SECTION 6C2-3 - 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 for correct workshop practices with regard to safety and/or property damage.

CONTENTS

1. GENERAL DESCRIPTION

1.1 SERVICE PRECAUTIONS

2. ELECTRONIC CONTROL

2.1 POWERTRAIN CONTROL MODULE

REMOVE

REINSTALL

PCM SECURITY LINK

2.2 PROM UNIT

REMOVE

REINSTALL

FUNCTIONAL CHECK

2.3 CAMSHAFT POSITION SENSOR

REMOVE

REINSTALL

2.4 ENGINE COOLANT TEMPERATURE

(ECT) SENSOR

REMOVE

REINSTALL

2.5 INTAKE AIR TEMPERATURE (IAT)

SENSOR

REMOVE

REINSTALL

2.6 MASS AIR FLOW (MAF) SENSOR

REMOVE

REINSTALL

2.7 OXYGEN SENSOR

REMOVE

REINSTALL

2.8 THROTTLE POSITION (TP) SENSOR

REMOVE

REINSTALL

2.9 VEHICLE SPEED SENSOR

REMOVE

REINSTALL

3. FUEL CONTROL SYSTEM

3.1 FUEL PUMP RELAY

FUEL PRESSURE RELIEF PROCEDURE

3.2 THROTTLE STOP SCREW – RESET

PROCEDURE

INSPECT

CHECK OR RESET

3.3 MODULAR FUEL SENDER ASM

REMOVE

REINSTALL

FUEL STRAINER AND FUEL LEVEL

SENSOR

FUEL PUMP ASSEMBLY

3.4 FUEL PUMP CONTROL MODULE (V6

SUPERCHARGED ENGINE)

REMOVE

REINSTALL

3.5 FUEL SYSTEM PRESSURE TEST

PROCEDURE

3.6 FUEL FILTER

REMOVE

REINSTALL

LEAK TESTING

3.7 FUEL PRESSURE REGULATOR

REMOVE

REINSTALL

3.8 FUEL RAIL SUPPLY AND RETURN HOSES

REPLACE

3.9 AIR CLEANER ASSEMBLY

REMOVE

REINSTALL

3.10 THROTTLE CABLE

REMOVE

REINSTALL

ADJUST

3.11 THROTTLE BODY

REMOVE

CLEAN AND INSPECT

THROTTLE BODY CLEANING PROCEDURE

REINSTALL

THROTTLE BODY IAC VALVE COUNT

CHECKING PROCEDURE

3.12 RAIL AND INJECTORS

REMOVE

REINSTALL

3.13 IDLE AIR CONTROL VALVE

REMOVE

CLEAN

REINSTALL

3.14 THROTTLE PEDAL ASSEMBLY

4. DIRECT IGNITION SYSTEM (DIS)

4.1 GENERAL SERVICE INFORMATION

TIMING ADJUSTMENT

CHECK EST SPARK TIMING OPERATION

4.2 IGNITION COIL(S)

REMOVE

TEST

REINSTALL

4.3 DIS MODULE

REMOVE

REINSTALL

4.4 CRANKSHAFT SENSOR

REMOVE

REINSTALL

4.5 KNOCK SENSORS

CHECKING KNOCK SENSOR OPERATION

REMOVE

REINSTALL

4.6 SPARK PLUG LEADS

REMOVE

BENCH TESTING SPARK PLUG LEADS

REINSTALL

4.7 SPARK PLUGS

REMOVE

CLEANING AND INSPECTION

REINSTALL

SPARK PLUG DIAGNOSIS

ANALYSIS OF SPARK PLUG CONDITION

5. AUTOMATIC TRANSMISSION

5.1 1-2 SHIFT SOLENOID

REMOVE

REINSTALL

5.2 2-3 SHIFT SOLENOID

REMOVE

REINSTALL

Techline

5.3 3-2 CONTROL SOLENOID

REMOVE

REINSTALL

5.4 PRESSURE CONTROL SOLENOID

REMOVE

REINSTALL

5.5 TRANSMISSION FLUID PRESSURE (TFP)

MANUAL VALVE POSITION SWITCH ASM

AND TRANSMISSION FLUID TEMP

SWITCH (TFT) SENSOR

REMOVE

REINSTALL

5.6 TCC "PWM" SOLENOID

REMOVE

REINSTALL

5.7 TCC ENABLE SOLENOID

REMOVE

REINSTALL

6. MISCELLANEOUS SYSTEMS

6.1 EVAPORATIVE EMISSION CONTROL CANISTER

REPLACE

6.2 CANISTER PURGE SOLENOID

REPLACE

6.3 SUPERCHARGER SYSTEM

SUPERCHARGER OIL LEVEL CHECK

SUPERCHARGER – REPLACE

6.4 BOOST CONTROL SOLENOID

REPLACE

6.5 BY-PASS VALVE ACTUATOR

REMOVE

REINSTALL

CHECKING ADJUSTMENT OF BY-PASS

VALVE ACTUATOR

6.6 A/C REFRIGERANT PRESSURE SENSOR

REMOVE

REINSTALL

1. GENERAL DESCRIPTION

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

System, used with the V6 Supercharged engine. Emphasis is placed on the proper procedures and repair of

components related to this specific system.

1.1 SERVICE PRECAUTIONS

The following requirements must be observed when working on vehicles:

1. Before removing any PCM system component, disconnect the battery ground 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° 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 co nnector into place is not necessar y if it is be ing

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 s ystem s .

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

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

connectors.

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

happens, corrosion of the terminals can take place.

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

incorrect results or damage good components.

12. All vol tag e meas urements using a vo ltmeter mus t us e a dig ital voltmeter with an inter na l impedance r at in g of at

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

13. When a test light ( 1) is s pec ified, a " low-p ower"

test light must be used. Do not use a high –

wattage test light. While a particular brand of

test ligh t is no t sug geste d, a sim ple t est o n an y

test light will ensure it to be OK for PCM c ircuit

testing. Connect an accurate (2) Ammeter

(such as a high-impedance digital multimeter)

in series with the test light being tested, and

power the test light-ammeter circuit with the

ve hicle batt ery (3).

If the am meter indicat es less tha n 0.3 Am p current

flow (300 mA), the test light is OK to use.

If the ammeter indicates more than 0.3 Amp

current flow (or 300 mA), the test light is NOT OK

to use.

Figure 6C2-3-1

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

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

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

that are not to be re-used, 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.

2. ELECTRONIC CONTROL

2.1 POWERTRAIN CONTROL MODULE

LT Section No. – 02-245

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 the y are the c orrect parts. If the y 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 6C2-3-2 – PCM Location

NOTE: W hen replacing the production PCM with a

service PCM (controller) (1), it is important to

transfer the broadcast code and production PCM

number to the service PCM label. This will allow

positive identification of PCM parts throughout the

service life of the vehicle.

IMPORTANT: To prevent internal PCM damage,

the ignition must be "OFF" when disconnecting or

reconnecting power to PCM (for example, battery

cables, PCM connec tors, Engine Control fus e F29,

jumper cables, etc.).

Figure 6C2-3-3 – PCM Mounting

REMOVE

1. Disconnect battery ground lead.

IMPORTANT: Disconnection of the battery affects

certain veh ic le el ec tr on ic system s . Refer to Sec tio n

00 CAUTIONS, 5. Battery Disconnection

Procedures before disconnecting the battery.

2. Remove lef t han d f ront s hroud pa nel l o wer trim

assembly (cowl panel trim), refer Section 1A3,

INSTRUM ENT PANEL AND CONSOLE in the

MY 2003 VY and V2 Series Service

Information.

Techline

3. Lift up mounting bracket to PCM upper

retaining tang (1), pull PCM (2) out then up to

remove it from the mounting bracket (3).

4. Remove wiring harness connectors (4) from

PCM, remove PCM (2) from vehicle.

5. If necessary, remove PCM PROM, refer

2.2, PROM UNIT - Remove, in this Section.

IMPORTANT: Replacement controllers are

supplied without a PROM so care should be taken

when removing the PROM from the defective

controller as it will be reused in the new controller.

Do not rem ove the pl astic c over of the PRO M. Use

of unapproved removal methods may cause

damage to the PROM or PROM socket.

Figure 6C2-3-4 – PCM Removal

6. If required, remove PCM mounting bracket (1)

by inserting a screwdriver into the retaining

tang slot (2), lever the screwdriver to release

tang. Pull br acket ( 1) out then down, to rel ease

from the cowl panel.

Figure 6C2-3-5 – PCM Mounting Bracket Removal

REINST ALL

1. If removed, r eins tal l PC M 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

2.2, PROM UNIT - Reinstall, in this Section.

3. Reconnect wiring harn es s connectors to PCM.

4. Assemble PCM into mounting bracket,

ensurin g wiring harn ess is routed in fr ont of the

mounting bracket.

5. Reinstall cowl panel trim, Refer to Section

1A3, INSTRUMENT PANEL AND CONSOLE,

in the MY 2003 VY and V2 Series Service

Information.

6. Reconnect battery ground lead, start vehicle

and allow to idle. Check vehicle for correct

operation.

Figure 6C2-3-6 – PCM Mounting Bracket Reinstallation

PCM SECURITY LINK

Whenever 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 / (3) 20 03 / VY Comm odore / Body / B ody Contro l Module / Securit y / BCM Li nk to PCM an d follo w

TECH 2 instructions.

For additional information regarding TECH 2 and TECH 2 test modes (including this linking procedure), refer to

Tec h 2 Diagnosis F or BC M in Se ction 12J BO DY CONT ROL MO DULE in the MY 200 3 VY and V2 S eries Serv ice

Information.

2.2 PROM UNIT

LT Section No. – 02-245

NOTE: A DTC 51 indicates a faulty PROM, or

incorrect installation.

IMPORTANT: The ignit io n shoul d al ways be "OFF "

when installing or removing the PCM connectors.

REMOVE

1. Remove PCM (1) from passenger

compartment, refer 2.1, POWERTRAIN

CONTROL MODULE - Remove, in this

Section.

2. Using a No.15 Torx bit, remove PCM PROM

access cover screws (2), then remove access

cover (3).

IMPORTANT: DO NOT remove any other screws.

Figure 6C2-3-7 – Access Cover Removal

3. Remove PROM (1) from PCM (2) by using

thumb and finger to push retaining clips (3) in

towards the PROM (1), then lift the PROM

straight up and out of the socket.

Figure 6C2-3-8 – PROM Removal

IMPORTANT: DO NOT remove the PROM

cover (1). Use of unapproved PROM removal

methods will cause damage to the PROM or

PROM socket (2).

Figure 6C2-3-9 – PROM

REINST ALL

1. Remove new PROM from its packaging and check the part num ber making sure it is the correct replacement

component.

2. Referr ing to Figure 6C2-3- 8, install P ROM (1) in PRO M sock et, ensuring t hat small n otches in the PRO M ali gn

with the small notches in the PROM socket.

3. Gently press down on the ends of the PROM until the retaining clips (3) click into the PROM socket.

4. Reinstall PROM access cover onto PCM then, using No.15 Torx bit, reinstall and tighten access cover screws

securely.

5. Reinstall PCM, refer 2.1, POWERTRAIN CONTROL MODULE - Reinstall, in this Section.

FUNCTIONAL CHECK

1. Turn ignition "ON."

2. If DTC 51 occurs or if the Powertrain Malfunction Indicator Lamp (MIL) is constantly activated with no DTC’s,

the PROM is not fully seated or is defective. In this event, remove or reinstall the PROM as per previous

instructions.

2.3 CAMSHAFT POSITION SENSOR

LT Section No. – 02-000

Figure 6C2-3-10 – Camshaft/Crankshaft Position Sensors

Legend

1. Crankshaft Balancer Retaining Bolt

2. Crankshaft Balancer

3. Screw – Camshaft Sensor Retaining

4. O-Ring – Camshaft Sensor Sealing

5. Sensor – Crankshaft Position

6. Sensor – Camshaft Position

7. Shield – Sensor

8. Washer

REMOVE

1. Dis c onnect batter y ground l ead.

2. Lift up retaining tang and disconnect wiring harness connector from camshaft position sensor (6).

3. Remove camshaft position sensor to front cover retaining screw (3).

4. Remove camshaft position sensor (6) and O-ring (4) from front cover.

REINST ALL

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 SCREW

TORQUE SPECIFICATION 11 Nm

4. Reconnect wiring harness connector to camshaft position sensor (6).

5. Rec onn ec t batter y ground l ead.

2.4 ENGINE COOLANT TEMPERATURE (ECT) SENSOR

LT Section No. – 02-000

IMPORTANT: Care must be taken when handling PCM engine coolant sensor. Damage to sensor will affect the

operatio n of th e engine managem ent system. Ensur e t hat t he c or rec t s e ns or is lo c ated bef or e s erv ic e is attempted.

The ECT sensor is located in the rear of the intake manifold below the engine thermostat housing.

