Warnings, Cautions and Notes 00–1
00–1
Section 00
Warnings, Cautions and Notes
ATTENTION
Before performing an y ser vice operation o r oth er pro cedu re describe d in the MY 2005 VZ Ser vice Info rmation ,
reference to this Section should be made for correct workshop practices with regard to safety and/or property
damage.
1 General Information ...............................................................................................................................3
2 Error and Suggestion Reporting...........................................................................................................4
3 Definition of WARNING, CAUTION and NOTE Statements ................................................................5
3.1 WARNING Defined................................................................................................................................................. 5
3.2 CAUTION Defined .................................................................................................................................................. 6
3.3 NOTE Defined......................................................................................................................................................... 7
4 Safety and Service Guidelines..............................................................................................................8
4.1 ABS Handling......................................................................................................................................................... 8
4.2 Brake Dust.............................................................................................................................................................. 9
4.3 Brake Fluid ........................................................................................................................................................... 10
4.4 Clutch Dust........................................................................................................................................................... 11
4.5 Engine Cooling..................................................................................................................................................... 12
4.6 Liquefied Petroleum Gas..................................................................................................................................... 13
4.7 Fuel and Evaporation Pipe.................................................................................................................................. 14
4.8 Relieving Fuel Pressure ...................................................................................................................................... 15
4.9 Opening a Fuel Line............................................................................................................................................. 16
4.10 Fuel Pipe Fitting................................................................................................................................................... 17
4.11 Fuel Pressure....................................................................................................................................................... 18
4.12 Petrol / Petrol Vapours........................................................................................................................................ 19
4.13 Fuel Storage......................................................................................................................................................... 20
4.14 Fuel Injector Lower O-Ring Removal ................................................................................................................. 21
4.15 Automatic Transmission Fluid Level Check / Refill Procedure ....................................................................... 22
4.16 Moving Parts and Hot Surfaces.......................................................................................................................... 23
4.17 Road-Testing........................................................................................................................................................ 24
4.18 Safety Glasses and Compressed Air ................................................................................................................. 25
4.19 Safety Glasses and Fuel...................................................................................................................................... 26
4.20 Seatbelt Replacement.......................................................................................................................................... 27
4.21 Servicing and Replacing Seatbelts .................................................................................................................... 28
4.22 Occupant Protection System.............................................................................................................................. 29
4.23 OPS Inflatable Restraint Module Disposal......................................................................................................... 30
4.24 OPS / SRS Special Tools..................................................................................................................................... 31
4.25 Vehicle Towing..................................................................................................................................................... 32
4.26 Vehicle Lifting ...................................................................................................................................................... 33
4.27 Window Removal................................................................................................................................................. 34
4.28 Window Retention................................................................................................................................................ 35
4.29 Work Bay Test...................................................................................................................................................... 36
4.30 Fasteners.............................................................................................................................................................. 37
4.31 Handling ESD Sensitive Parts............................................................................................................................. 38
4.32 Electronic Control Modules ................................................................................................................................ 39
Warnings, Cautions and Notes 00–2
00–2
5 Battery Disconnection Procedures ....................................................................................................40
5.1 Before Battery Disconnection............................................................................................................................. 40
5.2 Before Servicing Electrical Components ........................................................................................................... 41
5.3 Systems Affected by Battery Disconnection..................................................................................................... 42
5.4 Instruments .......................................................................................................................................................... 43
After Battery Reconnection................................................................................................................................. 43
5.5 Body Control Module........................................................................................................................................... 44
5.6 Entertainment System......................................................................................................................................... 45
5.7 Telematics ............................................................................................................................................................ 46
Before Battery Disconnection............................................................................................................................. 46
After Battery Reconnection................................................................................................................................. 46
5.8 Navigation System............................................................................................................................................... 47
Before Battery Disconnection............................................................................................................................. 47
After Battery Reconnection................................................................................................................................. 47
5.9 Sunroof................................................................................................................................................................. 48
After Battery Reconnection................................................................................................................................. 48
5.10 Memory Seats....................................................................................................................................................... 49
After Battery Reconnection................................................................................................................................. 49
Warnings, Cautions and Notes 00–3
00–3
1 General Information
To minimise the risk of death, injury and / or property damage, carefully adhere to the instructions in this Section.
