SECTION 00 - CAUTIONS AND NOTES
CAUTION
In order to minimise the chance of personal injury and/or property damage, carefully observe the instructions that
follow in this Section.
The HOLDEN LTD Service Information is intended for use by professional, qualified, factory trained technicians.
Attempting repairs or service without the appropriate training, tools, and equipment may cause injury to you or
others. This could also cause damage to the vehicle, or cause the vehicle to operate improperly.
Proper vehicle service and repair are important to the safety of the service technician and to the reliable operation of
all motor vehicles. If you need to replace a part, use the same part number or an equivalent part. Do not use a
replacement part of lesser quality.
The service procedures recommended and described in this Service Information are effective methods of
performing service and repair. Some of the procedures require the use of tools that are designed for specific
purposes.
Accordingly, any person who intends to use a replacement part, a service procedure, or a tool that is not
recommended by HOLDEN LTD, must first establish that there is no jeopardy to personal safety or the operation of
the vehicle.
This Service Information contains various CAUTIONS, NOTES and SAFETY PRECAUTIONS that you must
observe carefully in order to reduce the risk of personal injury during service or repair. Improper service or repair
procedures may damage the vehicle or cause it not to operate correctly. It is important to understand that these
CAUTIONS, NOTES and SAFETY PRECAUTIONS are not exhaustive. HOLDEN LTD cannot possibly warn of all
the potentially hazardous consequences of your failure to follow these instructions.
ERROR AND SUGGESTION REPORTING
If you find an error in any HOLDEN LTD Service Information, or if you have a suggestion about a HOLDEN LTD
Service Information, we want to hear from you.
A fax can be forwarded to the HOLDEN LTD Service Department on 03 9647 2525.
When faxing, please supply the following information:
• Your name.
• Your dealership's name and dealer code number.
• Your dealership's phone number.
• The model year and the vehicle type.
• The Service Information part number or CD-Rom version number.
• The Vehicle Identification Number (VIN) of the vehicle being worked on.
• The Service Information Section and page number(s).
HOLDEN LTD service personnel will respond to your concerns in the following ways:
• By delivering your concern to the Service Information's author.
• By eliciting a response from the author.
• By supplying you with an answer to your concerns.
For book based users, if possible please supply a marked up copy of the Service Information page in question.
For Electronic Service Information (CD-Rom) users: Please be prepared to provide any applicable identification
numbers pertaining to the electronic information that y ou are questioning.
The HOLDEN LTD Service Department contact fax number does not provide technical assistance. For technical
assistance, contact your technical assistance source in the usual manner.
DEFINITION OF CAUTION, NOTE AND IMPORTANT STATEMENTS
The diagnosis and repair procedures in HOLDEN LTD Service Information contain both general and specific
CAUTIONS, NOTES and IMPORTANTS. HOLDEN LTD is dedicated to the presentation of service information that
helps the technician to diagnose and repair the systems necessary for the proper operation of the vehicle. However,
certain procedures may present a hazard to the technician if they are not followed in the recommended manner.
CAUTIONS, NOTES and IMPORTANTS are elements designed to help prevent these hazards, however not all
hazards can be foreseen.
These statements are placed at strategic locations within the Service Information. These statements are designed
to help prevent the following from occurring:
• Bodily injury to the technician or others.
• Damage to the vehicle.
• Unnecessary vehicle repairs.
• Unnecessary component replacement.
• Improper repair or replacement of vehicle components.
CAUTION DEFINED
When encountering a CAUTION statement, you w ill be asked to take a necessary action or not to take a prohibited
action. If a CAUTION is not heeded, the following consequences may occur:
• Bodily injury to the technician.
• Bodily injury to other technicians in the workplace area.
• Bodily injury to the driver and/or passenger(s) of the vehicle, if the vehicle has been improperly repaired.
NOTE DEFINED
A NOTE statement calls special attention to a necessary action or a prohibited action. If a NOTE is not heeded, the
following consequences may occur:
• Damage to the vehicle.
• Unnecessary vehicle repairs.
• Unnecessary component replacement.
• Improper operation or performance of the system or component under repair.
• Damage to any system or components which are dependent on the proper operation of the system or
component under repair.
• Improper operation or performance of any systems or components which are dependent upon the proper
operation or performance of the system or component under repair.
• Damage to fasteners, basic tools, or special tools.
• The leakage of coolant, lubricant or other vital fluids.
