossmember to underbody insulators are

missing.

NOTE: Some vehicles within the following range may

have been built without these insulators.

From: 6G1YL54F63L949461 - 28 Nov 2002

To: 6G12X14F53L976377 - 12 Feb 2003

SERVICE RECTIFICATION

Summary: On complaint vehicles check if insulator is

missing. Install as required.

Procedure.

1. Raise car on hoist.

2. Inspect for presence of insulator (both sides).

Refer Figure 1.

3. Install new insulator if required. Refer PV SIP

procedure as follows:

Select - VY Series / Section 4A / 2.5 Rear Susp

crossmember front bush / On car replacement.

Note. New rear suspension front mounting to

underbody bolts will be required.

PARTS INFORMATION

Part No.: Description: Qty:

90447991 Insulator- Rear

Crossmember

92038482 Bolt – Rear susp. front

mounting to underbody

WARRANTY CLAIM INFORMATION

Description Install insulator - rear

crossmember both sides

Labour Op. No. F000185

Time 0.5 hr

Failure Code 29 missing

Figure 1. (Insulator = No. 4)

New TIS Option Available – “Default To

LPG On Startup”

VY & LPG, Sedan & Ute

(GROUP 6C) TL422-0302

The purpose of this techline is to inform Retailer

Service Departments of a new LPG calibration

available in TIS CD 39.0B which defaults to LPG on

startup.

This feature has been produced to meet the

requirements of those fleet operators who wish to

operate their vehicles on LPG for most of the time.

This calibration can be installed at customers

request. It should be pointed out to customers that

the requirement to keep petrol in the petrol tank as

detailed in the LPG Owners Handbook Supplement

still applies.

The part number for this calibration is 92160884 and

the display in TIS is;

LPG (Liquid Petroleum Gas) – Default LPG Starting.

HOLDEN SERVICE TECHLINE____________________________________________________________FEBRUARY, 2003

Engine Stall At Idle Or High Engine Idle

Speed

JR, JS, C20SEL, C22SEL

TR GSi X20XEV

(GROUP 6C) “REVISED” TL431-0302

This Techline supersedes the previous one in Issue 5,

June, 2002. It is revised by adding TR GSi with

X20XEV engine to the models affected . Note: For TR

GSi, a new engine calibration to suit the new IACV is

released on TIS CD 39.

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

SIP/2001/Group 6C titled “Engine Stall Diagnosis - 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 39 or later (and latest

Tech 2 Software ) 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,

HOLDEN SERVICE TECHLINE____________________________________________________________FEBRUARY, 2003

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

TR (Astra F) &

X20XEV

90519068.2616 93175683.2561

(**** = 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.

(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 TR Gsi

vehicles and all JR,JS 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.

HOLDEN SERVICE TECHLINE____________________________________________________________FEBRUARY, 2003

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.

PARTS INFORMATION

Obtain IACV kit 92066066 from HSPO.

Part No.: Description: Qty:

92066066 IACV Kit

Kit contains following:

1 - Diaphragm type IACV

1 - Gasket

1 - Patch Harness

1 - Cable Tie

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.

Poor AM Radio Reception –

Antenna/Power Leads Loose At Amplifier

TS Convertible

(GROUP 12) TL408-0302

PROBLEM DESCRIPTION

PIRs received indicate that some vehicles experience

poor AM reception due to loose antenna/power lead

connections at the amplifier.

PRODUCTION RECTIFICATION

Antenna/power lead connections at amplifier have

been reworked to ensure tightness from:

ISOVIN: Build Date:

W0L0TGF673B003373 Oct 2002

SERVICE RECTIFICATION

Check tightness of antenna/power lead connections

at amplifier.

This will require removal of the boot trim to access

the left hand quarter panel where the antenna is

mounted.

WARRANTY CLAIM INFORMATION

Description Antenna connector tighten

Labour Op. No. N000420

Time 0.6 hr

Failure Code 27 Loose

Engine Hood Insulator Deleted From

Production

TS With Z18XE 1.8L

(GROUP 1) TL439-0302

From the break point below the engine hood insulator

(Part Number 90559171) has been deleted on all

Astra with 1.8lt (Z18XE) engines. Vehicles fitted with

2.2lt engines will continue to have an engine hood

insulator fitted until further notice.

PRODUCTION CHANGE

ISOVIN: Build Date:

W0L0TGF0835088541 25/11/2002

HOLDEN SERVICE TECHLINE____________________________________________________________FEBRUARY, 2003

Brake Pipe Vibrates/Rattles During ABS

Self Test

VTII, VX, VU, VY, WH

(GROUP 5) TL433-0302

PROBLEM DESCRIPTION

During ABS self test, the brake pipes located near

the dash panel can vibrate excessively and cause a

rattle to be heard inside the vehicle.

The cause of this condition is insufficient retention of

the brake pipes in this area.

SERVICE RECTIFICATION

Fit additional support clip to pipes in engine bay as

shown in Figure 1 and Figure 2.

Figure 1. Clip added to vehicles with ABS only.

Figure 2. Clip added to vehicles with ABS & traction

control.

PARTS INFORMATION

Part No.: Description: Qty:

92138181 Clip 1

WARRANTY CLAIM INFORMATION

Description Install additional clip to

brake pipes

Labour Op. No. H000240

Time 0.2 hr

Failure Code 28 rattle

HOLDEN SERVICE TECHLINE____________________________________________________________FEBRUARY, 2003

New Control Valve Body, Spacer Plate & Gaskets For 4l60-E Auto. Trans.

All V & W with 4L60-E

(Group 7B) REVISED TL203A-0302

This Techline supercedes the previous one in Issue 1, Feb 2002. It is revised by updating spacer plate and gasket kit

part numbers. The previous techline should be destroyed.

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 later in this Techline)

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

24218822 - Gen3

24221350

24218187 - V6

24218188 - V6 S/C

24218186 - Gen 3

24221137

24221138

24221140

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.

HOLDEN SERVICE TECHLINE____________________________________________________________FEBRUARY, 2003

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

valve body gaskets and “C” for case gasket.

Figure 3. Post change identification. – “VB” for valve

body gasket & “CA” for case gasket

Figure 4. 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__________________________________________________________________MARCH, 2003

INFORMATION

Holden Assist (Telematics) Clarification

of Modes of Operation

VX / V2 / WH / VY

(GROUP 12) TL444-0303

PROBLEM DESCRIPTION

The Holden Assist Centre advises that some

Retailers are delivering new vehicles to customers

with the Telematics module in the incorrect operating

mode.

This has made it necessary to reiterate the

importance of the information previously published in

All Retailer Letters released in 2001. The bulk of this

information is repeated below.

SERVICE PROCEDURES

New Vehicle Delivery

When the vehicle is delivered from the assembly

plant the Telematics system is in “Pre-delivery

mode”. During vehicle pre-delivery, the “Pre-delivery

mode” of the Telematics module must be disabled

and the “Service mode” enabled using Tech 2.

For all Telematics module programming information

refer to SIP CD, VX / VY Series, Section 12Q .

After the vehicle is handed over to the customer, it is

then the customers responsibility to press the

“Holden Assist” button to register their personal

details with the Holden Assist Centre.

Your Retail outlet may wish to take this opportunity to

demonstrate the features of the Holden Assist

system to your customer.

When all the customer details have been confirmed,

the Holden Assist Centre will, by use of remote

control, disable “Service mode” and place into “Active

mode”.

Servicing

When a vehicle fitted with a Holden Assist system (in

Active mode) is presented to a Retail Outlet for any

service related work it is essential that the system is

placed into “Service Mode” using Tech 2.

In “Service mode”, the Telematics module will ignore

all button presses except for the “Holden Assist“

button. In addition, the unit will not transmit alert

messages for unauthorised entry or if battery is

disconnected. However, the unit will still transmit an

alert message if the SRS system (airbag and/or

seatbelt pre-tensioners) is activated.

On completion of service repairs, use Tech 2 to

disable “Service Mode” (leaving the vehicle in active

mode). Failure to do this will result in 5 beeps each

time ignition is turned ON.

Deactivation & Reactivation

In the situation where a customer wants the Holden

Assist system turned off, Retailers will be required to

de-activate Holden Assist by returning the module to

Pre-delivery mode.

In the situation where the customer changes their

mind and want Holden Assist reactivated, or when

the vehicle is sold and the Holden Assist system is

required by the new owner, the Retailer should

disable Pre-delivery mode leaving the Telematics

module in Service mode.

Summary of Modes of Operation

STATE OF

OWNERSHIP

TELEMATICS

MODULE - MODE

OF OPERATION

RESPONSIBILITY

During Shipping /

Pre-delivery

“Pre-delivery”

Assembly Plant

At vehicle

delivery

“Service”

Retailer

After delivery

“Active”

Customer via

Holden Assist

When Customer

presents for

service

“Service”

Customer via

Holden Assist or

Retailer via Tech 2

When Customer

requests de-

activation

“Pre-delivery”

Retailer

When Customer

sells the vehicle

“Service”

Customer advises

Holden Assist that

they have sold the

vehicle.

Holden Assist place

the account in “Sold”

mode and wait for

reactivation by the

new owner.

Note: To confirm the current mode of operation

refer to the Telematics module data list using

Tech 2.

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

SERVICE FIX

Body Control Module- Lock Up / Buzz

VT / VX / VU and V2 (CV6 only)

(Group 12) TL426-0303

This Techline supersedes the previous Techline on

this topic in Issue 1, Feb. 2002, (replace BCM).

PROBLEM DESCRIPTION

Symptoms of BCM Lockup condition are loss of

various BCM related functions resulting in engine no

start, no central locking, etc. This may be

accompanied by a ‘buzzing’ noise emitted from the

BCM.

When the BCM ‘buzzes’ 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 discharge that enters the BCMs’

internal circuitry, causing the BCM to malfunction.

To confirm diagnosis, temporarily remove the BCM

fuse (fuse 31 for vehicles from VT to VXI and fuse 29

for VXII onwards) to reset the BCM. The vehicle

should regain all functionality.

If all the symptoms of ‘lock up / buzz’ have not been

corrected continue with standard vehicle diagnosis.

PRODUCTION RECTIFICATION

BCMs with revised software to prevent “lock-up /

buzz” have been fitted to 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. Determine if the vehicle is post break point for the

revised BCM or if it has already had the revised

BCM fitted.

If the vehicle does not have the latest BCM

fitted continue to step 2.

If the vehicle already has the post break point

BCM fitted go to step 4.

2. 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.

3. Temporarily return the vehicle to service by

removing the BCM fuse (as previously described)

to reset the module.

4. Fit a slip ring patch harness supplied by HSPO part

number 92108841.

5. Remove the Remote Coded Key Reader (Item # 1

in figure 1), (refer to SIP CD VT SERIES Service

Manual, Section 12J-1, 2.4 Remote Coded Key

Reader).

6. Remove the key reader wiring harness connector

from the key reader and connect it to the male

terminal of the patch harness (Item # 2 in figure 1).

7. Connect the patch harness terminal with black

connector to the key reader terminal. (Item # 3 in

figure 1)

8. Connect the earth lead to the ignition lock housing

earth (underside of steering column). (Item # 4 in

figure 1)

9. Collect and cable tie the excess wiring neatly with

the cable tie, ensuring that there is no interference

when operating the Steering Column lever with the

steering wheel closest to the Instrument Cluster.

(Item # 5 in figure 1)

10. Feed Remote Coded Key Reader globe circuit over

the top of the Ignition lock housing.

11. Reinstall the upper and lower steering column

covers and Remote Coded Key Reader ensuring

that the Reader is aligned correctly (refer to SIP

CD VT SERIES Service Manual, Section 12J-1,

2.4 Remote Coded Key Reader).

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

PARTS INFORMATION

Part No.: Description: Qty:

N/A

Revised BCM (from

Australian Arrow via

request form)

N/A

Cable tie 2mm x 150mm

92108841

Slip ring patch harness

(from HSPO)

WARRANTY CLAIM INFORMATION

Use the following warranty claim information for the

installation of the BCM and or Patch Harness to

vehicles experiencing the BCM lock-up condition.

Description Slip Ring Patch Harness

(only) Installation

Labour Op. No. N000423

Time 0.4 hr

Failure Code 29

Description BCM Replacement and

Patch Harness Installation -

Pre Breakpoint vehicles only

Labour Op. No. N000336

Time 0.7 hr

Failure Code 48

Figure 1

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

SERVICE PROCEDURE

Rear Wheel Hub to Stub Axle Nut

Replacement Guidelines

XC Barina with rear disc brakes

(GROUP 4) TL453-0303

The following information is provided as it is not

available in current TIS. It will be added to future

versions of TIS.

Whenever the rear wheel hub to stub axle nut is

unscrewed for bearing replacement etc, the NUT

MUST BE REPLACED with a new one and torqued to

175 Nm.

Figure 1.

PARTS INFORMATION

Part No.: Description: Qty

09156693 Nut (M20) Rear wheel

hub to stub axle

Note. The nut also comes as part of the rear wheel

bearing kit 09196298.

INFORMATION

Clutch Fluid Discolouration

VX,VU,V2

(GROUP 7A) Repeated TL455-0303

This Techline is repeated (previously issued in Issue

5, June, 2002 page 6, but NOT included in Index

pages) to ensure technicians are aware of the

information.

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.

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

INFORMATION

SERVICE TECHLINES “ON-LINE”

(GROUP 0B) TL458-0303

Service Techlines are available “on-line” at Retailers through the “Holden Lionheart Portal”. The latest Techlines can

be viewed “on-line” immediately they have been approved for publication which means that you can have the latest

Techline information about 2 weeks earlier than you currently receive it. Note; two weeks is about the minimum

period of time it takes to print and distribute Techlines to Retailers via the Technicians Guild program or by direct mail

to Service Managers.

As Techlines are currently prepared on a monthly cycle it is suggested that you check for new bulletins at the

commencement of each month.

The Holden Lionheart Portal should be available on your Sales/Stock Controllers computer and should soon be on

most warranty clerks computers to allow them to access the new On Line warranty system due mid 2003. In order to

have the Holden Lionheart Portal installed on your Service Departments computer you will need to get the necessary

approval from your Retailer’s IT systems administrator.

Procedure For Viewing Service Techlines On Line.

Step 1. When the Holden Portal is accessed via Microsoft Internet Explorer the first screen to appear is as follows.

From the section titled “Bulletins” select Holden Service Bulletins.

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

Step 2. The next screen to appear is as follows. Select “1. Service Techline”. As you can see from this screen you

can also access other Service information such as Product Campaign Bulletins, All Retailer Letters etc.

Step 3. The next screen to appear is as follows. Select Group OB – General and look for the latest Issue number.

You can then open the file provided you have Acrobat Reader software installed. As Service Techlines are currently

prepared on a monthly cycle it is suggested that you check for new bulletins at the commencement of each month.

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

SERVICE FIX

Steering Column Buzz- Height Adjusting

Spring Vibrates

All V & W Models

(GROUP 9) TL440-0303

PROBLEM DESCRIPTION

Some vehicles may exhibit a resonance type buzz

from the steering column area. Typically the noise

may occur when driving at highway speeds on coarse

bitumen roads. The customer may perceive the noise

to come from the steering column, instrument cluster

area or the cockpit module in general

SERVICE RECTIFICATION

Summary: On complaint vehicles apply a tie strap

across the steering column adjust spring.

1. Open the fuse cover.

2. Perform a visual inspection of the steering column

adjust spring to ensure that the spring is

assembled correctly.

3. Attach a tie strap across the spring as shown in

the diagram below. Apply enough tension in the

strap to create 3 mm - 5 mm of deflection in the

spring. Do not overtighten.

PARTS INFORMATION

Part No.: Description: Qty:

92138154 Tie strap 1

WARRANTY CLAIM INFORMATION

Description Steering Column Adjust spring

- attach tie strap.

Labour Op. No. M000190

Time 0.2 hr

Failure Code 36 vibrates

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

SERVICE FIX

Ignition Key Jams In Off Position Or Is

Difficult To Turn from Off Position

TS, TT, XC Barina/Combo with “S”

Profile Ignition Keys/Barrels

(GROUP 9) TL421A-0303

This Techline supercedes the Advanced Service

Information in Issue 1, Feb, 2003. It is now

recommended to install the latest revised ignition

barrel instead of reworking existing parts. Production

breakpoints have also been provided.

PROBLEM DESCRIPTION

In some vehicles the ignition key may jam in the

“OFF” position or be difficult to turn from the “OFF”

position.

This condition only affects ignition barrels/keys with

“S” profile. It does not affect those with “D” profile. To

confirm profile type refer to Partfinder® TS

Catalogue, section 06-250A.

This condition results from the hard barrel pin

causing excessive wear of the soft alloy ramp section

of the barrel housing. Refer Figure 1.

PIN RAMP

Figure 1.

PRODUCTION RECTIFICATION

Revised ignition barrels have been fitted to vehicles

from the following breakpoints:

ISOVIN: Build Date:

XC Barina - W0L0XCF6824246086 30/04/02

XC Combo -

W0L0XCF2523030966

30/04/02

TS Astra - W0L0TGF4825195733 May 02

TT Zafira - W0L0TGF752H035990 Aug 02

SERVICE RECTIFICATION

Summary: For complaint vehicles install a new

ignition lock cylinder and tumblers.

To Remove and Reinstall the ignition lock cylinder

refer to TIS 2000 as follows:

TIS Screen ê

êê

ê Select the following ê

êê

Service

Information

Standard Information

Model Astra G/Corsa C/Zafira

Year 2002

Eng. -

Vehicle

Data

Trans. -

Asm.

Group

- Electrical Equipment & Instruments

+Switches, Control Units, Relays, Ign Lock

Standard

Info. Applic’n Repair (Remove,Install,Adjust)

Document List Lock Cylinder for strg. & ign. lock R & R

Tumbler Replacement

The old tumblers must be replaced with the new ones

supplied in the kit. To retain the same key coding,

remove the tumblers one at a time from the old lock

shaft, read the number stamped on the tumbler and

then install a new tumbler with the same code into the

new lock shaft in the equivalent slot.

Note. There are 4 different codes of tumbler and a

total of 10 tumblers per lock cylinder.

PARTS INFORMATION

Part No.: Description: Qty:

92146450 Barrel Kit – Ignition

(S profile)

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

SERVICE PROCEDURE

Clutch Pedal “Low” – Correct Bleeding

Procedure

V car with Gen III V8 & M/T

(GROUP 7A) TL456-0303

PROBLEM DESCRIPTION

Some retailers have reported difficulty in bleeding

Gen III V8 clutch hydraulic systems, and repeat

customer complaints of “low clutch pedal”, or “hard to

engage gears”.

The cause of these complaints is under investigation.

A number of vehicles have not displayed this

complaint condition until the hydraulic system has

been disturbed during clutch or transmission removal.

During investigation of returned components, it

appears that various methods of bleeding are being

used - with some methods being unsuccessful or

creating aeration of clutch hydraulic fluid.

Because of this, the following SIP procedure has

been repeated in this Techline and is recommended

for use whenever a Gen III V8 clutch hydraulic

system requires bleeding.

CLUTCH HYDRAULIC SYSTEM BLEEDING

PROCEDURE

The clutch hydraulic system must be bled whenever

the hydraulic line has been disconnected, or when a

leak has allowed air to enter the system. Air trapped

in the system can prevent full disengagement of the

clutch.

During bleeding operations, the master cylinder

reservoir must be kept at least half full with hydraulic

brake fluid.

1. Carefully clean any dirt from around the fluid

reservoir cap.

2. Remove the filler cap and top up reservoir as

required, with heavy duty hydraulic brake fluid,

such as Super DOT 4 Plus.

3. Using an 11 mm, 3/8 drive socket, short

extension and socket bar, loosen the slave

cylinder bleeder, located in the upper aperture of

the transmission adaptor plate/clutch housing, on

the left hand side.

4. Then, using just the socket and extension,

tighten the bleeder, using light finger force only.

5. Insert the end of the rubber tube of Tool AU529

over the end of the bleeder, positioned at the 9

o’clock position.

6. With the other end of the bleeder tool inserted

into a clean glass container such as a jar, that

has been partially filled with new brake fluid, open

the bleeder 1/4 turn, using the rubber on the

bleeder tool to provide the required grip. Ensure

that the end of the hose always remains

submerged in the brake fluid during bleeding

operations.

7. Using an assistant, slowly depress the clutch

pedal by hand, one single time and, while holding

the pedal depressed, close the bleeder using

Tool AU529. Once the bleeder is closed, the

clutch pedal can be allowed to slowly release.

(ENSURE PEDAL FULLY RETURNS TO THE

“UP” POSITION – lift by hand if required). Repeat

this process until all bubbles cease to appear at

the end of the bleeder hose.

NOTE: Do not pump the clutch pedal

repeatedly during bleeding operations, as

entrapped air will cause the fluid to foam,

making air removal extremely difficult. Also, as

the hydraulic steel piping is routed over the top

of the transmission housing, air can be trapped

in that section.

8. When all air has been removed, close off the

bleeder and remove Tool AU529. With the clutch

pedal still depressed, tighten the bleeder screw to

the correct torque specification.

CLUTCH SLAVE CYLINDER BLEEDER SCREW

TORQUE SPECIFICATION 18 Nm

9. Once all bleeding operations have been

completed, ensure that the reservoir fluid level is

correct.

NOTE 1: “Alternative methods” of bleeding as

mentioned in SIP should not be used on any vehicle

where repeated air entry type symptoms have been

identified. This is to ensure air entry does not occur

during the use of these methods. Only use these

methods as a ‘last resort’.

NOTE 2: Discolouration of fluid is no reason for

replacement of fluid – Refer Service Techline in Issue

3, March 2003.

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

INFORMATION

SRTA A/T Exchange Transmission Fitting

Precaution

V & W – with V8 Engine

(GROUP 7B) TL443-0303

Current Condition

Investigation of some returned transmissions from V8

engine vehicles show failure of components is related

to incorrect PCM calibrations being used.

Service Action

Whenever fitting a SRTA transmission, after the

mandatory transmission cooler flow check has been

carried out, technicians should flash program the

PCM with the latest Holden calibration for the vehicle

configuration.

Technicians must also ensure that the SRTA

Feedback form is marked accordingly.

SRTA Action

To remind technicians of this requirement, the

following information will soon be added to all SRTA

replacement transmissions and the Feedback form.

SRTA Feedback Form:

IMPORTANT! On all V8 vehicles confirm that

latest software is installed in the

transmission PCM. Yes

SRTA Transmission Tag:

IMPORTANT NOTICE !

It is essential that you check the transmission PCM

software calibration, ensure that it is the latest for

that model vehicle. If it is not the latest software, it

must be installed before releasing the vehicle.

SERVICE FIX

Stabiliser Bar Drop Link Upper Joint

Bush Splits

VT, VX, VU, VY, WH

(GROUP 3) TL437-0303

PROBLEM DESCRIPTION

The stabiliser bar drop link bushes may fail by

splitting.

