Service Department

A “HOLDEN” Product.

BRISBANE SYDNEY MELBOURNE ADELAIDE PERTH

For the latest and/or any missing Techline bulletins,

please refer to Holden Lionheart

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

SERVICE FIX

LSD Additive Available For Oil “Top-Up”

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

(GROUP 04) Re-Issue TL279A-0401

This Techline supercedes the previous one in Issue 4,

May, 2002. It is revised by correcting the kit contents

and clarifying that usage is only for “top-up”, NOT for

an axle “chatter” fix.

BACKGROUND

Many vehicles have previously had LSD additive and

a revised pinion seal installed for a “chatter” condition

(Refer to Dealer Letter DL 30/02).

The additive is now available separately, for any of

the above vehicles whose differentials require oil

replenishment or top-up following a repair.

This additive is NOT for use in correcting LSD

“chatter” complaints until a chatter kit has

been fitted.

LSD “chatter” complaints must still be corrected in

vehicles covered by warranty by the use of an LSD

“Chatter” Kit – Refer to Dealer Letter DL 30/02 which

advises the method of obtaining LSD Chatter Kits

Free of Charge and the Dana provision of automatic

kit replenishment at Retailers.

PRODUCTION RECTIFICATION

Final drives with the additive and revised seal

included have been fitted to vehicles from:

ISOVIN: Build Date:

6H8VXK69F1L762226 20/08/01

SERVICE RECOMMENDATION

This additive is ONLY for replenishment of oil to final

drive units that:

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

L762226;

(b). are built before breakpoint L762226 and have

had the additive and the seal installed as per DL

54/01 or RL 30/02. These vehicles are identified by a

metal ID tag fitted to the rear of the differential,

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

PARTS INFORMATION

Part No.: Description: Qty:

92145121 Additive Kit 1

This kit consists of: - 1 bottle, 100ml LSD Additive,

IMPORTANT: This additive is NOT suitable

for use in differentials that are not fitted with

the revised seal and additive – as seal

degradation and failure will result.

DIAGNOSIS HINT

Rear Axle Pinion Seal - Oil Leak

Diagnosis

V & W

(GROUP 4) TL0613-0401

PROBLEM DESCRIPTION

Technicians have reported “oil leaks” from the axle

pinion seal on the assumption that the seal is leaking.

Vehicles with such “leaks” have been investigated

and seals returned for checking. No faults could be

found and the oil leakage is only “assembly oil”.

Pinion oil seals are assembled to axles using oil to

assist installation. At times, excessive oil is used, and

after some use and temperature cycling of the axle,

this excessive oil can run out of the pinion nose –

appearing like an oil “leak” from a faulty or damaged

seal.

PRODUCTION RECTIFICATION

Holdens axle supplier will be changing from

installation oil to grease, used in lesser quantity, that

will not migrate out of the pinion seal.

Breakpoint information for this change will be advised

in a future Breakpoint Summary page entry in

Techlines.

SERVICE RECTIFICATION

Summary: Clean off excess oil.

Should any vehicle be presented with an apparent oil

“leak” at low kms or age – do not immediately replace

the seal - wipe off the excess oil and road test for any

continuing immediate leak. If none occurs, monitor the

vehicle at next service.

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

SERVICE FIX

Gear Shift Lever Rattle/Buzz - Caused by

Shifter Linkage Rattle

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

(GROUP 7A) REVISED TL608A-0401

This techline replaces the previous one TL608-0311

in issue 11,2003. It is revised by changing the

lubricants to ones that are currently available (shown

in red) and updating Production breakpoint

information.

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, introduced in production

from

ISOVIN: Built Date:

6G1YK42F14L213500 08/12/2003

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.

3. Place gear lever in neutral.

4. 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.

5. Remove shifter cover and boot assembly by

removing the three Philips head screws.

6. 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.

7. Remove the three self tapping screws (1)

retaining the front selector lever pivot assembly,

using a Phillips screwdriver – see Figure 1.

8. 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.

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

9. 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 NLGI No.2 lithium soap based EP

grease with molybdenum disulphide, such as Shell

Retinax HDX2 grease, BP Energrease LMS-EP 23 or

equivalent, to all moving parts in the rear selector

lever assembly.

2. Apply NLGI No. 3 Lithium based EP grease,

such as Shell Retinax LX 3 grease or equivalent, 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 _____________________________________________________________FEBRUARY, 2004

Figure 4 – front selector lever and pivot.

1. 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 a NLGI No. 3

Lithium based EP grease, such as Shell Retinax LX

3 grease, or equivalent. . 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 _____________________________________________________________FEBRUARY, 2004

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.

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

SERVICE FIX

Intermediate Steering Shaft Knock

JR, JS

(GROUP 9) REVISED TL362A-0209

This Service Techline supersedes the previous techline

on this topic TL362-0209 (Issue 9/2002). It is revised

by adding information on greasing the Intermediate

shaft.

PROBLEM DESCRIPTION

A knocking noise on turns caused by clearances within

the steering intermediate shaft components.

SERVICE RECTIFICATION

Summary: On complaint vehicles, replace the

intermediate steering shaft with a new shaft as per

following procedure. If the vehicle has previously been

fitted with a new shaft and still knocks, simply remove

the shaft and add grease as per following procedure

1. IMPORTANT: Disconnect the battery and wait at

least 1 minute for the capacitor in the control unit to

discharge. (Airbag safety precautions as outlined in

service manual Volume 1 must be observed).

2. Centre the steering wheel.

3. Remove foot well panels and air ducting.

4. Loosen the pinch bolts of the steering

intermediate shaft (Nos.1 and 2) and engage the

steering lock, see Figure 1.

5. Compress the steering intermediate shaft and

remove.

6. Unless already installed, fit a new steering

intermediate shaft kit 09119322.

IMPORTANT. Prior to installation, disassemble the

intermediate shaft and grease the sliding area with

grease p/n 90512280. Reassemble the shaft and

slide a few times to spread grease.

7. Release the ignition steering lock, then secure the

shaft using new pinch bolts (Torx screws) and an

appropriate thread locking sealant.

8. Torque the upper and lower pinch bolts to:

22 Nm/16 lbf.ft + 45° + 15°.

Failure to tighten these bolts correctly could result

in not eliminating the knock condition.

9. Refit air ducting and foot well panels.

10. Mark the steering wheel position and remove the

steering wheel using special tool Puller KM 210-A.

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

12. If necessary, with a screwdriver, depress the

clock spring locking tab and move the clockspring

until the driving lugs on the steering wheel locate

correctly into the clockspring.

13. Refit the steering wheel and secure the fastening

nut with the locking plate supplied.

Torque to 25 Nm/18 Ibf.ft.

14. Refit the air ducts and foot well panels.

15. Reconnect the battery.

16. Test drive the vehicle and ensure that the steering

is centered.

Figure 1.

PARTS INFORMATION:

Part No. Description Qty.

09119322 Repair Kit - Steering Coupling

Joint (consists of revised shaft,

2 Torx screws, 1 locking

washer)

90512280 Grease (High adhesion type)

100 gram

SPECIAL TOOL REQUIRED:

KM-210-A Puller

WARRANTY CLAIM INFORMATION

Description Repair Kit - Steering

Coupling Joint - Replace

Labour Op. No. E000302

Time 0.8 hr

Failure Code 28 rattle

Failure Code NOW E0028

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

SERVICE FIX

Rear Disc Brake Scraping Noise

VY Regular Cab & Crewman

(GROUP 5) REVISED TL0555B-0401

This Techline supercedes TL0555A-0310 in issue 10,

2003. It is revised by changing Service Rectification

from replacing rear axle asm. to machining the rear

disc brake rotors. This information was also released

in DL 6403 dated 16 Dec 03.

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 typical rear backing plate “scrape”

marks on the sealing flange - with disc brake rotor

removed

Figure 1.

PRODUCTION RECTIFICATION

Revised rear brake discs to provide clearance to the

backing plate were fitted from:

ISOVIN No.: Build Date:

6G1YK03F64L225326 23/01/2004

SERVICE RECTIFICATION

Summary: Machine the rear disc brake rotors as per

procedure on next page.

WARRANTY CLAIM INFORMATION

Description Remove, Machine & Re-

install Rear Brake Discs

Labour Op. No. H000257

Standard Time 0.4 hr

Add time for

Machining

0.4 hr

Failure Code 31

Failure Code NOW H0031 Poor Machining

NOTE: If machining is sublet, claim expense in “net

items” column. Please note that add times cannot be

claimed when work is sublet

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

REAR BRAKE DISC MACHINING PROCEDURE

1. Prior to removing brake discs ensure they are marked with side of vehicle and stud position, so that on re-

installation they are put back in the same position. This is to ensure that the least possible installed runout is

achieved.

2. Machine inner lip of the disc as per the drawings below.

3. Re-install brake discs.

1mm

Remove 1 mm of material

parallel to the disc friction

surface. See enlarged figure

below for detail. This is to

increase clearance between the

rotor and dust shield to

eliminate scra

Brake disc section

where machining is

required

Centre line of disc

Friction surfaces of disc

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

SERVICE FIX

Ignition Module Failure

XC & Z14XE

(GROUP 6Y) TL0611-0401

PROBLEM DESCRIPTION

On some vehicles the ignition coil module may fail

causing the engine to misfire and/or the vehicle not to

start. Diagnostic Troubles Codes P0300, P0301,

P0302, P0303, P0304 may be logged.

This problem is caused by the epoxy in the ignition

module becoming brittle and cracking, resulting in

internal arcing.

PRODUCTION RECTIFICATION

The corrective action for this problem has been to

replace the epoxy in the ignition module with a new

type of epoxy.

Revised ignition modules with the new epoxy have

been fitted to engines from engine Breakpoint

Z14XE20CB4883. (approx vehicle build date 10th

Oct 2003)

SERVICE RECTIFICATION

On vehicles where the ignition module has failed, fit a

new module from HSPO.

PARTS INFORMATION

NOTE: The new ignition module part number remains

the same.

The new ignition module can be identified by the

epoxy colour which is darker, and the date code

stamp. Refer Figure 2.

The date code is stamped on the top of the ignition

module (as seen in Figure 3).

The new module can be identified by a date code that

is post (after) 3J22.

where: 3 = 2003, J = September, 22 = Day

Part No.: Description: Qty:

19005212 Module – direct ignition 1

Attention Parts Managers:

Any ignition coils prior to breakpoint should be

returned to HSPO for credit via the CRRM system.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

Figure 1. Old module has light coloured epoxy

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

Figure 2. New module has dark coloured epoxy

Figure 3. Location of date code

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

DIAGNOSIS HINT

Dash Panel Creak – Glue Track Region

VY Utility & V2

(GROUP 1) TL625-0401

PROBLEM DESCRIPTION

While driving through uneven driveways or on

acceleration and braking a creak may be heard from

the lower dash area.

This creak noise may be due to dash panel sheet

metal contact within the “glue track” in the

transmission tunnel area.

SERVICE RECTIFICATION

To rectify vehicles with the above condition:

1. Attempt to reproduce the noise by jacking the

vehicle from one side at the recommended jacking

points.

2. Confirm that the noise is loudest on the glue track

in the transmission tunnel area (between the arrows

in Figure 1) using either chassis ears or a

stethoscope.

Note: Reproducing the creak while stationary may

not be possible in every case. The sensitivity of the

listening device will also affect the ability to

reproduce the creak.

Figure 1.

3. After confirming the creak is coming from the

transmission tunnel area (between the arrows in

figure 1), use a pry bar from inside the vehicle to

widen the glue track sufficient to separate the two

panels, starting at the area where the creak was

identified.

4. Confirm that the creak has been eliminated by

repeating step 1.

5. Fill the “widened” glue track with RTV 732

silicone sealer to prevent the creak from returning

and to ensure the join is sealed.

NOTE: Sufficient access to the transmission tunnel

may require removal of the HVAC unit.

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

SERVICE FIX

Front Exhaust On-Pipe Heat Shields

Vibrate

WK, VYII, V2 with Gen III

(GROUP 8) REVISED TL514B-0401

This Techline supercedes the previous techlines

TL514-0306 & TL514A-0308. It includes revised

service fix and parts information.

PROBLEM DESCRIPTION

A buzz/vibration from front exhaust pipe heat shields

(long type) which occurs on takeoff under light loads

such as driving uphill.

The insulator pads adhered to the inside of the heat

shields may have become detached.

Figure 1. Shows insulation pads adhered to inside of

long-type heat shields.

PRODUCTION RECTIFICATION

The long type heat shields were replaced with

shorter heat shields and underfloor reflective foil

insulators from:

ISOVIN: Build Date:

L172001 12/9/2003

NOTE:

On-pipe heat shields and underfloor stick-on

reflective foil insulators have been removed from all

vehicles with Gen III engines built from 9/1/04. All

vehicles built from this date are fitted with floor

mounted “bolt on” type heat shield.

SERVICE RECTIFICATION

Summary: On complaint vehicles featuring the long

type on-pipe heat shields install new shorter on-pipe

heat shields as per following procedure.

1. Remove existing long-type exhaust heat shields.

2. Check if there are underfloor stick-on reflective

foil insulators located as shown in Figure 2. If

not, order new part 92056511 and install as

follows

(a) Clean underfloor area using a solvent

soaked rag to remove any dirt, sealer or paint

overspray.

(b) Soften the new reflective foil insulator by

heating with a heat gun to approximately 40 deg C.

peel the adhesive paper from the reflective foil

and apply to the underfloor area in-line with the

exhaust pipe as shown in Figure 2. Smooth out

any bubbles.

3. Install new short-type heat shield kits 92210214

and 92210217 as shown in Figures 1 & 2.

PARTS INFORMATION

Part No.: Description: Qty:

92210214 Exhaust heat shield kit –

RHS (2 halves plus 4

nuts)

92210217 Exhaust heat shield kit –

LHS (2 halves plus 4

nuts)

92056511 Heat shield - self

adhesive

WARRANTY CLAIM INFORMATION

Description Replace heat shields both sides

and install underfloor reflective foil

Labour Op.

No.

L000223

Time

0.5hr

Failure

Code

36 vibration

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

Figure 1. Shows installation of new shorter “on-pipe” heat shields

Figure 2 Close up view of LHS underfloor stick-on heat shield

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

SERVICE FIX

Rear Brake Groan/Graunch - Repeat

Failure After Dampers Have Been Fitted

TS & TT MODEL YEAR 2002 Fitted with

Lucas Calipers

(GROUP 5) TL0441-0401

The procedure below should only be followed after

the previously issued information in Service Techline

July 2002, Issue 6 for Rear Brake Graunch has been

carried out (i.e. fitting dampers).

PROBLEM DESCRIPTION

Some vehicles are reported as having the low

frequency graunch still evident even after the

dampers have been fitted as per Service Techline

July 2002, Issue 6.

This noise must not be confused with brake squeal,

drag or scraping. Therefore, to avoid misdiagnosis,

the complaint noise needs to be

demonstrated/reproduced to a Technician/Service

Manager to confirm it is the low frequency graunch.

Cause

The dampers are tuned to damp out a specific

frequency. Testing has revealed that on vehicles

where the graunch is still evident with the dampers

fitted, the components are vibrating at a frequency

that is slightly different to that which the damper is

tuned for.

PRODUCTION RECTIFICATION

Dampers fitted in production from :

ISOVIN: Build Date:

W0L0TGF3535043736 27/09/02

Solid slide pins fitted in production from:

Calendar Week 36 (Sept) 2002.

SERVICE RECTIFICATION

Summary: Confirm complaint noise, confirm vehicle

has Lucas calipers, check damper installation, then

install solid slide pin kit.

IMPORTANT: Although the solid pin kit has been

successful in rectifying repeat graunch vehicles it will

not eliminate all brake noises. It is therefore vital to

confirm that the vehicle has the low frequency brake

graunch noise before proceeding to fit a solid pin kit.

Procedure:

1. Check that the damper to caliper attaching screw

has been set to the correct torque of 9-11Nm.

NOTE. Failure to check this torque may result

in the graunch noise remaining. Refer Figure 1.

Figure 1

2. Release/disengage the park brake. Remove park

brake handle cover and release tension on the park

brake cable by unscrewing the adjustment nut.

3. Remove rear wheels.

4. Push brake caliper actuation lever (1) with a

screwdriver downwards in direction of arrow and

detach parking brake cable. Remove the retention

clip (2) and withdraw parking brake cable from

bracket. Refer Figure 2.

Figure 2

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

Solid Pin

Rubber Sleeved

Shim Grease

5. Remove fastening bolts (1) from brake calliper –

counterhold with open-ended wrench (2). Refer

Figure 3

6. Remove the rear brake caliper from brake carrier

and secure to the rear spring with cable ties or

suitable wire.

7. Remove carrier from vehicle.

8. Remove the caliper slide pins from the brake

carrier. See Figure 4.

9. Swap the rubber sleeved pin for a plain pin as

supplied in the kit. Refer Figure 5.

Figure 4.

Figure 5 Shows difference between pins

10. Coat slide pins with silicon type grease (Dow

Corning No. 44 or equivalent)

11. Install the slide pins into the brake carrier

12. Install carrier shims as supplied into carrier with

installation grease (p/n 32960041), making sure

the carrier is cleaned with a wire brush to remove

old grease prior to installation of the new shims.

Note: Grease is to go between the shim and the

carrier. It is not the same grease as the slide pin

grease.

13. Install the new pads ,as supplied, into the carrier-

do not remove the self adhesive backing paper

from the pad.

14. Install the brake carrier to the vehicle. Use thread

locking compound – tightening torque 100 Nm/74

lbf.ft.

15. Clean the caliper piston and fingers where the

pads contact the caliper.

16. If necessary retract caliper piston to allow for new

pads.

17. Remove backing paper from pads self adhesive

section and slide the caliper into position over the

pads.

18. Install new mounting bolts (as supplied) for brake

caliper to brake carrier – tightening torque 25 Nm /

18 lbf. ft.

19. Repeat for the other side of the vehicle

20. Adjust handbrake cable.

21. Confirm that graunch noise has been eliminated.

PARTS INFORMATION

Part No.: Description: Qty:

93176419 Solid Slide Pin Kit 1

WARRANTY CLAIM INFORMATION

Description Solid Slide Pin Kit

Installation – Both sides

Labour Op. No. H000243

Time 1.0 hr

Failure Code 40 Noisy

NOW Failure Code H0040 Noisy

Plain pin

Rubber sleeve pin

HOLDEN SERVICE TECHLINE _____________________________________________________________FEBRUARY, 2004

SERVICE PROCEDURE

LPG Mixer Removal and Reinstallation

Precaution

HBD fitted LPG

(GROUP 6C) TL0607-0401

Whenever the LPG mixer is removed to service

spark plugs etc. it must be reinstalled in exactly the

same orientation it was in prior to removal. If the

mixer is twisted slightly from its original position, this

may result in the vapour hose fouling on the spark

plug leads. Figure 1 shows the parts in question.

Figure 1

SERVICE RECOMMENDATION

If the mixer is removed for any reason it should be

reinstalled in exactly the same orientation it was in

prior to removal. To ensure this happens, place

alignment marks on the mixer and elbow as shown in

Figure 2 prior to unclamping the mixer.

NOTE: Holden By Design (HBD) have been adding

alignment marks on the mixer and elbow as shown in

Figure 2 from July 2002.

Figure 2.

NOTE. Holden TAS report that they have had some

cases where the following DTCs have been set due

vacuum hoses (numbers 2 & 3 in Figure 3) being

swapped around when reinstalling the mixer.

P0132 - RH oxygen sensor signal voltage high

P0152 - LH oxygen sensor signal voltage high

Please ensure that these vacuum hoses are

reinstalled correctly if they are taken off when

removing the mixer.

Figure 3.

HOLDEN SERVICE TECHLINE __________________________________________________________________MARCH, 2004

INFORMATION

Gen III Oil Pan Drain Plug Sealing Washer

VY II

(GROUP 6A) TL0635-0402

At introduction of VY Series II, the engine oil pan drain

plug and sealing washer were revised as follows.

A. The plug changed from 13mm to 15mm hex.

B. The sealing washer was no longer available

as a serviceable part.

Therefore, when servicing vehicles do not remove

and discard the existing sealing washer from the plug.

Wipe the sealing washer to remove excess engine oil

and reinstall drain plug and washer assembly.

In the event the sealing washer is damaged, a

complete drain plug and washer assembly will need to

be fitted.

PARTS INFORMATION

Part No.: Description: Qty

11519408 Plug and seal assembly

oil pan drain A9W

NOTE: A9W is the production option code for

introduction of VY series II.

INFORMATION

Dana Contacts for Exchange Axles

V & W cars

(GROUP 4) TL0640-0402

Dana Automotive Systems Group is Holdens supplier

of V & W car rear and front drive axle units for vehicle

production, and exchange axle units for warranty

replacement. Dana has recently changed address

and contact details are as follows:

Dana Website

Dana should be contacted on their Website for all

warranty axle exchange requests and LSD “chatter”

kits.

For use of the Dana Website refer to Dealer Letters

DL 54/01 and DL 83/02.

Dana Website address is:

http://www.spiceraxle.com.au

Axle Warranty Enquiries

For any issues relating to supply of exchange axle

units not addressed by the Website – contact:

Robert Linton : (02) 9892 9237, Fax: (02) 9892 9310

Michael Morgan: (02) 9892 9343, Fax: (02) 9892

9442

Address Details

Dana Automotive Systems Group

205 - 231 Fairfield Road (Cnr. Foray Street)

Yennora, NSW 2161

These details will be updated in the next issue of

Passenger SIP.

INFORMATION

SPS Programming and Linking

All Models

(GROUP 0B) TL0664-0402

TAS receive many calls from retailer technicians who

run into problems when trying to perform the

"Program Immobiliser Function" or PCM to BCM link.

Please be aware that if you are installing a new

PCM/ECU you must do SPS programming before

carrying out the above.

This is only required for new PCMs/ECUs.

HOLDEN SERVICE TECHLINE __________________________________________________________________MARCH, 2004

DIAGNOSIS HINT

Interior Light Fuse Blows or Interior

Lights Staying On

VY / V2 / WK

(GROUP 12) TL0639-0402

CONDITION

Interior light fuse (number 6) blows or interior lights

stay on.

DIAGNOSIS HINT

If presented with a vehicle having either of above

conditions, it is recommended that the following areas

be inspected (in the order shown) for possible wiring

damage prior to performing the standard diagnosis.

1. The driver’s and passenger’s sun visor pivot area.

2. Rear map lamps (above the passengers doors).

3. Passenger door light switch circuit trapped behind

the PCM / PIM mounting bracket.

4. The wiring around the key reader slip ring.

5. Door sill screws holding the sill trim panels on.

6. Upper B pillar, B pillar trim clips or seat belt

bracket.

DIAGNOSIS HINT

Centre Rear Seat Belt Cannot Be

Withdrawn

(GROUP 1) TL0656-0402

A Retailer call to TAS has highlighted the following

issue relating to the operation of the centre rear seat

belt.

If the seat back is not correctly latched in the

vertical position, the centre rear seat belt “locks-

up” and cannot be withdrawn from the seat back.

Therefore, if a customer complains that the centre

rear seat belt has locked-up and cannot be

withdrawn, the first thing to check is if the seat back

is correctly latched in the upright position.

Please ensure that all your Service Advisors are

aware of this item.