The HOLDEN LTD Service Information is intend ed for use by professional, qualified, factory-trained technicians.
Attempting repairs or service without the appropriat e traini ng, tools and equipment may cause injury to you or others. It
could also cause damage to the vehicle or cause the vehic le to operate improperl y.
Proper vehicle service and repair ar e important to the safety of the service technician and to the reliable operation of all
motor vehicles. If you need to replace a part, use the same part number or an equivalent part. Do not use a replacement
part of lesser quality.
The service procedures recommended and described in this Service Information are effective methods of performing
service and repair. Some of the procedures require the use of tools designed for specific purposes.
Any person who intends to use a replacement part, service procedure or tool not recommended by HO LDEN LTD, must
first establish that it will not jeopardise p ersonal safety or operation of the vehicle.
This Service Information contains various W ARNING, CAUT ION and NOTE statements that you must observe carefully
to reduce the risk of death or injury during service, repair procedures or vehicle operation. Incorrect servic e or repair
procedures may damage the vehicle or cause operational f aults. WARNING, CAUTION and NOTE statements are not
exhaustive. HOLDEN LTD can not p ossib ly warn of all the potentially hazardous consequences of failure to follow these
instructions.
Warnings, Cautions and Notes 00–4
00–4
2 Error and Suggestion Reporting
If you find an error in any HOLDEN LTD Service Information or if you have a suggestion regarding HOL DEN LTD Service
Information, we want to hear from you.
Forward a fax to the HOLDEN LTD Service Department on 03 9647 2525.
When faxing, please sup pl y the following information:
• your name,
• your retailer's name and retail er code number,
• your retailer's phone number,
• the model year and the vehicle type,
• the Service Information part number or CD-ROM version number,
• the Vehicle Identification Number (VIN) on which work is being performed, and
• the Service Information Section and page number(s).
HOLDEN LTD service personnel will respond to your concerns in the following ways:
• by delivering your concern to the service information's author,
• by eliciting a response from the author, then
• by supplying you with an answer to your concerns.
For hard copy Service Information, please supply a marked-up copy of the Service Information in question.
For Electronic Service Information (CD-ROM), please pr ovide any applicable identification numbers pertaining to the
electronic information in question.
The HOLDEN LTD Service Department contact fax number does not provide technical assistance. For technical
assistance, contact your technical assistance source in the usual manner.
Warnings, Cautions and Notes 00–5
00–5
3 Definition of WARNING,
CAUTION and NOTE Statements
Diagnosis and repair proce dures in HOLDEN LTD Service Informatio n contain both general an d specific WARNING,
CAUTION and NOTE statements. HOLDEN LTD is dedicated to the presentation of service information that helps the
technician to diagnose a nd repair the systems necessary for proper o peration of the vehicle. Certain procedures may
present a hazard to the technician if they are not follo wed in the recommended manner. WARNING, CAUTION and
NOTE statements are designed to help prevent these hazards from occurring, but not all hazards can be foreseen.
WARNING, CAUTION and NOTE statements are placed at strategic locations within the Service Information and are
designed to help prevent:
• death or injury to the technician or others,
• damage to the vehicle,
• unnecessary vehicle repairs,
• unnecessary component repl acement, and / or
• incorrect repair or replacement of vehicle components.
3.1 WARNING Defined
A WARNING statement immediately precedes an operatin g procedure or maintenance practice which, if not correctly
followed, could result in death or injur y.