IMPORTANT DEFINED
IMPORTANT statements emphasise a necessary characteristic of a diagnostic or repair procedure.
Important statements are designed to do the following:
• Clarify a procedure.
• Present additional information for accomplishing a procedure.
• Give insight into the reason or reasons for performing a procedure in the manner recommended.
• Present information that will help to accomplish a procedure in a more effective manner.
• Present information that gives the technician the benefit of past experience in accomplishing a procedure with
greater ease.
ABS HANDLING CAUTION
Certain components in the Antilock Brake System (ABS) are not intended to be serviced individually. Attempting to
remove or disconnect certain system components may result in personal injury and/or improper system operation.
Only those components with approved removal and installation procedures should be serviced.
Whenever any component that forms part of the ABS (if fitted) is disturbed during Service Operations, it is vital that
the complete ABS system is checked, using the procedure as detailed in 4 DIAGNOSIS, ABS FUNCTION CHECK,
in Section 12L ABS or ABS/ETC in the VT Series I Service Information (V6 Supercharged) or VT Series II Service
Information (GEN III V8).
BATTERY DISCONNECT CAUTION
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical
loads must be OFF unless instructed otherwise in these procedures. Also, if a tool or equipment could easily come
in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these
precautions may cause personal injury and/or damage to the vehicle or its components.
BRAKE DUST CAUTION
Avoid taking the following actions when you service wheel brake parts:
• Do not grind brake linings.
• Do not sand brake linings.
• Do not clean wheel brake parts with a dry brush or with compressed air.
While HOLDEN LTD incorporates brake parts that are not asbestos based in their material composition, some
models or after market brake parts may contain asbestos fibres which can become airborne in dust. Use a water-
dampened cloth in order to remove any dust on brake parts. Equipment is available commercially in order to
perform this washing function. These wet methods help prevent fibres from becoming airborne.
BRAKE FLUID CAUTION
Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions:
• Eye contact - rinse eyes thoroughly with water.
• Skin contact - wash skin with soap and water.
CLUTCH DUST CAUTION
While HOLDEN LTD incorporates clutch parts that are not asbestos based in their material composition, some
models or after market clutch parts may contain asbestos fibres which can become airborne in dust. Use a water-
dampened cloth in order to remove any dust on clutch parts. Equipment is available commercially in order to
perform this washing function. These wet methods help prevent fibres from becoming airborne.
ENGINE COOLING CAUTIONS
Always wear protective safety glasses when working with spring type hose clamps.
Do not remove the radiator/surge tank cap while the engine coolant is above 50ºC.
Electric engine cooling fans in the engine compartment can start up even when the engine is not running. Keep
hands, clothing and tools away from any underhood electric fan.
LPG CAUTION
This vehicle may be equipped with LPG (Liquefied Petroleum Gas). As this fuel, in vapour form, is heavier than air,
vapours can accumulate in confined spaces. In the interests of safety, the LPG fuel system should be isolated at the
manual shut-off valve before any service work is carried out on the vehicle. Refer to the LPG leaflet included with
the Owner's Handbook for details or Section 8A2 - LPG SYSTEM for more specific servicing information relating to
this alternative fuel system. Only authorised LPG dealers may service the LPG system itself.
FUEL AND EVAPORATION PIPE CAUTION
In order to reduce the risk of fire observe the following guidelines:
• Replac e all nylon fuel pipes that are nick ed, scratched or dam aged during installation. Do not attem pt to repair
the sections of the ny lon fuel pipes.
• Do not hammer directly on the fuel harness body clips when installing new fuel pipes.
• Damage to the nylon pipes may result in a fuel leak.
• Always cover nylon vapour pipes with a wet towel before using a torch near them. Also, never expose the
vehicle to temperatures higher than 115°C (239°F ) for m ore than one hour, or mor e than 90°C (194°F) for any
extended period.
• Apply a few drops of clean engine oil to the m ale pipe ends before c onnecting f uel pipe fittings . This will ensure
proper c onnection and prevent a possible f uel leak. During norm al operation, the O-rings loc ated in the female
connector will swell and may prevent proper reconnection if not lubricated.
FUEL PIPE FITTING CAUTION
Always apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings.
This will ensure proper reconnection and prevents possible fuel leak.
During normal operation, the O-rings located in the female connector will swell and may prevent reconnection if not
lubricated.
