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, 2005

INFORMATION

Fitting Accessory Trailer Harness

ZC Model Year 2005

Group 12 Ref. No. TL0818- 0501

The following information is copied from HSPO Parts

Techline PT180 dated 9th Feb. 2005.

It describes the modification required when fitting a

trailer harness p/n 92148794 to a Model Year 2005 ZC

Vectra. This action is necessary due to a change to

the Rear Electrical Centre (REC) of this vehicle.

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

SERVICE FIX

Fuel Gauge Will Not Display Full After

Filling The Fuel Tank

VZ Gen III Ute

Group 12 Ref. No. TL0844 - 0501

CONDITION

Reports have been received of the fuel gauge not

displaying full after refilling the fuel tank.

CAUSE

The fuel gauge section of the Engine Control Module

calibration.

CORRECTION – Production

A revised fuel gauge calibration was programmed into

vehicles in production from the following breakpoint:

ISOVIN: Built Date:

**********L390626 21/01/2005

CORRECTION – Service

To rectify this condition it will be necessary to:

1. reprogram the PCM via the standard SPS process

using TIS 2000 version 58 or later and

2. reprogram the instrument cluster fuel gauge

calibration using Tech 2 with software version

13.8.

WARRANTY CLAIM INFORMATION

Description Reprogram PCM &

Instrument cluster

Labour Op. No. N000478

Time 0.6 hr

Failure Code N0057 Registers incorrectly

SERVICE FIX

Fuel Gauge Inaccuracy

VZ / WL V6 Sedan and Wagon

Group 12 Ref. No. TL0845 - 0501

CONDITION

Reports have been received of the fuel gauge not

displaying accurately at the lower section of the gauge.

CAUSE

Variation of the fuel gauge output calculated by the

Engine Control Module (ECM).

CORRECTION – Production

A revised fuel gauge calibration was programmed into

the Engine Control Module in vehicles from the

following breakpoint:

ISOVIN: Built Date:

L382346 09/12/04

CORRECTION – Service

To rectify this condition it will be necessary to:

1. reprogram the ECM via the standard SPS process

using TIS 2000 version 58 or later and

2. reprogram the instrument cluster fuel gauge

calibration using Tech 2 with software version

13.8.

Note: In addition to the above, if the vehicle was built

prior to the 06/10/04 (L345644), refer to Service

Techline number TL0809-0410 published in issue 10,

Nov. 2004, to ensure the fuel sender float arm is not

bent.

WARRANTY CLAIM INFORMATION

Description Reprogram ECM &

Instrument

Labour Op. No. N000475

Time 0.6 hr

Failure Code N0057 Registers incorrectly

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

SERVICE FIX

Hill Descent Control Icon Displayed When

Shifting Gear

VZ (non AWD)

Group 12 Ref. No. TL0843 - 0501

CONDITION

Reports have been received of the Hill Descent Control

Icon being displayed in the instrument cluster when

shifting from Park to Reverse to Drive

CAUSE

Instrument cluster operating software.

CORRECTION – Production

The instrument cluster software has been revised to

rectify this condition from the following vehicle

breakpoint:

ISOVIN: Built Date:

**********L366285 10/11/04

CORRECTION – Service

To rectify this condition reprogram the instrument

cluster operating software via the standard SPS

process using Tech 2 and TIS 2000 version 57 or later.

WARRANTY CLAIM INFORMATION

Description Reprogram instrument

cluster

Labour Op. No. N312700

Time 0.3 hr

Failure Code N0057 Registers incorrectly

SERVICE FIX

Service Reminder Incorrect

VZ V6 Sedan, Wagon and Ute

Group 12 Ref. No. TL0831A - 0501

This Techline supercedes the previous one in Issue

11, Dec, 2004. It is revised by adding procedure for

reconfiguring instruments.

CONDITION

Reports have been received of the 10,000 km service

reminder being displayed in the instrument cluster

instead of the 15,000 km.

CAUSE

Incorrect programming of the instrument cluster during

the production process.

CORRECTION – Production

The programming process has been revised to rectify

this condition from the following vehicle breakpoints:

ISOVIN: Built Date:

Sedan **********L313609 24/11/04

Wagon **********L373979 24/11/04

Ute **********L371431 24/11/04

CORRECTION – Service

To rectify this condition perform the following steps;

Step 1.

Using Tech 2 enter the configuration sub menu (an

example displayed below) within the instrument cluster

programming menu.

Step 2.

Scroll down to the Engine Type.

Step 3.

Select Modify and select V6.

Step 4.

Select Program.

Configuration

(5) 2005 VZ and WL Series

Instrument

Country Australia/NZ

Engine Type (Select Engine)

Speedometer 6000

SRS Configuration 6 Loop SRS

Transmission Type 4 Speed Auto.

Police Mode No

Seat Belt Warning On

-----------------------------------------------1/7-------

bort Modify Program

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

Step 5.

Inspect the instrument cluster, and reset the service

interval using Tech 2 if required.

WARRANTY CLAIM INFORMATION

Description Reprogram instrument

cluster

Labour Op. No. N312700

Time 0.3 hr

Failure Code N0057 Registers incorrectly

DIAGNOSIS HINT

RH Lower Dash Panel Insulator Rattle

AH Astra

Group 1 Ref. No. TL0849- 0501

CONDITION

Rattle emanating from the RHS lower IP panel while

driving over rough roads.

POSSIBLE RECTIFICATION

Remove the insulator trim and refit with the left front

corner secured above the bracket protruding from the

HVAC casing as shown blow.

Note: An alternative is to drill a hole through the

insulator trim in line with the hole in the HVAC case

bracket. The insulator trim can then be secured using

a cable tie or an additional clip.

Fig 1. Shows insulator trim fitted above HVAC case

bracket.

DIAGNOSIS HINT

Brake Fluid Discoloured

VY2, WK, V2. – All with amber coloured

brake fluid

Group 5 Ref. No. TL0824- 0501

CONDITION

Some dealer PIRs describe a fungus like deposit

visible in the brake fluid reservoir (Refer Figure 1).

The condition has only been observed since the

introduction of the amber coloured brake fluid ( Sep

2003.)

This condition has not previously been detectable due

to the green dye which was added to the brake fluid.

Figure 1.

CAUSE

Laboratory investigations have found the deposits are

made up of small amounts of additives that have been

extracted from the reservoir cap material by the action

of the brake fluid.

CONCLUSION

It has been determined that these deposits have no

effect on the brake system performance and integrity,

therefore DO NOT flush the brake fluid lines for this

condition.

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

SERVICE FIX

Blaupunkt 520 / 2020 CD Player

Inoperative Due To CD Not Ejecting

SB / JR / TS / TT / JS / XC /

GROUP 12 TL0479A-0501

This Techline supercedes the previous one in Issue

7,July 2003. It is reissued to revise the breakpoint (FD

reference number).

PROBLEM DESCRIPTION

Customers may complain of Blaupunkt 520 & 2020 CD

players becoming inoperative due to CD’s not ejecting.

After investigating the root cause Blaupunkt have

made a software revision to rectify this condition.

PRODUCTION RECTIFICATION

Blaupunkt implemented the software revision in all CD

players fitted to vehicles at the Port Of Entry on the 1st

of April 2004.

SERVICE RECTIFICATION

If you have a customer who presents a vehicle with the

above condition the following steps should be

performed.

Step 1. Determine if the CD player is pre or post

break point by removing it and inspecting the bottom

left corner of the label attached to the top cover for the

FD number. Refer photographs below.

Pre breakpoint units have an FD number below

FD482. Post break point units have an FD number

FD482 or higher.

If unit is Pre breakpoint go to Step 2.

If unit is Post breakpoint go to Step 3.

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

contact Blaupunkt as per the Special Warranty

Component Replacement Requirement section in

SIP and request approval to replace.

Step 3. If the CD player is post break point,

removing it from the vehicle to inspect the label will

have rectified the condition (disconnecting the power

supply).

Refit the CD player, check the operation and submit a

PIR indicating the FD number on the label and the

serial number stamped into the side of the CD player

case.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

FD482

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

INFORMATION

Tech 2, TIS 2000 Model Year Selection

ALL MODELS

GROUP OB TL0852-0501

This Techline is to clarify the correct procedure for

model year selection when using Tech 2 or TIS 2000.

For many programming operations and diagnostics

carried out using Tech 2 and TIS 2000 it is critical

that the correct model year is selected. This can be

easily identified by the tenth character of the VIN.

The screen below is an example of the Tech 2 Model

Year selection screen. The Numbers and letters on

the LH side in brackets are the values of the tenth

digit of the VIN for that model Year.

SERVICE PROCEDURE

Oil Filter Cap – Care During Removal and

Replacement (Cartridge Type)

TS & XC (X18XE1 or Z18XE Engines)

Group 6A Ref. No. TL0342A - 0501

This techline is repeated from 2002 as the problem

described below continues to occur.

PROBLEM DESCRIPTION

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

on cartridge type oil filters.

Damage (cracking) may occur on oil filter housing

caps during removal - if the cap is over-torqued when

a filter cartridge is replaced during regular

maintenance servicing.

Ensure only 15Nm is applied to the filter cap

when an oil filter cartridge is replaced.

All X18XE engines are fitted with cartridge type oil

filters.

Z18XE1 engines are fitted with two types of oil filters:

• Cartridge type – which requires the removal of the

filter housing cap to remove and replace the filter

element;

• Screw-on type – which requires only the filter

assembly to be removed and replaced.

Screw-on type oil filters were introduced to Z18XE

engines from: engine No Z18XE20V00605

SERVICE RECTIFICATION

Summary: Adhere to correct torque specification and

ONLY use the tools recommended below.

TORQUE SPEC.:

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

new oil filter cartridge.

Ensure only 15Nm is applied to the filter cap

when an oil filter cartridge is replaced.

REMOVAL TOOLS:

When removing filter housing caps on engines with

the cartridge type filter, use ONLY a 24mm ring

spanner or socket. This fully supports the cap

material and allows removal without damage to the

cap.

TIS 2000 drawings showing the use of a ratchet

handle and square drive special tool – these are

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

engines after the breakpoint shown above.

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

SERVICE FIX

DTC’s P0700, P0715, P0720

ZC with V6 & A/T

Group 7B Ref. No. TL0737- 0501

CONDITION

Customer may complain of “no shifting” or “incorrect

shifting” of transmission ratios.

DTC’s P0700, P0715 or P0720 may be stored (one

or all of the DTC’s).

CAUSE

It is possible that moisture has entered the speed

sensor connector, causing an incorrect or interrupted

signal.

CORRECTION – Production

Protective grease has been applied to speed sensors

from:

Trans. Serial No.: Built Date:

03MV735125 06/01/04

CORRECTION – Service

1. Disconnect the speed sensor connector and dry

out any moisture present.

2. If there is no evidence of corrosion or damage to

terminals apply grease 09163339 to connector to

stop future moisture entry.

3. If corrosion or damage is evident then replace

sensor. Also apply grease 09163339 to

connector to stop future moisture entry.

PARTS INFORMATION

Part No.: Description: Qty:

09163339 Grease. NYOGEL

760G 25 gm tube

93173888 speed sensor 1

WARRANTY CLAIM INFORMATION

Use Labour Time information in Warranty Information

section of current PV SIP CD.

NOTE: If there are re-occurences of the original

customer shift complaints together with the

above DTC’s, proceed as follows:

• Remove transmission valve body cover to

inspect for possible coolant entry to transmission

via the radiator oil cooler – which (in rare cases)

may cause the DTC’s to set.

NOTE: Remove the valve body cover

CAREFULLY and inspect for any water, or white

sediment in the cover. If water or white sediment

is evident, the radiator must be replaced, and

TAS should also be contacted for further

diagnostic information before any additional

work is carried out.

NOTE: Radiators with revised oil cooler sealing were

introduced into vehicle production from:

Ellesmere Port:

ISOVIN: Built Date:

W0L0ZCF6848035197 not available

Russelsheim:

ISOVIN: Built Date:

W0L0ZCF3541042598 not available

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

DIAGNOSIS HINT

Fluid Leak Diagnosis Using Black Light And Dye

All Models

Group: OB Ref. No. TL0837- 0501

This techline is repeated from year 2000 techlines.

The information provided in this techline is to assist Dealers in performing thorough and accurate diagnosis of

fluid leaks prior to commencing any rectification work or removing major components.

Components must NOT be replaced for “leaks” without thorough definition of leak sources.

Use of Black Light Dye and Black Light is highly recommended to trace leak sources. For extensive information

on the use of Black Light and Black Light Dye, refer to the following information repeated from a previous All

Dealer Letter.

Holden strongly recommends the use of the black light and dye method to diagnose fluid leak sources. This

method of leak detection is a proven, reliable method that identifies the specific leak source and/or location.

The black light and dye method can be used for various types of leak detection, when used with the appropriate

tracer dye it can be used for detecting engine and transmission fluid leaks, Refrigerant leaks, fuel leaks, and

coolant leaks.

The following pages provide answers to technicians’ questions about the various aspects of black light and

tracer dye, and how dealerships may use this tool to their advantage.

Black Light & Tracer Dye and Accessories

There are different types of tracer dye for different applications, plus for air-conditioning systems, an

injector is required to infuse the dye into the system. The following tracer dyes and accessories are

available from SPx Australia. Other equivalent products may be used in their place.

Contact details for SPx Australia – Ph.: (03) 9544 6222; Fax: (03) 9544 5222.

Application Part Number

Black Light Leak Detection

Lamp

16296

Replacement Black Light Bulb

AU 512

R134a Air Conditioning Tracer

Dye

(24 X 8ml bottles)

J41447

R12 Air Conditioning Tracer

Dye

(24 X 8ml bottles)

J39475

R134a Air Conditioning Injector

J41459

R12 Air Conditioning Injector

J41709

Petrol & Diesel Engine Fluid and

Transmission Fluid Tracer Dye

(24 X 1 oz bottles)

J28431-B

Coolant Tracer Dye

(24 X 1 oz bottles)

J29545-6A

Multi purpose dye

(engine oil, transmission & power

steering fluid, diesel & petrol)

16268

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

Black Light & Tracer Dye Useage Information

The following pages will answer most questions you may have about using Black Light and Tracer Dye.

Summary of the steps involved in detecting a fluid leak using black light and dye:

Pour specified amount of dye into the system.

Road test the vehicle under normal operating conditions, to allow the dye to mix with the host fluid/gas.

Define the leak source by directing the Black Light towards the suspect area. The fluid leak will appear as a

brightly coloured path leading to the source. Note: The colour of the dyed fluid can be checked on the dipstick,

or other component directly in contact with the host fluid/gas.

Repair fluid leak cause and recheck to ensure that leak has been rectified.

General Information

How much dye do you use? The following information is given as a guide only. Always refer to the label on the

bottle.

Engine, Transmission, Fuel

J28431-B Engine & Trans. Fluid Dye should be used as follows:

Petrol Engine Oil - 7.4ml per 3.79litres of oil (¼oz per 4-5 quarts)

Diesel Engine Oil - 7.4ml per 3.78litres of oil (¼oz per 4 quarts)

Automatic Trans. Fluid - 14.8ml per 5.68litres of fluid (2x¼oz per 6 quarts)

Manual Trans. Fluid/Oil - 7.4ml per 5.68litres of fluid (¼oz per 6 quarts)

Petrol or Diesel Fuel - 7.4ml per 7.57litres of fuel (¼oz per 2 gallons)

A/C Systems

J41447 R134a A/C Dye should be used as follows:

R134a A/C System - 7.4ml per A/C system (¼oz per system)

J39475 R12 A/C Dye should be used as follows:

R12 A/C System - 7.4ml per A/C system (¼oz per system)

Power Steering

J28431-B Engine & Trans. Fluid Dye can be used in Power Steering as follows:

Power Steering Fluid - 7.4ml per 5.68litres of fluid (¼oz per 6 quarts)

Engine Coolant Systems

J29545-6A Coolant Dye should be used as follows:

Coolant System Radiator Fluid - 7.4ml per 15.14 litres (¼oz per 16 quarts)

Note: These amounts are based on various tests - there may be occasions when good fluorescence is not

obtained with these amounts of dye, due to the condition of the host oil/fluid or the nature of certain additive

packages in the oil/fluid itself. If this occurs, use additional dye.

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

Q A

Do you need to use the

Fluorescent Enhancer Safety

Goggles?

Yes - they not only protect the technician, but also visually optimise the

dye fluorescence for enhanced leak detection. They are scientifically

designed to enhance fluorescence by eliminating light at wave lengths

that might interfere with the eye’s ability to view the dye’s fluorescent

light emission. Once you look at the dye with and without the goggles,

you will see the difference.

What life does the dye have

when left in coolant, ATF,

R12 and R134a refrigerant?

Indefinite - unless the ATF is “burnt” in an A/T clutch failure or if here is

an A/C compressor failure.

What life does the dye have

when left in engine oil?

Depends on how dirty the oil was when the dye was added. In clean petrol

engine oil, it will last 500+km. In diesel engine oil, it will not last as long

because of rapid carbon build-up.

Are there any adverse effects

of leaving dye in systems too

long?

None - and A/C dyes especially are very thermally stable and should last

100,000 km.

Is there a preferred method

of cleaning the dye from a

vehicle, if spilt?

IMPORTANT - Do NOT get dyes on any painted surfaces - use guard

covers when pouring dyes into any vehicle system or injecting A/C dyes. A

good cleaning solvent should clean any dye off any metal surfaces. A/C

dyes cannot be cleaned off hoses or plastic components.

What is the shelf life of the

dyes?

Indefinite, but it is recommended they be used within five years.

PETROL & DIESEL ENGINE & TRANSMISSION OIL LEAKS

Use J28431-B dye in quantities as specified in “General Information” section.

Putting dye into oil that is fairly clean will achieve the best fluorescence for le ak inspection because the greater

the carbon build-up in the oil, the more difficult to obtain good fluorescence from the dye. Therefore, if the oil

appears to be extremely dirty on the dipstick, additional dye may be required to obtain good fluorescence and

can be added without harm to the engine.

Q A

How do I know if the dilution

ratio of dye added is correct?

After adding dye at the recommended dilution ratio, operate the engine 3 to

5 minutes to allow dye to mix with oil. Then check the oil dipstick with

black light for the yellow-green fluorescent glow of the oil/dye mixture.

What is the proper procedure

for adding dye to the engine?

With the engine OFF. This will prevent possible splashing of the dye over

an area of the engine that may need inspecting.

How long does it normally

take for the dye to work?

Most leaks will appear after operating the engine 5 to 10 minutes. However,

it is recommended that the vehicle be taken for a short road test in order to

allow the dye to penetrate all leaks.

How long will it take for the

dye to penetrate very small

pinholes or porosity leaks?

To accurately detect leaks of this type, the vehicle should be operated for 1

to 3 hours under normal operating conditions. Suggestion: If such a leak is

suspected, add dye to the engine oil. Then have the vehicle owner use the

vehicle for the time recommended above. The owner should then return for

leak inspection with the black light.

Do I have to clean engine NO! Under black light, all petroleum-based products such as oil, grease, and

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

Q A

surfaces prior to using the

dye?

ATF will fluoresce blue. The dye will penetrate surface oil, grease and grit

to leave a yellow-green fluorescent trace (under black light) at the source of

the leak.

Do I have to clean the engine

after repairing the leak?

YES! But only at the source of the leak in order to allow the technician to

operate the engine and then re-inspect the leak repair to insure the job was

done right the first time. Suggestion: The dye/oil mixture can be removed

by using any engine degreaser or solvent-type shop cleaner.

After adding dye to the

engine oil, is it necessary to

change the oil prior to

returning the vehicle to the

customer?

NO! The dye is 100% compatible with engine oil and can remain in the

system without harm until the next oil change.

How long will it take for

ATF dye to work?

Most leaks will appear after operating the transmission for 5 to 10 minutes.

However, it is recommended that the vehicle be taken for a short road test in

order to allow ATF dye to penetrate all leaks. NOTE: All other application

and leak-detection procedures remain the same as given under the Engine

Dye Section (above). It is not necessary to clean transmission exterior

surfaces prior to using ATF dye. To detect small pinhole or porosity leaks,

the vehicle should be operated for 1 to 3 hours. The ATF dye mixture

should be cleaned from the source of the leak, and it is not necessary to

change ATF after adding dye.

How long will ATF dye be

effective in the transmission?

Because the transmission remains fairly clean internally and does not have

the carbon build-up problem present in petrol and diesel engines, the ATF

dye will be effective as long as the ATF is not changed or the ATF is not

“burnt” or discoloured by a transmission failure. Remember to check the

dipstick with the black light prior to inspecting for leaks to check

fluorescence, and do not forget to check the ATF cooler line for leaks.

BRAKE SYSTEM LEAKS

Q A

Can I use a fluorescent dye

in a brake system?

Never use any type of a fluorescent tracer dye in a brake system.

POWER STEERING LEAKS

Q A

How much dye should I use

for finding power steering

leaks?

Check the fluid capacity of the power steering system. You will probably

need to add only a small amount of dye at a dilution ratio of 7.4ml (¼ oz) to

5.68l (6 quarts) of power steering fluid. Run the system, then check the cap

or dipstick for fluorescence with the black light.

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

FUEL SYSTEM LEAKS

When a fuel system leak is suspected, it is recommended that the vehicle being tested have a quarter tank or less

of fuel. Trucks and larger capacity systems should be estimated as close as possible in order to keep the dye

requirement at a minimum and to keep the test procedure as economical as possible. If a difficult leak is

suspected, adding more dye than normal (a higher concentration) will produce the best results and will not harm

the system.

Q A

How do I know if enough

fuel dye has been added?

Any dipstick device that can be inserted into the filler tube can be used and

then inspected for fluorescence with the black light.

On a fuel-injected (PFI)

vehicle, can I use the fuel

rail for injecting dye?

NO! The small volume of petrol that will receive the dye is probably

insufficient for the dye to show up at an “O” ring injector leak for example.

COOLANT SYSTEM LEAKS

Q A

What is the proper procedure

for adding dye to the cooling

system?

Add dye with the engine off and radiator “cold”. This will prevent splashing

of dye and possible false readings. Also, add the coolant dye directly into

radiator and not into the reserve/surge tank found on some vehicles.

How do I clean the coolant

with dye off the radiator and

engine surfaces?

Use water with detergent and a small scrub brush.

How can I check for a

suspected coolant leak into

the engine oil?

Perform test as follows:-

Pull the engine oil dipstick and confirm the blue fluorescence of the engine

oil with the black light. (This is oil to which no dye has been added.)

With the engine off and the radiator cold, pour coolant dye into the radiator,

and operate vehicle for at least one day to allow coolant to leak into engine

oil.

With the engine off, pull engine oil dipstick and fluoresce dipstick with

black light.

If coolant is leaking into the engine oil, the dipstick should show some green

fluorescent droplets of coolant. Also, the engine oil might fluoresce a slight

whitish blue colour instead of the normal strong blue fluorescence of engine

oil.

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

USING DYE IN R134a or R12 A/C SYSTEMS

When dye is injected into an A/C system and the system has been operated under full pressure for 5 to 10

minutes, the dye will remain in the system even though the R134a or R12 has been evacuated for a repair. The

only time R134a or R12 dye must be replenished is when the A/C system is flushed of refrigerant oil.

Q A

How do I put R134a or R12

dye into an automotive car or

truck A/C system?

Put 7.4ml (¼ oz) of dye in the dye injector reservoir, and use a refrigerant

source to inject the dye into the A/C system.

How long will it take the

R134a or R12 dye to circulate

through the typical

automotive A/C system?

Operating the A/C system under full pressure, it will take the dye

approximately 5 to 10 minutes to circulate through most A/C systems.

However, this does not mean that the A/C leak will show up in that time

period.

How long after putting

R134a or R12 dye into the

A/C system and running the

system under full pressure

can I begin looking for the

A/C leak with the black light?

This depends on the size and location of the leak. As the refrigerant escapes

under pressure, it carries with it a very small amount of refrigerant lubricant.

This trace of lubricant is what you are looking for with the black light.

Therefore, the size of the leak will determine how long it takes for the

lubricant dye to appear and fluoresce under the black light. A hose porosity

leak would, therefore, take longer to appear than a fracture/fitting leak.

Example: A high-pressure side leak may take over a week or more to have

enough refrigerant escape to affect the cooling capacity of the A/C system,

return the car to the customer, and tell them to bring it back for leak

inspection when they again notice a lack of cooling by the A/C system. When

this car returns, the refrigerant that has escaped will leave a trace of

refrigerant lubricant with dye, which is what you will be looking for with the

black light.

How do I know if I have a

leaky service valve on the

low-pressure side if I just

used that valve to put dye into

the A/C system?

After putting the R134a or R12 dye into the A/C system through the low-

pressure service valve, clean the valve with a solvent if the refrigerant taking

the dye into the A/C system did not clean off the service valve, sufficiently to

remove all trace of dye. Do this before starting the A/C system.

How do I clean the R134a or

R12 dye off A/C components

and engine surfaces?

Use any shop degreaser or solvent to clean dye off A/C components or

engine surfaces.

Are these A/C dyes

compatible with my

refrigerant recovery and

recycle equipment?

These dyes have been tested and proven compatible by major manufacturers

of recovery and recycle equipment. When refrigerant is evacuated from an

A/C system, a small amount of compressor lubricant is also removed from

the system. The R134a or R12 dye is in solution with the system compressor

lubricant, therefore, is separated in the recovery/recycle unit along with the

compressor lubricant. Because of the small amount of compressor lubricant

removed by the recovery/recycle unit, there is no need to add additional R-

134a or R-12 dye to the A/C system for future leak detection.

How do I know if a vehicle’s

A/C system contains dye?

Remove the low-side service port sealing cap and direct the black lamp into

the valve stem area. If you do not see dye/lubricant in this area, depress the

valve stem only for an instant to help bring out some lubricant with the

refrigerant. Again direct the black light at the valve stem for traces of the

fluorescent dye/lubricant. Clean dye off service port.

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

Q A

How do I check for

refrigerant leaks in the

evaporator when I cannot use

the black light to see the

leak?

Use the black light to fluoresce the drain hole and see if a trace of the yellow

green dyes has washed down with the condensation. When the evaporator is

removed from the vehicle, use the black light to determine the exact location

of the leak on the evaporator. Remember to check the fittings to and from the

evaporator to be sure they are not the cause of the leak.

How do I check for the

dye/lubricant when I cannot

directly shine the black light

on all suspected leak areas?

Use a mirror to reflect the black light to the underside of a fitting, hose or

component. Also if a mirror cannot be used, a white cloth can be used to

wipe the suspected area, and then fluoresce the cloth with the black light to

check for traces of the yellow-green dye.

Can the dyes remain in the

A/C system after it has been

used for the initial leak

detection?

Dyes can safely and effectively remain in the A/C system after the initial

repair. Dyes can be used to detect future refrigerant leaks and can only be

removed from the A/C system by flushing out the system compressor

lubricant.

DIAGNOSIS HINT

Noise / Vibration With A/C Operating

VZ Series – V6

Group 2 Ref. No. TL0846- 0501

CONDITION

Any symptom of noise with the A/C operating.

POTENTIAL CAUSE

Compressor bracket mounting bolts/studs not

tensioned correctly.

SERVICE RECOMMENDATION

The compressor and compressor bracket

mounting torques must be checked before

replacing any components or commencing

further diagnostic work.

1. Torque A/C Compressor Bracket Front

Mounting Bolts (item 1 in Figure 1) - 58 +/-9

Nm.

2. Torque Studs Into Compressor Bracket

(item 2 in Figure 1) – 10 +/-2 Nm.

3. A/C Compressor To Bracket Attaching Nuts

(item 3 in Figure 1) – 22 +/-3 Nm.

4. A/C Compressor Bracket Rear Mounting

Bolt (item 4 in Figure 1) – 22 +/-3 Nm.

Figure 1. Compressor mounting bracket

HOLDEN SERVICE TECHLINE _______________________________________________________________FEBRUARY, 2005

INFORMATION

Holden Contacts and procedures

All Models

Group OB Ref. No. TL0679A- 0501

This Techline supercedes the previous one in Issue

3, April 2004. Revisions are shown in red.

This techline summarises some of the Holden

contact procedures and gives a quick reference

guide for contact numbers.

Security information.

To obtain security information for both Passenger

and LCRV vehicles the first step is to check

Lionheart. If the information is unavailable on

Lionheart then a completed security information

request form must be faxed through to the security

information department, as security information

cannot be given out by phone. Please note that

security information requests are processed by the

security information department and not TAS.

Please ensure you have the latest security

information request form, which is available on

Passenger Vehicle SIP for both Passenger and

LCRV. 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.

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.

All Daewoo TAS enquiries must be done by Fax.

Under no circumstances should you call TAS for

Daewoo enquiries.

