SECTION 6C1-3 – SERVICE

OPERATIONS - V6 ENGINE

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will consist of either seat

belt pre-tensioners and a driver’s side air bag, or seat belt pre-tensioners and a driver’s and front

passenger’s side air bags. Refer to CAUTIONS, Section 12M, of the VT Series I Service Information before

performing any service operation on or around SRS components, the s teering mechanism or wiring.

Failure to follow the CAUTIONS could result in SRS deployment, resulting in possible personal injury or

unnecessary SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas). In the interests of safety, the LPG fuel

sys tem should be isolated by turning 'OFF' the manual service valve and then draining the LPG service

lines, before any service work is carried out on the vehicle. Refer to the LPG leaflet included with the

Owner's Handbook for details or the appropriate section of this Service Information CD for more specific

servicing information.

GENERAL INFORMATION

NOTE: When fasteners are removed, always reinstall them at the same location from which they were removed. If

a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part

number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that

are not to be reused, or those requiring thread locking compound will be identified. The correct torque value must

be used when installing fasteners that require it. If the above conditions are not followed, parts of system damage

could result. WHA T THIS SECTION CONTAINS

This Section describes the proper service procedures to repair components of the Powertrain Management

Systems. Emphasis is placed on the proper procedures and repair of components related to the systems.

Techline

3.1 SERVICE PRECAUTIONS

The following requirements must be observed when working on vehicles:

1. Before removing any PCM system component, disconnect the battery earth lead.

2. Never start the engine without the battery being solidly connected.

3. Never disconnect the battery from the on board electrical system while the engine is running.

4. When charging the battery, disconnect it from the vehicle's electrical system.

5. Never subject the PCM to temperatures above 80 degrees C i.e. paint oven. Always remove PCM first if this

temperature is to be exceeded.

6. Ensure that all cable harness plugs are connected solidly and that battery terminals are thoroughly clean.

7. The engine management system harness connectors are designed to fit in only one way; there are indexing

tabs and slots on both halves of the connector. Forcing the connector into place is not necessary if it is being

installed with the proper orientation. Failure to take care to match the indexing tabs and slots to ensure the

connector is being installed correctly can cause damage to the connector, the module, or other vehicle

components or systems.

8. Never connect or disconnect cable harness plug at the PCM when the ignition is switched "ON."

9. Before attempting any electric arc welding on the vehicle, disconnect the battery leads and the PCM

connectors.

10. When steam cleaning engines, do not direct the steam cleaning nozzle at PCM system components. If this

happens, corrosion of the terminals can take place.

11. Use only the test equipment specified in the diagnostic charts, since other test equipment may either give

incorrect results or damage good components.

12. All voltage meas ur ements us ing a voltmeter must us e a digital voltmeter with an internal im pedanc e r ating of at

least 10 million ohms per volt (10 megohm/volt).

13. When a test light is specified, a "low-power" test light must be used. Do not use a high - wattage test light.

W hile a particular brand of test light is not suggested, a s imple test on any test light will ensure it to be OK for

PCM circuit testing. Connect an accurate ammeter (such as the high-impedance digital multimeter) in series

with the test light being tested, and power the test light-ammeter circuit with the vehicle battery.

Figure 6C1-3-1 Test Light Check

If the ammeter indicates than 3/10 amp current

flow (0.3 A or 300 mA), the test light is OK to use. If the ammeter indicates than 3/10 amp current flow (0.3

A or 300 mA), the test light is NOT OK to use.

BATTERY

DC AMPS

TEST LIGHT

3.2 POWERTRAIN CONTROL MODULE

Service of the Powertrain Control Module (PCM)

should normally consist of either replacement of

the PCM or PROM assembly.

If the diagnostic procedures call for the PCM to be

replaced, the PROM and PCM should be checked

first to see if they are the correct parts. If they are,

remove the PROM from the faulty PCM and install

it in the new service PCM. THE SERVICE PCM

WILL NOT CONTAIN A PROM. Trouble Code 51

indicates the PROM is installed improperly or has

malfunctioned. When Code 51 is obtained, check

the PROM installation for not being fully seated in

the socket. If it is installed correctly and Code 51

still shows, replace the PROM. Once the PCM is

replaced, you must then perform the Security Link

procedure. Refer to this section for the Security

Link procedure.

Figure 6C1-3-2 PCM Location

IMPORTANT:

• When replacing the production PCM with a

service PCM (controller), it is important to

transf er the broadcas t code and production PCM

number to the service PCM label. This will allow

positive identification of PCM parts throughout

the service life of the vehicle.

IMPORTANT:

• To prevent internal PCM damage, the ignition

must be "OFF" when disconnecting or

reconnecting power to PCM (for example,

battery cables, PCM connectors, PCM fuse

F31, jumper cables, etc.).

Figure 6C1-3-3 PCM Mounting

Techline

REMOVE

1. Disconnect battery earth lead.

2. Remove left hand f ront shroud panel lower trim

assem bly (cowl panel trim ), refer Section 1A2,

BODY DIMENSIONS in the VT Service

Information.

3. Lift up mounting bracket to PCM upper

retaining tang, pull PCM out then up to remove

it from the mounting bracket.

4. Remove wiring harness connectors from PCM,

remove PCM from vehicle.

5. If necessary, remove PCM PROM, refer 3.3,

PROM UNIT - REMOVE, in this Section.

IMPORTANT: Replacement controllers are

supplied without a PROM so care should be taken

when removing the PROM from the defective

controller as it will be reused in the new controller.

Do not rem ove the plastic cover of the PROM. Use

of unapproved removal methods may cause

damage to the PROM or PROM socket.

Figure 6C1-3-4 PCM Removal

6. If required, remove PCM mounting bracket by

inserting a screwdriver into the retaining tang

slot, lever screwdriver to release tang. Pull

brack et out then down to releas e from the cowl

nel.

Figure 6C1-3-5 PCM Mounting Bracket Removal

REINSTALL

1. If removed, reinstall PCM mounting bracket,

engaging bracket leg into slotted hole in cowl

panel. Lift up bracket and engage bracket

lower retainers and retaining tang into cowl

panel.

2. If required, install PROM into new PCM, refer

3.3, PROM UNIT - REINSTALL, in this

Section.

3. Reconnect wiring harness connectors to PCM

4. Assemble PCM into mounting bracket,

ensuring wiring harness is routed in fr ont of the

mounting bracket.

5. Reinstall cowl panel trim, refer to Section 1A1

- BODY in the VT Service Information.

6. Reconnect battery earth lead, start vehicle and

allow to idle. Check vehicle for correct

operation.

PCM SECURITY LINK

Once the PCM and or BCM have been replaced,

the new PCM and or BCM must be security linked

to each other. If this procedure is not performed,

the vehicle will not crank.

The PCM to BCM linking procedure is as follows:

Connect TECH 2 to DLC and select:

Diagnostic / (V) 1997 / VT Commodore / Body /

Body Control Module / Secur ity / BCM Link to PCM

and follow TECH 2 instructions.

For additional information regarding TECH 2 and

TECH 2 test modes (including this linking

procedure), refer to TECH 2 DIAGNOSIS FOR

BCM in Section 12J-1 L OW SERIES BCM or 12J-

2 HIGH SERIES BCM in the VT Service

Information.

Figure 6C1-3-6 PCM Mounting Bracket Reinstallation

3.3 PROM UNIT

DTC 51 indicates a faulty PROM, or incorrect

installation.

IMPORTANT:

The IG NITION SHO ULD ALW AYS BE "OFF" when

installing or removing the PCM connectors.

REMOVE

1. Remove PCM from passenger compartment,

refer 3.2, POWERT RAIN CONTROL MO DULE

- REMOVE, in this Section.

2. Using a No.15 torx bit such as Tool No.

J25359-19, remove PCM PROM access cover

screws, remove acce ss cover.

IMPORTANT:

• DO NOT remove any of the other screws.

Figure 6C1-3-7 Access Cover Removal

3. Rem ove PROM fr om PCM by using thumb and

finger to push retaining clips in towards the

PROM, then lift the PROM straight up and out

of the socket.

IMPORTANT:

DO NOT remove cover of the PROM. Use of

unapproved PROM removal methods will

cause damage to the PROM or PROM socket.

Figure 6C1-3-8 PROM Removal

REINSTALL

1. Remove new PROM from its packaging and

check the part number making sure it is the

correct replacement component.

2. Install PROM in PROM socket, ensuring that

sm all notches in the PROM align with the sm all

notches in the PROM socket.

3. Gently press down on the ends of the PROM

until the retaining clips click into the PROM

socket.

4. Reinstall PROM access cover onto PCM. Use

No.15 T orx bit ( Tool No. J 25359-19) to r einstall

and tighten access cover screws securely5.

Reinstall PCM, refer 3.2, POWERTRAIN

CONTROL MODULE - REINSTALL, in this

Section.

FUNCTIONAL CHECK

1. Turn ignition "ON."

2. Earth DLC diagnostic "test" terminal.

A. DTC 12 should flash four times. (No other

codes present.) This indicates the PROM is

installed properly.

B. If diagnostic trouble DTC 51 occurs or if

the "check powertrain lamp" (MIL) is on

constantly with no DTC's, the PROM is not fully

seated or is defective. In this event, remove or

reinstall the PROM as per previous

instructions.

Figure 6C1-3-9 PROM Identification

Figure 6C1-3-10 PROM Reinstallation

3.4 CAMSHAFT POSITION SENSOR

Figure 6C1-3-11 Camshaft/Crankshaft Position Sensors

REMOVE

1. Disconnect battery earth lead.

2. Lift up retaining tang and disconnect wiring

harness connector from camshaft position

sensor.

3. Remove camshaft position sensor to front cover

retaining bolt.

4. Remove camshaft position sensor and O-ring

from front cover.

REINSTALL

1. Apply light engine oil to O-ring on new camshaft

position sensor.

2. Assemble camshaft position sensor into front

cover hole.

3. Install camshaft position sensor to front cover

retaining bolt and tighten to the correct torque

specification.

CAMSHAFT POSITION SENSOR

RETAINING BOLT

TORQUE SPECIFICATION

11 Nm

3. Reconnect wiring harness connector to camshaft

position sensor.

4. Reconnect battery earth lead.

3.5 ENGINE COOLANT TEMPERATURE (ECT) SENSOR

SUPERCHARGED ENGINE

IMPORTANT:

• Care must be taken when handling PCM

engine coolant sensor. Damage to sensor

will affect the operation of the engine

management system. Ensure that the

correct sensor is located before service is

attempted. There are different engine

coolant temperature sensors: for the PCM,

the instrument panel gauge, and/or warning

lights. Sensors are located in the rear of the

inlet manifold below the engine thermostat

housing.

CAUTION: The Engine Coolant Temperature

(ECT) sensor is installed into a "wet" engine

coolant passage (in the inlet manifold, below the

thermostat housing). Drain the engine coolant

before removing the ECT sensor from the engine.

Position a coolant drain pan appropriately, then

loosen lower radiator hose at the radiator to drain

the coolant.

REMOVE

1. Disconnect battery earth lead.

2. Depressurize engine cooling system by

removing radiator cap in two stages.

CAUTION: DO NOT REMOVE RADIA TOR CAP

WHILE THE ENGINE COOLANT TEMPERATURE

IS ABOVE 50 DEGREES C.

3. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly.

4. Position a coolant drain pan appropriately

beneath the vehicle, then loosen lower radiator

hose at the radiator to drain the engine coolant.

5. Lift up retaining tang and disconnect wiring

harness connector from PCM ECT sensor. Lift

connector up away from sensor.

Figure 6C1-3-12 V6 Supercharged Engine Dress Cover

6. Carefully move powertrain wiring harness

down under the ECT sens or so as to allow tool

access to the sensor.

7. Using a 19 mm ring spanner, carefully loosen

and remove PCM engine coolant temperature

sensor.

Reinstall

1. Apply Loctite 242 (Holden's Specification

HN1256 Class 2, Type 2) sealant to sensor

threads.

2. Install ECT sensor into inlet manifold and

tighten to the correct torque specification.

3. Reconnect wiring harness connector onto ECT

sensor,

IMPORTANT: Recheck that wiring harness

connector and harness are correctly positioned.

The accessory drive belt passes very close to the

temperature sensor connectors. Future damage to

the harness could occur if not correctly positioned

now.

4. Reconnect battery earth lead.

5. Refill the engine coolant system, refer to

Section 6B1, ENGINE COOLING - V6

ENGINE in the VT Service Information.

6. Reinstall engine dress cover to the inlet

manif old, ensuring that s tud gromm ets in dress

cover remain in place. Tighten securing dome

nuts to the correct torque specification.

ECT SENSOR TO INLET MANIFOLD

TORQUE SPECIFICATION 15 - 20

Figure 6C1-3-13 ECT Sensor Location Supercharge

ENGINE DRESS COV E R SECURING

DOME NUT TO INLET MANIFOLD

TORQUE SPECIFICATION

4 - 6 Nm

NON-SUPERCHARGED ENGINE

IMPORTANT:

• Care must be taken when handling PCM

engine coolant sensor. Damage to sensor

will affect the operation of the engine

management system. Ensure that the

correct sensor is located before service is

attempted. There are different engine

coolant temperature sensors: for the PCM,

the instrument panel gauge, and/or warning

lights. Sensors are located in the front of

the inlet manifold below the engine

thermostat housing.