REMOVE

1. Dis c onnect batter y ground l ead.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to Sections 00

CAUTIONS, 5. Battery Disconnection Procedures before disconnecting the battery.

2. Depressurise engine cooling system by removing radiator cap in two stages.

CAUTION: Do not remove radiator cap while the engine coolant temperature is above 50°

°°

° C.

3. The ECT sensor is installed into a "wet" engine coolant passage (in the intak e manifold, below the thermostat

housing). Therefore, before removing the ECT sensor from the engine, position an appropriate coolant drain

pan beneath the engine coolant, then remove the lower radiator hose at the radiator to drain the coolant.

4. Remove four dome nuts (1) securing the

engine dress cover assembly (2) to the inlet

manifold studs (3), then lift and remove the

cover assembly (2) from the engine.

Figure 6C2-3-11 – V6 Supercharged Engine Dress Cover

5. Lift up retaining tang and disconnect wiring

harness connector (2) from Engine Coolant

Temperature (ECT) sensor (1). Lift connector

up away from sensor.

6. Carefully move powertrain wiring harness

down under the ECT sensor to allow tool

access to the sensor.

7. Using a 19 mm ring spanner, carefully loosen

and remove PCM engine coolant temperature

sensor.

Figure 6C2-3-12 – ECT Sensor Location

REINST ALL

1. Apply Loctite 242 (or equivalent) to the cleaned sensor threads.

2. Reinstall ECT sensor to intake manifold and tighten to the correct torque specification.

ENGINE COOLANT

TEMPERATURE SENSOR

TORQUE SPECIFICATION 18 Nm

3. Reconnect wiring harness connector onto ECT sensor.

NOTE: Recheck that the wiring harness connector and harness are correctly positioned. Damage to the harness

could occur if not correctly positioned at this time.

4. Rec onn ec t batter y ground l ead.

5. Ref ill the engi ne coolant s ystem , refer to Section 6B2, ENGINE COOLING - V6 S/C ENGINE in the MY 2003

VY and V2 Series Service Information.

6. Reinstal l engine dress co ver to the inlet m anif old, ens uring that s tud gr omm ets in dress c over rem ain in place.

Tighten securing dome nuts to the correct torque specification.

ENGINE DRESS

COVER DOMED NUT

TORQUE SPECIFICATION 5 Nm

2.5 INTAKE AIR TEMP ERATURE (IAT) SENSOR

LT Section No. – 03-250

REMOVE

NOTE: Care must be taken when handling IAT Sensor. Damage to IAT sensor will affect proper operation of the

fuel control system.

1. Dis c onnect batter y ground l ead.

2. Lift up tang on IAT sensor wiring harness

connector (1) and pull connector from sensor

(5).

3. Loosen intake air duct adaptor 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.

Figure 6C2-3--13 IAT Sensor Removal

REINST ALL

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.

3. Position new retainer (4) onto IAT sensor and then using a 20 m m socket, push the retainer full y onto the IAT

sensor.

4. Reassemble the air cleaner upper housing onto the air cleaner lower housing, ensuring that air filter element

remains in position.

5. Snap 5 retainer clips up into place over the top of the air cleaner upper housing.

6. Reconnect wiring harness connector (1) to IAT sensor (5).

7. Carefully assemble intake air duct and mass air flow sensor onto air cleaner upper housing.

IMPORTANT: Align notch on air cleaner housing adaptor with notch in air duct adaptor and notch in clamp.

8. Tighten air duct clamp securely.

9. Check that mass air flow sensor wiring harness connector has remained firmly in place.

10. Reconnec t batter y ground l ead.

2.6 MASS AIR FLOW (MAF) SENSOR

LT Section No. – 03-250

REMOVE

NOTE: Care must be taken when handling MAF sensor. Damage to MAF sensor will affect proper operation of

PCM control.

1. Dis c onnect batter y ground l ead.

2. Lift up tang on MAF sensor wiring harness

connector (3) and pull connector from

sensor (1).

3. Loosen clamp (2) on air duct adaptor, 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.

NOTE: Air duct adaptor (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

adaptor (5).

4303

Figure 6C2-3-14 – MAF Sensor Removal

REINST ALL

1. Reinstall MAF sensor (1) into air duct adaptor (5) and air duct, aligning all notches. Install clamps, aligning

notches, tighten clamps securely.

2. Reconnect MAF sensor wiring harness connector (3).

3. Rec onn ec t batter y ground l ead.

4. Start vehicle and check for air leaks.

2.7 OXYGEN SENSOR

LT Section No. – 00-450

NOTE 1: The oxygen sensor uses a permanently attached pigtail and connector. This pigtail should not be

rem oved from the ox ygen sens or. Damage or r emova l of the pigta il or connector will affec t proper operation of the

oxygen sensor.

NOTE 2: Take care when handling the oxygen sensor. The in-line electrical connector and louvred 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.

NOTE 3: The ox ygen sens or ma y be diff icult to remove when e ngine tem perature is belo w 60° C. Excessive force

may damage threads in exhaust pipe, or on the sensor.

NOTE 4: The V6 Supercharged application requires a four wire heated oxygen sensor. Be sure that any

replacements are of the correct type for this engine.

REMOVE

1. Dis c onnect batter y ground l ead.

2. Lift the retaining tang on oxygen sensor wiring

harness connector (1) and pull connector from

sensor pigtail connector.

For RH sensor, the connector is located at the

rear of the RH 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,

refer Figure 6C2-3-14.

For LH sensor, the connector is located at the

rear of the LH cylinder head and is accessed

from the rear of the engine compartment, refer

Figure 6C2-3-1 5.

4306

Figure 6C2-3-15 – RH Sensor Location

(Four Wire Sensor)

3. Raise vehicle and place on suitable safety

stands. Refer to Section 0A GENERAL

INFORMATION, in the MY 2003 VY and V2

Series Service Information.

4. Carefully unscrew oxygen sensor (2) from

exhaust pipe, refer NOTE 3, above.

REINST ALL

IMPORTANT: A special anti-seize compound is

used on the oxygen sensor threads. The

compound consists of a liquid graphite and very

sm all glass be ads . The graphit e will burn a wa y, but

the glass beads will remain, making the sensor

easier to remove at some future time.

Genuine replacement sensors already have the

compound applied to the threads. If a sensor is

rem oved f r om an engi ne, a nd, if for an y reas on it is

to be reinstalled, the threads must have the

specified anti-seize compound applied before

reinstallation.

Specified anti-seize compound is available from

authorised Parts Outlets as part number 5613695.

1. If necessary, coat threads of oxygen sensor

with specified anti-seize compound.

2. Reinstall oxygen sensor (2) into exhaust pipe

and tighten to the correct torque specification.

OXYGEN SENSOR TO

EXHAUST PIPE

TORQUE SPECIFICATION 40 – 50 Nm

3. Remove safety stands and lower the vehicle.

4. Reconnect oxygen sensor wiring harness

connector (1).

IMPORTANT: Ensure that the RH sensor pigtail

leads are retained by a clip attached to the torque

converter housing, refer Figure 6C2-3-14.

5. Rec onn ec t batter y ground l ead.

4307

Figure 6C2-3-16 – LH Sensor Location

(Four Wire Sensor)

2.8 THROTTLE POSITION (TP) SENSOR

LT Section No. – 03-300

REMOVE

1. Dis c onnect batter y ground l ead.

2. Remove four dome nuts securing the engine dress cover assembly to the inlet manifold studs, lift off and

remove t he cover assembly.

3. Loosen rear air duct clamp 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 TP sensor to throttle body

attaching screws (4).

9. Remove sensor (1) from throttle body (2)

taking care not to lose the drive adaptor (3).

NOTE: The driv e adaptor (3) is a plastic c over that

loosely slides over the end of the throttle shaft, on

the TP sens or side of th e throttle bod y. It is kept in

place when the TP sensor is in position on the

throttle body. The drive ad aptor can e asily fa ll from

the throttle shaft after the TP sensor is removed.

4308

Figure 6C2-3-17 – TP Sensor Removal

REINST ALL

1. Check that the drive adaptor is in place on the throttle valve shaft, refer to previous NOTE.

2. W ith throttle valve in the norm ally closed (idle) position, install TP sensor on to throttle valve shaft and throttle

body at a position 30 degrees clockwise past throttle body attaching screw holes.

3. Rotat e TP sensor anti-clock wise, aligning th e screw attachi ng holes in th e throttle bod y, then install TP s ensor

attaching screws and tighten to the correct torque specification.

TP SENS O R TO TH R OTTL E B ODY

ATTACHING SCREW

TORQUE SPECIFICATION 1 – 1.5 Nm

4. Reinstall throttle body, reinstall the two attaching nuts and tighten to the specified torque.

THROTTLE BODY

ATTACHING NUTS

TORQUE SPECIFICATION 15 – 20 Nm

5. Reinstall throttle body cable attaching bracket, secure with the attaching nuts and tighten to the specified

torque.

THROTTLE CABLE BRACKET

ATTACHING NUT

TORQUE SPECIFICATION 10 Nm

6. Install air cleaner duct to throttle body, and tighten clamp.

7. Reconnect TP sensor wiring harness connector.

8. Reinstall engine dress cover to the inlet manifold, ensuring that stud grommets in the dress cover remain in

place . Tighten securing dome nuts to the correct torque specification.

ENGINE DRESS COVER

DECORATIVE NUT

TORQUE SPECIFICATION 4 – 6 Nm

9. Rec onn ec t batter y ground l ead.

2.9 VEHICLE SPEED SENSOR

LT Section No. – 04-200

REMOVE

1. Raise rear of vehicle and support on safety

stands, Refer to Section 0A, GENERAL

INFORMATION in the MY 2003 VY and V2

Series Service Information.

2. Raise 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.

REINST ALL

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

transmission fluid.

2. Reinstall new VSS and O-ring into

transmission extension housing.

3. Reinstall retaining bolt (1) and tighten to the

correct torque specification.

VSS RETAINING SCREW

TORQUE SPECIFICATION 11 Nm

4. Reconnect wiring harness connector (2) to

VSS (3).

5. Remove safety stands and lower vehicle.

4310

Figure 6C2-3--18– VSS Location Automatic

Transmission

3. FUEL CONTROL SYSTEM

3.1 FUEL PUMP RELAY

LT Section No. – 02-250

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 strut

tower. Other than checking for loose connectors,

the only service possible is replacement.

FUEL PRESSURE RELIEF PROCEDURE

1. Depressurise fuel system, as follows:

a. Remove the fuel pump relay (1) from the

underhood electrical centre.

b. With the throttle closed, crank the engine.

The engine may start and idle until any

pressurised fuel in the delivery system is

exhausted.

c. When the engine stops, crank for

approximately 10 seconds to ensure that

all built-up pressure has been exhausted.

d. Reinstall the fuel pump relay.

Figure 6C2-3-19 – Fuel Pump Relay Location

3.2 THROTTLE STOP SCREW - RESET PROCEDURE

LT Section No. –

IMPORTANT: The idle speed for this V6 Supercharged engine application must be checked every 80,000 km. 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.

Throttle Stop Screw (1) controls the minimum

throttle ope ning (nominal "closed throttl e" position).

It is preset at the factory and must not be reset

unless:

a. T he scr ew is k nown t o hav e been inad verte ntl y

reset,

–OR–

b. 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 the

Throttle stop screw setting (RPM) ARE NOT

THE SAME!

Throttle stop screw setting (RPM) must always be

less than the PCM controlled idle speed, and is

check ed only after tem porarily disabling the PCM's

method of controlling idle speed; the Idle Air

Control (IAC) system. The throttle stop screw

setting is the least likely cause of an abnormal idle

condition.

Therefore, resetting the screw should only be

considered as a last resort. An incorrect setting is

likely to cause a deterioration in idle stability.

Figure 6C2-3-20 – Throttle Stop Screw Location

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

also 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 6C2-2A DIAGNOST IC TABLES.

2. Before performing steps 3 – 10, ensure that the

IAC system is functioning properly. Refer

Diagnostic TABLE A-7.1 (IAC System Check)

in Section 6C 2-2A , DIAGN OST IC TABLE S and

follow it to the "NO TROUBLE FOUND - IAC

OK" step before proceeding.

3. Engine must be at normal operating

temperature (above 90° C), preferable

achieved by driving for at least 15 minutes,

before continuing.

4. Set parking brake and block drive wheels.

Ensure transmission selector is in the ‘Park'

position.

5. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift and remove the cover assembly.

4311

Figure 6C2-3-21 – IAC Valve Harness Removed

6. Verify that the throttle cable and throttle linkage are not binding. The throttle lever attached to the throttle

butterfly shaft must be able to open fully, and shut fully and freely every time the accelerator pedal is fully

depressed and slowly released. Refer "3.10 THROTTLE CABLE – Adjust" in this Section if throttle cable

adjustment is required.

7. Install Tech 2, and select; Miscellaneous Tests / IAC System / Base Idle.

8. Ignition “ON”, engine running.

NOTE: If the vehicle has travelled 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 Tech 2, activate the ‘Base Idle’ test and follow the on-screen instructions on Tech 2.