PRODUCTION RECTIFICATION

New bushes made of revised rubber with increased

hardness, reduced compression set and improved

performance in high ambients have been fitted to

vehicles from:

ISOVIN: Build Date:

6G1YK54AX3L991753 20/03/2003

SERVICE RECTIFICATION

Summary: Install new bushes as required.

PARTS INFORMATION

Part No.: Description: Qty:

92159373 Bush droplink to strut

asm.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

SERVICE FIX

Accessory Drive Belt Tensioner

Rattle/Noise

TR with C16SE, C18SEL, X20XEV engine;

TS with X18XE1 or Z18XE engine

(Group 6Y) UPDATE TL446-0303

This Techline is revised by adding TS model and

changing the case type in warranty claim information.

Please discard previous TR Techline in Issue 1, Feb.

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.

PRODUCTION RECTIFICATION

TS Model: Decoupler pulleys were fitted to vehicles

from:

ISOVIN: Build Date:

W0L0TGF6915264049 N/A

TR Model: Decoupler pulleys were not fitted in

production.

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: inf[email protected]om.au

NOTE: These tools can also be obtained on loan

from your Zone Service office.

PARTS INFORMATION

TS:

Part No.: Description: Qty

93170214 Decoupler Pulley and Cap

Plug Asm.

TR:

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, 2003

SERVICE PROCEDURE

Entertainment System Additional Code

Indexes

VY, V2 Series II

(GROUP 12) TL450-0303

Due to a running change of components within the

VY and V2 Series II Blaupunkt Entertainment system

it has been necessary to add some additional code

indexes. This information is provided below as it is

not yet been added to PV SIP.

SERVICE RECOMMENDATION

When installing an upgrade or warranty replacement

radio, it is necessary to program the code index

within the unit to configure it to the particular vehicle.

To program the code index refer to PV SIP Section

12D / Entertainment System / 3.11 Program / F0:

Program Code Index.

Use the following table to obtain the correct code

index.

• If the code index in the replacement radio is

between 001 and 006 use column A,

• If the code index in the replacement radio is

between 007 and 012 use column B, in the

table below.

Note: The vehicle description 8VK or 8VL refers to its

luxury level and is found on the Body and Option

plate which is located on the radiator support panel

as can be seen below.

Vehicle

CD unit

Code Index A

Code Index B

All 8VK (Executive, Acclaim, SS, CV6 etc) Except 8VK80

Single

001

007

All 8VK (Executive, Acclaim, SS, CV6 etc) Except 8VK80

6 Stack

001

007

All 8VL (Berlina)

6 Stack

001

007

8VK80 & 8VK03 (Ute / Cab Chassis)

Single

003

009

8VK80 & 8VK03 (Ute / Cab Chassis)

6 Stack

003

009

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

INFORMATION

P/S Pump Pulley Replacement

All with Gen III V8

(GROUP 9) TL424-0303

When replacing a power steering pump it is

necessary to remove the pump pulley and fit it to the

replacement pump – refer to May 2001 Service

Techline bulletin: “Removing Pulleys & Hubs From

Power Steering Pumps – Repac Returns Precaution”.

Difficulty may be experienced when removing power

steering pump pulleys.

PRODUCTION RECTIFICATION

Revised power steering pump pulleys with extended

hub centres were introduced into production from:

ISOVIN: Build Date:

6H8VXK69F2L858938 03/05/02

SERVICE RECOMMENDATION

Summary: Three possible installations will be seen in

service – use one of the following procedures as

required:

1. Pumps with standard pulley and pulley location

on pump shaft:

• Pumps before L858938 are able to be removed by

existing special tools as per the relevant SIP

information.

2. Pumps with ‘Relocated’ Pulleys:

Some power steering pump pulleys have been

pressed further onto the power steering pump shaft

to correct engine drive belt squeal - as per Techline

of May, 2001, Issue 5. On these pulleys, the SIP CD

“Method 2” special tool will not fit.

• Remove pulley using press plates under the

pulley and refit using tools shown in the “Method

1” procedure in SIP CD, VT Series II

“Power Steering Service Operations” section.

3. Pumps with Extended Hub Pulleys:

Vehicles with pumps built after L858938, or with

current design pulleys ex-HSPO have a longer hub

centre. On these pulleys, the SIP CD “Method 2”

special tool will not fit.

• Remove pulley using press plates under the pulley

and refit using tools shown in the “Method 1”

procedure in SIP CD, VT Series II Power

Steering Service Operations section.

Note: These same situations will also be evident

when replacing a leaking pump front seal.

Caution:

High press pressures may be required to remove

some pulleys because of the interference fit that

exists. Should it not be possible to remove the power

steering pulley using press plates as per SIP, the

pump will need to be replaced. Note this on the

Defective Material Tag.

PARTS INFORMATION

Pulleys with the ‘longer’ hub centre are the only

replacement parts available from HSPO.

INFORMATION

Removing Pulleys & Hubs From Power

Steering Pumps Returned To Repac

VX, VU, V2, VY, WH

(GROUP 9) REPEAT TL425-0303

This Techline bulletin is repeated from May 2001 for

the benefit of technicians and Warranty personnel –

to ensure power steering pumps are dismantled and

returned in the correct manner – this will avoid

charge-back action being taken by REPAC.

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

Please circulate this Techline to your Warranty

personnel.

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

A number of power steering pumps returned to

REPAC under warranty still have hubs (on V6

pumps) and pulleys (on V8 pumps) assembled to

them.

This is a reminder to retailers that hubs and pulleys

can be easily removed from pumps using a standard

workshop hydraulic press with special press plates.

For special tools and removal procedures refer to

Passenger SIP CD, VT Series 1 Service Information,

Section 9A, Parts 3.10(V6) and 3.11(V8).

Provided there are no obvious signs of damage, a

“removed” hub or pulley can be reinstalled onto the

new pump following the installation procedures

shown in SIP.

Warranty Clerks NOTE:

The standard time for pump R & R (labour op.

M147000) includes an allowance for hub removal.

In light of the above, all retailers are requested to

remove pulleys and hubs from pumps before

returning them to REPAC.

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

SERVICE FIX

Antenna Extends and Radio Turns on by

Itself

VY / V2 Series II

(GROUP 12) TL445-0303

PROBLEM DESCRIPTION

There have been several reports where customer

advises that they have returned to their vehicle to find

the antenna is up and the radio on.

In some situations the customer will also find their

wipers going if they have switched the ignition off

while they are running.

This problem only occurs on vehicles, which have a

low or mid series BCM and also have electric

antenna.

SERVICE RECTIFICATION

The cause of this problem is water entry in to the two

pin connector at the electric antenna.

1. To rectify this problem, clean the water out of the

antenna connector.

2. Confirm that all seals are correctly located

around each wire in the connector and between

the mating surfaces of the connector.

3. Apply Nyogel grease to the connector cavity and

then re-assemble the connector.

4. Ensure that the connector positively engages.

Please PIR all cases including information about seal

condition and possible water entry points.

PARTS INFORMATION

Part No.: Description: Qty:

92146329 Nye Nyogel 760G

Grease – 30cc syringe

WARRANTY CLAIM INFORMATION

Description Dry water out of antenna

connector

Labour Op. No. N000426

Time 0.4 hr

Failure Code 51

INFORMATION

Tech 2 Unable to Communicate with

Instrument Cluster

V2 Series 2 (CV8 only)

(GROUP 12) TL447-0303

PROBLEM DESCRIPTION

There have been several reports of vehicles, where

Tech 2 is unable to communicate to the instrument

cluster.

When this situation occurs Tech 2 displays “Unknown

ECU”.

SERVICE RECTIFICATION

This problem can be rectified in service by using

Tech 2 software version 12.0 which will be released

on TIS 2000 version 40.

Update

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

INFORMATION

Brake And Clutch Fluid Colour Changed

In Production

VY, V2, WH

(GROUP 5 & 7A) TL438-0303

The brake and clutch fluid used in production for the

above models is changing colour from green to light

amber.

The new amber coloured fluid is identical in

specification to the green fluid except for the colour.

The fluids can be mixed in service in those situations

where the correct colour fluid is not available.

PRODUCTION BREAKPOINT

The amber coloured brake and clutch fluid is planned

for introduction into vehicles in the first week of April

2003.

Breakpoints will be published when they become

available.

ISOVIN: Build Date:

TBA TBA

PARTS INFORMATION

Part No.: Description: Qty:

92026651 Brake/clutch fluid

500ml green

TBA Brake/clutch fluid

500ml amber

DIAGNOSIS HINT

Radio Volume - Erratic Operation

Intermittently

VY / V2 Series II

(GROUP 12) TL475-0303

PROBLEM DESCRIPTION

Customers may report the following symptoms with

their radio:

The volume intermittently increases to maximum, or

the volume indicator increases to maximum while the

radio mutes or the radio mutes.

The above symptoms can occur when any of the

speaker circuits are interrupted in the following ways.

1. Intermittent Short to Ground or Battery

Supply

The volume indicator display on the radio will

increase to the maximum or decrease to the

minimum reading and when the volume knob is

turned it will go in the direction indicated on the

display.

E.g. Maximum indication on the display will result in

maximum volume on all speakers.

Note: In some situations it may not be necessary to

turn the volume control knob to have the volume

change.

2 Constant Short to Ground or Battery

Supply

The volume indicator on the radio may display the

maximum or minimum reading and the radio will

mute.

3. Short between both Positive and Negative

Speaker Wires

The radio will mute the affected circuit until the short

is removed.

PIRs Required

Technicians are requested to submit PIRs on any

vehicles in which the above conditions are found.

HOLDEN SERVICE TECHLINE__________________________________________________________________MARCH, 2003

SERVICE FIX

Door Checklink Bolts Loose

TS, TT, JS, XC

(GROUP 1) UPDATE TL285B-0303

This Techline supercedes the previous one in Issue

6/2002. It is revised by adding requirement to apply

threadlock compound to new checklink bolts.

PROBLEM DESCRIPTION

On some vehicles the door checklink attaching bolts

may loosen. Refer item 3 in Figure 1.

Figure 1.

PRODUCTION RECTIFICATION

Revised checklink attaching bolts have been fitted to

vehicles from:

ISOVIN: Build Date:

W0L0TGF4815283442 05/06/2001

SERVICE RECTIFICATION

On complaint vehicles, ensure that the latest

checklink attaching bolts p/n 13104167 are installed

and torque to 4.5 to 5.0 Nm.

IMPORTANT: Apply threadlocking compound Loctite

243 (or equivalent) to the bolt threads prior to

installation. Failure to do so may result in the bolts

coming loose again.

PARTS INFORMATION

Part No.: Description: Qty:

13104167 Bolt Checklink to door. 2 per

door

Threadlocking compound Loctite 243 can be

obtained from most industrial equipment suppliers.

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

HOLDEN SERVICE TECHLINE_________________________________________________________________ APRIL, 2003

SERVICE FIX

Battery Discharge -Telematics

VX / WH / V2 Series 1

(GROUP 12) TL476-0304

PROBLEM DESCRIPTION

Customers may complain of the vehicle battery going

flat prematurely or receiving repeat low battery alert

calls from Holden Assist when the vehicle is left for

several days.

PRODUCTION RECTIFICATION

Revised software to reduce the current draw of the

Telematics module has been installed from.

ISO VIN Build Date

6G1HK53B63L933021 25/10/02

SERVICE DIAGNOSIS

Ensure the Telematics module in the vehicle has

been placed in Service Mode.

Confirm that the vehicle has no other problems

causing excessive current draw by performing a

Battery Current Draw Test as described in SIP

Section 12A Battery & Cables.

Place the BCM into pre-delivery mode before

performing a Battery Current Draw Test to eliminate

the current draw from the interior illumination relay.

The current draw specification for a vehicle which has

Telematics fitted should be approximately 140 mA

after the vehicle has been left for a period of five

minutes.

Current draw above 140mA

If the Battery Current Draw proves to be higher the

source of the extra current draw should be isolated

and repaired.

Current draw below 140mA

If the Battery Current Draw is approximately 140 mA

or lower the Telematics module BIM software version

number should be checked.

The Telematics System Identification screen can be

viewed by using Tech 2 and making the following

selections; F0: Diagnostics / (1) 2001 / VX

Commodore / F3: Body / Telematics Module

This Identification screen will list the BIM software

version number. If this number is 71 or lower, the

module will require a software upgrade as follows.

For version numbers above 71 no further action is

required.

SERVICE RECTIFICATION

To have a customers module upgraded with the

revised software, complete the Telematics Change

Over Request Form located in the Change Over

section of SIP and fax it to Australian Arrow on (03)

9775 0954.

Australian Arrow will organise for a bridging

connector, acknowledgement form and a return

prepaid box to be shipped to your Retail Outlet.

It will be necessary to re-book the customer’s vehicle

once the package arrives.

When making the customer booking explain to the

customer that if they wish to have the software

upgraded in their vehicle they will be without the use

of the Telematics for a period of a maximum of ten

working days.

Removal of the Telematics module and fitting of the

bridging connector should only take approximately 15

minutes.

Before fitting the bridging connector ensure the

customer has completed and signed the

acknowledgement form. The original should be

filed for future reference.

Remove the Telematics module from the customers

vehicle and fit the bridging connector; this will allow

the customer to drive their vehicle until their

Telematics module with the revised software returns

from Australian Arrow.

When the revised Telematics module returns from

Australian Arrow it will be necessary to re-book the

customers vehicle to re-fit the Telematics module.

When making the customer booking for the module to

be re-fitted advise the customer that the vehicle will

be required for a minimum of two hours.

Once the revised Telematics Module is fitted it is

important to perform the following steps;

1. Use Tech 2 to confirm the VIN number in the

Telematics Module matches the actual VIN

number of the vehicle.

2. Use Tech 2 to disable Pre Delivery mode (you will

require TIS approval to perform this operation) and

program the Code Index using index number 001.

3. Perform a Telematics On Board Diagnostic

System Check as per the SIP Section 12Q

Telematics / 5 Diagnostics.

4. Set the BCM battery saver mode to 10 minutes.

5. Check vehicle battery condition; charge if required.

6. The vehicle can then be returned to the customer.

WARRANTY CLAIM INFORMATION

Description Software upgrade

Telematics Module

Labour Op. No. N000402

Time 1.0

Failure Code 50

HOLDEN SERVICE TECHLINE_________________________________________________________________ APRIL, 2003

INFORMATION

Holden Assist (Telematics) GPS Location

Difficulties On Initial Activation

V2II / VY / WK

(GROUP 12) TL478-0304

PROBLEM DESCRIPTION

The Holden Assist Centre advises that they are

having difficulties locating some new vehicles when

customers or Retailers perform a Holden Assist

button press for the first time.

SERVICE PROCEDURE

Due to the time taken for the Telematics module to

gain a GPS location (Latitude & Longitude), when

activated for the first time (eg new vehicle or the

module has been replaced) it is necessary to perform

the following process.

1. Before delivery to the customer the Telematics

module should be taken out of “pre-delivery”

mode and placed into “service” mode using

Tech 2.

2. Park the vehicle outside for at least one hour in a

location where the sky is clearly visible.

SERVICE FIX

Unable To Select Gears

VT,VX,VU,V2,VY with Gen III M/T

(GROUP 7A) TL475-0304

PROBLEM DESCRIPTION

In some cases where excessive effort is used for

gear changes, the Remote Shifter Mechanism front

pivot ball may dislodge from the nylon retainer. This

results in being unable to select gears.

If a customer complains of no gear selection and

rubbery shift feel, proceed with Service Rectification.

SERVICE RECTIFICATION

Summary: Install new remote shifter from HSPO

after fitting reinforcing plate kit obtained from TAS.

Note: For detailed procedures on removing and

reinstalling remote shifter refer to PV SIP CD.

1. Inspect remote shifter to determine if front pivot

ball has dislodged from nylon retainer. Refer to

Figure 1.

2. Once failure has been confirmed, remove remote

shifter assembly from transmission.

3. Check for damage to offset lever cup as shown in

Figure 2. Replace if damaged . If required, order

a new offset lever from HSPO.

4. Order a new remote shifter assembly from HSPO

using part numbers from latest Partfinder.

5. Have your nominated TAS contact person ring

TAS for a reinforcing plate service kit. The service

kit contains 1 steel reinforcing plate and three

attaching screws as shown in Figure 3.

NOTE: Prior to fitting the new remote shifter to the

transmission, fit the steel reinforcing plate service

kit on top of the triangular nylon retainer as per

instructions 6 to 8 below:

6. Remove and discard the 3 original attaching

screws for the triangular nylon retainer.

7. Slide steel reinforcing plate over the top of the

nylon retainer. This plate only fits in one direction.

Ensure countersinks for the screws face upwards.

8. Use the 3 screws provided with the service kit to

attach the steel reinforcing plate. Screw torque:

3.5 - 5.5 Nm. Refer to Figure 4 for illustration of

reworked assembly.

9. Fit new offset lever to transmission (if required).

10. Fit new remote shifter with steel reinforcing plate.

HOLDEN SERVICE TECHLINE_________________________________________________________________ APRIL, 2003

Figure 1. Failed Remote Shifter

Figure 2. Typical damage to offset lever cup

Figure 3. Steel Reinforcing Plate Service Kit

Figure 4. Remote Shifter with Steel Reinforcing Plate

installed.

PARTS INFORMATION

Part No.: Description: Qty:

92144962 Shifter asm – Pre VY

models up to L832047

(21/2/02)

92146309 Shifter asm – Pre VY

models from L832048

(21/2/02)

92146797 Shifter asm. – VY

Contact TAS Reinforcing plate

service kit

WARRANTY CLAIM INFORMATION

Description Replace remote shifter asm

& fit reinforcing plate kit

Labour Op. No. K000288

Time 2.7 hr

Failure Code 71 Pulled loose

HOLDEN SERVICE TECHLINE_________________________________________________________________ APRIL, 2003

INFORMATION

Entertainment System Code Index

ZC Vectra

(GROUP 12) TL467-0304

PROBLEM DESCRIPTION

The radio code index’s which are normally located in

TIS 2000 (for our Opel based products) are missing

for ZC Vectra.

SERVICE RECTIFICATION

Until TIS 2000 is updated with the latest information it

is recommended that the following code indexes are

used whenever a replacement radio is installed.

Model Number of CD's Code Index

Blaupunkt

2620

6 072

Blaupunkt

2020

1 074

Note 1. The above code indexes should only be

required if the original radio is replaced.

Note 2: During the radio manufacturing process,

Blaupunkt program radio’s with the correct code

index for the vehicle they will be fitted to, although

when using Tech 2, the code index will actually

display “0”. Therefore, it is normal for a new

vehicle fitted with its original radio to display “0”

code index.

Note 3. Once the code index has been programmed

with Tech 2 it will display whichever index is used.

SERVICE FIX

Gen III Idle Boom In Drive - Radiator

Contacts Mounting Bracket

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

(GROUP 1 & 6A) TL465-0304

PROBLEM DESCRIPTION

Excessive vibration felt inside the vehicle whilst idling

in Drive, with air conditioning on. Condition could

also be described as a “cyclic cabin boom”.

This condition can be caused by contact between the

radiator plastic end tanks and the upper support

brackets as shown in Figure 1.

SERVICE RECTIFICATION

Summary: Ensure that radiator is not making hard

contact with body mounting points.

Radiator End Tanks.

On any vehicle with the condition described above,

check for clearance between the radiator end tanks

and upper support brackets as shown in figure 1.

There should be at least 3mm clearance.

To provide sufficient clearance bend the bracket.

When bending the bracket, use care to avoid

cracking the radiator end tanks.

Retaining Clip.

Another item to check is the retaining clip mounting.

If the clip is wedged tightly between the radiator end

tank and the support bracket as shown in Figure 2

remove the clip and reduce its width by filing or

grinding. There should be at least 1mm clearance on

each side of the clip.

Destressing Exhaust System

If the above procedures do not reduce the

vibration/cyclic boom sufficiently, it may be

worthwhile looking at destressing the exhaust system

as described in previous Techline - Group 8, May,

2001.

HOLDEN SERVICE TECHLINE_________________________________________________________________ APRIL, 2003

Figure 1. Shows potential contact points of radiator

end tanks with body bracket. LHS.

Figure 2. Shows clip making hard contact between

end tank and bracket. LHS.

SERVICE FIX

Park Brake Scrape

VT, VX, VY, VU, V2, WH

(GROUP 5) TL452-0304

PROBLEM DESCRIPTION

Some customers may complain of an intermittent

cyclic scraping noise from the rear of vehicle while

driving. Sometimes the noise appears to go away

after re-applying park brake lever.

The above condition is caused by the secondary park

brake lining (front lining) contacting the drum (in

rotor) without the park brake being applied.

SERVICE RECTIFICATION

Summary: Lubricate park brake shoe contact points

as per following procedure.

Equipment / Materials Required.

• 200 mm vernier caliper capable of reading to

within 0.1mm or better.

• Molybdenum Disulphide grease (Use Shell RD5

or equivalent grease)

• “Brakleen” or similar solvent cleaning product

approved for cleaning brakes.

• Methylated spirits.

Lubricating Procedure (Refer Figure 1.)

1. Remove wheel, caliper and rotor.

2. Check park brake actuation area for gaps in the

following two areas:

Between the adjuster nut and anchor bracket

Between the tappet and anchor bracket

3. If there is a gap, the cable adjustment is too tight

at the park brake lever. Slowly de-adjust cable

until there is no gap.

4. Remove hold-down spring.

5. Remove shoe. If shoe is in good condition then

clean it with Methylated spirits and a rag.

Replace shoe if excessively worn, damaged or

corroded.

6. Hold adjuster nut and tappet in place in the

anchor bracket with rubber band.

7. Spray clean the park brake thoroughly with

'Brakleen' or equivalent.

8. Apply Molybdenum Disulphide grease (Shell RD5

or equivalent) to all six shoe contact points.

The 6 shoe contact points are as follows; 3 points

on the dirt shield, 1 on adjuster nut, 1 on tappet

and 1 on hold-down spring. Hint: If the vehicle is

not brand new, there should be witness marks on

the dirt shield where the shoe has been rubbing.

Grease should be applied to these rubbing

points.

Update

HOLDEN SERVICE TECHLINE_________________________________________________________________ APRIL, 2003

IMPORTANT. At no time should grease be allowed

to touch the friction material on the brake shoe

otherwise the shoe must be replaced. It cannot

simply be wiped clean! Please ensure a high level of

cleanliness when handling grease.

9. Remove rubber band holding adjuster nut and

tappet.

10. Re install shoe.

11. Reinstall hold-down spring. (replace if damaged)

12. Set shoe diameter to between 189.5 and 189.7

mm using the adjuster nut. Do not use the cable

at the park brake lever to make this adjustment!.

13. Clean rotor with "Brakleen" or equivalent and

rag.