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 Ph 1300 307 036

Bosch Technical Assistance Ph 1800 025 462

Clarion Ph 1300 730 730

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 (SIP, Partfinder) Ph 1800 810 103

Panasonic Ph 02 9986 7635

PBR Diagnostic assistance Ph 1800 468 727

Petro-Ject Ph 02 9890 5701

Ph 02 9890 5244

Philips/Siemens-VDO Ph 1800 335 282

Salmat Ph 03 9358

2900

Security Information Ph 03 9647 2001

Fax 03 9647 2865

SPX Australia Ph 03 9544 6222

TAS Ph 1800 033 417

Fax 03 9647 2495

Email [email protected]

Warranty Ph 1800 033 487

Update

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

Buzz Noise Caused By Steering Wheel

Adjusting Lever

VY, VZ, WK, WL

Group 9 Ref. No. TL0862- 0502

If an owner complains of a buzz type noise coming

from the steering column shroud area, one possible

cause for this could be the lack of clearance between

the steering column adjustment lever and the lower

plastic shroud as shown in Figure 1. Under certain

driving conditions the lever can vibrate against the

cover, resulting in a buzz noise.

To rectify, carefully bend the lever so it has clearance

to the plastic cover for all steering column positions.

i.e. from fully extended to fully retracted.

Figure 1. Shows potential area of contact

SERVICE FIX

Notchy Fore/Aft Movement on 6 & 8 Way

Front Seats

V2, VY & VZ Calais, WK, WL

Group 1 Ref. No. TL0847- 0502

CONDITION

On some vehicles fitted with 6 or 8 way power front

seats, there may be some roughness felt when moving

the seat through its full fore/aft horizontal travel.

CORRECTION - Service

After verifying that vehicle has the condition as

described above, perform the procedures A & B

shown on the following pages to both front seats.

PARTS INFORMATION

Part No.: Partfinder® Name Qty:

92138926 Dampener - front seat

adjuster track

1/seat

NOTE: Each dampener consists of one steel clip and 2

nylon friction components which will need to be

assembled as shown in illustration below.

WARRANTY CLAIM INFORMATION

Description Install dampener to seat adjuster

driveshaft – both front seats

Labour Op. No. C000541

Time 0.8 hr

Failure Code C0041 chatters

CORRECTION – Production

Seats (6 & 8 way type) with dampeners fitted to

driveshafts have been installed in vehicles from:

ISOVIN: Built Date:

**********L397250 07 Feb 2005

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

PROCEDURE A - Install dampener clip to driveshaft:

• Move seat to the mid position using seat

controls

Mid position is when the front of the track rails

are level.

• Raise seat to the full up position using seat controls

• For older vehicles that do not have the cable

tray style wiring harness – release the under

seat nappy retainer.

• Remove the side cover

• Undo the two front seat frame to cushion mounts – 13mm AF Nuts, 2 off.

• Tilt seat backward being careful not to over

stretch any of the wires.

On Older vehicles with underseat nappy

retainer:

The nappy will catch on the track assembly as

shown. It is not necessary to completely remove

the nappy as this will protect the wires from

being stretched too far.

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

On Later vehicles with cable tray style wiring

harness:

(A). Un-clip the cable tray from the track as

shown by lifting the front clips

(B). Pull the cable tray forward to disengage

the rear clips

IMPORTANT

Ensure that the earth connection wire is

correctly connected at both ends – it should be

clipped to cushion frame and connected to the

terminal on the lower track rail.

IMPORTANT

• Obtain a length of steel tube, a tyre lever or

similar, to be used for fitting the dampener as

shown below. Hook one end of the lever under

the rear crosses shaft and place a suitable size

piece of timber in between the metal bar and

drive shaft as shown. Ensure a 5mm min. gap

is present between the metal bar and lift motor.

This will ensure that the motor is not

damaged during fitment of the dampener.

Minimum 5mm

gap between bar

and motor

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

• Position the dampener by aligning the

retaining tang over the motor mount flange and

the friction pads over the drive shaft as shown.

• With the piece of wood on top of the clip to

protect the motor, push down on the lever until

the clip is pressed onto the drive shaft.

NOTE:

This photo shows the cable tray version with

cable tray disengaged and out of the way

• Tap the dampener retaining tang into place

with a hammer

This Photo shows the Dampener in final

position

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

• Refit cable tray if applicable

PROCEDURE B – Eliminate slackness in driveshaft joints.

• Move the track until the driveshaft V

grooves are in the upper position.

• Apply Loctite 680 (or equivalent) to the

groove and work into the joint under the plastic

spacer.

Be sure to place paper under the area to protect

the carpet from any drips.

• Operate the seat back and forward several times for a distance of 100mm.

After this, DO NOT operate the seat for at least 1 hour to allow the loctite to set.

NOTE The seat may be occupied during this time

• Lower seat cushion onto mounts and tighten the attaching nuts to 24-32Nm

• Reattach under seat nappy clip where applicable.

• Refit side cover.

• Repeat procedure on other front seat.

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Transfer Case “Hash” Noise Reduction

VY Adventra & Cross 8

(GROUP 7B) TL0721-0502

CONDITION

It is possible for a “hash” noise (similar to a synchro

ring rattle noise) to be heard in the passenger

compartment. Reports say the condition may occur in

the range of 40 – 60 km/hr on light acceleration or

deceleration.

CAUSE

The noise heard is normal transfer case internal gear

and bearing noises which are transmitted into the

passenger compartment via the solid attachment of

the A/T shift cable to the transmission case.

CORRECTION – Service

Summary: After verifying that vehicle has symptoms

as described above, fit the new insulated shifter cable

bracket with new attaching screws.

To fit these parts, refer to Passenger SIP section 7C4

for service operation 2.2 – this procedure allows

removal of the A/T selector cable for access to the

cable bracket on the side of the transmission.

(The revised bracket is similar in appearance to the

original cable bracket – so its location and orientation

are easily defineable).

When attaching the cable bracket with the new screws

torque screws to 17±3 Nm.

PARTS INFORMATION

Part No.: Description: Qty:

92174776 Bracket Asm., Shifter Cable 1

11098091 Screw, Bracket Mtg. 2

WARRANTY CLAIM INFORMATION

Description A/T Cable Bracket Asm. - Replace

Labour Op. No. K503100

Time 0.6 hr

Failure Code K0040 Noisy

CORRECTION – Production

The revised A/T shift cable bracket with insulating

bushes is scheduled to be fitted to vehicles in

production. Breakpoint details will be published in a

future techline.

SERVICE PROCEDURE

Inlet Manifold Removal Procedure

HFV6 Engine - VZ & WL

Group 6A Ref. No. TL0868- 0502

The current Passenger SIP CD advises to “split” the

inlet manifold upper and lower parts when servicing

Cylinder head/s, Fuel injector, Ignition coils and Spark

plug servicing.

It is NOT necessary to “split” the inlet

manifold for servicing of these parts!

The inlet manifold can be removed as a complete

assembly – this removes the need for the intermediate

gasket to be replaced.

In addition – the gasket between the inlet manifold

assembly and the cylinder heads is a reuseable

design which does NOT have to be replaced unless it

is damaged!

Passenger SIP CD is currently being updated to show

these revised procedures which simplify the servicing

of the manifold and related components, and negate

the need to replace any gaskets (unless damaged).

A copy of the revised procedure for Inlet Manifold

Assembly Complete (Remove & Reinstall) is available on

the Holden LIONHEART dealer website. (refer Service

Techlines, 2005, Group 6A) Please refer to this revised

procedure until the Passenger SIP CD is updated.

Your attention is also drawn to Figure 6A1–10 in the

revised procedure regarding the manifold mounting bolts:

Do not loosen or remove the short bolts (8)

(70 mm) holding the upper intake manifold to

the lower. These bolts are at the front left and

rear right of the upper intake manifold.

Removal of these bolts (that hold the upper and lower

manifolds together) may result in intermediate gasket

damage and subsequent engine performance concerns.

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

M/T Fault Diagnosis

6-Speed M/T (Gen III vehicles)

Group 7A Ref. No. TL0872- 0502

Technicians should be aware of additional 6-speed

M/T diagnosis information that has been made

available in All Dealer Letter DL 06/2005.

The information allows technicians to carry out

diagnosis on specific transmission complaints, and

complaints with related components that may be

confused as transmission faults.

Please refer to this letter for diagnosis information until

the information is released in the next Passenger SIP

CD.

DIAGNOSIS HINT

“Rear Brake Bulb Fail” Warning Indication

Displays In Instrument Cluster

VZ, WL

Group 12 Ref. No. TL0870 - 0502

CONDITION

Rear Brake Bulb Fail warning indication displayed in

instrument cluster even though bulbs are working

POTENTIAL CAUSE

Incorrect adjustment of the cruise control brake switch

against the brake pedal.

CORRECTION

The correct switch adjustment is achieved by the

following procedure;

1. Twist the cruise control switch anticlockwise a

quarter of a turn to release the latch.

2. Push the switch until the barrel rests against the

brake pedal while the pedal is in its rest position.

3. Twist the switch clockwise to lock the barrel in

place (clearance from the barrel to the pedal

should be 0.7+ / - 0.5mm).

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Glove Compartment Door Opens Too Far

VY, VZ, V2 II & III, WK, WL

Group 1 Ref. No. TL0854- 0502

CONDITION

Glovebox door rubber bump stops may tear in

service. As a consequence, the glovebox

compartment swings fully downward when opened

and is not restrained by the stops.

The bump stop is shown as key 2 in figure 1 below.

Figure 1.

CORRECTION – Service

1. Inspect the bump stops on both sides of the glove

compartment, to confirm whether one or both stops

are torn.

2. Remove the glove compartment following the

procedure outlined in Holden SIP Section 1A3 para

3.2, taking note to exercise particular care to avoid

damaging the glove compartment while removing

hinge pins.

3. Remove torn bump stop/s.

4. Fit new bump stops as follows:

- Fit standard bump stop (92096917) to one side of

glove compartment, and solid type bump stop

(92166561) to the other side. Figures 2 and 3

show the difference in construction of the standard

and solid bump stops

NOTE. Do not attempt to fit two of the solid type

bump stops, as the force required to fit the glove

compartment will result in damage to the glove

compartment.

5. Reinstall glovebox as follows:

- Engage lower hinge points, then rotate glove box

up into closed position whilst pushing sideways to

compress the flexible bump stop. This action is

required to provide clearance for the solid bump

stop as it wipes past the Instrument Panel structure.

NOTE: Failure to push glove box sideways as

described, may result in damage to the glovebox.

Figure 2.

Standard flexible bump

stop p/n 92096917

Figure 3.

Solid bump stop p/n

92166561

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92096917 Bumper instrument panel

compartment door

(Standard)

92166561 Bumper instrument panel

compartment door (Solid)

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

Update

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Water Enters Cabin Over Top Of Doors

VY, V2, WK

Group 1 Ref. No. TL0770 - 0502

CONDITION

During heavy rain, water may enter the cabin over the

top of door(s).

CAUSE

One possible cause for this condition is if the flocking

on the upper part of the door seal becomes saturated,

water may wick its way across the face of the seal and

into the cabin

CORRECTION - Production

Revised weatherstrips with a lip added as shown in

figure 1 have been fitted to vehicles from:

ISOVIN: Built Date:

WK - L283009

VY - L281359

V2 - L280361

21/05/2004

18/05/2004

Figure 1. Shows cross section through door seal

CORRECTION – Vehicles in Service

On vehicles with the above condition, the first step in

rectification is to ensure that the door window frame is

correctly located within the body opening. If after this

first step the water leak is still present, check if the

latest design window seals are fitted. If not, then order

new seals from HSPO and install as per procedure

shown in Passenger SIP CD.

PARTS INFORMATION

Refer Partfinder for door weatherstrip assembly part

numbers. All HSPO stocks of weatherstrips are to the

revised design.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

SERVICE FIX CAUTION

Hard To Select Gears After Rebuilding

Shifter Assembly

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

Group 7A Ref. No. TL0879-0502

Techline No. TL608A-0401 published in Feb. 2004

provided a procedure for rebuilding the gear shift

assembly to eliminate Shifter Linkage Rattle.

Since publishing this techline, the following issue has

been highlighted by the supplier of six speed Manual

Transmissions.

The supplier advises that on some transmissions

returned for gear selection complaints, the root cause

was the shifter assembly had been rebuilt incorrectly

by the dealer. The bridging piece (#1 in figure below)

was installed upside down and fouled on the shifter

base.

IMPORTANT: Whenever rebuilding the shifter

assembly, ensure the bridging piece/link is installed

the correct way up as shown in figure below.

NOTE: Returned transmissions that are found to have

the above condition due to incorrect repair procedure

may not be accepted for warranty.

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE HINT

Front Windows Will Not Close Fully

VYII, V2, WK, VZ

Group 1 Ref. No. TL0745- 0502

CONDITION

On some vehicles the Front Door Windows may not

close fully which could result in windnoise and/or water

leaks.

CAUSE

Two areas which may contribute to this condition are:

1. Window glass stops set too low

2. Window seals incorrectly installed.

CORRECTION

Reset window stops and check window seal

installation as per following procedures.

1. Window glass stops set too low.

a) Loosen window stops at front and rear of window.

Refer Figure 1.

b) Operate window into fully up position. If window

will not close completely, manually push window

up into position.

c) Tighten stops.

d) If possible, allow window to remain in closed

position for 48 hours to set seals

Figure 1. Front door window stops

2. Window seals incorrectly installed.

a) Ensure that seals are correctly installed into the

window frames.

Figure 2.

b) Ensure that the Weather Strip Assembly rear

upper corner moulding is installed correctly. Refer

Figures 3 and 4. NOTE: the thick section of the

rear corner moulding must be located over the

corresponding depression in the doorframe.

Figure 3. Shows typical incorrect installation where

corner moulding is not fully seated into the corner of door

frame. (Paper added for clarity)

Figure 4. Corner moulding installed correctly.

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

c) Inspect window seals to ensure that they are not

damaged or twisted out of shape. If seals are

damaged or badly twisted they should be

replaced.

e) If replacing the Weather Strip Assembly – “Front

Side Door Window Upper”, drive the window up

into the Moulding and ensure that there is between

2mm and 4mm coverage of the window by the

moulding. Cycle the window up and down a

number of times to ensure that the seals are well

bedded into the door frame.

f) If possible, allow window to remain in closed

position for 48 hours to set seals

INFORMATION

PC Serial Data Ports

All

Group OB Ref. No. TL0864 - 0502

Dealers planning to purchase a new pc or lap top,

must ensure that it has a serial data port. This is the

port which the RS 232 cable used for updating Tech 2

plugs into.

Some Dealers have purchased computers without

serial data ports on the assumption they could use a

serial data to USB adaptor, only to find that they do not

work!

Tech 2 can only be updated via the RS232 cable from

a serial data port, not a USB port.

INFORMATION

Release of Dexron III (“H” Revision)

Automatic Transmission Fluid (ATF)

All models with A/T

Group 7B Ref. No. TL0860- 0502

General Motors DEXRON III ATF specification has

been upgraded to DEXRON III (H-Revision).

Commercially available fluids labelled as “DEXRON III,

Approved for the H Specification”, can be used in any

transmission application which specifies the use of

DEXRON III, IIE, II or DEXRON.

Current stock of DEXRON III ATF can be used until

the supply is depleted.

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Rear Axle “Cyclic Knock” .

All V & W with IRS (non LSD)

Group 4 Ref. No. TL0602A- 0502

This Techline supercedes the previous one in Issue

11, Dec. 2004. It is revised by modifying the service

correction procedure and breakpoint information.

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 V and W models (non LSD) with the

exception of cab-chassis and crew-cab vehicles (beam

axle).

CORRECTION – Production

Revised rear axle assemblies with reduced clearance

circlip grooves in the inner axle shafts were phased

into vehicle production over the last 2 weeks of Sep

2004 commencing from vehicle:

ISOVIN: Built Date:

**********L334258 16/09/2004

CORRECTION – Service

Summary: After verifying that vehicle has symptoms

as described above, proceed as follows: THIS

PROCEDURE WILL REQUIRE THE VEHICLE TO BE

LEFT IN DEALERSHIP OVERNIGHT.

Procedure.

1. Contact Dana via their website to register a case

of “cyclic knock”.

Once case is approved, Dana will send a set of

differential inner-axle assemblies with “upper

spec. spline” and reduced clearance circlip

grooves for the complaint vehicle.

2. Remove LHS and RHS driveshafts.

NOTE: mark the inner CV joints of both

driveshafts before completely removing from the

vehicle.

(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. Install circlips to the new shafts supplied by Dana.

6. Clean all traces of oil from splines of the new

shafts and the matching splines in the differential.

Follow the pre-application cleaning instructions

provided on the Loctite 609 package.

7. Apply Loctite 609 to the splines on the shafts

before reassembling shafts into differential.

8. Allow Loctite to cure for 6 hours minimum before

proceeding.

9. Reverse 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

Update

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Front Suspension Clunk (Front Subframe)

VY & VZ Adventra

GROUP 3 TL0718A-0502

This Techline supercedes the previous one in Issue 6,

July, 2004. It is revised by changing all 4 subframe

mounting bolt toques to the same value.

Also refer to Techline TL0638-0403 published in Issue

3, 2004. which gives another possible cause for front

suspension clunk

CONDITION

Loud metallic clunk noise from front suspension

usually heard when driving over pot holes or braking

over speedhumps .

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 – Service

On any vehicle with the symptoms as described,

ensure that all 4 subframe mounting bolts are

tightened to 135 -140 Nm.

NOTE: As these bolts are being tightened only and

not removed they do not need replacing.

If they are removed for any reason then they should be

replaced as per the standard practice for micro-

encapsulated fasteners.

PARTS INFORMATION

Part No.: Description: Qty

92138605 Bolt Front suspension

frame - front

92138396 Bolt Front suspension

frame - rear

Update

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE PROCEDURE

Occupant Climate Control Blows Hot Air

VY, V2 II & III, WK and VZ (with OCC)

Group 2 Ref. No. TL0851- 0502

CONDITION

One or more of the following conditions may occur

intermittently:

• A/C blows hot air when cool air is selected.

• A/C blows hot air and changes mode to feet.

• ‘X ‘ appears on the OCC display

• Code 15 stored in the OCC module.

• In car temp. sensor reads –40° on Tech II.

CAUSE

A poor connection inside the in-car temperature

sensor causes an open circuit.

CORRECTION – Production

Production process for the manufacture of in-car

temperature sensors has been improved for vehicles

from:

ISOVIN: Built Date:

L405066 21/02/05

CORRECTION – Service

Perform normal SIP diagnosis.

Hint.

View the in-car temperature sensor reading on TECH

II while flexing the sensor body at the connector to

help identify an intermittently faulting sensor. Refer

Figure 1.

Figure 1. Shows in car temperature sensor

Replace the in-car temperature sensor if diagnosis

confirms it as faulty.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

16229818 Sensor Asm. – Inside Air Temp. 1

All HSPO stock has been cleansed of suspect faulty

sensors.

The date code breakpoint for certified stock is 12- 03 -

4 (manufactured Dec. 3rd, 2004).

The break point can be checked by inspecting the

label on the part as follows.

WARRANTY CLAIM INFORMATION

Use existing warranty information in SIP.

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Power Steering Shudder Service Fix

Hose Contamination

VY WK with V6 engine

Group 9 Ref. No. TL0880- 0502

A contamination issue affecting some of the power

steering shudder service fix hoses was recently

identified and has now been rectified.

The contamination occurred during the hose

production process.

SERVICE ACTION

Dealers should confirm that any service fix hose to

be fitted to a vehicle is post breakpoint.

Breakpoint:

All hoses manufactured from 11 Feb 05. date code

(11B5).

All hoses supplied by HSPO warehouse from 11 Feb

05 are certified parts.

The manufacturing date code is stamped around the

metal ferrule where the hose is attached.

Date Code Explanation.

For example 11B5, 11 being the day of the month, B

being the month of the year, ie Jan = A, Feb = B, Mar

= C etc, and 5 represents the year of the decade, ie

2005.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92174786 Power Steering Hose 1

NOTE: Pre breakpoint hoses that are fitted to

vehicles do not need to be replaced with post

breakpoint hose.

DIAGNOSTIC HINT

Transmission Slip Codes P0894, P1870

VY, VZ, WK, WL & 4L60E A/T

Group 7B Ref. No. TL0848 - 0502

The codes P0894 (VZ, WL) or P1870 (VY, WK) may

be logged causing the “check engine light“ to come

on.

Recent tear down analysis of transmissions replaced

for P0894 and P1870, reveals some instances where

the o-ring seal on the turbine shaft was either

missing or damaged. (refer Figure 1 item #618)

SERVICE HINT.

On any vehicle with the above symptoms, DO NOT

replace the transmission without first performing the

normal fault code diagnosis as per SIP. Pay

particular attention to the step which says to “check

the input shaft and housing assembly for

cut/damaged turbine shaft o-ring seal”.

Figure 1.

HOLDEN SERVICE TECHLINE ________________________________________________________________________________MARCH, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FI

Ignition Key Jams In Off Position – Or Is

Difficult To Turn From Off Position

TS, TT, XC Barina/Combo with “S”

Profile Ignition Keys/Barrels

Group 9 Ref. No. TL421B - 0502

This Techline supercedes the previous one in Issue

3, Mar. 2003. It is revised by adding a service hint

on how to freeup a jammed ignition lock.

PROBLEM DESCRIPTION

In some vehicles the ignition key may jam in the

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

position.

This condition only affects ignition barrels/keys with

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

To confirm profile type refer to Part Finder TS

Catalogue, section 06-250A.

This condition results from the hard barrel pin

causing excessive wear of the soft alloy ramp section

of the barrel housing. Refer Figure 1.

PIN RAMP

Figure 1.

PRODUCTION RECTIFICATION

Revised ignition barrels have been fitted to vehicles

from the following breakpoints:

ISOVIN: Build Date:

XC Barina - W0L0XCF6824246086 30/04/02

XC Combo - W0L0XCF2523030966 30/04/02

TS Astra - W0L0TGF4825195733 May 02

TT Zafira - W0L0TGF752H035990 Aug 02

SERVICE RECTIFICATION

Summary: For complaint vehicles install a new

ignition lock cylinder and tumblers.

To Remove and Reinstall the ignition lock cylinder

refer to procedure in TIS 2000 found as follows:

TIS Screen Ð Select the following Ð

Service Information Standard Information

Model Astra G/Corsa C/Zafira

Year 2002

Eng. -

Vehicle

Data

Trans. -

Asm.

Group

- Electrical Equipment & Instruments

+Switches, Control Units, Relays, Ign Lock

Standard

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

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

Tumbler Replacement

The old tumblers must be replaced with the new

ones supplied in the kit. To retain the same key

coding, remove the tumblers one at a time from the

old lock shaft, read the number stamped on the

tumbler and then install a new tumbler with the same

code into the new lock shaft in the equivalent slot.

Note. There are 4 different codes of tumbler and a

total of 10 tumblers per lock cylinder.

PARTS INFORMATION

Part No.: Description: Qty:

92146450 Barrel Kit – Ignition (S

profile)

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

Hint For Freeing Up Jammed Lock

The following method may help to rotate the jammed

ignition lock preventing the need to tow a vehicle or

assist when replacing the ignition barrel assembly.

1. Apply light clockwise pressure to the key while

fitted in the ignition lock.

2. With clockwise pressure still applied, lightly tap

the end of the ignition key with a small nylon

hammer.

CAUTION: DO NOT DAMAGE THE KEY HEAD

HOLDEN SERVICE TECHLINE ________________________________________________________________________________APRIL, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Door Check Link Attaching Bolt(s) Loose

AH Astra

Group 1 Ref. No. TL0895- 0503

CONDITION

On some vehicles one or more of the door check link

attaching bolts may loosen in service.

CORRECTION – Production

Door check link bolt torques increased to 27 (+2/-1)

Nm on vehicles from:

ISOVIN: Built Date:

W0L0AHL4855006365 23/08/2004

CORRECTION – Service

On any vehicle where a door check link attaching bolt

comes loose, remove all door checklink bolts, apply a

thread locking compound to threads then retighten

bolts to 27 Nm.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

INFORMATION

Oil Pan Sealant Availability and Usage

HFV6 Engine

Group 6A Ref. No. TL0888 - 0503

CONDITION

The current Passenger SIP CD specifies RTV sealant

p/n 12574611 for HFV6 engine oil pan replacement.

Unfortunately, because this sealant is not available

locally, there has been confusion over what sealant to

use in its place.

CORRECTION – Service

The sealant to be used for HFV6 engine oil pan

replacement procedures is p/n 92144969.

Future versions of Passenger SIP will be revised to

show p/n 92144969 as the replacement for 12574611.

PARTFINDER INFORMATION

PartFinder does not currently list any sealant part

number for the engine oil pan . Future versions of

PartFinder will show p/n 92144969 as the required

sealant for this application.

HOLDEN SERVICE TECHLINE ________________________________________________________________________________APRIL, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Service Engine Oil Warning Displays in the

Instrument Cluster.

VZ, WL

Group 12 Ref. No. TL0890- 0503

CONDITION

On some vehicles the “Service Engine Oil” warning

icon may display in the instrument cluster when the

ignition is cycled.

CAUSE

The “Service Engine Oil” feature is not available for the

local market and has been inadvertantly enabled in the

engine calibration.

If the above warning icon displays, the following reset

procedure must be performed.

Reset procedure

1. Press and hold the up and down buttons on the

trip computer mode switch while turning the ignition

key on until a beep is heard, the following will be

displayed.

2. Press the set button on the trip computer mode

switch until a beep is heard (approx 8-10 seconds) to

reset the service item.

The display will then revert back to the start up

sequence.

If more than one service items are set, the next

service item will be displayed.

Press the set button on the trip computer mode

switch to reset the next service item if required.

3. The following will then be displayed.

DIAGNOSIS HINT

Steering Wheel Radio Remote Control

Switches Function Incorrectly

VY, WL, V2 Series II & III

Group 12 Ref. No. TL0889- 0503

Blaupunkt receive a large number of requests for

changeover radios due to customers and dealers

experiencing the incorrect function when the steering

wheel remote buttons are depressed.

The majority of these complaints are not due to a fault

with the radio. Therefore, to avoid incorrect diagnosis,

perform the following checks. These checks are

designed to determine if there is a poor connection

between the remote control switches and the radio

causing a high resistance which results in the incorrect

function.

Checking Procedure

1. Remove the radio. Use a multi meter to measure

the resistance between terminals C11 & C12 in the X1

connector; when no buttons are depressed the

resistance should be approximately 3674 ohms.

2. When each of the following switches are

depressed the resistance measured should be

approximately as listed below.

Next up button 794 ohms

Mute button 284 ohms

Next down button 464 ohms

Volume up button 164 ohms

Mode button 1474 ohms

Volume down button 82 ohms

3. If a high resistance is detected, disconnect all

connections, inspect for damage or corrosion,

reconnect and measure the resistance again. If the

resistance has changed and the correct function of the

radio remote switches is achieved then the problem is

considered to be connection related.

4. If the fault is still present, use the wiring diagrams,

check each section of the circuit separately (wiring

harness, clock spring, radio remote switches) to allow

diagnosis of the faulty component. .

Note: When measuring the resistance of this circuit,

ensure that any probing does not deform the terminals

in vehicle harness.

If the fault still persists after performing the above

diagnosis, contact Blaupunkt for additional diagnosis

assistance and advise that you have completed these

checks.

Update

HOLDEN SERVICE TECHLINE ________________________________________________________________________________APRIL, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Tis 2000 and Tech 2 ECU Programming

Terminology

GROUP OB TL0902-0503

When trying to reset or program modules with TIS

2000 or Tech 2, “reset ECU” or “program ECU” is often

displayed. Many Dealers assume ECU stands for

Engine Control Unit. This techline is to clarify that

ECU stands for “Electronic control unit” not “engine

control unit” and therefore applies to the module you

are dealing with.

For example - If you are resetting a CIM and tech 2

displays “reset ECU” it is referring to the CIM because

that is the module you are resetting and have

accessed with tech 2.

DIAGNOSIS HINT

Programming New (Replacement)

Transmission Electronic Control Units (TCM)

VZ, WL V6 and Opel Vehicles

Group 7B Ref. No. TL0899-0503

CONDITION

Some dealers report multiple DTC’s set and no Tech 2

communication after replacing Transmission Control

Module (TCM).

CAUSE

Service replacement TCM’s are blank and require

programming via SPS (Service Programming System)

similar to engine ECU’s.

CORRECTION

After fitting a new TCM, it must be programmed via

SPS procedure which can be found in Passenger SIP

as follows:

Introduction and Tech 2 / Section 0C-Tech 2 /

Service Programming System (SPS) / SPS Process

NOTE: When you are programming a TCM and Tech 2

displays “program ECU” it is referring to the TCM not

the Engine Control Unit.

After the software download is completed clear any

stored DTC’s .

Recheck for any DTC’s.

DIAGNOSIS HINT

Cruise Control Not Working

ZC Vectra, AH Astra Manual Trans. Only

Group 6C Ref. No. TL0900-0503

CONDITION

Customer complains that Cruise Control intermittently

wont engage. Dealer cannot reproduce fault and no

related trouble codes are stored.

The above condition will occur if the driver starts the

engine and commences driving from rest without

initially depressing the brake pedal.

The engine ECU must see a valid active brake switch

input before it allows cruise control to function.

This situation is more likely to happen on a highway or

other similar open flat roads where starting and driving

off does not require use of the brake pedal.

This condition will not occur on a vehicle fitted with an

automatic transmission as the brake pedal must be

depressed in order to shift the T-bar out of Park.

Please explain to the driver -

The cruise control cannot be activated until the foot

brake has been operated at least once after the

ignition has been turned on.

This requirement is also explained in the Owner’s

Handbook.