CAUTION: The Engine Coolant Temperature

(ECT) sensor is installed into a "wet" engine

coolant passage (in the inlet manifold, below

the thermostat housing). Drain the engine

coolant before removing the ECT sensor from

the engine. Position a coolant drain pan

appropriately, then loosen lower radiator hose

at the radiator to drain the coolant.

Remove

1. Disconnect battery earth lead.

2. Depressurize engine cooling system by

removing radiator cap in two stages.

CAUTION: DO NOT REMOVE RADIA TOR CAP

WHILE THE ENGINE COOLANT TEMPERATURE

IS ABOVE 50 DEGREES C.

Figure 6C1-3-14 ECT Sensor Location Non-Supercharge

3. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly.

4. Position a coolant drain pan appropriately

beneath the vehicle, then loosen lower radiator

hose at the radiator to drain the engine coolant.

5. Lift up retaining tang and disconnect wiring

harness connector from PCM ECT sensor. Lift

connector up away from sensor.

6. Carefully move powertrain wiring harness

down under the ECT sens or so as to allow tool

access to the sensor.

7. Using a 19 mm ring spanner, carefully loosen

and remove PCM engine coolant temperature

sensor.

Reinstall

1. Apply Loctite 242 (Holden's Specification

HN1256 Class 2, Type 2) sealant to sensor

threads.

2. INSTALL ECT SENSOR INTO INLET

MANIFOLD AND TIGHTEN TO THE CORRECT

TORQUE SPECIFICATION.

Figure 6C1-3-15 Engine Dress Cover

V6 Non-Supercharged Engine

ECT SENSOR TO INLET MANIFOLD

TORQUE SPECIFICATION 15 - 20

3. Reconnec t wiring harness connec tor onto ECT

sensor,

IMPORTANT: Recheck that wiring harness

connector and harness are correctly positioned.

The accessory drive belt passes very close to the

temperature sensor connectors. Future damage to

the harness could occur if not correctly positioned

now.

4. Reconnect battery earth lead.

5. Refill the engine coolant system, refer to

Section 6B1-1, ENGINE COOLING - V6

ENGINE the VT Service Information.

6. Reinstall engine dress cover to the inlet

manifold, ensuring that stud grommets in

dress cover remain in place. Tighten securing

dome nuts to the correct torque specification.

ENGINE DRESS COV E R SECURING

DOME NUT TO INLET MANIFOLD

TORQUE SPECIFICATI O N 4 - 6

3.6 INTAKE AIR TEMP ERATURE (IAT) SENSOR

IMPORTANT:

• Care must be taken when handling IAT

Sensor. Damage to IAT sensor will affect

proper operation of the fuel control system.

REMOVE

1. Disconnect battery earth lead.

2. Lift up tang on IAT sensor wiring harness

connector and pull connector from sensor.

3. Loosen intake air duct adapter clamp that is

located closest to air cleaner assembly.

4. Disconnect air duct, with mass air flow sensor

attached, from air cleaner upper housing.

5. Unclip 5 retaining clips holding the air cleaner

upper housing in place.

6. Separate the upper and lower air cleaner

housings.

NOTE: Air filter should remain in the lower

housing.

7. Remove air cleaner upper housing and place

on bench.

8. Using a pair of side cutters, cut across the IAT

sensor retainer to remove it. Once removed,

discard retainer.

9. Pull out IAT sensor from air cleaner upper

housing.

Figure 6C1-3-16 IAT Sensor Removal

REINSTALL

1. Push new IAT sensor into air cleaner upper

housing, with triangular tang on the mounting

flange locating on the mating rib of the air

cleaner upper housing.

2. Pos ition the upper air cleaner housing assem bly,

with the IAT sensor on the work bench, pushing

up into the air cleaner upper housing.

Position new retainer onto IAT sensor and then

using a 20 mm socket, push the retainer fully

onto the IAT sensor.

3. Assemble the air filter element into the air

cleaner upper housing and place the upper

housing onto the air cleaner lower air cleaner

housing, ensuring that air filter element remains

in position.

4. Snap 5 retainer clips up into place over the top

of the air cleaner upper housing.

5. Reconnect wiring harness connector to IAT

sensor.

6. Carefully assemble intake air duct and mass air

flow sensor onto air cleaner upper housing.

NOTE: Align notch on air cleaner housing adapter

with notch in air duct adapter and notch in clamp.

7. Tighten air duct clamp securely.

8. Check that mass air flow sensor wiring harness

connector has remained firmly in place.

9. Reconnect battery earth lead.

3.7 MASS AIR FLOW (MAF) SENSOR

IMPORTANT:

Care must be taken when handling MAF sensor.

Damage to MAF sensor will aff ect proper operation

of PCM control.

REMOVE

1. Disconnect battery earth lead.

2. Lift up tang on MAF sensor wiring harness

connector and pull connector from sensor.

3. Loosen clamp on air duct adapter, closest to

MAF sensor.

4. Loosen clamp on air duct at MAF sensor and

pull back air duct from sensor.

NOTE: Air duct adapter (between air cleaner and

MAF sensor), both clamps, air duct and MAF

sensor itself have locating notches.

5. Remove MAF sensor from air duct adapter.

REINSTALL

1. Ins tall MAF sensor into air duc t adapter and air

duct, aligning all notches. Install clamps,

aligning notches, tighten clamps securely.

2. Reconnect MAF sensor wiring harness

connector

3. Reconnect battery earth lead.

4. Start vehicle and check for air leaks.

Figure 6C1-3-17 MAF Sensor Removal

3.8 OXYGEN SENSOR

IMPORTANT:

• The oxygen sensor uses a permanently

attached pigtail and connector. This pigtail

should not be removed fr om the oxygen

sensor. Damage or removal of the pigtail or

connector will affect proper operation of the

oxygen sensor.

• Take care when handling the oxygen

sensor. The in-line electrical connector and

louvered end must be kept free of grease,

dirt or other c ontaminants. Avoid using any

cleaning solvents. Do not drop or roughly

handle the oxygen sensor.

NOTE: The oxygen sensor may be difficult to

remove when engine temperature is below 60

degrees Celsius. Excessive force may damage

threads in exhaust pipe, or on the sensor.

NOTE: The Supercharger application requires a

four wire heated oxygen sensor. Be sure only a

four wire heated sensor is used for the

Supercharger application.

REMOVE

1. Disconnect battery earth lead.

2. Lift up retaining tang on oxygen sensor wiring

harness connector and pull connector from

sensor pigtail connector.

For R.H sens or, the connector is located at the

rear of the R.H cylinder head and is accessed

from the rear of the engine compartment. The

sensor pigtail leads are further retained by a

clip attached to the torque converter housing.

For L.H sensor, the connector is located at the

rear of the L.H cylinder head and is accessed

from the rear of the engine compartment.

3. Raise vehicle and place on suitable safety

stands. Refer to Section 3, FRONT

SUSPENSION, in the VT Service Information.

4. Carefully unscrew oxygen sensor from exhaust

pipe referring to previous NOTE.

Figure 6C1-3-18 R.H. Sensor Location (Two wire sensor)

REINSTALL

IMPORTANT:

• A special anti-seize compound is used on

the oxygen sensor threads. The compound

consists of a liquid graphite and very sma ll

glass beads. The graphite will burn away,

but the glass beads will remain, making the

sensor easier to remove.

• Genuine replacement sensors will already

have the compound applied to the threads.

If a sensor is r emoved from an engine, and,

if for any reason it is to be reinstalled, the

threads must have the specified anti-seize

compound applied before reinstallation.

Specified anti-seize compound is available from

authorized Holden Parts Outlets as part number

5613695.

1. If necessary, coat threads of oxygen sensor

with

specified anti-seize compound.

2. Install oxygen sensor into exhaust pipe and

tighten to the correct torque specification.

OXYGEN SENSOR TO

EXHAUST

MANIFOLD TO RQUE

SPECIFICATION

40-50

3. Remove safety stands and lower the vehicle.

4. Reconnect oxygen sensor wiring harness

connector.

NOTE: Ensure that the R.H sensor pigtail leads are

retained by a clip attached to the torque converter

housing

5. Reconnect battery earth lead.

Figure 6C1-3-19 L.H Sensor Location (Two wire sensor)

3.9 THROTTLE POSITION (TP) SENSOR

SUPERCHARGED ENGINE

Remove

1. Disconnect battery earth lead.

2. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly.

3. Loosen rear air duct c lamp to throttle body and

remove air duct.

4. Disconnect throttle cable, and if fitted cruise

control cable from throttle body linkage.

5. Remove the three (3) retaining nuts to throttle

cable bracket on side of throttle body.

6. Rem ove the two (2) throttle body retaining nuts

and throttle body.

7. Lift up retaining tang on TP sensor wiring

harness connector and pull connector from

sensor.

8. Remove the two (2) TP sensor to throttle body

attaching screws.

9. Remove sensor from throttle body taking care

not to lose the driver adapter.

NOTE: The "drive adapter" is a plastic cover that

loosely slides over the end of the throttle shaft, on

the TP sensor side of the throttle body. It is

captured in place when the TP sensor is in position

on the throttle body. The drive adapter could fall

from the throttle shaft after the TP sensor is

removed. Ensure that the drive adapter is not lost.

Figure 6C1-3-20 TP Sensor Removal Supercharge

Reinstall

1. Check that the drive adapter is in place on the

throttle valve shaft, refer to previous NOTE.

2. With throttle valve in the normally closed idle

position, install TP sensor on to throttle valve

shaft and throttle body at a position 30 degrees

clockwise past throttle body attaching screw

holes.

3. Rotate TP sensor anti-clockwise on throttle body,

and install TP sensor attaching screws and

tighten to the correct torque specification.

TP SENSOR TO THROTTLE BODY

ATTA CHI NG SCREW T O RQUE

SPECIFICATION

1 - 1.5 Nm

4. Install throttle body and two (2) attaching nuts.

THROTTLE BODY ATTACHING NUTS 15-20 Nm

5. Install Throttle Body cable attaching bracket.

THROTTLE CABLE BRACKET

ATTACHING NUTS

2-5 Nm

6. Install air cleaner duct to Throttle Body, and

tighten clamp.

7. Reconnect TP sensor wiring harness

connector.

8. Reinstall engine dress cover to the inlet

manifold, ensuring that stud grommets in the

dress c over remain in plac e . T ighten securing

dome nuts to the correct torque specification.

ENGINE DRESS COV E R SECURING

DOME NUT TO INLET MANIFOLD

TORQUE SPECIFICATI O N 4 - 6

9. Reconnect battery earth lead.

NON-SUPERCHARGED ENGINE

Remove

1. Disconnect battery earth lead.

2. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly .

Refer to Figure 6C1-3-15.

3. Lift up retaining tang on TP sensor wiring

harness connector and pull connector from

sensor.

4. Remove the two TP sensor to throttle body

attaching screws.

5. Remove sensor from throttle body taking care

not to lose the drive adapter

NOTE: The "drive adapter" is a plastic cover that

loosely slides over the end of the throttle shaft, on

the TP sensor side of the throttle body. It is

captured in place when the TP sensor is in position

on the throttle body. The drive adapter could fall

from the throttle shaft after the TP sensor is

removed. Ensure that the drive adapter is not lost.

Figure 6C1-3-21 TP Sensor Removal Non-Supercharge

Reinstall

1. Check that the drive adapter is in place on the

throttle valve shaft, refer to previous NOTE.

2. With throttle valve in the normally closed idle

position, install TP sensor on to throttle valve

shaft and throttle body at a position 30 degrees

clockwise past throttle body attaching screw

holes.

3. Rotate TP sensor anti-clockwise on throttle body,

and install TP sensor attaching screws and

tighten to the correct torque specification.

TP SENSOR TO THROTTLE BODY

ATTA CHI NG SCREW T O RQUE

SPECIFICATION

1 - 1.5 Nm

4. Reconnect TP sensor wiring harness connector.

5. Reinstall engine dress cover to the inlet manifold,

ensuring that stud grommets in the dress cover

remain in place . Tighten securing dome nuts to

the correct torque specification.

ENGINE DRESS COVER SECURING

DOME NUT TO INLET MANIFOLD

TORQUE SPECIFICATION

4 - 6 Nm

6. Reconnect battery earth lead.

3.10 VEHICLE SPEED SENSOR

AUTOMATIC TRANSMISSION

Remove

1. Jack up rear of vehicle and support on safety

stands. For location of jacking points, refer to

Section 0A, GENERAL INFORMATION in the

VT Service Information.

2. Lift up tang on VSS wiring harness connector

and pull connector from VSS

3. Remove VSS to transmission extension

housing bolt.

4. Remove VSS and O-ring seal from extension

housing by slowly prying out sensor with a flat

screwdriver.

Reinstall

1. Coat the VSS O-ring seal with a thin film of

transmission fluid.

2. Install new VSS and O-ring into transmission

extension housing.

3. Install retaining bolt and tighten to the correct

torque specification.

