2006 SERVICE TECHLINES

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 TECHLINES___________________________________________________________________________FEBRUARY, 2006

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

P1483 DTC stored in ECU

AH Astra with M/T

Group 6C & 12 Ref. No. TL1069 - 0601

CONDITION

Some Model Year 2005.5 vehicles may be presented

with an Engine Check Lamp on and DTC P1483 (Fan

Control 3 Circuit Low Voltage) stored in the engine

ECU. Vehicles with this condition may have been

incorrectly built with fuse 5 missing from the UEC

(Underhood Electrical Centre).

CORRECTION in PRODUCTION

This condition was rectified as of the following

breakpoint:

ISOVIN: Built Date:

W0L0AHL4855122854 12/01/05

CORRECTION in SERVICE

To rectify the condition described above, install a 30A

fuse into location 5 of the UEC as shown on the

attached diagram.

Note: If fan speed 3 is commanded by Tech 2 using

the Functional Test in a vehicle with manual

transmission, it is possible that a DTC P1483 will set.

This is a normal condition and no further work will be

required.

PARTS INFORMATION

Part No.: Description: Qty:

13133860 FUSE 1

INFORMATION

Introduction of DVD for TIS 2000

All

Group OB Ref. No. TL1025A - 0601

This Techline supercedes the previous one in Issue 10,

Nov, 2005. It is revised by adding a note on setup of the

DVD drive.

From January 2006 the previous CD-ROMs for TIS

2000 will be replaced by a DVD.

The major growth in data in recent years has made

this change necessary.

Please ensure that your TIS 2000 PC has a DVD

drive by 1.1.2006 at the latest.

Advantages of changing to DVD.

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

one DVD

• Simpler updates, without having to change the CD

several times

• Quicker updates

• Improved quality graphics

• Use of digital photos

• Conventional CD-ROMs can also be read by DVD

drives

Important Note - DVD Setup

To guarantee a smooth update for TIS 2000, it is

essential that any new DVD drive to be used for TIS

2000 DVD’s is allocated to the letter previously used

by the CD drive. If this is not done, TIS 2000 must be

uninstalled and the DVD drive set up as a new

installation.

For more information refer to Dealer Letter 25/05 and

the TIS 2000 Newsletter available on TIS 2000 CD66.

Fuse 5

HOLDEN SERVICE TECHLINES___________________________________________________________________________FEBRUARY, 2006

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

Common Upper Radiator Shroud.

VZ & WL

Group 6K Ref. No. TL1006 - 0601

Service technicians should be aware that the upper

radiator shroud for V6 and V8 engine vehicles has

been made common from the Tag numbers listed

below (detailed in Microcat).

Model Tag

VZ L438762

WL L438092

Important Service Note

The removable access panel above the radiator cap

has been deleted on V8 vehicles therefore it is now

necessary to remove the upper radiator shroud to

access the radiator cap.

All replacement radiator shrouds have superseded to

the latest part (92183569). The “Cover - Radiator

Filler” (92175359) has also superseded to the latest

shroud assembly (92183569).

SERVICE FIX

“Distance To Empty” Or “Average Fuel

Consumption” Information Incorrect/Inaccurate

VZ with LPG

Group 12 Ref. No. TL1064 - 0601

CONDITION

Customer advises that the “distance to empty” or

“average fuel consumption” information displayed in

their instrument cluster is incorrect or inaccurate.

CAUSE

During programming at the VAP (vehicle assembly

plant) some instrument clusters were not configured

for LPG operation.

When configured for LPG, the “Average Fuel

Consumption” and “Distance To Empty” are removed

from the trip computer display for both LPG & Petrol

operation.

The table below gives an example of the information

displayed in the instrument cluster.

Petrol

Only

Petrol / LPG

(Dual fuel)

Digital speedometer 3 3

Stop watch 3 3

Odometer 3 3

Trip meter 3 3

Distance to go 3 3

Time to go 3 3

Distance to Empty 3 2

Average Speed 3 3

Average Fuel 3 2

Overspeed presets 3 3

CORRECTION – Service

After verifying that vehicle has the above condition,

re-configure the instrument cluster using Tech 2 via

the following steps,

1. F0: Diagnostic / Model Year / Vehicle Type / F4:

Body / Instrument / F5: Program / F1:

Configuration.

2. Scroll through the list to the engine, select the

modify soft key then select V6.

3. Scroll through the list to LPG Fitted, select the

modify soft key then select Yes.

4. Select the program soft key.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

HOLDEN SERVICE TECHLINES___________________________________________________________________________FEBRUARY, 2006

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

Turn signal / Hazard Lamps Stay Illuminated

VZ, WL

Group 12 Ref. No. TL1067 - 0601

CONDITION

Customer advises that intermittently the turn signal /

hazard lamps may stay illuminated without the switch

being activated.

CORRECTION – Production

Revised body control modules (BCM) have been fitted

to vehicles in production from the 10/08/05.

CORRECTION – Service

If a customer presents a vehicle with the above

condition, request a changeover BCM from Australian

Arrow using the standard process which is found in

SIP or on Lionheart.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

INFORMATION

Electronic Odometer Programming

TK Barina, JF Viva,

Group 12 Ref. No.TL0481A-0601

This Techline supercedes the previous one in Issue 5,

2003. It is revised by adding TK & JF models.

When a replacement instrument cluster is installed

into one of the above models it is a requirement to

program the odometer to the value of the one

removed.

If your Service Department does not know of any

instrument repairers who are capable of performing

this operation on the above models, below are some

contacts of instrument repairers currently being used

by other Dealers.

Victoria

Automotive Instrument Repairs

59 C Glenvale Crescent,

Mulgrave, Victoria 3170

Phone (03) 9561 2366

Fax (03) 9561 9134

NSW

Macarthur Instruments

P.O. Box 3016

Narellan Delivery Centre, NSW, 2567

fax (02) 4659 7294

Mobile (0416) 241 903

QLD

Future Auto Instruments

113 Turpin Rd,

Labrador, QLD 4215

Mobile (0414) 518 766

New Zealand

Robinson Instruments

19 Fale Street

Freeman's Bay

Auckland

Phone (09) 3771565

Fax (09) 3580573

HOLDEN SERVICE TECHLINES___________________________________________________________________________FEBRUARY, 2006

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 RPM Flare During Upshift &

Hesitation/Flat Spot at 90 km/h

(Reprogram with Scan 100 and R-Card)

DAEWOO LACETTI with M/T

Group 6C Ref. No. TL1065 – 0601

CONDITION

Engine RPM flares or RPM “hangs-on” during gear

upshift.

Vehicle may also exhibit a hesitation or flat spot while

driving at approx. 90km/h.

NOTE: Only Manual Transmission Vehicles are

affected.

CORRECTION - Service

On complaint vehicles the ECM will need to be

reprogrammed with revised software using a Scan

100 tool and a Daewoo R-Card.

Contact your Aftersales District Manager for access to

a Scan 100 tool (if you don’t have one).

A Daewoo “Lacetti” R-card will need to be obtained

via TAS and will require a TAS case to be loaded

prior to dispatch of the R-card.

Note: this R-card contains different software to the

one for DTC 35 high idle as quoted in Service

Techline TL0978-0509 (refer Issue 9/2005) .

REPROGRAMMING PROCEDURE

Preliminary Checks.

A. Ensure battery is fully charged and all power

consuming devices are turned off.

B. Vehicle to be at full operating temperature.

IMPORTANT

The following procedure for using the “R-Card”

must be strictly adhered to.

Failure to do so may result in the irrecoverable

loss of the ECM.

Procedure

1. Ensure Scan 100 has the re-program card

inserted in the lower card slot.

Note, the main Scan 100 card is in the slot closest to

the screen of Scan100 and the re-program card is in

the lower slot. Both cards must be in the Scan 100.

2. Ensure the external 240 volt power supply is

connected to the Scan 100 unit.

3. Connect the Scan 100 to the vehicle via the data

lead and correct adaptor to the diagnostic link of the

particular vehicle. Check workshop manual for the

location of the diagnostic link connector.

4. Turn ignition on. Do not start the engine. Ignition

lights on dash illuminated.

5. Turn Scan 100 tool on.

6. Select GM DAEWOO then press enter.

7/ select (6) RE-PROGRAMMING then press ENTER.

8. select (4) MR140 or HV240 then press ENTER.

HOLDEN SERVICE TECHLINES___________________________________________________________________________FEBRUARY, 2006

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.

9. Select (1) ECM REPROGRAM (SCAN 100 --> ECM)

There will now be two available “files” to choose from

and they MUST be loaded in the following order.

(FIRST) LACETTI 1.8 DOHC M/T

2003-10-20 File Name: 96491309.

This file will update the ECM to avoid flat spotting /

hesitation.

(SECOND) LACETTI 1.8 DOHC M/T

2005-03-23 File Name 96491309

This file will reprogram the ECM to avoid engine

rpm “flare” between gears.

NOTE: Both files have the same file name -

”96491309”.

10. Select (01) LACETTI 1.8 DOHC M/T

2003-10-20 File Name: 96491309.

then press ENTER

Should the following message appear, then the

Calibration you are attempting, has already been

installed and you should go to step 13.

If this message does not appear then proceed to step 11.

11. A message should appear stating

“DO YOU START REPROGRAM OF ECM ?”.

Select “YES”

12. Wait for programming to finish.

A message stating that “REPROGRAM SUCCESSFUL

(GOOD)” will appear.

HOLDEN SERVICE TECHLINES___________________________________________________________________________FEBRUARY, 2006

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.

13. Turn ignition switch to the “off” position for 20

seconds. Turn ignition switch to “on” then start

engine.

14. Press “esc”. several times to return to the main

screen.

15. Repeat Steps 6 to 9.

16. Select (02) Lacetti 1.8 DOHC M/T

2005-03-23 File Name 96491309.

Press ENTER and repeat steps 11 to 14 as above.

Should the following message appear, then the

Calibration you are attempting, has already been

installed and no further action is required.

Should either of the 2 messages below appear, contact

TAS prior to disconnecting or exiting procedure with

Scan 100.

HOLDEN SERVICE TECHLINES___________________________________________________________________________FEBRUARY, 2006

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. TL0854A-0601

This Techline supercedes the previous one (TL0854-0502)

in Issue 2, Mar, 2005. It is revised as both previous bump

stops have been superseded by a new part number.

CONDITION

Glove compartment door rubber bump stops may

tear in service. As a consequence, the glove

compartment swings fully downward when opened

and is not restrained by the stops.

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

Figure 1.

CORRECTION – Production

Revised bumpstops have been fitted to vehicles from:

ISOVIN: Built Date:

0000000000L486687 3rd AUG 2005

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 using the

procedure outlined in Holden SIP Section 1A3 para

3.2, taking care to avoid damaging the glove

compartment while removing hinge pins.

3. Remove damaged bump stop/s.

4. Fit new bump stops 92186491.

5. Reinstall glove compartment as follows:

Engage lower hinge points, then rotate glove

compartment up into closed position whilst pushing

sideways to compress one of the bump stops. This

action is required to provide clearance for the other

bump stop as it slides over the Instrument Panel

structure.

PARTS INFORMATION

Part No.: Partfinder Name Qty:

92186491 Bumper instrument panel

compartment door

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty

Information section of current PV SIP CD

HOLDEN SERVICE TECHLINES___________________________________________________________________________FEBRUARY, 2006

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

CAN-bus Configuration Mismatch DTC’s

AH Astra, ZC Vectra

Group 12 Ref. No. TL1050 - 0601

CONDITION

Trouble codes (DTC’s) may be stored after replacing

modules that communicate on the CAN-bus network.

These DTC’s may be stored in multiple modules if the

configurations are different.

The configurations in these modules must all be

programmed the same, otherwise the following DTC will

set.

“CAN-bus Configuration Mismatch”

This highlights the importance of ALWAYS starting

diagnosis with a “Module / ECU Presence Check” as

shown in the following screen from Tech2.

Figure 1

This “Presence Check” not only checks the modules are

present and communicating on the CAN-bus, but also

checks that ALL the modules are configured the same.

If a mismatch is detected, Tech 2 will display the

module(s) concerned then automatically prompt you

through the configuration process.

This procedure saves time by not having to check and

reprogram each module individually.

INFORMATION

Camshaft identification

SB Barina,

TR / TS / AH Astra,

JR / JS / ZC Vectra

Group 6A Ref. No. TL1063-0601

When performing cylinder head repairs on the twin

cam engines fitted to the above models (see list of

engines below) some technicians have had difficulty

with identification of camshafts.

C18SEL, C16XE, C20SE, C22SE

X16XE, X18XE1, X20XEV, X25XE, Z18XE

Z20LET, Z22SE

Y26SE

Most camshafts can be identified by the following

markings which are located near the first cam bearing

or cam drive gear end.

The letter "H" or "C" or "Z" = inlet

The letter " I “ or "T" or "Y" = exhaust

Z32SE Engine has the following identification:

G = Inlet Camshaft

J = Exhaust camshaft

Location of Z32SE markings is as follows:

↑

Gear end of

camshaft

HOLDEN SERVICE TECHLINES___________________________________________________________________________FEBRUARY, 2006

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

SRS light Illuminates

JF Viva

Group 12 Ref. No. TL1045 - 0601

CONDITION

SRS light may be illuminated in the instrument cluster

with various SRS circuit DTC’s set in the SDM.

CAUSE

The SRS wiring harness under the centre console

between the SDM and the transmission shifter may

have been damaged by a sharp metal edge, causing a

short to ground and various DTC’s to set.

Damage may occur to any of the circuits contained

within this harness resulting in a variety of different

DTC’s.

Figure 1 Shows location of damage

CORRECTION – Production

Vehicle’s shipped from POE (Port Of Entry) after the

14/11/05 have been inspected for this condition.