HOLDEN SERVICE TECHLINE __________________________________________________________________MARCH, 2004

SERVICE PROCEDURE

Clutch Pressure Plate Bolt Torque

Revised

All with Gen III 6-Speed M/T

(GROUP 7A) TL0634-0402

The pressure plate bolt torque specification has been

revised in production to 70 +/- 7 Nm from:

ISOVIN: Built Date:

6G1VX12F04L234149 12/2/2004

NOTE: Whenever performing repairs to the clutch

assembly, ensure that the 6 pressure plate retaining

bolts are tightened in sequence as shown in PV SIP

and evenly over 4 stages until the correct torque is

reached.

CLUTCH PRESSURE PLATE

BOLT TORQUE SPECIFICATION.

Stage 1 15 Nm

Stage 2 35 Nm

Stage 3 55 Nm

Stage 4 70 Nm

Holden PV SIP will be updated at the earliest

opportunity to show this new specification.

SERVICE PROCEDURE

Revised Door Lock Knob Assembly

VYII, V2, WK

(GROUP 1) TL0636-0402

A revised door lock knob assembly has been

introduced which has a tool access slot added below

the red locking insert. This slot allows the red locking

insert to be released without damage. Refer Figure 1.

Figure 1. Shows a removal tool inserted into slot

below red locking insert.

PRODUCTION BREAKPOINT

Revised door lock knob assemblies with added

access slot have been fitted to vehicles from:

ISOVIN: Built Date:

L238377 18/2/2004

REMOVAL PROCEDURE.

1. Pull door lock knob up to reveal slot below red

locking insert.

2. Insert removal tool into slot.

3. Pull red locking insert outwards to allow door lock

knob to be withdrawn.

A removal tool can be manufactured from steel to the

following dimensions. (previously used for VN)

HOLDEN SERVICE TECHLINE __________________________________________________________________MARCH, 2004

INFORMATION

New design Blower Speed Controller for

ECC Vehicles

VYII, WK, V2

(GROUP 2) TL0642-0402

A new design HVAC blower speed controller has

been introduced into vehicles from:

ISOVIN: Built Date:

6G1YX54F44L236466 10/02/2004

Operating Characteristics Of New Blower

Speed Controller.

The main feature of the new blower speed controller

is an internal resettable circuit breaker. This circuit

breaker is to prevent damage to the blower motor

electrical circuit in the case of electrical current

surges, blower motor lock up on slower speeds or

extreme temperature build up.

If any of the above situations occur in the blower

motor circuit, the circuit breaker will open circuit and

render the blower motor inoperative.

The circuit breaker will reset after the ignition is cycled

from OFF to ON.

PROBLEM DIAGNOSIS

If a customer reports that “the blower motor switched

off while driving and resumed after the ignition was

cycled from OFF to ON do not replace the blower

speed controller as it has performed the function it

was designed for. Check the following:

- Blower motor and circuit for excessive current draw.

- Blower motor for foreign material caught in plastic

impeller.

In cases where the blower speed controller switches

the blower motor OFF regularly, and the above

checks do not reveal any abnormalities, replace the

blower motor as this could be the cause of excessive

current.

PARTS INFORMATION

Part No.: Description: Qty:

92162703 Blower Speed

controller ECC

The blower speed controller 92162703 can be used

as a replacement for previous controllers 92146630

and 92140666, from VT to VY.

Note that the new controller has 3 terminals whereas

the previous controllers had 4 terminals.

HOLDEN SERVICE TECHLINE __________________________________________________________________MARCH, 2004

SERVICE FIX

Blaupunkt Radio Speed Dependent

Volume Malfunction

TS / XC / ZC

(GROUP 12) TL0660-0402

This is advance service fix information. An updated

techline will be issued when Production Correction

information is available.

CONDITION

Customers may advise that the speed dependent

volume control feature does not function even when

the highest level of speed dependent volume control

is selected on the audio head unit.

CAUSE

The above condition is related to a change in the

software in Blaupuntkt audio head units from the

middle of 2003. The revised software can be

identified by adjusting the volume control; if the word

VOLUME is displayed, the head unit has the affected

software level.

CORRECTION in PRODUCTION

To be advised in a future techline

CORRECTION in SERVICE

To rectify customer complaints of this condition,

perform the following operation. Ensure that only the

PULSE setting is changed.

1. Turn radio off.

2. Push and hold number 5 and 6 buttons then

press ON.

3. Keep all three buttons pressed until the word

"Service" appears on the screen.

4. Release buttons.

5. Push "SEEK" button unit the word "PULSE 2"

appears on screen.

6. Push the "TUNE/TRACK" button left to reduce

setting to "PULSE 1".

7. Turn radio off then back on or leave for 10

seconds (Radio automatically exits service

mode)

NOTE: For reference, the configuration of

each parameter shown within the “Service” selection

should be as follows;

ZC Vectra equipped with a 2620 audio head unit

Range2

GID

MAXVOL40

P01 007

Pulse 1

ZC Vectra equipped with a 2020 audio head unit

Range2

10T CHAR

MAXVOL40

P01 007

Pulse 1

TS Astra equipped with a 520 audio head unit

Range2

MAXVOL40

P01 006

Pulse 1

XC Barina equipped with a 2020 audio head unit

Range2

MAXVOL40

P01 007

Pulse 1

HOLDEN SERVICE TECHLINE __________________________________________________________________MARCH, 2004

INFORMATION

Trailer Harness – Location of Electric

Brake Connection

AWD Adventra Wagon

(GROUP 0B) TL0647-0402

Trailer harnesses are fitted as standard equipment to

Adventra.

The trailer harness is connected to the vehicle wiring

harness behind the right hand tail light assembly.

The blue wire within the trailer harness used for

connecting electric brakes, has previously been tied

near the end of the harness connector. On Adventra,

this blue wire continues through the connector to the

vehicle harness and terminates approximately 10 -15

cm along the vehicle wiring harness behind the inner

rear panel / trim.

The wire and connector is taped to the vehicle

harness which is hidden behind the panel. Refer to

Figure 1 below.

Figure 1. Shows harness pulled down to reveal

electric brake connection.

HOLDEN SERVICE TECHLINE __________________________________________________________________MARCH, 2004

INFORMATION

Revision to Con Rod Big End

Manufacturing Process

All V6 3.8L Engines

(GROUP 6A) TL0650-0402

Commencing from Engine No. VA375970, fitted to

vehicle tag No. L179991, all 3.8L V6 engines are

fitted with connecting rods manufactured using the

latest powder forged metal technology and the “big

ends” are cracked apart in lieu of conventional

machining – refer illustration 6A2-1

The following information is provided for use by

technicians until the information is available in

Passenger SIP:

Powder forged cracked type connecting rods were

introduced into production as a running change

during September 2003. Illustration 6A2-1 shows the

difference in the early cast and machined type (A)

and later powder forged and cracked type (B)

connecting rods.

NOTE

Other than the revised manufacturing process and a

revised connecting rod cap bolt torque specification,

all other specifications and servicing procedures

relating to the connecting rods remain unchanged.

CAUTION

The early type connecting rods can be replaced

by the late type connecting rods.

However, to avoid confusion with having different bolt

torque values, when replacing early type connecting

rods with the late type, it is recommended that the

connecting rods be replaced as an engine set.

Illustration 6A2-1

Connecting Rods:

Early Type: Malleable Cast Iron 'I' Section

Late Type: Powder Forged ‘I’ Section

Length: (centre to centre)

Std V6 : 143.20 – 143.30 mm

S/C V6: 145.90 – 145.80 mm

Alignment: Bend 0.020/25.4 mm;

Twist 0.038/25.4 mm

Torque Wrench Specifications:

Early Type Connecting Rod (machined big

ends) Cap Bolts:

27 ±3 Nm plus 50 ±3° turn angle

Late Type Connecting Rod (cracked big ends)

Cap Bolts:

20 ±3 Nm plus 75 ±3 ° turn angle

HOLDEN SERVICE TECHLINE __________________________________________________________________APRIL, 2004

INFORMATION

Holden Contacts and Procedures

(GROUP OB) TL0679-0403

This techline summarises some of the Holden

contact procedures and gives a quick reference

guide for contact numbers.

Security information.

To obtain security information a completed security

information request form must be faxed through to

the security information department, as security

information cannot be given out by phone. TAS does

not process security information requests. Please

ensure you have the latest security information

request form, which is available on SIP. Contact

details are listed below. There can be up to a 4-hour

turn around on requests however if the information

needs to be obtained from overseas, it may take up

to 24 hrs. Do not phone the security information

department unless you have not received a response

in the normal turn around time. For further

information please refer to ADL 63/99.

Parts inquiries and information

If any information or assistance is required in regards

to part numbers or Partfinder, please refer to the

Holden Help section in Partfinder.

Warranty Authorisation and enquiries

Warranty can only be authorised by your Aftersales

District Manager. Labour times information is

available on SIP or from the warranty department.

For any other warranty inquiries please contact

Warranty Administration.

TAS

Technical Assistance Service (TAS) is a service

provided by Holden to assist Holden Dealers in

problem resolution.

TAS operating hours are:

Monday to Thursday 8.30am – 8.00pm and Friday

9.30am – 5.00pm Melbourne time. Contact to TAS

must be made by a Nominated Contact as outlined in

Section 5 of the TAS procedures manual. All

techlines, dealer letters and service information must

be checked prior to contacting TAS. The Nominated

Contact must not contact TAS until he/she has been

fully involved with the faulting vehicle and all Dealer

expertise has been exhausted. Problems should be

escalated through the Dealership to the senior

technician/foreman before contacting TAS.

TAS cases must be updated or closed within 30 days

unless a Dealer is waiting on a service fix to be

provided. It is the Dealers responsibility to update

cases. All cases should be recorded in the TAS

procedures manual, which should be referred to prior

to contacting TAS. Please note that an electronic

copy of the TAS procedures manual is also available

on passenger SIP.

Under no circumstances are TAS or other Holden

contact details to be supplied to customers or

independent repairers. TAS is a service restricted to

assisting Holden Dealer service departments.

Quick reference contact numbers

Air International Ph 1800 673 716

Australian Arrow Ph 03 9785 0792

Blaupunkt/Bosch Ph 1300 307 036

Clarion Ph 03 8558 1115

Fax 03 9551 0377

Customer Assistance Ph 1800 033 349

Dana Ph 02 9892 9237

Fax 02 9892 9310

www.spiceraxle.com.au

Delphi Ph 1800 335 777

Eurovox Ph 03 9237 0800

Fujitsu Ten Ph 03 9646 6008

Holden Assist Ph 1300 880 088

HSV Ph 03 9265 9500

Infomedia Ph 1800 810 103

Panasonic Ph 02 9986 7635

Petro-Ject Ph 02 9890 5701

Ph 02 9890 5244

Philips/Siemens-VDO Ph 1800 335 282

Salmat Ph 03 9358 2900

Security Ph 03 9647 2001

SPX Australia Ph 03 9544 6222

TAS Ph 1800 033 417

Fax 03 9647 2495

Email [email protected]

Warranty Ph 03 9647 1972

Ph 03 9647 2401

Ph 03 9647 1970

HOLDEN SERVICE TECHLINE __________________________________________________________________APRIL, 2004

DIAGNOSIS HINT

Electric Power Steering (EPS) Problems

Due To Poor Ground Point

XC Barina

(GROUP 9) TL0680-0403

Background Information

TAS has received calls from retailers regarding no

Tech 2 communication with the Electric Power

Steering (EPS), EPS light on in instrument cluster,

and/or repeat failure of the EPS module.

Investigation has found the EPS module high current

earth to ground point 4 at the drivers side A pillar, to

be loose, stripped or disconnected.

This ground point is located on a metal bracket to the

righthand side of the bonnet release lever as shown

in figure 1.

Important

When diagnosing any EPS related fault, check

ground point 4 retaining nut is fitted and tightened.

Figure 1

Figure 2.

SERVICE FIX

Front Suspension Clunk (Lower Control

Arm Rear Bush Movement)

VY Adventra

(GROUP 3) TL0638-0403

CONDITION

Clunk from front suspension usually heard when

wheel impacts deep pot hole.

CAUSE

One potential cause of front suspension clunk which

has been identified is movement of the control arm

bush in the cross member due to insufficient clamp

load.

CORRECTION – in Production

Front lower control arm bush rear bolt torque revised

on vehicles from:

ISOVIN: Built Date:

**********L237289 23/02/2004

CORRECTION – in Service

After verifying that vehicle has symptoms as

described above, increase torque on the front lower

control arm rear bush bolt to 175 – 185 Nm. Refer

bolt No. 4 in Figure 1.

Note. The bolt does not need to be replaced prior to

applying revised torque.

Figure 1.

Ground Point

Update

HOLDEN SERVICE TECHLINE __________________________________________________________________APRIL, 2004

SERVICE FIX

Front and Rear Accessory Mudflaps

Dislodge

(GROUP 1) TL0675-0403

CONDITION

Accessory mudflaps become dislodged.

CAUSE

The mudflaps are attached to a metal mounting

bracket with plastic “heat stakes”. These joints may

be damaged in service which allows the plastic

mudflap to detach from its mounting.

CORRECTION

On any vehicle where the mudflaps become

dislodged as a result of damage to the “heat stakes”,

perform the following procedure.

Use fasteners P/N 92138352, to re-attach the

mudflap to the metal mounting bracket by simply

screwing the fasteners into the original heat stake

positions. Refer Figure 2

NOTE: The fastener tip is covered in a sealant

material which needs to be removed prior to

screwing into the plastic. (Refer Figure 1)

Add fasteners to each heatstake position regardless

of whether they are broken or not. This will ensure

the mudflap does not fail in the same manner again.

Front – 2 screws per mudflap

Rear – 3 screws per mudflap

NOTE: Fasteners, as described in this techline, will

be applied to all new Holden accessory mudflaps.

PARTS INFORMATION

Part No.: Description: Qty:

92138352 Screw 10

WARRANTY CLAIM INFORMATION

Description Attach mudflap to mounting

bracket with screws (4

mudflaps)

Labour Op. No. C000517

Time 0.4 hr

Failure Code 71 / C0071 Pulled loose

Figure 1. Remove

sealer from screw.

Figure 2. Screwing into

heatstake

Figure 3. Add a screw to each heatstake position.

HOLDEN SERVICE TECHLINE __________________________________________________________________APRIL, 2004

SERVICE FIX

Fuel Odour and Dust Entry

VU, VY Ute

(GROUP 8) TL0603-0403

ThisTechline should be read in conjunction with

Techline TL509-0308 (issue 8, Aug. 2003) which

provides sealing procedures for preventing dust/fuel

odour entering cabin.

PROBLEM DESCRIPTION

Customer complains of fuel smell in cabin usually

after the vehicle has been parked for some time.

Investigations show that small amounts of fuel

vapour may permeate the fuel filler hose and result in

a fuel odour.

PRODUCTION RECTIFICATION

An improved fuel filler hose with lower permeability

was installed into vehicles from

ISOVIN: Built Date:

**********L209199 4/12/2004

In addition to the above, expanding foam has been

added into the rocker panels (to prevent dust/fuel

odours entering the cabin) on vehicles from:

ISOVIN: Built Date:

**********L238316 17/2/2004

SERVICE RECTIFICATION

Summary: On complaint vehicles, replace the fuel

filler hose and seal the dust/fuel odour pathways in

body as per following procedure .

1. Replace fuel filler hose with new hose shown in

Parts Information.

2. On vehicles built before tag L238316,

(A) Seal all dust/fuel odour pathways as

described in Techline No. TL509-0308 (Issue 8,

Aug. 2003).

(B) Seal the hole in the sheetmetal at the base of

the drivers side B-pillar behind the seatbelt

retractor as shown in Figure 1. Seal the hole with

butyl patches cut from part No. 92156600.

NOTE: Vehicles built after tag L238316 do not

require above sealing procedures as they have

expanding foam inside the rocker panels to restrict

dust/fuel odours.

Figure 1. Section of lower RHS B-pillar showing oval

shaped hole (behind seat belt retractor) that requires

covering with a butyl patch.

PARTS INFORMATION

Part No.: Description: Qty:

92211421 Hose fuel filler 1

92156600 Deadener (butyl

patch)

WARRANTY CLAIM INFORMATION

Description Replace fuel filler hose and

add butyl patch to oval hole

in base of RHS B Pillar

Labour Op. No. L000226

Time 0.9

Failure Code 74/ L0074

HOLDEN SERVICE TECHLINE __________________________________________________________________APRIL, 2004

SERVICE FIX

Low Speed Engine Cooling Fan Relay

Sticking On

VYI, WK, V2 II With Gen III

(GROUP 12) TL0673-0403

CONDITION

Engine cooling fan remains on continuously after

ignition is switched off. In some instances the

vehicle battery may be fully discharged.

CAUSE

Contaminant on internal relay contacts due to a

quality control issue at the relay manufacturer.

Relays from the suspect batch were fitted to all

vehicles built between Jan 03 and Jul 03.

CORRECTION - Production

Known good relays were fitted to vehicles from:

ISOVIN: Built Date:

**********L145369 11/07/2003

CORRECTION – Service

On vehicles affected by this condition, replace the

relay with one where the date code, as shown in

Figure 1, reads “IN 0314” or higher.

All relays manufactured prior to date code IN 0314

have been removed from HSPO stock.

PARTS INFORMATION

Part No.: Description: Qty

92092445 Low Speed Cooling Fan

Relay

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

DIAGNOSIS HINT

False Triggering Of Reverse Park Aid By

Tow Ball

VY, WK, V2

(GROUP 12) TL0654-0403

CONDITION

Reverse Park Aid is triggered for no “apparent

reason, i.e. there are no objects within range behind

the vehicle

POSSIBLE CAUSE

The reverse parking aid sensors may be detecting

the tow ball.

SUGGESTED CORRECTION

1. For vehicles with the above condition it is

recommended to adjust the bottom of the rear

bumper fascia rearwards by 10mm. This action is

intended to alter the angle of the sensors.

NOTE: Relocating the bottom of the fascia rearwards

by 10mm will require drilling new holes in the lower

attaching metal bracket for the 2 retainers.

2. Check the Rear Parking Aid system operation

again. If the system no longer detects and triggers off

the tow ball then adjustment is complete.

3. If the system continues to be triggered off the

tow ball, interchange the two inner sensors with the

two outer sensors and re evaluate system operation.

4. If the system continues to be triggered off the

tow ball perform the rear park aid diagnosis

procedure as shown in Passenger SIP.

Retainer

PULL

HOLDEN SERVICE TECHLINE __________________________________________________________________APRIL, 2004

SERVICE FIX

DTC’s P0171 & P0174 Fuel system lean,

Banks 1 & 2

VY II, V2 III, with GEN III V8 and M/T

(GROUP 6C) TL0682-0403

PROBLEM DESCRIPTION

DTC’S P0171 and P0174 setting (banks 1 & 2 lean

indication). After conducting extensive diagnosis

including checking for low fuel pressure, fuel quality

and vacuum leaks, no fault can be found.

The cause of codes P0171 & P0174 setting when no

evidence of running lean can be found, is

oversensitive PCM software calibration.

PRODUCTION RECTIFICATION

Breakpoint information for the introduction of revised

PCM software calibration into vehicle production will

be advised in a future Techline.

SERVICE RECTIFICATION

Revised PCM software to rectify P0171 and P0174

setting unnecessarily was released on TIS 2000 CD

50.

HOLDEN SERVICE TECHLINE __________________________________________________________________APRIL, 2004

SERVICE FIX

Low Speed Steering Shudder

VY with V6 engine (non S/C)

(GROUP 9) TL0615-0403

PROBLEM DESCRIPTION

Some vehicles may experience a shudder felt

through the steering wheel, when very low speed or

stationary steering operation is performed.

SERVICE RECTIFICATION

Summary: Fit revised high pressure power steering

hose between pump and steering gear.

Procedure:

1. Remove power steering high pressure hose

between pump and steering gear.

2. Fit revised high pressure power steering hose

(p/n 92174786) between the pump and steering

gear. Use new seals at the pump and the

steering gear (p/n 08526398).

3. The new hose has extra length which is to be

routed across the front of the engine. Refer figure

4. The two brackets that are integral to the new

hose are to be fixed to the front cross member

brace using screws (p/n 11069615) inserted into

existing holes as shown in figure 1 by arrows.

5. Top up power steering system and bleed as per

SIP procedure.

PARTS INFORMATION

Part No.: Description: Qty:

92174786 High Pressure Hose 1

11069615 Screw -Pressure power

steering hose

08526398 Seal – Pressure Pipe to

pump and steering gear

WARRANTY CLAIM INFORMATION

Description Power Steering Hose Kit

Installation

Labour Op. No. M000205

Time 0.5 hr

Failure Code 36/ M0036 vibrates

PRODUCTION RECTIFICATION

At the time of printing, the breakpoint for fitting

revised high pressure hoses to vehicles has not

been established. When it is established, this

techline will be updated on Holden Lionheart.

HOLDEN SERVICE TECHLINE __________________________________________________________________APRIL, 2004

SERVICE FIX

Steering Wheel Spokes - Satin Chrome

Finish Comes Off

V2, WK, VY

(GROUP 9) TL0655-0403

CONDITION

On some vehicles the satin chrome finish may come

away from the steering wheel spoke substrate

material.

CORRECTION in SERVICE

Summary: On complaint vehicles, replace faulty

spoke covers as per following procedure.

1. Remove steering wheel as per procedure in PV

SIP.

2. Detach rear cover from steering wheel.

3. Remove four spoke covers by undoing attaching

screws from rear.

4. Install new spoke covers.

5. Reinstall all parts.

PARTS INFORMATION

Part No.: Description: Qty

92147964 Cover package steering

wheel spokes (contains

4 covers)

WARRANTY CLAIM INFORMATION

Description Replace steering wheel

spoke covers

Labour Op. No. C000514

Time 0.5 hr

Failure Code 23 - Finish comes off

Failure Code NOW C0023 – Finish comes off

SERVICE FIX

Blaupunkt Radio Losing Time or CD Will

Not Eject

VY / V2 II

(GROUP 12) REVISED TL0580A-0403

This techline supersedes the previous one

TL580-0311) in Issue 11, Nov. 2003. It is revised

by removing WK from the models affected.

Please correct all previous copies of TL0580-0311.

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

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

DIAGNOSIS HINT

Tech 2 Communications with

ABS/ TC/ ESP

TS Convertible & SRi Turbo

(GROUP 5) TL0689-0404

TAS receive many calls where technicians are

experiencing difficulty when trying to communicate

with ABS on the vehicles listed above.

Technicians are selecting ABS/TC from the Chassis

menu on Tech 2 as they are unaware that ESP is

fitted standard to these vehicles. Tech 2 will continue

to display “waiting for data” until “abort” is chosen.

ESP should be selected from the Chassis menu. This

will allow Tech 2 communications for the

ABS/TC/ESP system including all data lists,

miscellaneous tests and diagnostic trouble codes.

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

SERVICE FIX

ABS Light Comes On, DTC 71 Set

VY, V2, WK

(GROUP 5) TL0685-0404

CONDITION

Customer reports the ABS Instrument panel light

comes on.

Dealer diagnosis reveals DTC 71 “Control Module

Internal Fault” is being logged. Diagnostic checks as

per SIP lead to module replacement.

CAUSE

An abnormality with the electronics in the ABS control

module which only occurs at vehicle start up.