HOLDEN SERVICE TECHLINE ________________________________________________________________________________APRIL, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

TIS 2000 Security Access and SPS Issues Due

To Hardware Key Incompatibility With New PC

All Models

Group OB Ref. No. TL0896- 0503

CONDITION

After installation of a new PC, Dealers may report

problems accessing security information or service

programming system (SPS). An error message may

appear. The problem may be intermittent.

CAUSE

New PC’s with a processor speed which is 2.0 Ghz or

greater are not compatible with older style “dongle”

hardware keys.

CORRECTION

To overcome this, a new “superpro” hardware key kit

(Parallel or USB) will need to be purchased through

SPX.

Please note: New hardware keys will need to be

registered before they will work.

The above information was explained in All Dealer

Letter 14/04

SERVICE FIX

Endgate Touches Rear Bumper Facia

VY and VZ Crewman

Group 1 Ref. No. TL0784 - 0503

CONDITION

On some vehicles the endgate may touch the rear

bumper facia when opened. In some cases paint

damage may occur.

CAUSE

Insufficient clearance between bumper facia and

endgate when opened.

CORRECTION – Production

Revised endgate cables (15 mm shorter) were

introduced into vehicle production from:

ISOVIN: Built Date:

**********L413997 22/3/05

CORRECTION – Service

On vehicles with the above condition, fit new endgate

cables 92183896 which are 15mm shorter than the

previous cable 92110192.

Refer Passenger SIP CD for cable replacement

procedure.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92183896 Cable assembly endgate

(cable length – 495 mm)

92110192 Cable assembly endgate

(cable length – 510 mm)

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

Cable Length

HOLDEN SERVICE TECHLINE ________________________________________________________________________________APRIL, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Finding Engine Diagnostic Trouble Codes (DTC’s) in SIP

VZ, WL V6 and V8

Group 6C Ref. No. TL0898- 0503

With the introduction of VZ / WL, finding engine related diagnostic trouble codes (DTC’s) in SIP has changed slightly

from previous models. The DTC’s are no longer in numerical order in the left hand menu. Refer picture below.

The revised procedure is shown below.

Procedure.

In SIP, select VZ/WL Service Information, V6 Engine, then Section 6C1-2 Engine Management V6 Diagnostics or

for Gen III V8, select Section 6C3-2 Powertrain Management Diagnostics.

Select Diagnostic Trouble Code Tables, then DTC list. (Refer # 1 below). From the main page find your DTC in the

lefthand column (refer # 2) together with the DTC description. In the right hand column is the DTC List reference

number and other related DTC’s (refer # 3).

From the menu on the lefthand side, select the reference number in the DTC List, (refer # 4). In here you will find the

DTC description, circuit diagram, additional information and the diagnostic procedure.

HOLDEN SERVICE TECHLINE ________________________________________________________________________________APRIL, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE PROCEDURE

Mandatory Receiver Dryer Replacement With

Compressor Replacement

TS Astra

Group 2 Ref. No. TL0885- 0503

The receiver dryer must be replaced whenever an

A/C compressor is replaced for internal failure.

If this is not done, it is most likely that there will be a

repeat failure of the A/C compressor.

The reason is the receiver dryer becomes blocked

with debris after a compressor failure. As the

pressure sensor is in the top of receiver dryer, it will

not read true system pressure due to the blockage.

The receiver dryer must be replaced whenever an

A/C compressor is replaced for internal failure.

SERVICE FIX

Ignition Coil Failure

VZ, WL – HFV6 engine

Group 6Y Ref. No. TL0893 - 0503

CONDITION

Failed ignition coil.

CORRECTION

On any vehicle that experiences a failed ignition coil,

proceed as follows.

1. Replace failed coil as per SIP.

Ensure that replacement coil does not have a

Manufacture date between 8th May 2004 and 10th

May 2004 (inclusive). Refer to picture for

Manufacture date stamp location. Date layout is

Year-Month-Day

2. Check the manufacture date on remaining

coils. Replace any coil if date is 04-05-08 or 04-05-09

or 04-05-10

PARTS INFORMATION

Part No.: Partfinder Name Qty:

12583514 Ignition coil 1

Attention Parts Managers:

Any new coils in stock which are identified as being

manufactured on the 8th, 9th or 10th May 2004

should be returned to HSPO via CRRM. Refer to

Parts News Letter issued by HSPO.

WARRANTY INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Excessive Engine Oil Consumption Due To

Faulty Cylinder Head Cover (Plastic Type)

ZC Vectra, TS Astra, TT Zafira, all with Z22SE

engine

Group 6A Ref. No. TL0805 - 0504

CONDITION

Some customers may report that their vehicle exhibits

the following symptoms;

1) Blue smoke coming from the exhaust and/or

2) High oil consumption

CAUSE

Positive crankcase ventilation passages within the

plastic cylinder head cover may not be to specification.

NOTE: The metal cylinder head covers are not

affected.

CORRECTION – Service

1. Confirm the customer complaint by conducting

a standard oil consumption test. When completed,

contact TAS to register a case and confirm if vehicle

has excessive oil consumption.

2. If TAS confirm that vehicle has high oil

consumption, proceed to check the cylinder head

cover for a possible manufacturing fault described as

follows.

3. Remove the cylinder head cover and inspect the

underside of the cover. A faulty cover can be identified

by a “sink” mark which is clearly evident as shown in

photograph below

4. A faulty cover should be replaced with a new

cover from HSPO. (If cover is not faulty contact TAS

for further advice). For removal and replacement

procedure refer to TIS 2000. .

CORRECTION – Production

Revised covers have been fitted to vehicles from:

ISOVIN:

ZC *********51010110

TT *********4H004812

TS *********5B000136 - Convertible

*********45123695 - SRi excluding turbo

PARTS INFORMATION

Part No.: Partfinder Name Qty:

13113034 Cover cylinder head (plastic)

includes gasket and fasteners

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

TIS Approval with Tech 2

All Vehicle Types

(GROUP OB) TL0903-0504

PROBLEM DESCRIPTION

Programming difficulties when trying to link

immobilizers or program keys, may be attributed to

the incorrect process of obtaining TIS Approval on

Tech 2.

Some programming difficulties have occurred when

technicians have got TIS Approval on Tech 2 before

going to the vehicle. THIS IS NOT THE CORRECT

PROCEDURE

Dealers are reminded that the correct procedure for

obtaining TIS Approval is to only connect the Tech 2

to TIS, AFTER the following message is displayed on

the Tech 2 screen when Tech 2 is connected to the

vehicle.

Failure to follow this procedure may result in

programming failures or unnecessary parts

replacements.

INFORMATION

Problems With Using Part Numbers

Identified With Tech 2

(GROUP OB) TL0909-0504

PROBLEM DESCRIPTION

Some dealers choose to order replacement

components using the part numbers stored in that

part. For example, if you were to replace an

instrument in a current VZ Commodore you could

obtain the part number by using the identification

data screen displayed on Tech 2.

This will generally lead to the incorrect part being

supplied.

You SHOULD NOT order parts using part

numbers obtained via Tech 2.

Only use part numbers from the most recent version

of Partfinder or Micro Cat.

If you have trouble identifying the correct part,

contact “Parts Technical Service” using the

information stored in Partfinder under the ‘Holden

Help’ tab.

NOTE: This information should also be passed to

your spare parts personnel!

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE PROCEDURE

Power Steering Gear Rack Pad Adjustment.

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

Group 9 Ref. No. TL0907- 0504

Dealers continue to replace complete steering

gear assemblies for complaint of knock or rattle

which, in most cases, can simply be rectified by

performing rack pad adjustment as described in

this Techline.

CONDITION

Knock or rattle is reported as coming from the

steering.

CAUSE

Steering gear rack pad adjustment not to

specification.

PARTS INFORMATION

In order to perform a rack pad adjustment, special

tools AU211-A, AU301 and E7115 will be required.

CORRECTION

Summary: After verifying that the reported

knock/rattle is coming from the steering gear, adjust

the rack pad as follows.

NOTE: The Steering gear does not have to be

removed from vehicle to perform the following

procedure.

1. Using tool AU211-A and ring spanner tool

AU301 loosen rack pad adjusting screw lock nut

approx. 2 turns. Refer fig 1

Figure 1

2. With the steering rack in the centralised position,

tighten the rack pad adjusting screw, using tool AU211-

A, to the correct torque specification 10.0 – 12.0 Nm.

3. Using angle wrench tool no. E7115 and the rack

pad adjusting tool AU211-A, turn the rack pad

adjusting screw back (counter – clockwise) 20°- 28°.

Refer Figure 2.

Figure 2.

4. Apply loctite 567 thread sealant or equivalent to

the cleaned threads of the rack pad adjuster lock nut.

5. While holding the adjusting screw with tool

AU211-A and a socket bar in the position set in steps

2 & 3, (refer Figure 3) tighten the lock nut to the

correct torque specification using tool AU301 and a

suitable torque wrench.

Rack pad adjusting screw lock nut torque

specification 55.0 – 65.0 Nm.

Figure 3.

Once the rack pad adjustment has been performed

the steering gear must be racked from lock to lock to

ensure localised wear has not appreciably affected

the setting. The gear should not bind or appear tight

over any part of the total travel. Should the gear

appear tight or still rattle/knock recheck the rack pad

adjustment. If this is not the cause, replace the

steering gear.

WARRANTY CLAIM INFORMATION

If applicable, use Labour Times information in

Warranty Information section of current PV SIP CD.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

Caster Rod Bush Replacement for Leaks

VZ & WL

Group 3 Ref. No. TL0912- 0504

CONDITION

Caster Rod bushes are being replaced unnecessarily

for reported symptoms of “leaking” and “causing a

clunk from the front suspension”.

CAUSE

Assessment of returned parts shows these bushes

are not leaking but are covered with excessive

assembly/shipping fluid which is applied during

manufacture.

Whilst the bush may appear to be leaking and

thought to be the cause of a clunk from the front

suspension, it has been confirmed that even if a bush

has a genuine leak and has lost all of its fluid it will

not cause a clunk/ knock in the front suspension.

CORRECTION – Service

To avoid misdiagnosis of the caster rod bush, do the

following.

1. Wipe bush of excess fluid.

If fluid appears to be trapped where the caster rod

passes through the centre of the bush remove

bush from vehicle and clean fluid from centre bore

of bush.

2. Confirm if fluid returns after cleaning. The vehicle

will have to be driven to put a load on the bush.

• If no more fluid appears the bush is OK.

• If bush is confirmed as leaking, replace bush.

DIAGNOSIS HINT

Engine Overheating Diagnosis Caution

VZ & WL with HFV6 Engine

Group 6K Ref. No. TL0913- 0504

CONDITION

PIR’s have been received by Holden regarding

complaints of “high temperature gauge readings”,

where technicians have replaced thermostats in an

attempt to correct the problem.

These thermostats, when returned to Holden for

testing, show No Fault Found.

CAUSE

As the thermostats are not at fault, it appears that

there is another cause for the high temperature

gauge readings.

The most likely cause is air entrapment in the engine

cooling system.

CORRECTION

As some technicians report that purely bleeding the

cooling system corrects the complaint condition we

would suggest the following approach.

1. Ensure the cooling system is correctly filled, and

bled according to SIP CD info.

2. Thoroughly check the cooling system cap, clamps

and fittings for security.

Tightening of hose clamps may be required in

case of “compression set” – i.e. after some

exposure to heating, cooling, etc, in a vehicle,

rubber hoses can take a “compression set” to a

reduced size created by the clamp. When this

occurs, clamps will ‘feel’ tight, but if the clamp

screw is backed off slightly then re-torqued, the

clamp screw will move to a position further on than

the original position because of the “set” size that

the hose has taken. (you have all seen the “clamp

imprint” in removed hoses - that is the “set” size).

Please PIR any causes for overheating that are

found and indicate corrective action taken.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Revision To Front Seat Side Covers

V & W models fitted with seat memory

modules (Calais, Statesman, Caprice,

Monaro)

Group 1 Ref. No. TL0885- 0503

Whenever replacing the front seat side covers on

above models the modification shown below may be

required in order to attach the memory module to the

new covers.

Part Numbers affected:

92148281, 92148282, 92148279 92148280.

The above situation has arisen as a result of

revisions to side covers in production where the

mounting points for old level memory module were

removed.

Original Covers. (Memory module mounted to

cover)

Revised Covers (Module mountings removed)

SERVICE PROCEDURE

Attach memory module to new revised side cover by

performing the following procedure. This will require

two 190mm long by 5mm wide plastic cable ties.

1) Fit module board to the plastic cover from the old

assembly

2) Fit cable tie around module and board in the

location shown.

3) Drill Hole Dia 6mm through the centre of the

flange shown

Module

mounted on

side cover

Module

mountings

deleted in new

covers

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

4) Fit module to side cover using one of the original

screws into the only available screw boss

5) Pass cable tie through the Hole drilled

previously, and around the module; pull tight and

trim the excess.

INFORMATION

CDC 40 Opera Audio Unit Serial Number

Identification

ZC Vectra and AH Astra

(GROUP 12 ) TL0915-0504

Whenever replacing a CDC 40 Opera radio via the

warranty changeover program it will be necessary to

obtain the serial number off the unit. The serial

number is located on the top of the unit (refer Figure

1) and on the side (refer Figure 2.)

Figure 1. Top View.

The serial number is a combination of “GM” plus the

2 groups of numbers on the bar codes as shown. In

this example the number is GM00410941644.

Figure 2. Side View

The serial number is stamped into the body of unit

and is also shown on the printed label.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

A/T Features

VZ/WL - All with A/T (non-AWD)

Group 7B Ref. No. TL0887- 0504

Introduction

Recent introduction of the 5L40E automatic

transmission to V and W cars has brought some new

features to both drivers and service technicians.

As some of the features may seem unusual to

drivers, the following information will assist

technicians and Dealership-front-counter-personnel

to understand the features and clarify any concerns

raised by vehicle owners/operators. Also, while

4L60E A/T is still in use, some significant revisions to

its characteristics have been made.

Comments from PIR’s, TAS, SMA and Foremen’s

meetings has prompted the publication of the

following information. This will assist Service front

counter personnel in assisting customers with

explanations of any transmission and vehicle

characteristics that may be confusing to them, and

assist service technicians when any such concerns

may be reported as “problems”.

Service Replacements

Before any consideration is given to replacing any

A/T in VZ or WL vehicles, refer to the information

below to ensure any customer concern is not a

characteristic of the current vehicle/transmission

configurations.

Dealer Letter DL44/04 was released regarding the

inclusion of the 5L40E transmission in the existing

SRTA program and allowable parts replacement -

refer to this letter before performing any transmission

diagnosis, parts replacement, or transmission

replacement.

If any concern exists that is not covered by DL44/04

or this bulletin, your nominated TAS contact should

contact TAS, after performing diagnosis and before

replacing a 5L40E transmission.

5L40E Automatic Transmission

Overview.

- 5L40E uses latest generation production-released

GM hardware strategy.

- Used in CTS Cadillac, BMW 3 and 5 Series, X5

and Range Rover diesel.

- Consumer Reports Magazine, believes "The five-

speed automatic transmission in the BMW, made

by General Motors, is about the best we've ever

experienced.“

- Holden localised 5L40E to suit our vehicles and

achieve primary objective – a shift quality that’s

smooth, crisp and seamless.

- Transmission shifts up to 6500rpm.

- Introduction after a three-year design, development

and testing program.

Shift Stabilisation Mode

The 5L40E automatic transmission features a “shift

stabilisation” mode which reduces busy shifting or

“hunting”, where the transmission seems unsure as

to which gear to remain in and shifts up & down in

order to keep the vehicle travelling at a constant

speed.

The shift stabilisation mode evaluates the speed,

load & current gear of the vehicle and calculates if it

would be able to hold the same load conditions if the

transmission upshifted to the next highest gear.

If the vehicle would be unable to hold the load

conditions in the next highest gear the shift

stabilisation mode prevents the upshift, as the upshift

would be followed shortly by a downshift once the

vehicle loses speed as it is unable to hold the

speed/load condition in the higher gear. In real world

scenarios - driving uphill - this reduces ‘busy shifting’

or ‘hunting’.

Performance Algorithm Liftfoot (PAL)

The 5L40E automatic transmission also features

adaptive shift characteristics, via software that

continuously evaluates driving conditions and driver

inputs, and reacts appropriately to how the vehicle is

being driven.

These adaptive shifts occur only with the

transmission in Power mode, they become active

after the driver uses a high throttle opening for a

short time period, followed by a sharp lifting of the

throttle eg. lifting off the throttle when entering a

corner. When in this “performance” mode, PAL

responds to driver requests or driving style - and to

operate it requires greater than three quarter throttle

pedal travel followed by a rapid pedal release -

hence the “liftfoot” description.

The transmission will react by holding gear instead of

upshifting when the throttle is released, if the driver

also slows down the vehicle, the transmission will

downshift gears at higher speeds than normal. Once

the control system determines the vehicle is being

driven in a “spirited” manner, the current gear is held

during acceleration. This assists with acceleration

out of a corner, resulting in the vehicle being in a

more suitable gear to assist in stability during

cornering and providing a more stable exit feel.

Both of these actions will assist when the vehicle is

driven in a sporty manner eg, through corners as the

lower gearing assists engine braking into corners

whilst holding gears will give better acceleration once

the throttle is re-applied.

Active Select (A/S)

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Active Select is for the drivers who like to take more

direct control of transmission shifts, as it allows them

to select the most appropriate gear for the current

conditions. Safety features include maximum and

minimum allowable engine speed control.

Shift “Busyness”

There are five gears, instead of the previous four as

in VY and earlier models, and these provide a more

“seamless” power application during acceleration.

In combination with the new Alloytec V6 engine, the

new T68 transmission controller uses current vehicle

operating conditions such as - engine speed, trans

input speed, throttle position, torque converter slip,

altitude and temperature to create a strategy for

optimum shift performance.

The controller has the ability to sense and

compensate for all these variables, allowing the

trans. to maintain consistent, optimum shift quality.

An additional gear allows the shift points to be

engineered to deliver an improved launch, while at

the same time delivering improved fuel economy -

this may be evident by rapid shifting or ‘holding’ in

gears during shifts - this will probably be most

noticeable in Power mode and ‘lift foot braking’ (IE:

does not shift ‘up’ but holds the lower gear, based on

Power mode selection and current driving style).

4L60E - Four Speed Auto. Trans.

In VZ, the 4L60E has received some subtle

improvements in reduced downshift delays and shift-

to-shift points, plus overall improvements have

resulted in a more integrated powertrain ‘feel’

between the Electronic Throttle Control (ETC) and

the transmission, providing better shift stabilisation

and consistency.

Transmission Controller

- New electronic architecture within Alloytec allows

introduction of more advanced (and commonised)

transmission control module and software

language.

- This new TCM software introduces more possible

calibration variables - 8448 compared with the 625

in previous TCM.

- The new software language allows processing of

larger amounts of information and does it faster.

- The programming of calibration variables

underwent extensive development and refinement

by Holden calibration engineers.

- Downshift sequencing is employed on both V6 and

V8 applications. Depending on vehicle speed, slow

to medium rates of throttle apply will result in a

single downshift while rapid rates of throttle apply

will result in a ‘jump shift’ (i.e. 4-2 as opposed to a

4-3 followed by a 3-2 downshift). The V6

transmission calibration makes greater use of this

‘jump shift’ algorithm.

Engine Clutch Control Capacity (ECCC) and torque

converter

- Upgraded ECCC allows partial lock-up or controlled

slip, thereby improving the feel and fuel economy

of an already efficient transmission.

- A new torque converter better matches the new

torque characteristics of the engine.

- Increased accuracy and change to the coupling

point of the converter match the engine torque

characteristics to vehicle response.

- Provides improved engine-transmission integration,

improved cooling and optimised fuel economy.

Brake Torque Management (BTM) - Applicable

to both 5L40E & 4L60E

BTM is a safety feature and is now a standard

feature for these vehicles.

The over-riding requirement is for a vehicle to be

able to be stopped from 100km/h in a specified

distance with full throttle application and a specified

brake load.

The way this is effected is slightly different in HFV6

and V8 applications because of the different

controllers and software types used.

In V8, if the brake pedal switch is activated at the

same time as the accelerator, torque is limited -

achieved by cutting fuel to cylinders.

In HFV6, if the engine speed is above a threshold

(approx. 1200rpm) AND

Vehicle speed is above a threshold (approx. 10km/h)

AND

Either of the brake switches is actuated,

then after a 2.5 second delay BTM is activated. In

BTM mode, torque is limited to that commanded at

25% accelerator pedal position.

It should be noted that the BTM feature is switched

off when Traction Control is switched off (where this

is possible).

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

Seat Track Height Adjuster Replacement

V & W

(GROUP 1) TL0735A-0504

This techline is being released due to Dealers

continuing to replace complete seat height

adjuster assemblies for conditions that can be

rectified via previously released techline

procedures.

In future, if a seat track height adjuster assembly

is replaced, it will be mandatory for the warranty

claim 3Cs to state that the relevant techline

procedure did not/will not rectify the condition.

__________________________________________

Refer to the following techline articles for the

available V & W car seat height adjuster repairs.

• Dampener Spring Fitted To Fore / Aft Drive

Shaft.

Notchy Fore / Aft Movement On 6 & 8 Way Front

Seats.

March, Issue 2, 2005 (Page 4).

• Seat Track Out Of Alignmenet

Seat Track Excessive Fore / Aft Movement Or

Loose. Applies to 2 & 4 ways seat height

adjuster (base model variants) built after April

2003.

October, Issue 9, 2004 (Page 11).

• Thicker Washer Available For Lead Screw

Nut.

Front Seat Fore / Aft Movement – 8 Way Seats.

August, Issue 7, 2004 (Page 18).

• Replacement Steel Clevis Nut

Seat Height Adjuster Inoperative, Disengaged

Thread.

September, Issue 9, 2003 (Page 7).

DIAGNOSIS HINT

Steering Wheel Radio Remote Control

Switches Function Incorrectly

VY / WK / V2 Series II & III

Group 12 Ref. No. TL0889A - 0504

This Techline supercedes the previous one in Issue

3, Apr, 2005. It is revised by correcting the model

affected from WL to WK.

Blaupunkt receive a large number of requests for

changeover radios due to customers and dealers

experiencing the incorrect function when the steering

wheel remote buttons are depressed.

The majority of these complaints are not due to a

fault with the radio. Therefore, to avoid incorrect

diagnosis, perform the following checks. These

checks are designed to determine if there is a poor

connection between the remote control switches and

the radio causing a high resistance which results in

the incorrect function.

Checking Procedure

1. Remove the radio. Use a multi meter to

measure the resistance between terminals C11 &

C12 in the X1 connector; when no buttons are

depressed the resistance should be approximately

3674 ohms.

2. When each of the following switches are

depressed the resistance measured should be

approximately as listed below.

Next up button 794 ohms

Mute button 284 ohms

Next down button 464 ohms

Volume up button 164 ohms

Mode button 1474 ohms

Volume down button 82 ohms

3. If a high resistance is detected, disconnect all

connections, inspect for damage or corrosion,

reconnect and measure the resistance again. If the

resistance has changed and the correct function of

the radio remote switches is achieved then the

problem is considered to be connection related.

4. If the fault is still present, use the wiring

diagrams, check each section of the circuit separately

(wiring harness, clock spring, radio remote switches) to

allow diagnosis of the faulty component. .

NOTE: When measuring the resistance of this circuit,

ensure that any probing does not deform the

terminals in vehicle harness.

If the fault still persists after performing the above

diagnosis, contact Blaupunkt for additional diagnosis

assistance and advise that you have completed

these checks.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Air Intake Duct Dislodges, Sets Codes

P0171, P0174

HSV WK/VY with Gen III V8

Group 6A Ref. No. TL0908 - 0504

CONDITION

PIR’s report the occurrence of DTC’s P0171 & P0174

(Lean exhaust codes).

CAUSE

Air inlet duct from air flow meter to throttle body

dislodges.

Initial installations of this duct on HSV enhanced

vehicles had no hose retaining lip

CORRECTION – Production

The first vehicle fitted with revised air duct (with a

retaining lip) - p/n 06M3030602 - was L113977 -

where the duct was fitted during HSV enhancements

on 11/11/03.

NOTE: HSV vehicles are not built or enhanced in

strict VIN/Tag No. order, so the enhancement date is

the best indication. IE: any vehicle enhanced after

11/11/03 will be fitted with the revised part.

Reference only:

ISOVIN: Built Date:

6G1KY54F24L113977 23/05/03

CORRECTION – Service

Summary:After verifying that vehicle has condition as

described above, fit a new inlet duct.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

06M3030602 Duct - Air Flow Meter to

Throttle Body.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

INFORMATION

Checking TIS 2000 Version Number

GROUP OB TL0924-0504

The latest version of TIS (and other service

information Cd’s) is published at the beginning of

each Techline Issue under the heading:-

‘Your Latest Electronic Service Information’.

To confirm which version of TIS2000 is loaded on

your PC proceed as follows.

From the TIS main screen click ‘Help’ from the top

menu bar, then click ‘About TIS 2000’ refer Figure 1.

In the ‘pop up’ is the current version of service

information installed. Refer figure 2.

In this example the current version is:

Opel/Vauxhall/Holden/Version 60.1 Domestic.

TIS 2000 – Isuzu GE/DO Version 16.0 (Isuzu

General Export Domestic)

Wiring Diagram – Version 19.0

Note: For instructions on how to download TIS 2000

Isuzu software into Tech 2, refer Techline Issue 2

March 2004.

Figure 1.

Figure 2.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Engine Vibration – Loose Engine Mount

Bolt

TS 1.8L Engine

Group 6A Ref.No. TL0247A - 0504

This Techline is Re-issued from Issue 3, Apr

2002, to draw technicians attention to the need

for engine mount bolt checking during vehicle

servicing.

PROBLEM DESCRIPTION

PIR’s have been received that mention

engine/transmission vibration – and diagnosis has

shown that a loose/missing rear powerplant mounting

bolt was the cause.

SERVICE RECTIFICATION

Summary: Refit/Replace bolt and Apply Loctite 243.

Should diagnosis of a “vibration” complaint define

that a rear powerplant mounting bolt is:

a/. Loose – remove the mating nut, apply Loctite 243

(or equivalent) to the bolt threads and refit the nut,

and torque to 55Nm.

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

apply Loctite 243 (or equivalent) before installation

and torque to 55Nm.

Rear Engine Mounting Assembly Precaution.

Note: when attaching the damper block to the

(upper) bracket – ensure the raised “key” section (3)

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

bracket, as shown in Figure 1.

Figure 1.

For Reference: The above diagram is taken from TIS

2000 – Refer to the relevant TIS 2000 section when

replacing engine/powertrain mounts.

PARTS INFORMATION

Use the following parts ONLY when replacement of

missing parts is required:

Part No.: Description: Qty:

11098991 Bolt – Damper to

Bracket.

11098811 Nut – Damper to

Bracket.

WARRANTY CLAIM INFORMATION

Description Engine mount bolt/nut -

Replace

Labour Op. No. J000704

Time 0.3 hr

Failure Code 27 (Loose) or

29 (Part Missing)

NOTE. Tightening a loose bolt is not considered

warranty but part of the routine maintenance service

checking procedure

HOLDEN SERVICE TECHLINE __________________________________________________________________________________MAY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Hard to Select Gears

VT2,VX,VU,VY,V2,VZ with V8 & MM6 M/T

Group 7A Ref. No. TL0840 - 0504

For complaint of “Hard To Select Reverse Gear

Only” refer to Techline TL0914 – 0504 which

explains the revisions to the reverse synchroniser

blocker ring.

CONDITION

Customer reports hard to select gears. Initially, it may

be First and Reverse and then eventually the

customer experiences high shift effort into all gears.

CAUSE

Possible lack of lubrication of clutch and input shaft

splines resulting in the clutch disc binding on input

shaft and not fully releasing from flywheel..

CORRECTION – Production

Lubrication added from:

ISOVIN: Built Date:

6G2VX12U55L282597 10/12/04

CORRECTION – Service

1. Measure transmission spin down time.

Engine at idle speed and transmission in neutral.

Depress clutch pedal and measure time by listening

for input shaft to stop spinning. Transmission roll

over noise can be used to determine spin down time

and is best heard by squeezing gear lever. Spin

down time should be no greater than 2 seconds

2. If spin down time is greater than 2 seconds, clean

and lubricate transmission input shaft spline. Refer

to Holden SIP CD for correct grease type to be used.

3. If spin down time is less than 2 seconds then this

is not likely to be the cause of high shift effort.

Further diagnosis will be required to identify problem.

Contact TAS if further diagnosis assistance is

required.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD.

SERVICE FIX

Hard to Select Reverse Gear Only

VT2,VX,VU,VY,V2,VZ with V8 & MM6 M/T

Group 7A Ref. No. TL0914 - 0504

CONDITION

Hard to select REVERSE gear under all conditions

(hot and cold).

CORRECTION – Production

To overcome the above condition the reverse gear

synchroniser blocker ring has been revised from

bronze to steel with a carbon lining.

Transmissions with this revision were introduced into

vehicles from:

ISOVIN: Built Date:

6G2VX12U55L363449

(Trans. Serial No. TB010072)

22/11/04

CORRECTION – Service

STEP 1.

