SECTION 6C1-3 - SERVICE OPERATIONS -
V6 SUPERCHARGED ENGINE
IMPORTANT:
Before performing any Service Operation or other procedure described in this Section, refer to Section 00
CAUTIONS AND NOTES in VX Service Information for correct workshop practices with regards to safety
and/or property damage.
NOTE: When fastener s are rem oved, always reinstall them at the sam e location from which they were rem oved. 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 or system damage
could result.
WHAT 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 equipm ent spec ified in the diagnos tic T ables, s ince other test equipm ent may either give incorrec t
results or damage good components.
12. All voltage measurements using a voltmeter must use a digital voltmeter with an internal impedance rating of at
least 10 million ohms per volt (10 megohm/volt).
13. W hen a test light is spec ified, a "low-power" test light mus t be used. Do not use a high - wattage test light. While a
particular brand of test light is not suggested, a simple test on any test light will ensure it to be OK for PCM circuit
testing. Connect an accurate amm eter (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 less than 3/10 amp
current flow (0.3 A or 300 mA), the test light is OK
to use.
If the ammeter indicates more than 3/10 amp
current flow (0.3 A or 300 mA), the tes t 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:
W hen replacing the production PCM with a service
PCM (controller) (1), it is important to transfer the
broadcast code and produc tion PCM num ber to the
service PCM label. This will allow positive
identification of PCM parts throughout the service
life of the vehicle.
IMPORTANT:
To prevent inter nal PCM damage, the ignition m ust
be "OFF" when disconnecting or reconnecting
power to PCM (for example, battery cables, PCM
connectors, PCM fuse F31, jumper cables, etc.).
3
2
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4202
Figure 6C1-3-3 PCM Mounting
REMOVE
1. Disconnect battery earth lead.
2. Remove left hand f ront shroud panel lower trim
assembly (cowl panel trim), refer
Section 1A1, BODY in VT Series I
Service Information.
3. Lift up mounting bracket to PCM upper
retaining tang (4), pull PCM out then up to
remove it from the mounting bracket (1).
4. Remove wiring harness connectors (2) from
PCM, remove PCM (3) 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 car e should be taken when removing the
PROM from the defective controller as it will be
reused in the new controller. Do not remove the
plastic cover of the PROM. Use of unapproved
rem oval methods may cause dam age to the PRO M
or PROM socket.
1
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4294
3
4
5
Figure 6C1-3-4 PCM Removal
6. If required, remove PCM mounting bracket (1)
by inserting a screwdriver into the retaining
tang slot, lever screwdriver to release tang.
Pull bracket out then down to release from the
cowl panel.
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4295
1
Figure 6C1-3-5 PCM Mounting Bracket Removal
REINSTALL
1. If removed, reins tall PCM mounting brac ket (1),
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 VT Series I
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) 2000 / VX Comm odore / Body /
Body Control Module / Security / 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 LOW SERIES BCM
in VX Service Information or
Section 12J-2 HIGH SERIES BCM in VX Service
Information.
1
4296
Figure 6C1-3-6 PCM Mounting Bracket Reinstallation
3.3 PROM UNIT
DTC 51 indicates a faulty PROM, or incorrect
installation.
IMPORTANT:
The IGNIT ION SHO ULD ALW AYS BE "OFF" when
installing or removing the PCM connectors.
REMOVE
1. Remove PCM (1) from passenger
compartment, refer 3.2, POWERTRAIN
CONTROL MODULE - REMOVE, in this
Section.
2. Using a No.15 torx bit such as Tool No.
J25359-19, remove PCM PROM access cover
screws, remove access cover (3).
IMPORTANT:
DO NOT remove any of the other screws.
3
4204
2
1
Figure 6C1-3-7 Access Cover Removal
3. Remove PROM (4) from PCM by using thumb
and finger to pus h 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.
REINSTALL
1. Remove new PROM from its packaging and
check the part number making sure it is the
correct replacement component.
2. Install PROM (4) in PROM socket, ensuring
that small notches in the PROM align with the
small notches in the PROM socket.
3. Gently press down on the ends of the PROM
until the r etaining clips (1) clic k 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 securely.
23
2
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4297
4
Figure 6C1-3-8 PROM Removal
5. 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 DT C's, the PROM is not
fully seated or is defective. In this event,
remove or reinstall the PROM as per
previous instructions.
1
4298
2
Figure 6C1-3-9 PROM Identification
3.4 CAMSHAFT POSITION SENSOR
Figure 6C1-3-10 Camshaft/Crankshaft Position Sensors
REMOVE
1. Disconnect battery earth lead.
2. Lift up retaining tang and disconnect wiring harness connector from camshaft position sensor (6).
3. Remove camshaft position sensor to front cover retaining bolt (3).
4. Remove camshaft position sensor and O-ring (4) from front cover.
REINSTALL
1. Apply light engine oil to O-ring (4) on new camshaft position sensor (6).
2. Assemble camshaft position sensor (6) into front cover hole.
3. Install camshaft position sensor (6) to front cover retaining bolt (3) and tighten to the correct torque
specification.
Camshaft Position Sensor
Retaining Bolt
Torque Specification
11 N.m
4. Reconnect wiring harness connector to camshaft position sensor (6).
5. Reconnect battery earth lead.
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4300
45
1
8
7
6
3.5 ENGINE COOLANT TEMPERATURE (ECT) SENSOR
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 m anif old
below the engine thermostat housing.
IMPORTANT:
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.
IMPORTANT:
Do not remove radiator cap while the engine
coolant temperature is above 50 degrees c.
3. Remove four dome nuts securing the engine
dress cover assembly (2) 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 (2) and dis connect wir ing
harness connector (3) from PCM ECT sensor
(1). 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 (1) into inlet manifold and
tighten to the correct torque specification.
3. Reconnect wiring harness connector (3) onto
ECT sensor (1),
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.
1
2
3
4
4301
Figure 6C1-3-11 V6 Supercharged Engine Dress Cover
5
4
3
4208
2
1
Figure 6C1-3-12 ECT Sensor Location Supercharge
5. Refill the engine coolant system, Refer to
Section 6B1, ENGINE COOLING - V6
ENGINE in VX 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.