CORRECTION – Production

Revised ABS control modules have been fitted to

vehicles from:

ISOVIN: Built Date:

**********L239319 20/2/2004

NOTE: Revised modules fitted in production and

supplied from HSPO are identified with blue paint as

shown in the attached photographs.

CORRECTION – Service

After verifying that vehicle has symptoms as

described above, fit a new ABS control module and

hydraulic modulator assembly.

This can only be obtained from HSPO after receiving

approval from BOSCH via the Prior Approval

program.

PARTS INFORMATION

Part No.: Description: Qty

92093868ABS control module &

hydraulic modulator assembly

(V6 & V8 without traction

control)

92093870ABS control module &

hydraulic modulator assembly

(V6 with traction control)

Attention Parts Managers!!

Any ABS control module & hydraulic modulator

assemblies prior to breakpoint (i.e units without blue

paint mark) should be returned to HSPO for credit via

the CRRM system.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

Figure 1. 92093868

Figure 2. 92093870

Update

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

INFORMATION

TIS 2000 error message when accessing Service Information or Security Access

TIS 2000

(GROUP OB) TL0690-0404

This techline is to be used in conjunction with Technicians guild article number 8 of 2003

PROBLEM DESCRIPTION

TIS 2000 displays error codes when user attempts to access some functions. Prior to seeking help from

TAS, it is recommended you perform the following checks.

When accessing Service Information the following screen may appear.

To overcome this problem, click the “ok” button in the message box. Click on the word “configuration” at the top of

the screen, select “options”. Starting from the left tab make sure the following selections are made.

Language: English (united states)

Country: Australia or New Zealand as applicable

Salesmake: Opel (unless doing Isuzu product then select Isuzu, do not select Holden for any product)

Dealership: Holden

WWW: Do not tick the enable java box

Click “ok”

After the settings have changed, a message box will appear advising that the salesmake settings have changed and

TIS must be restarted, click YES to this. Another message about closing open sessions will appear. If there are no

other open sessions click “YES”. Restart TIS and retry service information. If you continue to have problems with

service information a TAS nominated contact should contact TAS.

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

When accessing Security Access the following message may appear.

(Make sure your hardware key is installed prior to attempting to obtain Security Access).

Click the “ok” button in the message box and then click on the word “configuration” at the top of the screen.

Select “I/O management” and make sure “Dongle” is highlighted (unless you have the new super pro USB hardware

key in which case “super pro” will need to be highlighted). Press the “test” button on the right hand side. The

following message may appear.

Click “ok” in the message box and then press the “properties” button on the right hand side. A box displaying the

current com port that is selected will appear. Click on the black arrow on the right of the message box; this will

display the other com ports available. Select a different com port than the one displayed (not LPT1) and click ok.

Press the test button again. If more than 2 com ports available then this may have to be done again on all com ports

until it passes. When message appears saying “Driver test successful” click “ok” and close I/O management box.

Retry Security access.

If problems still occur a TAS nominated contact should contact TAS.

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

INFORMATION

TIS 2000 Update And Uninstall Procedure

(GROUP 0B) TL0691-0404

TAS receive many calls where a TIS 2000 Update or

a new TIS 2000 Installation has failed. This techline

is to clarify the following procedures:

• Update TIS 2000

• Uninstall TIS 2000

• TIS 2000 Configuration Options

If your Dealership has a PC specialist, it would be an

advantage to utilise his/her expertise.

Update TIS 2000

To update TIS 2000 proceed as follows:

• Place TIS CD1 in your disc drive, wait a few

seconds and then click on the icon, which

opens TIS 2000. This will then see the disc as

an update and continue to upload. On

completion of the first, it will request that you

load the second disc. When the second disc

is inserted, click OK in the dialog box to begin

the upload.

• Both LCV TIS and Wiring Diagrams CD’s

should be treated as an Update.

Uninstall TIS 2000

To uninstall TIS 2000 proceed as follows:

• Remove any cd’s from all drives.

• Shut down and Restart your computer (PC).

• Click on the Start button (lwr left of screen).

• Move up to programs then across to TIS 2000

and again across to TIS 2000 Uninstall.

Select Uninstall from this menu.

• When the Uninstall is fully complete it should

advise if it was successful. If not, you will

need to run through the following procedures.

• Click on the Start button again and choose

Search or Find, moving over to Files or

Folders.

• Type cosids in the search field, and then

choose local hardrives in the look-in field.

Now select Search/Find now. This will

generate a search for the TIS 2000 main files.

(If any files are found it will be displayed in the

large box to the right, if not continue to next

step)

• Delete all files that have been found, by

selecting with your mouse and hitting the

delete button on your keyboard.

• Now click on the Start button again and scroll

up to Settings, then move across to Control

Panel. In this menu, double click on

Add/Remove Programs and look for the

following items:

JAVA 2 RUNTIME ENVIRONMENT STD EDITION

and

JAVA SERVLET DEVELOPMENT KIT.

• If they are available, select one at a time then

hit the Change/Remove button for each.

Close this window.

• It is now very important to restart your

computer.

TIS 2000 CONFIGURATION OPTIONS

When attempting a complete TIS 2000 install, place

CD1 in the drive and this should now begin the

installation. It will request the second CD when

required.

Follow all prompts until the installation is complete.

NOTE: it is very important that you select the following

configuration when prompted:

• Language – English

• Country – Australia/New Zealand (whichever

is applicable)

• Salesmake – OPEL

• Dealership – HOLDEN

• WWW – not checked (ticked)

You will also need to select which COM port you

would like your TECH 2 and Hardware Key to

communicate with. You must ensure these are both

the same. E.g.; COM1 or COM2.

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

INFORMATION

Sat Nav Computer Upgrade

All with HBD SATNAV

(GROUP 12) TL0658-0404

The PC5100 Navigation Computer Part No. 92145886

has been superseded by an upgraded PC5400

Navigation Computer Part No. 92147898.

The PC5100 Navigation Computer Part No. 92145886

is no longer available.

PRODUCTION BREAKPOINT

The improved PC5400 Navigation Computer

92147898 has been fitted to vehicles from:

ISOVIN: Built Date:

6G1YK52A84L226898 23/1/2004

SERVICE REPLACEMENT PROCEDURE

If a vehicle with a PC5100 Navigation Computer

(92145886) ever requires replacement with a PC5400

Navigation Computer (92147898) the following

additional parts are required for correct operation:

• Patch harness Part No. 92147901 (includes zero

ohm link).

• Disc - Navigation Data (Map) Part No. 92211882.

The patch harness is installed in line between the

Navigation Computer and the vehicle wiring harness.

Installation procedure:

1. Disconnect vehicle battery.

2. Remove the vehicle wiring harness connector

from the back of the Navigation Computer located

in the boot.

3. Replace the plug-in resistor in the vehicle wiring

harness with the zero ohm links.

4. Remove the Navigation Computer from the cradle

using the removal tools.

5. Plug the patch harness 92147901 into the vehicle

wiring harness.

6. Insert the patch harness connectors into the back

of the newly installed Navigation Computer.

7. Install the PC5400 Navigation Computer Part No.

92147898 into the Cradle.

8. Reconnect vehicle battery.

9. Follow installation instructions as supplied with

the Disc - Navigation Data (Map) Part No.

92211882.

10. NOTE: When inserting a C-IQ Map disc (this is

the Map disc p/n 92211882 compatible with the

PC5400 Part No. 92147898) into a system for the

first time, a code to activate the map data will be

required. This code can be obtained from

Siemens VDO direct on 1800 335 282.

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

Oil Sender Adaptor Fouls On HSPO Oil

Filters

HSV vehicles with optional gauges

(GROUP 6A) TL0598A-0404

This techline supersedes previous techline TL0598-

0311. All copies of that techline should be marked

“superseded”.

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 adaptor part No 06G – 030601 provides more

clearance (refer Figure 2). On vehicles with a built

date prior to 6 Feb. 2003, sender part No. 12J-020608

will also be required. Both parts are 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

The above information has been supplied by HSV for

distribution to all Holden dealers……………………

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

SERVICE FIX

Antenna Extends and Radio Turns on by

Itself

VY / WK / V2 Series II & III

(GROUP 12) TL445A-0404

This Techline supercedes TL445-0303 published in

Issue 3, March 2003. This Techline now includes

information on a replacement antenna connector.

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 an electric

antenna.

The cause of this problem is water entry into the two

pin connector at the electric antenna.

SERVICE RECTIFICATION

Summary: Remove water from antenna connector. If

damaged or corroded replace connector.

1. Remove all water from 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.

Antenna Connector Replacement

If the antenna connector is damaged or corroded a

replacement connector and lead is available from

HSPO (refer parts information).

When replacing the antenna connector ensure that

the wires are joined using the methods outlined in

Passenger vehicle SIP.

MY2003 VY & V2 II Including Ute / Wiring Diagrams /

Section 12P-Wiring Diagrams / 5. Wiring Repair

Procedures / Performing Wiring Harness Repairs.

Note: Once the wires are joined, ensure they are

appropriately insulated using electrical tape or heat

shrink tubing.

Ensure the wires are connected to the correct location

(the replacement connector wires are both black).

PARTS INFORMATION

Part No.: Description: Qty:

92146329 Nye Nyogel 760G

Grease – 30cc syringe

92147807 Connector & Lead 1

WARRANTY CLAIM INFORMATION

Description Dry water out of antenna

connector

Labour Op. No. N000426

Time 0.4 hr

Failure Code N0115

Description Connector Replacement

Labour Op. No. N000460

Time 0.5 hr

Failure Code N0100

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

INFORMATION

VIN – Vehicle Identification Number

ALL

(GROUP 0B) TL0692-0404

It has come to our attention that some technicians

have difficulty interpreting the 17 digit Vehicle

Identification Number (VIN). This number is also

known as ISOVIN which stands for “International

Standards Organisation Vehicle Identification

Number”.

It is important for technicians to understand the

makeup of VIN as many Holden systems/processes

may require the model year, body style and engine

type from the VIN.

To refer to the makeup of VIN refer to Passenger

Vehicle SIP as follows.

VT, VX, V2, VU, WH – SIP Section 0A, 8.5

VY, V2II, WK – SIP Section 0A, 9.5

The Vehicle Owners Handbook always has an

explanation of VIN in Section 8.

NOTE: The model year for vehicle manufacturing

does not change from January 1 each year, but

usually in September/October in the calendar year

before.

For example, a vehicle built in October 2003 will have

a ‘4’ (2004 model year) listed as the tenth digit in the

VIN.

SERVICE FIX

Whistle from HVAC case

VY II, V2 II, WK

(GROUP 2) TL0641-0404

CONDITION

A “whistle” noise from the HVAC that increases as the

blower fan speed is increased.

CAUSE

Distortion of the evaporator upper cover to the HVAC

case. This distortion causes a gap of between 1 and

2 mm between the HVAC case and the evaporator

cover.

CORRECTION in PRODUCTION

HVAC assemblies with two extra screws attaching the

evaporator upper cover to the HVAC case have been

fitted to vehicles from:

ISOVIN: Built Date:

6G1KY54F74L233256 29/01/04

CORRECTION in SERVICE

Remove the IP pad and HVAC assembly and add 2

additional screws to evaporator cover as per the

procedure on following page.

NOTE: Zone approval must be obtained prior to

proceeding with this work.

PARTS INFORMATION

Part No.: Description: Qty:

92147967 Screw (pack of 10) 1

Butyl Mastic sealer can be obtained from most

hardware retailers.

WARRANTY CLAIM INFORMATION

NOTE: Zone approval is required to claim for this

work.

Description Add 2 extra screws to

HVAC evaporator cover.

Labour Op. No. D000345

Time 4.3 hr

Failure Code D0042 Leaks

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

Instruction For Adding 2 Extra Screws To Evaporator Cover.

NOTE: Zone approval must be obtained prior to proceeding with this work.

1 Recover the refrigerant.

2 Remove the vehicle instrument panel pad

3 Remove the HVAC assembly.

4 Detach the ECC aspirator tube (if fitted) and the Two (2) self tapping screws retaining the upper

cover to the HVAC.

5 Remove the evaporator upper cover.

6. Drill a 5mm hole

through the plastic

tabs of the upper

cover. Note: on

the underside of

this cover the tabs

already have a

recess to guide the

drilling position.

(refer to diagram)

EVAPORATOR UPPER COVER

2 SELF TAPPING SCREWS

RECESS IN TAB (BOTH SIDES OF

COVER

)

–

DRILL 5MM HOLE

UNDERSIDE OF EVAPORATOR COVER

TAB

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

pply Butyl mastic to

the groove area of

the evaporator upper

cover as shown in

the diagram.

9. Two (2) extra self

tapping screws are

required to reinstall

the evaporator upper

cover. These screws

are available

through HSPO p/n.

92147967 (packet of

10)

10. Refit the evaporator

upper cover using

the Four (4) self

tapping screws

ensuring that the

tongue and grooves

joints are correctly

joined together.

11. Reassemble all

removed

components in their

reverse order.

7. When the upper

cover is refitted the

self tappers used in

the new positions will

be inserted into the

screw bosses shown

in diagram.

BOSS IN HVAC CASE,

AIR ON SIDE (2 PLACES)

HOLES FOR SELF

TAPPING SCREWS

PPLY BUTYL MASTIC

INTO THE GROOVE IN

THIS AREA

UNDERSIDE OF EVAPORATOR COVER

GROOVE

AROUND

COVER

PPLY BUTYL MASTIC

INTO THE GROOVE IN

THIS AREA

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

SERVICE FIX

Park Brake Shoe Scrape

VT, VX, VY, VU, V2, WH, WK

(GROUP 5) TL0452A-0404

This techline supercedes TL452-0304 published in

Issue 4, 2003. The rectification procedure now

involves fitting a spring to centralise the park brake

shoe.

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 park brake

shoe front lining contacting the drum (in brake disc)

without the park brake being applied.

PRODUCTION RECTIFICATION

A spring, to centralise the park brake shoe in the

drum, is scheduled to be added to vehicles in June.

When this happens, the vehicle breakpoint details

will be published in the Breakpoint Summary.

SERVICE RECTIFICATION

Summary: Fit centralising spring to park brake shoe

as per following procedure.

Refer to Passenger SIP for any procedures not

specified.

1. Raise and support the vehicle. Ensure the park

brake lever is fully released.

2. Remove the rear wheel and brake caliper.

3. Mark the brake disc and hub prior to disassembly

to ensure same fitment position on re-assembly.

(Do not use excessive force to remove the disc as

it may be catching on the shoes. Back off the

shoe adjusting nut, if required, with a screwdriver

through the disc service hole).

4. Remove the park brake shoe as per SIP

procedure.

5. Spray clean the parkbrake thoroughly with

Brākleen or equivalent product.

6. Remove the upper rear mounting bolt. (Refer Fig. 1)

7. Install the spring bracket, and re-fit the upper

mounting bolt. Tighten to 75Nm. (Refer to Fig. 2 )

8. Drill a 4mm hole in park brake shoe outer flange

using attached template as a guide.

NOTE: Only one hole is required per shoe as

shown in Figure 3.

9. Carefully apply a thin film of Molybedenum

Disulphide grease (Shell RD5 or equivalent) to all

shoe contact points (refer Fig 1). Ensure that

grease does not contaminate the shoe brake lining

surfaces

10. Re install park brake shoe.

11. Install the new centralising spring as shown in

Figure 2. The spring should provide a small

amount of tension on the shoe. It should not sit

loose.

12. Clean brake disc with Brākleen or equivalent.

13. Set the shoe diameter to between 189.5 and 189.7

mm across the mid-point of the linings using the

adjuster nut. Do not use the cable at the park

brake lever to make this adjustment.

14. Refit brake disc in its original position according to

the marks made earlier.

15. Re-fit caliper and wheel.

16. With vehicle on ground, ensure correct operation

of park brake. Adjust cable if necessary as per

procedure in SIP.

PARTS INFORMATION

Part No.: Description: Qty

9214781

Park brake shoe scrape kit

(includes 2 brackets and 2

springs)

WARRANTY CLAIM INFORMATION

Description Install Park Brake Shoe

Spring kit – both sides

Labour Op. No. H000260

Time 1.2 hr

Failure Code H0040 noisy

Update

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

Fig 1. Shows Left Hand Side Park Brake Components

Figure 2. Shows installation of centralising spring & bracket – Left Hand Side of vehicle.

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

Figure 3. Template for drilling holes in shoe (FULL SIZE)

HOLDEN SERVICE TECHLINE __________________________________________________________________ MAY, 2004

SERVICE FIX

Horn Switch Contacts Corroded

XC Barina Sri (leather steering wheel)

(GROUP 12) TL0695-0404

CONDITION

Corrosion build-up on horn switch contacts.

CAUSE

A chemical reaction, between the copper in the switch

contacts and a polyurethane additive contained in

leather steering wheels, occurring in a high humidity

atmosphere.

CORRECTION – Production

Steering wheels manufactured with revised materials

and production processes to eliminate horn contact

corrosion have been fitted to vehicles from:

ISOVIN: Built Date:

W0L0XCF6844321975 19/04/04

CORRECTION – Service

Summary: Clean the horn switch contacts as per

following procedure.

Refer to TIS CD for any procedures not specified.

1. Remove switches/wiring harness from steering

wheel.

2. Disassemble switches to access contacts as

shown in Figures 1 and 2.

3. Wipe corrosion from contacts with a clean cloth.

4. Reassemble switches.

5. Reinstall switches into steering wheel.

WARRANTY CLAIM INFORMATION

Description Whatever Asm - Replace

Labour Op. No. N000466

Time 0.4 hr

Failure Code N00100 terminal corroded

PARTS INFORMATION

Part No.: Description: Qty:

09196058 Buttons – Horn, with

harness

Figure 1 Shows corrosion buildup.

Figure 2. Corrosion buildup on switch contacts.

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

SERVICE FIX

Fuel Gauge Problems Due To Auxiliary

Pickup Pipe Mislocated Inside Tank

VY Regular Cab / Crewman & Cross 8

(GROUP 8) TL0672-0405

CONDITION

Customers may report one of the following conditions:

• They can only get 35 to 40 litres of fuel in fuel

tank when fuel gauge shows Empty.

• Fuel gauge reads Empty after filling tank.

CAUSE

Auxiliary pickup pipe becomes dislodged from its

normal location in the tank and in some instances

may rest on top of the float arm.

CORRECTION - Production

A stiffening wire inserted into the MRA auxiliary

pickup pipe is scheduled to be added to vehicles in

early June. When available, vehicle breakpoint

details will be added to this techline on Holden

Lionheart.(on-line)

ISOVIN: Built Date:

TBA TBA

CORRECTION – Service

Summary. Remove MRA and install wire into auxiliary

pickup pipe as follows.

1. Remove the MRA from fuel tank as per SIP

procedure.

2. Place MRA on a flat bench and position the

components as shown in Figure 1. With the float

arm in the 9 o’clock position locate the auxiliary

pipe in the 2 o’clock position by twisting hose on

the MRA fitting. (use pliers if necessary).

3. Take stainless steel wire and insert the end

without the loop into the plastic filter through

either of the two slots on the upper side as shown

by the arrows in Figure 2.

4. Push the wire into the pickup pipe until the

locating notch touches the end of the filter as

shown in Figure 3.

5. Lift the notch up over the end of the filter so that it

locks into the filter as shown in Figure 4.

6. With the MRA sitting flat on the bench ensure that

the plastic filter sits parallel to the bench as

shown in Figure 4.

7. Reinstall MRA into the fuel tank taking care to

ensure that the auxiliary pickup pipe is sitting in

the secondary part of the fuel tank.

Figure 1. Layout of MRA prior to inserting wire.

Figure 2 Insert wire into either of the slots shown

Figure 3. Shows locating notch just prior to inserting

into the filter

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

Figure 4. Shows final position of locating notch.

PARTS INFORMATION

Part No.: Description: Qty:

92148344 Wire 1

WARRANTY CLAIM INFORMATION

Description Install wire into MRA

auxiliary pickup pipe

Labour Op. No. L000242

Time 0.9 hr – Regular cab

1.1 hr – Crew cab

Failure Code L0057 Registers incorrectly

SERVICE PROCEDURE HINT

Transfer Case Mounting Bush

Replacement

VY AWD Adventra & Cross 8

(GROUP 3) TL0704-0405

Whenever ordering a replacement transfer case from

spare parts, please note that it does not come with

the mounting bush 92114780. If required, this bush

will need to be ordered separately.

NOTE: If the existing mounting bush is still

serviceable you will need special tool DT- 47597 to

remove it from the old transfer case. This tool is

available from SPX.

PARTS INFORMATION

Part No.: Description: Qty:

92114780 Mount Assembly –

Transmission & Transfer

case

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

SERVICE FIX

Gen III V8 - PCV Valve Pipe Material Revised

VT, VX, VY Series I, V2 up to 3L959133 ,

WH, WK up to 4L162085

(GROUP 6A) TL0622-0405

CONDITION

Some vehicles may experience the following

symptoms;

• Engine idles roughly,

• High pitch hissing noise

• Engine light on

• The following DTCs may set: P0131, P0151,

P0171, P0174.

CAUSE

Failure of the PCV valve pipe at the elbow as shown

by arrow in following diagram.

NOTE: WK and VY Series II vehicles are not affected

by this condition as they have a different PCV system.

CORRECTION - Service

Summary: Replace PCV valve pipe assembly, clear

DTCs with Tech2 and reset fuel trim cells.

NOTE: New PCV valve pipe assemblies from HSPO

are made from a revised material to prevent the

above failure condition.

PARTS INFORMATION

Part No.: Description: Qty:

12590632 Pipe – PCV valve 1

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

INFORMATION

Tech 1 Dealer Cartridge

VR - VS

(GROUP OB) TL0714-0405

In order to obtain a Tech 1 Dealer cartridge with

security function, Dealers are required to fax a

request with their Dealer letterhead to the publications

department with details of the cartridge they require.

The fax number is listed below.

Fax: 03 9647 2525

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

SERVICE PROCEDURE HINT

Clutch Slave Cylinder Bleeder Alignment

All with Gen III V8 and Manual

Transmission

(GROUP 7A) TL0705-0405

Whenever reinstalling the clutch slave cylinder on

Gen III models it is important to ensure the bleed

screw is aligned centrally in the bell housing opening.

Figure 1 shows a bleeder that is not located centrally

in the bell housing opening. In this condition it will not

be possible to fit a socket to the bleed screw for

subsequent bleeding operations once the

transmission is reinstalled.

To align the bleeder it is recommended to install a

long socket to the bleed screw (refer Figure 2) prior to

tightening the 2 slave cylinder retaining bolts.

Figure 1. Bleeder not central in opening.

Figure 2.

SERVICE FIX

Transmission Selector Lever Loose Pivot

VY Adventra

(GROUP 7B) TL0661-0405

CONDITION

Transmission selector lever feels loose in operation

due to the selector lever pivot pin working loose.

CORRECTION – Production

Transmission shifters with revised pivot pins (knurled)

and circlips to prevent loosening have been fitted to

vehicles from:

ISOVIN: Built Date:

LX8

6G1YM34F64L239771

20/02/04

CX8

6G1YM84F84L236786

23/2/04

CORRECTION – Service

Summary: On complaint vehicles fit a new (knurled)

pivot pin and circlip.

1. Remove the transmission gear selector

assembly from the vehicle as per the procedure in

SIP CD.