4. Reconnect wiring harness connector to VSS.

Remove safety stands and lower vehicle.

VSS RE T AINING BO LT T ORQUE

SPECIFICATION 11 Nm

Figure 6C1-3-22 VSS Location Automatic Transmission

MANUAL TRANSMISSION For vehicle speed sensor removal and

reinstallation, refer to Section 7B-1 MANUAL

TRANSMISSION - V6 in the VT Service

Information.

Figure 6C1-3-23 VSS Location Manual Transmission

3.11 FUEL CONTROL SYSTEM

FUEL PUMP RELAY

The fuel pump relay is located in a relay housing,

in the engine compartment. The relay housing is

positioned forward of the right side (driver's side)

strut tower, in front of the cooling system coolant

recovery reservoir. Other than checking for loose

connectors, the only service possible is

replacement.

FUEL PRESSURE RELIEF PROCEDURE

NOTE:If the following procedure is not taken

before servicing fuel lines or connections, fuel

spray into the engine compartment could occur.

1. Remove "Fuel Pump Relay" from engine

compartment relay housing.

2. With throttle closed, crank engine - engine may

start and idle until fuel supply remaining in fuel

line is exhausted. W hen engine stops, engage

starter again for 10 seconds to ensure

dissipation of any remaining fuel pressure.

3. Refit fuel pump relay.

Figure 6C1-3-24 Fuel Pump Relay Location

Techline

THROTTLE STOP SCREW - RESET

PROCEDURE

IMPORTANT:

• The Throttle Stop Screw controls the

minimum throttle opening (nominal "Closed

throttle" position). It is preset at the factory

and must not be reset unless:

1. The screw is known to have been

inadvertently reset,

-OR-

2. Clearly instructed to do so by a diagnostic

chart.

• Engine idle speed, which will vary with

engine temperature, is PCM - controlled and

is not adjustable.

PCM - Controlled idle speed and

Throttle stop screw setting

ARE NOT THE SAME!

• Throttle stop screw setting (RPM) must

always be less than the PCM controlled idle

speed, and is checked only after

temporarily disabling the PCM's method of

controlling idle speed, the Idle Air Control

system. The throttle stop screw setting is

the least likely cause of an abnormal idle

condition, therefore resetting the screw

should only be considered as a last resort.

An incorrect setting is likely to cause a

deterioration in idle stability.

• Before any adjustments are made, ensure

that no vacuum leaks exist. Check all

vacuum hoses, MAF air ducts, inlet

manifold gasket, throttle body-to-manifold

attachment, and any vacuum-operated

devices. The engine must be at normal

operating temperature before any checking

or rese tting is attempted.

• With this engine control system, any

vacuum leak will result in a low/rough idle

speed.

Figure 6C1-3-25 Throttle Stop Screw Location

CHECK OR RESET

1. Before performing this procedure, perform the

On-Board Diagnostic System Check, and

follow it upto and including step 9 action

column. Refer to Chart A - On Board

Diagnostic System Check, in Section 6C1-2A,

DIAGNOSTIC CHARTS – V6 ENGINE in the

VT Ser vice Inf ormation. If values are norm al or

within typical ranges proceed to step 2 below

2. Ensure that the IAC system is functioning

properly. Refer to Diagnostic Chart A-7.1 V6

PCM - IAC system in Section 6C1-2A,

DIAGNOSTIC CHARTS - V6 ENGINE in the

VT Service Information, and follow it to step

3"NO TROUBLE FOUND WITH IAC

SYSTEM".

3. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly.

IMPORTANT: Verify that the throttle cable and

throttle linkage are not binding. The throttle lever

attached to the throttle butterfly shaft must be able

to open fully, and shut fully and freely every time

the accelerator pedal is fully depressed and slowly

released. If throttle cable adjustment is required,

refer to THROTTLE CABLE in this Section of the

VT Service Information.

4. Engine must be at normal operating

temperature (above 90 degrees C), it is

preferable to achieve by driving the vehicle for

at least 15 minutes, before continuing.

5. Set parking brake and block drive wheels.

Ensure transmission is in `Park' (auto) or

neutral (manual).

6. Ignition "ON," ensure that all electrical loads

are turned "OFF," i.e. air conditioning, lights

etc. "OFF."

7. Connect TECH 2 to DLC and select:

Diagnostics / Appropriate Model Year / VT

Comm odore / Engine / V6 / Confirm Prom I.D. etc.

/ Misc ellaneous tests / IAC system / Bas e Idle / and

follow TECH 2 instructions.

IMPORTANT:If engine stalls while following TECH

2 instructions, turn the throttle stop screw ½ a turn

in the clockwise direction and repeat the base idle

checking procedure. If adjustment of the throttle

stop screw is necessary, adjust screw to obtain an

engine speed of 450 – 550 RPM.

Figure 6C1-3-26 IAC Valve Harness Removed

8. Reset IAC. To do this, either:

Start engine, use TECH 2 scan tool and select

IAC reset, and follow TECH 2 instructions.

-OR-

Start engine, allow engine to run for 5 seconds,

then turn engine "OFF" for 10 seconds to

“Reset” the IAC valve.Restart engine and check

for proper idle.

9. Reinstall engine dress cover to the inlet

manifold, ensuring that stud grommets in the

dress cover remain in place. Tighten securing

dome nuts to the correct torque.

ENGINE DRESS COVER SECURING

DOME NUT TO INLET MANIFOLD

TORQUE SPECIFICATION

4 - 6 Nm

MODULAR FUEL SENDER ASSEMBLY

REMOVE

TOOL REQUIRED

J 39765, FUEL SENDER LOCKNUT WRENCH

NOTE: Do not handle the modular fuel sender

assembly by the fuel pipes.

1. Relieve the fuel system pressure. Refer to the

FUEL PRESSURE RELIEF PROCEDURE in

this Section of the VT Service Information.

2. Disconnect battery earth lead.

3. Remove fuel tank, refer to Section 8A, FUEL

TANK, in the VT Service Information.

4. Remove the modular fuel sender retaining ring

using the J 39765 Fuel Sender Locknut

Wrench.

IMPORTANT: When removing the modular fuel

sender assembly from the fuel tank, the reservoir

bucket on the fuel sender assembly is full of fuel.

The modular fuel sender assembly must be tipped

slightly during removal in order to avoid damage to

the float. Place any remaining fuel into an

approved container once the modular fuel sender

assembly is removed from the fuel tank.

IMPORTANT: The modular fuel sender assembly

will spring-up when the locking ring is removed.

5. Pull the modular fuel sender straight up while

draining the fuel from the reservoir.

6. Clean the fuel sender assembly O-ring sealing

surface.

7. Inspect the fuel sender assembly O-ring

sealing surface.

Figure 6C1-3-27 Modular Sender Assembly

REINSTALL IMPORTANT: Always replace the fuel sender O-ring

when reinstalling the fuel sender assembly.

1. Position the new fuel sender ass embly O-ring on the fuel tank. IMPORTANT: Care should be taken not to fold over

or twist the fuel pump strainer when installing the

fuel sender assembly, as this will restrict fuel flow.

Also, assure that the fuel pump strainer does not

interfere with full travel of float arm.

2. Install the fuel sender assembly and the fuel

sender ass em bly retainer ring using the J 39765

Fuel Sender Locknut Wrench.

3. Reinstall fuel tank, refer to Section 8A FUEL

TANK, in the VT Service Information.

4. Reconnect battery earth lead.

5. Inspect system for leaks.

MODULAR FUEL SENDER ASSEMBLY (SERVICEABLE FUEL LEVEL SENSOR)

REMOVE

NOTICE: Do not handle the modular fuel sender

assembly by the fuel pipes.

1. Relieve the fuel system pressure. Refer to the

FUEL PRESSURE RELIEF PROCEDURE in

this section.

2. Disconnect battery earth lead.

3. Remove fuel tank, refer to Section 8A, FUEL

TANK, in the VT Service Information.

4. Remove modular fuel sender assembly. Refer

to MODULAR FUEL PRESSURE ASSEMBLY

Removal procedure in this Section of the VT

Service Information.

DISASSEMBLE

1. Remove the CPA (connector position

assurance) clip from the fuel level sensor

assembly electrical connectors, then remove

the electrical connectors from the fuel pump

and the fuel sender cover assembly.

2. Compress the fuel level sensor retaining tangs

and remove the fuel level sensor assembly

from the fuel pump reservoir housing.

Figure 6C1-3-29 Fuel Level Sensor Assembly

Assemble

1. Ass emble the f uel level sensor ass embly to the

fuel pump reservoir housing.

2. Assemble the electrical connectors to the fuel

pump and cover assembly.

3. Assemble the CPA (connector position

assurance) clip to the fuel level sensor assembly

electrical connectors.

4. Assemble the rubber pad on the bottom of the

modular fuel sender assembly.

Reinstall

1. Install the fuel sender assembly. Refer to

MODULAR FUEL SENDER ASSEMBLY

Reinstall in this Section of the VT Service

Information.

2. Reinstall fuel tank refer to Section 8A, FUEL

TANK, in the VT Service Information.

3. Reconnect battery earth lead.

4. Inspect system for leaks.

MODULAR FUEL SENDER ASSEMBLY (FUEL PUMP NON-SUPERCHARGED ENGINE)

NOTICE: The fuel pump for the Supercharge V6 is not replaceable, the complete Modular Fuel Sender Assembly

must be replaced for the Supercharge engine.

REMOVE

1. Remove the MODULAR FUEL SENDER ASSEMBLY. Refer to this section for removal procedure.

2. Remove external fuel strainer .

3. Remove CPA #8 ( connector position ass urance) fr om electric al connector and disconnect fuel pum p electric al

connector. Refer to figure 6C1-3-30.

4. Gently release tabs on side of fuel sender to cover assembly. Begin by squeezing the sides of the reservoir

and releas ing the tab opposite the fuel level sens or. Move clockwise to r elease the second and third tab in the

same manner. Refer to figure 6C1-3-31.

5. Lift cover assembly out far enough to disconnect the fuel pump electrical connection.

6. Carefully pry snap ring (#21) out of groove on fuel pump outlet. Refer to figure 6C1-3-30 view B.

7. Rotate f uel pump baffle (#18) counterclock wise and rem ove baffle pum p assem bly f rom retainer ( #7). Refer to

figure 6C1-3-30.

8. Replace the fuel pump seal/dampener. Refer to figure 6C1-3-33.

9. Install fuel pump outlet retainer (#21) on fuel pump outlet (#20). Index the snap ring so that the ends are

positioned in the groove (#22) facing the fuel pump electrical connector. Refer to figure 6C1-3-30 view A and B.

10. Install new f uel pump and baff le assembly onto reservoir retainer (#7) and rotate clockwise until seated. Refer

to figure 6C1-3-30.

11. Place fuel pump outlet (#20) over retainer (#7) so that snap ring ends (#21) face fuel pump electrical

connection and press firmly into place making certain the snap ring is seated and over each tab on outlet.

Refer to figure 6C1-3-30.

12. Lower retainer assembly (#7) partially into reservoir. Line up all three sleeve tabs.

13. Install fuel pump connector and CPA #8 to fuel sender cover (#7). Refer to figure 6C1-3-30.

14. Install new external fuel strainer (#14). Refer to figure 6C1-3-30.

15. Reinstall Modular Fuel Sender Assem bly to fuel tank as outlined in MO DULAR FUEL SENDER ASSEM BLY in

this section, and reinstall fuel tank.

16. Inspect fuel system for leaks.

Figure 6C1-3-30 Modular Fuel Sender Assembly Expanded View

Below are the descriptions that correlate to the figure 6C1-3-30 above.

1. Harness Assembly (Above Cover) - Fuel Pump

And Fuel Sender Wiring.

2. Connector Assembly - Fuel Sender Wiring.

3. Fuel Pipes (3).

4. Cover Assembly - Fuel Sender.

5. Pipe (Convoluted) - Fuel Sender Outlet.

6. Support Assembly (Hallow Support Or Guide

Pipes)

- Fuel Pump Reservoir.

7. Retainer - Fuel Pump Reservoir.

8. Connector Position Assurance (Cpa).

9. Harness Assembly (Below Cover) - Fuel Pump.

10. Harness Assembly (Below Cover) - Fuel Level

Sender.

11. Reservoir - Fuel Pump Fuel.

12. Sensor Assembly - Fuel Level.

13. Pump Assembly ( Jet Pump Assembly) - Fuel

Pump Reservoir.

14. Strainer (External) - Fuel Sender.

15. Pad (Bumper) - Fuel Sender.

16. Valve (Secondary Umbrella Valve) - Fuel Pump

Reservoir Inlet Check.

17. Strainer - Fuel Pump Fuel.

18. Baffle (Isolator Cup) - Fuel Pump.

19. Pump Assembly (Turbine) - Fuel.

20. Outlet - Fuel Pump.

21. Snap Ring - Fuel Pump Outlet.

22. Pipe - Jet Pump.

Figure 6C1-3-31 Modular Fuel Sender Assembly Grasping View

Figure 6C1-3-32 Fuel Pump Removed From Modular Sender Assembly

Below are the descriptions that correlate to the figure 6C1-3-32 above.