14. Refit rotor, caliper and wheel.

15. Ensure correct operation of park brake. Adjust

cable if necessary as per service adjustment

procedure.

WARRANTY CLAIM INFORMATION

Description Lubricate park brake shoe

contact points – both sides

Labour Op. No. H000248

Time 1.0 hr

Failure Code 40 noisy

Legend for Figure 1.

2. Park Brake Shoe

4. Brake shoe hold down spring

5. Anchor bracket

6. Brake shoe adjusting screw.

7. Brake shoe adjusting nut

8. Adjuster pawl

9. Brake shoe actuating lever

10. Park brake push rod.

11. brake shoe adjuster tappet

12. Lever to dust shield cover

Figure 1. Grease points (on areas that contact shoe only) shown with arrows

HOLDEN SERVICE TECHLINE_________________________________________________________________ APRIL, 2003

INFORMATION

White Marks On Interior Trim

All Models

(GROUP 1) TL468-0304

PROBLEM DESCRIPTION

There have been some dash trims returned to

REPAC that were replaced for exhibiting white stains.

Investigation has found that these stains are in areas

where customer hands are likely to contact the trim.

In all cases the stains were able to be removed using

dish washing liquid diluted with water.

SERVICE PROCEDURE

Quick Connect Fittings

All

(GROUP OB) TL466-0304

The purpose of this techline is to remind technicians

of the importance of always checking quick connect

fittings after reconnection. This is normally done by

pushing/pulling on both sides of the fitting.

Refer to the following drawings from PV SIP which

shows the checking method for some of the different

types of quick connect fittings.

Figure 1. Fuel line fitting (Plastic collar type)

Figure 2. Fuel filter fitting.

Figure 3. 4L60E Auto Trans Cooler lines.

To check A/T cooler pipe quick connect fittings after

reconnection, attempt to pull the pipe free. A 2nd

check is to slide each verifier disc (#2) up to the

fitting. If it engages with the fitting then the pipe has

been correctly installed. NOTE the verifier disc

should be left in this position.

(NOTE; figure 3 shows the quick connect removal

tool J41623 in position)

HOLDEN SERVICE TECHLINE_________________________________________________________________ APRIL, 2003

INFORMATION

Automatic Transmission Filler Plug Warning

ZC Vectra

(GROUP 7B) TL449-0304

The automatic transmission oil filler plug (internal hex type) is located just next to the transmission switch on top of

the transmission for both the AF23-5 and AF33-5 transmissions. Figure 1, item #3 shows location of the filler plug.

This filler plug must not be confused with the large hex bolt on top of the transmission shown with the “DO NOT

REMOVE” label.

IMPORTANT

DO NOT loosen or remove the large hex bolt on top of the transmission otherwise the

transmission will have to be replaced. This bolt is sealed with white paint up to trans. serial

number 02MV717209. Transmissions after this serial number use a pentagon bolt. Note: This bolt

anchors the B4 band internally in the transmission

Figure 1.

HOLDEN SERVICE TECHLINE_________________________________________________________________ APRIL, 2003

INFORMATION

New Body Repair Procedure - MIG Brazing

(Approved Equipment Suppliers)

ZC Vectra

(GROUP 01) TL477-0304

SERVICE INFORMATION

The body panels used on the ZC Vectra utilise a new

range of high tensile steels that must not be welded

during repair using traditional MIG welding. Panels

should only be joined using the MIG brazing repair

procedures outlined in TIS.

If the panels on ZC Vectra are MIG welded, the

composition of the panel metal at the weld will

change, reducing the tensile strength, which

could affect the vehicle performance in durability

and crash performance. Should a MIG weld be

applied the affected panels must be replaced and

then joined using the correct procedure.

MIG Brazing is a low temperature procedure that has

the following advantages:

• Does not alter the composition of the panel

metal.

• Does not remove as much of the panels anti-

corrosive coat.

• Leaves a brazing bead that is more corrosion

resistant

• Lowers distortion to components being joined.

• Allows larger gaps to be filled.

MIG Brazing equipment to Holden’s standards can be

obtained from the following suppliers:

Approved MIG Suppliers

Migatronic

Southern Cross Industrial Supplies P/L

(Includes NZ)

851 Ramsden Drive

Albury NSW 2640

(PO Box 485 Lavington NSW 2641)

Ph: 02 6040 1991

1800 645 587

Fax: 02 6040 1980

E-mail: [email protected]

Web: www.scws.com.au

Kemppi

Kemppi Australia (Includes NZ)

PO Box 404

2/58 Lancaster Street

Ingleburn NSW 2565

Ph: 02 9605 9500

Fax: 02 9605 5999

Web: www.kemppi.com.au

E-mail: [email protected]

Fronius

Paul England and Staff

1 Longview Court

Thomastown Vic 3074

Ph: 03 9466 4060

Fax: 03 9464 2106

Web: www.paulengland.com.au

E-mail: [email protected]

Eutectic New Zealand P/L

Po Box 12559

Unit 0, 20 Sylvia Park Road

Penrose, Auckland

Ph: 95735386

Fax: 95735388

E-mail: [email protected]

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

DIAGNOSIS HINT

Instrument Cluster Lens Replacement

ALL

(GROUP 12) TL497-0305

Holdens Returned Parts Assessment Centre (REPAC)

continues to receive complete instrument cluster

assemblies replaced for complaint of “lens scratched”.

Please note that for most models, replacement lenses

are available from HSPO.

For lens replacement procedure refer to the Service

Instructions in the relevant CD, i.e.

• TIS or

• LCRV SIP or

• PV SIP

WARRANTY CLAIM INFORMATION

For lenses replaced under warranty, use Labour

Times information in Warranty Information section of

current PV SIP CD.

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

INFORMATION

Wheel Nut Usage - Alloy & Steel Wheels

All V & W

(GROUP 10) REVISED TL255A-0305

This Techline supercedes the previous one in Issue 3,

April 2002 by revising Note 2 and updating the table.

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.

Nuts specified for use with steel wheels must not

be used on alloy wheels which do not have steel

nut seats.

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.

NOTE 2.

Nuts that are specified for use with alloy wheels

(e.g. 22526184 & 92100089) may in some

circumstances be used on steel wheels. For

example when a vehicle fitted with alloy wheels

has a puncture and a steel spare wheel is fitted

temporarily.

The following table shows many of the nuts specified

in Partfinder® together with the model usage.

Always refer to Partfinder® to determine which nut is

specified for a particular wheel.

Part Number For use on: Models

22526184

Alloy wheels -

without steel nut

seat

May be used

temporarily with

steel wheel.

Refer Note 2.

WK,WH,V2,VY,

VX,VU, VS,VT

92037665

Alloy wheels -

with steel nut

seats.

WH, VT, VS

92100089

Alloy wheel –

without steel nut

seats

May be used

temporarily with

steel wheel.

Refer Note 2.

92045082

Steel wheel only VX,VU,VT,VS,

VP, VR,

92112268

Steel wheel only VY,VX,VU,VT

92015262

Steel wheel only VY,VX,VT,VS,

VP, VR, VQ, VB

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

SERVICE FIX

Roof Joint Moulding Loosens/Detaches

From Roof

VY Ute

(GROUP 01) TL463-0305

PROBLEM DESCRIPTION

The roof joint moulding may become loose and in

some cases detach from vehicle roof. The condition

may be more likely to occur in hot weather.

PRODUCTION RECTIFICATION

To overcome the above condition, roof mouldings

made from revised material have been fitted to

vehicles from:

ISOVIN: Build Date:

6G1YK42F23L102713 02/04/2003

SERVICE RECTIFICATION

Summary: On vehicles built prior to the above

breakpoint where the mouldings have detached from

roof, fit the latest roof mouldings available from

HSPO.

For removal & reinstallation procedures for mouldings

refer to Passenger Vehicle SIP.

PARTS INFORMATION

Part No.: Description: Qty:

92059950 Moulding asm roof panel

joint front finish RH

92059951 Moulding asm roof panel

joint front finish LH

Note: All the mouldings in HSPO are made from the

latest revised material.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

INFORMATION

Battery Replacement During Warranty

VTII / VU / VX / V2 / VY / WH

(GROUP 12) TL482-0305

PROBLEM DESCRIPTION

During Holden’s regular warranty claims analysis it

has been noted that some Retailers are fitting

incorrect batteries to the above listed vehicles.

When replacing any battery under warranty it is

important to ensure that the correctly specified battery

is fitted for the particular vehicle.

SERVICE RECOMMENDATION

The most accurate method of ensuring the correct

battery is fitted is to order it using the part number

specified in Partfinder®.

Early in VT production the battery specification

changed from a Calcium / Calcium battery to a Silver /

Calcium battery.

This change did not affect the Cold Cranking Amps or

the Reserve Capacity but increased the expected

service life.

Through the introduction of silver / calcium alloys in

the production of the positive plates and also a roll

hardening process, the incidence of plate growth and

cracking (which can lead to premature battery failure)

has been dramatically reduced.

Battery material content is generally listed on the label

on top of the battery as follows,

The AG9 represents Silver and the Ca represents

Calcium.

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

DIAGNOSIS HINT

Rattle Inside Vehicle (Transmission

Selector Cable)

TS with A/T

(GROUP 7B) TL495-0305

We have received a few isolated reports (PIRs) of a

rattle coming from inside the vehicle which usually

occurs under load, e.g. when lightly accelerating up

hills.

In these cases the transmission selector cable has

been found to be rattling against the Transmission

Control Module located under the centre console.

Technicians report that complaints have been fixed by

wrapping the selector cable with foam in the position

where it rattles.

SERVICE FIX

Water Leak Into Foot Well

(GROUP 1) TL423-0305

Techline Issue 7, 2002 – Page 11 ( V2 Passenger

Side Rocker Panel Water Entry) should be read in

conjunction with this bulletin when completing this

repair.

PROBLEM DESCRIPTION

Water leaks into the foot well/s while driving in heavy

rain.

An unsealed section between two panels in the rear

wheel house allows water and some dirt to enter the

rocker panel. When the volume of water entering

exceeds the capacity of the rocker panel drain holes,

the rocker panel will fill with water and overflow into

the foot well.

The rocker panel moulding could also be applying

pressure to the rocker panel drain plugs preventing

the rocker panel from draining.

PRODUCTION RECTIFICATION

An improved sealing and inspection process has been

introduced from the following ISOVIN:

ISOVIN Date

6G12X14F73L125374 27 May 2003

SERVICE RECTIFICATION

1. Inspect the front of the rear wheel arch to confirm a

gap is present as shown in fig 1.

Figure 1

2. Mark the alignment of the rocker panel drains on

the moulding by placing a small dot near the drain

plugs using a permanent marker.

3. Remove the rocker panel moulding (refer SIP if

required).

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

4. Remove the 4 side drain plugs (Part Number

92036150) and clean any dirt from the rocker panel

drain holes. Refer figure 2.

Fig 2 (there is only one plug shown in this photo)

5. Run water into the gap in the rear wheel house

panels to confirm the leak occurs in this area. This

will also flush any dirt from the rocker panel

preventing further blockage.

6. Check that the drain holes in the rocker panel are

clear.

7. Install four new drain plugs in the rocker panel (do

NOT re-use old plugs).

8. Dry around the gap in the rear wheel house and

seal using Dow Corning 795 grey sealant as

required.

9. File out sufficient material from the rocker

moulding at the previously marked drain locations

to provide clearance and prevent the moulding

from contacting and sealing the drain plug.

10. Refit the rocker panel moulding.

11. Repeat steps 1-8 for the opposite side if a water

leak has been reported on that side. If no water

leak has been reported check for a gap in the

panel sealing as described in Step 1 and seal if

required.

PARTS INFORMATION

Description Plug – Side Door Opening

Frame Hole

Part Number 92036150

Quantity 4 per side

WARRANTY CLAIM INFORMATION

Description Rocker Panel

Water Leaks

- RHS

Rocker Panel

Water Leaks

- LHS

Labour Op. No A000291 A000294

Time 0.6hrs 0.6hrs

Failure Code 87 87

SERVICE FIX

Console Storage Compartment Lid

Broken

(GROUP 1) TL472-0305

PROBLEM DESCRIPTION

Centre console storage compartment door

mechanisms (front and rear) are being broken in

service.

The main cause of breakage is that doors are being

forced open by pulling. The correct opening method

is to push the door and allow the opening mechanism

to function as intended.

PRODUCTION RECTIFICATION

To address the above problem, design changes have

been made which:

(a) reduce finger access to the top edge of the door

and

(b) strengthen the linkage arm pin.

The latest design storage compartment assemblies

can be identified by the rib added below each

mounting hole as shown in drawing below.

Revised storage compartment assemblies have been

fitted to vehicles from:

ISOVIN: Build Date:

6G1YL54A53L973271 11/02/2003

SERVICE RECTIFICATION

On complaint vehicles fit a new storage compartment

assembly of the latest design from HSPO.

PARTS INFORMATION

Part No.: Description: Qty:

92146467 Storage compartment

assembly -Front

92109643 Storage compartment

assembly - Rear

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

INFORMATION

MRA Removal Tool Modifications

VT, VX, VY, V2, WH, WK

(GROUP 8) TL490-0305

A design change to the Modular Reservoir Assembly

(MRA) scheduled for production commencement

29/5/03 will necessitate a modification to all existing

MRA service removal tools as detailed below.

The design change involves the addition of a locating

tab to the top of the MRA as shown in Figure 1. This

will provide a consistent orientation of the MRA when it

is installed into the fuel tank.

The design change will be implemented on all body

styles except ute.

LOCATING TAB

Figure 1.

PRODUCTION BREAKPOINTS

A production breakpoint for MRAs with locating tab is

not yet available. Details will be published in the

Breakpoint Summary when they are known.

ISOVIN: Build Date:

TBA TBA

MRA REMOVAL TOOL MODIFICATIONS

There are two versions of the MRA tool. They are part

numbers J39765 and AU 469.

1. Identify which leg requires modification by referring

to Figures 2 and 3.

2. Remove 3mm material (full depth of flange) as

shown in Figure 4 by machining or grinding.

3. Remove any sharp edges or burrs to prevent tool

binding on MRA when in use.

The modified tool is now compatible with MRA's with

and without the additional locating tab and should be

used in accordance with installation and removal

instructions in SIP.

Figure 2. Shows leg to modify on Tool J39765

Figure 3. Shows leg to modify on Tool AU469 (Note:

Photograph shows leg already modified)

Figure 4. Shows amount of metal to be removed.

(Applies to both tools.)

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

SERVICE FIX

Central Door Locking - Poor Range

MY02 TS Convertible

(GROUP 12) TL246-0305

PROBLEM DESCRIPTION

Some TS Astra convertible vehicles may experience

poor operating range of the central door locking system

when using the remote sender.

A revised central locking module and remote sender

have been developed to rectify this poor range issue.

The central locking module is located at the bottom of

the right hand “A” pillar as shown in Figure 1.

Figure 1.

The original module used a 315 MHz frequency remote.

The new module uses a 433 MHz remote sender

therefore it is important to ensure the correct remote is

obtained to match the revised module. If the incorrect

frequency remote sender is used, it will not be possible

to program using Tech 2.

The frequency is shown on the remote in following

location.

PRODUCTION RECTIFICATION

433 MHz modules have been fitted to vehicles from:

ISOVIN: Build Date:

W0L0TGF672B009028 31/01/2002

SERVICE RECTIFICATION

Summary: On complaint vehicles built prior to

Production Breakpoint replace 315 MHz Central Locking

Module (& remote) with 433 MHz module (& remote).

Before starting this procedure ensure that you have the

vehicle security code and both customer keys

1. To replace the central locking module, unclip the

front of the right hand side sill cover and remove the

Torx headed screw which secures the lower “A” pillar

cover.

2. Remove the Torx headed screw behind the blanking

plug in the front of the lower “A” pillar cover. Refer

Figure 2.

3. Once both these screws are removed the cover can

then be removed.

4. This will expose the central locking module which can

be detached from the “A” pillar by removing the two

plastic nuts.

5. Unplug the existing module and install the revised

433 MHz module.

6. Refit the “A” pillar and the sill covers.

7. Program the module and both remotes using Tech 2

updated with software version 10.9 or later.

IMPORTANT: The Central Locking module can only

be programmed once, therefore it is imperative that

the correct information is programmed into the

module.

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

The following defines the programming steps using

Tech 2.

Step 1

Step 2

Step 3

Step 4

Step 5

Step 6

Step 7

Step 8

Step 9

Main Menu

F0: Diagnostics

F1: Service Programming System (SPS)

F2: View Capture Data

F3: Tool Options

F4: Download / Upload Help

Vehicle Identification

Select one of the following

Model Year(s)

(2) 2002

(1) 2001

(Y) 2000

(X) 1999

(W) 1998

(V) 1997

Vehicle Identification

Select one of the following

Vehicle Type(s)

VX Commodore

VU Utility

WH Statesman & Caprice

VT Commodore

Corsa-B

Corsa-C

Astra-F

Astra-G

System Selection Menu

(2) 2002 Astra - G

F0: Engine

F1: Transmission

F2: Chassis

F3: Body

Vehicle Identification

Select one of the following

Body

Immobiliser

Airbag

Instrument

Engine Cooling Module

Add On Heater

Electronic Climate Control

Central Door Lock

Anti Theft Warning

Triple Info Display

Body

(2) 2002 Astra - G

Anti Theft Warning

Turn On Ignition

Confirm

Body

F0: Diagnostic Trouble Codes

F1: Data Display

F2: Snapshot

F3: Actuator Test

F4: Programming

Programming

F0: Erase Remote Keys

F1: Program Remote Keys

F2: Program Anti Theft

F3: Program Country Code

F4: Program Central Door Lock. System

Body

(2) 2002 Astra - G

Anti Theft Warning

Partnumber 13515B00

Identifier B0

Confirm

Body

(2) 2002 Astra - G

Anti Theft Warning

Partnumber 17157B00

Identifier B1

Confirm

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

Step 10

Step 11

Step 12

Step 13

Step 14

Step 15

Step 16

Step 17

Step 18

Your

vehicle

security

code

Program Central Door Lock. System

(2) 2002 Astra – G

Anti Theft Warning

Enter Security Code !

0000

Press ENTER key to continue

Program Central Door Lock. System

(2) 2002 Astra – G

Anti Theft Warning

Enter Security Code !

0000

Not Okay Okay

Program Central Door Lock. System

(2) 2002 Astra – G

Anti Theft Warning

Programming Active Please Wait !

Vehicle Identification

Select one of the following

Body

Immobiliser

Airbag

Instrument

Engine Cooling Module

Add On Heater

Electronic Climate Control

Central Door Lock

Anti Theft Warning

Triple Info Display

Programming

(2) 2002 Astra – G

Central Door Lock

Turn On Ignition !

Confirm

Your

vehicle

security

code

Program Central Door Lock. System

(2) 2002 Astra – G

Anti Theft Warning

Central Door Locking System

Programming Completed !

Confirm

Program Central Door Lock. System

(2) 2002 Astra – G

Anti Theft Warning

Please Reselect System !

Confirm

Body

F0: Diagnostic Trouble Codes

F1: Data Display

F2: Snapshot

F3: Actuator Test

F4: Programming

Programming

(2) 2002 Astra - G

Central Door Lock

Part number 13515B00

Identifier

Confirm

Programming

(2) 2002 Astra - G

Central Door Lock

Part number 17157B00

Identifier

Confirm

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

Step 19

Step 20

Step 21

Step 22

Step 23

Step 24

Step 25

Step 26

When you have finished programming, exit out of Tech 2

screens and disconnect the Tech 2.

Test the operation of both remote keys!!!

PARTS INFORMATION

The following parts have previously only been available

from TAS. They can now be purchased from HSPO.

Part No.: Description: Qty:

93174750 Central locking module

(433MHz)

09153235 Remote Sender

(433MHz)

WARRANTY CLAIM INFORMATION

Description R&R Central Door Locking

module(433MHz)

Labour Op.No. N000372

Time 0.6 hr

Failure Code 33

Program Remote Key

(2) 2002 Astra – G

Central Door Lock

Enter Security Code !

0000

Press ENTER key to continue

Program Remote Key

(2) 2002 Astra – G

Central Door Lock

Hold Remote Key To The Receiver And

Activate Several Times !

Your

vehicle

security

code

Programming

F0: Erase Remote Keys

F1: Program Remote Keys

F2: Program Anti Theft

Program Remote Key

(2) 2002 Astra – G

Central Door Lock

Enter Security Code !

0000

Not Okay Okay

Your

vehicle

security

code

Program Remote Key

(2) 2002 Astra – G

Central Door Lock

Do you want to Program the next remote

key?

NO Yes

Program Remote Key

(2) 2002 Astra – G

Central Door Lock

Remote Key Successfully Programmed !

Confirm

Program Remote Key

(2) 2002 Astra – G

Central Door Lock

Hold Remote Key To The Receiver And

Activate Several Times !

Program Remote Key

(2) 2002 Astra – G

Central Door Lock

Remote Key Successfully Programmed !

Confirm

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

INFORMATION

New Entertainment System Code Index

VY, V2 Series II

(GROUP 12) TL450A-0303

This Techline supercedes the previous one in Issue 3,

Mar, 2003. It is revised by adding Calais, CV8 and all

HSV to the table.

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

Due to a running change of components within the VY

and V2 Series II Blaupunkt Entertainment system it

has been necessary to add some additional code

indexes.

SERVICE RECOMMENDATION

When installing an upgrade or warranty replacement

radio, it is necessary to program the code index within

the unit to configure it to the particular vehicle.

To program the code index refer to PV SIP

Section 12D / Entertainment System / 3.11 Program /

F0: Program Code Index.

Use the following table to obtain the correct code

index.

• If the code index in the replacement radio is

between 001 and 006 use column A,

• If the code index in the replacement radio is

between 007 and 012 use column B, in the table

below.

Note: The vehicle description 8VK or 8VL refers to its

luxury level and is found on the Body and Option plate

which is located on the radiator support panel as can

be seen below.

Vehicle

CD unit

Code Index A

Code Index B

All 8VK (Executive, Acclaim, SS, CV6 etc) Except 8VK80

Single

001

007

All 8VK (Executive, Acclaim, SS, CV6 etc) Except 8VK80

6 Stack

001

007

All 8VL (Berlina)

6 Stack

001

007

8VK80 & 8VK03 (Ute / Cab Chassis)

Single

003

009

8VK80 & 8VK03 (Ute / Cab Chassis)

6 Stack

003

009

8VX (Calais / CV8) and All HSV

6 Stack

004

010

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

INFORMATION

Blaupunkt Audio Head Unit Displays

“MECH ERROR” and Won’t Accept CD’s

VY / V2II / WK (Six stack CD only)

(GROUP12) TL480-0305

PROBLEM DESCRIPTION

There have been several reports of Blaupunkt six

stack audio head units not accepting CD’s and LCD

display showing “MECH ERROR”.