2. Remove the existing selector pivot pin and

replace with new pivot pin and circlip as listed in

Parts Information below.

3. Reinstall all parts.

PARTS INFORMATION

Part No.: Description: Qty

92148174 Pin Kit – A/T Selector

Lever Pivot (pin & circlip)

WARRANTY CLAIM INFORMATION

Description Lever asm selector (auto

floor shift) - Replace

Labour Op. No. K500100

Time 0.8 hr

Failure Code K0027 Loose

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

SERVICE FIX

Brake Booster Check Valve Noisy

VY, V2, WK

(GROUP 5) TL0659-0405

CONDITION

Brake booster check valve noisy in operation.

CORRECTION – Production

Check valves with new rubber diaphragm material

have been fitted to vehicles from:

ISOVIN: Built Date:

**********L242772 26/02/04

CORRECTION – Service

Summary: After verifying that vehicle has condition as

described above, fit a new brake booster check valve.

PARTS INFORMATION

Part No.: Description: Qty:

92148176 Check Valve

Assembly

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

INFORMATION

TIS 2000 – FINDING A CODE INDEX

SB XC TR TS JR JS

(GROUP 12) TL0712-0405

Often TAS receive calls from dealers who are having

trouble locating the code index in TIS 2000 for the

vehicles listed above. The following procedure is

recommended for finding these code indexes.

1. From the TIS 2000 main screen, select

Checking Procedure (Tech 2).

2. Choose Diagnostic Mode, then click Next.

3. Now enter in as many of the Vehicle Details as

possible, then click Next.

4. Double click on the word ‘Vehicle’ and this will

expand to display the vehicle type/model. Then

double click vehicle type/model and it will display

‘General Vehicle Checking Procedure’. Click

on this once to highlight the phrase and then

choose Next.

5. The screen now shown is ‘Validate Vehicle

Options’. This is completely optional but may

help to refine your search. Complete if the

options are known and then choose Next.

6. You will then be prompted to select the

Diagnostic Mode in which to search. For the

models listed above please use ‘Non-Guided’.

7. Now expand group ‘B’ (functional group test) at

the top left of screen by clicking on the + sign.

This will open up a list of all of the functional

groups relating to the vehicle chosen e.g. audio,

instrument, airbag etc.

8. Choose the group you would like the code index

for. Do this by moving the mouse pointer over the

actual word e.g. Audio System, then select once

highlighted. From here you will be required to

use the right of screen and may need to answer

some questions to further refine your search.

9. By using the and symbols at the

lower right of the screen, continue to answer the

questions above until you are presented with the

final table supplying your code index. Note that

you may need to scroll down the page to view

the full table.

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

SERVICE FIX

Drive Belt Squeal - Power Steering Pump

Pulley Misalignment

VY & WK with V6 Engine

(GROUP 6A) TL0671-0405

PROBLEM DESCRIPTION

A squeaking noise from engine bay at idle and while

driving. On closer examination the squeaking noise

can be heard coming from where the accessory belt

rubs on the flange of the power steering pump pulley.

The root cause of this condition may be traced to

misalignment of the power steering pump pulley with

the crank pulley and alternator pulley. Investigation of

cases of misalignment has shown that the pump

pulley hub has not been pressed far enough onto the

pump shaft.

SERVICE RECTIFICATION

Summary: Ensure the pulley hub is located in the

correct position as per following procedure.

1. Remove drive belt and power steering pump

pulley.

2. Using vernier calipers check that the assembled

dimension “A” from the rear of power steering

pump to front of hub equals 128 ± 0.3 mm. Refer

Figure 1.

3. If required, press hub further on to the shaft as

per Holden SIP procedure "3.12 Power Steering

Pump Pulley Hub - V6 Engine" until the 128 ±

0.3mm is achieved.

4. Reinstall all components.

Figure 1.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

SERVICE FIX

Tow Bar Tongue Rattle

VY Adventra

(GROUP 1) TL0697-0405

CONDITION

Tow bar tongue rattles in tow bar.

CORRECTION – Production

Tow bars with a threaded hole for an anti rattle bolt

are scheduled for fitment in production in June. When

this occurs, vehicle breakpoint details will be

published in the Service Techline Breakpoint

Summary.

CORRECTION – Service

Summary: On vehicles with tow bar tongue rattle, fit

an “anti rattle” bolt as detailed on next page..

PARTS INFORMATION

Part No.: Description: Qty

11091693 Bolt (M10 x 1.5 x 30mm) 1

92066006 Nut (M10 x 1.5) 1

WARRANTY CLAIM INFORMATION

Description Remove towbar, drill and

tap hole for anti rattle bolt

and reinstall

Labour Op. No. R000115

Time 0.7 hr

Failure Code R0028 Rattle

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

AWD Wagon Anti-Rattle Bolt Fitment Instructions

Step 1) Remove tongue from towbar.

Step 2) Remove towbar from vehicle.

Step 3) Mark-up position of hole/thread as per drawing below. Note that the thread is on the left side (passenger side)

of the towbar when looking from the rear of vehicle.

Step 4) Drill an 8.5mm hole, and tap an M10 x 1.5 thread at the location specified in the above diagram.

Step 5) Refit towbar to vehicle.

Step 6) Install tongue into towbar and fit hitch/lock pin.

Step 7) Screw bolt 11091693, with locking nut 92066006, into the threaded hole.

Step 8) Torque anti-rattle bolt to 10Nm and secure by tightening locking nut.

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

SERVICE FIX

Engine Front Cover Bolt Oil Leak

Correction

VY with V6 Engine

(GROUP 6A) TL0646-0405

CONDITION

Oil leak from the front timing cover bolt. Refer Figure

Figure 1.

CAUSE

Inadequate sealing surface under the head of the oil

filter adaptor retaining bolt. Refer Figure 2. This

allows oil to travel internally and weep externally from

front timing cover bolt.

Figure 2.

CORRECTION – Production

Revised oil filter adaptors with machining of the

sealing surface under the bolt head have been fitted

to engines in vehicles from:

ISOVIN: Built Date:

6G1YK52A14L268085 20/4/04

CORRECTION – Service

On vehicles with oil leaking from the front timing

cover bolt, fit a revised oil filter adaptor assembly p/n

92067787. For replacement procedure refer to the

Passenger SIP CD.

PARTS INFORMATION

Part No.: Description: Qty:

92067787 Adaptor assembly -

Oil filter

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

SERVICE FIX

Rear Spring Squeak

VYII Crewman, Regular Cab, Cross 8

(GROUP 4) TL0700-0405

CONDITION

Rear spring squeaks during suspension movement.

CAUSE

Misalignment of bottom leaf spring causing it to rub

on the spring guide bracket as shown in Figure 1.

Figure 1. LHS spring as viewed from rear end.

CORRECTION – Production

Correctly aligned rear springs have been fitted to

vehicles from:

ISOVIN: Built Date:

6G1YM34FX4L244648 2/3/2004

CORRECTION – Service

Summary: On vehicle with symptoms as described

above, realign bottom leaf of springs on both sides of

vehicle as follows.

Tap side of bottom leaf spring (not bracket) with a

heavy hammer until the leaf is aligned with the triple

leaf pack above it.

Figure 2. Forward section of LHS spring.

WARRANTY CLAIM INFORMATION

Description Realign bottom leaf of rear

springs – both sides

Labour Op. No. F000194

Time 0.3 hr

Failure Code F0025 Misaligned

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

INFORMATION

Repairing Vehicles After SRS Deployment

(Refer SIP and TIS2000)

ALL

(GROUP 0B) TL0711-0405

On vehicles involved in accidents that result in airbag

deployment, there are many requirements that need

to be followed with regard to proper repair of the

damaged vehicle. This will include the mandatory

replacement of certain vehicle and airbag system

components.

SIP and TIS 2000 have the latest repair information

which should be adhered to before releasing

previously damaged vehicles back to customers.

Listed below is a quick reference guide to finding this

information for all current model Holden vehicles.

Here you will find the information regarding all Airbag

repair procedures including a full list of mandatory

parts replacement following a deployment.

V & W Car

• Using the latest version of Passenger SIP,

select the model you require from the main

menu, go to

Electrical Section 12M / 2.10, Repairs and

Inspections After an Accident for Version

6.2 SRS or

Electrical Section 12M / 2.6, Repairs and

Inspections After an Accident for Version

8.0/8.1 SRS.

Note: you may need to read the General

Information section first to see if the SRS you

have selected refers you back to a previous

model.

SB, XC, TR, TS, JR, JS, ZC, TT

• Select Service Information from the main

menu of TIS 2000. Click on Standard

Information and then click ‘Next’. Add all

relevant vehicle data in the fields provided and

again click ‘Next’. Tick the boxes named

‘General Vehicle Information’ from the

assembly group as well as ‘Warnings,

Disclaimers, Safety’ from the application box.

Now click ‘Next’.

• As you will see, this is where all General

Warnings and Safety Regulation information is

stored for all functional groups for our imported

vehicles listed above.

• Scroll down to the bottom of the document list

to find the heading

‘Safety Regulations – Restraint Systems’.

Select and then click ‘Next’.

UBS JACKAROO

• Using the latest version of LCV SIP, select the

model you require from the main menu, go to

Electrical Section 12M SRS/ General

Description/Repairs and Inspections

Required After an Accident

RA RODEO

• Using the latest version of LCV SIP, select the

model you require from the main menu, go to

Restraints/Section 9A SRS Servicing/

Repairs and Inspections Required After an

Accident

UES FRONTERA 2001/2002

• Using the latest version of LCV SIP, select the

model you require from the main menu, go to

Electrical/Section 12M2 – SRS/ SRS Airbag

System Inspection Standards for Repair

YG CRUZE

• Using the latest version of LCV SIP, select the

model you require from the main menu, go to

Restraints/Section 10 Restraint System/2.1

Inspection and Repair Required After a

Collision

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

INFORMATION

Field Service Remedies (Helpful Hints) Available in TIS 2000

JR,JS, & ZC Vectra, TS Astra, SB & XC Barina, TT Zafira,

(GROUP 0B) TL0709-0405

TIS 2000 contains service information on known product issues on Opel based vehicles worldwide.

When confronted with a problem on one of the above listed models for which there is no published Holden Service

Techline, it maybe helpful to refer to TIS 2000 to see if there is a relevant “Field Service Remedy” for the problem

being experienced. To search for this information use the following procedure.

From the main TIS screen, select Service Information. On the Service Information screen (Refer Figure 1) there are

two headings you can select as shown by the arrows.

Figure 1.

Option 1. “Technical Service Bulletin (field remedy) - by symptom” Select this heading then click Next.

The next screen which appears is “Select the vehicle data”. Enter as many of the vehicle details as possible then

click Next. The next screen which appears is shown in Figure 2.

Figure 2

Choose from “Assembly Group” the

group you are interested in. For example:

 Body equipment

 Heating Ventilation, Air Conditioning(HVAC)

 Front Wheel Suspension Wheels and Tyres

 Brakes

 Engine and engine aggregrates

 Clutch and Transmission

 Electrical Equipment

 etc

Now choose from “Complaints” the actual

symptoms. For Example:

 Noise,vibration rattle

 Warning lights, telltale

 No start, stall

 Cold driveability, rough idle

 Backfires, misfires

 Corrosion, rust, dirt,

 Leaks

 Poor operation, incorrect operation

 etc

Now click Next. What appears next is a list of Field Remedies in which there may be one or more known issues

relating to the area of your selection that may have valuable information to help assist in your diagnosis.

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

Option 2. “Technical Service Bulletin (field remedy) - by assembly group.” Select this heading then click Next.

The next screen which appears is “Select the vehicle data”. Enter as many of the vehicle details as possible then click

Next. The next screen which appears is shown in Figure 3.

Now choose the area of the vehicle you are interested in and click Next. For example if you select “Steering”, a list of

field remedies (if any) will be displayed on steering issues. If there are no field remedies for that particular assembly

group it will be “greyed out”.

Figure 3.

IMPORTANT:

Remember that not all Field Remedies are applicable to Opel vehicles imported into Australia. When reading a Field

Remedy it is important to check that the model, engine, transmission and any options specified are relevant to

Australian vehicles.

The following table gives the equivalent Opel Model designation

Holden Designation Opel Designation

JR/JS Vectra Vectra - B

ZC Vectra Vectra - C

TR Astra Astra - F

TS Astra Astra - G

TT Zafira Zafira

SB Barina Corsa - B

XC Barina Corsa - C

NOTE: Found within these Field Remedies there may be labour operation details, that are not applicable to the

Australian Market. Also, special part numbers are sometimes mentioned but are not listed in Partfinder and are also

not available from HSPO.

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

INFORMATION

Service Techlines “On- Line” – New Group “00 Advance Information”

(GROUP OB) TL0698-0405

In order to speed up the process for providing the latest service fix information to the Holden Dealer network the

following procedure is now operational.

New Service Techlines are now placed onto the Holden Lionheart Portal as soon as they have been approved for

release.

They will first appear in the group “00 – Advanced Information”.

The “Reference” will be the issue number of the next full issue of Service Techlines to be printed.

Once the next issue has been printed and delivered, each individual Techline in group “00 – Advanced

Information” will be moved into its relevant grouping. For example, an item on brakes will be moved into Group

HOLDEN SERVICE TECHLINE __________________________________________________________________JUNE, 2004

SERVICE FIX

Supercharger Belt Chirp/Squeal on Cold

Start

V & W with Supercharged V6

(GROUP 6A) TL0487-0405

PROBLEM DESCRIPTION

Some customers may report a belt squeal or chirp for

a short time during engine cold starts.

SERVICE RECTIFICATION

Summary: Fit a new supercharger drive belt.

For complaints of belt ‘chirp’ or ‘squeal’ on start-up,

replace the existing drive belt with a new belt, part

number 92062955 or 92067829

Ensure that the new belt to be fitted carries part

number 92062955 or 92067829 on the outer surface

of the belt.

Before returning the vehicle to the customer, carry

out a quick supercharger drive belt system alignment

check – by running a long straight edge over the

pulleys, to ensure the tensioner or idler pulleys are

not out of alignment by more than 2mm.

Should the tensioner or idler pulleys be out of

alignment by more than 2mm – replace the relevant

pulley and mounting to ensure alignment is

corrected.

PARTS INFORMATION

Part No. Description Qty

92062955

92067829

Belt - Supercharger 1

WARRANTY CLAIM INFORMATION

Description Supercharger Belt - Replace

Labour Op. No. J607050

Time 0.2 hr

Failure Code J0040 (noisy)

SERVICE PROCEDURE HINT

Spigot Bearing Installation Precaution

Gen III V8 engine & Manual Transmission

(GROUP 6A) TL0703-0405

This is a reminder to Technicians that replacement

engine assemblies generally do not come with a

spigot bearing installed. For manual transmission

vehicles, this bearing will need to be ordered and

fitted prior to engine installation.

NOTE: Failure to fit a spigot bearing will result in

excessive vibration when operating clutch pedal.

On the other hand, when installing a replacement

engine in an automatic transmission vehicle,

ensure that a spigot bearing has not been installed

by mistake.

In this situation, when the torque convertor is bolted

up to the flex plate, the spigot bearing will dislodge

the welch plug in the end of the crankshaft resulting

in an external oil leak.

Figure 1. Manual Transmission engine shown

HOLDEN SERVICE TECHLINE __________________________________________________________________JULY, 2004

SERVICE FIX

Front Suspension Clunk (Front Subframe)

VY Adventra

(GROUP 3) TL0718-0406

Technicians should also refer to Techline TL0638-

0403 published in Issue 3, 2004. which gives another

possible cause for front suspension clunk

CONDITION

Clunk from front suspension usually heard when

wheel impacts deep pot hole.

CAUSE

One possible cause for this condition is fore-aft

movement of the front subframe relative to the body

due to insufficient clamp load at the attaching points.

CORRECTION – Production

Correction in progress at time of publication.

Breakpoint information will be published when it

becomes available.

CORRECTION – Service

Summary: Check existing subframe mounting bolt

torques. If loose, replace mounting bolts and tighten

to torque settings as shown below.

1. Check tightness of existing bolts using “follow on”

torque method. If torques are below the values in

steps 3 & 4 then proceed to step 2. If torques are

above these values then this techline procedure is

not applicable.

2. Replace all 4 subframe mounting bolts one at a

time with new parts.

NOTE: These are “micro encapsulated” bolts

which have a locking compound on the threads

and should only be reused once. As a general

rule, if in doubt as to previous useage, always

replace a micro encapsulated fastener.

3. Torque the two front bolts to 135-140 Nm.

4. Torque the two rear bolts to 120-125 Nm.

PARTS INFORMATION

Part No.: Description: Qty

92138605 Bolt Front suspension

frame - front

92138396 Bolt Front suspension

frame - rear

HOLDEN SERVICE TECHLINE __________________________________________________________________JULY, 2004

SERVICE FIX

Low Clutch Pedal, Difficult To Select

Gears, Vibration In Pedal At Idle (Pressure

Plate Bolts Loose)

All with Gen III 6-speed M/T

(GROUP 7A) TL0723-0406

CONDITION

Low clutch pedal engagement and disengagement,

difficult to select gears, vibration through clutch pedal

at idle or clutch fluid leaking.

A possible cause for the above conditions is loose

clutch pressure plate bolts.

CORRECTION – Production

The pressure plate bolt torque has been revised to 70

+/- 7 Nm on vehicles from:

ISOVIN: Built Date:

**********L234149 12/2/2004

CORRECTION – Service

Summary: After verifying that vehicle has symptoms

as described above, proceed as follows.

NOTE: Always refer to Holden SIP CD for any

procedures not detailed in this techline.

1. Switch engine off and check clutch pedal feel. The

clutch pedal should feel firm (with no spongy feel)

throughout the complete travel. Start engine and

re-check clutch pedal feel. If the clutch pedal

becomes spongy or soft on the initial travel this is

an indication that the pressure plate bolts are

loose.

2. When inspecting the clutch, look for uneven

pressure plate finger heights or a gap between the

pressure plate and flywheel both of which indicate

loose pressure plate bolts.

3. Remove slave cylinder release bearing and

inspect stroking sleeve on slave cylinder for

abnormal wear. Replace slave cylinder assembly

only if the stroking sleeve is worn.

4. Remove pressure plate and flywheel assembly

and reset self adjusting mechanism prior to

reinstalling into vehicle. Refer to Passenger SIP

CD for procedure.

5. Replace clutch pressure plate and flywheel

assembly and driven disc only if there is damage

to the components (eg. cracks)

6. Replace pressure plate bolts with new bolts from

HSPO and tighten to 70+/-7Nm

Tighten bolts in correct sequence in 4 stages :

Stage 1 Tighten all bolts to 15 Nm

Stage 2 Tighten all bolts to 35 Nm

Stage 3 Tighten all bolts to 55 Nm

Stage 4 Tighten all bolts to 70 Nm

Pressure plate bolt tightening sequence

PARTS INFORMATION

Refer to Partfinder for current part numbers.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

HOLDEN SERVICE TECHLINE __________________________________________________________________JULY, 2004

SERVICE FIX

Door Lock Malfunction

VY, WK, V2

(GROUP 1) TL0667-0406

CONDITION

Door lock will not unlock or lock intermittently.

CAUSE

This condition may be due to binding up of the lock

mechanism due to insufficient operating clearances in

the linkages.

CORRECTION – Production

Locks produced with modified operating clearances

within the linkages have been fitted to vehicles from:

ISOVIN: Built Date:

**********L225024 20/01/2004

CORRECTION – Service

Summary: After verifying that vehicle has symptoms as

described above, fit a new lock assembly from

Holden Service Parts Operation (HSPO).

NOTE. All lock assemblies currently available from

HSPO have been checked for correct operating

clearances in the linkages.

PARTS INFORMATION

Refer to Partfinder for part numbers

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

INFORMATION

HSPO Tow Bar Attaching Bolt Revised

VY Crewcab

GROUP 1 TL0630-0406

To enable better access for a tightening tool, the tow

bar attaching bolts shown in Figure 1 have been

changed from hexagon head to Allen head type bolts.

This change took effect from 16th March 2004 at

Holdens supplier of tow bars.

Figure 1.

PARTS INFORMATION

NOTE: The two Allen head bolts come as part of the

tow bar small parts kit.

Part No.: Description: Qty:

92606817 Small parts kit – tow bar

assembly

Update

HOLDEN SERVICE TECHLINE __________________________________________________________________JULY, 2004

SERVICE FIX

Front Seat Adjuster Cable Dislodges

ZC Vectra

(GROUP 1) TL0688-0406

CONDITION

Cannot adjust front seat forwards or rearwards.

CAUSE

Front seat adjusting cable (with ball end) dislodges

CORRECTION – Production

Revised adjustment cable with cylindrical shaped end

have been fitted to vehicles from 6/6/2003:

CORRECTION – Service

Summary: On vehicles with condition as described

above, fit a new seat adjustment cable with cylindrical

end.

Procedure.

1. Remove front seat.

Refer TIS procedure “ Front Seat, Remove and

Install”, group “C”, Service Instruction Vectra-C.

2. Remove adjuster cable (1) from seat adjustment

guide by clipping off holder (2) Refer Figure 1.

Figure 1.

3. Remove cable from retaining clips. Refer Figure 2.

Figure 2

4. Install new adjuster cable. Refer Figure 3.

Figure 3

5. Reinstall front seat.

Refer TIS procedure “ Front Seat, Remove and

Install”, group “C”, Service Instruction Vectra-C.

6. Repeat procedure for other front seat.

PARTS INFORMATION

Part No.: Description: Qty:

13100008 Cable adjustment front

seat

1 per

seat

WARRANTY CLAIM INFORMATION

Description Replace seat adjuster cable

– both seats

Labour Op. No. C000520

Time 0.7 hr

Failure Code C0071 Pulls Loose

HOLDEN SERVICE TECHLINE __________________________________________________________________JULY, 2004

INFORMATION

Electrical Circuit Information, (Additional Information) Found in TIS 2000

SB, TR, TS, JR, JS, (Some info. XC, TT,)

(GROUP 12) TL0732-0406

TIS 2000 contains extra information relating to electrical circuits, wiring connector end views, (known as Terminal

Assignments), electrical component locations, and other valuable information regarding vehicle electrical systems.

This Additional Information which is found within “Checking Procedures,” relates to the Opel range of vehicles NOT

FOUND in the usual TIS 2000 Wiring Diagrams section.

The Additional Information is for the electrical systems in which TECH2 IS USED for diagnosis,

For example:

Engine Multi Information Displays Immobiliser

Transmission Instruments Air bag

Anti Lock Brakes Audio Systems Central Locking

Electric Hydraulic Steering

This information can be found within “Checking Procedures” by selecting the blue colored “ADD INFO” icon at the

bottom of the screen, Refer Figure 1. Next displayed is the selection menu shown in Figure 2. Click on the “+” box

for “Electrical System Picture Information”. Then you have a choice of Block Diagrams, Terminal Assignment, Parts

Location, and Wiring Schematic which may be divided into two or more separate diagrams.

Pictures of circuit diagrams, connector terminal pin outs along with all necessary abbreviations are shown in Figures

3 and 4.

NOTE: There is also some Electronic System Picture Information for the later range of Opel product such as

XC Barina, TT Zafira, but for ALL Opel vehicles as of MY02, this information is found in TIS 2000 Wiring Diagrams.