Perform procedures outlined in Transmission

Diagnostic chart shown in All Dealer Letter DL06/05 -

entitled:

Chart 2 - Manual Trans. “Hard to Select Gears”

STEP 2.

If after completing step 1 the customer complaint

cannot be rectified, install a new Reverse gear

synchroniser ring 92143258 (carbon lined)

NOTE: This blocker ring is also specified for use on

5th/6th gear synchro assembly.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92143258 Blocker Ring (Steel with

carbon lining)

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Camshaft Drive Belt Maintenance Service

Interval Clarification

ZC with 3.2L V6 Engine

Group 6A Ref. No. TL0905 - 0505

The service maintenance interval for the camshaft

drive belt, tensioner assembly, idler pulley, and return

roller have been changed.

The maintenance interval is now as follows:

120,000km or 8 year Intervals

• Engine toothed belt, tensioner assembly, idler

pulley, and return roller - Replace.

• Engine tooth belt crank drive gear - Inspect .

NOTE. Initial copies of the owners handbook

specified that the above service be performed at

60,000 km or 4 year intervals. Owners handbooks with

the new intervals were printed from Sep.2004

(commencement of Model Year ‘05)

If you have a vehicle where the owners handbook

specifies the 60,000km maintenance interval, please

refer this to your service manager.

SERVICE HINT

Ignition Barrel Jams In Off Position –

Alternate Method For Freeing Up Barrel

TS, TT, XC, with “S” profile Ignition

Keys/Barrels

Group 9 Ref. No. TL0935 - 0505

Further to earlier techline titled “Ignition Key Jams In

The Off Position Or Is Difficult To Turn From Off”

released in issue 2 Page 20, 2005, this techline offers

an alternative method for rotating a seized ignition

barrel. This procedure will assist in mobilising a vehicle

so that it can be moved to a workshop for repair.

1. Remove the ignition barrel rubber surround.

2. Insert a seal pick between the barrel and outer

housing and raise the key retaining plunger as show in

figure 1 so that it is fully visible in the key slot.

Figure 1.

3. Press the barrel centre in (usually 2 – 4mm) and

hold, then remove the seal pick.

Note: If the key retaining plunger is not fully raised so

that it is visible in the key slot, the barrel centre will not

press inward.

4. While still holding the barrel centre in as shown in

figure 2, insert the key and rotate to mobilise the

vehicle.

Figure 2.

Key retaining

plunger in the

raised

osition.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Low Speed Engine Cooling Fan Relay Sticking

VY, WK, V2 II & III, VZ, WL

(GROUP 12) TL0929-0505

This Techline supercedes the previous one in Issue 3,

April, 2004 (TL0673-0403). It is revised by adding a

change to the affected model ranges, production and

parts break points.

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 Jun 04.

CORRECTION - Production

Known good relays were fitted to vehicles from:

ISOVIN: Built Date:

**********L425282 08/04/2005

CORRECTION – Service

On vehicles affected by this condition, replace the

relay with one where the date code, as shown in

Figure 1, reads “IN 0423” or higher.

Figure 1

PARTS INFORMATION

Part No.: Description: Qty

92092445 Low Speed Cooling Fan Relay 1

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

SERVICE FIX

A/T Shift Pattern/Sports Mode Concerns

AH Astra

Group 7B Ref. No. TL0934A - 0506

CONDITION

Some customers may complain or comment about

poor performance, cabin booms in normal driving

mode, and/or holding gears until redline when in sports

mode.

CAUSE

Automatic Transmission Calibration.

CORRECTION – Service

If a customer complains about the above described

conditions, reprogram the Transmission Electronic

Control Unit via the standard Service Programming

System (SPS) method using TIS 2000, CD 61 or later.

IMPORTANT: During SPS programming, the Country

Of Registration must be set to Australia. If this is left as

“Other” an error message will advise that the vehicle

currently has the latest calibration.

The latest transmission calibration installed off TIS

2000 CD 61 has the following revisions:

'Normal' driving mode - Revision in shift points and

lock up points for torque converter (occurring slightly

later in RPM range compared to current production

calibration). This improves performance feel, where

engine won't labour, and also reduces cabin booms.

'Sports' driving mode - Revision in shift points, where

auto transmission won't hold in gears until redline.

Improved Calibration Details:

Opel Part No. 55560969 Software Version No. 1010.

To identifiy vehicles that have had the above

procedure performed, apply a service history label on

the the inner left side of the glovebox door and mark

the coordinate “A-2” with a ball point pen to indent the

foil sticker. Refer following figure.

CORRECTION – Production

Breakpoint details will be published when this occurs.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

Update

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

Blaupunkt Audio Unit Insufficient Volume -

(Dynamic Distortion Limiting Function)

VY & VZ ute

Group 12 Ref. No. TL0928 - 0505

CONDITION

Customer complains that there is insufficient volume

output from the audio unit in their vehicle particularly

when playing music with a lot of bass.

CAUSE

The most likely cause for the customer complaint is the

Dynamic Distortion Limiting (DDL) function in the audio

unit is turned on.

In most instances, the customer would be unaware of

this feature and the fact that it can be turned off or on

via the radio controls.

CORRECTION

Advise the customer of this DDL feature which is

explained in the audio system handbook and the

owners handbook. Show them how to switch the

feature Off if they wish to do so. The following

procedure is extracted from the audio system booklet.

1. Turn off the radio using the “OFF” button.

2. Push and hold the “ON” button and the preset 1

button until the display shows “Options Menu”, then

release the buttons. The display will initially show the

current setting for “Confirmation Beeps”.

3. Press the volume knob momentarily a couple of

times to scroll through the options until DDL is

displayed.

4. Turn the volume knob clockwise or anticlockwise to

turn DDL ON or OFF.

NOTE: This is not a warranty rebill item as there is no

defect in the vehicle.

SERVICE FIX

Wagon Third Row Accessory Seat –

Seat Back Release Cable Breaks

VT, VX, VY, VZ

Group 1 Ref. No. TL0881 - 0505

CONDITION

Seat back release cable breaks.

CORRECTION

On seats with the above condition, replace the cable.

Do not replace the entire seat assembly when

replacement of the cable will rectify the problem.

NOTE: Previously, this cable was not available as a

replacement part. It can now be obtained through

HSPO.

Replacement Procedure.

Instructions are included with each kit.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92149039 Third Row Seat - seat back

release kit

WARRANTY CLAIM INFORMATION

Description Replace 3rd row seat back

release cable

Labour Op. No. R902210

Time 1.0 hr

Failure Code R0001

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

Knock From Front Suspension - Stabiliser Bar

Drop Link Ball Joint Nut(s) Loose.

WL, VZ

Group 3 Ref. No. TL0920 - 0505

CONDITION

Knock from front suspension.

PIRs received from dealers report they are finding the

stabiliser bar to drop link ball joint attaching nut to be

loose.

CAUSE

Investigations have shown that there was inadequate

torque applied to this nut during assembly.

CORRECTION – Production

The nut torque is within specification from the following

breakpoint.

ISOVIN: Built Date:

All vehicles built from this date 10/03/2005

CORRECTION – Service

Summary: After verifying that vehicle has condition as

described above, retorque nut to specification.

Procedure

1) Check nut torque on top and bottom ball studs on

both droplinks (left and right hand sides).

2) If all nuts are found to be torqued correctly then the

cause of the complaint / noise is elsewhere.

3) If one or more nuts are loose or missing, clean ball

stud thread to ensure no grit is present, reinstall and

torque nut to specification shown in PV SIP.

INFORMATION

Replacing Central Door Locking Sender Units

(315 MHz or 433 MHz)

TS Astra, TT Zafira, JR & JS Vectra

(GROUP 12) TL0931-0505

PROBLEM DESCRIPTION

Technicians often call TAS in order to define which

types of remotes are required for the vehicle they are

working on. This is unclear at times as the imprint on

the rear of the remotes has usually worn off by this

time, making it very difficult to read.

The procedure recommended by TAS is to gain access

to the central door module in order to obtain the part

number of the module which is displayed on it.

Take that part number to your Spare Parts Department

where it will describe in Partfinder or Microcat the type of

module fitted to that car. The remotes can then be ordered

for that frequency type, either 315 MHz or 433 MHz.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Fuel Gauge and Low Fuel Light Operation.

VZ & WL

Group 12 Ref No. TL0891 - 0505

When investigating fuel gauge or low fuel light

operation complaints, explain to the customer the

following system operation characteristics .

Note: The values quoted below are the design intent

and are only appropriate for vehicles without a

recognised problem.

Low Fuel Warning Operation

When the low fuel warning illuminates constantly (and

the audible warning operates) there is approximately 8

to 15 litres of fuel remaining in the tank and the fuel

gauge will indicate the following position.

Note: Some model variants may have different fuel gauge markings

although the needle position will be approximately the same.

Very Low Fuel Warning Operation

When the very low fuel warning illuminates constantly

(and the audible warning operates) there is

approximately 2 to 9 litres of fuel remaining in the tank

and the fuel gauge will indicate the following position.

Note: Some model variants may have different fuel gauge markings

although the needle position will be approximately the same.

Zero DTE Warning Operation

When the trip computer indicates zero DTE there is

approximately 0 to 7 litres of fuel remaining in the tank

and the fuel gauge will indicate the following position.

Note: Some model variants may have different fuel gauge markings

although the needle position will be approximately the same.

Attached below is a table of the approximate fuel tank refill

/ remaining fuel values for each body style at each warning

indication under normal operating conditions.

Coupe

Cab

Chassis

Ute

Sedan

Wagon

Vehicle Type

55 to 62

49 to 56

53 to 60

58 to 65

Litres to

Refill

8 to15

Litres

Remaining

Low

Fuel

Warning

61 to 68 55 to 62 59 to 66 64 to 71

Litres to

Refill

2 to 9

Litres

Remaining

Very

Low

Fuel

Warning

63 to 70 57 to 64 61 to 68 66 to 73

Litres to

Refill

7 to 0

Litres

Remaining

Zero

DTE

Warning

70 64

Litres of Usable Fuel*

Note: All refill values need to be substantiated by a dealership

employee.

*Quoted usable fuel capacities are achieved by using

the recommended refill method detailed below.

Recommended refill method.

The following fuel fill method is recommended.

Step 1. Bowser nozzle at full flow rate until it shuts off

once, then wait approximately 5 seconds.

Step 2. Bowser nozzle at approximately 75% flow rate

until it shuts off for the second time, then wait

approximately 5 seconds.

Step 3. Bowser nozzle at approximately 50% flow rate

until shut off for the third time.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Cruise control drops out intermittently and

sets DTC B3794

ZC Vectra

Group 12 Ref. No. TL0906 - 0505

CONDITION

Customers may advise that the cruise control drops

out intermittently and will not re-engage until the

ignition is cycled.

When Tech 2 is connected and the vehicle is checked

for DTC’s B3794 may be found.

CAUSE

This condition is caused by a poor connection between

the cruise control stalk and the CIM.

CORRECTION – Production

Revised CIM has been fitted to vehicles from:

ISOVIN: Built Date:

W0L0ZCF6851049996 01/12/2004

CORRECTION – Service

Perform the following:

1. Check for DTC’s using Tech 2.

2. If DTC B3794 is set, perform the standard TIS

diagnosis. If this diagnosis leads to a stalk switch

replacement, replace the CIM also.

PARTS INFORMATION

Revised parts can be identified by the date stamp

located on the top RH corner.

0 4 1 0 3 0 XXXX is Breakpoint for revised parts

(y y mm dd XXXX) i.e. 30/10/2004 or later.

HSPO stock has been culled and only parts

manufactured after the breakpoint will be shipped to

distributors.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

SERVICE FIX

Clock In Multi Function Display (MFD) Loses

Time

Group 12 Ref. No. TL0901- 0505

CONDITION

Some customers may complain the clock in their MFD

is losing time.

CORRECTION – Production

A revision to the MFD was introduced into production

as of the following break point.

ISOVIN: Built Date:

**********L328959 7/9/2004

CORRECTION – Service

If a customer presents a vehicle with the above

condition, replace the MFD.

The amount of time lost as stated by the customer

must be recorded on the Repair Order so this can then

be recorded in the 3 Cs of the warranty claim.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Cruise Control Accelerates To Set Speed

Too Rapidly.

ZC Vectra with Z22SE engine

Group 12 Ref. No. TL0810- 0504

CONDITION

Some customers may report the following condition

which occurs whilst driving with cruise control set -

After the vehicle loses speed while driving uphill, it

then accelerates too rapidly back to the set speed.

Another customer description may be that when they

press the resume switch to return to the previously set

speed the vehicle accelerates too quickly.

CORRECTION

A revised engine calibration has been developed to

address this condition and is available on TIS 2000

from CD 56 onwards.

IMPORTANT: The revised calibration is only suitable

for vehicles without an EGR valve. If the vehicle is

fitted with an EGR valve (Engine No. prior to

Z22SE11293531), it will need to be deleted as per the

following procedure prior to SPS programming the

vehicle.

Procedure for EGR Deletion .

1. Remove EGR valve. (Refer TIS)

2. Close exhaust gas recirculation port with a cover

plate (part No. 24575592) and new gasket (part No.

12570863). The groove on the plate has to point in the

direction of the radiator and the plate labelling facing

upwards.

Torque the two cover plate attaching bolts to 23 Nm.

3. Fix the EGR wiring harness connector with a cable

strap. (face connector opening towards rear).

4. Program ECU via the standard Service

Programming System (SPS) method using TIS 2000,

CD 56 or later (select without EGR).

IMPORTANT

Always ensure the latest Tech 2 software from TIS

is loaded into your Tech 2 before attempting any

reprogramming using SPS method.

WARRANTY CLAIM INFORMATION

For SPS programming only, use the standard labour

times information in Warranty Information section of

current PV SIP CD.

If the vehicle has an EGR valve which needs to be

removed, use the following information.

Description Remove EGR valve, add cover

plate, and reprogram ECU

Labour Op. No. J000776

Time 0.6 hr

Failure Code J0057 registers incorrectly

PARTS INFORMATION

Part No.: Partfinder Name Qty:

24575592 Cover plate- EGR valve

opening

12570863 Gasket - EGR valve to cyl

head

Figure 1. Shows EGR cover plate with groove facing

towards front of vehicle.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

EGR Malfunction

ZC Vectra with Z22SE engine

Group 6C Ref. No. TL0919 - 0505

CONDITION

Drivers may report that their vehicle runs rough or

lacks power.

The telltale light comes on and P1404 DTC is set

(EGR valve sticking).

Dealers have been responding to these conditions by

fitting a new EGR valve.

CORRECTION – Production

The EGR-valve was removed in production (during

Model Year 2004) from Engine No. Z22SE11293531

CORRECTION – Service

On complaint vehicles where diagnosis finds that an

EGR valve is faulty, it should not be renewed but

removed altogether as per the following procedure.

Procedure.

1. Close exhaust gas recirculation port with a cover

plate (Part No. 24575592). Replace gasket when doing

so. (Part No. 12570863). The groove on the plate has

to point in the direction of the radiator with the plate

labeling facing upwards.

2. Fix the superfluous wiring harness connector with a

cable strap (face connector opening to rear of vehicle).

3. Program ECU via the standard Service

Programming System (SPS) method using TIS 2000,

CD 56 or later (select without EGR).

PARTS INFORMATION

Part No.: Partfinder Name Qty:

24575592 Cover plate- EGR valve

opening

12570863 Gasket - EGR valve to cyl

head

12569559 EGR valve 1

WARRANTY CLAIM INFORMATION

Description Remove EGR valve, add cover

plate, and reprogram ECU

Labour Op. No. J000776

Time 0.6 hr

Failure Code J0057 registers incorrectly

Figure 1. Shows EGR cover plate with groove facing

towards front of vehicle.

SERVICE FIX

A/T Shift Harshness

WK V8

Group 7B Ref. No. TL0933- 0505

CONDITION

Some customers may complain of shift harshness

during:

1-2, 2-3 upshifts, 3-2 downshift in ‘normal’ mode;

1-2 and 2-3 upshifts in ‘Power’ mode.

CAUSE

Sensitivity of some vehicle powertrains to the

production calibration.

CORRECTION – Service

Should a customer complain of shift harshness as

described above, reprogram with calibration 92183020

available from TIS CD 58 onward.

WARRANTY CLAIM INFORMATION

Description WK V8 A/T Shift Reprogram

Labour Op. No. K000303

Time 0.3 hr

Failure Code NOW K0043 Shifts Hard

Update

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

High Idle Speed with A/C On

VZ Gen III with M/T (excluding cab chassis

variants)

Group 6C Ref. No. TL0932- 0505

CONDITION

Customer may complain that when the A/C is turned

on, the engine intermittently has a high idle speed, that

will not drop to normal idle speed for some seconds

after throttle is closed (IE: on deceleration or between

gear changes).

CAUSE

Powertrain management system calibration incorrectly

compensates for A/C compressor loading during

certain air flow conditions.

CORRECTION – Production

Revised calibrations with revised control parameters

have been installed in vehicles from:

Sedan (Cal # 92182878):

ISOVIN: Built Date:

6G1ZK54F85L389596 17/01/05

Coupe (Cal # 92182884):

ISOVIN: Built Date:

6G1ZX14F95L389519 20/01/05

Utility (Cal # 92182880):

ISOVIN: Built Date:

6G1ZK42F05L390626 21/01/05

CORRECTION – Service

If the calibration number does not match the revised

calibration (as in breakpoints above) - reprogram using

TIS CD 59 or later.

WARRANTY CLAIM INFORMATION

Description VZ V8 M/T Idle Reprogram

Labour Op. No. J000773

Time 0.3 hr

Failure Code NOW J0057

DIAGNOSIS HINT

DTC U0155 set in Engine ECU

VZ & WL V6

(GROUP 6C) TL0923-0505

PROBLEM DESCRIPTION

Vehicles may log DTC (diagnostic trouble code)

U0155, “CANbus no communication with gateway” in

the engine ECU. Many dealers are following the

diagnostic procedure in SIP believing this DTC is

causing a vehicle concern.

Engineering is currently investigating the cause of this

DTC and have advised that this DTC does not cause

any vehicle concerns.

If confronted with a vehicle that has this DTC, be

aware that this should not be the cause for any

concern and should be ignored.

Do not replace any parts for this DTC.

INFORMATION

Searching for Techlines, Dealer Letters etc. on

Holden Lionheart (Portal)

(GROUP OB) TL0921-0504

This Techline describes two methods for locating

Techlines, Dealer Letters, Campaign Bulletins etc. on

Holden Lionheart.

• CONVENTIONAL method

• SEARCH ENGINE method.

The CONVENTIONAL method is similar to looking up

information in a text book. You commence by looking

in the Table Of Contents at the front of the book then

looking up the page reference then scanning down the

page until you find the section you’re looking for.

The “SEARCH ENGINE” method involves entering

your search criteria in a Search window and then

letting the search engine find the techlines

automatically.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

START

1. After logging onto Holden

Lionheart select “Holden Service

Bulletins” as indicated by yellow

arrow.

Figure 1.

2. The next screen to appear shows

all items in the Holden Service

Bulletin Database arranged by Date.

The most recent items are on the top

of the list. To view the item, click on

the ►next to the date.

HINT: Check this screen everyday

to view the latest information

issued by Holden Service

Department.

If you select the “Category” button as

indicated by red arrow, the screen

shown in Figure 3 will appear.

Figure 2

3. In this example we will show how

to locate a Service Techline. Now

select “Service Techline” from the list

shown.

The next screen to appear is shown

in Figure 4 on next page.

Figure 3.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Following is a description of how to locate information by the conventional method or by using the search

function.

4 (A). Conventional Method.

As an example, we will look for a

techline on

Y V6 oil leak from

engine front cover.

Choosing the right year and the right

Group to look in are the keys to

finding a techline quickly.

As VY was produced from 2002 to

2004 you should commence looking

in 2004. Choose group 6A – Engine

and look through list of techlines until

you find the right one, which in this

example was published in Issue

05/2004

The drawback with this

“Conventional” method is knowing

which year and group to look in. It

can also be time consuming

scanning through long lists of

techlines.

Figure 4

4 (B). SEARCH-Function

Method

From the screen shown in Figure 5,

click on the “Search” key. This will

bring up the screen shown in Figure

Figure 5

This is the search screen we use for

entering our search criteria (i.e. an

accurate summary of what we are

searching for)

Figure 6

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

As an example we will search for

techlines related to JR & JS Vectra

Ignition Barrel Jamming.

In the “Search for” window, type in

the following “search string”.

“JR and JS and Ignition key”.

Don’t touch the next 2 boxes titled

“Sort results by” or “Return a

maximum of”.

Tick the last 2 boxes i.e. Use Word

variants and Fuzzy search. Refer to

later explanations of these terms.

Now click the “Search” button.

Figure 7

The search result is 2 documents as

shown in Figure 8.

Click on the hot-key section (in blue)

to view the techlines.

Figure 8.

Defining Your Search Criteria

If we had entered only “ignition key”

in the search window the search

engine would have located 22

techlines as shown in Figure 8.

If we had entered only “ignition”, the

search engine would have located

85 techlines.

So you can see the importance of

defining your search criteria as

accurately as possible so you don’t

end up with huge numbers of items

to read through.

Rule of thumb: the less information

in the “search window” the more

information comes back.

If at anytime you wish to go back to

the “Search” function press the

“Back” arrow in the top left side of

the toolbar. Refer red arrow.

Figure 9.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

To search for a Dealer Letter,

Campaign Bulletin, Field rework or

Warranty Bulletin, use the same

procedure as that described for a

Service Techline.

IMPORTANT: You must first select

the category you want from the

Category screen (Figure 10) before

proceeding with search.

Figure 10.

General Search.

To find ALL published information on

a subject, select “Search” from

screen shown in Figure11.

As an example, enter “Daewoo” in

the search field

This “search” will give you everything

that contains the word “Daewoo” .eg.

Dealer letters, Techlines, Recalls,

Warranty etc.

Figure 11

General Notes On Searching.

• If you perform a search and the results are not what you were looking for; to conduct another search, you will

need to hit the “← Back arrow” in the Microsoft Internet Explorer menu at top left of page. This will bring up a

new search window that you can enter new search criteria into after deleting the previous search criteria.

• The search engine cannot search any “attached” files such as Word, Excel, Pdf, on Holdens database. It can only

search for words that appear on the viewing page for each individual item.

Word Variants

If you tick this box in the search panel, and type in “cat” in the “Search For” window, the search engine will find every

word that has cat in it, eg. catalytic, category, cats, etc. This is useful if you cannot remember the exact spelling of a

word or you forget the s when the word is plural.

Fuzzy Search.

EXAMPLE 1. Search for techlines with DTC P0335 in the Subject title.

If you accidentally type in DTCP0335 without a space between C and P, and do a Fuzzy search, the search engine

will still bring up all techlines containing “DTC P0355”.

EXAMPLE 2. Search for techlines containing 4JX1 in the subject title.

If you accidentally type in 4JX, a fuzzy search will still find all techlines with 4JX1 in the title. This feature doesn’t

seem to work if you forget to enter the first letter. in this example, doing a Fuzzy search on JX1 will not find anything.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FI

C Pillar Exterior Moulding (Applique)

Detaches

VY & VZ Adventra

Group 1 Ref. No. TL0911 - 0505

CONDITION

Left hand or Right hand C Pillar moulding comes loose

or detaches from the rear quarter window.

CAUSE

Inadequate adhesion.

CORRECTION

Reattach C pillar moulding (Appliqué) as per following

attached instructions.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92120547 Applique –quarter window rear

92120548 Applique –quarter window rear

92149056 Velcro patch 1

92146444 Urethane 300ml cartridge 1

92145403 Primer 1

____________________________________________________________________________________________

PROCEDURE.

Step 1 - Remove Applique from vehicle (if still attached). Order replacement appliqué if damaged.

Step 2 - Remove any broken clips from the upper and

lower Applique mounting points.

If there is any damage to the rear quarter window

assembly (except for a loose or damaged velcro

patch), replace the window with the appropriate part

number. Check when window arrives that velcro patch

is firmly attached to the centre of the pillar section.

Step 3a - If window assembly does not need

replacing, check for Velcro patch adhesion to the

window assembly. If Velcro patch is missing, order

92149056 from HSPO and attach as per steps 3b to

3d. If Velcro patch is loose, remove and reattach as

per steps 3b to 3d.

If Velcro patch is firmly attached, move to step 4.

Step 3b - Remove velcro patch. Clean surface beneath patch by cleaning with methylated spirits or prepsol and a

clean lint free cloth.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Step 3c - On the cleaned surface apply a coat of primer 92145403. Allow surface to dry for a minimum of 10

minutes.

Step 3d - Remove adhesive tape backing from Velcro patch and attach to window moulding within the rectangular

marked section. Apply pressure to the entire surface of the Velcro to ensure adhesion is uniform.

Step 4 - Clean upper two grooves in

window assembly using methylated spirits

or prepsol and a lint free cloth.

Step 5 – Apply primer 92145403, to the

two upper grooves in window assembly.

Allow 10 minutes to dry.

Step 6 - On new Applique(s) - clean upper

sections indicated in photograph opposite

with methylated spirits or prepsol and a lint

free cloth.

Step 7 – Now apply primer 92145403, to

the upper two sections just cleaned in step

6. Allow 10 minutes to dry.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JUNE, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Step 8 - Using urethane p/n 92146444,

apply a 10 mm bead 5mm from edge of

foam as shown in photograph..

Step 9 - Install new applique (as per

procedure in Passenger SIP) by first

sliding bottom edge of appliqué (1) into the

holes (3) then pushing top edge into

retaining holes (2).

Step 10 – Using a soft roller, roll top edges

of applique to ensure the Velcro tape and

the urethane have contact with glass

SERVICE FIX

EGR Malfunction

ZC, and Z22SE engine

Group 6C Ref. No. TL0919B - 0507

This Techline supercedes the previous one in Issue 5,

June, 2005. It is revised by removing the EGR Valve

from the Parts Information as it is NOT required.

CONDITION

Drivers may report that their vehicle runs rough or

lacks power.

The telltale light comes on and P1404 DTC is set

(EGR valve stuck).

Dealers are currently responding to these conditions

by fitting a new EGR valve.

CORRECTION – Production

The EGR-valve was removed in production (during

Model Year 2004) from Engine No. Z22SE11293531

CORRECTION – Service

On complaint vehicles where diagnosis finds that an

EGR valve is faulty, it should not be renewed but

removed altogether as per the following procedure.

Procedure.

1. Close exhaust gas recirculation port with a cover

plate (Part No. 24575592). Replace gasket when doing

so. (Part No. 12570863). The groove on the plate has

to point in the direction of the radiator with the plate

labeling facing upwards.

2. Fix the superfluous wiring harness connector with a

cable strap (face connector opening to rear of vehicle).

3. Program ECU with SPS as of TIS 2000, CD 56

(select without EGR).

PARTS INFORMATION

Part No.: Partfinder Name Qty:

24575592 Cover plate- EGR valve

opening

12570863 Gasket - EGR valve to cyl

head

WARRANTY CLAIM INFORMATION

Description Remove EGR valve, add cover

plate, and reprogram ECU

Labour Op. No. J000776

Time 0.6 hr

Failure Code J0057 registers incorrectly

Figure 1. Shows EGR cover plate with groove facing

towards front of vehicle.

Update

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JULY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

DTC’s U0415 and U2108 set in ECM and PIM

VZ Cab Chassis, Crewman, and Ute without

ABS

Group 8 Ref. No. TL0954- 0506

CONDITION

The following DTC’S may be current in the Engine

ECU (Electronic Control Unit) and PIM (Powertrain

Interface Module)

• DTC U0415 - Invalid data from ABS

• DTC U2108 - CANBUS no communication with ABS.

No warning lights are displayed in the instruments.

CAUSE

These DTC’s are characteristic for base model cab

chassis/Crewman and Utility vehicles which ARE

NOT fitted with ABS.

CORRECTION

DO NOT replace engine ECU’s or PIM’s for these

fault codes. There is no fault and no correction

procedure is required

Holden PV SIP will be updated to highlight the fact

that DTC’s U0415 and U2108 are characteristic on

the above models which are not fitted with ABS.

SERVICE FIX

Holden Assist Advise Customer of Invalid

Location Information

VY / V2II & III / WK / WL

Group 12 Ref. No. TL0953-0506

CONDITION

Customers may report that Holden Assist has advised

that they are receiving invalid or no location

information from their vehicle intermittently.

CORRECTION - Production

Vehicles were built with revised software from:

ISOVIN: Build Date:

6G1******* L426688 06/04/05

CORRECTION - Service

1. Using Tech 2 review the location information in

the Telematics module GPS data list by selecting

the following,

Diagnostic/Model Year/Vehicle Type/Body/Telematics

Module/Data Display/Global Positioning System

2. (a) If there is no location information displayed in

the data list refer to PV SIP Section 12 K / 4.4

Strategy Based Diagnostics.

(b) If the location information is displayed,

reprogram the Telematics module via the

standard SPS process using TIS 2000 version 62

or later.

Note: Check that the VIN number is correct. If VIN is

incorrect, you will require a Change Over module from

Australian Arrow, which can be obtained via the

standard Change Over process.

The Telematics module will automatically be left in

SERVICE mode after completing the programming

process.

Note: The vehicle should be returned to the customer

with the Telematics system in the same operating

mode, in which they left it. If this is not known, it

should be left in SERVICE mode.