Engine Dress Cover Securing
Dome Nut To Inlet Manifold
Torque Specification
4 - 6 Nm
ECT Sensor To Inlet Manifold
Torque Specification 15-20
Nm
3.6 INTAKE AIR TEMPERATURE (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 (1) and pull connector from sensor
(5).
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 (2) in place.
6. Separate the upper and lower air cleaner
housings.
IMPORTANT:
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 (4) to remove it. Once
removed, discard retainer.
9. Pull out IAT sensor (5) from air cleaner upper
housing.
4215
1
2
5
4
3
Figure 6C1-3-13 IAT Sensor Removal
REINSTALL
1. Push new IAT sensor (5) into air cleaner
upper housing (2), with triangular tang on the
mounting flange locating on the mating rib of
the air cleaner upper housing.
2. Position the upper air cleaner housing
assembly, with the IAT sensor on the work
bench, pushing up into the air cleaner upper
housing.
Position new retainer (4) 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 plac e over the top
of the air cleaner upper housing.
5. Reconnect wiring harness connector (1) to
IAT sensor (5).
6. Carefully assemble intake air duct and mass
air flow sensor onto air cleaner upper housing.
IMPORTANT:
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 (3) and pull connector from
sensor (1).
3. Loosen clamp (2) on air duct adapter, closest
to MAF sensor (1).
4. Loosen clamp (4) on air duct ( 5) at MAF sensor
(1) and pull back air duct (5) from sensor.
IMPORTANT:
Air duct adapter (between air cleaner and MAF
sensor), both clamps, air duct and MAF sensor
itself have locating notches.
5. Remove MAF sensor (1) from air duct
adapter (5).
REINSTALL
1. Install MAF sensor (1) into air duct adapter (5)
and air duct, aligning all notches. Install
clamps, aligning notches, tighten clamps
securely.
2. Reconnect MAF sensor wiring harness
connector (3).
3. Reconnect battery earth lead.
4. Start vehicle and check for air leaks.
5
4
1
3
4303
2
Figure 6C1-3-14 MAF Sensor Removal
3.8 OXYGEN SENSOR
IMPORTANT:
• The oxygen sensor uses a permanently
attached pigtail and connector. This pigtail
should not be removed from 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
contaminants. Avoid using any cleaning
solvents. Do not drop or roughly handle the
oxygen sensor.
IMPORTANT:
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.
IMPORTANT:
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 (1) 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 VT
Series I Service Information.
4. Carefully unscrew oxygen sensor (2) from
exhaust pipe referring to previous NOTE.
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4306
1
Figure 6C1-3-15 R.H. Sensor Location
(Four 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 small
glass beads. The graphite will burn away, but
the glass beads will rem ain, mak ing the sensor
easier to remove.
• Genuine replacement sensors will already
have the compound applied to the threads. If a
sensor is removed 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 ox ygen sensor (2) into exhaust pipe and
tighten to the correct torque specification.
3. Remove safety stands and lower the vehicle.
4. Reconnect oxygen sensor wiring harness
connector (1).
IMPORTANT:
Ensure that the R.H sensor pigtail leads are
retained by a clip attached to the torque converter
housing
5. Reconnect battery earth lead.
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Figure 6C1-3-16 L.H Sensor Location
(Four wire sensor)
Oxygen Sensor To Exhaust
Manifold Torque Specification 40-50
N.m
3.9 THROTTLE POSITION (TP) SENSOR
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. Remove 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.
IMPORTANT:
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.
41
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4308
3
Figure 6C1-3-17 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 thr ottle 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
Attaching Screw
Torque Specification
1 - 1.5 N.m
4. Install throttle body and two (2) attaching nuts.
Throttle Body Attaching Nuts 15-20 N.m
5. Install Throttle Body cable attaching bracket.
Throttle Cable Bracket
Attaching Nuts 2-5
N.m
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 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 N.m
9. Reconnect battery earth lead.
3.10 VEHICLE SPEED SENSOR
AUTOMATIC TRANSMISSION
REMOVE
1. Jack up rear of vehicle and support
on safety stands, Refer to
Section OA, GENERAL INFORMATION in VT
Series I Service Information.
2. Lift up tang on VSS wiring harness connector
(2) and pull connector from VSS (3).
3. Remove VSS to transmission extension
housing bolt (1).
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 (1) and tighten to the
correct torque specification.
4. Reconnect wiring harness connector (2) to
VSS (3).
5. Remove safety stands and lower vehicle.
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4310
3
Figure 6C1-3-18 VSS Location Automatic Transmission
MANUAL TRANSMISSION
For vehicle speed sensor removal
and reinstallation, Refer to
Section 7B-1 MANUAL TRANSMISSION - V6
ENGINE of the VT Series I Service Information.
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4223
Figure 6C1-3-19 VSS Location Manual Transmission
VSS Retaining Bolt 11
Tor
q
ue S
p
ecification N.m
3.11 FUEL CONTROL SYSTEM
FUEL PUMP RELAY
The fuel pump relay (1) 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
IMPORTANT:
Unless this procedure is followed before servicing
fuel lines or connections, f uel spray into the engine
compartment could occur!
1. Remove "Fuel Pump Relay" from engine
compartment relay housing.
2. With throttle closed, crank engine - engine m ay
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 pressure.
3. Refit fuel pump relay (1).
1
4239
Figure 6C1-3-20 Fuel Pump Relay Location
THROTTLE STOP SCREW - RESET PROCEDURE
IMPORTANT:
Engine idle for this V6 application must be check ed
every 80,000KM. If the IAC valve counts are
greater than 25 at idle, the throttle body must be
removed and cleaned. Refer to
Throttle Body Cleaning Procedure in this
Section.
The T hrottle Stop Screw (1) controls the minimum
throttle opening (nominal "Closed throttle"
position). It is preset at the factory and must not
be reset unless:
I. The s crew is known to have been inadvertently
reset,
-OR-
II. Clearly instructed to do so by a diagnostic
Table.