10. Adjust the throttle stop screw to obtain engine idle speed of 450 – 550 rpm.

11. 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 DOME NUT

TORQUE SPECIFICATION 4 – 6 Nm

3.3 MODULAR FUEL SENDER ASSEMBLY

LT Section No. – 03-074

REMOVE

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. Dis c onnect batter y ground l ead.

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

TANK, in the MY 2003 VY and V2 Series

Service Information.

4. Rem ove the m odular fuel s ender ret aining r ing,

using Tool No. J39765 Fuel Sender Locknut

Wrench.

CAUTION: When removing the modular fuel

sender assembly from the fuel tank, the

reservo ir buck et on the fuel send er as sembl y 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.

NOTE: The modular fuel sender assembly will

spring-up when the locking ring is rem o ved.

5. Pull the modular fuel sender straight up while

draining the fuel from the reservoir.

6. Clea n the fuel send er as s e mbly O-Ring s e al in g

surface.

7. Inspect the fuel sender assembly O-Ring

sealing surface.

Legend

A. Fuel Flow In

B. Fuel Flow Return

C. Fuel Vapour

1. Aspirator

2. Jet Pump Filter

3. External Strainer

4. Primary Umbrella Valve

5. Secondary Umbrella Valve

6. Internal Strainer

7. Roller Vane Fuel Pump

Figure 6C2-3-22 – Modular Fuel Sender Assembly

REINST ALL

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 or twist the fuel pump strainer when installing the fuel sender

assem bly, as this wi ll restrict f uel flow. Also, ensure that th e fuel pum p strainer d oes not interf ere with full travel of

float arm.

2. Reinstall 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 8A1 FUEL TANK, in the MY 2003 VY and V2 Series Service Information.

4. Rec onn ec t batter y grou nd lead.

5. Inspect system to ensure that no fuel leaks are evident.

FUEL STRAINER AND FUEL LEVEL SENSOR

NOTE: The f uel strainer is not serviced separat ely. Should the strainer be clogged or damaged, the com plete fuel

module assembly must be replaced.

FUEL PUMP ASSEMBLY

NOTE: The fuel pump for the V6 Supercharged engine is not serviced separately. The complete Modular Fuel

Sender Assembly must be replaced, if the pump is found to be faulty.

3.4 FUEL PUMP CONTROL MODULE (V6 SUPE RCHARGED ENGINE)

REMOVE

1. Dis c onnect batter y ground l ead.

2. Move right rear upper wheelhouse trim cover to

gain access to fuel pump control module

retaining bolt.

3. Remove control module 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.

REINST ALL

1. Reconnect body wiring harness connector to

module.

2. Reinstall 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. Conn ec t battery ground lead.

NOTE: If necessary, check fuel pump control

module operation, refer to Table A-4.1 FUEL

PUMP ELECTRICAL CIRCUITS, in Section

6C2-2A DIAGNOSTIC TABLES.

Figure 6C2-3-23 Fuel Pump Control Module Location

3.5 FUEL SYSTEM PRESSURE TEST

PROCEDURE

A Fuel S ystem Pr ess ur e Test is par t of s everal of the Diagnostic T ables an d S ymp tom check s . To perf orm this tes t,

follow this procedure:

CAUTION: To reduce the risk of fire or personal injury, it is necessary to relieve fuel system pressure

before performing this test. See "Fuel Pressure Relief Procedure" in this Section.

IMPORTANT: At no time m ust the fuel in let 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 3.1 FUEL PUMP RELAY – Fuel Pressure Relief Procedure, in this

Section. Turn ignition "OFF."

2. Remove four dome nuts (1) securing the

engine dress cover assembly (2) to the intake

manifold studs (3), then lift and remove the

cover assembly (2) from the engine.

Figure 6C2-3-24 – V6 Supercharged Engine Dress Cover

3. Remove Schrader valve cap on fuel rail fitting.

Connect a daptor, Tool AU453 to t he Schra der

valve fitting (1), located on engine fuel rail.

4. Connect fuel gauge AU338 and hose, to

Schrader valve adaptor, then proceed to

step 5.

Figure 6C2-3-25 – Fuel Gauge Installation V6

Supercharged Engine

5. With Tech 2 installed, enable fuel pump to pressurise the fuel system.

6. Fuel gauge re ading shou ld be 290 – 410 k Pa for the V6 SUP ERCHARG ED engine app lication. If this pres sure

is not reached, R efer to Table A-4.1 FUEL PUMP ELECT RICAL CIRCUIT S, in Section 6C2- 2A DIAGNOS TIC

TABLES.

7. Relieve fuel pressure as described in 3.1 FUEL PUMP RELAY – Fuel Pressure Relief Procedure, in this

Section.

8. Remove fuel pressure gauge and adaptor.

9. Reinstall Schrader valve cap.

10. Check for fuel leaks as described in 3.6 FUEL FILTER – Leak Testing, in this Section.

3.6 FUEL FILTER

LT Section No. – 03-075

REMOVE

IMPORTANT: Relieve the fuel system pressure

before servicing any fuel system connection.

Refer to the Fuel Pressure Relief Procedure in

3.1, FUEL PUMP RELAY – Fuel Pressure Relief

Procedure, in this Section.

1. Relieve fuel pressure as described in

3.1, FUEL PUMP RELAY - Fuel Pressure

Relief Procedure in this Sec tion .

2. Dis c onnect batter y ground l ead.

3. Raise rear of vehicle and support on safety

stands, refer to Section 0A, GENERAL

INFORMATION in the MY 2003 VY and V2

Series Service Information.

4. Place a drain tray beneath fuel filter.

5. Remove the fuel filter from the retaining

bracket (1) with the fuel lines still connected to

the fuel filter to allow easier access.

Figure 6C2-3-26

Quick Connect Fittings (Plastic Collar)

6. Grasp the quick-connect fittings on each side

of the fuel filter. Twist the female connectors

1/4 turn in each directio n in order to loos e n any

dirt within the quic k-connec t fittin g.

Figure 6C2-3-27

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 .

CAUTION: Wear safety glasses when using

compressed air, in order to prevent eye injury.

Figure 6C2-3-28

Techline

8. Use Tool No. AU533 to squeeze the release

tabs, by pushing down on the quick connect

fitting. This action compresses both release

tabs. With AU533 in place, push the

connection together to release tension on the

locking tabs and then pull to separate the two

components. Repeat this operation for the

second connection, to release the fuel filter.

NOTE: Tool No AU533 is available in two pipe

sizes; Red for 5/16” and Blue for 3/8”. Only the

blue (3/8”) tool is required for this operation.

9. Remove fuel filter from vehicle and discard

safely, remembering that some fuel will still

remain in the filter.

Figure 6C2-3-29

If Tool No. AU533 is not available, an alternative

method of removing the filter, is as follows:

10. Hold the fuel f ilter firm ly in one hand to support

the filter.

11. Using your o ther hand, gr asp one of the quick -

connect fittings and squeeze the plastic

retainer release tabs (1) on each side of the

fitting whi le pushing the fitti ng firmly toward the

fuel filter to release any tension on the release

tabs.

Figure 6C2-3-30

12. With the tension release tabs still held in the

squeezed position, move the complete quick-

connect fitting away from the fuel filter to

separate the connector fitting from the fuel

filter.

13. Apply the sam e method f rom steps 10 to 12 for

the remaining quick-connect fitting.

Figure 6C2-3-31

REINST ALL

IMPORTANT: The fuel filter (6) must be installed

with the flow arrow (5) on its body pointing in the

same direction as the fuel flow to the front of the

vehicle.

Legend:

1. Evaporative Emission Control Canister

2. Vapour Line to Purge Solenoid

3. Fuel Tank Vapour Line

4. Fuel Feed Line from Modular Fuel Sender

Assembly

5. Fuel Flow Direction Arrow

6. Fuel Filter

7. Fuel Return Line

Figure 6C2-3-32 – Fuel Filter Installation

IMPORTANT: In or der t o r educ e t he ris k of fire and

personal injury, 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 ensure proper reconnection and prevent a

possible fuel leak.

During normal operation, the O-ring located in the

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

reconnection if not lubr icated.

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

male fuel filter end.

Figure 6C2-3-33

2. Push both th e quic k -conne ct f itting a nd the fuel

filter together, causing the retaining tabs to

snap into place. Apply this method to both

ends of the fuel filter and the respective quick-

connect fittings.

Figure 6C2-3-34

3. Once installed, pull and push on both the

quick-connect fitting and the fuel filter in order

to make sure the connection is secure. Apply

this method to each end of the fuel filter and

the respective quick-connect fittings.

Figure 6C2-3-35

4. Re-install the fuel filter to the retaining

bracket (1).

5. Conn ec t battery ground lead.

6. Check for fuel leaks , refer to 3.6 FUEL FILTER

– Leak Testing in this Section.

7. Remove safety stands and lower vehicle.

Figure 6C2-3-36

LEAK TESTING

Before s tarting the eng ine, f ollowing th e insta llation of any fu el s ystem com ponent, check the fue l system for le aks

using the following procedure:

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

2. Us e Tech 2 "O utpu t Test" for "Fue l P ump." En abl in g t he ou tput test will ac ti vat e t he f uel pum p to pr es s uris e the

fuel system.

3. W ith fuel pr essur e appl ied t o the s ystem , check fuel s ystem for leaks , partic ularl y at points m ark ed (  ), shown

next.

Figure 6C2-3-37 – Leak Testing V6 Supercharged Engine

Legend

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. Modular Fuel Sender Assembly.

10. Fuel Tank.

3.7 FUEL PRESSURE REGULATOR

LT Section No. – 03-375

IMPORTANT: T he fuel pressure regulator and fuel return hose is onl y serviced as a com plete assembly. The fuel

pressure return hose cannot be removed from the fuel pressure regulator.

REMOVE

1. Relieve fuel pressure as described in

3.1 FUEL PUMP RELAY – Fuel Pressure

Relief Procedure, in this Section.

2. Dis c onnect batter y ground l ead.

3. Remove four dome nuts securing the engine

dress cover assembly to the inlet manifold

studs, lift off and remove cover assembly.

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

Figure 6C2-3-38 – Fuel Pressure Regulator Location

7. Using a shop towel to catc h an y spil led fue l, lif t

and t wist the fuel press ure r egulator 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 this engine

application, disconnect fuel return hose quick

connect at dash panel connection, only if

replacing fuel pressure regulator.

REINST ALL

1. If a new fuel pressure regulator is not being

installed, fit new O-rings to the fuel pressure

regulator and lightly lubricate the O-rings with

clean engin e oil.

2. Install the fuel pressure regulator in the fuel

pressure regulator housing.

3. Install the retaining snap ring to the fuel

pressure regulator using commercially

available snap ring pliers.

4. Reins tall the v acuum hose to the f uel pressure

regulator.

5. Reinstall the fuel return hose quick connect to

dash panel connector.

6. Rec onn ec t batter y ground l ead.

7. Check f or fuel le ak s; ref er in 3.6 FUEL FILTER

– Leak Testing, in this Section.

8. Reinstall engine dress cover, ensuring that

stud grommets in dress cover remain in place.

Tighten securing dome nuts to the correct

torque specification.

ENGINE DRESS

COVER DOME NUT

TORQUE SPECIFICATION 4 – 6 Nm

NOTE 1: Compressed air must never be used to

test or clean a fuel pressure regulator, as damage

to the fuel pressure regulator may result.

NOTE 2: In order to prevent damage to the fuel

pressure regulator do not immerse in solvent.

Figure 6C2-3-39 – Fuel Pressure Regulator Removal

3.8 FUEL RAIL SUPPLY AND RETURN HOSES

LT Section No. – 03-375

REPLACE

The fuel supply hose (1) is an assembly with the

fuel rail. Both components are NOT serviced

separately. For removal or replacement of the fuel

supply hose, refer to Fuel Rail and Injectors in

this Section.

The fuel return hose (2) is an assembly with the

fuel pres sure regulat or. Both c omponents are NOT

serviced separately. For removal or replacement,

refer to the Fuel Pressure Regulator in this

Section.

Figure 6C2-3-40 Fuel Lines

3.9 AIR CLEANER ASSEMBLY

LT Section No. – 03-250

REMOVE

1. Loosen air duct clamp (1), then disconnect the mass air flow sensor (9) from the upper air cleaner housing (2).

2. Pull up retaining tang on IAT sensor wiring harness connector (not shown) and remove connector from sensor.

3. Unclip 5 clips (5) securing the air cleaner upper housing (2).

4. Remove air cleaner upper housing (2) and air cleaner element (3) as an assembly.

5. Remove the two scrivets (7) securing the pre-filter intake duct (8) to the radiator upper shroud.

6. Remove three fasteners (6) securing air cleaner lower housing (4) to fender inner panel insulators.

7. Disengage the pre-filter air intake duct (8) from the lower housing (4), then remove air cleaner lower housing

(4).