A WARNING statement alerts you to take a necessary action or not to take a prohibited action. If a WARNING statement
is ignored, the following consequences may occur:
• death or injury to the technician or other personnel working on the vehicle,
• death or injury to other people in or near the workplace area, and / or
• death or injury to the driver and / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
Warnings, Cautions and Notes 00–6
00–6
3.2 CAUTION Defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data.
A CAUTION statement directs special attention to a necessary action or a prohibite d action. If a CAUTION statement is
ignored, the following consequences may occur:
• damage to the vehicle,
• unnecessary vehicle repairs,
• unnecessary component replacement,
• faulty operation or performan ce of the system or component being repaired,
• damage to any system or components which depend on the proper op eration of the system or component being
repaired,
• faulty operation or performan ce of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• damage to fasteners, basic tools or special tools and / or
• leakage of coolant, lubric ant or other vital fluids.
Warnings, Cautions and Notes 00–7
00–7
3.3 NOTE Defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or cond ition that
requires highlighting.
A NOTE statement also emphasises a nec essary characteristic or characteristics of a diagnostic or repair procedure. A
NOTE statement is designed to:
• clarify a procedure,
• present additional information for accomplishing a procedur e,
• give insight into the reason or reasons for pe rforming a procedure in the recommen ded manner,
• present information that helps to accomplish a procedure in a more effective manner, and / or
• present information that gives the technician the benefit of past experience in accomplishing a procedure with
greater ease.
Warnings, Cautions and Notes 00–8
00–8
4 Safety and Service Guidelines
4.1 ABS Handling
Certain components in the Anti-lock Brake System (ABS) ar e not inte nded to be serviced individually. Attempting to
remove or disconnect certain system components may result in personal injury and / or improper system operation. Only
those components with approved removal and installation proce dures should be serviced.
Whenever any component that forms part of the ABS is disturbed during Service Operations, it is vital that the complete
ABS system is checked, using the procedure as detailed in the following Sections:
• Alloytec V6 engine (Bosch System 8)
• Section 5B1 ABS – ABS with Electronic Brake-force Distribution (EBD)
• Section 5B2 ABS-TCS – ABS with Electronic Brake-force Distribution (EBD) and Traction Control System
(TCS)
• Section 5B3 AWD ABS-TCS – All wheel drive ABS with Electronic Brake-f orce Distrib ution (EBD) and
Automatic Brake Distribution (ABD)
• Section 5B4 ABS-TCS with ESP – ABS with Electronic Brake-force Distribution (EBD), Traction Control
System (TCS) and Electronic Stability Program (ESP)
• GEN III V8 engine (Bosch System 5.3)
• Section 5B5 ABS – ABS only
• Section 5B6 ABS-TCS – ABS with Electr onic Brak e-force Dist ribut ion (EBD) and Traction Contr ol System
(TCS)
• Section 5B7 AWD ABS-TCS – All wheel drive ABS with Electronic Brake-force Distribution (EBD) and
Automatic Brake Distribution (ABD)
Warnings, Cautions and Notes 00–9
00–9
4.2 Brake Dust
When servicing wheel brake parts:
• Do not grind brake linings.
• Do not sand brake linings.
• Do not clean wheel brake parts with a dry brush or with compressed air.
Although HOLDEN LTD incorporates brake parts that are not asbestos-based in their material composition; after-market
brake parts may contain asbestos fibr es, which can become airborne in dust. Use a water-dampened cloth to remove
any dust on brake parts. Alternatively, use commercially available equipment to wash the parts. These wet methods help
prevent fibres from becoming airborne.
Warnings, Cautions and Notes 00–10
00–10
4.3 Brake Fluid
Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions immediately:
• Eye contact – rinse eyes thoroughly with water.
• Skin contact – wash skin with soap and water.