Engine idle speed, which will vary with engine
temperature, is PCM - controlled and is not
adjustable.
PCM - Controlled idle speed (IAC) and
Throttle stop screw setting (RPM) ARE NOT
THE SAME!
4346
Figure 6C1-3-21 Throttle Stop Screw Location
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 lik ely cause of an abnorm al 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.
IMPORTANT: - Inspect
• 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 resetting is attempted.
WITH THIS ENGINE CONTROL SYSTEM, ANY
VACUUM LEAK WILL RESULT IN A
LOW/ROUGH IDLE SPEED.
CHECK OR RESET
1. Before performing this procedure, perform the
On-Board Diagnostic System Check. Refer to
Section 6C1-2A In VX Service Information.
2. Before perform ing steps 3 - 10, ensure that the
IAC system is functioning properly. Refer
Diagnostic TABLE A-7.1 (IAC system check)
in Section 6C1-2A, DIAGNOSTIC TABLES -
V6 ENGINE in VX Service Information, and
follow it to the "NO TROUBLE FOUND - IAC
OK" step before proceeding.
3. Engine must be at normal operating
temperature (above 90 degrees C), preferable
achieved by driving for at least 15 minutes,
before continuing.
4. Set parking brake and block drive wheels.
Ensure transmission is in `Park' (auto) or
neutral (manual).
5. Remove four dome nuts securing the engine
dress cover assembly to the inlet manifold
studs, lift off and remove the cover assembly.
6. Verify that the throttle cable and throttle linkage
are not binding. The throttle lever attached to
the throttle butterfly shaf t must be able to open
fully, and shut fully and freely every time the
accelerator pedal is fully depressed and slowly
released.
Refer "Throttle cable - adjust" in this Section if
throttle cable adjustment is required.
7. Install Tech-2 scan tool, and select
Miscellaneous tests, IAC System, Base Idle.
8. Ignition “ON”, engine running.
1
2
4311
Figure 6C1-3-22 IAC Valve Harness Removed
NOTE:
If the engine has completed less than 3,000
km, do not reset the throttle stop screw
unless the RPM is above 600. Otherwise,
RPM should be 500 - 600. If reset is
necessary, adjust throttle stop screw to
obtain engine speed of 450 - 550 RPM.
9. Using the T ech- 2 scan tool, ac tivate the Base
Idle test and follow the instructions on the
Tech-2 scan tool.
10. Adjust the base idle screw to obtain engine
idle speed of 450-550 RPMs.
11. Reinstall engine dress cover to the inlet
manifold, ensuring that stud grommets in the
dress c over remain in plac e. T ighten s ec uring
dome nuts to the correct torque.
Engine Dress Cover Securing Dome
Nut To Inlet Manifold
Torque Specification
4 - 6 N.m
MODULAR FUEL SENDER ASSEMBLY
REMOVE
TOOL REQUIRED
J 39765, FUEL SENDER LOCKNUT WRENCH
IMPORTANT:
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, VX Service Information.
4. Remove the modular fuel sender retaining ring
using the J 39765 Fuel Sender Locknut
Wrench.
IMPORTANT:
W hen 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.
4. Pull the modular fuel sender straight up while
draining the fuel from the reservoir.
5. Clean the fuel sender assembly O-ring sealing
surface.
6. Inspect the fuel sender assembly O-ring
sealing surface.
Figure 6C1-3-23 Modular Sender Assembly
REINSTALL
IMPORTANT:
Always replace the fuel sender O-ring when
reinstalling the fuel sender assembly.
1. Position the new fuel sender assembly 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
assem bly, 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 assembly retainer ring using the J
39765 Fuel Sender Locknut Wrench.
3. Reinstall fuel tank, Refer to Section 8A FUEL
TANK, VX Service Information.
4. Reconnect battery earth lead.
5. Inspect system for leaks.
MODULAR FUEL SENDER ASSEMBLY (SERVICEABLE FUEL STRAINER AND FUEL LEVEL SENSOR)
REMOVE
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.
2. Disconnect battery earth lead.
3. Remove fuel tank, Refer to Section 8A, FUEL
TANK, VX Service Information.
4. Remove MODULAR FUEL SENDER
ASSEMBLY. Refer to removal procedure in
this Section.
DISASSEMBLE
1. Note the position of the fuel sender strainer for
installation.
2. Support the reservoir with one hand and grasp
the fuel sender strainer with the other hand.
3. Pull the fuel strainer off of the fuel sender
assembly.
Figure 6C1-3-24 Fuel Strainer
4. Inspect the fuel sender strainer. If the fuel
sender strainer is contaminated, the fuel tank
should be cleaned.
5. Discard the fuel sender strainer after
inspection.
6. Disassemble the electrical connectors from the
fuel level sensor assembly of the fuel pump
and the cover assembly.
7. Disassembly the fuel level sensor assembly.
ASSEMBLE
1. Assemble the fuel level sensor assembly.
2. Assemble the electrical connectors to the fuel
pump and cover assembly.
3. Assemble the rubber pad on the bottom of the
modular fuel sender assembly.
4. Position the new fuel sender strainer on the
modular fuel sender and push on the outer
edge of the fuel sender strainer until the fuel
sender strainer is fully seated.
REINSTALL
1. Install the fuel sender assembly. Refer to
MODULAR FUEL SENDER ASSEMBLY for
reinstallation of sender assembly to fuel tank.
2. Reinstall fuel tank Refer to Section 8A, FUEL
TANK, VX Service Information.
3. Reconnect battery earth lead.
4. Inspect system for leaks.
Figure 6C1-3-25 Fuel Level Sensor Assembly
MODULAR FUEL SENDER ASSEMBLY (SUPERCHARGED ENGINE)
IMPORTANT:
The fuel pump for the Supercharge V6 is not
replaceable, the complete Modular Fuel Sender
Assembly must be replaced for the Supercharge
engine
FUEL PUMP CONTROL MODULE (SUPERCHARGED ENGINE)
REMOVE
1. Disconnect battery earth lead.
2. Move r ight rear upper wheelhouse trim cover 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.
NOTE:
If necessary, check fuel pump control module
operation,
Refer to Table A-4.1-1 Fuel Pump Electrical
Circuits, 6C1-2A Diagnostic Tables in VX Service
Information.
