VK Commodore Workshop Manual

Eommodore. Holden Ealais.
Holden
VK SERIES
FOREWORD
The information in this Supplement, when used in with Holden Commodore'VB' series Service conjunction Manual M38145, 'VB' Station Wagon Supplement M38265, VC Service Manual Supplement (Number 1) , lmprovedPerformance M38366 and Number 2 M38401 L6 & VB EnginesServiceManual M38338and VH Series M38731,providesnew specServiceManualSupplement ifications and new service procedures lor Holden Commodore and Holden Calais VK Series vehicles. Transmission,front brake and rear axle assemblies are similar to those used in other GMH vehicles.No major service repair and overhaul procedures are given for these assemblies,and reference should be made to existingService Manuals. The Section lndex on this page enables the user to quickly locate the numeric identifiers for each group of Sections. Bend the Manual back to expose the black tabs on the pages and locate the tab indicating the identifier for the group of Sections you wish to find. An index is included at the beginningof each Section. In addition. numeric identifiers are also used to signify the individualoperationswithin the Sections.Specifications are providedat the end of each for vehicle components Section where apProPriate. Summarieso1 Special Service Tools, where required, are also includedat the end of Sections. Service Tools, unless otherwise specified, are available from: AustraliaPtY' Ltd. I Kent-Moore Avenue, Unit 3, 9 Pioneer N.S.W.Australia'2120. Thornleigh. Telex 22355 Telephonel02l 848'9777 does not endorse, prefer, or General Motors-Holden's products of this firm nor for for the responsibility assume any such items which may be available from other makers. contained illustrations and specifications All information, in this Supplement are based on the latest product apProval. informationavailableat the time ol publication The right is reserved to make changes at any time without notice. 1984. MA R C H , E F F E C T IVE : MA N U ALN O.M3 9 1 0 1 S E RV IC E 009 0 l.s.B.N. 0.86836 P RI NTED IN A U S T R A L IA
SUPPLEMENT MANUAL SERVICE

INDEX SECTION
OA
B GE N E R A LIN FOR MA TION LU B R IC A TION
A-
B o DY
GR ILLE C _ R A D IA TOR BARS D _ B U MP E R
2 3 4
A - vENTTLATToN&HEATING B _ AIRCONDITIONING FRoNTSUSPENSToN A- REARSUSPENSToN AXLE B _ REAR JOINTS & UNIVERSAL SHAFT C _ PROP BRAKES
AB _ C _ D E _ F E N GTN E ME cH A N IcA L E N GIN E C OOLIN G FU E L E N GIN E E LE C TR IC A L E N GIN E E MIS S ION C ON TRO L E N GIN E TU N E E N GIN E
5
6
A - cLUrcH
B _ MA N U A LTR A N S MIS S IO N TR A N S MIS SI O N C _ A U TOMA TIC
8 9
A_ FUELTANK SYSTEM B - EXHAUST sTEERTNG
10
wHE E t & s rY RE S
A _ B A TTE R Y & C A B LE S S Y S TE M B _ LIGH TIN G WI NDSHI ELD GA , U GE S, C - IN S TR U ME N TS H ORN &S W IP E R S /W A S H E R D _ R A D IO& TA P EP I-A Y E R & E _ W IR IN GH A R N E S S E SFUSES F - W IR IN GD IA GR A MS
SALES PTY. LIMITED GENERAL MOTORS_HOLDEN'S SERVICE DEPARTMENT

COPYRIGHT _ GE N E R A L MOTOR S -H OLD E N 'S S A LE S P TY , LTD i n w hol e or i n oart prohi bi tedw i thout w rrtten approval Re p r o cju cti on
INFORMATION OA-1 GENERAL
OA SECTION
INFORMATION GENERAL
INDEX
Ref. 1. 2. 3. 4. 5. 6. 6.1 6.2 6.3 Page Subject 0A-1 GENERALDESCR|PT|ON.........--................... MODEL AVAILABILITY & BASE oA-2 EOUIPMENT 0A-2 POWERTRAIN COilBlNAT|OlilS.....-.......... 0A-3 ENGINE DAT4............ 0A'3 EXTERIORDIUENSIONS 0A-4 SERtAL NUMBERS.........................i. PLATES oA-4 LOCATIONOF IDENTIFICATION 0A-4 SAFEW CO]IIPLIANCEPLATE ...... BODY & OPTIONIDENTIFICATION 0A-4 Ref. 6.4 6.5 6.6 7. Page Subject NUMBERING VEHICLE IDENTIFICATION 0A-5 SYSTEM 0A-6 SERIALNUMBER...... VEHICLE 0A-6 ENGII{ESERIAL NUMBEB...... ADDITIONALGENERALINFORMATION....nA-A ElectrlcalTransients and Radio Frequency Interference Radio Frequency lnterference .......... NA-A Electrlcal Transients 0A-7
.:E 9t'9 r
I
DESCRIPTION 1 . GENERAL
The VK Series is a minor facelift of the VH Series changes. incorporating exterior,interiorand mechanical The model line-up differs from the VH Series, with the deletion of the 69 body style (4 door, 4 window sedan) and the introductionof the '19 body style (4 door, 6 windowsedan). MOD ELL IN E U P 8V K 19
8VK35 8VL 19 8VL35 8VX1 9
C o m m o d o re SL
Commodore SL Com m odor e Ber lina Commodore Berlina Calais
4 door.6 w i ndow Se d a n
Station Wagon Sedan4 d o o r , 6 w i n d o w Station Wagon Sedan4 d o o r , 6 w i n d o w
The 3.3 litre L6 engine, equipped with ElectronicSpark Timing (EST), is the base engine tor SL and Berlina models, and the 3.3 litre LO engine equipped with Electronic Fuel Injection (EFl) is the base engine on Calaismodels. The three speed Trimatic Automatic Transmissionis standardequipmenton Calais and Berlinamodels and is availableas an ootion on CommodoreSL models.The is standard Torquemaster four speed manualtransmission SL models. on Commodore The 5.0 litre V8 engine is availableon all models as an is also available option.A five speed manualtransmission as an option on all 3.3 litre L6 EST engines The following charts contain model availability,power train combinations, engine data and exterior dimensions for VK Seriesmodels.
OA.2GENERALINFORMATION 2. MODELAVAILABILITY & BASE EQUIPMENT

TR A N S MIS S ION B O DY S T Y LE MODEL NO. M O D EL NAM E No . OF DOORS ENGINE TY P E
Sedan S/Wagon Se d a n S/ Wa g o n Sedan
S H I FT LOC . F l oor Fl oor Fl oor F l oor Fl oor
REAR A X LE R A TIO :l
?na
TY R E S
WH E E LS
8VK19 8VK35 8VL19

t'V LJ5
C o m mo d o r eSL C o m mo d o r eSL C o m m o d o r e Be r lin a C o m m o d o r e Be r lin a Calais
4 5 4 5 4
3.3 EST 3.3 EST 3.3 EST 3. 3 EST

J.J EFI
4 S peedManual 4 S peedManual 3 Speed Auto 3 Speed Auto 3 Speed Auto
8VX19
3.08 3.08 3.08 3.08
1 4 5.50 JJX 14 S teel BR78S c R 7 8 S 1 4 6.0 JJX 14 S teel c R 7 8 S 1 4 6.O JJX I4 S teel c R 7 8 S 1 4 6.0 JJX 14 S teel P20s/ 6.0 JJX l 5 A l l oy 60HR 15
3. POWERTRAIN COMBINATIONS
E NGINE TRANSM I SSI O N TYPE
R E A RA X LE R A TIO: 1 M O D EL A VA IL AB I LITY
SL Sedan SL Station Wagon BerlinaSedan BerlinaStation Wagon SL Sedan SL Station Wagon Ber linaSe d a n BerlinaStation Wagon SL Seda n SL Station Wagon Ber linaSe d a n BerlinaStation Wagon SL Seda n Ber linaSe d a n Calais All M ode l s
FIR S TGE A R R A TIO: 1
BASE
PERFORMANCE
4 SpeedManual
3.50
3.08
3. 3 Litre S ix C ylin de r EST
5 SpeedManual
3.24
3.36
SpeedAutomatic
2.31
3.08
3 .3 L i tr e Si x C yl inder EFI
5. 0 Litre E ight C ylind er
Sp eedAut om at ic
2.31
3.08
3 SpeedAu tomatic
z .J I
2.60
3.08
OA.3 GENERALINFORMATION 4. ENGINEDATA

ENG I NE DESI G NATI O N
3.3 L]TR EE S T 3298 8.8 6 x 82.550 92.O75 31.5 86 kw @4200 232 Nm @2400
3.3 LITR E E FI
5.0 LITR E
D ISP L AC EME N T P IST ON N OM.- c c R AT IO: 1 C O MP R E SS IO N OF C YL IN D E R S N U MB ER B O R Ex ST R O K E-mm T AX AB L EH .P.R ACo r SA E POWER K .W.D IN @ R .P.M. N m D IN T OR O U E @ R .P.M.
3298 8.8 6 92.075x 82.550 31.5 106kw @4400 266 Nm @3200
5044 9.2
R
101.60 x 77.775 51.2 117kw @ 4000 336 Nm @2400
DIMENSIONS 5. EXTERIOR
BODY D IME N S IO N S O V EB AL LL E N GT H O V ER AL LWID T H O V ER AL LH EIGH T W H E EL B AS E _ FRONT O V ER H A N G _ R EA R O V ER H A N G T R E AD- F R ON T r R E AD - R E AR MOD E LS SEDAN 8 VK 19 4713.5 1 722 I 378 2668 922.5 1 1 23 1 451 .3
t4 l o.3
MO DELS W A GON S TA TION 8V X 19 4713.5 I 1722 1360

2668
8V L19 4713.5 1722 1374 | 2668 922.5 1123 1451 .3 1416.5
8V K 35 4716.5 1722 1401 2668 922.5 1126

t45 | .J
8V 135 4716. 5 1722 1465 2668 92 2. 5

ttl o
922.5 1123
t45 I .J
.3 1451 1440
in mm Dimensions
1416.5
1440
OA-4GENERALINFORMATION 6. SERIALNUMBERS
The complete vehicle and various components of the vehicle are identified by number plates or numbers stampedinto the part. lt is essentialthat when compiling warranty claims or product and field reports that the vehicle identification number 'VlN' is quoted in conjunction with the identificationnumber of the component affected.
6.1 LOCATIONOF IDENTTFICATION PLATES

Plates are attached to the left side wheelhousereinforcement and the front panel upper (reler Fig. 0A-l). SAFEW COMPLIANCE PLATE- Refer Fig. 0A-2. BODY AND OPTION IDENT|F|CAT|ON PLATE - Refer Fig. 0A-3. VEHICLEIDENTIFICATION PLATE- Refer Fig. 0A-4.
Flgure 0A-1
(Not applicable to Export). Plate stamped with the following information: Flefer Fig. 0A-2. AUSTRALTAN DEStcN RULENOS.(A.D.R.) VEHICLE MAKE- HOLDEN. VEHICLE MODELNAME AND STYLE. MONTHAND YEAR OF MANUFACTURE. VEHICLE SERIALNUMBER. SEATING CAPACITY OF VEHICLE. GROSSVEHICLE MASS IN KILOGRAMS.
6.2 SAFETYCOMPLIANCE PLATE
T H IS VEH IC LE W AS M AN U F AC T U R ED BY GEN ER AL M OT OR S- H OLD EN 'SLI M IT ED T O C OM PLY W IT H AU ST BALIAN D ESIG N R U LES N O S. 1,2, 3A. 40,58. 6, 7, 8, 108, 11. 12, 14, 15, 15, 1aA,20 21, 22A, 23A, 24, 25A, 27C , 28A, n, 31, 34
3-84 GVw
Ks
AVKOOOOOTA s EAT IN G c Ap. s
T H IS PLAT E IS AF F IXED W IT H T H E APPR OVAL O F T H E AU ST R ALIAN M O T OF VEH IC LE C ER T T F IC AT IONBO AR D
Flgure 0A-2
6.3 BODY& OPTIONIDENTIFICATION PLATE

Plate stampedwith the followinginformation - Refer Fig.0A-3. MODEL: Combination of lettersand numbers identitying the Body, Model and Style. BODY NO.: plantSuffix. Reference number followed by Assembly
A - Adelaide NZ - New Zealand
GE N E FA L MOTOR S _H OLD E N 'S LIMITE D C OR R E S P ON D E N C MU E S T B E A R TH E S E N U MB E R S MOD E L: B OD Y N O.: TRIM: P A IN T: B U ILT: E N G.44 V K 8V L19 621423A 1442-63X 567-30518 MA R 84
M - Melbourne
TR A N S . M4O A X LE GU 4 MA D E IN A U S TR A LIA
TRIM: Exterior Paint Colour and Trimcombination. PAINT: Exterior PaintMaterial and Colour identificatron. BUILT: Thedateof manufacture by calendar monthanovear in which the body shell and power train are
conjoined and the vehicle is driven or moved from the production line-
Figure 0A-3
OA-5 GENERALINFORMATION
6.4 VEHICLEIDENTIFICATION SYSTEM NUMBERING
The Vehicle ldentificationNumberingSystem (V.l.N.) is based on the uniform Car Model Designation System' This is to identify the vehicle in one coded series of characters. The significance of these characters or blocks of characters is explained below, using as an example identification number:8L19LD L60oO25K
r
MODELDESIGNATION Division
M O T O R S - HL O O E N 'S LIMITEO GENERAL
Degreeof Luxury
Body Style Code ENGINECODE MODELYEAR CODE ASSEMBLYPLANT CODE SERIAL(Sequence)NUMBER SERIESCODE MODELDESIGNATION Division - 1st Character- 8 - StandardNumeralallocatedto GMH Limited Degree of Luxury - 2nd Character- L :"BERLINA" X. "CALAIS' 'SL' L. COMMODORE K - COMMODORE ldentification 19 Body Style 4th character & 3rd code Body style (4 6 window) door, 19 - Sedan 35 - StationWagon CODE ENGINE Code. Sth Character- L - Engine ldentification T - 5.0 litre " litre EFI 3.3 K EST L - 3.3 litre MODELYEAR CODE 6th Character- D - ldentifiesModel Year. This letter changes 1st September each year & relates to GM Internal OnlY:OPerations F-1986 E-1985 D-1984 ASSEMBLYPLANT CODE Code:' 7th & 8th Characters - J6 - AustralianAssemblyPlant ldentification Jl thru J9 - Melbourne L1 thru J9 - Adelaide NUMBER SERIAL(Sequence) serial Number. 9th to 13th character - 00025 - sequentialProduction at NOTE: This designatesthe SeriatUnit Number each Vehicle Plant, starting at (00001) and continues in Numerical Sequence regardless of vehicle typeCODE SERIES - K 14th Character e.o.'VK'.
for each Model Programme. GMH LimitedModel Code Designation
Flgure 0A-4
0A-6 GENERALINFORMATION
6.5 VEHICLESERIALNUMBER
The vehicle serial number is stamped on the top of the left hand side strut tower - Refer Fig. 0A-5. 1. DESIGNRULECOMPLIANCE LETTER. 2. VEH ICLE S E RI E S ' V K ' . 3. ASSEMBLY PLANTSERIALNUMBER. 4. ASSEMBLY PLANTIDENTIFICATION 'A' ADELAIDE. 'M'ME LB O URNE . 5. REQUIREMENT IN EVENT OF SERIAL NO. DUPLICATION. 6. REQUIREMENTIN EVENT OF SECOND OR FURTHER SERIALNO. DUPLICATION.
AVK OOOOO1 A
II
nEr
Fllol E
TT
R2
T I
Figure 0A-5
6.6 ENGINE SERIALNUMBER

The engine number for 3.3 litre engine is stamped on a pad above the right hand engine mountingboss, and at top front left side of cylinder and case for 5_0 litre engines. NUM B E R P RE F IX J ENGINE VL VK VT E N GIN E T YP E
J.J ilIr e tr S I
3. 3 lit r e EFI 5. 0 llt r e Aut om at ic
7. ADDITIONAL GENERAL INFORMATION

ELECTRICAL TRANSIENTS AND RADIO FREQUENCY INTERFERENCE Electronic circuits are used in VK Series rnodels to performa number of functionsassociated with electronic instruments, electronicfuel injectionand electronicspark timing.These circuitscan be damagedor cause mallunction by electricaltransientsor excessiveradio frequency (RF)radiation. RADIO FREQUENCY INTERFERENCE One of the chief sources of RF interlerence is the ignitionsystem;other sourcesincludeCB radio and radio telephonesThe followingare normallyused to suppress RF interference. Resistors e.g. high tension cables and connectors. Capacitors and choke coils. Metal braid lor screening leads or suppression covers made from conductivematerialfor screening equipment. To prevent damageto equipment: Do not replace interference- suppressedhigh tension ignitioncables or conneclorswith un_ suppressed types. Do not remove or reposition interferencesup_ pressionfiltersor cagacitors.
OA.7 GENERALINFORMATION
ELECTRICAL TRANSIENTS Electricaltransientsare high voltage spikes producedby of electric currents. the sudden switchingor interruption Older style timinglightsand batterychargerscan produce hence it is importantto use only good serioustransients, quality equipment suitable for use with electronic systems. It is also good practice to ensure that the battery is disconnectedbefore using a battery charger. or relayscan fitting of solenoids,indicators Indiscriminate also causetransients.
S O U R C E SOF INT ERF ERENCE I N A M O T OR VEHICL E ( E X A M P L E) 1 . A L T E RNAT OR 2 . E L E CT RIC F UEL PUM P 3 , E L E CT RIC WINDSCREEN W A S HER 4 . B L OWER M OT OR 5 . E L ECT RIC WINDSCREEN W I P ER 6 . S P ARK PL UGS 7 . I G NIT ION DIST RIBUT OR 8 . r G N lr lo N co lL 9. HORN 1 0 . I N DICAT OR WIT H VOL T AGE S T A BIL IZ ER ( e . 9 .F UEL GAUGE)
ld1a T;-
!* \
= \ Lja
T*fl'-ffi#m^
-#
rfrh
I iltl ,dH
' '1iitT
l :: :..1
)w l l rrn
Vlr
-
ffifffin4-"Fu
E:T l :l
--:-=-..
A D D I T I ONAL SOURCEOF INT ERF ERENCe; I P O O R EL ECT RICAL CONNECT IONS I B E T W E EN T HE VABIOUS M ET AL PART S i O F T H E VEHICL E ( e .9 .BET WEEN T HE i E N G T NEAND F T REWAL L ) . I
rdlfu 'o ___,--l

[ :\': ::::l
\
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Figure 0A{
l/
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I
1
OB.1 LUBRICATION
SECTION OB
LUBRICATION
INDEX
Ref. 1. 1. 1 1. 2 Page Subiect 0B-1 GENERALINFORMATION 0B-2 LUBRICANTS.................. RECOMMENDED 0B-2 BRAKE FLUID REPLACEMENT....... Ref. 1.3 1.4 1.5 Subject AIR CLEANEB.......... FUEL FILTER COOLINGSYSTEM Page 0B-2 0B-3 0B-3
1. GENERAL INFORMATION
This section provides details of the lubricants specific to VK seriesvehicles. lnstructions on the time or distance intervals at which services should be canied out are contained in the Service and Maintenance Section of the VK Series Owner Handbook.
CAPACITIES
E N GIN E S IZE
En gin e- Ser v ic eRef ill Add for Oil Filter Ma nu alTr ans m is s ion (ProductionOption MC6) Ma nu alTr ans m is s ion (ProductionOption M76) ( Dr y ) ( lnc . Co n v e r t e r ) Au tom at ic Tr ans m is s ion Ref ill . Se rvi c e CoolingSystem BrakeHydraulic System 3.3 Litre 5.0 Litre
CAPACITY
3.7 Litres 4.33 Litres
A LL 3.3 Litre EST 3.3 Li treE S T 3.3 Li tre 5.0 Litre 3.3 Li tre 5.0 Li tre
3.3 Litre 5.0 Litre
3 Litres 1.6 Li tres 2.75 Litres 6.1 Li tres 8.7 Li tres 2.3 Li tres 2.3 Li tres
8.5 L i t r e sa p p r o x 12.0 Litresapprox
A LL
.62 Litres
10
OB.2LUBRICATION
1.1 RECOMMENDED LUBRICANTS
COM P O NE NT S
E ngin e 3.3 Litre EST 3.3 Litre EFI
GMH S PE C IF IC AT ION
LU B R IC A N TS
5.0 Litre Manua l Tran smissio n P ro du ctio n Optio n M C6 P rod uction Optio n M 76 A ut omatic Tran smiss ion R earAxle Rear Axle L .S.D. Power Steering Brake System
SE O ils Se O it s SF O ils f or s ev er e s er v ic e . Refer Owners Handbook. SE O ils
For grades a n d a p p l i c a t i o n ,r e f e r F i g . 0 B - i For grades a n d a p p l i c a t i o n ,r e f e r F i g . 0 B - 1
For grades a n d a p p l i c a t i o n ,r e f e r F i g . 0 B - 1
HN1 046 HN1 855 GM9985286

HNi 181 if unav ailabl e HN1561
SAE 8OW9O GearOil 80W Castrol

DEXRON I[ Automatic Transmission Fluid
EPSAE90
DEXRON If Automatic Transmission Fluid P o l y g l y c o lB r a k e F l u i d t o G M S p e c i f i c a t i o n HN1796
GN49985286 HN1 796
-1oo
oo
1oo
2oo
3oo
4oo
5oo
D E GR E E S _ C E N TIGR A D E
Fagure0B-1
1.2 BRAKE FLUID REPLACEMENT

The polyglycolbrake lluid used in VK Series models is hydroscopicand absorbs moisture from the air throuoh the brake hoses etc. The boiling resistanceof the flu'id decreasesas the moisturecontent increasesand so the possibilityof a vapour lock under heavy brakingconditions increaseswith the age of the fluid. Therefore,for maximum brake effectiveness,a two yearly change of brake fluid is mandatory. ServiceInstructions for changing brake fluid are covered in Section 5, Service Ooeralioi 2.1 in this Supplement.
1 . 3 AI R C L E A N E R
The air cleaner element may be partiallycleanedof dust by lightly tappingthe element. lt shouldnot be washedor oiled.The time or distance intervals at whichthe element requrres servicing depends on the vehicle operating conditions. Underdustyconditions, the element shouldbe checked for restrictionmore often that for normal citv operation.
11
LUBRICATION OB.3
The air cleaner elementshould be replacedat the time or distance interval specified in the VK Series Owner Handbook. ol the tor the removaland installation ServiceInstructions air cleaner element (Fig. 0B-2), on vehicles with electronic fuel injection are covered in Section 6C, ServiceOperation3.6 in this Supplement.
f,\ A IR FLOW ME TE R A IR C LE A N E R H OU S IN G
;A l R FLOW DUCT
Figure 0B-2
1.4 FUELFILTER
On 3.3 litre engineswilh electronicspark timing, a fuel {ilter is located in the suction side of the fuel line and attachedto the right hand fender panel. Refer Fig. 0B-3' On electronic fuel iniected vehicles, the fuel filter (Fig. OB-4) is located on the pressure side of the tuel pump and attached to the floor pan of the vehicle, in front of the differential. Fuel lilters should be replaced at the time or distance specifiedin the VK SeriesOwner Handbook. intervals of the for the removala;rd installation Instructions Service fuel filter on electronictuel iniectedvehiclesare coverecl 3.15 in this Supplement. in Section6C, ServiceOperation
TO FU E L P U MP -\.
IN LIN E
>-}îq c; ---l-')w-t
-\
ll----*i-rl
MOU N TIN G BRACKET
R+
FR ON T OF C A R
Figure 0B-3
1.5 COOLING SYSTEM

The cooling systemis filled initiallywith a coolantmixture comprising 1.5/o to 3.0% (by volume) of corrosion HN1109. inhibitor to GMH specilication It is recommended that the coolant be drained, the systemflushed and refilledwith clean water and inhibitor rnixtureat the time and distanceintervalssel out in the VK SeriesOwner Handbook. Reier to Service Operation 2.2, Section68 'Cooling for details. System'of this Supplement
;
N S U LA T OR R U B B E R _l
/t..\\
hl
\ _\) )\
'\\
--\
MOU N TIN G
ruurll , \, 'Y ;r/ , \1'l /
iii'')i'-\
i6* q (- ,f.1'.t*./','ffi\->(l a'

Figure 0B-4
| 6/: ryy-^,R
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iA lr
C LA MP B OLT
12
BODY 1A-1
1A SECTION
BODY
OF THIS SECTION CONTENTS
Ref. 1. 2. 3. 4. 5. Subjecl GENERALINFORMA UNDERBODY REAR QUARTER GLASS STATTONARY 1A-3 1A-19 1A-21 ............. Rel. 6. 7. 8. 9. 10. Page Subject 1A.31 SEATS& SEAT BELT ASSEMBLIES.....-.... 1A-39 .................... EXTERTOR ORNAMENTATION ...... 1A-s1 ROOF RACK ..... 1A-53 BODY ELECTR|CAL............ 1A-67 SPEC|ALTOOLS ...,....
INFORMATION 1. GENERAL
INDEX
Ref. 1.1 Page Subiect 1A-1 GENERALDESCR|PT|ON.............................. I Ref. | 1.2 Subject SERVICENOTES Page 1A-1
DESCRIPTION 1.1 GENERAL

This Section contains descriptions and procedures lor interior and exterior body service operationson VK Series Commodoreand Calais models.When used in conjunction with previously released Commodore Service Publications, it will provide information necessary for etficient servicing of VK body styles and their related assemblies. The VK Series includes two different body styles: the '19 Style, which is a six window sedan and the 35 style StationWagon. The stationary fifth and sixth windows on the new 19 Styles are retained in their upper rear quarter apertures with urethane adhesive, which creates a bond between the glass and the metal flange to which it is applied.On 35 Styles, the tailgate window is retained with urethane adhesive; the same material which is used in production and back windows' to retainthe JB CamiraWindshields Also featured on VK Series are revised transmission consoles, new instrumentpanel facia and instruments, seat and door trim designs and 'see through' head restraintson front seats. On the Calais model, see through head restraints are fitted to the rear seats. Electricallycontrolled exterior rear vision mirrors are also standard on this model. An adjustablelumbarsupportbuilt into the drivers seat back is includedon Berlinaand Calaismodels. VK external features include new exterior ornamentation, decals, tailgate handle on 35 body style, radiator grille and colour co-ordinated front and rear bumper bar assemblies. Front turn signal lamps and rear lamp assembliesare also new.
A-A sEcrroru
S E A T B ELT
FlgurelA-'l involving high heat application, appropiate precautions against fume inhalation such as the wearing ol respirators,forced ventilation,etc., are mandatory.Whenever possible, such repairs should be canied out without the use of high temperature producing equiPment. IMPORTANT: Whenever items such as body side mouldings,Dealer name plates,mud/9lash guards,etc., which require piercingof sheet metal panels,are added a possibility to a vehicle after it has been manufactured, exists for sheet metal corrosionto occur in areas where the metal has been pierced, as well as other areas Abrasion affected by water entry at the point of piercing. of the painted or treated surfaces by the 'added-on' material may contribute to corrosion and unsightly appearances. The reliabilityand performanceof 'add-on' equipment of the maker installations must become the responsibility and the installer (Dealer or vehicle owner). For this used in your reason,you should evaluatethe procedures Dealership (and outside sublet shops) to assure that sheet proper steps are being taken to provideappropriate metal corrosion protection to offset the etfects of 'add-on'equipment. CAIJTION: To avoid damage when servicing instrument panels, trames, instrumentc/usters, etc., it ls essentia/to handle these componentswith the utmost care.
NOTES 1.2 SERVICE

CAIITiON: As a sound deadening medium, a small volume of polyurethane foam is installed into the upper section ot the rear body pillars of VK Commodore sedans, as illustrated in shaded areas in Fig. 1A'1. During norma! seruice, there is no risk associated with its use. However, when polyurethane is subiected to high temperatures such as during welding or naked flame cutting, this material can release black pungent fumes. During repair of these pafts of the body structure
13
1A-2 BODY
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14
BODY 1A.3
2. UNDERBODY
INDEX
Ref. 2.1 2.2 Page Subject & HOIST DIUENSIONS UNDERBODY 1A-2 LOCATIONS. 1A-3 TRANSMISSIONCONSOLE.MANUAL...... 1A-3 llodel - 'SL' 1A-3 Remove 1A-3 Relnstall Models - Calais & Berllna fltted with Power Operated Slde 1A-3 Wlndows...... 1A-3 Remove........ 1A-3 Reinstall CONSOLE. TRANSMISSION 1A-5 AUTOMATIC 1A-5 Remove.,,..-.. 'tA-5 Relnstall Rel. 2.4 Subject SHROUDLOWERTRIM . RIGHT& LEFT HAND ......--..Remove....--.. Reinstall ROCKERPANELCOVER- RIGHT& LEFT HAND. Remove........ Reinstall FLOORCOVERING Remove....,........... Reinstall Page 1A-6 1A-6 1A-6 1A-6 1A6 1A-6 1A-7 1A-7 1A-7
AND 2.1 UNDERBODY DIMENSIONS HOISTLOCATIONS

Refer Fig. 1A-1A.
2.2 TRANSMISSION CONSOLE. MANUAL

M O DE L. ' S L ' Remove batterygroundcable. 1. Disconnect 2. Unscrew knob from gearshift control lever, then screw cover buttons and screws securing front and reat of console to transmission tunnel (refer Fig. 1A-2). 3. Partially raise console then disconnect electrical prior to removalof transmission console. connectors Reinstall Reverseremovaloperations, ensuringthat non hardening sealer is appliedto the threads of the console attaching (refer Fig. 1A-2). screwspriorto their installation MODELS. CALAIS & BERLINA FITTED WITH POWER OPERATED SIDE WINDOWS Remove batterygroundcable. 1. Disconnect 2. Unscrew knob from gearshift control lever then removecover from handbrakelever. 3. With console compartmentlid raised, remove rear end of carpet in base of console which covers screws securingrear end of console to transmission tunnelbracket(referFig. 1A-3) then removescrews. raise rear end of console,disconnectelectr4. Partially ical connectors,then easing console reanvards to disengage front end of console from attaching bracket (refer Section B-B, Fig. 1A-3) remove console assembly. Reinstall Reverseremovaloperations.
15
1A.4 BODY
cll---->c,
{ 4 P L A C E S)
Ascnew.-----..---..-->s
(4 PLACES) i
# W
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WIPER IWASHER SWtTCH ASM. H E A TE D R E A R WTN D OW GE A B S H IFT LE V E R C ON TR OL B OOT
sw l rcHA ssE MB LY
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R E TA IN E R (9 P LA C E S }
VIEW
TR A N S MIS S ION C ON S OLE A S M.
SECTION A_A
...-..--.
A 1 1", 2.4- 3 .4 Nm
>:\
EOOT ST RAP T O B E P LA C E D T OWARDS F RON T OF C A R
VIEW rF r l
S E A L S C R E WWITH N ON .P OR ITE OR E OU IV A LE N T N ON -H A R D E N IN G S E A LE R . (4 P LA C E S )
Flgure 1A-2
TR A N S MTS S TON C ON TR OL C OV E R _
FOR A U TO TR A N S
r coN rR oL--r 3? I:3 ,.- g:3I: lf LEVER BOOT

B E FOR E IN S TA LLA TION A P P LY N E OP R E N EC E ME N T TO IN S ID E OF B OOT OV E R A R E A S H OWN THUS, /////// FOR C ON N E C TTON '/- R E FE R S E C TION 12E
":
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SECTION B_B
REFE R S E C T I O N 1 2 E
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E LE C T R I C D O O R W I NDO W R E G U L A T O R S SW I T C H A S S E M B L Y
acARPET / /
TR A N S MIS S ION C ON S OLE A S M.
A P P LY TR IM A D H E S IV E OV E R A R E A S H OWN THUS \\\\\\\
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Figure 1A-3
16
BODY 1A-5
. 2.3 TRANSMISSION CONSOLE AUTOMATIC
Remove 1. Disconnect batterygroundcable. 2. Using a wide bladed screwdriver, carefullyprise cap from console (refer Section C-C, Fig. 1A-4)turn cap through 90C, then remove cap of 'T' bar gear control lever. 3. Remove gear lever location indicator scale from console (referSectionsA-A and B-B, Fig. 1A4). 4. On 'SL' models, remove screw cover buttons and scrervs securing lront and rear end of console to transmission tunnel (refer Fig. 1A-2). 5. On Berlina and Calais models. raise console compartment lid and remove rear end of carpet in base of console which covers screws securing rear end of console to transmissiontunnel bracket (refer SectionB-8, Fig. 1A-3)then removescrews. 6. Partially raise rear end of console, disconnect electrical connectors then, easing console rearwards to disengage front end of console from attaching bracket (reler Section B-8, Fig. 1A-3),then remove screws and consoleassembly. Reinstall Reverse removal operations ensuring that the note in Fig.1Arelerringto automaticconsolescale installation 4. is observed.
CONSOL E CAP _
+---___> <.,/ '

C ON TR OL LE V E R OP E N IN G C OV E R R E T A IN S C A LE A S SH OW N
sEcrroru A-A
W I T H G EAR SHIF T L EVER I N N E U T RAL , AL IGN' N' ON S C A L E WIT H INDICAT OR A R R O W ON COVER BEF R E T A I N I NG SCAL E.
B--B srcrroru
C ON S OLEC A P
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C-C sEcrroru
(4 P LA C E S )
TRANSMISSION INDICATOR_ TRIMATICAUTOMATICTRANSMISSION SELECTOR

Figure 1A-4
17
1A-6 BODY
2.4 SHROUD LOWERTRIM - RIGHT& LEFT HAND
REMOVE 1. Prise front end of front rocker panel cover from rocker panel (refer SectionA-A, Fig. 1A-5)then ease lower front end of linishing lace and weatherstrip assemblyfrom door opening pinchweldflange (refer SectionA-A, Fig. 14-6). 2. Using a fabricated trim clip removal tool (refer Special Tool Section) located between shroud lower trim and shroud panel and direcily under fastener head (referSiections B-B and F-F, Fig. 14-6) carefully prisefastenersfrom shroud panel,removing trim. REINSTALL Reverseremovaloperations.
2.5 ROCKERPANELCOVER- RIGHT& LEFT HAND

REMOVE 1. Using a wide bladed prising tool positionedbetween outer edge of cover and rocker panel,carefullyprise cover from door opening lower pinchweld flange (refer Fig. 1A-5). REINSTALL Locate front cover over door opening lower pinchweld flange, ensuringthat ends of cover overlapends of door opening finishinglace, then using the hand or a rubber mallet, tap top of cover until it completely engages retaining flange. NOTE:On rear covers,locate front end of rear cover so that it butts against the rear end of the front seat belt retractorcover priorto tappingcover into position.
f R E AR ROCKER P ANEL COVER \
FR ON T R OC K E R P A N E L C OV E R
._s ec r r oHA - A
secrrorv C-C
secrroru B_B ROCKERPANEL COVER INSTALLATION

Figure 1A-5
18
BODY 1A-7
C A R P E T P R OTE C TOR FLU TE D FA C E D OWN .
8V L, X S E C TION A _A
EVK
TR IM -J FA STE NE R S E C TION B _B (R IGH T S ID E ON LY )
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ON E P IE C E FLOOR C A R P E T N OTE : S E R V IC E R E P LA C E ME N T _ TWO P IE C E
SHROUD
T R AN SM ISSION C ON SO LE -.
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SEC T I O N D_D SECTION F _F 8 VL , X ( L E F TS I D EON L Y) Figure 1A
SECTI O N C- C
2.6 FLOORCOVERING
REMOVE 1. Disconnect batterygroundcable. 2. Bemove front end rear rocker panel covers and shroudlower trims (reler 2.5 and 2.4 in this Section). 3. Removetransmission console(reler 2.2 or 2.3 in this Section). 4. Remove panel cover assembly from heater case (referFig- 1A-7). 5. Removefront seat and rear seat cushionassemblies. Remove front seat belt retractor covers and seat belt inner and outer, lower attaching bolts (refer 6.3 in this Section). Using a fabricated trim clip removal tool (refer Special Tool Section) located between edge ol carpet and rocker panel and directly under head ol carpet attachingplug, prise plugs from rocker panels (refer Section C-C, Fig. 14-6) then remove floor covering. REINSTALL Reverseremovaloperations.
.
NOTE: Separate front and rear floor coverings are available from GM P & A as ServiceReplacements-
LOWE B IN S T R U \4E \T P A N E L E X TEN S ION
- H E A TE R C A S E TO P A N It. C OV E R A S M.
Figure 1A-7
19
BODY 1A-9
3. FRONTEND
INDEX
Ref. 3.1 3.2 Subject SEHVICENOTE PANELLOWERTRIM. INSTRUMENT RIGHT & LEFT HAND Page 1A-9 1A-9 3.5 3.3 Relnstall 1A-10 ............ Ref. 3.4 Page Subject PANEL LOWER. RIGHT INSTRUUENT ....... 1A-16 HAND .. 1A-16 Remove ......-...1A-16 Reinstall PANEL LOWER. LEFT INSTRUMENT RADIO AND HAND INCLUDING 1A.16 PLAYERRECEIVER.... RADIO/CASSETTE 1A-16 ..................... Remove........ ... 1A-17 Relnstall
3.1 SERVICENOTE
CAIITION: To avoid damage when seruicing instrument panels, frames, instrumentclusters,etc., it is essentt/to handle these components with the utmost care.
PANEL LOWERTRIM . 3.2 INSTRUMENT RIGHT& LEFT HAND

REMOVE 1. From under instrumentpanel and using a labricated trim clip removal tool (refer Special Tool Section) located directly under head of trim clip, carefully panel prise clips from attachingholes in instrument. trtm' lower (refer SectionA-A' Fig. 1A-8)removtng NOTE: Removal of right hand lower trim necessitates strap which partiallysecures of adlustable disengagement trim t; Jteeringcolumn(refer SectionD'D' Fig' 1A-8)'
5 T RIM CL IP _ 5 PL ACESR/SIDE \ - a PL AcES L /slDE EXc. c6o \ L islDE&c6 o \- 2 PL AcEs "r
REINSTALL that leadingedge of ensuring Reverse removaloperations left hand trim is correctlylocatedbeneaththe dash panel bracket and into wiring harness grommet (refer Section C-C, Fig. 1A-8) and that the leading edge of the right pedal supportcap' hand trim is locatedin the accelerator in SectionB-B, Fig. 1A-8. as illustrated
L O W E R P ART I N S T R U M ENT PANEL
A-A secrtoru
L H INSTR U ME N T PANEL LOWE R TR IM 8V X & C 6O
A C C E L ERAT o R- - 7 PEDAL |, c r l o p n F IT r - AP \< \
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R H IN S TR U ME N T-/ P A N E L LOWE B TR IM A D JU S TA B LE-_\ S TFA P R E TA IN FR ON T E D GE OF IN S TR U M E N TP A N E L LOWE R TR IM R IGH T S ID E T O S TE E R IN G C OLU MN D A S H P A N E L S E A L WITH A D JU S TA B LE S TR A P ,
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ASSEM BL ED IN ACCEL ERAT OR PEDAL SUPPORTCAP AS SHOWN
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T R I M BOARD T O BE A S S EM BL ED INT O W I R I N G HARNESS G R O I\4 M ET
TU C K E D A WA Y OR TR IMME D .
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Figure 1A-8
20
1A.10BODY
3.3 INSTRUMENT PANELPAD
REMOVE 1. Disconnect batterygroundcable. 2. Remove screw attached lower cover from upper sectionof steeringcolumn(refer Fig. 1A-9).
U P P E RS TE E R IN G C OLU MN C OV E R
3.
4.
5.
6. 7.
8. 9.
10.
Remove screws securinginstrumentframe, centre air outlet nozzle and touch panel lrom instrumentcover, disengage electrical connectors from main wiring harness (refer Fig. 14-10) then remove fram6 assembly. Remove screws securing top of instrument panel lower extension to base of instrument location cover (referFig. 1A-10). Remove screws securing combined instrument assemblyto instrument location cover (refer Fio.1A_ 1 1) ease assembly.rearward then disengage eiectrical connectorsand on all models,excepi those with electronic instruments, the speedo cable from j) then remove speedohead (referView A, Fig. 1A-1 instrument assembly. Remove instrumentlocationcover (refer Fig. 14_11) front radio speaker grille and speaker assem-bly lrefei View B, Figs. 14-12and 14-13). Using a fine bladed screwdriver, carefullyprise right hand and left hand upper and lower inserts from within side vent upper ouflet assemblies prior to removingscrews securing upper air outlet assemblies to instrumentpanel pad assembly(refer Fig. 14-14) then removeoutlet assemblies. With instrument panel compartment open, remove screws securing rearward edge o{ instrument Danel pad to instrument panelbrace (referFig. 14-14). Usinga 10 mm socketattachedto a ratchet handle, loosen right and centre nuts securingpad assembly to instrument panel brackets(refer Fig. 1A_11). Usin! the same tool with a 630 mm entensioninstalledoi the left hand attachingnut (use left hand upper air outlet apertureto gain access) loosen off left hand nut. Ease pad reanaards,disengagingpad studs from anstrument panel slotted brackets. With left hand of rnstrument panel pad raised, remove pad assembly fromvehicle.
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Flgure 1A-9
REINSTALL Reverseremovaloperations, includingtry-outof electrical ctrcurts, air ducting, vacuum hoses and temperarure controlcable disturbedduringremovaloperations-
21
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1A-16BODY
3.4 INSTRUMENT PANEL LOWER. RIGHTHAND
REMOVE 1. Disconnect batteryground cable. 2. Remove screws securing instrument frame, centre air outlet nozzle and touch panel from instrumentcover (refer Fig. 14-10), disengage electrical connectors from main wiring harness then remove frame assembly. 3. Usjng a fine bladed screwdriver, carefully prise out right hand upper and lower inserts from -within side vent upper outlet assembly. Remove screws securing upper air ouflet assembly to instrumentpanel pad (referFig. 14-14)then remove ouflet assembly. 4. Remove screw attached lower cover from upper sectionof steeringcolumn (refer Fig. 1A-9). 5. F_romunder right hand side of instrument panel, disengage electrical connectors from rear of light switch and dimmer control, vacuum hoses and temperature control cable, remove panel cover, then screws securing right hand instrument panel lower to base of instrumentlocation cover (refer View 'B' and Section A-A, Fig. 1A-14) then remove instrument panel lower. 6. Using a wide bladed screwdriver, carefully prise headlampswitch and dimmer control housing,ihen dimmer control from right hand instrumeni panel lower. REINSTALL Reverseremovaloperations, includingtry-out of electrical circuits, air ducting, vacuum hoses and temperature control cable disturbed during removaloperations.
3.5 INSTRUMENT PANEL LOWER. LEFT HAND, INCLUDING RADIO AND RADIO/CASSETTE PLAYER RECEIVER
REMOVE 1. Disconnectbattery earth cable. 2. Removetransmission console (reler 2.2 or 2.3 in this Section). 3. Remove heater case to panel cover assembly (refer Fig. 1A-10). 4. Remove left hand instrument panel lower trim (refer SectionA-A, Fig. 1A-8). 5. With instrument panel compartment open and with the blade of a screwdriver located between head of hinge pin and right hand compartment side, prise out hinge pin compartment(refer Fig. 1A-t5) ihen re_ move comDartment. 6. Removeleft hand shroud lower trim (refer2.4 in this Section). 7. Removelett hand upperside vent ouilet (refer 3.4 in this Section). 8. Remove touch switch control panel and electrical connector (referFig. 1A-10). 9. Remove screws securing the centre nozzle and instrument locationframe assembly(refer Fig. lA_10) disengageelectricalconnectors from front e-nO wiring harness, then removeframe assemblv.
B U MP E R (2 P LA C E S )
\N
IN S TR U ME N T P A N E L C OMP A R TME N T
Figure 1A-15
27
BODY 1A-19
4. REARQUARTER
INDEX
Ref. 4.1 Page Subiect OUARTERWINDOWINNERUPPERTRIM 1A.19 1A-19 ilodels - 19 Body Styles ....................
WINDOWINNERUPPER 4.1 QUARTER T R IM