The cause of this problem is that the transportation

locking pins have not been removed from the unit.

SERVICE RECTIFICATION

At PDI or after an exchange audio head unit has

been fitted, if it’s discovered that the unit will not

accept CD’s or the LCD displays shows “MECH

ERROR” perform the following operation.

Remove the audio head unit from the vehicle and

inspect the top panel to ensure that the three

transportation locking pins have been removed as

per the diagram below.

If transportation pins are found to be present perform

the following steps,

1. Remove the tape from location #1 (2 places) then

remove both rubber spacers.

2. Rotate transportation pin in location #2 counter

clockwise then remove from the unit.

3. If no transportation pins are present and the unit is

still faulting contact Blaupunkt on 1300 707 036

for diagnosis assistance.

Note: Even if the transportation pin in location #2 is

not obvious, look into the hole to ensure that it has

not been broken off. If the pin has been broken off

and is unable to be removed request a Change Over

unit from Blaupunkt (refer to DL 08/03 or the change

Over section in SIP).

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

SERVICE FIX

Rear Door Hard To Close, Water Leak Or

Seal Alignment

VY SEDAN AND WAGON

(GROUP 1) TL484-0305

PROBLEM DESCRIPTION

The rear door glass currently has one stop in the

front channel to stop the glass at the end of its run.

This allows the rear of the glass to over travel

deforming the door frame weather seal. Figure 1

shows the over- travel condition.

This condition can cause high closing effort for the

rear doors, water leaks and poor appearance.

Vehicles fitted with electric windows are more likely to

be affected due to the higher closing force of the

window.

Figure 1. Lift weather seal to inspect glass

alignment.

PRODUCTION RECTIFICATION

The rear run channel will be lanced to form a stop.

The Breakpoint is yet to be achieved and will be

advised when available.

SERVICE RECTIFICATION

Summary: On complaint vehicles install a window

stop to the rear door rear channel as per following

procedure.

1. Move the window to the lowest position.

2. Remove the door trim (refer SIP procedure).

3. Loosen the screws (#1) shown in Fig. 2.

4. Remove screw (#3) shown in Figure 2.

5. Work the top of the channel toward the centre of

the door so the stop can be installed as shown at

position 3 in Figure 2.

6. Re-secure the rear run channel.

7. Adjust the stop so the window stops level with the

rear fixed glass as shown in Figure 3.

8. Torque the adjusting screw to 1-2Nm and confirm

the correct stopping position has been achieved.

9. Confirm that original complaint has been

corrected.

10. Reinstall the interior door trim (the plastic shield

must be correctly installed and sealed).

Figure 2

Figure 3. Lift weather seal to inspect glass

alignment.

Rear fixed glass and window

glass must follow the same line

HOLDEN SERVICE TECHLINE___________________________________________________________________ MAY, 2003

PARTS INFORMATION

Part No.: Description: Qty:

90224863 Nut – Window Glass

Stop

92138330 Screw – Window

Glass Stop

WARRANTY CLAIM INFORMATION

Description Rear Window Stop - LHS

Labour Op. No. C000488

Time 0.5 hr

Failure Code 25

Description Rear Window Stop - RHS

Labour Op. No. C000485

Time 0.5 hr

Failure Code 25

HOLDEN SERVICE TECHLINE________________________________________________________________ JUNE, 2003

SERVICE FIX

DTC P0335 sets, CEL Illuminates

TS with Z18XE engine

(GROUP 6C) TL209A-0306

This Techline supercedes the previous one in Issue 1,

Feb, 2002. For all cases of DTC P0335 follow the

procedure in this updated techline.

PROBLEM DESCRIPTION

Engine DTC P0335 sets unecessarily. CEL (Check

Engine Light) on dash illuminates.

Investigations show this condition is caused by an

engine software calibration issue.

PRODUCTION RECTIFICATION

Initial rectification is being done at Port Of Entry. Final

rectification will be done at the Vehicle Assembly Plant

1. Port Of Entry.

A revised engine calibration has been reprogrammed

into vehicles at Port of Entry (POE) commencing from:

ISOVIN Date

- 6th June 2003

Vehicles with revised software can be identified by an

“X” in the B1 co-ordinate of the Service History Label

as per Figure 1.

2. Vehicle Assembly Plant

A breakpoint for introduction of the revised engine

calibration into vehicle production will be given in a

future Techline Breakpoint Summary.

FIGURE 1.

SERVICE RECTIFICATION

Summary: Reprogram ECU with TIS CD 42.0 or later.

1. On complaint vehicles, ensure that the ECU has

not already been programmed at Port Of Entry as

shown by a mark in the B1 co-ordinate of the

Service History Label.

2. Reprogram the ECU with revised software from

TIS 2000 CD 42.0 (Tech 2 software version 12.2).

IMPORTANT: If Tech 2 software version 12.2 is not

loaded, then Tech 2 will be unable to communicate

with the reprogrammed ECU.

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

fuse panel cover as shown in Figure 1 and mark

the B1 co-ordinate of the label.

WARRANTY CLAIM INFORMATION

Description Reprogram ECU - DTC P0335

Labour Op. No. J000707

Time 0.4 hr

Failure Code 57 Registers incorrectly

HOLDEN SERVICE TECHLINE________________________________________________________________ JUNE, 2003

INFORMATION

Clutch Master Cylinders with Adjustable

Pushrods - Precaution

VT, VX, VU, MY 2002 V2 – All with M/T

(GROUP 7A) Revised TL510-0306

This Techline supersedes the previous one in Issue 2,

February, 2001. It is revised by adding VX & V2 to

models, and breakpoint information on introduction of

non-adjustable pushrods.

SERVICE RECOMMENDATIONS

The clutch master cylinder adjustable type pushrod

should NOT be adjusted in any way.

The pushrod length is pre-set in master cylinder

production.

This dimension must remain unchanged to assure

correct clutch hydraulic system operation.

SERVICE RECTIFICATION

As there is a possibility that technicians may attempt

to adjust this pushrod length, the following Figure 1.

with correct setting dimension is provided only for

purpose of resetting.

Setting this dimension will require master cylinder

removal.

The dimension provided is specifically for VT, VX, MY

2002 V2 & VU models.

Figure 1.

The following information is provided for reference

only:

INTRODUCTION OF NON ADJUSTABLE

CLUTCH MASTER CYLINDER PUSHRODS

Non-adjustable master cylinder pushrods were fitted

to vehicles from:

VX, VU with V6:

Tag No.: Build Date:

L867739 18/05/02

VX, VU with V8:

Tag No.: Build Date:

L867195 18/05/02

V2: All from 2003 Model Year.

VY: All

Figure 2. Clutch Master Cylinder with Non adjustable

Push rod.

HOLDEN SERVICE TECHLINE________________________________________________________________ JUNE, 2003

SERVICE FIX

Gear Lever Rattle Caused By Remote

Shifter Linkage

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

(GROUP 7A) TL464-0306

PROBLEM DESCRIPTION

On some vehicles under certain driving conditions the

gear shift lever may rattle. This condition must not be

confused with a gear knob rattle/buzz which may

occur on some vehicles.

The cause of the rattle can be due to excessive

clearances in the remote shifter linkage mechanism.

PRODUCTION RECTIFICATION

Revised remote shifter assemblies to eliminate rattle

are planned for production around September 2003

timeframe. Breakpoint details will be provided at that

time.

SERVICE RECTIFICATION

As mentioned above, revised remote shifter

assemblies will not be available from the supplier until

around Sep. 2003. In the interim, Holden Service

Engineering has arranged the supply of revised shifter

assemblies which have been precision machined and

fitted with anti-rattle washers. These revised shifters

are available via an exchange program run by TAS.

Exchange Program Procedure.

1. To obtain a revised shifter assembly have your

nominated TAS contact person ring TAS to register

a case.

2. TAS will contact you when a revised shifter is

available and they will arrange to have it freighted

to your Retailership.

3. Retailer can then make a firm customer booking to

install the revised shifter.

4. Return the replaced shifter using the REPAC

return process, immediately the shifter is

removed.

Do not wait for the next REPAC report!

WARRANTY CLAIM INFORMATION

For vehicles repaired under warranty :

Description Replace transmission

remote shifter assembly

Labour Op. No. K000291

Time 2.7 hr

Failure Code 28 rattle

SERVICE FIX

Front Exhaust Pipe Heat Shield Vibrates

WK with Gen III

(GROUP 8) TL514-0306

PROBLEM DESCRIPTION

A buzz/vibration from front exhaust pipe heat shields

which occurs on takeoff under light loads such as

driving uphill.

For shield location refer to Figure 2, item 4.

The cause of the buzz has been traced to loose

insulation pads which are normally located as shown

in Figure 1. On complaint vehicles these pads may

become dislodged.

Figure 1. Location of insulator pads

PRODUCTION RECTIFICATION

Exhaust heat shields with revised adhesive for

attaching insulators have been fitted to vehicles from:

ISOVIN: Build Date:

6G1KY54F74L119610 12/5/03

SERVICE RECTIFICATION

Complaint vehicles can be rectified by fitting new heat

shields which are currently only available through

TAS.

To obtain new heat shields register a case with TAS

who will then arrange for shields to be forwarded to

your Retailership.

Update

HOLDEN SERVICE TECHLINE________________________________________________________________ JUNE, 2003

WARRANTY CLAIM INFORMATION

Description Replace front exhaust

heat shields

Labour Op. No. L000217

Time 0.5 hr

Failure Code 36 vibration

Figure 2. Item 4 = post catalytic converter heat shields

HOLDEN SERVICE TECHLINE________________________________________________________________ JUNE, 2003

INFORMATION

Change To Upper Radiator Shroud

Attachment on LHS

VTII, VX, VY, VU, V2, All with Gen III

(GROUP 6K) TL470-0306

PRODUCTION CHANGE

An additional fastener has been added to the left

hand side of the upper radiator shroud.

Revised shrouds with additional fastener on LHS

have been fitted to vehicles from:

ISOVIN: Build Date:

6G12X14F33L978113 19/02/2003

SERVICE REPLACEMENT

Whenever fitting a new shroud p/n 92160585 to a

vehicle built prior to the above breakpoint a hole will

need to be drilled in the body panel to take an extra

fastener.

Procedure.

1. Install the new shroud in position with 4 existing

fasteners.

2. Drill 8mm hole in panel at outer position as

shown in Figure 1. Ensure when drill breaks

through that it does not touch other components

underneath.

3. Apply rust inhibitng paint to exposed metal

surfaces.

4. Install new fastener as shown in Figure 2.

5. All labels from the old shroud should be

transferred to the new shroud. Fit new labels if

required. Refer Partfinder for correct label part

numbers.

PARTS INFORMATION

Part No.: Description: Qty:

92138218 Fastener 1

92160585 Radiator shroud

upper

Figure 1.

Figure 2.

HOLDEN SERVICE TECHLINE___________________________________________________________JULY, 2003

INFORMATION

DTC P0601 Sets After SPS Programming

Using TIS 2000 CD Version 42 & 43

VY V6 Cab Chassis

(GROUP 6C) TL535-0307

PROBLEM DESCRIPTION

It has been discovered that DTC P0601 (V6 PCM –

Powertrain Control Module Memory) sets after

performing SPS reprogramming of the Powertrain

Control Module (PCM) using TIS 2000 version 42 &

43.

The check powertrain lamp will illuminate

continuously and the DTC will not clear.

The cause of this DTC is a faulty calibration file,

which was released on TIS 2000 CD 42 & 43.

SERVICE RECOMMENDATION

It should not be necessary to reprogram the PCM in

any Cab Chassis, as there is no later calibration than

the one programmed in production.

The present calibration part numbers displayed on

TIS 2000 will be different between the Service and

Production calibration although the calibration is

identical.

SERVICE RECTIFICATION

If you believe that you need to replace or reprogram

the PCM in any V6 Cab Chassis a TAS nominated

contact should contact Holden Technical Assistance.

TIS 2000 version 44 will have revised software, which

will enable programming where required.

SERVICE FIX

Radio Popping Noise

(GROUP 12) TL520-0307

PROBLEM DESCRIPTION

Investigations show that the radio can experience a

“popping” noise heard through the speakers.

Investigations have found that the above condition;

• will only occur if the battery open circuit voltage

is low and,

• is initiated by pressing most buttons on the radio

after engine start up. Eg Station preset buttons.

Investigations have also shown that on vehicles with

the complaint condition, charging the battery to

maximum charge solves the problem.

SERVICE RECTIFICATION

Retailers are advised to check all new vehicles for

the problem during pre delivery.

If detected, charge the battery to maximum capacity

as per Retailer letter 82/00.

SERVICE PROCEDURE

Clutch Bleed Screw Correct Torque

All with Gen III V8 & MM6 M/T

(GROUP 7A) TL536-0307

PROBLEM DESCRIPTION

Excessive wear has been noticed on clutch slave

cylinder bleed screw seats, on warranty replaced

slave cylinders returned via REPAC. This is most

likely caused by over torqueing of the bleed screw.

SERVICE RECTIFICATION

Clutch slave cylinder bleed screws must be torqued

to the correct nominal torque of 18 Nm (tolerance:

15-20 Nm).

HOLDEN SERVICE TECHLINE___________________________________________________________JULY, 2003

SERVICE FIX

Front Door Wind Noise

V2, VY, WK

(GROUP 1) UPDATE TL350A-0307

This Techline supercedes the previous one in

Issue 9, Oct, 2002. It is updated by adding VY &

WK models and two additional causes of wind

noise.

PROBLEM DESCRIPTION

Customer complains of excessive windnoise (air

rush / turbulence) coming from the driver or

passenger doors.

Investigations show three major sources of wind

noise can be as follows:

Area 1. (Refer Figure 1)

A gap between the guide rail (forward edge) and

the glass can cause wind rush noise. Check for

gap over full length of window using a .05mm

feeler gauge.

Figure 1.

Area 2. (Refer Figure 2).

A gap between the B pillar weatherstrip and the

drop window guide rail can cause wind rush

noise.

The best method for checking this gap is to slide

a piece of paper (or business card) between the

window rail and B pillar weatherstrip as shown.

If the paper slides easily with no resistance then

a gap exists and must be rectified. If a slight

resistance can be felt for the full length of the

seal then no work is required in this area.

Figure 2. Check gap over full length of window

Area 3. (Refer Figure 3A and 3B).

A gap between the door frame weatherstrip and

the door panel at the bottom of the A pillar as

shown in Figure 3A can cause a wind rush

noise.

Figure 3B shows how the weatherstrip should

look when installed correctly.

Figure 3A. Incorrect installation (Gap showing)

Figure 3B Correct installation (No gap)

LH A Pilla

LH Front

Guard

Mirro

LHF Doo

HOLDEN SERVICE TECHLINE___________________________________________________________JULY, 2003

SERVICE RECTIFICATION

Summary: On any vehicle with front door wind

noise check the 3 areas described and rectify as

required.

Area 1.

If there is a gap as described above, carefully

apply a smear of urethane as required to

eliminate the gap.

Ensure all excess is wiped away.

Area 2.

If there is a gap as described above, remove the

B pillar moulding (refer procedure in PV SIP) and

proceed to adjust the B pillar weatherstrip until

the gap is eliminated. Use

If the weatherstrip does not have enough

adjustment, modify the slots as shown in Figure

5 to achieve the desired condition.

NOTE. The desired condition is achieved when

a slight resistance is felt whilst withdrawing the

paper.

Tighten screws and refit the B pillar moulding.

Operate the window and check that in the

upwards direction, the top edge of the guide rail

does not tend to “dig” into the B pillar

weatherstrip. If this occurs, use a nylon

hammer and carefully tap the very top edge of

the guide rail towards the window (away from the

weatherstrip). Refer Figure 6.

Area 3.

If there is a gap as described above, remove the

weatherstrip from the door frame and begin to

refit from the bottom edge of the door at the

lower A pillar. Figure 4 shows how the

weatherstrip should look when installed correctly.

PARTS INFORMATION

Part No.: Description: Qty:

92146444 Sealer urethane 300ml

tube

Figure 5. Modify 2 lower slots as shown only if

required to achieve correct adjustment.

Figure 6.

HOLDEN SERVICE TECHLINE___________________________________________________________JULY, 2003

INFORMATION

Adhesive Residue On New Vehicles

As Delivered From Port Of Entry

TS, XC, ZC

(GROUP 1) TL528-0307

PROBLEM DESCRIPTION

The above vehicles usually have a protective

plastic film on the horizontal panels to protect

them during shipping.

This plastic film is removed at Port Of Entry

(POE). Any traces of the adhesive used to apply

the film to the panel are also removed at POE .

However, there have been a few reports from

Retailers of new vehicles, during pre delivery

detailing, having traces of this adhesive on

panels. It is also reported that this material is

extremely hard to remove.

SERVICE RECOMMENDATION

Should vehicles be received “off the truck” with

adhesive residue marks on panels, immediately

remove with product such as Prepsol.

Failure to remove as soon as possible may

result in this residue “curing” onto panels thus

making future removal very difficult.

SERVICE FIX

Glovebox Lid Distorted

(GROUP 1) TL536-0307

PROBLEM DESCRIPTION

Some customers may report that the glove box

lid looks distorted particularly on the left hand

side.

PRODUCTION RECTIFICATION

The glovebox lid has been revised by adding

extra strengthening ribs and changing to a more

heat stable material.

Vehicles were fitted with revised glovebox

assemblies from:

ISOVIN: Build Date:

6G1YK52A73L982236 10 Mar 2003

SERVICE RECTIFICATION

On any vehicle with the above condition, install a

revised glovebox assembly which includes the

inner and outer panels. In Partfinder this

assembly is known as a “Compartment asm.

instrument panel”.

The lock assembly will need to be transferred

across from the old glovebox.

Refer to Partfinder for the latest part number

applicable to the trim colour in the customers

vehicle.

PARTS INFORMATION

Part No.: Description: Qty:

refer

Partfinder

Compartment assembly

instrument panel

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINE___________________________________________________________JULY, 2003

SERVICE FIX

Blaupunkt 520 / 2020 CD Player

Inoperative Due To CD Not Ejecting

SB / JR / JS / TS / TT / XC

(GROUP 12) TL479-0307

PROBLEM DESCRIPTION

Customers may complain of Blaupunkt 520 &

2020 CD players becoming inoperative due to

CD’s not ejecting.

After investigation into the root cause Blaupunkt

have made a software revision to rectify this

condition.

PRODUCTION RECTIFICATION

Blaupunkt implemented the software revision in

all CD player fitted to vehicles at the Port Of

Entry on the 1st of November 2001.

SERVICE RECTIFICATION

If you have a customer who presents a vehicle

with the above condition the following steps

should be performed.

Step 1. Determine if the CD player is pre

or post break point by removing it and inspecting

the bottom left corner of the label attached to the

top cover for the FD number. Refer photographs

below.

Pre breakpoint units have an FD number below

FD187. Post break point units have an FD

number FD187 or higher.

If unit is Pre breakpoint go to Step 2.

If unit is Post breakpoint go to Step 3.

Step 2. If the CD player is pre break point,

contact Blaupunkt as per the Special Warranty

Component Replacement Requirement

section in SIP and request approval to replace.

If your Retailship Outlet does not stock a

replacement CD player refit the original unit and

rebook the customer to enable fitment of the

new unit when it arrives.

Step 3. If the CD player is post break

point, removing it from the vehicle to inspect the

label will have rectified the condition

(disconnecting the power supply).

Refit the CD player, check the operation and

submit a PIR indicating the FD number on the

label and the serial number stamped into the

side of the CD player case.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINE___________________________________________________________JULY, 2003

DIAGNOSIS HINT

Rear Décor Panel Condensation

(GROUP 1) TL398-0307

PROBLEM DESCRIPTION

Some deck lid lamp and moulding assemblies

are being replaced unnecessarily when

condensation is apparent on the lens.

Because this moulding is vented to atmosphere,

small amounts of condensation may appear

depending on the relative humidity and

temperature conditions. This is a temporary

condition which will eventually disappear and

does not cause any adverse reaction.

NOTE: Normal condensation should not be

confused with the accumulation of water in the

bottom of the moulding. In these cases, damage

or poor sealing should be investigated.

SERVICE RECOMMENDATION

Diagnosis of Condensation.

Condensation can be defined as a visible

concentration of small droplets of water formed

in localised areas on the inside surface of the

lens, surrounded with fogging(misting).

Condensation is usually found in the corners with

little or no internal air flow, and towards the top

where the air is warmest.

Do not replace lamp and moulding assemblies

when condensation is apparent on the lens.

Diagnosis of Water Ingress

Where there is a collection of water on the

bottom surface of the moulding:

• check for poor sealing (incorrectly located,

damaged, perished or missing seals).

• check for damage to external surfaces

(cracks , chips, dents or gouges.

Repair or replace moulding / seals as necessary

to address water ingress.

PARTS INFORMATION

Part No.: Description: Qty:

92142116 Lamp & Moulding Asm –

deck lid

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

SERVICE FIX

Instrument Cluster Programming Error

Using Tech 2 Software Version 12.305

VY / V2II / WK

(GROUP 12) TL543-0308

PROBLEM DESCRIPTION

After programming the instrument configuration using

Tech 2 software version 12.305 from TIS CD 43.1 the

following icon is displayed on the Multi Function

Display and will not clear.

SERVICE RECTIFICATION

To rectify this condition perform the following steps;

Step 1.

Re-enter the configuration sub menu (an example

displayed below) within the instrument cluster

programming menu.

Step 2.

Scroll down to the Engine Type.

Step 3.

Select Modify, (there is no need to change anything).

Step 4.

Select Program.

This will rectify the condition. If any problems are

encountered using this method an alternate method is

to change the Tech 2 software back to 12.2 and

perform the standard configuration.

INFORMATION

Propshaft Front Coupling Improvements

VTII GenIII & M/T, Sedan & Wagon

(GROUP 4) TL346-0308

There has been an improvement to the rubber

material used on the propshaft front coupling on the

above models.

SERVICE RECOMMENDATION

Whenever a propshaft front rubber coupling

replacement is required use latest repair kit as shown

in Parts Information below.

The procedure for coupling replacement is found in

SIP as follows:

VT Series I/Section 4C – Propellor Shaft & Uni joints

/2 Service Operations/2.3 – Front Flexible Joint

PARTS INFORMATION

Part No.: Description: Qty:

92146806 Repair Kit Rubber

Coupling-

Parts Managers Note:

Any of the previous kits part number 92142811 should

be returned to HSPO for credit via the CRRM system.

Configuration

(4) 2004 WK Series

Instrument

Country

Australia/NZ

Engine Type V8

Speedometer

6301

SRS Configuration 6

Loop SRS

Transmission Type

Automatic

Occupant Climate Control Present

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

SERVICE FIX

Steering Gear Squeak

JR, JS, JS II

(GROUP 9) UPDATE TL504-0308

This Techline supercedes the previous one in Issue

11, Nov, 2001. It includes details of an oil additive

which provides additional resistance to squeaks.