CORRECTION – Service

If presented with a vehicle shipped from POE prior to

14/11/05 with the SRS light on, perform the following

steps:

1. Carefully inspect the SRS harness in the

location described above.

2. If wiring damage is discovered, repair and re-

insulate.

3. Ensure the sharp edge on the metal bracket

shown below is covered with a piece of

convoluted tube to prevent further damage.

Figure 2. Shows convoluted tubing placed over sharp

edge.

PARTS INFORMATION

Use any commercially available convoluted tubing of

approx. 9mm diameter.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD for wiring repairs.

HOLDEN SERVICE TECHLINES___________________________________________________________________________FEBRUARY, 2006

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

Driveline Clunk/Backlash from Rear Axle

VZ (with IRS or Beam Axle)

Group 4 Ref. No. TL0853 - 0601

This Techline provides a Lash Check procedure for IRS

Rear Axle Assemblies and supersedes the previous bulletin

(TL0815-0410) on VY/VZ Differential Clunk Noise in Issue

10, Nov. 2004.

IMPORTANT BACKGROUND INFORMATION

Before commencing the procedures provided in this

Techline and to ensure that unnecessary

measurements or repairs are not conducted,

Technicians and Service Advisors must be aware of

and have read the following Service Techlines:

- Explanation of Driveline Clunk or backlash Noise –

refer July 2005 (Issue 6, page 16).

- Suspected Clunk from Driveline - refer October

2005 (Issue 9, page 10 – spare wheel related).

Service Advisors in particular need to ensure that they

clearly understand the reported condition so that the

condition can be reproduced by the dealership

technician and so that customers can be immediately

advised of those conditions that are normal drivetrain

related operating noises.

DO NOT proceed any further if the clunk noise is

confirmed as a normal or characteristic driveline

system operating noise.

Various components in the driveline system can

produce noise as a result of the application and

release of torque through the driveline. This Techline

provides the procedures to be followed to determine

whether the cause of abnormal “Clunk” noise is

caused by excessive clearance within the differential

unit.

The procedures below provide a structured and

accurate method of measuring combined differential

assembly backlash in both Beam axle assemblies and

IRS final drive units when the noise is classified as

abnormal or excessive when compared to other

equivalent specification vehicles. This measurement

procedure will also ensure that components are not

replaced unnecessarily

A. Evaluation of Concern

- Road test the vehicle to repeat the customer

reported concern

- Use the Driveline Noise Definition Worksheet

attached to record details of the complaint condition.

- This worksheet will also record the necessary

information for the Dana Website Request Form

should a replacement diff be required.

- It is essential that the driving conditions, when the

reported concern occurs, is recorded.

- It is also important that the condition is compared

to an equivalent specification vehicle to assist

determining whether the concern is a normal or

characteristic noise or is abnormal.

- If an equivalent vehicle is not available to

compare against and you are unsure whether the

noise level is normal or abnormal, then proceed to

Step B. Otherwise, no further action is required.

B. Vehicle set up for measurement

- Prepare vehicle for measurement by accelerating

forward and then reverse with moderate throttle.

- Drive vehicle onto a four post hoist.

- Apply handbrake firmly

- Raise vehicle

C. Differential Lash Check

For Beam Axle Assemblies

Perform a rear axle backlash check using the

procedure described in PV SIP found as follows:

Section 4B2 – Rear Final Drive and Live Axle

2 – Minor Service Operations

2.6 – Combined Rear Axle Backlash Check

Should the measured backlash be greater than 3.0mm

– the measured backlash dimension MUST be

included in the Dana request application.

The combined backlash specification for the Beam

Rear Axle Assembly is 3.0 mm

DO NOT request a replacement axle if backlash is less

than 3.0mm.

For IRS Final Drive Units

1. Attach magnetic dial indicator base to the diff

housing and probe the pinion flange as shown in

Photo 1 below.

Photo 1: Diff pinion flange measurement.

2. Have an assistant TWIST both inner driveshaft

CV’s in the same direction against the applied

handbrake and HOLD in this position.

HOLDEN SERVICE TECHLINES___________________________________________________________________________FEBRUARY, 2006

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. Rotate the propshaft with hand torque in one

direction and set the dial indicator to zero.

4. Rotate the propshaft with hand torque in the

opposite direction and take a reading of the travel.

5. Provided a rotational movement is applied to the

propshaft and even torque is applied in both

directions, then the measurement taken

represents the lash within the differential unit.

6. Repeat the measurement procedure above with

both the inner driveshaft CV’s twisted in the

opposite direction to step 5 above, to confirm an

accurate and repeatable lash measurement.

7. The combined backlash specification for the IRS

Differential unit is 3.0 mm.

8. Record both measurements taken and the

specification value on the Repair Order.

D. Service Correction

When the lash check shows that the differential lash

reading is within specification then the differential unit

is not the cause of the abnormal clunk noise condition.

When the lash check shows a lash measurement of

greater than 3.0 mm then request a replacement

beam axle or IRS Diff unit from Dana – refer to your

Zone Aftersales representative in case approval is

required.

HOLDEN SERVICE TECHLINES___________________________________________________________________________FEBRUARY, 2006

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.

Attachment to Service Techline TL0853-0601

Driveline Noise Definition Worksheet Date: _____________________

Dealership: _____________________________________ Dealer Code: _____________________

Completed by: __________________________________ Return Fax No.: ______________________

ISOVIN No.: ___________________________________________

Axle Serial No. _______________________

Axle Part No.: _______________________

Vehicle Type: VY VZ

Crewman (Beam) 1-Tonner (Beam) Sedan/Wagon/Ute (IRS)

Engine: V6 V8

* Confirm the customer complaint via road test THEN describe it using the chart below:

Circle comments as required.

Noise Description (Circle)

CLUNK WHINE SQUEAK GRIND

For CLUNK – Backlash Measured is: _______ mm

Affected Speed Range:

10 20 30 40 50 60 70 80 90 100 110

Gear: Automatic

(Circle Lever Position):

D 4 3 2 N R

Gear: Manual

(Circle Gear Selected):

1 2 3 4 5 6 R

Accelerator Applied:

OR When at Coast:

Light Medium Heavy Cruise

Yes No

Dealer Action: Order new axle from Dana

Have axle rebuilt * Supply Sub-Let Report with PIR

Nothing

Other: Define: ___________________________

Zone Authorisation Number: ______________________________ (For use on Dana Website Request)

Additional Comments:

Dana WERN No. (if supplied): ____________________________

HOLDEN SERVICE TECHLINES______________________________________________________________________________MARCH, 2006

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

A/C Compressor not working

AH Astra & ZC Vectra fitted with ECC

(Electronic Climate Control)

Group 2 Ref. No. TL1077-0602

CONDITION

Air conditioning is not cold, or A/C compressor does not

operate on vehicles fitted with ECC after vehicle

delivery.

DIAGNOSIS HINT

As a result of ECC settings being unintentionally

changed by the user, the A/C compressor can be

permanently turned off via the A/C selection menu in the

information display.

When the A/C compressor is set to off, “ECO”

(Economy) is displayed as shown in the following screen

which is from an early type ZC Vectra.

(ZC Vectra, early type – shows A/C off).

CORRECTION

Customers should be educated on how to set the ECC

so that the compressor is set to “on”.

The procedure for doing this is as follows.

Press the main ECC control button to enter the A/C

Menu screen. From the options which are displayed,

ensure the A/C compressor is switched on by placing

the “X” in the box. Refer picture below.

1. Air Distribut.

2. A/C

3. Autom. blower

(AH Astra-shows A/C on)

Note. Warranty claims must not be submitted for this

condition as this is an ECC setting issue only.

A/C

HOLDEN SERVICE TECHLINES______________________________________________________________________________MARCH, 2006

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

Yaw Rate Sensor Orientation

VZ, WL, with ESP (Electronic Stability

Program)

Group 12 Ref. No. TL1078-0602

This techline is written to inform technicians of the

correct orientation of the Yaw Rate sensor as fitted to

the above models as it has been proven possible to

reinstall it in the opposite direction.

Please refer to the attached diagram which is taken

from Passenger Vehicle SIP.

It is important to note the orientation in relation to the

front of the vehicle and also the electrical connector

into the sensor. The attaching nut torque is 7-11 Nm.

HOLDEN SERVICE TECHLINES______________________________________________________________________________MARCH, 2006

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

A/T Malfunction or Shift Problems, Various

DTC’s set.

V & W models with 4L60E or 4L65E A/T

Group 7B Ref. No. TL1076 - 0602

CONDITION

Customer may report various symptoms that suggest

incorrect shifts, changes or deterioration in the

transmission functions, and the Powertrain lamp may

be “on”.

Tech 2 may show various DTC’s are set.

DIAGNOSIS HINT

First - Define if the transmission is definitely NOT

functioning correctly – Refer to Information Techline

(TL0887-0504) in May, 2005, Issue 4, page 13.

If the transmission features information detailed in this

techline does not explain the customer’s concern, then

proceed as follows:

A possible cause for the above symptoms is a “poor”

harness connection to the transmission. Therefore it is

essential when performing any A/T related diagnostics,

to include checking the harness connection to the

transmission as follows.

1. Unplug the connection at the transmission.

2. Visually inspect for any damaged terminals. (bent

or burnt)

3. Replace harness if burnt, and/or attempt to

restraighten any bent terminals using fine nose

pliers.

4. Reconnect harness plug firmly.

5. Road test vehicle for original complaint.

SERVICE FIX

Front Lower Control Arm Bush Squeak

XC Barina

Group 3 Ref. No. TL0994 - 0602

CONDITION

On some vehicles a creak noise may be heard coming

from the front suspension control arm bush when

travelling over speed bumps.

CORRECTION – Service

After verifying vehicle has the condition as described

above, fit revised bushes (part number 93188303) to

the front lower control arms.

These revised bushes have been developed to

overcome the creak condition.

Revised bushes should be fitted to both front lower

control arms as per procedure in TIS.

PARTS INFORMATION

Part No.: Description Qty:

93188303 Lower control arm bush 2

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

HOLDEN SERVICE TECHLINES______________________________________________________________________________MARCH, 2006

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

Rear Park Assist (RPA) Behaves Erratically

With Trailer Attached

VY,VZ (wagon, sedan, coupe) WK,WL,V2 with

Factory Fitted RPA

Group 12 Ref. No. TL0991 - 0602

CONDITION

Customer complains that their vehicle’s Rear Park

Assist (RPA) system behaves erratically when they

hook up a trailer.

CAUSE

The above condition may be caused by fitment of the

wrong trailer harness, or an incorrectly fitted harness.

Notes:

The correct harness for use on VZ and WL models

fitted with RPA is part number 92144494. (Flat 7 pin ).

There are two other harnesses available for the above

models which are for vehicles without RPA (option

code UD7). Ensure that neither of these harnesses is

fitted.

The correct harness 92144494 must be installed as

per the procedure shown in the fitting instructions. A

copy of these instructions (p/n FD1095) may be found

in Passenger Vehicle SIP under “Accessories Fitting

Instructions”.

If your trailer has a round plug, you must use one of

the adapter harnesses as specified in Microcat.

SERVICE PROCEDURE

Front Brake Caliper Anchor Bolts

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

Group 5 Ref. No. TL1070 - 0602

IMPORTANT REMINDER

The front caliper anchor bolts are a “single use” only

bolt which means they must be replaced after removal.

(Also refer to PV SIP)

Also, these bolts must be tightened using the torque

turn method. (refer SIP for torque specification)

Front caliper attaching bolts.

HOLDEN SERVICE TECHLINES______________________________________________________________________________MARCH, 2006

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/h

VY & VZ – One Tonner & Crewman

Group 4 Ref. No. TL0631C-0602

This Techline supersedes the previous one in Issue 11, Dec.,

2005. It is UPDATED by adding V6 M/T to the models which

can now be fitted with the revised pinion flange (2-spoke).

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 have been introduced into

production on the specific models as listed:

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

spring. – Crewman V8 (A/T & M/T), (RWD & AWD)

• A 2-spoke pinion flange – Crewman V8 A/T (RWD

only)

Breakpoint for both countermeasures in Crewman is:

ISOVIN: Built Date:

**********L218227 09/03/2004

CORRECTION – Service

Summary: After verifying that complaint vehicle has

condition as described above, fit revised bushes in

front eye of rear springs of ALL vehicles. Also, for V8

& V6( M/T) Rear Wheel Drive ONLY - fit a 2-spoke 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 (A/T & M/T) and V6(M/T) Rear Wheel Drive

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, and V6 (M/T only)

92146565 Flange Nut

V8, and V6 (M/T only)

WARRANTY CLAIM INFORMATION

Description Replace Bush, Leaf Spring

Front Eye – Both Sides

Labour Op. No. F000197

Time 1.6 hr.

Add for V8 & V6(M/T) Rear

Wheel Drive Only - Fitting

of revised Pinion Flange

0.5 hr.

Failure Code F0040 noisy

A/T – automatic transmission. RWD – Rear wheel drive

M/T – manual transmission AWD – All wheel drive

Update

HOLDEN SERVICE TECHLINES______________________________________________________________________________MARCH, 2006

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

Exhaust drone at 2500rpm

TT Zafira, TS Astra – Z22SE engine

Model Year 2003 & 2004

(GROUP 8) TL1085-0602

CONDITION

Customers may complain of an exhaust boom, drone

or resonance noticed at 2500rpm with the engine

under load.

CORRECTION - SERVICE

On customer complaint vehicles only, install a new

front engine pipe 55558954 which includes a revised

flex element. This will reduce the noise which arose on

model year 2003 and later vehicles when the exhaust

system was revised.