Warnings, Cautions and Notes 00–11
00–11
4.4 Clutch Dust
Although HOLDEN LTD incorporates clutch parts that are not asbestos-based in their material composition; after-market
clutch parts may contain asbestos fibres, which can become airborne in dust. Use a water-dampened cloth to remove
any dust on clutch parts. Alternativel y, use commercially availabl e equipment to wash the parts. These wet methods help
prevent fibres from becoming airborne.
Warnings, Cautions and Notes 00–12
00–12
4.5 Engine Cooling
Always wear protective safety glass es when working with spring-type hose clamps.
Do not remove the screw-on cooling system cap while the engine co olant is above 50°C (122° F).
Electric engine cooling fans in the engine compartment can start up even when the engine is not running. Keep hands,
clothing and tools a way from any un der-hood electric fans.
Warnings, Cautions and Notes 00–13
00–13
4.6 Liquefied Petroleum Gas
The vehicle may be equipped with Liquefied Petroleum Gas (LPG). As LPG fuel vapour is heavier than air, vapours can
accumulate in confined spaces . In the interests of safety, the LPG fuel system should be isolated at the manual shut-off
valve before any service work is performed on the vehicle. Refer to the LPG information included with the Owner's
Handbook for details or Section 8A2 LPG System for more specific servicing information relating to this alternative fuel
system. Only authorised LPG service sites may service the high pressure side of the LPG system.
Warnings, Cautions and Notes 00–14
00–14
4.7 Fuel and Evaporation Pipe
To reduce the risk of fire, observe the following guidel ines:
• Replace all damage d nylon fuel pipes. Damage to the nylon pip es ma y result in a fuel l eak. Do not attempt to
replace only the damaged se ction or sections of nylon fuel pipes.
• Do not hammer directly on the fuel harness body clips when installing new fuel pipes.
• Always cover nylon vapour pip es with a wet towel before using a torch near them. Also, never expose the vehicle to
temperatures higher than 115°C (239°F) for more than o ne hour or more than 90°C (194°F) for any extended
period.
• Apply a few drops of clean engin e oil to the male pipe ends before connecting fuel p ipe fittings. This ensures
proper connection and prevents a possible fuel leak. During normal operation, the O-rings located in the female
connector swell and may pr event proper reconnection if not lubricated.
Warnings, Cautions and Notes 00–15
00–15
4.8 Relieving Fuel Pressure
Relieve the fuel system pressure before servicing fuel system components. Refer to the following Sections for further
details:
• Section 6C1-3 Service Operations for V6 Engine.
• Section 6C3-3 Service Operations for GEN III V8 Engine.
After relieving the fuel system pressure, a small am ount of fuel may be released when servicing the fuel lines or
connections. To reduce the risk of death or injury, cover the regulator and fuel line fittings with a shop towel before
disconnecting. This will catch any fuel that may leak or spray out. Place the towel in an approved co ntainer when the
disconnection is complete.
Warnings, Cautions and Notes 00–16
00–16
4.9 Opening a Fuel Line
When opening a fuel line to proceed with a service pr ocedure such as checking the fuel s ystem press ure, wrap a shop
cloth around the fuel pressure connection. The cloth will absorb any fuel leaked during th e connection of the fuel
pressure gauge. Place the cloth in an approved container when the con nection of the fuel pressure gauge is completed.
Warnings, Cautions and Notes 00–17
00–17
4.10 Fuel Pipe Fitting
Always apply a few drops of clean engine oil to the male pipe ends before connectin g fuel pipe fittings. This ensures
proper reconnection and prevents possible fuel leaks. During normal o peration, the O-rings located in the female
connector swell and may pr event reconnection if not lubricated.
Warnings, Cautions and Notes 00–19
00–19
4.12 Petrol / Petrol Vapours
Petrol or petrol vapours are highly flammable. A fire could occur if an ign ition source is present. Never drain or store
petrol in an open container. Always ensure that a dry chemical (Class B) fire extinguisher is nearby when servicing fuel
systems.
