SECTION 00 - CAUTIONS AND NOTES

CAUTION

Caution: in order to minimise the chance of personal

injury and/or property damage, carefully observe the

instructions that follow in this Section.

The Service Manuals of HOLDEN Ltd are intended for

use by professional, qualified, factory trained

technicians. Attempting repairs or service without the

appropriate training, tools, and equipment may cause

injury to you or others. This could also cause damage

to the vehicle, or cause the vehicle to operate

improperly.

Proper vehicle service and repair are important to the

safety of the service technician and to the reliable

operation of all m otor vehicles. If you need to replace a

part, use the same part number or an equivalent part.

Do not use a replacement part of lesser quality.

The service procedures recommended and described

in this Service Manual are effective methods of

performing service and repair. Som e of the procedures

require the use of tools that are designed for specific

purposes.

Accordingly, any person who intends to use a

replacement part, a service procedure, or a tool that is

not recom mended by HOLDEN Ltd, must first establis h

that there is no jeopardy to personal safety or the

operation of the vehicle.

This Service Manual contains various CAUTIONS,

NOTES and SAFETY PRECAUTIONS that you must

observe car efully in order to reduce the risk of personal

injury during service or repair. Improper service or

repair procedures may damage the vehicle or cause it

not to operate correctly. It is important to understand

that these CAUTIONS, NOTES and SAFETY

PRECAUTIONS are not exhaustive. HOLDEN Ltd

cannot possibly warn of all the potentially hazardous

consequences of your failure to follow these

instructions.

ERROR AND SUGGESTION REPORTING

If you find an error in a HOLDEN Ltd Service Manual, or

if you have a suggestion about a HOLDEN Ltd Service

Manual, we want to hear from you.

A fax can be forwarded to the HOLDEN Ltd Service

Department on 03 9647 2525.

When faxing, please supply the following information:

•Your name.

•Your dealership's name and dealer code number.

•Your dealership's phone number.

•The model year and the vehicle type.

•The Service Manual part number or CD-Rom

version number.

•The vehicle identification number (VIN) of the

vehicle being worked on.

•The Service Manual Section and page number(s).

HOLDEN Ltd service personnel will respond to your

concerns in the following ways:

•By delivering your concern to the Service Manual's

author.

•By eliciting a response from the author.

•By supplying you with an answer to your concerns.

For book based users, if possible please supply a

marked up copy of the Service Manual page in

question.

For Electronic Service Information (CD-Rom) users:

Please be prepared to provide any applicable

identification numbers pertaining to the electronic

information that you are questioning.

The HOLDEN Ltd Service Department contact fax

number does not provide technical assistance. For

technical assistance, contact your technical assistance

source in the usual manner.

DEFINITION OF "CAUTION", "NOTE"

AND "IMPORTANT" STATEMENTS

The diagnosis and repair procedures in HOLDEN Ltd

Service Information contain both general and specific

CAUTIONS, NOTES and IMPORTANTS. HOLDEN Ltd

is dedicated to the presentation of service information

that helps the technician to diagnose and repair the

systems necessary for the proper operation of the

vehicle. However, certain procedures may present a

hazard to the technician if they are not followed in the

recommended manner. CAUTIONS, NOTES and

IMPORTANTS are elements designed to help prevent

these hazards, however not all hazards can be

foreseen.

These statements are placed at strategic locations

within the Service Manual. These statements are

designed to help prevent the following from occurring:

•Bodily injury to the technician or others.

•Damage to the vehicle.

•Unnecessary vehicle repairs.

•Unnecessary component replacement.

•Improper repair or replacement of vehicle

components.

CAUTION DEFINED

W hen encountering a CAUTION statement, you will be

asked to take a necessary action or not to take a

prohibited action. If a CAUTION is not heeded, the

following consequences may occur:

•Bodily injury to the technician.

•Bodily injury to other technicians in the workplace

area.

•Bodily injury to the driver and/or passenger(s) of the

vehicle, if the vehicle has been improperly repaired.