PARTS INFORMATION

Part No.: Description: Qty:

55558954 Exhaust Front Pipe 1

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

SERVICE FIX

PCM, ECU, TCM, SPS Programming &

Instrument Cluster programming

All HSV models as follows -

VTII VX VY V2 VZ WH WK WL

Group 12 Ref. No. TL1084-0602

Please be aware that when replacing a PCM, ECU, TCM

or Instrument Cluster in the above mentioned HSV

models, the initial programming needs to be completed

by HSV.

Note that this only applies to NEW modules and NOT for

software updates, as TIS 2000 will allow updates once

the initial software is loaded by HSV.

To minimise the logistics of this procedure, contact HSV

on (03) 9265 9500 for their Technical Liaison personnel

to arrange for prompt parts programming and delivery.

HOLDEN SERVICE TECHLINES______________________________________________________________________________MARCH, 2006

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 Oil Life” Reset

VZ & WL HSV Gen 4 (LS2)

Group 12 Ref. No. TL1083 - 0602

When servicing any HSV vehicle fitted with an LS2

engine the “engine oil life” must be reset in the

engine control module using Tech 2 when the engine

oil is changed.

Failure to reset the engine oil life may result in the

following warning being displayed in the instrument

cluster when the ignition is cycled.

CORRECTION – Service

Summary

If this icon is displayed in the instrument cluster it will

be necessary to perform the following two procedures:

Instrument Cluster Service Engine Oil reset & Engine

Control Module “Engine Oil Life” reset.

If the vehicle is presented for scheduled servicing and

the “Service Engine Oil” icon is not displayed on the

instrument cluster it will only be necessary to perform

the Engine Control Module “Engine Oil Life” reset.

Instrument Cluster Service Engine Oil reset

procedure

If the above warning icon displays, the following

instrument cluster 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.

Engine Control Module “Engine Oil Life” reset

procedure

1. Connect Tech 2 to the vehicle and make the

following selections,

F0: Diagnostics / Model Year / Vehicle Type /

F1: Engine / V8 Gen IV / F6: Programming /

F2: Reset Engine Oil Life

Select the “Yes” soft key

Select the “Confirm” soft key

SERVICE ADVISORS NOTE

If the “Service Engine Oil” icon appears between

scheduled services on a HSV Gen 4 (LS2) (and it

has been reset at the previous service) it may

indicate the vehicle is being used under extreme

conditions.

It may be necessary to discuss with your

customer the need for additional servicing.

For additional service requirements please refer

to the vehicle service booklet.

HOLDEN SERVICE TECHLINES______________________________________________________________________________MARCH, 2006

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 excluding HSV Gen 4 (LS2)

Group 12 Ref. No. TL0890B - 0602

This Techline supersedes TL0890A-0503 in Issue 10, November

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.

Engine Type Build Date: ISO VIN:

Gen III (LS1) 05/10/2005 6G1ZK14F96L516298

HFV6 2/12/2005 **********L535578

CORRECTION – Service

The following solution applies only to Gen III & HFV6

vehicles. The solution for HSV Gen 4 is published in

Techline # TL1083 – 0602 .

If the above warning icon displays, the following reset

procedure must be performed.

4. 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.

5. 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.

6. The following will then be displayed.

7. 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 69 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”.

8. 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”.

9. 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.

HOLDEN SERVICE TECHLINES______________________________________________________________________________MARCH, 2006

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 Service Engine Oil

Warning

Labour Op. No. J000791

Time V8 - 0.4 hrs

V6 - 0.5 hrs

Failure Code J0057

NOTE: Labour operation number and time covers

instrument cluster, ECU / PCM and fuel gauge re-

programming.

INFORMATION

Coolant Usage/Replenishment Precaution

JF Viva & TK Barina

Group 6K Ref. No. TL1088 - 0602

Technicians should be aware of the possible coolant

colours and specifications for these models.

When replacing coolant, refer to the Vehicle Owner

Handbook information.

(Refer to TK Barina handbook information as follows)

Coolant specification

(if coolant is ORANGE/RED)

50%Clean water and 50% Extended life

anti-freeze Coolant (orange) conforming

to Holden Spec.GM6277M

Part Number 92145527(5 litre)

Coolant specification

(if coolant is BLUE)

50% Clean water and 50% Silicate

Coolant(green), conforming to

Holden Spec HN 2217

When replacing or replenishing coolants please note

the following:

- Orange & Red coolant can be mixed;

- Blue & Green coolants can be mixed.

DO NOT mix any other combinations of these coolants

or cooling system damage may result.

INFORMATION

Drive Belt “Excessive Wear” Appearance

VZ & WL with LS1 or LS2 V8

Group 6A Ref. No. TL1043 - 0602

Technicians (or customers) may believe that drive

belts are “excessively worn” when the belt backing

discolours or develops “stripes” or “lines” - evident at

the back of the belt as shown below:

On belt surface:-

On belt, as fitted to

an engine:

DO NOT replace belts because of this discoloration or

the “lines” or “stripes” that are evident

This is normal wear and tear from dust being trapped

between the back of the belt and idler pulleys, etc. –

and may occur more rapidly when a vehicle is driven in

dusty areas.

Discoloration is from imbedded dirt which also

increases the visibility of the back side indentations

which are inherent in the construction of this type of

belt. The “lines” coincide with pressure points created

by the belt inner reinforcing cords as in this sketch:

HOLDEN SERVICE TECHLINES______________________________________________________________________________MARCH, 2006

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

Holden Contacts and procedures

All

Group OB Ref. No. TL0679B-0602

This Techline supercedes the previous one (TL0679A-0501) in

Issue 1, Feb 2005. It contains UPDATED information.

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 the New Online

Warranty system (NOW). If the information is

unavailable on NOW then a completed security

information request form must be faxed through to the

Vehicle Security Information Centre, as security

information cannot be given out by phone. Please note

that security information requests are processed by the

Vehicle Security Information Centre and not TAS.

To ensure you have the latest security information

request form always refer to Service Forms in the

Service Bulletin section of the Holden Lionheart Portal.

Fax completed forms to the Vehicle Security

Information Centre on fax 03-96472865.

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 42/05.

Accessories and parts inquiries

If any information or assistance is required in regards

to Microcat, part numbers, Holden accessories or if

you need to contact HSPO Customer Assistance,

please refer to the Holden Help section in Microcat.

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.

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

Autostrada Ph 1800 634 343

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

Ph 02 9892 9343

Fax 02 9892 9310

www.spiceraxle.com.au

HBD DVD support (Delphi) Ph 03 8558 8313

Eurovox Ph 03 9237 0800

Fujitsu Ten Ph 03 9646 6008

Holden Assist Ph 1300 880 088

Hollandia/Webasto sunroof Ph 02 9540 4811

Fax 02 9540 4316

HSV Ph 03 9265 9500

Impco Ph 03 9584 5644

Infomedia (SIP, Partfinder) Ph 1800 810 103

Lumen Ph 03 8787 1000

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]

Triple M Ph 1800 773 030

Warranty Ph 1800 033 487

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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

Convex Mirrors On Driver’s Side

XC Tigra, TK Barina sedan,

Group 1 Ref. No. TL1098 - 0603

Some dealers report they are seeing new models such

as the above, being delivered with convex** type

external mirrors on the drivers side.

NOTE: A recent change in Australian Design Rules

(ADR’s) has now made it possible for new vehicles to

be built with “convex” mirrors on both sides of the

vehicle.

Therefore, DO NOT REPLACE the drivers side mirror

on these new vehicles thinking that they have not been

built to specification.

** Convex mirror – Objects viewed in this type of mirror

are actually closer than they appear.

DIAGNOSIS HINT

Replacement Body Control Modules (BCM)

sourced from HSPO

All V & W cars

(GROUP 12) TL1103-0603

TAS continue to receive many calls from dealers who

say they are unable to link a new replacement BCM to

the PCM/PIM.

This problem will occur if the BCM has been sourced

from HSPO and the dealer is still using the original

remotes. It is a mandatory requirement that both

remotes are replaced whenever the BCM is

sourced from HSPO.

TIP: If Tech 2 asks you to “disarm the theft deterrent

with a programmed remote key”, this is an indication

that you have not replaced the remotes or

programmed them first.

If the BCM is obtained under warranty through the

changeover program, the original remotes are to be

used (unless specified otherwise).

INFORMATION

Finding Locksmiths to cut ‘Z’ (snake) profile

keys

MY 2005 onwards – XC Barina, TS Astra, AH

Astra, ZC Vectra, TIGRA

(GROUP OB) TL1089-0603

As of model year 2005, some of our imported vehicles

have what is called a ‘Z’ or ‘snake’ style door/ignition

key profile.

As specialised equipment is required to cut this type of

key, some locksmiths may not be able to do this.

Following, is one example of a web site link that may

assist dealers to contact a locksmith in their area to

ensure they can cut this type of key.

www.masterlocksmiths.com.au

From the home page as shown, select ‘find a

locksmith’, choose Australia or New Zealand as

required and follow the prompts.

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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

Keyless Entry Remote Key Programming

Daewoo Leganza With Factory Fitted Keyless

Entry System

(GROUP 12) TL1096-0603

To program the remote key for the keyless entry system

you will need a Scan 100 tool.

Dealers who do not possess a Scan 100 tool will need to

obtain one on loan from their Zone office.

NOTE: There is no option on Tech 2 to program the

remote key for the keyless entry system on this model

as this function has not been written into the Tech 2

Software.

Programming Procedure using SCAN-100

1. From the Model Selection screen select

“GM DAEWOO” then press enter

2. From the Coding System screen select “CODING

ONLY” then press enter

3. Enter the “secret number” using 0 0 0 0

4. Select “KEYLESS ENTRY” then press enter

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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.

5. Select Lanos, Leganza, Matiz, Tacuma, Kalos

then press enter

6. After selection of this screen continue to follow the

prompts as shown on the Scan 100.

DIAGNOSIS HINT

Instruments Customisation Mode Options

Missing

VY,VZ, WK,WL

(GROUP 12) TL1090-0603

Condition

Customer advises that when selecting the

customisation mode within the multi function display

(MFD) of the Instrument cluster, some features as

described in the Owners Handbook are no longer

available.

Cause

TAS cases have shown this symptom occurs after the

customer has fitted an aftermarket accessory radio.

Because the genuine (factory fitted) radio

communicates on the serial data bus, it needs to be

present in order to display all of the audio features

within the MFD. Therefore, the genuine radio must be

refitted to display ALL previous options.

If this is not possible, it must be explained to the

owner/installer that the serial data circuit must remain

open with nothing connected to it or other

communications issues may arise.

NOTE: Any faults which arise as a result of fitting

aftermarket (non genuine) accessories as described

above are not covered under warranty.

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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

HSPO Replacement Seat Base Assemblies

VZ, WL

Group 1 Ref. No. TL1097- 0603

Some replacement HSPO front seat base assemblies

may have an earth lead attached to the inner seat

track as shown in Figure 2.

Situation A. - Existing seat base has an earth lead

attached.

If you are supplied with a replacement seat base with

an earth lead attached which is replacing a seat base

that already has an earth lead attached, then simply

replace the seat base and reattach the earth lead to

the location provided in the seat cushion frame as

shown in Figure 1.

Figure 1

Situation B. Existing seat base DOES NOT have an

earth lead

If you are supplied with a replacement seat base with an

earth lead attached which is replacing a seat base that

does not have an earth lead attached proceed as

follows:

1. Remove the earth lead by cutting the wire as close

to the inner track as possible as shown in Figure 2.

(DO NOT ATTEMPT TO DRILL OUT THE RIVET)

2. Replace the seat base as per PV SIP instructions.

3. After installation of the seat base assembly, fit a

seat base to seat frame earth spring (Part No.

92190159), as per Product Campaign 06-H-02.

NOTE: On vehicles where the campaign has

previously been completed, ensure the earth

spring is reinstalled correctly. Refer to product

campaign 06-H-02 bulletin for details of correct

fitment.

Figure 2.

INFORMATION

Use Of Accessory Cargo Barrier With Factory

Fitted LPG

VZ Wagon

Group OB Ref. No. TL1101 - 0603

The genuine Holden accessory cargo barrier cannot

be fitted on vehicles with factory fitted LPG (option

code LW2).

When the spare wheel is relocated it intrudes into the

space that the cargo barrier would normally occupy.

Microcat is currently being updated to show that the

cargo barrier cannot be fitted on vehicles with factory

fitted LPG.

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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

Intermittent Loss of Sound from the Audio

System

WK, WL, Caprice

Group 12 Ref. No. TL1102 - 0603

Customers may advise the sound from the audio

system intermittently drops out.

The following information has been received via dealer

PIR’s and is published to minimise diagnosis time

when investigating problems related to the above

symptom.

Inspect the wiring in the right hand rear quarter panel

next to the premium sound amplifier for wiring damage

(short to ground) in the location highlighted in figure 1

and figure 2.

Figure 1

Figure 2

If damage is discovered, repair the damaged circuits

and re-insulate to avoid a repeat failure.

See Figure 2

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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 P1106 “Boost Pressure Control Device

Malfunction”

TS Astra Z20LET

Group 12 Ref. No. TL1099 - 0603

CONDITION

Customers may advise the CEL light illuminates.

When Tech 2 is connected DTC P1106 “Boost

Pressure Control Device Malfunction” is set in the

engine ECU.

CAUSE

The cause of this condition may be a poor connection

in an earth splice joint within the engine harness (refer

circuit diagram in figure 1).

This splice joint provides an earth for the Coolant

Temp Sensor (B61), Intake Manifold Absolute

Pressure Sensor (B21) and the Air Mass Meter (B46).

Figure 1

CORRECTION – Service

Confirm DTC P1106 is set in the engine ECU either

history or present.

5. Locate the section of the engine harness indicated

in figure 2, on the passenger’s side of the engine

bay under the intake hose, next to the battery.

Figure 2.

6. Remove the tape from this section of the engine

harness and locate the splice joint shown in figure 3.