PROBLEM DESCRIPTION

Customers may complain of a squeak noise from the

steering column/rack area when turning the steering

wheel from side to side. Dealer investigation narrows

the source of the squeak to the steering gear.

PRODUCTION RECTIFICATION

Revised pinion housing seals made of a different

material have been fitted to steering gears in

production from:

ISOVIN: Build Date:

W0L0JBF6817005134 06/09/00

SERVICE RECTIFICATION

For complaint vehicles built after the above

breakpoint or which have already had the rebuild kit

92144993 fitted, add 50 ml of oil additive p/n

90004033 to the power steering fluid.

___________________________________________

For complaint vehicles built prior to the above

breakpoint install a rebuild kit that contains the revised

seals as per following procedure.

1. Obtain a repair kit as detailed in the “Parts

Information” section and ensure the contents of the

kit are as follows:

a. 1 x Valve Housing

b. 1 x Lower Housing Pinion Seal

c. 1 x Needle Bearing Sleeve

d. 1 x Upper Housing Pinion Seal

e. 1 x Retaining Washer

f. 1 x Large O-ring

g. 2 x Retaining Clips

h. 4 x Small O-rings

NOTE. Parts (a) to (e) should already be assembled.

2. Remove the steering gear from the vehicle as per

the procedures detailed in the latest TIS2000 CD.

This repair should be conducted in a clean

environment to minimise the chance of

contamination.

3. Mark the steering gear pipes with a permanent

marker or paint pen to clearly identify where to

reinstall them.

4. Using a small hammer (16 oz or 450gm ball pein is

ideal), carefully tap the pipe retaining clips to

remove them from the steering gear body. Discard

these clips. Refer to Figure 1.

Figure 1

5. Remove the pipe retaining plate bolt from the pinion

housing using a Torx T30 bit. Remove the pipe

retaining plate from the steering gear.

6. Carefully pull the pipes from the steering gear body

and pinion housing. THESE PARTS ARE NOT

SERVICED SEPARATELY AND CANNOT BE

PURCHASED IF DAMAGED! Remove the sealing

O-rings from the pipes and discard them. Refer

Figure 2.

Figure 2

7. Remove the two bolts securing the pinion housing

to the steering gear body using 5mm internal hex

bit.

8. Twist the housing to break the seal and remove it

from over the pinion shaft. Refer to Figure 3.

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

Figure 3

9. Remove the large O-ring installed in the steering

gear body that seals the pinion housing and discard

it.

10. Locate the replacement large O-ring in the rebuild

kit and lubricate it with power steering fluid.

11. Carefully install the large O-ring over the spigot in

the steering gear body.

12. Inspect the seals fitted to the valve housing for

grease between the sealing lips. If none is present,

fill the space between the sealing lips with an

Extreme Pressure Grease to NLGI # 00

specification, such as Castrol EPL00.

13. Carefully fit the new pinion housing over the pinion

shaft.

14. Install the two bolts through the pinion housing and

into the steering gear body. Torque these bolts to

17 Nm.

15. Locate the replacement small O-rings in the rebuild

kit and lubricate them with power steering fluid.

16. Carefully install the small O-rings onto the steering

gear pipes.

17. Install the long pipe back into the correct ports in

the steering gear body and pinion housing.

18. Install the short pipe back into the correct ports in

the steering gear body and pinion housing.

19. Install the pipe retaining plate and bolt back onto

the pinion housing. Torque the retaining bolt to 12

Nm.

20. Locate the new pipe retaining clips in position on

the pipe to gear interface. Using the small hammer,

lightly tap these clips onto the rack until they are

home against the pipes.

21. Reinstall the steering gear into the vehicle as per

the procedures detailed in the latest TIS2000 CD.

22. Add rear axle oil additive part number 90004033 (50

ml) into power steering fluid.

PARTS INFORMATION

Part No.: Description: Qty:

92144993 Repair Kit – P/S 1

90004033 Oil additive-50ml

bottle. (Labelled as

Rear Axle Oil Additive)

WARRANTY CLAIM INFORMATION

For vehicles repaired under warranty.

Description Install Pinion Housing

Repair Kit & oil additive

Labour Op. No. M000184

Time 3.7 hr

Failure Code 40

Description Install oil additive only

Labour Op. No. M000196

Time 0.2 hr

Failure Code 40

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

SERVICE FIX

Ignition Key Can Be Removed In Any

Gear

DTC B3601 (Key Capture Relay Circuit

Malfunction) Present in CIM

ZC Vectra AF32 / AF22

(GROUP 12) TL550-0308

PROBLEM DESCRIPTION

Customers may report that they are able to remove

the ignition key with the gear selector in any gear. (ZC

Vectra is designed to stop the ignition key being

removed unless the gear selector is in park.)

When performing a DTC check Technicians may find

DTC B3601 Key Capture Relay Circuit Malfunction

present in the Column Integration Module (CIM).

CAUSE

If the ignition key is forced to the off position when the

automatic transmission selector is still in gear the key

capture relay will dislodge from the CIM and allow the

ignition key to be removed.

SERVICE RECTIFICATION

Summary. Relocate Key Capture Relay into the

Column Integration Module as follows.

1. Remove the upper and lower steering column

covers as per TIS 2000 and inspect the lower right

hand side of the CIM below the ignition barrel as per

Figure 1. below.

Figure 1.

Figure 2 below is a picture of the Key Capture Relay

when it is dislodged.

Figure 2.

2. Pushing up on the Key Capture Relay until a

click is heard will relocate it into the CIM as shown in

the picture below.

Figure 3.

3. When the Key Capture Relay is correctly

relocated reassemble the steering column covers as

per TIS 2000 and use Tech 2 to clear DTC B3601.

IMPORTANT NOTE FOR SERVICE ADVISORS:

Discuss with your customer the correct operation of the

ignition switch to avoid this problem reoccurring in the

future.

WARRANTY CLAIM INFORMATION

Description Refitting Key Capture Relay

Labour Op. No N000444

Time 0.5 hr

Failure Code 28 rattle

Key Capture Relay

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

SERVICE FIX

Front Exhaust Pipe Heat Shield Vibrates

WK with Gen III

(GROUP 8) REVISED TL514A-0308

This Techline supercedes the previous one in Issue 6,

2003. It includes additional service fix and parts

information.

PROBLEM DESCRIPTION

A buzz/vibration from front exhaust pipe heat shields

which occurs on takeoff under light loads such as

driving uphill. Refer to Figure 4 for location of shields

in question.

The cause of the buzz is a combination of loose

insulation pads and insufficient clearance between the

shields and exhaust support bracket. The insulation

pads are adhered to the shields as shown in Figure 1.

They may become detached and move around.

Figure 1. Location of insulation pads

PRODUCTION RECTIFICATION

Exhaust heat shields with revised adhesive for

attaching insulators have been fitted to vehicles from:

ISOVIN: Build Date:

6G1KY54R74L119610 12/5/03

SERVICE RECTIFICATION

To rectify a complaint vehicle proceed as follows.

A. For vehicles built prior to above breakpoint:

1. Fit a set of new heat shields obtained from HSPO.

2. Crimp shields together as described in Crimping

Procedure below.

B. For vehicles built after the above breakpoint:

1. Inspect heat shield insulation pads. If loose, brittle

or missing, fit new heat shields from HSPO.

2. Crimp shields together as described in the

following procedure.

Shield Crimping Procedure. (refer Figure 2 & 3)

At a distance of 10 to 15mm forward from the exhaust

support bracket, cut the flange of the upper shield

(use tin snips) then use multigrips to crimp the shields

together as shown.

NOTE: This crimping process only needs to be done

on the “inboard” side of the heat shields as shown.

Figure 2. Shows LHS heat shield assembly after

crimping flanges together.

Figure 3. Shows crimping of RHS heat shield

assembly. (Note. There must be clearance between

shield and bracket as shown).

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

Figure 4. Item 4 = heat shield

Item 5 = exhaust support bracket

PARTS INFORMATION

Part No.: Description: Qty:

92147239 Exhaust heat shield –

Right side (2 halves)

92147240 Exhaust heat shield –

Left side (2 halves)

WARRANTY CLAIM INFORMATION

Description Crimp front

exhaust heat

shields only –

both sides

Replace &

crimp front

exhaust heat

shields – both

sides

Labour Op.

No.

L000220 L000217

Time

0.3 0.5 hr

Failure

Code

36 vibration 36 vibration

HOLDEN SERVICE TECHLINE ________________________________________________________________ AUGUST, 2003

INFORMATION

Tow Bar Attaching Bolts

VY Regular Cab

(GROUP 1) TL539-0308

PROBLEM DESCRIPTION

Some Regular Cab vehicles were built with two M10

weldnuts in the rear frame crossbeam instead of

M12 weldnuts. These weldnuts are used for

installation of the towbar assembly 92160067.

NOTE: The towbar kit is only supplied with M12 bolts

Refer Figure below for location of the weldnuts

concerned.

PRODUCTION RECTIFICATION

M12 weldnuts have been fitted to the rear cross

beam on vehicles from:

ISOVIN: Build Date:

6G1YK03A73L141969 14/07/03

SERVICE RECTIFICATION

If, during installation of the towbar, it is observed that

the vehicle has M10 weldnuts the following action

should be taken.

Order two of part number 11091693 (M10 bolt) and

two of part number 11010024 (washer) from HSPO.

Install M10 bolts and washers in the location shown

below and torque to 60 Nm.

TORQUE M10 BOLT to 60 Nm

NOTE: Testing has shown it is acceptable to use

M10 bolts in the 2 locations in question provided the

specified bolts and torque are used.

PARTS INFORMATION

Part No.: Description: Qty:

11091693 M10 Bolt 2

11010024 Washer 2

Chassis Rear Cross Beam - Location Of Weldnuts Concerned.

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

SERVICE FIX

Cabin – Dust Entry

VU, VY Utility

(GROUP 1) TL509-0308

PROBLEM DESCRIPTION

Dust enters the cabin through gaps at the panel joins

in the B Pillar area.

PRODUCTION RECTIFICATION

Expanding sealer will be added to the panels in

production. Break Point summary will be updated

when information is available.

SERVICE RECTIFICATION

Summary: Seal pathways in the rocker panel and B-

pillar through which dust can enter the cabin. This

procedure may also help to prevent odours entering

the cabin.

Stage 1. - Blocking Rocker Panels - RHS & LHS

1. Remove the tonneau floor front and the both side

panel covers (Side panel covers shown Fig. 4)

2. Remove the Fuel Tank Asm in order to gain

access to the RHS rocker area ( refer SIP as

required )

3. Remove the tonneau floor drain tube and clamp

from both sides.

4. Identify the 50mm hole in the rocker panel,

shown in figure 1.

Figure 1. Blocking LHS Rocker Panel

5. The rocker panel is divided into two sections.

Inspect the inner rocker panel through the 50mm

hole and identify the second hole.

Note: For the service fix to be effective both

sections of the rocker must be filled with

expanding foam.

6. Use commercially available expandable

polyurethane foam such as Parfix "Foam Fix" by

Parburys available in a 340g container (or

equivalent). Be sure to follow the manufacturers

recommended safety procedures. Two cans may

be required to fill both sections.

7. Use a suitable solvent such as acetone for

cleaning any spillages.

8. Insert the extension tube, provided with the

expandable foam, through the second hole and

into the outer (closest to outer of vehicle) section

of the rocker panel.

9. Apply expandable foam as directed on can,

ensuring to move extension tube up and down to

fill rocker cavity completely from top to bottom.

10. Withdraw extension tube and fill the inner

(closest to centre of the vehicle) side of rocker as

shown in figure 1.

11. Repeat steps 8 - 10 for the opposite side rocker

panel, again ensuring that both sections of rocker

are completely filled.

12. Leave foam to cure and do not disturb.

Instructions on can will indicate when foam is dry.

Stage 2. Blocking the upper B-pillar areas.

1. Order 2 off large Butyl Patches 500mm x 120mm

from HSPO, P/N = 92156600.

Figure 2. Aluminium backed butyl patches used to

cover gaps.

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

2. Survey between the side panel inner and outer via

the side panel opening, using your fingertips to

locate the four panel gaps as shown in figure 3.

HINT: Locate corner A as shown in figures 3 & 4.

Use corner A as your reference then navigate to the

other positions using the joins and curves shown in

the attached photos.

Figure 3. Shows cutaway section of RHS B pillar

with external panel removed. Note the four gaps in

sheetmetal that need to be covered with patches.

Figures 6 and 7 show close up views of gaps.

Figure 4 Shows location of Corner A.

3. Clean the area around gaps 1 - 4 (refer fig. 3)

with prepsol to ensure the patches adhere

correctly.

4. Cut sections of butyl patch to cover each of the

gaps. Suggested sizes are-

Gap 1 - patch size = 50mm x 120mm

Gap 2 - patch size = 60mm x 150mm

Gap 3 - patch size = 50mm x 70mm

Gap 4 - patch size = 50mm x 50mm

5. Apply patches to each of the gaps as illustrated

in figure 5 (RHS of vehicle shown). Place patches

over the difficult to apply positions first (3 & 1).

Then place patches over positions (2 & 4)

Figure 5. Shows the four gaps covered with patches

6. As application of the butyl patches is a blind

operation, exact placement of patches will be

difficult. Apply additional patches as required.

7. With your index finger feel around gaps to ensure

that they are effectively covered and then push

on the patches to make them conform and

adhere to the sheetmetal.

8. Complete the sealing operation for both sides of

the vehicle.

9. Once sealing is completed, reassemble all

components removed.

Figure 6. Close up of gap 1 which is up against the B

-pillar. All of the area enclosed by the red line should

be sealed

Side Panel

Corner A

Corner

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

Figure 7. Gaps 2 and 4 are easy to reach,

whilst gap 3 is behind the drain tube.

PARTS INFORMATION

Part No.: Description: Qty:

92156600 Deadener - Rear

component lid panel

WARRANTY CLAIM INFORMATION

Description Dust Entry – Seal Panels

Labour Op. No. A000297

Time 1.5 hr

Failure Code 88 - Dust Leak

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

INFORMATION

Answering Customer Queries About Fuel

Consumption Labelling On New Vehicles

Passenger Vehicles

(GROUP OB) TL540-0308

The following information is provided to assist

frontline service staff when customers have concerns

that they are not achieving the fuel consumption

figures as shown on the label that was originally

attached to the inside of the windscreen on their new

vehicle.

• As from 1st Jan 2001 a new Australian Design

Rule (ADR 81/00) came into effect which requires

every new vehicle built to have a fuel consumption

label attached to the inside of the windscreen.

• The primary intention of the labelling is to provide

prospective new car buyers with a means of

comparing the fuel consumption of different

vehicles that have been tested to a standardised

procedure.

• The figure shown on the label is the fuel

consumption that model vehicle achieves (on

average) when tested on a dynamometer to the

City Cycle procedure of Australian Standard

AS2877 for Fuel Consumption Testing.

• An owner may experience different figures to

those on the label depending on driving habits,

driving conditions and condition of the vehicle.

A study conducted for the former Department Of

Primary Industries and Energy, found that on

average, drivers may use up to 15% more fuel than

the published figures for city cycle driving

conditions.

Please ensure that all your Sales, Service and

Predelivery staff are made aware of the above

information.

Note: Further information on this topic can be

accessed via the Holden Lionheart Portal on your

retailers PC. On the menu page, go to the section

titled “Useful Links” and select “Australian

Greenhouse Office Fuel Consumption Guide.

This will take you to the website

www.greenhouse.gov.au

SERVICE FIX

Cruise Control Returns To Set Speed

Too Rapidly

ZC Vectra with Z32SE

(GROUP 12) TL552-0308

PROBLEM DESCRIPTION

Some customers may report the following condition

which occurs whilst driving with cruise control set -

After the vehicle loses speed while driving uphill, it

then accelerates too rapidly back to the set speed.

Another customer description may be that when they

press the resume switch to return to the previously

set speed the vehicle accelerates too quickly.

SERVICE RECTIFICATION

A revised engine calibration has been developed to

address this condition and is available on TIS CD

43.1.

The new calibration can be down loaded via the

standard Service Programming System (SPS)

method.

IMPORTANT

Always ensure the latest Tech 2 software from

TIS is loaded into your Tech 2 before attempting

any reprogramming using SPS method.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD.

Update

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

SERVICE FIX

Gear Shift Lever Rattle/Buzz caused by

- Knob and/or

- Remote Shifter Linkage

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

(GROUP 7A) REVISED TL464A-0308

This Techline supercedes the previous one in Issue

6, 2003. It is revised by addition of a detailed rattle

diagnosis procedure and recommendations for fixing

gearshift knob rattle.

PROBLEM DESCRIPTION

During acceleration in any gear a rattle noise may be

emitted from the gear knob and shifter area. The

noise is usually more prominent when vehicle is cold.

There are two possible sources of this noise:

Gear Knob rattle: - this is a plastic rattle sound

Shifter Linkage: - this is a metallic rattle sound

SERVICE RECTIFICATION

Summary: Correctly identify the source of the rattle

(knob or shifter Linkage) and rectify as explained

below.

Gear knob rattle

Gear knob rattle can be heard during heavy

acceleration above 3000rpm in any gear. While

accelerating, twist the gear knob clockwise or anti-

clockwise then slowly release the knob – if the rattle

is reduced or eliminated – this confirms the gear

knob is rattling. This test is best done with a cold

vehicle, as it is much easier to reproduce the rattle

when cold.

When the rattle is confirmed as coming from the gear

knob, proceed as follows.

For VT/VX: Glue the gearshift knob to the lever as

described in Techline in Issue 2/2002.

For VY: Install a new gear knob and lever assembly

from HSPO. These parts have glue added internally

to stop rattles, and are identified by two white paint

dots on the metal shaft of the lever.

IMPORTANT. Gear knob rattle is more intrusive

than shifter linkage rattle. Therefore, correctly

identifying gear knob rattle and rectifying as

described above will have the greatest impact on the

condition described above.

Shifter Linkage Rattle

The shifter linkage rattle occurs mainly during heavy

acceleration in 3rd or 4th gear above 2500rpm. The

rattle is more prominent if you touch the back of the

gear knob with your finger when in 3rd gear, or when

you touch the front of the gear knob with your finger

when in 4th gear. It is recommended that this test be

done with a known non-rattling gear knob/lever fitted,

so that no confusion exists.

Once shifter linkage rattle is confirmed with a non-

rattling gear knob, contact TAS as per following

procedure for supply of a revised shifter assembly.

NOTE: These shifter assemblies have been precision

machined and fitted with anti-rattle washers.

TAS Shifter Exchange Program.

1. Your nominated TAS contact person should

ring TAS to register a case.

2. TAS will contact you when a revised shifter is

available and they will arrange to have it freighted to

your Retailership.

3. Retailer can then make a firm customer

booking to install the revised shifter.

4. Return the replaced shifter using the REPAC

return process, immediately the shifter is

removed. Do not wait for the next REPAC report!

5. Please fill out ALL details on the return

paperwork supplied with the shifter for closure of

your TAS case and to ensure no parts charge is

levied against your Service Department.

WARRANTY CLAIM INFORMATION

For vehicles repaired under warranty :

Description Replace transmission

remote shifter assembly

Labour Op. No. K000291

Time 2.7 hr

Failure Code 28 rattle

Update

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

SERVICE FIX

Holden Assist Receives Invalid Location

Information From Vehicle

VY / V2II / WK with Telematics

(GROUP 12) TL538-0308

PROBLEM DESCRIPTION

Some customers may report that Holden Assist has

advised them that invalid location information is being

received from their vehicle.

The cause for this condition has been traced to a

defect in Telematics software version 001.000.005

when subjected to low GPS signal strength.

This defect causes the Telematics module to transmit

invalid location information when the Holden Assist

button is pressed.

PRODUCTION RECTIFICATION

Software revision 001.000.010 introduced into vehicle

production to rectify this condition from:

ISOVIN: Build Date:

6G1YX54F63L137064 23/06/03

SERVICE RECTIFICATION

If a customer reports the above problem and the

vehicle is built prior to the above breakpoint, install

new software into Telematics module with Tech 2 as

per the following procedure.

IMPORTANT: The following procedure can only be

performed using Tech 2 software version 12.305

from TIS CD 43.1. (or later)

1. Access the Telematics with Tech 2. by making

the following selections:-

Model Year / Vehicle Type / F1:Body /Telematics

Module

If the Telematics module has version 001.000.005

software (old) the following screen will appear.

2. To reprogram the module return to the main

menu as shown in next screen and select “F1:

Service Programming System (SPS)”.

3. The following screen will be displayed on Tech 2.

Follow the screen prompts, and request info from the

Telematics module by selecting “F0: Request Info”.

4. Make the following selections appropriate to the

vehicle being reprogrammed.

Model Year /Vehicle Type / F1:Body / Telematics

Module

5. When prompted by Tech 2 go to your PC,

open TIS 2000 and enter the SPS application

from the main menu.

6. Follow the standard SPS prompts ensuring that all

vehicle information is correct for the vehicle you are

programming.

7. Once the programming information has been

downloaded into Tech 2 return to the vehicle and

follow the screen prompts as per the standard SPS

process.

8. When the programming process is complete,

Tech 2 will prompt to select the continue soft key, and

the following screen will be displayed.

Body

(4) 2004 WK Series

Telematics Module

Use Service Programming System (SPS) to Program this

ECU before Continuing !

Software Version Number 001.000.005

Confirm

Main Menu

F0: Diagnostics

F1: Service Programming System (SPS)

F2: View Capture Data

F3: Tool Options

F4: Download/Upload Help

Service Programming System (SPS)

Version 2.021

F0: Request Info.

ECU to be programmed must be installed before request info.

Tech 2 is ready to request data from the vehicle!

Service Programming System (SPS)

Version 2.021

F0: Request Info.

ECU to be programmed must be installed before request

info.

Tech 2 is ready to request data from the vehicle!

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

9. When this screen is displayed select the EXIT key

to return to the Main Menu.

10. At this stage the programming process is

complete and you will be able to communicate with

the Telematics module.

11. Using Tech 2 access the Telematics module by

making the following selections;

Model Year / Vehicle Type / F1:Body / Telematics

Module

12. Check the VIN number. If different to vehicle

VIN, you will require a Change Over module from

Australian Arrow, which can be obtained via the

standard Change Over process.

13. The Telematics module will automatically be left

in SERVICE mode after completing the programming

process.

NOTE: The vehicle should be returned to the

customer with the Telematics system in the same

operating mode as it was delivered to your

retailership. If unsure which mode the Telematics

module was in when it arrived at your retailership, it

should be left in SERVICE mode.