NOTE DEFINED

A NOTE statement calls special attention to a

necessary action or a prohibited action. If a NOTE is

not heeded, the following consequences may occur:

•Damage to the vehicle.

•Unnecessary vehicle repairs.

•Unnecessary component replacement.

•Improper operation or performance of the system

or component under repair.

•Damage to any system or components which are

dependent on the proper operation of the system or

component under repair.

•Improper operation or perform ance of any systems

or components which are dependent upon the

proper operation or performance of the system or

component under repair.

•Damage to fasteners, basic tools, or special tools.

•The leakage of coolant, lubricant or other vital

fluids.

IMPORTANT DEFINED

IMPORTANT: statements emphasise a necessary

characteristic of a diagnostic or repair procedure.

Important statements are designed to do the following:

•Clarify a procedure.

•Present additional information for accomplishing a

procedure.

•Give insight into the reason or reasons for

performing a procedure in the manner

recommended.

•Present information that will help to accomplish a

procedure in a more effective manner.

•Present information that gives the technician the

benefit of past experience in accomplishing a

procedure with greater ease.

ABS HANDLING CAUTION

Caution: Certain components in the Antilock Brake

System (ABS) are not intended to be serviced

individually. Attem pting to remove or disconnec t certain

system components may result in personal injury and/or

improper system operation. Only those components

with approved removal and installation procedures

should be serviced.

Whenever any component that fo rms part of the ABS ( if

fitted) is disturbed during Service Operations, it is vital

that the complete ABS system is checked, using the

procedure as detailed in 4 DIAGNOSIS, ABS

FUNCTION CHECK, in Section 12L ABS or ABS/ETC

(V6 Engine) or Sectio n 12L ABS or ABS/ETC (GEN III

V8) of the VT Series Service Information.

BATTERY DISCONNECT CAUTION

Caution: Before servicing any electrical component,

the ignition key must be in the OFF or LOCK position

and all electrical loads must be OFF unless instructed

otherwise in these procedures. If a tool or equipment

could easily come in contact with a live exposed

electrical terminal, also disconnect the negative battery

cable. Failure to follow these precautions may cause

personal injury and/or damage to the vehicle or its

components.

BRAKE DUST CAUTION

Caution: Avoid taking the following actions when you

service wheel brake parts:

•Do not grind brake linings.

•Do not sand brake linings.

•Do not clean wheel brake parts with a dry brush or

with compressed air.

While HOLDEN Ltd incorporates brake parts that are

not asbestos bas ed in their material composition, some

models or after market brake parts may contain

asbestos fibres which can become airborne in dust.

Use a water-dampened cloth in order to remove any

dust on brake parts. Equipment is available

commercially in order to perform this washing function.

These wet methods help prevent fibres from becoming

airborne.

BRAKE FLUID CAUTION

Caution: Brake fluid may be irritating to the skin or

eyes. In case of contact, take the following actions:

•Eye contact—rinse eyes thoroughly with water.

•Skin contact—wash skin with soap and water.

CLUTCH DUST CAUTION

While HOLDEN Ltd incorporates clutch parts that are

not asbestos bas ed in their material composition, some

models or after market clutch parts may contain

asbestos fibres which can become airborne in dust.

Use a water-dampened cloth in order to remove any

dust on clutch parts. Equipment is available

commercially in order to perform this washing function.

These wet methods help prevent fibres from becoming

airborne.

ENGINE COOLING CAUTIONS

Caution: Always wear protective safety glasses when

working with spring type hose clamps.

Caution: Do not remove the radiator/surge tank cap

while the engine coolant is above 50º C.

Caution: Electric engine cooling fans in the engine

compartment can start up even when the engine is not

running. Keep hands, clothing and tools away from any

underhood electric fan.

LPG CAUTION

This vehicle may be equipped with LPG (Liquefied

Petroleum Gas). As this fuel is heavier than air in the

vapour form , and in the interests of saf ety, the LPG fuel

system should be isolated at the manual shut-off valve

before any service work is carried out on the vehicle.