Figure 3

7. Remove the suspect splice joint (under the black

heat shrink in figure 3, from the harness and

renew the splice joint. Reconnect the four earth

circuits.

Note: If unsure of the approved method of wiring

repair refer to PVSIP VZ / Wiring Diagrams / Section

12P / 5. Wiring Repair Procedure / 5.3 Splicing Wiring

Using Spice Clips.

8. Re-insulate the splice joint after repair and re-tape

the engine harness.

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP disc.

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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

Searching for Service Information on Holden Dealer Portal - “Lionheart”

(GROUP OB) TL0921A-0603

( This Techline supercedes the previous one in Issue 5, June 2005. It is UPDATED with the latest procedure. )

This Techline describes how to find the following Service Information on the Holden Dealer Portal - “Lionheart”.

• Service Techlines

• All Dealer Letters

• Campaign Bulletins

• Field reworks

• Warranty Processing

• Special Warranty Component Replacements

• Service Forms.

PROCEDURE.

When you logon to the Holden Portal the Lionheart Home page will appear as shown in Figure 1.

Now select “Holden Service Bulletins”

as indicated by yellow arrow.

Figure 1

The next screen to appear is shown in

Figure 2.

HINT: This screen should be thought of as

an email inbox.

You should check this screen everyday to

view the latest information issued by

Holden Service Department.

The date at the top of the list is when

the newest bulletins were posted onto

Lionheart. In the example in Figure 2

this date is 06/03/2006.

Figure 2.

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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 view the bulletins for the 06/03/2006,

click on the “►” symbol next to the date

and a list of bulletins will appear as

shown in Figure 3.

To view any bulletin click on it.

Figure 3.

Category

If you select the “Category” button as

indicated by the red arrow in Figure 3

the screen shown in Figure 4 will

appear.

Now select the category you want.

As an example, select “Service

Techline”

The next screen to appear is shown in

Figure 5.

Figure 4

From this screen you select the model

you are interested in.

For example, click on the “►” next to

RA Rodeo

The next screen to appear is shown in

Figure 6.

NOTE: To view the full list of models

you will need to turn over to the next

page by clicking on the “next” arrow at

the top or bottom of the screen

To go back a screen, press “previous”

Figure 5

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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.

Now select the Group you are interested

in.

Example - select 02-HEATING & A/C

The next screen to appear is shown in

Figure 7.

Figure 6.

Now look through the list of Techlines

to find the one you are interested in.

NOTE: Techlines are arranged in

order of date with the newest at top of

list.

Figure 7.

Search USING THE SEARCH METHOD TO FIND INFORMATION ON LIONHEART

If you select the SEARCH function

from the screen in Figure 8 it will

search through all the Service

Information Categories as follows:

• Service Techlines

• All Dealer Letters

• Campaign Bulletins

• Field reworks

• Warranty Processing

• Special Warranty Component

Replacements

• Service Forms.

To shorten the search process, select

the SEARCH function only after you

are in the particular category you are

interested in.

Following, is a description of how to

search for Service Techlines.

Figure 8

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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.

Searching for Service Techlines

From the screen shown in Figure 9

click on the “Search” key. This will

bring up the screen shown in Figure

10.

Figure 9

This is the search screen used for

entering “keywords” to search for.

It is important to enter the right words

here in order to find what your looking

for.

Figure 10

As an example (Figure 11) try

searching for Techlines related to JR

& JS Vectra Ignition Barrel

Jamming.

In the top window, type in the following

“search string” exactly as shown.

“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. Shown

with the red arrow.

Figure 11

The search result is 2 documents as

shown in Figure 12.

Click on the hot-key section (in blue)

to view the techlines.

Figure 12.

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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.

Notes on choosing “Keywords”

for searching

If we had only entered “ignition key”

without any model descriptor, this

would have located 25 items as shown

in Figure 13.

If we had only entered “ignition”, the

search would have located 86 items.

This demonstrates the importance of

selecting the right “keywords” to

search with so you don’t end up with

large numbers of items to read

through.

Rule of thumb: - The less

information in the “search window”

the more information comes back.

HINT: 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 in Figure

13.

Figure 13.

Searching by Techline Number

Use this procedure if you have an

existing techline and you want to

check to see if there is a later version

on Lionheart.

Example. - Search for the latest issue

of techline TL0679.

Type “TL0679*” in the search window

as shown in Figure 14.

Tick the last 2 boxes - “Use Word

variants” and “Fuzzy search”.

The latest version found will be

TL0679B-0602.

Figure 14

Searching Other Categories

The search procedure described

above for Service Techlines may also

be used for Dealer Letters, Campaign

Bulletin, Field rework, Warranty

Bulletin, etc. You must first select the

category you want from the Category

screen (Figure 15) before proceeding

with search.

Use the same procedure as that

described for a Service Techline.

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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 15.

Doing a “General” search.

To find ALL published information on

a particular subject, select “Search”

from screen shown in Figure16.

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 16

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 as shown in Figure 13. This will bring up the “active” search window. Delete the current

search keywords then enter some new keywords and press “search” again.

• The search engine cannot search any “attached” files for keywords. For example, in Figure 17, the search engine

will search through every word that actually appears on the screen as shown. It cannot search through the

attached file, viz “02-587A RA Airmix cable adjust.pdf”.

Figure 17

HOLDEN SERVICE TECHLINES________________________________________________________________________________APRIL, 2006

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.

• “Use Word Variants”

If you tick this box in the search panel (refer Figure 18) 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.

Figure 18.

• 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 type in 4JX, a fuzzy search will still find all techlines with 4JX1 in the title.

NOTE: this feature doesn’t work if you forget to enter the first letter. In this example, doing a Fuzzy search on JX1 will

not find anything.

HOLDEN SERVICE TECHLINES_________________________________________________________________________________MAY, 2006

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

Glove Box Light Deletion

VZ (MY06 base level vehicles only)

Group 12 Ref. No. TL1121 - 0604

Customers may advise their new vehicles glove box

light is missing.

Technicians need to be aware that as of MY06, base

level vehicles have intentionally been built without a

glove box light and associated wiring.

Base level 2006 model year vehicles can be identified

by the “K” and the “6” (highlighted) in the VIN as per

the following example:

6G1ZK32B26L544522

Base model = K, Model Year 2006 = 6

Don’t try to fit the glove box light because the vehicle

has no wiring to support it.

SERVICE HINT

Programming New Instrument Clusters

(Programming Odometer Value)

All with programmable instruments

Group 12 Ref. No. TL1112-0604

This is a reminder to all technicians when programming

new instrument clusters, to confirm the odometer value

is correctly entered before programming.

IT IS NOT POSSIBLE TO CORRECT THE

VALUE ONCE PROGRAMMED.

All 6 digits have to be entered correctly as shown in the

following examples.

Example 1. - value to be entered is 15,000 km’s.

Enter as 015000.

Example 2. – if the value to be entered is 8100 km’s.

Enter as 008100

Example Tech 2 screen

All 6 Digits

Must be

used

HOLDEN SERVICE TECHLINES_________________________________________________________________________________MAY, 2006

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

Instrument Cluster Telltales Illuminated And

No Communication With Tech 2

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

Group 12 Ref. No. TL1124 - 0604

PROBLEM DESCRIPTION

If presented with a vehicle where the instrument cluster

telltales are illuminated and Tech 2 will not

communicate with any module on the serial data

network. Usually the engine will start and run.

This condition is caused by a loss of communication on

the serial data network.

Diagnosis Hint

If the engine runs, then the problem is not between

the PCM/PIM and BCM which is the primary serial data

line but rather on the secondary serial data line from

the BCM to the other modules, i.e., ECC/OCC, Radio,

ABS, PSA, SDM, Instruments, Telematics, AIM, and

Memory Seat Module. (N.B. not all vehicles will have

all these modules fitted).

If the engine does not run, then there may be an

issue relating to the primary serial data circuit between

the PCM/PIM and BCM or one of these modules.

NOTE. There is a specific diagnostic chart in

Passenger Vehicle SIP to assist technicans in

diagnosing serial data concerns. Please ensure that

this is followed prior to contacting TAS. This chart can

be found by selecting the vehicle type, then selecting

electrical system, 12J Body control module, diagnosis

and then serial data communication. An example of

where this chart is located for a VT is shown as

follows.

Acronyms Used In Techline TL1124-0604

ECC - Electronic climate control

OCC - Occupant climate control

ABS - Antilock brake system

PSA - Premium sound amplifier

SDM - Sensing diagnostic module

AIM - Audio interface module

PCM - Powertrain control module

BCM - Body control module

PIM - Powertrain interface module

SIP - Service information package

TAS - Technical assistance service

DIAGNOSIS HINT

Additional Electric Antenna Fuse

VZ (with Lux or High Series BCM), WL

Group 12 Ref. No. TL1116 - 0604

Technicians need to be aware when diagnosing an

inoperative electric antenna which has no power at the

antenna connector, that an additional 5 amp in-line

fuse was added to the above vehicle variants in

production from 30/03/06.

This additional fuse was added to protect the BCM in

the event of overload caused by damage to the electric

antenna.

Figure 1 shows the location of the additional fuse in the

drivers kick panel (next to the accelerator pedal).

Figure 1

HOLDEN SERVICE TECHLINES_________________________________________________________________________________MAY, 2006

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

Power Windows “Auto Drop” Function

Inoperative

XC Tigra

Group 12 Ref. No. TL1123 - 0604

When opening the doors or the roof on an XC Tigra,

the driver and/or passenger window should drop down

to create clearance so the door or roof can be opened

easily. This function is also linked to the auto-down

function of the power windows.

PROBLEM DESCRIPTION

If you are presented with a vehicle where the windows

do not drop when the roof or door is opened, and the

window auto-down function does not work, then the

electro-hydraulic roof control unit may be programmed

with “assembly mode” enabled.

This condition may occur when:

 a vehicle is new,

 a window regulator or hard-top control module is

replaced

 the battery is disconnected.

CORRECTION

To disable “assembly mode” the control unit will need

to be reprogrammed as follows.

Programming is done with Tech 2 by selecting body,

electro-hydraulic hardtop, programming and then either

“replace driver’s window lifter” or “replace passenger’s

window lifter” as required.

Follow the Tech 2 prompts and answer the questions

accordingly.

• If “assembly mode” is enabled, then disable it by

following instructions on Tech 2 and then retest the

window operation.

• If “assembly mode” is disabled, follow normal

diagnostic processes in TIS 2000 to determine the

cause of the concern.

SERVICE FIX

Unable to Electrically Lock Or Unlock

Individual Doors

VY, WK, V2, VZ, WL

Group 12 Ref. No. TL0982 - 0604

CONDITION

Random failures of front or rear door lock actuators

causing individual doors not to electrically unlock or

lock.

CORRECTION – Service

Perform standard diagnosis using PV SIP.

If diagnosis identifies the door actuator as being faulty

replace the complete lock and actuator assembly

(parts listed below).

NOTE: When repairing vehicles during the

warranty period, replace the lock and actuator

assembly. Do not replace the actuator only.

Replacement of the lock and actuator assembly is

overall more cost effective than replacing the actuator

on its own, when comparing the labour time and cost

of parts for each situation.

PARTS INFORMATION

Part No.: Description

92187613 RHR Lock & Actuator Assembly

92187612 LHR Lock & Actuator Assembly

92187611 RHF Lock & Actuator Assembly

92187610 LHF Lock & Actuator Assembly

WARRANTY CLAIM INFORMATION

Part No.: Description

C622000 Lock Asm. RH Front Door - Replace

C623000 Lock Asm. LH Front Door - Replace

C642000 Lock Asm. RH Rear Door - Replace

C641000 Lock Asm. LH Rear Door - Replace

HOLDEN SERVICE TECHLINES_________________________________________________________________________________MAY, 2006

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

Sluggish On Takeoff and/or Transmission

Thumps After Takeoff

VZ, WL, Gen 3 A/T only

Group 7B Ref. No. TL1080 - 0604

CONDITION

Customers may complain that intermittently their car is

sluggish on take off, feeling like it may not be in 1st

gear. The transmission may also “thump” as it

downshifts from 2nd to 1st gear

This fault is very intermittent and may not easily be

reproduced by the dealer.

CAUSE

It is caused by erratic transmission output shaft speed

signal to the PCM at low speed, causing the vehicle to

initially take off in 2nd gear.

A revised calibration is available via TIS 2000 Version

70.0.

CORRECTION – Service

On any vehicle with the above symptoms, the

following 3 steps must be performed.

1. 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 70 or later.

NOTE: For detailed instruction on this process refer

to Holden Lionheart portal - Service Techlines\ TIS

2000\ Programming Procedures\ “Engine ECU/PCM

SPS”.

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\ TIS

2000\Programming Procedures\ “Instrument Cluster

SPS”.

3. 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\ TIS

2000\ Programming Procedures\ “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.

WARRANTY CLAIM INFORMATION

Description Reprogram PCM, Instrument

cluster Fuel Gauge

Labour Op. No. K000318

Time V8 - 0.4 hrs

Failure Code K0047 Flat spot or hesitates

NOTE: Labour operation number and time covers

instrument cluster, ECU / PCM and fuel gauge re-

programming.

DIAGNOSIS HINT

Engine Won’t Start After Vehicle Has

Experienced A Flat Battery

DAEWOO Matiz

Group 6C & 12 Ref. No. TL1125-0604

CONDITION

Vehicle is presented with condition where engine will

crank and not start. DTC P1602 may be logged in

ECU. Problem usually happens after vehicle has

experienced a flat battery due to ignition or lights left

on, etc.

POTENTIAL CAUSE

It is possible for the vehicle Immobilizer system to

“lose” the key coding if the battery voltage goes low.

SUGGESTED CORRECTION

• Ensure the vehicle battery is in good condition and

fully charged.

• Ensure all the vehicle’s keys are available prior to

performing the key coding and neutral conversion

procedure using either Tech 2 or Scan 100.