1. RESERVOIR ASSEMBLY 2. OUTLET TUBE 3. FUEL PUMP ASSEMBLY 4. FLEX MEMBER

5. RETAINER - FUEL PUMP RESERVOIR

Figure 6C1-3-33 Fuel Pump Seal/Dampener

FUEL SYSTEM PRESSURE TEST

A Fuel System Pressure Test is part of several of

the Diagnostic Charts and Symptom checks. To

perform this test, follow this procedure:

CAUTION: To reduce the risk of fire or personal

injury, it is necessary to relieve fuel system

pressure before performing this test. See "FUEL

PRESSURE RELIEF PROCEDURE" in this

Section.

WARNING: AT NO TIME MUST THE FUEL INLET

HOSE OR RETURN LINE HOSE BE CLAMPED

OR BENT OVER AS THIS WILL CAUSE A

PERMANENT KINKING OF THE INNER

SECTION OF THE HOSE ASSEMBLY AND WILL

RESULT IN RESTRICTED FUEL FLOW.

1. Relieve fuel pressure, refer to 3.11, FUEL

CONTROL SYSTEM - Fuel Pressure Relief

Procedure, in this Section of the VT Service

Information.

2. Turn ignition "OFF."

NOTE: Supercharged Engine

For Supercharger application, use fuel pressure

gauge AU338 or SD28018 with tool AU453

schrader fitting adapter. Remove schrader valve

cap. Connect the schrader valve fitting adapter to

the schrader valve fitting located on Supercharge

fuel rail. Connect fuel gauge to schrader valve

adapter, then proceed to step 7.

NOTE: Non-Supercharged Engine

For Non Supercharger application, proceed to step

3. Remove four dome nuts securing the engine

dress c over ass em bly to the mounting brack ets

studs, lift off and remove the cover assembly.

4. Open Tool No. 7370 and install over fuel inlet

line.

5. Close 7370 and pull into fuel line quick connect

to release it f rom the f uel inlet line, pull back on

quick connect.

NOTE: Before conducting the next step, inspect

tube adapter (P/N 216812) on fuel pressure gauge

hose to ensure that it is free from any damage or

burrs. This is necessary so as to ensure that the

tube does not damage the sealing ring in the quick

connect. If the sealing ring becomes damaged, fuel

leakage will occur.

Figure 6C1-3-35 Non-Supercharged Engine

6. Install fuel pressure gauge AU338 or SD28018

& hose SD28057 fitted with Coupler 7434 and

tube 216812 in the pressure line, between the

fuel inlet line and the fuel inlet hose quick

connect.

Measure

7. Using TECH 2 scan tool , enable fuel pum p so

that the "fuel pump" can pressurize the system.

8. Fuel gauge reading should be 270 - 350 kPa

for NON-SUPERCHARGE application, and

290 - 410 kPa for SUPERCHARGE

application. If not, refer to Chart A-4.1 for

NON-SUPERCHARGE, and Chart A-4.1-1 for

SUPERCHARGE in Section 6C1-2A,

DIAGNOSTIC CHARTS - V6 ENGINE in the

VT Service Information.

9. Relieve fuel pressure, refer to 3.11, FUEL

CONTROL SYSTEM - Fuel Pressure Relief

Procedure, in this Section of the VT Service

Information.

10. Remove fuel pressure gauge and adapter.

11. Turn ignition “OFF”.

12. Reinstall fuel line (V6 Non-Supercharged

Engine) or install schrader valve cap (V6

Supercharged Engine).

13. Check for fuel leaks, refer to 3.11, FUEL

CONTROL SYSTEM - Leak Testing, in this

Section of the VT Service Information.

Figure 6C1-3-36 Supercharged Engine

FUEL FILTER

REMOVE

IMPORTANT Relieve the fuel system pressure

before servicing any fuel system connection. Refer

to the Fuel Pressure Relief Procedure in

3.11, FUEL CONTROL SYSTEM in this Section.

1. Relieve fuel pressure as described in

3.11, FUEL CONTROL SYSTEM - Fuel

Pressure Relief Procedure in this Section.

2. Disconnect batt er y earth lead.

3. Raise rear of vehicle and support on safety

stands, refer to Section OA, GENERAL

INFORMATION in the VT Service Information.

4. Place a drain tray beneath fuel filter.

5. Remove the fuel filter from the retaining

brack et (1) with the fuel lines still connected to

the fuel filter to allow easier access.

Figure 6C1-3-37

QUICK CONNECT FITTINGS

(PLASTIC COLL AR)

6. Grasp the quick-connect fittings both sides of

the fuel filter. Twist the female connectors 1/4

turn in each direction in order to loosen any dirt

within the quick-connect fitting.

Figure 6C1-3-38

7. Using compressed air, blow any dirt out of the

quick-connect fitting to aid the release of any

tension or binding on the release tabs .

IMPORTANT

W ear safety glas ses whe n using com pres sed air in

order to prevent eye injury.

Figure 6C1-3-39

Techline

8. Hold t he fuel filt er firm ly in one hand t o support

the filter.

9. Using your ot her hand, gra sp one of the quick -

connect fittings.

10. Squeeze the plastic retainer release tabs (1)

on each side of the fitting while pushing the

fitting fir mly toward the fue l filter to rele ase any

tension on the release tabs.

Figure 6C1-3-40

11. With the tension release tabs still held in the

squezed position, move the complete quick-

connect fitting away from the fuel filter to

separate the connector fitting from the fuel

filter.

12. Apply the same method from step 8 to 11 for

the remaining quick-connect fitting.

Figure 6C1-3-41

13. Alt ernatel y for steps 8 to 11, us e tool AU533 t o

squeeze the release tabs, release the quick

connect fittings and rem ove both fuel pressure

hoses from the fuel filter.

14. Remove fuel filter from vehicle and disguard

safely remembering that some fuel will still

remain in the filter.

Figure 6C1-3-42

REINST ALL

IMPORTANT The fuel filter must be installed with

the flow arrow (6) on its body pointing in the same

direction as the fuel flow to the front of the vehicle.

Figure 6C1-3-43 Fuel Filter Installation

IMPORTANT Before connecting fuel filter quick-

connect fittings, always apply a few drops of clean

engine oil to the male ends of the fuel filter.

This will ens ure proper rec onnection and pr event a

possible fuel leak.

During normal operation, the O-ring located in the

fem ale connec tor will s wel l and ma y prevent proper

reconnection if not lubr icated.

1. Apply a few drops of clean engine oil to each

male fuel filter end.

Figure 6C1-3-44

2. Push both the quick-connect fitting and the fuel

filter together in order to cause the retaining

tabs to snap into place. Apply this method to

both ends of the fuel filter and the respective

quick-connect fittings.

Figure 6C1-3-45

3. Onc e installed, pull and p ush on bo th the quic k-

connect fitting and the fuel filter in order to

make sure the connection is secure. Apply

method this to both ends of the fuel filter and

the respective quick-connect fittings.

Figure 6C1-3-46

4. Install a new fuel filter to a new retaining bracket

(1).

5. Connect battery earth lead.

6. Check for fuel leaks, refer to

3.11, FUEL CONTROL SYSTEM – Leak

Testing in this Section of the VT Service

Information.

7. Remove safety stands and lower vehicle.

Figure 6C1-3-47

LEAK TESTING

Prior to starting the engine, following the installation of any fuel system component, check the fuel system for leaks

using the following procedure:

1. Check to ensure that there is a sufficient level of fuel in the fuel tank.

2. Use sc an tool "Output T est" for "Fuel Pum p." Enablin g the output t est will acti vate the f uel pum p to press urize the

fuel system.

3. Check fuel system for leaks, particularly at points marked in figure 6C1-3-49 and 6C1-3-50.

FUEL PUMP CONTROL MODULE (SUPERCHARGED ENGINE ONLY)

Remove

1. Disconnect battery earth lead.

2. Move r ight rear upper wheelhouse trim c over to

gain access to fuel pump control module

retaining bolt.

3. Remove retaining bolt.

4. Remove module from upper wheelhouse

brace, disengage module cover front tab from

brace locating hole.

5. Disconnect body harness connector from

module.

Reinstall

1. Reconnect body wiring harness connector to

module.

2. Install module to upper wheelhouse brace,

engaging module front tab to brace locating

hole.

3. Install retaining bolt.

4. Install right rear upper wheelhouse trim cover.

5. Connect battery earth lead.

IMPORTANT: If necessary, check fuel pump

control module operation. Refer to Chart A-4.1-1

V6 PCM - Fuel Pump Electrical Circuit

(Supercharged Engine) in Section 6C1-2A,

DIAGNOSTIC CHARTS - V6 ENGINE in the VT

Service Information.

Figure 6C1-3-48 Fuel Pump Control Module Location

Figure 6C1-3-49 Leak Testing Non-Supercharged Engine

Figure 6C1-3-50 Leak Testing Supercharged Engine

FUEL PRESSURE REGULATOR

SUPERCHARGED ENGINE

1. Relieve fuel pressure as described in 3.11,

FUEL CONTROL SYSTEM - Fuel Pressure

Relief Procedure in this Section.

2. Disconnect battery earth lead.

3. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove cover assembly.

Refer to Figure 6C1-3-12.

4. Disconnect vacuum hose from fuel pressure

regulator.

5. Clean any dirt from the fuel pressure regulator

retaining ring.

6. Using snap ring tool, remove snap ring from

fuel pressure regulator.

Figure 6C1-3-51 Supercharged Engine Fuel Pressure

Regulator Location

7. Using a s hop towel to catc h any spilled f uel, lift

and twist the fuel pr essure regulator in or der to

remove the fuel pressure regulator from the

fuel pressure regulator housing.

8. Cover the fuel pressure regulator housing to

prevent contamination from entering the fuel

system.

9. Using Tool No. 7371 for supercharged engine

application, disconnect fuel return hose quick

connect at dash panel connection, only if

replacing fuel pressure regulator.

REINSTALL

1. New O-rings on the fuel press ure regulator, if a

new fuel pressure regulator is not being

installed. lubricate the O-rings lightly with

clean engine oil.

2. T he fuel press ure regulator in the f uel pressure

regulator housing.

3. Install the retaining snap ring to the fuel

pressure regulator using the snap ring tool.

4. The vacuum hose to the fuel pressure

regulator.

5. Fuel return hose quick connect to dash panel

connector.

6. Reconnect battery earth lead.

7. Check for fuel leaks as described in 3.11,

FUEL CONTROL SYSTEM - LEAK TESTING

in this section.

8. Reinstall engine dress cover to the inlet

manif old, ensuring that s tud gromm ets in dress

cover remain in place. Tighten securing dome

nuts to the correct torque specification.

NOTE: Compressed air must never be used to test

or clean a fuel pressure regulator, as damage to

the fuel pressure regulator may result.

In order to prevent damage to the fuel pressure

regulator do not immerse in solvent.

Figure 6C1-3-52 Supercharge Fuel Pressure Regulator

Removal From Fuel Rail

NON-SUPERCHARGED ENGINE

1. Relieve fuel pressure as described in 3.11,

FUEL CONTROL SYSTEM - Fuel Pressure

Relief Procedure in this Section.

2. Disconnect battery earth lead.

3. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove cover assembly.

Refer to Figure 6C1-3-15.

4. Rem ove f uel rail ass em bly, refer to FUEL RAIL

AND INJECTORS in this section.

5. Disconnect vacuum hose from fuel pressure

regulator.

6. Clean any dirt from the fuel pressure regulator

retaining ring.

7. Using snap ring tool, remove snap ring from

fuel pressure regulator.

8. Using a s hop towel to catc h any sp illed fuel, lift

and twist the fuel pr essure regulator in or der to

remove the fuel pressure regulator from the

fuel pressure regulator housing.

9. Cover the fuel pressure regulator housing to

prevent contamination from entering the fuel

system.

Figure 6C1-3-53 Non-Supercharged Engine Fuel Pressure

Regulator Location

10. Using Tool No. 7370 for Non-Supercharger

application, disconnect fuel return hose quick

connect at dash panel connection, only if

replacing fuel pressure regulator.

Reinstall

1. New O-rings on the fuel press ure regulator, if a

new fuel pressure regulator is not being

installed. lubricate the O-rings lightly with

clean engine oil.

2. T he fuel press ure regulator in the f uel pressure

regulator housing.

3. Install the retaining snap ring to the fuel

pressure regulator using the snap ring tool.

4. Install the fuel rail. Refer to FUEL RAIL AND

INJECTOR for installation.

5. The vacuum hose to the fuel pressure

regulator.

6. Fuel return hose quick connect to dash panel

connector.

7. Reconnect battery earth lead.

Figure 6C1-3-54 Fuel Pressure Regulator

8. Check for fuel leaks as described in 3.11,

FUEL CONTROL SYSTEM - LEAK TESTING

in this section.

9. Reinstall engine dress cover to the inlet

manif old, ensuring that s tud gromm ets in dress

cover remain in place. Tighten securing dome

nuts to the correct torque specification.

NOTE: Compressed air must never be used to test

or clean a fuel pressure regulator, as damage to

the fuel pressure regulator may result.