Refer to the LPG leaflet included with the Owner's

Handbook for details or the appropriate Section of this

Service Information CD for more specific servicing

inform ation relating to this alternative fuel system. Only

authorised LPG dealers may service the LPG system

itself.

FUEL AND EVAP. PIPE CAUTION

Caution: In order to reduce the risk of fire observe the

following guidelines:

•Replace all nylon fuel pipes that are nicked,

scratched or damaged during installation. Do not

attempt to repair the sections of the nylon fuel

pipes.

•Do not hammer directly on the fuel harness body

clips when installing new fuel pipes.

•Damage to the nylon pipes may result in a fuel leak.

•Always cover nylon vapour pipes with a wet towel

before using a torch near them. Also, nev er expose

the vehicle to temperatures higher than 115

(239

F) for more than one hour , or mor e than 90

(194

F) for any extended period.

•Apply a few drops of clean engine oil to the male

pipe ends before connecting fuel pipe fittings. This

will ensure proper reconnection and prevent a

possible fuel leak. During normal operation, the O-

rings located in the f emale connector will swell and

may prevent proper reconnection if not lubricated.

FUEL PIPE FITTING CAUTION

Caution: Always apply a few drops of clean engine oil

to the male pipe ends before connecting fuel pipe

fittings.

This will ensure proper reconnection and prevents

possible fuel leak.

During normal operation, the O-rings located in the

female connector will swell and may prevent

reconnection if not lubricated.

FUEL STORAGE CAUTION

Caution: Do not drain fuel into an open container.

Never store fuel in an open container due to its highly

flammable nature.

PETROL/PETROL VAPOURS CAUTION

Caution: Petrol or petrol vapours are highly flammable.

A fire could occ ur if an ignition sourc e is pres ent. Nev er

drain or store petrol in an open container. Have a dry

chemical (Class B) fire extinguisher nearby.

FUEL INJECTOR LOWER O-RING

REMOVAL CAUTION

Caution: Verify that the lower (small) O-ring of each

injector does not remain in the lower manifold.

If the O-ring is not removed with the injector, the

replacement injector with new O-rings will not seat

properly in the injector socket. Improper seating could

cause a fuel leak, with the risk of fire.

MOVING PARTS AND HOT SURFACES

CAUTION

Caution: While wor king ar ound a r unning engine, av oid

contact with moving parts and hot surfaces.

RELIEVING FUEL PRESSURE CAUTION

Caution: Relieve the fuel system pressure before

servicing fuel system components.

After relieving the fuel system pressure a small amount

of fuel may be released when servic ing the fuel lines or

connections. In order to reduce the chance of personal

injury, cover the regulator and fuel line fittings with a

shop towel before disconnecting. This will catch any

fuel that may leak out. Place the towel in an approved

container when the disconnection is complete.

FUEL PRESSURE NOTE

NOTE: Do not allow the fuel pressure to exceed the

specified value because damage to the fuel pressure

regulator or the fuel pressure gauge may result.

ROAD TEST CAUTION

Caution: Road test a vehicle under normal driving

conditions and obey all traffic laws. Do not attempt any

manoeuvres that could jeopardise vehicle control.

SAFETY GLASSES AND COMPRESSED

AIR CAUTION

Caution: Wear safety glasses when using compr essed

air in order to help prevent eye injury.

SAFETY GLASSES AND FUEL CAUTION

Caution: Always wear safety glasses when working

with fuel in order to help protect the eyes from fuel

splash.

SEAT BELT REPLACEMENT CAUTION

Caution: Replace belts, retractors, and hardware in

use during all but a minor collision. Also, restraint

systems should be replaced and anchorages properly

repaired if they were in areas damaged by collision,

whether the belt was in use or not. If there is any

question, replace the belt system. Damage, whether

visible or not, could res ult in the res tr aint not functioning

correctly in the event of an accident.