FUEL STORAGE CAUTION
Do not drain fuel into an open container. Never store fuel in an open container due to its highly flammable nature.
PETROL/PETROL VAPOURS CAUTION
Petrol or petrol vapours are highly flammable. A fire could occur if an ignition source is present. Never drain or store
petrol in an open container. Have a dry chemical (Class B) fire extinguisher nearby.
FUEL INJECTOR LOWER O-RING REMOVAL CAUTION
Verify that the lower (small) O-ring of each injector does not remain in the lower manifold.
If the O-ring is not removed with the injector, the replacement injector with new O-rings will not seat properly in the
injector socket. Improper seating could cause a fuel leak, with the risk of fire.
MOVING PARTS AND HOT SURFACES CAUTION
While working around a running engine, avoid contact with moving parts and hot surfaces.
RELIEVING FUEL PRE S SURE CAUTION
Relieve the fuel system pressure before servicing fuel system components.
After relieving the fuel system pressure a small amount of fuel may be released when servicing the fuel lines or
connections. In order to reduce the chance of personal injury, cover the regulator and fuel line fittings with a shop
towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container
when the disconnection is complete.
FUEL PRESSURE NOTE
Do not allow the fuel pressure to exceed the specified value because damage to the fuel pressure regulator or the
fuel pressure gauge may result.
ROAD TEST CAUTION
Road test a vehicle under normal driving conditions and obey all traffic laws. Do not attempt any manoeuvres that
could jeopardise vehicle control.
SAFETY GLASSES AND COMPRESSED AIR CAUTION
Wear safety glasses when using compressed air in order to help prevent eye injury.
SAFETY GLASSES AND FUEL CAUTION
Always wear safety glasses when working with fuel in order to help protect the eyes from fuel splash.
SEAT BELT REPLACEMENT CAUTION
Replace belts, retractors, and hardware in use during all but a minor collision. Also, restraint systems should be
replaced and anchorages properly repaired if they were in areas damaged by collision, whether the belt was in use
or not. If there is any question, replace the belt system. Damage, whether visible or not, could result in the restraint
not functioning correctly in the event of an accident.
If a seat belt pre-tensioner is deployed, the seat belt pre-tensioner assembly together with the seat adjuster and
guide rail assembly must be replaced.
If disposing of an undeployed seat belt buckle and pre-tensioner assembly, refer to the disabling procedure in
Section 12M SUPPLEMENTAL RESTRAINT SYSTEM in the VT Series Service Information.
SERVICING AND REPLACING SEAT BELTS NOTE
To prevent possible seat belt damage, refer to the following items before servicing or replacing seat belts.
Seat belts must be serviced as follows:
• All belts need to be serviced as a set to ensure the belt components are from the same supplier.
• All attachment hardware must be replaced, not reused.
• Keep sharp edges and damaging objects away from belts.
• Avoid bending or damaging any portion of the belt buckle or latch plate.
• Do not bleach or dye belt or strap webbing. Clean with a mild soap solution and water.
• W hen installing lap or shoulder belt anchor bolts, start the bolts by hand to ensure that the bolts are threaded
straight.
• Do not attempt repairs on seat belt retractor mechanisms. Replace defective assemblies with new service
replacement parts.
SHOP TOWEL FUEL LEAK CAUTION
Wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leakage that occurs during
the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel
pressure gauge is completed.
SRS CAUTION
This vehicle is equipped with a Supplemental Restraint System (SRS).
An SRS will consist of either seat belt pre-tensioners and a driver's air bag, seat belt pre-tensioners and driver's and
front passenger's air bags or seat belt pre-tensioners, driver's and front passenger's air bags and left and right hand
side front air bags.
Refer to the SAFETY PRECA UTIONS in Section 12M SUPPLEMENTAL RESTRAINT SYSTEM in the VT Series
Service Information before performing any service operation on, or around, any SRS components, the steering
mechanism or wiring.
Failure to follow these SAFETY PRECAUTIONS could cause unwanted air bag deployment, or otherwise unneeded
SRS repairs, or could result in the SRS not functioning correctly when required.
In order to help avoid accidental air bag deployment, whenever you service a vehicle that requires repair of the SRS
and another vehicle system, we recommend that you first repair the SRS, then go on to the other system.
SRS INFLATOR MODULE DISPOSAL CAUTION
In order to prevent accidental deployment of the air bag, do not dispose of an undeployed inflator module as normal
shop waste. The undeployed inflator module contains substances that could cause personal injury if the stored
container is damaged during disposal.