MODELS. 19 BODY STYLES Remove 1. Depress front edge of rear seat cushion assembly then ease assembly rearwardsto disengageassembly retainer from brackets attached to the floor (refer SectionA-A, Fig. 1A-16)removeand place assembly onto a clean protected surface. NOTE: On rear seats fitted with head restraints, it is necessary to remove the head restraints and guide sleeves(refer 6.4 in this Section)prior to removalof rear seat back assembly. 2. Unclinch tabs securing seat back frame to rear (referView A, Fig. 1A-16). wheel-houses 3. Lift seat back frame from retaining brackets attached to the rear compartment front panel (refer Section B-8, Fig. 14-16) then place rear seat back assembly onto a clean protected surface.
C U S H ION A S M.R E TA IN E R
R E A R FLOOR BRACKET
A-A secrroru
REAR C OMP A R TME N T FR ON T P A N E L
SEAT BACK R E TA IN E R
secrroru B-B k=- ,
Flgure 'lA-16
Remove rear seat belt upper attachment (refer SectionB-B, Fig. 1A-17).
Figure 1A-17
28
1A.20BODY
5. From inside rear compartment,tap out fasteners securingtrim to rear parcel shelf (refer Section A-A, Fig. 14-18) on side from which quarterwindow trim is to be removed.
REAR PARCEL S H E LF TR IM
FA5
III\EH
(3 P LA C E S )
SECTION A_A Figure 1A-18
6.
Ease rear door opening finishing lace from leading edge ol quarter windowinner upper trim, then usini a broad bladed screwdriver locatedbetweentrim and quarter inner panel,adjacent to trim fasteners (refer Sections A-A and B-B, Fig. 14-19) carefully prise fasteners and trim lrom rear quarter inner upper panet.
Reinstall Fleverse removaloperations. NOTE: Damaged barbs on trim panel fasteners requtre fastenerreplacement.
IaUARTER WI N D O W I N N E RU P P E R
FA S TE N E R S _\
secrroru A-A
{4 P LA C E S R /L)
secrloru B-B
(1 P LA C E R i L)
Figure 1A-19
29
BODY 14.21
GLASS 5. STATIONARY
INDEX
Re{5. 1 5.2 5.3 Page Subject ..... 1A-21 DESCRIPTION 1A-21 ........-........... SERV|CENOTES REAR OUARTERWINDOWASSEMBLY....1A-22 1A-22 Models - 19 Body Sty|es..................-. ...........1A'22 Remove........ Quarter Window Aperture Check .--. 14'23 1A-23 Reinstall Ref. 5.4 Subject Page
Reinstall ... Long Method..... Reinstall ...
'tA-28 1A-29 1A-29
5.1 DESCRIPTION
Toughenedglass is fitted to rear quarterapertureson 19 body styles and to tailgateson 35 body styles. These glasses are bonded to the rear quarter upper panel and tailgate qperture flanges with a self curing metal to glass urethaneadhesive. ln situations necessitating complete removal of the original urethane,such as damage to window apertures where paint finish or base metal is exposed,a urethane adhesivekit has been developedand must be used to maintainthe originalstructuralspecifications. 2 'Long Method'.The repair kit for this Part No. 9201861 operationcontains: 300 ml UrethaneAdhesive. 25 ml Glass Primer- Clear. - Black. 25 ml GlassPrimer 435-56 25 ml BodYPrimer. NecessaryaPPlicators. lnstructions. - Long Method, NOTE: For tailgatewindow replacement an additional auxiliary kit, Part No. M39097, which is required. contains300 ml of urethaneadhesive, ADDITIONALCOMPONENTSREOUIRED (Not part of package) as required. mouldings Appropriate referredto as A second method lor window replacement the 'Short Method' is used when original urethane adhesiveleft intact on the window apertureflanges after glass removal can serve as a satisfactory base Jor the reinstallalionof the original or new glass. This would occur when the glass is being removedto overcome a severewater leak, or when a glass is broken-
The repair kit developedto servicethis Short Methodor 1 Minor Water Leak correction is part number9201861 and contains: 300 ml Urethane Adhesive. 25 ml ClearGlass Primer. 25 ml Glass Black Out Primer. NecessaryApplicators. Instructions. from:These replacement kits are available Dimet, 53 ShowersStreet. Preston, Vic. 3072. kit which is only An additionalshort method replacement recommendedfor rear quarter windows on sedans, is availablefrom GM P & A under Part No. M38977 and contains300 ml of silicone. for minor water leak This materialis also recommended glass. stationary correction on all urethaneinstalled
NOTES 5.2 SERVICE

WORK GLOVESMUST BE WORN AT ALL WARNING: WITH GLASS. TIUES WHEN OPERATING NOTE: Skinning (partial curing) ol the urethane comAt 23oC and mences after exposureto the atmosphere. 50 % relative humidity, skinning commences after 30 minutes. Therefore, installation of tailgate window mouldingsmust be completedwithin that time limit on station wagons. Complete curing of urethane at this temperatureand humidity takes 72 hours. tool for cutting through the urethane The recommended is the glass sealant removalTool No. J24402,which can Australia Pty. Ltd. be obtainedfrom Kent-Moore
30
1A-22 BODY
5.3 REAR QUARTERWTNDOW ASSEMBLY
MODELS. 19 BODY STYLES Remove The quarterwindowglass removalprocedureis similarfor both the 'Short' and 'Long' Installation Methods with one exception.lf the Short Method installation is to be used, more care must be taken during glass removalto ensure that an even bead of urethane adhesive rematns on quarter window aperture flanges to serve as a base for the replacement glass. 1. To prevent damage to paint finish and trim and to minimiseclean up, mask and place protectivecovers over parts adjacent to glass. 2. Using fingers or a wide bladed screwdriver, carefully prise ..otf _leading edge of roof drip guner teal mouldingfrom garnish moulding (retei S6ctron nUAM, Fig. 14-20). 3. Remove screw securing rear end of quarter reveal moulding lower (refer Section AN_AN; Fig. 1A-20) and removemoulding.
\ *a o " R o o F D R r p GUTTER MOULDING
QU A R TE R WIN D OW GA R N IS H MOU LD IN G A S S E MB LY S E C TION A M_A M
OU A R TE R WIN D OW GA R N IS H MOU LD IN G
LOWE R OU A R TE R WIN D OW R E V E A L MOU LD IN G
sE crtoN A N -A N
Figure 1A-20
4.
Femove remaining screws securinggarnish moulding to rear quartr aperture (refer Fig. 14_21) thei remove garnish moulding,which is ittached to the outer surfaceof the glass with four (4) short strips of buVl, .centrallyspaced at top, Oottdm and sides of garnish moulding (refer View H, Fig. 14_22) then removegarnishmoulding.
Fagure1A-21
31
BODY 1A-23
B U TY L S TR IP S (4 P LA C E S ) V IE W
Flgure 1A-22
5.
6. 7.
Locate blade of Tool No. J24402, glass sealant remover, beveen inside of glass and urethaneas illustratedin Fig. 14-23, then cut through urethane, aroundcompleteperipheryof glass. Carefully lift glass out of aperture. lf there is evidence of glass adhesion to urethane, re-apply cuttingtool to problemarea. place glass on a lf originalglass is to be reinstalled, protectedbench or holdingfixture and using a sharp scraper, carefully remove original urethane lrom glass. Clean glass with a suitable oil-free cleaning agent such as Prepsolor equivalent.
J24402 GLA S S S E A LA N T R E MOV A L TOOL
A P P R OX IMA TE A R E A E OU A LS ON E S OU A R E cE N TIME TR E ---7
NOTE: Do not use petroleum base solvents to clean glass or aperture flange as the presence of oil will prevenlthe adhesionof new urethane/silicone.
\ 7\
170
H N 1749 U R E TH A N E A D H E S IV E V IE W
Flgure 1A-23
OUARTER WINDOW APERTURE CHECK Thoroughly check rear quarter window aperture flange to ensure that no surface irregularities exist' Correct any is being used' that do. lf 'Short Method'glass installation or voids' check originalurethaneon flange for looseness Where these exist, cut away any loose urelhaneand fill in any voids or uneveness in bead' using urethane/silicone. Reinstall Short Method 1. Short Method installationof rear quarter glass is used where the maximum amount of original urethaneadhesiveis left intact on the body opening to form a base for the replacement glass- This method should be used when replacinga cracked glass or leak conditionthat cannot be overcomeby using minor water leak repair procedures. Any previous service installation using other adhesive materialsrequirescomplete replacementof material to achievean effectiveglass to metal bond.
32
1A-24 BODY
2. Thoroughly clean surface of glass to which new urethane/siliconeis to contact (includingedge of glass). Use clean cloths with a suitaSle oil_free cleaningsolvent,such as prepsolor equivalenlURETHANE ONLY Usingan applicator in Kit,.applyHN1747(clearglass ?lr"r) around entire perimeter of glass'edge and 12 mm in.from edge of glass.This is-a wipe o"n/wipe off operation,using clean lint free cloths'(referView E, Fig. 14-24). -
')
URETHANE ONLY U.sing a.second applicator, apply HN1748 (black-out glass primer) around entire perimeterof glasJ edge and on,.glassbondingsurface (refer View-G, Fig. 1"A_ 24). Allow primer to dry for lS minutes. Avoid touchingprimedarea of glass. Install glass with its inner surface facing upwardsinto garnishmouldingas illustrated in View H, Fig. 1A_24, then firmly press glass onto butyl strips loEateo on garnishmouldingrecess. Apply a smooth continuous bead of urethaner silicone between centre and outer edge on top of originalurethaneand aroundentire periireterof body opening. Silicone bead should be a minimum of 6 mm in diameter. 7. Installglass.andgarnishmouldingassemblyinto rear quarter window aperture,applying sufficieni pressure on assembly to evenly distribute silicone between glass and aperture flange to effect a watertightseal.
4.
(B LA C K OU T) P R IME R
B U TY L S TR IP S (4 P LA C E S ) V IE W
Figure 'lA-24
Install screws securinggarnish mouldingto the top and sides of the windowaperture(referFig. 1A-25). 9. Water leak test quarter window using a moderate spray of water. NOTE: Do not direct a heavy stream of water onto freshly applied silicone.lf watei leak is evident,remove garnish moulding and apply additional silicone to teak area, using a flat bladed tool to work fresh siliconernro the sourceof the leak, then installgarnishmoulding.
8.
S C RE W r5r 'l P tr
AUtrJ
i ,9 v
Figure 1A-25
33
BODY 14.25
10. Installscrew attachedquarter reveal mouldinglower to lower section of garnish moulding(refer Section AN-AN,Fig. 1A-26). 11. Locatehookededge of roof drip gutterrear moulding over reanrard outer edge of garnishmoulding,then with the hand, lightly tap opposite side of moulding over garnish moulding (refer Section AM-AM' Fig. 1A-26). '12. Removepaint and trim protectivemaskingtape and covers. NOTE: White spirit is recommended for removal of siliconefrom paint finishand trim'
R E A R R OOF D R IP GU TTE R M OU LD IN G OU A R TE R WIN D OW GA R N IS H MOU LD IN G A S S E MB LY
Long Method The long method of glass replacementis used when original urethane adhesive material cannot serve as a glass. base lor replacement be used on vehiclesrequiringmetal This method should or paint repair to the quarter window aperture flange when original adhesive is completely removed and replacedwith new urethanefor glass installation. This method is also used when the quarterwindow has been previouslyreplaced, using the Short Method. In could such instances,the build-up of urethane/silicone positionthe glass too far out of the opening. 1. Using the glass sealant removal tool andlor sharp scraper,removeoriginalurethanefrom around entire flange. perimeter of quarterwindow aperture 2. Using an applicator supplied in 'Long Method' Repla c e m e n tKi t N o .9 2 0 2 3 1 2 3 , appl y H N 1752 (Flangeprimer)to any section of the quarterwindow aperture flange that is back to bare metal or has been cleaned back to original paint surface (refer Views A, B, C & D, Fig. 1A-27).Allow primerto dry Avoid touchingprimedarea. for 30 minutes.
F L ANGE PRIM ER
sE crroNA M-A M
LOWE R OU A R TE R W IN D OW R E V E A L MOU LDIN G
AN-AN sEcrroN
Figure 1A-26
E
u,.*lEl
u,.*lfl
Figure 1A-27
34
1A-26 BODY
Thoroughly clean inner surface of glass to which urethaneis to be appliedas well as around complete edge of aperture flange. Use clean cloths with suitable oil-freecleaning solvent such as prepsol or equivalent4. llging an applicator in Long Method Kit, appty HN1747 (clear glass primer) around entire perimeier gf glass edge and 12 mm in from edge of glass. This is a wipe on/wipe off operation,ushg clean lint free cloths (referView E, Fig. 14-28). 5. To maintain appearance and minimise clean up, install a foam sealingdam, part Number920181i9 to glass.Commencing at either lower corner of glass, locate dam around entire perimeterof glass, 7 mm from edge on inner surface (refei View F. Fig. 1A-28). NOTE: A suitablegauge to maintainthe dam 7 mm from edge of glass can be readily fabricated by cutting a 7 mm notch in a piece of wood. Locate the 7 mm dimension of the gauge onto the inner surface of the glass, locatingthe outside edge of the dam on the end of the 7 mm dimension. 6. U.singa second applicalor,apply HN174g (black_out glass primer)around entire perimeterof glass edge qnd on glass bondingsurface (refer View-G, Fig.1;A291. Allow primer to dry for 15 minutes. Avoid touchingprimedarea of glass. 7. Tidy up strips of butyl centrally located on top, bottom and on both sides ol garnish moulding(refer View H, Fig. 14-29) 8 . Install glass with its inner side facing upwards into garnishmouldingas illustrated in Vievrr H, Fig. 14-29. Firmly press glass onto butyl strips locateJ at four places on garnishmouldingrecesso Using a hand operatedapplicator with specialnozzle supplied in kit, apply a smooth continuousbead of HN1749 urethane adhesive, 17 mm high and 7 mm at base, around entire perimeterof inner surface of glass (referView J, Fig. 1A-29). 3.
\--
12.O
VI EW
'fE[F[-cTJl
Figure 1A-28
7.O
-\
-'/
APPRO X A R E A E O U A L S O NE SO UA R E CE NTI METR E
oo**,r l*
MOU LD IN G URET HANE ADHE S IV E B U TY L S TR IP S (4 P LA C E S )
Figure 1A-29
35
BODY 'IA-27
NOTE: In cold weather, the placement of cartridges adlacent to a source of warmth, will assist the flow of urethanewhen using a hand applicator. 10. Installglass and garnishmouldingassemblyinto rear quarter window aperture (refer Views K and L' Fig. 1A-30) applyingsufficientpressureon assembly to evenly distribute urethane between glass and aperture flange to effect a watertight seal' 11. Install screws securing garnish mouldingto top and sides of the quarter window aperture (refer Fig. 1A-30). 12. Water test quarterwindow using a moderatespray of water. NOTE: Do not direct a heavy stream of water onto freshly applied urethane. ll a water leak is evident, urethaneto removegarnishmouldingand apply additional the leak area, using a flat bladed tool to work urethane into source of leak, then installgarnishmoulding.
GLA S S P A IN T-OU T
GA R N IS H V IE W V IE W
x\
'\\
'\w
\\
Figure 'lA-30
Install screw attached quarter reveal mouldinglower to bottom horizontalpart of garnish moulding(refer SectionAN-AN,Fig. 1A-31). 14 . Locate hooked edge of roof drip gutter rear moulding then over rearwardouter edge of garnish moulding, with the hand, lightly tap opposite side of moulding over garnish moulding (refer Section AM-AM, F ig. 1 A -3 1 ).
IJ
B E A R R O OF D R IP GU TTE R MOU LD IN G
OU A R TE R WIN D OW GAR N IS H MOU LD IN G A S S E MB LY
AM-AM sEcrroN
SC R EW
---
wrNDow LowER OuARTEB R E V E A LM O U L DIN G
sE crroNA N -A N
Figure 1A-31
36
1A-28BODY
5.4 TAILGATEWINDOW
MINOR WATER LEAK CORRECTION Locate area of leak. Workingon inside surfaceof glass, apply paint scraper or similar wide blade tool between glass and lacing. Gently flex lacing away from glass in area concerned. Clean any foreign material from this area. Apply HN1770siliconeto area concerned ro correct leak. SHORT METHOD Remove 1. Disconnect battery ground cable and on Berlina model, remove tailgatewindow wiper arm and blade assemblyand electrical demistconnector. 2. Apply protective tape to paintwork adjacent to mouldings as shown in View A, Fig. tA_32, and place protective covering adjacent to gliss. 3. Removemouldingsystem:a. Side mouldings- Inserta paint scraperor similar wide blade tool between moulding and body. Apply a rolling action towards the glass as shown in View A, Fig. 14-33, over fult iength of moulding to loosen, carefully remove moulding intact for reuse. b. Upper and lower mouldings - Methodas for side mouldings. 4. Remove all glass fragments from original glass adhesiveleavingadhesiveintact on tailgate. 5. Using clean, lint free cloths, dampenedwith an oil free solvenl such as Prepsolor equivalent, thorough_ ly clean surfaceof glass which siliconeis to contact. including glass edges. CAUTION: Do not use petroleum based solvents,as the presence of oil will prevent adhesion of the fresh urethane/silicone.
P R OTE C TIV E TA P E
V IE W
Figure 14-32
P R OTE C TIV E TA P E
Reinstall 1. URETHANE ONLY Prime the edge of glass and on the glass bonding surface '12 mm lrom the edge with glass primeri clear (HN1747).This is a wipe on wipe otf operation (referView B, Fig. 14-35). URETHANE ONLY Prime the edge of glass and on the glass bonding surface 7 mm from the edge with gl-assprimer : black (HN1748) and ailow to dry for 15 minutes (reler View C, Fig. 14-35). Apply 6.0 mm bead of urethane/silicone to original adhesiveand also to the groove left in the adhelive by the mouldings. With tailgatein near horizontal positionfit new qtass. Refit upper and lower mouldings. Refitside mouldings. Apply tape to hold mouldings in position where reguired. This tape to be left on' for 24 hours mtntmum.
V IE W
Figure 1A-33
2.
3. 4. 5. 6. 7.
37
BODY 1A-29
8. positionfor a minimumof Leavetailgatein horizontal 5 hours, after which time vehicle may be driven providing tailgate is not slammed excessively for 24 hours. 9. On Berlina model, install tailgatewindow wiper arm and blade assemblyand demist electricalconnector and on both models,battery ground cable10. Remove maskingtape from tailgate, clean adiacent paint finish and glass, then remove protectivecovering from interior.
,/-C OLD
K N IFE
r TA ILGATE W IN D OW U P P E RMOU LD IN G
KN I F E BLAD E
U R E TH A N E '
TA ILGA TE TO B E IN N E A R H OR IZON TA L P OS ITION
Figure 1A-34
LONG METHOD Remove 1. Disconnect battery ground cable and on Berlina model, remove tailgatewindowwiper arm and blade demistconnector. assemblyand electrical to paintwork adiacent to protective tape 2. Apply mouldings as shown in View A' Fig. 1A-32, and place protective coveringadiacentto glasssystem:3. Removemoulding - Inserta paint scraperor similar a. Side mouldings wide blade tool between moulding and body' Apply a rolling action towards the. glass as shown in View A, Fig. 14-33, over tull length of moulding to loosen, carefully remove moulding intact for reuse. - Method as for side b. Upper and lower mouldings mouldings. 4. Remove all glass fragments and urethane, using blade of glass sealant removal Tool No' J24402 in Fig. 1A-34. illustrated to removeall traces of original NOTE: lt is not necessary urethane. However, any remaining urethane must be smoothand firm.
Reinstall 1. Prime body aperturewith body primer (HN1752)and allow to dry for 30 minutes (refer View A' Fig. 1A-35). 2. Prime the edge of glass and on the glass bonding surface 12 mm from the edge with glass primer This is a wipe on wipe off operations clear (HN1747). (referView B, Fig. 1A-35). 3. Prime the edge of glass and on the glass bonding surface 7 mm from the edge with glass primer black (HN1748)and allow to dry for 15 minutes (referView C, Fig. 1A-35).
Figure 1A-35
38
1A.30 BODY
4.
5,
o.
7.
9. 10.
Apply an even bead of urethaneadhesive(HN1749) 9.0 mm x 7.0 mm to blading flange as shown In View B, Fig. 1A-36, using nozzle cut as shown in ViewC, Fig. 14-36). Fit the glass immediatelythe urethane bead is appliedto the body. lmmediately the glass is installed, fit mouldingsystem after. ensuring that enough urethane is pr6sent to bond the mouldings.(Apply additional adhesive to bond mouldingsif required.) Apply tape to hold mouldings in position where reguired. This tape to be left on for 24 hours mrntmum. Leavetailgatein horizontal positionfor a minimumof 5 hours, after which the vehicle may be driven providing tailgate is not slammed extessively for 24 hours. On Berlina model, install tailgate window wiper arm and blade assemblyand demist electricalconnector and on both models,batterygroundcable. Remove.masking tape from tailgate,clean adjacent paint finish and glass, then remove protectivecovering from the interior.
h"'
vrew lel
Figure tA-36
39
BODY 1A-31
6. SEATS& SEAT BELT ASSEMBLIES

INDEX
Re{. 6.1 6.2 Page Subject 1A-31 DESCRIPTION LUMBARSUPPORT. DRIVERSSEAT ...... 1A-31 1A-31 Models - Berlina and Calais 1A-31 Remove...-...1A-33 Reinstall AND FRONTSEAT BELT RETRACTOR 1A-33 BUCKLEASSEMBLIES 1A-33 Remove........ 1A-34 Reinstall Ref. 6.4 Page Sublect REAR SEAT BELT RETRACTOR 1A-34 .........-......... ASSEMBLY
6.1 DESCRIPTION
New seat trim materialsand patterns are released for VK models. New features on front seats include 'see through' head restraints on all models and on the drivers seat on Berlina& Calais models,a knob operatedlumbar support is built into the seat back assembly(refer Fig- 14-37). On the Calais model, see through head restraints are fitted to the rear seat backs.
Figure 1A-37
. DRIVERSSEAT 6.2 LUMBARSUPPORT

MODELS. BERLINA AND CALAIS Remove 1. Slide seat fully fonrvardand remove bolts securing rear end of seat adiusterto floor (reler Fig. 1A-38). 2. Slide seat rearward and remove bolts securing lront end of seat adiuster. 3. Removeseat from vehicle and place face down on a clean protected surface.
-S
SCREW (20.0 - 25.0 N m)
OU TB OA R D C OV E R
c vtout'lrtru
A-A sEcrroru
L A P P LY 5.0 D IA B E A D OF S E A LE F A R OU N D TOP E D GE OF H OLE S IN FLOOF P A N B E FO R E IN S TA LLA TION OF S E A T A S M.
Figure 1A-38
40
1A-32 BODY
4. From under driver's seat cushion, remove elastic straps which are looped under tension over sear cushion spring convolutionsand which retain lower edge of seat back carpet assembly(refer Fig. 1A-39) ancl tape carpet up out of the way.
S E A T B A C K C OV E R C A R P E T R E TA IN E R
Figure 1A-39
5.
Remove hog rings securing seat back cover retainerto front retainer(refer Fig. 1A-40).
S E A T B A C K C OV E B R E TA IN E R .,W''
C LIP
Figure 1A-40
Locate the forked end of a door interiorhandle clip removal tool (refer Fig. 14-41) inside of lumbar support handle, then press tool downwards ro disengage'horse shoe' type retainingclip from slot in splinedspindle, then removehandle.
IN TE FIOR D OOR H A N D LE C LIP R E MOV A L TOOL
LU MA A R S U P P OR T C ON TR OL K N OB N OTE : i w l rH LU MB A B suppoR r,
IN 'SOF T 'PO SIT ION , IN ST ALL H AN D LE U PF IIG H T & PAR ALLEL T O F R AM E. I ]
R E C LI N FR C ON TR OL K N OB
Figure 1A-41
41
BODY 1A.33
7. Carefullyease sides of seat back cover upwards, exposing heads of screws securing lumbar support bracketsto sides of seat frame (referFig. 14-42).
Figure 1A-42
Remove attaching screws, then lumbar support assemblyout through bottom oi seat back assembly (referFig. 1A-43).
S E A T C U S H ION A S M
Reinstall ensuringto adequatelyseal Reverseremoval operations, seat assembly attaching screw threads (refer Section A-A, Fig. 14-38) and to observe lumbar support control . knob note in Fig. 1A-4'l
Figure 1A-43
6.3 FRONTSEAT BELT RETRACTOR AND BUCKLEASSEMBLIES

REMOVE 1. With front seat located fully forward, remove cover from bolt securing upper seat belt attachment lo centre pillar (refer Section A-A, Fig. 14-44) then removebolt and upperattachment. 2. Using a pointed tool, carefully prise out the pins securingthe seat belt retractorcover to the centre pillar(refer SectionC-C, Fig. 1A-44). 3. Remove cover from bolt securing seat belt lower to floor pan, then remove bolt and lower attachment seat belt attachment. 4. Ease front end of rear rocker oanel cover and rear end of front rocker oanel cover uowardsto release lower part of retractor cover, ease upper tastener from centre pillar, releasing cover and seat belt retractor (refer Fig. 1A-44).
42
1A-34BODY
. /. L OCAT E SEAT BEL T 7 T ONGUE WIT HIN 7 6 .0 m m OF T HE _t ^ SASH GUIDE.
SPACER
-bULI
UPPER A TTA C H ME N T C OV E R a BUCKL E ,/ ASM. WA V E WA S H E R S E A L WITH N ON H A R D E N IN G S E A LE R
SECT I O N A_A
SECTION B_B
Z W I T H SEAT IN FULL F O R W A R D P O S I T I O N T HE I NBO ARD P A R T O F B E L T IS T O BE I NSTA LLE D A T A N A N G L E WHICH PASSEST H R O U G H I N T E RSECT ION O F SEAT C U S H I O N & S E A T BACK C O NTO U R S .
LOWER ATT A C H M E N T BOLT SEAL WIT H NON HARDENING

JtrALtsH
sEcrtoN c-c
r..
S E A T B E LT R E TR A C TOR C OV E R
Fagure 1A-44 5. Remove cover and bolt securing seat belt buckle assemblyto transmission tunnel (refer Section B-B. Fig. 1A-44)then removebuckleassemblv.
REINSTALL Reverseremovaloperations, ensuringthat both lower bolt threadsare sealedwith non hardening sealerand that all seat belt attachingbolts are torquedto 53 - 71 Nm.
6.4 REAR SEAT BELT RETRACTOR ASSEMBLY

Remove '1 . Depresstop of seat back adjacentto head restraint sleeve to gain access to clip, retainingsleeve (refer Section A-A, Fig. 14-45). Using i ttat btaded screwdriver, carefullydisengagesleeve clips then lift out head restraints. 2. Twist head restraint sleeves in an anti_clockwise directionthen lift sleeves out of bracketswelded to the rear parcelshelf(referSection A-A. Fiq. 1A-45).
43
BODY 14.35
S LE E V E
RESTRAI NT 7
,-\
IN S E R T S LE E V E IN TO MOU N TIN G B R A C K E T, R OTA TE A N D P U S H S LE E V E D OWN . E N S U R IN G TH A T LU GS A , B & C P A S STH R U N OTC H E S IN TOP OF MOU N TIN G B R A C K E T & E N GA GE A S S H OWN IN S E C TION S AA. BB.
LUG A
MOU N TIN G B R A C K E T S E C TION A _A
LUG B SECTION B_B
Figure 'lA-45
e
Depress front edge of seat cushion assembly rearwards to disengage assembly retainer from brackets attached to the floor (refer Section A-A, Fig. 1A-46)remove,then place assemblyon a clean protected surface. Unclinch tabs securing seat back frame to rear wheelhouses (refer View A, Fig- 1A-46) lift trame from retaining brackets attached lo the rear compartment front panel (refer Section B-8, Fig. 1A-46) remove, then place frame assembly on a clean protected surface.
cusHloN ASM.-1 RETAINER \
I eR ncret
R EAR
F LO O R
S E C TION A _A
C OMP A R TME N T FR ON T P A N E L
SEAT BACK R E TA IN E R
B_B SECTION
r C LIN C H ... OV E R TA B
Figure 1A-46
44
1A-36BODY
From inside rear compartment,tap out fasteners securingtrim panel to rear parcel shelf (refer Section A-A, Fig. 1A-47)disconnectretractorseat belt guides from outer edges of rear parcel shelf (refer Section A-A, Fig. 14-48) parfly raise rear parcel shelf trim, disconnect speaker connectors from rear harness, then remove rear parcelshelf trim. Remove bolts securing tear seat belt lower attachments,includinglap type seat belts, to floor pan and rear wheelhousepanels (refer Section C_C and D-D, Fig. 14-48). Remove cover, then bolt securing rear seat belt upper attachmentto quarter inner upper panel (refer SectionB-B, Fig. 1A-48). From inside of tear compartment, remove bolt securingrear seat belt retractorassemblyto quaner inner panel (refer Section A-A, Fig. 14-49) remove retractor assembly,feeding seat belt, buckles, etc. out throughslot on outer edge of rear parcel shelf.
REAR PARCEL S H E LF TR IM
\'
1r SECTION A_A Figure 1A-47
luur-ZtU.l1.l1 :-irlli=i:
'/...-'_,.-', (3PLACES) / tYfrn lnnrn
Reinstall R.everse.removal operations, ensuringthat the threads o{ all seat beft lower attachingbotts aie aJequitery seateO harde.ning seatei (refer Sectionsb_C anO O-O, :,,1h Frg. ?^"-ol. tA-4E) and that all rear seat belt attachingbolts are torquedto 50-70 Nm duringinstallation. NOTE: On 35 body styles, the retractor assembliesare mountedonto the rear quarterinner panels (refer Section A-A, Fig. 1A-49).
SASH GU I D E
SEAT BELT RETRACTOF ASSEMBLY
B OLT A
N\/ i\/ ti
/S\
_-+ASSEIVIBLY
r}
sEcloN B-B
-2pLACES
-t, t
C A NC HoRTo 8 E
VERT I CA L L Y UPW A RD SW H E N FITTED .{ u.-J . :-+y-. f ,/ - e OL r I
A
JtrAL
sEcrtoN A-A
-2pLAcES
WITH N ON H A R D E N IN G S E A LE R
WIT H NON / - S EAL HARDENT NGSEAL ER A X IS OF S Y MME TR Y OF A N C H OR TO B E P A R A LLE L TO V E H IC LE IN FR ON T V IE W
ENSURE w,"i'r,c HARNESs r s c LEAR OF ANCHOR WHEN ANCHO R I S FI TTED, _ 2p LACES sE cr to N C-C .,'l . so - ro i.rFigure 14-48
t-ro.t
secrroru D-D
45
BODY 1A-37
if.gl----=--h c ur DE
SEAT BELT TONGUE=-
#i3fitl?"fal'^ri;. t--'
LN< 4
oF sASHGUIDE l
i''' ,.
(f",- i '''\ | -\:1-'.,',,
.' '' .-'.' ..".1 A eo.t u,a* R

A X IS OF S Y MMETR Y OF A N C H OR TO B E P A R A LLE L
ro vE H rcLE r Ror ur 0 rru

V IE W. N OTC H TOW A R D S FR ON T OF C A R
srcrroru A-A
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46
BODY 1A.39
ORNAMENTATION 7. EXTERIOR
INDEX
Ref. 7.1 7.2 7.3 Page Subject ....... 1A-39 DESCR|PTION.................... 1A-46 .............. FRONTPILLAR DRIP MOULDING 1A-45 Remove 1A-46 Reinstall 1A.46 ASSEMBLYREAR.......... DRIP MOULDING 1A'46 Models - 19 Body Sty|es.............'...... 1A-46 Remove ...... 1A-46 Reinstall 1A-47 ROOF DRIP I'OULDING 1A-47 Reinstall FRONT& REAR DOOR SIDE MOULDING 1A-47 ....- 1A-47 Model - Ca1ais............ ...........1A-47 Remove........ 1A-47 .......-......... Reinstall FRONTFENDERSIDE & SIDE PANEL 1A.48 .............. ASSEMBLIES FRONTMOULDING 1A-48 Model - Calais Ref. 7.7 Page Subject TAIL LAMP REVEALMOULDING ... 1A-48 ASSEMBLY Models - SL and Berlina, 19 Body 1A-48 ..........-. Styles 1A-48 ............ Remove
7.4 7.5
7.8
7.9
7.6
7.1 DESCRIPTION
on the VK seriesconsistsof deep Exteriorornamentation section body side mouldingson Calais and wide section on SL and Berlina19 and 35 body body side mouldings name appears on the styles. The Commodore/Berlina rear of 19 and 35 body styles except on Calais, which lid and featuresa Calaisbadge on the rear compartment front fenders.Calaisemblemsare also fitted to the front fender and engine hood. Holden and Lion badges are fitted to the lront and rear of all modelsexcept the front of the Calais, which features a Holden badge on its radiator grille. Badges for option engines and for electronic iniection are fitted to the front fenders of sedans excepl on the Calais, which leatures these badges on the rear compartmentlid. On models fitted with the base engine (E-S.T.) automatic transmission together with power steering,an 'Executive'applique is appliedto the quarterwindowson sedansand rear door stationary windows on station wagons. Belt line mouldingsare fitted to all models (reler Figs. 14-50, 1A -54, 1A -51, 1A -52,1A -53, 1A -55). Clips,fastener studs, bushes,screws and contact adhesive secure the various exterior mouldings,badges, emblems,etc. to the VK body styles. The tailgatewindow exteriormouldingsare embeddedin the urethanesecuringthe windowin the tailgateaperture. Replacementproceduresfor these mouldingsare incluGlass Sectionof this Supplement. ded in the Stationary
47
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SECTIONAZ_AZ
ER G S n e e r - v N o N H A R D E N TNsEAL A T O E F FEC T O V E RH O L E S WA T E R T I G H S TEAL.
51
14.44 BODY
O U A R T ER WINDOW G A R N I S H M OUL DING
SECTION AN_AN NO TE : MO ULDIN G A S M . O T R R E VEAL T O BE A S S E MB L E D I N C O N J U N CT IONWIT H O T R WI N D O W G A R N I S H M OUL DING.
SECTI O N AP _ A P
MOU LD IN G A S M. QTR WIN D OW GA R N IS H FOR IN S TA LLA TION R E FE R S TA TION A R Y GLA S S TH IS S U P P LE ME N T S E C TION A M_A M N OTE : MOU LD IN G D R IP GU TTE R R E A R To BE IN S TA LLE D A FTE R MOU LD IN G A S M. OTR R E V E A L A N D GA R N IS H TV IOU LD IN G.
SCREW 3 P LA C E S R /LH
SECTION AT_AT
F A S T E NE R S T UD SECT ION AS - AS 1 PL ACE Ri L H F RONT FE N D E R 5 PL ACES R/L H F RONT D OOR 3 PL ACES R/L H REAR D OOR WA S H E R I P LA C E R /LH SCREW 1 P LA C E R i LH
S E C T I O N A R _ AR 1 PLACE R / L H F R O N T F E NDER 6 PLACE S R / L H F R O N T D O OR
4 p L AcE s R/ LH RE A R Do6 ;"
D R rL L 2 s sI
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SECTION AU -AU
ON ![! o ,a H or_e
OF WEL D ST UD AS CL OS E A S POSSIBL ET O WEL D ST UD LOC A TION .
SECTION AS_AS F O R E M E R G E N CU Y S EO N L Y
SECTION AX_AX
SECTION AV_AV SECTI O N AW _AW A r.r - 2 .4 Nm
C LIP - 2 P LA C E S
SECTION AY_AY G Q e e e r - v N o N H A R D E N T Ns E A L E Ro v E R HOLES TO EFFECT A WA T E R T I G HS TE A L .
Figure 1A-54
52
BODY 1A.45
GROM M ET 1 PL ACE R/L H
S TU D 1 P LA C E R /LH 1 PL ACE R/L H
SECTION AE_AE AD_AD SECTI O N
DRrLL 2.3s oN I !l! o,o HoLE

OF WEL D ST UDS AS CLOS E A S POSSIBL ET O WEL D STU D L OCAT ION, ;
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SCREW 1 P LA C E R /LH
T W AS H E R 1 PL A C E R / L H
R EAR PIL L AR IVIOUL DING
3 P LA C E S R /LH
sEcroNAF-AF
F O R E M E RGENCY USE ONL Y
sEcrroN AF-AF
GA S K E T
SECTION AK_AK
r BUSH 2 P LA C E S R /LH
REAR L AM P
sEcrroN AJ-AJ
REAR BUM PER BAR
* R OOF D R IP MOU LD IN G REAR
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SECTIO N AH_AH
SECT I O N AL_AL
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2 . 4 - 3 .4 Nm ' I. 8 - 2 .4 Nm
G E AL EBo vER S n e e l v N o N H A R D E N T Ns HOLES TO EFFECT A WA T E RTIGH SEAL T Figure 14-55
53
14.46 BODY
7.2 FRONTPILLARDRIP MOULDING
Remove With.front door open, removethe screw and clip securing moulding to front body pillar and front fender (refei Sections S-S, T-T, and V-V, Fig. 1A-56) removing moulding. Reinstall Reverseremoval operationsensuringthat the front pillar mouldingis correcily installedover ihe front of the roof drip moulding as illustratedin Section U-U, Fig. 1,4-56 and that the screw securingthe centre of the mouldinoto the front body pillar is adequately sealed with ion hardening sealer.
BUSH 1 P LA C E R /LH 3 P LA C E S R /LH
C LIP 1 P LA C E R /LH
SECTION T_T
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G E A L E Ro v E R Q a e e r - v N o N H A R D E N T Ns HOLES TO EFFECT A WA T E R T I G H S TEAL. Figure 1A-56
7.3 DRIP MOULDING ASSEMBLY REAR

MODELS. 19 BODY STYLES
R OOF D R IP MOU LD IN G
Remove Grasp.theleadingedge of the moulding, pulling carefully it off the rear quarter window garnish moulding,aliowin! the trailing end of the drip moulding rear to oecome disengaged (refer SectionAM-AM, Fig. tA-57). tleinstall Locate the rear hooked edge of the mouldingover the rear.-quaner window garnishmoulding, then lighilytap the moulding into position, ensuring that th6 rear drip mouldingis correctly installedover the rear of the roof drip mouldingas i[ustratedin SectionU-U, Fig. 14-56.
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sE crtoNA M-A M
N OTE : MOU LD IN G D R IP GU TTE R R E A R To B E IN S TA LLE D A FTE R MOU LD IN G A S M. OTR R E V E A L A N D GA R N IS H MOU LD IN G.
Figure 1A-57
54
BODY 1A-47
7.4 ROOFDRIP MOULDING
Remove 1. With the front door open, removethe screw securing the top of the drip mouldingto the front body pillar (refer SectionT-T, Fig. 1A-56). 2. Using Tool No. 1A7 located as illustratedin Fig.1458, under top of front pillar drip moulding,carefully ease top of pillar mouldingoff front end of roof drip (referSectionU-U,Fig. 14-56). moulding 3. Using a similarprocedure with Tool No. 1A7, remove the roof drip moulding, carefully disengaging rear end of roof drip moulding from top of drip moulding assemblyrear (referSectionU-U, Fig. 14-56). Reinstall ensuring that the ends of the Reverseremovaloperations roof drip mouldingare correctlyinstalledunder the front pillar and rear assemblydrip mouldingsas illustratedin Sections T-T and AL-AL in Figs. 14-56 and 14-57 and that the screw securingthe tront pillar drip mouldingis sealer. adequately sealedwith a non hardening
Figure 1A-58
7.5 FRONT& REARDOORSIDE ASSEMBLIES MOULDING

MODEL - CALAIS Remove 1. With front ot (ear door open, removescrew securing rear lower sectionof mouldingto door (referSection AU-AU,Fig. 1A-59). 2. Apply maskingtape adlacentto top of mouldingto protect paint finish, then using a wide bladed carefullyprise upper section of moulding screwdriver, assembly out of retaining bushes (refer Section AR-AR, Fig. 1A-59)then raise mouldingassemblyoff the clips securingthe lower section of the moulding assembly to the door (refer Section AS-AS, Fig. 1A-59). Reinstall Reverseremovaloperations.
FA S TE NE F S TU D
AS-AS sECrroN
1 P LA C E R /LH FR ON T FE N D E R 5 P LA C E S R /LH FR ON T D OOR 3 P LA C E S R /LH R E A R D OOR
sE crtoNAR- AR
1 P LA C E R /LH FR ON T FE N D E R 6 P LA C E S R /LH FR ONT D OOR 4 P LA C E S R /LH R E A R D OOR
WA S H E R 1 P LA C E R /LH SCREW I P LA C E R /LH
AU-AU sEcrroN
sEcrroN AT-AT cE A L ERo vER Q n e e l v N o N H A R D E N T Ns T HOLES TO EFFECT A WA T E R TIGH SEAL
Figure 1A-59
55
1A.48 BODY
7.6 FRONTFENDER SIDE& SIDE PANEL FRONTMOULDING ASSEMBLIES
MOD EL . CA LA I S Remove From inside the wheelhouse,remove screw securing moulding to rear quarter or front fender panel (refei SectionAT-AT,Fig. 1A-59)then removemoutding. Reinstall Reverseremoval operationsensuringto adequatelyseal 'sealer the attaching screw with non hardening as illustrated in SectionAT-AT,Fig. 1A-59. NpJe: Rear compartment lid mouldingon SL and Berlina 19 body styles and body side and tallgate mouldingson SL.and Berlina35 body styles as well is nameplateiand emblems on all models are secured in position with contact adhesive.lt is necessaryto apply heat to these mouldingsprior to removing them from' the panets to avoid bendingthe outer surfaceof these mouldinos. CAUTION: Ensure that source of heat is not too close or temperaturetoo high to damage paint finish. When replacingthese mouldings, the corresponding panel surface must be clean and smooth and be subjeited to warmth prior to installationof the moulding to effect a sound bondingof the mouldingto the panel.
7.7 TAIL LAMP REVEALMOULDING ASSEMBLY

MODELS. SL AND BERLINA 19 BODY STYLES Remove 1. With rear compartmentlid open, remove the screw securing the upper section of the moulding to the reat quaner outer panel (refer Section AK-AK. Fig. 14-60). 2. Apply masking tape adjacent to the semi vertical section of the mouldingto protect paint finish, then using a wide bladedscrewdriver, prise lower carefully -bush section of moulding out of retaining (refer SectionAJ-AJ,Fig. 1A-60). Reinstall Reverse removaloperationsensuringto adequatelyseal the attaching screw with non hardening sealer as illustrated in SectionAK-AK,Fig. 14-60-
GA S K E T S E C TION A K _A K 2 P LA C E S R /LH
/z\,
A A,
1.8 - 2.4 N m 2.4 - 3.4 N m
sE crtoN A J-A J
GA LE R Qneel v N oNH A R D E N TN sE ovE R
H OLE S TO E FFE C T A WA TE R TIGH T S E A L.
M ODEL . CA LA I S Remove With rear compartment lid open, remove the nuts securingthe mouldingassemblyto the rear quarter outer panel (refer Sections AW-AW and AX-AX, Fig. iA-61) removingthe moulding assembly. Reinstall Reverseremoval operationsensuringthat adequarenon hardening..sealer is applied betweenthe back panel and nut, as illustrated in Sections AW_AW and AX-AX, F i g . 1 4 -61) .
Figure 1A-60
56
BODY 1A.49
A
NUT 4 P LA C E S
SECTION A X_ AX
A W_ A W SECTION
N oN H A B D E N TN Gs E A LE R Onppl v OV E R H OLE S TO E FFE C T A WA TE R TIGH T S E A L.
tt-2.4Nm Figure 1A-61
MOULDING 7.8 REAR LAMP EXTENSION ASSEMBLY