Figure 6C2-3-41 – Air Cleaner Housing Removal – V6 Supercharged Engine

Legend

1. Hose Clamp

2. Upper Air Cleaner Housing.

3. Air Cleaner Element.

4. Lower Air Cleaner Housing.

5. Clips (5 places)

6. Fasteners ( 3 places)

7. Scrivets (2 places).

8. Pre-Filter Intake Air Duct.

9. Mass Air Flow (MAF) Sensor.

10. Air Intake Duct to Throttle Body.

REINST ALL

1. Ass em ble air clea ner lo wer hous ing onto m ounti ng ins ulat ors. Rei nstal l secur ing nuts and ti ghten to the corr ect

torque specification.

AIR CLEANER LOWER

HOUSING NUT

TORQUE SPECIFICATION 5 – 7 Nm

2. Engage the pre-filter in the air intake duct into the lower housing and secure duct to radiator upper shroud,

using two scri vets.

3. Assem ble the air c leaner el ement into t he air cl eaner upper housing and place th e upper ho using a nd elem ent

assembly onto the lower air cleaner housing, ensuring that air filter element remains in position.

4. Snap the 5 retainer clips into place to the top of the air cleaner upper housing.

5. Reconnect wiring harness connector to IAT sensor.

6. Carefully assemble air duct adaptor onto air cleaner upper housing.

NOTE: Align notch on air cleaner housing adaptor with notch in air duct adaptor 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. Rec onn ec t batter y ground l ead.

3.10 THROTTLE CABLE

LT Section No. – 03-325

REMOVE

1. Remove four dome nuts securing the engine dress cover assembly to the inlet manifold studs, lift off and

remove t he 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, INSTRUM ENT PANEL AND CONSOLE, in the MY2003 VY and V2 Series Service Information.

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

7. Withdraw cable assembly from engine compartment.

REINST ALL

1. Assemble outer cable into dash panel.

2. Attach inner cable to throttle pedal lever.

3. Install outer cable to mounting bracket.

4. Attach inner cable to throttle body linkage.

5. Adjust cable as in following instructions.

Figure 6C2-3-42 Throttle Cable V6 Supercharged Engine

Legend

1. Cable Adjusting Nuts (Do not

remove)

2. Mounting bracket

3. Mounting bracket nuts (3 places).

4. Correct Outer Cable Positioning

5. Cruise control cable.

6. Throttle cable.

7. Main wiring harness.

8. Main wiring harness retention clip.

9. Throttle cable.

10. Inner cable.

11. Throttle pedal lever.

12. Clip

13. Cruise control ca ble.

14. Lower clip.

15. Bracket.

16. Throttle cable.

17. Upper clip.

ADJUST

1. Remove instrument panel lower right side trim

(if not already rem oved, Ref er to Section 1 A3,

INSTRUM ENT P ANEL AND CONSOLE, in the

MY 2003 VY and V2 Series Service

Information.

2. Ensure throttle pedal is free to move from

closed to fully open position. Check that throttle

pedal comes to rest at the correct closed

throttle position (against pedal stop).

3. Adjust o uter ca ble lock nuts so that inner c able

has a deflection of 10 – 15 mm (2) without

moving the throttle linkage from idle stop.

4. Tighten cable lock nuts to the correct torque

specification.

OUTER THROTTLE

CABLE LOCK NUT

TORQUE SPECIFICATION 2 – 5 Nm

5. Check for Wide Open Throttle and smooth

operation of throttle pedal.

6. Reinstall engine dress cover to the intake

manif old, ensurin g that stu d gromm ets in dres s

cover remain in place.

7. Tighten securing dome nuts to the correct

torque specification.

4322

Figure 6C2-3-43

ENGINE DRESS

COVER DOME NUT

TORQUE SPECIFICATION 4 – 6 Nm

8. Refit instrument panel lower right side trim,

Refer to Section 1A3, INSTRUMENT PANEL

AND CONSOLE, in the MY 2003 VY and V2

Series Service Information.

3.11 THROTTLE BODY

LT Section No. – 03-300

REMOVE

1. Disconnect battery ground lead.

2. Remove four dome nuts securing the engine dress cover assembly to the intake 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. Disconnect the emission control purge hose from the throttle body connection.

7. Loosen both hose clamps securing the crankcase ventilation hose, then remove the hose and clamps from the

engine.

8. Disconnect throttle inner cable (1) from throttle

body linkage (2). Loosen outer throttle cable

lock nuts (3) at mounting bracket (5) and lay

cable away from engine.

9. If vehicle is fitted with cruise control,

disconnect cruise control outer cable (4) from

the mounting bracket (5) and push inner cable

forward off throttle body linkage (2).

10. If required, remove the mounting bracket (5)

retaining nuts (6) and remove bracket from the

throttle body.

Figure 6C2-3-44

11. Remove throttle body to intake manifold

attaching nuts (3).

12. Remove throttle body and gasket (1) from

manifold.

4324

Figure 6C2-3-45

CLEAN AND INSPECT

Gasket surfaces on throttle body and manifold.

IMPORTANT: If re-using the old throttle body, you must perform the throttle body Cleaning Procedure before

reinstalling.

NOTE: There is a specific throttle body assembly for this engine application. When replacing the throttle body

always refer to the current PartFinder® CD ROM for the correct part number.

THROTTLE BODY CLEANING PROCEDURE

1. Remove throttle body (1) from vehicle.

2. Remove the TP sensor (2) and IAC valve (3)

from the throttle body.

3. Using an approved injector cleaner, clean the

carbon build up around the pintle of the IAC

valve (3).

4. On the throttle body, clean the carbo n build up

around the IAC air port, throttle body bore and

throttle blade (4).

5. Reinstall TP sensor (2) and IAC valve (3) to the

throttle body (1).

6. Continue with the reinstallation of the throttle

body to the engine.

Figure 6C2-3-46 Throttle Body Cleaning

REINST ALL

1. Install a new throttle body gasket (1), then the

throttle body (2) to intake manifold.

2. Install throttle body attaching nuts (3) and

tighten to the correct torque specification.

THROTTLE BODY

ATTACHING NUT

TORQUE SPECIFICATION 15 – 20 Nm

3. Reinst all canister purge control hose to throttle

body.

4. Reinstall engine positive crankcase ventilation

hose to throttle body and tighten hose clamps

to secure.

5. Reinstall wiring harness connectors to IAC

valve and TP Sensor.

4324

Figure 6C2-3-47

6. Reinstall throttle cable mounting bracket (5)

attaching nuts (6) and tighten to the correct

torque specification.

THROTTLE CABLE

BRACKET NUT

TORQUE SPECIFICATION 10 Nm

7. Reconnect inner throttle cable (1) to throttle

body linkage (2).

8. If vehicle is fitted with cruise control, reinstall

cruise control cable (4) 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. Reconnec t batter y ground l ead.

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

12. Check throttle cable adjustment, refer

3.10, FUEL CONTROL SYSTEM – Throttle

Cable Adjust in this Section.

Figure 6C2-3-48

13. Check cruis e control c able adj ustm ent, Refer to Section 12E, C RUISE CONT ROL in the MY 200 3 VY and V2

Series Service Information.

14. Reinstall engine dress cover to the inlet manifold, ensuring that stud grommets in the dress cover remain in

place.

15. Tighten securing dome nuts to the correct torque specification.

ENGINE DRESS

COVER DOME NUT

TORQUE SPECIFICATION 4 – 6 Nm

THROTTLE BODY IAC VALVE COUNT CHECKING PROCEDURE

1. Start engine and run until normal operating temperature (85° C) is reached.

2. Ensure transmission is in Park or Neutral.

3. Turn off all accessories (A/C, radio etc.)

4. Install Tech 2 and display Engine Data.

5. Confirm the IAC valve counts are at 15 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

tampered with. If the Throttle Stop Screw has not been tampered with, replace the throttle body.

3.12 RAIL AND INJECTORS

LT Section No. – 03-375

IMPORTANT: The fuel inlet hose is an integral part of the fuel rail. Both components are NOT serviced separately.

REMOVE

1. Relieve fuel pressure Refer 3.1 FUEL PUMP RELAY – Fuel Pressure Relief Procedure in this Sect ion.

2. Dis c onnect batter y ground l ead.

3. Thoroughly clean around injector to intake manifold ports, using compressed air.

CAUTION: Always wear eye protection when using compressed air to clean around components such as

these, to avoid eye damage!

4. Remove four dome nuts securing the engine dress cover assembly to the inlet manifold studs, lift off and

remove t he cover assembly.

5. Remove alternator bracket.

6. Use Tool No. 7371 for the fuel supply (1) and

7370 for the fuel return quick connectors (3).

Open, then close over the fuel line to be

disconnected (view ‘A’)

7. While pushing on the quick connect with one

hand, push the release tool into the quick

connect with the other. Pull back on the quick

connect to disconnect.

8. Repeat for the other line, then plug all

openings to prevent foreign matter entry.

Figure 6C2-3-49 – Fuel Line Connections

9. Remove vacuum hose from fuel pressure

regulator (4).

10. Disconnect fuel pr es sur e r e gulator ( 4) f r om fuel

rail (5). Refer to Fuel Pressure Regulator in

this Section.

11. Disconnect electrical connectors from injectors.

12. Remove four nuts (2), and one bolt (1),

securing fuel rail (5) to supercharger body.

13. Remove fuel rail assembly (5) from

supercharger.

Figure 6C2-3-50 – Supercharged Engine Fuel Rail

14. Remove injector retaining clips. Withdraw

injectors from fuel rail.

IMPORTANT: During the servicing process, to

prevent dirt and other contaminants from entering

the fue l pass ages, cap all f ittings and plug all h oles

with clean shop rag.

Figure 6C2-3-51 – Fuel Injector Installation

REINST ALL

Reinstallation is the reverse to the removal process, except for the following:

1. Reinstall each fuel injector to the fuel rail, using new O-rings, lubricated with a smear of clean engine oil.

2. Reinstall the fuel rail to the supercharger body, securing with four nuts and one bolt, tightening to the correct

torque specification.

FUEL RAIL ATTACHING BOLT

TORQUE SPECIFICATION 20 – 30 Nm

FUEL RAIL ATTACHING NUT

TORQUE SPECIFICATION 8 – 12 Nm

3. Reinstall connectors to fuel injectors, checking that each is securely installed.

4. Re- c onnect eac h f ue l h os e quick connec t to the c orr ec t dash panel c o nnec t or. While holding the pipe, p us h t h e

quick connect onto the pipe until a click is heard. Tug on each to ensure that the connection is secure.

NOTE: The tagged line and hose are on the fuel return.

5. Reinstall the fuel pressure regulator to the fuel rail.

6. Reinstall the vacuum hose to the fuel pressure regulator.

7. Reinstall the alternator bracket, tightening the fasteners to the correct torque specification.

GENERATOR BRACKET

BOLT AND NUT

TORQUE SPECIFICATION 40 – 60 Nm

8. Reinstall battery ground cable.

9. With Tech 2 connected, command Fuel Pump "ON", using Output Test and inspect fuel system for leaks.

10. Reinstall engine dress cover to the inlet manifold, ensuring that stud grommets in the dress cover remain in

place. Tighten securing dome nuts to the correct torque specification.

ENGINE DRESS COVER

DOME NUT

TORQUE SPECIFICATION 4 – 6 Nm

3.13 IDLE AIR CONTROL VALVE

LT Section No. – 03-300

REMOVE

1. Dis c onnect batter y ground l ead.

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

IAC valve (1).

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: When insta lling a n ew IAC va lve, be

sure it has the correct part number.

Figure 6C2-3-52 – IAC Valve Removal

IMPORTANT: Before installing a new IAC valve,

measure distance "A" between tip of valve pintle

and the flange mounting surface. If it is greater

than 28 mm, it m us t be reduc ed to prevent d amage

to the valve when it is installed.

Figure 6C2-3-53 – IAC Measured Distance

6. To reduce the length of the pintle extension,

exert firm pressure on valve pintle to retract it.

(A slight side-to-side movement may be

helpful).

Figure 6C2-3-54 – IAC Retraction Method

REINST ALL

1. Lubr icate IAC valv e O-ring with li ght engine oil.

If necessary, in stall on to valve assembly.

2. Reinstall IAC valve (1) into throttle body with

wiring harness connector (3) facing up, as

shown.

3. Install IAC valve attaching screws (2) and

tighten to the correct torque specification.

IAC VALVE TO THROTTLE

BODY SCREW

TORQUE SPECIFICATION 1.0 – 1.5 Nm

4. Reinstall the IAC valve wiring harness

connector (3).

5. Reinstall battery ground lead.

6. If required, clear any DTC’s using Tech 2.

7. Start engine, and allow engine to run for 5

seconds then turn engine OFF to "Reset" the

IAC valve; OR

Use Tech 2. Select ‘IAC RESET’ to reset 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.