If a seat belt pre-tensioner is deployed, the seat belt

pre-tensioner assembly together with the seat adjuster

and guide rail assembly must be replaced.

If disposing of an undeployed seat belt buckle and pre-

tensioner assembly, refer to the disabling procedure in

Section 12M SUPPLEMENTA L RESTRAINT SYSTEM

of the VT Series Service Information.

SERVICING AND REPLACING SEAT

BELTS NOTE

NOTE: To prevent possible seat belt damage, refer to

the following items before servicing or replacing seat

belts.

Seat belts must be serviced as follows:

- All belts need to be serviced as a set to assure the

belt components are from the same supplier.

- All attachment hardware must be replaced, not

reused.

Keep sharp edges and damaging objects away from

belts.

Avoid bending or damaging any portion of the belt

buckle or latch plate.

Do not bleach or dye belt or strap webbing. Clean with

a mild soap solution and water.

When installing lap or shoulder belt anchor bolts, start

the bolts by hand to ensure that the bolts are threaded

straight.

Do not attempt repairs on seat belt retractor

mechanisms. Replace defective assemblies with new

service replacement parts.

SHOP TOWEL FUEL LEAK CAUTION

Caution: Wrap a shop towel around the fuel pressure

connection. The towel will absorb any fuel leakage that

occurs during the connection of the fuel pressure

gauge. Place the towel in an approved container when

the connection of the fuel pressure gauge is completed.

SRS CAUTION

Caution: This vehicle is equipped with a Supplemental

Restraint System (SRS).

An SRS will consist of either seat belt pre-tensioners

and a driver's air bag, seat belt pre-tensioners and

driver's and front passenger's air bags or seat belt pre-

tensioners, driver's and front passenger's air bags and

left and right hand side front air bags.

Refer to the SAFETY PRECAUTIONS in Section 12M

Supplemental Restraint System (Ver. 6.2) and

Section 12M Supplemental Restraint System (Ver.

8.0/8.1) of the VT Series Service Information before

performing any service operation on, or around, any

SRS components, the steering mechanism or wiring.

Failure to follow these SAFETY PRECAUTIONS could

cause unwanted air bag deployment, or otherwise

unneeded SRS repairs, or could result in the SRS not

functioning correctly when required.

In order to help avoid accidental air bag deployment,

whenever you service a vehicle that requires repair of

the SRS and another vehicle system, we recommend

that you first repair the SRS, then go on to the other

system.

SRS INFLATOR MODULE DISPOSAL

CAUTION

Caution: In order to prevent accidental deployment of

the air bag, do not dispose of an undeployed inflator

module as normal shop waste. The undeployed inflator

module contains substances that could cause personal

injury if the stored container is damaged during

disposal.

Refer to the relevant air bag and/or pre-tensioner

scrapping procedures in Section 12M Supplemental

Restraint System (Ver. 6.2) and Section 12M

Supplemental Restraint System (Ver. 8.0/8.1) of the

VT Series Service Information.

SRS SPECIAL TOOL CAUTION

Caution: In order to avoid deploying the air bag when

troubleshooting the SRS system, use only the

equipment specified in this Service Manual and the

instruc tions given in this Service Manual. Failure to use

the specified equipment as instructed could cause air

bag deployment, or unnecessary SRS system repairs,

or could result in the SRS not functioning correctly

when required.

VEHICLE LIFTING CAUTION

Caution: When components are removed from the

vehicle and the vehic le is supported by a hoist, per form

the following steps:

Chain the vehicle to the hoist at the same end as the

components that are being removed.

Ensure the vehicle is supported at the opposite end

from which the components are being removed.

WINDOW REMOVAL CAUTION

Caution: When working with any type of glass, use

approved safety glasses and gloves.

WINDOW RETENTION CAUTION

Caution: When replacing stationary windows , Urethane

Adhesive Kit Betaseal 554.02, or a urethane adhesive

system meeting HOLDEN Ltd Specification HN1890,

must be used to maintain original installation integrity.