M O DE LS . 1 9 B O D Y ST Y L ES Remove With rear compartment lid raised remove the nuts securing the assembly to the back panel upper (refer SectionAG-AG, Fig. 14-62)and removeassembly. NOTE: To disassemblethe mouldingassembly,remove the screws securing the outer to inner panels of the assembly(refer SectionAG-AG,Fig. 14-62). Reinstall Reverseremovaloperations.
R E A R E N D P A N E L A S M.
sEcrroN AG-AG
A t.t - 2.4N m
Figure 1A-62
57
1A-50BODY
7.9 MOULDING ASSEMBLY REAR COMPARTMENT LID
M ODEL . CA LA I S Remove With rcat compartment lid open, remove the nuts securingthe mouldingto the rear compartmentlid (refer SectionAV-AV,Fig. 14-63)then removethe moulding. Reinstall Reverse . removal operations ensuring that adequate sealingwith non hardeningsealer is appliedbetween the inside o{ the attachingnuts and rear compartmentlid as illustrated in SectionAV-AV,Fig. 14-63.
sEcrtoN AV-AV G E A L E Ro v E R Q n n e r - v N o N H A R D E N T Ns HOLES TO EFFECT A WA T E R T I G H S TEAL Figure 1A3
7.10 EMBLEMASSEMBLY HOOD

MODEL . CA LA I S Remove With enginehood raisedand using a plasticmallet,lightly tap ends of emblem studs protruding through tubular retainingclips in the engine hood (refer Section Ay_Ay, Fig. 14-64) until it is possibleto removeemblemReinstall !9ve1s9 removal operations ensuring that the tubular clipsfullyretainthe embrem.
C LIP - 2 P LA C E S
sEcrtoN AY-AY G Q n e e r - v N o N H A R D E N T Ns E A L E Ro v E R HOLES TO EFFECT A WA T E R T I G H S T EAL. Figure 1A-64
58
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46
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BODY 1A.53
9. BODYELECTRICAL
INDEX
Ref. 9.1 9.2
Subject DESCRIPTION EXTERIORREAR VIEW MIRROR& 1A-54 MOTORASSEMBLY ........1A-54 Remove ..-........ 1A-54 Reinstall REAR SWITCHASSEMBLY. EXTERIOR Page .... 1A-53 Ref. 9.6 9.7 Page Subiect ... 1A.61 LIMIT SWITCHASSEMBLY ..................... 1A-61 Remove........ .... 1A-61 Reinstall ELECTROIIICTODULEASSEMBLY..........14.62 1A-62 ..................... Remove.....-.. .... 1A-62 Reanstall 1A-62 CABLE ASSEMBLY 1A2 Remove.-...... 1A-64 Reinstall SLIDINGSUNROOFMOTORASSEMBLY.. 1A.65 1A-65 ilotor Assembly Remova|.................. 1A-65 Motor Assembly Feinstallation....-..-.. 1A-65 Motor Drive Gear Removal....--.......... 1A-65 Motor Drive Gear Reinstallation........ ..--.......... 1A-66 SYSTEMTlMlNG...--....
9.3
vtEwMrRRoRs.................
...... lA-ss
9.9
9.4
1A-55 ..................... Remove........ ... 1A'55 Reinstall SLIDINGGLASS PANEL ..........1A'55 SUNROOF 1A-55 ...._................ Remove......._ 1A-55 ............... Reinstall Vertical Adjustment ol Sliding 1A-59 ................-..... Panel Reinstall 1A-60 ................
9.10
9.1 DESCRIPTION
The electrically operated e!.terior rear view mirror assemblyfitted to Calaismodels consistsof a mirrorwith its electric drive motor contained in the door mounted mirror housingassembly(refer Fig. 1A-66). The electric motor, which is activated by a switch mounted onto the transmissionconsole (refer View A, of the mirrors. Fig. 14-67) providescompleteadiustment An 'ln-line' one amp fuse and holder assembly is attached to the mirror switch electrical harness and is
located under the transmissionconsole (refer View A, Fig. 1A-67). Choice of the mirror to be adiustedinvolvespushingthe raised bar of the switch to the left or right. Depressing the four way directionalarrows illustratedon the upper face of the switch will provide the desired mirror adjustment. Electricallyoperated venting sun roofs are released as ProductionOption CF5 for 19 body styles except 'SL' models.
60
1A.54 BODY
7l
' ,'-.., \\
\ . EXTERIOR R E A RV I E W M t R R o RA N D M o r o R A s M . uMrRnoR coNTROCONDUIT
o .tg- r 19Nm
Figure 1A{6
9.2 EXTERIOR REAR VIEW MIRROR& MOTORASSEMBLY

REMOVE 1. With the front door window in the lowered position, disconnect the batteryground cable. 2. Remove door armrest,interior trim and upper front corneroJ water deflector. 3. Using a wide bladed screwdriver,caretullyprise off cover from front door window frame inner. then removeseal (referFig. 14-66). 4. Prise out fronl lower section of glass run channel from rear edge of mirrorhousingassembly. 5. From within door panels,disengage mirrorassembly connectorfrom door electricalharness. 6. Remove screws securing mirror assembly to door upper frame (refer Fig. 1A-66) then ease assembly rearuardsand out of upper door frame. REINSTALL Reverseremovaloperations.
61
BODY 1A.55
. EXTERIOR 9.3 SWITCHASSEMBLY REARVIEW MIRRORS
REMOVE 1. Disconneclbatteryground cable. carefullyprise cap 2. Using a wide bladed screwdriver, and bezel covering top of switch assembly (refer console. View A, Fig. 1A-67)'fromtransmission 3. Using a similar procedure, carefully prise switch assembly from lransmission console. Disengage switch connector from front end electrical wiring harness,then removethe switchassembly. REINSTALL ReverseremovaloPerations.
E S C U TC H E ON \ \ E X TE R IOR R E A R V IE W --\ MIR R OR S S WITC H N S IT,I.\.
T R AN SM ISSIO N C O N SO LE
Figure 1A-67
SLIDINGGLASS PANEL 9.4 SUNROOF

REMOVE 1. Place sunroofslldingpanel in VENT position. lull rean'vard' 2. Slide sunshade 3. Remove side finishing covers attaching screws (Fig. 1A-70). 4. Loosen rear guides shaft screws until rear of sliding panel drops down using 3 mm allen wrench (Fig. 1A-71). 5. Remove front guide shoulder bolts using 7 mm socket (referFig. 14-71). 6. Remove slidingpanel upwardthroughroof opening' REINSTALL Reverseremovaloperations.
62
1A.56 BODY
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1A.58 BODY
SIDE FIN IS H IN G C OV E R
Figure 14-70
b<
- R E A R GU ID E S H A FT S C R E W -FR ON T GU ID E S H OU LD E R E OLT
/.
F ig u re 14-71
65
BODY 1A.59
VERTICAL ADJUSTMENT OF SLIDING PANEL ',|. Activate sun roof switch assemblyuntil rear end of glass panel is fullYlowered. 2. Fully engage rear guide shaft screw illustrated in Fig. 1A-72 into cam block, then back off screw a half turn. 3. Torque shaft screw lock nut to 2.03 - 2.71 Nm.
REAR CAM A S S E MB LY -
'-Ro-\ R E A R C A M B OLTS
,TFR ON T GU ID E S H OU LD E R E OL T
Figure 1A-72
66
1A.60BODY
9.5 WIND DEFLECTOR FRAME
REMOVE 1. Placesliding panelin full rear position. 2. Remove 'C' clip retainerand flat washer from both sides (refer Fig. 1A-73). 3. Press both wind deflector frame arms inboard to removearms from housingstudsREINSTALL Reverse removalooerations.
Figure 1A-73
67
BODY 1A.61
9.6 LIMIT SWITCHASSEMBLY
REMOVE
1. Removewell and drop headlinerfrom the front right side of the housing. 2. Scribe line on tube at tube entrance to switch assembly(refer Fig. 1A-74). Remove two (2) switch assembly mountingscrews (refer Fig. 1A-74). 4. Removeswitch assemblyby slidingoff of tube.
REINSTALL
Prior to installation of new switch, remove cotter pin from switch assembly(refer Fig. 'lA-74). Position switch assembly to scribe line of tube. Attach with two (2) screws removed above.
Figure 1A-74
68
1A-62BODY
9.7 ELECTRONIC MODULE ASSEMBLY
REMOVE 1. Remove weltanddropheadliner at frontof housing. 2. Uncouple connector at module assembly. 3. Remove screwsattaching module assembly to roof rail(refer Fig. 1A-75). REINSTALL Reverse removal ooerations.
A TTA C H IN G S C R E WS
t--
------)
-'--,
M ODUL E ASSEM BL Y
Figure 1A.75
9.8 CABLEASSEMBLY
REMOVE ''l . Drop headliner at rear of housing. 2. Remove__cable guide lower retainer cover (reter Fig. 1,4-76). 3. Disengage cablesfrom drive gear (referFig. tA_76). 4. Remove sliding panel as describedin g.4 Sunroof Sliding Glass Panel, Remove and Reinstall (refer Fig. 14-69).
69
BODY 1A.63
Figure 1A-76
70
1A.64 BODY
Move trough rod and cable assembliesreanarard of notch in track, to slide front guide shoes reanivard to notch,rotate and remove(refer Fig. 1A_72). 6. Rotate right hand front guide shoe fonivard to remove trough assembly(refer Fig. 1A-77). 7. Remove sunshadeby adding a slight hano pressure upwardto disengage front track. 8. Remove three (3) screws retainingeach track (refer Fig. 1A-78). 9. Lift front of track up and disengage from housing. 10. Removecable assemblyfrom track at rear. REINSTALL Reverse .removal operations using care to install sunshadein lowestslot in track. Refei to ,system Timing, (refer Fig. 1A-80). 5.
Figure 1A-77
71
BODY 1A.65
Figure 1A-78
MOTOR 9.9 SLIDINGSUNROOF ASSEMBLY

MOTOR ASSEMBLY REMOVAL 'l . Drop headlineral rear of housing. 2. Uncoupleconnectorfrom motor assembly. 3. Remove rear housing support brackets and lower rear of housing. 4. Removetwo (2) hex head screws attachingmotor to mounting brackets using 7 mm socket (refer Fig. 1A-79). MOTOR ASSEMBLY REINSTALLATION ReverseremovaloPerations. MOTOR DRIVE GEAR REMOVAL 1. Drop headlinerat rear ol housing. 2. Remove two (2) screws from cable guide lower retainercover (refer Fig. 14-76). 3. Use small screwdriver or other suitable tool to remove 'C' clip attachingdrive gear to motor shaft (referFig. 14-76). MOTOB DRIVE GEAR REINSTALLATION Reverseremovaloperations.
MOTOB A S S E MB LY
MOU N TIN G BRACKET
\b
C A BT E R E TAIN E R
Figure 1A-79
72
1A.66 BODY
C A B LE H OU S IN G
/.'sLoI
Figure 1A-8O
9.10 SYSTEM TIMING

1.
z.
Remove drive gear from motor as describedin g.9 Sliding Sunroof Motor Assembly,Motor Drive Gear Removaland Reinstallation in this Section. Position both cable housingsto slots in tracks as shownin Fig. 14-80. Reinstall..drive gear and reverse removal operations as describedin 9.9 SlidingSunroof Motor Assembly, Motor Drive Gear, Removaland Reinstallation in thts Section.
73
BODY 1A.67 TOOLS 10. SPECIAL

F A B R I C A TED T RIM CL IP REM OVAL T OOL
Uf,MM
t_ f
mm_ ^ 9 .0 1^ 8 .0 m m <-75.0 mm---
E N D C ON S TR U C TION TO S U IT H A N D LE R E OU IR E ME N TS
10.0 mm D IA
- 8 .5 mm
G L A S S S EAL ANT R E M O V A L T OOL
R OOF S ID E MOU LD IN G R E MOV A L TOOL
147
R A D I O _ RADIO/CASSET T EPL AYER R E M O V AL T OOL S
-rl
.{tl
-T1l
cMT113
74
GRILLE1C.1 RADIATOR
1C SECTION
GRILLE RADIATOR
INDEX
Ref. 1. Sublect DESCRIPTION Page 1C-1 Ref. 1.1 Sublect SERVICENOTES Remove Reinstall Page
rc-r
1G l 1C- 1
1. DESCRIPTION
The new one piece plastic radiator grille fitted to VK series is painteil silver on Calais model, whilst on other models, they are painted cool or warm grey, depending on the body colour'
NOTES 1.1 SERVICE

Remove 1. With enginehood raised,removescrewssecurlng (refer Fig. 1C'1). grille uppersuppctrt to radiator pegsout of grille lift then grille fonrvard, 2. Easetop of facia. in the bumper grommets installed Relnstall operations. removal Reverse
NUT l 2 PL ACES \
A
g S C R EW \ 2 P L ACES
&
A/
scREl/-\6tr
-,/---'- 7/
-7
Figure 1C-l
. . u - 4 .6N m
/ |^r o- 3. 4 N m
75
76
1D.1 BAR ASSEMBLIES FRONT& REAR BUMPER
1D SECTION
BAR ASSEMBLIES FRONT& REARBUMPER
INDEX
Ref. 1. 1. 1 Page Subject 1D -1 DESCRIPTION tD -1 SERVICENOTES 1D -1 lntroduction. 1D-2 Recommended Materials GolourFinishing of Replacement 1D-3 Parts 1D-2 Repairing Colour Coat .'...................'.. Warning - Use of BodY 1D-2 Golour Lacquer........ FRONTBUMPERBAR ASSEMBLY............ 1D-3 1D-3 Remove........ 1D-3 Disassemble 1D-3 Reassemble 1D-3 Reinstall Ref. 1.3 Subject REAR BUMPERBAR ASSEMBLY Models 19 Body Sty1es............ Remove........ Disassemble Reassemble Reanstall.. Models 35 Body Sty1es............ Remove Disassemble Reassemble Reinstall Page 1D-4 1D- 4 10-4 1D- 4 'tD-4 10- 4 1D-6 1D-6 1D-6 1D-6 1D-6
1. 2
1. DESCRIPTION
Front and rear bumper bar assemblies titted to VK Brightfinishing construclion. models are of polycarbonate strips featuringa rubber upper edge are clippedover lhe top edge ol the side and part ol the centre front bumper fitted to 19 body facias.-Onthe rear bumper assemblies upperedge stripscoverthe complete the finishing styles, whilston the 35 body of the rear bumperbar assembly strips are fitted to the rear bumper styles these finishrng faciasonly (reterFigs. 1D-1,1D-2,1D-3and 1D-4).
NOTES 1.1 SERVICE

INTRODUCTION The paint systemfor the VK bumpersand side mouldings is relatively straight fonrrrardas long as the correct materials are used. lf normal refinish lacquers and will be damaged solvents are applied the polycarbonate by solvent attack- Therefore, a warning label will be attached to the exterior surface of all unpaintedspare parts suppliedto the field.
CAUTION: Painting - Cleansingof this patt for painting must be by methylated spirits wipe only. Do not use lacquer thtnners or other cleaning thinners, as these may damage the plastic- Top Coat with GMH approved paint and thinners as specifiedin this Section. are compiledto The following service recommendations guide Dealerships, on the correct materialsand methods VK Series bumperbars to be employedwhen refinishing and side mouldings,also when preparingnew parts for serviceinstallation.
77
1D.2 FRONT& REAR BUMPERBAR ASSEMBLIES

RECOMMENDED MATERIALS installed Irol.9nq rear bumperbars and side moutdings to VK Series are made from high impaCt strength polycarbonate plastic. It is essential that only GMH approvedmaterials,paints and thinners, be employedwhen paint repair operations are performedand when preparingnew parts lor installa_ tion to the vehicle. Use of the wrong materials will affect finishedqualitvand will affect the polycarbonate material. The GMH approvedmaterials are: . MethylatedSpirits- for cleansingbeforepainting. r Paint - Berger Polycarbonate Lacquerin the following cotours:
S ilver Warm Gre y C ool G r e y
Bumper)The paint repair area should be to the nearest convenientbreakline. Spot repairsare not recommended due to possiblecolour match problems. 1. 91l9il9 - dependingupon the degree of damage, P320 (or.coarsergrit).wet or Ory sa-ndpaper may be requiredfor initialsanding.Finishsand wiin eCOtigrit paper to remove sanding marks and dry scuff Lll over the whole of the area to be resprayed. 2. Cleaning - wipe the area to be paintedat least twice with a clean cloth soaked in meihylatedspiritswiping dry with a new clean cloth each time. 3. Painting - mix the polycarbonatelacquer with appro_ ved.thinners(approximately 1:1 ratio) and spray'the repaired area to build colour followed by one wet coat all over to achieve colour uniformitv. 4. Drying - allow 10 minutesair flash then use a heat tamp or similar set up to warm the painted surface f9r 99 minutes. (Surface temperature of the part should not exceed gOoC) Lamp baking will speed removal of the special slow solvents in-the laiquer and hardenthe paintfilm. WARNING. USE OF BODY COLOUR LACQUER Normal lacquersused for refinishpaintingof sheet metal are not suitable for repainting the VK polvca;gon"r" bumpersand side mouldings.
G MH4 J 0 2 2 G MH4 H 0 1 6 G MH4 H 0 1 5 -
Be rg eH r H9991 Be rs eH r Hgg89 B e rg eH r Hg990
. Thinner- Berger LT2p6. The Berger lacqueris a specialacryliclacquerdeveloped for polycarbonateand requires NO primer. The polycarbonateparts are moulded in-colourfor ease of top coating. When ordering spare parts quote the GMH colour number and name,for exampleWarm Grey (GMH 4H0 1 6 ).
COLOUR FINISHING OF REPLACEMENT PARTS Spare parts are suppliedunpainted, to be coated before installation to the vehicle. Observethe followingprocedures:1. Order part with the plastic self colouredto match the requiredtop coat colour. 2. Inspect surface, if slight transit damage is present this can be rectified by dry sandingwith-pa0O paper. 3. Cleaning - wipe the surface at least twice using a clean cloth soaked in methylatedspirits,wiping-dry with a new clean cloth each time. 4. Paint - mix. the polycarbonate lacquer to spraying -1:i viscosity with approved thinners (approximately ratio), and apply one full wet coat. Allow aboul two minutesflash time and apply a secondfull coat. lt is important that only sufficient paint to achieve coverageis applied,too high a paint thicknessmay reduce adhesion.(Correctfilm thichnessis 30 - 35 microns.) 5. Drying - allow 10 minutes air flash then use a heat tamp or similar set up to warm the paintedsurface {or 30 minutes (part surfacetemperaiure should not exceed 90oC). Lamp baking will speed removatof the special slow solvenlsin the lacquerand harden the paint film to enable assemblyof the part to the vehicle.
REPAIRING COLOUR COAT Superficial damage to the paint film and/or plastrc surface may be rectifiedby sandingand repainting. parts havingdeep gouges etc. in the plaltic surfaceshould be replaced as repair methods using filling materials and thinningdown of the plastic section mai reduce overall rmpactstrength.Under no circumstances shouldpaint be washed otf with lacquer thinners. (i.e. Sections of the
78
1D-3 FRONT& REAR BUMPERBAR ASSEMBLIES

1.2 FRONTBUMPERBAR ASSEMBLY
REMOVE 1. Raise and support tront end of vehicle on jack stands. 2. From within front end section of front wheel openings, remove screws securing sides of front Oirmpeibar assemblyto front {enders(refer Sections B-B and C-C,Fig. 1D-1). Jront bumperbar assemblyfully supportedand With 3. from under front of vehicle, remove bolts securing inner bracket assemblies from side frames (refer Section A-A, Fig. 1D-1) removinglront bumper bar assemblY. Disassemble 1. Disengage lower edge of finishing strip. assembly trom ioi'cn in bumper bar side facia(s) (refer Section GC, Fig. 1D-2)then raiseand removefinishingstrip' 2. Remove screws securing bumper bar facias to front bumper bar inner bracket assemblies (refer Section A-A, Fig. 1D-2). 3. Remove screws and nuts securing side tacia(s) to centre lacia (refer Section B-8, Fig' 1D'2) then remove side facia(s). Reassemble operations. Reverseto disassembly REINSTALL Reverseto removaloPerations.
F R O N T B UM PER B A R A S M.
h
FRoNT reruoea/
PANEL A
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F RONT BUM PER BAR INNER ERACKET ASM - R & LH zl. BOLT 4L 2 PL ACES Ri L
fl
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u,r*E
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FR ON T FE N D E R l PANEL \ FA S TE N E R-I 'r P LA C E R /L
WASHER 2 PL ACES R/L
SCR E Wl 2 PL ACESR/L
\
\
A-A \ secrtoru
__if 7-,
F RONT F ENDE R J PANEL R/L
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Figure 1D-1
S E C TION B _B
79
1D-4FRONT& REAR BUMPER BAR ASSEMBLIES
,,6\scR.*
4 PL ACES R&L SIDE NUT 4 PL ACES
N d L JIUE
FRONT B U M P E R BAR B R A C K E T ASM .
A FTE R A S S E MB LY OF B U MP E R B A R LOC A TE A N D S N A P C LIP FIN IS H E R S TR IP SR /L OV E R B U MP E R B A R A S M,
secrroru B-B sgcrroru C-C

5- R H F IN ISH tN G \ST R IP
secrroru A-A
5ilocer\
R&L SIDE
L H F IN IS HIN G S T RIP \
ant
7-
CENT RE F ACIA ASSEM BL Y
R H S I D EF A C I A ASSEMBLv 7
,R H i FR ON T B U MP E R B A R IN N E R BRACKET ^sM7
A,
/ z\
6-8 N m 10-' r 5 N m
wa5H5q---.7s ,:. 2( I'

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3 PL ACES R&LS ID E
LH FR ON T B U MP E RB A R IN N E R B R A C K E T A S M.
Figure 1D-2
1.3 REAR BUMPER BAR ASSEMBLY

MODELS 19 BODY STYLES Remove 1. From under rear quarter panels, remove screws securinglower section of side facias to rear quarter panel(referSection C-C,Fig. 1D-3). 2. With rear bumper bar assembly fully supported, remove nuts and screws securing rear bumper bar assemblyto rear end of vehicle (refer SectionsA-A and B-8, Fig. 1D-3) and unscrew licenceplateholder from centre facia then removeassemblv. Disassemble 1. Disengage lower edge of finishing strip assembly from notches in right and left hand sides of bumper bar assembly(referFig. 1D-3)then raise and remove finishing strips. 2. Remove screws and nuts securing bumper Dar assemblymountingbracketsto centre facia and side facia(s)to centre facia (refer SectionsB-B and D-D, Fig. 1D-3)then remove side facia(s). Reassemble Reversedisassembly operations. Reinstall Reverse removal operationsensuring that the sealing instructions for the rear bumper bar assemblvattachino screwsand nuts illustrated Fig 1D-3are observed
80
R H FIN IS H IN G S TR IP l \
R H S ID E = FA C IA A S M.
7;i l' *
-4t\
Z".--l4.l
C ENT RAL IZ E AND SNAP_ CL IP F INISHER ST RIPS OVER BUM PER BAR ASSEM BL Y
\.r*r*.
A S M.
ro",o
\.*
r,o.
FA C IA A S M.
A
SCREW , 7 - 2 PL ACESR&L
FA STE NE R l P LAC E R & L
secrtonC-C
A
A-A SECTION
NUT _ 2 PL ACES
,Ar scnewl
4P LA C E S R & L/
NUT---T\ 4PLAC ESR &L
WAHSER _ 2 PL AC E S J
T SCREW \ 2 PL ACESR&L
B_B SECTION
S E C TION D_D
V
A A A 6- 8 Nm , o- 2 7N m 8- 1 1 N m
V
Q n e e l v N oN H A R D E N IN G S E A LE R A TTA C H ME N T H OLE S AROU N D 8U I.1P E C
E-'
-E
E_E SECTI O N
u,r *lIl R&L s r D E

Figure 1D-3
81
5 ra
1D-6FRONT& REAR BUMPERBAR ASSEMBLIES

MODELS 35 BODY STYLES Remove 1. Disc.onnectbattery ground cable then carefully prise out licence plate lamp assemblies from top of centre facia and disconnect electrical connectors. 2. From under rear quarter panels, remove screws securinglower section of side facias to rear euarter panel (refer SectionGC, Fig. lD-a). 3. With tailgate raisedand rear quarterinner trim oanel covers removed, remove screws securing rear bumper bar assembly to rear quarter panel (refer Section A-A, Fig. 1Da). 4. From within spare wheel compartmenl and with rear bumper bar assemblylully supported,remove nuts secunng assemblyto back panel lower (refer Section B-8, Fig. 1D-4)and removeassembly. Disassemble 1. Disengage lower edge of finishing strip assembly from notches on side facia(s) (refer Section A_A, Fig. 1D- ) then raiseand removefinishing strip(s). 2. Remove nuts and screws securing bumper bar assembly mounting brackets to centre facia and centre facia to side facia(s) (refer SectionsB_B and D-D, Fig. tD-4) then removeside facia(s). Reassemble Reverse disassembly operations. Reinstall Reverse removal operationsensuring that the sealing instructions for the rear bumper bar lssembly attachin! screwsand nuts illustrated in Fig. 1D-4are observeo.
82
FIH S ID E FA C IA A S M.
R H F IN ISH I N G ST R IP
LH F IN ISH IN G
I i>!P
FI NI SHER S T R I PR / 1 . l a . SNAP- CLI P BAR A S S E M B L Y , O VERBUM PER "h"
---D
_4
- C E N TR E FA C IA A S M.
LH S ID E FA C IA A S M.
WA S H E R 2 P LA C E S
B U MP E R A S M
C_C SECTION
A-A secrrom
WASHER 2 PL ACES
r NUT I + pr-aces RlrSCREW ., 4 P LA C E S R /L,/3'
SCREW 2 PL ACES Ri L
B-B SECTION
S ecrl Ot'D t -D
SECTI O N E- E
/\
6-8
Nm Q a e e lv No N H A R D E N TN GS E A LE R AROUND B U MP E R A TTA C H ME N T H OLE S
A A
lAl R/L vrEW srDE
1 2 - 1 6Nm 81 1 Nm
Flgure 1D-4
83
5 ta t-. k
& HEATING2A.1 VENTILATION
2A SECTION
VENTILATION & HEATING
INDE X
Ref. 1. 1. 1 Subject GENERALDESCRIPTION Page 2A-3 2A-4 2A-4 2A-4 2A-4 244 2A-4 2A 2A-6 2A-6 2A-6 2A-7 2A-7 2A-7 2A-7 Ref. 1.5 1.6 1.7 1.8 1.9 Subject Page BLOWERMOTOR......... 2A-9 Remove........ 2A'9 Reinstall 2A-9 BLOWERMOTORHOUSING ASSEMBLY..2A. 10 Remove........ 2A- 10 Reinstall 2A- 10 HEATERASSEMBLY 2A-11 -....... Remove........ .........-.....-.... 2A-11 Reinstall ..- 2A-11 HEATERCOREAND PIPEASSEMBLY...... 2A-13 Remove........ .................... 2A-13 Reinstall ... 2A-13 WATERVALVEASSEMBLY.HEATER coRE .-........ 2A-14 --_-.-Remove..-..... .................... 2A-14 Reinstall ... 2A-14
1. 2 1. 3
1. 4
SERVICENOTES UPPERSIDEVENT OUTLETS.RIGHT & LEFT HAND Remove.,...... Reinstall TEMPERATURE MOOESELECTION, CONTBOLAND BLOWER FAN SWITCH.. ilodels - A11.........-..-.. Remove Reinstall
24.2 VENTILATION & HEATING
--J
Flgure 2A-1
EL OWER M OT OB SWIT CH
T EM PERAT URE CONT ROL HEAT ' V E N T C ON TR OLS
OFF N O A IR FLOW
Figure 2A-2
VENTILATION & HEATING2A-3 1 . GENERAL DESCRIPTION

The ventilating and heatingsystemfeaturedon VK Series models allows air enteringthe syslem via the grilles at the rear of the engine hood to pass throughthe blower motor housingand heater assemblies and to be heated, mixed or allowed to remain at ambient temperature, as required. The air then enters the passenger compartment throughthe centre and or side upperventilatoroutlets,or through the demist or footwell outlets (refer Fig. 2A-1 ) dependingon the position of the mode or temperature control levers illustrated in Fig. 2A-2. Fig. 2A-2 also with the illustrates the air flow within the heaterassembly variousmodesactivated. On sedans, air from the passenger compartmentexhausts throughventilatoroutlets located behindthe right and lelt hand side drip mouldingassemblyrear,illustrated via in Fig. 2A-3. On stationwagons,the air is exhausted the edges of the rear quarter inner trim panels,into the throughtailgatehinge roof, then out into the atmosphere pockets. The volumeof air trom the centre or side upperventilator outlets (refer View A, Fig.2A-1) is controlledby a regulatingwheel below the outlet inserts illustratedin Fig. 2A-4. The air llow can be directed as required by the ventilatorupper outlet inserts. tilting and/or swivelling To slop the air supply from the upper side vent outlets, wheel to the right,and on the centre rotate the regulating air outlet. rotate the wheel downwards until a stop is reached. where the The heatingsystem utilisesan air mix principle is compartment temperature of air enteringthe passenger lever illustrated in Fig. 2A-2 controlledby a temperature which operates the mixture door. This regulates the volume of air passingthroughthe heatercore. The temperature, mode and blower motor control in Fig. 2A-2 consistsof a four speed assemblyilfustrated fan switch,which regulates the rate at which forced air is deliveredinto the vehiclethroughthe variousoutlets,and two sliding levers. The left hand lever controls the air temperatureentering the vehicle in all modes and the mode required. right hand lever,the particular
Figure 2A-3
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Figure 2A-4

1.1 MANUALCONTROLS
The mode control leverhas five positions: DEM In this positionthe air flows onto the windscreen through the demistvents on top of the instrument panel-A small amountof air also goes to the floor ouilets FLOOR in this positionthe main air flow is directedto the floor outletswith a smallamountgoing to the demistvenrs. VENT This setting directs all the ambient or heated air to the centre and side vents. The air flow and directioncan oe individually adjusted at each vent. BI L EVEL This positiondirects air to the centre and side venls as well as to the floor vents. OFF ln this positionthe fan is switchedoff and no outsideair is admittedvia the ventilation system.This setting is only recommended to be used for short periodswhen driving in very dusty or smokeyconditionswith all the wrnoows closed. Return the mode lever to one of the other settingsas soon as conditionspermit, NOTE:The blowermotorfan automatically swi166ss .r 1. its lowest speed when the mode control lever is moved away from OFF position. Fan speed can then be rncreased by selecting a highernumber.
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2A.6 VENTILATION & HEATING

1.2 SERVICE NOTES
The non air conditioned air ducting on VK Series illustrated in Fig. 2A-5 as polypropolene tubing with matingindentations and protrusions which retain the ends of the ductingtogether.Screwsinstalled throughthe right and left hand air outlet ducting to the centre air distribution duct, ensurecorrectretentionof the ductino in its designedlocation.Should any of this air ducting be disturbedduring under instrumentpanel operations,it is essential to ensure that such ducting be correctly reinstalledso as to prevent possibleair leaks at these joinsand connections. Removalof any of the ducting necessitates removal of the instrumentpanel lower trim on the side from which the ducting is to be removed. Other than the blower housing to heater assembly duct, removal of other cluctingnecessitates removal of the touch control panel and the instrument panel location cover illustrated in Fig. 24-6.
1.3 UPPER SIDE VENT OUTLETS, RIGHT & LEFT HAND

REMOVE Usinga fine bladed screwdriver, carefullyprise right hand and left hand upper and lower inserts from within side vent upperassemblies prior to removingscrews,securing the upper air outlet assembliesto ths instrumentoanel pad assembly as illustratedin Fig. 2A-7, then remove outlet assembly. REINSTALL Reverseremovalprocedures.
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TEMPERATURE 1.4 MODESELECTION, FAN SWITCH BLOWER AND CONTROL
M O DE LS . AL L Remove the batteryearth cable. 1. Disconnect 2. Remove the transmissionconsole assembly (refer 2.2, Body Sectionof this Supplement). 3. From the left hand side of the heater assembly' the front end of the control cable from the disengage in View B' Fig. 2A-8. door rod, illustrated temperature 4. Remove the touch switch control panel and the centre nozzleand instrumentlocation{rame assembin Fig. 2A-9. ly illustrated temperature,mode, booster fan and the 5. Remove wiper dwell control knobs. 6. Remove the lower instrumentpanel enension illustrated in Fig. 2A-9. NOTE: Do not removethe wiper dwell control switch. 7. Remove the screw securing the top o1 the temperature and mode control assembly to the instrumentpanel frame illustratedin Fig. 2A-8' then mode conpartly ease out assembly,disconnecting trol vacuumhoses and electricalconnector' 8. Remove ihe rear end of the cable from the control lever. temperature Reinstall Reverseremovalprocedures.
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1.5 BLOWERMOTOR
REMOVE batteryearth cable. 1. Disconnect 2. From under the left hand side of instrumentpanel and using a fabricatedtrim clip removal tool (refer 10 SpecialTools,at the end o{ Section28) remove the lefi hand instrument panel lower trim (refer F ig. 2A -1 0 ).
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From under the instrument panel, disengage the blower motor to main wiringharnessconnector,then the blower motor, removethe two screws supporting securingthe motor to the blower housingillustrated the motor. in Fig. 2A-11,removing
REINSTALL removalprocedures. Fleverse

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2A-10VENTILATION & HEATING

1.6 BLOWERMOTORHOUSING ASSEMBLY
REMOVE 1. Disconnectbattery earth cable and blower moror to main wiringharnessconneclor2. From under left hand of instrument panel ano usrng a fabricatedtrim clip removal tool (iefer 10 Speciai Tools at the end of Section 28) remove the instrument panel lower trim (refer Fig. 2A_10). 3. From insidethe engine compartment, removethe left hand air inlet deflector and the screw attached air inlet seal ring secured to the left hand side of the plenum chamber,as illustratedin Fig. 2A_11. Re_ move the ring assembly 4. With the instrumentpanel compartmentopen and with the blade ol a scredriverlocated between the head of the hinge pin and the right hand companment side, prise the hinge pin into the compartment as illustrated in Fig. 2A_12, then remove the companment. 5. Removethe blowermotor housingto heaterassembly duct illustrated in Fig. 24_13. 6. From the base of blower motor housing,remove bolt securing lower part of housing to le'ii hano dash panel lower,illustrated in Fig. 2A_13. 7. Removethe nuts securingthe blower motor housing to the studs attached to the left hand side of the plenum chamberillustratedin Fig. 2A-13, removtng the housingassembly. REINSTALL Reverse removalprocedures.
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1.7 HEATERASSEMBLY
REMOVE 1. Disconnect the batteryearth cable. 2. Disconnect the vacuumfeed hose at the check valve then from inside the engine compartment,remove the rubber grommetfrom the dash and the coolant hoses from the inlet and outlet heater core oioes illustrated in Fig. 24-141 CAUTION:The heater can easily be damaged in the area of the core tube attachment seams whenever undue force is exerted on them. When the heater hoses do not readily come otf the tubes, the hoses should be cut just fotward of the core tubes. The portion ol the hose remaining on the tube should then be split longitudinally. Once the hoses have been split, they can be removed from the tubes without causing damage to the core. 3. Remove the instrument panel lower (refer 3.4 in Section 1A, Body Section). 4. Remove heat/vent control assemblyfrom instrument panel (refer Fig. 2A-8). 5. Remove the blower motor housing to heater in Fig. 2A-13. assemblyduct illustrated 6. Remove the ends oi the ducting attached to the in Fig. 2A-15. heaterassemblyillustrated 7. Remove the bolt securing the lower part of the heater assembly to the floor pan bracket, as in View A Fig. 24-13. illustrated 8. Removethe two bolts securingthe top of the heater assemblyto the instrumentpanel brace as illustrated in Fig. 24-13, then removethe heaterassembly. REINSTALL Reverse removal procedures,ensuring that the heater core pipe grommetis correctly installedto fully seal the hole in the lower dash panel. Also check that the electricals and ducting disturbed during the removal procedures are operatingeffectively.
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1.8 HEATERCOREAND PIPI ASSEMBLY
REMOVE 1. Remove the heater assembly as previously described. 2. With the right hand side of the heater assembly uppermost,disconnect door rod adjusting retainer clip 'A', then remove screw 'B', both illustratedin Fig. 2A-16. 3. With the heater assembly in the upright position, remove the screw attached bracket'A' illustratedin Fig.2A-17,then slideout the core and pipe assembly from the heater case. REINSTALL Reverseremovalprocedures.
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1.9 WATERVALVE ASSEMBLY HEATER CORE
REMOVE 1. From inside the engine compartment, remove the heatercore hosesillustrated in Fig. 2A-.14. CAUTION: The heatercan eastly be damagedin the area of the core tube attachment seams wienever unctue force is exerted on them. When the heater hoses do not readily come off the fubes, the hoses shou/d be cut just fonarardof the core tubes. The portion of he hose remainingon the tuDeshould then be split longitudinaily. Once the hoses haye been split, they'can be removed from the tubes wfthout causingdamage to the core. 2. Remove:he rubber grommetserling the heatercore ptpespassrng through the lowerdash panel. 3. Usrnc a cross recess headed screwdrrverlocated ns de of the dash inner panel hole adjacentto the realer core outlet pipe, remove the four screws securing the water valve assemblyto the heatercore prpe illustrated in Fig. 24-19, then remove the valve assembly, taking care not to loose the ,O, rino located between the valve and heater core outlei ptpe. REINSTALL Reverseremoval Drocedures.
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28-1 AIR CONDITIONING
28 SECTION
AIR CONDITIONING
INDEX
Ref. 1. 2. 2. 1 Page Ref. Subiect 2B-1 3.4 ............................ GENERALTNFOFMATTON 2B-3 GENERALDESCRrPT1ON.............................. 2B-3 MANUAL CONTROLS 2B-3 'DEiI' 2B-3 'FLOOR' 2B-3 'VENT' 2*4 'BI LEVEL' 2B-.4 'NORM' 28.4 'MAX' 2H 'OFF' 2B-5 Retrlgerant Glrcult 2B-8 3.5 Gompressor 2B-9 Thermostatlc Swltch 2B-9 Evaporator.. 3.6 Thermostatlc Expanslon Va1ve.......... 2B-9 2B-9 Recelver Dehydrator.. 2B-9 Condenser 2B,-11 SERVICEOPERATIONS i 3.7 COilPRESSORDBIVE BELT TENSION 2B -11 AND ADJUSTMENT.... OIL CHARGE CHECKINGCOMPRESSOR 2B.11 ON VEHICLE Addlng Oll Durlng Component 2B-11 Replacement 2B-11 Compressor 3.9 Reln8talllngthe Orlglnal 2B-11 Compressor Installlng a New Compressor.. 2B -11 4. 2* 11 Evaporator.. 28-11 5. Condenser 2g-11 Revelver Dehydrator.. SYSTEMCHARGING........2B.-12 REFRIGERANT Fllllng Charglng Cyllnder ..........2B-12 Installatlon of Charglng 2B-12 . 28-13 Chargfng System Eyacuatlonand Leak Test........ 28-13 2B-13 Purglng (lf Necessary) ..-........... . 28-13 Charglng System FunctlonalTestlng ot System.. 28-13 Page Subject COMPRESSOR INSPECTION PROCEDU RES...._...._....._.___. 2g-14 2B-14 Leak Test CompressorSmoothness Test..........2B-14 29.14 Glutch Test .............. Nolse....................... 28-14 Remove.......,. 28- r 6 28- 16 Relnstall Disassembly 28- 16 Reassembly 28-18 Air Gap Adiustment.. 28'-20 EVAPORATOR ASSEMBLY 28'20 Remove 28,-20 Reinstall ............. 2B-2s EVAPORATOB COREAND PIPE 29-27 ASSEMBLY 28,-27 Remove............... 2V27 Reinstall AND AUXILIARYFAN CONDENSOR 29-27 ASSEMBLY 29-27 Remove........ 28-27 Relnstall 28-27 AUXILIARY FAN 28-27 ........-.. Remove
3. 3.1
s.2
INFORMATION 1 . GENERAL
system used on VK air conditioning The Air International models is a cycling clutch system with thermostatic and a Sanden TR 70 Spiral expansionvalve (C.C.T.X.V.) CompressorThe following information provides basic service system' air conditioning operationsfor the C.C.T.X.V. includingthe TR 70 SpiralCompressor.
2B..2 AIR CONDITIONING
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28.3 AIR CONDITIONING DESCRIPTION 2. GENERAL

expansionvalve The VK cycling clutch and thermostatic (C.C.T.X.V.)air conditioning system permits cooled' heated,mixed or ambientair to flow throughthe vehicle, dependingon the positionol the mode and temperature control leverssystem via the Air entering the air conditioning/heating grille at the rear of the engine hood, passesthroughthe blower motor housing and evaporator and heater assemblies,to be cooled or heated as required,then enters the passengercompartmentthrough the centre and/or side upper ventilator outlets, or through the demist or footwell outlets (refer Fig. 2B-1) dependingon the position of the mode or temperature control levers illustratedin Fig. 2B-2. Fig. 2B-2 also illustratesthe air flow within the system with the various modes activaled. A four speed high capacity blower lan forces air trom the plenum chamber, through the evaporator and heater then out throughthe variousoutlets into the assemblies, passenger compartment. NOTE: The blower motor is automaticallyswitched on to low speed whenever the mode control lever is moved from'OFF' oosition. On Sedans, air lrom the passengercompartmentexhausts through the ventilatoroutlets located behind the right and left hand side rear drip mouldingassemblies, in Fig. 2B-3. illustrated On station wagons, the air is exhaustedvia the edges of the rear quarterinner trim panels,into the roof, then out throughthe tailgatehinge pockets' into the atmosphere The controls illustratedin Fig. 2B-2, consist of a four speed fan switch and two sliding levers.The left hand lever regulatesthe temperatureot the air entering the vehicle in all modes and the right hand lever enables The mode lever mode required. selectionof the particular has seven oositions.
Figure 2B-3
2.1 MANUALCONTROLS
' DE M ' In this position,the air flows mainlyonto the windscreen through demist vents on top o{ the instrumentpanel. A small amount of air goes to the floor outlets.The air is cooled to reduce humidityand then can be reheatedto to demistthe windscreen. the settingrequired 'FLOOR' to the Jloor the main air flow is directed In this position, outlets with a small amount of air going to the demrst does not operate compressor vents. The air conditioning in this mode.
'VENT' This setting directs all air to the centre and side vents. The air flow and directioncan be adiustedat each vent vanes and thumb wheels.The air can also by directional at these vents to achieve the be shut off individually desired comfort. The air conditioningcompressordoes not ooeratein this mode.
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2B-4AIR CONDITIONING
'BI LEVEL' This positiondirects the air both to the centre and side vents as well as to the floor ouilets. When using Bl LEVEL with the temperaturelever in an intermediate position, warm air will be directedto the feet and cooled air to the face (centreand side vents). Cooledair is availableto both loot and tace levels when the temperature lever is positioned at cold. 'NORM' This setting directs outside air through the centre and side vents, used for most coolingneedson hot days.The air is cooled to reduce humidityand remove dust and pollen etc. lt can then be reheated if required to a lemperature determined by the temperature control lever. 'MAX' Use fcr maximumcoolingor quick cool down on very hot days. On this settingthe cabin air is recirculated throuoh the air conditioningsystem. No outside air is admit6d through the inlet grille and therelore the driver should returnto NORMAL setting once interiortemperaturehas reachedan acceptablelevel. This mode is also used to exclude unwanteo oust or fumesfrom enteringthe system. 'OFF' On this setting the fan is switched off and the door is closed so that no outisde air is admitted and the air conditloning compres$r does not operate. NOTE: The fan automatically switches on to its lowest speed vyhenthe mode lever is moved awav from OFF position. Fan speed can then be increasedbv setectrno a highernumbet. 1. Outside air is used in all modes except MAX and OFF. Do not operatein MAX or OFF for long periods as no outsideair is admittedto the vehicle. 2. When driving in very dusty conditions,i.e. follownq anothervehicle,use 'MAX' or ,OFF' mode deoendin6 on whether you requirethe air conditioneron or oi respectively. Through door and window seals either setting wll prevent outside air from entenng until drivingconditionspermit return to one of the other settings.SelectionoJ 'NORM' A/C with high blower speeds and all wrndowsclosed, will presiunze the intenor of the vehicle, excluding dust entry. 3. Undermost conditions it is recommended that 'MAX' (recirculated air) setting be avoidedif occupanrsare smokingas residues from the tobaccosmoke adhere to the evaporatorand air ducts and will result in stalesmelling air inside the vehicle. 4. Automatic Transmission lf your vehicle is stopped for long periods in hot weatherwith the engine runningand air conditroner operating, setect 'NEUTRAL'or 'pARK'. This will increase your enginespeed which in turn aids engine coolingand air conditioner performance. 5. 'OFF' you should only use this setting with the windowsopen. 6 The following procedure should be carried oul regularly during those periods of the year (e.g. winter) when the air. conditioningmodes may nor normally be used.
_t)
AIR CONDITIONING 28.5