ENGINE DRESS

COVER DOME NUT

TORQUE SPECIFICATION 4 – 6 Nm

Figure 6C2-3-55 - IAC Valve Reinstall

3.14 THROTTLE PEDAL ASSEMBLY

GENERA L DESCRIPTION

The s ervice operations f or the throttle pedal ass emblies for MY 2003 VY and V2 Series vehicles fitted with V6 S/C

engines is the same as vehicles with V6 engines, refer to Section 6C1-3, 3.14 THROTTLE PEDAL ASSEMBLY.

NOTE: There are differences in the throttle cable adjustment procedures for the various engines available. The

service procedure for the throttle pedal assembly does not require the throttle cable adjustment to be altered.

However, if throttle cable adjustment is required, refer to the correct Section for the appropriate engine option.

4. DIRECT IGNITION SYSTEM (DIS)

4.1 GENERAL SERVICE INFORMATION

TIMING ADJUSTMENT

The Direc t Ignition S ystem ( DIS) system fully contro ls the spark tim ing. No adjust ment for s park timing is pr ovided.

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 Tech 2 is used,

and B y-Pass m ode is s elec ted. T o chec k for EST operatio n, ru n the e ngine with t he thr ottle f ixed at a stea dy 1,60 0

– 1,800 rpm , then enter the "By-Pass" m ode of oper ation, using T ech 2. If the engin e speed cha nges (drops ), EST

spark timing is operating. An EST system fault will set a DTC. Use appropriate DTC Table in 6C2-2A to correctly

diagnose the system .

4.2 IGNITION COIL/S

LT Section No. – 02-225

REMOVE

1. Dis c onnect batter y ground l ead.

IMPORTANT: Disconnection of the battery affects certain vehicle electronic systems. Refer to Section 00

CAUTIONS, 5. Battery Disconnection Procedures before disconnecting the battery.

2. Remove spark plug leads from coil towers,

noting lead numbering with reference to coil

tower numbers.

NOTE 1: Slightly twist spark plug leads before

removing from coil towers

NOTE 2: All sp ar k plug leads and c o il terminals ar e

number ed to c orr espond to the cylinder n umbering.

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) from module (3), taking care not

to bend module terminals.

5. Install coil(s) (2) onto module (3), aligning

module terminals with mating slots on

underside of coil.

6. Reins t al l c oi l sec uri ng s c rews ( 1) a nd t ig hten to

the correct torque specification.

DIS IGNITION COIL TO MOUNTING

PLATE SCREW

TORQUE SPECIFICATION 5.0 Nm

7. Reconnect spark plug leads (3) to coil

term inals, ensuring correct lead to coi l term inal

relationship.

8. Reconnect battery ground lead, start engine

and ensure eng ine operate s corr ectl y.

Figure 6C2-3-56 – Ignition Coil To Module.

TEST

1. Visually inspect the removed coil/s for any

signs of external damage or spark tracking.

2. Using a Digital Multimeter (DMM) set to

resistance, measure the coil primary winding

resistance by probing into terminals from the

underside of the coil assembly.

IGNITION PRIMARY WINDING

RESISTANCE SPECIFICATION 0.3 – 1.5 Ω

NOTE: Some DMM lead probes may be too large

to contact the primary winding connections inside

the coil housing. If this is the case, use a suitable

size test terminal from J35616-A Connector Test

Adaptor Kit.

Figure 6C2-3-57

3. Check the resistance of the coil secondary

windings to ensure that the reading is within

specifications.

IGNITION SECONDARY WINDING

RESISTANCE SPECIFICATION 5,000 – 7,000 Ω

4. Replace any coil assembly whose primary

and/or secondary winding resistances are

outside the specified levels.

Figure 6C2-3-58

REINST ALL

1. Reinstall coil/s (2) onto module (4), aligning

module terminals with mating slots on

underside of coil.

2. Reins t al l c oi l sec uri ng s c rews ( 1) a nd t ig hten to

the correct torque specification.

DIS IGNITION COIL TO

MOUNTING PLA TE SCREW

TORQUE SPECIFICATION 5.0 Nm

3. Reconnect spark plug leads (3) to coil

term inals, ensuring correct lead to coi l term inal

relationship.

4. Reconnect battery ground lead, start engine

and ensure eng ine operate s corr ectl y.

Figure 6C2-3-59 – Ignition Coil To Module

4.3 DIS MODULE

LT Section No. – 02-225

REMOVE

Figure 6C2-3-60

Legend

1. Bolt (tighten first)

2. DIS Module and Ignition Coils Assembly

3. Bolt (tighten third)

4. Drive Belt Tensioner Assembly Bracket

5. Bolt (tighten second)

6. Left Hand Cylinder Head

1. Dis c onnect batter y ground l ead.

2. Remove all spark plug leads from coil towers

(1), noting lead numbering with reference to

coil towers numbers.

NOTE 1: Slightly twist spark plug leads before

removing from coil towers

NOTE 2: All sp ar k plug leads and c o il terminals ar e

number ed to c orr espond to the cylinder n umbering.

On service replacement coils, the cylinder

numbering does not appear on top of any coil

assembly, refer to cylinder numbering on the

module.

3. Loosen screw attaching 14-pin wiring harness

connector (3) to module until you can pull

connector from module.

4. Remove bolts securing the DIS module and

coil assembly, to the left hand cylinder head

(refer Figure 6C2-3-58). Place the DIS module

and coil assembly carefully to one side.

5. Remove coils from module, taking care not

to bend module terminals. Refer to

4.2 IGNITION COIL/S, Remove in this Section.

Figure 6C2-3-61 – DIS Ignition Module Remove

REINST ALL

1. When replacing a DIS module assembly, remove module to coil terminal and 14 pin harness connector terminal

seals from original module. Install onto new module, taking care not to damage seals. If any seals is/are

damaged, replace with new parts.

2. Place coils onto module, aligning module terminals with mating slots on underside of coil. Refer to

4.2 IGNITION COIL/S, Reinstall, in this Section.

3. Reinstall ignition module assembly (5) to mounting plate, locating raised lugs (2) on both module and plate

together.

NOTE: T he lugs on t he un derside of the m odule will onl y mate with the m ounting plate ho les i n one way, to e nsure

correct assembly relationship.

4. Reinstall screws (3) securing coils and module to mounting plate and tighten in the sequence described in

Figure 6C2 – 3 - 68 and to the correct torque specification.

DIS IGNITION COIL TO MOUNTING

PLATE SCREW

TORQUE SPECIFICATION 4.0 – 5.0 Nm

5. Reinstall DIS module and coil assembly to the left hand cylinder head, securing with the two retaining bolts,

tightened to the correct torque specification.

DIS MODULE AND COIL ASSEMBLY

MOUNTING BOLT

TORQUE SPECIFICATION 40 – 50 Nm

6. Reconnect spark plug leads to coil terminals, ensuring correct lead to coil terminal relationship.

7. Reconnect 14-pin wiring harness connector to module assembly and tighten attaching screw to the correct

torque specification.

DIS MODULE HARNESS

CONNECTOR SCREW

TORQUE SPECIFICATION 0.6 – 1.2 Nm

8. Snap powertrain wiring harness retainer onto coil and module assembly and it's mounting plate.

9. Rec onn ec t batter y ground l ead.

10. Start engine and ensure engine operates correctly.

4.4 CR ANKSHAFT SENS OR

LT Section No. – 02-000

REMOVE

1. Remove battery ground lea d.

2. Remove the four dome nuts securing the engine dress cover, then remove the cover assembly.

3. Remove both engine accessory drive belts. Refer 2.9 SUPERCHARGER DRIVE BELT in Section 6A1-2

ENGINE MECHANICAL – V6 SUPERCHARGED ENGINE for the outer belt and 2.7 DRIVE BELT, in Section

6A1-1 ENGINE MECHANICAL V6 ENGINE, for the inner belt.

4. Remove the crankshaft balancer.

5. Disconnect the crankshaft position sensor

connector (2) by using a fine bladed

screwdriver to lever the locking tang away (1)

from the sensor, then pull on the conn ector (2)

to remove.

Figure 6C2-3-62

6. Rem ove the s ensor shie ld by car efull y leveri ng

each corner from the front cover studs, then

move the shield to and fro until it comes clear.

Figure 6C2-3-63

7. Remove the studs (1) that attach the sensor (2)

to the front cover (3).

8. Rem ove the sensor ( 2) from the f ront cover (3)

and carefully set to one side.

Figure 6C2-3-64

REINST ALL

1. Using a suitable tap, clean the threads in the

front of the cylinder block of old sealant.

2. Reins tall the s ensor onto the f ront cover dowel

pin.

3. Apply Loctite 242 or equivalent to the cleaned

sensor mounting stud threads.

4. Reinstall the attaching studs and tighten to the

correct torque specification.

SENSOR TO FRONT COVER

TORQUE SPECIFICATION 25 Nm

5. Reinstall the shield onto the front cover studs,

ensuring that the shield retainers are fully

engaged over the ends of the studs.

6. Reinstall the wiring harness connector to the

sensor, ensuring that the locking tang is fully

engaged.

7. Visually inspect the interrupter rings mounted

on the rear of the crankshaft balancer, for any

damage or distortion. Replace the crankshaft

pulley if damage or distortion is found.

Figure 6C2-3-65

8. Reinstall the crankshaft pulley. Refer to

2.19 CRANKSHAFT BALANCER in Section

6A1-1 ENGINE MECHANICAL – V6 ENGINE.

NOTE: Do not install the drive belts at this stage.

9. Rotate the crankshaft to check that the

interrupter rings do not contact the sensor. If

contact is made with the sensor at any point

then the rings are distorted, requiring balancer

replacement.

10. Reinstall the engine accessory drive belts.

Refer 2.7 DRIVE BELT, in Section 6A1-1

ENGINE MECHANICAL V6 ENGINE, for the

inner belt and 2.9 SUPERCHARGER DRIVE

BELT in Section 6A1-2 ENGINE

MECHANICAL – V6 SUPERCHARGED

ENGINE for the outer belt.

11. Reinstall the en gine dres s cover , tighte ning the

domed retaining nuts to the correct

specification.

ENGINE DRESS

COVER DOME NUT

TORQUE SPECIFICATION 4 – 6 Nm

12. Reinstall the battery ground lead.

13. Start the engine and ensure that the engine

operates correctly.

Figure 6C2-3-66 Camshaft/Crankshaft Position Sensors

Legend

1. Camshaft Sprocket

2. Camshaft Sensor Interrupter Magnet

3. Front Cover

4. Camshaft Sensor

5. Crankshaft Sensor

4.5 KNOCK SENSORS

LT Section No. – 02-000

CHECKING KNOCK SENSOR OPERATION

The PCM's knock sensor input will reduce t he EST spark advance wh en detonati on is present. T his sensor signals

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

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

To c heck the "knock retard" f unc tion of the i gn ition system, run the engi ne with t he throttle fixed at a ste ady 1,600 –

1,800 RPM, quickly and repeatedly ‘rap' on the engine block, cylinder head, or intake manifold with a small

hamm er. T he engine spee d shoul d drop, due t o the ti m ing advanc e being re duc ed. W hen you stop ‘rapp ing' on the

engine, the engine speed should return to the original level.

CAUTION: Each knock sensor screws into the cylinder block coolant jacket. If the engine coolant is hot,

take extreme caution to prevent personal injury caused by hot coolant draining from the cylinder block.

REMOVE

NOTE: Exercise extreme care when handling knock sensors. To avoid visually undetectable damage, do not drop a

knock sensor.

1. Allow the engine to cool to ambient temperature (less than 50° C), then carefully remove the radiator cap.

2. Place a clean container (of at least 12 litres capacity) under the engine for the engine coolant to drain into.

NOTE: To reduc e t he impact on the en vir o nment and maintenance costs , whe ne ver t he c o ola nt is drained f r om the

engine, the service records are to be checked to determine when the coolant was last changed. If more than six

months life is lef t before th e next coolan t change, t hen the dr ained coola nt can b e re-used. For further inform ation,

refer to Section 6B2 ENGINE COOLING – V6 SUPERCHARGED.

3. Drain engine coolant into drain tray by disconnecting radiator lower hose (1) from the front cover connection.

4. Raise the fr ont of the vehicl e and support with s afety stands. Ref er to Section 0A GENERAL INFORMATION,

in the MY 2003 VY and V2 Series Service Information for details of jacking points.

5. Identify the correct wiring harness connector

(1) (oval s haped), v iew ‘A’. Do not c onfus e with

the oil pressure sensor connector (2), view ‘B’.

6. Squeeze t he 'wide ends' of the c onnector, then

pull to release the connector from the sensor.

NOTE: While the right hand sensor is detailed, the

procedure for the left hand sensor is similar.

Figure 6C2-3-67

7. Remove the bolts that attach the heat shield (3 or 8).

8. Remove the heat shield/s (2 or 5).

9. Place a suitable drain tray beneath the engine.

10. Loosen, the n remove the s ensor from the cylinder block, using a 22 m m socket with uni versal joint a nd socket

extension bars.

