SECTION 00 - CAUTIONS AND NOTES
CONTENTS
1. CAUTION
2. ERROR AND SUGGESTION REPORTING
3. DEFINITION OF CAUTION, IMPORTANT
AND NOTE STATEMENTS
‘CAUTION’ DEFINED
‘IMPORTANT’ DEFINED
‘NOTE’ DEFINED
4. SAFETY AND SERVICE GUIDELINES
ABS HANDLING
BRAKE DUST
BRAKE FLUID
CLUTCH DUST
ENGINE COOLING
LIQUEFIED PETROLEUM GAS
FUEL AND EVAPORATION PIPE
FUEL PIPE FITTING
FUEL STORAGE
PETROL / PETROL VAPOURS
FUEL INJECTOR LOWER O-RING
REMOVAL
MOVING PARTS AND HOT SURFACES
FUEL PRESSURE
RELIEVING FUEL PRESSURE
ROAD-TESTING
SAFETY GLA SSES AND COMPRESSED AIR
SAFETY GLASSES AND FUEL
SEATBELT REPLACEMENT
SERVICING AND REPLACING SEATBELTS
SHOP TOWEL FUEL LEAK
OCCUPANT PROTECTION SYSTEM
OPS INFLATABLE RESTRAINT MODULE
DISPOSAL
OPS / SRS SPECIAL TOOLS
VEHICLE LIFTING
WINDOW REMOVAL
WINDOW RETENTION
WORK BAY TEST
FASTENERS
HANDLING ESD SENSITIVE PARTS
ELECTRONIC CONTROL MODULES
5. BATTERY DISCONNECTION PROCEDURES
BEFORE BATTERY DISCONNECTION
BEFORE SERVICING ELECTRICAL
COMPONENTS
SYSTEMS AFFECTED BY BATTERY
DISCONNECTION
INSTRUMENTS
BODY CONTROL MODULE
ENTERTAINMENT SYSTEM
TELEMATICS
NAVIGATION SYSTEM
SUNROOF
1. CAUTION
To minimise the risk of death, injury and/or property damage, carefully observe the instructions 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. It 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 designed for specific purposes.
Any person who intends to use a replac ement par t, service procedur e, or tool not recom m ended by HOLDEN LTD,
must first establish that it will not jeopardise personal safety or operation of the vehicle.
This Service Information contains various CAUTION, IMPORTANT and NOTE statements that you must observe
caref ully to reduce the risk of death or inj ury during service, repair procedures or vehicle operation. Incorrect servic e
or repair procedures may damage the vehicle or cause operational faults. CAUTION, IMPORTANT and NOTE
statem ents are not exhaustive. HOLDEN LT D can not possibly warn of all the potentially hazardous consequences
of failure to follow these instructions.
2. ERROR AND SUGGESTION REPORTING
If you find an error in any HOLDEN LTD Service Information or if you have a suggestion regarding HOLDEN LTD
Service Information, we want to hear from you.
Forward a fax to the HOLDEN LTD Service Department on 03 9647 – 2525.
When faxing, please 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) on which work is being performed, and
• the Service Information Section and page number(s).
HOLDEN LTD service personnel will respond to y our concerns in the following ways:
• by delivering your concern to the service information's author,
• by eliciting a response from the author, then
• by supplying you with an answer to your concerns.
For hard copy Service Information, please supply a marked-up copy of the Service Information in question.
For Electronic Service Information (CD–ROM), please provide any applicable identification numbers pertaining to
the electronic information in question.
The HOLDEN LTD Service Department contact fax number does not provide technical assistance. For technical
assistance, contact your technical assistance source in the usual manner.
3. DEFINI TION OF CAUTION, IMPORTANT AND NOTE STATEMENTS
Diagnosis and repair procedur es in HOLDEN LT D Service Inf orm ation contain both general and specific CAUTIO N,
IMPORTANT and NOTE statements. HOLDEN LTD is dedicated to the presentation of service information that
helps the technician to diagnose and repair the systems necessary for proper operation of the vehicle. Certain
procedures may present a hazard to the technician if they are not followed in the recommended manner. CAUTION,
IMPORTANT and NOT E s tatements ar e designed to help pr event thes e hazards f rom occ ur ring, but not all hazards
can be foreseen.