Once every two weeks, with the engine running, switch the air conditioner on by selecting either 'DEM','Bl LEVEL','NORM'or'MAX' mode.The unit shouldbe run for at least 5-10 minutes. This procedure recirculates the oil within the compressor and lubricatescompressorshaft seals. This will help to prevent the drying out of the seals with subsequentoperatingfailure of the system. 7. The air conditioner operates most etficiently with all windows closed. However, to speed up the cooling of the car interior on very hot days, it is recommended that the windowsshould be opened for the first minuteto allow the hot air to escaoe. REFRIGERANT CIRCUIT in Fig. 2B-4 incorporates The refrigerant circuil illustrated the followingmajor components: A eompressor, thermostatic switch, evaporator, thermostatic expansion valve, receiver dehydrator and a condenser. tube and Figs. 2B-5, 28-6 and 2B-7 illustraterefrigerant hose routingand connections.
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NOTES
28.8 AIR CONDITIONING

COMPRESSOR The compressor fitted to VK models illustratedin cut away section in Fig. 2B-8 is the TR 70 manufactured by Sanden. lt is a new design based on a gyrating spiral within a spiral principle. Two spiral componentshave 2.8 turn involutespiral walls projectedfrom discs. Both spiral components are housed in a cylindricalcasing, with one in a fixed position and the other interleaved with the former at an angular relationship of 1800, The free moving componentsare driven by a crankshaftin an orbiting motion.The orbiting motion of the free moving component provides a processin two pairs of comprescontinuous compression sion pockets. The compressoris belt driven from the engine crankshaft through an electro magneticclutch. In the cycling clutch system,the compressoris run intermittently, automatically turning on and off in response to an electric signal controlled by the thermostaticswitch. The compressor will cycle as necessaryto maintainminimumtemperature withoutthe evaporator core freezing.
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THERMOSTATIC SWITCH The switch,througha capillary tube, 'senses'variations in the temperature of the evaporator core and, by makingor breaking the electricalcircuit to the compressorclutch coil, causes the clutch to engage and disengage,thus keepingthe evaporator core just above freezing.
EVAPORATOR The evaporator assembly located under the instrument panel and adjacentto the instrument panel compartment, cools and dehumidifiesthe air before it enters the passenger compartment ol the car. THERMOSTATIC EXPANSION VALVE The thermostatic valve regulatesthe supplyof expansion liquidrefrigerant to the evaporator. IMPORTANT:No attempt should be made to adjust this valve or damageto the compressor may occur. RECEIVER DEHYDRATOR The receiver dehydratorserves as a reservoirfor storage of high pressure liquid produced in the condenserand incorporatesa screen sack filled with dessicantto absorb traces of moisture. A sight glass built into the top of the receiverdehydrator (reter Fig. 2B-5) enablesa quick check of the amountof relrigerantcharge in the system.lf the refrigerant charge is low, a persistant frothingconditionwill be visibleat this sight glass. To overcome this condition, refer to the Diagnostic Chart at the end of this Section.
CONDENSER The condenseris mountedforwardof the engineradiator and is therefore exposed to a flow of ram air from the movementof the vehicle and from the engine fan. The purposeof the condenseris to convertthe high pressure, high temperature refrigerant gas discharged by the compressor into high pressure liquid refrigerant. An auxiliaryelectric cooling fan is centrallymounteddirectly in front ol the condenser. and 150 cc The system carries1050 g of R12 relrigerant oil. ol Suniso No. SGSrefrigerant
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Figure 2B-9
Figure 28-10
AIR CONDIT IONIN2B G .11 OPERATIONS 3. SERVICE

DRIVEBELT 3.1 COMPRESSOR AND ADJUSTMENT TENSION
Adjust the compressr drive belt using belt tension dial gauge 982350or equivalent. On 6 CylinderEngines: Before adjusting the compressordrive belt bolt (refer Fig. 2B-9), slacken off the idler pulley clampingnut. On torque clampingnut to 40 of belt adjustment, completion - 50 Nm. Engines: On 8 Cylinder nut assembly Slackenoff the idler pulleyarmlclamping (refer Fig. 2B-10),adjustcompressor drive belt tension, then torqueclampingnut assemblyto 40 - 50 Nm. of a new belt only, the At the time of initial installation strand tension should be 64 kg (140 lbs) plus or minus 2.25 kg (5 lbs) but after ten minutes'run-in'or with used belts, a value of 43 kg (95 lbs) plus or minus 2.25 kg (5 lbs) applies. NOTE: A new compressor will contain 150 cc ol factory installedrelrigerant oil. lf there are no signs of excessive refrigerant oil loss, add the followingamount of oil dependingon the component being replaced. COMPRESSOR Beinstalling the Original Compressor 1. Drain and measure the refrigerantoil contained in the compressor. 2. Replace the oil in the compressorwith the same amountof new refrigerant oil. Installing a New Gompressor 1. Drain and measure refrigerant oil from original compressor. 2. Drain factory installed refrigerant oil from new comoressor. 3- Measure the same amountol new refrigerant orl that was drainedfrom the originalcompressor anc install this amountof oil into the new comDressor. EVAPORATOR Drain as much of the originaloii as possibletrom the then add the same amountof new refrigerant evaporator, oil, either to the originalor new evaporator. CONDENSER Drain as much of the onginal o l as possiblefrom the then add the same amountof new refrigerant condenser, or new condenser. oil, eitherto the original RECEIVER DEHYDRATOR from the Drain as much of the originaloil as possible receiver dehydrator, then add the same amount of new . oil, either to the original or new receiver reirigerant dehydrator. NOTE: lf the condenser, evaporator or the receiver oil, or dehydratorcontainsmore than 25 cc of refrigerant the compressormore than 150 cc of refrigerant oil, then it must be assumedthat the system containsexcess oil. This condition necessitatescomplete f lushing of the whole system with R12 gas and 150 cc of new refrigerant oil added to the compressor.
OIL COMPRESSOR 3.2 CHECKING ON V E H IC L E C H A R GE

The compressoris chargedat the factory with 150 cc of Suniso No. 5GS refrigerantoil. Only this Vpe of oil oil. or changing shouldbe used when adding check the oil level in the It is not necessaryto regularly compressor.In general,the compressoroil level should only be checked in cases where a maior loss of system oil has occurred,such as:a. A broken hose or severe leak. relrigerant system b. Collision damage to components. to be in the system. c. lf excess oil is suspected from system,then remove the 1 . Dischargerefrigerant compressor. 2. Removedischargeport cap of the compressorthen oil. drain and measurethe refrigerant carelully 3. Flushoil from rest of system using R12 gas. oil to the compressor. 4. Add 150 cc of new refrigerant port first ensuringthat cap after Install the discharge 5. the seal 'O' ring is not twisted and that the seat and 'O' ring are clean. Tighten the cap to 8-12 Nm torque. system. then recharge 6. Evacuate NOTE: Never over tighten the discharge port cap to leak.Removethe cap and replace a refrigerant overcome the 'O' ring. ADDING OIL DURING COMPONENT REPLACEMENT Some oil is lost whenever air conditioning syslem are replaced. components Where the system has been ruptured, a leak has occurred or a compressor has to be removed and the entire systemmust be flushed reinstalled or replaced, with R12 gas. system must The completeair conditioning IMPORTANT: oil to functioncorrectly. conlain 150 cc of refrigerant
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28'-12 AIR CONDITIONING

3.3 REFRIGERANT SYSTEMCHARGING
The followingprocedures are accomplished by using the manifoldgauge set illustrated in Fig. 2B-11, which allows the rate of refrigerantdischarge to be controlled,thus minimizing loss of compressor oil from the system. CAUTION: The wearing of safety goggles is mandatory duing system charging. Filling Charging Cylinder 1. Open valve on bottom ol chargingcylinder allowing refrigerant to enter cylinder. 2. Bleed cylindervia valve on top (behindcontrol panel) as required to allow refrigerantto enter. lt will be necessaryto close bleed valve periodically to allow boilingto subsideto check level in sight glass.When refrigerant reaches desired level, close valve at bottom of cylinder and be certain bleed valve is closedsecurely. Installation of Charging Station 1. Close all valves on chargingstation. 2. Remove cut-out swilch from high pressure charging port, disconnectswitch leads from compressorand main wiring harness, then reconnect main winng harnessdirect io compressor. 3. Connecthigh pressureand low pressurelines to the gaugeset fittingson the compressor. 4. Connect vacuum pump line and charging cylinder hose to gauge set.
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AIR CONDIT ION IN28-13 G

Charging System The chargingprocessincludesthe followingsteps:o Fillingchargingcylinder . Evacuation and leak test o Purging(if necessary for repairs) o Final charging o Functional Test Evacuation and Leak Test 1. Open vacuum control valve and gauge set low pressurevalve, turn pump on. After severalminutes, the low pressuregauge readingshould decreaseto 98 to 102 kPa vacuum. should be reduced 3.5 kPa for NOTE: This specification every 300 metres above sea level. Allow pump to operate for 15 minutes after this gauge reading is recorded, close vacuum control valve and tum otf pump if system holds vacuum for 5 minutes,commencecharging system. 2. lf system does not hold vacuum for at least 5 minutes, open refrigerant valve and allow approx 450 grams of refrigerant to enter system. Close refrigerantvalve and locate source of leak using a leak detector,and repairleak. NOTE: Various types and makes of leak detectorsare currently in use. Whichever leak detector is used, it is important to follow the manufacturersinstructions in prior to regard to adjustmentand setting the instrument conductingthe test. Inspect for leaks by slowly moving the probe of the detector around all hose connections and points of possible leakage. Refrigerant Rl2 is heavierthan air and will be more apparentat the bottom of a fitting. 3. Close high and low pressurevalves at gauge set, purge systemas describedbelow. 4. Repeat steps 1 and 2 until system will hold vacuum for at least 5 minutes. Purging (lf Necessary) vacuumline at chargingstationvacuumpump Disconnect and lay end of line on a clean rag on the floor. Crack open high and low pressure control valves and allow refrigerantto purge from system. Refrigerantis completely purgedwhen hissingceases. NOTE: oil may a. Do not open valves too much or compressor Oil loss can be be dischargedwith the refrigerant. line. easilydetectedon rag at discharge b. Refrigerant must not be purged through vacuum pump as this will aerate oil in pump thus reducing sealingetficiency. c. Reconnect vacuum line and close high and low pressurecontrolvalves on manifold and gaugeset. and leak test. d. Repeatevacuation Charging System DO NOT STARTENGINE 1. Partially charge system with 170 grams (6 ozs) of refrigerantR12 by slowly openingthe high pressure valve at the gauge set; gauges should register a pressure,if not, check systemfor blockage. 2. Close high pressurevalve, and rotate comPressol at least 12 turns by hand to ensure that no liquid refrigerant is trapped in the suction side of the compressor and that the internal components are coated with lubricant. NOTE: Failure to comply with this proceduremay result in permanentdamageto the compressor. 3. Open high pressureside refrigerantvalve and allow full charge to enter system- 1050 g Do not exceed this amount. 4. lf the charge will not transler completelyirom the station to the system,close the high pressurevalve controlsfor at the gauge set, set the air conditioning cooling, check that the engine compartmentis clear of obstructions,start the engine and run at rdle speed. Compressoroperationwill decrease the low side pressurein the system.When low side pressure falls below 275 kPa, crack open low side valve to refrigerant draw in the remaining charge.At no time should the rate of refrigerant drawn in be such that hydraulic noises are created in the compressorby Adjustlow side valve opening the pumpingol liquid. to achievethis 5. Remove gauge lines from system and replace protective cap over low pressure schrader valve fitting, then tighten cap securely.fit cutout switch to high pressure schrader valve and !nten securely and leak check. 6. Disconnect main wiring harness irom compressor and reconnect cut-out switch leads to marn winng harnessand compressor. WARNING: NEVERRUN COMPRESSOR WITHOUTREFRIGERANT IN THE SYSTEM, AS COMPRESSOR FLOW. RELIES ON REFRIGERANT LUBRICATION functronal test. 7. Perform Functional Testing of System of the air The functionaltesting is a quick measurement conditioner system perlormance. The air outlet vent temperaturesand the compressor head and inlet pressures are compared with specified tolerances at the prevailing ambienttemperature. test proceedas follows:To performthe functional This test must be performedwith the vehicle In the shadei.e.'nosun load. caps and cut out swrtchfrom 1. Removethe protective the schrader valves on the compressor discharge and inlet fittings.Connect compressorlead to main wiring harness. 2. Connect the manifoldand gauge set charginglines and adaptors to the air conditroningsystem as show ni n Fi g. 2B -11. 3. Close all doors,windowsand the enginehood. 4. Set the temperature control lever to the cold position,blowerfan to high and mode switch to A/C 'MAX' position. type fan 5. Place and operatea high volume industrial in front of the radiator grille to ensure adequate and condenser. coolingof radiator of this fan. 6. Measureambienttemperature face leveloutletvents. 7. Open all air conditioning 8. Start engine and run at 2000 rpm with transmrsslon in neutral. 9. Measure the temperatureat the centre outlet after runningenginefor 5 minutes. 10. Compare actual pressures and temperatureswith test table. those on functional
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FUNCTIONAL TEST TABLE
A mbient A i r oc Temp. A ux . Fan Air B last Ce n tr e Ou tle t Air T e m p .
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lf operatingpressuresand temperatures are within the specificatronslisted in this f unctional test table, the refrigerant section of the air conditioningsystem is functionrng conectly.
3.4 COMPRESSOR INSPECTION PROCEDURES

LEAK TEST Seeping oil does not necessarily indicate leaking refrigerant. Look for the followingproblems: . Shaft seal area seeping oil. Feet under seal area betweenclutch and compressor. . Dislocation of front boss 'O' nng (protruding section). o Oil aroundserviceport. fittings. . Oil aroundfillerhole.'O' ring,stripped threads. o Oil aroundcrackrn compressor housing. IMPORTANT: Alwaysclean away all oil, grease,etc., and blow away residual refrigerantbefore starting detection procedures. Reter to Systemor SupplierManualsfor the proper techniquesto be used for Halide or 'Electronic' Leak Detectors. HalideFlame Detectors- Any portionof the compressor, rncluding the seals,which showsa leak indication on the f lamewill require leak repar. 'Electronic' Shop Type Detectors+ In the seal area. Se: the instrument1/4 to 1/3 range above maximum selsrtivity. All other portionsof the compressor - set the detector at maximum sensitivity. ("Detectors with a mlnlmum leak rate of 14-28cc per year). 'Soap 3ubble' - Any bubbtes, on any portion of the compressor indicate a leak requiring repair. COMPRESSORSMOOTHNESSTEST (Compressor installed) 1. Disconnect refrigerant hoses, discharging system. 2. Disengage clutch. 3. Rotatearmatureplate by hand. 4. While rotating,if severe rough spots or 'catches' are felt, repairor replacethe compressor. CLUTCH TEST 1. lf fieldcoil lead is broken, repairlead or replacefield
coil.
Check current draw and voltage. The amperage range requtrement is 3.0 to 3.5 at 12 volts. Note the followingsymptomsand remedies. o A very high amperage reading - A short within the field coil. . No amperage reading - An open circuit in the winding. o An intermittent or poor system ground resultsin lower voltage at the clutch. Check for tight fit of coil retainingcirclip. Check to determrneprooer systemground. o Replace field coil if open or short circuit is found. 3. Air Gap - An incorrect air gap could cause erratic engagementor disengagement and/or clutch ratile. Check the air gap with a feeler gauge 0.35 0.65 mm. Adjustas outlinedlater in this Section. 4. Suspected BearingNoise - Carry out the following: Removebelt. Disengage clutch. Rotaterotor pulleyby hand. Listen for bearing noise. Feel for hard spots. lf excessive, repairor replacecompressor. NOISE Checkfor: 1. Loose belt, torque to 43 kg (used),64 kg (new) plus or minus2.25 kg. 2. Broken bracket and/or compressorbody mountingreplace brokencomponent. 3 Missing,broken or loose bolts at compressor and engrne fixingpoints. 4. Torqueboltsto specifications. 5. Looseor wobbling enginecrankshaft pulley. 6. Alternalor bearing. 7. Air pump (wherefitted). B. Water pump bearing. 9. Engine valves. 10. Timinggears. 11, Looseenginemounting bolts. 12. Low refrigerant charge can be determinedby persistant foaming in the receiver dehydratorsight glass and low suction pressure together with low head pressure. 13. Oil Level- Insufficient oil can cause unusualnoise. Remove 1. Dischargesystem as previously ouilined in 'Refrigerant SystemProcessing.' 2. Removehoses from compressor and tape or plug all connectionsto prevent absorptionof moisturefrom the atmosphere into the system. 3. SlackenofJidlerpulleyclamping nut and/or bolt then disconnect the drivebelt. NOTE: On 6 cylinder engines,it will be necessary to release the tensron from the compressor drive belt adjusting bolt.illustrated in Fig. 2B-9. 4. Disconnect electrical connector then remove the attaching bolts and compressorfrom the mounting bracket. 5. lf the original or a new compressor is being reinstalled,or replaced, refer to 'Add Oil Durino Component Replacement' 2.3 in this Section.
2.
AIR CONDIT IONIN2B G -15
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2B-16AI R CO N D I T I O N I N G
Reinstall Reverseto removalprocedures notingthe lollowing: 1. Torque mountingbolts as shown in Figs. 2B-9 or 2 8 -1 0 2. Leave protective plugs or caps until ,ust before connectingtubes or hoses to prevent absorptionol moisture trom the atmosphere into the system. 3. Installnew 'O' ring seals after lubricating them with refrigerantoil, then torque hose connectionsas shownin Figs.2B-5,28-6 or 2B-7 4. Adjust the drive belt as outlined under 'Compressor Drive Belt TensionAdjustment' to 43 kg (used) or 64 kg (new)plusor minus2.25 kg. 5. Charge the system as outlined under 'Refrigerant Syslem Processing.'Parts illustratedin Fig. 2B-12 which are servicedfor the TR70 Spiral compressor i n cl ude: 1. ArmaturePlate 2. ArmaturePlate BalanceWeight RotorPulley A FieldCoil Core 5. ShaftBearing - Front 6 FrontBoss 7 Shah Seal Assembly
Disassembly CAUTION: Tool No. 41267, sea/ seat remover and installer must be used to ensure that no contamtnatpn i.e. dirt, humapperspiratton. etc., /s allowed onto the sea! area. With a new seal, tt ts tmperative that it be unpacked carefulty and fifted onto Tool 41267 for in_ stallationonto the compressor shaft. 1. Mount holdingfixtureAU2S8 into a vice, then usino the pins suppliedwith the fi).ture,secure the coml pressor assemblymounting holes onto the holding fixturebossesas illustrated in Fig. 2B-13.
Figure 28-13
insertpins of turningstop tool AU259 into holes o{ armalure, then using an 8 mm socket with ratchet handle attached,remove armatureanchor borr as illustrated in Fig. 2B-14, then removearmature.
Figure 2B-14
t- -
AIR CONDITIONING 28-17

3. Remove shim(s)trom top of compressorshaft then using wing circlip pliers J6083, remove the circlip securing the clutch rotor to the clutch core as illustratedin Fig.28-15, then lift the clutch rotor assemblyoff the compressor shaft. NOTE: lf difficultyis experiencedin removingthe clutch bearing,locate the ends of two bladed screwdrivers into grooves inside of clutch rotor, then using a lever action, lever clutch rotor up and off the compressor shaft.
Figure 2B-15
4.
Loosenthe clutch lead wire clamp releasing the lead, then using wing circlip pliers J6083, remove the circlip securing the clutch core assembly in the stepped section of the front nose as illustratedin Fig. 28-16, then removethe clutch core assemblyofl the compressor shaft.
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Figure 28-16
c-
5.
Using a 10 mm socket with a ratchet handle attached, remove the iour bolts securing the front nose to the front end plate as illustratedin Fig. 2817. Lift the front nose off the compressorshaft as illustrated in Fig. 2B-18, then remove the square sectioned'O' ring from the end plate.
Figure 2B-17
Figure 28-18
2B-1 8A I R CO N D I T I O N I N G
6. Installthe 'O' ring protecting tool AU261 over the end of the compressorshafi then install the seal head removaland installation tool 41267 over the protectrng tool and compressorshafl, as illustrated in Fig. 2B-19. Depress then rotate the tool in a clcckwise directionto engage cutouts in bottom ol 'lool with seal head retainer, then remove the seal head.
Figure 2B-19
Depressarms of the seal seat removaland installaricr tool AU260and installthe tool into the insideol the seal seat as illustrated in Fig. 28-20.Allow the ends of the tool to expandand engageinto recesses on the base ot the seal seat. Using a pullingaction, lift seal seat out of seal head.
Figure 28-20
Depressarms of the seal seat removaland installation tool AU260 and installthe ends of the tool in betweenthe base of the metal cap retainerto which the felt seal is attachedand the front nose. Carefully work the ends of the tool around the base of the felt seal retainer, then usinga pullingaction,lift felt seal assembly out of the front nose as illustrateo rn Fio- 28-21.
Figure 2B-2't
Reassembly
1. Install rhe felt seal assembly onto the felt seal y rnstalling assemb tool AU262,then installthe seal assembry firmlyinto the bore ol the front nose. as illustrated tn Fig.28-22.
Figure 28.22
-.).
AIR CONDIT IONIN2B G -19

2. With the seal seat installed on the end of tool oil to the seat 'O' ring, then AU260,apply refrigerant insiall the seal seat into the bore o{ the front nose with the 'O' ring uppermost- Using the felt seal tool AU262 locatedon top of the assemblyinstalling seal seat, exert sufficient downward pressure to correcllyinstallseal seat. NOTE: Refer to cautionaryparagraph at start of Disassemblyprocedures. 3. With 'O' ring protectingtool AU261 installedon end of compressorshaft and with seal head installedin end of tool 41267, thoroughlyair blow seal head, oil to 'O' ring. then apply refrigerant 4. lnstall seal head onto compressorshaft illustratedin Fig. 28-23, then applyingdownwardpressure,rotate tool and head to align flats on the base of the seal shaft. head with those on the compressor 5. Remove 'O' ring protectingtool AU261 from end ol compressorshaft then install square sectioned 'O' ring into grooveon the end Plate.
*
Figure 28-23
Align notched edge of front nose with front plate in Fig. 28-24 and install the retainingbolt illustrated front nose, ensuringthat the square sectioned 'O' nng on the front plate remains in its groove-Apply downwardpressureon the front nose to overcome spring tension from the seal head, then install and torquefront nose to front end plate attachingbolts in to 14.711.98Nm. sequence diagonal
Figure 28-24
lnstall the clutch core assemblyto the f ront end dimple in tne nose, aligningthe locatingproiection with cut cut base of the clutchcirclipcore assembly in end plate. Usingwing circlip pliersJ6083, install in Fig. 28-25 as illustrated clutchcore assembly
Figure 28-25
2B-20AIR CONDITIONING
8. Replace the clutch lead wire and tighten the retainingclamp. then install the clutch rotor. using wing circlipp|ers J6083to to securethe rotor to the clutchcore as illustrated in Fig. 28-26. 9. Install the shim(s)to the end of the comoressor shaft. NOTE: These shims adjust the air gap (refer air gap adjUS1ment in subsequent serviceoperations).
Figure 28-26
10. Instalithe clutch armature,aligningflat on end of compressor shaft with corresponding f lat on armature.Using turning stop tool AU259 and an 8 mm socket with ratchet handle attached, install and torguearmature anchorbolt to 9.81r .98 Nm. as illustrated in Fig. 28-27.
Figure 29-27
A IR GAP A DJ US T M E N T Measureair gap between clutch armatureand clutch rotor assemblies, using feeler gauges as illustratedin Fig. 28-28. Recommended air gap is 0.35 - 0.65 mm. lf adjustment of the air gap is indicated, remove anchor bolt and armature clutch assembly (refer preceding instructions) then adjustshim thickness to achievethe recommended air gap.
Figure 2&28
3.5 EVAPORATOR ASSEMBLY

REMOVE 1. Disconnect the batteryearth cable. 2. Evacuate the system (refer 'Refrigerant System Processing' in this Section). 3. Disconnect the inlet and outlet refrigerant pipe connections illustrated in View 'A', Fig. 28-33, from the evaporatorcore. 4. Removetransmission console(reler2.p or 2.3 in the BodySectionol this Supplement). 5. Remove heater case to panel cover assembly,lower instrument panel extention, touch switch control panel and centre nozzle and instrumentlocation lrame illustrated in Fiq. 2ts-29.
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in Remove combined instrumenlassemblyillustrated Fig. 28-30. 7. Disconnect temperature cable at heater assembly and partially remove vent/heat control assembly- Do vacuumhoses or electril connector. not disconnect Remove screws securing left hand and centre of instrumentlocation cover to instrumentpanel pad in Fig. 28-30. and frame illustrated 9. Remove centre nozle hose assembly and screws securingright and left hand air ductingto centre air in Figs. 28-30 and 28-31. duct illustrated 10. Remove instrument panel compartment and rear releasebutton. comDartment 11. Remove left hand upper air outlet assembly and screw securingleft hand ol instrumentpanel pad to in Figs. 2B-30 and 28-32. frame iflustrated 12. Firmly support left hand instrumentpanel lower and remove all of the screws securingthis panel to the panel frame illustrated in Fig. 28-32. instrument 13. Flemove left harrd air outlet duct illustrated in Fig. 28-31, from under left hand side of instrument panel, taking care not to place undue pressureon left hand instrumentpanel lower. 14. From under the instrument panel, disconnect the drain tube illustratedin View 'A' Fig. 28-33 from the assemblY. base oJ the evaporator '1 5. Positiona wooden wedge betweenthe left hand side panel panel pad and the instrument of the instrument frame to gain access to the two bolts illustratedin Fig. 28-33, which secure the top ol the evaporator panel frame,then using a assemblyto the instrument socket enension and a ratchet handle, remove the bolts securing the evaporator assembly to the panel frame. instrument
2B.-24 AIR CONDITIONING

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Figure 28.33
16. From inside the engine compartment,remove the in Fig. 28-33, securingthe front two bolts illustrated assemblyto the lowerdash panel. of the evaporator CAUTION: Cap or plug evapontor core pipes and refrigerant tube connections as soon as connectionsarc broken to prevent absorption of moisture from the atmosphereinto the system. in Fig. 28-33, which 17. Removethe clamps illustrated retain and seal the ends of the evaporatorhousing to the heater and blower motor housing assembly, disconnect the electrical connectors and vacuum remove the evaporator hoses,then carefully ass
REINSTALL Reverseremovaloperations noting the following: 1. l{ the original is to be installed, or a new evaporator referto 'AddingOil DuringComponent Replacement' in this Section. 2. Leave protective plugs or caps until just before connectingtubes or hoses to preventabsorptionof moisture from the atmosphereinto the system. 3. Install new 'O' ring seals, lubricating them with refrigerant as oil then torque A/C hose connections in Figs.2B-5,28-6 and 2B-7. illustrated 4. Charge the system as outlined under 'Refrigerant in this Section. SystemProcessing' 5. Checkout the electrics and air ductsdisturbed durinq the removaiand installation ooerations.
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Figure 28-34

CORE AND PIPE 3.6 EVAPORATOR ASSEMBLY
REMOVE 1. Remove evaporatorassembly as described in the precedingprocedures. 2. Remove the spring clips illuslratedin Fig. 28-34 which secure the upper and lower sections of the case together. evaporator 3. Remove the heavy mastic insulationmaterialadiacent to the expansion valve and inlet and outlet pipes. 4. Whilst removingthe upper section of the evaporator case, carefullyease the TXV sensor tube illustrated in View 'A' Fig. 28-34, from the slot in the inside case. 5. Removethe rubbersealinggasketand the inlet pipe core and illustratedin Fig. 28-34 from the evaporator pipe assembly. 6. Carefullywithdrawthe core from the lower sectionof the evaporatorcase taking care not to contact the aluminiummesh waler collector screen attached to the rear section of the pipe and core assemblyby hand. this water collectoris chemicNOTE:Duringmanufacture, ally treated to create a slippery surface to accelerate moisturemovement.Acid depositswhich can result from this chemictouchingthis surfaceby hand can neutralize ally treated surface. REINSTALL the new assemblynote the following: When installing 1. Drain as much of the original refrigerant oil as possible from the originalevaporatorcore, then add oil, eitherto the the same amountof new refrigerant core. originalor new evaporator assemblycontainsmore than 25 cc lf the evaporator of refrigerantoil, assume syslem containsexcell oil and flush system,then add 150 cc of new refrigerant oil to compressor. 2. Leave protective plugs or caps until just before connectingtubes or hoses to prevent absorptionof into the system. moisturefrom the atmosphere with clean refrigerant 'O' ring seals coated 3. Use new oil when makinginlet and outlet tube connections' until 4. Leave final tighteningof the tube connectrons is securelyinstalled. the evaporator test the leak test, charge and performance 5. Evacuate, system. NOTE: Removal and reinstallationof the thermostatic expansionvalve and the thermostaiand switch assembly necessitateremoval of the evaporatorassembly. attached to condenser assembly, illustrated in Fig. 28-36. Removethe screws illustrated in Fig. 28-36 securing the right hand bracket to the condenser and the radiator side supportpanel. Disconnect the inlet and outlet refrigerant pipe connectorslocated on the right hand side of the condenser assembly.
5. 6.
CAUTION: Cap or plug disconnected connectors on pipes and on condenser immediatelyto prevent moisture being absorbedfrom the atmosphereinto the syslem. 7. 8. Disconnectthe horn bracket lead, then remove the horn and bracket assembly from the lett hand radiatorside supportpanel. From under the Jront lower valance panel, remove the two screwsillustrated in Fig. 28-36, securingthe right and lett hand bracketsattachedto the base ol the condenser assembly. Remove the screw illustratedin Fig. 28-36 securing the left hand upger support bracket to the radiator side supportpanel,then removethe condenser and fan motor assembly. auxiliary
9.
REINSTALL the new When installing Reverseremovalprocedures. note the following: asser"rbly. from the 1. Drainas muchof the original oil as possible orginal condenser,then add the same amount ol new refngerantoil, either to the original or new condenser. lf the condenser contains more than 25 cc ol refrigerantoil, assume system contains excess oil oil and flush system.Add 150 cc of new refrigerant to the compressor. 2. Leave protective plugs or caps until just before connectingtubes to prevent absorptionof moisture into the system. from the atmosphere 3. Use new 'O' ring seals coated wtth clean refrigerant inletand outlettube connections. oil when making 4. Leave final tighteningof the tube connectionsuntil is finallyinstalled. the condenser test the leak test, charge and performance 5. Evacuate, svstem.
FAN 3.8 AUXILIARY

REMOVE the battery earth cable and the auxiliary 1. Disconnect fan electncalconnectorlocatedon the left hand side assembly. of the condenser 2. Remove the conneclor body from the end of the auxiliary1an lead, then attach a length of string to the end ol the lead. grilleillustrated in Fig. 2B-35. the radiator 3. Remove 4. Remove the nuts securing the auxiliaryfan to the then removethe fan and lead assembly, condenser, leaving enough of the string previouslyattached to the fan lead adjacent to the top of the radratorto installation oJ the fan lead. facilitate subsequent REINSTALL Reverseremovalprocedures.
FAN AND AUXILIARY 3.7 CONDENSOR ASSEMBLY

REMOVE 1. Disconnectbatteryearth cable. 2. Evacuate the system (refer 'Refrigerant System in this Section). Processing' grille,illustrated in Fig. 28-35. 3. Removethe radiator 4. Disconnect the electrical connectors,then remove fan blade from the fan motor assembly the auxrfrary
\ JT 2 PLAC -S
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Figure 28-35
_AADIATOR 3F:!E
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A S S E MB LES C R E WTO C ON D E N S E R & B R A C K E T A FTE B OU TLE T TU B E IS C ON N E C TE D TO C ON D E N S E RR E FE R FIGS .2B -5 A N D 28-7
0.8 - 1 .4Nm
Figure 28-36

DEHYDRATOR 3.9 RECEIVER
REMOVE 1. Evacuate the system (refer 'Refrigerant System Processing' in this Section). pipes from 2. Disconnectthe inlet and outlet refrigerant the inlet and outlet sides of the receiverdehydrator in Fig. 28-37. illustrated CAUTION: Cap or plug disconnected connectors on pipes and on receiver dehydratorimmediately to prevent absorption of moisture from the atmosphere into the system. 3. Loosen the screw clamp illustrated in View 'A', Fig. 28-37, then slide the receiverdehydrator out ol the clamp. NOTE: lf the receiver dehydrator is left open to the atmosphere for more than 15 minutes, the receiver dehydratorshould be replaced. REINSTALL Reverse removal procedures. When installinga new assemblynote the following: 1. Drain as much ol the originaloil as possiblefrom the original receiver dehydrator, then add the same amount of new refrigerantoil, to the original or new receiver dehydrator. ll the receiver dehydratorcontains more than 25 cc of relrigerantoil, assumesystem containsexcess oil oil and flush system.Add 150 cc of new refrigerant to compressor. 2. Leave protective plugs or caps until just before connecting tubes to prevent absorption of moisture from the atmosphereinto the system. 3. Use new 'O' ring seals coated with clean refrigerant oil when making inlet and outlet tube connections. 4. Leave final tighteningol the tube connectionsuntil clamp is fully tightened. the receiverdehydrator 5. Evacuate,leak test, charge and performancetest the syslem.
- POWERST EERING R ESERVOI R SIGH T G LA S S R E C E TV E R D E H Y D R ATOR
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28.30 AIR CONDITIONING 4. DIAGNOSIS CHART

N ORM AL AIR F L OW
C h e ck th a t h e a te r ta p is off wher eve. s on "COLD Check d a rr te mper atu' 9 at cutr el lozzle posr lron
C OMP LA IN T _ TN S U FFIC IE N TC OOLIN G C H E C K A IR FLOW
NOR M A L N O Z Z L E AIR TEMPERATURE

C h e c k fo r a i r l e a ks th rcu gh fr r e w a l l , d o ors. w i n d o w s o r from neater .
HIGH NOZ Z L E A IR T EM PERAT UF E
F OAM ING
System is pr obably low on r efr ig er ant. Check for leaks, r epair and add refr i ger ant. lf foam ing still occur s, che c k for r estr iction in r efr iger ant system between condenser and sight glas s .
N O FOA MIN G
Sy s tem m ay be ei ther ful l y c har ged or em pty . F eel hi gh and l ow pr es s ur e pr pes at c om pr es s or . H i gh pr es s ur e pi pe s houl d be w ar m ; l ow pr es s ur e pi pe s houl d be c ol d. l f pi pes ar e not i ndi c ati ng pr oper r em per atur es _ recharge system as recommended. lf nozzle air tem per atur e i s s ti l l hi gh, c hec k ev aO or ator .
C H E C K E V A P OR A TOR P RE S S U R E L O W E V A P O R A TOF OR CO M P R E S S O R S U C T I ON PRESSURE

Ch e ck e va p o ra to r o utlet line Ou tl e t l i n e wa rm.
] H IGH E V A P OR A TOR OR C OMP R E S S OR S U C TION P R E S S U R E TH E R MOS TA TTC S WITC H

C hec k for c l utc h c y c l e.
C h e ck fo r l i q u i d l i n e resr : cr on ( F r o st sp o t o n l i n e ) l f r or , C h e ck fo r p i u g g e d T .X . valve. l f n ot, C h e ck fo r ce fe cti ve T .X. valve by r e m ovrn g va i ve a n d b l o wing thr ough v a l v e l f u n a b l e to b l o w thr ough valve b u l b i s d rsch a rg e d . Re p lace T.X. va ve
C Y C LE
o.K
C LU T C H ON I D i s c onnec t c l utc h l w i r e.
CL UT CH DISENGAGES
C LU TC H R E MA IN S E N GA GE D HIGH D IS C H A R GE P R E S S U R E
C l utc h i s defec ti v e.
L O W D I S C H A R GE rhts55uHE
C h e c k fo r sl i p p i n g cl u rch or slipping belt. C r g c k fo r su cti o n l rn e re str ictionR e m o v e co mp re sso r, te a rdown, inspect for d e t ? c t s a n d re p a i r.
Check engi ne c ool i ng fan and c ondens er cooling fan, and for r es tr i c ted ai r fl ow tnr u COn dens er . Check T.X. v atv e bul b c ontac t and r ns ul ati on. Cor r ect if nec es s ar y . Check for r efr i ger ant r es tr i c ti on j n c ondens er . Aeiur n bends at equat el ev ati on s houl d be acpr ox i m atel y s am e tem per atu r e. I f te6pg1s 1g1s of bends i s appr ec i abl y di ffer ent. the c ool er bend ncr cates a r es tr i c ted c i r c ui t. R epl ac e c ondens er i i r estr ction i s found. l f c ondens er r s O.K., c hec k tor ai. in s y s tem . T o c hec k : O bs er v e noz z l e ai r temper atur e and c om pr es s or dr s c har ge pr es s ur e whr ,e slow l y di s c har gi ng s y s tem at r ec ei v er i nl et connectr on
NOZ Z L E AIR T EM PERAT URE DROPSAS COM PRESSOR DISCHARGE PRESSUREDROPS

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N OZZLE A IF TE MP E R A TU R E I N C R E A S E SA S C OMP R E S S OR D IS C H A R GEP B E S S U R ED R OP S

T .X. v al v e s uper heat s ettr ng i s l ow . R epl ac e T .X. v al v e
Lea^ test r ur r "- , r "p"ir as necessar \, dischar ge, evacuate and r ecnar ge.
] I
28.31 AIR CONDTTIONING
N O OR LOWA IR FLOW
C hec k bl ow er oper atton
BL OWER NOT OPERAT IT { G

Ch e ck for blown fuse, defective blower switch, b ro ke n wir e, loose connection, defective b l o we r m otor .
N OR MA L B LOWE R OP E R A TION
C hec k {or l oos e or di s c onnec ted ai r d!s tr tbr t,o n ro s e s R es tr i c ted or l eak i ng ai r duc ts , par ti al l y c l os e c a L r outl et v al v e or c l os ed ev apor ator c or e. l { abov e c hec k i s O .K., c hec k for i c e bl oc k r ng e v a 9 o ' a i o '
IC E B LOC K IN G E V A P OR A TOR
Ai l ow s y s tem to w ar m up. F es tar i :n- o ne. C hec k el aO :.a:or Pr es s ur e m r gd a:a 7 afl er r es tar t and ou i c c $r ol e,'ap3r al or Pr es s u re .
tF:t r uJ l r r L
SY;I T C H
NORM AL EVAPORAT OF OR SUCT ION PB ES S U R E COM PRESSOR

Check dischar ge Pr essur e
C hec k i o'c l u:c n
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C LU TC H O\
D i s c onnec t c l utc h w rre
,L n -L! U t5 tr !Jr r tr )
C L UT CH OF F C h e c ke le ctr ica lcir cur t t h r o u g h th e r m o sta tic s w i t c h a n d clu tch so le n o r d

T her m os tati c s w r ::r i s defec ti v e.
C l utc h i s d e f e c t i v e
L O W D I S CHARGE PRESSURE
C h e ck fo r restr iction in liquid line, p a rti a l l Y P luggd T.X. valve, or d e fe cti ve T.X. valve Replace T' X' va l ve i f d e fective.
N OR MA L D IS C H A R GE P RE S S U R E
Refri ge'at on s v s i .m l s O .K. ' I . Chec k i o' nc : !\ai e' v al v e s hut- ot1 2. Chec k i o- P'3Pg' func ti on of ai r SeleCiOr doOr. door and sea a.oLnc :emperature 3. Chec k fo'c r c Pe'oPer ati on s \'s :em . Add a p p ro x 4. Non- foam r g s gr t gl as s does not al w av s r d c ate a ful l y c har ged D l s c har ge or r ec har ge s /s l em as sp e c i f i e d 200 g R '12 anc obs er y e per for m anc e ) or ai o- c a,e. 5. Chec k tor c 'c ae- s eal ar ouno ev apo A s v m otc m of ex c es s oi l i s a s l i ppi ng c l utc h o r b e 6. C hec k for ex c es s or l r n s y s tem removeexcessoi l rn s y s tem or br ok en 3er : at s peeds i n e xcessof 1OOkmi h. To and maxrm um c o o a ) l dl e en- one f or 10 m i nutes w rl h co.trol s set at hi gh bl ow er i f the c om p re s s o fr om c om pr es s or m eas u'e oi l and dr ai n s y s tem , b ) D i s c har ge has an or l ov e rc n a rg ' c ontai ns m o'e than 85 c c of r ef'ger ant oi l , the s y s tem c ) R em ov e T X. v al v e. r em ov e the ex c es s otl I d) F tur n the r em ai ni ng c om ponents w r th R - 11 to v al v e' e) D r ai n the ex c es s oi l fr om the T .X. v al v e and i ns tal l I f) l ns tal l the c om pr es s or w i th 95 c c of new r efr i ger ant oi l ' j g) Ev ac uate and r ec har ge s Ys tem
29.32 AIR CONDITIONING 5. SPECIALTOOLS

T he Comp resso r To ols ar e av a able eit her in k it f or m as T o o l N o . A U 2 6 3 , o r a s s e p a r a t e i t e m su n d e r t h e i r i n d i v i d u a l T ool numb er. A Be lt Te ns ionG augeis als oav ailable.Th e s eS p e c i a lT o o l s a r e a v a i l a b l e from. Kent M oor e - A u s t r a l i aP t y . L t d . Unit 3, 9 Pion e e rA v e n u e , THO RNLEI G H , N . S W 2 1 2 0 . Teephone. (021 8489717 Terex 22355
F AB RICAT ED T RIM C LIP R E MOV A L TOOL 0 .5 mm
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E N D C ON S TR U C TION TO S U IT H A N D LE R E OU IR E ME N TS
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AU263 _ SANDENCOMPRESSOR TOOL KIT