Figure 6C1-3-26 Fuel Pump Control Module Location
FUEL SYSTEM PRESSURE TEST
A Fuel System Pressure Test is part of several of
the Diagnostic Tables and Symptom checks. To
perform this test, follow this procedure:
IMPORTANT:
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.
IMPORTANT:
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 as described in
3.11, FUEL CONTROL SYSTEM - FUEL
PRESSURE RELIEF PROCEDURE, in this
Section. 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 2.
1
4
2
4313
3
Figure 6C1-3-27 Fuel Gauge Installed
Supercharged Engine
Measure
2. Use scan tool , enable fuel pump so that the
"fuel pump" can pressurize the system.
3. Fuel gauge reading should be 290 - 410 kPa
for SUPERCHARGE application. If not, Refer
to Diagnostic TABLE A-4.1-1 for
SUPERCHARGE in Section 6C1-2A,
DIAGNOSTIC TABLES – in VX Service
Information.
4. Relieve fuel pressure as described in
3.11, FUEL CONTROL SYSTEM – (FUEL
PRESSURE RELIEF PROCEDURE), in VX
Service Information.
5. Remove fuel pressure gauge and adapter.
6. Reinstall schrader valve cap (Supercharged
Engine).
7. Check for fuel leaks as described in
3.11, FUEL CONTROL SYSTEM – (LEAK
TESTING), in this Section.
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 6C1-3-28
QUICK CONNECT FITTINGS
(PLAST IC 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 6C1-3-29
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 6C1-3-30
Techline
8. Hold t he fuel filt er firm ly in one hand t o support
the filter.
9. Using yo ur other hand , grasp 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 6C1-3-31
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 6C1-3-32
13. Alternat ely for s teps 8 to 11, use too l AU533 to
squeeze the release tabs, release the quick
connect fittings and remove 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 6C1-3-33
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 6C1-3-34 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 e nsure proper r econnection 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 may prevent pr oper
reconnection if not lubr icate d.
1. Apply a few drops of clean engine oil to each
male fuel filter end.
Figure 6C1-3-35
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 6C1-3-36
3. Once ins talled, pul l and pu sh on both t he quick -
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 6C1-3-37
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 6C1-3-38
LEAK TESTING
Prior to star ting the engine, following the installation of any fuel system c omponent, c heck the f uel system f or leaks
using the following procedure:
1. Check to ensure that there is a sufficient level of fuel in the fuel tank.
2. Use scan tool "Output T est" for "Fuel Pump." Enabling the output test will activate the f uel pump to pressurize
the fuel system.
3. Check fuel system for leaks, particularly at points marked in figure 6C1-3-39.
Figure 6C1-3-39 Leak Testing Supercharged Engine
1. Fuel Pressure Regulator.
2. Fuel Injector(6 places).
3. Fuel Pressure Supply Line.
4. Fuel Return Line.
5. Fuel Rail.
6. Fuel Pressure Supply Line.
7. Fuel Filter.
8. Fuel Return Line.
9. To Swirl Pot.
10. Intank Fuel Pump.
11. Fuel Tank.
2
3
4315
6
7
8
10 9
11
4
5
1
FUEL PRESSURE REGULATOR
IMPORTANT:
The fuel pressure regulator and fuel return hose is
ONLY serviced as a complete assembly. The fuel
pressure return hose cannot be removed from the
fuel pressure regulator.
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 6C1-3-11.
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.
4236
1
Figure 6C1-3-40 Supercharged Engine Fuel Pressure
Regulator Location
7. Using a s hop towel to c atch 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.
IMPORTANT:
• 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 6C1-3-41 Supercharge Fuel Pressure Regulator
Removal From Fuel Rail
FUEL RAIL
IMPORTANT:
• The f uel inlet hose is an assem bly with the fuel
rail. Both components are NOT serviced
separately. For removal or replacement of the
fuel inlet hose, refer to
Fuel Rail And Injectors in this section.
• The fuel return hose is an assembly with the
fuel pressure regulator. Both components are
NOT serviced separately. For removal or
replacement, refer to the appropriate
Fuel Pressure Regulator for the engine
application.
1
3
2
4
4316
5
6
Figure 6C1-3-42 Supercharged Engine
AIR CLEANER 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 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 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 flow sensor wiring harness connector has remained firmly in place.
9. Reconnect battery earth lead.
Figure 6C1-3-43 Air Cleaner Housing Removal Supercharge
1. Clamp Tighten Specification (1.5 – 2.5 N.m). 6. View A
2. Air Cleaner Upper Housing. 7. Rivets (2 places).
3. Air Cleaner Element. 8. Cold Air Intake Duct.
4. Air Cleaner Lower Housing. 9. Mass Air Flow (MAF) Sensor.
5. Lower Housing Mounting Bolt (2 places) 7.5 – 12.5 N.m 10. Air Intake Duct to Throttle Body
Air Cleaner Lower Housing
Securing Nut 5 – 7 N.m
Torque Specification
110 1
1
2
3
4
4319
5
7
6
9
8
6
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 Series I Service Information.
6. Disconnect inner cable plastic spacer from throttle pedal lever.
7. Withdraw cable assembly from engine compartment.
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.
6. Adjust cable as in following instructions.
Figure 6C1-3-44 Throttle Cable Supercharged Engine
1. Note: do not detach adjusting nuts from cable. 11. Inner cable.
2. Mounting bracket. 12. Throttle pedal lever.
3. Mounting bracket nuts (3 places). 13. Clip.
4. Position throttle cable in circular hole before 14. Cruise control cable.
tightening adjustment nuts. 15. Lower clip.