CAUTION: Take extreme care to avoid scalding from residual hot coolant draining from the sensor hole.

Figure 6C2-3-68

Legend

1. Lef t Hand Kn ock Senso r

2. Knock Sensor Shield LHS

3. Attaching Bolts

4. Wiring Harness Connector

5. Knock Sensor Shield RHS.

6. Right Hand Knock Sensor

7. Wiring Harness Connector

8. Attaching Bolts

REINST ALL

1. Check that the sensor threads are undamaged.

2. If the original sensor is being reinstalled, clean the old sealant from the sensor threads and apply a light coating

of Loctite 242 or equivalent.

NOTE: The threads on a new sensor are c oated with a seala nt during product ion. Do not appl y additio nal sealant.

This will reduce the effectiveness of the sensor.

3. Reinstall the sensor, then tighten to the correct torque specification. Do not over-tighten.

KNOCK SENSOR

TORQUE SPECIFICATION 16 – 22 Nm

4. Reconnect the wiring harness connector to the sensor, ensuring that the connector is securely fitted onto

sensor.

5. Reins tall the k nock sensor heat shiel d, securing with t wo attaching bolts for each shield . Tighten to the cor rect

torque specification.

HEAT SHIELD

ATTACHING BOLT

TORQUE SPECIFICATION 25 – 35 Nm

6. Refill the cooling system and test coolant concentration.

7. Pressure test the cooling system for leaks. Refer to Section 6B2 ENGINE COOLING – V6 SUPERCHARGED.

8. Reconnect the battery ground lead, start the engine and check for coolant leaks and correct engine operation.

4.6 SPARK PLUG LEADS

LT Section No. – 02-030

REMOVE

NOTE: Pulling or bend ing s park plug leads c an cause hidden damage. F ollo w the rem oval steps caref ully to a void

damage.

1. Firmly grasp the boot at the end of the spark plug lead, both at the spark plug and the coil end.

NOTE: Grasp the boot, not the cable.

2. Twist the boot in both directions to relieve any suction and to break the seal.

3. Pull the boot straight off the spark plug and ignition coil.

4. Repeat this procedure for each spark lead at both the spark plug and the coil ends.

5. Carefully remove the spark plug leads from the support brackets and lift from the engine.

Figure 6C2-3-69 – Spark Plug Lead Routing and Security – V6 Supercharged Engine

Legend

1. Spark Plug Lead Support Bracket

2. Clip – Spark Plug Lead Support Bracket

3. Dipstick Tube Bracket

4. Harness Retainer

5. Ignition Coil and DIS Module Tab

BENCH TESTING SPARK PLUG LEADS

1. Connect an ohmmeter capable of reading to 50 kilohms to each end of the lead.

2. Record the reading of each lead.

3. Measure and record the length of each lead.

4. For each lead, calculate the resistance over 30 cm.

5. Compare the resistance reading of each lead to the specification.

‘ELECTRICFIL’ SPARK PLUG LEAD

RESISTANCE per 30 cm 475 Ohms

6. Replace any lead/s with resistance values that are significantly different from the specification.

REINST ALL

IMPORTANT: Ens ure tha t all lea ds are c or rec tl y route d and fit each to its c or res pond ing s par k plug an d the ignit io n

coil post.

Figure 6C2-3-70 - Spark Plug Numbering

Legend

1. Right Hand Spark Plug Lead Harness Assembly

2. Ignition Coil and DIS Module Assembly

3. Left Hand Spark Plug Lead

1. As with th e rem oval proc ess, alwa ys hand le the lea ds b y each boot an d push squ arel y onto the spark plug and

ignition coil post.

2. Reinstall the spark plug leads to their respective support, ensuring that each is pushed firmly to each support.

4.7 SPAR K PLUGS

LT Section No. – 02-030

REMOVE

1. Remove spark plug leads from each spark plug, remembering to only grasp the lead boot and twist in both

directions to relieve any suction and to break the seal.

2. Pull the boot straight off the spark plug.

3. Repeat this procedure for each spark lead.

4. Using a jet of compressed air remove any foreign material from around each spark plug cavity.

CAUTION: Use eye protection during this operation to prevent eye damage

5. Using a 16 mm spark plug socket and suitable equipment, loosen then remove each spark plug.

IMPORTANT: Af ter spark plug removal, place each in order of rem oval. This will enable an y a bnormal spark plug

condition to be identified with the correct cylinder.

6. Plug all spark plug holes in each cylinder head to prevent foreign material ingress.

CLEANING AND INSPECTION

1. Replace any plug that has cracked insulation,

broken insulation or loose electrodes.

2. Clean any oil from the plugs using a

degreasing agent.

3. Dry the plugs using compressed air.

4. Clean the spark plugs as per the

manufacturer's instructions using a purpose-

built machine (sand blasting type).

5. Inspect the spark plugs for defects. Refer to

4.7 SPARK PLUGS, Spark Plug Diagnosis in

this Sec tion for identificat ion of the c ondition of

spark plugs.

6. Ensure that the threads are clean and in good

order.

7. Use a round wire feeler gauge to check the

spark plug gap.

8. Adjust the gap to the correct specification by

gently bendi ng the out er elec trode.

Figure 6C2-3-71

SPARK PLUG GAP

V6 SUPERCHARGED ENGINE 1.3 mm

REINST ALL

1. Remove the rag/s from the spark plug holes.

2. Fit each spark plug carefully to avoid

damaging the thread.

3. Tighten the plugs to the correct torque

specification using a 16 mm spark plug socket.

SPARK PLUG

TORQUE SPECIFICATION 15 – 25 Nm

4. Reinstall spark plug leads to all spark plugs

after installation.

SPARK PLUG DIAGNOSIS

Poor Spark Plug Per formance

A spark plug can perform poorly due to wear, dirt, ca rbon fouling, excessive electrode wear, a broken insulator or

excessive gap.

NOTE 1: When re-gapping a spark plug, always make the gap adjustment by bending the ground (side) electrode.

NOTE 2: When replacing spark plugs, use genuine spark plugs or recommended of the correct heat range.

Worn or Dirty Plugs

Worn or dirty plugs can give satisfactory operation while the vehicle is idling, but break down under load.

This can cause:

•

••

•

poor fuel economy

•

••

•

power loss

•

••

•

acceleration loss

•

••

•

difficult starting

•

••

•

gener al l y poor engin e perf o rmance.

Carbon Fouling

Carbon fouling is indicated by black carbon deposits. The black deposits are usually the result of slow-speed

driving and short runs. In these circumstances, the optimum engine operating temperature is seldom reached.

Fouling can also be caused by:

•

••

•

worn piston rings

•

••

•

f ault y ignit ion

•

••

•

rich fuel mixture

•

••

•

spark plugs that are rated too cold.

Excessive Ele c trod e We a r

This often indicates:

•

••

•

the engine is operating at high speeds

•

••

•

the engine is operating at levels that are consistently greater than normal

•

••

•

a plug that is rated too hot

•

••

•

excessively lean fuel mixture

•

••

•

plug/s overheating due to insufficient tightening (caused by combustion gases leaking past the threads).

Broken Insulator

IMPORTANT: Do not use a spark plug with a broken insulator.

Broken insulators are usually the result of improper installation or carelessness.

Breaks in the upper insulator can result from a poor fitting spark plug socket or an outside blow. The cracked

insulator m a y not show up until oil or mois ture penetra tes the crac k. T he crack is often jus t below the c rimpe d part

of the shell and may not be visible.

Break s in the lo wer insu lator often r esult f rom c areles s re- gapping and ar e usua lly vis ible. T his can als o res ult f rom

the plug operating too hot. For example, in periods of high speed operation or under heavy loads.

ANALYSIS OF SPARK PLUG CONDITION

Figure 6D1-3-72

Legend

1. Normal 5. Deposit fouling B 8. Pre-ignition

2. Carbon fouled 6. Deposit fouling C 9. Heated shock failure

3. Oil fouled 7. Detonation 10. Insufficient installation torque

4. Deposit fouling A

Normal Operation (1)

Brown or greyish-tan deposits and slight e lectrode wear indicate correct spark plug heat ra nge and mixed periods

of high and low speed driving.

Carbon Fouled (2)

Dry, fluffy black carbon deposits possibl y due to poor ignition output, weak coil, faulty spark plug leads, excessive

idling, s low sp eeds under light load. If spar k plu g temperatures rem ain t oo lo w for norm al com bus tion, the depos its

are not burned off.

Oil Fouled (3)

Wet, oily deposits with minor electrode wear possibly due to oil leaking past worn piston rings.

Breaking in a new or recently overhauled engine before the rings are fully seated may also result in this condition.

Deposit Fouling A (4)

Red brown, yellow and white coloured coatings on the insulator tip which are by-products of combustion. They

come from the fuel and the lubricating oil which generally contain additives. Most powdery deposits have no

adverse effect on spark plug operation; however, they may cause intermittent missing under severe operating

conditions.

Deposit Fouling B (5)

Deposits sim ilar to t hose identif ied in Depos it f oulin g A ( 4). T hese are a lso by-pro ducts of com bus tion fr om the f uel

and lubric ating o il. Exc essive val ve stem clearanc es and/or def ective int ake valve seals allow too m uch oil t o enter

the combustion chamber. The deposits will accumulate on the portion of the spark plug that projects into the

cham ber and will be hea vie st on th e side f acing the int ak e valve. W hen you detec t this c ondi tion i n onl y one or two

cylinders, check the seals.

Deposit Fouling C (6)

Most powd ery deposits identified in Deposit f ouling A (4) have no advers e effec t on the operation of the spark plug

as long as they remain powdery.

Under cert ain cond it ions of oper at io n ho we ver , t hes e d epos its melt a nd f orm a s hin y gl a ze coat in g o n th e ins ulat o r.

W hen hot, this acts as a g o od e lec tric a l conduct or a llo wing th e c urr ent to f lo w al o ng t he dep os it ins t ead of s par k ing

across the gap.

Detonation (7)

Commonly referred to as engine knock or ‘pinging’, detonation causes severe shocks inside the combustion

chamber causing damage to parts.

Pre-ignition (8)

Burnt or blistered insulator tip and badly eroded electrodes probably due to the excessive heat.

This is often caused by a cooling system blockage, sticking valves, improperly installed spark plugs or plugs that

are the wrong heat rating (too hot).

Sustained high speed with a heavy load can produce temperatures high enough to cause pre-ignition.

Heat Shock Failure (9)

A rapid increase in spark plug tip temperature under severe operating conditions can cause heat shock and result

in fractured insulators. This is a common cause of broken and cracked insulator tips.

Insufficient Installation Torque (10)

Poor contact between the spark plug and the cylinder head seat.

The lac k of proper he at transf er that results f rom poor s eat contact ca uses overheati ng of the sp ark plug. In many

cases, severe damage occurs, as shown.

Dirty threads in the cylinder head can cause the plug to seize before it is seated.

IMPORTANT: The recommended installation torque may be obtained before the taper seat engages with the

cylinder hea d.

Ensure that the cylinder head and spark plug threads are free of deposits, burrs and scale before installation.

5. AUTOMATIC TRANSMI SSI ON

LT Section No. – 04-275

5.1 1-2 SHIFT SOLENOID ‘A’

Figure 6C2-3-73 – 1-2 Shift Solenoid Location

REMOVE

1. Dis c onnect batter y ground l ead.

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

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the MY 2003

VY and V2 Series Service Information.

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

4. Place drain tray under transmission.

5. While supporting the oil pan, remove the oil pan bolts from the front and both sides.

6. Loos en the r e ar oi l p an b olts b y about 4 turns each and, while st il l s upp orti ng th e oil pan, light ly tap the sides of

the oil pan with a rubber hammer to break the gasket seal.

7. Lower the front of the oil pan and drain the fluid into a suitable container, then remove the rear oil pan bolts

completely and remove the oil pan from the transmission.

8. Remove old oil pan gasket and discard.

9. Remove the fluid filter. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in Section 7C4

AUTOMATIC TRANSMISSION -–ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

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

11. Remove solenoid retainer (395) by using a small flat blade screwdriver. Pry the retainer down until it can be

grasped.

NOTE: The 1–2 shift solenoid has a slight spring pressure behind it, and may pop out on its own after retainer is

removed.

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

REINST ALL

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

2. Hold sole no id in plac e with finger pressur e whi le insta ll ing retai ner (395) .

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

4. Install new fluid filter and seal. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in Section 7C4

AUTOMATIC TRANSMISSION -–ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

5. Clean oil pan and case mating surfaces. Check that magnet is still magnetised, and attached to the oil pan.

6. Install new oil pan gasket and reinstall oil pan and retaining bolts, tightening to the correct torque specification.

TRANSMISSION OIL PAN BOLTS

TORQUE SPECIFICATION 11 Nm

7. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.