CO M PRI SI NGTHE F O L L O WI N G T O O L S
A U 2 61
,O' RIN G P R OTE C TIN G TOOL
Z
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FE LT S E A L A S S E ME LY N S TA LLIN G TOOL
A U2 5 8
C O M PRESSOR HOL DING F I X T URE
41267
S E A L H E A D R 'MOV A L IN S TA LLA TIC N TOOL
AU260
W I N G C I RC L IP P L IE R S
S E A L S E A T R E MOV A L A N D IN S TA LLA TION TOOL
FRONTSUSPENSION 3.1
SECTION 3
FRONTSUSPENSION
INDEX
Ref. 1. Subject Page GEI{ERAL DESCR|PT|ON.............................. 3-1 I Ref. | 2. Subject FRONT STRUT USAGE
Page 3-1
1. GENERALDESCRIPTION
The front suspension on VK Series models remains the same as on VH Series models, with the exception.ol the front strut shock absorbers.These have been revised to suit the differenl variation in vehicle load and to maintain satisfactory damping control. VK strut inserts are not interchangeable with previous Commodoremodels. Service operationsare as described in Section 03 of the VB ComniodoreService Manual p/N M3g14S.
2. FRONTSTRUTUSAGE
All VK Series models have the front strut assemblies painted black, there is no colour identificationas per previous models. Commodore For non-standard strut identification, refer to the 'Body and ldentification Plate'. The plate includes vehicle optional information if it is fitted with XWs - Outback Pack or FE-ZSportsSuspension Pack,refer Fig. 3-1.
Figure 3-1
4A.1 REAR SUSPENSION
4A SECTION
REAR SUSPENSION
INDE x
Ref. 1. 2. Page Subject 4A'1 ...................r.......... GENERALDESCRIPTION 4A-1 ........'..............!........ SERVICEOPERATIONS Ref. 3. 3.1 Page Subject 4A-2 ...............-...................r........ SPECIFICATIONS 4A-2 REAR SHOCKABSORBER USAGE...........I
DESCRIPTION 1 , GENERAL
on VK Series models remains the The rear Suspension same aS on VH Series models,with the exceptionof the shock absorbers.These have been revised to suit the differentvariationin vehicle load over VH Series models. Serviceoperationsare as describedin Section 04 of the VB CommodoreServiceManual.
OPERATIONS 2. SERVICE
Service operations arc as described in the VB CommodoreServiceManualPart Number M38145. NOTE: Any service operation that requires the removal and reinstallation of the upper control arm to axle attachingbolts, on installationthey must be inserted in an inwarddirection,Refer Fig. 4A-1.
Flgure 4A-l
44.2 REAR SUSPENSION 3. SPEC|F|CAT|ONS

3.1 REAR SHOCKABSORBER USAGE
M O DE LS
ID EN TIFIC A TI ON LA B E L
E X TE N D E D LEN GTH (mm)
C OLOU R
A ll 19 St y les ( Sedans ) Ex c . XW S/ FE2 All 35 St y les ( St at ionW agons ) Ex c . XW S/ FE2 19 St y les ( Sedans ) wit h x w5 , FE2 35 S t y les ( St at ionW agons ) r I W it h XW SiFE2 | 19 St y les ( Sedans ) vG
522.5/528,5
Black
ffi1/635
Yellow
LG
523.51527 .5
Yellow
With FEz
XWs - O ut bac k Pac k FEz - Sus pens r on Sy s t em Pac k
582/588
B l ack
NOTES
REAR AXLE 48.1
48 SECTION
REAR AXLE
INDEX
Ref. 1. Page Subiect 4B-1 GENERALDESCR|PT|ON.............................. I Ref. | 2. Subiect SERVTCE OPEBAT|ONS................... Page 4B-1
1. GENERAL DESCRIPTION
There are two different size Salisbury Rear Axle Assembliesused with VK Series models. 1. A Salisbury type axle with 178 mm diameter ring gear is used as standard eguipment on all models except those with the 5.0 litre engine. 2. A Salisbury type axle with 1gO mm diameter ring gear is used on models with s.O litre engine. Limited slip differentialis avaitabteon all models.
2. SERVICEOPERATIONS
There have been some revisions to the rear axle assemblies for VK compared with those fitted to VH Series models. 1. The hypoidpinionhas been shot peened. 2. The ditlerentialpinion shaft has been nickle plated. 3. The hypoid pinion bearing spacer has been surface hardened,by a process of nitro carburizing. NOTE: Components from previous Holden models must not be substituted for the above components when overhauling the rear arde assemblies on VK Series models. The remainder of the axle components are identical to those used on previousHolden models. For servicing and overhaul procedures refer to the VB Commodore ServiceManualPart No. M38145.
PROPELLER SHAFT& UNIVERSAL JOINTS4C-1
sEcTtoN 4c
PROPELLER SHAFT& UNIVERSAL JOINTS
INDEX
Ref. 1. Subject Pqge PROPELLER SHAFT IDENTIFICATION......4G1 I Ref. I 2. Subject UNIVERSAL JOINTS page IC]T
1. PROPELLER SHAFT IDENTIFICATION

The following chart sets out the propeller shaft usage for VK Series models.
PROPEL L ER S H A FT E N G IN E 3.3 litre EST TRANSM ISSION PART NO. C OLOU R
MC6 M4o
M76
ll s2o24162 |
1l
BLACK
with gr ey band
il gzoz41 63 |
i | ll
a LAcK
1 41i th vi ol et band
eLA C K w i th 92024160 I I o p al i ne greenband

B LAC K w i th sk y bl ue band
3.3 litre
D A R K GR E E N wi th w hi te band
2. UNIVERSAL JOINTS
On VK Series models, with the EFI engine, the propeller shaft is fitted with universalioints the same as used on 5.0 litre models. For service operations refer to Section 04 of the VB Commodore ServiceManualPart No. M38'145. The phasing of the front and rea( yokes on propeller shafts fitted to 3.3 litre models, has changed from parallelto 90o apart.
BRAKES5.1
SECTION 5
BRAKES
I NDEX
Ref. 1.
1 .1
1.2 2. 2.1
Page Subject INFORMATION .........r.........r..-..... 5-1 GENERAL 5-1 NOTES ...' ...........r .o....r r ........!.r .r ....... S E R V ICE BRAKE BOOSTER - 6 CYLINDER ........,..D't 5-1 5-2 SERVICE OPERATIONS .................r...r..r.-..... BRAKE FLUID CHANGE................................*2
Ref. 2.2
Subject Page BRAKE BOOSTER...........,................., 5-2

R gm O V.......- ..r .....- .............r o....r ....... . . . . . . . r 5 -2
3. 4.
ReinStall .-......-...r...........................'......... 5-g SPEC1F1CAT|ONS..................r...r..................... 5-4 TORQUE WRENCH SPECIFICATIONS........ 5.4
1 . GENERALNFORMATION
brake booster With the exceptlon o fa non-serviceable position and modifiedbrake pipes to suit mastercylinder VK models,the brake system for VK is on all 6 cylinder to VH models. similar
NOTES 1.1 SERVICE

The polyglycol brake fluid used in VK Series models is hygroscopic and absorbs moisture f rorn the air through the brake hoses etc. The boiling resistance of the f luid decreases as the moisture content increases and so the possibility of a vapour lock under heavy braking conditions increases with the age of the fluid. Therefore, for maximum brake effectlveness, a two yearly change of brake fluid is rnandatory. To prevent the absorption of moisture from the air, it is recommended that the brake f luid be stored in small (500 ml) containers and that any surplus fluid remaining in a container after use be discarded. NOTE: The approved brake fluid (GMH Specification HN1796) is available from GM P & A in 500 ml containers under part number 92018952 and 250 rnl containers, part number 92018951. lf pressure bleeding equipment is used, it must be of an approved type with a diaphragm separatrng the brake fluid from the air. CAUTIOAT; Brake fluid ls extremely damaging to paint. lf fluid shoutd accidentally touch a painted surlace, immediately wash from paint and clean painted sur-face.
. 6 CYLINDER 1.2 BRAKEBOOSTER

A single diaphram brake booster is fitted to all 6 cylinder VK models. The brake booster is similar to that used on JB Camira models. The booster cannot be serviced and must be replaced if defective.
5-2 BRAKES 2. SERVICE OPERATIONS

2.1 BRAKEFLUIDCHANGE
1. 2. 3. 4. Thoroughly clean master cylinder especially around wheel brake line connections. Disconnect wheel brake lines from master cylinder and remove reservoir cap. Allow master cylinder to drair, until empty. (Refer F ig. 5 -1) Fill master cylinder reservoir with f resh, specified brake fluid from a sealed 500 ml container and ensure reservoir is at least half full for remainder of procedure.
Allow fluid to flow from open connection ports until fluid is free of air. 6. Reconnect wheel brake pipes to master cylinder and tighten to torque specified at end of section. 7. Bleed at each wheel using diaphragm type pressure bleeding equipment, until fluid removed is free of air. NOTE: lf pressure equipment if not available, proceed to bleed brake system manually (at least 6 pumps per wheel brake). 8. 9. 10. 1 1. 12. 13, 14, Loosen left hand caliper bleed screw. Remove left hand caliper anchor plate retaining bolts. (See Fig. 5-2) Hold caliper upside down and remove bleed screw to drain contents of caliper into suitable receptacle. Hand tighten bleed screw and reinstall caliper assembly. Tighten anchor plate retaining bolts to torque specified at end of section. Repeat step 8 to 12 tor right hand caliper assembly. Bleed front calipers.
5.
Figure 5-1
D IS C R OTOR <
./\
')
2t
C A LIP E R A N C H OR P LA TE R E TA IN IN G B OLTS
E R A K E C A LIP E R
Figure *2
2.2 BRAKE BOOSTER

REMOVE
Disconnect electrical lead and three brake pipes from master cylinder.(Refer Fig. 5-3). 2. |.Jnscrew nuts securing master cylinder support bracket to adjacent spring tower. (Refer Fig. 5-3) 3. Remove master cylinder to bracket bolt and remove bracket. (Refer Fig. 5-g). 4 . Remove nuts securing master cylinder to power booster studs. (Refer Fig. 5-3). 5 . Remove master cylinder taking care not to disturb power booster push rod. NOTE: Do not depress brake pedal with master cytinder removed or reaction disc may become dislodged In booster. 1.
BRAKE E OOS TE R
BR A C K E T
Figure 5-3
BRAKES5-3
6. 7. Remove vacuum hose from brake booster body' Remove two brake booster assembly retaining nuts at brake pedal support, from inside the vehicle. (Refer Fig. 5-4)-
Figure 5-4
8.
9.
Remove brake push rod retainingclip and washer from brake pedal and lift push rod off brake pedal stud. (ReferFig. 5-5) engine booster assembly from withdraw from gasket and bracket Remove compartment. boosterstuds.
WA S H E R
telPr-@ \J/ v +_
P U S H R OD .-P U S H R OD BRA KE S TU D Fi gure 5-5
REINSTALL 1. Locatebracketand gasketon boosterstuds. 2. Place boosterassemblyin positionand fit push rod over brake pedal stud. Refit washerand clip to stud' 3. Reinstalltwo booster retainingnuts and tighten to torque specifiedin rear of Section4. Refit vacuumhose to boosterbody' 5. carefullypositionmastercylinderover power booster push roo' and retainingstuds and torque retaining nuts to torque specified at end of this Section. supportbracketto springtower and master Resecure cylinder. this 6. Tightenall bolts to torquesspecifiedat end of is bleeding pressure lf system. brake Bleed Section. to reconnected be must lines employed,the brake rnaster cylinder before commencing bleeding procedure.
5.4 BRAKES 3. SPECIFICATIONS

B rake Flu id G M S p e c i f i c a t i o nH N 17 9 6 (GM P & A Part No. 92018952- 500 mts) 92018951- 2b0 mts) S i n g l eV a c u u m S u s p e n d e d 230 mm
B ra ke Boo ste rfu se m bly Type Vacuu m Piston Diam et er
4. TORQUE WRENCHSPECIFICATIONS
Nm
Brak e Boos t er Ret ainingNut s Ma s t erCy linder t o Br ac k etBolt Mas t erCy linder Br ac k ett o PanelNu t s Mas t erCy linder t o Br ak e Boos t er Pres s ur e Dif f er ent ialW ar ningSwit c h Ca liperAnc hor Plat eRet ainingBoft s Brak e Pipest o M as t erCy linder Nut s . .
20-25 15-18 20-25 19-28 1.4- 1.8 70-85 8-11
MECHANICAL 6A.1 ENGINE
SECTION 6A
MECHANICAL ENGINE
INDEX
Ref. 1. 1. 1 1.2 Page Subject 6A-1 .............................. GENERALDESCRIPTION 3.3 LITREENGINEWITH ELECTRONIC SPARK TlitlNG (EST) ......r.................!.'..t.t... 6A-2 3.3 LITRE ENGINEWITH ELECTRONIC FUEL INJECTION (EFI) ....,..r!.......r..r....r......... 6A-3 Inlet ManifOld ........r.r.rr....-...........r....r.... 6A-4 6A-4 ......-............rrirrrrrrrrrrrroo SySteJfl EXhaUSt 6A-4 ................................ SERVICE OPERATIONS 6A-4 coilPRESSIoN TEST....r.......-....................... 6A-5 HEAD (EST)....'.....r....r..........!.... GYLINDER 6A-5 Rem OV ......... r..........! rr.1....... ................... t
Ref. 2.3
Subject Page CYLINDER HEAD (EFl).................................. 6A-5

RgmOV.............r.....r.r..r............r.......r......6A-5 RginStall ......r......r...r,........................-......6A-7
2.4 2.5 3.
ENGINEASSEMBLY(EST)....................-....... 6A-7
RgmOV9..............r..r.................'..........r..... 6A-7
(EFl) ............................ ENGINEASSEMBLY 6A-8

RemOV.t.........r...........r........................!..r 6A-8
2. 2.1 2.2
ReinStall .............r...,....r........................... 6A-1 3 TORQUE WRENCH SPECIFICATIONS........ 6A-13
Three different engines are released for use with VK Series models. A 3.3 litre engineequippedwith ElectronicSpark Timing (EST) is standard on SL and Berlinamodels. equipment A 3.3 litre engine with ElectronicFuel Iniection(EFl) is standard on Calais and available as an option on all sedan modelswith automatictransmission. The 5.0 litre VB engine with automatic transrnission. which carriesover from the VH Series,is availableas an optionon all models. The changesto the 3.3 litreenginehave been rntroduced to reduce emissions and improve fuel economy. A surnmar/ of the modificationsused for each 3.3 litre follows. engine
6A-2 ENGINEMECHANICAL
1 . 1 3 . 3 L I T REE N GIN E WIT H ELECTRONIC SPARKTIMING(EST)
This engine uses the Bosch Electronic Spark riming system, refer Section 6D, lgnition System, of this Supplement for details. Detailed revisions have been made to the following engine components, to suit the requirements of the EST engine. The cylinder head and inlet valves incorporate changes to improve gas flow refer Figs. 64-1 and 6A-2. Cylinder head gasket, has a pigmented dark brown colour for identification, and is of a heavy duty construction. Spark plugs, copper cored with thicker electrodes.
Figure 6A-1
y 'V K ' 3 . 3 L I T RE
\ \ \\
f 'V H '3.3 LITR E
\\-<
\\ \
\, \-'V H '3.3 LITR E
Figure 6A-2 The cylinder head is also revised to accept the air pump type Air Injection Reactor system. The cylinder block has been modified at the rear to accept the mounting of the EST speed sensor, refer Fig GA-3 The flyrrheel and torque converter assemblies have three timing pins added around their circumference. There is also a dowel pin added to the rear face of the crankshaft to accurately locate the flyr,vheelor automatic drive plate. Pistons have been revised to suit the engine operatrng characteristics.
S P E E DS E N S OR
S E N S ORMOU N T
Figure 6A-3
ff
ENGINE MECHANICAL 6A.3

WITH 1.2 3.3 LITREENGINE (EFl) INJECTION FUEL ELECTRONIC
This engine uses the Bosch LE-2 JetronicFuel Iniection for details. system.ReferSection6C of this Supplement Detailed revisions have been made to the following of the EFI to suit the requirements engine components, engine. The cylinder head and inlet valves incorporatechanges to improvegas flow. Refer Figs. 6A-4 and 6A-5.
Fi gure 6A -4
/-
'.K 33LrrR E _.V H' 3.3 LITR E
T
a-
,1
:-'.";'-'14
\
\
\-'V H ' 3.3 LITR E

LIT R E
- _,!/K'3.3
Figure 6A-5 Spark plugs, copper cored with thicker electrodes. Exhaust valves, with improved material specifications, are identified by a forged 'S' in the valve head recess. Refer Fig. 6A-6. Cylinder head gasket, has a pigmented dark brown colour for identification, and is of a heavryduty construction. Camshaft: Cam profiles have been revised. For valve timing details refer chart below. NOTE: Timing includes ramps. Opening ramp 26o Closing ramp 32o. I nc lu di n g Ram p s lnle t Va lv e
Figure 6A-6
BTC Opens ABC Closes Duration

O pensBTC ATC Closes Dur at ion
Exh au stValv e
Va lve Open O v er laP Pistons have been revised to suit the engine operating characteristics. Timing Gears: Revised gear tooth design for camshaft drive gear set and improved material for steel crankshaft 9ear. The timing case cover has been modified with the addition of an oil redirection rib (Fig. 6A-7). This allows additional oil flow to the timing gears.
- OIL R E D IR E C TE D R IB
Figure 6A-7
t-
6A-4 ENGINE MECHANICAL

I NLE T MANIFOL D A new ram tuned inlet manifold is used to optimise mid range torque. lt has the diameter and length of the runners tuned so that a positive pressure pulse arrives at the inlet valve just prior to its closing. This forces extra air rnto the cylinder giving a pressure charging effect which can be as high as 15 kPa.
Figure 6A-8
EXHAUST SYSTEM A substantial power and torque increase has been achievedby the use of exhaustextractorsin conjunction with a singleexhaustsystern. The exhaust extractors,which are manufacturedf rom stainlesssteel, nave a low heat retention,helping to minimise under hood ternperatures. For further details of the exhaust systffi, reter to Section88 of this Supplement.
K"
Figure 6A-9
2. SERVICE OPERATIONS
For service and overhaul operations not listed in this Supplement, refer to the lmproved performanceL6 and V8 EngineServiceManual,Part No. Mgg3g8.
2.1 COMPRESSION TEST

on EFI equipped vehicles, the control relay must be remcved f rom the f use box (refer Fig. 6A-10), before commencing a compression test, to prevent the injection of fuel which may be blown out the spark plug holes
Figure 6A-10
6A.5 MECHANICAL ENGINE

HEAD (EST) 2.2 CYLINDER
REMOVE
Removalproceduresfor the cylinder head on an engine equippedwith EST are the same as for a VH LO rnodel with the air pump Vpe Air InjectionReactorsystem. and removalof The only additions are the disconnection wiring at the throttle positionswitch, coolant temperature 1. sensorand enginespeedsensor,refer Fig. 6A-1
- P IN K LE A D IN S L E E V E (A N TI D IE S ELIN G S OLE N OID ) TH R OTTLE P OS ITION S WITC H C ON N E C TOR-r \ C OOLA N T TE MP E R A TU R E S E N S OR r C ON N E C TOR
Fi gure 6A -11
HEAD (EFl) 2.3 CYLINDER

REMOVE 1. Disconnect battery earth lead. Carry out removal outlinedin 3.9 'Air Flow Duct' and 3.11 operations 'lnlet Manifold'in Section6C 'Fuel Iniection'of this Supplement. 2. Secure exhaust extractors away from the cylinder head. 3. Remove the radiatorpressurecap, drain the radiator by removal of lower radiatorhosetf the cooling system ts hot, the radiator cap CAUT/rOIT; must not be removed quickly - it should be rotated slowly to the first stop, which permitsthe pressurein fhe system to release stowty through the overtlow pipe. The cap must not be removed completely until all escape of steam has ceased, or there is a danger of water or steam scatding the operator. Do not tilt the cap during rotation to the first stop or some steam may escape through the top of the radiator neck instead of through the overtlow pipe. and heaterhoses. 4. Removetop radiator fuel system aS per 3.2 'Depressurize' 5. Depressurize Section6C of this suPPlement. 6. Remove fuel return line mountingbolts from rocker coverand engineside plate-Refer Fig.6A-12' T. Disconnectfuel return line frorn flexible fuel hose and plug open end with a suitableplug. 8. Disconnect electrical connector from auxiliary air valve.
R E TU R N LIN E MOU N TI N G B O LT
#
I I
FLE X IB LE _ FU E L H OS E
T
L F U EL R ET U R N LINE
Fi gure 6A -12
6A.6 ENGINEMECHANICAL
9. Disconnect throttle cable from mounting bracket. Refer Fig. 64-13.
C R U IS E C ON TR OL P OWE R U N IT TH R OTTLE C A B LE
V A C U U M_ H OS E
BRACKET
A U X ILIA R Y A IR V A LV E
'- E LE C TR IC A L C ON N E C TOR TO A U X I LIA R Y A I R V A LV E OU N TI N G B O LT P LA C E S )
Figure 6A-13
10 . Remove fuel hoses from fuel damper, plug with plugs.Refer Fig. 6A-14. suitable 1 1. Remove cruise control power unit bracket mounting to cylinderhead bolts and removebracketassembly. ReferFig. 64-14. 12. Disconnect high tension wires and remove spark plugs, disconnect coil positive and negative wires and removecoil attaching bolt and coil. 13 . lf fitted with air conditioning, loosen drive belt idler pulleyand disconnect drivebelt.
Fi gure 6A -14
14. Remove compressor mounting and bracket bolts and position compressor and bracket away from the cylinder head. Refer Fig. OA-15. NorE: Do not bend metal pipes at compressor. This could lead to fracture of the pipes. 15. Remove the ventilation valve, valve rocker cover attaching bolts, the cover and gasket. 16. Remove rocker arm pivot borts, rocker arm pivot, rocker arms and push rods. NOTE: Remove each set (one set per cylinder) as a unit. It is important that the originar rocation of all pivots and arms is retained on assembly. For this purpose, parts should be placed rn a special rack, Tool No. 6A35. 17. Remove the cylinder head bolts, cylinder head and gasket. Place cylinder head on two blocks of wood to prevent damage.
C OMP RE S S OR
C OM P F ESSO R M OU N T I N G
PU LLEY J AD J U ST IN G BO LT
E N S U R E N U T IS R E TIGH TE N E D A FTE R B E tT A D JU S TME N T R E FE R S E C TION 28 FOR D E TA I Fi gure 6A -15
MECHANICAL ENGINE 6A.7

REINSTALL Installationis reversal of removal instructions.However, and Inspection' Operations','Cleaning additional'Service as describedin the lmproved PerformanceLO and V8 Engine Service Manual, Part No. M38388, must be carried out. Attentionmust also be paid to the followingitems. Correct adjustment of the throttle cable and cruise 3.3 and 3.4, control power unit cable, ServiceOperations of this Supplernent. Section 6C, 'Fuel Injection', Check for fuel leaks hs described in Service Operation 3.2 'Leak Testing', Section 6C, 'Fuel Iniection' of this Supplernent.
(EST) 2.4 ENGINEASSEMBLY

REMOVE
for a 3.3 litre engine equipped Removalprocedures with EST are the same as for VH LG modelswith the air pump type Air InjectionReactorsystem. 2. The only additions are, the removal of wiring connectionsat the throttle position switch, coolant temperaturesensor and engine speed sensor.Refer Fig. 6A-16.
1.
-P IN K LE A D IN S L E E V E (A N TI D I E S E LIN G S OLE N OID TH R OTTLE P OS ITION S WITC H C ON N E C TORC OOLA N T

r C ON N EC T OR o- ''
\
\_ - - [./
--1i'');,
- - t-
,,
Fi gure 5A -16
NOTE:The speed sensor must be removedfrom the rear the cylinderblock of the cylinderblock before separating 7. Refer Fig. 6A-1 and the transmission.
S P E E DS E N S OR
S E N S ORMOU N T
Figure 6A-17
6A-8 ENGINE MECHANICAL
FAN SHROUD -
ry
,- U P P E R S U P P OR T C LIP
^ _RADI A T O R
LowcootRrvtJ
S E N S OR
V IE W
Figure 6A-18
2.5 ENctNEASSEMBLY (EFt)

REMOVE 1. Disconnect battery earthlead. 2. Remove bottom radiator hose and drain cooling system. Rernove top rediator hose. Disconnect automatic transmission cooler linesfrom radiator. 3. Disconnectradiatorfan shroud from radiator. Remove upper radiatorsupport clips, lifi up radiator. From the front of the radiator,disconnectthe low coolant sensor wire, if so equipped. Refer
4. 5. 6. 7. 8. F ig. 6 A-18 Remove radiator, taking care not to damage low coolant sensor, remove shroud. Drain o il pa n. Remove air flow duct as per Service Instruction 3.9, Section 6C 'Fuel Injection'of this Supplement. Remove engine hood. Loosen generator, and if fitted, power steering pump, air conditioningcompressor and remove driv-e belts. Ref er Fig OA-19 . Disconnect brake booster vacuum hose f rom inlet manifold.
WA TE R P U MP ,. r GE N E R A TOR
9.
C ON D ITION IN G C OMP RE S S OR
P OWE R S TE E R IN G P U MP
C R A N K S H A FT Figure 6A-19
tr
v -

10, Disconnect cannister to throttle body purge hose, from cannister. Refer Fig. 6A-20.
{\\r \ \\
CAN TH R PUR
Flgure 6A-20 1 1. Rernove four retaining bolts from the cooling fan assembly, remove fan and associated parts. Fig. 6A-21.
C OOLIN G FA N MOU N TI N G BO LTS (4 P LA C E S }-l

F AN
nt
Vl-\J
I tTa !- l | \Jr
I
,.r-w A TE R P U MP r P ULLE Y
F. \ IF
C R A N K S H A FT PU LLE Y
- B E TA IN IN G B oLT (4 P LA C E S)
'-gggLt\G FA N
Flgure 6A-21
12. On models with air conditioning, remove the compres$r and mounting bracket from its position(refer Fig. 6A-22) and support it out of the way without the hoses. disconnecting
C OMP RE S S OR
C OMP RE S S O R MOU N TI N G B OLT (4 P LA C E S ) ] PUL "' S TIN G A D JU B O LT E N S U R E N U T IS R E TI GH TE N E D A FTE R B E LT A D JU S TME N T R E FE R S E C TION 28 FOR D E TA I LS
Figure 6A-22
6A-10ENGINE MECHANICAL
1 3 . Remove power steering pump mountingand adjusting bolts (refer Fig. 64-23) and supportpump out of the way withoutdisconnecting the hoses. 1 4. Disconnect heaterhoses from engine.
P U LLE Y A D JU S TIN G B OLT
P OWE R S TE E R IN G P U MP
Figure 6A-23 1 5 Drsconnect wiring harness connectionsfrom starter
motor, generatorand engine earth frorn generator bracket.Refer Fig. 6A-24.

R IN G H A R IN I ESS floN -]
-=l
I IFUJSIB LE /
Ltf
N5l
1,"
1 6. Disconnect winngconnections at oil pressuresender
\- I-
(S TA R TE R S OLE N OID )
fi IE D LE AD
(GE N E R A TOR )
V IOLE T LE A D (S TA R TER S OLE N OI D )
B LA C K LE E O ) (C ONN E C T TO E N G. B LOC K }
Figure 6A-24
unit, coolant temperaturesender, ignition coil and auxiliary air valve Refer Fig. 64-25.
rM A IN \
\
WIR IN G H A R N . C ON N .
, LT. GR E E N , P IN K & ',,oR A N GE LE A D S (TR A N S MIS S ION H A R N E S S )
.. i.
,,-D K GR E E N LE A D
T4// I*_,.!
.---v
(cootillrEyP)
^ ::
tr
_ _.
9.R5f q BLACKLEADSIN
S LE E V E (A U X ILIA R Y A IR V A LV E )
,, ,
-:
\t
--
D K . 3 LU E ,-eoo ] (OI L P RE S S U R E) B R C WN LE A D IN S LE E V E (IGN ITION C OIL)
.R E E N LE A D ;" /ss. (A /C C OMP R E S S OR ) E X C . C 6OTA P E B A C K TOH A R N E S S WITH GM658M
Figure 6A-25

1 7. Disconnect auxiliary air valve hose f rorn inlet manifold. Disconnect throttle cable fronn bracket, and if so equipped, cruise control power unit cable from throttle body and vacuum hose from vacuum adaptor as rear of inlet manifold. Refer Fig 6A-26. 1 8. Depressure fuel system as per 3.2 'Depressurize', Section 6C, of this Supplement. 19. Remove fuel lines from fuel damper and plug with suitable plugs.
c R U t s E c o N T R O^g _ UNlT =.r ,!i/-, 'OWER

,,.-THR OTTLE CA BLE
\- l - - \
VACUUM H OS E
\J
-t,'F,r. ,-
----:t
rl-1 i
AuXILIAR Y AIF 'r Ar - r .'F
) \ .-
E LE C TR IC A L C ON N E C TOR TO A U X ILIA RY A IR V A LV E MOU N TIN G B OLT (2 P LA C E S }
Fi gure 6A -26
20 Removebracketmounting to cylinderhead bolts and removebracketassembly. Refer Fig. 6A-27.
Figure 6A-27
throttle from fuel injectors, 21. Removewinngconnectors position switch, coolant temperaturesensor. Refer Fig. 6A-28.To avoiddamage, do not pull on wiresat the connectors, Remove f lexiblef uel hose from fuel return line at enginesideplate,
FFi bl -?
?-tin I F r\ftH
-- Y E _LOW LE A D IN SLE E V E (l D r-= B OOS TS OLE N OID )

_
SENSCB
_ TH R OTTLE V A LV E ITC H S \,V
Figure 6A-28
6A.12 ENGINEMECHANICAL
2 3 . P lug open end of flexible fuel hose with a suitable plug. Refer Fig. 6A-29.
R E TU R N LIN E MOU N TI N G B OLT
F LE X I B LE FU E L H OS E
--{L
-- MOU N TIN G B O LT
RETURTTT ilrr r
FU E L R E TU R N LIN E
Flgure 6A-29
24. Removevacuum hoses from vacuum adaptorat the rear of the inlet rnanifold, remove adaptor. Refer Fig. 64-30. 25. Raisethe vehicleand place on jack stands. 26. Disconnect the gear shift from the transmission, refer to VB Commodore Service Manual, Clutch and Transmission Section. 27. Remove the speedorneter cable frorn the extension housing, or if fitted. disconnect speed sensorwires at the extenslon housing. Disconnectdetent solenoid wire and TCS swtch from the transmission. 28. Removetailshaftand inserta protectorin the end of the transmission housingto preventloss of extension fl u i d
VACUUM A D A P TOR
Flgure 6A-30 29. Install rool No. oAgT engine lifting hook or equivalent, raise engine slightly and remove the f ront engine mountrng to crossmember bracket through bolt s. Refe r Fig. 6 A-31 .
k' --'id G:-)A.b

f)\(
'm
)'R,M$
-'(Sl
{{\.^
wX
^F ^gojt
r cRossMEMEER
-#di,)oFlgure 6A-31
tt' r \
V1
BRACKET T H R . U G H B 'L T
::,
ENGINE MECHANICAL 6A-13

30. Disconnect exhaust system from exhaust extractors. Refer Fig. 6A-32. 31 . Remove engine rear crossmember. 32. Raise the engine with the front tilted upwards and lift the engine and transmission out of the vehicle.
D IS C ONN E C T H ERE
Flgure 6A-32
REINSTALL 1. Installation is reversalof removal. 2. Refer Section 6C, 'Fuel Injection'in this Supplement
for conect hose and electrical connections.
3. Add recommended oil and coolant. 4. Check fuel system for leaks as described in service 5. 6.
o pe ratio n 3. 2' Leak Tes t ing' Sec t ion 6 C , 'F u e l I n jection', in this Supplement. Start engine, check and adjust ignition timing, and for full throttle opening, check for air leaks. Check for oil and coolant leaks.
3. TORQUEWRENCH S P E CI F I CA T I O NS
Nm
EngineSpeedSens ort o C y l i n d e rB l o c k B o l t Cy linder Headt o Cy linder Bi o c k Roc k er Ar m Piv ot t o Cy l r n d e rH e a d Roc k erCov ert o Cy linde r H e a d Fuel Ret ur n Line M ount i n g B o l t s Fuel Ret ur n Line t o Pr es s u r e R e g u l a t o rN u t . Air Flow Duc t M ount ing B o l t Air Flow Duc t M ount ing B r a c k e tt o C 'T l i n d e H r eadBolt Air Condit ioningCom pr e s s o M r ounting Bolts Br ac k etBolt s Com pr es s or Alt er nat c r M ount ing Nut Alt er nat or Adjus t ing Bolt . Power St eerng Pum p M o u n t i n g& A d j u s t i n g B o l t s Bo l t s Cooling Fan Reiar ning EngineM ount ing Nut s M oun t i n g B o l t s Rear Tr ans m is s ic n Rear Cr os s m em ber M oun t i n g B o l t s Ex haus tClam p Nut s
30-40
54 tl rrst torque ) 102 ri q3i torque )
30-38 3-6 8 - 10 25-30 8-11 20-27 20-27 40-54 20-25 12-16 40-51 27 -36 34-46 34-46 40-50 24 -32
ENGINE COOLIN G 68-1
SECTION 68
E NG I NE CO O LI NG
INDEX
Ref.
1. 2. Page 68-1 GENERAL DESCR|PTION.................!r........... 68-1 SERVICE OPERATIONS ..,.....................or......
Subject
Ref. 2.1
Subject Pa g e RADIATOR OVERFLOW/WINDSHIELD WASHERBOTTLE.................................,........ 6B-1 . FLUSHSYSTEM...-.. 68-2 COOLING SYSTEM

RgmOV...............o...........,........................ 6B- 1 ReinStall .....r....r.........o...........-....-............ 6B-1
2.2
The cooling system employed on VK Series models is canied over from VH, with only a few minor changes. The radiator overflow/windscreenwasher bottle has been (Fig. 68-1). redesigned and repositioned All VK 3.3 litre engines have the thermostat housing, fan pulleysand fan belt from the L6 2.8 litre VH engine.
Service operations are as described in the VB and VH Series Service Manuals, except where noted in this Section.
2.1 RADIATOR WASH ER OVERFLOW/WINDSHIELD BOTTLE

REMOVE 1. Removeradiatoroverflowcap from bottle. 2. Disconnect windshield washer hose and electrical connectorfrom washerpump. 3. Remove two mounting screws (Fig. 68-1) and lift bottle assemblyout from its position. REINSTALL is reversalof removal. 1. Installation 2. Fill the radiator overflow boille up to the required level, as indicatedby the mark on the outsideof the bottle. 3. Fill up windshield washer bottle and test washer operation.
COOLING 68-2 ENGINE
M OUNT ING SCRE W
RA DIA T O R O V E R F L OW/ WI ND S H IE L D W A S HE R BOT T L E .WIN D S H IE LD WA S H E R H OS E
A MO U N T I N G
\ SCR EW
)<
-/\
'-t/
lp' c AD VE
I(--_-/.
3.0 - 4.0 Nm
Flgure 68-1
2.2 COOLING SYSTEM I FLUSH SYSTEM

1. 2. 3. 4. 5. 6. 7. 8. Placedraintray undervehicle. Removetop radiatorhose from thermostat housing. Removethermostat housingand thermostat. Place water hose into the top radiatorhose, tum on water pressure,and flush untrl water coming from rylinder head is clear. Flush heater core by removingtop heater hose from thermostat housingaM flush untrlclear. Flushradiatorby rernoving bottomradiatorhose from waterpump and flush until clear. Removeoverflowbottle,as per serviceoperation2.1, and flush. with the system f lushed clean, replace thermostat housing gasket and refit all cooling system components. Mix a coolant concentration of approximately 21 mls of corrosion inhibitor, GMH Specification HN1109, with every litre of clean water. Add to the coolingsystem and check for leaks.
ENGINE F UE L6C .1
SECTION 6C
ENG I NE FUEL
CONTENTSOF THIS SECTION
Subject Page ELECTRONIC FUEL lNJECTlON....-.r......................... 6C-1 CARBURETTOR (3.3 EST) ...........r.................r.......... 6C-67 5.0 LITRE ENGINE FUEL SYSTEM ..rr......!............. 6C-87
FUEL INJECTION ELECTRONIC

INDEX
Ref. 1. 1. 1 Page Subject 6C-2 GENERAL DESCRIPTION....,r.............r,.....o... 6C-2 MAIN COITPONENT SYSTEMS ...................r 6C-2 Alr FIOW SyStgm ...r.....r.......r.........r.......r 6C-3 FUgl SyStem.........D.......r'..................r...... 6C-5 Elgctrical System .t...........r....'.!............. FUNCTION OF MAIN COMPONENT 6C SYSTEMS ............................r........t.r............r..... Air FlOw SyStem r........................r......r.t. 6C-8
2. 2.1 2.2 2.3 Ref . 3.11 Sublect Page INLET MANfFOLD .....,.................................... 6C-35 Rgm OV...............................................r.... 6C-35 RginstalI .........,,.,...........r......................... 6C-37 AUXILIARY AIR VALVE ...............,................ 6C-37
RgmOv.............. r....r.r.....r....o....rr...... ........ 6C'37
3.12
1. 2
3.13
6C 6C-g ElgCtrlcal System ..r........r.'..!.r.......!rr.r... 6C-12 PRINCIPLES OF OPERATION.........r...r,.,...,r 6C-12 FUEL INJECTION TIMING ............................ 6C-12 FUEL INJECTION QUANTIW ...r...r.............r 6C-12 ENRlCHMENTS........r.........-.......................r..... 6C-12 Enrlchmgnt Sensors r.r...................-..r.. 6C-12 Accelgratlon Enrichment ...............t....
FUgl SyStem ................rrrr.r..r...!......r.t!.r...
R gi nstal l ............. r.............r....,...........r,.... 6C -37 TgS t...................-.........r...... .......... 6C ' 37 FU E L P U MP .r...............r..........o...r..r,.... 6C -38 Rgmov.............r.........r...,...... 6C-38 Reinstall .....................-..--..... -r.3... 6C-38 TeStin$ ..............-...-............................o.... 6C-38
3.14
3.15
FUEL DAMPER 6C-40 - REAR ........,.......................

R gm OV.......'..................-.'..........'r"......... 6C*f0 RginStall ....".....r........!r............................ 6C'40 FUEL FILTER ........r...,..,...........r...-.................. 6C-40 R gmov g................r...................!.......!.t.-.,. 6C-40 Reinstall ......... ..r..r..........r............ 6C-40 6C-40 FUEL DAMPER ' FRONT .............r.......,..rr.... r.......................!... Rgmov....-.......r r.......... 6C'40 RginSt?ll ..-....,....... .Fr..r...r......r.....r... 6C-40 FU E L R 4IL....................,..o...........r...............,.... 6C ' 4 1 RgmOv......t.........r.r..r.........r.. r..... 6C'4 1 R gi n stal | .........-....r..............,...............r.... 6C-42 1N JE C TOR S .......r..r............................,........r..... 6C ' 42 P R E S S U R E R E GU LA TOR .............r.,..r.,..,...... 6C ' 42 R gmOV........'......r............D....................... 6C'42 Rei nstal | ......... r..J.....rr.!D.....................,-.... 6C-42 6C'42 CONTROL UNIT r.,..r...,........r..t.......!................ R gmOv..........r.................r-..-...,r......rr,-...6C-42 6C -43 R gi OS tal l ...........'............r....-.........r..........
2.4 2.5 2.6
Full Throttle (Hlgh Load) 6C -14 EnflChmgnt................-............r-..r............ 6C -14 FUEL SHUT OFF ' COASTING r.....,..!.......... VOLTAGE CORRECTION FUNCTION ........ 6C-14 6C-14 coilPoNENT OPERATION .......-.................. 6C-14 Air FlOw SyStem ..,.'.....................r!'......r
FUgl SyStem .......r .r ...............r .r .- .........r .... 6C-17
3.16
3.17
3. 3. I 3.2
3.3 3.4 3.5
3.6 3.7
6C-20 Elgctrical Systgm ...r....................-......... 6C-24 sERVlcE oPERATIONS ................................ 6C-24 SERVICE NOTES .....r......r............................... 6C-24 FUEL SYSTEM .....o.......................................... 6C-24 Lgak TgStin$ ...'........-............................. o......6C-24 Depressurlzin$ ............................... 6C-25 Fugl Hosgs and G|amps...................r.. 6C-26 THROTTLE CABLE ADJUSTMENT.............. CRUISE CONThOL POWER UNIT CABLE 6C-26 ADJUSTM E NT .......-..........r........r.-.................... ADJUSTING IDLE SPEED AND ]TIIXTURE 6C-26 6C-27 ldlg Speed Adjustment...............r.r...... 6C-27 ldlg llixture Ad1ustment...........,.......... 6C-28 AIR cLEANER ELEMENT.............r.........r....-. 6C-28 ReplaCgmgnt o...............'.....i..............-.... 6C-29 AIR CLEANER HOUS1NG.....................r........ 6C-29 R g mOV........ .............. . ..............4.....1........ 6C-30 r................-.-.........tr....... RginStall ............ 6C-30 AIR FLOW METER.........,........-......,.......,........ 6C-30 RgmOV.....-......r..........r.rt......-.........t........ 6C -31 R ginStall ................r.......................-......... 6C-32 .............-.-.r.rr....................t..'............. TeSt 6C-32 AIR FLOW DUCT ....r.r..r.......,'..r..........-........... 6C-32 RemOV..................t...r............................. 6C-33 R ei nStall ...........r......................-......-........ 6C-33 THROTTLE BODY ......-...,.......rr..r......r.-...r.-.... ... . ..................... R e m OV ..' -.................... ". 6C-33 6C-34 RginStall ..-..............................r....'......r."'
3.18 3.19
3.20
3.21
6C-43 THROTTLEPOSITION SWITCH..................