Warnings, Cautions and Notes 00–20
00–20
4.13 Fuel Storage
Do not drain fuel into an open container. Never store fuel in an open co ntainer due to its highly flammable nature.
Warnings, Cautions and Notes 00–21
00–21
4.14 Fuel Injector Lower O-Ring Removal
Verify that the lower (small) O-ring of each injector does not remain in the intake manifold. If the O-ring is not removed
with the injector, the replacement injector with new O-rings will not seat properly in the injector socket. Improper seating
could cause a fuel leak, with the risk of fire.
Warnings, Cautions and Notes 00–22
00–22
4.15 Automatic Transmission Fluid Level
Check / Refill Procedure
Vehicles fitted 5L40E five speed automatic transmissions are not fitted with a dipstick and tube assem bly for fluid level
checking and refilling p urposes. These procedures are carri ed out when the plug, located on the left-hand side (RWD) or
right-hand side (AWD) of transmission housi ng, is removed. The engine must be running when the transmission fluid fill
plug is removed, or excessive fluid loss will occur. Transmission fluid may be hot. Since the actual fluid level is unknown,
stand clear when removing the fill plug. Have a container ready to capture any lost fluid. Do not turn the eng ine off with
the fill plug removed, as you can be injured by hot transmission fluid being expelled out of the oil fill opening. Refer to
Section 7E4 On-vehicle Servic ing for further details.
Warnings, Cautions and Notes 00–23
00–23
4.16 Moving Parts and Hot Surfaces
While working around a ru nning engine, avoid contact with moving parts and hot surfaces.
Warnings, Cautions and Notes 00–24
00–24
4.17 Road-Testing
Road-test a vehicle under normal driving conditions and obey all traffic laws. Do not attempt any manoeuvres that may
endanger you or other roa d users.
Warnings, Cautions and Notes 00–25
00–25
4.18 Safety Glasses and Compressed Air
Wear safety glasses when using compressed air to help prevent eye inj ury.
Warnings, Cautions and Notes 00–26
00–26
4.19 Safety Glasses and Fuel
Alwa ys wear safety glasses wh en working with fuel to help protect the eyes from fuel splash.
Warnings, Cautions and Notes 00–27
00–27
4.20 Seatbelt Replacement
Replace seatbelts, retractors and hard ware in use dur ing all but a minor collision. Restraint systems should be replaced
and anchorages proper ly repaired if they were in areas damaged by collision, whether the seatbelt was in use or not. If
there is any doubt, replace th e seatbelt system. Damage, whether visible or not, could result in the restraint not
functioning correctly in an accident.
If a seatbelt pretensioner is deployed, the seatbelt pretensioner assembl y together with the seat adjuster and guide rail
assembly must be replaced.
If disposing of an undeployed seatbelt buckle and pretensioner assembly, refer to the disabling procedure in
Section 12M Occupant Protection System.
Warnings, Cautions and Notes 00–28
00–28
4.21 Servicing and Replacing Seatbelts
To prevent possible seatb elt d amage, refer to the following items when servicing or replacing seatbelts.
NOTE
All seatbelts must be replaced as a set to ensure
that the seatbelt components are from the same
supplier.
Seatbelts must be serviced as follows:
• All attachment hardware must be replaced, not reused.
• Keep sharp edges and dam aging objects away from seatbelts.
• Avoid bending or damaging any portion of the seatbelt buckle or latch plate.
• Do not bleach or dye seatbelt or strap webbing. Clean with a mild soap solution and water.
• When installing lap or shoul de r seatbelt anchor bolts, start the bolts by hand to ensure that the bolts are threa ded
correctly.
• Do not attempt repairs on seatbelt retractor mechanisms. Replace defect ive assemblies with new service
replacement parts.
Warnings, Cautions and Notes 00–29
00–29
4.22 Occupant Protection System
This vehicle is equipped with an Occupant Protection System (OPS) incorporating a Supplemental Restraint System
(SRS).