5. Cruise control cable. 16. Bracket.
6. Throttle cable. 17. Throttle cable.
7. Main wiring harness. 18. Upper clip.
8. Main wiring harness retention clip.
9. View a.
10. Throttle cable.
17
13
18
14
12 11
10
15 16
123
4
7
85
4321
6
9
9
ADJUST
1. Remove instrument panel lower right side trim
(if not already removed, Refer to
Section 1A3, INSTRUMENT PANEL, in
Section 1 of the VX 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 loc k nuts so that inner cable
is tensioned with a deflection of 10 to 15 mm
(2) 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 dr ess
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 I Service Information.
1
2
4322
Figure 6C1-3-45 Throttle cable adjustment
Throttle Outer Cable Lock 2 – 5
Nut Torque Specification N.m
Engine Dress Cover Securing
Dome Nut To Inlet Manifold 2 – 4 N.m
Torque Specification
THROTTLE BODY REMOVAL
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 throttle cable from throttle body
linkage (4).
9. If vehicle is fitted with cruise control, remove
cruise control cable from throttle body linkage
(3).
10. Remove throttle cable mounting bracket
attaching nut(s) (2).
1
5
4
3
2
4325
Figure 6C1-3-46
11. Remove throttle body to inlet manifold
attaching nuts (3)
12. Remove throttle body and gasket (1) from
manifold.
CLEAN
Gasket surfaces on throttle body and manifold.
IMPORTANT:
If reusing the old throttle body, you must perform
the throttle body Cleaning Procedure before
reinstalling.
INSPECT
There is a specific throttle body assembly for the
V6 application only. Although the throttle body for
this application looks very similar to previous V6
application, the main distinctive difference is the
addition of a sm all air flow hole in the throttle blade
above the throttle blade shaft. Also, the Idle Air
Control (IAC) valve air passage has been
redesigned to allow more air flow. Refer to
Fig. 6C1-3-39.
3
4324
12
Figure 6C1-3-47
IMPORTANT:
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
4233
Figure 6C1-3-48 Throttle Body Identification
THROTTLE BODY CLEANING PROCEDURE
1. Remove throttle body from vehicle.
2. Remove the TP sensor (4) and IAC valve (2)
from the throttle body.
3. Using an approved injector cleaner, clean the
carbon build up around the pintle of the IAC
valve(2).
4. On the throttle body, clean the carbon build up
around the IAC air port, throttle body bore and
Throttle Blade.
5. Reinstall TP sensor to throttle body.
6. Reinstall IAC valve to throttle body.
Continue with the reinstallation of the throttle body
to the engine.
2
1
43
4348
Figure 6C1-3-49 Throttle Body Cleaning
THROTTLE BODY REINSTALL
1. Install throttle body gasket (1) and throttle body
(2) to inlet manifold.
2. Install throttle body attaching nuts (3) 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 (2).
3
4324
12
Figure 6C1-3-50
Throttle Body Attaching 15 – 20
Nuts Torque Specification N.m
Throttle Cable Mounting
Bracket Attaching Nut 2 – 4 N.m
Torque Specification
7. Reconnect throttle cable (4) to throttle body
linkage.
8. If vehicle is fitted with cruise control, reinstall
cruise control cable (3) 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.
13. Check cruise control cable adjustment, Refer
to Section 12E, CRUISE CONTROL in VX
Service Information.
14. 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.
1
5
4
3
2
4325
Figure 6C1-3-51
THROTTLE BODY IAC VALVE COUNT CHECKING PROCEDURE
1. Start engine and run to operation temperature
85°C.
2. Transmission in Park or Neutral.
3. Turn Off all accessories (A/C, radio etc.)
4. Install Tech 2 scan tool and display Engine
Data.
5. Confirm the IAC valve counts are at 15 counts
or less at idle.
If the counts are not at 15 or less, perform the
Throttle Stop Screw Reset Procedure if the screw
has been tam pered with. If the Throttle Stop Screw
has not been tampered with, replace the throttle
body.
Engine Dress Cover Securing
Dome Nut To Inlet Manifold 4 – 6 N.m
Torque Specification
FUEL RAIL AND INJECTORS
IMPORTANT:
The f uel inlet hose is an ass embly with the f uel rail.
Both components are NOT serviced separately.
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.
2
4
3
4327
1
5
Figure 6C1-3-52 Supercharged Engine Fuel Rail
7. Using Tool No. 7371 for Supercharger
application, disconnect fuel inlet hose quick
connect at dash panel connection.
8. Disconnect electrical connectors from injectors.
9. Remove four nuts, and one bolts securing
Fuel Rail to intake plenum.
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 6C1-3-53 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).
5. Pressure regulator to fuel rail.
6. Fuel return hose quick connect to dash panel
connector (5).
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.
10. Turn ignition "ON" and inspect fuel system for
leaks.
1
3
2
4
4316
5
6
Figure 6C1-3-54
Engine Dress Cover
Securing Dome Nut To 4 – 6
Inlet Manifold Attaching N.m
Nut Torque Specification
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 (3) and pull connector from
valve.
4. Remove IAC valve to throttle body attaching
screws (2).
5. Remove IAC valve (1) 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:
W hen installing a new IAC valve, be sure it has the
correct part number.
2
4330
1
3
Figure 6C1-3-55 IAC Valve Removal
IMPORTANT:
Before installing a new IAC valve, measure
distance "1" 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.
3
4312
2
1
4
Figure 6C1-3-56 IAC Measured Distance
Exert firm pressure on valve pintle to retract it. (A
slight side-to-side movement may be helpful).
Figure 6C1-3-57 IAC Retraction Method
REINSTALL
1. Lubricate IAC valve O-ring with light engine oil.
If necessary, install on to valve assembly.
2. Reinstall IAC valve (1) into throttle body with
wiring harness connector (3) facing up.
3. Install IAC valve attaching screws (2) and
tighten to the correct torque specification.
4. Reconnect IAC valve wiring harness
connector (3).
5. Reconnect battery earth lead.
6. If required, clear any DTCs using scan tool.
7. Start engine, and allow engine to run for 5
seconds then turn engine "OFF" to "Reset" the
IAC valve
or
Us e the Scan T ool, selec t IAC RESET to r eset
the IAC valve.
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.