6C-43 RgmOV..'........,.........r.............................. 6C-43 Rginst?ll .....,.......,.................................r.. 6C'4 3 Ad justmeJ|t...............................,.......,...... COOLANT TEMPERATURE SENSOR ........ 6C-44 6C-44 Re plaC....................... '......r................-.... 6C-44 On Engine TgSt...............o...'.......-.........r 6C-45 Off Engine Tgst ...............................r.... 6C'46 CONTROL RELAY ...................................,......
6C-46 R gmOV......'........r...r..."'.....r-............-...... 6C'46 RginStall ...................r.............................r 6C-47 DIAGNOSIS..'.....r.....-..'........'.....?....r................
3.22
3.23
3.9
4.
4.1
3.9
3.10
4.2 5. 6. 7.
6C-47 CIRCUIT TESTING PROCEDURE................ Electronic Fuel Injection 6C-47 Test Equipmgnt .........-.-.,..r......r..........., TROUBLE DIAGNOSISr............,.......... 6C-61 6C-64 SPECIFICATIONS -...i......,....o.......i..'....---.-.-..... 6C5 TORQUE WRENCH SPECIFICATIONS........ 6C-66 SPECIAL TOOLS ..-.........................................
lrr
FUEL 6C.2 ENGINE 1. GENERAL DESCRIPTION

The Electronic Fuel Injection (EFI) used on VK series vehicles is the Bosch LE-2 Jetronic system. The LE-z Jetronic is an electronically controlled fuel injectionsystem which injects fuel at regular intervals into the inlet ports adjacent to the inlet valves. lt provides a method of more precisely metering f uel to satisfy the various engine operatingconditrons. In a carburettor type fuel system, the intake manifold design must strike a medium between low and high speed requirementsfor air flow. At idle, air flow is very low and in order to keep the fuel mixed with air, it is necessary to have small passages to keep up the air
velocity.when power is required,it is desirableto have as largea manifold passageas possible. To supplyboth these requirements the manifoldmust be a comprornise which resultsin passagesof such a size which limitsboth low and high speed performance. With EFI systerns, the elimination of the carburettor enables the induction passages to be designed to optimizeair flow and an increased engine performance can be expected with the resultant improvementin volumetric efficiency. Air is induced into the engine through the inlet manifold,and fuel is injected under pressureinto the inlet valve port.
A tn
I r F- FA
F L OW
''.r= | trH
A IR F LOW
'
DUcr
,- TH R OTTLE B OD Y
IN LET M AN IF O LD
/(^ /
/ A rR.L E A N E R HO U S IN G
AIR F LOW SYSTE M

Figure 6C-1
1.1 MAII'I COMPONENTSYSTEMS

The Bosch LE-z Jetronic Fuel Injection system can oe divided into three main component systems, they are: AI R F LOW SYSTEM C OMP RISING: Air Cleaner - Filters incc m r ng air f low f or t he englne. Ref er F ig. 6 C-1. Air Flow Meter - Measures the air inlet flow and sends an electricalsignal to the control unit where the required au/tuel ratio is computed. Refer Fig 6C-1. Arr Flow Duct - Transfers air f low f rom air cleaner to t hrot t lebo dy. Refe r Fig . 6C - 1.
F UE L6C .3 ENGINE
Throttle Body - Located between the air flow duct and the inlet manifold, the throttle body incorporates the throttle valve with provision f or Exhaust Gas Recirculation, spark advance, canister purge signals and Positive Crankcase Ventilation connection. The throttle valve is connected to the accelerator linkage and controls the flow of air into the inlet manifold. Refer Fig. 6C-1. Inlet Manifold - Distributes air to the inlet ports of the cylinder head. Refer Fig. 6C-1 . Auxiliary Air Valve - Allows an additional amount ol air to bypass the throttle valve, to maintain idle stability with a cofd engine. Refer Fig. 6C-2.
Figure 6C-2
FUEL SYSTEM CO M P RI S IN G : Fuel Tank - Containsa very fine strainerattachedto the fuel pick up on the fuel gauge senderunit. Also included at aeration in the fuel tank, is a fuel swirl pot, to minimise fuel pick up point. Refer Section 8A of this Supplement for furtherdetails. Fuel Pump - An electric, rotary roller pump. Refer Fig. 6C-3.
Fi gure 6C -3
frcm to removefuel pulsations Fuel Damper- Designed the fuel system. Two dampers are fitted in the fuel system.Refer Fig. 6C-4.
\,
Fi gure 6C -4
6 C . 4 EN GIN EFUE L
Fuel Filter The filter contains a fine paper efement. R e f er F ig 6 C-5.
Figure 6C-5
Fuel larl Drstributespressurized fuel to the injectors. Refer Fg. 6C-6. lt incorporates a schrader valve (wrth a specra fuel resistant valve core) for bleeding down fuel pressure and carryingout diagnostic procedures.
fIN JE C TOR \ R E TA tN tN G
FU E L R A IL-.
\crre
I\l OU N TIN G B OLT {3 PLA C E S )
Figure 6C
I n ject ors Ele ctricallycon t r of led f r on t he : ont r ol unit . T h e a-ount of fu el spr ay ed r nt c t he r nlet por t s is c o ntroled b y th e le ng th of t im e t ne : on: r c t unit s ignals t h e ' nlectorsto rema in op er ^ Ref e' F, g O C- 7.
Fi gure 6C -7
Pressure Feg ula tor - Ma intainst he r equir edf uel pr es s ur e u n der all lo ad co nd ition s. Ref er Fig. 6C- 8.
*H
A&';rdr''
s{l''
Figure 6C-8
E NG I NEF UEL 6 C - 5
ELECTRICAL SYSTEM
COMPRISING: Control Unit - Processes signalsfrom the enginesensors to calculate the amount of time the injectors rernain open. Refer Fig. 6C-9. Control Unit Inputs- Include:ignitioncoil, air flow meter, throttle position switch, engine coolant temperature sensor, inlet air temperaturesensor and ignition switch position.
Fi gure 6C -9
lgnition Coil - The control unit receives ignition pulses from the ignition coil. From this informationthe control enginespeed.Refer Fig. 6C-10. unit calculates
Figure 6C-10
Air Flow Meter - The control unit receives information about the engine'sload conditionfrom the air flow signal 1. sent from the air flow meter.Refer Fig. 6C-1
Throttle Position Switch The control unit recerves information f rom the throttle position switch when the en gin e is id ling or under high load. Refer Fig. 6C-12
Figure 6C- 12
6C.6 ENGINE FUEL

Coolant Temperature Sensor - The control unit receives information about the engine coolant temperature from this sensor. The sensor is of a Negative Temperature Coefficient design. The resistance of the sensor decreases as the engine temperature increases, thereby allowing the control unit to shorten the injection pulse w idt h signal. Refe r Fig. 6 C- 13
Figure 6C-13 Air Temperature Sensor - The air temperature sensor is located in the inlet passage of the air flow meter housing. It is also of the Negative Temperature Coefficient design, and it applies a correction factor to the air flow meter output signal to compensate lor changes in inlet air t e m perature .Re fer Fig . 6C - 14.
I I
I
I
A IR TE MP E R A TU R E
Figure 6C- 14
lgnition Switch - The control unit receives a signal from the ignition switch when the vehicle is starting, and this allows a richer mixturefor starting. Refer Fig. 6C-1s.
Figure 6C-15
The location of the various cornponents are shown in Figs.6C16, 6C-1 7.
ENGINE FUEL6C.7
LOCATION OF COMPONENTS
A t R F L OW- r METER \
\
A I R C L E A NER HOUSING A IR FLOW D U C T ,- TH R OTTLE P OS ITION S l VI TC H
TH R OTT LE B OD Y
r-4 \:t
S='-
,--->
FU E L D A MP E R _
,/ t\-,4
FU E L TA N K llil ,11,^/,,, J
_FU E L R A IL
I- IN LET M AN IF OLD
FU E L P uMPl -
P R ESSURE R E GU L AT OR
FU E L TA N 11 GA U GE U N
C ON TR OL R E LA Y - S IT-A T=] FU E L FILTE R C ON TR OL U N IT
I\ FU S E B OX
U N D E R I',E A -- .'=H IC LE E H IN D L -': 33w 'L P A N E L
Fi gure 6C - 16
l i '\J =C - C R S
_ 6 P LA C E S
I -)
D AI.T PER -
PUM P
D A M P ER
Fi gure 6C -17
f,.r
FUEL 6C.8 ENGINE

1.2 FUNCTIONOF MAIN COMPONENT SYSTEMS AIR FLOWSYSTEM
Inlet air flows through the air cleaner housing and is rneasured by the air flow meter. Air continues along the air flow duct into the throttle body. Air flow to the engine is controlled by the throttle butterfly opening inside the throttle body. During engine warm up, additional air flow is bypassed behind the throttle butterfly to increase engine speed, by the action of the auxiliaryair valve. Refer Fig 6C-18.
FUEL SYSTEM Fuel is drawnfrom the fuel tank by the electricfuel pump and it is fed under pressure through the fuel damper. Pulsations caused by the fuel pump are deadenedby the fuel damper.From the damper the fuel flows through a fuel filter, and through a second fuel damper to reduce the fuel pulsationsgeneratedby the openingand closing of the injectors.The fuel continueson into the fuel rail and then is injected into the inlet ports through the injectors. Fuel pressurein the system is governed by the pressure regulator, in such a manner that the pressuredifference between fuel pressure and inlet manifold vacuum is maintained at 303 kPa (3 bar). Excess fuel is returnedto the fuel tank by the pressureregulator via the fuel return line.ReferFig. 6C-19. ELECTRICAL SYSTEM The control unit receives informationfrom the various sensorsand, based on this information, it sends out an electncalpulse to the injectors,the duration of which controlsthe amount of time the injector nozle remains open In{ormaton gatheredincludes,inlet air flow from the air flow rneter, engine coolant and inlet air temperatures from their respectivesensorsand engine speed from the ignitron coil pulses.ReferFig. 6C-20.
ENGINE FUEL6C-9
Figure 6C- 1I
Fi gure 6C -19
'I
6C.10 ENGIN E FU E L
o
I
() (0
o
L
(\I
tt
-9
E NG I NEF UEL 6 C - 1 1
Control Unit Signals
The main f unction of the control unit is to generate injection pulses, Upon receiving electrical signals from the engine sensors, the control unit generates a pulse whose duration (injector opening time) is controlled to provide an optimum quantity of fuel according to the engine requirements. Because the opening and closing reaction time of the injectors is dependant on battery voltage, the control unit also varies the injection pulse width to compensate for fluctuations in the system voltage.
T I- .'i R C T T LE
PC SIT ION
S\VIT C H
3C C LA N T TE MPE R A TU R E SE N S O R
t-?
IGNITION COI L
t'i
IGN I TI O N SW I TC H
AIR F L OW M ET ER
C ON TR OL U N IT
I N J EC T O R S
s,
A I R T EN1 PERAT URE S ENSOR
Fi gure 6C -21
FUEL 6C-12ENGINE 2. PRINCIPLES OF OPERATION

2 . 1 F U ELI NJE C T ION T IMIN G
With many early fuel injection systems, fuel was injected into the inlet port just prior to the beginning of the intake stroke. This is not the case with the LE-z Fuel Injection System. The signal for injection begins with the control unit receiving ignition pulse signals from the ignition coil. With a six cylinder engine, there are six ignition pulses for every two engine revolutions (three pulses every revolution). Upon receiving the third ignition pulse from the coil, the control unit sends the signal for injection to commence. All the fuel injectors are electricallyconnected in parallel to the control unit so they all inject sirnu ltaneously. Cnc injection of fuel provides only half the required quantity necessary for the operation of the 4-stroke cycle of the engine, therefore injection is made twice during one 4-stroke cycle, i.e. once every engine revolution. Refer Fig. 6C-22.
Figure 6C-22
2.2 FUEL INJECTION QUANTITY

Vehicle engine speed and load are the two requirements needed to calculate the basic fuel requirements for any engine operating condition. With LE-z, the speed of the engine is signalled from the ignition coil and engine load is monitored by the air flow meter. The signals from these two sensors provide the control unit with data to select the basic fuel rnjection quantity.
2.3 ENRICHMENTS
The basic fuel injection quantity is not enough for all engine operating conditions. Extra fuel quantity is required for cold starting, engine warm up and acceleration. Refer Fig. 6C-23. Various sensors produce electrical signals which are directed to the control unit so as to provide the extra fuel quantity.
ENRICHMENTTABLE
A FTE F S TA R T E N R IC H ME N T
o
LIJ l TL
WA R M U P E N R IC H ME N T C OLD S TA R T E N R IC H ITl E \T B A S IC FU E L R E OU IR E ME N T C R A N K I\G TIME /TE MP
Figure 6C-23
ENRICHMENT SENSORS Air and Coolant TemperatureSensors

Enrichment signals are generated from both sensors. The lower the air or coolant temperature, the longer the injection signal, the longer the inlectors remain open and the larger the quantity of fuel injected, until the engine reaches operating temperature when enrichment conpensationis no longer required.
ENGINE F U E L6C .13

Throttle Position Switch
The switch contains two contact point sets, one monitoring the closed throttle position and the other f or high load. An enrichment signal is sent to the control unit when either of the contact point sets are closed. At closed throttle, the idle contacts are closed and high load points are open. At part throttle, both contact point sets are open. At high load, the closed throttle contacts are ooen and high load contacts closed. lgnition Switch The start enrichment signal is generated in the 'START' position of the ignition switch. Various fuel enrichment corrections are computed as a result of these signals in order to provide optimum fuel injection under all engine operating conditions.
Cold Start
When the ignition switch is turned to the 'START' p osition a nd t he engine is ln t he' c r ank r ng 'm o d e , t h e control unit delivers 3 injection pulses pr rev and extra fuel is injected into the inlet ports. Cold start enrichment can last for a period up to 10 seconds depending on the temperature of the engine. Refer Fig. 6C-24.
FU E L
I \ r\ rt a l Y ^ ^ N t Tt ' 1 -V | | | I
TIME
Figure 6C-24
After Start
When the ignition switch is released to the 'ON' position from 'START', the cold start enrichment drops off. The 'after start' enrichment is provided to compensate for the sudden decrease in fuel quantity from 'START' to 'ON'. The control unit multipliesthe basic fuel inlectionquantity pulse by a factor of 1.7 at OoC, this factor decreases until the engine speed becomes greater than 600 rpm. Refer Fig. 6C-25 17t
r./LLTIP LIC A TION F A C TO R 1.0
I
I
I
Fi gure 6C -25
Warm Up
The warm up enrichment provides smooth engine operation once the engine is started. The control unit agatn multiplies the basic fuel lnjection quantity by a factor which is controlled by the engine's coolant temperature. Refer Fig. 6C-26.
MU LTIP LIC A TIC \ FA C TOR

I
: OrI
zdoc
TE MP
rooc
Figure 6C-26
^l
6C.14 ENGIN EFU E L

ACC E LE RATION ENRIC HM ENT
1.3
The control unit receives a signal from the air flow meter about an increase in airflow and if the coolant temperature is less than 70 o C, acceleration enrichment takes place. The control unit multiplies the basic fuel injection quantity by a factor to increase the fuel quantity delivered. The enrichment signal lasts approximately 2 seconds. Refer Fio. 6C-27.
r',,l U LTIP LIC A TION F A C TOR
(HtcH LOAD)ENRTCHMENT FULLTHROTTLE

The high load contacts within the throttle position switch close when the throttle is opened greater than 40o. With closed contacts, the controf unit receives an electrical signal and the basic fuel injection quantity is increased by 8 percent to give the au fuel ratio required for maximum p o wer
Figure 6C-27
2 . 4 F U E LS H U TOF F - C OA S T IN G
When the accelerator pedal is lifted so the vehicle is coasting, the closed throttle contact points wrthrn the throttle position switch close. With the points closed. the control unit receives an electrrcalsignal and fuel rnlection is stopped until the engrne speed drops to approxirnately 1 800 rpm. With en grn e s peed below 1800 r pm , f uel injection commences again to prevent the engine from cutting out. Refer Fig 6C-28.
FU E L S H U T OFF
LU uJ (n LU
=
L!
,C ON S TA N T :TH R OTTLE
IN JE C TION S TA R TS A GA IN N O FU E L U S ED
2.5 VOLTAGE CORRECTION FUNCTION

Ljnder conditions of low system voltage, such as would occur with a battery in a low state of charge, the inlectors are slightly slower to open. Under these conditions, the pulse wrdth is automatically extended to ensure the full quantrtyof fuel is inlected
TIME
Figure 6C-28
2.6 COMPONENT OPERATION

AIR FLOW SYSTEM Air Flow meter
The function of the air f low meter is to generate an electrical srgnal to the control unit proportional to the amount of air flow into the engine. This signal is the base engine load signal to determine the correct amount of fuel to be injected. fn the inlet passage of the air flow meter there is a moveable flap and as the air flows through the passage rt exerts a force on this flap. Depending on the air flow and the opposing force cf the flap return spring, the f lap is held open in a certain angular position which is converted to an electrical signal by a potentiometer (variable resistor).
C Ot\4P E N S A TION r
F LAP
D A MP IN G C H A MB ER
ID LE MIX TU R E A D JU S TIN G S C RE W
_ B Y -P A S S S E N S OR F LA P
Figure 6C-29
ENGINE F UEL6C .15

when the air flow flap is moved with a change in air flow, a terminal connected to the air flow flap shaft slides on the variable resistor, causing the output voltage to the control unit to change. Connected to the air flow flap is a compensation flap working in a damping chamber. The need for the extra flap and chamber is to provide the air flow flap with a damper so that it cannot be disturbed by pulsations from inlet manifold vacuum during engine operation. In order to set the air fuel ratio at idle, an adjustable air bypass passage is provided. By varying the quantity of air which is allowed to bypass the flap, the air flow meter signal can be changed sufficiently to alter the air fuel ratio at idle.
r ID LE MIX TU R E \, A D JU S TING S C RE W
BY.PASS FLAP - SEN SC R
C O M PEN SAT I O N F LAP D A[/PIN G C H A\,188R
Fi gure 6C -30
Throttle Body
The throttle body is located on the inlet manifold and it contains a throttle butterfly valve. This valve controls the inlet air flow corresponding to movement from the accelerator pedal. The butterfly valve shaft is connected to the throttle position switch.
A D JU S TE R (D O N OT R E MOV 'E CAP TH ROTT L E A D JU S TER
- T i-. l FC TTL E B ODY
Figure 6C-31
_ T H R O T T LE
PO SIT ION
ID LE S P =ED A D JU S -E 3
H S U /ITC
--TFFOTTLE LE \/E R ID LE LOA D C OMP E N S A TOR Fi gure 6C -32
6 C-1 6ENG I NE FUEL

ldle speed adjustment is carried out by loosening off the idle speed adjuster lock nut and screwing the adjuster in or out to set the desired idle speed. This allows a variance in the amount of air to bypass the throttle butterfly valve. This variance in air flow is measured by the air flow meter, and so the control unit changes the injector pulse width accordingly. Refer Fig. 6C-93.
ID LE S P E E D
ADJUST|NG S c R =y \ __f
A IR FLOW M E TE R F LA P
ID LE MIX TU R E A D JU S TIN G S C R E W
Figure 6C-33
When the vehicle is fitted with air conditioning, an idle load compensator solenoid is installed in the throttle body. When the air conditioning compressor rs operating, the solenoid is energized. This allows an extra quantity of air to bypass the throttle butterfly valve. The control unit increases the pulse width signal to the injectors because of the greater arr flow past the air flow meter and the engine idle speed is increased.Refer Fig. 6C-34.
TH R OTTLE -.\ \.. VA LVE
ID LE LOA D I '\coMP E N S A TOR
L- AIR F LO W M ET ER F LAP
ID LE MIX TU R E A D JU S TIN G S C R E W
Figure 6C-34
AuxiliaryAir Valve
when ine en gin e is cold . it m us t pr oduc e higher t or que durt ng td ie to o ve rco me r nc r eas ed f r ic t ional r es is t anc es , T heref o.e. in ad ditio n to a r ic her ar r , ' f uelr at io dur ing c old startrng ard warm up period, addrtronal rnixture is required tc rn cre ase th e engine' s r Cle s peed r ne addit ional n ixtu re is ob t ained by t he ac t ic n of t he auxiliary ar vaive The auxiliary air valve cperatior. rs conrolled by an electric heater coil whrch. w''ren the engine is cold. permits air to bypass the thrortie valve and enter the inle t man if old.The addit ional air ent enng the induction system causes the flap within the arr flow meter to deflect and the potentiometersignals the control unit that more fuel is requrredthereby maintainingthe air f uel rat io con sta nt. Refe r Fig 63- 35
TH R OTTLE \./A LV E -
A IR F LOW ME TE R
I\
Au) . l r - IAEY- /\f-A \t-
\
L , o LE MI X TU R E A D JU S TIN G S C RE W
Alf'1
n -' ,
Fi gure 6C -35
-------
F U E L6C .17 ENGINE

The auxiliary air valve contains a slotted disc that rotates to open, close or partially close an air passage in the valve. Current f lows through the heater coil which controls the operation of a bimetal spring which rotates the slotted disc. The current flow to the valve begins when the ignition is switched to 'STAFT' and continues whenever the engine is run nin g. With a cold engine, the bimetal strip keeps the disc positioned to open the air passage, permitting air from the air flow duct to enter the throttle body, bypassingthe throttle valve. As the heater coil warms up. the bimetal strip deflects, gradually closing the air passage in the valve until at a predeterminedtemperature, the dtsc has completely closed the passage and idle compensation via the auxiliaryair valve ceases. Refer Fig. 6C-36.
S LOTTE D D IS C
AIR O U T LET
-- ! E A TE R
A IR IN LE T
Figure 6C-36
FUELSYSTEM Fuel Pump fuel pump is a roller-cell to The electric Vpe. Current
operate the fuel pump is fed through a control relay, located in the fuse box. Refer Fig. 6C-37. The pump is driven by a permanent magnet electric motor which is permanentlyimmersed in fuel.
Figure 6C-37
The rotor disc, which is eccentrically mounted in the pump housing, is fitted with metal rollers in notches erence which are pressed against the around its circumf thrust ring of the pump housing by centrifugal force and act aS seals. The f uel is carried in the cavtties which form between the rollers. The fuel flows directly around the electric motor. There is no danger of explosicn, however, because there rs never an ignitable mixture rn the pump housing. The pump delivers more fuel than :he rnaximum requirement of the engine So that the pressure in the fuel system can be maintainedunder all operatrng conditions.
- AR \''IAT tR =
fr
S ID E
OU TLE T
,(
t ,i
'1t
t
\ \_
I Notj
F= TU R N
PRESSURE R E LIE F V A LV E
R OLLE R C E LL P U MP
VA L
Fi gure 6C -38
6C.1 8ENG I NE FUEL

The pump incorporates a check valve to maintainsystem pressureafter the pump is shut off. Also incorporated, is an internal relief valve which provides protection from pressure. excessive The fuel pump capacity is 130 l/hr. NorE: This type of pump can be noisy when pumping aerated fuel, as can occur with a low fuel level in the tank under very hot conditions. lt is not harmful to the pump. The fuel pump is a sealedunit and is not repairable.
RESSURE
P U MP H OU S IN G R OL LE R R OTOR D IS C
i
FU E L N OT U N D E R P R E S S U R E FU E L S U P P LY
:._----_:
i:
t:
ffi
lri;::::Si.;.:.:t
D-r):i+t:t:\-.aiat ]:
FU E L U N D E R P R E S S U R E
Figure 6C-39 Fuel Damper The purpose of the fuel damper is to suppress the fuel flow pulsations from the fuel pump and the injectors. Two dampers are used in the system. The first is situated at the pressure outlet of the fuel pump and the other is placed prior to the fuel entry into the fuel rail. Changes in the f uel pressure drscharged f rom the fuel pump and the opening and closrng of the injectors, are monitored by the diaphragm and spring, which varies the volume of the f uel chamber thereby suppressing fuel pressure pulsations.Refer Fig. 6C-40. The fuel dampers are sealed units and are non adjustable in service and are not repairable.
FUEL DAMPER
A IR C H A MB E R
D IA P H R A GM FU E L C H A MB E R
FU E L IN LE T
F U E L OU TLE T TY P IC A L
Figure 6C-40
Fuel Injectors
Each fuel injector incorporates a solenoid, controlled by electric pulses from the control unit together with an armature attached to a pintle vafve which, when activated, opens inwardly. A spring holds the pinile valve closed as long as the solenoid is not activated. When the solenoid is energized,the pintle valve opens and the fuel is metered and atomised as it enters the inlet port. Since the f uel pressure drop across the injector is always constant, the amount of f uel delrvered is direcily proportional to the pulse width and thei'efore,the time the i n j ectoris ope n. Typical inlection time for most engine cperating condrti_ons range from 2.5 to 10 milliseconds.Refer Fig. 6C-41 for internal view of a typical injector.
FI LTE R E LE C TRIC A L C ON NE C TION
S OLE N OID WIN D IN G S OLE N C ID

R AR M AT t- .,r I
N E E D LE
T YPI C A L
Figure 6C-41
E NG I NEF UEL 6 C .1 9
The injector has around each end, a sealing 'O' ring, which should be replaced every time the injector is removed. Refer Fig. 6C-42. The cap on the injector tip is to protect the injector pintel f rom damage during handling and f itting and also, to provide heat insulation to prevent vapour formation. lt SHOUL D N O T BE REM O VED. Ref er Fig. 6C - 4 2 .
s S E A LIN G R IN G \,O'
\
\s
..,,r.*t\
T IP l ) ,J SU LA TO R 1 I I
I
S E A LIN G 'O' R IN G / Fi gure 6C -42
Fuel Pressure Regulator The fuel pressureregulator(Fig. 6C-43) is a diaphragm operated relief valve used to maintain f uel system pressureto 303 kPa above the inlet manifolddepression. senses fuel pressureon one side while The diaphragm the other side is exposed to inlet manifold vacuum. A spring, rnounted in the engine vacuum side of the a nominal pre-load of pressure. establishes diaphragm, With the f uel pump constantly supplying fuel to the regulator,a situationof too much fuel at the regulatoris created.When pressuregreaterthan 303 kPa above the inlet manifold depression is sensed, the diaphragm rnovesto allow excess fuel to be routed back to the fuel tank. The continuousflow of excess fuel to the petrol tank helps ensure that the injectedfuel is cool and vapour f ree. The regulator is a sealed unit and cannot be repaired.
FU E L R E TU R \ _ C ON N E C TION
gR ESSU R E
RE G U L A TO R
f FU E L \ coN N E C TION
V ALV E P LA TE
1
.\
--?
---J
;:;:;i;i;i;i;l
--i
"' ,'i, :
-i
V A LV E H O LD E R
,-J+
SPR IN G
:.DIAPHRAGM
TY P I C A L
Fi gure 6C -43
Fuel Filter
Due to the extremely close tolerances of various components in the fuel system, it is necessary to fit a special, fine filter for the fuel. The filter retains impurities which maybe present in the f uel and which could affect the function of the fuel injection system. The fuel filter contarns a paper element. Refer Fig. 6C-44.
Figure 6C-44
6C.20ENGINE FUEL
when replacing the filter it is of the utmost importance that the arrow on the housing indicating the flow is complied with. Refer Fig. 6C-4S. The filter must be replaced every 40,000 kms or 2 years, whichever comes first.
Fi gure 6C -45
Fuel R ail The fuel rail guarantees the same fuel pressure at each injector. The fuel rail has a storage function. lts volume compared with the amount of fuel injected during each workrng cycle of the engine is large enough to prevent varrationi in pressure, The injectors,connected to the fuel rail, are therefore subjected to the same fuel pressure. The fuel rail also facilitates fitting of the inlectors, and also lncorporates a schader valve f or breeding down fuel pressure and carrying out diagnostic procedures. Refer Fig. 6C-46.
IN JE C TOR
Figure 6C-46
ELECTRICAL SYSTEM Control Unit

The electronic control unit is a pre-programmed analog computer consisting of custom electronic circuits housed in a metal case. The control unit is rnounted behind the passenger side front cowl panel trim. Refer Fig. 6C-47. The control unit recerves information on the quantity of air drawn into the engrne,coolant temperature, position of the throttle valve, the starting process, as well as engine speed. lt processs this information and transmits electnc pulses to the injectors. lt is connected with the electrical components in the system by means of a multiple pin plug and wiring harness.
,,-
P rAJ5trl\btrF{ A S S E N GE R
a' ,/
s r D Ec o w L P A N EL
C ON TR OL U N IT
/.
Figure 6C-47
Coolant TemperatureSensor
The coolant temperature sensor is located towards the front of the cylinder head. on the manifold side. Refer Fig. 6C-48.
Figure 6C-48
ENGINE F UE L6C -2 1
The control unit receives a signal from the coolant temperature sensor and uses it as one of the factors in determining the amount of fuel enrichment required. As coolant temperature rises, the output of the temperature sensor is changed. With this change, the control unit varies the amount of f uel enrichrnent by changing the duration of the fuel injector opening. Refer Fig 6C-49. lf the sensor is diagnosed as defective, it rnust be replaced. NOTE: The coolant temperature sensor for EFI is common with the sensor used for Electronic Spark Timing .
C OO LA N T TE MP E R A TU R E S EN S OR
C ON TR OL U N IT
IN J EC T OR S
Fi gure 6C -49
Inlet Air Temperature Sensor The inlet air temperature sensor is built into the air flow meter housing. Refer Fig. 6C-50. The function of this sensor is to compensate for changes in inlet air temperature by applying a correctionto the air flow meter outputvoltage.
A IR TE MP E R A TU R E S E N S OR
TH E R M IS TOR
Figure 6C-50
Throttle Position Switch The throttle position switch is attached to the throttle body and is operatedby the movementof the throttle butterfly valve shaft. The switch contains two sets of points,one set monitorsclosed throttle positionand the . highload position. ReferFig. 6C-51 other set monitors The closed throttlecontactsare closed when the throttle butterflyvalve is positioned at idle, and are open at any otherthrottleposition. The closed throttle contacts when closed, provide the control unit with an electricalsignal for the deceleration fuel shut off function. Deceleraticn condition is detected from the closed throttle contacts and engine rpm above 1800. Under these conditions, which occur while decendinghills or slowingdown from highwayspeeds,injectionis stopped to save fuel.As the engineslowsto 1800 rpm the fuel is in preparation for idle. reintroduced
TH R OTTLE V A LV E S H A FT I D LE C ON TA C T _
Fi gure 6C -51
6C-22ENGINE FUEL
Enrichment is also provided at higfr load as srgnalledby the closing contacts in the throttle position switch, when the throftle blade angle exceeds 40c Ar electricalsignal from the throttle position switch rS sent to the control unit tc increasethe injector pulse wrdth Refer Fig. 6C-52.
TH R OTTLE B OD Y
/l . T HR O T T L E
PO S IT I ON SW IT C H
/l
Figure 6C-52
Control Relay
The electrical supply to the f uel pum p. c ont r ol unit , injectors, auxiliary air valve, throtile Dosrton switch and air flow meter is controlled by the control relay. The control refay itself is actuated by the ignition switch and also with either: a . T he en gin e cra nking . b. The ignition coil pulses being over the equivalent of 150 eng rne rpm.
Figure 6C-53
, unng engtn e cra nkrng ,volt age f r om t he ignit ion s wr t c h a-d from the starter ^notcr solenoid croses the control reiay points. This allows current to flow from the banery, Supolyrngpower to the ccmpcnents mentioned above. F e f er F ig. 6C-5 4.
TC E LE C Tq,C A I_ COMPCir.! ri -S
I I I
B A TTE R Y
r---J
I
i
TC FU E L
P'- :"4P
3 rGN tTtoN S WITC H S TA R TE R S OLE N OID
EN G IN E C R AN K IN G
Fi gure 6C -54
ENGINE FUEL6C-23
Voltage frorn the ignition switch is still present at the control relay after the vehicle has started. The rotational speed reached as the engine starts, is high enough to generate the engine running signal, which is taken from the ignition coil pulses being above 150 engine rpm. Refer Fig. 6C-55.
coMPoNrrry:
i I I r - - - 'J I
TO E LECTR I CA L
'_+
I =
EA R TH
B A TTE FY I G N I TI O N S W I TC H I G N I TI O N COIL
i
TO FU E L P U MP
EN GIN E R U N N IN G
Figure 5C-55 The control relay remains switched on as long as the ignition is switched on and the engine is running. lf the ignition coil pulses stop because the engine has stopped, for instance in the case of an accident, the control relay switches off. This safety circuit prevents the fuel purnp from pumping fuel when the ignition is switched 'CN' but the engine is not running.Refer Fig. 6C-56.
_l
PO IN T S O PEN
B A TTE R Y S U P P LY TO E LE C TR IC A I E tf fS C C IvIP ON D S TOP P E

B A TTE R Y I G N I TI O N S W I TC H
IGN ITION C OIL P U LS E S B E LOW 150 R P M (E N GINE SP E E D ) E N GIN E S TA LLE D
Figure 6C-56
6C-24ENGINEFUEL 3. SERVICE OPERATIONS

3.1 SERVICE NOTES
IMPORTANT:The following must be observed when working on vehicles with the electronic fuel injection system. 1. Never start the engine wrthout the battery being solidlyconnected. 2. Do not use a quickchargeunit to start the engine. 3. Never separate the battery from the 'on board' electrical systemwhilethe engineis running. 4. when charging the battery, disconnect it from the vehicle's electrical system. 5. Before makrngany test on the fuel injection system, ensure that the ignition coil and distributorare in order, as the control unit operationis triggeredfrom tr,e ignition coil. checks should also be made of rgnrtron tirningand spark plug condition. 6. Never subject the control unit to temperatures above 80oc (1760F) i.e. paint oven, alwaysremovecontrol unit first if this temperature is to be exceeded. 7. Ensure that all cable harness prugs are connected solidly and that battery terminals are thoroughly clean. 8. Never connect or disconnectcable harnessplug at controlunit when the ignition is switched on. 9. when making a compressron test, remove control relay from the fuseboxto deactivate the fuel pump and prevent fuel being inlected during engine cra n king. 10. Depressurize f uel system as per service operation 3.2 in this Section before disconnecting any high pressurefuel line, to reducethe residualpressurein the fuel lines. NOTE:with very hot engine up to a litre of fuel may be expelfed under high pressure. 11- Before ?.terpting any electric welding on the vehicle,disconnectthe battery leads and Ine control unit connector. 12. when steam creaningengines, do not direct the steam cleaningnozzleat any EFI components. lf this happens, corrosionof the terminalsn take place. 13. Never attempt to bench test the fuel purnp as it is designed to run with the internalsimmersedin fuel. Running on a bench withoutany fuel can cause the pumpto explode. 14. The throtile body must be removed every 40,000 kTr o]' 2 years whichever occurs first, ani ExhaustGas Recirculation depositscleanedfrom the throttle blade and throtile bore. Reset idle speed after reinstallation. Failure to observe this requirement will result in the engine idle speed decreasing and stalling. 15. Disconnect the batterybefore workingon either the fuel or electrical systems of the EFl. 16. Handle all EFr components carefully to avoid damage, particularly the air flow meter.
3.2 FUEL SYSTEM

LEAK TESTING
Prior t o startin g the en gin e. f ollc wr r g t he ins t allat ion of a fuel system component. checx the fuel system for leaks. 1 check to e nsure th a::her e r s a s uf f ic ientlev el of f uel rn the fuel tank. 2 Activatefuel purnp tc pressurisesystem by: a Disconnect purcle lead f rom starter motor solenoid. c lold ign itionswitc h in ' c r anK' pos it iont o r un f ue D ump . 3 let -. n ign itionto'o ff'pos it ion. j 3re:k fu el syste m fo r leak s par t r c uiar lvar Dc r nt s -larked O in Fig. 6C-57. 5 ?ect f., aay fuel leaks. 6 R eccnre c: ea d to sta r t er m ot O r s olenor c D E P RE S SURIZING The f uel lines of ihe E Fl system retain a residual pressure,even when tne encine is switched 'oFF'. For reasons of safety, rt rs necessary to depressurize the fuel system before any sectro- c. ine pressure side of the fuel pump is disconnected The syst em is de pre ssur iz ed, . r s in?: r e nos e f r om f uel p ressuregau ge pa rt n o. SD 28018 o^ t he Sc ^r ader v alv e f t t ting at t he fron t of the fu el r ar l. The end c 3nnec t or of t're hose has a built in valve core depressor
F U E L6C .25 ENGINE
IN J EC T OR S
- 6 PLAC ES- r
F UE TAN
DAM PE R
Figure 6C-57
The following procedure should be used when the system:depressurizing gauge,SD28018. 1. Detachhose from fuel pressure valve fittingin fuel rail. 2. Removecap from schrader 3. Insert 'Gauge' end of hose into a containerwith a capacityof at least one litre. 4. Slowly install the other end of the hose to the schradervalve fitting and allow fuel to escape into the container(Fig.6C-57A). 5. When fuel flow ceases,remove hose from fittingand hose to gauge. reinstall cap. Reinstall
Flgure 6C-57A
FUEL HOSES AND CLAMPS inspectall fuel hosesfor cracksand swelling, Periodically replaceany hose that showssigns ol deterioration. NOTE:The EFI systernuses a specialgradeof fuel hose that is necessaryto withstandthe high fuel pressures and temperaturesof the system. The diameter of the hose is also matchedto the fuel pipes and clamps to Use only the correct,genuine ensure positiveretention. fuel hose, emission EFI system fuel hose. Carburettor hose or non genuinehose, even though it may have a rating,ls not suitable. high pressure to designed Hose clampson the EFI systemare specially exert an even clampingforce around the circumference edgesto avoidcuttinginto of the hose and have rounded the fuel hose. Tighten to the correct torque (refer Torque Wrench and never use non genuine substitute Specifications) hose clamps.
6C-26ENGINE FUEL
3.3 THROTTLE CABLEADJUSTMENT
1. 2. Depress accelerator pedal to floor. Adjust throttle cable outer lock nuts so that the throttle valve is fully open. Tighten lock nuts to 3.0 t o 4.0 Nm (Fig. 6 C-58) Allow accelerator pedal to assume free position. Adjust screw on pedal lever so that the pedal has no free play, but the cable is taut and idling speed is not affected (Fig. 6C-58).
A C C E LE R A TOR P E D A L 7 A D JU S TIN G S C R E W i
3. 4.
v.-\J-
iI _ TH R OTTLE V A LV E
TH R OTTLE C A B LE OU TE R LOC K N U TS
A ccE LE R A ToR pE D A L-----7 Figure 6C-58
3.4 CRUISE POWERUNIT CONTROL CABLEADJUSTMENT

1.
2. 3.
Ensure ignition is switched 'off ' and the throttle butterfly valve is completely closed. Check slack in cable. Refer Fig 6C-60. To adjust the cable to obtain the correct amount of slack, loosen off lock nut Refer Fig. 6C-59. Turn the adjusting link to get the desired slack of 5.0 to 10.0 mm as sho wn in Fig. 6C- 60.
E N S U R E P OWE R U N IT LIN K IS IN S TA LLE D TH IS WA Y
A D JU S TIN G L IN K
Figure 6C-59
Figure 6C-60
3 . 5 AD J U ST I NG ID L ES P E E D AND M IX T U R E
B efore m aking a ny a dju s t nnent st o t he idt e s enr ngs , ensure that:1. T he en gin e oil a nd wat er ar e at nor m al oc er at r ng ternperatures, preferablyachreved by drivinc 2 . T ransmission in Pa rk o r Neut r al. 3 Air conditioning(if fitted) turned off 4. Disconnectcanister purge hose but do not plug (refit after test).
E NG I NE F UEL 6 C - 2 7
Connect an ACCURATE CO-meter and tachometer. Record values and compare to those specified on the Vehicle Emission Control Information Label in the engine compartment and listed in Specifications in this Section. NOTE: Nominal values are for 'run in' engines. New engines should not be readjusted unless outside the range of 700 to 900 rpm during the first 1500 kms. The following checks must be performed and any defects corrected before any idle adiustrnents are made to the EFI system. 1. lgnition timing. 2. Manifold vacuum is present at fuel pressure regulator. (Disconnect vacuum hose at regulator and install vacuum gauge to hose.) 3. Throttle lever closing on to stop - if not check a. Throttle position switch adjustment. b. Throttle linkage and springs. 4. No leaks at hoses and duct between atr flow meter and manifold. 5. Running on all cylinders - if not check for a. Defective spark plugs and leads. b. Open circuit to injector. 6. Auxiliary air valve fully shut - check by pinching off air hose and observing engine speed - if speed drops, check for a. Engine not sufficientlywarmed up. b. Open circuit in electrical supply to auxiliary au valve. c. Auxiliaryair valve installed upside down. 5. 6.
IDLE SPEEDADJUSTMENT adiustthe from specifications, ln the case of deviation idlespeed as follows:
1. 2. Loosenoff lock nut (Fig.6C-61). Turn the idle speed Install an accuratetachometer. adjusting screw to achieve the correct idle speed . Fig. 6C-61 the idle speed, Screwingthe adjusterout, increases in, decrea*s the idle speed.The specifica' screwing tion for a 'run in' engineis:- 850 t 50 rpm. ADJUST DO NOT UNDERANY CIRCUMSTANCES LEVERSTOP (ReferFig. 6C-61). THE THROTTLE The specafter speed adjustment. 3. Check CO-reading for a 'run in' engineis .5 to 1.So/oCO. ification
LOC K N U T -
T - J R OT T LE
-=V E R S TOP ;
.,/
ID LE S P E E D ,/' A D JU S TIN G S C R E W_
Figure 6C 1
ADJUSTMENT IDLE MIXTURE

This is preset and should not normally be adiusted. In the case of deviation from specification and all previous checks have been carried out and abnormalitres corrected, adjust the idle mixture as follows:1. Use only an ACCURATE Co-meter.
6C-28ENGINE FUEL
Pierce and remove the plastic cap on the air flow meter to expose the mixture adjustingscrew. Refer Fig. 6C-62. 3, Turning the screw in, nchensthe mixture, screwingit out leans the mixture. ldle CO-specification is .5 to 2.
4. 5. 1.5%. Recheck idle speed after mixture adjustment. Reseal mixture adjusting screw with a new servtce, plastic cap. The service cap is coloured red, and is available from GM P & A, Part Number VS16400.
Figure 6C-62
3 . 6 AI R C L E A N E R E L E ME N T
REPL AC E M E NT 1. Drsconnect batteryearth lead. 2. Loosenhose clamp around arr flow duct at air flow meter.Refer Fig. 6C-63 3. Disconnect wiring harnessconnectorat the air flow meter, remove harness from retainer. Refer Fig. 6C-63.
- H OS E C LA MP A IR FLOW D U C T F LOW ME TE R
Figure 6C3
Remove air Fig. 6C-63A.
flow
duct
mounting
bolt.
Refer
H OS E C LA MP A IR FLOW D U C T H OS E C LA *'/
\/ .----\ // --\\ ---v:\ /
Figure 6C3A
ENGINE FUEL6C-29
iJnclipsnap locks around upper air cleaner housing. Refer Fig. 6C-64. 6. Lift upper air cleaner housing from its position and removefrom air flow duct. NOTE:When removing be the upper air cleanerhousing, particularly careful not to damage or knock the air flow meter. 7. Rernove air cleanerelementfrom upperhousing. 5.
- - - - - Al R
C:EA\ER H OU S I N G
SIJ AP LO C K
Fi gure 6C -64
8.
Fit new air cleaner element into upper housing and check that it is seated correctly. Refer Fig. 6C-65. Refit upper housing, wiring connector battery lead and air flow duct hose clamp.
Figure 6C-65
HOUSING 3.7 AIR CLEANER

REMOVE
1. 2. Disconnect battery earth lead. Disconnect wiring harness connector at the air flow meter, remove harness from retainer. Refer Fig. 6C-66. Loosen the hose clamp around air flow duct at air flow meter. Refer Fig. 6C-66.
C ONN E C TOR
F L3,'y ' * '.tET =R -
3.
t,
rl
Figure 6C-56
4.
Remove engine ventilation hose from the lower inner panel of the air cleaner housing. Refer Fig. 6C-67.
Figure 6C-67
FUEL 6C.30ENGINE
5. 6. Remove air flow duct mounting bolt. Refer Fig. 6C-67A. Remove the three air cleaner housing mounting nuts (refer Fig. 6C-66) and withdraw air cleaner housing by first sliding the air flow meter from the air flow duct and then removing the housing assembly.
H OS E C LA MP
A I R FLOW D U C T
H OS E C LA MP ;
REINSTALL 1. Installation is reversal of removal.