CAUTION, IMPORT ANT and NOT E s tatem ents are plac ed at strategic locations within the Service Inf orm ation and
are designed to help prevent:
• death or injury to the technician or others,
• damage to the vehicle,
• unnecessary vehicle repairs,
• unnecessary component replacement, and/or
• incorrect repair or replacement of vehicle components.
CAUTION DEFINED
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not
correctly followed, could result in death or injury.
A CAUTION statement alerts you to take a necessary action or not to take a prohibited action. If a CAUTION
statement is ignored, the following consequences may occur:
• death or injury to the technician or other personnel working on the vehicle,
• death or injury to other people in or near the workplace area, and/or
• death or injury to the driver and/or passenger(s) of the vehicle or other people, if the vehicle has been
improperly repaired
IMPORTANT DEFINED
An IMPORTANT statement immediately precedes an operating procedure or maintenance practice which, if not
correctly followed, could result in damage to or destruction of equipment, or corruption of data.
An IMPORT ANT s tatem ent dir ects special attention to a neces sary action or a prohibited action. If an IMPORT ANT
statement is ignored, the following consequences may occur:
• damage to the vehicle;
• unnecessary vehicle repairs;
• unnecessary component replacement;
• faulty operation or performance of the system or component being repaired;
• damage to any system or components which depend on the proper operation of the system or component being
repaired;
• faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair;
• damage to fasteners, basic tools or special tools; and/or
• leakage of coolant, lubricant or other vital fluids.
NOTE DEFINED
A NOT E statem ent im m ediately precedes or f ollows an operating proc edure, maintenanc e practice or condition that
requires highlighting.
A NOTE statement also emphasises a necessary characteristic or characteristics of a diagnostic or repair
procedure. A NOTE statement is designed to:
• clarify a procedure,
• present additional information for accomplishing a procedure,
• give insight into the reason or reasons for performing a procedure in the recommended manner,
• present information that helps to accomplish a procedure in a more effective manner, and/or
• present information that gives the technician the benefit of past experience in accomplishing a procedure with
greater ease.
4. SAFETY AND SERVICE GUIDELINES
ABS HANDLING
Certain com ponents in the Anti-loc k Brak e 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 is disturbed during Service Operations, it is
vital that the complete ABS system is checked, using the procedure as detailed in Section 5B,
4.4 ABS & ABS/TCS FUNCTIONAL CHECK.
BRAKE DUST
When servicing wheel brake parts:
• Do not grind brake linings.
• Do not sand brake linings.
• Do not clean wheel brake parts with a dry brush or with compressed air.
Although HOLDEN LTD incorporates brake parts that are not asbestos-based in their material composition, after-
market brake parts may contain asbestos fibres which can become airborne in dust. Use a water-dampened cloth to
rem ove any dus t on brake parts. Alter natively, us e comm ercially available equipment to wash the parts. T hese wet
methods help prevent fibres from becoming airborne.
BRAKE FLUID
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
Although HOLDEN LTD incorporates clutch parts that are not asbestos-based in their material composition, after-
market clutch parts m ay contain asbestos fibres which can becom e airborne in dust. Use a water-dampened cloth
to remove any dust on clutch parts. Alternatively, use commercially available equipment to wash the parts. These
wet methods help prevent fibres from becoming airborne.
ENGINE COOLING
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 50°C (122°F).
Electric engine cooling fans in the engine compartment can start up even when the engine is not running. Keep
hands, clothing and tools away from any under-hood electric fans.
LIQUEFIED PETROLEUM GAS
The vehicle m ay be equipped with liquefied petroleum gas (LPG). As LPG f uel vapour is heavier than air, vapours
can ac cu mulate in c onf ined s pac es. In the inter es ts of safety, the LPG fuel system should be is olated at the manual
shut-off valve before any service work is performed on the vehicle. Refer to the LPG information included with the
Owner's Handbook for details or Section 8A 2 LPG SYSTEM for m ore spec ific servic ing inform ation relating to this
alternative fuel system. Only authorised LPG dealers may service the high pressure side of the LPG system.