WARRANTY CLAIM INFORMATION

Description Reprogramming

Telematics Module

Labour Op. No. N000438

Time 0.3 hr

Failure Code 57 Registers Incorrectly

SERVICE FIX

Engine Cover to Clutch Hose Rattle

VT, VX, VU, V2 with LS1 (Gen III) V8

(GROUP 6A) TL542-0308

PROBLEM DESCRIPTION

An engine cover “rattle” may occur in vehicles built

with a plain clutch hydraulic hose and clamps (built

prior to L867194).

This hose may twist and rub against the engine

cover, creating an engine cover “rattle” noise.

PRODUCTION RECTIFICATION

A convoluted hose with ‘quick-connect’ fittings,

allowing stress-free positioning of the hose, has been

fitted in production from:

ISOVIN: Build Date:

6H8V2X37F2L867194 22/5/2002

SERVICE RECTIFICATION

Summary: Fit a new Clutch Hose Asm.

If the above condition is confirmed – replace the

existing plain hose and its two clamps with a

convoluted hose p/n 92145810. This hose is a “snap

fit” onto the existing fittings and needs NO clamps to

retain it. These “snap fit” connections allow the hose

to rotate freely to an unstressed position, clear of the

engine cover.

PARTS INFORMATION

Part No.: Description: Qty:

92145810 Hose Asm. - Clutch. 1

WARRANTY CLAIM INFORMATION

For replacement of plain clutch hose with convoluted

hose – use existing clutch hose labour operation

number and time in the current PV SIP CD.

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

SERVICE FIX

Engine Cover Rattle Noise

V & W Models with LS1 (Gen III) V8

(GROUP 6A) UPDATE TL523-0308

This Techline should be used in conjunction with the

previous Techline on this topic (Issue 5, Nov. 2002),

Additional information is supplied together with a NEW

Labour Operation No. for use with both Techlines.

PROBLEM DESCRIPTION

Engine cover “rattle” at idle, or just above idle speed.

This rattle is caused by the engine cover contacting

components under the cover, or the engine cover not

being restrained firmly by the rubber bumpers on which

it is located.

SERVICE RECTIFICATION

Summary: Ensure latest type rubber bumpers are

fitted, and add four foam damper pads.

NOTE: The following procedure is condensed from the

Nov., 2002 Techline, as most engine cover rattle

complaints will have been addressed by that bulletin.

The following procedure is for complaints of “engine

cover rattle” noise on any Gen III V8:

1. Remove four engine cover retaining nuts and

remove the engine cover.

2. 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, Section A-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.

3. Ensure the “new” design bumpers are

fitted – as per Figure 1 below.

4. Fit four self adhesive foam pads, 92087589 to

underside of engine cover in locations as shown in

Figure 2 below, locations A, B, C, D. To fit the pads,

remove the protective film from the adhesive side of

the foam pad.

5. Re-fit engine cover. 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. (see

separate Techline bulletin regarding Engine Cover

to Clutch Hose “Rattle”).

Fit and Torque the four engine cover retaining nuts to

8-12Nm.

Figure 1.

HOLDEN SERVICE TECHLINE_________________________________________________________________AUGUST, 2003

Figure 2 – Underside of Engine Cover.

WARRANTY CLAIM INFORMATION:

Use the following information:

Description Fit Engine Cover Rattle Fix Parts

Labour Op. No. J000725

Time 0.3 hr

Failure Code 28 (Rattle)

NOTE: the above Labour Operation No. replaces the

previously used Labour Operation No. J000651 as

given in previous Techline on this topic (Issue 5, Nov.

2002). J000651 can no longer be used.

PARTS INFORMATION

In addition to the parts quoted in the Nov., 2002

Techline, use:

Part No.: Description: Qty

92087589 Damper, Engine Cover 4

HOLDEN SERVICE TECHLINE______________________________________________________________SEPTEMBER, 2003

SERVICE FIX

Front Suspension Noisy – Strut Dust

Cover Fouls On Strut Tube

TS Astra

(GROUP 3) TL560-0309

PROBLEM DESCRIPTION

The dust cover section of the upper spring seat

contacts the strut tube, making a scraping noise over

bumps.

The cause of this condition is misalignment of the

upper front spring seat during assembly.

Figure 1 shows the condition.

Figure 1

PRODUCTION RECTIFICATION

Upper spring seat revised to eliminate misalignment

during assembly on vehicles from.

ISOVIN: Build Date:

W0L0TGF4835227725 10/06/03

SERVICE RECTIFICATION

Summary: Re-align upper spring seat as per following

procedure.

1. Inspect the dust cover.

2. If cover is undamaged, go to step 3.

NOTE: If the dust cover is damaged, the spring seat

upper should be replaced. Replace as per TIS and

ensure correct alignment is achieved as follows.

3. Remove strut from the vehicle as per TIS.

4. Use a spring compressor to relieve the tension on

the spring as per TIS.

5. Once the tension on the spring is relieved, the

upper spring seat (including dust boot) will be

able to be rotated so that the dust cover is parallel

to the strut tube as shown in figure 2.

Figure 2

6. Release spring compressor and re-install strut

into vehicle as per TIS.

7. Perform a wheel alignment on the vehicle.

PARTS INFORMATION

Part No.: Description: Qty:

90468618 Seat-front spring,

upper

WARRANTY CLAIM INFORMATION

Description Boot/Bumper, piston rod-

Replace

Labour Op. No. E130210 (RHS), or

E130220 (LHS)

Time 0.9 hr

Failure Code 25 misaligned

Description Wheel Alignment

Labour Op. No. P201120

Time 0.7 hr

Failure Code

HOLDEN SERVICE TECHLINE______________________________________________________________SEPTEMBER, 2003

SERVICE FIX

Seat Height Adjuster Inoperative –

Disengaged Thread

VX, VY, V2, VU & WH

(GROUP 01) TL537-0309

PROBLEM DESCRIPTION

The seat height adjuster becomes inoperative due to

the adjusting shaft dislodging from the clevis (plastic

type). NOTE. The plastic clevis nut was introduced into

seats in mid 2000.

PRODUCTION RECTIFICATION

A new seat base assembly featuring a metal clevis nut

was introduced from the breakpoints shown below.

The new seat base is currently not interchangeable with

the pre B/P seat base.

Vehicle Breakpoints:

VY 31/3/03

WK Start of production

VY ute 20/5/03

V2 Series III Start of production

SERVICE RECTIFICATION

Install the metal clevis nut to seat if the plastic clevis

nut has failed as per following procedure.

1. Operate the seat height adjustment to the highest

upward position.

2. Remove the seat assembly refer to the appropriate

section of SIP if required.

Note: Be careful not to scratch any interior trims when

removing and installing the seat, use a guard cover to

protect the trims if required.

Note: Pay special attention to the instructions for the

deactivation of the side air bags (if fitted)

3. Cover a cleaned workbench with a clean soft cloth

or clean cardboard to avoid damage to the seat

cushion material. Refer diagram 1.1.

4. Place the seat on the workbench with the cushion

facing downwards. Add a piece of cardboard or rag

on the seat cushion under the seat drive motor to

aid in retrieving any parts that might fall.

5. Locate the Clevis nut located on the seat track

mechanism (refer diagram 1.2). Using a small

sharp cold chisel, shear off the Clevis nut retaining

pin “staking” (refer diagram 1.2) on both sides of

the retaining pin. Note: You many have to turn the

retaining pin to access the staking on the underside

of the pin. Using a small flat blade screwdriver “pry”

the locking tab for the retaining pin away from the

pin square head. The retaining pin can now be

turned using a 10mm open spanner.

6. Once the Retaining pin “staking” has been

removed, knock the pin through the mounting

bracket using a suitable pin punch and hammer.

Refer diagram 1.3

Clean

protective

covering Drive motors

1.1

Nylon

Clevi

s nut

Retaining

Small sharp

cold chisel

1.2

1.3

Pin Punch

HOLDEN SERVICE TECHLINE______________________________________________________________SEPTEMBER, 2003

7. Using a flat blade screwdriver “pry” the Clevis nut

out of the mounting on the seat track.

Note: Avoid damaging the Clevis bracket tab. Refer

to diagram 1.5.

8. Unscrew / remove the Clevis nut from the electric

seat motor spindle in an anti-clockwise direction.

9. Grease the electric seat motor spindle and Clevis

pivot hole with High Temperature / Pressure

Grease.

10. Using Vise grips flatten the retaining pin locking

tab, on the inner of the bracket only, to allow later

assembly of the 8mm internal locking star washer

(Refer to diagram 1.5)

11. Screw the new metal (service pack) Clevis nut ½

way onto the electric seat motor spindle.

12. Place the Clevis nut into the mounting bracket with

the stop plate facing downwards towards the seat

cushion (refer to diagram 1.7). Move the retaining

pin mounting (pivots) until the Clevis nut pivot hole

lines up.

13. Insert the new retaining pin (service pack) through

the Clevis nut mounting (refer diagram 1.6 for pin

fitment direction). Move the retaining pin locking tab

(moved away at step 5) into a position to lock the

square head of the retaining pin.

14. Support the retaining pin head with the end of a flat

blade screwdriver (refer to diagram 1.6). Fit the

retaining pin 8mm internal locking star washer

(from service pack) over the retaining pin end.

Using a 10mm extra deep socket and your hand

push the locking washer all the way towards the

Clevis nut mounting face. Refer to diagram 1.6.

15. If the Clevis bracket tab was bent during initial

retaining pin removal gently tap it back into position

using a hammer. Refer to diagram 1.7.

16. Following steps 5 through 15 replacing the other

Nylon Clevis nut.

17. Refit the seat to the vehicle as described SIP.

PARTS INFORMATION

Part No.: Description: Qty:

92147358 Kit Clevis Nut

(One kit does one

seat)

WARRANTY CLAIM INFORMATION

Description Clevis Nut Kit

C000493 - RHF

Labour Op. No. C000496 - LHF

Time 1.0 hr

Failure Code 07 Stripped

Limiting stop plate facing

towards cushion

1.7

Clevis bracket

tab

1.5

Locking tab

Retaining pin

locking

washer side

1.6

Screwdriver

10mm Extra deep

socket

Pin fitment

direction

Clevis nut

mounting

1.4

HOLDEN SERVICE TECHLINE______________________________________________________________SEPTEMBER, 2003

SERVICE PROCEDURE

Access To Differential Oil Filler Plug

VY Regular Cab

(GROUP 4) TL554-0309

If difficulty is experienced in accessing the differential

oil plug due to the location of the Load Sensing Valve

(LSV) chain, the following procedure is

recommended to access the plug.

• Remove the nut which attaches the LSV chain

bracket to the Diff. housing bracket and swing the

bracket with chain attached out of the way.

The following photograph shows the nut to be

removed.

• When reattaching the chain bracket, torque the

attaching nut to 5 – 8 Nm.

IMPORTANT:

1. DO NOT bend the chain to gain access to the

plug

2. DO NOT remove the chain adjuster from its

bracket.

Either of these actions may alter the adjustment of

the load sensing valve.

SERVICE FIX

Insufficient Clearance Between Tow Ball

And Number Plate Support

VY Regular Cab fitted with Triple M tray

(GROUP 1) TL558-0309

PROBLEM DESCRIPTION

On some vehicles fitted with a Holden towbar and

Holden endorsed Triple M tray (manufactured prior to

mid August 03) there is insufficient clearance between

the tow ball and the number plate support. This may

result in the tow bar hitch fouling the number plate

support.

SERVICE RECTIFICATION

If you have a vehicle with the above condition, contact

Triple M Holdings P/L on freephone 1800 773 030 to

obtain two longer number plate support mounting

brackets and mounting bolts.

The effect of fitting these longer brackets is that the

number plate support member is moved towards the

front of the vehicle by 80mm thereby eliminating the

above condition. Refer photograph below.

PRODUCTION RECTIFICATION

The above condition was rectified on Holden

endorsed Triple M trays from mid August by fitting the

longer (180mm) number plate support brackets.

WARRANTY CLAIM INFORMATION

Description Fit revised number plate support

brackets to Triple M tray – both

sides

Labour Op. No. R000112

Time 0.4 hr

Failure Code 62 Improper clearance

HOLDEN SERVICE TECHLINE______________________________________________________________SEPTEMBER, 2003

INFORMATION

Tail Lamps Revised – Additional Datum

VY Sedan

(GROUP 12) TL551-0309

The tail lamp housing has been modified as follows

to improve fitment of the tail lamp during vehicle

assembly.

♦ A second datum pin has been added to the lower

section of the housing. NOTE; a matching hole

for this datum pin has been added to the rear

quarter panel.

Figure 1. Rear of tail lamp showing position of 2nd

datum pin

PRODUCTION BREAKPOINT

Tail lamps with the additional datum pin have been

fitted to vehicles from:

ISOVIN: Build Date:

* * * * * * * * * * L150811 22/07/03

SERVICE REPLACEMENT LAMPS

All replacement tail lamps supplied from HSPO will

have the second datum pin as described above.

When fitting a new tail lamp to a vehicle built prior to

the breakpoint the 2nd datum pin on the new tail lamp

assembly will need to be removed. This can be done

using a pair of side cutters. Figure 2 shows pin after

removal.

Figure 2. Shows datum pin cut off flush with the

outer ring

When fitting a new tail lamp to a vehicle built after the

breakpoint the datum pin does not need to be

removed.

HOLDEN SERVICE TECHLINE______________________________________________________________SEPTEMBER, 2003

SERVICE FIX

Front Bumper Extension (Skirt) Loose or

Detached

XC, TS, TT

(GROUP 1) TL544-0309

PROBLEM DESCRIPTION

Front bumper extension (lower rubber skirt) dislodges

from the bumper fascia.

This condition is a result of the extension coming into

contact with obstacles such as concrete parking

barriers, steep driveways etc.

SERVICE RECTIFICATION

Summary: For those customers who frequently

dislodge the front bumper extension as described

above, it is recommended to add additional fastening

to the new extension as per the following procedure.

For TT models only. - Remove front brake air ducts

from both sides before commencing.

Step 1. - Add screw and nut at either end of

bumper extension.

1a. Drill a 5 mm hole through the bumper

extension and fascia at location shown in Fig 1

approx 60mm from end of extension. (To avoid

slipping of the drill bit, drill a 2mm pilot hole

first.)

1b. Insert screw 92138639 upward through hole

and tighten with nut 92138265.

1c. Repeat for other side of car.

Step 2. - Install plastic rivets to bumper extension.

2a. Drill an 8mm hole adjacent to each of the

normal attaching points as shown in Figures 1

and 2. (To avoid slipping of the drill bit, drill a

2mm pilot hole first.)

2b. Insert rivets 90087290 upward through the

8mm holes as shown in Figure 2.

Figure 2. Shows a plastic rivet installed next to the

normal skirt attaching lug.

PARTS INFORMATION

Part No.: Description: Qty:

ref Partfinder Extension - XC, TS, TT

92138639 Screw 2/car

92138265 Nut 2/car

90087290 Rivet 10/car

Figure 1. Shows location of plastic rivets and screw on RHS half. - (Same for LHS)

LOCATE PLASTIC RIVETS

ADJACENT TO NORMAL

ATTACHMENT POINTS

LOCATE SCREW

APPROX 60mm

FROM END OF

FASCIA

HOLDEN SERVICE TECHLINE______________________________________________________________SEPTEMBER, 2003

SERVICE FIX

Power Steering Rack Bellows Heat

Affected

V & W with Gen III engine

(GROUP 9) TL415-0309

PROBLEM DESCRIPTION

On some vehicles the steering rack bellows may be

affected by excessive radiated heat from the exhaust

system. HSV vehicles which feature extractor

systems may be more prone to this condition.

To address this condition new bellows containing

silicone are now available as a service replacement

part.

SERVICE RECTIFICATION

On vehicles where one or both bellows have been

affected by heat, install two new bellows part number

92146712.

Refer to PV SIP CD for procedure on bellows

replacement.

PARTS INFORMATION

Obtain the following parts from HSPO.

Part No.: Description: Qty:

92146712 Bellows Tie rod 1

WARRANTY CLAIM INFORMATION

For vehicles repaired under warranty use Labour

Times information in Warranty Information section of

current PV SIP CD

HOLDEN SERVICE TECHLINE______________________________________________________________SEPTEMBER, 2003

DIAGNOSIS HINT

Holden Assist Receives Invalid Location

Information From Vehicle – Summary of

Causes

VY / V2II / WK with Telematics

(GROUP 12) TL563-0310

PROBLEM DESCRIPTION

Some customers may report that Holden Assist has

advised them that invalid location information is being

received from their vehicle.

There are three known possible causes for this

problem as described below.

Cause #1 - Software

This condition has been traced to a defect in

Telematics software version 001.000.005 when

subjected to low GPS signal strength. This defect

causes the Telematics module to transmit invalid

location information when the Holden Assist button is

pressed.

Cause #2 – Connector disconnected

The Telematics antenna has two functions, one

function is to send and receive GSM (digital phone)

signals, the other is to receive the GPS (satellite)

signal.

In the Telematics system there is a remote lead

which connects the Telematics antenna to the

Telematics module. Located near the antenna end of

this lead is an in-line connector (taped over) as shown

in Figure 1.

On some Telematics antenna’s this in-line connector

has become disconnected causing the Telematics

antenna to be separated from the Telematics module.

Figure 1

Cause #3 – Terminal Crimping

At the Telematics module end of the Telematics

antenna lead there is a terminal, which is crimped on

to the coaxial cable. During the manufacture of this

lead the terminal in some instances has been over

crimped causing a short between the centre core and

the outer shield of the coaxial cable.

SERVICE RECTIFICATION

Cause #1

Follow Techline issue 8 page number 17.

Cause #2 & Cause #3

The most effective diagnosis for both of these

problems is to plug a new antenna into the Telematics

module, this should be done prior to disassembling

the vehicle to confirm the Telematics antenna is at

fault.

Note: Once the Telematics antenna is connected

allow up to1.5 hours to gain a location. Location

information can be displayed using Tech 2 referring to

the GPS data list.

If location information is still not displayed on Tech 2,

a nominated contact should contact Technical

Assistance (TAS).

SERVICE PROCEDURE

Reflash Procedure Precaution

TS & XC with Z18XE Engine

(GROUP 6C) TL569-0309

PROBLEM DESCRIPTION

Following reflashing/reprogramming an ECU in a

Z18XE engined vehicle, Diagnostic Trouble Codes

(DTC’s) relating to the Electronic Throttle Control

(ETC) may be set and driveability issues may be

experienced.

SERVICE RECTIFICATION

Following reflash/recalibration:

1. Key Ignition OFF for 10+ seconds;

2. Key Ignition ON (engine NOT started) for an

additional 10+ seconds.

These steps allow sufficient time for the ETC to

perform self-tests and relearn its default positions.

If these steps are not followed – and DTC’s set or

driveability issues are experienced, - turn the engine

OFF and perform the steps 1 & 2 above, then with

Tech-2 – proceed to clear all DTC’s stored in the ECU

and TCM.

HOLDEN SERVICE TECHLINE______________________________________________________________SEPTEMBER, 2003

SERVICE FIX

Cruise Control Accelerates To Set Speed

Too Rapidly

ZC Vectra with Z32SE (Except Automatic

Transmission part number 09186327 JA)

(GROUP 12) REVISED TL552A-0309

This Techline supercedes the previous one in Issue 8,

Aug 2003. It has been revised to inform that the fix

calibration is not available for vehicles fitted with part

number 09186327 JA automatic transmission.

PROBLEM DESCRIPTION

Some customers may report that with the cruise

control set - after the vehicle loses speed while driving

uphill, it then accelerates too rapidly back to the set

speed.

Another customer description may be that when they

press the resume switch to return to the previously set

speed the vehicle accelerates too quickly.

SERVICE RECTIFICATION

A revised engine calibration has been developed to

address this condition and is available on TIS CD

43.1. NOTE; this calibration is not available for

automatic transmissions part number 09186327 JA

The new calibration can be down loaded via the

standard Service Programming System (SPS)

method.

IMPORTANT

Always ensure the latest Tech 2 software from TIS

is loaded into your Tech 2 before attempting any

reprogramming using SPS method.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD.

SERVICE FIX

Low Steering Assist (Intermittent)

VTII / VX / WH with Variotronic Power

Steering Option NV7

(GROUP 12) TL462-0309

PROBLEM DESCRIPTION

Some customers may complain that, intermittently,

the effort required to operate their steering increases

immediately after starting their vehicle.

SERVICE RECTIFICATION

When a customer presents their vehicle with the

above complaint the following steps should be

performed in sequence.

Step 1. Inspect the following wiring for terminal

retention and open circuits;

a. Circuits number 3 from the battery to fuse 15

and circuit number 139 from fuse 15 to the

steering solenoid YE58.

b. Circuits number 556 from connector YE58

steering solenoid to connector YB175, terminal

4 of the BCM.

c. The BCM power supplies from circuit number

740 from fuse 31 to terminal 5 YB176 and circuit

number 39 from fuse 14 to terminal 20 YB175

d. The BCM earth circuit number 155 from terminal

1 YB176 to earth point 3 and circuit number 151

from terminal 10 YB174 to earth point 3.

Step 2. Ensure that the slip ring is located

correctly on the ignition barrel and that it is making a

good connection with the key when it’s inserted into

the barrel.

Step 3. If no faults are detected during the

above checks, order a revised BCM and 2 remote

keys from HSPO. NOTE; BCMs and remotes to

rectify this condition were previously only obtainable

from Australian Arrow via TAS.

PARTS INFORMATION

Refer to latest Partfinder for part numbers of BCMs

and remote keys.

WARRANTY CLAIM INFORMATION

Description R&R BCM & program 2

keys - Variotronic Fix

Labour Op. No. N000441

Time 0.8hr

Failure Code 60 Calibration Incorrect

HOLDEN SERVICE TECHLINE______________________________________________________________SEPTEMBER, 2003

SERVICE FIX

Rear Disc Brake Scraping Noise

VY Regular Cab

(GROUP 4 & 5) TL555-0309

PROBLEM DESCRIPTION

Some vehicles may experience a scraping noise from

the rear brakes when loaded, cornering or travelling

over bumps at low speed.

Investigations show this noise is caused by the disc

brake rotor scraping on the backing plate sealing

flange, because of insufficient clearance. Figure 1

below shows the exact contact area.

Figure 1 – Showing typical rear backing plate “scrape”

marks on the sealing flange - with disc brake rotor

removed

PRODUCTION RECTIFICATION

Revised rear axle assemblies with increased

clearance between rotor and backing plate have been

fitted to vehicles from:

ISOVIN No.: Build Date:

6G1YK03A33L167677 02/09/03

SERVICE RECTIFICATION

Summary: Replace Axle assembly.

• For any vehicle with the above condition:

Replace the rear axle assembly with a new

changeover unit from DANA. (Refer to the SIP CD

VY “Special Warranty Component Replacement

Requirements” section).

NOTE: When requesting an exchange axle unit –

ensure the description “Disc Brake Scraping” is

shown on the request.

Use the standard procedure as outlined in SIP for

replacing the rear axle assembly.