2. Check for air leaks.
-l/, )) /// /,/
Figure 6C7A
3.8 AIR FLOW METER

REMOVE 1. Disconnect batteryearth lead. 2. Loosen hose clamp around air flow duct at air flow rneter.Refer Fig. 6C-68. 3. Disconnect wiring harnessconnectorat the air flor meter, rernove harness f rom retainer. Refer Fig 6C-68.
A IR FLOW ME TE R WIR IN G H A R N E S S C ONN E C TOR
R E TA IN E R B O LT
Figure 6C-68
4.
Remove air Fig. 6C-68A.
flow
duct
mounting
bolt.
Refer tu PPo Rr BRACKET I
/--/
FLOW r -A tR DUCT
-c
Figure 6C8A
________
E NG I NE F UEL 6 C - 3 1
5. Open snap locks and remove air flow meter with upper section of air cleaner housing. Refer Fig. 6C-69. Remove air flow meter harness retainer bolt. Refer Fig. 6C-68. from upperhousing. 7 . Removeair cleanerelement
L=ANER t'l G
S NA P LOCK S
Fi gure 6C -69
8.
Remove air flow meter mountingbolts f rom upper Refer Fig. 6C-70. innerair cleanerhousing.
Fi gure 6C -70
NOTE: A Square 'O' ring is used to seal between the air flo w mete r and air c leaner hous ing.Ref er F i g . 6 C - 7 1 .
REINSTALL
1. 2. 3. lnstallation is reversal of removal. Ensure 'O' ring is in Place. Check air flow meter flap for correct functioning by moving it all the way to the stop. The movement must not be ierkY. 4. Use a clean lint free cloth to remove any dirt in the area of the flap. DO NOT use any solvent or compressed air to clean the passage of the air flow meter. 5. Tighten air flow meter moulting bolts, and the wiring harness retainer bolt. 6. Refit air cleaner element to upper housing7. Check for air leaks.
Fi gure 6C -71
-q
FUEL 6C.32ENGINE
TEST
lf the following test is to be conducted on the vehicle, disconnect the battery earth lead and the wiring harness connector at the air flow meter. 1. Measure the resistance between terminals 7 and 5 while sliding the air flow flap. lf the resistance is at any value other than 0 and infinity, air flow meter is normal. Refer Fig. 6C-72.
Figure 6C-72 2. Check insulation resistance between the air f low meter body and any of the terminals. lf continuity exists, the air flow meter is defective and must be replaced. Refer Fig. OC-73.
Fi gure 6C -73
3.9 AIR FLOW DUCT

REMOVE
2 Loosen hose clamp and remove hose to the auxilrary air valve from the air flow duct. Refer Fig. 6c-74
S U P P OR TB R A C K E T
-i-----
DUCT
A IR FLOW
.{
,/--T
't
A U X ILIA R Y A IR V A LV E
H OSE
Figure 6C-74
ENGINE FUEL6C.33
3.
4. Remove the engine ventilation hose bracket bolt from underneath air flow duct. Refer Fig. 6C-74A. Remove the air flow duct mounting bolt from support bracket. Refer Fig. 6C-74.
E N GIN E V E N TI LA TI ON
Figure 6C-74A
5.
Loosen the hose clamps around each end of the air flow duct (refer Fig. 6C-75) and withdraw duct from its position.
H C S= C LA\1P -
AIR F LO !'J D - ]-
REINSTALL
1. 2. Installationis reversalof removal. Check for air leaks at all connections to air flow duct (this will effect the air fuel ratio).
Figure 6C-75
BODY 3.10THROTTLE
REMOVE
1. Disconnect battery earth lead. 2. Remove air flow duct as per 3.9. 3. Disconnect throttle cable from throttle body linkage
and air f low duct mounting bracket. Remove the upper accelerator return spring. Refer Fig. 6C-76.
TH R OT-|-uI _ B oD Y \:
A C C I:E R A TOR C A B LE A C S E ::R A TOR r _C C K --:-rlTS '-r--------=h-f
R E -I-LR NS P R TN G\ :*.'.---.--.{ -
".,]OU N TIN G ERACKET
A C C EL E R A TO R LIN K A GE B FA C K E T
Figure 5C-76
6C.34ENGINE FUEL
4. lf fitted, remove cruise control power unit cable retarnerfrom throttle linkage. Refer Fig. 6C-77.
Y--L'|NKAGE ,----&{ fr ^tr /v
[r ,NKNUr ,l ,rTlRo.rr-LE
\p
P OWE RU N IT C A B LE R E TA IN E R
Figure 6C-77
Disconnect vacuum hos es t o t hr ot t le body . not ing positions for correct reinstallation Refer Fic. 6C-78.
C A N IS TE R TO TH R OTTLE B OD Y P U R GE -
TV S S WITC H TO -I TH R OTTLE B OD Y Fi gure 6C -78
E N GIN E V E N TI LA TI ON
6.
Disconnect throttle positron switch wiring harness connector and, i{ fi:ted. rdle load compensator power f eed wire. Re fer F'E. 6C- 79. Remove the /- mcunting nuts securing throttle body to the inlet nanifold and remove throtile body and gasket. Refer Fig 6C-79. Remove the two bolts securing the throtile linkage bracket to the throttle body and disconnect the throttle rod from the throttle lever ball. Refer Fig. 6C-76.
TH R OTTLE B OD Y
MOU N TIN G N U TS (4 P r-A C E S )
MOU N Tl N G S TU D S
6g
ID LE LOA D _ C OMP E N S A TOI TH R C TTLE _
PO SIT IS\ SW IT C H
RE IN S T AL L I n st aliat ion is reversalo f r em ov al not ing t he f ollowr ng: Use a new throttle body to intet manifold gasket. Before fifirng the throttle body wrpe Exhaust Gas Recirculationdeposit from the throtile blade and bore. 3low o ut the s mail d rilling s fo r t he s par k , EG R and c anr s t e r signals with compressed air. NOT E : Reset the id le s peed on r eins t alt at r on af ler c leaning,r e fer 3.5 Check for full throttle and adjust throttle cable as required,refer 3.3. lf fitted with cruise control, check cruise control power unit cable adjustment.refer 3.t. Start engine and check for air leaks
Figure 6C-79
FUEL 6C.35 ENGINE

3.11 INLET MANIFOLD REMOVE 1. Disconnect earthlead. battery
2. 3. Remove air flow duct as per 3.9. Disconnect all vacuum hoses frorn inlet manifold and throttle body and remove inlet manifold vacuum adaptor from rear of manifold. NOTE: Observe hose positions f or correct reinstallation refer Figs. 6C-80, 6C-81. HOSE NOS. 1 15 2 4 5 3 SS To To To To To t r ans duc er . s peeds ens or l M oC t her m os t athous ingTVS . brake booster. aux iliar y air v alv e. v ac uum aut om at ict r ans m is s ion m odulat or v alv e. r egulat orv alv e, To f uel Pr es s ur e EG R v alv et o c y linder head EGR T V S s w i t c h . i
1)
* tr'
Figure 6C-80
HOSE NOS. T h r ot t le body t o c y linderheadEG R T V S s w i t c h . 61 T hr ot t le body t o t her m os t athousi n gT V S . 38 60 C anis t er t o t h r ot t le body pu r ge. Enginev ent ilat ionhos e. 6
38
Fi gure 6C -81
4.
Disconnect throttle cable from throttle body linkage and air f low duct mounting bracket. Remove the upper accelerator return sPring.Refer Fig. 6G82.
TH R OTT L E B OD Y
A C C E LE R A TORA E TU R N S P RIN G
.-
- AC C ELE R A TOR CA B LE ,_LOC K N U TS
: --_- -__l =l -{ F
R ET U R N
SPR lN G
Figure 6C-82
6C.36ENGINE FUEL
5. lf fitted, remove cruise control power unit cable retainer from throttle linkage. Refer Fig. 6C-83.
LIN K N U T
THROTTLE
LIN K A GE
1)-\--
C R U IS E C ON TR OL P OWE R U N IT C A B LE R E TA IN E R ------>
Figure 6C-83 6. Disconnect wiring harness connectors from the throttle position switch, idle load cornpensator if fitted, coolant temperature sensor, injectors and generator. Refer Fig. 6C-84. unclip wiring harness clips around fuel rail and top radiator hose and withdraw wiring harness towards the rear of the engine.
C OOLA N T TE MP E R A TU R E S E N S OR_ID LE LOA D C OMP E N S A TOR I N JE C TOR S r6 P LA C E S )
PC S IT IO N
Figure 6C4
7 8. 9.
Disconnect E.G.R. pipe from inlet and extracto' manifolds.Refer Fig. 6C-85. Depressurizefuel system as per 3.2. Disconn ect fue l rail h os e and f uel r et ur n hos e f r om fuei regulator.
Figure 6C-85
FUEL6C.37 ENGINE
10. Remove inlet manifold brace bar. Refer Fig. 6C-86. 11. Remove manifold to cylinder head attaching nuts and bolts. 12. Release inlet manifold from cylinder head. Once clear of manifold mounting studs, remove manifold and feed the automatic transmission modulator pipe from the manifold.
REINSTALL
Clean inlet manifold and cylinderhead mating faces and E.G.R. exhaust gas pipe and manifold surfaces. Install new gaskets Installationis reverse of removal operations. Tighten manifoldbolts, working from the centre outwards.Refer for details. TorqueWrench Specification Installinlet manifold brace after torquingup the manifold to head nuts and bolts.Tightenthe top end of the brace first to ensure the slotted end is correctlypositionedon the extendedhead bolt. Test fuel system for leaks as per instruction3.2 and check full throttle and adjust throttle cable as required, refer 3.3. lf fitted with cruise control, check cruise control power refer 3.4. unit cable adjustment, Start engineand check for air leaks.
I
'T
I
Figure 6C6
AIR VALVE 3.12 AUXILIARY

REMOVE
1. 2. 3. 4. Disconnect battery earth lead. Disconnect harness plug at top of valve. Refer Fig. 6C-87. Loosen hose clamps at each end of the valve and disconnect hoses. Refer Fig 6C-87. Unscrew both mOunting screws and remove auxiliary air valve. Refer Fig. 6C-87.
,.ff
,tr -
33'{
,.- -A I R FL O W D ri c T
REINSTAL L 1. Installation is reversal of removal. Valve is to be installed with the wiring plug connection upwards. Ensure that the cylinder head and auxiliary air valve mating surfaces are clean to provide the required heat transfer. Check for air leaks.
AIR
H A 3 \ E S SP IU G
5**t
HOSz_--'-i'
fi--lt
\ ,:,_[
2.
__---t,
H OSE C LA MP S
TEST witha coldengineThistestmustbe performed

Start engine and pinch the rubber hose between the throttle body and the air valve. When the air valve is cold, the engine speed should decrease as the hose is Pinched. With the air valve hot, the engine speed remarns unchanged as the hose is Pinched.
;i6 1'ffiirui6 M o u N r lN G SC R EW
S/ \-f{T \\!./ f l *- O (2 PLACES)
AIR IN LET H OSE
| \l -t al
-z-
A U X ILIA R Y A rR vA L v E
Figure 6C-87
6C.38ENGINE FUEL
3 . 1 3F U E L P U MP
REMOVE
1. 2. 3. Disconnect battery earth lead. Drain tank to below level of fuel outlet. Disconnect wiring harness connections on the pump. Note which way the wiring connectors are fitted to the pump. Refer Fig 6C-88. Place a drain tray underneath pump. Depressurizefuel system as per 3.2 Remove fuel pump clamp bolt and clamp. Refer Fig. 6C-88 Loosen hose clamps at either end of the fuel pump and slide hoses off, withdraw fuel pump. Fig. OG8B,
FU E L D A MP ER OU TLE T H OS E
4. 5. 6. 7.
rlt
v(
FU E L P U MP
,,U P B OLT
H OS E C LA MP
Z F U EL D AM PER
_==-_
rl L"H AR N ESS T ER M IN ALS
R EI NS T A L L Installationis reversal of removal. When installingthe fuel purnp ensure that the fuel line hose clamps are properly seated and check for fuel leaks as per 3.2.
[ *,*,*]
TESTING Volume Test 1. Depressurize fuelsystern as ger3.2.

Remove gauge hose f rom f uel rail, and using a schrader valve remover, remove valve core. Refit gauge hose to schrader valve fitting. 3. Place free end of gauge hose in a container with a volume measurementscale. NOTE: Ensure the container has a volume greater than 1 litre and that fuel tank has a sufficient level of fuel. 4. Remove purple lead from starter motor solenoid. 5. Activate fuel purnp by switching ignition to the 'START' position. 6. The volume pumped should be at least one litre in 30 seconds. lf the volume pumped is not sufficient: a. Jack up rear of vehicle and place on safety stands. b. Disconnect f uel hose between fuel pump and fuel filter at the fuel purnp end. Install one end of a suitable length of fuel hose to the fuel pump outlet pipe and insert the end in a container with a volume measurement scafe of at least 1 litre capacity. 7 . Retest as per steps 5 and 6. lf volume pumped is sufficient, fuel filter is blocked. 8. lf volume pumped is not sufficient: a. Remove fuel pump inlet pipe, install a test hose to the fuel pump inlet. lmmerse hose in a container having more than a litre of clean fuel. b. Place the fuel pump outlet test hose In the empty test container. 9. Retest as per steps 5 and 6. lf volume pumped is sufficient, the fuel tank sender unit stainer is blocked. Remove tank unit as per instruction 2.6 in section 8A of this supplement. lf volume pumped is not sufficient, replace f uel pump. 2.
Figure 6C8
Pressure Test
1. Install fuel pressure gauge and hose (par1 no. SD28018) to schrader vafve fitting at front of fuel rail (Fig. 6c-89). Hose has built in valve core depressor.
FUEL6C.39 ENGINE
2. gauge' Start engine and read fuel pressure 25O 20 kPa at Pressureshould be approximately idle. The moment the acceleratorpedal is moved pressure should increase to approximately300 kPa (accelerator must be opened rapidly to give 'C' manifoldvacuum). check for clogged 3. lf fuel pressureis not as specified, or deformedfuel lines, blockedfuel filter or pick up strainer. 4. lf above the specified value, check condition and connectionof vacuum hose to pressureregulator,if hose is satisfactory,replace regulator and retest. lf replacefuel pumpthe pressureis still not achieved, Fuel Pressure Test r For Internal Leakage 1. Installfuel pressuregauge part no. SD28018as per previoustest. 2. Start engine and allow to idle, note fuel pressure gauge reading. 3. Switch engine 'off' and observe pressure gauge of an drops,it is an indrcation tt ihe reading reading. internalfuel leakage. 4. Under the vehicle,clamp the fuel pump outlet hose' Observe the fuel pressure gauge reading. lf the reading stops dropping, the fuel pump has an internaituet leakageand must be replaced. 5. lf the reading continuesto drop, while the hose is clamped, rernove the purple lead from the starter motor solenoid. Turn the ignition to the 'START' positionand allow the fuel pump to run. Once the iuel pressure reading has reached the same as recordedin step 2, switch'off ignition' regulator 6. Clampthe fuel returnline from the pressure and observe the pressure gauge reading' lf the reading stops dropping, the pressure regulator is faulty and must be rePlacedto drop, removethe fuel rail 7. lf the readingcontinues mountingbolts from inlet manifold' g. Carefullyremove fuel rail and iniectorsfrom the inlet and rest the fuel rail on the manifold' manifold steP 5. out Carry 9. 10. Observewhich iniector/sis leaking' 11. Replace iniector/s which are faulty. Replace the and lubricate sealing'o' rings on all other iniectors, usingPetroleum iellY. 12. Refit fuel rail assemblY13. Refit starter motor solenoid wire- Start engine and check fuel pressure gauge reading. Switch'off' drop' engineand checkfor pressure 14. Remove pressure gauge and install scrader valve cap.
Figure 6C-89
6C .40ENG I NE FUEL
3.1 4 FUEL DA MP E RT RE A R REMOVE
1. 2. 3. 4. 5, Disconnect battery earth lead. Depressurizefuel system as per 3.2. Raise rear of vehicle and support on jack stands. Loosen hose clamp on fuel outlet hose frorn damper, rernove hose. Refer Fig 6C-90. Remove fuel damper mountrng nut from bracket, loosen hose clamp between damper and fuel pump. Refer Fig. 6C-90. Lift damper f rom mounting bracket and withdraw from fu el p ump ho se .
H O SE C LAM P
@
r"
---''
-/ ----'-'
/t
UT A CK E T
t: rl
lr
J]
1r
l ti
ti
6.
H OS E MOU MOU N
RE I NS T AL L 1. 2. Installationis reversalof removal. C hec k for fue l le aks a s per 3. 2.
j
Figure 6C-90
3 .1 5 F U E LF IL T E R
REMOVE 1. Disconnect battery earthlead. 2. Depressurize fuel systemas per g.Z. 3. Raiserear of vehicle and supporton jack stands. 4. Placea draintray underneath filter. 5. Loosenhose clampsand disengage fuel hoses from filter. ReferFig. 6C-91. 6. Loosenfilter mounting clamp bolt and removefilter. Re fe rF ig. 6C- 91. REINSTALL 1. Replacing filteris reversal of rernoval. NOTE:Direction of fuel flow arrowon filterbody rnustbe complied with (arrowto pointto front of vehrcie). 2" Make sure the fuel line hose clamps ate properly g.Z. seated and checkfor fuel leaks.relerinstruction
> C LA MP
C LAM P BO LT H OS E C I-A I'I,P-, T O EN G I N E'
FR OM FU E L P U MP
'/
Fi gure 6C -91
3 .16 FUEL D AMP E R I FRONT R EM O V E

i 2. 3. 4. Drsconnectbattery earth lead. Depre ssurize fu el syst em as per 3. 2. Locsen fu el lin e ho s e c lam ps at eac h s ide of dampe r, d lscon ne ctfuel hos es . Ref er Fig. 6C- 92 R emo ve mo un ting nu t . Ref er Fig 6c - 92 and wit hdraw d amp er.
FU E L H OS E
fr,-
r-1u\l
| !/t-
D AM P E R
R E I NS T ALL 1. 2 Inst alla tion is re ve rsa lof r em ov al. Check fo r fu el lea ks a s per 3. 2.
\:3J\TIN G \-T FU E L H OS E --.^ ,{,2 A U X I LIA R Y A IR V A LV E Figure 6C-92
ENGINEFUEL 6C-4 1
3 .1 7 F U E L R A IL
REMOVE
1. Disconnect batteryearth lead. fuel system as per 3.2. 2. Depressurize the fuel return line from the fuel pressure 3. Disconnect regulator, disconnectvacuum hose to the regulator. 4. Disconnectwiring harness connectorsat the throttle position switch, idle load compensator if fitted, coolant temperaturesensor, injectorsand generator wiring.Refer Fig. 6C-93. Unclipwiring harnessretaining clips aroundfuel rail and top radiatorhose, and withdraw wiring harness to the rear of the inlet manifold.
Flgure 6C-93
5.
Remove the bolt securing the inlet manifoldbrace bar at the manifold and the nut on top of the cylinder head stud. Remove brace bar. Refer Fig. 6C-94.
Figure 6C-94 6.
retaining Remove the injector clips.Refer Fig. 6C-95.

F U E LR Ar L
rq f
4 $s
/ ' , *J Ec r o R
-rfrt-
K
Figure 6C-95
IP
6C.42ENGINE FUEL
Remove the 3 fuel rail mounting bolts. Refer Fig. 6C-95. Using compressed air, blow off dirt around the injectors. 8. Pull fuel rail towards the inlet manifold and CAREFULLY loosen injectors from the inlet manifold or fuel ra il. 9. Remove all injectors and place in a clean location. 10. Withdraw fue! rail toward front of engine, pushing down slightlyon top radiator hose. 7. REINSTALL Before reinstallating any injector, replace both sealing 'O' rings. lt will be necessary to cut the old 'O' rings fronn the injectors.Take care not to damage the tip insulator. S mear t he se alin g 'O' rings wit h pet r oleum jelly . lns er t each injector into the fuel rail, then install retaining clips. With all inlectors in fuel rail, carefully position numbers 5 and 6 cylinder injectors into the manifold ports. Next, posrtron the centre two injectors, then the remaining two injectors. With all injectors correctly positioned in the manifold, push fuel rail squarely in to fully engage injectors. Installationis reversal of removal, Check for fuel leaks as per 3.2.
IN JEC TOR R E TA IN IN-TG C LIP
l.t':llnar,
FU E L R A I L
.op'g { . , . ' rv y I rl \ \ l D \ , rL | -}
i 3 PLA C E S )
*r'i ,,
IN JE C TOR
Figure 5C-96
3 . 1 8I N JE C T OR S
For removal and reinstalling instructions, reter to Fuel Rail Rem ove an d Rein sta ll,3. 17.
3 . 1 9PR E S S U R R E E GU L A T OR
REMOVE
1. 2. 3. 4. 5. Disconnect battery earth lead. Disconnect vacuum hose at the pressure regulator. Refer Fig. 6C-97. D epr essu rize fue l syst em as per 3. 2. D isco nn ect th e f ue l c c nnec t ions t c anC f r om t he pressurereg ula tor.Re f er Fig. 6C- 97. R emo ve reg ula tor mo unt ing nut on f uel r ail br ac k e t and remove regulator.Refer Fig. 6C-97.
RE IN S T ALL 1 2 lnstallation is reversal of removal. Check for fuel leaks as per instruction3.2.
Fi gure 6C -97
3 . 2 0C ON T R OL U N IT
REMOVE
'1 2 Make su re ig nitio n is s wit c hed ' oFF' and dr s c onnec t battery earth lead. Rem o ve the left h an d c c w c anel t r im f r om t he f r ont passe ng ercomp artm ent "as des c r ibed in Sec t ion 1A of t his Su pp leme nt.
ENGINE FUEL6C-43
3. Remove the two control unit mounting screws. Refer Fig.6C-98.
LE FT H AN D ----r.
H AR N ESS PLU G
/B MOU N TIN G B C -TS (2 P LA C E S T Figure 6C-98
4.
Disconnectthe wiring hamess plug from the control unit by pulling up tang and swing hamess out from control unit. Refer Fig. 6C-98A.
REINSTALL fnstallation is reversal of removal.
Figure 6C-98A
POSITION 3.21 THROTTLE SWITCH

REMOVE 1. 2. 3. 4. Disconnect battery earth lead. Disconnect wiring harness plug from throttle position switch. Remove vacuum fitting from manifold next to throttle position switch. Remove 2 mounting screws and withdraw switch from throttle shaft. Refer Fig. 6C-99. ii r/ / _ T H R OTTL E P o s tr to N S WI TC H
TH R OTTLE B OD Y
-i rl
REINSTALL
Installation is reverse of removal, however the following should be noted. Ensure that the f lat section of throttle shaft slides into the correct position inside the throttle switch. Refit vacuum fitting into manifold and check that the automatic transmission modulator pipe rs f itted securely into the vacuum fitting. Do not tighten mounting screws as switch must be adjusted.
f J N TI N G SCREWS
Figure 6C-99
ADJUSTMENT
1. The throttle position switch is to be positioned so that the closed throttle contacts open with the slightest throttle opening. lf the position of the switch is correct, a 'click' from within the switch is heard on opening the throttle.
6C.44ENGINEFUEL
2. lf t her e is n o'click', r ot at e t he s wit c h s light ly and then operate the throttle, continue adiusting the switch until the correct position is found. Reler F ig 6C-9 9A. 3. Check that the switch is not preventing the throttle butterfly from returning to its stop and tighten mounting screws. NoTE: The high load switching contacts are non adjustable and are automatically set when the closed throttle adjustment is made.
Figure 6C-99A
3.22 COOI-ANT TEMPERATURE SENSOR

R EPL ACE 1. Disconnect batteryearth lead. 2. Remove wiring harness connector from coolant temperature sensor.ReferFig 6G100. 3. Draincoolantfrom engineto belowsensorlevel. 4. Removesensorfrom cylinderhead. 5. ApplyGMH sealantP/N 3835214, to sensorthreads, refit into cylinderhead. 6. Refit harnessconnector. 7. Add coolantto radiator and check for leaks. O N EN GI NE T E S T The temperature reading and resistance shouldbe made beforeand after enginewarm up. Engine Cold 1. Disconnect batteryearth lead. 2. Disconnect wiring harness temperature sensor.
3.
Figure 6C-100
connector
from
Remove radiator cap, place a thermometer in the radiatorcoolant and read coolant temperature.
s.
5. 6.
Usrng an ohmmeter, measure the resistance across the terrninals of the temperature sensor. Refer F ig 6C-10 1. Connect wiring harness connector and battery earlh lead. w arm up e ng ine su ffic ient lyand t hen f ollow s t eps 1 t hru 4 . Che ck re su lt s wit h t he f ollowing c har t . lf results indicate suspect temperature sensor, perform the more accurate test below.
C OOLA N T TE MP E R A TU R E S E N S OR
Fi gure 6C -101
--
----
F UE L6C -45 ENGINE

OFF ENGINE TEST RemoveSensoras per steps 1 thru 4 tor replacement. With the temperaturesensor suspendedin a beaker of 50/50 glycol/water, record resistance across the ReferFig. 6C-102. at varioustemperatures. terminals Check the resultswith the followingchart.
Fi gure 6C -102
tI
RNT C
8000 6000 4000 3000 2000
1000 800 600 R E S IST ANCE 400 300 200
100
80 60 40 30
20
40
60
T E I \ 1 'E R A T U R E Figure 6C-103 lf, in either test, the resistance of the Sensorwith respect to coolant temperature is not as specified in the above graph the sensor is faultY.
01
6C.46ENGINE FUEL
3.23 CONTROL RELAY
REMOVE
1. Remove fuse box cover. Fig 6C-104.
F U S E B OX C OV E R
Figure 6C-104
2.
Pullout relayfrom its position. Ref er Fig. 6C- 105
REIN STALL Installation is reversal of removal.
Figure 6C-105
F UE L6C -47 ENGINE

4 . DI A G NO S I S
PROCEDURE TESTING 4.1 CIRCUIT
TEST FUEL INJECTION ELECTRONIC EQUIPMENT
A set of special equipment has been developed for diagnosing and testing the EFI system of VK Series vehicles. The set consists of an ignition diagnostic system (part no. SD28013) and a companion electronic fuel injection accessory kit (part no. SD280 14). Part Nos. SD28013 and SD28014 are marketed only as a set and are not available separately. The EFI accessory kit includes a fuel pressure gauge. The ignition diagnostic system on its own, serves aS an effective ignition tester. The ignition diagnostic system and the EFI accessory kit must be used together when testing the EFI system. Operating instructions for the ignition system tests and the EFI system tests are included as part of the test equiprnent package. Details on availability of the test equipment are obtainable from: General Motors-Holden's Sales Pty. Ltd. Service Division, Box 5 48 D, G PO , Me lbo ur ne3001. Australia. Should the recommended EFI test equipment not be available, the following material may be used for checking the Fuel Iniection System. 1. 12-volt, 2 watt test lamp with standard test probes. 2. Ohmmeter, measurement range 0 to 5000 ohms. 3. Tachometer. The cable harness plug must be separated from the control unit in order to test the cable harness and the engine sensors. Since the contact terminals on the plug strip are not marked, the contacts must be counted for the various tests. Te rmina ls 1 t hr ough 13 ar e loc at ed on t he l o n g t e r m i n a l strip; terminal 1 is next to the cable entrance. Refer Fig. 6C-1 05 A. Terminals 14 through 25 are on the shorter terminal strip. Refer Fig. 6C-105A. Terminal 14 is next to the cable entranceSome tests involve cranking the engine, therefore appropriate safety precautions must be observed.
25
14
13
MU LTI_P LU G TE R M \A LS
Fi gure 6C -105A
6C.48ENGINEFUEL
LU J
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E NG I NEF UEL 6 C - 4 9
Function or Component to be Tested Fue l p ump operatin g
Test With
re Measu Between Ter m ina l s
Test Status
lnd ication (correct) Test lamp lights l f p u m p r u n s ,i t can be heard.
l f D ef ecti ve
N otes
Tes t lam p | + and- on I f uel pum p
lgnition in crank p o si t i o n
Look for break i n cabl e harness or bl ow n fuse or faul ty rel ay.
runs but ergi ne w i l l not run creck fuel pres s ure anc \.c ;urne pumpe I'pum p aS P erS g' \' l C e I op.ra i ro- 3 13
Re layclo si ng
be lCan lhear d or , t es t lam p , Tes t lam P
Lis t ent o r elay . 87 and ear t h 30 and 31
lgnition :n i lcrank I Position Relay rernoved lgnitionon lgnition in crank

D O Si ttO r .
R e l a yc l i c k sw h e n C h e c k c ur r e n t activatec. supply wires t o r el a y. L a mP i ; g h t s

Lamp l i gnts B reak i n suppl y cr earth l eads to
tP /
R e f e r Fi g . 6 C 1 0 7
Batte ry su pply to rela y lgn ition swit c h sign al I Cra nk sig na
C h e c kfu si b l e link.
r Tes t lam p , Test lam p i
15 & ear th 50 & ear t h
Lamp lights Lump lights I j
B . e a<
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B r e a k r n c - '- : ^ : supply in sta:::: s o l e n o i dc i r c ui t . B r e a ki n l e a d f rom - coil t e r m i n a lo r f a u l t y i gn i t i o n s y s t e m

C h ec k ',: , brea k cabl n3-nass C heck rnj ec:o-s i ndi vi duatl v w i th ohmmete: va l ue 16 oh ms. R efe. F
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lr.t,
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1 & earth
Engine crankrng
Lannp f l i ckers aS ?nE ,n3 tU rnS
6C 108
Inje cto rvalv es an d wiring
Oh m m e te r
Cy l. 1 t hr u 3 Ter m . 12 & 9 Cy l. 4 t hr u 6 Ter m. 24 & 9
'
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A p p r o xi m a t el y lgnitionoff nect 3 to 4 ohms Di s c o n wrring p lS ugs har:^,eS a t ai . f ro r , r meter& arx, a i r v a l v e& throttle position switch. l g ni t i o n o n & in crank position L a r n pl i g h t s
R e f e r Fi g . 6 C 1C g R e f er Fi g . 6 C ' 10
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Lampf lickers brightlyinitially and dimswithin 10 s e c o n d s
C h:c< w ri ng for supci v si gnal s at ccntrol uni t connector. l f control uni t i s consi dered fau ty test i ts operat,or' on another veh'c e.
S u p p l y v o lta g e t o c o n t r o l u n it
T e st la m o
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l g n i t i o n r '. and in c-ark positicn
Lamp lights
R el ay def ect i r.'e C heck i or break n w i ri ng f'orn N o.9 term na C hec< for break n w i ri ng f rom batte-y suppl y, fusi bl e i i nk bl ow rr.
t,
6C-50ENGINE FUEL
F unction o r Component to be Tested Measure Between Ter m inals 9and5 9and 13 9and25
9and1
Test With
Test Status
Indication (correct)
Lamp l i ghts
l f D ef esti ve
Notes
C ont rol unit Te st la m p a nd systeme arth i I n it iat ion of i n ject ionim pu lse Test lam p
lgnit ion on and in c r an k pos it ion Operate starter br ief ly
Check for break l e a d s5 , 1 3 & 2 5 . C h e c kf o r b r e a k i n R efer wiring - ignition c o i l t e r m i n a lt o N o . 1 c o n n e c t o rt e r m . Faulty ingjtion system, C h e c kf o r b r e a k i n wiring between s t a r t e r& t e r m i n a l 5 0 o n r e l a y .B r e a k in wire from c o n n e c t o rt e r m . 4 to starter. C h e c kf o r b r e a k i n c a b l eh a r n e s s or replace throttle F o s i t r o ns w i t c h . 6C-1 1 1
Lamp f l i ckers
Sta rt s ignal f r o m sta rt er f or co n t r o l u nit

I I
Test lamp
4and5
Op e r a te star te r b r ie fly
Lamp lights
Test lamp will light only in crank mode. lf l a m p l i g h t sw i t h ignitionon, check why term. 50 has power. Refer Fig.6C-112 R e fe r F i g . 6 C - 1 13
O perat iono f id le ' O h m m ete r contactsin t h rot t le valve switch
2 ano 9
lgnit ion of f Ac c eler ato r peda I in id l e pos it ion
0 ohms approx.
Ac c eler at o r pedals ligh t l y ccoh ms depr es s ed

O perat ion o f f u l ' l o ad c ont act s i n th r ot t le v alv e body O h m m e:3 r
3 anc 9
lg n r t:o r , o f f Acce le .a to r' p e d a l ir id l e Po sr tr o n Acce le - a to r p e d a ' fu lly d e p r e sse d
cc ohms
C h e c kf o r b r e a k i n ,r c a b l e h a r n e s so r e p l a c et h r o t t l e p o s i t r o ns w i t c h .
R ef er F i q. 6C - 114
0 ohms approx.
C oolant t e mperatu re n sor se
O h r n m te r
1C anC 5
lg n itio n o ff
Breakin cabfe harness or replace 0'C - 5500 ohms tem perature zO'C-2450ohms s e n s o r
Temoerai ure oepentant
8O"C-320 ohms 97'C- 200 ohms

A r f low me t e r
Ohmmet er
7and5
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- v!
lf the resistance i s B - e a <a i d o r s h o r t R e f e r F i g . 6 C - 11 6 a t a n y v a l u eo t h e ' c , r s s , 1 n c a b l e t h a n 0 o r i n f i n i t v h a - n e s sA . rr flow

the ai r fl ow
i s OK .
Lamp
rne:3r sensor oefE ct r ve, C neck for breaks i n auxi i i ary ai r val ve ear:h and vol tage s.rppl y w i ri ng.
Aux il; ary air va l v e c irc uit
T e s t l am p
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Rem ov eplug f r om aux . air v alv em eas ur e l ac r os s t.rtr. I of v alv e I

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ENGINEF UE L6C .6 1
4.2 TROUBLEDIAGNOSIS
The LE-2 Fuel InjectionSystem can be checkedwith the is found in any cornponent, following.lf any abnormality refer to the testing procedures in the 'Circuit Testing in this Supplernent. Procedure' or 'ServiceOperations' Beforeattemptingany test, check the followingitems. 1. Check all wiring hamess connections to all components, particularlythe 25 pin connector on the control unil, the air flow rneterconnectorand coolant temperature sensorconnector.
Make sure the ignition and starting systems are in good order 3. The LE-2 system accurately meters the inlet air flow so any air leak can cause an improper air-fuel ratio, resulting in taulty engrne operation. NOTE: when connecting or disconnecting harness connections, ensure that the ignition switch is 'OFF' and the negative battery terminal is drsconnected. Failure to do so will damage the control unit. 2.
EngineCondition
Possible Cause
En gin e
Fault y ig n itio n sYStem, Fault y f uel pum p ope r a t i o n .
high tensiori Disconnect a n d c h e c kf o r s p a r k ,
sp a r k
C h e c ke l e c t r i c a lc o n n e c t i o n s . R e n i c v es t a r t e rm o t o r s o l e n o i dw 'i t ?zi -I :* 'n i g r '', i t r o l t o " S T A R T , " p u m p a c t i o n sh o u c o e n e a r d . C n e c kf u e l c r 3 s s u r e a n d v o l u m e p u r np e c C h e c k i g n i t o 1 rs i g n a li n p u t . C h e c kt h e o p e : a t , o no f r e l a y . C h e c ke a c h c i r c urt
lm pr oper ignit ion s ig n a li n p u t . Pr obr emin t he f ollow i n g c i r c u i t s : c ooiant t em per a t u r es e n s o r . Air f low s ens or . Fuel in jec t or s . Cont r ol u n it . No f uel - t ank em pty . En gin ef lo oded, spa rk p lug swet . Eng inesta rt s ,t hen sta lls circuit sensor open c oolant t em pe r a t u r e E'Fl system. G oesf ully r ic h. Fault y ignit ion s igna l: n p u t . Fuel pum p not f unc t o n i n g c o r r e c t l y .
C h e c k c i r c ui t a n d c o n n e c t o n s . f a ui t y s e n s o ri f p r o v e dd e f ecti v Replace e
C heck i gni ti on s gna l rnput. C heck el ectri ca, connecti ons at fuel purnp C heck operati on cf cor-trol rel ay. C heck fuel pump p'essure and vol ume purnped. C heck ci rcui ts and ccrnponent opera ti or^. S tart engi ne (col d), pi nch the hose w h c h l eads 'rom the ai r val ve to behi nd the thro tti e body . R esul ts: It i dl e speed drops, perf orm c .c u i t tes t. -') l f i dl e speed remai ns hi gh or unst abl e, perf orrn th e f ol l ow i ng checks : C heck for mani fol d vacuum ,eak s , i f no probl em i s found, perform the f ol l ow i ng c i rcu i t tests : Throttl e posi ti on srvi tch (i dl e c ontac t and ful l l oad contact). C ontrol uni t ground ci rcui t. A i r f l ow meter potenti ometer. A i r regul ator and fuel pump c i rc ul t. A i r regul ator ci rcui t. C ontrol u n i t pow er i n put c i rc u i t. In j ector ci rcu i t.
Fault y c oolant t em p e r a t u re or air f low s ens orc ir c uit s . lre. M alf unc t ioningaux i li a r y a ir i , 'a
FUEL 6C.62ENGINE
E ngineC on ditio n Enqine M isfire s Po s s ible Caus e Fa ult y ignit ions y s t em . FueI bl oc k age. Checks
C h e c k i g ni t i o n s y s t e m . C h e c kf u e l l i n e f o r b l o c k a g e s in: Tank filter Fuelfilter Fuel pipes F u e l i nj e c t o r s Drain tank and lines. Perform fuel pressure test. check all connectors f o r l o o s e n e so sr c o r r o s i o n , i n c l u d in g e a r t h c i r c u i t s . C h e c kc o n t r o l r e l a yo p e r a t i o n . P e r fo r m c i r c ui t t e s t . C h e c k i nj e c t o r so p e r a t i o n . T r y a n o t h e rc o n t r o l u n i t . Check ignitionsystem. M a k e s u r et h r o t t l e b u t t e r f l y not,amming. o p e n i n gf u l l y a n d
Wat er in f uel. ue. Lo w f uel pr es s r Lo os eHar nes s c onnec t or s . lmpr oper c ont r o r eiay o per at ion. Fa ult y EFlc ir c u : De fec t iv e injec t o' v ar v es . Malfunc t ioninoc ont r ol unit . Eng ne lacks p owe r Fault y ignr t o^ s , / s t em . Malf unc t ion ng r n t hr ot t le v alv e bod y . fu laif unc t ion in air f low m et er Fuet bloc k age.
C h e c k a i r f l o w f l a p m o v e m e n t . C h e c kt h a t o p e n ss m o o t h l y a n d f u l l y . C h e c kf u e l l i n e f o r b l o c k a g e s in: Tank filter Fuelfilter F u e l p ip e s F u e l i nj e c t o r s C h e c k e l e m e n tc o n d i t i o n . C h e c k e n g i n ec o m p r e s s i o n s . C h e c k s w i t c h o p e r a t i o na n d w i r , n g P e r fo r m f u e l p r e s s u r e test. C h e c k e a c hc i r c u i t . P e r f o r mc o m p o n e n tc h e c k s wh ere necessary.
Blo c k edo, r t t er . Poor enginec ondit ion. Chec k c i' c u it s in t hr ot t le pos it ion s w i t c h . LOw f ue, pr es s ur e. Pr oblem r n t he f ollowing c ir c uit s : Air and c oolantt em per at ur es e n s o r s . Fuel pum p. Air f low m et er . Thr ot t le pos it ions wit c h c ont ac t s . lgnit ion c oi I t o c ont r ol r elay . Cont r ol ur ' : power input c ir c ui t . I njec t or c - c u t . Engine sur g e
M a ffu n ctio n r ' g a ir flo w m e te r . I n t a ke a ir lsa ka g e a t th e fo llo win g M a n ' c d g a ske ts. A . t cr l r r r e te r h o se s. lmp'o3e' f u e l p r e ssu r e . cc r)tsl
C h e c k a i r f l o u ; m e r e r m e c h a n i c am l ovement. U s i n ga f i n g e r ,c n e c k f l a p m o v e m e n tf o r s m o o t f ' o p e r a t i o n . C n e c kf o r i n t a k e a i r l e a k s . ruet p.essure P e r t o . '^ n test. C h e c k 'c r c c r e c t v a c u u mh o s ec o n n e c t i o n s i g " l t i o n C , s t rb ';u t o r o p e r a t i o n . Check EGR operation. C n e c k e a c nc i r c u i t . T h e n p r o c e e dl c c o m p o n e n t checks.
N c ' a cu u m a d va n ce . F o -' i' r , EG R syste m . P r ob le r n n th e fo llo win g cir cu is: T h r o tiie p o sitio n switch , d le contact a n d fu il lo a d co n ta ct. Air f lo u .,m e te r . Co n tr o l u n it cir cu it. Air te m p e r a tu r e se n so r . Co o la n t te m p e r a tu ' e se ^ s3 r . Au xilia r y a ir va lve cir cu i lg n itio n co il to co n tr o l r e a y. Co n tr o l u n it p o we r in p u t o r cu it . I n je cto r c ir cu it.
ENGINE FUEL6C-63
E ngine Condition PossibleCause Checks
F lat spo t o n acce lera tion
lm pr oper r gnit ion s y st e m . M alfunc t ioningair f low m e t e r . I nt ak e air leak age at f o l l o w i n g p o i n t s . M anif old gas k et s . Air f low m et er ho s e s . lm pr oper f uel pr es s ur e . lm pr oper EFf c ir c uit . EG R s y s t em .
C h e c k i g n i t i o ns y s t e ma n d v a c u u r r a i ',,a n ce signal. l o v em e n : C h e c ka i r f l o w m e t e r m e c h a n i c a n U s i n ga f i n g e r ,c h e c k f o r s m o o t h f r a p mo ! e - e - : C h e c kf o r i n t a k ea i r l e a k s .
P eri orm fuel pressure test. P er+crrn compl ete ci rcui t test, then p e r fo r m ccmpcnerl ts cteck. l nccrrec:,tac -rrn hose connecti ons. E GR ooe'a: o-
C h e ck
pe t r ol Excessive con su mptio nCO rea din g h ig h
lm p r o p e r ig n itio n tim ing or i gni ti on system.
lm pr oper air c leanerf i i t e . r e, lm pr oper f uel pr es s u : Pr oblemin t he f ollow i n g c i r c u : t s Coolant t em per a t u r es e n s o r . Ai r tem perature sensor , Th r ot t le pos it ion s w i t c h , i d l e c o n t a c : and f ull load c ont a c t . Air f low m et er . Aux iliar y air v alve . Fuel pum p c ir c ur t . I njec t or c ir c uit s . Cont r ol unit def ec t ive ,
C heck i gn rtrcr : - - i a- d 'vacuum advanc e s i gnal . C heck i gni ti on syS i 3- ':- .ct spark. C heck ai r cl eaner f rte' a-c'?: 3Je :f n ec es s ary . P erform fuel pressure tes'.
C h e c ke a c hc i r c u i t , t h e n p r o c e : c I check.
::-3 f , ^ e n t
C heck operati on of good u n i t.
uni t, w i th a k now n
Difficult to s t ar t a fter sta ndin g h ot
FueI s y s t emn o t h o ld ing pressu'e a i ow ,nc f uel t o boil in in je cto r s w hen engi ne s iopped.
Fueipressure s t a y sa t 2 5 0 - 2 0 k P af o r t h o u r a fte r e ^ g ^ e s t o p p e d .L e a k i n gv 3 r r si n p r e ssu r e r e g u i a to r r o r ; u e c u 'l r p . L o o s ef u e l p c e c o n n e cti o n s,
ld le sp e e d to o L o w. Eng inestallswhen re turn ingto idle f r om t small thro ttle opening
Fue l pu mp nois y 1. Und er ve r y hot co nd ition s 2. Un de r n or m aI co nd itron s
Aer at edf uel due t o lo v vf u e l l e v e li n t a n k c om bined wit h v er y n c t f u el . Filt er on f uel pic k up i r : i a n K r e s t r r c t e d . Rearf uel dam per inop e r a t i v e . j-,,e Rubber m ount ing c us h i o n so n c-mp br ac k etdef ec t iv e. Pum p wor n out .
N u scti on requi rec f qui et -nder norm al ccncj i ti ons. Wi l i nc: damag: pump. R ernove sender uni t i .or-r ta ^ k and cl ean f i l ter R ep ace damper. R eca - pump mounti ng system. R ep ace fuel pump.
6C.64 ENGINEFUEL 5. SPECIFICATIONS