Figure1. Figure.2

Figure 3 Figure 4

Add Info

HOLDEN SERVICE TECHLINE __________________________________________________________________JULY, 2004

SERVICE FIX

Noise when Cruise Control is Activated or

Deactivated

VY, WK all with Cruise Control

(GROUP 12) TL0717-0406

CONDITION

A knock or thud noise can be heard in some vehicles

when the cruise control is activated and/or deactivated.

CAUSE

This noise is caused by a lack of clearance between

the cruise control module and the ABS/cruise control

module mounting bracket and is transmitted into the

cabin through the body.

CORRECTION – Service

Add washer 92094572 to rear mounting point as

shown in Figure 1 to give clearance between the cruise

control module assembly and the sheet metal bracket.

Figure 1. Add spacer washer to rear mounting point

PARTS INFORMATION

Part No.: Description: Qty:

92094572 Washer 1

WARRANTY CLAIM INFORMATION

Description Add spacer washer to

cruise control module

Labour Op. No. R000118

Time 0.3 hr

Failure Code R0040

CORRECTION – Production

The sheetmetal bracket the cruise control module is

bolted to has been modified to provide clearance to

bolt heads. Fitted to vehicles from:

ISOVIN: Built Date:

**********L300701 22/6/2004

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

DIAGNOSIS HINT

DTC’s P0335 & P0340 Crankshaft and

Camshaft Sensor “INCORRECT” Signal

All Opel Engines

(Group 6C) TL0754-0407

PROBLEM DESCRIPTION

TAS receives many calls relating to crankshaft and

camshaft sensor diagnostics, P0335 and/or P0340

sensor(s) incorrect signal.

Dealers are reporting that after extensive diagnosis of

the wiring and connections, the sensors and/or ECU

have been replaced, the DTC’s are still present.

The DTC description of “Incorrect Signal” differs from

“No Signal”. A DTC for either sensor referring to

incorrect signal usually means the signal is present,

but may not be correct or complete due to a mismatch

between the two sensors.

POSSIBLE CAUSE

Incorrect cam timing can cause either of these codes

to set. Often these codes may appear shortly after a

service where the cam belt required replacement or

any other reason where the timing belt required

removal then reinstallation.

If, after thorough diagnosis of the sensor and all

associated wiring, connectors and terminals, no fault

can be found, be sure to check for correct camshaft

timing.

INFORMATION

Vehicle Search Function in SIP and NOW

All

(Group OB) TL0753-0407

Due to a technical problem, the vehicle search

function was removed from PV SIP 6.5 but was able

to be reinstated on SIP 6.6.

It should be noted that vehicle searches can now be

performed using the New Online Warranty system

(NOW). The information received from New Online

Warranty system (NOW) is the latest and most

accurate information available.

For information on using the New Online Warranty

system (NOW) contact the Warranty Administration

Department. Contact numbers are listed in the April

Techline issue 3/2004.

SERVICE PROCEDURE

Telematics Module Change Over

Procedure

VX VY WH WK V2

(Group 12) TL0752-0407

PROBLEM DESCRIPTION

Australian Arrow have advised that they have

received a number of returned telematics modules

where the module is still registered to the vehicle it

was removed from. This indicates that the

replacement module has not been registered with

Holden Assist as only one module can be registered

against a vehicle at any one time.

CORRECT PROCEDURE

It is a requirement of the change over procedure that

the replacement telematics module be “tested &

registered” after it is fitted to the vehicle. This is done

by pressing the Holden Assist button on the mirror

and registering the vehicle details with Holden Assist.

Please refer to the telematics change over procedure

whenever you are required to replace a telematics

module. This can be found in Passenger Vehicle SIP.

NOTE. Failure to carry out the above procedure will

result in the Holden Assist system not having the

correct vehicle details registered against the

telematics module in the customers vehicle.

SERVICE FIX

Park Brake Shoe Scrape

VT, VX, VU, V2, WH, WK

VY with IRS only

(Group 5) TL0452B-0407

This techline supercedes the previous one (TL0452A-

0404) published in Issue 4, 2004. It is revised by

clarifying which models the service fix can be applied

to. Note that the park brake shoe scrape kit cannot

be fitted to vehicles with a “live” axle, e.g. VY regular

and crew cab.

Please mark your printed copies with this revision.

The revised techline can be found on the Holden

Lionheart Portal.

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

SERVICE FIX

Front Strut Spring Noise

VX, VY, V2, WH, WK

(Group 3) TL0746-0407

CONDITION

A knock/graunch noise from front suspension when

driving at low speeds over speed humps, gutters

undulating roads etc.

CAUSE

Possible causes for the above condition are:

1. Lower coil of the spring touching on side lip of

spring seat. Refer Figure 1.

2. Spring coils touching on body sheet metal within

the wheel arch area.

Figure 1. Shows rub mark on spring coil

CORRECTION – Vehicle Production

Production changes are in progress to rectify this

condition. Breakpoint details will be advised in a

future techline.

CORRECTION – Vehicles in Service

Note: For procedures not given in detail, refer to PV

SIP.

Diagnosis.

1. Check tightness of all front suspension fasteners.

If all ok proceed to step 2.

2. Inspect body sheet metal around inside of strut

tower (wheel arch) for signs of spring coil rubbing.

3. Inspect the second lower coil on inboard side of

spring for signs of chipped or marked paint as

shown in Figure 1.

4. If witness marks are evident in above steps 2 & 3,

go to procedure A.

Procedure A (Both sides of vehicle)

1. Remove spring from strut assembly and re install

upside down. i.e. with the thin coil end resting on

the spring seat.

2. Carefully reinstall the upper bearing (yellow

plastic housing) ensuring that it is located

correctly in the upper spring seat.

3. While the strut is removed from the vehicle, cycle

the control arm up and down. If a graunching

noise is heard from the lower control arm rod front

hydraulic bush, then do procedure B after

completing step 4.

4. Reinstall strut assembly into the vehicle.

Install new strut to steering knuckle attaching

bolts and nuts. Tighten bolts while applying

pressure to the top of the brake rotor ensuring

that the camber adjustment bolt is against the

strut tube. This removes the need to perform a

front-end alignment.

Procedure B (Only do this if the check in Procedure

A, step 3 confirms it is required)

1. Remove the front lower control arm rod nut.

(Number 7 in Figure 2)

2. Install new nut as specified in SIP, but do not fully

tighten yet.

3. Bounce the front of the vehicle up and down

several times to settle the suspension.

4. Torque the control arm rod nuts to 140 – 155 Nm

as specified in SIP.

Figure 2.

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

PARTS INFORMATION

Part No.: Description: Qty:

11090821 Bolt – front

suspension strut

92138205 Nut – front

suspension strut

11084241 Nut – control arm rod

lower

WARRANTY CLAIM INFORMATION

Description Invert spring – both sides

Labour Op. No. E000370

Time 1.7 hrs

Failure Code E0040 Noisy

DIAGNOSIS HINT

Excessive Noise During ABS Self test

VX, VY, WH, WK

(Group 5) TL0734-0407

The characteristic noise/pulsation generated by the

ABS modulator during “self test”, can be made worse

if the modulator motor rubs on the mounting bracket

as shown in Figure 1.

Figure 1

To increase the clearance between modulator motor

and bracket, insert a spacer washer as shown in Figure

Figure 2.

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

SERVICE PROCEDURE

A/T Cooler Flush & Flow Rate Check

Requirement

V & W – with A/T

(Group 7B) TL0748-0407

CONDITION

Returned parts analysis shows that there is often

debris from failed transmissions causing cooler

blockages.

Failure to reverse flush, and carry out a transmission

cooler flow rate check may result in a repeat

transmission failure, if a cooler blockage exists.

SERVICE RECOMMENDATION

It is recommended that Service Managers, Workshop

Controllers or Service Advisors advise technicians to

perform a cooler flush and flow rate check by adding

the wording “Cooler Flush & Flow Rate Check

Required” to Repair Orders whenever:

• a changeover or replacement transmission is

installed.

• fluid contamination is suspected.

• whenever the oil pump and/or torque converter is

replaced.

All Service personnel should take note of the following

statement which is repeated from the All Dealer Letter

on SRTA Auto/Trans. replacement (DL 40/00). Pay

particular attention to the charge-back expense that

may result from NOT flushing and flow rate checking

a transmission.

“Dealerships are required to flush and flow rate check

the vehicles’ auto. trans. cooling circuit when

changing a transmission. Lack of cooler flush and flow

rate checking has resulted in repeat transmission

replacements. In addition, cooler flow restrictions

result in specific heat damage to components and

gear failure due to restricted lubrication, which is

obvious during transmission teardown at the SRTA

remanufacturing facility. Any transmissions returned

to SRTA which exhibit extreme damage such as this,

may be subject of cost recovery from SRTA, of the

remanufacture cost and the replacement of

transmission components – current cost is $2800.00+

per transmission.

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

Following is a copy of reverse flush and flow rate

checking procedure from Passenger Vehicle SIP.

2.1 TRANSMISSION COOLER REVERSE

FLUSH AND FLOW RATE CHECK – ALL

LT Section No. – 04-200

IMPORTANT: It is essential that a reverse flush and oil

cooler flow rate check is performed, after ANY of the

following situations:

• Transmission is replaced.

• Fluid contamination is suspected.

• Whenever the oil pump and/or torque converter is

replaced.

NOTE: The reverse flush must be completed prior to

conducting a flow rate check.

Reverse Flush

The recommended procedure for reverse flushing the

transmission cooler and lines, particularly after an

overhauled or replaced transmission has been installed

into the vehicle, is as follows:

1. Disconnect both cooler lines at the transmission and

at the radiator cooler end. Refer to 3.15 TRANSMISSION

COOLER PIPES/HOSES, in this Section. Do not lose the

pipe to fitting sealing washer, when the pipe is removed.

2. Carefully check the cooler inlet fitting (lower) to see

whether any material is evident at this point. If so, dislodge

and remove with a suitable tool and/or compressed air

blown in the reverse direction through the cooler.

3. Using a commercially available pressure spray gun

and clean solvent, such as white spirit:

a. Back flush through both cooler lines.

b. Back flush through the cooler, including an external

cooler (if fitted).

c. Blow compressed air through return and inlet pipes

to remove solvent.

d. Flush pipes with transmission fluid.

4. Check the cooler pipe to cooler fitting, sealing

washers for damage, replacing as required.

5. Reconnect cooler lines to the transmission and

cooler but leave the cooler return line to transmission

connection open.

6. Conduct a flow rate test as described below, to

ensure that any restriction has been cleared.

7. If flow rate is satisfactory, reconnect the return line to

the transmission quick connect fitting.

8. Tighten the cooler pipe flange buts at the cooler end

(V6 engines only) to the specified torque. Refer to 3.15

TRANSMISSION COOLER PIPES/HOSES, Reinstall for

the correct procedure.

OIL COOLER PIPE TO RADIATOR FITTING TORQUE

SPECIFICATION V6 Engines

25 Nm

9. Lower vehicle and check fluid level as detailed in 2.1

FLUID LEVEL CHECK, in this Section.

FLOW RATE CHECK

IMPORTANT: Do not run engine any longer than absolutely

necessary, as too low a fluid level can cause aeration and

foaming.

1. When installing the transmission assembly, leave the

cooler return line disconnected from the transmission

(upper fitting).

2. Ensure that the fluid level is to the ecommended

level, as detailed in 2.1 FLUID LEVEL CHECK, in this

Section.

3. Place a container underneath the disconnected

cooler line.

4. With the selector lever in the Neutral position, start

the engine and observe the fluid flow into the container,

after all air bubbles have ceased and a steady flow is

evident. Measure the flow rate.

Result: The fluid flow rate should be approximately 0.7 litre

in a 20 second period, with cold automatic transmission

fluid (ATF). With ATF at normal operating temperature (86

– 93° C), the flow rate will increase and should be

approximately 1.2 litres in a 20 second period.

If the flow rate is less than this specification, the source of

the restriction must be located and rectified. Possibilities

are either radiator tank cooler, faulty flexible hoses and/or

external cooler (if fitted).

5. Reinstall the cooler return line to the transmission

quick connect. Refer to 3.15 TRANSMISSION COOLER

PIPES/HOSES, Reinstall for the correct procedure.

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

SERVICE FIX

Poor Fitment Of Carpet In Load Area

VYII Wagon

GROUP 1 TL0696-0407

CONDITION

Gap between carpet and luggage tie down rail at rear

of load area as shown in Figure 1.

CORRECTION – Vehicle Production

Clips were added to retain carpet to the luggage tie

down rails on all wagons built from 11/6/2004:

CORRECTION – Vehicles In Service

Summary: On vehicles with above condition, fit

retaining clips as per following procedure.

1. Attach clips to carpet at locations shown in Fig 1.

2. IMPORTANT: When attaching clips to the edge of

the carpet as shown in Figure 2, ensure the clip

“barb” digs into the underside of the carpet.

3. Press the clip into the rail as shown in Figure 3.

Ensure the clip locks in under the lip of the rail as

shown in Figure 4.

4. Repeat procedure for other side of load area.

PARTS INFORMATION

Part No.: Description: Qty:

92138869 Clip, Quarter Lower trim Pack of 5

WARRANTY CLAIM INFORMATION

Description Install retaining clips to carpet

in load area - both sides

Labour Op. No. C000523

Time 0.3 hr

Failure Code C0071 Pulled loose

Figure 1. Attach clips at arrows

Figure 2. Firmly push clip onto edge of carpet

Figure 3 Push clip into rail

Figure 4. Sectioned view showing clip installed into load rail

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

DIAGNOSIS HINT

Compressor – Intermittent, Knocking

Noise

V & W Cars

(Group 2) TL0741-0407

Some customers may complain of a knocking noise

from engine bay when slowing down just before

stopping at the traffic lights”. This particular noise is a

normal characteristic of this compressor under high

ambient operating conditions.

On the following two pages is a description of when

and why this knock occurs including internal diagrams

of the variable stroke compressor.

Where appropriate, this information should be

conveyed to customers to reassure them that the

“knock” will not affect compressor performance or

durability.

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

NOTE: The following information does not apply if a continuous noise is heard.

SYMPTOM WHEN CONDITION COMMENTS

Intermittent

Knocking noise

Short Duration

(3 Sec or less)

Slowing down.

Stopped at

traffic lights

High Ambient

Temperature.

This is an operational noise experienced on some compressors

when the pumping capacity is self adjusting.

Occurs under unique ambient and system conditions and is not

indicative of internal fault or damage inside compressor

• A typical condition under which the noise is heard is on a hot day when a vehicle slows down or stops (e.g. at

traffic lights), thus reducing the airflow through the condenser. This reduction in airflow increases the demand

on the A/C system to maintain cooling capacity.

• When the load on the A/C system increases the compressor responds by increasing it’s stroke and therefore

refrigerant pumping capacity to maintain system cooling (see image below). During transition to maximum

stroke the wobble plate mechanism slides along the shaft. On some compressors when the stroke increases

very rapidly the wobble plate mechanism can vibrate briefly in response to the pumping action of the pistons

producing the “knocking” noise. The reason the wobble plate mechanism can vibrate is there is a very tight

clearance between the mechanism and the shaft that must be present to allow movement.

• The vibration as described above does not affect the compressor performance or indicate any internal

compressor damage or fault and will not shorten the reliability or durability of the compressor.

1. Piston 2. Wobble plate 3. Field coil connector 4. Front plate 5. Drive shaft

6. Rotor pulley 7. Guide ball 8. Guide pin 9. Control valve 10. Reed valve plate

11. Front seal 12. Pressure relief valve (V8 5.0 Lonly) 13. Mesh strainer (Suction port)

14. Bearing plate 15. Sliding Sleeve.

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

Minimum Stroke (destroked)

The Crankcase pressure behind the Pistons is equal to

the pressure in front of the Pistons. Causing the

“Wobble” plate to change it’s angle to almost vertical.

Reducing the stroke of the Pistons and the output off

the Compressor. Approx 0.9 Cubic Inch Capacity

Maximum Stroke

The Crankcase pressure behind the Pistons is less

than the pressure in front of the Pistons. Causing the

“Wobble” plate to change it’s angle . Increasing the

stroke of the Pistons and the output off the

Compressor. Approx 10 Cubic Inch Capacity

SERVICE FIX

Water Leaks Into Rear Load Area

VU, VY Utility - With Hard Tonneau Cover

(Group 1) TL0629-0407

CONDITION

Water leaks into rear load area on some vehicles

when washing vehicle or in heavy rain.

CAUSE

Load area seal design.

CORRECTION – PRODUCTION

Improved seal kits 92147943 have been fitted to all

HSPO hard tonneau cover kits from:

Tonneau Cover Serial No: Built Date:

14967 27/4/04

CORRECTION – VEHICLES IN SERVICE

After confirming that customers vehicle has the

condition as described above, fit a new seal kit part

number 92147943.

Revised fitting instructions “FD1000/22AP04” are

supplied in the kit.

NOTE: Prior to fitting the new seal kit, the old cap

seals and the drain seals must be removed from the

vehicle.

PARTS INFORMATION

Part No.: Description: Qty:

92147943 Load compartment

seal kit

WARRANTY CLAIM INFORMATION

Description Replace Load

Compartment Seal Kit

Labour Op. No. R000224

Time 0.7 hours

Failure Code R0042 leaks

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

DIAGNOSIS HINT

Intermittent Remote Key Operation –

DTC 24 (Remote Key Rolling Code Error)

VY, V2 series II & III, WK

(Group 12) TL0744-0407

CONDITION

Customers may advise that, intermittently, their

central locking remote key doesn’t work until the key

is cycled in the ignition.

CAUSE

When a body control module (BCM) has been

replaced under warranty via the change over

program it is more susceptible to setting DTC 24

(Remote Key Rolling Code Error) after an additional

remote key is programmed.

CORRECTION

When presented with a vehicle with the above

condition perform the following steps,

Step 1. Check for DTC 24 in the BCM. If the code

is present or in history, continue with step

2. If DTC 24 has not been set continue

with standard diagnosis as per SIP.

Step 2. Check the vehicle history in the New

Online Warranty system to determine if the

vehicle has been fitted with a change over

BCM.

Step 3. If the vehicle has not been fitted with a

change over BCM continue with standard

diagnosis as per SIP.

If the vehicle has been fitted with a

change over BCM contact Australian

Arrow for additional diagnosis assistance.

Note: Prior to contacting Australian Arrow please

ensure all vehicle remote keys have been

supplied by the customer. Further diagnosis is

not possible without all remote keys.

DIAGNOSIS HINT

Intermittent Remote Key Operation –

External Electrical Interference

All V & W

(Group 12) TL0739-0407

CONDITION

Remote keys and BCM’s are being replaced by

dealers attempting to rectify customer reports of

intermittent operation of the central door locking

system.

Testing of returned components shows that a high

percentage of these parts are not faulty.

CAUSE

High levels of external environmental electrical

interference can potentially cause intermittent

operation of remote key.

The following are examples of generators of external

interferences;

• Telephone transmitter towers

• Television transmitter towers

• Radio transmitter towers

• Multi story and under ground car parks

• Over head and under ground power lines,

transformers or sub stations

• Wireless computer networks

• Electronic dog collars

• Other vehicles central locking remotes

• Remote transmitters (ie: Roller Doors)

• Automatic Doors (ie: Supermarkets,

Hospitals)

• Vehicle access tunnels (ie: Sydney Harbour,

Melbourne City Link)

• Climatic conditions such as rain

Some vehicle accessories or luggage can also cause

interference with remotes keys. The following are

examples of items which are known to have caused

remote operational issues:

• Excess or metallic base window tinting

• Large metallic objects in vehicle (ie: golf

clubs, fire extinguishers)

• Excess keys on key-Ring

• Satellite, digital or analogue mobile phones

• Faulty in-vehicle phone wiring connections

• Aftermarket electronic accessories

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

CORRECTION

Before attempting diagnosis on vehicles for

intermittent operation of the central locking remote

it is important to find out from the customer the

exact operating conditions and location where

the fault occurs so that the root cause of the

problem can be determined.

Remote keys and BCM’s should not be replaced for

customer reports of intermittent operation, unless the

problem can be reproduced and the same problem

does not occur on another vehicle of the same

specification in the same location.

SERVICE PROCEDURE

Cylinder Head Expansion (Welch or Welsh) Plug Replacement Guidelines

V & W carlines V6 and Gen III V8

(Group 6A) TL0733-0407

The following information is repeated from Warranty processing Bulletin 19/04

Please note that Standard Times for replacing expansion plugs are now based on using the following procedures.

V6 / V8 Cylinder Head - Rear Plug

Replacement of the plugs in the rear of the cylinder heads requires removal of the engine/transmission assembly.

V6/V8 Cylinder Head - Front Plug

Replacement of the plugs in the front of the cylinder head can be done in the car.

NOTE The V8 right hand side front plug will require removal of the water pump.

Plug Sealant – Always apply a sealer such as Loctite 242 (or equivalent) around the plug prior to installation.

WARRANTY CLAIM INFORMATION

The following Labour Times information will be included in PV SIP number 6.6.

LAB OP LAB CODE DESCRIPTION STD TIME

J314740 WELSH PLUG, CYL HEAD FRONT - REPLACE CYLS 1,3,5,(7) .5

ADD FOR :GEN III .1

J314750 WELSH PLUG, CYL HEAD FRONT - REPLACE CYLS 2,4,6,(8) .7

ADD FOR :GEN III .7

J314760 WELSH PLUG, CYL HEAD REAR - REPLACE CYLS 1,3,5,(7) 6.5

REMOVE ENGINE & TRANS FOR V6 & GEN III -

ADD FOR: GEN III .3

ADD FOR: AWD 1.0

ADD FOR: A/C .5

J314770 WELSH PLUG, CYL HEAD REAR - REPLACE CYLS 2,4,6,(8) 6.5

REMOVE ENGINE & TRANS FOR V6 & GEN III -

ADD FOR: GEN III .3

ADD FOR: AWD 1.0

ADD FOR: A/C .5

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

SERVICE FIX

Electric Seat - Fore Aft Movement

VT,VX & VY series I - Calais models only

V2 series I & II,

WH, WK up to L162085 (A9W)

(Group 1) TL0699-0407

CONDITION

Fore-aft movement of front seat. Usually most

noticeable under braking when vehicle comes to a

sudden low speed stop.

CAUSE

The lead-screw nut, which is fixed to the lower

section of the seat track, may be loose in its

mounting plate.

CORRECTION – Vehicles In Service

Summary: This condition can be rectified without

replacing the seat track.

After confirming the complaint condition, replace the

steel washer shown in Figure 4. The thicker washer

provides extra compression of the rubber insulators

and thus reduces the amount of movement between

the lead screw nut and the mounting plate.

Confirmation of condition.

To confirm that seat has fore-aft movement, sit in the

seat and attempt to slide the seat backward and

forward as shown in Figure 1. If there is noticeable

travel in the sliding section of the seat, then proceed

as follows.

1. Move the seat adjustment to the mid position

2. Remove the seat track covers and remove the 4

seat mounting bolts.

3. Tip the seat assembly backward and rest against

the rear seat. Ensure that both the seats are

protected against accidental damage.

4. Remove the Lead screw nut retaining bolt (torx

head). Refer Figure 2.

5. Remove existing steel washer (2.5mm) and

replace with washer 92148372 (3.5mm). Refer

Figure 3.

6. Reinstall the retaining torx bolt and torque to 40

to 45 Nm. Refer Figure 4.