In order to prevent damage to the fuel pressure

regulator, do not immerse in solvent.

Figure 6C1-3-55 Non-Supercharged Engine Fuel Pressure

Regulator Removal From Fuel Rail

FUEL RAIL

SUPERCHARGED ENGINE

NOTE: T he f uel inlet and return hos es are s erviced

separately from the fuel rail.

NON-SUPERCHARGED ENGINE

NOTE: The fuel inlet and return hoses are an

assembly with the fuel rail. Both components are

NOT serviced separately. For removal or

replacem ent of the fuel r ail assembly refer to FUEL

RAIL AND INJECTORS in this section.

Figure 6C1-3-56 Supercharged Engine

Figure 6C1-3-57 -Non-Supercharged Engine

AIR CLEA NER ASSEMBLY

Remove

1. Loosen air duct adapter located closest to air

cleaner assembly.

2. Disconnect air duct from air cleaner assembly.

3. Pull up retaining tang on IAT sensor wiring

harness connector and pull connector from

sensor.

4. Unclip 5 clips holding the air cleaner upper

housing in place.

5. Remove air cleaner upper housing and air

cleaner element assembly.

6. Remove three nuts securing air cleaner lower

housing to fender inner panel insulators.

7. Disengage air cleaner lower inlet assembly

from lower housing. Remove air cleaner lower

housing.

Reinstall

1. Assemble air cleaner lower housing on to

mounting insulators.

2. Install securing nuts and tighten to the correct

torque specification.

3. Assemble the air cleaner element into the air

cleaner upper housing and place the upper

housing onto the air cleaner lower air cleaner

housing, ensuring that air filter element

remains in position.

4. Snap 5 r etainer clips up into place over the top

of the air cleaner upper housing.

5. Reconnect wiring harness connector to IAT

sensor.

6. Carefully assemble air duct adapter onto air

cleaner upper housing.

NOTE: Align notch on air cleaner housing adapter

with notch in air duct adapter and notch in clamp.

7. Tighten air duct clamp securely.

8. Check that mass air f low sensor wiring harness

connector has remained firmly in place.

9. Reconnect battery earth lead.

Figure 6C1-3-58 Air Cleaner Housing Removal

Non-Supercharge

AIR CLEANER LOWE R HOUSING

SECURING NUT T ORQUE

SPECIFICATION

5 - 7 Nm

Figure 6C1-3-59 Air Cleaner Housing Removal Supercharge

THROTTLE CABLE

Remove

1. Remove four dome nuts securing the engine dress

cover assembly to the inlet manifold studs, lift off

and remove the cover assembly.

2. Loosen outer cable lock nuts at throttle body mounting bracket.

3. Remove inner cable from throttle body linkage.

4. Disconnect outer cable from mounting bracket.

5. Remove instrument panel lower right side trim assembly retainers and lower trim, refer to Section 1A3,

INSTRUMENT PANEL, in the VT Service information.

6. Disconnect inner cable plastic spacer from throttle pedal lever.

7. Withdraw cable assembly from engine compartment.

Figure 6C1-3-60 Throttle Cable Supercharged Engine

Figure 6C1-3-61 Throttle Cable Non-Supercharge

Reinstall

1. Assemble outer cable into dash panel.

2. Attach inner cable to throttle pedal lever.

3. Install outer cable to mounting bracket.

4. Attach inner cable to throttle body linkage.

5. Adjust cable as in following instructions.

Adjust

1. Remove instrument panel lower right side trim

(if not already removed, refer to Section 1A3,

INSTRUMENT PANEL, in the VT Service

Information).

2. Ensure throttle pedal is free to move from

closed to f ully open position. Check that throttle

pedal comes to rest at the correct closed

throttle position (against pedal stop).

3. Adjust outer cable lock nuts s o that inner cable

is tensioned with a deflection of 10 to 15 mm

without moving throttle linkage from idle stop.

4. Tighten cable lock nuts to the correct torque

specification.

5. Check for Wide Open Throttle and smooth

operation of throttle pedal.

6. Reinstall engine dress cover to the inlet

manif old, ensuring that s tud gromm ets in dress

cover remain in place. Tighten securing dome

nuts to the correct torque specification.

7. Refit instrument panel lower right side trim,

refer to Section 1A3, INSTRUMENT PANEL &

CONSOLE, in the VT Service Information.

Figure 6C1-3-62 Throttle cable adjustment

THROTTLE OUTER CABLE LOCK NUT

TORQUE SPECIF I CATION 2 - 5

THROTTLE BODY

Supercharged Engine

Remove

1. Disconnect battery earth lead.

2. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly .

Refer to Figure 6C1-3-11.

3. Disconnect wiring harness connectors from

IAC valve and TP sensor.

4. Loosen air duct clamp at throttle body.

5. Remove air flow duct from throttle body.

6. Remove engine positive crankcase ventilation

hose from throttle body union.

7. Remove canister purge hose from throttle

body.

8. Disconnect inner throttle cable from throttle

body linkage.

9. If vehicle is fitted with cruise control, remove

cruise control cable from throttle body linkage.

10. Remove throttle cable mounting bracket

attaching nut (3).

11. Remove throttle body to inlet manifold

attaching nuts.

Figure 6C1-3-63

12. Remove throttle body and seal from manifold.

Clean

Gasket surfaces on throttle body and manifold.

Reinstall

There are specific throttle body assemblies for

vehicles with automatic and manual transmissions.

If replacing a throttle body, ensure that the correct

type is fitted. Identification is by a drill point

marking on the throttle body used for vehicles with

manual transmission.

1. Install throttle body seal and throttle body to

inlet manifold.

2. Install throttle body attaching nuts and tighten

to the correct torque specification.

3. Reinstall canister purge control hose to throttle

body.

4. Reinstall engine positive crankcase ventilation

hose to throttle body union.

5. Reinstall wiring harness connectors to IAC

valve and TP Sensor.

6. Reinstall throttle cable mounting bracket

attaching nut (1) and bolts (2).

Figure 6C1-3-64

Techline

7. Reconnect inner throttle cable to throttle body

linkage.

8. If vehicle is fitted with cruise control, reinstall

cruise control cable to throttle body linkage.

9. Install air duct onto throttle body, align clamp

and air duct locating notches. Tighten air duct

clamp at throttle body securely

10. Reconnect battery earth lead.

11. Start engine then look and listen for air leaks.

12. Check throttle cable adjustment, refer 3.11,

FUEL CONTROL SYSTEM - Throttle Cable

Adjust in this Section.

Check cruise control cable adjustm ent, refer to

Section 12E, CRUISE CONTROL in the VT

Service Information.

13. Reinstall engine dress cover to the inlet

manifold, ensuring that stud grommets in the

dress cover remain in place. Tighten securing

dome nuts to the correct torque specification.

Figure 6C1-3-65 Throttle Body Identification

Non-Supercharged Engine

Remove

1. Disconnect battery earth lead.

2. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly.

3. Disconnect wiring harness connectors from

IAC valve and TP sensor.

4. Loosen air duct clamp at throttle body.

5. Remove air flow duct from throttle body.

6. Remove engine positive crankcase ventilation

hose from throttle body union.

7. Remove canister purge hose from throttle

body.

8. Disconnect inner throttle cable from throttle

body linkage.

9. If vehicle is fitted with cruise control, remove

cruise control cable from throttle body linkage.

10. Remove throttle cable mounting bracket

attaching nut (1) and bolts (2).

11. Remove throttle body to inlet manifold

attaching nuts.

12. Remove throttle body and seal from manifold.

CLEAN

Gasket surfaces on throttle body and manifold.

Figure 6C1-3-66

Reinstall

There are specific throttle body assemblies for

vehicles with automatic and manual transmissions.

If replacing a throttle body, ensure that the correct

type is fitted. Identification is by a drill point

marking on the throttle body used for vehicles with

manual transmission.

1. Install throttle body seal and throttle body to

inlet manifold.

2. Install throttle body attaching nuts and tighten

to the correct torque specification.

3. Reinstall canister purge control hose to throttle

body.

4. Reinstall engine positive crankcase ventilation

hose to throttle body union.

5. Reinstall wiring harness connectors to IAC

valve and TP Sensor.

6. Reinstall throttle cable mounting bracket

attaching nut and bolts.

7. Reconnect inner throttle cable to throttle body

linkage.

8. If vehicle is fitted with cruise control, reinstall

cruise control cable to throttle body linkage.

Figure 6C1-3-67

9. Install air duct onto throttle body, align clamp

and air duct locating notches. Tighten air duct

clamp at throttle body securely

10. Reconnect battery earth lead.

11. Start engine then look and listen for air leaks.

12. Check throttle cable adjustment, refer 3.11,

FUEL CONTROL SYSTEM - Throttle Cable

Adjust in this Section.

Check cruise control cable adjustm ent, refer to

Section 12E, CRUISE CONTROL in the VT

Service Information.

13. Reinstall engine dress cover to the inlet

manifold, ensuring that stud grommets in the

dress cover remain in place. Tighten securing

dome nuts to the correct torque specification.

Figure 6C1-3-68 Throttle Body Identification

FUEL RAIL AND INJECTORS

Supercharged Engine

Remove

1. Relieve fuel pressure as described in "FUEL

PRESSURE RELIEF PROCEDURE" in this

Section.

2. Disconnect battery earth lead.

IMPORTANT: Thoroughly clean around injector to

inlet manifold ports.

3. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly.

4. Remove alternator bracket.

5. Remove vacuum hose from Fuel Pressure

Regulator.

6. Disconnect fuel pressure regulator from fuel

rail. Refer to FUEL PRESSURE REGULATOR

in this section.

7. Using Tool No. 7371 for Supercharger

application, disconnect fuel inlet hose quick

connect at dash panel connection.

Figure 6C1-3-69 Supercharged Engine Fuel Rail

8. Disconnect electrical connectors from injectors.

9. Remove four (4) nuts, and one (1) bolts

securing Fuel Rail to intake plemun.

10. Remove fuel rail from intake plenum.

11. Remove injector retaining clips. Withdraw

injectors from fuel rail.

IMPORTANT: When servicing the fuel rail

assembly, precautions must be taken to prevent

dirt and other contaminants from entering the fuel

passages. It is recommended that fittings be

capped, and holes plugged, during servicing.

Figure 6C1-3-70 Supercharged Engine Fuel Injector

Installation

Reinstall

1. Fuel Rail to Fuel Injectors.

2. Four nuts and one bolt securing Fuel Rail to

intake Plenum.

3. Electrical connector to Injectors.

4. Fuel inlet hose quick connect to dash panel

connector.

5. Pressure regulator to fuel rail.

6. Fuel return hose quick connect to dash panel

connector.

5. Vacuum hose to Fuel Pressure Regulator.

6. Alternator bracket.

7. Reinstall engine dress cover to the inlet

manifold, ensuring that stud grommets in the

dress cover remain in place. Tighten securing

dome nuts to the correct torque specification.

8. Battery earth cable to battery.

9. Turn ignition "ON" and inspect fuel system for

leaks.

ENGINE DRESS COVER

SECURING DOME NUT TO

INLET MANIFOLD ATTACHING

NUT TORQUE SPECIFICATION

4 - 6

Figure 6C1-3-71

Non-Supercharged Engine

NOTE: The fuel inlet and return hoses are serviced

as an assembly with the fuel rail. Both components

are NOT serviced separately.

Remove

NOTE: The fuel rail and injectors are attached to

the bottom of the two-piece air inlet plenum. The

top of the air inlet plenum must be removed to gain

access to the bolts that secure the inlet plenum to

the inlet manifold. The inlet plenum is then

removed, bringing with it the attached fuel rail and

injectors.

1. Relieve fuel pressure as described in "FUEL

PRESSURE RELIEF PROCEDURE" in this

Section.

2. Disconnect battery earth lead.

3. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly.

IMPORTANT: Thoroughly clean around injector to

inlet manifold ports.

4. Remove the intake air duct from the throttle

body.

5. Remove the purge hose and crankcase vent

hose from the throttle body.

6. Remove the brake booster vacuum hose, and

two small vacuum hoses, from the air inlet

plenum.

7. Dis connec t electrical c onnectors fr om inject ors,

TP sensor, and Idle Air Control valve.

Figure 6C1-3-72

8. Remove eight hex - head bolts securing

plenum cover to air inlet plenum. Lift and

remove cover.

NOTE: Plenum cover uses a soft o-ring - style

gasket between the cover and the air inlet plenum.

Gasket should remain attached in the cover.

IMPORTANT: After removing plenum cover,

BE VERY CAREFUL TO NOT DROP ANYTHING

INTO THE EXPOSED INLET MANIFOLD PORTS

NOTE: Anything dropped into these ports can, and

most likely will, cause serious engine damage due

to foreign objects being ingested into the engine

combustion chambers through the intake valves.

9. Remove vacuum hose from fuel pressure

regulator.

10. Using Tool No. 7370 for Non-Supercharger

application, disconnect fuel inlet hose quick

connect at dash panel connection.

11. Disconnect fuel pressure regulator from fuel

rail. Refer to FUEL PRESSURE REGULATOR

in this section.