IMPORTANT:

DO NOT attempt to rectify the above condition by

machining the brake rotor in the area that contacts the

backing plate.

WARRANTY CLAIM INFORMATION

Description Rear Axle Asm. –

Replace for Disc Scrape

Labour Op. No. F000191

Time 2.1 hr

Failure Code 31

HOLDEN SERVICE TECHLINE______________________________________________________________SEPTEMBER, 2003

INFORMATION

ABS Replacement

V & W

(GROUP 5) TL567-0309

If ABS replacement is required under new vehicle

warranty, first seek approval from BOSCH via the

Prior Approval Process.

When BOSCH approval is given, the ABS Control

Module and Hydraulic Modulator assembly must be

replaced as a complete unit.

DO NOT REPLACE INDIVIDUAL COMPONENTS.

INFORMATION

Service Techline Numbering System

All

(GROUP OB) TL568-0309

The purpose of this item is to explain about a new

Techline numbering system which commenced in

Issue 2 / March 2002.

Every Techline now has its own unique number as

indicated in the heading box above.

How To Interpret The Number.

To help explain what the number means we will use

this Techline’s number, TL568 – 0309, as an

example.

TL568. This is a specific number which is assigned

to each new Techline. It is the next sequential

number from the Master List of techlines.

If there is a letter after the number, e.g. TL560A, this

signifies the first reissue. TL560B signifies the 2nd

reissue and so on. Techlines are reissued for various

reasons such as revisions, updates, repeats etc.

0309

03 = The year of publication (2003)

09 = The issue number.

RECOMMENDATION

The Techline number should be quoted whenever you

refer to a specific Techline in conversations with TAS,

CAS, Holden Aftersales personnel etc.

HOLDEN SERVICE TECHLINE________________________________________________________________OCTOBER, 2003

DIAGNOSIS HINT

Cruise Control “Drops Out” Due to

Incorrect Programming of CIM

(GROUP 12) TL581-0310

Some customers may report that the cruise control

intermittently drops out for no apparent reason. This

condition usually occurs when the vehicle is

attempting to maintain vehicle speed while on an

incline (going up a hill) or reduces vehicle speed

(going down a hill) with the cruise control set.

Investigations show that the cause for this condition is

incorrect programming of the Column Integration

Module (CIM).

When programming the configuration list within the

CIM there are three options, which can be selected

“Not Present”, “Present” and “Adapt. C.”.

Currently vehicles in Australia or New Zealand only

have standard cruise control not Adaptive cruise

control.

SERVICE RECTIFICATION

To rectify a vehicle with this condition the following

procedure needs to be followed.

Step 1. Ensure that you have all the following before

continuing with this procedure,

• The vehicle security code (on security card

when vehicle is delivered).

• All the keys for the vehicle.

(Failure to reprogram any keys will render

those keys inoperative until they are

reprogrammed.

• Tech 2 with the latest level of software and

CANdi adaptor.

Step 2. Using Tech 2, perform the following

selections, as well as any steps displayed on Tech 2.

F0: Diagnostics / Model Year / Vectra C / F0: Vehicle /

F2: Programming / Body / CIM / Reset CIM

Step 3. Once the CIM has been reset, Tech 2 will

return you to the CIM selection menu.

Now Select Program CIM and follow the Tech 2

screen prompts to the 6th screen, do not change any

parameters (except the one labelled “Cruise Control”),

continue to select the “Program “ & “Confirm” soft

keys until the parameter labelled “Cruise Control” is

displayed.

When this parameter is displayed use the arrow keys

on Tech 2 to highlight it and use the “Modify” soft key

to modify.

Select “Present” if the vehicle has cruise control or

“Not Present” if the vehicle does not have cruise

control.

Now select the “Program “ soft key and continue with

the Tech 2 screen prompts until all programming is

complete.

Note:

• When Tech 2 requests you to select the

Immobiliser programming routine, select “CIM

Installed”.

• When Tech 2 requests you to insert non

programmed transponders, use the original

vehicle keys.

Step 4. Check that the vehicle starts with all keys.

Step 5. Check for any current DTC’s and rectify as

required.

HOLDEN SERVICE TECHLINE________________________________________________________________OCTOBER, 2003

SERVICE FIX

Drivers Seat Squeaks in Fully Down

Position

VY built from April ‘03

(GROUP 1) TL577-0310

PROBLEM DESCRIPTION

Customer may complain of a squeak from the driver’s

seat while driving with the seat in the fully down

position.

This condition may be due to the seat cushion side

cover contacting the seat rail trim cover when the seat

is fully down. Refer Figure 1

Figure 1. Shows contact point

SERVICE RECTIFICATION

Summary: On complaint vehicles rework the side

cover as follows:.

1. Remove the seat side cover as per SIP

procedure.

2. Trim material from the cover as shown in Figure 2

Grinding on a bench grinder is the preferred

method to remove material. Remove any sharp

edges.

3. Reinstall side cover

4. Check that interference condition is eliminated.

Figure 2.

WARRANTY CLAIM INFORMATION

Description Trim seat side cover

Labour Op. No. C000499

Time 0.4 hr

Failure Code 62 Improper clearance

HOLDEN SERVICE TECHLINE________________________________________________________________OCTOBER, 2003

SERVICE FIX

Windnoise due to Gap in External

Rearview Mirror Mounting Base

(GROUP 1) TL0557-0310

This techline should be read in conjunction with

Techline TL350A-0307 published in Issue 7, 2003.

PROBLEM DESCRIPTION

Front door windnoise complaints may be caused by

an excessive gap between the mirror base and

window seal as shown in Figure 1.

Figure 1. Shows gap in mirror mounting base

SERVICE RECTIFICATION

Summary: Rectify complaint vehicles by reworking

mirror as per following procedure.

1. Remove mirror from door as per procedure in

Passenger SIP CD.

2. Cut rubber seal back 1mm from the top of the

upper screw mounting boss (refer to Figure 2).

3. File up to 1mm from the upper screw mounting

boss and hard landing (refer to Figure 2).

Caution. Do not remove too much material off

the screw boss and hard landing otherwise the

window operation (and seal) may be adversely

affected.

4. Refit mirror to door.

5. Check that window operates correctly.

6. If wind noise is still evident, ensure that the

service rectification procedures in Techline

TL350A-0307 are performed.

WARRANTY CLAIM INFORMATION

Description Rework exterior mirror

mounting bosses

RHS - C000505

Labour Op. No.

LHS – C000508

Time 0.5 hr per side

Failure Code 45 wind noise

Figure 2. Shows areas to be reworked.

HOLDEN SERVICE TECHLINE________________________________________________________________OCTOBER, 2003

SERVICE FIX

Drivers Footrest Loose

(GROUP 1) TL0506-0310

PROBLEM DESCRIPTION

If the driver's footrest becomes loose, it may be

observed upon removal of the footrest, that the lower

retaining bracket is bent parallel to the floor as shown

in Figure 1. In addition, the plastic legs on the

underside of the footrest may be permanently

damaged as shown in Figure 2.

Figure 1. Shows lower retaining bracket bent parallel

to the floor.

Figure 2. Underside of footrest showing retaining

legs with permanent damage. Footrests with the

retaining legs spread as shown must not be reused.

SERVICE RECTIFICATION

Summary: On vehicles where the footrest has come

loose as described, install a new footrest as follows.

(1) Remove old footrest by removing retaining pin.

Do not reuse old footrest.

(2) Bend the lower metal retaining bracket so that it

is at right angles to the floor. Refer Fig 3.

Figure 3. Lower retaining bracket rebent to upright

position

(3) Insert pin into floor brackets as shown in Figure 4.

When the pin is fully inserted it must protrude

through bracket B. Bend brackets as required to

achieve this. Remove pin and go to next step.

Figure 4. Shows incorrect pin installation. Pin must

protrude through bracket B.

(4) Align new footrest with retaining pin bracket and

fully insert pin. Refer Figure 5. It is

recommended to pivot the footrest upwards and

check from underneath that the pin is correctly

installed.

HOLDEN SERVICE TECHLINE________________________________________________________________OCTOBER, 2003

Figure 5.

(5) Tuck footrest lip under the centre console trim as

shown in Figures 5 & 6.

Figure 6

(6) Prior to locking the lower edge of the footrest to

the floor bracket, check that the footrest retaining

legs line up with the bracket. Bend the bracket as

required to achieve alignment.

(7) Press footrest down until a click is heard as the

barbed legs engage with the first slot in the floor

bracket.

(8) Push footrest fully down until a 2nd click is heard.

Check the footrest is firmly locked down by gently

levering with a screwdriver as shown in Figure 7.

Figure 7. Checking retention to lower bracket

PARTS INFORMATION

Part No.: Description: Qty:

24453499 footrest 1

WARRANTY CLAIM INFORMATION

Use following Labour Times information which will be

updated in the Warranty Information section of the

next PV SIP CD

Description Footrest - Replace

Labour Op. No. C001100

Time 0.3 hr

Failure Code 27 loose

HOLDEN SERVICE TECHLINE________________________________________________________________OCTOBER, 2003

INFORMATION

CDs Jammed in Blaupunkt Audio Head

Units -

VY, V2, WK

(GROUP 12) TL578-0310

Where an audio head unit defect involves CD’s that

do not eject from the unit, Retailer Technicians are

reminded they:

• MUST NOT open the unit to retrieve

the CD’s or forcefully remove them.

• MUST complete the form titled “CD’s Enclosed”

and fax it to Blaupunkt together with the

completed Audio Replacement Authorisation

Request form. Note, both these forms are to be

found in PV SIP CD in the section:

“SPECIAL WARRANTY COMPONENT

REPLACEMENT REQUIREMENTS”

Blaupunkt will exercise all care for the safe remova lof

jammed CDs and prompt return to the Retailer or

directly to the customer (as applicable).

WARNING

Retailers who do not comply with the above

requirement, requesting that the unit not be opened

prior to return, will be charged back by Holden for the

cost of the unit as this voids warranty.

DIAGNOSIS ASSISTANCE HELP LINE

If you require diagnosis assistance of any kind on

Blaupunkt audio units call Blaupunkt on toll free

number 1300 307 036

DIAGNOSIS HINT

DTC P0403 & P1405 set after

Reprogramming ECU

XC SRi (Z18XE engine) built between

W0L0XCF0834185543 (Feb 03) &

W0L0XCF0834255266 (Mar 03)

(GROUP 6C) TL0566-0310

PROBLEM DESCRIPTION

Currently, if a vehicle built within the range specified

has the ECU reprogrammed with the latest software

from TIS 43, 44 or 45, the following DTCs can

become logged:

• P0403 (EGR circuit malfunction)

• P1405 (Feedback Sensor EGR)

Root Cause.

Commencing Feb. 2003 the above models received a

revised catalytic converter and the EGR valve was

deleted. These changes required a new ECU

calibration to be released.

The VIN number breakpoint (for introduction of these

changes) used in TIS2000, versions 43, 44, & 45 is

incorrect as it prompts cars with the new hardware

changes to be re-flashed using the old calibration

software “09 115 113.2307". It should prompt for new

calibration software “55 351 753.2305" to be installed.

SERVICE RECTIFICATION

This issue will be rectified with TIS 2000 version 46

which will be at Retailers in early Nov. 2003.

Until TIS 2000 version 46 is available, be aware that

any XC SRi vehicle between W0L0XCF0834185543

and W0L0XCF0834255266 will set DTCs P0403 and

P1405 after reprogramming the ECU.

HOLDEN SERVICE TECHLINE________________________________________________________________OCTOBER, 2003

SERVICE FIX

Soft Tonneau Cover Rattle

VU, VY Ute

(GROUP 1) TL582-0310

PROBLEM DESCRIPTION

Some customers may complain of a rattle noise from

the soft tonneau cover when driving in high cross

wind conditions.

Investigations show the rattle is causd by the two rear

cross bars rattling in their plastic support brackets.

PRODUCTION RECTIFICATION

The plastic support brackets have been modified by

decreasing the diameter of the socket to 9.4 - 9.6mm

as shown in Figure 1. This diameter was previously

10.5 – 10.7mm.

Revised brackets with reduced clearance have been

fitted to vehicles in production from:

ISOVIN: Build Date:

6G1YK43A04L192447 29/10/03

SERVICE RECTIFICATION

On complaint vehicles proceed as follows.

1. If vehicle is fitted with cross bar brackets with a

hole diameter greater than 9.6mm install new

brackets from HSPO.

2. Ensure that the tonneau cover is tensioned

correctly as per page 3-24 of Owner's Manual (refer

'Note' under Fitting tonneau cover to front bar).

_______________________

PARTS INFORMATION

Part No.: Description: Qty:

92089554 Bracket - tonneau

cover bar

NOTE: The part number of the revised bracket (with

the smaller hole) has not changed.

Attention Parts Managers:

Any of the old brackets with hole diameter in the

range of 10.5 – 10.7mm should be returned to HSPO

for credit via the CRRM system.

WARRANTY CLAIM INFORMATION

Description Replace tonneau bar

brackets

Labour Op. No. C000502

Time 0.2hr

Failure Code 28 rattle

HOLDEN SERVICE TECHLINE________________________________________________________________OCTOBER, 2003

SERVICE FIX

Rear Disc Brake Scraping Noise

VY Regular Cab & Crewman

(GROUP 4 & 5) “REVISED” TL555A-0310

This Techline supercedes the previous one

TL555-0309 in Issue 9, Oct, 2004. It is revised by

adding Crewman to the affected models.

PROBLEM DESCRIPTION

Some vehicles may experience a scraping noise from

the rear brakes when loaded, cornering or travelling

over bumps at low speed.

Investigations show this noise is caused by the disc

brake rotor scraping on the backing plate sealing

flange, because of insufficient clearance. Figure 1

below shows the exact contact area.

Figure 1 – Showing typical rear backing plate

“scrape” marks on the sealing flange - with disc brake

rotor removed

PRODUCTION RECTIFICATION

Revised rear axle assemblies with increased

clearance between rotor and backing plate have been

fitted to vehicles from:

ISOVIN No.: Build Date:

6G1YK03A33L167677 02/09/03

SERVICE RECTIFICATION

Summary: Replace Axle assembly.

• For any vehicle with the above condition:

Replace the rear axle assembly with a new

changeover unit from DANA. (Refer to the SIP CD

VY “Special Warranty Component Replacement

Requirements” section).

NOTE: When requesting an exchange axle unit –

ensure the description “Disc Brake Scraping” is

shown on the request.

Use the standard procedure as outlined in SIP for

replacing the rear axle assembly.

IMPORTANT:

DO NOT attempt to rectify the above condition by

machining the brake rotor in the area that contacts the

backing plate.

WARRANTY CLAIM INFORMATION

Description Rear Axle Asm. –

Replace for Disc Scrape

Labour Op. No. F000191

Time 2.1 hr

Failure Code 31

HOLDEN SERVICE TECHLINE________________________________________________________________OCTOBER, 2003

INFORMATION

Loss of ECC Temperature Memory

VX, WH and V2 built after Aug. 2001

(GROUP 2) TL507-0310

PROBLEM DESCRIPTION

Customers may complain that the temperature setting

on the ECC controller has changed from the last time

they used it.

The above condition occurs as a result of revised

software that was introduced into ECC controllers

from Aug 2001.

SERVICE RECTIFICATION

On vehicles with the above condition, fit a new ECC

controller from HSPO (part numbers below) which

have been programmed with pre-Aug 2001 software

to eliminate the above condition.

PARTS INFORMATION

Part No.: Description: Qty:

92111236 ECC control module

– dual zone

92111235 ECC control module

– single zone

WARRANTY CLAIM INFORMATION

Use normal Labour Times information in Warranty

Information section of current Passenger SIP CD

SERVICE FIX

Revised Trailer Wiring Harness

(GROUP 12) TL573-0310

PROBLEM DESCRIPTION

The intensity of the trailer parking lamps varies under

some conditions.

The above condition is restricted to those vehicles

fitted with the original HSPO harness p/n 92145316.

SERVICE RECTIFICATION

A revised trailer wiring harness that rectifies the

above condition is now available from HSPO.

If a customer complains of the above condition it is

recommended that the existing harness be replaced

with revised harness p/n 92147274.

PARTS INFORMATION

Part No.: Description: Qty:

92147274 Trailer harness with

conrol unit

Attention Parts Managers:

Trailer wiring harness p/n 92145316 should be

quarantined and then returned to HSPO for credit via

the CRRM system.

WARRANTY CLAIM INFORMATION

Description Trailer Wiring Harness-

Replace

Labour Op. No. R603600

Time 0.8 hr

Failure Code 48 Electrical Harness

Problem

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

SERVICE FIX

Fuel Gauge Intermittently Reads Incorrect

Value

V2 II & V2III, WK, VYI & II - excluding VY

Series 1 Ute

(GROUP 12) TL605-0311

PROBLEM DESCRIPTION

Customers may advise that the fuel gauge reads

inaccurately in the region below a quarter of a tank.

The root cause of this condition has been isolated to

the fuel gauge calibration.

PRODUCTION RECTIFICATION

A revised fuel gauge calibration was introduced into

VYII, V2 III and WK production except V6

Supercharged models from:

ISOVIN: Build Date:

6G1YK82A74L199047 11/11/03

SERVICE RECTIFICATION

The revised calibration for all models, except V6

supercharged and VY Series 1 Regular Cab, will be

available on TIS 2000 CD 47, Tech 2 software version

12.700, which is scheduled for despatch on the

17/12/03. An updated techline advising of a revised

calibration for those models not included will be

published in Feb. 2004.

If presented with a vehicle where the customer

advises of this condition perform the following steps:

1. Check the F-4 co-ordinate of the Vehicle Service

History Label located on the inner side of the

lower instrument panel cover. If this co-ordinate

location is marked, the instrument cluster re-

calibration has already been performed. If no

label or co-ordinate markings are present

continue to step 2.

2. To reprogram the fuel gauge calibration refer to

SIP Electrical System / Section 12 C Instruments /

3.15 Programming.

3. After re-programming the fuel gauge calibration a

service history label is required to be fitted to the

inner side of the lower instrument panel cover and

co-ordinate F-4 marked with an X.

WARRANTY CLAIM INFORMATION

Description Re-program Fuel Gauge

Calibration

Labour Op. No. N000453

Time 0.3 hrs

Failure Code 57 Registers incorrectl y

Failure Code NOW N0057 Registers incorrectly

SERVICE FIX

Cabin Boom In Speed Range from

80 – 100 Km/h

VY Reg. Cab, VY Crew Cab, with V6 A/T

(GROUP 1 & 4) TL0595-0311

PROBLEM DESCRIPTION

Some vehicles may experience excessive cabin boom

in the speed range of 80 – 100 km/hr with the TCC

engaged.

PRODUCTION RECTIFICATION

A revised TCC engagement speed (higher) has been

introduced via PCM calibration into vehicles from:

ISOVIN: Build Date:

6G1YK32A54L152926 09/09/03

SERVICE RECTIFICATION

To rectify complaint vehicles, reprogram the PCM

using the latest “High Speed TCC” software as follows

from TIS 46 (or later).

NEW

92209181 - High Speed TCC application.

REPLACES

92165801 - Low Speed TCC application

92163781 - “ “ “

92169214 - “ “ “

IMPORTANT. Vehicles that do not have

the complaint condition must not be

reprogrammed with the High Speed TCC

software.

WARRANTY CLAIM INFORMATION

Description Reflash PCM

Labour Op. No. J000740

Time 0.4 hr

Failure Code 36 Vibrates

Failure Code NOW J0036 Vibrates

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

INFORMATION

Hydraulic Lifter Noise

Gen III V8 Engine

(GROUP 6A) TL0604-0311

This bulletin has been released to dispel “concerns” of

hydraulic lifters or lifter guides causing “lifter noise”

and needing replacement during an engine rebuild.

___________________________________________

A small number of lifter guides were manufactured

with distortion. These parts were identified by the

moulding cavity number “10” on the underside of the

guide. Not all parts identified with the “10” are

affected.

The parts with distortion were used in only a small

range of engines and the tooling was revised in

production to remove the possibility of distortion.

The lifter guides with distortion caused loud lifter

noise early in vehicle life, thus were replaced

immediately when the sound was identified.

PRODUCTION RECTIFICATION

The range of engines that contained a small number

of affected lifter guides was:

From Engine No.: Engine Build Date:

VF010010001 01/01/01

To Engine No.: Engine Build Date:

VF011520001 01/05/01

Improved cavity “10” lifter guides were used from:

Engine No.: Build Date:

VF011520002 01/06/01

SERVICE PRECAUTION

To ensure no distorted lifter guides are re-used during

an engine repair – inspect the underside of the lifter

guides for the presence of the moulding cavity

number - as shown in Figure 1 - if a guide with the

number “10” are fitted – place lifters in the guide and

inspect for noticeable mislocation of any lifter. All

lifters should be vertical – on the same centre line as

the lifter guide. If there is any noticeable mislocation

as shown – replace the lifter guide with a new part

from HSPO.

Figure 1 - showing the obvious distortion that a

‘suspect’ lifter guide will cause.

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

INFORMATION

Engine Oil Dipstick Revision

VY Series II with V6

(GROUP 6A) TL0606-0311

The oil dipstick has been revised by the inclusion of a

cross-hatched section to show the normal ‘operating

range’ for the engine oil level.

The revised dipstick is shown as “Type 1” in Figure 1

below.

The previous dipstick is shown as “Type 2”.

Figure 1 is a copy from the latest Owner Handbook

published for VY Series II since September, 2003.

Figure 1.

Revised oil level dipsticks have been fitted to vehicles

from:

ISOVIN: Built Date:

6G1YK52AX4L206913 TBA

For reference: the first engine using this new dipstick

is: Engine No. VA395155.

SERVICE FIX

TCC Engagement Shudder

JS with C22SEL Engine

(GROUP 7B) TL0591-0311

PROBLEM DESCRIPTION

Some vehicles may display an unacceptable

“shudder” feeling during Torgue Converter Clutch

(TCC) engagement at approx. 80 km/h.

This “shudder” may be pronounced when decelerating

and re-applying throttle around 75 – 85km/h - when

TCC re-applies.

The cause of this shudder is the calibration of the

Transmission Control Module (TCM).

A new TCM with revised calibration to overcome this

condition has been released for service usage.

SERVICE RECTIFICATION

Summary: Fit a new TCM.

Vehicles that display this shudder may be corrected

by fitting a new TCM.

NOTE: There are two different types of TCM – which

must be selected from the “Parts Information” section

below. Inspect the vehicle to define the type of TCM

installed to the vehicle, before ordering the part from

HSPO.