8. Rec onn ec t batter y grou nd lead.

9. Check transmission fluid level. Refer to "Fluid Checking Procedure" in this Section 7C4.

5.2 2-3 SHIFT SOLENOID ‘B’

LT Section No. – 04-275

Figure 6C2-3-74 – 2-3 Shift Solenoid Location

REMOVE

1. Dis c onnect batter y ground l ead.

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

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the MY 2003

VY and V2 Series Service Information.

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

4. Place drain tray under transmission.

5. While supporting the oil pan, remove the oil pan bolts from the front and both sides.

6. Loos en the r e ar oi l p an b olts b y about 4 turns each and, while st il l s upp orti ng th e oil pan, light ly tap the sides of

the oil pan with a rubber hammer to break the gasket seal.

7. Lower the front of the oil pan and drain the fluid into a suitable container, then remove the rear oil pan bolts

completely and remove the oil pan from the transmission.

8. Remove old oil pan gasket and discard.

9. Remove the fluid filter. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in Section 7C4

AUTOMATIC TRANSMISSION -–ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

10. Disconnect 2–3 shift solenoid (367B) electrical connector.

11. Remove solenoid retainer (395) by using a small flat blade screwdriver. Pry the retainer down until it can be

grasped.

NOTE: The 2–3 shift solenoid has a slight spring pressure behind it, and may pop out on its own after retainer is

removed.

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

REINST ALL

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

2. Hold sole no id in plac e with finger pressur e whi le insta ll ing retai ner (395) .

3. Reconnect 2–3 shift solenoid (367B) electrical connector.

4. Install new fluid filter and seal. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in Section 7C4

AUTOMATIC TRANSMISSION – ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

5. Clean oil pan and case mating surfaces. Check that magnet is still magnetised, and attached to the oil pan.

6. Install new oil pan gasket and reinstall oil pan and retaining bolts, tightening to the correct torque specification.

TRANSMISSION OIL PAN BOLTS

TORQUE SPECIFICATION 11 Nm

7. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.

8. Rec onn ec t batter y grou nd lead.

9. Check transmission fluid level. Refer to "Fluid Checking Procedure" in this Section 7C4.

5.3 3-2 CONTROL SOLENOID

LT Section No. – 04-275

Figure 6C2-3-75 – 3-2 Shift Solenoid Location

REMOVE

1. Dis c onnect batter y ground l ead.

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

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the MY 2003

VY and V2 Series Service Information.

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

4. Place drain tray under transmission.

5. While supporting the oil pan, remove the oil pan bolts from the front and both sides.

6. Loos en the r e ar oi l p an b olts b y about 4 turns each and, while st il l s upp orti ng th e oil pan, light ly tap the sides of

the oil pan with a rubber hammer to break the gasket seal.

7. Lower the front of the oil pan and drain the fluid into a suitable container, then remove the rear oil pan bolts

completely and remove the oil pan from the transmission.

8. Remove old oil pan gasket and discard.

9. Remove the fluid filter. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in Section 7C4

AUTOMATIC TRANSMISSION -–ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

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

11. Remove solenoid retainer (395) by using a flat blade screwdriver.

NOTE: The 3-2 control solenoid has spring pressure behind it and may pop out after retainer is removed.

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

REINST ALL

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

2. Hold solenoid firmly in place with finger pressure while installing retainer (395).

3. Reconnect 3-2 control solenoid electrical connector.

4. Install new fluid filter and seal. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in Section 7C4

AUTOMATIC TRANSMISSION – ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

5. Clean oil pan and case mating surfaces. Check that magnet is still magnetised, and attached to the oil pan.

6. Install new oil pan gasket and reinstall oil pan and retaining bolts, tightening to the correct torque specification.

TRANSMISSION OIL PAN BOLTS

TORQUE SPECIFICATION 11 Nm

7. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.

8. Rec onn ec t batter y grou nd lead.

9. Check transmission fluid level. Refer to "Fluid Checking Procedure" in this Section 7C4.

5.4 PRESSURE CONTROL SOLENOID

LT Section No. – 04-275

REMOVE

1. Dis c onnect batter y ground l ead.

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

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the MY 2003

VY and V2 Series Service Information.

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

4. Place drain tray under transmission.

5. While supporting the oil pan, remove the oil pan bolts from the front and both sides.

6. Loos en the r e ar oi l p an b olts b y about 4 turns each and, while st il l s upp orti ng th e oil pan, light ly tap the sides of

the oil pan with a rubber hammer to break the gasket seal.

7. Lower the front of the oil pan and drain the fluid into a suitable container, then remove the rear oil pan bolts

completely and remove the oil pan from the transmission.

8. Remove old oil pan gasket and discard.

9. Remove the fluid filter. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in 7C4 AUTOMATIC

TRANSMI SSIO N -–ON -V E HICLE SER VICING, in the MY 2003 VY and V2 Series Service Inf ormation.

10. Remove thr e e 1- 2 ac cumulator cover b olts ( 5 8)

(59)

NOTE: Accumulator will be full of fluid.

11. Remove 1–2 accumulator cover assembly (57).

12. Remove pressure control solenoid (377)

electrical connector.

13. Rem ove pressure con trol sole noid retainer bolt

(364A), then retainer (378).

14. Remove pressure control solenoid assembly

(377).

Figure 6C2-3-76 – Pressure Control Solenoid Location

REINST ALL

1. Reins tall sol eno id ass embly (37 7).

NOTE: Solenoid has a flat cut out on one side of it's retaining flange that goes toward retaining bolt. Solenoid

retainer has a matching flat to allow the retainer to be correctly installed

2. Reinstall solenoid retainer (378).

3. Reinstall solenoid retainer bolt (364A), tightening to the correct torque specification.

SOLENOID RETAINER BOLT

TORQUE SPECIFICATION 11 Nm

4. Reinstall pressure control solenoid electrical connector.

5. Reinstall 1–2 accumulator cover assembly (57).

6. Reinstall accumulator cover bolts (58) (59) and tighten to the correct torque specification.

ACCUMULATOR COVER BOLT

TORQUE SPECIFICATION 11 Nm

7. Install new fluid filter and seal. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in 7C4

AUTOMATIC TRANSMISSION -–ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

8. Clean oil pan and case mating surfaces. Check that magnet is still magnetised, and attached to the oil pan.

9. Install new oil pan gasket and reinstall oil pan and retaining bolts, tightening to the correct torque specification.

TRANSMISSION OIL PAN BOLTS

TORQUE SPECIFICATION 11 Nm

10. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.

11. Reconnec t batter y ground l ead.

12. Check transmission fluid level. Refer to "Fluid Checking Procedure" in this Section 7C4.

Figure 6C2-3-77 – Pressure Control Solenoid Assembly

5.5 TRANSMISSION FLUID PRESSURE MANUAL VALVE SWITCH ASSEMBLY (TFP)

AND TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR

LT Section No. – 04-275

REMOVE

1. Dis c onnect batter y ground l ead.

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

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the MY 2003

VY and V2 Series Service Information.

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

4. Place drain tray under transmission.

5. While supporting the oil pan, remove the oil pan bolts from the front and both sides.

6. Loos en the r e ar oi l p an b olts b y about 4 turns each and, while st il l s upp orti ng th e oil pan, light ly tap the sides of

the oil pan with a rubber hammer to break the gasket seal.

7. Lower the front of the oil pan and drain the fluid into a suitable container, then remove the rear oil pan bolts

completely and remove the oil pan from the transmission.

8. Remove old oil pan gasket and discard.

9. Remove the fluid filter. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in Section 7C4

AUTOMATIC TRANSMISSION -–ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

1. Remove the Transmission Fluid Pressure

Manual Valve Position Switch Assembly (TFP)

retaining bolts.

2. Remove the TFP (69) and shield (106) from

the valve body.

Figure 6C2-3-78

REINST ALL

1. Reinstall transmission fluid pressure switch

assembly (69) and shield (106) to the control

valve body.

2. Install five (5) trans fluid pressure switch

assembly retaining valve body bolts (62 – ‘A’

and 70 – ‘D’). Starting at ‘1’ and work ing in the

pattern shown by the arrows, tighten bolts to

the correct torque specification.

TRANSMISSION FLUID

PRESSURE SWITCH BOLT

TORQUE SPECIFICATION 11 Nm

Figure 6C2-3-79

3. Reinstall transmission fluid pressure switch

assem bl y electrical connector.

4. Install new fluid filter and seal. Refer

3.1 FLUID CHANGE AND FILTER

REPLACEMENT, in Sec ti o n 7C 4 AUTOMAT I C

TRANSMISSION – ON-VEHICLE SERVICING,

in the MY 2003 VY and V2 Series Service

Information.

5. Clean oil pan and case mating surfaces.

Check that magnet is still magnetised, and

attached to the oil pan.

6. Install new oil pan gasket and reinstall oil pan

and retaining bolts, tightening to the correct

torque specification.

TRANSMISSION OIL PAN BOLTS

TORQUE SPECIFICATION 11 Nm

7. Lower vehicle and add approximately 4.8 litres

of DEXRON â III automatic transmission fluid.

8. Rec onn ec t batter y grou nd lead.

9. Check transmission fluid level. Refer to

"Fluid Checking Procedure" in this Section 7C4.

5.6 TCC "PWM" SOLENOID

LT Section No. – 04-275

REMOVE

1. Dis c onnect batter y ground l ead.

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

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the MY 2003

VY and V2 Series Service Information.

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

4. Place drain tray under transmission.

5. While supporting the oil pan, remove the oil pan bolts from the front and both sides.

6. Loos en the r e ar oi l p an b olts b y about 4 turns each and, while st il l s upp orti ng th e oil pan, light ly tap the sides of

the oil pan with a rubber hammer to break the gasket seal.

7. Lower the front of the oil pan and drain the fluid into a suitable container, then remove the rear oil pan bolts

completely and remove the oil pan from the transmission.

8. Remove old oil pan gasket and discard.

9. Remove the fluid filter. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in Section 7C4

AUTOMATIC TRANSMISSION – ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

10. Disconnect TCC "PWM" solenoid electrical connector.

11. Remove solenoid retainer (1) by using a flat

bladed screwdriver.

12. Remove TCC "PWM" Solenoid assembly (2)

with O-ring seal.

Figure 6C2-3-80 – TCC “PWM” Solenoid Location

REINST ALL

1. Reinstall TCC "PWM" Solenoid with O-ring assembly.

2. Reinstall TCC "PWM" Solenoid retainer.

3. Reinstall TCC "PWM" solenoid electrical connector.

4. Install new fluid filter and seal. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in Section 7C4

AUTOMATIC TRANSMISSION – ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

5. Clean oil pan and case mating surfaces. Check that magnet is still magnetised, and attached to the oil pan.

6. Install new oil pan gasket and reinstall oil pan and retaining bolts, tightening to the correct torque specification.

TRANSMISSION OIL PAN BOLTS

TORQUE SPECIFICATION 11 Nm

7. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.

8. Rec onn ec t batter y grou nd lead.

9. Check transmission fluid level. Refer to "Fluid Checking Procedure" in this Section. 7C4

5.7 TCC ENABLE SOLENOID & INTERNAL HARNESS ASSEMBLY

LT Section No. –

REMOVE

1. Dis c onnect batter y ground l ead.

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

transmission fluid is cold.

2. Raise vehicle and support on safety stands. Refer to Section 0A, GENERAL INFORMATION in the MY 2003

VY and V2 Series Service Information.

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

4. Place drain tray under transmission.

5. While supporting the oil pan, remove the oil pan bolts from the front and both sides.

6. Loos en the r e ar oi l p an b olts b y about 4 turns each and, while st il l s upp orti ng th e oil pan, light ly tap the sides of

the oil pan with a rubber hammer to break the gasket seal.

7. Lower the front of the oil pan and drain the fluid into a suitable container, then remove the rear oil pan bolts

completely and remove the oil pan from the transmission.

8. Remove old oil pan gasket and discard.

9. Remove the fluid filter. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in Section 7C4

AUTOMATIC TRANSMISSION – ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

10. Disconnect wiring harness connectors from all

electrical components, except the Torque

Converter Clutch (TCC) Solenoid (this solenoid

is hard wired and cannot successfully be

disconnected):

Legend:

1. Transmission Fluid Pressure Manual Valve

Position Switch Assembly (TFP).

2. 1-2 Shift Valve Solenoid.

3. 2-3 Shift Valve Solenoid.

4. Pressure Control Solenoid (PCS).

5. TCC Pulse Width Modulated (TCC PWM)

Solenoid.

6. 3-2 Control Solenoid.

NOTE: The security tang on the PCS (4), is located

at the rear of the connector.

Figure 6C2-3-81

11. Remove the TCC Pulse Width Modulated

(PWM) solenoid retainer clip (395), then the

solenoid (396).

NOTE: This step is necessary to allow access to

one of the TCC Enable Solenoid retaining bolts

underneath it.

Figure 7C2-3-82

12. Remove two bolts (68) holding the TCC

solenoid assembly.

Figure 7C2-3-83

13. Lift the TCC solenoid assembly from oil pump.

NOTE: If removal of the wiring harness/TCC

Solenoid from the transmission case is required, it

will not be pos sible until the control v alve body has

been removed.