FUEL AND EVAPORATION PIPE
To reduce the risk of fire, observe the following guidelines:
• Replace all damaged nylon fuel pipes. Damage to the nylon pipes may result in a fuel leak. Do not attempt to
replace only the damaged section or sections of nylon fuel pipes.
• Do not hammer directly on the fuel harness body clips when installing new fuel pipes.
• Always cover nylon vapour 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 more than one hour or more than 90°C (194°F) for any
extended period.
• Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This ensures
proper connec tion and prevents a pos sible fuel leak . Dur ing norm al operation, the O-rings located in the fem ale
connector swell and may prevent proper reconnection if not lubricated.
FUEL PIPE FITTING
Always apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings.
This ensures proper reconnection and prevent possible fuel leaks.
During normal operation, the O-rings located in the female connector swell and may prevent reconnection if not
lubricated.
FUEL STORAGE
Do not drain fuel into an open container. Never store fuel in an open container due to its highly flammable nature.
PETROL / PETROL VAPOURS
Petrol or petrol vapour s ar e highly flam mable. A f ire c ould occ ur if an ignition s ourc e is pr esent. Never drain or store
petrol in an open container. Always ensure that a dry chemic al (Class B) f ire extinguisher is near by when servic ing
fuel systems.
FUEL INJECTOR LOWER O-RING REMOVAL
Verify that the lower (small) O-ring of each injector does not remain in the intake manifold.
If the O- ring is not removed with the injec tor, the replacem ent 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
While working around a running engine, avoid contact with moving parts and hot surfaces.
FUEL PRESSURE
Do not allow the fuel pressure to exceed the specified value as damage to the fuel pressure regulator or the fuel
pressure test gauge may result.
RELIEVING FUEL PRESSURE
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. T o reduce the risk of death or injur y, cover the regulator and fuel line fittings with a shop towel before
disconnecting. This will catch any fuel that may leak or spray out. Place the towel in an approved container when the
disconnection is complete.
ROAD-TESTING
Road-test a vehicle under normal driving conditions and obey all traffic laws. Do not attempt any manoeuvres that
may endanger you or other road users.
SAFETY GLASSES AND COMPRESSED AIR
Wear safety glasses when using compressed air to help prevent eye injury.
SAFETY GLASSES AND FUEL
Always wear safety glasses when working with fuel to help protect the eyes from fuel splash.
SEATBELT REPLACEMENT
Replace seatbelts, retractors and hardware in use during all but a minor collision. Restraint systems should be
replaced and anchor ages properly repaired if they were in areas dam aged by collision, whether the seatbelt was in
use or not. If there is any question, replac e the seatbelt system. Dam age, whether visible or not, could res ult in the
restraint not functioning correctly in an accident.
If a seatbelt pr etensioner is deployed, the seatbelt pretensioner ass embly together with the seat adjuster and guide
rail assembly must be replaced.
If disposing of an undeployed seatbelt buckle and pretensioner assembly, refer to the disabling procedure in
Section 12M, 2.2 SYSTEM DISABLING AND ENABLING PROCEDURE.
SERVICING AND REPLACING SEATBELTS
To prevent possible seatbelt damage, refer to the following items when servicing or replacing seatbelts.
Seatbelts must be serviced as follows:
• All seatbelts need to be serviced as a set to ensure that the seatbelt components are from the same supplier.
• All attachment hardware must be replaced, not reused.
• Keep sharp edges and damaging objects away from seatbelts.
• Avoid bending or damaging any portion of the seatbelt buckle or latch plate.
• Do not bleach or dye seatbelt or strap webbing. Clean with a mild soap solution and water.
• When installing lap or shoulder seatbelt anchor bolts, start the bolts by hand to ensure that the bolts are
threaded correctly.
• Do not attempt repairs on seatbelt retractor mechanisms. Replace defective assemblies with new service
replacement parts.
SHOP TOWEL FUEL LEAK
Wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leaked 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.