• If this fails to get the car started, then carry out

normal immobilizer diagnosis as per Daewoo SIP.

HOLDEN SERVICE TECHLINES_________________________________________________________________________________MAY, 2006

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

Discolouration And Paint Swelling Observed

At Pre Delivery

AH Astra

Group 1 Ref. No. TL1107 - 0604

Condition:

There have been isolated reports of paint

discolouration on horizontal surfaces on AH Astra at

pre delivery.

The light metallic colours seem to be the most

commonly affected.

Cause:

When applying the wrapguard (used for paint

protection when shipping), it is impossible to avoid

folds and bubbles. Moisture can be trapped in these

folds and bubbles and, over the shipping time, can

cause paint swellings and discolourations.

Correction:

After removal of the wrapguard at Port Of Entry, these

swellings and discolourations will normally disappear

after the car has been exposed to the sun for a couple

of days.

If the swellings and discolourations are still evident at

Predelivery Inspection, they may be treated with the

application of heat.

For small areas, a heat gun may be used to gently

heat the area until the condition is reversed. DO NOT

OVERHEAT the surface.

For larger areas, and closer control of the application

of heat, a baking oven may be used.

NOTE: The temperatures and times typically required

to achieve reversal of the condition are described in

the material specifications of the shipping wrapguard

as follows.

2.0 hr ± 5 min at 60°C ± 3°C or if this fails,

0.5 hr ± 5 min at 80°C ± 3°C

If the swellings and discolourations are still evident

after heating, then you should seek Zone approval for

a paint repair.

HOLDEN SERVICE TECHLINES_________________________________________________________________________________MAY, 2006

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

Low Traction Event Occurs Unnecessarily

During Take Off

VZ, WL, without ESP

Group 5 Ref. No. TL1042A-0604

This Techline supercedes the previous one in Issue 11,

Dec, 2005. It is UPDATED to include auto transmission

vehicles.

CONDITION

During take off, a low traction event occurs

unnecessarily. The low traction indicator is illuminated.

POSSIBLE CAUSE

This condition could be due to an insufficient air gap

between rear wheel speed sensors and tone wheel.

SUGGESTED 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

DIAGNOSIS HINT

ABS/ESP Warning Light Illuminates

Unnecessarily, DTC C0245 Logged.

VZ, WL, with ESP

Group 5 Ref. No. TL1127-0604

CONDITION

When shifting between gears whilst stationary e.g. -

Park to Drive or Drive to Park, the ABS warning light

illuminates and DTC C0245 is logged.

POSSIBLE CAUSE

This condition could be due to an insufficient air gap

between rear wheel speed sensors and tone wheel.

SUGGESTED CORRECTION

Check air gap measurement and adjust if required.

 Check air gap of both of the rear wheel speed

sensors.

 Air gap needs to be 1.5mm.

 If less than 1.5mm, use shim part number

90278359 to achieve the correct air gap spacing.

DO NOT replace the ABS module for this condition.

PARTS INFORMATION

Part No.: Description Qty:

90278359 Shim 1

HOLDEN SERVICE TECHLINES_________________________________________________________________________________MAY, 2006

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

LPG Heater Hose Connection Leak

VZ LPG

Group 6M Ref. No. TL1095 - 0604

CONDITION

A coolant leak at the heater hose connections for the

LPG converter.

CAUSE

The fittings that are installed into the existing heater

hoses to provide coolant to the LPG converter,

consists of an alloy spigot and a nut to retain the fitting

into the heater hose. It is the nut component of the

fitting that is loose and causing the leak. Refer Figures

1 and 2.

Figure 1

CORRECTION – Production

Loctite was applied to the heater hose fitting nut on

vehicles from

ISOVIN: Built Date:

- 07/03/06

CORRECTION – Service

Summary: After verifying that vehicle has condition as

described above, apply loctite to the nut on the fitting

and re-tension.

Procedure

1. Loosen nut from fitting to expose thread.

2. Apply a spot of loctite 262 or equivalent to the

thread.

3. Reinstall nut and torque to 4 Nm.

Figure 2.

WARRANTY CLAIM INFORMATION

Description Rectify leak at LPG heater

hose connection. (2 places)

Labour Op. No. J000803

Time 0.4 hr

Failure Code J0042 leaks

SERVICE PROCEDURE

HFV6 Timing Cover Removal

VZ, WL

Group 6A Ref. No. TL1110 - 0604

When performing any work on a HFV6 engine that

requires removal of the front timing cover, technicians

must ensure that they are following the procedure

outlined in SIP.

Particular attention needs to be paid to draining the

coolant prior to removal of the timing cover.

Failure to do this may result in coolant entering the oil

pan and contaminating the oil. This may lead to

incorrect diagnosis of a perceived engine problem (e.g.

head gasket) or damage to the engine.

Refer to Passenger Vehicle SIP section 6A1 for the

correct procedure.

HOLDEN SERVICE TECHLINES_________________________________________________________________________________MAY, 2006

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)

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

Group 3 Ref. No. TL0718B-0604

This Techline supercedes the previous one in Issue 2, Mar,

2005. It is revised by including all V & W models as shown. It

also applies to 2WD / AWD and all model variants

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 – Production

Torque on all front cross member bolts increased to

135 – 140 Nm from:

ISOVIN: Built Date:

**********L540735 28/11/2005

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

Figure shows AWD front end.

Update

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JUNE, 2006

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 On Rear Of Cylinder Head

VY, VZ, WK, WL, V8 Engine

Group 2 Ref. No. TL0867A - 0605

This Techline supercedes the previous one (TL0867-0510)

in Issue 10, Nov. 2005. It is UPDATED by including A/T

models and by revising the method of correction.

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 – Vehicle Production

Production rectification happened in two stages.

The 1st stage was to revise the shape of the clutch pipe

on M/T vehicles to provide greater clearance between

the heater hoses and cylinder head.

Revised clutch pipe was fitted to M/T vehicles from:

ISOVIN: Built Date:

**********L484030 01/08/05

The 2nd stage was to add a butyl patch to the rear of

RH cylinder head to protect the heater hoses from

sharp edges.

Butyl patches were added to all V8 models from:

ISOVIN: Built Date:

**********L816323 12/4/06

CORRECTION – Vehicles in Service

On any vehicle where the heater hose is being

replaced, proceed as follows:

Manual Transmission Vehicles.

1. On vehicles built before 1/8/2005, route the new

hose between the clutch pipe and the dash panel as

shown in Figure 1.

On vehicles built after 1/8/2005 (fitted with revised

shape clutch pipe) route the new hose in front of the

clutch pipe.

2. If not already fitted, apply butyl patch 92018621 to

the rear of the cylinder head as shown in Figure 2.

Ensure that the head surface is thoroughly clean

before applying patch.

Automatic Transmission Vehicles.

If not already fitted, apply butyl patch 92018621 to

the rear of the cylinder head as shown in Figure 2.

Ensure that the head surface is thoroughly clean

before applying

PARTS INFORMATION

Part No.: Description Qty:

92018621 Butyl sheet 1

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

Figure 1. Heater hose routing on M/T vehicles built prior to L484030 (built 1/8/2005)

Route hoses behind clutch pipe

Dash panel

glue track

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JUNE, 2006

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. Butyl patch (92018621) applied to rear of

RH cylinder head (Auto. Trans. engine shown)

INFORMATION

Oxygen Sensor Software Improvements

VZ, WL, with 190 kW HFV6

VZ Cross 6 AWD with 175 kW HFV6

Group 6C Ref. No. TL1133 - 0605

Revised software to improve the durability of Oxygen

sensors in the above models was introduced from TIS

2000 version 69.0.

Therefore, whenever replacing the O2 sensors on any

models as listed above, the engine calibration should

be updated with the latest software from TIS 2000

version 69.0 and later.

IMPORTANT:

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.

1. 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 69 or later.

NOTE: For detailed instruction on this process refer

to Holden Lionheart portal, Service Techlines\

TIS 2000 \ Programming Procedures \ “Engine ECU

/ PCM SPS”.

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 \ TIS

2000 \ Programming Procedures \ “Instrument

Cluster SPS”.

3. 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\ TIS

2000\ Programming Procedures\ “Instrument Cluster

Fuel Gauge Calibration”.

NOTE: The software revisions for improved O2 sensor

durability were introduced in vehicle production at

Model Year 2006.

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JUNE, 2006

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

“Safety Mode / Reduced Performance”

Displayed in Instruments MFD

VZ,WL, V6 and 6.0L V8 (L76) Auto. Trans. only

(GROUP 12) TL1109-0605

CONDITION

The customer may report seeing the warning “Safety

Mode / Reduced performance” displayed in instrument

cluster MFD (Multi Function Display). Refer figure 1.

Also, the automatic transmission may default to top gear.

(Fail safe mode)

No DTC’s are set, and Tech 2 can communicate with all

modules including the TCM (Transmission Control

Module) i.e. it passes an ‘ECU presence check’

Figure 1. Instrument Cluster MFD Message

POSSIBLE CAUSE

A possible cause of this fault is no ignition power supply

to the TCM

Note: Ignition supply voltage can be seen using Tech 2

in transmission datalist: “IGNITION VOLTAGE – 12V”

Note: Tech 2 will continue to communicate with the TCM

even without ignition power.

V6 Engine: A potential cause of this is a poor

connection or backed out terminal in either connector

X103 8 pin located near the engine ECU Refer figure 2

or connector X104, a 4 pin connector located at the rear

of the L/H cylinder head, Refer figure 3.

Ignition power supply to the TCM is via fuse 8 and then

passes through these connectors.

V8 6.0L (L76) Engine: The ignition supply to the TCM on

an L76 V8 engine passes through connector X101, a 5 pin

located near the air cleaner housing. Refer figure 4.

SUGGESTED CORRECTION

If presented with a vehicle with the condition as

described above, use Tech 2 to check the ignition supply

voltage into the TCM.

If no voltage is present, check fuse 8 (Automatic

Transmission) is ok. If this fuse is blown, check the entire

circuit to locate the reason for the failure. If the fuse is

intact, ensure proper terminal retention in the

connectors X103 & X104 V6, or X101 V8 and the

connectors are secured together properly.

If this fails to correct the problem then do standard

electrical fault diagnosis on the remainder of the circuit.

Figure 2 (V6)

Figure 3 (V6)

Figure 4 (6.0L-V8)

Front of Engine

Engine Computer

Rear of

Engine

X101

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JUNE, 2006

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

Replacing Entertainment Head Units (Radios)

ZC, AH, XC with BLAUPUNKT CD30 or CD40

Units Fitted

(GROUP 12) TL1138-0605

PROBLEM DESCRIPTION

Many dealers contact TAS because they have replaced

Blaupunkt CD 30 or CD 40 radio head units and then

found that the unit is not working properly or there are

messages on the information display such as “display

safe” or “radio safe”.

Dealers need to be aware that these radio units are

security linked to the information display in the vehicle

and need to be reset prior to being removed from the

vehicle. The replacement radio then needs to be linked

to the display with Tech 2. The radio also needs

various parameters to be programmed in with Tech 2.

Radio Replacement procedure

Whenever removing a radio unit and replacing it

with another, the following procedure must be

adhered to.

1. Obtain vehicle security number, ie immobiliser

number (refer vehicle security card, dealer records or

Dealer Letter 42/05).

2. With Tech 2 select the following.

Infotainment system, EHU (entertainment head unit),

programming, reset ecu, and then follow the Tech 2

prompts.

3. Remove the radio.

4. Fit the new radio.

5. With Tech 2 select the following.

Infotainment system, EHU (entertainment head unit),

programming, program ecu, and then follow the Tech 2

prompts.

NOTE: Failure to reset an entertainment head unit prior

to replacement may result in the radio not being

accepted under warranty.

INFORMATION

Fuel Filter Staining

XC, TS, TT, ZC

Group 6M Ref. No. TL1128 - 0605

CONDITION

Dealers have been reporting stained appearance of the

end cap of the fuel filter as shown in photograph.

Investigations have resulted in improvements to the

fuel filter manufacturing process to eliminate the above

condition.

Fuel filters from the improved manufacturing process

have been fitted to vehicles from:

ISOVIN: Built Date:

W0L0XCF2553051901 29/04/2005

W0L0TGF485G091908 28/04/2005

Dealers are requested to only submit PIRs if the above

condition is observed on vehicles built after the above

breakpoints.

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JUNE, 2006

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

Noise From Centre Of Steering Wheel When

Turning

AH Astra

Group 9 Ref. No. TL1094 - 0605

CONDITION

Chafing noise from Column Integration Module (CIM)

may occur when turning steering wheel.

CAUSE

Relative movement between centre of steering wheel

and the unlocking mechanism of the winding spring.

CORRECTION

Summary: After verifying that vehicle has condition as

described above, fit noise insulating tape as per

following procedure. Do Not replace CIM for this

condition.

1. Remove the steering wheel as per procedure in

TIS 2000. Refer Standard Service Information,

Group M "steering wheel replace”, (Document No.

00601214).

NOTE: When removing the steering wheel do not

move the position of the steering angle sensor

otherwise the sensor must be recalibrated.

2. Add a 20 mm strip of self adhesive anti-squeak

tape (cut from 92149173) to cover the indentation

in the hub on the underside of the steering wheel.

Refer figure 1. Trim tape to shape of the boss. i.e.

cut off any overhang.

NOTE: To improve the adhesion of the tape, degrease

the hub first. Ensure that you wait 45 minutes before

reinstalling the steering wheel to allow the adhesive

tape sufficient time to cure.

Figure 1. View of underside of steering wheel.

Figure 2.

PARTS INFORMATION

Part No.: Description Qty:

92149173 tape (20 cm length) 1

WARRANTY CLAIM INFORMATION

Use standard Labour Times found in the Warranty

Information section of the current PV SIP disc for

Remove and Replace Steering Wheel.