An OPS consists of one of the following combinations:
• seatbelt pretensioners and a driver's airbag,
• seatbelt pretensioners, and driver's and front passenger's airbags, or
• seatbelt pretensioners, driver's and front passenger's airbags, and left and right-hand side front airbags.
Refer to Section 12M Occupant Protection System before performing any service operation on, or around an y OPS
components, the steering mechanism or wiring.
Failure to follow these SAFETY PRECAUTIONS could cause unwanted airbag deployment or otherwise unneeded OPS
repairs, or could result in the OPS not functioning correctly when requ ired.
To help avoid accidental airbag deployment , whenever you service a vehicle that requires repair of the OPS and another
vehicle system, we recommend that you firs t repair the OPS, then go on to the other system.
Warnings, Cautions and Notes 00–30
00–30
4.23 OPS Inflatable Restraint Module
Disposal
To prevent accidental deployment of the airbag, do not dispose of an undeplo yed inflatable restraint module as normal
shop waste. The undeployed inflatable restraint module contains substances that could cause personal in jury if the
stored container is damaged during disposal.
For information regarding airb ag and / or pretensioner scrapping procedures refer to Section 12M Occupant Protection
System.
Warnings, Cautions and Notes 00–31
00–31
4.24 OPS / SRS Special Tools
To avoid deployi ng the airbag when troubleshooting the OPS system, use only the equipment specified in this Service
Information and the instructions given in this Service Information. Failure to use the specified equipment as instructed
could cause airbag deployment or unnecessary OPS system repairs, or could result in th e OPS not functioning correctly
when required.
Warnings, Cautions and Notes 00–32
00–32
4.25 Vehicle Towing
Vehicles with automatic transmissions must not be to wed with either front (AWD models) or rear wheels off the ground,
or for more than 55 kilometres or at over 55km/h unless both front (AWD models) and rear propeller shafts are remov ed.
If towing of the vehicle is not possible in accordance to these requireme nts, the vehicle must be transported on a truck
tray.
All the recommendations stated in Chapt er 10 Tow and Load of the AWD Crew Cab O wner's Handbo ok should be
followed, as appropriate. In particular, the information provided u nder the heading of Towing Your Vehi cle must be
complied with.
Warnings, Cautions and Notes 00–33
00–33
4.26 Vehicle Lifting
If the vehicle is to be elevated using a two-post hoist, ensure that the hoist pads are located as specifie d in Section 0A
General Information.
If the vehicle is to be elevated using a four-post hoist, ensure that the park brake is on. Any hoist mechanisms designed
to prevent the vehicle rolling off the hoist when elevated, must be activated and functioning correctly whenever the hoist
is used.
All hoist operating instructions, lifting limitations, maintenance proce dures and maintenance intervals should be strictly
adhered to.
Warnings, Cautions and Notes 00–34
00–34
4.27 Window Removal
When working with any type of glass, use approved safety glasses and gloves.
Warnings, Cautions and Notes 00–35
00–35
4.28 Window Retention
When replacing stationary windows, the uret hane adhesive specified in this Service Information (or a urethan e adhesive
system meeting HOLDEN LTD specifications), must be used to maintain original installation integrity. Failure to use the
correct urethane adhesive may result in poor retention of the window.
Warnings, Cautions and Notes 00–36
00–36
4.29 Work Bay Test
One or more of the following guidelines may apply when performing specific required tests in the work bay:
1 When servicing a vehicle fitted with an ABS / (Traction Control System) TCS or a Limited Slip Differential (LSD)
rear axle, do not operate the engine with the transmissio n i n gear a nd one rear wheel raised. If the ABS / TCS
system is operational or the vehicle is equipped with LSD, with the vehicle in this situation, the driving force will be
transmitted to the wheel on the ground and cause the vehicle to move.