OCCUPANT PROTECTION SYSTEM
This vehicle is equipped with an Occupant Protection System (OPS) incorporating a Supplemental Restraint System
(SRS).
An OPS consis ts of either seatbelt pr etens ioners and a driver 's airbag, s eatbelt pr etensioner s , and driver's and front
passenger's airbags, or seatbelt pretensioners, driver's and front passenger's airbags, and left and right-hand side
front airbags.
Refer to Section 12M, 2.1 SAFETY PRECAUTIONS before performing any service operation on, or around, any
OPS components, the steering mechanism or wiring.
Failure to follow these SAFETY PRECAUTIONS could cause unwanted airbag deployment or otherwise unneeded
OPS repairs, or could result in the OPS not functioning correctly when required.
To help avoid accidental airbag deployment, whenever you service a vehicle that requires repair of the OPS and
another vehicle system, we recommend that you first repair the OPS, then go on to the other system.
OPS INFLATABLE RESTRAINT MODULE DISPOSAL
To prevent accidental deployment of the airbag, do not dispose of an undeployed inflatable restraint module as
normal shop waste. The undeployed inflatable restraint module contains substances that could cause personal
injury if the stored container is damaged during disposal.
For information regarding airbag and/or pretensioner scrapping procedures refer to Section 12M,
2.1 SAFETY PRECAUTIONS.
OPS / SRS SPECIAL TOOLS
To avoid deploying the airbag when troubleshooting the OPS system, use only the equipment specified in this
Service Inf orm ation and the instr uctions given in this Service Inf orm ation. F ailure to use the s pecif ied equipm ent as
instructed could cause airbag deployment or unnecessary OPS system repairs, or could result in the OPS not
functioning correctly when required.
VEHICLE LIFTING
If the vehicle is to be elevated using a two-post hoist, ensure the hoist pads are located as specified in
Section 0A GENERAL INFORMATION.
If the vehicle is to be elevated using a f our-post hois t, ensure the handbr ak e is on. Any hoist mec hanism s designed
to prevent the vehicle rolling off the hoist when elevated, must be functioning correctly.
All hoist operating instructions, lifting limitations, maintenance procedures and maintenance intervals should be
strictly adhered to.
WINDOW REMOVAL
When working with any type of glass, use approved safety glasses and gloves.
WINDOW RETENTION
When replacing stationary windows, the urethane adhesive specified in this Service Information (or a urethane
adhesive system meeting HOLDEN LTD specifications), must be used to maintain original installation integrity.
Failure to use the correct urethane adhesive may result in poor retention of the window.
WORK BAY TEST
One or more of the following guidelines may apply when performing specific required tests in the work bay:
When servicing a vehicle fitted with an ABS/TCS system or a Limited Slip Differential (LSD) rear axle, do not
operate the engine with the transmission in gear and one rear wheel raised. If the ABS/TCS system is operational or
the vehicle is equipped with LSD, with the vehicle in this situation, the driving for ce 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 people should stay clear of rotating components and balance weight areas to avoid possible injury.
• When operating an engine in the workshop for an extended time, do not overheat the engine or transmission.
W hen 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 the PARK position while the drive wheels are spinning.
• Turn off the ignition to stop the powertrain components from spinning.
FA STENERS
Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that
specific application. Fasteners requiring replacem ent or fasteners requiring the use of thread locking com pound 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 to avoid
damage to parts and systems.
HANDLING ESD SENSITIVE PARTS
Electrostatic dischar ge (ESD) can dam age m any solid-state elec trical com ponents. Not all com ponents s usceptible
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, or
• walking.
2. Do not touch the exposed electric terminals on a component with your finger or a tool. The connector 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:
• bridging connectors or component terminals,
• grounding components or connectors, or
• 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; or
• on top of an electrically-operated appliance or piece of equipment, such as a TV, radio or oscilloscope.
9. Do not drop the solid-state component.
ELECTRONIC CONTROL MODULES
Do not touc h the c onnec tor pins or solder ed c omponents on the cir cuit boar d of any control m odule as it may cause
electrostatic discharge (ESD) damage to the module.