7. Repeat for the other seat track.

8. Reposition seat and reinstall the 4 seat mounting

bolts. Tighten to 35 to 50Nm.

9. Reinstall the seat track plastic covers.

10. Repeat procedure for other front seat.

Figure 1. Fore-Aft movement check

Figure 2 Removing lead-screw retaining bolt.

Figure 3. Replace steel washer

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

Figure 4.

PARTS INFORMATION

Part No.: Description: Qty:

92148372 Seat Fore/Aft Kit

(contains 4 washers)

WARRANTY CLAIM INFORMATION

For vehicles covered under warranty.

Description Replace seat track lead screw

nut washers – Both front seats

Labour Op. No. C000526

Time 0.6 hr

Failure Code C0027 loose

INFORMATION

Revised ABS Replacement Guidelines

V & W

(Group 5) TL0567A-0407

This Techline supercedes the previous one in Issue

9, Sep, 2003. All copies of the previous techline

should be marked “Cancelled”. The following

information is also contained in All Dealer Letter

25/2004.

Holden now recommends replacing the ECU

(Electronic Control Unit) component of the ABS

module as a separate part.

Previous policy was to replace the complete ABS

module only during the warranty period.

When diagnosis as per SIP indicates a fault with the

ECU component of the ABS module the ECU can be

removed and replaced from the ABS module.

Although the ECU is a relatively robust unit,

technicians still need to take care and follow correct

procedures in order to avoid ECU damage.

The procedure for ECU replacement is in Passenger

Vehicle SIP.

Service Prior Approval Process (SPAP) is still

required for ABS module or ECU replacement as per

Special Warranty Component Replacement

Requirements in SIP.

HOLDEN SERVICE TECHLINE _________________________________________________________________AUGUST, 2004

INFORMATION

Disabling Seat Belt “Audible” Warning

VY, V2 Series 2 & 3, WK – Police use only

Group 12 TL0722-0407

IMPORTANT: The procedure described in this

techline is to be performed on Police vehicles

ONLY when requested by the Police to do so.

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

Before commencing, ensure Tech 2 has software

version 13.101 or greater.

Using Tech2, perform the following selections.

F1: Diagnostics / Model Year / VY Series / F3: Body /

Instrument / F5: Program / F1: Configuration

You will then be presented with the configuration list

similar to the one below.

Scroll down using the arrow key to show the

following screen. You will notice that Seat Belt

Warning is a new addition.

Place the cursor over ‘Seat Belt Warning’ then

select Modify to display the following screen.

Using the arrow keys select OFF, and then select

the Modify key.

Tech 2 will then display the following screen.

Select Program to save the change to the

configuration list.

NOTE: on some instrument clusters you may

notice that the Engine Type is flashing. You will be

required to update this field or programming will

not be successful.

Enabling Seat belt warning

The seat belt warning can be enabled again by

repeating the above procedure and when you

reach screen No. 3, use the arrow keys to select

ON before proceeding.

Configuration

(4) 2004 VY Series

Instrument

Engine Type V6 & V6 SC

Speedometer Pulses 6307

SRS Configuration 4 Loop SRS

Transmission Type Manual

Occupant Climate Control Not Present

Police Mode No

Seat Belt Warning OFF

________________________________1/8____

Engine Type

Abort Modify Program

Please Reselect System !

Configuration

(4) 2004 VY Series

Instrument

Seat Belt Warning

OFF

____________________________________1/2____

Abort Modify

Configuration

(4) 2004 VY Series

Instrument

Country Australia / NZ

Engine Type V6 & V6 SC

Speedometer Pulses 6307

SRS Configuration 6 Loop SRS

Transmission Type Manual

Occupant Climate Control Not Present

Police Mode Yes

________________________________1/8____

Country

Abort Modify Program

Configuration

(4) 2004 VY Series

Instrument

Engine Type V6 & V6 SC

Speedometer Pulses 6307

SRS Configuration 6 Loop SRS

Transmission Type Manual

Occupant Climate Control Not Present

Police Mode Yes

Seat Belt Warning On

________________________________1/8____

Engine Type

Abort Modify Program

HOLDEN SERVICE TECHLINE _____________________________________________________________SEPTEMBER, 2004

DIAGNOSIS HINT

Loss of Power with No DTC’s set

Opel Engines with Electronically

Controlled Throttles

(GROUP 6C) TL0771-0408

PROBLEM DESCRIPTION

TAS have received calls reporting - “intermittent loss

of power or engine appears to return to idle while

driving”.

Preliminary checks show no stored DTC’s relating to

electronic throttle failure and/or pedal position sensor

(located within accelerator pedal assembly).

In most cases the symptoms can be reproduced,

although no fault can be found relating to these

components or associated wiring.

POSSIBLE CAUSE

On engines with electronic throttles, the status of the

brake pedal switch is monitored by the engine ECU,

and is used to control throttle position.

If, during normal driving or accelerating, the ECU

sees a brake pedal input as being active for a

predetermined period of time, the ECU will command

the throttle to return to idle position until brake pedal

status returns to inactive, or vehicle speed

significantly decreases.

This operating characteristic of the ECU does not

cause any trouble codes to set and has often led to

time consuming misdiagnosis of ECU’s and electronic

throttle components.

SERVICE RECOMMENDATION

If presented with a vehicle fitted with electronic throttle

control with any of the above symptoms:

1. Check the adjustment and sensitivity of the

brake light switch. This can be done using

Tech 2; then selecting Engine - “Data list” and

monitoring brake pedal switch or brake pedal

status.

Adjust brake pedal switch as required.

2. If the brake light switch does not require

adjustment, then the above condition may be

caused by the customers driving technique; i.e.

driving with left foot resting on brake pedal and

right foot on accelerator pedal. This should be

discussed with the customer.

DIAGNOSIS HINT

Cruise Control Inoperative DTC P0567

Opel Models with Z18XE Engine

(GROUP 12) TL0781-0408

PROBLEM DESCRIPTION

Customer may complain that cruise control becomes

Inoperative.

CAUSE

Investigation has found that if the cruise control is set

and the driver holds the decel button to reduce

vehicle speed and simultaneously applies the brake,

DTC P0567 will set in the engine ECU and the cruise

control will become inoperative.

SERVICE RECTIFICATION

This is a function programmed into the engine ECU

as a safety feature. Operator education is required to

provide the driver with an understanding of the

system to prevent further incident.

The DTC will need to be cleared by Tech 2 before

normal operation can be achieved.

HOLDEN SERVICE TECHLINE _____________________________________________________________SEPTEMBER, 2004

SERVICE PROCEDURE

Rear Lamp Failure Warning – Re-learn

Procedure

VY, V2, WK

(GROUP 12) TL0779-0408

PROBLEM DESCRIPTION

Rear lamp failure warning light is showing on dash

when all rear lights are working normally.

SERVICE RECTIFICATION

Technicians are reminded of the requirement to

perform the bulb re-learn procedure after the battery

has been disconnected or the power supply to the

BCM has been removed.

The following bulb relearn procedure is taken from

SIP.

Refer Section 12J – Body Control Module / 4 – BCM

Diagnostics / 4.20 – Rear Lamp failure warning

system

PREVIOUS MODELS REMINDER

All earlier Holden vehicles equipped with a BCM that

has the rear lamp function, also require the bulb re-

learn procedure to be carried out.

For VP / VQ / VR / VS / VT / VX Vehicles please refer

to the relevant sections in SIP or the workshop

manuals.

In SIP this can be found under High series BCM,

Diagnosis section.

HOLDEN SERVICE TECHLINE _____________________________________________________________SEPTEMBER, 2004

INFORMATION

Inspection Of Seat Back Upholstery

All V & W Models with Side Impact

Airbags

(GROUP 1) TL0759-0408

In the event of an airbag deployment, the Side Impact

Airbag uses the “burst seam” (shown in Figure 1) as a

controlled path out of the seat.

Because the “burst seam” together with the seat

cover fabric and seat foam comprise part of the

airbag system, damage to any of these components

may influence the deployment characteristics of the

airbag.

Therefore, any customer vehicle in which the seat

back upholstery is worn/damaged in the area

identified by the light grey shading in Figure 1, should

be inspected thoroughly for evidence of the following:

• Extensive wear through or tearing of fabric

• Loose or broken “burst seam” threads

• Extensive damage to foam pad.

Replace damaged components as required.

NOTE: Superficial scratches and wear on the front

seat plastic backcover will not influence airbag

deployments and does not require rectification.'

Figure 1.

High Intensity Discharge (HID) lights

Various HSV models at VY2 level

(GROUP 12) TL0768-0408

For full technical details on HID lights refer to HSV

Bulletin No. 079/04 which can be viewed on the

Holden Lionheart Portal website. It can be found

under Service Techlines, Year 2004, Group 12 -

Electrical.

Ohlins Suspension

VYII GTS Coupe and sedan

(GROUP 3) TL0769-0408

For a detailed explanation of Ohlins Suspension refer

to HSV Bulletin No. 078/04 which can be viewed on

the Holden Lionheart Portal website. It can be found

under Service Techlines, Year 2004, Group 3 –

Front Suspension.

Tyre Pressure Monitoring System - TPMS

Various HSV models at VYII level

(GROUP 10) TL0761-0408

TPMS stands for Tyre Pressure Monitoring System.

This system monitors Pressure, Temperature and

Pressure deviation. It will warn the driver of an

impending flat tyre or over temperature condition that

may damage tyres.

TPMS has a remote sensor in each wheel that sends

tyre temperature and pressure information via RF

wireless signals to a receiver inside the vehicle.

For a full description of TPMS refer to HSV Bulletin

No. 076/04 which can be viewed on the Holden

Lionheart Portal website. It can be found under

Service Techlines, 2004, Group 10 - Wheels &

Tyres.

HOLDEN SERVICE TECHLINE _____________________________________________________________SEPTEMBER, 2004

SERVICE PROCEDURE

A/C Compressor Startup Procedure on

Vehicles Stored For Long Periods

ZC Vectra

(GROUP 2) TL0686-0408

The following information should be passed onto

dealership personnel who are responsible for

retrieving vehicles from the new vehicle storage yard.

CONDITION

There is a possibility of compressor internal damage

occurring on some new vehicles on first start after a

lengthy storage period. e.g. Held in dealer holding

yard for months prior to sale.

SERVICE RECOMMENDATION

The following procedure is recommended when

starting any new ZC Vectra after it has been stored in

a dealer holding yard.

This procedure will help ensure that the compressor

internal moving parts are properly lubricated/bedded-

in prior to being subjected to high speed

engagement.

Procedure

1. Open all instrument panel air outlet vents.

2. Ensure A/C is switched off.

3. Start engine and stabilise idle speed. (approx 5

seconds)

4. Switch HVAC fan to max speed.

5. Switch on A/C and let it run for 5 – 10 minutes

without interruption at engine speed under 1500

rpm.

HOLDEN SERVICE TECHLINE _____________________________________________________________SEPTEMBER, 2004

INFORMATION

A/T Shifter Slide Replacement Parts

ZC Vectra

(GROUP 7B) TL0561-0408

Holden REPAC still receive complete A/T shifter

assemblies, replaced under warranty, in which only

the convoluted slide component has been damaged.

The convoluted shifter slide (item 12 in Figure 1) is

now available as a replacement part.

From now on, do not replace complete shifter

assemblies when only the slide is damaged.

NOTE: The other components which are also

available as replacement parts are items 9,10,11 &

13 in Figure 1.

Figure 1. Shows A/T shifter assembly (6) and

individually serviced parts 9,10,11,12,13.

PARTS INFORMATION

Part No.: Description: Qty:

93176688 Slider – gear selector

control

(refer item 12 in Figure 1)

HOLDEN SERVICE TECHLINE _____________________________________________________________SEPTEMBER, 2004

SERVICE FIX

Erratic Fuel Gauge Operation Within the

Full to ¾ Range

VY Ute and Cab Chassis

(GROUP 12) TL0778-0408

CONDITION

Customers advise that their fuel gauge drops from

full within a very short distance or when the gauge is

between full and ¾ it will intermittently return to full

without adding fuel.

CAUSE

Fuel gauge calibration.

CORRECTION – Production

Revised fuel gauge calibration was introduced into

vehicles from the following breakpoint:

ISOVIN: Built Date:

******************L304521 20/07/04

CORRECTION – Service

Use Tech 2 with software version 13.404 (or later)

available on TIS 2000 CD 54 to reprogram the fuel

gauge calibration in the instrument cluster.

Note: When investigating fuel gauge complaints on

any Cab Chassis vehicle ensure that the fuel

pick up hose is not mislocated inside the fuel

tank refer to Techline TL0672 published in

June 2004 page 5.

WARRANTY CLAIM INFORMATION

Refer to PV SIP

HOLDEN SERVICE TECHLINE _____________________________________________________________SEPTEMBER, 2004

SERVICE FIX

Door Lock Malfunction - Revised

VY, WK, V2

(GROUP 1) TL0667A-0408

This techline supersedes the previous article ‘Door

Lock Malfunction’ released in issue 6, 2004 which

recommended replacing the door lock with a new

assembly. This techline issue advises repairing the

lock assembly in lieu of replacing with a new part.

CONDITION

Door lock will intermittently not unlock via remote key

or snib button.

CAUSE

This condition may be caused by binding up of the

latch mechanism due to insufficient operating

clearances at the paddle actuating lever pivot - Refer

fig 1.

CORRECTION – Production

Locks produced with modified operating clearances

within the linkages have been fitted to vehicles from:

ISOVIN: Built Date:

**********L225024 20/01/2004

CORRECTION – Service

Summary: Repair the lock by creating clearance at

the external door handle actuating lever pivot.

1. Remove the door lock from the vehicle and

remove the paddle actuating lever return spring as

shown in figure 1.

2. Check the paddle actuating lever for binding

or sticking as follows: Hold the lock assembly upright

in the “as installed” position then raise the actuating

lever (at red arrow) and release the lever. Check if

the paddle actuating linkage falls under its own

weight.

3. If the linkage DOES fall under its own

weight as per test in step 2, then replace the door

lock assembly.

4. If the linkage DOES NOT fall under its

own weight the paddle actuating lever pivot

needs to be loosened off as per following

procedure

5. Using an 8mm bar or suitable substitute tool

(e.g. pin punch) carefully work the rivet up and down

– left and right continually until the rivet can be

rotated 360o with finger effort; refer figure 3.

Note: When working the rivet, do not permanently

distort the rivet mounting plate. Loosen the rivet only

sufficiently to allow 360o rotation by finger effort.

Paddle Actuating

Return Spring

Linkage

should fall

under its own

weight.

Rotate rivet 360o

Fig 1

Fig 2

Fig 3

Paddle actuating

lever pivot.

8mm diameter bar

or equivalent tool.

HOLDEN SERVICE TECHLINE _____________________________________________________________SEPTEMBER, 2004

6. Install the return spring (lubrication is not

required)

7. Check that the linkage has correct

movement and does not catch on any other

components.

8. Install the lock assembly to the door (Torque

screws to 3-5 NM)

9. Ensure the inner door trim water seal is

sealed correctly to prevent any water leaks.

10. Check the operation of the door lock (manual

and remote), interior and exterior door handles.

WARRANTY CLAIM INFORMATION

Refer PV SIP if new lock assembly was fitted.

Refer table below if lock was repaired.

Lock

location

Labour Operation Time Allowed

RHF C000529 0.8 Hr

LHF C000532 0.8 Hr

RHR C000535 0.6 Hr

LHR C000538 0.6 Hr

HOLDEN SERVICE TECHLINE _____________________________________________________________OCTOBER, 2004

INFORMATION

Change To Electric Mirror Operation

ZC Vectra

(GROUP 12) TL0780-0409

A new feature has been added to the electric mirror

operation on above model from the start of 2004.

Now, whenever the drivers mirror is adjusted Up or

Down, the passenger mirror will automatically adjust

Up or Down to suit.

This change was introduced on ZC models from:

ISOVIN: Built Date:

W0L0ZCF6848050018 27 Jan 2004

(This “built date” is normally shown on a label attached

to the top of the strut tower.)

DIAGNOSIS HINT

Clicking noise from front wheels

YG Cruze

GROUP 10 TL0791-0409

PROBLEM DESCRIPTION

Clicking noise from front wheels when turning. It may

sound like a clicking drive shaft or front wheel bearing.

DIAGNOSIS HINT

Recent investigation has shown that on YG Cruze

vehicles the above condition can be caused by over-

tightened wheel nuts.

Therefore, the first step in diagnosing this condition

should be to verify that the wheel nuts are tightened

using a HAND HELD TENSION WRENCH and

torqued to the spec of 85 Nm (63 lbf-ft) as specified in

LCRV SIP.

NOTE: If the complaint vehicle is built before

23/01/2003, VIN - JSAGHY81S00111647, the front

wheel bearings should be replaced as recommended

in the June 2003 Techline. Refer to techline for more

details.

HOLDEN SERVICE TECHLINE _____________________________________________________________OCTOBER, 2004

SERVICE FIX

Radiator – Rattling Creaking noise

ZC Vectra

(GROUP 6K) TL0766-0409

CONDITION

Noise heard in passenger compartment when driving

on uneven road or driving off from rest. Can be

mistaken for front suspension noise.

CAUSE

Upper radiator pins/bumpers creak during relative

movement between components.

CORRECTION – Production

Revised radiator upper bumpers have been fitted to

vehicles from:

ISOVIN: Built Date:

W0L0ZCF3541135295 30/6/2004

CORRECTION – Service

In cases of customer complaint, replace the two

radiator upper bumpers with new parts as listed below.

Refer to TIS 2000 for replacement procedure.

PARTS INFORMATION

Part No.: Description: Qty

13186475 Bumper - radiator to front

panel upper

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

SERVICE PROCEDURE

ECU Replacement Procedure

All OPEL Products

GROUP 6C TL0793-0409

TAS receive a high number of calls from technicians

unsure of the correct procedure to use when replacing

an ECU on OPEL products.

The following, is a step by step procedure that must be

used whenever replacing an ECU on OPEL products.

REPLACEMENT PROCEDURE

1. Obtain the security number before starting.

2. Reset the original ECU with Tech 2 as follows:

1. F0 Diagnosis

2. F3 Body / immobiliser

3. F3 Additional Functions

4. F2 Reset Engine Control Unit

5. Enter Security Code

6. Press OKAY if correct security code has been

entered

7. The following warning will appear: “Warning

Engine will not start after reset”

8. Programming Completed.

3. Remove original ECU and install the new ECU.

1. F1 Service Programming system (SPS)

2. F0 Request Info. When finished, disconnect

Tech 2 from vehicle and go to your PC that has

TIS installed. Select Service Programming

System and download the new calibration for

that vehicle. Return to the vehicle and download

the new calibration into the new ECU.

3. To link the new ECU to the vehicle proceed as

follows:

4. F0 Diagnosis.

5. F3 Body / Immobiliser.

6. F4 Programming

7. F0 Program Immobiliser Function

8. Get programming approval from TIS. Once

approval has been obtained, return to

programming immobiliser function.

9. Enter the correct Engine type

10. Engine controller installed.

11. Perform the CAN and VARIANT configuration,

in ECU programming menu.

12. Follow the remaining Tech 2 instructions

HOLDEN SERVICE TECHLINE _____________________________________________________________OCTOBER, 2004

SERVICE PROCEDURE

ECU Programming Precaution

All Opel engines with Electronic Throttle

Control

GROUP 6C TL0795-0409

After using Tech 2 to reprogram an existing ECU or

program a new ECU the following MUST BE

ADHERED TO as the final step in the procedure.

1. Key Ignition OFF for 10+ seconds;

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

additional 10+ seconds.

3. Start engine.

These steps allow sufficient time for the Electronic

Throttle Control to perform self-tests and relearn its

default positions.

If the above procedure is not adhered to, the following

may occur:

• Setting of DTC’s relating to the Electronic

Throttle Control.

• Driveability issues

• Engine may not start.

To rectify the above conditions, the following

procedure must be performed.

1. Key Ignition OFF for 10+ seconds.

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

additional 10+ seconds.

3. Connect Tech 2

4. Clear all DTC’s stored in ECU and TCM.

INFORMATION

Steering Wheel Painted Spoke Covers

VY, WK

(GROUP 9) TL0724-0409

The purpose of this techline is to advise that the

painted steering wheel spoke covers are now

available as a replacement kit.

Previously, only the satin chrome spoke covers were

available as replacement parts; Refer Techline No.

TL0655-0403 published in Issue 3, April 2004. The

replacement procedure and warranty information is

identical and is repeated below for information.

PARTS INFORMATION

Part No.: Description: Qty

92148830 Cover package steering wheel

spokes (dark tempest)

REPLACEMENT PROCEDURE

1. Remove steering wheel as per PV SIP procedure.

2. Detach rear cover from steering wheel.

3. Remove four spoke covers by undoing attaching

screws from rear.

4. Install new spoke covers.

5. Reinstall all parts.

WARRANTY CLAIM INFORMATION

Description Replace steering wheel

spoke covers

Labour Op. No. C000514

Time 0.5 hr

Failure Code 23 - Finish comes off

HOLDEN SERVICE TECHLINE _____________________________________________________________OCTOBER, 2004

SERVICE FIX

Diff Whine 80 – 100 km/hr

VY Crewman V8 Auto - excluding Cross 8

GROUP 4 TL0631-0409

CONDITION

Some vehicles may experience an unacceptable

“whine” noise from the differential at approximately 80 -

100 km/h at light to medium throttle cruising.

This noise should not be confused with noises

resulting from possible faulty diff bearings or gears.

CORRECTION – Production

Two countermeasures introduced into production are:

• revised (lower) durometer rubber bush in the

front eye of the leaf spring.

• revised (2 spoke) pinion flange.

ISOVIN: Built Date:

**********L218227 9/3/2004

CORRECTION – Service

Summary: After verifying that vehicle has condition as

described above, fit a new diff companion flange and

revised bushes in front eye of rear springs.

Procedure.

(For specific procedures not covered in detail refer to

current PV SIP.)

1. Remove rear springs.

2. Press out existing front eye bush from each spring.

3. Press in new eye bush 92148815.

4. Reinstall spring assemblies.

NOTE: There are four large washers p/n

76543210 that need to be fitted – one on each side

of the front spring eye bush as spacers/locators.

These washers are only fitted to vehicles with the

revised spring eye bushes (so any future removal

of springs should be done carefully – to ensure

that any washers fitted in these locations are

replaced).

5. The revised pinion flange 92176653 should be

fitted with the new nut 92146565 exactly as per

procedure found in PV SIP.

Section 4B – Final Drive & Drive Shafts

2. Minor Service Operations

2.11 Pinion Flange / Replace using old seal.

6. The alternative to step 5 is to have a sublet

repairer (diff specialist) fit the flange. – any such

repairer must use a torque reading tension wrench

to ensure the pre-load before and after are the

same, otherwise, preload related noise/failure may

occur at a later date.

PARTS INFORMATION

Part No.: Description: Qty:

92148815 Bush Rr Spring Front 2

76543210 Washer, Rear 4

92176653 pinion flange

92146565 Flange nut 1

WARRANTY CLAIM INFORMATION

Description Replace bush, leaf spring

front eye – both sides and

replace diff pinion flange

Labour Op. No. F000197

Time 2.1 hr

Failure Code F0040 noisy

HOLDEN SERVICE TECHLINE _____________________________________________________________OCTOBER, 2004

DIAGNOSIS HINT

Seat Track - Excessive Fore/Aft Movement

or “Loose”

V & W with 2 Way and 4 Way Seat Track

Only

(GROUP 1) TL0735-0409

The following applies only to vehicles built after

April 2003.