2
4330
1
3
Figure 6C1-3-58
IAC Valve To Throttle Body
Attaching Screws 1-1.5 N.m
Torque Specification
3.13 DIRECT IGNITION SYSTEM (DIS)
TIMING ADJUSTMENT
The Dire ct Ignition System (DIS) system fully contr ols the spark tim ing. No adj ustment for spar k 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-1 is
used, and By-Pas s m ode is selected. To c heck for EST operation, run the engine with the throttle fix ed at a steady
1600-1800 RPM, then enter the "By-Pass" mode of operation with the Scan Tool. If the RPM changes (drops),
EST spark timing is operating. An EST system fault will set a DTC. Use proper DTC Table in Section 6C1-2A of
the VX Series Service Information to correctly diagnosis the system.
IGNITION COIL(S)
REMOVE
1. Disconnect battery earth lead.
2. Remove spark plug leads (3) 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
number ed 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 (1) securing coil(s) to module
and mounting plate.
4. Pull coil(s) (2) f rom m odule (4), taking care not
to bend module terminals.
REINSTALL
1. Install coil(s) (2) onto module (4), aligning
module terminals with mating slots on
underside of coil.
2. Install coil securing screws (1) and tighten to
the correct torque specification.
3. Reconnect spark plug leads (3) to coil
terminals, ensuring correct lead to coil terminal
relationship.
4. Reconnect battery earth lead, start engine and
ensure engine operates correctly.
4
4331
23
1
Figure 6C1-3-59 Ignition Coils To Module
DIS Coil To Mounting Plate
Securing Screw Torque 4 – 5 N.m
Specification
DIS MODULE
REMOVE
1. Disconnect battery earth lead.
2. Remove all spark plug leads (1) 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 (5), 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
number ed 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 ( 2) attaching 14-pin wiring harness
connector to module (5) until you can pull
connector from module.
5. Remove screws securing coils (3).
6. Remove coils from module, taking care not to
bend module terminals.
7. Remove ignition module assembly (5).
1
4332
5
3
2
4
Figure 6C1-3-60 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 (5) to mounting plate, locating raised lugs (2) on both module and plate
together.
IMPORTANT:
The lugs on the underside of the module will m ate with the mounting plate holes in one way only to ens ure correct
assembly relationship.
4. Reinstall screws (3) securing coils and module to mounting plate and tighten to the correct torque specification.
DIS Coil To Mounting
Plate Securing Screw
Torque Specification
4 - 5 N.m
5. Reconnect spark plug leads (1) to coil terminals, ensuring correct lead to coil terminal relationship.
6. Reconnect 14-pin wiring harness connector to module assembly and tighten attaching bolt (2) to the correct
torque specification.
Wiring Harness Connector To
DIS Module Attaching Bolt
Torque Specification
0.6 - 1.2 N.m
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 VX 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 (3) behind crankshaft
position sensor shield (1), lever each corner of
the shield from front cover studs, remove
shield.
6. Remove crankshaft sensor bracket to front
cover attaching studs (2) and remove sensor
assembly (4).
REINSTALL
1. Install crankshaft sensor assembly (4) onto
front cover dowel pin.
2. Install and tighten s ensor brack et to fr ont cover
attaching studs (2) to the correct torque
specification.
Crankshaft Position Sensor
To Front Cover Attaching 20 - 30 N.m
Stud Torque Specification
3. Reinstall crankshaft position sensor shield (1)
onto front cover studs (2), ensuring deflector
retainers fully engage over ends of studs.
4. Reconnect wiring harness connector to
crankshaft sensor (4).
5. Reinstall crankshaft balancer, Refer to
Section 6A1, ENGINE MECHANICAL - V6
ENGINE in VX Service Information.
IMPORTANT:
Do not reinstall drive belt at this stage.
6. Rotate crankshaft so as to check that
interrupter rings do not contact sensor.
IMPORTANT:
If the interrupter rings contact 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.
3
4333
2
4
1
Figure 6C1-3-61
Figure 6C1-3-62 Camshaft/Crankshaft Position Sensors
1. Bolt.
2. Crankshaft Balancer.
3. Retaining Bolt.
4. O-Ring.
5. Crankshaft Position Sensor.
6. Camshaft Position Sensor.
7. Crankshaft Position Sensor Shield.
8. Washer.
2
3
4300
45
1
8
7
6
3.14 1-2 SHIFT SOLENOID
Figure 6C1-3-63 1-2 Shift Solenoid Location
REMOVE
1. Disconnect battery earth lead.
IMPORTANT:
To avoid personal injury from accidental hot oil spillage, perform fluid change only w hen transmission fluid is cold.
2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the VT
Series I 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. Rem ove the remaining 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.
IMPORTANT:
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 Specification 11
N.m
6. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.
7. Reconnect battery earth lead.
8. Check transmission fluid l. Refer to "Fluid Checking Procedure" in Section 6C1-2A in VX Service Information.
3.15 2-3 SHIFT SOLENOID
Figure 6C1-3-64 2-3 Shift Solenoid Location
REMOVE
1. Disconnect battery earth lead.
IMPORTANT:
To avoid personal injury from accidental hot oil spillage, perform fluid change only w hen transmission fluid is cold.
2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the VT
Series I 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. Rem ove the remaining 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 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 Specification 11
N.m
6. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.
7. Reconnect battery earth lead.
8. Check transmission fluid level. Refer to "Fluid Checking Procedure" in Section 6C1-2A in VX Service
Information.
3.16 3-2 CONTROL SOLENOID
Figure 6C1-3-65 3-2 Shift Solenoid Location
REMOVE
1. Disconnect battery earth lead.
IMPORTANT:
To avoid personal injury from accidental hot oil spillage, perform fluid change only w hen transmission fluid is cold.
2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the VT
Series I 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. Rem ove the remaining 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.
IMPORTANT:
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.
7. Install new gasket and reinstall oil pan. Tighten bolts to the correct torque specification.
Transmission Oil Pan Bolt
Torque Specification 11
N.m
7. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.
8. Reconnect battery earth lead.
9. Check transmission fluid level. Refer to "Fluid Checking Procedure" in Section 6C1-2A in VX Service
Information.