Failure to use the urethane adhesive kit may result in

poor retention of the window.

WORK BAY TEST CAUTION

Caution: One or more of the following guidelines may

apply when performing specific required tests in the

work bay:

When servicing a vehicle fitted with the ABS/ETC

system, or an LSD rear axle, do not run the engine with

the transmission in gear and one rear wheel raised. If

the ABS/ETC system is operational or the vehicle is

equipped with LSD, with the vehicle in this s ituation, the

driving force will be transmitted to the wheel on the

ground and cause the vehicle to move.

When a test requires sp inning the drive wheels with the

vehicle jacked up, adhere to the following precautions:

- Do not exceed 56 km/h when spinning one drive

wheel with the other drive wheel stopped. This limit is

necessary because the speedometer indicates only

one-half the actual vehicle speed under these

conditions.

- If all of the drive wheels are spinning at the same

speed, do not exceed 112 km/h.

- All persons should stay clear of the rotating

components and the balance weight areas in order to

avoid possible personal injury.

- When running an engine in the workshop for an

extended period of time, use care not to overheat the

engine and the transmission.

When a tes t r equires jac king up the v ehic le and r unning

with the wheels and brake rotors removed, adhere to

the following precautions:

- Do not apply the brake with the brake rotors removed.

- Do not place the transmission in PARK with the drive

wheels still spinning.

- Turn off the ignition in order to stop the powertrain

components from spinning.

FASTENER NOTE

NOTE: Use the correct fastener in the correct location.

Replacement fasteners must be the correct part

number for that application. Fasteners requiring

replacement or fasteners requiring the use of thread

locking compound or sealant are identified in the

service procedure. Do not use paints, lubricants, or

corrosion inhibitors on fasteners or fastener joint

surfaces unless specified. These coatings affect

fastener torque and joint clamping force and may

damage the fastener. Use the correct tightening

sequence and specifications when installing fasteners

in order to avoid damage to parts and systems.

IGNITION OFF WHEN DISCONNECTING

BATTERY NOTE

NOTE: Always turn the ignition OFF when connecting

or disconnecting battery cables, battery chargers, or

jumper cables. Failing to do so may damage the

Powertrain Control Module (PCM) or other electronic

components.

SDM-RSD NYLON FUEL LINES NOTE

NOTE: Do not attempt to straighten the kinked nylon

fuel lines. Replace any kinked nylon fuel feed or return

pipes in order to prevent damage to the vehicle.

PCM AND ESD NOTE

NOTE: Do not touch the connector pins or soldered

components on the circuit board or it may cause

electrostatic discharge (ESD) damage to the PCM.

HANDLING ESD SENSITIVE PARTS NOTE

Electrostatic discharge (ESD) can damage many solid

state electrical components. Not all components that

are susceptible to damage from ESD are labelled with

the ESD symbol. Exercise caution when handling all

solid state electrical components.

Avoid damaging solid state electrical components by

taking the following precautions:

- Discharge personal electricity by touching a metal

ground point after each of the following activities:

•Sliding across the vehicle seat.

•Sitting or rising.

•Walking.

- Do not touch the exposed electric terminals on a

component with your finger or a tool. The connector

that you are checking may be tied into a circuit that is

susceptible to damage by ESD.

- Do not allow a screwdriver or a similar tool to contact

exposed terminals when disconnecting a connector.

- Do not remove the protective packing of the solid

state component until you are ready to install the solid

state component.

- Unless specified in a particular diagnostic procedure,

avoid the following activities:

•jumpering components or connectors.

•grounding components or connectors.

•using test equipment probes on components or

connectors.

- W hen a diagnosis requires the use of test equipm ent

probes, connect the ground lead first.

- Touch the solid state component's package to a

ground before opening.

- Do not lay the solid state component in any of the

following locations:

•On a metal workbench.

•On top of an electrically operating appliance or

piece of equipment, like a TV, radio or oscilloscope.

- Do not drop the solid state component.