12. Using Tool No. 7370 for Non-Supercharger

application, disconnect fuel return hose quick

connect at dash panel connection.

13. Fully loosen (but do not remove) five bolts

securing inlet plenum to inlet manifold.

14. Carefully lift air plenum (and attached fuel rail

with injectors) from inlet manifold. Careful

rotate the front of the inlet plenum up and

towards the windscreen. Gently lower the

plenum assembly to rest on the inlet manifold,

with the fuel rail and injectors facing forward

and tilted slightly up.

Figure 6C1-3-73

IMPORTANT: Place a clean piece of cardboard

between the inlet manifold and plenum assembly,

to prevent foreign objects from entering inlet

manifold ports.

15. Remove injector retaining clips. Withdraw

injectors from fuel rail. Remove fuel rail from air

inlet plenum ONLY if replacement of fuel rail is

needed.

IMPORTANT: When servicing the fuel rail

assembly, precautions must be taken to prevent

dirt and other contaminants from entering the fuel

passages. It is recommended that fittings be

capped, and holes plugged, during servicing.

IMPORTANT: Any time the fuel sy stem is opened

for service, the O-ring seals used with related

component(s) should be replaced, including those

used between the air inlet plenum and inlet

manifold, and between the plenum and it's cover.

Reinstall

1. Injectors using new O-rings, coat O-rings with

engine oil.

2. Injector retaining clips.

3. Air inlet plenum assembly (containing fuel rail

assembly and throttle body) onto intake

manifold, carefully placing injectors into intake

manifold ports. Tighten five bolts to the correct

torque specification.

Figure 6C1-3-74

AIR INLET PLENUM ASSEMBLY TO

INLET MANIFOLD ATTACHING BOLT

TORQUE SPECIF I CATION

15 Nm

4. Air inlet plenum cover to inlet plenum. Tighten

bolts to the correct torque specification.

AIR INLET PLENUM COVER TO AIR

INLET PLENUM ASSEMBLY

ATTACHING BOLT TORQUE

SPECIFICATION

10 Nm

5. Vacuum hoses:

- Brake booster vacuum hose to inlet plenum.

- Crankcase vent hose to throttle body.

- Purge vacuum supply hose to bottom of

throttle body.

- HVAC vacuum hose (small hose) to back of

inlet plenum.

6. Pressure regulator to fuel rail.

7. Fuel return hose to dash quick connector.

8. Fuel inlet hose to dash quick connector.

9. Electrical connectors to fuel injectors, TP sensor,

and Idle Air Control valve.

10. Reinstall engine dress cover to the inlet manifold,

ensuring that stud grommets in the dress cover

remain in place. Tighten securing dome nuts to

the correct torque specification.

11. Negative battery cable.

12. Check for fuel leaks as described in 3.11, "LEAK

TESTING" in this Section of the VT Service

Information.

3.12 IDLE AIR CONTROL VALVE

REMOVE

1. Disconnect battery earth lead.

2. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly.

3. Lift up retaining tang on IAC valve wiring

harness connector and pull connector from

valve.

4. Remove IAC valve to throttle body attaching

screws.

5. Remove IAC valve from throttle body.

CLEAN

IAC valve sealing surfaces on throttle body, to

assure proper seal of O-ring and contact of IAC

valve flange.

IMPORTANT: When installing a new IAC valve, be

sure it has the correct part number.

NOTE: Before installing a new IAC valve, measure

distance "A" between tip of valve pintle and the

flange mounting surface. If it is greater than 28

mm, it must be reduced to prevent damage to the

valve when it is installed. Exert firm pressure on

valve pintle to retract it. (A slight side-to-side

movement may be helpful).

Refer to Figure 6C1-3-60.

Figure 6C1-3-75 IAC Valve Removal

REINSTALL

1. Lubricate IAC valve O-ring with light engine oil.

If necessary, install on to valve assembly.

2. Reinstall IAC valve into throttle body with

wiring harness connector facing up.

3. Install IAC valve attaching screws and tighten

to the correct torque specification.

4. Reconnect IAC valve wiring harness connector

5. Reconnect battery earth lead.

6. If required, clear any DTCs us ing TECH 2 sc an

tool.

7. Connect TECH 2 Scan Tool to DLC and select:

Diagnostics / Appropriate Model Year / VT

Commodore / Engine / V6 / Confirm Prom I.D.

etc. / Miscellaneous tests / IAC system / IAC

Reset / and follow TECH 2 instructions.

Start engine, and allow engine to run for 5

seconds, then turn engine "OFF" for 10

seconds to "Reset" the IAC valve. Restart

engine and check for proper idle.

8. Reinstall engine dress cover to the inlet

manifold, ensuring that stud grommets in the

dress cover remain in place. Tighten securing

dome nuts to the correct torque specification.

IAC VALVE TO THROTTLE BODY

ATTACHING SCREWS

TORQUE SPECIFICATI O N

1-1.5 Nm

Figure 6C1-3-76 IAC Measured

Distance

Figure 6C1-3-77 IAC Retraction Method

3.13 DIRECT IGNITION SYSTEM (DIS)

TIMING ADJUSTMENT

The Direct Ignition System (DIS) system fully controls

the spark timing. No adjustment for spark timing is

provided. There are no timing marks on the

crankshaft balancer or engine.

CHECKING EST SPARK TIMING OPERATION

The PCM will force the Electronic Spark Timing (EST)

spark advance to 10 degrees BTDC when the TECH

2 scan tool is connected to the DLC and By-Pass

Spark mode is selected. To check for EST operation,

run the engine with the throttle fixed at a steady 1600-

1800 RPM, then enter the "By-Pass Spark" mode of

operation with the TECH 2 scan tool. If the RPM

changes (drops), EST spark timing is operating. An

EST system fault will set a DTC. To correctly

diagnose the EST system use the proper DTC chart

in Section 6C1-2A of the VT Service Information.

IGNITION COIL (S)

Remove

1. Disconnect battery earth lead.

2. Remove spark plug leads from coil towers,

noting lead numbering with reference to coil

tower numbers.

NOTE: 1. Slightly twist spark plug leads before

removing from coil towers

NOTE: 2. All spark plug leads and coil terminals

are numbered to correspond to the cylinder

numbering. On service replacement coils the

cylinder numbering does not appear on top of any

coil assembly, refer to cylinder numbering on the

module.

3. Remove screws securing coil(s) to module

and mounting plate.

4. Pull coil(s) from module, taking care not to

bend module terminals.

Reinstall

1. Install coil(s) onto module, aligning module

terminals with mating slots on underside of

coil.

2. Install coil securing screws and tighten to the

correct torque specification.

DIS COIL T O MOUNTING

PLATE SECURING

SCREW TORQUE

SPECIFICATION

4 - 5 Nm

3. Reconnect spark plug leads to coil terminals,

ensuring correct lead to coil terminal

relationship.

4. Reconnect battery earth lead, start engine

and ensure engine operates correctly.

Figure 6C1-3-78 Ignition Coils To Module

Techline

DIS MODULE

Remove

1. Disconnect battery earth lead.

2. Remove all spark plug leads from coil towers,

noting lead numbering with reference to coil

towers numbers.

3. From beneath powertrain harness retainer at

front of coil and module assembly, gently pull

down on the retainer lower locating tangs and

pull retainer from coil and module assembly.

NOTE: 1. Slightly twist spark plug leads before

removing from coil towers

NOTE: 2. All spark plug leads and coil terminals

are numbered to correspond to the cylinder

numbering. On service replacement coils the

cylinder numbering does not appear on top of any

coil assembly, refer to cylinder numbering on the

module.

4. Loosen bolt attaching 14-pin wiring harness

connector to module until you can pull

connector from module.

5. Remove screws securing coils.

6. Remove coils from module, taking care not to

bend module terminals.

7. Remove ignition module assembly.

Figure 6C1-3-79 Ignition Module Removed

Reinstall

1. When replacing module assembly, remove

module to coil terminal and 14 pin wiring harness

connector terminal seals from original module.

Install seals onto new module, taking care not to

damage seals. If any seal(s) is damaged in any

way, install new seal(s).

2. Place coils onto module, aligning module

terminals with mating slots on underside of coil.

3. Reinstall ignition module assembly to mounting

plate, locating raised lugs (2) on both module and

plate together.

NOTE: The lugs on the underside of the module will

mate with the mounting plate holes in one way only to

ensure correct assembly relationship.

4. Reinstall screws securing coils and module to

mounting plate and tighten to the correct torque

specification.

DIS COIL T O MOUNTING PLAT E

SECURING SCREW TO RQUE

SPECIFICATION

4 - 5 Nm

5. Reconnect spark plug leads to coil terminals,

ensuring correct lead to coil terminal relationship.

6. Reconnect 14-pin wiring harness connector to

module as sembly and tighten attaching bolt to the

correct torque specification.

WIRI NG HARNESS CONNECTOR TO

DIS MODULE ATTACHING BOLT

TORQUE SPECIF I CATION

0.6 - 1.2 Nm

7. Snap powertrain wiring harness retainer onto coil

and module assembly and it's mounting plate.

8. Reconnect battery earth lead.

9. Start engine and ensure engine operates

correctly.

CRANKSHAFT SENSOR

Remove

1. Disconnect battery earth lead.

2. Using a 15 mm ring spanner on drive belt

tensioner pulley pivot bolt, rotate tensioner

pulley assembly anti-clockwise and remove

drive belt from generator drive pulley. Release

drive belt tensioner and remove drive belt.

3. Remove crankshaft balancer, refer to Section

6A1, ENGINE MECHANICAL - V6 ENGINE in

the VT Service Information.

4. Lift up retaining tang on crankshaft sensor

engine wiring harness connector and pull

connector from sensor assembly.

5. Using a prying device behind crankshaft

position sensor shield, lever each corner of the

shield from front cover studs, remove shield.

6. Remove crankshaft sensor bracket to front

cover attaching studs and remove sensor

assembly.

Reinstall

1. Install crankshaft sensor assembly onto front

cover dowel pin.

2. Install and tighten s ensor brack et to fr ont cover

attaching studs to the correct torque

specification.

CRANKSHAFT POSITION SENSOR

T O F RONT COVER ATTA CHING 20 - 30 Nm

STUD TORQUE SPECIFICATION

3. Reinstall crank shaft position sensor shield onto

front cover studs, ensuring deflector retainers

fully engage over ends of studs.

4. Reconnect wiring harness connector to

crankshaft sensor.

5. Reinstall crankshaft balancer, refer to Section

6A1, ENGINE MECHANICAL - V6 ENGINE in

the VT Service Information.

NOTE: Do not reinstall drive belt at this stage.

6. Rotate crankshaft so as to check that

interrupter rings do not contact sensor.

NOTE: If the interrupter rings contac t the sensor at

any point during balancer rotation, the interrupter

rings have excessive runout and the balancer

assembly must be replaced.

7. Reinstall serpentine belt.

8. Reconnect battery earth lead.

9. Start engine and ensure engine operates

correctly.

Figure 6C1-3-80

Figure 6C1-3-81 Camshaft/Crankshaft Position Sensors

3.14 1-2 SHIFT SOLENOID

Figure 6C1-3-82 1-2 Shift Solenoid Location

REMOVE

1. Disconnect battery earth lead.

CAUTION: To avoid personal injury from accidental hot oil spillage, perform fluid change only when

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the VT

Service Information.

3. Clean all dirt from around oil pan and transmission case.

4. Place drain tray under transmission.

5. Loosen two bolts at the rear and one at the front of the oil pan. Remove the rem aining bolts. W hile holding oil

pan, allow the front of the oil pan to drop away, emptying oil into a drain tray.

6. Remove remaining bolts, then lower pan and empty fluid from pan.

7. Remove old oil pan gasket and discard.

8. Disconnect 1-2 shift solenoid (367A) electrical connector.

9. Remove solenoid retainer (379) by using a small flat blade screwdriver. Pry the retainer down until it can be

grasped.

NOTE: Solenoid has a slight spring pressure behind it, and may pop out on its own after retainer is removed.

10. Remove solenoid assembly (367A) with O-ring seal. Ensure that 1-2 shift valve (366) remains in place.

REINSTALL

1. Push solenoid assembly (367A) into valve body.

2. Hold solenoid in place with finger pressure while

installing retainer (379)

3. Reconnect 1-2 shift solenoid (367A) electrical

connector.

4. Clean oil pan and case mating surfaces. Check

that magnet is still magnetized, and attached to

the oil pan.

5. Install new gasket and reinstall oil pan. Tighten

bolts to the correct torque specification.

TRANSMISSION OIL PAN BOLT

TORQUE SPECIF I CATION 11

6. Lower vehicle and add approximately 4.8 litres of

DEXRON  III automatic transmission fluid.

7. Reconnect battery earth lead.

8. Check transmission fluid level. Refer to 4L60E

Transmission Fluid Checking Procedure in

Section 6C1-2A, DIAGNOSTIC CHARTS - V6

ENGINE in the VT Service Information

3.15 2-3 SHIFT SOLENOID

Figure 6C1-3-83 2-3 Shift Solenoid Location

REMOVE

1. Disconnect battery earth lead.

CAUTION: To avoid personal injury from accidental hot oil spillage, perform fluid change only when

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the VT

Service Information.