WARRANTY CLAIM INFORMATION

Description Reprogramming Telematics Module

Labour Op. No. N000438

Time 0.3 hr

Failure Code 57 Registers Incorrectly

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JULY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Fuel Gauge Conservative Refill (High

Reserve)

VZ V6 Ute

Group 12 Ref. No. TL0952 - 0506

CONDITION

Reports have been received of not being able to add

enough fuel into the tank once the low fuel warning is

displayed.

Note- Refer to Techline TL0891-0505 “Fuel Gauge

and Low Fuel Light Operation” published in issue 5,

June 2005.

CAUSE

The fuel gauge section of the Engine Control Module

calibration.

CORRECTION – Production

A revised fuel gauge calibration was programmed into

vehicles in production from the following breakpoint:

ISOVIN: Built Date:

**********L444651 18/05/2005

CORRECTION – Service

To rectify this condition it will be necessary to:

1. reprogram the Engine ECU via the standard SPS

process using TIS 2000 version 62 or later and

2. reprogram the instrument cluster fuel gauge

calibration using Tech 2 with software version

14.1 or later.

WARRANTY CLAIM INFORMATION

Description Reprogram PCM &

Instrument cluster

Labour Op. No. N000481

Time 0.5 hr

Failure Code N0057 Registers incorrectly

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JULY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

ESP Early Intervention

VZ & WL with ESP

Group 5 Ref. No. TL0944 - 0506

CONDITION

Customer complains that the ESP is activating

unnecessarily. A buzz from the ABS module is heard

during this event.

The above condition may be caused by incorrect

centralisation of the steering gear where the SAS

(Steering Angle Sensor) is calibrated to this “off

central” point.

RECOMMENDED ACTION

Summary: Centralise the steering gear, adjust toe

and steering wheel to new central point and

recalibrate the steering angle sensor (SAS). The

relevant procedures are as follows.

1. Verify the position of the steering gear using tech 2. In

the ABS data list monitor the SAS position from the

zero (0°) position. With the engine idling turn the

steering wheel to lock one side and note the reading

(The steering wheel will have to be turned very firmly

against the rack lock stop to get the maximum travel

reading) . Turn the wheel back to centre (0°) and now

turn wheel to lock in the other direction and note the

reading. The difference from side to side can be no

more than 8°. Total travel from lock to lock should

add up to approximately 1000°. Note the total travel

reading that can consistently be achieved.

2. If the reading difference from side to side is greater

than 8°, proceed to locate the steering gear central

point and recalibrate the SAS as follows.

3. Centralise the steering gear position. This can be

done with tech 2, once again monitoring the SAS

reading. Using the above noted total travel reading

divide this by 2, and this will be the central point from

lock either side of travel.

4. Turn the wheel to lock on one side, note the SAS

reading, turn the steering back towards centre by the

amount determined in step 3. This now should be the

central position of the steering rack. Confirm by

turning the wheel to the opposite lock and check that

there is an equal amount of travel in each direction.

5. The toe will now have to be adjusted around this

central rack position.

6. The steering wheel will also have to be moved to this

central rack position.

7. Finally, the steering angle sensor will need to be

recalibrated so that the central rack position is set to

0°. Refer to procedure in PV SIP.

SERVICE FIX

Check Engine Light On, DTC P1372 Set

TS & XC with Z18XE Engine

Group 6C Ref. No. TL0937- 0506

CONDITION

Customer reports Check Engine Light comes on.

Dealer finds DTC P1372 is logged.

CAUSE

The above trouble code can be logged due to

crankshaft sensor transmitter disc being not to

specification.

CORRECTION – Production

The problem has been rectified in production from

Engine No Z18XE20EX5207

CORRECTION – Service

On vehicles with the above complaint, reprogram the

Engine Electronic Control Unit via the standard

Service Programming System using TIS 2000 CD 62

or later.

Model: Part Number Software Version

TS 55559287 1025

XC 55355042 1026

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JULY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Gear Knob Rotates

VZ with HFV6 Aisin 6 Speed M/T

Group 7A Ref. No. TL0949 - 0506

CONDITION

Customers may complain that the gear knob rotates up

to 15 degrees in either direction as shown in figure 1.

Some dealers are replacing the gear knob and boot

assembly (P/N 92209169) in an attempt to fix the

problem. In most cases a replacement gear knob will

not fix the rotation.

Figure 1.

CAUSE

Excessive clearance between the internal mating

surfaces of the gear knob and shifter rod.

CORRECTION – Service

Should a customer report rotational movement or

'loose fitting' of the gear knob perform the following

steps;

1. Remove the gear knob and boot assembly. Refer to

Holden PV SIP for procedure.

2. Apply sufficient urethane or silicon based adhesive*

to fill the slot in the top of the lever (see figure 3).

3. Refit gear knob and boot assembly. Ensure the

teeth at the end of the inner plastic core anchor over

the lip at the base of the lever to prevent the gear knob

from lifting off.

4. Allow enough time for the adhesive to cure.

Note: The customer should be advised not to apply

excessive force to the knob until full strength bonding

is achieved in about 24 hours.

* Adhesive Details

- Urethane adhesive p/n 92143609 can be

purchased from HSPO.

- Loctite “BlackMax 5900” and Dow Corning 735 may

be purchased from most bearing suppliers or

engineering products retail outlets.

Figure 2. Internal rib inside inner core of gear knob

Figure 3. Fill slot in top of lever with adhesive.

WARRANTY CLAIM INFORMATION

Description Gear shift lever knob – R & R

Labour Op. No. K101100

Time 0.3 hr

Failure Code N0027 Loose

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JULY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Repairs - Console and Phone Storage

Compartments

VY, VZ, WK WL Series

Group 1 Ref. No. TL0942 - 0506

Many console and phone storage compartment

assemblies are being replaced under warranty when

they could have been repaired.

Dealer service technicians should be aware that

replacement components are available to rectify some

failures within the console and phone storage

compartments.

IMPORTANT: Warranty claims may not be accepted

when compartment assemblies are replaced instead of

repairing.

The following repair procedures have been published

in Techlines.

1. Front and Rear Console Storage Compartment –

Door Latch Replacement – Nov 04, Issue 10 –

Page 9.

This techline should be completed when the lever arm

is broken or when the compartment will not close

due to insufficient interference in the lever pivot. If

the lever arm falls under its own weight, when the lever

pivot is fitted to the compartment, only the lever arm

should be replaced.

2. Phone Storage Compartment Lid Won’t Open –

Dec 04, Issue 11 – Page 13.

The new link arm should be fitted to both sides of the

phone storage compartment when required to rectify

the reported concern.

INFORMATION

Using The Internet To Obtain Warranty

Exchange Axle Units From Dana

V & W

Group 4 Ref. No. TL0640A - 0506

This Techline supersedes the previous one in Issue 2,

March, 2004. It is re-issued to highlight the

requirement to use Internet communications with

DANA and NOT fax.

Warranty axle exchange requests are to be provided to

Dana via their internet website rather than by the

previously used fax method. The fax method is still

being employed by many Dealer Service departments.

Using the fax method results in slower processing and

supply of exchange axle assemblies because of the

necessary multiple handling of fax sheets, transferring

to a computerised database, plus the necessity to reply

by fax (not always reliable).

Using the website allows Dealer personnel to track

their current Dealer requests plus a log of the “previous

50” requests.

Dana Automotive Systems Group is Holdens supplier

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

production, 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.

Information on the use of the Dana Website have been

published in Dealer Letters DL 54/01 & RL 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 and advice on access to exchange axle

assemblies via the Dana website are shown in

Passenger SIP.

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JULY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

A/T Shift Pattern / Sports Mode Concerns

AH Astra

Group 7B Ref. No. TL0934A - 0506

This Techline supersedes the previous one, TL0934-

0505. It is revised by adding the note on selecting

“Country of Registration.” during SPS programming.

CONDITION

Some customers may complain of poor performance,

cabin booms in normal driving mode, and/or holding

gears until redline when in sports mode.

CORRECTION – Service

If a customer complains about the above described

conditions, reprogram the Transmission Electronic

Control Unit via the standard Service Programming

System (SPS) method using TIS 2000, CD 61 or later.

IMPORTANT: During SPS programming, the Country

Of Registration must be set to Australia. If this is left as

“Other” an error message will advise that the vehicle

currently has the latest calibration.

The latest transmission calibration installed off TIS

2000 CD 61 (or later) has the following revisions:

'Normal' driving mode - Revision in shift points and

lock up points for torque converter (occurring slightly

later in RPM range compared to current production

calibration). This improves performance feel, where

engine won't labour, and also reduces cabin booms.

'Sports' driving mode - Revision in shift points, where

auto transmission won't hold in gears until redline.

Improved Calibration Details:

Opel Part No. 55560969 Software Version No. 1010.

To identifiy vehicles that have had the above

procedure performed, apply a service history label on

the the inner left side of the glovebox door and mark

the coordinate “A-2” with a ball point pen to indent the

foil sticker. Refer following figure.

CORRECTION – Production

Breakpoint details will be published when this occurs.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

DIAGNOSIS HINT

Squeak From Steering Gear Input Shaft

VY, VZ, WK & WL

Group 9 Ref. No. TL0945- 0506

CONDITION

Squeak appearing to come from the region of the input

shaft of the steering gear.

One possible cause for this squeak has been identified

as insufficient lubrication of the dust boot.

SERVICE RECOMMENDATION

When attempting to diagnose/rectify the above

complaint, it is recommended to lubricate around the

top lip of the dust boot with a product such as Dow

Corning 200 fluid 30000 CST, or other equivalent

silicone based lubricant.

SERVICE FIX

Soft Tonneau Cover Pull Tabs Break

VY, VZ Utility and Crewman

Group 1 Ref. No. TL0916 - 0506

CONDITION

The tonneau cover pull tabs break in service.

CORRECTION – Service

The tonneau cover should be repaired by replacing the

pull tabs. This will require subletting to an auto

trimmer. The repair instructions are shown on the next

page.

WARRANTY CLAIM INFORMATION

Description R & R soft tonneau cover

Labour Op. No. R407200

Time 0.3 hr

Failure Code R0001 Broken

The sublet cost is to be entered in the relevant area of

the warranty claim. Use Sublet Type EX (external trim)

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JULY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Soft Tonneau Cover Tab Repair Procedure

Tab Material.

The recommended tab material is “Tarpol TS” which can

be purchased from RADINS phone (03) 9587 5600. This

material is a heavy duty, PVC coated, tear stop fabric

from a woven, high tenacity polyester cloth. When

ordered the material must be black in colour and the mat

surface finish exposed.

Step 1

Cut recommended material to dimensions specified

below.

Step 4

Fold and insert new pull tab under plastic extrusion

and through slot. Ensure mat surface finish is

exposed.

Step 2

Carefully unstitch the thread away from the plastic

extrusion (approx 50mm).

Step 5.

Pull tab through slot.

Step 3

Fold and insert new pull tab under plastic extrusion and

through slot. Ensure mat surface finish is exposed.

Step 6

Re stitch Pull Tab through existing thread holes of

plastic extrusion in order to maintain strength.

Slot

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JULY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FI

EGR Malfunction, DTC P0400 Sets

XC Combo (Z16SE Engine) Model Years 2003

& 2004 Only

Group 6C Ref. No. TL0941- 0506

CONDITION

Drivers may complain of engine running ‘rough’ and/or

may stall at times during this ‘rough running’ period,

and engine check lamp illuminates.

Technicians may find a DTC P0400 set.

CAUSE

Deposits of contaminants built up between the EGR

pintle and its guide causing the pintle to seize.

CORRECTION – Service

Summary: On complaint vehicles ensure EGR valve is

fully closed before disabling its operation with revised

engine management software.

If diagnosis of driveability complaints leads to an EGR

malfunction and DTC P0400 is logged, perform the

following steps:

Step 1. Check position of the EGR Valve.

The position of the EGR valve can be found by

performing the 'Actuator test' with TECH 2, selected as

follows:

Diagnostics,

Model Year,

Vehicle Type,

Engine,

Actuator test,

EGR Solenoid test,

EGR position Feedback.

(1a). If the EGR position feedback is between 0.15V

and 1.5V after performing the test (Test Status:

Inactive) the EGR valve is closed - Go to Step 2.

(1b). If the EGR position feedback is higher than

1.5V after performing the actuator test (Test Status:

Inactive) the EGR valve is not completely closed and

should be replaced with a new one from HSPO.

Perform the actuator test again when the new

valve is installed to ensure the valve closes fully.

Once confirmed, proceed to step 2.

Step 2. Reprogram ECU.

Reprogram the ECU with modified software,

available from TIS CD 61 and onward, to deactivate

the EGR function.

Note: two ECU hardware numbers exist for the

vehicle - the correct hardware number and revised

ECU software part numbers are listed below.

ECU Hardware

Number

Service ECU

Part No.

EGR Disable

ECU Software

Part No.

DEL 0115351289 9391340 12 214 840.7

DEL 0115214590 12214810 12 237 460.6

Step 3. Vehicle Marking

All vehicles that are modified according to the above

information are required to be clearly marked by a

yellow paint dot on the upper side of the EGR valve

housing. This will alert service technicians that the

engine management system has been revised and

the EGR is disabled.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

Update

HOLDEN SERVICE TECHLINE __________________________________________________________________________________JULY, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Explanation of Driveline “Clunk” or “Backlash

Noise”

All Rear Drive Vehicles

Group 4 Ref. No. TL0956 - 0506

Some owners of rear wheel drive vehicles may

comment that the vehicle exhibits a “clunk” noise while

driving when the accelerator is depressed and then

released.

Similarly, owners of vehicles equipped with either

manual or auto transmissions may comment that the

vehicle exhibits a “clunk” noise when shifting between

Park & Drive, Park & Reverse or Drive & Reverse.

Whenever two or more gears interact with one another,

there must be a certain amount of clearance between

those gears in order for the gears to operate properly.

This clearance or freeplay (backlash) can translate into

a clunk noise whenever the gear is loaded and

unloaded quickly, or whenever the direction of rotation

is reversed.

The more gears/components you have in a system, the

more freeplay the total system will have.

The clunk noise that owners sometimes hear may be

the result of a stackup of freeplay (backlash) between

the components in the driveline.

For example: The potential for a driveline clunk would

be greater in a 4WD or AWD vehicle than in a 2WD

vehicle.

This is because in addition to the freeplay from the rear

axle gears, the drive shaft joints, and the transmission

(common to all vehicle types), the 4WD transfer case

and front drive shaft/s (and their associated

clearances) add additional freeplay to the driveline.

In service, dealers are discouraged from attempting to

repair driveline clunk conditions for the following

reasons:

• Driveline clunk is almost never the result of one

individual component with excessive freeplay, but

rather the result of the cumulative effect of

freeplay (backlash/lash) that is present in all of the

driveline components.

Because all of the components in the driveline

have a certain amount of freeplay (backlash) by

design, changing driveline components may not

result in a satisfactory freeplay (or driveline clunk)

reduction.

• While some owners may find the clunk noise

objectionable, this will not adversely affect the

durability or performance of the vehicle or its

components.

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Check Engine Light Illuminates and the PCM

Sets DTC P1626 until key is cycled

VY AWD

Group 12 Ref. No. TL0927- 0507

CONDITION

Customers may advise that intermittently the check

engine light illuminates and when the ignition is cycled

it goes out.

When DTC’s are checked with Tech 2, a history DTC

P1626 may be found in the PCM.

CAUSE

A weakness in PIM software caused intermittent loss

of communication between the PIM and the PCM.

CORRECTION – Service

After verifying that vehicle has the condition described

above, fit the revised PIM following the standard SIP

procedure.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92184712 Powertrain Interface Module

(PIM)

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

DIAGNOSIS HINT

Headlamps Intermittently Don’t Switch Off

Automatically After Leaving The Vehicle

VY, V2II & III, VZ, WK, WL

Group 12 Ref. No. TL0969-0507

Customers may report that occasionally the headlights

don’t switch off automatically after they leave the

vehicle.

When investigating this complaint, dealers need to

ensure the door light switch in the drivers side A pillar

is correctly grounding to the body through the screw

and switch base and the BCM is receiving the door

light switch input.

If no obvious fault can be found, the customer needs to

be questioned about when the problem occurs.

If the customer is switching the ignition key off prior to

the vehicle being stationary, the headlights will not

turn off automatically (i.e. coasting to a stop or rapid

parking, key off combination).

Customers need to be made aware this feature is

designed into the vehicle for their safety to ensure the

headlights don’t turn off while they are driving in the

event of a fault within the vehicle.

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

TIS 2000 Fails Update/Installation Procedure

All

Group: OB Ref. No.: TL0964 - 0507

The purpose of this Techline is to advise Dealers of

possible causes for TIS 2000 failing to update or install

due to the CD data not being read by the CD Drive.

Upon investigations carried out at Holden Dealerships

it has been found that the main causes for this are:

Faulty or Dirty CD-ROM.

For cases where a dirty CD is thought to be the

problem, cleaning the CD will usually correct the error.

CD-ROM cleaning kits are available through retail

outlets such as office suppliers and computer stores.

In cases where the CD shows visible sign of damage

or, after cleaning it still fails to update or install, a

replacement CD will be required.

Note: If a replacement TIS 2000 CD is required,

contact Andrew Janson on (03) 9647 7632 at Holden

Aftersales Service.

Faulty or dirty hardware (CD Drive).

For cases where faulty or dirty hardware is thought to

be the problem, trying the CD in another CD drive is a

good way of confirming if the original CD drive is at

fault. If the suspect CD is placed in another drive and

works successfully, this is a clear indication that the

original CD drive is faulty or dirty.

Note: Typical Service Department environments are

very harsh on computers. With this in mind, when

faulty or dirty hardware is thought to be the cause, it

would be advisable to use a computer that is kept in a

less harsh environment (less dust), or use a computer

that has had a new CD Drive recently installed.

If the CD Drive is found to be faulty, it is strongly

recommended that a CD/DVD reader be purchased as

a replacement, as TIS 2000 will be delivered only on

DVD media from the beginning of 2006. For more

information regarding TIS 2000 on DVD, refer to All

Dealer Letter 25/05.

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

TAS Vehicle Call Groups

Group OB Ref. No. TL0963 - 0507

TAS receive many calls where the caller has selected the incorrect group on the phone system for the vehicle model

they are enquiring about. Please refer to the following dialling options (numbers) when navigating through the TAS

phone system.

Introductory Message

HOLDEN dial 1 SAAB dial 2

Bulletin Board

- dial 1

LCV & Daewoo vehicles

- dial 2

• Jackaroo

• Frontera

• Cruze

• Rodeo

• ALL DAEWOO

badged vehicles.

Holden Passenger vehicles

- dial 3

• Commodore / sedan /

wagon / ute / 1 tonner /

crewman / AWD

• Statesman, Caprice

• Monaro

• Zafira

• Astra

• Vectra

• Barina

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

Euro 3 Exhaust System Fitted to VZ AWD

175kw Engine

VZ AWD Models with Alloytec 175 Kw engine

Group 6C Ref. No. TL0959-0507

From the start of production of the above models, the

HFV6 175 kw engines have been upgraded to Euro 3

fuel and exhaust system which means they now have

four O2 sensors. i.e. 2 before and 2 after the catalytic

converter.

This now makes engine fault diagnosis the same as for

the 190 kw engine for O2 sensor diagnostics only.

INFORMATION

“Service Vehicle Soon” Displayed In

Instrument Cluster

VZ and WL

(GROUP OB) TL0972-0507

TAS has received several calls where Dealers advise

that the instrument cluster displays “Service Vehicle

Soon”. It appears that some Dealers believe it to be a

service reminder or are unsure what it means and

therefore call TAS.

“Service Vehicle Soon” does not mean that the vehicle

is due for its scheduled service, but rather that the

engine ECU has logged a Diagnostic Trouble Code

(DTC).

If this is displayed check for DTC’s and follow the

normal diagnostic procedure laid out in SIP.

The following is taken from SIP relating to the service

vehicle soon message. Please ensure that all such

information is checked prior to calling TAS.

Service Vehicle Soon – Non Emissions Related Fault

The Service Vehicle Soon message is displayed if the ECM

or the PCM (for V8) has detected an engine fault. It appears

as a large warning symbol.

A chime sounds with this warning.

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

Front Control Arm Rod Hydraulic Bush Fault

Diagnosis.

VZ, WL

Group 3 Ref. No. TL0965- 0507

CONDITION

Vehicle has one or more of the following symptoms.

1. Front end knocking under brakes.

2. Vehicle veering.

3. Abnormal tyre wear.

CAUSE

A possible cause for the above conditions is the front

control arm rod hydraulic bush is incorrectly

assembled or has components missing.

CORRECTION

Check bush for any of the conditions shown in

diagrams below. Replace any faulty bushes.

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

Knock From Underneath Vehicle

VZ AWD HFV6 Cab Chassis

Group 8 Ref. No. TL0939 - 0507

CONDITION

Audible knock from underneath vehicle usually on

rough road surfaces or on flat road under high engine

torque.

POSSIBLE CAUSE

Exhaust pipe contacting transmission cross member

due to insufficient clearance.

SUGGESTED CORRECTION

On any vehicle where the exhaust pipe is suspected of

contacting the transmission cross member, try the

following procedure.

1. Loosen the front exhaust pipe to manifold flange

joints and the four exhaust transmission brace

bolts.

2. Place a 20mm chock between the right hand pipe

and transmission cross member. Refer figure 1.

3. Torque up the four front pipe to manifold flange

joints and exhaust brace bolts. Refer PV SIP

instructions.

4. Remove the chock used in step 2.

5. The result should be a 15mm clearance between

both LH and RH exhaust front pipes to cross

member.

Figure 1. Place 20mm chock at location of red arrow

SERVICE FIX

“Soft” Clutch Pedal or Cruise Control

“Drop-out”

ZC, 4 Cyl, M/T

Group 7A Ref. No. TL0960- 0507

CONDITION

Cruise control may intermittently NOT set

intermittently ‘drop out’,

the clutch pedal may feel ‘soft’.

CAUSE

Clutch pedal return spring broken.

CORRECTION

Summary: Replace clutch pedal return spring, NOT

the pedal box assembly.

Note: Previously this breakage necessitated replacing

the whole pedal box - but a clutch pedal return spring

has now been made available to reduce the

complexity/cost of repairs and minimise the

disturbance to the vehicle.

When a clutch pedal return spring breakage is

confirmed - replace only the broken spring as per

service procedures in TIS under clutch pedal

replacement.

Do not replace the pedal (box) assembly.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

93183937 Spring - Clutch Pedal 1

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD (SUP Section).

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Rear Axle “Cyclic Knock” .

All V & W with IRS (non LSD)

Group 4 Ref. No. TL0602B- 0507

This Techline supercedes the previous one in Issue 2,

Feb., 2005. It is revised by removing breakpoint

information and upgrading the correction procedure.

CONDITION

Cyclic knock noise may occur when coasting or on

light throttle in speed range between 40-70km/hr while

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 (circlip) and clearance of the inner

axle shaft (splines) within the differential.

Condition affects V & W models with IRS (non LSD).

CORRECTION

After verifying that vehicle has symptoms as described

above, proceed as follows: THIS PROCEDURE WILL

REQUIRE THE VEHICLE TO BE IMMOBILISED

AFTER THE REPAIR FOR AT LEAST SIX HOURS.

Procedure.

1. Contact Dana via their website to register a case

of “cyclic knock”.

Once case is approved, Dana will send a set of

differential inner-axle assemblies with “upper

spec. spline” and reduced clearance circlip

grooves for the complaint vehicle.

2. Remove LHS and RHS driveshafts.

NOTE: mark the inner CV joints of both driveshafts

before completely removing from the vehicle.

(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. If the shafts supplied by Dana do not come with

circlips installed, then Install new circlips p/n

92140242.

5. Clean all traces of oil from splines of the new

shafts and from the matching splines in the

differential. Follow the pre-application cleaning

instructions provided on the Loctite 609 package.

6. Apply Loctite 609 to the splines on the shafts

before assembling the new shafts into the

differential.

7. NOTE: Do NOT start the engine, move the

differential shafts, or install the driveshafts

- Allow Loctite to cure for 6 hours minimum

before proceeding.

8. At the end of the six hour minimum

immobilisation time - Reverse both driveshafts

before reinstalling. (This means: reinstalling

driveshafts with the original inner CV joint now on

the outer end).

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92140242 Ring - Rear Axle Shaft

Retainer (circlip)

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 _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

TIS 2000 Vehicle Related Diagnostic

Procedure (Finding DTC’s & Code Index’)

MODEL: ZC Vectra & AH Astra

(GROUP OB) TL0973-0507

SERVICE INFORMATION

Due to the introduction of the multiple CAN-BUS

system now used on ZC Vectra and AH Astra the use

of Tech 2 and TIS 2000 diagnostic procedure has

changed as result of this. Locating diagnostic trouble

codes (DTCs) and programming code indexes within

TIS 2000 has also changed because of this.

A new “Vehicle Related Diagnostic Procedure” must

now be followed.

For a more detailed explanation of the entire new

diagnostic procedure refer to Technicians Guild No.6

2003.(Highly recommended)

PROCEDURE

When using Tech2 on AH and ZC, before checking for

DTC’s an ECU presence check must always be

performed first. Refer figures 1 & 2

Figure 1

Figure 2

After successfully completing an ECU presence check,

the next step is checking for DTC’s; select F1 “Vehicle

DTC Information. Refer figure 2.

Any diagnostic trouble codes stored now belong to

“functional groups”, and the additional information

displayed on Tech 2 along with the DTC number is

vital for locating the relevant procedure in TIS 2000.

Refer figure 3 for an example of a stored DTC.

This DTC B3913 is rear window lifter enable circuit

high current, although it is reported by the Body

Control Module (BCM), the DTC belongs to the

functional group known as “Windows”, and it is this

functional group that must be referred to in TIS.

Tech 2 Display

Figure 3

To locate this DTC in TIS 2000 select “Vehicle” then

“Vehicle Related Diagnostic Procedure” from the

Electronic System Selection menu in Checking

Procedures. Refer figure 4. Selecting systems such as

Engine, Drive Train, Chassis or Body as previously

done on earlier Opel vehicles to obtain the DTC

procedure can no longer be performed this way for

AH and ZC.

Figure 4

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Next, select the desired diagnostic mode:

“Guided Electronic System Diagnosis” refer figure 5.

Figure 5

Displayed next is the new Diagnostic System Check

menu. Refer figure 6

This entire diagnostic process must be followed from

start to finish, starting with preliminary measures, then

the diagnostic system check, finishing with the system

end test.

New Diagnostic System Menu

Figure 6

To locate the DTC B3913 reported by the functional

group known as windows, select Table B-007 Vehicle

wide Trouble Codes, refer figure 6. Then find the

functional group of windows located with the list of

functional groups refer figures 7 & 8. Displayed here is

a list of all the groups, starting with Vehicle, Engine

Controls, Transmission/Transaxle, Anti lock Brakes

etc.

Figure 7

Figure 8

Functional Groups Continued

Functional Groups

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

LOCATING PROGRAMMING CODE INDEX

To locate Programming Code Indexes, from the same

diagnostic system check menu, refer figure 6, select

“Table B-004 Programming Code Index”,

Displayed next is a list of all the electronic modules and

the Tech 2 menu they belong to. Refer figure 9

Code Index Numbers

Figure 9

DIAGNOSIS HINT

No Tech 2 Communication with 4 cyl Z22SE

Engine ECU

TS Astra, Zafira

(GROUP OB) TL0974-0507

PROBLEM DESCRIPTION

Tech 2 will not communicate with 2.2 Litre Z22SE

engine ECU fitted to Astra and Zafira using Tech 2

software 14.200 from TIS 2000 Cd 62.

CORRECTION

Revised Tech 2 software to rectify this will be released

on TIS Cd 63 scheduled for release in August 2005.

SERVICE RECTIFICATION

To communicate with Z22SE engine ECU, install Tech

2 software version 14.103 by selecting the custom

download option in TIS 2000.

NOTE: once diagnosis is completed ensure Tech 2 is

reloaded with software 14.200 again.

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

TPMS Module Unable To Detect One Or Both

Front Tyre Pressures & Sets DTC 9 or 10

WL Caprice, HSV Grange

Group 12 Ref. No. TL0970- 0507

CONDITION

Customers may advise they intermittently receive

warnings in their instrument cluster MFD (multi function

display) reporting no pressure reading from one or

both front tyres.

DTC 9 Front Left Pressure Sensor Circuit Range /

Performance and DTC 10 Front Right Pressure Sensor

Circuit Range / Performance may also set in the TPMS

module.

CAUSE

Reception limitation due to the location of the TPMS

module.

CORRECTION – Production

Vehicles in production have had the TPMS module

moved to a location which has better reception from

the following breakpoint.

ISOVIN: Built Date:

**********L473538 12/07/05

CORRECTION – Service

1. Remove the Rear Window Trim Panel Assembly

following the instructions in PV SIP section 1A8

Headlining and Interior Trim / 2.11 Rear Window

Trim Panel Assembly .

2. Remove the TPMS module from its bracket,

remove the two white harness securing clips which

locate the rear window panel insulator and remove

the rear window panel insulator (refer figure 1 & 2).