CONDITION

Symptoms may include:

• Seat track has slight movement under acceleration

and braking.

• Seat stiff to move fore/aft.

CAUSE

The seat track runners may have been slightly

misaligned when the seat was installed in vehicle

assembly.

CORRECTION

1. Remove seat track trims to gain access to all

seat-track-to-floor attaching bolts.

2. Loosen all seat-track-to-floor mounting bolts

(Do not remove the bolts).

3. While sitting in the seat, move the seat to the

mid position, where all bolts can be accessed

without moving the seat, and ensure both track

latches are engaged.

4. Without moving the seat, tighten bolts to 35-

50 Nm in the following sequence. (Refer figure 1).

1. Rear Inboard,

2. Front inboard,

3. Front Outboard,

4. Rear Outboard.

Important: The seat must always be latched

completely and correctly when tightening the

mounting bolts.

5. Check that carpet has not been caught

between the seat track and floor panel at all

mounts positions.

6. Check for elimination of the symptoms.

Figure 1

HOLDEN SERVICE TECHLINE _____________________________________________________________OCTOBER, 2004

SERVICE FIX

Fluttering Noise From HVAC on High Fan

Speed

VYII, WK

GROUP 2 TL0787-0409

CONDITION

A fluttering noise (like helicopter rotor noise) may be

evident on some VY series 2 vehicles coming from the

HVAC assembly.

This noise, if present, will occur when HVAC control

mode is on highest blower fan speed, “blend mode”

(demist/floor), either hot /cold temperature setting and

vehicle at idle.

The noise is caused by the floor mode door vibrating in

it’s stop position. If you hold the demist door

linkage/gear under the HVAC case drivers side, you

will also note that these also vibrate when the noise

occurs.

CORRECTION – Production

HVAC units with floor actuators the same as the face

actuator (92140681) have been fitted to all models

from:

ISOVIN: Built Date:

**********L318160 11 AUG 2004

CORRECTION – Service

Summary: Replace the floor mode actuator (black

coloured actuating rod) with a face mode actuator

(white coloured actuator rod).

Procedure:

1. Remove the fuse panel cover from below the

steering column.

2. Remove the drivers side centre-console side

cover.

3. From under the HVAC assembly, locate the floor

vacuum actuator as shown in figure 1.

4. Remove the pink and orange vacuum lines from

actuator.

5. Remove the actuator mounting screw shown in

Figure 1.

6. Disconnect the actuator rod from the demist lever.

7. Carefully pull on the vacuum actuator to withdraw it

from the rear attaching screw. (This is made

possible due to the forked rear mounting) Do not

loosen or remove the rear attaching screw.

8. Install new vacuum actuator 92140681 in the

reverse order to removal.

Figure 1. Shows floor actuator to be replaced.

Figure 2. Shows underneath view of HVAC unit

PARTS INFORMATION

Part No.: Description: Qty:

92140681 Vacuum actuator

WARRANTY CLAIM INFORMATION

Description Replace floor/demist

vacuum actuator

Labour Op. No. D021420

Time 0.6 hr

Failure Code 40 noisy

IMPORTANT: The time shown in SIP (4.2hrs) against

labour operation No. D021420 for replacing the floor

actuator no longer applies. That time was based on

removing the HVAC unit from the vehicle as specified

in SIP. That procedure is now superseded by the

procedure shown in this techline.

HOLDEN SERVICE TECHLINE _____________________________________________________________OCTOBER, 2004

SERVICE FIX

Welch Plug Leaks

Gen III V8 Engine

GROUP 6A TL0777-0409

CONDITION

Suspected coolant leak from the cylinder head welch

plugs.

CORRECTION – Service

Summary: Confirm if stain or actual leak. If leaking,

add cooling system pellets to seal leaks. If pellets are

unsuccessful then replace welch plugs.

Inspection:

If there is evidence of a coolant leak at the cylinder

head welch plugs, the area should be cleaned and

inspected to determine if an actual leak is present or if

it is only a coolant stain.

Coolant Stain:

At the engine manufacturing plant, some engines are

built with cooling system sealing pellets to ensure

complete sealing of the welch plugs. A small amount

of seepage (which causes the staining) may occur

during the first 15 minutes of operation before the

coolant pellets dissolve and seal the plug to cylinder

head area.

Coolant leak:

If an actual leak is present, the cooling system should

be partially drained (say 2-3 litres) then refilled with the

addition of 2 crushed sealing pellets (part number

92140053) added to the coolant mixture. Refer to SIP

procedure 6B3 - 2.3 for refilling procedure.

NOTE 1. There are 3 pellets in the packet but only 2

are required per engine.

NOTE 2. Although SIP states not to use sealing pellets

with extended life antifreeze coolant (conforming to

GM6277M), the use of sealing pellets part number

92140053 is acceptable.

After filling the cooling system, the engine should be

operated for at least 15 minutes before inspecting for

leaks again.

If the welch plugs continue to leak after installing the

sealer pellets, new welch plugs should be installed as

follows.

NOTE 3. Please PIR all cases where sealer pellets

were not successful in stopping leaks.

NOTE 4. To replace plugs in the rear of the cylinder

heads, first remove the engine/transmission assembly.

1. Lower the coolant level so there is no coolant in the

cylinder heads.

2. Remove the cup welch plugs and clean the bores.

3. Apply Primer N (Loctite product number 7649) to the

new plug.

4. Apply Loctite 620 adhesive to the welch plug bore in

the cylinder head.

By applying adhesive and accelerator to the seperate

components, you avoid any cross contamination. This

will avoid any potential pre-curing of adhesive that is

applied to an activated surface.

5. The vehicle should be allowed to sit for a minimum

of 1 hour prior to refilling with coolant and retesting

engine for leaks.

NOTE: The above commercial products have been

found to be suitable for use in this repair procedure.

Other equivalent products may be used in their place.

PARTS INFORMATION

Part No.: Description: Qty:

92140053 Sealing pellets

(pack of 3)

WARRANTY CLAIM INFORMATION

Refer to Warranty Claim Information in latest PV SIP

(6.6 onwards).

HOLDEN SERVICE TECHLINE _____________________________________________________________OCTOBER, 2004

SERVICE FIX

Front Door Lock Malfunction

VY, WK, V2

(GROUP 1) TL0667B-0409

This techline supersedes the previous one in issue 8,

2004. It is revised by making the repair procedure only

applicable to front door locks and rewording step 3 of

procedure. Please mark all previous copies as

superseded.

CONDITION

Front door lock(s) will intermittently not unlock via

remote key or snib button.

CAUSE

This condition may be caused by binding up of the

latch mechanism due to insufficient operating

clearances at the paddle actuating lever pivot - Refer

fig 1.

CORRECTION – Production

Locks produced with modified operating clearances

within the linkages have been fitted to vehicles from:

ISOVIN: Built Date:

**********L225024 20/01/2004

CORRECTION – Service

Summary: Repair the lock by creating clearance at the

external door handle actuating lever pivot.

1. Remove the door lock from the vehicle and

remove the paddle actuating lever return spring as

shown in figure 1.

2. Check the paddle actuating lever for binding or

sticking as follows: Hold the lock assembly upright in

the “as installed” position then raise the actuating lever

(at red arrow) and release the lever. Check if the

paddle actuating linkage falls under its own weight.

3. If the linkage falls under its own weight as per

test in step 2, do not perform step 5. Further diagnosis

for the lock intermittently not unlocking is required.

4. If the linkage DOES NOT fall under its own

weight the paddle actuating lever pivot needs to be

loosened off as per following procedure

5. Using an 8mm bar or suitable substitute tool

(e.g. pin punch) carefully work the rivet up and down –

left and right continually until the rivet can be rotated

360o with finger effort; refer figure 3.

Note: When working the rivet, do not permanently

distort the rivet mounting plate. Loosen the rivet only

sufficiently to allow 360o rotation by finger effort.

Paddle Actuating

Return Spring

Linkage

should fall

under its own

weight.

Rotate rivet 360o

Fig 1

Fig 2

Fig 3

Paddle actuating

lever pivot.

8mm diameter bar

or equivalent tool.

HOLDEN SERVICE TECHLINE _____________________________________________________________OCTOBER, 2004

6. Install the return spring (lubrication is not

required)

7. Check that the linkage has correct movement

and does not catch on any other components.

8. Install the lock assembly to the door (Torque

screws to 3-5 NM)

9. Ensure the inner door trim water seal is sealed

correctly to prevent any water leaks.

10. Check the operation of the door lock (manual

and remote), interior and exterior door handles.

NOTE: It is not possible to use the above tool on the

rear door locks.

WARRANTY CLAIM INFORMATION

Refer PV SIP if new lock assembly was fitted.

Refer table below if lock was repaired.

Lock location Labour Operation Time Allowed

RHF C000529 0.8 Hr

LHF C000532 0.8 Hr

SERVICE PROCEDURE

Checking Transfer Case Oil Level

VY AWD Models

GROUP 3 TL0796-0409

The following extract from PV SIP is provided to

highlight the method for checking oil level in the

transfer case on AWD models.

2.1 Checking Transfer Case Lubricant

Level

1. Ensure that the vehicle is level.

2. Clean the area around the filler plug (1).

3. Remove the filler plug and gasket using a suitable size

ring spanner.

4. The level is correct when the lubricant just reaches the

filler plug threads in the rear transfer case housing, when

COLD.

5. Replace the filler plug gasket, then reinstall the filler

plug, tightening to the correct torque specification.

6. Should the lubricant level be found to be low, then the

reason must be investigated and corrected.

7. After correction of the leakage condition, drain and refill

the transfer case. Refer to 2.2 Draining/Filling Transfer

Case Lubricant, in this Section.

Transfer case filler plug torque specification 32 Nm

NOTE

The above view shows the transfer case mount bracket and

rear crossmember removed, to more clearly show the filler

plug location.

HOLDEN SERVICE TECHLINE _____________________________________________________________OCTOBER, 2004

Engine Rough Idle – Valve Spring Failure

300 Kw V8 engine

GROUP 6A TL0762-0409

The complete HSV Techline can be viewed on the

Holden Lionheart Portal website.

It can be found under Service Techlines, Year 2004,

Group – HSV.

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

SERVICE FIX

A/T Shift Improvements

VY AWD (Adventra & Cross 8)

(GROUP 7B) TL0790-0410

CONDITION

Some customers may report the following:

“aggressive” or “harsh” downshifts or,

“driveline clunk” on light throttle upshifts

CORRECTION – Service

A service fix calibration has been released on TIS CD

54 that improves the above shift conditions. Therefore,

customer complaint vehicles should be reflashed with

current calibration provided on TIS CD 54 (or later).

WARRANTY CLAIM INFORMATION

Use existing Labour Time information in current PV SIP

CD as follows:

Description PCM - Reprogram

Labour Op. No. J987710

Time 0.4 hr

Failure Code NOW K0084 (Hard Shift, Hot)

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

SERVICE FIX

Gear Shift Linkage Rattle/Failure

XC Barina with M/T

(GROUP 7A) TL0574-0410

PROBLEM DESCRIPTION

A rattle noise may develop in the gear shift linkage on

vehicles which operate for lengthy periods on roads

where substantial amounts of dirt, dust, debris, etc, are

deposited on the shift linkage. Eventually, this may

result in gear shift linkage pivots wearing and

dislodging, with subsequent gear selection problems.

SERVICE RECTIFICATION

On complaint vehicles where the gearshift linkage

pivots have worn excessively, install an improved

linkage assembly as follows:

1. Disconnect battery.

2. Raise vehicle.

3. Remove shift guide from shift rod.

4. Lower vehicle.

5. Remove fastening clip of coolant reservoir

(Picture I, item 2). (Item 1 for other markets Diesel

vehicles only)

6. Unclip coolant hose and lay coolant reservoir aside.

7. To remove universal joint, remove hollow pin with

KM-569-A (Picture III).

Note: For removal of universal joint (1) press in

retaining spring (arrow) of hollow pin (2):

8. Remove safety clip for linkage (Picture IV, item 1).

Note: Safety clip will be destroyed at removal.

9. Detach and remove linkage assembly upwards.

10. Install new linkage assembly, p/n 93176772 and fix

safety clip.

Important: Lubricate all movable parts with silicone

grease, p/n 90167353

11. Install universal joint, secure with new hollow pin.

Important: Retaining spring must engage audibly.

12. Raise vehicle.

13. Install shift rod to shift guide.

Note: Do not fasten the clamp yet.

14. Lower vehicle.

(Step 15 on next page)

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

15. Adjust transmission shift linkage

See TIS working procedure "Transmission Shift

Linkage, Adjust (F13/F17)", Group "K", Service

Instruction Corsa-C (Holden Barina).

16. Install coolant reservoir.

17. Install coolant hose.

18. Connect battery.

19. Program volatile memories (radio, etc).

20. Road test vehicle to confirm correct gear selection.

PARTS INFORMATION

Part No.: Description: Qty:

9317677

Linkage Asm. 1

9016735

Silicone Grease, 100gm 1

9052318

Pin – Guide Control to

Trans.

NOTE: Grease shown above is a bulk quantity, NOT

for each repair.

WARRANTY CLAIM INFORMATION

Use existing Labour Operation and Time as shown in

Passenger SIP.

INFORMATION

Seat Belt Warning Inoperative Above 25

Km/h

VZ & WL

GROUP 12 TL0817- 0410

Holden is currently investigating reported instances of

where the seat belt warning chime does not operate

following re-configuration of the instrument cluster.

Until the cause of this condition and a solution is

available technicians should avoid re-configuration

where possible.

When a solution is available a further Techline will be

published.

In the event that a customer reports the seat belt chime

is not functioning a nominated contact should contact

Holden Technical Assistance (TAS) for advice.

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

SERVICE FIX

Front and Rear Console Storage

Compartment – Door Latch Lever

Replacement

VY, VZ, WK, WL

GROUP 1 TL0755-0410

This techline should be read in conjunction with

techline TL472-0305 of May, 2003 which described the

requirement to replace complete storage compartment

assemblies for breakage of the door latch lever.

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

The purpose of this techline is to advise that the

storage compartment door latch levers are now

available as individual replacement parts. The

replacement procedure is shown as follows.

Replacement Procedure – Door Latch Lever.

1. Push down firmly on the door stops shown in

Figure 1 to allow the door to fully open as shown in

Figure 2.

2. Rotate the latch lever 180 deg. (refer Figure 3) to

allow the lever to be withdrawn.

3. Install new lever and reconnect to door.

4. Return door to original position. (Figure 1)

PARTS INFORMATION

Part No.: Description: Qty:

92148457 Lever - instrument panel

compartment door latch

Figure 1.

Figure 2

Figure 3.

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

SERVICE FIX

Fuel Gauge Indicates Higher Level Than

Actual - (Bent Float Arm)

VZ, WL

GROUP 8 TL0809-0410

CONDITION

Fuel gauge indicates higher level of fuel than is actually

in tank.

CAUSE

One possible cause is that the Modular Reservoir

Assembly (MRA) float arm may have been bent during

installation into the tank.

CORRECTION – Production

Checks to ensure that float arm is not bent have been

implemented in vehicles from:

ISOVIN: Built Date:

**********L345644 6/10/04

CORRECTION – Service

1. Remove all useable fuel by pumping using vehicle

fuel pump. Do not remove MRA at this stage.

2. Measure the fuel sender resistance at the body

harness connector for the MRA using a multimeter.

Resistance should be 248.5 +/- 3.3 ohm.

3. If measured resistance is outside of specification

remove MRA and check for a bent float arm. If

resistance is within specification call TAS for

assistance.

4. If arm is bent, carefully rebend to achieve

dimension A shown in picture below.

NOTE: Prior to measuring “A”, ensure that the

bottom of the float is parallel to the surface that the

MRA is sitting on. Dimension A can be determined

from the table below.

5. Recheck the sender operating resistance with float

positioned as shown in picture. i.e. at Empty

position.

Resistance should be 248.5 +/- 3.3 ohm. (245.2 -

251.8 ohm)

6. If resistance is within specification reinstall MRA

into fuel tank.

7. Before filling with fuel, recheck resistance as

before, to ensure arm has not been bent .

MRA Part No. Model Dimension

92159903 WL Gen 3 V8 2.0 +/- 2

92163120 WL, VZ Sed & Wag – V6 2.0 +/- 2

92163122 VZ Ute - V6 5.5 +/- 2

92174478 VZ all Gen 3 V8 5.5 +/- 2

92176989 HSV - VZ Ute Gen 4 V8 5.5 +/- 2

92176988 HSV - VZ Sed. Gen 4 V8 2.0 +/- 2

92148352 VZ Cab Chassis tba

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

INFORMATION

Holden Lionheart Portal – Improvements For Viewing Latest Service Bulletins

GROUP OB TL0821-0410

To assist dealers to check the most recent Service Bulletins “posted” onto the Portal we have made the following

revisions.

When you logon to the Lionheart Portal and select “HOLDEN SERVICE BULLETINS”, the first page now appears as

shown in FIGURE 1. The date at the top of the list is the most recent date that a Service Bulletin was loaded onto

the Portal. In this example Retailer Lettter RL 44/04 was loaded onto the Portal on the 26/10/2004. To view the

bulletin simply click on it.

If you wish to view bulletins by category, select the “Category” button at the top of the page shown with red arrow.

This will take you to FIGURE 2, where you can then select whichever category you wish to view. To return to first

page (FIGURE 1) select the “Close” button.

FIGURE 1

FIGURE 2

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

SERVICE FIX

Diff. Period Whine 80 – 110 km/hr

VY, VZ, V8 One-Tonner & Crewman

(excluding Cross 8)

GROUP 4 TL0631A-0410

This Techline supercedes the previous one in Issue

9, Oct, 2004. It is revised by adding V8 One-Tonner

and correcting the washer part number.

CONDITION

Some vehicles may experience an unacceptable

period whine noise from the differential at

approximately 80 - 110 km/h at light to medium

throttle cruising.

A certain level of rear axle assembly noise is normal

and to be expected on these light commercial type

vehicles due to their cab chassis structure and

associated load carrying requirements.

NOTE: This noise must not be confused with noises

resulting from possible faulty differential bearings or

gears.

CORRECTION – Production

Two countermeasures introduced into production are:

• A softer rubber bush in the front eye of the leaf

spring. - Crewman V8 Auto & M/T

• A 2-spoke pinion flange - Crewman V8 Auto

Breakpoint for both countermeasures is:

ISOVIN: Built Date:

**********L218227 9/3/2004

CORRECTION – Service

Summary: On complaint vehicles, fit a 2-spoke diff

pinion flange and softer bushes in front eye of rear

springs.

Procedure. (For specific procedures not covered in detail

refer to latest PV SIP.)

1. Remove rear springs.

2. Press out existing front eye bush from each

spring.

3. Press in new eye bush 92148815.

4. Reinstall spring assemblies.

NOTE: There are four large washers p/n

92175916 that need to be fitted – one on each

side of the front spring eye bush as

spacers/locators. These washers are only fitted

to vehicles with the revised spring eye bushes.

5. The revised pinion flange 92176653 should be

fitted with the new nut 92146565 exactly as per

procedure found in PV SIP:

Section 4B – Final Drive & Drive Shafts,

2. Minor Service Operations,

2.11 Pinion Flange / Replace using old seal.

CAUTION: Overtightening of the pinion nut may

result in excessive bearing preload and bearing

damage.

6. The alternative to Dealers doing step 5 is to have

a sublet repairer (diff specialist) fit the flange.

Any such repairer must use a torque reading

tension wrench to ensure the pre-load before and

after is the same, otherwise, preload related

noise/failure may occur at a later date.

PARTS INFORMATION

Part No.: Description: Qty:

92148815 Bush Rr Spring Front 2

92175916 Washer 4

92176653 pinion flange 1

92146565 Flange nut 1

WARRANTY CLAIM INFORMATION

Description Replace bush, leaf spring

front eye – both sides and

replace diff pinion flange

Labour Op. No. F000197

Time 2.1 hr

Failure Code F0040 noisy

Update

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

DIAGNOSIS HINT

Differential Clunk Noise

VY & VZ One-Tonner & Crewman

GROUP 4 TL0815-0410

CONDITION

A clunk noise heard coming from the rear end of the

vehicle during “tip-in” or “tip-out” or whilst operating

the clutch on M/T vehicles.

Tip-in = applying the throttle (lightly)

Tip-out = de-applying the throttle.

CAUSE

A possible cause for the clunk is excessive backlash

in the rear axle.

CORRECTION - Service

Step 1. Perform a thorough under-vehicle

visual inspection of the entire driveline, including

transmission, propshaft CV's and rear axle for any

obvious looseness.

Step 2. Perform a rear axle backlash check

using the procedure described in PV SIP found as

follows:

Section 4B2 – Rear Final Drive and Live Axle

2 – Minor Service Operations

2.6 – Combined Rear Axle Backlash Check

IMPORTANT: Backlash reading should be 3.0 mm

maximum, when measured on the head of one of

the pinion flange bolts. PV SIP currently states

7.0 mm. which is now revised to 3.0mm and will

be corrected in the next issue of SIP.

Should the measured backlash be greater than

3.0mm when requesting a replacement axle

assembly – the measured backlash dimension MUST

be included in the Dana request application (via the

Dana website).

DO NOT request a replacement axle if backlash is

less than 3.0mm, as a replacement axle assembly is

not expected to improve the noise heard.

NOTE: A certain level of rear axle assembly noise is

normal and to be expected on these light commercial

type vehicles due to their cab chassis structure and

associated load carrying requirements.

Update

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

SERVICE PROCEDURE

Resetting Automatic Power Window

Operation - Includes Comfort Opening

& Closing On ZC Vectra & AH Astra

All OPEL Vehicles with Power Windows

GROUP 12 TL0812-0410

The following 3 functions apply to ALL Opel vehicles

with power windows:

• Auto up and down if the window switch button is

held for more than 0.5 second,

• Pinch Guard. During the auto up operation the

window will stop, then retract downward

approximately 100mm if anything prevents it from

reaching the top of its travel.

• Automatic closing of any power window from the

drivers door lock, when the key is held in the lock

position for more than 1 second.

Comfort Opening & Closing – ZC & AH.

• A new feature fitted only to ZC Vectra and the

new AH Astra is opening or closing all the

windows via the remote key. Holding down the

unlock button will lower the windows. Holding

down the lock button will raise the windows.

All the above automatic functions will be lost if

the vehicles battery is disconnected, or the

appropriate fuse or power supply to the power

window system is disconnected. Each electric

window motor has its own module attached to it.

This also applies whenever a door wiring harness is

disconnected.

RESETTING PROCEDURE

To reset all the above automatic functions, do the

following:

1. Reconnect power supply to the power window

system or an individual door that may have been

disconnected

2. Turn on the ignition.

3. Ensure all windows are at the top.

4. For each window, hold down the “up button” at

the drivers door main switch for 5 seconds –

usually a “click” will be heard coming from each

door.

5. After this, ensure that each window’s automatic

up and down function operates.

DIAGNOSIS HINT

Reverse Gear Selection “Hard”

VZ V6 with M/T

GROUP 7A TL0822-0410

Condition

Some customers may be concerned by a high effort

being required when shifting into Reverse gear.