2 When a test requires spinning the drive wheels with the vehicle jacked u p, adhere to the following precautions:
• Do not exceed 56 km/h when spinning on e drive wheel with the other drive wheel stopped. This limit is
necessary because the speedometer indicates onl y one-half the actual vehicle speed u nder these conditions.
• If all of the drive wheels are spinning at the same speed, do not excee d 11 2 km/h.
• All people should stay clear of rotating components and balance weight ar eas to avoid possible injury.
• When operating an en gine in the workshop for an extended time, do not overheat the engine or transmission.
3 When a test requires jacking up the vehicle and running with the wheels and brake rotors removed, adhere to the
following precautions:
• Do not apply the brake with the brake rotors r emove d.
• Do not place the transmission in the PARK p ositio n while the drive wheels are spinning.
• Turn off the ignition to stop the powertrain components from spinning.
Warnings, Cautions and Notes 00–37
00–37
4.30 Fasteners
Use the correct fastener in the correct location. Replacement fasteners must be the correct part numbers for that specific
application. Fasteners requiring replacement or fasteners requirin g the use of thread locking compou nd or sealant are
identified in the service procedure. Do not use paints, lubricants or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. T hese coatings affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners to avoid damage to parts and systems.
Warnings, Cautions and Notes 00–38
00–38
4.31 Handling ESD Sensitive Parts
Electrostatic Discharge (ESD) can damage many solid-state electrical components. Not all components susceptible to
damage from ESD are labelled with the ESD symbol. Exercise caution when handli ng all solid-state electrical
components.
Avoid damaging solid-state electrical components by taking the following precautions:
1 Discharge personal electricity by touching a metal ground p oint after each of the following activities:
• sliding across the vehicle seat,
• sitting or rising, or
• walking.
2 Do not touch the exposed elec tric terminals on a component with your finger or a tool. The connector you are
checking may be tied into a ci rcuit that is susceptible to damage by ESD.
3 Do not allow a screwdriver or a similar tool to contact exposed terminals when disconnecting a connector.
4 Do not remove the protective packing of the solid-state component until yo u are ready to install the solid-state
component.
5 Unless specified in a particular diagnostic procedure, avo id the following activities:
• bridging connectors or component terminals,
• grounding components or con nectors, or
• using test equipment probes on comp onents or connectors.
6 When a diagnosis requires the use of test equipment probes, connect the ground lead first.
7 Touch the solid-state component's package to a ground before opening.
8 Do not lay the solid-state component in any of the following locations:
• on a metal workbench, or
• on top of an electrically oper ated appliance or piece of equipment, such as a TV, radio or oscill oscope.
9 Do not drop the solid-state component.
Warnings, Cautions and Notes 00–39
00–39
4.32 Electronic Control Modules
Do not touch the connector pins or soldered compo nents on the circuit board of any control module as it may cause
electrostatic discharge damage to the modu le.
Warnings, Cautions and Notes 00–40
00–40
5 Battery Disconnection
Procedures
5.1 Before Battery Disconnection
Always turn the ignition to the OFF position before connecting or disconnecting battery cables, batter y chargers or
jumper cables. Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.
CAUTION
When performing any service procedure on
the vehicle that involves disconnecting the
battery cables or any procedure that may
cause the battery voltage to fall below
12 volts, the Telematics module Service Mode
must be enabled. Refer to Section 12K
Telematics.
If the Telematics module Service Mode is not
enabled a ‘Battery Removal Alert’ is
transmitted to the Holden Assist Centre
whenever the battery is disconnected, or a
‘Low Battery Voltage Alert’ when the battery
voltage is low.
Warnings, Cautions and Notes 00–41
00–41
5.2 Before Servicing Electrical Components
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads
must be off unless instructed otherwise in this Service Information.
If a tool or item of equipment could come in contact with a live or an exposed electrical terminal, disconnect the
NEGATIVE battery cable. Always disconnect the negative cable from the battery before the positive cable.