5. BATTERY DISCONNECTION PROCEDURES
BEFORE BATTERY DISCONNECTION
When performing any service procedure on the vehicle that involves disconnecting the battery cables or
any procedure that may cause the battery voltage to fall below 12 volts, the telematics module Service
Mode MUST BE ENABLED. Refer to Section 12K, PROGRAMMING – SERVICE MODE.
If the telematics module Service M ode is not enabled a ‘Battery Removal Alert’ is transmitted to the Holden
Assist Centre whenever the battery is disconnected, or a ‘Low Battery Voltage Alert’ when the battery
voltage is low.
Always turn the ignition to the OFF position before 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.
BEFORE SERVICING ELECTRICAL COMPONENTS
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical
loads must be off unless instructed otherwise in this Service Information.
If a tool or item of equipment could come in contact with a live or an exposed electrical terminal, disconnect the
NEGATIVE battery cable. Never disconnect the battery by removing the positive cable before the negative cable.
Failure to follow these precautions may cause injury. Damage to the vehicle and/or service equipment may also
occur.
Refer to the following for further information on specific vehicle systems affected by battery disconnection.
SYSTEMS AFFECTED BY BATTERY DISCONNECTION
The service technician should be aware that certain vehicle systems will be affected by battery disconnection.
Where applicable, specific procedures must be carried out before battery disconnection to avoid unnecessary
complications, time wastage and customer dissatisfaction.
Vehicle systems affected by battery disconnection are:
• instruments,
• body control module,
• entertainment system,
• telematics,
• navigation system, and
• sunroof.
INSTRUMENTS
If the battery is disconnected, the Instrument Dimmer Level will set to a 35% illumination default.
After Battery Reconnection
HOLDEN LTD r ecom m ends that the c ustom er be inf orm ed that the above s etting has changed to a Fac tory Default
Setting as a result of service work performed on the vehicle. Customers should also be advised that they can
consult their vehicle handbook if they wish to restore functions to their original settings.
BODY CONTROL MODULE
If the battery is disconnected, the following BCM-controlled operating parameters require resetting:
• instrument dimmer level, refer to INSTRUMENTS in this section;
• antenna height, refer to ENTERTAINMENT SYSTEM in this section; or
• rear lamp failure warning system, refer to Section 12J, 1.20 REAR LAMP FAILURE SYSTEM.
ENTERTAINMENT SYSTEM
If the battery is disconnected:
• The audio system PIN code remains stored and does not have to be entered into the system when the battery
is reconnected.
• Priority station settings remain stored.
• The antenna height memory setting defaults to 5 seconds of upward mast travel which raises the antenna
approximately 60 cm.
NOTE: If the BCM is removed and replaced with another BCM, the audio system PIN code has to be re-entered into
the audio system.
TELEMATICS
Before Battery Disconnection
The telematics system must be placed into Service Mode. Refer to Section 12K, PROGRAMMING – SERVICE
MODE.
After Battery Reconnection
The telematics system must be placed into Active Mode. Refer to Section 12K, PROGRAMMING – ACTIVE
MODE.
NAVIGATION SYSTEM
Before Battery Disconnection
Before rem oving battery power fr om the vehicle, the s atellite navigation system m ust be shut down cor rectly. Thirty
seconds is required to allow the satellite navigation computer to store the vehicle’s current location. When the
satellite navigation system is shut down correctly, the eject button on the satellite navigation computer is not
illuminated.
After Battery Reconnection
If the battery has been disconnected within thirty seconds after turning off the ignition, the satellite navigation
computer store the vehicle’s previous position and not its current position. This causes a prolonged period of
satellite navigation calibration when the system is reactivated and m ay cause customer dissatisfaction. Ensure the
satellite navigation system is calibrated to its current location before returning the vehicle to the customer.
SUNROOF
If the battery is disconnected, sunroof memory settings are lost.
After Battery Reconnection
To restore operation of the sunroof system, the starting point and end point of the sunroof travel have to be
reinstated into the sunroof memory. Refer to Section 1F1, 2.4 CALIBRATING THE SUNROOF CONTROL UNIT.