3.17 PRE S SURE CONTROL SOLENOID
REMOVE
1. Disconnect battery earth lead.
IMPORTANT:
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 I 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)
IMPORTANT:
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 6C1-3-66 Pressure Control Solenoid Location
REINSTALL
1. Install s olenoid assem bly (377) . Note: Solenoid has a flat cut out on one s ide of it's retaining f lange. 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
N.m
4. Install pressure control solenoid electrical connector.
5. Install 1-2 accumulator cover assembly (57).
8. Install accumulator cover bolts (58) (59) and tighten to the correct torque specification.
]
Accumulator Cover Bolt
Torque Specification 11
N.m
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 Specification 11
N.m
10. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.
11. Reconnect battery earth lead.
12. Check transmission fluid level. Refer to "Fluid Checking Procedure" in Section 6C1-2A in VX Service
Information.
Figure 6C1-3-67 Pressure Control Solenoid Assembly
3.18 TRANSMISSION FLUID PRESSURE SWITCH ASSEMBLY (TFP) AND
TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR
Figure 6C1-3-68 Transmission Fluid Pressure Switch Assembly (TFP)
1. Start Torque Sequence Here 60. Valve Assembly, Control Body
A. M6 x 1.0 x 65.0 – 11 N.m 69. Switch Assembly, Transmission Fluid Pressure
D. M6 x 1.0 x 17.7 – 11N.m 70. Bolt, Transmission Fluid Pressure Switch Assembly.
8. Case, Transmission
REMOVE
1. Disconnect battery earth lead.
IMPORTANT:
To avoid personal injury from accidental hot oil spillage, perform fluid change only w hen transmission fluid is cold.
2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the VT
Series I 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. Rem ove the remaining 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).
1
66
8
60
69
4334
70
REINSTALL
1. Install trans fluid pressure switch assembly (69).
2. Install five (5) trans fluid pressure switch assembly retaining valve body bolts (68 and 70). Tighten bolts to the
correct torque specification
Transmission Fluid Pressure Switch
Assembly (TFP) Retaining Valve
Body Bolt Torque Specification
11 N.m
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 Specification 11
N.m
7. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.
8. Reconnect battery earth lead.
9. Check transmission fluid level. Refer to "Fluid Checking Procedure" in Section 6C1-2A in VX Service
Information.
3.19 TCC "PWM" SOLENOID
Figure 6C1-3-69
REMOVE
1. Disconnect battery earth lead.
IMPORTANT:
To avoid personal injury from accidental hot oil spillage, perform fluid change only w hen transmission fluid is cold.
2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the VT
Series I 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. Rem ove the remaining 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. Install TCC "PWM" Solenoid with O-ring assembly (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 Specification 11
N.m
7. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.
8. Reconnect battery earth lead.
9. Check transmission fluid level. Refer to "Fluid Checking Procedure" in Section 6C1-2A in VX Service
Information.
3.20 TCC ENABLE SOLENOID
Figure 6C1-3-70
REMOVE
1. Disconnect battery earth lead.
IMPORTANT:
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 I 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.
1
4335
Figure 6C1-3-71
1. Start Torque Sequence Here
A. M6 x 1.0 x 65.0 –11 N.m
D. M6 x 1.0 x 17.7 – 11 N.m
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. Rem ove TCC "PW M" solenoid assem bly (396)
with O-ring seal.
12. Remove TCC ENABLE solenoid assembly
bolts (68).
13. Remo ve T CC ENABLE s olenoid assem b ly ( 66)
with O-ring seal.
14. Remove all electrical connectors from
components.
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. Remove 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 socket (or
34.5 mm I.D. pipe with a slight chamfer on the
inside) over the top of the transmission pass-
thru connector.
IMPORTANT:
This may be difficult due to the clearance of the
floor pan transm ission tunnel and the transmission
case.
22. Pry downward on the top of the socket or pipe
Using a prybar or sim ilar s haped 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).
IMPORTANT:
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).
IMPORTANT:
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 accumulator cover bolts (58) (59). Tighten to the correct torque specification.
1-2 Accumulator Cover Bolt
Torque Specification 11
N.m
7. Install TCC "ON-OFF" solenoid assembly (66).
8. Install TCC "ON-OFF" solenoid bolts (68). Tighten to the correct torque specification.
TCC Solenoid Bolt
Torque Specification 11
N.m
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
Harness Retaining Bolt
Torque Specification
11 N.m
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 magnetized, 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 Specification 11
N.m
17. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.
18. Reconnect battery earth lead.
19. Check transmission fluid. Refer to "Fluid Checking Procedure" in Section 6C1-2A in VX Service Information.
3.21 KNOCK SENSOR
CHECKING KNOCK SENSOR OPERATION
The PCM's k nock sens or input will reduce the EST spark advance when detonation is present. T his sens or 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 s teady 1600 - 1800 RPM, quick ly and repeatedly `r ap' 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.
IMPORTANT:
Both k nock sensor s are threaded into the engine block cylinder cooling jack ets, which is a "wet" area of the engine
coolant system. W hen 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 front of vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in VT
Series I Service Information for location of jacking points.
4. Squeeze together 'wide ends' on sensor wiring harness connector (4&8) (connector is oval shaped) and pull
connector from sensor (3&10).
IMPORTANT:
To achieve this step it m ay be necessary to remove the knock sensor heat shield attaching bolts (1&5, 7&11) and
heat shields (2&11).
Figure 6C1-3-72
1. Attaching Bolt. 7. Attaching Bolt.
2. Knock Sensor Shield. 8. Wiring Harness Connector.
3. R.H Knock Sensor. 9. L.H Side of Engine View.
4. Wiring Harness Connector. 10. L.H Knock Sensor.
5. Attaching Bolt. 11. Knock Sensor Shield.
6. R.H Side of Engine View. 12. Attaching Bolt.
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.
10 11
1
4
5
7
8
9
12 23
6
4253
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 threads. If worn away, apply a light coating of Loctite
242 (Holden's Specification HN1256 Class 2, Type 2) to sensor threads.