Failure to follow these precautions ma y cause injury. Damage to the vehicle and / or servic e equipment may also occur.
Refer to the following for further information on specific vehicle systems affected by battery disconnection.
Warnings, Cautions and Notes 00–42
00–42
5.3 Systems Affected by Battery
Disconnection
Service technicians should be aware that certain vehicle systems will be affected by battery disconnection. Where
applicable, specific procedure s must be carried out before battery disconnection to avoid unnecessary complicati ons,
time wastage and customer dissatisfaction.
Vehicle systems affected by batter y disconnection are:
• instruments,
• body control module,
• entertainment system,
• Telematics,
• navigation system, and
• sunroof.
Warnings, Cautions and Notes 00–43
00–43
5.4 Instruments
If the battery is disconnected, the instrument dimmer level is set to a 35% illumin ation default and the following
accumulative values will be reset:
• Trip Time
• Trip Distance
• Fuel Used
• Average Fuel
• Average Speed
• Stop Watch
After Battery Reconnection
HOLDEN LTD recommends that the customer be informed that the above settings have changed to a factory default
setting as a result of service work performed on the vehicle. Customers sho uld also be reminded that they may restore
the instrumentation illumination setting to th eir desired level by adjusting the ill umination control at the headlamp switch.
Warnings, Cautions and Notes 00–44
00–44
5.5 Body Control Module
If the battery is disconnected, the following BCM-controlled oper ating parameters require resetting:
• Instrument dimmer level, refer to 5.4 Instruments in this Section;
• Antenna height, refer to 5.6 Entertainm ent System in this Section; or
• Rear lamp failure warning syst em, refer to Section 12J Body Control Module.
Warnings, Cautions and Notes 00–45
00–45
5.6 Entertainment System
If the battery is disconnected:
• The audio system PIN code remains stored and does not have to be entered into the s ystem when the battery is
reconnected.
• Priority station settings remain stored.
• The antenna height memory setting defaults to 5 seconds of upward mast travel which raises the antenna
approximately 60 cm.
NOTE
If the BCM is removed and replaced with another
BCM, the audio system PIN code has to be
re-entered into the audio s ystem.
Warnings, Cautions and Notes 00–46
00–46
5.7 Telematics
Before Battery Disconnection
The Telematics system must be placed into Service Mode. Refer to Section 12K Telematics.
After Battery Reconnection
The Telematics system must be placed into Active Mode. Refer to Section 12K Telematics.
Warnings, Cautions and Notes 00–47
00–47
5.8 Navigation System
Before Battery Disconnection
Before removing battery power form the vehicle, the satellite navigation system must be shut down correctly. Thirty
seconds is required to allow the satellite n avigation computer to store the vehicle's last location. When the satellite
navigation system is shut down correctly, the eject button on the satellite navigation computer is not illuminated.
After Battery Reconnection
If the battery has been disconnected within thirty seconds after turning off the ig nition, the satellite navigation computer
will store the vehicle’s previous positi on and not its current position. This causes a prol onged period of satellite
navigation calibration when the system is reactivated and may cause customer dissatisf action. Ensure that the satellite
navigation system is calibrated to its current location before returning the vehicle to the customer.
Warnings, Cautions and Notes 00–48
00–48
5.9 Sunroof
If the battery is disconnected, sunroof memory settings are lost.
After Battery Reconnection
To restore operation of the sunroof system, the start and end points of the sunroof travel will have to be reinstated into
the sunroof memory. Refer to Section 1F2 Sunroof.
Warnings, Cautions and Notes 00–49
00–49
5.10 Memory Seats
If the battery is disconnected, power seats will require recali bratin g on vehicles fitted with a driver’s 8-way memory seat.
After Battery Reconnection
To restore operation of the front seats, the start and end points of the seat movements will have to be reinstated into the
front seat memory. Refer to Section 1A7 Seat Assemblies.