Use sharp blade to trim

tape to shape of hub.

(cut off overhang)

Add tape to this area

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JUNE, 2006

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 End Suspension – Metallic Clunk Noise

AWD Adventra, X6 and X8 Crewman

Group 3 Ref. No. TL1079 - 0605

Note: Previous techlines on AWD clunk must be carried

out before attempting this procedure. Refer Techlines:

TL0638-0403 (Issue 3, 2004) and TL0718B-0604

(Issue 4, 2006).

CONDITION

A metallic clunk is heard from the front suspension

when braking over rough surfaces.

CAUSE

Excessive movement of the lower control arms which

cause impact noise to be transferred through the

bushes into the suspension cradle.

CORRECTION – Service

Summary: After verifying that vehicle has condition as

described above, remove and rotate front lower control

arm front bush by 45 degrees.

Figure 1. (Drivers side)

Figure 2. (Passenger side)

Figure 3. Shows front bush in original orientation

1. Place vehicle on hoist and remove the front

wheels.

2. Remove the steering tie rod ball joint from the

knuckle.

3. Support lower control arm with a transmission jack.

4. Remove the front and rear bush bolts from the

control arm and lower the control arm out of the

cradle, supporting it on the transmission jack.

Note: It is not necessary to remove the control

arm from the vehicle. It can rest on the

transmission jack and remain connected to the

control arm ball joint.

5. Use control arm front isolator bush removing tool

number CH-47568 (details of tool in SIP) to remove

the front bush from the cradle. Refer figure 4.

Figure 4.

6. Rotate bush 45 degrees toward the centre of the

vehicle as per figure 1 and 2.

7. Reinstall bush into the cradle using tool CH-47568.

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JUNE, 2006

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 5.(Reinstalling bush)

8. Install bush to the dimensions 338+/-0.5mm from

the rear of the bush to the rear bush mount as

per figure 6.

9. The bush should have the voids at a 45 degree

angle from vertical as per figure 7.

10. Reinstall lower control arm ensuring new bolts

are used.

11. Reinstall steering arm to knuckle.

12. Repeat procedure on other side of vehicle.

Figure 7 Passenger side bush after rotation)

PARTS INFORMATION

Part No.: Description Qty:

92138666 Bolt-Lower control arm-Front 2

92138729 Bolt-Lower control arm-Rear 2

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD.

E100010 - Bush Asm Front Lower Control Arm replace

both sides.

Figure 6. The distance from the inner flange of the front isolating bush (1) to the rear land (2) for the rear

bush in the front crossmember cradle (3) is to be 338 +/- 0.5mm

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JUNE, 2006

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

Auto. Trans. Shift Improvement with Cruise

Control Engaged

VZ Adventra Model Year 06 with V6

Group 7B Ref. No. TL1114 - 0605

CONDITION

Customers may complain that, while cruise control is

engaged, their vehicle:

• holds an unnecessarily low gear on hills;

• overshoots the set speed on hill crests;

• holds a low gear for too long.

CAUSE

Transmission calibration.

CORRECTION – Service

Should the customer complain, and after verifying that

vehicle has condition as described above, reflash the

PCM with the latest software from TIS 2000 Version

71.0 (or later).

Calibration detail:

92192030 – VZ Adventra, Non-SX6 (replaces 92189905)

92192031 – VZ Adventra, SX6 (replaces 92189906)

WARRANTY CLAIM INFORMATION

Use Labour Times information in Warranty Information

section of current PV SIP CD

Model Year Identification

6 G 1 Z K 5 2 B 0 6 L 8 7 6 5 4 3

Model Year Code: 6 = 2006

SERVICE FIX

HVAC Air Recirculation Door Servo Motor

Clicks Continuously

ZC Vectra

(GROUP 2) TL1139-0605

CONDITION

A continuous clicking noise may be heard from the

HVAC case area when recirculation is turned on. This

may be caused by internal gear failure in the recirc

door motor.

CORRECTION – Production

Revised recirculation door servo motor with improved

internal gears has been fitted in production from:

ISOVIN: Built Date:

W0L0ZCF6861035268 21/10/05

CORRECTION – Service

Once this has been confirmed as the cause of the

noise, replace the recirculation door motor with a

revised part. Do not fit old level parts.

PARTS INFORMATION

Part No.: Description: Qty:

13192013 Motor- servo, air flap 1

The part number for the servo motor has not changed.

The old parts have 11V printed on the label in the top

right corner. The revised parts have 13V printed in the

same location and a date stamp of 10/10/05 or later.

Refer to figure 1.

Figure 1

WARRANTY INFORMATION

Use standard Labour Times found in the Warranty

Information section of the current PV SIP disc.

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JULY, 2006

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

Trip Computer Fuel Readings Inaccurate

Group 12 Ref. No. TL1149 - 0606

CONDITION

Customers may advise their trip computer average fuel

and average speed displays are inaccurate.

For example, some customers have advised the

average fuel value displayed by their instrument cluster

is 99.9 litres per 100 km and the average speed

displayed is approximately 4.5 km/h.

CAUSE

This condition may be caused by incorrectly

programming the instrument cluster configuration.

CORRECTION – Vehicle Production

Vehicles built from the 18th of May 2006 have been

confirmed to be programmed correctly.

CORRECTION – Vehicles In Service

Summary: After verifying that vehicle has condition as

described above, program the correct PPK value using

Tech 2.

1. Using Tech 2 check the instrument cluster

configuration list to ensure the PPK value has

been programmed correctly.

2. Road test the vehicle to confirm the customer

complaint has been rectified.

WARRANTY CLAIM INFORMATION

Use standard Labour Times found in the Warranty

Information section of the current SIP disc.

INFORMATION

Central Locking Remote Battery

Replacement

JF Viva & TK Barina

Group 12 Ref. No. TL1147 - 0606

When required during scheduled servicing, the above

vehicles require the central locking remote batteries to

be replaced.

The battery required for a JF Viva is CR1616 and is

available from HSPO.

The battery required for the TK Barina is CR1620 and

is not available from HSPO. This battery will need to

be sourced from your local electrical retailer.

CR1616 and CR1620 are not interchangeable

because they are different thicknesses.

DON’T TRY TO MAKE THE WRONG BATTERY FIT !

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JULY, 2006

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

SRS Light Illuminates and DTC 161 sets in

the SRS module

VZ / WL

Group 12 Ref. No. TL1146 - 0606

CONDITION

Customers advise the SRS light has illuminated after

the vehicle battery voltage has been low.

A check with Tech 2 reveals that DTC 161

“Configuration Mismatch” is set in the SRS module

CAUSE

This DTC may set for several reasons listed below,

1. When the SRS configuration programmed in the

instrument cluster is different from that

programmed in the SDM.

2. If the instrument cluster is disconnected from the

vehicle and the ignition is cycled.

3. If the battery voltage is low enough for the

instrument cluster to switch off but the SDM to be

still powered and the ignition is cycled.

CORRECTION – Vehicles In Service

Discuss with the customer the events prior to the SRS

light illuminating,

1. Check the instrument cluster configuration is

correct for the vehicle and if incorrect, rectify.

2. Check if the instrument cluster has previously been

removed and the ignition cycled (e.g. visited a

panel shop).

3. Check if the vehicle battery voltage has been low

or if the vehicle has required jump starting.

Don’t just clear the DTC. Determine what caused the

DTC to set. Once cause is rectified, then clear the DTC.

DIAGNOSIS HINT

Electronic Throttle Control, DTC P1555

TS, AH Astra

Group 6C Ref. No. TL1047 - 0606

PROBLEM DESCRIPTION

Customer may complain of check engine light coming on

intermittently and/or reduced engine power. This fault

may be very intermittent.

A DTC check may indicate a history fault code as follows:

DTC P1555 Throttle Position Sensor – Load signal not

plausable with Engine Load.

This DTC may not be easily reproduced on a roadtest.

DIAGNOSIS HINT

This is a reminder to technicians that DTC P1555 is a

“calculated” DTC based on mass airflow, engine load

and current throttle position. It does not necessarily

mean a fault with the electronic throttle body or

associated wiring.

POTENTIAL CAUSE

DTC P1555 is often caused by restrictions or leaks into

the air intake system, before or after the mass airflow

meter. It may also be caused by the airflow meter being

inadvertantly reinstalled back-to-front.

SUGGESTED ACTION

• Ensure the mass airflow sensor is installed facing in

the correct direction by inspecting the arrow which

indicates the direction of air flow through the sensor.

• Check the entire air intake system, including the air

filter and the air box intake, for leaks or restrictions

caused by leaves or bags etc.

• If all the above checks are ok, follow standard

diagnosis as per TIS.

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JULY, 2006

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

Rear Wheel Speed Sensor Damage

VY,VZ, One Tonner & Crewman with ABS

Group 5 Ref. No. TL1108 - 0606

CONDITION

The warning “ABS Fault" displays in instrument

cluster, ABS inoperative, DTC C0045 or DTC C0050

present.

CAUSE

The wheel speed sensor harness may be dislodged or

damaged by road debris

Figure 1. Damaged wheel speed sensor harness

CORRECTION

1. After verifying that vehicle has condition as

described above, install a new "Sensor Asm - rear

wheel speed."

2. To ensure retention of sensor harness, attach 3

cable-ties (92138082) adjacent to the 3 retainer

clips as shown in Figure 2.

PARTS INFORMATION

Part No.: Description Qty:

Refer

Microcat

Sensor Asm – rear wheel

speed

92138082 Cable tie

Figure 2. Add 3 cable ties as shown.

INFORMATION

V8 Engine Identification by Engine Number

Prefix

V & W Series – 5.7/6.0 litre V8

Group 6A Ref. No. TL1087 - 0606

Technicians may have difficulty identifying V8 engine

types, for diagnosis of any problems, or procuring parts,

etc, as the V8 engines - LS1 (5.7 litre), L76 (6.0 litre),

LS2 (HSV 6.0 litre) and L98 (6.0 litre) - look similar.

The following table defines V8 engine number prefixes

that are stamped on 5.7 or 6.0 litre V8 engines, to help

identify the type of engine being worked on:

Engine Type Engine No.

Prefix

LS1 (5.7 litre) VF * Purge Valve

behind T/body

L76 (6.0 litre) 6MB

LS2 HSV (6.0 litre) VF * Purge Valve

above Eng No.

L98 (6.0 litre) – VZ A/T 7NB

L98 (6.0 litre) – VZ M/T CAK

L98 (6.0 litre) – VE A/T 7NC

L98 (6.0 litre) – VE M/T 7ND

LS2 HSV (6.0 litre) - VE ZLF

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JULY, 2006

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

Correct A/T Identification for SRTA Requests

VY, VZ, WL, V2, RA, VE, WM

Group 7B Ref. No. TL1148 - 0606

CONDITION

Incorrect SRTA exchange transmissions are being

received at Dealerships from SRTA.

CAUSE

Incorrect identification of transmission type requested

by Dealership personnel via incomplete/incorrect

information on SRTA TRANSMISSION ORDER FORM.

NOTE: Transmission serial numbers no longer carry

serial numbers that coincide with vehicle build date or

model year.

CORRECT PROCEDURE

(1). Vehicles with Original Equipment (OE)

Transmission:

The transmission serial number as read

off the transmission case must be

provided to SRTA to ensure that a correct

exchange transmission will be supplied.

The following diagram shows the location of the

transmission serial number – for recording on the

SRTA TRANSMISSION ORDER FORM:

(2). Vehicles fitted with a SRTA Transmission:

Transmission ID/Serial number location For

SRTA Transmissions ONLY

SRTA transmissions are identified by a GREEN plate

attached to the RH side of the transmission case with

the word “Hydramatic” at the top of the plate.

For Reference only: ACDelco® remanufactured

transmissions are identified by a BLUE plate attached to the

RH side of the transmission case with the word ACDelco at

the top of the plate.

Both of these plates “over-ride” the O.E. number

stamped on the trans. case, and include: Model

Identifier, Julian Date and Individual Transmission

Serial No. (as mentioned above).

This information MUST be used where a SRTA

transmission suffers a failure requiring replacement of

the unit. Warranty acceptance on such a unit is

defined by distance travelled, or date of fitting the unit

to date of failure (24 month/50000km parts warranty

applies).

NOTE: Both SRTA and ACDelco remanufactured

transmissions are painted silver and OE transmissions

are unpainted, plain cast alloy.

SRTA Action

SRTA will no longer supply exchange transmissions

based solely on either model or ISOVIN numbers

supplied on a SRTA TRANSMISSION ORDER FORM.

Forms supplied without serial numbers from the

transmission – as noted above - will not be honoured

and the Dealer will be requested to arrange for the

serial number – RECORDED FROM THE VEHICLE -

to be supplied.

To avoid customer inconvenience, ensure

that the transmission serial number is

recorded when the transmission is first

diagnosed as requiring replacement.

Serial No.

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JULY, 2006

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

Installing New A/C Compressor - Oil Balance

Procedure

All

Group 2 Ref. No. TL1106 - 0606

A new compressor contains a complete A/C system oil

charge.

Therefore, whenever a compressor is replaced, the

following procedure must be performed in order to

maintain the correct amount of compressor lubricant in

the system.

DO NOT install a new compressor without first

performing the oil balance procedure.

OIL BALANCE PROCEDURE

STEP 1. Drain and measure (and record) the quantity

of oil removed from the old compressor.

STEP 2. Drain the oil from the new compressor into a

clean measuring container.

STEP 3. Refill the new compressor with the new oil

removed in step 2, but using the same quantity as

drained from the old compressor in step 1.

NOTE: In cases where a refrigerant hose has blown or

a compressor housing is cracked, the complete A/C

system will have to be flushed to remove all traces of

oil and foreign material. The new compressor can then

be installed with no oil balance check required.