Cause

This transmission has First and Reverse gears

located side by side. The Reverse gear detent has

been designed with a distinct “step” in the

mechanism to ensure that either gear cannot be

selected accidentally.

If Reverse gear is selected slowly – a very high effort

will naturally be required to overcome the “step”.

Solution

If Reverse gear is selected “with momentum” - IE: if

the lever is moved rapidly towards the Reverse gate -

the mechanism “step” is easily overcome and the

reverse selection will be achieved with much less

effort.

This method of selecting Reverse gear should be

explained to any customers who raise “hard” Reverse

selection as a concern.

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

DIAGNOSIS HINT

DTC P0100 / Poor Idle / Engine Stall

(Non - IACV Related Causes)

JR, JS, C20SEL, C22SEL

(GROUP 6C) TL0708-0410

This information is repeated from June 2002

Techline.

CONDITION

PIR’s have been received advising that vehicles have

not responded to fitting of new IAC valves as

described in June 2002 Techline titled “Engine stall at

idle” or “High engine idle speed”. These reports

mention that vehicles have a DTC P0100 (MAF

Sensor Voltage Low) set and the engine idle is

unstable or may stall at odd times.

CAUSE

Investigations have shown that possible causes for

above symptoms are as follows.

A. Blocked PCV hose/port in throttle body.

The hose/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.

B. Loose elbow in air intake duct (above throttle

body);

C. Damaged TPS housing on the throttle body;

D. Damage/deterioration to secondary PCV hose;

E. Purge valve hoses fitted in reverse.

F. MAF sensor faulty

G. Fuel Pump or Injection valve relay fitment.

H. Crankshaft or Camshaft sensor.

NOTE: As a general rule, any stall that occurs above

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

ensure a cause is found and corrected.

CORRECTION

On any vehicle with the condition as described

above, check the identified potential problem areas

(A - H) and rectify as required.

A. BLOCKED PCV HOSE/PORT IN THROTTLE BODY

Blockage of the PCV hose/port causes the engine to

run on IACV air only. Engine system calibration is

based on specific air flow through the PCV port PLUS

IACV air at high vacuum times (idle/decel) and thus,

loss of air flow through the hose/port can result in

poor idle and possibly stall.

NOTE: The following procedure applies to JR/JS

C22SEL engined vehicles built prior to introduction of a

revised PCV system that feeds PCV gas into the lower

part of the inlet manifold – these were built from:

WOLOJBF19YL557427, Build Date 16/02/00, Engine

No.: C22SEL25015395.

Diagnosis:

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. This port is shown in the cross

section diagram below, looking from rear of throttle

body

Contamination builds up

in PCV connector, Calibrated hole

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

PCV hose. No further action is required.

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

clean the port as follows.

This hole can be carefully cleaned out as follows:

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

engineering supplies outlet. NOTE: this drill bit

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

hole is calibrated. Enlarging the hole will result in

incorrect air flow, and causing driveability or further

code setting problems.

2. Remove the main air intake hose from the throttle

body;

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

drill into the connection and rotate the drill BY

HAND until the deposits in the connection are

dislodged and the drill freely passes through the

calibrated hole into the throttle body inlet passage.

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

throttle body port completely, then open the throttle

blade fully and hold it fully open, insert the drill bit

until it protrudes from the calibrated hole – then

remove drill bit and then close throttle blade.

5. Clean the connection with a solvent or spray

cleaner and remove any debris left in the

connection hole and throttle body;

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

and re-assemble previously removed components.

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

B. LOOSE ELBOW IN AIR INTAKE DUCT ABOVE

THROTTLE BODY

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

duct, the additional un-metered air entering the

system can cause driveability problems, poor idle,

and a P0100 to set.

If the elbow is loose – replace the inlet duct

(containing the elbow).

C. DAMAGED TPS HOUSING ON THE THROTTLE BODY

While this should be a rare occurrence - if the TPS

housing has been damaged in some way that allows

air/water/dust, etc to enter the body, the resulting

contamination can cause incorrect

operation/readings. EG: Damage during any service

operations, engine/trans. removal, etc. Any TPS

found with damage to the external body must be

replaced with a new TPS.

D. DAMAGED/ DEGRADED SECONDARY PCV HOSE

Stalling may be caused if the secondary PCV hose

(Item 2 shown in the diagram below) is split or torn, or

the inner hose walls deteriorate:

Damage (split or torn):

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

to incorrect airflow readings which affect the engine

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

Degraded:

Degradation of the hose can result from age and

exposure to PCV gases, and external contaminants

which affect the hose. The hose should be carefully

examined for physical degradation, EG: softness,

cracking, hardness, etc, and replaced if necessary.

Extreme build-up of PCV contaminants to the point

where the hose is blocked or cleaning is

uneconomical also dictates that the hose should be

replaced.

Deterioration of hose inner walls:

Allows particles of the deteriorated hose material to

separate from the hose, and these may become

lodged in the ‘early design’ or “old” IACV leading to a

stall. This will not occur with the ‘later design’ or

“new” IACV – however, the hose should be examined

and replaced where necessary.

NOTE: kinking, or clamping any other components to

the secondary PCV hose is NOT permitted.

E. PURGE VALVE HOSES FITTED IN REVERSE

The hoses at the canister purge valve must be fitted

the correct way – with the throttle body hose at the

top purge valve fitting – as shown below:

If these hoses are reversed – damage to the purge

valve may result – if this has occurred it is

recommended that the purge valve be replaced.

F. MAF SENSOR FAULTY

Stalling associated with the MAF Sensor can occur

either while vehicle is moving or stationary. Usually a

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

fluctuating idle, so correct diagnosis of type of stall is

required).

Some findings on failed MAF Sensors have been:

♦ Fretting corrosion of the MAF Sensor terminals.

(Replace suspect terminals.)

♦ Connectors not fully or correctly installed. (Check

connections and re-install if required.)

♦ Incorrect routing or attachment of sensor wiring.

(Check wiring against a known OK vehicle to ensure

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

not pick up any ‘stray’ electrical signals from other

wiring or components.)

G. RELAY INCORRECT FITMENT

If the “Fuel pump” or “injection valves” relays are not

properly fitted – with their terminals fully engaged in

the mating connector/wiring, a stall may be caused.

Check relays for full and proper connection, re-install

if required. Some relays are a very tight fit and may

not have been fully seated on fitting or subsequent

replacement.

H. CRANKSHAFT OR CAMSHAFT SENSOR

Refer to Techline bulletins of February and March,

2000 relating to these sensors – available on your

SIP CD. Replace any pre-breakpoint parts.

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

DIAGNOSIS HINT

Water In Decklid

VY, VZ, V2, WK, WL,

Group 1 TL0767-0410

CONDITION

Water in decklid.

CAUSE

Two possible water entry areas are shown in Figure

1. Production Drain Holes

There are two holes in the leading edge of the

decklid used as drain holes in the corrosion

protection dipping process. These holes are normally

sealed prior to the painting process. Refer Figure 2.

2. Seam

The seam between the outer and inner decklid

panels should be inspected for missing sealer. Check

full circumference of the decklid. Refer Figure 3.

CORRECTION

Seal drain holes or gaps in seam as required with a

sealer such as silicone RTV sealer part number

92140051 (75g tube) .

PARTS INFORMATION

Part No.: Description: Qty:

92140051 Silicone RTV sealer 75g

tube

Figure 1. Potential water entry points.

Figure 2. Shows an “un-sealed” drain hole.

Figure 3. Shows gap which can occur in seam

sealer.

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

SERVICE FIX

Front Seat Easy Entry Function

Inoperative In Forward Direction

V2 Series 3

GROUP 1 TL0801- 0410

CONDITION

Front seat does not move forward when the “Easy

Entry” lever is unlatched and the seat back tilted

forward.

CAUSE

A potential cause for this condition is poor retention of

the micro switch in its housing. (Refer to Figure 1 for

location of switch). If the switch is loose in its

housing, the Easy Entry lever cam will fail to activate

the switch. To verify if this is the cause, remove the

front seat back upper cover and check if the micro

switch is firmly retained in its housing.

CORRECTION – Service

Summary: After verifying that vehicle has condition

as described above, fit a new micro switch housing

as per following procedure.

Procedure.

(For specific procedures not covered in detail, refer to PV SIP.)

1. Remove seat-back cover.

2. Remove lumbar knob.

3. De-trim the side of seat to gain access to the 2

micro switch housing attaching screws located

just below the lumbar knob.

4. Remove micro switch housing from seat frame.

5. Detach micro switch from old housing and

discard housing.

6. Take new housing and rotate U shaped cam to

the up position as shown in Figure 2.

7. Insert micro switch into the new housing & press

firmly until the securing hooks snap into place.

8. Feed the switch wire through the hook in the

housing.

9. Re-attach switch housing to the seat frame.

10. Re-trim seat side.

11. Re-assemble seat back.

Figure 1.

Figure 2. Shows microswitch installed into housing.

PARTS INFORMATION

Part No.: Description: Qty:

92148933 Retainer power seat

switch/wiring -RH

92148934 Retainer power seat

switch/wiring - LH

WARRANTY CLAIM INFORMATION

At the time of printing, warranty claim

information was still being developed. Until this

information is published, contact your Aftersales

District Manager.

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

INFORMATION

Intake Manifold Runner Control Valve

Clunk

Alloytec V6 “190”

GROUP 6C TL0799-0410

A small number of customers may notice a light clunk

sound coming from the Alloytec 190 engine at low

engine speeds and high loads.

In most cases this sound will be due to the operation

of the Intake Manifold Runner Control (IMRC) valve

fitted to the Alloytec 190 engine.

The purpose of the IMRC is to alter the volume of the

intake manifold runners. Varying the intake manifold

takes advantage of natural pulse / pressure waves

occurring in the manifold that are created by the

process of air induction into the cylinders. At a given

engine speed, the manifold can be tuned to increase

the air charge into the cylinders via the returning

pulse waves to achieve higher engine torque.

Note the IMRC valve is two position only as shown

below, open (A) / closed (B), It is not continuously

variable. In the rest position the valve is open.

Use this techline to help customers understand the

reason for the noise they are concerned about.

A = VALVE OPEN

B = VALVE CLOSED

HOLDEN SERVICE TECHLINE _______________________________________________________________NOVEMBER, 2004

Service Tools

HSV – Z Series Coupe

GROUP OB HSV Bulletin 099/04

There are 2 new service tools required for mechanical

repairs on this new model.

• Pinion flange holding tool.

• Pinion flange extractor tool.

For complete details refer to HSV Bulletin No. 99/04

on the Holden Lionheart Portal website. It can be

found under Service Techlines, Year 2004, Group

OB – General Information.

Service Readiness

HSV – Z Series

GROUP OB HSV Bulletin 101/04

For complete details on the following:

Tech II Software, SIP, Technician Training, Special

Service Tools, Revised Service Schedules, Exterior

Changes, Interior Changes and New Powertrain

Features,

refer to HSV Bulletin No. 101/04 on the Holden

Lionheart Portal website. It can be found under

Service Techlines, Year 2004, Group OB - General

Information.

Tech II Software

HSV - Z Series

GROUP OB HSV Bulletin - 108/04

Should you require Engine or Transmission

calibrations for HSV VZ or WL before January 2005

contact HSV on (03) 9265 9500. for further

instructions.

Engine and transmission calibrations will be available

on TIS 2000 in January 2005.

Refer to HSV Bulletin No. 108/04 on the Holden

Lionheart Portal website. It can be found under

Service Techlines, Year 2004, Group OB – General

Information.

Matt Paint Finish

HSV – Z Series

GROUP 1 HSV Bulletin 100/04

This new model has matt finish paint accents which

require specific care.

For complete details refer to HSV Bulletin No. 100/04

on the Holden Lionheart Portal website. It can be

found under Service Techlines, Year 2004, Group 1 -

Body.

Use Of Mobil 1 in HSV LS1 Engines

HSV

GROUP 6A HSV Bulletin - 115/04

This bulletin provides information on use of Mobil 1 in

LS1 engines and clarifies the oil consumption

specification for these engines.

Refer to HSV Bulletin No. 115/04 on the Holden

Lionheart Portal website. It can be found under

Service Techlines, Year 2004, Group 6A – Engine.

Tyre Rotation Caution

HSV AWD Coupe 4

GROUP 10 HSV Bulletin - 102/04

On the HSV Coupe 4 model the front to rear tyre

rotation cannot be performed due to the rear wheels

being wider than the front wheels.

For complete details refer to HSV Bulletin No. 102/04

on the Holden Lionheart Portal website. It can be

found under Service Techlines, Year 2004, Group 10

– Wheels & Tyres.

HOLDEN SERVICE TECHLINE _______________________________________________________________DECEMBER, 2004

INFORMATION

Incorrect Fuse Fitted

VZ, WL

Group 12 Ref. No. TL0823- 0411

Some dealers may observe that fuse No. 29 - ECM /

TCM / BCM & Telematics (V6,V8) in the engine

compartment fuse/relay box is a different rating to that

shown on the cover.

Typically, a 7.5A fuse is fitted in a V6 and a 15A fuse in

a V8 although a 10A fuse is shown on the cover.

Despite this discrepancy, Engineering Dept. advise

there are no adverse consequences.

However, we suggest if you are replacing fuse 29 for

any reason, it be replaced with a fuse of the same

rating as that shown on the fuse box cover.

The above situation will be rectified in vehicle

production at the earliest opportunity.

INFORMATION

Tripmeter Resets When Battery

Disconnected

VZ , WL

Group 12 Ref. No. TL0827- 0411

After the battery is disconnected and reconnected on

the above models, the tripmeter will reset to the value

shown on the odometer. If the odometer reading is

greater than the maximum allowable trip distance of

99,999 the trip meter will reset to this value (99,999).

This is normal operation.

On previous models the trip distance will reset to zero

when the battery is disconnected / reconnected.

HOLDEN SERVICE TECHLINE _______________________________________________________________DECEMBER, 2004

SERVICE FIX

Front Seat Plastic Side Covers Fracture

At Attaching Point

TT Zafira

Group 1 Ref. No. TL0801- 0410

CONDITION

Front seat side outer cover comes loose at front

attaching point.

CAUSE

Side cover mounting tab breaks.

CORRECTION – Production

A washer has been added under the head of the side

cover front attaching screw on vehicles from:

ISOVIN: Built Date:

All vehicles built from 01/07/04

CORRECTION – Service

Summary: On vehicles with above condition, replace

broken side cover and add specified washer under the

front attaching screw.

Remove Cover

1) Remove seat belt cover.

2) Remove screw to plastic cover height adjuster and

plastic clip handle (RHS only)

3) Remove plastic adjuster wheel.

4) Remove height adjuster handle retaining clip (RHS

only)

5) Remove attaching screw - seat cover side outer.

Re-assemble

1) Replace damaged seat side cover with a new one.

2) Refit plastic clip handle height adjuster (rh side

only)

3) Refit plastic adjuster wheel.

4) Fix screw to plastic cover height adjuster and

plastic clip handle (rh side only).

5) Add a washer p/n 92171381 under attaching screw

as shown in Figure 3.

PARTS INFORMATION

Part No.: Partfinder Name: Qty:

90455894 Cover - Seat Rail Outer

– Drivers side

90455889 Cover - Seat Rail Outer

– Passenger side

92171381 Washer 1/ side

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD.

Figure 1

Figure 2

Figure 3

HOLDEN SERVICE TECHLINE _______________________________________________________________DECEMBER, 2004

INFORMATION

Activating “Transport Mode” on 6 Stacker

CD Unit

AH Astra, ZC Vectra (Model Year 05)

Group 12 Ref. No. TL0828- 0411

Whenever a “CDC 40 OPERA” audio head unit is to be

returned to Bosch for warranty purposes, the unit must

be set into TRANSPORT MODE as per the following

procedure.

This action is necessary to avoid internal damage to

the CD mechanism during shipping.

TRANSPORT MODE - CDC 40 OPERA

Audio Units

Activation:

1. Switch off Radio

2. Press “MAIN” button (see Figure 1) on Radio and

hold while switching on via ON/Off Button.

3. Keep “MAIN” button pressed for approx. 5 seconds,

until beep is heard.

When transport mode is active, a spring is visible in a

small window at the back of the unit . Refer Figure 2 &

3. When transport mode is inactive, there is no spring

visible in the window. Refer Figure 4.

Notes:

• This procedure MUST be performed before

removal of the radio from the vehicle.

• It can be done any time the unit is powered up,

either before or after security deactivation has

been performed with Tech 2.

• Programming the unit takes it out of transport

mode automatically.

Figure 1. Shows “MAIN” button.

Figure 2.

Figure 3

Figure 4.

HOLDEN SERVICE TECHLINE _______________________________________________________________DECEMBER, 2004

SERVICE FIX

Front Bumper Fascia Stained

VZ models with Chrome Engine Hood

Mouldings

Group 1 Ref. No. TL0825- 0411

CONDITION

Front fascia is stained by a fluid which appears to be

leaking from the chrome moulding on the front edge of

the engine hood.

CAUSE

Some residual process fluid used in the production of

the engine hood chrome moulding slowly leaks out of

the moulding via the cavity plug and onto the front

fascia.

CORRECTION – Production

Chrome mouldings with the offending production fluid

removed have been fitted to vehicles from:

ISOVIN: Built Date:

**********L355929 22/10/2004

CORRECTION – Service

Summary: After verifying that vehicle has condition as

described above, proceed as follows.

1. Remove stain from front fascia by paint

finesse/polishing if possible. Only repaint the

fascia if staining cannot be removed.

2. Replace the engine hood chrome moulding

92211005 to prevent repeat failures. DO NOT

SIMPLY WIPE CLEAN AS THE CONDITION WILL

PROBABLY RE-APPEAR.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92211005 Moulding Hood Front

(Chrome)

NOTE: All HSPO stock of 92211005 is ok.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

HOLDEN SERVICE TECHLINE _______________________________________________________________DECEMBER, 2004

SERVICE FIX

Rear Axle “Cyclic Knock” .

All V & W with IRS (non LSD)

Group 4 Ref. No. TL0602- 0411

CONDITION

Cyclic knock noise which may occur when coasting in

speed range between 70-40km/hr whilst driving in a

straight line.

This condition is confirmed if the cyclic knock noise

disappears when the vehicle is driven in a slalom

motion.

CAUSE

Excessive axial float of the inner axle shafts within the

differential.

Problem affects all V and W models with the exception

of cab-chassis and crew-cab vehicles.

CORRECTION – Production

Revised rear axle assemblies with reduced clearance

circlip grooves in the inner axle shafts are being

phased into vehicle production with completion

expected in December 2004. When it becomes

available, breakpoint information will be published.

CORRECTION – Service

Summary: After verifying that vehicle has symptoms as

described above, proceed as follows:

Procedure.

1. Contact Dana via their website to register a case

of “cyclic knock”. Once approved, Dana will send

a set of “upper spec spline” differential inner-axles

for the complaint vehicle.

2. Remove LHS and RHS driveshafts.

(Refer SIP Section 4B, 2.7 "Driveshaft Assembly”)

3. Remove LHS and RHS inner-axles from

differential.

(Refer SIP Section 4B, 2.9 "Inner Axle Shaft Seal".

Note: Diff does not need to be removed from

vehicle.)

4. Remove circlip from each inner-axle.

5. Place each circlip in a vice using protective jaws,

with the "c" opening facing downward and

clamped across the middle diameter (Refer Fig.

1).

6. Use a hammer to bend the circlip to the

approximate angle/deflection shown in Fig. 1.

7. Install circlip to the new shafts (supplied by Dana)

then reassemble shafts into differential.

8. “Invert” both driveshafts before reinstalling. This

means reinstalling driveshafts with the inner CV

joint now on the outside.

WARRANTY CLAIM INFORMATION

For vehicles covered under warranty use the following

information.

Description Diff Cyclic knock noise

reduction procedure

Labour Op. No. F000200

Time 1.8 hr

Failure Code F0040 noisy

HOLDEN SERVICE TECHLINE _______________________________________________________________DECEMBER, 2004

Figure 1. Shows modification to Inner Axle shaft C clip

INFORMATION

Misfire With Traction Control Enabled

VZ & WL Gen 3 V8

Group 6C Ref. No. TL0830- 0411

Dealers have reported a misfire condition on above

models when loading up the engine while stationary

This is normal operation when traction control is

enabled as the system recognises this condition as a

traction control event.

Cylinders are disabled at random to reduce engine

torque and avoid wheel spin (unlike previous models

VT-VY).

INFORMATION

Service Reminder Intervals Incorrect

VZ & HFV6

Group OB Ref. No. TL0831- 0411

CONDITION

Service reminder set incorrectly to show 10,000km

service intervals instead of 15,000 km.

CORRECTION – Production

Instrument clusters with correct service reminder

intervals have been fitted to vehicles from:

ISOVIN: Built Date:

All vehicles built from 24/11/2004

CORRECTION – Service

Explain situation to customer when vehicle booked in

for service.

Rectify by reconfiguring instrument cluster with Tech

2 at next service opportunity.

HOLDEN SERVICE TECHLINE _______________________________________________________________DECEMBER, 2004

SERVICE FIX

Phone Storage Compartment Lid Won’t

Open

VY, V2, VZ, WK, WL

Group 1 Ref. No. TL0716- 0411

CONDITION

Phone Storage Compartment Lid not functioning

correctly – one or both of linkage arms disconnecting

from damper.

CORRECTION – Production

Phone storage compartments with revised linkage

arms have been fitted to vehicles from:

ISOVIN: Built Date:

**********L327099 2 Sep 2004

CORRECTION – Service

Summary. Repair phone compartment instead of

replacing.

On any vehicle where the phone storage

compartment linkage arms have disconnected, (refer

figure 1) install revised arms to both sides.

The difference between the old and new arms is

shown in Figure 2.

Figure 3 shows the new arm installed.

PARTS INFORMATION

Part No.: Partfinder Name Qty

92148008 Rod – Front floor console

compartment door latch

release

WARRANTY CLAIM INFORMATION

Description Phone compartment

damper arm– Replace

Labour Op. No. C457500

Time 0.2 hr

Failure Code C0029 part missing

Figure 1. Shows door mechanism minus the arm.

Figure 2. Shows the old and new design arms

Figure 3. Shows new arm installed

HOLDEN SERVICE TECHLINE _______________________________________________________________DECEMBER, 2004

SERVICE FIX

LHS O2 Sensor Wiring Insufficient

Clearance To Exhaust Heat Shield

VZ with HFV6 (175 kw)

Group 6C Ref. No. TL0819- 0411

CONDITION

On some vehicles the Left Hand O2 sensor wiring

harness may have insufficient clearance to the heat

shield (less than 30mm).

CORRECTION – Production

An additional clip was added to restrain the harness

on vehicles from:

ISOVIN: Built Date:

**********L358859 28/10/2004

CORRECTION – Service

On vehicles where the wiring harness is observed to

have less than 30mm clearance to the exhaust heat

shield install a clip as shown in figure 1.

PARTS INFORMATION

Part No.: Description: Qty:

92168425 Clip 1

WARRANTY CLAIM INFORMATION

Description Install LH O2 sensor wiring

restraining clip

Labour Op. No. J000764

Time 0.2 hr

Failure Code J0062 improper clearance

Figure 1. Add clip as shown to restrain LH O2 sensor harness.