Figure 1

Figure 2

3. Using figure 7 (diagram located at the end of this

article) as a reference measure and cut out the two

holes required to mount the TPMS module on the

rear window panel insulator.

Note: Module alignment is critical.

4. Attach flocking tape part number 92145740 (or

equivalent) to the end of the module as per figure 3.

Figure 3

5. Secure the TPMS module to the rear window panel

insulator using cable tie part number 92138082.

Trim the excess length from the cable tie once the

module is secure (as per the figure 4).

Figure 4

White Harness Clips

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

6. Turn the insulator over and attach flocking tape (or

equivalent) to the exposed cable tie (as per figure 5).

Figure 5

7. Reinstall and reconnect the rear window panel

insulator and module (as per figure 6).

Figure 6

8. Reconnect & Reassemble the vehicle as per PV

SIP section 1A8 Headlining and Interior Trim / 2.11

Rear Window Trim Panel Assembly.

9. Road test to ensure the vehicle has no rattles and

squeaks, check the rear park assist functions and

that the tyre pressures are being displayed in the

MFD of the instrument cluster.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92138082 Cable Tie 1

92145740 Flocking tape 1 roll per

dealership*

* Note: The flocking tape part number is for an 11

metre roll of tape. Approx 200mm is required for each

vehicle.

WARRANTY CLAIM INFORMATION

Description Relocate TPMS module

Labour Op. No. N000487

Time 0.5 hr

Failure Code NOW N0057

HOLDEN SERVICE TECHLINE _______________________________________________________________________________AUGUST, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the proper service fix of a vehicle. If a condition is described, do not assume

the service fix applies to a vehicle or that the vehicle will have that condition.

Figure 7

Module Locating Reference

Cut cable tie holes here

New Module Location

← 195mm →

← 152mm →

↕ 38mm

↕ 60mm

Old Module Location

White harness clip

Not drawn to scale

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Dust Entry Into Tail Lamps

VY,VZ Crewman

Group 12 Ref. No. TL0946 - 0508

CONDITION

Dust and bugs may enter the tail lamp through the vent

hole in rear of lamp.

CAUSE

Inadequate sealing .

CORRECTION – Production

Rear lamps with dust shields have been fitted to

vehicles from:

ISOVIN: Built Date:

**********L486157 10/8/05

CORRECTION – Service

Install dust shields to both sides as follows.

1. Remove inspection cover from inside the rear tub.

2. Remove foam filled plastic bag.

3. Remove the two inboard (closest to centre of

vehicle) tail lamp retaining nuts.

4. Disconnect the wiring harness.

5. Install the dust shield into position ensuring the

wiring harness is pulled through the centre of the

dust shield.

6. Refit the two retaining nuts.

7. Reconnect the tail lamp wiring harness.

8. Reinstall foam filled plastic bag

9. Reinstall inspection cover.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92179296 Dust shield RH 1

92179297 Dust shield LH 1

WARRANTY CLAIM INFORMATION

Description Install Dust shields Both

sides

Labour Op. No. N000490

Time 0.4 hr

Failure Code N0012 Foreign material

Figure 1. Cutaway view showing LHS lamp without

dust shield.

Figure 2. Cutaway view showing LHS lamp with dust

shield installed

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Starter Motor Engagement Problems

VZ, WL with Gen III engine

Group 12 Ref. No. TL0926 - 0508

CONDITION

Customers may advise of intermittent starter motor

engagement or starter motor “machine gunning” similar

to the vehicle having a flat battery.

CAUSE

This condition may be caused by Electrical Static

Discharge (ESD) damaging the PIM.

CORRECTION – Production

A revised PIM with increased ESD protection has been

fitted to vehicles from:

CORRECTION – Service

If this problem is intermittent it may be difficult to

reproduce, discuss the symptom with the customer to

ensure the problem was not caused by low battery

charge then replace the PIM with the revised part.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92184307 Powertrain Interface Module 1

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

ESP Early intervention

VZ & WL with ESP

Group 5 Ref. No. TL0944A - 0508

This Techline supercedes the previous one (TL0944-

0506) in Issue 6, July, 2005. It is revised by the

addition of a 15 min. drive to reinitialise the ABS

module.

CONDITION

Customer complains that the ESP is activating

unnecessarily. A buzz from the ABS module is heard

during this event.

CAUSE

The above condition may be caused by incorrect

centralisation of the steering gear where the SAS

(Steering Angle Sensor) is calibrated to this “off

central” point.

NOTE. When investigating this condition the service

technician will need to determine if the customer

complaint is a normal or an abnormal ESP event. For

information which may help to determine this, refer to

Techline No.TL0980-0508 in Issue 8, 2005.

RECOMMENDED ACTION

Summary: Centralise the steering gear, adjust toe and

steering wheel to new central point and recalibrate the

steering angle sensor (SAS). The relevant procedures

are as follows.

1. Verify the position of the steering gear using tech 2. In

the ABS data list monitor the SAS position from the

zero (0°) position. With the engine idling turn the

steering wheel to lock one side and note the reading

(The steering wheel will have to be turned very firmly

against the rack lock stop to get the maximum travel

reading) . Turn the wheel back to centre (0°) and now

turn wheel to lock in the other direction and note the

reading. The difference from side to side can be no

more than 8°. Total travel from lock to lock should add

up to approximately 1000°. Note the total travel

reading that can consistently be achieved.

2. If the reading difference from side to side is greater

than 8°, proceed to locate the steering gear central

point and recalibrate the SAS as follows.

3. Centralise the steering gear position. This can be

done with tech 2, once again monitoring the SAS

reading. Using the above noted total travel reading

divide this by 2, and this will be the central point from

lock either side of travel.

4. Turn the wheel to lock on one side, note the SAS

reading, turn the steering back towards centre by the

amount determined in step 3. This now should be the

central position of the steering rack. Confirm by turning

the wheel to the opposite lock and check that there is

an equal amount of travel in each direction.

5. The toe will now have to be adjusted around this

central rack position.

6. The steering wheel will also have to be moved to suit

this central rack position.

7. The steering angle sensor will need to be recalibrated

so that the central rack position is set to 0°. Refer to

procedure in PV SIP.

8. FINALLY, the vehicle will need to be driven on the

road for approximately 15 minutes to reinitialise the

ABS module.

INFORMATION

Electronic Stability Program (ESP) Operation

VZ & WL with ESP

Group 5 Ref. No. TL0980 - 0508

CONDITION

Customer reports a loud buzz from under the bonnet

on corners at medium to low speed.

CAUSE

The above condition is normal operation of the ABS

module during an ESP event.

SERVICE RECOMMENDATION

To relieve any customer concern about the noise we

suggest you verify that the steering gear is centralised

as per Service Techline TL0944A-0805 in Issue 8,

2005. After verifying this, and the condition still exists,

explain to the customer that during an ESP event the

ABS module will cycle and a buzz can be heard.

This should be explained in conjunction with reference

to the information on ESP in the owners handbook.

ESP can intervene during a wide range of conditions. It

is not limited to high speed wet conditions and while

the customer may consider it not necessary, it is doing

its job as per design intent.

Confirmation of normal operation by comparing the

customers vehicle to another must be done with a

vehicle of the same level. i.e Acclaim compared with

Acclaim. This is due to the calibration being different

for each level vehicle where Acclaim is different to

Calais and different again to Statesman.

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

DTC’s P0700, P0715, P0720

ZC with A/T

Group 7B Ref. No. TL0737A - 0508

This Techline supercedes TL0737- 0501 published in

Issue 1, Feb. 2005. Please cross out all copies of

that techline.

CONDITION

Customer may complain of “no shifting” or “incorrect

shifting” of transmission ratios.

One or all of the following DTC’s may be stored:

P0700, P0715 or P0720

CAUSE

There are 2 possible causes for the above condition.

1. Moisture may have entered the speed sensor

connector, causing an incorrect or interrupted signal.

2. Coolant may have entered the transmission via the

radiator oil cooler

CORRECTION – Production

1. Protective grease applied to speed sensors from:

Trans. Serial No.: Built Date:

03MV735125 06/01/04

2. Radiators with revised oil cooler sealing were

introduced into vehicle production from:

ISOVIN: Built Date:

Ellesmere Port:

W0L0ZCF6848035197

not available

Russelsheim

W0L0ZCF3541042598

not available

CORRECTION – Service

1. Disconnect the speed sensor connector and dry

out any moisture present.

2. If there is no evidence of corrosion or damage to

terminals apply grease p/n 09163339 to connector

to stop future moisture entry.

3. If corrosion or damage is evident, replace the

sensor and/or connector as required. Also apply

grease 09163339 to connector to stop future

moisture entry.

4. Remove transmission valve body cover

CAREFULLY and inspect for possible coolant

entry to transmission via the radiator oil cooler. If

there is evidence of moisture contamination,

proceed to step 5. If there is no evidence of

moisture contamination, no further action is

required.

5. If the vehicle ISOVIN is prior to those shown in the

Production Correction table, replace the radiator.

If ISOVIN is after those shown, pressure check

radiator. If radiator fails pressure test, replace

radiator then go to step 6. If radiator passes

pressure test, proceed to step 7.

6. Flush the transmission to remove traces of

water/coolant contamination. The transmission

can be flushed using a commercial flushing unit or

as follows.

Disconnect the transmission to radiator oil cooler

line and drain into a suitable container. With

engine idling and A/T in Neutral, flush approx 10 to

12 litres of the specified trans. fluid through the

transmission. After flushing, reconnect cooler line

and check fluid level is correct.

7. Check the routing of the transmission breather

hose. The breather hose outlet must not be

located in the plastic gutter that drains A/C

condensate. Refer Figure 1.

Figure1 – Breather hose incorrectly located.

8. Relocate the breather hose so that it is clear of the

drain channel as shown in Figure 2. Secure hose

to conduit with tie straps as required.

Figure 2. Relocated A/T breather hose

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

PARTS INFORMATION

Part No. Description Qty

09163339 Grease. NYOGEL 760G -

25 gm tube

93173888 speed sensor 1

93160393 Automatic transmission oil

1 litre (Esso ATF 3309)

WARRANTY CLAIM INFORMATION

Refer to your District Aftersales Manager.

DIAGNOSIS HINT

DTC P0704 Clutch Switch Input High

AH, TS, XC, JS, Fitted with M/T

Group 7A Ref. No. TL0990 - 0508

PROBLEM DESCRIPTION

Customers may advise that intermittently the check

engine light illuminates and after the ignition is cycled

the light goes out.

Initial checks reveal the only DTC that may be set is a

history P0704 (Clutch Switch Input High).

If, after checking the clutch switch circuit and switch

operation including adjustment as per TIS 2000, no

fault is found, the problem is probably induced by the

driver.

CAUSE

The driver may be accelerating up through the gears

and then decelerating again without completely lifting

their foot off the clutch, meaning the ECU does not see

the “clutch status” input change as the vehicle

accelerates, (This can be seen with Tech 2 in ECU

data).

DTC P0704 sets when the ECU sees the vehicle

accelerate to above approximately 57km/h then come

to a stop several times without the clutch switch input

changing. This is most likely to happen in heavy traffic

together with the driver resting their foot on the clutch.

CORRECTION

After verifying that clutch switch operation and

adjustment is correct, customers need to be made

aware that their driving habit is the likely factor for

inducing this fault.

Do not replace engine ECU’s and/or clutch

switches for this condition.

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Excessive Engine Oil Consumption Due To

Faulty Cylinder Head Cover (Plastic Type)

ZC, TS, TT, all with Z22SE engine

Group 6A Ref. No. TL0807A - 0508

This Techline supercedes TL0807-0504 published in

Issue 4, May, 2005. It is revised by clarifying

replacement requirements - as some technicians are

incorrectly replacing cam covers that have no defect.

CONDITION

Some customers may report that their vehicle exhibits

the following symptoms;

1) Blue smoke coming from the exhaust and/or

2) High oil consumption

CAUSE

Positive crankcase ventilation passages within the

plastic cylinder head cover may not be to specification.

NOTE: The metal cylinder head covers are not

affected.

CORRECTION – Service

1. Confirm the customer complaint by conducting

a standard oil consumption test.

2. If vehicle has high oil consumption, proceed to

check the cylinder head cover for a possible

manufacturing fault described as follows.

3. Remove the cylinder head cover and inspect the

underside of the cover. A faulty cover can be identified

by a “sink” mark which is clearly evident as shown in

Figure 1.

4. A faulty cover should be replaced with a new

cover from HSPO. (If cover is not faulty contact TAS

for further advice). For removal and replacement

procedure refer to TIS 2000.

CORRECTION – Production

Known OK covers have been fitted to all vehicles from:

ISOVIN:

ZC *********51010110

TT *********4H004812

TS *********5B000136 - Convertible

*********45123695 - SRi excluding turbo

NOTE: All plastic covers in vehicles with lower

ISOVIN’s should be inspected when required, and

only replaced if the defect exists.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

13113034 Cover, cylinder head (plastic)

includes gasket and fasteners

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

NOTE: Cam covers replaced that show no defect

will NOT be accepted under warranty.

Figure 1. A faulty cover will have a sink mark shown at position of yellow arrow

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Drive Belt Squeal, Power Steering Pump

Pulley Misalignment

VZ & WL with HFV6 engine

Group 6A Ref. No. TL0985 - 0508

CONDITION

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.

CAUSE

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.

CORRECTION – Production

Vehicles with power steering pump pulleys installed

to the correct alignment were built from:

ISOVIN: Built Date:

**********L468921 30/06/05

CORRECTION – Service

In the event of the above condition being

experienced, inspect the position of the power

steering pump pulley on the power steering pump

shaft.

Correct location is for the hub of the pulley to be flush

with the end of the pump shaft within 0.3 mm.

If the face of the pulley hub is found to overhang the

end of the pulley shaft by greater than 0.3 mm

(.012”), the pulley should be pressed further on to the

shaft so that the face of the pulley hub is flush with

the end of the pump shaft.

The procedure to be used is shown in Holden SIP,

Chapter 9 - Steering, Section 3.12,. which is

reproduced below.

NOTE. The final test as to whether the pulley is

located correctly is to use a straight edge to check

the alignment of the drive belt pulleys. This

procedure was published in techline in Issue 5, 2001

- Group 6A titled “Gen 3 V8 ENGINE DRIVE BELT

SQUEAL”.

1 Assemble the drive nut (1) and thread insert (2) into

the forcing screw of Tool 7005. Ensure that adequate

graphite grease is applied to the forcing screw and

nut.

2 Tighten the forcing screw assembly by hand onto the

pump shaft (3), until it bottoms out against the

shoulder.

NOTE

Do not use a spanner for this operation.

3 Turn the drive nut against the pulley (4) until the pulley

is at the correct installation depth.

NOTE

Do not allow the forcing screw to turn during this

operation. Do not use power tools or exceed a

torque of 90.0 Nm. If the pulley cannot be

installed within this torque, replace the complete

pump assembly.

4 Once the pulley is installed, remove the forcing screw

from the pump shaft.

5 Install the power steering pump, refer to 3.12 Power

Steering Pump.

Figure 9 – 155

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

EGR Malfunction, DTC P0400 Sets

XC Combo (Z16SE Engine)

Model Years 2003 & 2004 Only

Group 6C Ref. No. TL0941A - 0508

This Techline supercedes TL0941- 0506 published in

Issue 6, JUL 05. Please cross out your copy of that

techline .

CONDITION

Drivers may complain of: engine running ‘rough’ and/or

may in isolated cases stall at very low speeds during

this ‘rough running’ period, and engine check lamp

illuminates.

Technicians may find a DTC P0400 set.

CAUSE

Deposits of contaminants built up between the EGR

pintle and its guide causing the pintle to seize.

CORRECTION

If diagnosis leads to an EGR malfunction and DTC

P0400 is logged, proceed as follows.

MODEL YEAR 2003 VEHICLES.

The service fix action detailed below MUST NOT be

applied to MODEL YEAR 2003 vehicles until TIS CD

64 becomes available.

Until then, if a 2003 vehicle has an EGR

malfunction, replace the EGR valve and reprogram

the engine ECU using TIS CD 51 or earlier to CD

40.

Failure to comply with this may induce problems

with the cooling fans which could cause the engine

to overheat under certain driving conditions.

MODEL YEAR 2004 VEHICLES.

Step 1. - Check position of the EGR Valve.

The position of the EGR valve can be found by

performing the 'Actuator test' with TECH 2, selected as

follows:

Diagnostics,

Model Year,

Vehicle Type,

Engine,

Actuator test,

EGR Solenoid test,

EGR position Feedback.

(1a). If the EGR position feedback is between 0.15V

and 1.5V after performing the test (Test Status:

Inactive) the EGR valve is closed - Go to Step 2.

(1b). If the EGR position feedback is higher than

1.5V after performing the actuator test (Test Status:

Inactive) the EGR valve is not completely closed and

should be replaced with a new one from HSPO.

Perform the actuator test again when the new

valve is installed to ensure the valve closes fully.

Once confirmed, proceed to step 2.

Step 2. - Reprogram ECU.

Reprogram the ECU with modified software,

available from TIS CD 61 and onward, to deactivate

the EGR function.

The correct hardware number and revised ECU

software part numbers are listed below.

Step 3. - Vehicle Marking

All vehicles that are modified according to the above

information are required to be clearly marked by a

yellow paint dot on the upper side of the EGR valve

housing. This will alert service technicians that the

engine management system has been revised and

the EGR is disabled.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

Update

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Engine ECU Cannot Be Linked To Immobiliser

All Holden vehicles with programmable ECU’s

– TS, ZC, AH

Group 6C Ref. No. TL0961- 0508

CONDITION

Dealers report that they cannot link the engine ECU

and the immobiliser after fitting a replacement engine

ECU from spare parts.

CAUSE

To link the immobiliser to a new engine ECU (from

spare parts) the immobiliser must be able to

communicate with the engine calibration. As new

engine ECU’s from spare parts are blank (i.e. they do

not contain any engine information) they cannot be

linked to an immobiliser until they are SPS

programmed.

CORRECTION

A summary of the correct steps in replacing an engine

ECU are as follows.

• Reset the original engine ECU prior to removing.

• Install new ECU.

• Program new ECU with the correct engine

calibration. (use SPS programming)

• Link the ECU and immobiliser.

TS Astra - the linking is done via the immobiliser.

AH & ZC - the linking is done via the engine ECU

Procedure for TS Astra.

1. Obtain the security number.

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 and

proceed as follows.

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.

To link the new ECU to the vehicle proceed as follows:

3. F0 Diagnosis.

4. F3 Body / Immobiliser.

5. F4 Programming

6. F0 Program Immobiliser Function

7. Get programming approval from TIS. Once

approval has been obtained, return to

programming immobiliser function.

8. Enter the correct Engine type

9. Engine controller installed.

10. Perform the CAN and VARIANT configuration,

in ECU programming menu.

11. Follow the remaining Tech 2 instructions.

Procedure for AH Astra and ZC Vectra

1. Obtain the security number.

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

1. F0 Diagnostics

2. Model year

3. Vehicle

4. Engine

5. Type (ie; Z18XE)

6. Programming

7. Reset ECU

3. Remove original ECU and install the new ECU and

proceed as follows.

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.

To link the new ECU to the vehicle proceed as follows:

4. Link the new ECU with Tech 2 as follows:

1. F0 Diagnostics

2. Model year

3. Vehicle

4. Engine

5. Type (ie; Z18XE)

6. Programming

7. Link ECU

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE PROCEDURE

Installation Procedure for USB Super Pro

Hardware Key

TIS 2000

Group OB Ref. No. TL0988-0508

In order for a new USB (universal serial bus)

hardware key (refer figure 1) to work the

appropriate system driver must be installed. This

techline is based on Windows XP but other

systems should be similar although screen shots

and messages may differ.

Figure 1

Unsuccessful Installation

If the dealer has already performed an

unsuccessful installation of the system driver,

please start with Step 8 and check the entry in the

Device Manager. From there, proceed back to

Step 1.

Step 1 - New Installation

Do NOT insert the USB hardware key until

prompted by TIS2000!

To install the system driver in TIS 2000:

• start TIS 2000

• select the ‘Configuration’ menu at top of screen

then ‘Security Device System Driver’

• click on the box for 'Click here to add'

• click on the button ‘Continue’

• follow the instructions in the next two pop-up

windows

You will then see the following pop-up from the

operating system:

Figure 2

Click on the button 'Continue Anyway'.

Step 2

This is the last window in TIS 2000 for the

installation process. In the lower right corner you

can see that Windows XP has found a USB device

'USB Token', but is has not been recognized as

'Rainbow SuperPro' (refer figure 3). Some

operating systems may detect the USB device

correctly as a 'Rainbow SuperPro'. In these cases

no further action is required.

Figure 3

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Step 3

A few seconds after the hardware key has been

connected to the USB port, Windows XP displays

the following window:

Figure 4

• select the button 'Yes, this time only'

• click on the button Next

Step 4

Figure 5

• insert CD 1 of the latest TIS version

• select 'Install the software automatically'

• click on the button Next

• the computer will search for the correct

driver on the TIS CD

Step 5

You will then see the following pop-up from the

operating system:

Figure 6

In contrast to the image at Step 1 the computer has

recognized the hardware 'Rainbow USB SuperPro'.

• click on 'Continue Anyway'

Step 6

While the correct system driver for the SuperPro

USB key is being installed, you will see the

following window: Figure 7.

Figure 7

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Step 7

This is the final window when the installation is

complete:

• click on the button 'Finish'

The set up is now finished.

Figure 8

Step 8

If the dealer has already performed an

unsuccessful system driver installation, remove the

USB hardware key then check the Device

Manager:

To open the Device Manager, click with the right

mouse button on:

• my computer (on the desktop)

• select Properties

• select Hardware

• select Device Manager

The correct entry in the Device Manager of

Windows XP will look like figure 9.

Figure 9

A wrong entry in the Device Manager may look like

this: Figure 10

Figure 10

HOLDEN SERVICE TECHLINE ___________________________________________________________________________SEPTEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Explanation of notes ‘a’ and ‘b’ from Figure 10.

a) Other devices - Unsupported Device or USB

superpro with a question mark ?

-> click on that entry with the right mouse button

and select delete or uninstall

b) USB Token or USB SuperPro with an

exclamation mark !

-> Rainbow SuperPro was not recognized.

-> the installation was not successful.

-> Click on that entry with the right mouse button

and select delete or uninstall.

After deleting the incorrect entries, go to Step 1.

Make sure the USB hardware key is NOT

connected until requested by TIS2000.

July 2005

HOLDEN SERVICE TECHLINE ___________________________________________________________________________OCTOBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Radio Stays On After Ignition/Acc Turned Off

(Ignition Key Removed)

AH, ZC, XC fitted with Blaupunkt CDC30 &

CDC40 Audio Units

(GROUP 12) TL0917-0509

CONDITION

Customers may report that their radio stays on after

the ignition is turned off and the key is removed, or the

radio can only be turned off via the on/off button on the

radio.

CAUSE

The new Blaupunkt audio units have a programming

feature where the radio can be set to turn off via the

ignition switch the conventional way, or only by the

on/off button on the audio head unit.

This new feature is called “ignition logic” programming.

The factory setting is for the radio to turn off when the

ignition key is removed from the lock.

This feature may have accidentally been changed by

the customer.

CORRECTION

If presented with a vehicle where the customer

requests the radio to turn off when the ignition key is

removed, press the “settings” button on the audio

control panel (refer Figure 1) then set the radio to

“ignition logic on” by placing an “X” in the box as

shown in Figure 2

NOTE: A CDC 40 Audio unit is displayed in Figure 1.

On CDC 30 units, the “settings” button is in a different

location.

Figure 1 - CDC 40 Opera Radio

Figure 2 - Info Display

HOLDEN SERVICE TECHLINE ___________________________________________________________________________OCTOBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Requesting Immobiliser Security Codes

All Models

(GROUP OB) TL0936-0509

Many Dealers request immobiliser security numbers

from the Holden Vehicle Security Information Centre

for vehicles that don’t have an immobiliser or don’t

require an immobiliser number. Refer to the

following examples.

• Some variants of SB Barina, TR Astra, TF Rodeo,

and UT and MX Frontera’s do not have an

immobiliser fitted.

• VZ & WL Gen 3 vehicles have a BCM security

number but do not have an immobiliser security

number. Note that VZ & WL V6 vehicles require

an immobiliser security number.

• All YG Cruze’s require an immobiliser and BCM

number and these can be found in LCRV SIP.

As you can see from these examples, it is important

to ensure that the vehicle you are requesting security

information for actually has an immobiliser or

requires an immobiliser number.

It is therefore recommended that you check the

available Service Information for location of

components.

New Procedure For Obtaining Security Numbers.

(The following information is extracted from All

Dealer Letter 42/05 dated 19 Sep,2005.)

To obtain an immobiliser security number you MUST

FIRST check on-line via the NOW warranty system

for the information.

If the security information is not available via the

NOW system or a specific security number is not

working on a vehicle, Dealers need to fax Holden a

revised security information request form (copy on

Lionheart). It is mandatory that all fields on the form

are completed, including reference to any security

information obtained from the NOW system.

It is important to note that Holden will not be

processing security information requests that are

incomplete or on the old form. Please discard any

earlier versions of the form. Dealers are also

reminded not to fax multiple requests for the same

vehicle VIN.

Please note that TAS do not process requests for

Security Codes.

Also, there is a revised “Vehicle Security Information

Change Advice” form (copy on Lionheart). Dealers

should use this form to advise Holden of any

changes to a vehicle’s security information.

INFORMATION

Revisions to CIM, SRS Module & Drivers

Airbag

ZC Vectra

(GROUP OB) TL1000-0509

This techline is written to raise technicians

awareness of changes which have occurred to the

CIM, SRS module and Driver Airbag assemblies on

the above model.

ZC Vectra has been upgraded over the past few

model years, which has seen the introduction of

multi-stage drivers airbag. There has also been a

revised CIM and a new programming option within

the SRS module on some models.

These changes can be physically seen when

replacement of either the CIM or Airbag is carried

out, as there are TWO connectors which are fitted to

the inflator assembly. (driver airbag)

Some recent TAS cases have shown that because

incorrect CIM, SRS module or Drivers airbag part

numbers were ordered for vehicles, the result was a

lot of wasted diagnosis time and programming

difficulties being experienced.

To avoid this situation occurring, technicians should

write down the vehicle VIN and options and also

check the data list within the SRS module to

determine if the vehicle is fitted with a multi-stage

drivers airbag.

DIAGNOSIS HINT

Suspected Clunk From Driveline

VY,VZ Utility, One Tonner and Crewman

Group 4 Ref. No. TL0997- 0509

When investigating customer reports of “clunk” from

rear of vehicle at low speed during tip-in/tip-out, do

not automatically assume it is the differential or

driveline that is at fault.

Some recent cases have shown that the above

condition was not caused by the differential/driveline

but was the result of the spare wheel being loose and

moving in its mounting cradle.

In these cases the spare wheel had not been fully

raised and/or correctly inflated.

HOLDEN SERVICE TECHLINE ___________________________________________________________________________OCTOBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Tech 2 Custom Downloads

All

Group OB Ref. No. TL0999 - 0509

At times service departments may need to use TIS 2000 to change Tech 2 software to an earlier version.

The following instructions detail the correct procedure to do this.

1.From the TIS 2000 main menu select Software Download

2. Select “Tech 2” from the upper menu and “Custom” from the lower menu.

HOLDEN SERVICE TECHLINE ___________________________________________________________________________OCTOBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

3. Select Holden

When presented with the above screen, from the Applications for Downloading area, select the version and language

you wish to download. Once highlighted, press the Select button. The detail of what will be downloaded will now

appear on the right of the screen. If the details are correct Select download.

HOLDEN SERVICE TECHLINE ___________________________________________________________________________OCTOBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

EGR Malfunction, DTC P0400 Sets

XC Combo (Z16SE engine)

Model Years 2003 and 2004 Only

Group 6C Ref. No. TL0941B - 0509

This Techline supercedes TL0941A-0508 published in

Issue 8, Sep. 2005. The procedure is updated with advice

to not replace the EGR valve. Either fit a revised gasket or

discard valve and fit a blanking plate. Also, TIS CD 64 now

allows MY 2003 vehicles to be repaired with this service

fix.

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

CONDITION

Drivers may complain of: - engine running ‘rough’

and/or may, in isolated cases, stall at very low speeds

during this ‘rough running’ period, and engine check

lamp illuminates.

Technicians may find DTC P0400 set.

CAUSE

Deposits of contaminants built up between the EGR

pintle and its guide causing the pintle to seize.

CORRECTION in Service

Summary: On complaint vehicles ensure EGR valve

is fully closed before disabling its operation with

revised engine management software. If EGR valve

is not fully closed, remove and refit valve using

revised gasket that has EGR port blocked off.

CAUTION: The following service fix action must

not be applied to Model Year 2002 vehicles. On

these vehicles address EGR complaints only by

fitting a new EGR valve.

On any Model Year 2003 or 2004 vehicle with the

condition as described above, proceed as follows.

Step 1. - Check position of the EGR Valve.

The position of the EGR valve can be found by

performing the 'Actuator test' with TECH 2, selected

as follows:

Diagnostics,

Model Year,

Vehicle Type,

Engine,

Actuator test,

EGR Solenoid test,

EGR position Feedback.