Step 1.

Drain, measure, and record

the quantity of oil removed

from the old compressor.

Step 2.

Drain the oil from the new

compressor into a clean

measuring container.

Step 3.

Refill the new compressor with

the new oil removed in step 2,

but using the same quantity as

drained from the old compressor

in step 1.

HOLDEN SERVICE TECHLINES_________________________________________________________________________________JULY, 2006

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

Sluggish On Takeoff and/or Transmission

Thumps After Takeoff

VYII, WKII, Gen 3 A/T only

Group 7B Ref. No. TL1132 - 0606

CONDITION

Customers may complain that intermittently their car is

sluggish on take off, feeling like it may not be in 1st

gear. The transmission may also “thump” as it

downshifts from 2nd to 1st gear shortly after takeoff.

This fault is very intermittent and may not easily be

reproduced by the dealer.

CAUSE

It is caused by erratic transmission output shaft speed

signal to the PCM at low speed, causing the vehicle to

initially take off in 2nd gear.

A revised calibration is available via TIS 2000 Version

72.0.

CORRECTION – Service

On any vehicle with the above symptoms, the following

must be performed.

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 72.0 or later.

NOTE: For detailed instruction on this process refer to

Holden Lionheart portal - Service Techlines\ TIS 2000\

Programming Procedures\ “Engine ECU/PCM SPS”.

WARRANTY CLAIM INFORMATION

Use standard Labour Times found in the Warranty

Information section of the current SIP disc.

Reverse Mount Wheels

HSV VZ Series

Group 10 Ref. No. TL1150 - 0606

HSV have released a new “Reverse Mount” wheel on

selected models. With this wheel the tyre must be

removed / fitted over the rear flange of the wheel.

For more details, refer to HSV Bulletin 052/06 which

can be found on the Lionheart portal. Look in Service

Bulletins / Service Techlines / HSV / Group - 10 .

DIAGNOSIS HINT

Engine Stalls, DTC P0100 and/or P0110 set

TS with X18XE1

Group 6C Ref. No. TL1130 - 0606

CONDITION

Engine stalls and trouble code P0100 and/or P0110 is

set.

On any vehicle that experiences the above symptoms,

refer to Opel Field Remedy 2033 which may be found

in TIS 2000 version 72.0 onwards.

Field Remedy 2033 gives details of a procedure for the

installation of additional earths to the engine ECU.

The pathway to Field Remedy 2033 is as follows:

Select Service Information

Select Salesmake - Opel

Select Astra – G

Select Direct Document Search

Select Technical information

In the search window type - “E0002033”. (this will

take you directly to Field Remedy 2033).

HOLDEN SERVICE TECHLINES_____________________________________________________________________________AUGUST, 2006

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

Compliance Identification Changes

WL, VZ (Ute, Crewman, Wagon)

Group 1 Ref. No. TL1151 - 0607

Technicians and dealer staff should be aware that

recently the location and type of compliance

identification has changed. The riveted plate under the

bonnet has been replaced with an adhesive label

located on the Left Hand B Pillar, just below the door

striker. An example of the new style label is shown in

figure 1.

PRODUCTION BREAK POINT

Tag Date

L845299 28-06-06

Figure 1.

Note: The date shown on this label is the compliance

date, not the built date. The built date is shown on the

body and option plate.

INFORMATION

Introduction of Reverse Lip Rear Main Seal

V & W – with Alloy V8 Engine

Group 6A Ref. No. TL1140 - 0607

CONDITION

V8 engines are now being built with a new style

“reverse lip” rear main oil seal.

This seal can be fitted to all previously built engines

whenever replacement is necessary.

Don’t be confused!

Technicians should note that the installed seal has the

appearance of the previous type seal being installed

backwards (BUT – you will be able to read the part

number – see below).

Installation Instructions:

This seal is assembled in the same manner, and with

the same special tool as the previous seal.

No procedures are changed by the introduction of this

new design seal.

Identification:

The reverse lip seal has the part number applied to the

outside face of the seal as shown in the diagram below.

This diagram is from the Installation Instructions that

are included in the packaging with a new seal:

Part No. must

face outwards

HOLDEN SERVICE TECHLINES_____________________________________________________________________________AUGUST, 2006

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

Two Stage Unlock - Programming

ZC Vectra, MY 2004.5 onwards

(GROUP 12) TL1157-0607

To switch between single and two stage unlock

perform the following steps:

1. Remove key from the ignition.

2. Locate the ‘all doors lock/unlock’ button on the

driver’s door.

3. Press and hold this button down, then hold

down the ‘unlock’ button on the remote key.

4. Continue to hold these buttons until a double

beep is heard. The beeps are to confirm the

programming has been successful.

5. Use the remote to confirm the change in

operation.

NOTE: When holding the buttons down in step 4, the

comfort opening feature (all windows drop) may

operate. This is normal when changing this feature.

To disable the Two Stage Unlock feature, repeat the

same procedure as above, although only a single beep

will be heard.

It will be important to ask the customer if they

would like both keys to operate in the same way. If

so, both keys will need to be present to program as

this feature is linked to each individual remote.

INFORMATION

Vehicle Speed Locking Feature

ZC Vectra, MY 2004.5 onwards

(GROUP 12) TL1160-0607

From 2004.5 model year, the “Speed Locking” feature

was added to ZC models. With this feature, the doors

and luggage compartment can be set to lock at a pre-

determined vehicle speed.

To activate this feature perform the following steps:

1. Remove key from the ignition.

2. Locate the ‘all doors lock/unlock’ button on the

driver’s door.

3. Press and hold this button down, then hold

down the ‘lock’ button on the remote key.

4. Continue to hold these buttons down until a

double beep is heard. The beeps are to confirm

the programming has been successful

5. Drive the vehicle with the doors unlocked to

confirm the change in status when the pre-

determined vehicle speed is reached.

NOTE: When holding the buttons down in step 4, the

comfort closing feature (all windows lift) may operate.

This is normal when changing this feature.

All doors and the luggage compartment will be

unlocked when the ignition is switched to the off

position or when the ‘all doors lock/unlock’ button is

depressed.

To disable this feature, carry out the same procedure

as above, although only a single beep will be heard.

It will be important to ask the customer if they

would like both keys to operate in the same way. If

so, both keys will need to be present to program as

this feature is linked to each individual remote.

HOLDEN SERVICE TECHLINES_____________________________________________________________________________AUGUST, 2006

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

Engine Automatically Reverts To Petrol After

Running On LPG For Several Seconds

VZ with LPG

Group 6M Ref. No. TL1155 - 0607

CONDITION

When vehicle is running on petrol and then switched

over to LPG, it may only run for several seconds before

switching back to petrol by itself. The LPG/Fuel

selection switch will beep.

CAUSE

The above condition can be caused by the LPG

Manifold Air Pressure (MAP) sensor adjustment not set

to specification.

CORRECTION

After verifying the vehicle has same condition as

described above, proceed to adjust the MAP pressure

as follows.

1. The adjusting screw is located on the LPG

converter which is mounted underneath the LPG

computer. The heat shield requires removal to

gain access to the adjusting screw.

Refer figures 1 & 2

Figure 1

Figure 2

2. Locate the wiring connector on the MAP sensor,

connect a multimeter to the green & white wires

and while turning the adjusting screw set the

voltage to 3.6 – 3.7 volts. Turn screw clockwise

to increase the voltage and anticlockwise to

decrease voltage.

IMPORTANT: This adjustment must be done

with the engine idling in LPG mode.

3. Reinstall plastic plug to cover adjuster screw

and refit the protective heat shield.

4. Confirm the complaint condition is rectified

The above MAP sensor circuit diagram is extracted

from the LPG Harness Wiring Diagram in SIP.

Refer – MY 2005 Service Information

- Fuel & Exhaust Systems

- Section 8A2 VZ LPG Conversion kit

- Service & Diagnostics

- Wiring Schematics

Alternative Procedure

As an alternative to the above, for those dealers with

the Sequent diagnostic software Interface, correct

Delta P setting during operation at idle is 1500 millibar.

LPG

ECU

LPG ‘MAP’ sensor

LPG Converter

Remove cover plug to access adjusting screw.

Turn clockwise to increase voltage,

anticlockwise to lower voltage.

MAP Sensor connector

White Wire

Green Wire

Adjusting

Screw

HOLDEN SERVICE TECHLINES_____________________________________________________________________________AUGUST, 2006

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

Vehicle Configuration Index (VCI) Process

Added To SPS

TIS 2000 Version 73 Onwards

Group OB Ref. No. TL1159 - 0607

The Service Programming System (SPS) menu has

been revised (as shown below) with the release of TIS

2000 version 73 and now includes a new selection

called Vehicle Configuration Index (VCI).

This new selection should only be used when instructed

by TAS. It will enable calibrations not included on TIS

2000 to be programmed into specific control modules via

the SPS process.

When the selection screen appears it will default to

normal. Select the next option, unless requested by TAS

and continue programming in the usual manner.

Below are copies of the SPS selection screens.

Screen 5 (bordered in red) is the new VCI screen.

Screen 1

Screen 2

Screen 3

Screen 4

Screen 5

Screen 6

HOLDEN SERVICE TECHLINES_____________________________________________________________________________AUGUST, 2006

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

Description Of HVAC and A/C System Changes for VE

Group 2 Ref. No. TL1145 - 0607

The following information has been supplied by Air International, supplier of the air conditioning

system for the new VE models.

The new VE Heating and Air conditioning system has a number of significant improvements compared to

the previous VZ Heating and Air conditioning system. These are listed below:

 The vacuum actuators used to operate vent mode positions and temperature adjustment are

discontinued and electric actuators are now used for each mode and temperature adjustment

 There are now three (3) different levels of the HVAC. They are Single Zone (S.Z), Dual Zone (D.Z) and

Tri Zone (T.Z)

 The newly added Tri zone (T.Z) has an electric actuator that adjusts both temperature and air flow

direction (rear console vent and floor) to the rear passengers via a separate rear control

 The VE electric actuators use photo interrupters ( potentiometers in VZ ECC) for door feed back

position. The VE actuator is quieter and more responsive. The actual position of the doors and

movement can now been viewed and checked using the scan tool.

 Evaporator sensor is supplied as part of the HVAC wiring harness.

 The VE evaporator is larger in overall size and thickness is reduced to 38 mm (VZ 68mm) The increase

in size improves performance, and the reduction in thickness reduces overall weight of the HVAC

assembly.

 Temperature split in Bi-level mode and the mode change strategy has been improved.

 A permanent air bleed to the side windows in face and demist mode has been added to ensure no

frost / mist build up on the window glass.

 Improved HVAC case assembly - less joints to avoid air noises and condensate leaks.

 A HVAC Command Module (HCM) located at the passenger side blower housing area of the HVAC is

now used. The HCM controls mode positions, temperature adjustment, A/C compressor output

(displacement) via the ECV (electronic control valve in the compressor) and the blower fan speeds.

The HCM, if replaced as a spare part would have to be configured to suit the vehicle as the HCM is

provided as a T.Z spare part – only

 The compressor is “clutch less” and operates continuously. It uses an ECV (electronic control valve)

that is connected to the HCM (HVAC Control Module). The HCM will vary the voltage to the ECV which

will then alter the stroke (displacement) when required. There is no electrical connection to the

compressor clutch.

HOLDEN SERVICE TECHLINES_____________________________________________________________________________AUGUST, 2006

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 OF HVAC AND A/C SYSTEM CHANGES FOR VE – continued.

 In VE, higher air flow is available from the HVAC vents owing to less restrictive internal passages,

upgraded blower motor output and improved HVAC internal door design. Air flow has increased from

120 litres a second to 142 litres a second. The blower motor also has improved sound quality and the

current draw is less than VZ.

 The blower speed resister or amplifier is no longer a separate component. In VE, the blower speed

resister or amplifier is part of the heat sink located in the HCM.

 Recirculation mode has two (2) settings for the duration the recirculation door is closed. The duration is

altered depending on ambient temperature. (above and below 30 degrees C)

 Recirculation has a partial mode that is automatically selected as part of normal operation. It is

designed to purge CO2 build up, and allow a mixed mode to enable good performance whilst

maintaining some fresh air.

 For the A/C system “plumbing”, slim line sealing washers are used instead of rubber o’rings at all joints

including the TX Valve to evaporator. The slim line washer has far superior sealing quality compared to

the rubber o’ring that could “rotate” during fitment.

 The solar load sensor (ECC) now incorporates two (2) sensors; one (1) for passenger side and one (1)

for the drivers side of the vehicle.

 A heater tap is no longer used; temperature control is via the HVAC air mixing flap which has

improved sealing capabilities.

 A relearn of the minimum and maximum operating stop positions of the electric mode / temperature

actuators can be performed at any time by holding the rear window demist button down for 5 seconds

with the ignition “on”.

Refer next page for diagram of how the HCM (HVAC Control module) interacts via CAN Bus line to other

modules

IMPORTANT NOTE: PLEASE READ

“The flat sealing washers used for the TXV, tube joints, compressor, and

condenser MUST be installed in a DRY condition. No lubricating oil is to be

used as this will damage the rubber seal incorporated in the sealing washer,

this especially applies to using R12 mineral oil as it WILL cause the rubber

seal to swell and distort causing a refrigerant leak

PCM

MODULE

A/C System

Pressure

Transducer

Engine

Cooling

Fans

Vehicle Road

eed

Engine RPM

Engine Coolant

Tem

erature

A/C

Compressor

Off Request

Supply

Volta

Max A/C

Compressor

Displacement

IPC

BCM

MODULE

DLC

Dual Wire CAN

T.Z Rear Mode /

Temp Control

Secondary Power

Circuit To HCM

Primary

Power Circuit

To HCM

Heated

Rear

Window

Ambient

Reading

Display

Mode Vent

Positions

Blower Fan

eeds

Set (by owner)

Temperature

Adjustments

A/C

Compressor

On /Off

Request

Signal In

Signal Out

Solar Load

Sensor

In Car

Temperature

Sensor

Evaporator

Tem

erature Sensor

Blower Fan Speeds

HVAC Mode Positions

via Electric Actuators

Supply Voltage

Ignition/Battery

Ambient

Temperature

Sensor

Rear Demist

Relay

A/C

Compressor

Output

Compressor

Output. ECVD

Target Position

Compressor

Output. ECVD

Actual

HCM

MODULE

IRC

MODULE

HCM (HVAC Control module) INTERACTION VIA CAN BUS LINE TO OTHER MODULES

Single Wire

HOLDEN SERVICE TECHLINES_____________________________________________________________________________AUGUST, 2006

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/h

VY & VZ – One Tonner & Crewman

Group 4 Ref. No. TL0631D-0607

This Techline supersedes the previous one in Issue 02, March,

2006. It is UPDATED by clarifying the application of service

fixes and models.