3. Clean all dirt from around oil pan and transmission case.

4. Place drain tray under transmission.

5. Loosen two bolts at the rear and one at the front of the oil pan. Remove the rem aining bolts. W hile holding oil

pan , allow front of oil pan to drop away, emptying oil into a drain tray.

6. Remove remaining bolts, then lower oil pan and empty fluid from pan.

7. Remove old oil pan gasket and discard.

8. Disconnect 2-3 shift solenoid (367B) electrical connector.

9. Remove solenoid retainer (379) by using a small flat blade screwdriver. Pry the retainer down until it can be

grasped

10. Remove solenoid assembly (367B) with O-ring seal. Ensure that 2-3 shuttle valve 369 remains in place.

REINSTALL

1. Push solenoid assembly with O-ring seal (367B)

into valve body

2. Install solenoid retainer (379).

3. Reconnect 2-3 shift solenoid electrical connector.

4. Clean oil pan and case mating surfaces. Check

that magnet is still m agnetized and attached to the

oil pan.

5. Install new gasket and reinstall oil pan. Tighten

bolts to the correct torque specification.

TRANSMISSION OIL PAN BOLT

TORQUE SPECIF I CATION 11

6. Lower vehicle and add approximately 4.8 litres of

DEXRON  III automatic transmission fluid.

7. Reconnect battery earth lead.

8. Check transmission fluid level. Refer to 4L60E

Transmission Fluid Checking Procedure in

Section 6C1-2A, DIAGNOSTIC CHARTS - V6

ENGINE in the VT Service Information

3.16 3-2 CONTROL SOLENOID

Figure 6C1-3-84 3-2 Shift Solenoid Location

REMOVE

1. Disconnect battery earth lead.

CAUTION: To avoid personal injury from accidental hot oil spillage, perform fluid change only when

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the VT

Service Information.

3. Clean all dirt from around oil pan and transmission case.

4. Place drain tray under transmission.

5. Loosen two bolts at the rear and one at the front of the oil pan. Remove the rem aining bolts. W hile holding oil

pan, allow the front of the oil pan to drop away, emptying oil into a drain tray.

6. Remove remaining bolts, then lower pan and empty fluid from pan.

7. Remove old oil pan gasket and discard.

8. Remove strainer.

8. Disconnect 3-2 control solenoid (394) electrical connector.

9. Remove solenoid retainer (379) by using a split ring puller or similar hooked tool.

NOTE: Solenoid has spring pressure behind it and may pop out after retainer is removed.

10. Remove solenoid assembly (394) with O-ring seal.

REINSTALL

1. Push solenoid assembly with O-ring seal (394)

into valve body

2. Hold solenoid firmly in place with finger pressure

while installing retainer (379).

3. Reconnect 3-2 control solenoid electrical

connector.

4. Install strainer.

5. Clean oil pan and case mating surfaces. Check

that magnet is still magnetized, and attached to

the oil pan.

6. Install new gasket and reinstall oil pan. Tighten

bolts to the correct torque specification.

TRANSMISSION OIL PAN BOLT

TORQUE SPECIF I CATION 11

7. Lower vehicle and add approximately 4.8 litres of

DEXRON  III automatic transmission fluid.

8. Reconnect battery earth lead.

9. Check transmission fluid level. Refer to 4L60E

Transmission Fluid Checking Procedure in

Section 6C1-2A, DIAGNOSTIC CHARTS - V6

ENGINE in the VT Service Information.

3.17 PRE S SURE CONTROL SOLENOID

REMOVE

1. Disconnect battery earth lead.

CAUTION: To avoid personal injury from

accidental hot oil spillage, perform fluid change

only when transmission fluid is cold.

2. Raise vehicle and support on safety stands.

Refer to Section 0A, GENERAL

INFORM ATION in the VT Service Information.

3. Clean all dirt from around oil pan and

transmission case .

4. Place drain tray under transmission.

5. Loosen two bolts at the rear and one at the

front of the oil pan. Remove the remaining

bolts. While holding oil pan, allow the front of

the oil pan to drop away, emptying oil into a

drain tray.

6. Remove remaining bolts, then lower pan and

empty fluid from pan.

7. Remove old oil pan gasket and discard.

8. Remove strainer.

9. Rem ove three 1- 2 accum ulator cover bolts (58)

(59)

NOTE: Accumulator will be full of fluid.

10. Remove 1-2 accumulator cover assembly (57).

11. Remove pressure control solenoid (377)

electrical connector.

12. Remove pressure control solenoid retainer bolt

(364), then retainer (378).

13. Remove pressure control solenoid assembly

(377).

Figure 6C1-3-85 Pressure Control Solenoid Location

REINSTALL

1. Install solenoid assembly (377). Note: Solenoid

has a flat cut out on one side of it's retaining

flange. Flat cutout goes toward retaining bolt.

Solenoid retainer has a matching flat to allow

retainer to be properly installed

2. Install solenoid retainer (378).

3. Install solenoid retainer bolt (364). Tighten bolt to

the correct torque specification.

SOLENOID RETAINER BOLT TORQUE

SPECIFICATION 11

4. Install pressure control solenoid electrical

connector.

5. Install 1-2 accumulator cover assembly (57).

6. Install accumulator cover bolts (58) (59) and

tighten to the correct torque specification.

ACCUMULATOR COVE R B O LT

TORQUE SPECIF I CATION 11

7. Install new strainer.

8. Clean oil pan and case mating surfaces. Check

that magnet is still magnetized, and attached to

the oil pan.

9. Install new gasket and reinstall oil pan. Tighten

bolts to the correct torque specification.

TRANSMISSION OIL PAN BOLT

TORQUE SPECIF I CATION 11

10. Lower vehicle and add approximately 4.8 litres of

DEXRON  III automatic transmission fluid.

11. Reconnect battery earth lead.

12. Check transmission fluid level. Refer to 4L60E

Transmission Fluid Checking Procedure in

Section 6C1-2A, DIAGNOSTIC CHARTS - V6

ENGINE in the VT Service Information

Figure 6C1-3-86 Pressure Control Solenoid Assembly

3.18 TRANSMISSION FLUID PRESSURE SWITCH ASSEMBLY (TFP) AND TRANSMISSION

FLUID TEMPERATURE (TFT) SENSOR

Figure 6C1-3-87 Transmission Fluid Pressure Switch Assembly (TFP)

REMOVE

1. Disconnect battery earth lead.

CAUTION: To avoid personal injury from accidental hot oil spillage, perform fluid change only when

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the VT

Service Information.

3. Clean all dirt from around oil pan and transmission case.

4. Place drain tray under transmission.

5. Loosen two bolts at the rear and one at the front of the oil pan. Remove the rem aining bolts. W hile holding oil

pan, allow the front of the oil pan to drop away, emptying oil into a drain tray.

6. Remove remaining bolts, then lower pan and empty fluid from pan.

7. Remove old oil pan gasket and discard.

8. Remove strainer.

9. Disconnect trans fluid pressure switch assembly electrical connector.

10. Remove five (5) trans fluid pressure switch assembly to valve body bolts (68 and 70).

11. Remove trans fluid pressure switch assembly (69).

REINSTALL

1. Install trans fluid pressure switch assembly (69).

2. Install f ive (5) trans f luid pressur e switch assem bly

retaining valve body bolts (68 and 70). Tighten

bolts to the correct torque specification

TRANSMISSION FLUID PRESSURE

SWITCH ASSEM BLY ( TFP) RETAINING

VALVE BODY B OLT T O RQUE

SPECIFICATION

3. Reconnect trans fluid pressure switch assembly

electrical connector.

4. Reinstall strainer.

5. Clean oil pan and case mating surfaces. Check

that magnet is still magnetized, and attached to

the oil pan.

6. Install new gasket and reinstall oil pan. Tighten

bolts to the correct torque specification.

TRANSMISSION OIL PAN BOLT

TORQUE SPECIF I CATION 11

7. Lower vehicle and add approximately 4.8 litres of

DEXRON  III automatic transmission fluid.

8. Reconnect battery earth lead.

9. Check transmission fluid level. Refer to 4L60E

Transmission Fluid Checking Procedure in

Section 6C1-2A, DIAGNOSTIC CHARTS - V6

ENGINE in the VT Service Information.

3.19 TCC "PWM" SOLENOID

Figure 6C1-3-88

REMOVE

1. Disconnect battery earth lead.

CAUTION: To avoid personal injury from accidental hot oil spillage, perform fluid change only when

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the VT

Service Information.

3. Clean all dirt from around oil pan and transmission case.

4. Place drain tray under transmission.

5. Loosen two bolts at the rear and one at the front of the oil pan. Remove the rem aining bolts. W hile holding oil

pan, allow the front of the oil pan to drop away, emptying oil into a drain tray.

6. Remove remaining bolts, then lower pan and empty fluid from pan.

7. Remove old oil pan gasket and discard.

8. Remove strainer.

9. Remove TCC "PWM" solenoid (396) electrical connector.

10. Remove Solenoid retainer (379) by using a split ring puller or similar hooked tool.

11. Remove TCC "PWM" Solenoid assembly (396) with O-ring seal.

REINSTALL

1. Ins tall TCC "PW M" Solenoid with O-ring assem bly

(396).

2. Install TCC "PWM" Solenoid retainer (379).

3. Install TCC "PWM" solenoid electrical connector.

4. Install strainer

5. Clean oil pan and case mating surfaces. Check

that magnet is still magnetized, and attached to

the oil pan.

6. Install new gasket and reinstall oil pan. Tighten

bolts to the correct torque specification.

TRANSMISSION OIL PAN BOLT

TORQUE SPECIF I CATION 11

7. Lower vehicle and add approximately 4.8 litres of

DEXRON  III automatic transmission fluid.

8. Reconnect battery earth lead.

9. Check transmission fluid level. Refer to 4L60E

Transmission Fluid Checking Procedure in

Section 6C1-2A, DIAGNOSTIC CHARTS - V6

ENGINE in the VT Service Information.

3.20 TCC ENABLE SOLENOID

Figure 6C1-3-89

REMOVE

1. Disconnect battery earth lead.

CAUTION: To avoid personal injury from

accidental hot oil spillage, perform f luid change

only when transmission fluid is cold.

2. Raise vehicle and support on safety stands.

Refer to Section 0A, GENERAL

INFORM ATION in the VT Service Information.

3. Clean all dirt from around oil pan and

transmission case .

4. Place drain tray under transmission.

5. Loosen two bolts at the rear and one at the

front of the oil pan. Remove the remaining

bolts. While holding oil pan, allow the front of

the oil pan to drop away, emptying oil into a

drain tray.

6. Remove remaining bolts, then lower pan and

empty fluid from pan.

7. Remove old oil pan gasket and discard.

8. Remove strainer.

9. Remove TCC "PWM" solenoid (396) electrical

connector.

10. Remove TCC "PWM" solenoid retainer (379)

by using a split ring puller or similar hooked

tool.

11. Remove TCC "PW M" solenoid assembly (396)

with O-ring seal.

12. Remove TCC ENABLE solenoid assembly

bolts (68).

13. Remove T CC ENABLE solenoid assem bly (66)

with O-ring seal.

14. Remove all electrical connectors from

components.

Figure 6C1-3-90

15. Remove the three valve body bolts retaining the

transmission wiring harness.

16. Remove three 1-2 accumulator cover bolts (58)

(59).

17. Remove 1-2 accumulator cover assembly (57).

18. Rem ove pressure control solenoid (377) electrical

connector.

19. Remove pressure control solenoid retainer (378).

20. Remove pressure control solenoid assembly

(377).

21. Place a 12 point 1-5/16" deep well sock et (or 34.5

mm I.D. pipe with a slight chamfer on the inside)

over the top of the transmission pass-thru

connector.

NOTE: This may be difficult due to the clearance of

the floor pan transmission tunnel and the transmission

case.

22. Pry downward on the top of the socket or pipe

Using a prybar or similar shaped tool, push the

pass thru connector down through and out of the

transmission case .

REINSTALL

1. Coat TCC ENABLE Solenoid O-ring with

petroleum jelly then install new wiring harness

assembly (containing new TCC ENABLE

solenoid) into transmission case.

2. Install pressure control solenoid assembly (377).

NOTE: Solenoid has a flat cut out on one side of it's

retaining flange. Flat cutout goes toward retaining bolt.

Solenoid retainer has a matching flat to allow retainer

to be properly installed

3. Install pressure control solenoid retainer (378).

NOTE: Ensure that flat of the retainer is correctly

placed into the cutout on the solenoid flange. Tighten

retainer bolt to 11 N m.

4. Install pressure control solenoid (377) electrical

connector.

5. Install 1-2 accumulator cover assembly (52).

6. Install three 1-2 acc umulator c over bolts (58) ( 59).

Tighten to the correct torque specification.

1-2 ACCUMULATOR COVER B OLT

TORQUE SPECIF I CATION 11

7. Install TCC "ON-OFF" solenoid assembly (66).

8. Install T CC "ON-O FF" solenoid bolts (68). Tighten

to the correct torque specification.