IMPORTANT:
On a new sensor, do not apply sealant to threads as thr eads are coated with a sealant during produc tion. Applying
additional sealant will affect the sensor's ability to detect engine knock.
3. Install sensor (3&10) and tighten to the correct torque specification.
IMPORTANT:
Ensure that knock sensor is never over tightened as damage to the sensor can occur.
Knock Sensor Tightening
Torque Specification 16 – 22
N.m
4. Reconnect wiring harness connector (4&8) to sensor. Ensure that connector is securely fitted onto sensor.
5. If removed, reinstall knock sensor heat shield (2&11) and attaching bolts (1&5,7&12). Tighten bolts to the
correct torque specification.
Knock Sensor Heat
Shield Attaching Bolt
Torque Specification
25 - 35 N.m
6. Refill cooling system and pressure test for leaks, refer Section 6B1, ENGINE COOLING - V6 ENGINE in VX
Service Information.
7. Reconnect battery earth lead.
Figure 6C1-3-73
1. Attaching Bolt. 7. Attaching Bolt.
2. Knock Sensor Shield. 8. Wiring Harness Connector.
3. R.H Knock Sensor. 9. L.H Side of Engine View.
4. Wiring Harness Connector. 10. L.H Knock Sensor.
5. Attaching Bolt. 11. Knock Sensor Shield.
6. R.H Side of Engine View. 12. Attaching Bolt.
10 11
1
4
5
7
8
9
12 23
6
4253
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).
3. Pull up on solenoid wiring harness connector
and pull connector from solenoid (3).
4. Remove bolt ( 4) f r om solenoid br ac k et ( 5) . T his
bolt attaches to the rear of the right hand
cylinder head, remove solenoid.
REINSTALL
1. Reinstall canister purge solenoid (3) to rear of
cylinder head and install bracket bolt (4).
Tighten bolt to the correct torque specification.
2. Reconnect hoses and wiring harness
connector to canister purge solenoid (3),
ensuring connections are correct.
3. Reconnect battery earth lead.
4256
12
54
3
Figure 6C1-3-75
Purge Control Solenoid 30-40
Attaching Bolt N.m
3.24 S UP ERCHARGER SYSTEM
IMPORTANT:
To minimize the chances of unwanted fuel spray
and underhood fuel spill, always depressurize the
fuel pipes before performing service that requires
rem oving or disconnec ting of any portion of the fuel
system, refer 3.11, FUEL CONTROL SYSTEM –
(FUEL PRESSURE RELIEF PROCEDURE), in
Section 6C1-3 SERVICE OPERATIONS in VX
Service Information.
SUPERCHARGER OIL LEVEL CHECK
IMPORTANT:
A small amount of oil seepage through the front
seal, (behind the pulley) of the supercharger
assem bly is a normal c ondition. This oil seepage is
caused by m inute traces of oil esc aping around the
seal due to normal pressure build up in the oil
cavity within the super charger as sem bly. A build up
of belt dust and/or airborne dust can adhere to the
thin oil film, which causes the oil seepage to
appear worse than it really is. The supercharger
assembly should not be replaced due to the
seepage 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, ENGINE MECHANICAL in the VT
Series I Service Information.
2
4336
1
Figure 6C1-3-76
IMPORTANT:
Do not remove the oil plug (2) 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 tem peratur e can cause
hot oil to overflow. This could result in oil loss and
possible personal injury.
IMPORTANT:
The supercharger oil level should be checked at
the specified service intervals outlined in the
Owner's Handbook.
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.
IMPORTANT:
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.
IMPORTANT:
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 Fill Plug 10
Torque Specification N.m
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 Series I Service Information.
512
3
4
4337
Figure 6C1-3-77
BOOST CONTROL SOLENOID
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. 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 Attaching Bolt
Torque Specification 8 N.m
2. Connect boost source and signal hose to solenoid ports.
3. Reconnect wiring harness connector to solenoid.
Figure 6C1-3-78 Boost Control Solenoid Location
1
1
3
4265
3
2
BY-PASS VALVE A CTUATOR
REMOVE
1. Remove four dome nuts securing the engine
dress cover assembly to the inlet manifold
studs, lif t off and r emove the cover ass embly.
Refer to Figure 6C1-3-11.
2. Vacuum hose (1) from actuator port.
3. Using a pointed scribe, mark position 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 bolts (3) sec ur 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 rem oval procedures , noting the f ollowing
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.
1
2
7
4
3
4338
5
6
Figure 6C1-3-79 By-Pass Valve Actuator
By-Pass Valve Actuator Bracket
To Supercharger Housing Securing 26 N.m
Bolt Torque Specification
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, lif t off and r emove the cover ass embly.
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 refer to TABLE 2-6, step 21 for proper
operation of the By-Pass Valve Actuator.
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.
5. Tighten actuator to supercharger housing
securing bolts to the correct torque
specification.
1
2
3
4
4339
5
Figure 6C1-3-80 By-Pass Valve Actuator Tool Installation
6. Once the adjustment has been checked and
corrected, Refer to Section 6C1-2C
FUNCTIONAL TEST, TABLE 2-6 V6 PCM -
Boost Control System Functional Check within
this section for proper operation of the by-pass
valve actuator.
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.
1
2
4340
Figure 6C1-3-81 By-Pass Valve Actuator Adjustment
Engine Dress Cover Securing
Dome Nut To Inlet Manifold 4 – 6
Attaching Nut N.m
Tor
q
ue S
p
ecification
By-Pass Valve Actuator Bracket
To Supercharger Housing Securing 26 N.m
Bolt Torque Specification
3.25 A/C REFRIGERANT PRESSURE SENSOR
REMOVE
1. Electrical connector at Sensor (1).
2. Sensor from High pressure line.
REINSTALL
1. Install Sensor to high pr essure line, and tighten
to the correct torque specification.
A/C Refrigerant
Pressure Sensor 5 – 7 N.m
Torque Specification
2. Install electrical connector to Sensor (1).
1
4261
Figure 6C1-3-82 A/C Refrigerant Pressure
Sensor Location