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.

NOTES: This noise must not be confused with noises

resulting from possible faulty differential bearings or

gears.

All Wheel Drive (AWD) Models have axles with

different pinion flanges to Rear Wheel Drive (RWD)

models, thus the revised pinion flange mentioned

cannot be used – AWD models can have the front

spring eye bushes changed only.

PRODUCTION CHANGES

Crewman models have had two countermeasures

introduced into production only on the specific models

listed here:

• Crewman V8 (A/T & M/T), (RWD & AWD) - A

softer rubber bush in the front eye of the leaf

spring.

• Crewman V8 A/T (RWD only) - A 2-spoke pinion

flange.

Breakpoint for both the above countermeasures in

Crewman ONLY is:

ISOVIN: Built Date:

**********L218227 09/03/2004

CORRECTION – SERVICE

Summary:

PART 1. - For all beam axle vehicles,

Install revised rear spring front eye bushes if not

already fitted.

PART 2. - For RWD V8 (A/T & M/T) & RWD V6 (M/T

only)

Install a 2-spoke diff pinion flange and rear spring front

eye bushes if not already fitted).

PART 1. - For all beam axle vehicles.

Install revised rear spring front eye bushes if not

already fitted.

Procedure:

(For procedures not covered in detail, refer latest SIP DVD).

1. Remove rear springs.

2. Press out existing front spring eye bush from

each spring.

3. Press in new spring front eye bushes p/n

92148815.

4. Reinstall spring assemblies.

NOTE: The four large insulation washers p/n 92175916

are required 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.

PART 2. - For RWD V8 (A/T & M/T) and

RWD V6 (M/T only)

Install a 2-spoke diff pinion flange and rear spring front

eye bushes (as noted in Part 1 above) if not already

fitted.

1. Revised pinion flange p/n 92176653 should be

fitted with a new nut p/n 92146565 exactly as per

procedure found in SIP: viz;

Section 4B – Final Drive & Drive Shafts,

2. Minor Service Operations,

2.11 Pinion Flange/Replace using old seal.

CAUTION: Overtightening or undertightening of

the pinion nut may result in excessive bearing

preload and bearing damage.

2. The alternative to Dealers doing step 1 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 will occur at a later date.

HOLDEN SERVICE TECHLINES_____________________________________________________________________________AUGUST, 2006

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:

92148815 Bush Rr Spring Front 2

92175916 Washer

92176653 Pinion Flange

V8 (A/T & M/T), or

V6 (M/T only)

92146565 Flange Nut

V8 (A/T & M/T), or

V6 (M/T only)

WARRANTY CLAIM INFORMATION

Description Replace Bush, Leaf Spring

Front Eye – Both Sides

Labour Op. No. F000197

Time 1.6 hr.

Add for V8 & V6(M/T) Rear

Wheel Drive Only - Fitting

of revised Pinion Flange

0.5 hr.

Failure Code F0040 noisy

Terminology

A/T – automatic transmission. RWD – Rear wheel drive

M/T – manual transmission AWD – All wheel drive

INFORMATION

Engine Spigot (Pilot) Bearing

TK & JF with M/T

Group 7A Ref. No.: TL1156 - 0607

TAS has received calls from dealers asking if these

vehicles are fitted with a spigot (pilot) bearing.

These vehicles do not have a spigot (pilot) bearing

located in the crankshaft, as the manual transmission

input shaft is supported by two bearings internally.

Service information contained in SIP referring to pilot

bearings refers to an earlier design engine/vehicle.

Parts and Service personnel should not try to obtain or

fit spigot (pilot) bearings to the engines in these

vehicles.

HOLDEN SERVICE TECHLINES_____________________________________________________________________________AUGUST, 2006

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

Dexron® VI Usage Information

VE/WM with 4, 5 & 6 Speed A/T

Group 7B Ref. No. TL1120 - 0607

Automatic Transmission Fluid (ATF) specification has

been upgraded - to Dexron® VI ATF for all auto

transmissions in VE & WM models

Dexron® VI ATF is the only specification fluid

permitted on VE/WM model auto transmissions:

• 6 speed A/T (6L80E);

• 5 speed A/T (5L40E);

• 4 speed A/T (4L60E).

This updated ATF provides improvements in:

• Shift quality

• ATF ‘life’;

• Clutch friction stability;

• Clutch durability;

In addition, the lubrication, oxidation,

foaming/aeration characteristics are all improved.

Dexron® VI is also in use in SRTA transmissions.

Service Recommendations

This is the first usage of Dexron VI ® ATF and there

are specific precautions and guidelines to be followed

in the usage of this ATF.

Dexron® VI is backwards compatible with previous

Dexron® ATF that is in use in Holden vehicles.

However, previous Dexron® ATF’s cannot be used in

vehicles where Dexron® VI is specified.

This compatibility concern exists because of the

different characteristics of the various types of ATF.

Use of the incorrect Dexron® ATF in an auto. Trans.

Will result in shift complaints – “unacceptable” shifts,

“poor” shifts, “harsh” shifts, etc after a service or trans

component replacement, etc.

Fluid Availability

Dexron® VI ATF is available from HSPO in two sizes:

1 Litre - 88861004

4 Litre - 88861043

Dexron® VI may not be generally available in the

marketplace at this time. Check with your oil supplier

about their Dexron® VI introduction timing if you intend

to obtain this ATF from other than HSPO in the future.

HOLDEN SERVICE TECHLINES__________________________________________________________________________ SEPTEMBER, 2006

INFORMATION

Interior Lamp Operation

VE, WM

Group 12 Ref. No. TL1174 – 0608

Dealer staff need to be aware that on VE/WM models

the interior dome lamp functionality is ambient light

dependant unless overridden by the switch within the

roof console. Its operation is driven by the BCM, with

input from the solar sensor fitted to the top centre of

the instrument panel.

Therefore, if a customer complains that the interior

lights do not work; ensure they are aware of the

operation as stated in the owner handbook. DO NOT

replace the BCM for this complaint.

To test the functionality of the dome lamp, place a rag

or thin book over the sensor and lock/unlock the

vehicle with the remote key or open a door. The lamp

should work because the sensor’s capability of

detecting light has been diminished.

Please pass this information to your dealership’s front-

line staff to avoid unnecessary customer complaints

and/or bookings.

INFORMATION

Radiator Shroud Usage

VE with P.O. LE0 V6 Engine

Group 6K Ref. No. TL1161 - 0608

CONDITION

PIR’s have been received advising that Technicians

believe radiator shrouds, on vehicles with base level

V6 engine P.O. (Production Option) LE0, have not

been fitted in production.

REASON

Vehicles with base level V6 engine do NOT have a

radiator shroud fitted.

Only vehicles with premium V6 (P.O. LY7) and V8 (P.O.

L89/LS2) engines have radiator shrouds fitted.

SERVICE ACTION

Do NOT fit radiator shrouds to vehicles built with P.O.

LE0 V6 engine.

This is not an error in build specification – and

cannot be claimed under warranty.

For reference – the shroud picture is shown bel ow:

HOLDEN SERVICE TECHLINES__________________________________________________________________________ SEPTEMBER, 2006

INFORMATION

A/T Fluid Availability

Daewoo Matiz with A/T

Group 7B Ref. No. TL1137 – 0608

CONDITION

There have been difficulties in obtaining the specified

ATF (Auto. Trans. Fluid) for the small number of Matiz

auto trans equipped vehicl es in Australia.

CAUSE

Previously released Daewoo bulletins advised the use

of an ATF specification that is no longer available in

Australia.

FLUID AVAILABILITY

ATF for these vehicles is now available from HSPO.

Part No.: Description Qty:

93742563 Auto Trans Fluid – 1 Litre 1

INFORMATION

P/S Fluid Usage

TK Barina

Group 9 Ref. No. TL1180 - 0608

CONDITION

Technician concern has been raised about correct fluid

to be used in power steering system, as the fluid colour

in early build vehicles is a “straw” colour, where the

specified fluid is Dexron® III (normally red/pink).

CAUSE

Early build vehicles were filled with Dexron® III fluid

with no red dye included.

SERVICE ACTION

It is not necessary to replace any power steering fluid

that is not “red/pink”.

Use Dexron® III for any power steering fluid

replacement during repairs or for any top-ups required.

SERVICE FIX

Fuel Gauge Drops To Empty & DTC P0460

Sets In The Engine ECU

VZ, WL, all with HFV6 MY06

Group 12 Ref. No. TL1164 - 0608

CONDITION

Customers may advise their fuel gauge drops to empty

and the low fuel light comes on or “Fuel Gauge Error”

message displayed in instrument cluster.

DTC P0460 "Fuel Level Sender range / performance"

sets in the engine ECU

CORRECTION – Vehicles In Service

On any vehicle with the above condition reprogram the

engine ECU as per the standard SPS process using

Tech 2 and TIS 2000 version 74 or later.

WARRANTY CLAIM INFORMATION

Use standard Labour Times found in the Warranty

Information section of the current PV SIP disc.

INFORMATION

Rear Drive Shaft (LH & RH) Attaching Bolt &

Retaining Plate Revisions

VY Series, All with IRS

Group 4 Ref. No. TL1183 - 0608

Rear driveshaft to trunnion/differential flange attaching

bolts and retaining plates have been superseded in

HSPO to use existing VZ parts - 92180093 Bolt , and

92180086 Retaining Plate.

This revision also requires a revised bolt torque - to the

VZ specification (50Nm + 90 deg turn a ngle).

Current VY SIP information is to be revised in the next

issue to advise:

- Bolt replacement is mandatory;

- Torque specification revised to current VZ torque

specification - 50Nm + 90 deg turn angle.

Both bolts (and retaining plates where n ecessary) need

to be replaced with the latest type whenever the bolts

are removed for any reason.

HOLDEN SERVICE TECHLINES__________________________________________________________________________ SEPTEMBER, 2006

INFORMATION

Introduction Of Extended-Life Anti-Freeze

Engine Coolant

TK Barina, JF Viva

Group 6K Ref. No. TL1179 - 0608

The cooling system in the above models is now filled

with extended life anti-freeze coolant, conforming to

Holden specification number GM 6277M.

Vehicle Production Breakpoint

Extended-life anti-freeze coolant has been fitted to

vehicles from:

TK hatch - KL1TJ23737B68561 6 May 2, 2006

TK Sed - KL1TJ53777B029209 May 2, 2006

JF Viva - KL1NA196J7K485172 July 3, 2006

This new coolant is designed to last in the vehicle for

five years or 240,000 km, whichever occurs first.

The new coolant colo r is orange/red.

If the cooling system needs to be topped up or

replaced, use a mixture of 50 percent clean water and

50 percent extended life coolant conforming to GM

6277M.

NOTE: Other coolants may be used provided they

comply with the Holden specification number GM

6277M.

WARNING.

• Never mix different types of coolant.

• Using other than the specified coolant may cause

premature engine, heater core, or radiator

corrosion.

PARTS INFORMATION

Part No.: Description Qty

92145527 Coolant engine 5 Litre (G M

6277M) 1

HOLDEN SERVICE TECHLINES__________________________________________________________________________ SEPTEMBER, 2006

INFORMATION

Brake Rotor Replacement Guidelines

ZC Vectra, TS & AH Astra, XC Barina

Group 5 Ref. No. TL1158 - 0608

To achieve maximum life of the brake rotors on the

above vehicles the following guidelines should be

observed in regard to brake rotor repla c ement.

TIS 2000 quotes three thickness dimensions for the

brake rotors:-

1. Thickness new.

2. Permissible remaining thickness after precision

turning.

3. Minimum thickness.

NOTE: This information is found in:- TIS2000 Service Information /

front wheel brake and rear wheel brake/ Technical Data.

If machining rotors & fitting new pads:

- the rotors can be machined down to the “permissible

remaining thickness after precision turning” and a new

set of pads can be installed.

Rotors should only be replaced if the “permissible

remaining thickness after precision turning” falls below

the dimension given in TIS2000.

If fitting new pads only:

- provided the rotor thickness is equal to/greater than

the “permissible remaining thickness after precision

turning,” a new set of pads can be in stalled.

INFORMATION

Knock Sensor Wiring Protection Precaution

VE, WM

Group 12 Ref. No.: TL1176 - 0608

Condition

Reflective hoods have been fitted to engine wiring

harnesses for the protection of V6 Crank Sensor and

V8 Knock sensor connectors from radiated exhaust

heat.

Service Precaution

If these hoods are removed for any reason, they

should be refitted to the original location to ensure that

the sensors are protected from heat radiated from the

exhaust or catalytic converters.

The photograph below shows a typical protective hood

installation – where the hood protects the wiring

harness connector from radiated heat.

Minimum 3.

Thickness after

precision turning 2.

New 1.

Do not replace rotors

if final thickness after

machining is within

cross hatched region

Heat reflective

hood fitted over

connector