(1a). If the EGR position feedback is between

0.15V and 1.5V after performing the test (Test

Status: Inactive) the EGR valve is closed - Go to

Step 2.

(1b). If the EGR position feedback is higher than

1.5V after performing the actuator test (Test Status:

Inactive) the EGR valve is not completely closed. In

this case, install gasket p/n 55560700 which has

EGR port blanked out. Refer Figure 1. Tightening

torque of attaching bolts is 20Nm.

NOTE: If gasket 55560700 is unavailable, remove

EGR valve completely and install a blanking plate

12554606 with the old gasket 24411213.

Step 2. - Reprogram ECU.

Reprogram the ECU with modified software,

available from TIS CD 64 and onward, which

deactivates the EGR function. The correct hardware

number and revised ECU software part numbers are

listed in the table on the next page.

CAUTION: TIS2000 CD numbers prior to 64 must

not be used for reprogramming on Model Year

2003 vehicles.

Step 3. - Vehicle Marking

All vehicles that are modified according to the above

information are required to be clearly marked by a

yellow paint dot on the upper side of the EGR valve

housing. This will alert service technicians that the

engine management system has been revised and

the EGR is disabled.

PARTS INFORMATION

Part No.: Part Name Qty:

55560700 Gasket – EGR (Revised type) 1

12554606 Blanking Plate (EGR) 1

HOLDEN SERVICE TECHLINE ___________________________________________________________________________OCTOBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

WARRANTY CLAIM INFORMATION

Description Deactivate EGR valve

Labour Op. No. J000788

Time 0.2 hours

Add 0.2 hr if fitting revised

EGR gasket

Failure Code N0012 foreign material

HARDWARE & SOFTWARE PART NUMBERS

XC Combo Model Year 2003

ECU - Hardware Number

DEL 0115351289

ECU - Service Part

Number

09391340

EGR Disable ECU

Software Part Number

12 214 840.8

Available as of TIS CD 64

XC Combo Model Year 2004

ECU - Hardware Number

DEL 0115214590

ECU - Service Part

Number

12214810

EGR Disable ECU

Software Part Number

12 237 460.6

Available as of TIS CD 61

INFORMATION

Removal and Reinstallation Of Front Brake

Hose On Vehicles In The Range L384762 –

L452327

VZ except AWD, WL

Group 5 Ref. No. TL0996 - 0509

Vehicles built in the range from L384762 to L452327

were fitted with a rivet in the front strut brake hose

attaching bracket to prevent the hose slipping from the

strut bracket. Vehicles built after L452327 (27/5/05)

were fitted with a restraining clip 92183627 instead of

the rivet.

If any vehicle in the range from L384762 to L452327,

requires normal removal of the front brake hose from

the strut, the rivet as mentioned above, will need to be

removed. Use a 3.2mm drill bit to drill out the rivet.

WHEN REINSTALLING THE BRAKE HOSE AND

ABS CABLE, A CLIP PART NUMBER 92183627

MUST BE INSTALLED TO RETAIN THE BRAKE

HOSE.

The procedure for installing the clip is shown on the

next page.

NOTE: Safety Recall Campaign number 05-H-04,

required the clip 92183627 to be fitted to all vehicles

(VZ except AWD and WL) built prior to L384762.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92183627 Clip retainer – front brake 1

HOLDEN SERVICE TECHLINE ___________________________________________________________________________OCTOBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

HOLDEN SERVICE TECHLINE ___________________________________________________________________________OCTOBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

DTC’s P0700, P0715, P0720

ZC with A/T

Group 7B Ref. No. TL0737B - 0509

This Techline supercedes TL0737A-0508 published in

Issue 8, Sep. 2005. It is updated by revising steps 5 and

6 of the procedure.

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

CONDITION

Customer may complain of “no shifting” or “incorrect

shifting” of transmission ratios.

One or all of the following DTC’s may be stored:

P0700, P0715 or P0720

CAUSE

There are 2 possible causes for the above condition.

1. Moisture may have entered the speed sensor

connector, causing an incorrect or interrupted

signal.

2. Coolant may have entered the transmission via the

radiator oil cooler

CORRECTION – Production

1. Protective grease applied to speed sensors

from:

Trans. Serial No.: Built Date:

03MV735125 06/01/04

2. Radiators with revised oil cooler sealing were

introduced into vehicle production from:

ISOVIN: Built Date:

Ellesmere Port:

W0L0ZCF6848035197

not available

Russelsheim

W0L0ZCF3541042598

not available

CORRECTION – Service

1. Disconnect the speed sensor connector and dry

out any moisture present.

2. If there is no evidence of corrosion or damage to

terminals apply grease p/n 09163339 to connector

to stop future moisture entry.

3. If corrosion or damage is evident, replace the

sensor and/or connector as required. Also apply

grease 09163339 to connector to stop future

moisture entry.

4. Remove transmission valve body cover

CAREFULLY and inspect for possible coolant

entry to transmission via the radiator oil cooler. If

there is no evidence of moisture contamination, no

further action is required If there is evidence of

moisture contamination, proceed to step 5. .

5. If vehicle ISOVIN is prior to those shown in the

Production Correction table, replace the radiator,

then proceed to step 6.

If vehicle ISOVIN is after those shown, pressure

check radiator. If radiator fails pressure test,

replace radiator then go to step 6. If radiator

passes pressure test, proceed to step 6.

6. Refit transmission valve body cover and flush the

transmission to remove traces of water/coolant

contamination. The transmission can be flushed

using a commercial flushing unit or as follows.

Disconnect the transmission to radiator oil cooler

line and drain into a suitable container. With

engine idling and A/T in Neutral, flush approx 10 to

12 litres of standard Dexron A/T fluid through the

transmission.

After flushing, reconnect cooler line and refill

transmission with the specified A/T fluid as

shown in Parts Information.

7. Check the routing of the transmission breather

hose. The breather hose outlet MUST NOT be

located in the plastic gutter that drains A/C

condensate. Refer Figure 1.

Figure1 – Shows breather hose incorrectly located.

8. Relocate the breather hose so that it is clear of the

drain channel. Refer Figure 2. Secure hose to

conduit with tie straps as required.

HOLDEN SERVICE TECHLINE ___________________________________________________________________________OCTOBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Figure 2. Shows relocated A/T breather hose.

PARTS INFORMATION

Part No. Description Qty

09163339 Grease. NYOGEL 760G -

25 gm tube

93173888 speed sensor 1

93160393 Automatic transmission oil

1 litre (Esso ATF 3309)

WARRANTY CLAIM INFORMATION

Refer to your District Aftersales Manager.

SERVICE FIX

TPMS Module Unable To Detect One Or Both

Front Tyre Pressures & Sets DTC 9 or 10

WL Caprice, HSV Grange

Group 12 Ref. No. TL0970A - 0509

This Techline supercedes the previous one, TL0970 -

0507, in Issue 7 Aug. 2005. It is updated with advice to

fit the latest module 92183577 if not already fitted.

Please add this information to your original copy of the

techline.

Refer to the Holden portal website “Lionheart” for the

full revised techline.

SERVICE FIX

EGR Malfunction

ZC Vectra, TS Astra, TT Zafira,

- all with Z22SE engine

Group 6C Ref. No. TL0919A - 0509

This Techline supercedes TL0919-0505 in Issue 5, June,

2005. It is updated by removing the EGR Valve from the

Parts Information as it is not required. TS and TT have

also been added to the models affected .

CONDITION

Driver may report that vehicle runs rough or lacks

power and the telltale light comes on.

Technician finds DTC P1404 is set (EGR valve stuck).

CORRECTION – Production

The EGR-valve was removed in production (during

Model Year 2004) from Engine No. Z22SE11293531

CORRECTION – Service

On complaint vehicles where diagnosis finds that an

EGR valve is faulty, it should not be renewed but

removed altogether as per the following procedure.

Procedure.

1. Close exhaust gas recirculation port with a cover

plate (Part No. 24575592). Replace gasket when doing

so. (Part No. 12570863). The groove on the plate has

to point in the direction of the radiator with the plate

labelling facing upwards.

2. Fix the redundant wiring harness connector with a

cable strap (face connector opening to rear of vehicle).

3. Program ECU with SPS as of TIS 2000, CD 56 and

onward (select without EGR).

Figure 1. Shows EGR cover plate with groove facing

towards front of vehicle.

Update

HOLDEN SERVICE TECHLINE ___________________________________________________________________________OCTOBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

24575592 Cover plate- EGR valve

opening

12570863 Gasket - EGR valve to cyl

head

WARRANTY CLAIM INFORMATION

Description Remove EGR valve, add cover

plate, and reprogram ECU

Labour Op. No. J000776

Time 0.6 hr

Failure Code J0057 registers incorrectly

INFORMATION

Servicing Roof Rails

VY & VZ Adventra

Group 1 Ref. No. TL0884 – 0509

The roof rails and the front and rear plastic mouldings

are now available as individual replacement parts.

Previously, only the complete roof rail assemblies

could be purchased from spare parts.

From now on, if a roof rail is to be repaired under

warranty, only replace the individual component at

fault. DO NOT replace the complete roof rail assembly.

For instructions on DISASSEMBLY and

REASSEMBLY refer to PV SIP by selecting the

following path:

VY / Service Information / MY2004 VY AWD Wagon /

External Fittings / Section 1A9 / 2 Service Operations /

2.7 Roof rack carrier Asm

PARTS INFORMATION

Part No.: Partfinder Name Qty

92116853 (RH) Carrier - luggage 1

92116849 (RH) moulding - luggage carrier front 1

92116851 (RH) moulding - luggage carrier rear 1

92116852 (LH) Carrier - luggage 1

92116848 (LH) moulding - luggage carrier front 1

92116850 (LH) Moulding - luggage carrier rear 1

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Introduction Of DVD for TIS 2000 in Jan. 2006

All

Group OB Ref. No. TL1025 - 0510

From January 2006 the previous CD-ROMs for TIS

2000 will be replaced by a DVD.

The major growth in data in recent years makes this

change necessary.

Advantages to the user:

• the previous data set of 4 CDs will be replaced by

one DVD

• simpler updates, without having to change the CD

several times

• updates as a whole will be produced more quickly

• improved quality graphics

• use of new illustrations is possible, e.g. digital

photos

• conventional CD-ROMs can also be read by DVD

drives

Please ensure that your TIS 2000 PC has a DVD drive

by 1/1/2006 at the latest.

This subject was covered in All Holden Dealer Letter

DL 25/05 .

INFORMATION

Immobiliser Security Code Requests via

NOW

JS VECTRA

GROUP OB TL1021-0510

It is possible when searching for Immobiliser security

codes on the NOW system for JS Vectra, that it will

display the Immobiliser Code as a BCM code.

Although JS Vectra does not have a BCM, the NOW

system uses this menu field to display the immobiliser

security code.

INFORMATION

Bluetooth Phone Kit

VZ SSZ Sedan, HSPO Accessory

(GROUP OB) TL1024-0510

Holden now offers the Bluetooth Mobile Phone kit

through HBD and HSPO, and also as a standard feature

on the VZ SS-Z Sedan.

Customers should be made aware that mobile phones

with Bluetooth capability are not necessarily compatible

with the Holden Bluetooth mobile phone kit.

Dealers should refer to the ‘Bluetooth Compatibility’

document for the most up-to-date listing of tested mobile

phones. This document is available for download from

the Holden Dealer Web Centre,

www.holden.com.au/dwc. Go to the ‘HBD & Genuine

Accessories’ section and look in the ‘Bluetooth’ folder.

If you do not have the password to access the Dealer

Web Centre, speak to someone in your sales

department.

Mobile phones listed as ‘Not yet tested’ have not yet

been tested by the supplier, so we are unable to

comment of the compatibility of these phones with the

Holden Bluetooth phone kit until testing is complete.

INFORMATION

Radio Security Code Requests

XC, AH, ZC with CDC30 and CDC40 audio

head units

GROUP OB TL1020-0510

This is a reminder to the dealers who send Radio

Security Code Requests through to the vehicle security

information centre.

When requesting radio PIN codes for XC, AH and ZC

fitted with Blaupunkt CDC30 or CDC40 audio head

units, be aware that the Vehicle Security Code is also

the radio security code.

Update

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Front Wheel Camber Spec. Correction

VY/VZ - All AWD

Group 3 Ref. No. TL1031 - 0510

This bulletin is to advise of a correction to the camber

specification on all AWD vehicles.

FRONT WHEEL ALIGNMENT AT CURB WEIGHT

Wheel Alignment Angle Specifications - All

Models

Camber – 0° 12' ± 0° 18’

Caster 8° 30' ± 1° 15'

Toe-in Degrees Total 0° 10’ ± 0° 10'

Degrees per Wheel +0° 5’ to +0° 5’

Toe-out on Turns 1° 42’ @ 20 ° turn angle

± 1° 30'

Steering Axis Inclination

Angle

13° 18’ ± 1° 30'

Included Angle 13° 06’ ± 1° 30'

This revised information will be included in the next

issue of SIP CD.

Please ensure all service personnel involved in

alignment work are advised of this correction.

DIAGNOSIS HINT

V6 Poor Performance On Vehicles fitted with

LPG

V & W series

Group 6C Ref. No. TL1018 - 0510

CONDITION

When investigating customer complaints of poor

engine performance on either Petrol or LPG the

following diagnosis is suggested.

SUGGESTED DIAGNOSIS

First of all, confirm that there are no DTC’s or other

obvious faults that may impact engine performance.

Next, remove the rocker covers and check the valve

guides for excessive wear. Excessive valve guide

wear can generate valve train noise which is

transmitted to the engine block. The knock sensor may

then detect this noise as engine detonation and thus

retard the spark timing. The result is reduced engine

performance.

If excessive wear is found in the valve guides refer to

SIP or work shop manual for appropriate repair

procedure.

DIAGNOSIS HINT

Fault lights Appear in Instruments

Dealer Cannot Reproduce Fault

All Models & All Electronic Systems

Group 12 Ref. No. TL1019 - 0510

CONDITION

Customer reports that fault lights intermittently appear

in instrument cluster, such as ABS/Trac, Airbag, Check

Engine Light, etc.

After checking the related electronic system with Tech

2 there may be ‘History’ DTC’s that have been set.

After following the diagnostics related to that system

no fault can be found.

POSSIBLE CAUSE

After questioning the customer you may find that the

fault light(s) only appear immediately after start, or

during cranking, and not while driving.

A possible cause is low voltage during cranking due to

poor battery condition or battery connections.

If electrical faults and/or DTC’s occur during engine

cranking, by the time the customer has driven the

vehicle to the dealership, there may be enough surface

charge in the battery to cause a “No Fault Found”

scenario.

Dealerships should check the condition of the battery

by conducting a battery load test to remove any

possible surface charge.

The above scenario highlights the necessity to follow

strategy based diagnostics. For more information on

Strategy Based Diagnostics, refer to All Dealer Letter

DL 12/05 which can be found on Lionheart or in PV

SIP.

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

Steering Column Knocking Noise.

XC Barina & Combo

Group 9 Ref. No. TL1017 - 0510

CONDITION

Knocking noise in the area of steering column.

POSSIBLE CAUSE

The tightening torque of the upper screw of the

steering intermediate shaft may be too low.

Refer item 1 in following picture.

SUGGESTED CORRECTION

Check screw for tightening torque as specified in TIS.

Replace screw if required as per TIS procedure.

DIAGNOSIS HINT

Engine Cranks But Will Not Start Intermittently

VZ, WL, 190 & 175 kw V6 engine

Group 12 Ref. No. TL1014 - 0510

CONDITION

Intermittently, engine will crank for 5 seconds but will

not start and run. On a DTC search the following low

voltage codes may have been set. P0560 P0458

P0693 P0691 P0628 P0646 P0276 P00273 P0270

P0267 P0264 P0261 P2092 and P2088.

Vehicle may also display the message below in the

instrument cluster.

POSSIBLE CAUSE

There may be an intermittent loss of power to the

engine control relay circuit for the injectors and engine

sensors.

SUGGESTED CORRECTION

On a vehicle with the symptoms described above,

check the engine control relay circuit for loose wiring

connectors etc. or a possible faulty relay.

Please submit PIRs on any vehicle seen with this

condition. Include rectification if applicable.

HOLDEN SERVICE

TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could

assist in the proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle

will have that condition.

INFORMATION

Seat Belt Warning Operation

VY, VZ, Ute & Cab Chassis (One Tonner)

(GROUP 12) TL1022-0510

This techline is written to highlight the differences in the seat belt warning on VY & VZ Ute & Cab Chassis 2

door vehicles (One Tonner) versus the seat belt warning on Sedan, Wagon, Monaro and Crewman.

The differences are highlighted in the following information which is a direct copy of the latest owners

handbook in vehicle production from Sep/Oct 05.

The following warning is applicable to all models.

The following warning is applicable to Sedan, Wagon and Crewman models only.

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Service Engine Oil Warning Displays in the

Instrument Cluster.

VZ & WL with Gen III only

Group 12 Ref. No. TL0890A - 0510

This Techline supersedes TL0890-0503 in Issue 3, April

2005. It is UPDATED by adding new information for Service

Correction and Warranty Claims.

CONDITION

On some vehicles the “Service Engine Oil” warning icon

may display in the instrument cluster when the ignition

is cycled.

CAUSE

The “Service Engine Oil” feature which is not available

for the local market, has been inadvertently enabled in

the engine calibration.

CORRECTION – Production

Revised engine calibrations were introduced over a one

week period ending in the production breakpoint below.

Build Date: ISO VIN:

05/10/2005 6G1ZK14F96L516298

CORRECTION – Service

The following solution applies only to Gen III vehicles. The

solution for HFV6 and HSV Gen 4 will be advised in a future

techline.

If the above warning icon displays, the following reset

procedure must be performed.

1. Press and hold the up and down buttons on the trip

computer mode switch while turning the ignition key

on until a beep is heard, the following will be

displayed.

2. Press the set button on the trip computer mode

switch until a beep is heard (approx 8-10 seconds) to

reset the service item.

The display will then revert back to the start up

sequence.

If more than one service items are set, the next

service item will be displayed.

Press the set button on the trip computer mode

switch to reset the next service item if required.

3. The following will then be displayed.

4. Re-program the ECU or PCM (engine or

powertrain control module) as per the standard SPS

(Service Programming System) process using Tech 2

and TIS 2000 version 65 or later.

NOTE: For detailed instruction on this process refer

to Holden Lionheart portal, Service Techlines,

Section OD – TIS, “Reprogramming Procedure –

Instrument Cluster SPS”.

5. Re-program the Instrument cluster as per the

standard SPS (Service Programming System) process

using Tech 2 and TIS 2000 version 65 or later.

NOTE: For detailed instruction on this process refer

to Holden Lionheart portal, Service Techlines,

Section OD – TIS, “Reprogramming Procedure –

Engine ECU / PCM SPS”.

6. Re-program the Fuel Gauge Calibration in the

instrument cluster using Tech 2 software version

14.502 or later from TIS 2000 version 65 or later.

NOTE: For detailed instruction on this process refer

to Holden Lionheart portal, Service Techlines,

Section OD – TIS, “Reprogramming Procedure –

Instrument Cluster Fuel Gauge calibration”.

CAUTION:

Software downloaded from TIS 2000 CD 65 or later is

not compatible with old instrument cluster software,

old engine ECU / PCM software or old fuel gauge

calibration from earlier releases of TIS 2000.

Therefore these three files must be used as a set

whenever programming an engine control module,

instrument cluster or fuel gauge calibration.

For example,

- If you re-program the engine control module you must

re-program the instrument cluster and fuel gauge

calibration using software from TIS 2000 CD 65 or later.

- If you replace and re-program the instrument cluster

module you must re-program the engine control module

and fuel gauge calibration using software from TIS 2000

CD 65 or later.

Update

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

- If you re-program the fuel gauge calibration you must

re-program the engine control module and instrument

cluster using software from TIS 2000 CD 65 or later.

WARRANTY CLAIM INFORMATION

Description Service Engine Oil

Warning

Labour Op. No. J000791

Time V8 - 0.4 hrs

Failure Code J0057

NOTE: Labour operation number and time covers

instrument cluster, ECU / PCM and fuel gauge re-

programming.

INFORMATION

M/T Shift Fork Repair

V Car with Gen III V8 & M/T

Group 7A Ref. No. TL0925- 0510

Previously, when performing transmission repairs or

rebuilds, shift forks have had to be replaced merely

because the plastic pads attached to the forks have

been damaged and were not available as replacement

parts.

This is to advise that these shift fork plastic pads are

now available as separately serviced parts from HSPO.

In future, replace only the plastic pads unless other

physical damage has occurred to the shift fork to render

it unserviceable.

The pads are a push fit onto the fork ends.

PARTS INFORMATION

Part No.: Description Qty:

12523233 Pad - 5-6 & Rev. Shift Fork 2/fork

12523208 Pad - 1-2 & 3-4 Shift Fork 2/fork

INFORMATION

CDC 40 Opera Audio Unit Serial Number

Identification

ZC Vectra and AH Astra

(GROUP 12 ) TL0915A - 0510

This Techline supercedes TL0915-0504 in Issue 4, 2005. It is

updated by including the 3 groups of numbers on the bar

code in Figure 1 (was 2). Thanks to Adam Tipping of Hunter

Holden DC706 for reporting this on a PIR.

Whenever replacing a CDC 40 Opera radio via the

warranty changeover program it will be necessary to

obtain the serial number off the unit. The serial number

is located on the top of the unit (refer Figure 1) and on

the side (refer Figure 2.)

Figure 1. - Top View.

The serial number is a combination of “GM” plus the 3

groups of numbers on the bar codes as shown. In this

example the number is GM0041 4 0941644

Figure 2. - Side View

The serial number is stamped into the body of unit and

is also shown on the printed label.

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

ABS Light Comes On, DTC 71 Set

VY, V2, WK

(GROUP 5 ) TL0685A - 0510

This Techline supersedes TL0685-0404 in Issue 4, 2004. It is

updated with the current replacement guideline which is to

replace the Electronic Control Unit instead of the complete

hydraulic modulator / ECU assembly.

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 electronic 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 were originally identified with blue

paint as shown in the attached photographs. The blue

paint is no longer applied to replacement HSPO

replacement parts.

CORRECTION – Service

After verifying that vehicle has symptoms as described

above, fit a new ABS electronic control unit (ECU).

The ECU can be removed and replaced from the ABS

module.

The procedure for ECU replacement is in Passenger

Vehicle SIP.

Although the ECU is a relatively robust unit, technicians

still need to take care and follow correct procedures in

order to avoid ECU damage.

Service Prior Approval Process (SPAP) is required for

ECU replacement as per Special Warranty Component

Replacement Requirements in SIP.

PARTS INFORMATION

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

Figure 1. P/N 92093868

Figure 2. P/N 92093870

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Leaf Spring Squeaks

VY & VZ Crewman, Reg. Cab., Cross 8

Group 4 Ref. No. TL0855 - 0510

CONDITION

Squeak from leaf springs.

CAUSE

Contact between spring leaves.

CORRECTION – Production

Revised leaf spring assemblies with Delrin isolation

between each leaf have been fitted to vehicles from:

ISOVIN: Built Date:

**********L467474 4/7/2005

CORRECTION – Service

Summary: After verifying that the source of spring

squeak is inter leaf contact, install Delrin isolators

between each individual leaf in the spring pack as per

following procedure.

1. With vehicle on hoist, remove rear road wheels

to reduce weight as the differential will need to be

raised off the leaf springs.

2. Remove and discard the four U bolt retaining

nuts under leaf spring pack. Move bottom retaining

plate clear of leaf spring, letting it hang from the shock

absorber as shown in following figure.

3. Raise differential with a transmission jack so the

centre bolt can be removed.

4. Remove leaf spring centre-bolt nut carefully as

the bottom helper leaf will drop and only be supported

by the helper guide and hand brake cable bracket.

5. Remove and discard existing Delrin isolator that is

between helper leaf and 1st leaf . Refer following figure.

6. Insert the new Delrin isolators in between each

spring leaf (3 places).

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

7. Install new centre bolt and torque nut to 49 – 61

Nm.

8. The centre bolt nut will need to be staked with a

centre punch at two opposing points on the nut face.

(Only 1 shown)

9. Lower the differential back into location.

10. Using the new U bolt nuts, bolt the bottom

retaining plate to the bottom of the spring pack. Ensure

that the nuts are tightened evenly to achieve an equal

number of threads protruding from the nuts. Torque to

90 Nm.

11. Ensure that the bottom helper spring guide is

centralised so it has clearance to the sides of the spring

leaves.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92185953 Kit – Crewman (Longer

Centre Bolt)

92185952 Kit - Reg. Cab (1 tonner) and

Cross 8

WARRANTY CLAIM INFORMATION

Description Leaf Spring Squeak Kit –

Install

Labour Op. No. F000203

Time 1.0 hr

Failure Code NOW F0090

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

DVD Changes From Panasonic to Blaupunkt

WL Caprice

Group 12 Ref. No. TL1005 - 0510

The DVD player in WL Caprice was changed from

Panasonic to Blaupunkt from vehicle tag L514978 (built

11th Oct 2005).

This new Blaupunkt system is able to play DVD's, audio

CD's, MP3's and Video CD's. It includes a new remote

control and new Blaupunkt headphones.

The headphone jacks are now located under the

headrest. In addition, an input jack located on the left-front

seat headrest allows audio and video connection from an

auxiliary device such as a camcorder or video game unit.

Headphone Storage

The headphones are to be stored one inside the other

(see picture) to fit within the centre armrest storage

compartment. This action will need to be performed at

Predelivery.

Figure 1. Shows arrangement of new headphones in

storage compartment

Diagnostics

In short term – refer draft version on Lionheart. Refer

Service Techlines\Advanced Information

Longer term - Final version will be on SIP.

Warranty Changeover Procedure.

In the event a warranty replacement unit is required,

refer to procedure on “Lionheart” which is found as

follows - Service Bulletins / Category / Special warranty

Component Replacement

INFORMATION

Ethanol Fuel Usability

All Post - 1986 Holden Vehicles

Group 6M Ref. No. TL1011 - 0510

The information shown below is taken from the Holden

website (www.holden.com.au). Customers can be referred

to the website for additional information should there be

any need.

Holden vehicles manufactured since 1986 will operate

satisfactorily on Ethanol fuel blend “E10”, with the

exception of the following vehicles that do not operate

satisfactorily on E10 fuel:

Apollo (1/87 - 7/89),

Nova (2/89 - 7/94),

Barina (1985 - 1994),

Drover (1985 - 1987),

Scurry (1985 - 1986),

Astra (1984 - 1989).

Owners of these vehicles should refer to the vehicle's

Owner's Manual for recommended fuel usage.

Purchasing fuel

When purchasing fuel, Holden recommends that

vehicles are operated on fuel containing no more than

10% ethanol.

Purchasing your fuel from a reputable retailer may

reduce the risk of purchasing fuel containing more than

10% ethanol or other abnormal properties. Under no

circumstances should you use fuel containing more

than 10% ethanol.

Use of such fuels may result in engine malfunction,

starting and operating difficulties, and materials

degradation. These adverse effects could result in

permanent damage to your vehicle.

It is also important to note that when ethanol blends

are used, fuel consumption can be expected to

increase due to the lower energy content of ethanol. It

is important to note the use of any fuel, other than the

fuel specified in the vehicle's Owner's Manual, may

seriously damage your vehicle and may void your

Warranty. Only good quality, clean fuel should be

used.

The use of fuel containing more than 10% ethanol may

also affect your New Vehicle Warranty.

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Erratic Fuel Gauge Operation in the Lower Half

of the Tank.

VZ / WL (excluding Gen 4 HSV)

Group 12 Ref. No. TL0975-0510

PROBLEM DESCRIPTION

Customers may complain that their fuel gauge is

erratic in the lower half of the tank or the low fuel

warning operates intermittently when the fuel level is

not low.

PRODUCTION RECTIFICATION

Revised fuel gauge calibrations were introduced over a

one week period ending in the production breakpoint

below.

Build Date: ISO VIN:

05/10/2005 6G1ZK14F96L516298

SERVICE RECTIFICATION

The revised calibrations are available on TIS 2000 CD

65 which was delivered to dealers in mid October

2005.

If presented with a vehicle where the customer advises

of the above condition perform the following steps:

1. Prior to performing any programming, observe and

note the position of the fuel gauge (e.g. ¼, ½, ¾ or

full).

2. Re-program the Instrument cluster as per the

standard SPS (Service Programming System)

process using Tech 2 and TIS 2000 version 65 or

later.

NOTE: For detailed instruction on this process

refer to Holden Lionheart portal, Service Techlines,

Section OD – TIS, “Reprogramming Procedure –

Instrument Cluster SPS”.

3. Re-program the ECU or PCM (engine or

powertrain control module) as per the standard

SPS (Service Programming System) process

using Tech 2 and TIS 2000 version 65 or later.

NOTE: For detailed instruction on this process

refer to Holden Lionheart portal, Service Techlines,

Section OD – TIS, “Reprogramming Procedure –

Engine ECU / PCM SPS”.

4. Re-program the Fuel Gauge Calibration in the

instrument cluster using Tech 2 software version

14.502 or later from TIS 2000 version 65 or later.

NOTE: For detailed instruction on this process

refer to Holden Lionheart portal, Service Techlines,

Section OD – TIS, “Reprogramming Procedure –

Instrument Cluster Fuel Gauge calibration”.