TCC SOLENOID B OLT TORQUE

SPECIFICATION 11

9. Install TCC "PWM" Solenoid assembly (396).

10. Install TCC "PWM" Solenoid retainer (379).

11. Install TCC "PWM" solenoid electrical connector.

12. Install three valve body bolts retaining wiring

harness. Tighten to the correct torque

specification.

VALVE BODY WIRING HA RNESS

RETAI NI NG B O LT T ORQUE

SPECIFICATION

13. Install all electrical connectors onto components.

14. Install new strainer and seal.

15. Clean oil pan and case mating surfaces. Check

that magnet is still m agnetized, and attached to the

oil pan within the square marked.

16. Install new gasket and reinstall oil pan. Tighten

bolts to the correct torque specification.

TRANSMISSION OIL PAN BOLT

TORQUE SPECIF I CATION 11

17. Lower vehicle and add approximately 4.8 litres of

DEXRON  III automatic transmission fluid.

18. Reconnect battery earth lead.

19. Check transmission fluid level. Refer to 4L60E

Transmission Fluid Checking Procedure in

Section 6C1-2A, DIAGNOSTIC CHARTS - V6

ENGINE in the VT Service Information.

3.21 KNOCK SENSOR

CHECKING KNOCK SENSOR OPERATION

The PCM's knock sensor input will reduce the EST spark advance when detonation is present. This sensor signals

the PCM of engine noise, and the PCM determines if the noise is detonation, or normal mechanical noise. The

PCM can be "tricked" into thinking that detonation is present by lightly `rapping' on the engine with a small hammer.

To check the "knock retard" function of the ignition system, run the engine with the DLC diagnostic test terminal

NOT earthed. With the throttle fixed at a steady 1600 - 1800 RPM, quickly and repeatedly `rap' on the engine block,

cylinder head, or inlet manifold with a small hammer. The RPM should drop, due to the timing advance being

reduced. When you stop `rapping' on the engine, the RPM should come back to the original starting point.

CAUTION: Both knock sensors are threaded into the engine block cylinder cooling jackets, which is a "wet" area of

the engine coolant system. When either knock sensor is removed from the engine block engine coolant will drain

out. ALLOW ENGINE TO FULLY COOL DOWN TO AMBIENT TEMPERATURE BEFORE SERVICING KNOCK

SENSOR. Make sure to have a drain pan available to catch engine coolant.

REMOVE

1. Allow engine to cool to ambient temperature (less than 50 degrees Celsius), then remove radiator cap.

2. Disconnect battery earth lead.

3. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the VT

Service Information.

4. Squeeze together 'wide ends' on sensor wiring harness connector (connector is oval shaped) and pull

connector from sensor.

NOTE: To achieve this step it may be necessary to remove the knock sensor heat shield attaching bolts and heat

shields.

Figure 6C1-3-91

5. Place a suitable drain tray beneath the knock sensor location.

6. Using a 22 mm socket, universal joint and suitable length socket bars, loosen and remove knock sensor from

the cylinder block, taking extreme care to avoid any draining coolant if it is hot.

REINSTALL

1. Ensure that the threads in the sensor mounting

hole in cylinder block are clean.

2. If reinstalling original sensor, inspect sealant on

sensor thr eads. If worn away, apply a light coating

of Loctite 242 (Holden's Specification HN1256

Class 2, Type 2) to sensor threads.

NOTE: On a new sensor, do not apply sealant to

threads as threads are coated with a sealant during

production. Applying additional sealant will affect the

sensor's ability to detect engine knock.

3. Install sensor and tighten to the correct torque

specification.

NOTE: Ensure that knock sensor is never over

tightened as damage to the sensor can occur.

KNOCK SENS OR TIGHTENING

TORQUE SPECIF I CATION 16 - 22

4. Reconnect wiring harness connector to sensor.

Ensure that connector is securely fitted onto

sensor.

5. If removed, r einstall knock sensor heat shield and

attaching bolts. Tighten bolts to the correct

torque specification.

KNOCK SENSOR HEAT SHIELD

ATTACHING BOLT TORQUE

SPECIFICATION

25 - 35 Nm

6. Refill cooling system and pressure test for leaks,

refer Section 6B1, ENGINE COOLING - V6

ENGINE in the VT Service Information.

7. Reconnect battery earth lead.

3.22 EVAPORATIVE EMISSION CONTROL CANISTER

1. The Emission Control Canister is located

underneath the vehicle by the fuel filter. For

Canister removal and reinstallation procedures,

refer to Section 6E1 EMISSION CONTROL - V6

ENGINE in the VT Service Information.

Figure 6C1-3-92

3.23 CANISTER PURGE SOLENOID

REMOVE

1. Disconnect battery earth lead.

2. Mark hoses on canister purge solenoid (top,

bottom), and pull hoses from solenoid.

3. Pull up on solenoid wiring harness connector

and pull connector from solenoid.

4. Remove bolt from solenoid bracket. This bolt

attaches to the rear of the right hand cylinder

head, remove solenoid.

REINSTALL

1. Reinstall canister purge solenoid to rear of

cylinder head and install bracket bolt. Tighten

bolt to the correct torque specification.

2. Reconnect hoses and wiring harness

connector to canister purge solenoid, ensuring

connections are correct.

3. Reconnect battery earth lead.

Figure 6C1-3-93

3.24 S UP ERCHARGER SYSTEM

CAUTION: To minimize the chances of unwanted

fuel spray and underhood fuel spill, always

depressurize the fuel pipes before performing

service that requires removing or disconnecting of

any portion of the fuel system, refer 3.11, FUEL

CONTROL SYSTEM - Fuel Pressure Relief

Procedure, in Section 6C1-3 SERVICE

OPERA TIONS in the VT Service Information.

SUPERCHARGER OIL LEVEL CHECK

NOTICE: A small amount of oil weepage through

the front seal, (behind the pulley) of the

supercharger assembly is a normal condition. This

oil weepage is caused by minute traces of oil

escaping around the seal due to normal pressure

build up in the oil cavity within the supercharger

assembly. A build up of belt dust and/or airborne

dust can adhere to the thin oil film, which causes

the oil weepage to appear worse than it really is.

The supercharger assembly should not be

replaced due to the weepage described. If the

supercharger oil is visually dripping or puddling

from the supercharger front seal, the supercharger

assembly will need to be replaced. Refer to

Section 6A1-2, ENGINE MECHANICAL V6

SUPERCHARGED ENGINE in the VT Service

Information.

Figure 6C1-3-94

CAUTION: Do not remove the oil plug when the

engine is warm. The engine should be cool to the

touch. Approximately 2-3 hours after running.

Removing the oil plug at warm engine temperature

can cause hot oil to overflow. This could result in oil

loss and possible personal injury.

1. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly .

Refer to Figure 6C1-3-11.

NOTICE: To prevent contamination of the

supercharger oil, clean the area around the oil fill

plug before removing.

2. Using a 3/16" allen key socket, remove

supercharger oil filler plug.

3. Check oil level.

INSPECT: The oil level should be maintained to a

level at the bottom of threads in the oil filler plug

inspection hole in the supercharger housing.

IMPORTANT: DO NOT USE PETROLEUM

BASED OIL. USE ONLY GM P/N 12345982

SYNTHETIC OIL. USE OF ANY OTHER OIL MAY

CAUSE SUPERCHARGER FAILURE.

4. Reinstall oil filler plug, ensuring sealing O

ring is in place on plug. Tighten plug to the

correct torque specification.

SUPERCHARGED OIL FIL L PL UG 10

TORQUE SPECIFICATION Nm

5. Reinstall engine dress cover to the mounting

brackets, ensuring that stud grommets in the

dress cover remain in place. Tighten securing

dome nuts to the correct torque specification.

SUPERCHARGER

For Supercharger removal and reinstallation

instructions, refer Section 6A1-2, ENGINE

MECHANICAL V6 SUPERCHARGED ENGINE in

the VT Service Information.

Figure 6C1-3-95

IMPORTANT: The supercharger oil level should be

checked at the specified service intervals outlined in

the Owner's Handbook.

BOOST CONTROL SOLENOID REMOVE

1. Remove four dome nuts securing the engine

dress cover assembly to the inlet manif old studs,

lift off and remove the cover assembly.

2. Boost source and signal hose from solenoid

Ports.

3. Pull back retaining tang on wiring harness

connector and remove connector from solenoid.

4. Remove solenoid bracket to cylinder head

attaching bolt and remove solenoid.

REINSTALL

1. Assembly solenoid to cylinder head, install and

tighten attaching bolt to the correct torque

specification.

BOOST CONTROL SOLENOID BRACKET

TO CYLINDER HEAD A T T ACHING BOLT

TORQUE SPECIF I CATION 8 Nm

2. Connect boost sourc e and signal hos e to solenoid

ports.

3. Reconnect wiring harness connector to solenoid.

Figure 6C1-3-96 Boost Control Solenoid Location

BY-PASS VALVE ACTUATOR

REMOVE

1. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly.

Refer to Figure 6C1-3-11.

2. Remove vacuum hose from by-pass valve

actuator port.

3. Using a pointed scribe, mark position of

actuator mounting bracket around head of

securing bolts. This will aid in reinstallation so

as to ensure that actuator is assembled in the

same position.

4. Remove two (2) bolts s ecur ing actuator brac ket

to supercharger housing.

5. Lift actuator assembly upwards and then down

so as to rotate by-pass valve to actuator rod

lever clock wise through 180 degr ees f rom its at

rest position. Disengage actuator rod from the

lever by sliding out the crimped end of the rod

from slot in the lever, remove actuator.

REINSTALL

Reinstallation of the by-pass valve actuator is the

reverse of removal procedures, noting the following

points:

1. If reinstalling original by-pass valve actuator,

ensure that aligning marks made on actuator

bracket on removal are realigned before final

tightening of bolts.

2. If necessary check by-pass valve actuator

adjustment as per the following procedure.

Figure 6C1-3-97 By-Pass Valve Actuator

BY-PASS VALVE ACTUATOR

BRACKET TO SUPERCHARGER

HOUSING SE CURING BOLT TO RQUE

SPECIFICATION

26 Nm

CHECKING ADJUSTMENT OF BY-PASS VALVE ACTUATOR

1. With ignition "OFF".

2. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove the cover assembly.

Refer to Figure 6C1-3-11.

3. Install tool 24505373 onto By-Pass Valve

Actuator.

NOTE: If tool 24505373 will not fit properly onto

By-Pass Valve Actuator, the Actuator bracket

and/or linkage may be bent, and need adjustment.

Once the adjustment is made, and the tool is

properly installed onto the valve, remove the tool

and check for proper operation of the By-Pass

Valve Actuator. Refer to step 21, chart 2.6 V6 PCM

–Boost Control System Functional Check in

Section 6C1-2C, FUNCTIONAL CHECKS – V6

ENGINE in the VT Service Information.

4. If swaged section of actuator rod does not rest

on f oot of 24505373, loosen ac tuator brac ket to

supercharger housing bolts and slide actuator

up or down until the correct position is reached.

Tighten bracket to supercharger bolts without

moving actuator position. Remove tool

24505373.

6. Tighten actuator to supercharger housing

securing bolts to the correct torque

specification.

BY-PASS VALVE ACTUATOR

BRACKET TO SUPERCHARGER

HOUSING SE CURING BOLT TO RQUE

SPECIFICATION

26 Nm

Figure 6C1-3-98 By-Pass Valve Actuator Tool Installation

6. Once the adjustment has been checked and

corrected check for proper operation of the by-

pass valve actuator . Refer to chart 2.6 V6 PCM

–Boost Control System Functional Check in

Section 6C1-2C, FUNCTIONAL CHECKS –

V6 ENGINE in the VT Service Information.

7. Reinstall engine dress cover to the mounting

brack ets, ensuring that s tud gromm ets in dress

cover remain in place. Tighten securing dome

nuts to the correct torque specification. Refer

to Figure 6C1-3-11.

ENGINE DRESS COVER SECURING

DOME NUT TO MOUNTING BRACKE T

TORQUE SPECIFICATI O N

4 - 6 Nm

Figure 6C1-3-99 By-Pass Valve Actuator Adjustment

3.25 EX HAUST GAS RECIRCULATION (EGR) VALVE

REMOVE

1. Remove engine dress cover.

2. Electrical connector at EGR valve.

3. Two EGR valve retaining nuts.

4. EGR valve assembly.

5. Gasket.

REINSTALL

1. Install gasket.

2. Install EGR valve assembly and two retaining

nuts.

3. Install electrical connector.

4. Reinstall engine dress cover.

EGR RETAINING NUT T O RQUE

SPECIFICATION 30 Nm

Figure 6C1-3-100 EGR Valve Location

Figure 6C1-3-101 EGR Valve Removal View

3.26 A/C REFRIGERANT PRESSURE SENSOR

REMOVE

1. Electrical connector at sensor.

2. Sensor from High pressure line.

REINSTALL

1. Install sensor to high pressure line, and tighten.

A/C REFRIGERANT COMPRESSOR 5 - 7

SENSORTORQUE SPE CIFICATI O N Nm

2. Install electrical connector to sensor.

Figure 6C1-3-102 A/C Refrigerant

Pressure Sensor Location