Refer to the relevant air bag and/or pre-tensioner scrapping procedures in
Section 12M SUPPLEMENTAL RESTRAINT SYSTEM in the VT Series Service Information.
SRS SPECIAL TOOL CAUTION
In order to avoid deploying the air bag when troubleshooting the SRS system, use only the equipment specified in
this Service Information and the instructions given in this Service Information. Failure to use the specified
equipment as instructed could cause air bag deployment, or unnecessary SRS system repairs, or could result in the
SRS not functioning correctly when required.
VEHICLE LIFTING CAUTION
When components are removed from the vehicle and the vehicle is supported by a hoist, perform the following
steps:
Chain the vehicle to the hoist at the same end as the components that are being removed.
Ensure the vehicle is supported at the opposite end from which the components are being removed.
WINDOW RE MOV AL CAUTION
When working with any type of glass, use approved safety glasses and gloves.
WINDOW RETENTION CAUTION
When replacing stationary windows, Urethane Adhesive Kit Betaseal 554.02, or a urethane adhesive system
meeting HOLDEN LTD Specification HN1890, must be used to maintain original installation integrity. Failure to use
the urethane adhesive kit may result in poor retention of the window.
WORK BAY TEST CAUTION
One or more of the following guidelines may apply when performing specific required tests in the work bay:
When servicing a vehicle fitted with the ABS/ETC system, or an LSD rear axle, do not run the engine with the
transmission in gear and one rear wheel raised. If the ABS/ETC system is operational or the vehicle is equipped
with LSD, with the vehicle in this situation, the driving force will be transmitted to the wheel on the ground and cause
the vehicle to move.
When a test requires spinning the drive wheels with the vehicle jacked up, adhere to the following precautions:
• Do not exceed 56 km/h when spinning one drive wheel with the other drive wheel stopped. This limit is
necessary because the speedometer indicates only one-half the actual vehicle speed under these conditions.
• If all of the drive wheels are spinning at the same speed, do not exceed 112 km/h.
• All persons should stay clear of the rotating components and the balance weight areas in order to avoid
possible personal injury.
• W hen running an engine in the workshop for an extended period of time, use care not to overheat the engine
and the transmission.
When a test requires jacking up the vehicle and running with the wheels and brake rotors removed, adhere to the
following precautions:
• Do not apply the brake with the brake rotors removed.
• Do not place the transmission in PARK with the drive wheels still spinning.
• Turn off the ignition in order to stop the powertrain components from spinning.
FASTENER NOTE
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that
application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener
joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the
fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage
to parts and systems.
HANDLING ESD SENSITIVE PARTS NOTE
Electrostatic discharge (ESD) can damage many solid state electrical components. Not all components that are
susceptible to damage from ESD are labelled with the ESD symbol. Exercise caution when handling all solid state
electrical components.
Avoid damaging solid state electrical components by taking the following precautions:
1. Discharge personal electricity by touching a metal ground point after each of the following activities:
• Sliding across the vehicle seat.
• Sitting or rising.
• Walking.
2. Do not touch the exposed electric terminals on a component with your finger or a tool. The connector that you
are checking may be tied into a circuit that is susceptible to damage by ESD.
3. Do not allow a screwdriver or a similar tool to contact exposed terminals when disconnecting a connector.
4. Do not remove the protective packing of the solid state component until you are ready to install the solid state
component.
5. Unless specified in a particular diagnostic procedure, avoid the following activities:
• Jumping components or connectors.
• Grounding components or connectors.
• Using test equipment probes on components or connectors.
6. When a diagnosis requires the use of test equipment probes, connect the ground lead first.
7. Touch the solid state component's package to a ground before opening.
8. Do not lay the solid state component in any of the following locations:
• On a metal workbench.
• On top of an electrically operating appliance or piece of equipment, like a TV, radio or oscilloscope.
9. Do not drop the solid state component.
PCM AND ESD NOTE
Do not touch the connector pins or soldered components on the circuit board or it may cause electrostatic discharge
(ESD) damage to the PCM.
IGNITION OFF WHEN DISCONNECTING BATTERY NOTE
Always turn the ignition OFF when connecting or disconnecting battery cables, battery chargers, or jumper cables.
Failing to do so may damage the Powertrain Control Module (PCM) or other electronic components.