5. Once all programming is complete ensure the fuel

gauge returns to a similar position as noted in step 1.

NOTE: When the ignition is first switched on it may

take several minutes to display the original fuel

level.

CAUTION:

Software downloaded from TIS 2000 CD 65 or later is

not compatible with old instrument cluster software,

old engine ECU / PCM software or old fuel gauge

calibration from earlier releases of TIS 2000.

Therefore these three files must be used as a set

whenever programming an engine control module,

instrument cluster or fuel gauge calibration.

For example,

- If you re-program the engine control module you must

re-program the instrument cluster and fuel gauge

calibration using software from TIS 2000 CD 65 or later.

- If you replace & re-program the instrument cluster

module you must re-program the engine control module

and fuel gauge calibration using software from TIS 2000

CD 65 or later.

- If you re-program the fuel gauge calibration you must

re-program the engine control module and instrument

cluster using software from TIS 2000 CD 65 or later.

WARRANTY CLAIM INFORMATION

Description Fuel Gauge Calibration

Upgrade

Labour Op. No. N000493

V6 0.5 hrs Time

V8 0.4 hrs

Failure Code N0057

NOTE: Labour operation number and time covers

instrument cluster, ECU / PCM and fuel gauge re-

programming.

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Rear Muffler Rattle.

VZ Wagon & Sedan with 175 Kw V6

Group 8 Ref. No. TL1006 - 0510

CONDITION

A rattle may be generated if the rear muffler makes

contact with the heat shield.

CAUSE

Insufficient tension on the rear muffler hanger bracket.

CORRECTION – Production

Revised mufflers with reduced clearance between the

hanger bracket pins have been fitted to vehicles from:

ISOVIN: Built Date:

**********L428040 08/04/05

CORRECTION – Service

Summary: After verifying that vehicle has condition as

described above, modify the hanger bracket on the muffler as

follows.

1. Remove hanger bracket rubber bushes.

2. Reduce the distance between the hanger bracket

pins on the muffler by 11mm (from 92mm to

81mm) as shown in Figure 1.

A B

Figure 1.

3. The flat brace between the hanger pins will need

to be pushed down to facilitate closing the distance

between the pins - see Figure 1, View B.

4. Reinstall hanger bracket rubber support bushes.

WARRANTY CLAIM INFORMATION

Description Modify hanger bracket pins

Labour Op. No. L000257

Time 0.2 hr

Failure Code L0028 rattles

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

EGR Malfunction

ZC Vectra, TS Astra, TT Zafira,

- with Z22SE engine

Group 6C Ref. No. TL0919B - 0510

This Techline supersedes TL0919A-0509 in Issue 9, 2005. It

is updated with advice that this fix does not apply to TS

and TT models built prior to Model Year 2003. Refer engine

number breakpoints below.

CONDITION

Drivers may report that their vehicle runs rough or

lacks power.

The telltale light comes on and P1404 DTC is set

(EGR valve stuck).

CORRECTION – Service

The correction procedure detailed below applies to the

following vehicles:

ZC Vectra with Eng. No. built before Z22 SE11 293 531

TS Astra Sri MY 2003 vehicles (and later) built after the

following engine numbers.

11 133 945 - MT

11 131 764 - AT

TT Zafira Equipe MY 2003.5 and

TS Astra Convertible MY 2003 vehicles (and later) built

after the following engine numbers.

11 133 885 - MT

11 133 302 - AT

NOTE: The above Engine Number Breakpoints are

important as vehicles built prior to these Breakpoints

have a different engine management calibration and

catalytic converters. Incorrect application of the

correction procedure to pre breakpoint vehicles can

result in catalytic converter failure.

Procedure.

On complaint vehicles where diagnosis finds that an

EGR valve is faulty, it should not be renewed but

removed altogether as per the following procedure.

1. Close exhaust gas recirculation port with a cover

plate (Part No. 24575592). Replace gasket when doing

so. (Part No. 12570863). The groove on the plate has

to point in the direction of the radiator with the plate

labelling facing upwards.

2. Fix the redundant wiring harness connector with a

cable strap (face connector opening to rear of vehicle).

3. Program ECU with SPS as of TIS 2000, CD 56 and

onward (select without EGR).

PARTS INFORMATION

Part No.: Partfinder Name Qty:

24575592 Cover plate- EGR valve

opening

12570863 Gasket - EGR valve to cyl

head

WARRANTY CLAIM INFORMATION

Description Remove EGR valve, add cover

plate, and reprogram ECU

Labour Op. No. J000776

Time 0.6 hr

Failure Code J0057 registers incorrectly

Figure 1. Shows EGR cover plate with groove facing

towards front of vehicle.

INFORMATION

Fuel Gauge Fixes Quick Reference

VY, V2 II & III, WK, VZ & WL

Group 12 Ref. No. TL1015 - 0510

To assist technicians in diagnosing fuel gauge

complaints on the above models, a summary of

various fuel gauge fixes which have previously been

published as Techlines is provided on the back page

of this issue.

HOLDEN SERVICE TECHLINES___________________________________________________________________________NOVEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Heater Hose Rubs Through On Rear Of

Cylinder Head

VY, VZ, Gen III Engine & M/T

Group 2 Ref. No. TL 0867 - 0510

CONDITION

There have been isolated cases where the heater

hose has been damaged due to contact with the rear

of the right hand side cylinder head.

CORRECTION – Production

A revised shape clutch pipe has been introduced into

production to provide greater clearance between the

heater hoses and cylinder head.

The revised clutch pipe has been fiitted to vehicles

from:

ISOVIN: Built Date:

**********L484030 01/08/05

CORRECTION – Service

On any vehicle built prior to L484030 where the

heater hose is being replaced, route the new hose

between the clutch pipe and the dash panel as shown

in Figure 1.

Secure the heater hose to the clutch line with a cable

tie and adjust the hose to ensure there is maximum

clearance to the rear of the cylinder head.

For vehicles built after L484030 (with revised shape

clutch pipe) the heater hoses must be routed forward

of the clutch pipe.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

Figure 1.

Route hoses behind clutch pipe

Dash panel

glue track

Update

service fix applies to a vehicle or that the vehicle will have that condition.

Fuel Gauge Fixes Quick Reference - VY, V2 II & III, WK, VZ & WL

Group 12 Ref. No. TL1015- 0510

MODEL CONDITION BREAKPOINT TECHLINE REFERENCE

VY I & II / WK / V2 II & III

(excluding VY I Ute)

Fuel Gauge Intermittently Reads Incorrect Value

(May run out of fuel before the gauge reads empty)

L199047 (11/11/03)

TL605-0311 / 2003 Issue 11 Page 7

VY I & II Cab Chassis

(Crewman / Regular Cab / X8)

Fuel Gauge Problem Due To Auxiliary Pickup

(Can’t get enough fuel in the tank when the gauge reads empty)

V6 L288194 (08/06/04)

V8 L291976 (15/06/04)

TL0672-0405 / 2004 Issue 5 Page 5

VY I & II Ute & Cab Chassis

(Crewman / Regular Cab / X8

Erratic Gauge Operation within the full to 3/4 range

(Gauge drops to ¾ and then goes back to full when the ignition is cycled)

L304521 (20/07/04)

TL0778-0408 / 2004 Issue 8 Page 14

VY / WK / V2 II & III

Implausible DTE & slow to return to full

(Excessively high or low distance to empty)

(Fuel gauge does not display full for a long period of time after filling)

No production break point

Published via February 2005 SMA Handout

(Refer TAS)

Fuel gauge indicates higher than actual

(Bent sender arm)

L345644 (06/10/04)

TL0809-0410 / 2004 Issue 10 Page 10

VZ Gen III Ute

Fuel gauge will not display full after refilling the fuel tank

L390626 (21/01/05)

TL0844-0501 / 2005 Issue 1 Page 5

VZ / WL V6 Sedan & Wagon

Fuel gauge inaccuracy

(May run out of fuel before the gauge reads empty)

L382346 (09/12/04)

TL0845-0501 / 2005 Issue 1 Page 5

VZ / WL

Low fuel warning operation clarification

(To clarify complaints of low fuel warning coming on too early)

Information to clarify operation

TL0891-0505 / 2005

VZ V6 Ute

High reserve

(Can’t get enough fuel in the tank when the low fuel light comes on)

L444651 (18/05/05)

TL0952 – 0506 / 2005 Issue 6 Page 8

VZ / WL

Erratic gauge operation in the lower half of the tank

(When the tank is ¼ full the gauge will display between ½ and empty if the ignition is

cycled on an incline)

L516298 (05/10/05)

TL0975-0510/ 2005 Issue 10

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

Rattle Caused By Heater Tap Touching

Ignition Coil

VZ & WL with HFV6

Group 2 Ref. No. TL0801-0511

Prior to investigating any rattle or buzz suspected of

coming from the Instrument Panel, it is recommended

to first check that the heater tap is not rattling against

the RH rear ignition coil.

Since the start of VZ production, a strip of insulating

foam has been fitted between the heater tap and RH

rear ignition coil to prevent a rattle or buzz noise.

However, it is possible that this insulating strip may

have dislodged or removed during service.

If required, install a suitable insulating strip between

the heater tap and the coil.

DIAGNOSIS HINT

Low Traction Event Occurs Unnecessarily

During Take Off.

VZ with M/T and traction control

Group 5 Ref. No. TL1042-0511

CONDITION

During take off, a low traction event occurs

unnecessarily. Low traction indicator is illuminated.

CAUSE

This condition could be due to insufficient air gap

between rear wheel speed sensors and tone wheel.

CORRECTION

Check air gap measurement and adjust if required.

1. Check air gap of both of the rear wheel speed

sensors.

2. Air gap needs to be 1.5mm.

3. If less than 1.5mm, use shim part number

90278359 to achieve the correct air gap spacing.

PARTS INFORMATION

Part No.: Description Qty:

90278359 Shim 1

Update

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Poor Retention Of Cargo Blind At D Pillar

VZ Wagon

Group 1 Ref. No. TL1029 - 0511

Note:The cargo blind should not be replaced for this

condition.

CONDITION

The cargo blind may detach from the D-pillar locators

when vehicle is driven on rough roads or with heavy

closing of the tailgate.

CORRECTION – Service

Summary: Pack out the interior trim at D-pillar to

provide better retention of the cargo blind in its

extended position.

1. Remove the rear quarter trim screw from both

sides.

Figure 1

2. Pack out the D-pillar trim by fitting two rubber

washers on the quarter trim screw, between the

quarter trim and body panel.

Figure 2

3. Remove the D-pillar trim and install 10mm thick

(approx.) adhesive backed foam in the location

shown in figure 3. This helps to align the quarter

and D-pillar trims.

Figure 3

4. Reinstall the trims and blind. Check the retention

of the blind and fitment of trim. Add or remove

washers or tape where required to improve fit.

PARTS INFORMATION

Part No.: Description Qty:

92138041 Washer 4

WARRANTY CLAIM INFORMATION

Description Pack out rear quarter trims

Labour Op. No. C000544

Time 0.2 hr

Failure Code C0027 loose

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Use of Correct Adhesives For Fixed Glass

All Vehicles

Group 1 Ref. No. TL1002 - 0511

Dealers should be aware of the importance of using the correct adhesive when replacing (or subletting the

replacement of) fixed glass windows in any vehicle. Use of an incorrect adhesive could affect the structural integrity

of the body.

Below is an example extracted from Passenger Vehicle SIP, explaining some of the requirements when replacing

fixed glass. Refer to SIP for a full description of service procedures and requirements.

Please provide a copy of the relevant SIP procedure to your sublet repairer to comply with when installing fixed

glass.

PV SIP - Section 6A1 Stationary Windows – General Information

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Commonisation of Wheel Nuts

Group 10 Ref. No. TL0801-0511

Commencing on the 5/11/2005, (vehicle tag L532313)

all vehicles supplied with steel wheels will now be fitted

with the nut designed for use with alloy wheels.

Steel wheel nut part number 92015262 will be replaced

by alloy wheel nut part number 22526184.

The alloy wheel nut has a longer taper which is

suitable for use on both alloy and steel wheels. Refer

figure 1

Figure 1. Alloy wheel nut p/n 22526184

Figure 2. Steel wheel nut p/n 92015262

INFORMATION

Precaution for Removal of Dealer Service

Reminder Label

JF Viva Hatch & Wagon

Group 12 Ref. No. TL1041- 0511

This vehicle is fitted with a glass mounted radio

antenna which is adhered to the right hand top inside

corner of the front windscreen where the service label

is usually located, as per figure 1.

Figure 1

When adhering service reminder labels to these

vehicles do not locate it on top of the radio antenna.

Please take care not to damage the radio antenna

when removing the service reminder label from

windscreen.

Do not use sharp tools to remove the service

reminder label, for example razor blades or

scrapers.

Damage caused to the antenna circuit when

removing the service reminder label will not be

accepted as a warranty claim.

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Power Steering Cooler Hose Leaks

VZ, WL

Group 9 Ref. No. TL1001- 0511

CONDITION

On some vehicles, power steering fluid may leak from

the cooler hose connections with hose clamps. Refer

item B in following figure.

CAUSE

Compression “set” of the hose after installation in

production causes the hose clamp to relax tension at

the hose to pipe connection.

CORRECTION – Service

1. On vehicles with the above condition, re-tension

hose clamps to 3 Nm.

2. If hose clamp is not sealing and is visibly deformed

replace hose clamp.

3. DO NOT REPLACE HOSE UNLESS DAMAGED.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

SERVICE FIX

PIM Replacement Prior To Reprogramming

Engine ECU for Vehicles Built Prior to 17/11/05

VZ , WL, Gen 4 HSV

Group 12 Ref. No. TL1033-0511

PROBLEM DESCRIPTION

Due to an incompatibility issue between the latest

engine ECU calibration and the Powertrain Interface

Module (PIM), it will be necessary to install a revised

PIM prior to reprogramming the engine ECU’s in any

VZ / WL series HSV vehicle fitted with a Gen 4 engine

using TIS 2000 CD 66 (or later).

PRODUCTION RECTIFICATION

A revised PIM has been fitted in production from the

following breakpoint.

Build Date: ISO VIN:

17/11/05 6G1ZK42U45L535469

Note: A significant number of vehicles built prior to the

breakpoint above have been rectified at HSV and can

be identified by an “X” in co-ordinate E-1 of the service

history label .

SERVICE RECTIFICATION

When presented with a HSV Gen 4 which requires re-

programming of the engine ECU for any reason

perform the following,

1. Check co-ordinate E-1 of the vehicle service

history label (located on the inside of the fuse

panel cover) to ensure the vehicle has not

previously had the revised PIM installed.

2. Ensure your Tech 2 is updated with software

version 14.601 or later (available from TIS 2000

CD 66).

3. Refer to Passenger Vehicle SIP for the PIM

replace and program procedure.

4. Install the new PIM part number 92181129.

5. Mark co-ordinate number E-1 of the vehicle

service history label for ease of future

identification.

PARTS INFORMATION

Part No.: Description: Qty:

92181129 Revised PIM 1

WARRANTY CLAIM INFORMATION

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

Description HSV Gen 4 PIM

Replacement

Labour Op. No. J000794

Time 0.4 Hrs

Failure Code N0095

Note: This labour operation number can only be

claimed once. All vehicles rectified at HSV have been

excluded.

DIAGNOSIS HINT

Tail lamp – Condensation or Water Entry

AH Astra

Group 12 Ref. No. TL1044-0511

Many AH tail lamp assemblies are being replaced

unnecessarily for complaint of “condensation” or “water

entry”.

This techline is provided to help technicians

understand the AH tail lamp design and how to

differentiate between water entry and condensation.

These are vented lamps with clear lenses which are

more prone to display visible fogging (condensation).

Under certain climatic conditions (high humidity) when

vehicles are parked after use, the vent system will

draw moisture-laden air into the lamp which

condenses on the lens as it cools down. This fogging

will usually disperse when the vehicle is driven, or if

the tail lamps are left on for 3-4 minutes. If a customer

uses their tail lamps on a rainy day, or washes the

vehicle after having the tail lamps on, they could

expect to notice condensation some time after the

vehicle has been parked - this is normal.

DIAGNOSIS PROCEDURE

In the event a customer complains of condensation in

tail lamps, inspect the tail lamp to determine if there

are signs of normal fogging, or if the lamp has water

entry due to poor sealing.

Condensation (Fogging).

Condensation will appear as a mist on the lens

however will not have distinguishable water droplets.

This normally needs no dealership action, as the

fogging will disperse during the time the vehicle is left

standing or after 3-4 minutes with the lamps on. As a

check in the dealership, leave tail lamps on for 5 to 10

minutes max. and recheck if condensation has

disappeared. If condensation is still present, then the

lamps are more likely to have the condition of “water

entry”.

Water Entry.

If a lens has severe condensation with water droplets

then investigation into the cause of water entry must

be carried out. Any obvious cause of water entry (e.g.

connector covers left off) should be corrected and

lamps dried out by leaving switched on for 10 minutes.

If the tail lamp does not clear, the lamp will require

replacement. A clear description of diagnosis should

be quoted in the 3C’s information tag when the lamp is

returned to Repac.

Figure 1. Water Entry (Heavy droplets)

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

TIS 2000 Diagnostic Charts for Customer

Complaints/Symptoms When no DTC’s are set

ZC Vectra , AH Astra

(GROUP OB) TL1049-0511

For all electronic systems in ZC and AH models, TIS

2000 provides diagnostic charts for customer

complaints/vehicle symptoms when there are no DTC’s

stored.

These diagnostic charts are found via the following

selection path:

- Checking procedures,

- Vehicle / Vehicle Related diagnostic procedure,

- Guided Electronic system Diagnosis

Then, from the main selection screen, select “vehicle

wide symptom chart/customer complaint” as shown in

Figure 1.

Then select the electronic system the fault belongs to.

For example; ‘Central Door Locks’ then choose the

relevant fault: Refer to figure 2.

Figure 1

Figure 2

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Ashtray Door Not Staying Closed

TS Astra

Group 1 Ref. No. TL1009 - 0511

CONDITION

Ashtray door will not stay closed.

CAUSE

The above condition can occur if the ashtray door is

forced open by pulling instead of pushing to open. This

action deforms the locking pin on the lever arm.

CORRECTION

Summary: DO NOT REPLACE THE ASHTRAY.

Instead, remove the ashtray, and rework bent pin in

linkage arm as per following procedure.

STEP 1. With the ashtray door open, use a small

screwdriver to carefully lift the plastic tang in the centre of

the linkage arm (at location of arrow). Whilst lifting the

tang, move the arm fully upwards as shown in the 2nd

photo to enable it to be withdrawn.

STEP 2. Remove linkage arm from ashtray.

STEP 3. Carefully straighten the pin as shown in the

following photograph.

NOTE: If the pin cannot be successfully straightened

replace the ashtray assembly.

STEP 4. Refit linkage arm and rotate downwards until

the tang locates into the slot as shown by arrow.

STEP 5. Reinstall ashtray into console.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD for Removal and

Replacement of the ashtray.

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Transfer Case Noise Reduction (Isolated A/T

Shifter Cable Bracket)

VY & VZ - Adventra and Cross 8

GROUP 4 & 7B Ref. No. TL0721A-0511

This Techline supercedes the previous one in Issue 2,

March, 2005. It has been re-issued as there have been a

number of PIR’s mentioning this condition, where

technicians have not identified the service correction

detailed below. The information is also updated by adding

Model applications and Breakpoints.

CONDITION

It is possible for a minor “hash” noise (similar to a

synchro ring rattle noise) to be heard in the passenger

compartment. Reports say the condition may occur in

the range of 40 – 60 km/h on light acceleration or

deceleration.

CAUSE

This noise heard is normal transfer case internal gear

and bearing noises which are transmitted into the

passenger compartment via the solid attachment of the

A/T shift cable to the transmission case.

CORRECTION – Production

Revised brackets with insulating bushes have been

fitted to VZ vehicles from:

ISOVIN: Built Date:

**********L419407 18/04/05

CORRECTION – Service

Summary: After verifying that vehicle has symptoms as

described above, fit a new bracket assembly with new

attaching screws.

To fit these parts, refer to SIP section 7C4 for service

operation 2.2 – this procedure allows removal of the

A/T selector cable for access to the cable bracket on

the side of the transmission.

(The revised cable bracket is similar in appearance to

the original cable bracket, so its location and

orientation are easily defineable).

When attaching the cable bracket with the new screws,

Torque screws to 17&3 Nm.

The picture below shows the revised bracket and

screws:

PARTS INFORMATION

Part No.: Description: Qty:

92174776 Bracket Asm., A/T Cable 1

11098091 Screw, Bracket Mtg. 2

WARRANTY CLAIM INFORMATION

Description A/T Cable Bracket Asm - Replace

Labour Op. No. K503100

Time 0.6 hr

Failure Code K0040 - Noisy

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

DIAGNOSIS HINT

Oxygen Sensor Replacement Precautions

VZ/WL

Group 6C Ref. No. TL1059- 0511

CONCERN

This information is supplied so that technicians are

aware of the possibility of oxygen (O²) sensor damage

and/or misdiagnosis and acts as a warning that such

damage and over-replacement of NFF parts will no

longer be accepted as warranty. This Techline should

be circulated to technicians and Warranty

Administrators.

A large number of oxygen sensors replaced under

warranty have been investigated and are shown to be

No Fault Found after testing.

Some exhibit damage to the sensor body, internal

ceramic or wiring harness, caused during replacement

by the use of incorrect or inappropriate tools.

These results indicate there may be possible confusion

in diagnosis and methods of replacement being used

by technicians; EG: ‘sets’ of sensors replaced instead

of one.

CAUSES

Diagnosis Error - Excessive Replacements -

A number of claims have occurred where multiple O²

sensors have been replaced (sets of 2 or 4).

Technicians must be aware that it is NOT necessary to

replace all sensors or sets of sensors, and it is rare to

need to replace more than one sensor.

Any replacement of more than one sensor must be

verified by reference to the diagnostics that were

carried out - in the CCC’s area of the warranty claim.

O² Sensor - Incorrect Removal Practices – Sensors

have been returned where there is damage to the O²

sensor or the wiring by the use of wrong tools EG:

Multi-grips, vice-grips or spanners that have slipped off

and distorted the sensor body and cracked the internal

ceramic element.

The nature of the sealant used on oxygen sensors

means that a very high torque load is required to

“break” the sealant (which hardens to a glass-like

material).

Sensors should be initially loosened with a flare nut or

with a proprietary sensor removal socket (various

types are available, such as slotted-side deep sockets

as used for sensor/thermal switch removal).

An open end spanner should only be used for initial

removal where there is restricted tool access.

These precautions ensure no damage is done to the

sensor or its wiring. Final removal can be done with an

open end spanner. An open-end spanner can be used

to refit the sensor, but the sensor removal tool/flare nut

spanner should be used to torque the sensor.

Do NOT cut O² sensor wiring during removal of any

sensor. O² sensors that have wiring cut will not be

accepted under warranty.

The SIP warning note is repeated here for reference:

Using incorrect tools (such as multigrips, vice-grips,

etc.) to remove sensors is not acceptable, as there is

the risk of damage to the sensor or its internal ceramic

section, if the tool should slip off, this makes root

cause evaluation impossible (the intent of returning

failed components is to allow root cause analysis

which allows rectification of production or manufacture

concerns that could cause customer concerns).

Unnecessary Replacements

Replacement of other engine components - such as

spark plugs, ignition coils, etc, may contribute to

‘sooting’ or ‘contamination’ of O² sensors, and a short

to medium test drive may be required to “clean” off the

sensors. Sensors should NOT automatically be

replaced until a test drive (to clean) is carried out.

Aftermarket Exhaust Systems

Manufacturers standard exhaust systems allow

compliance with emission regulations and the location

and performance of O² sensors is validated during

extensive testing. Location of O² sensors is critical to

the correct operation of the engine management

system and any vehicle’s continuing compliance with

emission regulations.

Aftermarket exhaust systems may not meet the strict

criteria for compliance with the emission regulations -

this can be the result of location of the O² sensor in the

exhaust pipe, location in the exhaust system, distance

from engine, distance from cat. Converter, or other

criteria that cause the sensor signal to diverge from

standard configuration.

It is recommended that exhaust system components

only be replaced with Holden genuine components as

used in the original build specification for the relevant

vehicle.

Any vehicle that is subject of an engine management

system malfunction and is fitted with a non-genuine or

aftermarket exhaust system will be required to be

returned to the standard exhaust configuration for the

vehicle, before any warranty repairs are initiated.

Should this not be done, all attempts to rectify the

complaint condition should be addressed as retail

repairs.

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Transmission Selector Lever Loose

(Replace Pivot Pin)

VY Adventra

(GROUP 7B) TL0661A-0511

This Techline has been re-issued as there have been a

number of PIR’s mentioning this condition, where

technicians have not identified the service correction

detailed below.

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 23/02/04

CORRECTION – Service

Summary: On complaint vehicles fit a new (knurled)

pivot pin and circlip. Do NOT replace A/T Shifter

Assembly for this condition.

Caution: Existing pivot pins must NOT be deformed to

stop dislodging.

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

INFORMATION

IRS Axle Rear Cover Plate Usage (Exchange

Axle Units or Replacement Parts)

V & W with IRS

Group 4 Ref. No. TL1057 - 0511

The following information is supplied so that Parts or

Service personnel do not attempt to exchange or re-

order parts in the belief that ‘incorrect parts’ have been

supplied.

Currently, IRS axle units are supplied with either ABS,

or non-ABS type rear covers.

In the near future, to de-proliferate the number of IRS

axle assembly covers, exchange IRS axle units will be

supplied with ABS type covers.

HSPO supplied IRS Axle assemblies and covers will

also be supplied as ‘ABS only’ style when existing

stocks of ‘Non-ABS’ parts are exhausted. The ABS

Sensor holes on non-ABS covers will be plugged as

shown below.

ABS Type Cover

Non-ABS Type Cover

(Sensor hole plugged)

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

INFORMATION

Tremec 6-Speed M/T Identification

V Series Gen III V8 & M/T

Group 7A Ref. No. TL1003- 0510

Background

This Techline is provided to allow technicians to define

the transmission serial numbers and date codes of

build, for Tremec 6-speed manual transmissions.

Where the Build Date & Serial No. is required - as in

the M/T Checksheet returned with any replaced M/T

assembly - the following information will assist.

These notes appear in the various Service and Parts

CD information:

The following diagrams and example photographs

allow definition of the label/tag information mentioned:

This label shows the Trans. Serial No. on the top LH

corner of the label, in the same format as it is shown in

Holden records - such as in NOW.

The serial number is shown in a different format on the

metal tag (see below).

As the metal tag format is different, the serial number

in Holden records can be obtained prior to trans

removal by searching in NOW, and is confirmed by

comparing to the serial number on the tag to the

computer record.

The above tag shows information as follows:

Bottom RH Corner:

Serial number - is shown

in a shortened format -

refer to notes on metal tag

(above). (Holden Records

will show TB011241).

Top RH Corner:

On this M/T, Build Date is “H2141”, this is deciphered

as:

H = alpha character for month = August

(Note: Letter “I” is NOT used!)

21 = 21st day of the month = 21

4 = Year

= 2004

1 = No. of shift of that day = 1st

This trans was built on 21st August, 2004 (1st shift), but

quoting the code “H2141” is sufficient for the M/T

Checksheet.

HOLDEN SERVICE TECHLINES___________________________________________________________________________DECEMBER, 2005

Holden Techlines are written to inform technicians of conditions that may occur on some vehicles, and to provide information that could assist in the

proper service fix of a vehicle. If a condition is described, do not assume the service fix applies to a vehicle or that the vehicle will have that condition.

SERVICE FIX

Diff. Period Whine, 80 – 110 km/hr

VY & VZ – One-Tonner & Crewman

GROUP 4 TL0631B-0511

This Techline supercedes the previous one in Issue 10, Nov.,

2004. It is revised by extending the usage of front spring eye

bushes.

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 on

V8 engine vehicles are:

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

spring. – Crewman V8 A/T and M/T only,

• A 2-spoke pinion flange – Crewman V8 Auto

(NOT Cross-6 or Cross-8)

Breakpoint for both countermeasures in Crewman is:

ISOVIN: Built Date:

**********L218227 09/03/2004

These changes have not been introduced into other

vehicle production, but the revised spring eye bushes

may be fitted to other vehicles fitted with ‘beam’ axles

to reduce the axle noise transfer into the vehicle

passenger compartment.

CORRECTION – Service

Summary: After verifying that vehicle has condition as

described above, fit revised bushes in front eye of rear

springs of ALL vehicles. In V8 RWD (Rear Wheel

Drive) ONLY - also fit a new diff pinion flange.

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 p/n 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. For V8 Engine RWD vehicles ONLY: Revised

pinion flange p/n 92176653 should be fitted with a

new nut p/n 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 (V8

ONLY)

92146565 Flange Nut (V8 ONLY) 1

WARRANTY CLAIM INFORMATION

All Vehicles except V8 RWD (Rear Wheel Drive):

Description Replace Bush, Leaf Spring

Front Eye – Both Sides

Labour Op. No. F000197

Time 1.6 hr.

Add for V8 (RWD

ONLY) – Fitting of

Pinion Flange

0.5 hr.

Failure Code F0040 noisy

Update