Figure 7C5-84

14. As required, remove the control valve body

from the transmission, refer 1.6 CONTROL

VALVE BODY AND WIRING HARNESS, in

Section 7C5 AUTOMATIC TRANSMISSION –

UNIT REPAIR, in the MY 2003 VY and V2

Series Service Information.

15. Support the rear of the transmission, then

remove the rear crossmember and

engine mount. Refer 3.14 TRANSMISSION

ASSEMBLY, Remove, in Section 7C4

AUTOMATIC TRANSMISSION – ON-

VEHICLE SERVICING, in the MY 2003 VY

and V2 Series Ser v ice Infor mation.

16. Lower the rear of the transmission to provide

sufficient clearance (without placing undue

stress on any electrical wiring or engine cooling

system hoses) and remove the electrical

connector to the transmission, as follows:

NOTE: When lowering the rear of the

transmission, take care that the engine exhaust

manifold does not hit the firewall.

a. Roll back the dust boot from the pass-

through connector, to gain access to the

connector.

b. Squeeze the widest part of the connector

inwards ( bold arr o ws), the n pull DI RECTLY

UPWARDS.

IMPORTANT: Do not wriggle the connector

from side to side during the disconnection

process. If this does occur, there is a real

possibility of the connector pins being

permanently damaged.

Figure 6C2-3-85

17. 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: T his may be difficult due to the clearance of the floor pan transm ission tunnel and the transmission

case.

18. Using a suitable lever, pry downward on the top of the socket (or pipe) to compress the connector retaining

lugs, push the pass thru connector down, through and out of the transmission case.

REINST ALL

1. Coat TCC Ena ble So len oi d and pas s- thru c on nec tor O- rings with petroleum j ell y then ins tal l ne w T CC EN AB LE

solenoid and wiring harness assembly into the transmission case. Check that each of the four lugs is clear of

the case, to ensure correct fitment.

2. Reinstall control valve body, refer 3.10 CONTROL VALVE BODY AND ASSOCIATED COMPONENTS, in

Section 7C5 AUTOMATIC TRANSMISSION – UNIT REPAIR, in the MY 2003 VY and V2 Series Service

Information.

3. Install TCC "ON-OFF" solenoid assembly.

4. Reinstall TCC "ON-OFF" solenoid bolts and tighten to the correct torque specification.

TCC SOLENOID BOLT

TORQUE SPECIFICATION 11 Nm

5. Reinstall TCC "PWM" Solenoid assembly and retain with the spring clip.

6. TCC "PWM" solenoid electrical connector.

7. Ensure that the wiring harness is located correctly over the control valve body bolt heads.

8. Reinstall all electrical connectors onto components.

9. Install new fluid filter and seal. Refer 3.1 FLUID CHANGE AND FILTER REPLACEMENT, in Section 7C4

AUTOMATIC TRANSMISSION -–ON-VEHICLE SERVICING, in the MY 2003 VY and V2 Series Service

Information.

10. Clean oil pan and case mating surfaces. Check that magnet is still magnetised, and attached to the oil pan.

11. Install new oil pan gasket and reinstall oil pan and retaining bolts, tightening to the correct torque specification.

TRANSMISSION OIL PAN BOLTS

TORQUE SPECIFICATION 11 Nm

12. Lower vehicle and add approximately 4.8 litres of DEXRON â III automatic transmission fluid.

13. Reconnec t batter y ground l ead.

14. Check transmission fluid level. Refer to "Fluid Checking Procedure" in this Section 7C4.

6. MISCELLA NEOUS SYSTEMS

6.1 EVAPORATIVE EMISSION CONTROL CANISTER

LT Section No. – 03-165

REPLACE

1. The Emission Control Canister (1) is located

underneath the vehicle adjacent to the fuel

filter. For Canister removal and reinstallation

procedures, Refer to Section 6E2 EMISSION

CONTROL – V6 SUPERCHARGED ENGINE,

in the MY 2003 VY and V2 Series Service

Information.

Figure 6C2-3-86

6.2 CANISTER PURGE SOLENOID

LT Section No. – 03-165

REPLACE

1. Dis c onnect batter y ground l ead.

2. Mark hoses on canister purge solenoid (top –

‘1’ and lower ‘2’) and pull hoses from

solenoid (4).

3. Pull up on solenoid wiring harness connector

and pull connector from solenoid (4).

4. Remove bolt (5) from solenoid bracket (6)

(located at the rear of the right hand cylinder

head), then remove solenoid.

5. Reinstall canister purge solenoid (4) to rear of

cylinder head and install bracket bolt (5).

Tighten bolt to the correct torque specification.

PURGE CONTROL SOLE NOID

BRACKET BOLT

TORQUE SPECIFICATION 30 – 40 Nm

6. Rec onnect hoses (1 and 2) and wiring har ness

connector (3) to canister purge solenoid (4),

ensuring connections are correct.

7. Rec onn ec t batter y ground l ead.

Figure 6C2-3-87

16.3 SUPERCHARGER SYSTEM

LT Section No. – 00-375

IMPORTANT: T o minim ise the chances of un wanted fuel spra y and underhood f uel spill, always depressurise the

fuel pipes bef ore per form ing s ervice that r equires rem oving or disc onnec ting of any portion of the fuel s yste m , refer

3.1 FUEL PUMP RELAY – Fuel Pressure Relief Procedure, in this Secti on.

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 norm al c ondi tion. T his oi l se epage is ca used b y m inute tr aces of oi l esc aping around the s eal due to

norm al pressure build u p in the oil cavit y within the super charger assem bly. A build up of belt dust and/or air borne

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

drippin g or pud dl ing f r om the s uperc harger f ront s ea l, t he s up erc har ger as s embly will n eed to be replac ed. R efer to

Section 6A2, ENGINE MECHANICAL – V6 SUPERCHARGED ENGINE, in the MY 2003 VY and V2 Series

Service Information.

NOTE 1: 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 temperature can cause hot oil to

overflow. This could result in oil loss and possible personal injury.

NOTE 2: The supercharger oil level should be checked at the specified service intervals outlined in the MY 2003

VY and V2 Series, Owner's Handbook.

1. Remove four dome nuts securing the engine dress cover assembly to the inlet manifold studs, lift off and

remove t he cover assembly.

2. To prevent contamination of the supercharger

oil, clean the area around the oil fill plug before

removing.

3. Using a 3/16" Allen key socket, remove

supercharger oil filler plug.

4. Check oil level, which 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 us e petrole um bas ed oil. Us e

only GM P/N 12345982 synthetic oil. Use of any

other oil may cause supercharger failure.

5. Reinstall oil filler plug, e nsuring sealing O ring

is in place. Tighten plug to the correct torque

specification.

SUPERCHARGER OIL

FILLER PLUG

TORQUE SPECIFICATION 10 Nm

6. 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.

ENGINE DRESS

COVER DOME NUT

TORQUE SPECIFICATION 4 – 6 Nm

4336

Figure 6C2-3-88

SUPERCHARGER – REPLACE

For Supercharger removal and reinstallation instructions, Refer to Section 6A2, ENGINE MECHANICAL – V6

SUPERCHARGED ENGINE, in the MY 2003 VY and V2 Series Service Information.

6.4 BOOST CONTROL SOLENOID

LT Section No. – 03-300

REPLACE

1. Remove four dome nuts securing the engine dress cover assembly to the intake manifold studs, lift off and

remove t he cover assembly.

2. Remove boost source and signal hoses from solenoid ports, taking note of each location.

3. Pull back retaining tang on wiring harness connector and remove connector from solenoid (1).

4. Remove solenoid bracket to cylinder head attaching bolt (2) and remove solenoid (1).

5. Reinstall solenoid to cylinder head, install and tighten the attaching bolt (2) to the correct torque specification.

BOOST CONTROL SOLENOID

BRACKET BOLT

TORQUE SPECIFICATION 8 Nm

6. Re-connect boost source and signal hose to solenoid ports.

7. Reinstall wiring harness connector to solenoid.

8. Reinstall engine dress cover to the mounting brackets, ensuring that stud grommets in dress cover remain in

place. Tighten securing dome nuts to the correct torque specification.

ENGINE DRESS

COVER DOME NUT

TORQUE SPECIFICATION 4 – 6 Nm

Figure 6C2-3-89 – Boost Control Solenoid Location

6.5 BY-PASS VALVE ACTUATOR

LT Section No. – 03-300

REMOVE

1. Remove four dome nuts securing the engine

dress cover assembly to the intake manifold

studs, lift off and remove the cover assembly.

2. Disconnect vacuum hose (1) from actuator

port.

3. Using a pointed scribe, mark position of the

actuator mounting bracket around head of

securing bolts (7). This will aid in reinstallation

to ensure that actuator (2) is reassembled in

the same position.

4. Remove two bolts (3) sec ur ing actu ator brac k et

(6) to the supercharger housing.

5. Lift actuator assembly (2) upwards and then

down to cause the by-pass valve to actuator

rod lever (5) to rotate clockwise through 180°

from the ‘at rest’ position. Disengage actuator

rod (4) from the lever (5) by sliding out the

crimped end of the rod from slot in the lever,

the remove the actuator (2).

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Figure 6C2-3-90 By-Pass Valve Actuator

REINST ALL

Reinstallation of the by-pass valve actuator is the reverse of removal procedures, noting the following points:

1. If reinstalling the original by-pass valve actuator, ensure that aligning marks made on actuator bracket on

removal, are aligned before final tightening of bolts to the correct torque specification.

BY-PASS VALVE ACTUATOR

BRACKET BOLT

TORQUE SPECIFICATION 26 Nm

2. If necessary, check by-pass valve actuator adjustment as detailed in the following procedure.

CHECKING ADJUSTMENT OF BY-PA SS VALVE ACTUATOR

1. Ensure that the ignition is switched to the "OFF" position.

2. Remove four dome nuts securing the engine dress cover assembly to the intake manifold studs, lift off and

remove t he cover assembly.

3. Install Tool No. 24505373 onto the By-Pass

Valve Actuator (1).

NOTE: If Tool No. 24505373 does not fit properly

onto the by-pass valve actuator (1) and the swaged

section (3), of the actuator rod, then the actuator

bracket (4) and/or linkage may be bent, and/or

need adjustment. After the adjustment has been

made and the tool is properly installed onto the

valve, remove the tool and refer to Table

2.6 V6 PCM – SUPERCHARGED ENGINE

BOOST CONTROL SYSTEM FUNCTIONAL

CHECK, in 6C2-2C FUNCTIONAL CHECKS, in

this Section, Step 21 for correct operation of the

by-pass valve actuator (1).

Figure 6C2-3-91 By-Pass Valve Actuator Tool Installation

BY-PASS VALVE ACTUATOR

BRACKET TO SUPERCHARGER

HOUSING SECURING BOL T

TORQUE SPECIFICATION 26 Nm

4. If Tool No. 24505373 does not easily fit on the

bracket and swaged portion of the actuator rod,

loosen the actuator bracket to supercharger

housing bolts (2) and slide actuator (3) up or

down (‘A’) until the correct position is reached

and the tool c an be installe d without for ce (‘B’).

With Tool No.24505373 still installed, tighten

bracket to supercharger bolts (1) to the correct

torque specification, without moving actuator

position.

BYPASS VALVE ACTUATOR

ATTACHING BOLT

TORQUE SPECIFICATION 26 Nm

5. Remove Tool No. 24505373.

6. When the adjustment has been checked

and/or corrected, refer to Table

2.6 V6 PCM – SUPERCHARGED ENGINE

BOOST CONTROL SYSTEM FUNCTIONAL

CHECK, in Section 6C2-2C FUNCTIONAL

CHECKS, to check for proper operation of the

by-pass va lv e actu ator.

Figure 6C2-3-92 By-Pass Valve Actuator Adjustment

7. Reinstall engine dress cover to the mounting

brack ets, ens uring that stu d grom m ets in dress

cover remain in place. Tighten securing dome

nuts to the correct torque specification.

ENGINE DRESS COVER

ATTACHING DOME NUT

TORQUE SPECIFICATION 4 – 6 Nm

6.6 A/C REFRIGERANT PRESSURE SENSOR

LT Section No. – 08-200

REMOVE

1. Disconnect the electrical connector (1) at the

pressure sensor.

CAUTION: While there is a Schrader valve

under the pressure sensor, slight refrigerant

loss may occur, when the sensor is initially

loosened. F or t his re aso n , wear prot ectiv e h and

and eye wear, during this operation.

2. Using suitable socket equipment, remove the

sensor from the high pressure line.

REINST ALL

1. Reinstall pressure sensor to the high pressure

line, tightening to the correct torque

specification.

A/C REFRIGERANT

PRESSURE SENSOR

TORQUE SPECIFICATION 5 – 7 Nm

2. Reinstall electrical connector (1) to the

pressure sensor.

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Figure 6C2-3-93 – A/C Refrigerant Pressure Sensor