PARTS INFORMATION

NOTE: There are two types of TCM’s used in this

engine/transmission configuration, as follows:

For vehicles up to ISOVIN W0L0JBF19XL446840:

TCM Code “DA”, production part 92059174, (large

type TCM) is used – replaced by New Service Part:

Part No.: Description: Qty:

92147244 Trans. Cont. Module 1

For vehicles from ISOVIN W0L0JBF19XL446841:

TCM Code “DB”, production part 92077883 (small

type TCM) is used – replaced by New Service Part:

Part No.: Description: Qty:

92147245 Trans. Cont. Module 1

WARRANTY CLAIM INFORMATION

Use existing Labour Operation for TCM replacement:

Description Replace TCM

Labour Op. No. K509600

Time 0.4 hr

Failure Code 41 Chatters

Failure Code NOW K0041

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

Oil Sender Adaptor Fouls On HSPO Oil

Filters

HSV vehicles with optional gauges

(GROUP 6A) TL0598-0311

The following information has been supplied by HSV

for distribution to all Holden retailers

Oil sender adaptor part No 06G - 020601 as fitted to

HSV vehicles with optional gauges does not provide

enough clearance for some types of oil filters fitted in

service. Refer Figure 1.

New part No 06G – 030601 provides more clearance

(refer Figure 2.) and is available from your HSV

State Distributor.

Figure 1. Old Adaptor

Figure 2. New Adaptor

LIST OF HSV DISTRIBUTORS

SUTTONS PARTS

22 CARTER ST, LIDCOMBE, N.S.W., 2141

PH: 02 9648 3688

FAX: 02 96471483

Email: [email protected]

HSV Specialist. Miss Kerri Wilkens

MD/General Manager Mr Darrall Elson

PRESTON MOTORS

1551 SYDNEY RD, CAMPBELLFIELD, VICTORIA

3061

PH: 03 9359 3999

FAX: 03 9357 3350

Email: [email protected]

HSV Specialist. Mr. Shaun Lacey

MD/General Manager Robin Mc Clean

ZUPPS PARTS

1032 BEAUDESERT RD, COOPERS PLAINS, QLD

4108

PH: 07 3259 5051

FAX: 07 3875 1773

Email: [email protected]

HSV Specialist.Mr Richard Morris

MD/General Manager Mr Robert Lemon

AMCAP BBK

171 WELSHPOOL RD, WELSHPOOL, W.A. 6106

PH: 08 9351 6666

FAX: 08 9351 6636

Email: [email protected]

HSV Specialist. Mr Noel Learson

MD/General Manager Mr Peter Hewett

METRO HOLDEN

THEBARTON, 1 PORT RD, S.A. 5031

PH: 08 8354 0555

FAX: 08 8352 6678

Email: [email protected]

HSV Specialist. Mr Roger Kramer

MD/General Manager Mr Trevor Olsen

Update

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

INFORMATION

Built Date Explained

All Imported Vehicles – XC, TS, TT, JS,

ZC, UES, UBS, RA, YG

(GROUP OB) TL0606-0311

Holden Breakpoint Information in Service Techlines,

SMA handout material, Partfinder, etc. usually refers

to a BUILT DATE.

The BUILT DATE is the date the vehicle was

assembled in the factory.

Whenever quoting vehicle details in PIRs, talking to

TAS, etc., always quote the vehicle BUILT DATE.

The BUILT DATE is located in various locations on

imported vehicles.

On TS it is shown on a small label on the radiator

panel. On ZC it is shown on a small label on the strut

tower.

On UBS Jackaroo the BUILT DATE is shown on the

Body/Option plate on the dash panel as shown in

Figure 1.

Figure 1. Body/Option plate - Jackaroo

IMPORTANT. The BUILT DATE described above

must not be confused with the date stamped on the

Safety Compliance Plate rivetted to the dash panel.

Refer Figure 2.

The date shown on the Safety Compliance Plate, for

imported vehicles only, is the date when the plate

was attached to the vehicle at the Port Of Entry (POE)

into Australia. This date can be from 2 to several

months after the vehicle BUILT DATE because of the

time taken for shipping the vehicle to Australia plus

storage at POE.

Figure 2. Safety & Compliance plate - Jackaroo

SERVICE HINT

Transferring Information from Old to New

Modules

All

(GROUP 12) TL0589-0311

When installing a new module the following

information is generally required for inputting into the

new module.

• Vehicle options

• Vehicle configuration

• Code Index

Prior to removing any module, it is recommended to:

1. Connect Tech 2.

2. Record on paper the Vehicle options, Vehicle

configuration, and Code Index.

3. Confirm all the values recorded in step 2 using

TIS 2000 or SIP.

4. Once these values are confirmed they can then

be entered into the new module when called for

by Tech 2 during the installation process.

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

SERVICE FIX

Alloy Pad Detaches from Accelerator

Pedal

TS Models with Alloy Pedals

(GROUP 1) TL0594-0311

PROBLEM DESCRIPTION

On some vehicles the alloy pad may detach from the

accelerator pedal. Refer Figure 1.

SERVICE RECTIFICATION

Summary: On complaint vehicles, reglue alloy pad to

accelerator pedal as follows.

NOTE: This fix is only applicable to the accelerator

pedal.

(1) If required, carefully remove alloy pad completely

from the accelerator pedal.

(2) Thoroughly clean the matching contact surfaces

of the alloy pad and the accelerator pedal with a

solvent such as X55 or Prepsol.

(3) Allow solvent to dry completely before next step.

(4) Apply Loctite 770 primer or equivalent to

completely cover the contact surfaces on both

alloy pad and accelerator pedal.

(5) Allow primer to dry completely (2 - 5 minutes).

(6) Apply Loctite 480 or equivalent, sparingly along

the ridges of the accelerator pedal. Loctite

application must be completed within 1 minute to

avoid curing prior to assembly.

(7) Place alloy pad on accelerator pedal and apply

light even pressure for 1 - 2 minutes until glue

initially sets.

(8) It is recommended to allow a minimum of 1 hour

before using the accelerator pedal.

PARTS INFORMATION

Part No.: Description: Qty:

55351855 Pad -alloy 1

Solvents and adhesives mentioned above can be

obtained from commercial suppliers. They are not

stocked by HSPO.

WARRANTY CLAIM INFORMATION

Description Alloy pad - Replace

Labour Op. No. C000511

Time 0.3 hr

Failure Code 71 Pulled loose

Failure Code NOW C0071

FIGURE 1

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

SERVICE FIX

Blaupunkt Radio Losing Time or CD Will

Not Eject

VY / V2 II / WK

(GROUP 12) TL580-0311

PROBLEM DESCRIPTION

Customers may complain of the clock in their

Blaupunkt radio losing time or that the CD will not

eject.

After investigation into the root cause, Blaupunkt has

made a software revision to rectify this condition.

PRODUCTION RECTIFICATION

Blaupunkt has implemented a software revision for all

radios introduced into production as of the following

break point.

ISOVIN: Build Date:

6G1YX54AX4L170039 8/09/03

SERVICE RECTIFICATION

If a customer presents a vehicle with the above

condition, request a replacement radio using the

standard change over request procedure which is

found in SIP “ SPECIAL WARRANTY COMPONENT

REPLACEMENT REQUIREMENTS” section .

IMPORTANT: The Main Software Version number

must also be included on the request form.

Below is an example of the Identification Data screen

displayed on Tech 2 where this information can be

found.

Identifier 404

Part number 92118704

Production Date 60103

Main Software Version ????

Panel Software Version 1A22

Serial Number 804697

VIN Digit 1-10 6G1YK54A74

VIN Digit 11-17 L169008

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

SERVICE FIX

Recommended Lubricant For Clutch

Pedal Squeak

VT, VU, VX, VY Series 1 – Manual Trans.

(GROUP 7A) TL0588-0311

PROBLEM DESCRIPTION

It has come to Holdens attention that many vehicles

are experiencing repeat repairs for clutch pedal

squeak.

It is believed that these repeat repairs are due to

incorrect lubricants being used and in particular,

aerosol spray lubricants which are considered not

suitable for this job.

SERVICE RECOMMENDATION

To avoid repeat repairs on complaint vehicles,

lubricate the clutch pedal to master cylinder

connection as follows.

1. Refer procedure in PV SIP to perform the

following.

2. Disconnect the clutch master cylinder push rod

(1) by removing the spring clip (2) and washer (3)

from the pin on the clutch pedal (4).

3. Use a brush to apply Molybond GA10 grease, or

equivalent, to the pin and both sides of the

washer. Do not over apply grease to avoid it

dripping onto the carpet.

4. Reassemble all components.

NOTE. The above procedure does not apply to VY

series II vehicles which have a new “quick connect”

(plastic) design for connecting the master cylinder to

the clutch pedal.

VY Series II was introduced from:

ISOVIN: Build Date:

6G1YK52A94L156716 06/08/03

Update

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

INFORMATION

Front Spring Chock Removal

Various Models

(GROUP 3) TL0590-0311

Front spring chocks are currently fitted to the following

models to reduce instances of damage to front facias

when loading and unloading vehicles from vehicle

transporters. A label advising of spring chocks is

attached to the windscreen of these vehicles.

• VY ‘S' Pack Sedan

• VY 'SS' Sedan

• VY 'SS' Crewman

• VY 'SS' Chassis Cab

• VY 'SS' Ute

• VY 'SS' Wagon

• VY Calais

• V2 Monaro

• HSV vehicles

• XC Sri Barina

Holden is still receiving reports of vehicles being

delivered to customers with chocks not removed!

The spring chocks MUST be removed before

delivery to the customer.

To remove, lift vehicle on hoist, so the front springs

are unloaded, and remove chock from each front

spring. Figure 1 shows spring chocks in Barina Sri.

Other vehicles use timber chocks.

Figure 1. Shows spring chock arrangement in an XC

SRi.

SERVICE FIX

Clutch Pedal Low or Clutch Not

Disengaging Due to Air In Hydraulic

System

All with Gen III V8 & MM6 M/T

(GROUP 7A) TL0570-0311

PROBLEM DESCRIPTION

Some customers may report that the clutch pedal

feels soft and has a low disengagement point (close

to the dash panel). The customer may also report

difficulty in selecting gears.

The above condition has been found to be the result

of a chemical corrosive reaction between the clutch

fluid and the slave cylinder body. During this

chemical reaction, gas is created in the hydraulic

system resulting in the “soft” pedal.

PRODUCTION RECTIFICATION

Clutch slave cylinders made with revised composition

alloy to resist the chemical reaction will be fitted to

vehicles built from early December 2003. When this

occurs, a vehicle tag number will be published in a

future service techline breakpoint summary.

SERVICE RECTIFICATION

Summary: On complaint vehicles, fit revised alloy

clutch slave cylinder p/n 92067460.

Procedure.

1. Check for leaks or damage to the reservoir,

master cylinder and hydraulic lines and rectify as

required.

2. Replace the slave cylinder assembly with new

part number 92067460 from HSPO. Refer to PV

SIP CD for replacement procedures.

3. Use only the specified clutch fluid* for filling and

bleeding the clutch hydraulic system.

* The specified clutch fluid is: Heavy Duty Brake

Fluid Conforming to Holden Specification HN1796

(Super DOT4 ). Refer Passenger Vehicle SIP CD.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

PARTS INFORMATION

Part No.: Description: Qty

92067460 Slave cylinder assembly –

Clutch (revised alloy)

92026651 Brake/Clutch fluid 500ml bottle 1

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

SERVICE FIX

Gear Shift Lever Rattle/Buzz caused by

- Knob and/or

- Remote Shifter Linkage

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

(GROUP 7A) REVISED TL464B-0311

This Techline supercedes the previous one (TL464A-

0308) in Issue 8, 2003. It is revised by removal of the

TAS Shifter Exchange Program.

PROBLEM DESCRIPTION

During acceleration in any gear a rattle noise may be

emitted from the gear knob and shifter area. The

noise is usually more prominent when vehicle is cold.

There are two possible sources of this noise:

Gear Knob rattle: - this is a plastic rattle sound

Shifter Linkage: - this is a metallic rattle sound

SERVICE RECTIFICATION

Summary: Correctly identify the source of the rattle

(knob or shifter Linkage) and rectify as explained

below.

Gear knob rattle

Gear knob rattle can be heard during heavy

acceleration above 3000rpm in any gear. While

accelerating, twist the gear knob clockwise or anti-

clockwise then slowly release the knob – if the rattle is

reduced or eliminated – this confirms the gear knob is

rattling. This test is best done with a cold vehicle, as

it is much easier to reproduce the rattle when cold.

When the rattle is confirmed as coming from the gear

knob, proceed as follows.

For VT/VX: Glue the gearshift knob to the lever as

described in Techline in Issue 2/2002 Group 7A.

For VY: Install a new gear knob and lever assembly

from HSPO. These parts have glue added internally

to stop rattles, and are identified by two white paint

dots on the metal shaft of the lever.

IMPORTANT. Gear knob rattle is more intrusive than

shifter linkage rattle. Therefore, correctly identifying

gear knob rattle and rectifying as described above will

have the greatest impact on the condition described

above.

Shifter Linkage Rattle

The shifter linkage rattle occurs mainly during heavy

acceleration in 3rd or 4th gear above 2500rpm. The

rattle is more prominent if you touch the back of the

gear knob with your finger when in 3rd gear, or when

you touch the front of the gear knob with your finger

when in 4th gear. It is recommended that this test be

done with a known non-rattling gear knob/lever fitted,

so that no confusion exists.

Once shifter linkage rattle is confirmed with a non-

rattling gear knob, refer to Techline No. TL608-0311

in Issue 11/2003 which gives details on reworking the

remote shifter assembly to eliminate the rattle.

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

SERVICE FIX

Gear Shift Lever Rattle/Buzz - (Shifter

Linkage Repair)

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

(GROUP 7A) TL608-0311

PROBLEM DESCRIPTION

Complaints may be received of gear shifter “rattle” at

various engine speeds/road speeds. Most common

complaints are from 3rd or 4th gears.

The condition is a “metallic rattle” which can be heard

by removing the gear knob/lever assembly, then

revving the engine in neutral with medium to heavy

throttle, above 2500rpm – as a quick diagnosis. The

shifter linkage rattle occurs mainly during heavy

acceleration in 3rd or 4th gear above 3000rpm. The

rattle is more prominent if you touch the back of the

gear knob with your finger in 3rd gear, or if you touch

the front of the gear knob with your finger in 4th gear.

It is recommended that this test be done with a known

non-rattling gear knob, so no confusion exists.

NOTE: the following procedure must not be carried

out until diagnosis and any necessary repair, as

described in Issue 11, November, 2003 Service

Techline for “Knob Rattle/Buzz” has been carried out.

EG: Where the Gear Lever & Knob Assembly has

been assessed and changed if necessary, and the

source of “gear lever rattle” has been defined as

coming from the shifter mechanism – NOT the lever

and knob assembly.

PRODUCTION RECTIFICATION

Revised shifter assemblies with anti-rattle feature, as

described in this bulletin, are to be introduced in

production shortly. When this occurs, the breakpoint

information will be included in the next Techline

Breakpoint Summary published.

SERVICE RECTIFICATION

Summary: Fit a Shifter Upgrade Kit as described

below.

NOTE: Upgraded “exchange” Shifters have been

supplied via TAS and HSPO since mid 2003 – These

parts do NOT need upgrading as described below,

and must not be upgraded or claimed for as warranty.

These exchange assemblies are identified by the

presence of either four red fibre washers between the

bridging piece and levers, or the black plastic “linked”

washers (6) shown below.

Bridging piece and related retaining parts (latest

types shown).

REMOVAL

1. Disconnect the battery earth lead.

2. Place gear lever in neutral.

3. Remove Gear shift knob/boot/lever assembly, and

centre console including the console cap - as per

the relevant procedures in Passenger SIP Sections

7B3 and 1A3 for the model vehicle being rectified.

4. Remove shifter cover and boot assembly by

removing the three Philips head screws.

5. Remove shift lever boot retaining plate:

Early build vehicles – remove the four bolts

securing the shift lever boot retaining plate,

from inside the vehicle, and lift off the plate;

Late build vehicles – remove the four nuts securing

the shift lever boot retaining plate to the floor pan

after raising the vehicle on a hoist. Front LH nut

access is limited, remove using an open end

spanner.

6. Remove the three self tapping screws (1)

retaining the front selector lever pivot assembly,

using a Phillips screwdriver – see Figure 1.

7. Remove the four hex head screws (2) holding the

rear selector lever pivot retaining plate (3), from

the baseplate (4) – see Figure 1.

Figure 1.

Update

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

8. Lift the front and rear selector levers and bridging

piece assembly up and out of the shifter base

plate (4) on the transmission, as shown in Figure

1. Ensure the ball seat (7) and seat support ring

(8) remain in the base plate (2) (these parts shown

in Figure 3).

DISASSEMBLE

CAUTION: During the disassembly process - wear

safety glasses to avoid possible eye injury.

1. Using a small flat bladed screwdriver, remove

circlip (1) from the rear lever/bridging piece retaining

pin (2) – see Figure 2.

Figure 2.

2. NOTE: BEFORE STARTING THIS STEP note

carefully the position and direction of the shifter upper

lever bolt holes and the shaft ‘cutaway’ for

reassembly! This determines the final position of the

gear lever, and gear knob direction! Refer Figure 5.

Tap or press the retaining pin – see Figure 2A - out of

the rear selector lever and bridging piece. This pin is

an interference fit into the selector lever, and may

need to be pressed out of the assembly. This can be

done by clamping the rear lever/pin in a vice, using a

spacer to fit over the pin head (if a suitable spacer is

not available, a suitable sized socket may be used).

Figure 2A. Rear Selector Lever Pin Removal.

3. After pin removal, retain the rear retaining plate (3),

the wave springs (4), and guide (6) shown in Figure 3

for re-use. Note the order of removal of the wave

springs and guide for re-assembly.

Figure 3 – showing rear selector shaft and rear

pivot components.

REASSEMBLE

Reassembly uses parts 1, 3, 4, 6, 7, 8 (in Figure 3)

and the following new parts in the Shifter Upgrade Kit,

• Front Selector Lever

• Front Selector Lever Retainer (triangular plastic)

• Front Selector Lever Retainer O-Rings (2)

• Rear Selector Lever

• Bridging Piece

• Anti-rattle “bridged” washers (black plastic)

• Pins

• small Bushes (blue plastic)

• Large Bushes (blue plastic)

• Circlips

CAUTION: During the reassembly process - wear

safety glasses to avoid possible eye injury.

1. Place the guide (6), wave springs (4) and rear

retaining plate (3) onto the new rear selector lever

(5) - shown in Figure 3 - in reverse order to their

removal.

Note: Apply 10% molybdenum disulphide grease

such as Molybond GA 10, or equivalent, to all

moving parts in the rear selector lever assembly.

2. Apply NLGI No. 4 EP grease to the new retainer

(triangular ball socket) of the new front selector

shaft, then assemble by hand, pushing the front

selector lever (1) into the plastic retainer (2) – see

Figure 6. NOTE: ensure the plastic ball retainer is

located with O-ring section toward the ball end of

the lever as shown in Figure 4 below.

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

Figure 4 – front selector lever and pivot.

3. Install the new “linked” anti-rattle washers (2) to the

new bridging piece (1) – refer Figure 5 below.

Ensure correct diameter holes match the holes in

the bridging piece.

Figure 5 – showing anti-rattle ‘linked’ washer

location.

4. Install the new (blue) bushes to the bridging piece

(outer) holes after lubricating with NLGI No. 4 EP

grease. Ensure the bushes are in the correct size

holes in the bridging piece/anti-rattle washers.

5. Install the new bridging piece assembly (3) to the

two new front and rear selector lever assemblies –

refer Figure 4 above. NOTE: Ensure that the rear

selector lever top retaining screw ‘cut-away’ and

holes are positioned the same way as when

removed from the shifter, and the chamfer on the

bridging piece is to the bottom, as shown in Figure 5

above. Figure 6 shows the correct location of rear

selector lever for both types of shifter:

Figure 6. Shows correct ‘cut-away’ and hole

locations.

6. Install new pivot pins to bridging piece/selector

levers and press home by clamping in a vice - use a

spacer to fit over the pin circlip grooved pin end and

blue bush (if a suitable spacer is not available, a

suitable sized socket may be used). Refer Figure 7.

NOTE: the pins fit easily into the bushes and

bridging piece holes, but are an interference fit into

the lever holes – after initial pressure to start the

pins into the lever holes – STOP - inspect the pin

installation for straightness - then complete the

pressing operation.

Figure 7. Selector Lever Pin Installation.

7. When the pin head butts up against the blue bush,

stop the pressing operation so that the bushes and

bridged washers are not damaged, then fit new

circlips (1) to secure each pin – refer Figure 8.

HOLDEN SERVICE TECHLINE______________________________________________________________NOVEMBER, 2003

Figure 8. – Circlips in final installed position.

8. Install new O-ring seals ‘A’ & ‘B’ to front selector

lever ball socket (2) – see Figure 9.

Figure 9 – front selector lever and pivot.

9. Reinstall the assembled bridging piece/selector

levers (3) into the base plate (4) on the transmission

and reinstall the four rear retaining plate bolts (2) –

see Figure 9 - tightening to the correct torque

specification: 10 –12 Nm.

10. Reinstall the front selector pivot assembly retaining

screws (1) to the baseplate (4) on the transmission

– see Figure 10 - tightening to the correct torque

specification: 5-8 Nm. Note: If a triangular metal

reinforcing plate was fitted to the shifter – refer to

Additional Information at the end of this Techline.

Figure 10.

11. Reinstall dust cover and boot assembly (4 screws)

to the remote shifter assembly on the transmission.

12 Reinstall the gearshift remote lever boot and plate

and secure to the floor pan as follows:

Early build vehicles – install the four bolts, from

inside the vehicle, tightening to the correct torque

specification: 6-14 Nm.

Later build vehicles - install the four nuts, with

vehicle raised on a hoist, tightening to the correct

torque specification: 15 Nm.

13 Reinstall the gear shift knob/boot/lever assembly

and console/console cap as per procedures in

Passenger SIP Sections 7B3 and 1A3 for the

relevant model.

14 Reinstall the battery ground lead.

PARTS INFORMATION

Use Figure 6 (above) for identification of the shifter

type fitted to the vehicle. To do this, remove the

console boot to determine the angle of the gear lever

retaining bolts and cut-away. Select the correct part

number kit as follows:

Part No.: Description: Qty

92147248 VT/VX type Shifter

Upgrade Kit

92147246 VY type Shifter Upgrade

Kit

WARRANTY CLAIM INFORMATION

Description Shifter Asm – Rattle

Upgrade

Labour Op. No K000294

Time 1.0 hr

Failure Code 28 rattle

Failure Code NOW K0028

Additional Information:

If a shifter assembly removed from a vehicle is fitted with

the triangular metal reinforcing plate shown below, the

triangular plate and retaining screws (which are longer

than standard screws) should be refitted to the shifter

assembly before reassembly Step 10 above. This action

is only as a precaution, as the new front lever pivot

(white plastic) is a stronger material than the original

part which makes fitting of triangular reinforcing plates

no longer necessary.