Air Flow System Components: Air Flow Meter: No mina l air flo w A ux iliary Air Va lve : Air flo w Ave rag e time to s hut at +20 oC a nd 1 4 v olt s Nomin al resis t anc e Leakage Fuel S ection : F uei Pu mp: Flo w ca pa city F uel Pre ssure : At idle pedal The moment the accelerator (zero enginevacuum) is depressed F uel Filter: Flow rate Pressu re dro p . . Filter are a po re s iz e Ave rag e Injector: Static f low Dynamic flow . Permissable leakage P ressure Re gu lato r: Fu el p ressu re 3 0 3 k P a = 6 k P a a t 4 }l / h r w i t h r e g u l a r o rv a c u u m connecilon open to atmosphere. 185 cm3 /min = 3orc at 303 kpa 4.38 cm3 /1000 strokest 3% at aboveatmosphencpressure 0.015 cm3 /min at 303 kPa aboveatmosphencpressure (1 drop/min) 1.5 l/hr 10 kpa maximum at 120 llhr 3000 cm2 8 - 10 micro metre 250 kPa 300 kPa minimum 130 l/hr at 12 voltsand 303 kPa pressure 17 ! 2 m3/hr 4 minutes 30 - 40 ohms 1.0 m3 /hr (maximum with slotted disc closed) 500 m3/hr
El ec t ric al S e c t i o n :
Control Unil Calib rat ionSum m ar y : Ba se ca blib ration. . . . . . . Warm-upenrichmentfactor After start enrichmentfactor Cold start injection pulse Acceleratorenrichment{actor . Full loa d e nric hm enrf ac t or . Fue l cut off on dec ee: ar ion Coolant TemperatureSensor : Temp era rure oc . . . Re sistan ce k oh m s F uel Pu mp Co ntro ' R e ay " Hold in vo ltag eat t e' r ninal No. 15 . . . Ho ld in ign ition pu s esai t er m inalNo. l Throttle PositionSwitch: ld le co nta ct o peningangr e ld le co nta ct clos ingangle Fu ll lo ad co nta c t c los ingangle ldle sp ee dat n orma l o per at ingt em per ar ur e run-in en gin e ldle mixture a t n orm al aper at ingt em per at ur e run-in en gin e .
3.4milliseconds I .2 at ZOoC 1.7 at OoC 16 millisecondsar OoC 1.3 below 50oC 8Yo increase U n t i l 18 0 0 r o m -l0ll 8.26 - 10.56 5.5 volts minrrnur,. 150 rpm min mum l.0o from dle end oosition 0.2o from dle end position 4 0 "! 2 f r o m : d e e n d o o s i t i o n g50 t 50 rom .5 - 1.b%CO - 2 0 =j 2.28 - 2.72
-gor1 0.290 - 0.364
ENGINEFUEL 6C.65 SPECIFICATIONS 6. TORQUEWRENCH

Nm
I nlet M anif old M oun t i n g N u t s Ex haus t Ex t r ac t or M o u n t i n g B o l t s a n d N u t s EG R M ount ing Bolt s E G R Feed Pipet o I n l e t M a ni f o l d B oIt s EG R Feed Pipet o M a n i f o l d N u t s , I nlet M anif old Br ac eB o l t I nlet M anif old Br ac eN u t t o C y l i n d e r H e a d S t u d . Fuel Rail M ount ing B o l t s lat or M o u n t i n g N u t Regu Pr es s ur e laio. F u e l L i n e G l a n d N u t s Regu Pr es s ur e Fuel Ret ur n Line Br a c k e tt o R o c k e r C o v e r B o l t Fuel Ret ur n Line Br a c k e tt o S i d e P l a t eB o l t A; r CleanerHous ingM o u n t i n g N u t s A r Duc t t o Suppor t B r a c k e t B o l t Thr ot t le Body M oun t n g N u t s Thr ot t le CableLoc k N u t s , F uel Pum p Suppor t B r a c k e t N u t s Fuel Pum p I ns ulat o r s Rear Fuel Clam perM o u n t i n g N u t M ou nt ing Plat ef or S u p p o r t B r a c k e tB o l t s Fuel Filt er Suppor t B r a c k e t N u t s . Thr ot t le Valv eSwit ch M o u n t i n g S c r e w s F - . r el Pipe Hos eClam p s Air Flow M et er M ou n t i n g B o l t s Ai r F low M et er Har n e s sR e t a i n e rB o l t
41-48 41-48 20-25 20-25 27 -36 20 -25 20-25 2A -27 25-30 25-30 8 - 10.6 4 - 10 8 - 10.6 20-27 8 - 10.6
a4 z-.+
15-25 15 - 25 15-25 15-25 3-4 1 - 1.5 1 8-11 20-27
6 C-66 EN GIN E FU E L 7. SPECIAL TOOLS
E NG I NEF UEL 6 C .6 7
(3.3 EST) CARBURETTOR

INDEX
Ref. 1. 1.1 2. 2.1
Page Subject 6C7 .......r...................-.. DESCRIPTION GENERAL 6C-67 ..................-........................... CARBURETTOR 6C8 OPERATIONS.................. MINORSERVICE 'ON ADJUSTMENTS CARBURETTOR 6C8 VE H I C LEt ...............................................r.....r.... 6C8 ChOkg OperatiOn ..'...t......................-.... 6C8 ldlg Speed Adjustment........................ 6C8 Fast ldlg Adjustment..r......................... THROTTLE POSITION SWITCH 6C-68 ADJ USTM ENT ....................................t.......t....r 6C-70 MAJOR SERVICEOPERAT1ONS..................
Ref. 3.1
2.2
4. 5. 6. 7.
Page Subject CARBURETTOR ...........................................o.. 6C-70 Rem OV......................................o............. 6C'70 6C-70 Disassemb1y..............................r...... 6C-72 ChgCkS .........................................'....o..... 6C-73 ReaSSgmbly............................................ AdjustmgJlt.......o...................................... 6C-75 ...!.r.............. RginStall ...-.............. 6C'79 DIAGNOSIS .............r.,.........r.......r.....r............r. 6C0 SPECIFICATIONS ..........................,............o...r 6C-85 TOROUE WRENCH SPECIFICATIONS........ 6C.86 6C'86 SPECIAL TOOLS .........................-..........-.......
3.3 litre VK The fuel system emPloyedon carburettored Series enginesis similarto VH 3.3 litre models,except
for revisions tc the Varajet ll carburettor as noted rn tftis Section.
1.1 CARBURETTOR
The carburettor used on VK is a Varalet ll. Differences betyveen VH and VK models include, new float bowl design, deletion of the spark advance signal port and a high mass choke coil which holds the choke valve open foi longer periods after the vehicle is switched off. There is also the addition of a delay valve in the choke vacuum break hose, to aid in quicker starting and a revised secondary air valve restraint mechanism (Refer No. 60, Fig. 6C-1 21). A throttle position switch has been added to the carburettor and is mounted on the air horn, refer has lever The accelerator pump Fig. 6C- 117. inCorporated a lever which actuates the throttle position switch. For throttle position switch operation refer to Section 6D, lgnition System, of this Supplement. The internal calibration has been changed to suit the characteristics o{ the 3.3 litre EST engine. Calibration details are listed in the Specifications at the end of this Section. WARNING: TO AVOID THE POSSIBILITY OF ALTE' RING THE CERTIFIED EMISSION CONTROL SETTING OF THE CARBURETTOR, NO MAJOR SERVICE OPER. ATIONS MAY BE CARRIED OUT ON IT DURING THE EARLY LIFE OF THE VEHICLE EXCEPT FOR RE. MOVAL AND INSTALLATION. THE EXTENT OF THE WORK WHICH MAY BE CARRI. ED OUT ON VEHICLES WHICH HAVE COVERED LESS KM IS SET OUT IN THE 'MINOR SER. THAN 8O,OOO VICE OPERATIONS.' IF THIS IS INSUFFICIENT, THE CARBURETTOR MUST BE REPLACED.
'\ P OS TTTON S W ITC H Fl gure 6C -117
6 C . 68 ENGIN E FU E L
2. MINORSERVICE OPERATIONS
2.1 CARBURETTOR ADJUSTMENTS'ON VEHICLE'
CHOKEOPERATION NOTE:
Ensure cover index is set to specification, refer Fig. 6C-118 and specificationsat the end of this Section. b. Engine temperature must be within 5 oC of arnbient temperature. 1. Remove air cleaner and open and close throttle to set choke. 2. Switch ignition on. Do not start engine. 3. Depress and release the choke butterfly to enable the position of the control spring to be determined. The choke should be fully open withrn two to five minut es. lf the choke does not perform to specification,check for binding or stuck choke valve or linkage. lf necessary, replace choke cover and bi-metallic coil assembly. a.
Flgure 6C-118
IDLE SPEED ADJUSTMENT 1. Ensuresparkplugsare correctly gapped. 2. Ensure engine is at normal operatingtemperature. (Drive 10 kms or idle engine for 15 minutes or more.) 3. Ensurechoke is fullyopen. NoTE: The throttlepositionswitch must be closed. 4. Ensurethrottlecable is adjustedcorrectly. 5. Ensuretransmission is in Neutralor Park. 6. Ensure air conditioning is OFF. 7. Adjust mixture by-pass adjusting' screw (shown in Fig. 6C-1 19) to set idle to specification. WARNING: To MAINTAIN DESIGNED EMtsstoN LEVELS, DO NOT ADJUST IDLE STOP SCREW OR IDLE MIXTURE SCREW.
Fl gure 6G119
FAST IDLE ADJUSTMENT 1. Engineat operating temperature. plug vacuumhoseto air preheat 2- Removeair cleaner" sensor. 3. Start engine. 4. Throttlepositionswitchmust be closed. NOTE: The throttle positionswitch may be simulatedin the closed positron by removing both electrical conne'ctorsfrom the switch and connectingthem together with a bridgewire. 5- with fast idle screw on lowest step of fast rdle cam as shownin Fig. 6c-120,enginespeedshouldbe to specification. Adgust fast idrescrewif necessary.
FA S T ID LE CAM
LOWEST STEP
I D LE A D JU S T SCREW
Flgure 6C-120
2.2 THROTTLE POSITION SWITCH ADJUSTMENJ'

Fol adjustrnent instructions,refer to service operation 2.7 in section 6D, lgnition system of this Supplement.
ENGINEFUEL 6C-69
F-to
66
fr -u I
471 pl
v
Vj
/14 -t-\
43 -'/
w -,>;)
6
d-':li
tfu
,t-
35
l
t. .t
36 enA yv ff_r,
N E X TP A G EF O RL EGEN D REFER
Fi gure 6C -121
6C.70ENGINE FUEL
L EG EN D F OR F IGU R E 6 C -1 2 1 1. R e t a i n e r to va cu u m b ra ke s cr ew 2 . Ba f f l e f la p sh a ft 3 . N e e d l e r e ta i n e r 2 n d sta g e 4. A i r h o r n ve n t scre e n a n d retainer 5 . B a f f l e f la p 6. B a f f l e f la p scre w 7. C h o k e va l ve 8. C h o k e va l ve scre w 9 . Ai r h o r n to fl o a t b o wl screw 1 0 . A i r h o r n to fl o a t b o wt screw 1 1 . Ai r h o r n a sse mb l y 1 2 . Pu m p l e ve r a n d scre w a sse rnbly 1 3 . Ai r h o r n to f i o a : b o w i g a sket 1 4 . F l o a t p r vo t i n se rl 1 5 . Pu m p p i srcn a sse mb l y 16. F l o a t r eta ,7 '1 gp r ro 1 7 . F l o a t a n c re ve r a sse mb l y 18. F l o a : i e ve - to n e e d l e cl i p 19. F l o a r n e e d ,e va i ve a n d se a t assem bly 2 0 . F i o a t n e e d re va l ve se a t se a l 21 . Pu m p i nl e t b a l l 22. P i s t o n c u p 2 3 . P i s t o n r etu rn sp ri n g 24. 25. 26. 27. 28. 29. 30. r etai ner i nl et f i l ter f i l te. f l ar e nut s pr i ng batl M ixtur e bypass s c r ew and s eal as m . M ixtur e bypass s eal Dischar ge pur np Car bur ettor f uel Car bur ettor f uel Dischar ge pum p Dischar ge pum p 46. 47 . 48 . 49. 50. 51 . 52. 53. 54. 55, 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. F l oat bow l M eter i ng pr i m ar y j et Pow er pi s ton s p r i ng Pow er pi s ton as s em bl y M eter i ng pr i m ar y r od and s pr i ng as m . C hok e l i nk c am end c l i p C hok e l i nk c am end bus h F as t i dl e c am to c hok e l i nk C hok e s haft C hok e l ev er C hok e l i nk c l i p C hok e l i nk bus h C oi i c ontac t s l eev e C hok e l ev er bus h Sec ondar y s haft s pr i ng Vac uur n br eak hos e C hok e c ov er and ther m os tat r etai ner Vac uum br eak hous i ng and s tem as m . C ov er and ther m os tat as s em br y Vac uum br eak del ay v al v e T h r ottl e pos r r i on s w i tc h Br ac k et
32. Float bcwl to thr ottl e body gas k et 33. Ant r d ieseling sol enoi d 34. Pum p iink 35. ldr e needle scr e w and s eal as s em bl y 36. ld,s nedle seal 37 . Thr ottle body to f l oat bow t s c r ew 38. Secondar y dr ive s pr i ng 39. Pr imar y thr ottle l ev er 40. Fast idle scr ew a nd s pr ng as s em bl y 41 . Thr ottle body 42. Basic idle scr ew and s pnng as s em bl y 43. Fast idle cam r e tai ner 44. Fast idle cam as s em bi v 45. Fast idle cam oiv ot
3. MAJORSERVICEOPERATIONS
3.1 CARBURETTOR
REMOVE 1. Disconnect batteryearth cable. 2. Removewing nut holdingair cleanerand removeair cleaner. 3. Disconnect electrical leads, fuel line and vacuum hosesfrom carburettor. 4. Remove throttle linkage and cable assembly from bracket. 5. Remove carburetlor to mount nuts and remove carburettor.
DISASSEMBLY
1. 2. Remove fuel line flare nut and filter. Remove anti-dieselingsolenoid. Remove vacuum hose from throttle body and rernove the three screws from choke retaining ring. Remove choke cover and vacuum break dssembly (Fig. 6C-1zz).
Figure 6C-122
----
ENGINEF UEL 6C .71

Press off securingclip and withdrawchoke valve link from fast idle cam slot (Fig. 6C-123). 4 . Rernove pivot screw from acceleratorpump actuatrng lever. 5. Unscrew two short and four long retaining screws and remove air horn and throttle position switch Gasketremainson float bowl. assembly. pump is spring loaded. NOTE: The accelerator NOTE: Do not rest air horn on protudingtubes. 3.
Figure 6C-123
6. 7.
(Fig. 6C-124). Remove acceleratorpump assembly Remove gasket.
Figure 6C-124
8.
Remove power piston assemblyusing a patr of side as a fulcrum(Fig. 6C-125\ cutters and screwdriver NOTE: Prefcrredmethod is to 'flick' the piston down and allow the spring to hammer againstthe plastic retaining sleeve. This is repeated untit the assembly can be removed. IANG DO NOr LEVER UF CN HORTZONTAL CAUTIOAT: ABOVE POWER P'SION ASSEMBLY. GRIP POWER P/S7'ON ACHOSS INDENIAT/ONS /N BODY, ABOVE PLAST/C/NSEFI.
Figure 6C-125
9.
Remove f loat pivot insert and float assembly tFig. 6C-126) remove seat and seal. 10. Using a suitablescrewdriver,
ai|r
Fi g u re 6C - 126
6C.72ENGINEFUEL
1 1. Using a suitable screwdriver, remove (F.g. 6G1 27). main iet
Figure 6C-127
12. Remove four screws accessiblefrom undersideof carburettorand separatethrottfe body assemblyfrom float bowl assembly(Fig. 6C-128).
Figure 5C- 128
CHECKS Clean all parts in suitable cleaning fluid. Blow dry with compressed au. Jets and ports should be blown dry in normaldirection of flow. All mating surfaces should be cleaned and checked to ensurethere are no imperfections. With float bowl upright, fill pump area with fuel. Check that fuel level does not drop. lf fuel is escaping, blow check ball passagesout with compressedair. Check main meteringrod. Ensure rod is conect unit, see specifications. Replaceif necessary. Check throttle body finkage for freedom of movement. Ensure there is no binding of throttle valves (Fig.6C-12s).
Figure 6C-129
ENGINE F UEL6C -73

REASSEMBLY Ensure float bowl assembly. 1. Placegasket on inverted gasket is correctly located. Place throttle body assemblyover gasket and retain with four screws. (Fig. 6C-130). linkageoperation Re-check
Figure 6C-130
2. 3.
reinstall needle valve Using a suitable screwdriver, seat and sealingring. Using suitable screwdriver, reinstall main iet (Fig.6C-131).
Fi gure 6C - 131
4.
Reinstall power piston and primary metenng rod assembly. Remember spring under power Piston (Fig.6C-132).
Figure 6C-132
5.
Hook float needle valve on float arm, Reinstallfloat (Fig. 6G133). and needlevalve assembly
Fi gure 6C - 133
6C.74ENGINEFUEL
6. Hold needlevalve actuatingarm as shown and push down until valve rests on seat. Distancefrom top of f loat to top face of float bowl should be to (Fig. 6C-1 specification 34).
Figure 6C- 134
Adjustif necessary by bending arm (Fig. 6G13S).
7.
Reinstallfloat pivot insert. Reinstallgasket in correct orientation.

Figure 6C- 135
8.
(Fig.6C-136). pumpassembly Reinstall accelerator
FiEure 6C-136 9.
Reinstall air horn assembly ensuring accelerator pump push rod passes throughcorrect hole in air horn and gasketis correcilyseated(Fig. 6C-197). 10. Reinstall pump actuating accelerator linkageon lever and reinstall pivot screw. Reinstallthrottle position switchto air horn.
Figure 6C- 137
F UE L6C .75 ENGINE

11. Reinstallchoke valve link into fast idle cam slot. Ensure plastic sleeve is in place. Replace securing clip (Fig.6C-138).
Fi gure 6C -138
12. Reinstallvacuum break assemblyand choke cover. Ensurechoke spring correctlyengageschoke actuating lever. Screw retainingring in place, ensuring arow on choke cover pointsto specifiedindex mark (Fig.6C-13e). vacuumhose. Reinstall 13. Reinstallfilter, fuel inlet flare nut and antidieseling solenoid.
Figure 6C-139
ADJUSTMENT Wide Open Throttle

Hold fast idle cam down and open throttlecompletely - ensure2nd stage valve is open as well. 2. Measure clearance between tang on intermediate lever and spring end. Bend tang on intermediate lever to adjust (Fig. 6C-140).Check Specifications sectionfor measurement.
1.
^-C YJ
SEC OIJ D AR Y
900 PR IM A R Y
\
tr
-_-L
PR IM AR Y
C VER D R IVE
Fi gure 6C - 140
FUEL 6C.76ENGINE
Secondary Throttle Opening 1. Open prirnary valve, ensuring secondary valve remainsclosed (lock engaged). 2. Measure clearance between tang on secondary throttle lever and intermediatelever. Bend tang on secondarythrottle lever to adjust (Fig. 6C-141).See for measurement. specifications
C LOS IN G FOR C E B E N D TA N G TO A D JU S T S E C ON D TH R OTTLE C LOS E D
Figure 6C-141
Secondary Closing Setting 1. ldle stop lever against slow idle stop screw (Fi g .6C- 142) . Movement of secondary throttle valve should be to specification. Bend tang on intermediate lever to adjust.
ID LE ST OP LEVER AG AIN ST BASIC ID LE SC R EW
FU LL C LOS E D P OS ITIONr
OP E NIN G FOR C E B E N D TA N G TC A D JU S T_
Fi gure 6C -142
VacuumBreak Settings 1. Choke Setting.

a. b. Set the automatic choke to closed. Remove vacuum hose to vacuum break unil (Fig. 6C-143). Use hand vacuum pump J2393701 or equivalant to apply vacuum to vacuum break unit to fullv retract stem.
Figure 6C- 143
ENGINE FUEL 6C.77

Distance between choke valve and carburettor wall (Fig. 6C-144). should be to specification Adjustby turningscrew 'B' (Fig. 6C-144). NOTE: This adjustmentshould be perforrnedin conjunction with 'Air Valve Setting' below. (Remember that interferencebetween air vafve lever and vacuum break stem will affect travel of vacuum break stem.) Lock stop screw with paint after adjustment.
.\,
Fi gure 6C -144
2.
Air Valve Setting to apply vacuumto or equivalent a. Use J23987-01 break unit. b. Clearancebetween air valve lever and vacuum break stem should be to specification (Fig.6C-145). c. Bend tang to adjust.
V A C U U T\4 B R E A K S TE M FU LL IN _ WITH V A C U U M A P P LIE D
A IR V ALV E FU LL C LOS E D
Figu;'e 6C- 145
FUEL 6 C-7 8ENG I NE

Second Step Setting With choke coil cold (ambienttemperature), ensure fast idle screw is seated on second highest or 2nd step of cam (Fag. 6C-146). With light pressure applied on choke valve, clearance between valve and carburettor throat should be to specification.
C H OK E V A LV E
OPENING FORCE oN--1 cHoKE VALVE \
r\
cLostNG FoRcEoN c H O K Ec o I L L E V E R
--
T O P O R F IR ST J
Fi gure 6C - 146
Bend choke link to adjust (bendingincreases clearance, reducesclearance). straightening See Fig. 6C-.,147.
Figure 6C-147
Wide Open Kick Setting

1. 2. 3. Choke valve held closed. Primary throttle lever held fully open. Push choke valve against kick lever to remove backlash. Dimension A, choke valve to carburettor throat clearance, should be to specification (Frg. 6C-148). Bend lever on fast idle cam to adjust. NOTE: Secondary throttle lockout lever must be fully engaged in tang on interrnediate lever.
,s3--.,_J
C LOS IN G FOR C E ON C H OK E C OIL LE V E R . OP E N IN G FOR C E ON C H OK E LE V E R . P R IMA R Y TH R OTTLE WID E OP E N . Figure 6C-148
FUEL6C.79 ENGINE
Secondary Lockout Lever Rotation 1. Choke controlleverheld fully open (use elasticband choke closingforce.) to overcomeautomatic Clearancebetweensecondarylockout lever and tang on specification intermediate lever should be to (Fig.6C-14e). lf dimension is inconect, check 'Secondary Lockout Setting'below.
C H OK E FU LL H OTT
Figure 6C- 149
Secondary Lockout Setting 1. Chokecontrolleverclosed. throttleleverwide open' 2. Primary 3. secondary lockout lever fully engaged. secondary throttle valve should have clearance as specified (Fig.6C-1s0). valve leverto adiust. Bend tang on secondary
r v- r J1 n
/v 4
,r h . PL -
S E C OND A R Y TH R OTTLE V A LV E FU LL C LOS E D P OS ITION ,A '
S E C. LOC K OU T E N G A GE D
P R IMA R Y TH R OTTLE R OTA TE D TO WID E OP E N
Fi gure 6C -150
Accelerator PumP
1. 2. Throttle closed, carburettor set 10r idle, choke held off slowly depress accelerator pump plunger until secondary spring resistance is felt. The distance travelled from reit position should be to specifications (Fig. 6 G 151) Bend pump arm to adiust (at B). Readjust throttle position switch if pump-arm is bent' Refei to Section 6D of this Supplement for details'
3. 4.
REINSTALL
1. 2. 3. 4. 5. Clean all mating surfaces. Take care that material does not fall into manifold. Using new gasket, install carburettor.Torque nuts to specification. Reinstallfuel line, electricalleads and vacuum hoses' Reinstallair cleaner.Torque nut to specification' Install air pre-heat, engine ventilation and vacuum hoses on air cleaner.
Fi gure 6C '1 51
FUEL 6C-80ENGINE 4. DIAGNOSIS

The following DiagnosisCharts rnust not be taken as approval to carry out major operationson vehicles with less than 80,000 kms.
ENG I NE CRA N K S _ N O S T A R T
N O S TART COL D
N O S TA R T H OT
CORRECT ST ART ING EROCEDUREUSED ST I L L NO ST ART
U S E P R OP E R i S TA R TIN G P R OC E D U R E I
LI
C OR R E C T S TA R TI N G P R OC E D U R EU S E D S TILL N O S TA R T
CHECK VACUU[1 HOSESAND EL EC;RICAL L EADS
C H E C K A LL V A C U U M H OS E SA N D E LE C TR IC A L LE A D S
? i-/
rf\E ENG FLOODE D

CHOK E V A L V E NO T U N T O A D I N G
C H OKE VAL VE NOT CL OSING
'l :
N o FU E L IN C A R B U R E TTOR
C H E C K ITE MS 1 & 2 UNDER N O S TA R T C OLD
CHECK AUT OM AT IC CHOKE COI L ADJUST MET \T
N O FU E L IN TA N K
CHE CK T H R O T T L E LI NK A G E F O R F U LL T B A V E L (W . C.T H R O T T L E )
CH ECK F OF BI NDI NG OR ST UCK CHOKE VAL VE OR L i\KAGE
FU E L LIN E S OR F ILTE R S P LU GGED
CHE C K F L C A T NEEDL E A N D S E A T FOR LEAKAGE
D E FE C TIV E FU E L P U MP . P R E S S U R ETE S T
CHECK A\D ADJUST VACUUM BREAK, = AST I DL E, AND UNL OADER
CHE C K F L O A T * L E V EL . F LO A T F O R D A M A G E
C H E C K FLOA T N E E D LE FOR S TIC K IN G IN S E A T OR tsIN D IN G F LOA T
DO NO T A D J U S T F L O A T L = ' ",EL = XCEPT AFT E R M A J O R O V E R H A i.J t-
r-r.t'
ENGINE FUEL6C.8 1
ENGI N E S T A L L S
S T AL L S COL D
S TA LLS H OT
U SE PROPER E S T A R TING PROCEDUR
U S E P R OP E R S TA R TIN G P R OC E D U R E
C H E C K AL L VACUUM H O S E S& EL ECT RICAL L EADS
C H E C K A LL V A C U U M H OS E S& E LE C TR IC A L LE A D S
C H E CK I DL E SPEEDT
C H EC K ID LE
C HOKE COIL I NCORRECT L Y ADJUST ED
CHOK E C OI L ADJU S TED CORR E C TLY ST A L LIN G CON TIN U E S
FU E L LE V E L H IGH IN * F LOA T B OWL
FUEL LEVEL CK
CHECK C H OK E VALV E A N D L IN K A GE FOR BIND IN G OR STIC K IN G
FU E L P U MP P R E S S U R EH I GH TE S T FU E L P U N 1P
S EC ON D A R Y THR OTTLE STIC K IN G OP EN
F LOA T N E E D LE S E A T LE A K IN G IF UNA B LE TO CHECK ADJI.JS T, IDL E S Y S TE M FOR DIRT , A IR LE A K S , PL UGGED P A S S A GE S
GA SK E TS N OT S E A LIN G CA U S IN G A IR OR FU E L LE A K S
F LC AT
LEAKIN G C R BIN D IN G
CARBURETTOR FLOOD I N G OR HIGH FLOA T LE V E L
I D LE P A S S A GE S P LU G GE D ,ID LE A IR B LE E D S P LU GGE D
T EST F UE L PUMP
i C H E C K FOR D IR TY I on LE A K TN G FLoA T
r vE E D L E
D O N O T ADJUST F L OAT L EVEL EXCEPT A F T E R MAJOR OVERHAUL
R E F E R SECT ION 2 F OR CORRECT A D J U S TM ENT PROCEDURE.
.fr,
--'..''"-ll'
6C-82ENGINEFUEL
P OOR HIGH SPEED PERFO RM ANCE
ENGINE RUNS ROUGH, SURGES
C H E C K F O R F U L L T HROT T L E O P E N I N G A T C A R BURET T OR A D J U S T T H R O T T LE L I NKAGE A S N E C E S SARY
C H E C K A LL V A C U U M H OS E S A N D E LE C TR IC A L LE A D S
C H E C K FU E L P U MP PRESSURE
A I R V A L V E B INDING, S T I CK I NG
FU E L FILTE R S OR S C R E E N S P LU GGE D OR D IR TY
A I R V A L V E OR S E C O ND A R Y VAL VE N O T U N L O C KING
MA IN ME TE R IN G JE T P LU GGE D , LOOS E OR WR ON G P A R T
P R I M A R Y O R S ECONDARY M E T E R I N G R OD BENT O R J E T S B L OCKED
P R IMA R Y ME TE R IN G R OD B E N T, A LTE R E D OR IN C OR R E C T P A R T
PO W E RP I S T O N S T U CK OR BINDING CH E C K F O R D I S T O RT ED SPRING
F L O A T L E VEL * I N C O R R E CT
F L OAT ST ICKING, M ISAL IGNED
P OWE RP IS TON S TIC K !N G D IR TY , S P R IN G MIS S IN G, OR IN C OR R E C T P A R T
FLOA T A D JU S TME N T IN C OR R E C T * G A S K E T S N O T SEAL I NG M A Y B E H A R D OR BRIT T L E C H E C K F O R L O OSE SCREWS F LOA T B E N T OR MIS A LIGN E D
A D JU S T ID LE S P EE D I TO S P E C IF IC A TION S
C H E C K ID LE S Y S TE M FOR D IR TY OR P LU GGE D P A S S A GE S
GA S K E TS N OT S E A LI N G. MA Y B E H A R D OR B R ITTLE , C H E C K FOR LOOS E S C R E WS
S E C ON D A R Y TH R OTTLE V A LV E S TIC K IN G OP E N OR MIS A LIGN E D
DO NOT A D J U S T F L O A T L EVEL EXCEPT A F T E R M A J O R O V E R H A UL
RE F E R S E C T I O N 2 F O R CORRECT ADJ US T M E N T P R O C E DURE
ENGINEFUEL 6C.83
P OOR FU E L E C ON OMY
R U N C ON S U MP TIONTE S T C H E C K D R IV E R H A B ITS
IF C ON S U MP TIONIS P OOR , C H E C K TH E FOLLOWIN G
C H E C K C H OK E V A LV E A N D LIN K A GE FOR B IN D IN G OR S TIC K IN G
C H E CK POWER PIST ON S P R I NG F OR DIST ORT ION
C H E C K P OWE R P IS TON FOR S TIC K IN G OR B E IN G B E N T OR LOOS E
C H E C K P OWER P IS TON V A C U U M P A S SA GE SFOR LE A K S OR B E IN G P LU GGE D
C H E CK M ET ERING RODS F OR BEING B E N T OR WRONG PART
C H E C K MA IN ME TE R IN G JE T FOR B E IN G P LU GGE D , LOOS E , OR IN C OR R E C T P A R T
tvl A K E S U R E GA S K E TS S E A L P R C P E R LY ON A LL V A C U U M PA S S A GE S
C A R B U R E TTOR FLOOD IN G. S E E B E LOW
C H E C K FLOA T N E E D LE S E A T FOR LE A K IN G FR OM D IR T, WE A R , D A MA GE , LOOS E NE S S
FLOA T B E N T, S TIC K I N G MI S A LI GN E D , MI S A D J U S TED
C H E C K A N D A D JU S T . ID LE S P E E D
GA S K E TS N OT S E A LIN G OR C A S TIN GS LE A K IN G
P U MP D IS C H A R GE B A LL N OT S E A TIN G, C H E C K FOR D IR T, D E FE C TIV E S E A T OR D IS C H A R GES P R IN G
C A R B U R E TTOR FLOOD IN G
R U N F U E L P U MPTE S T CHECK PRESSURE
CH E C K FLOA T N E E D LE A N D S E A T FOR D IR T, WE A R , D A MA G: OR LOOS E P A R TS . C LE A N FU E L S C qE E N S A N D FILTE R S
CH E C K F LOA T I-E V E L, C H E C K FOR D IS TOR TE D FLOA T A R N |SOR IMP R OP E RA LIGN ME N T
CHE C K FOR FLOA T B OWL LE A K S (FILL B OWL WIT H FU E L ON B E N C H A N D OB S E R V E FOR LE A K S ) C H E C K S E A L ON A LL B OWL GA S K E TS D O N OT ' ADJUST F L OAT L EVEL EXCEPT A F T E R M AJOR OVERHAU L R E FE R S E C TION 2 FOR C OR R E C T A D JU S TME N T P R OC E D U R E .
6C-84ENGINE FUEL
ENG I NE HESI TATE S O N A C C E L E R A T I O N
A IR VALVE EINDING OA STICKING
A C C E LE R A TOR P U MP C IR C U IT D IR TY , P LU GGE D OR IN OP E R A TIV E _ B A LL N OT S E A TIN G _ P LU N GE R N OT S E A LIN G
A I A ' / A L V E OR SECON DARY T : r q C TT L E VA L VE L OCKOUT I,JOT OPERAT ING
LOW FU E L LE V E L IN F LOA T B OWL
SE CONDARY T HROT T L E V A L VE ST ICKING OPEN S L I GHT L Y - CHECK FO R DAM AG E
C H E C K FU E L P U MP P RE S S U R E
ENG I NE SLUG G I S H O N A C C EL E R A T I O N
E NG I NE S L U G G I S H O N ACCELE R A T I O N D U R I N G CO LD D R I V E A W A Y
E N GIN E S LU GGIS H ON A C C E LE R A TION WA R M OR C OLD
ADJ US T A U T O M A T I C CH O K E C O I L
AIR VAL VE BIN D IN G OR ST ICKIN G
FU E L FILTE R IN C A R B U R E TTOF D IR TY OR P LU GGE D . FLOA T S TIC K IN G OR N OT P R OP E R LY A D JU S TE D *
A DJ US T V A C U U M B R E A K
CHE CK A I R V A L V E O R SECO ND A R Y T H R O T - I - L E VALV E L O C K O U T
S ECONDARY N OZZ LE PL UGGED OR DIRT Y: S E C ON D A R Y M ET ERING ROD M TS A LIGN ED, ST ICKING, DIRT Y OR B E N T, SECONDARY M ETE R IN G JET PL UGGE D
P OIV E RP IS TON S TU C K , B IN D IN G, LOOS E
\l A IN ME TE R IN G JE T D IR TY , P LU GGE D OR IN C OR R E C T P A R T. MA IN ME TE R IN G R OD D IR TY , B E N T, S TIC K IN G OR IN C OR R E C T P A R T
TH R OTTLE V A LV E S TIC K I N G
ID LE S P E E D T N OT P R OP E R LY A D JU S T E D
DO NO T A D J U S T F L O A T L EVEL EXCEPT AFT E R M A J O R O V E R H AUL .
RE F E R S E C T I O N 2 F O R CORRECT ADJ US T M E N T P R O C E D URE
ENGINE FUEL6C.85 5. SPECIFICATIONS

CARBU RET TO R - 2 Bar r elVar ajet ll Ca libra tionlt em ( Aut om at ic and M anualTr a n s m ission ) P.O. E. Bl eed 1. 4 2 m m P.O.E. Noz z le 1.85 mm P.O.E.Tu be . 0.65 mm Se co nd ar yM et er ingJ et 3.20 mm Se co nd ar yM et er ing Rod Full dia. 2 . 9 75 r nm 1.970mm Se co nd ar yM et er ing Rod Tip dia. . r y Ai r Bleed Se co nd a i .00 mm Primary Noz z le Relat ion 3.50 mm Main Well Boos t Bleed . . 1,00mm Auxiliary W ell Bleed 1.00 mm N OTE: P .O .E. Pull O v er Enr ic hr nent FUEL PUM P: Pressu re Test
ldle Tube M.B.P. Restriction Top M.B.P.Inlet . . M . B . P . D o w n C h a n n e li n F l o a t B o w i P r i m a r y M e t e r i n gR o d P r i m a r y M e t e r i n gJ e t . . ldie Need l e O r i fi c e l d l e P o r t Wi d t h ldte Por: Length
M.B .P . l / xi ure B '7-P ass
0 .6 5 m m 1 .6 0 m m 5 .5 0 m m 7 .0 0 m m 1 18 mm 1 .8 3 m m 2 .2 0 m m 0 .7 0 m m 3 .0 0 m m
22 - 26 kP a @ 1000 'crn
FI C A T I O N S ( A U T O M A T I C & M A N U A L T R A N S M I S S I A DJ USTM ENTSPECI ONS) F IG . REF. N. A. 6 C-134
ITE M
LI Q UI D FUEL LEVE L ( Fu e l l e v e lt o f l o a t b o w l t o p - n o g a s k e t ) DRY FLO AT LEVEL SET T I N G ( F l o a t t o p t o f u e l b o w l t o p - n o g a s k e t )
sPEc.
1 7.Om m 8 .0 m m 90 Deg. 90 Deg.
6 C_1 40 i W I DE O PEN TH RO TTLE - P RI M A R Y 6C_ 140 I W I DE O PEN THRO TTLE - S E C O N D A R Y 6 C-140 6C_ 141 6C-1 42 6C_ 144 6 C-145 W I DE O PEN THRO TTLE - P R I M A R Y O V E R D R I V E SECO NDARY TH RO TTLE O P E NI N G I N I T I A L SECO NDARY CLO SI NG S E T T I N G CHO KE SETTI NG AI R VALVE SETTI NG
'tA "tt Att _
'
0. 5mm
0.45 mm
tt
0.60mm 4.2 m m 0.3 m m

3.70 mm
^t,
tt
^tt
A"=
Att =
D ST E P 6C- 1 4 6 I SE C ON SE T T IN G 6C_1 4 8 I W ID EOP ENK IC KSE T T I N G 6C- 1 4 9 I SE C ON D A R Y LE V E RR OTA TION L O C KOU T 6C_1 5 0 I S EC O N D A R Y L O C KOU TS E TTIN G
6C_ 151 I RCCELERATO R PUM PSE T T I N G
N A.
A"= A"= A"=

At'=
10. 0m m
2 .0 m r n 0 .4 m m 8.0 m rn 14.5 cc 1 N.L 84 Deg. 2 - 3 mins
PUM P CAPACI TY FO R 1O S L O W S T R O K E S CHO KE CO VER I NDEXI N G AI R VALVE O PENI NG
N A. N A. N A.
I
T rMEAT 22oc I c H o K E o P EN T N G
ENG I NE I DLE SPEED ( fn Neut r al - M anualTr ans m is s i o,n Park- Auto Transmission Air Condit ioning" O FF" , Engin eWa r m) ENG I NE FAST I DLE SPEED L; wes t s t ep of f as t idie c am 1, 1 5 0 ! 2 5 r p m 850 t 25 rpm
6C.86ENGINEFUEL 6. TORQUEWRENCHSPECIFICATIONS
Nm Carburettorto Manifold Stud Nuts * Air C leanerSt ud. . Throttle Position Switch to Mounting Screws Throttle Position Switch Mounting to Air Horn Screws Throttle Linkage Bracketto Manifold Bolts . . Accelerator Cable Lock Nuts . * Usethread locking sealantsuch as Loctite 675. 14 - 16 10 0.5 - 0.7 3.b - 4.s 12 - 16 3 - 4
7. SPECIALTOOLS
HAND VACUUM PUM P
J23987 -01
( or egui v al ent)
FUEL6C-87 ENGINE
5.0 LITREENGINEFUELSYSTEM
INDEX
Ref. 1. 2. 2.1 Page Subiect 6C-87 GENERAL DESCRlPTlON.........!.................'.. 6C8 SERVICE OPERATIONS .......-.r...................." 6C8 FUEL PUi|P......................t..t................."""'i"' 6C-88 R e m O V . . . . . . . . - . . . . . . . '! " t " t " " " " - t t " 't t " " " t " " ' R glnSta ll ..................r........................ ts.o.- 6C8 r r ...r .....- .....- ..........o..d..ts .....6C8 RELAY C ONT ROL 6C8 R gmOV...............r.....r..........-................... R glnStall .......r .!r r ..r .....- ................... .......... 6C8
I Ref. 1 2.3 2.4 2.5
2 .2
Page Subject 6C8 FUEL FLOW TEST....r...r....................o.....,...... 6C-89 TEST.........'......o..........-.'.. PUMPPRESSURE 6C-89 ..............o-.. coNTRoL RELAY OPERATION 6C9 Battery Supply Voltage ............,.o...o... 6C-89 lgnltlon Supply Voltage .........r.....o..o... 6C-89 Control Relay Output .............r-..........
6C'90 SP EC I Fl CATIONS ....r.r...r.......!..........r..6..........
r3.
I
DESCRIPTION 1. GENERAL
All 5.0 litre VK Series models are equipped with a in high revised fuel pump system to improvedriveability conditions. ambienttemPerature The mechanicalfuel pump has been deleted, a cover plate is added to the fuel pump access hole on the ilming case cover. The inline plastic fuel filter has been deleted and replaced by a revised fuel vapour separator 52. a gauze filter screen,refer Fig. 6C-1 incorporating fuel electric an The revised fuel pump system includes, pump mounted on the fuel gauge tank unit, inside the iuel tank, refer Fig. 6C-153. The operation of the fuel pump is controlledby a control relay insidethe fuse box. The principleof operationis the same as describedfor Fuel the EFI System control relay, refer to 'ElectrOnic The fuel lines in Section6C of this Supplement. Injection' hive also been revisedwith the deletionof the mechanical fuel pumPand inlinefilter. The float level height has also been revisedto 11.5 mm (.460 ins.). Refer to the Section10 'Enginef.un" Up' of ine lmproved Performance Engine Service Manual Part procedures. No. M38338,for adiustment
FU E L R E TU R N
TO C A R B U R E TTOR
F(l ure 6C -152
6C-88ENGINE FUEL 2. SERVICE OPERATIONS

2 . 1 F U E LP U MP
REMOVE
1. Remove fuel gauge tank unit, reter to service operation 2.6, Section12C of this Supplement. 2. Disconnect wiringfrom tank unit to fuel pump. 3. Remove filter from pump. Slide upper rubber connectorfrom fuel pump outlet,then removepump by slidingout from lower bracket.
REINSTALL Instalfation is reversal of removal procedure. NOTE: The electric fuel pump is a sealed unit and non repairable.
,
L
LOWEB E R A C K E T -\
FU E L GA U GE TA N K U N tT_i I
I l
-\
.,
--.
--
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I
r''rr
i - gP P E R R U B B E R MOU N T
\- W Ai N G C ON N EC T IO N
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Figure 6C-153
2.2 CONTROL RELAY

REIIOVE
1. 2. Remove fuse box cover. Pull out relay from its position in the fuse box, reter F ig. 6C-15 5.
FU S E 8C X C OV E R
R E I NS T A LL lnstallation is reversal of removal procedures. lf the engine fails to start and the normal diagnosis procedure indicates to a fault in the fuel supply to the carburettor, check fuel pump pressure and fuel flow.
Figure 6C-154
_ C ON TR OL R E E B OX
Figure 6C-155
2.3 FUEL FLOWTEST

1.
2.
Disconnect the carburettor fuel line at the carburettor - prior to the vapour seperator. Disconnect '+' wire at rgnitioncoil terminal, place a suitable container at the end of the fuel line and crank the engine a few revolutions. lf litile or no fuel flows from the open end of the pipe, then the fuel pipe is blocked or fuel purnp is inoperative.
FUEL6C.89 ENGINE
TEST 2.4 PUMPPRESSURE
lf fuel flows in good volume from the pipe at the fuel deliverypressuremay then be checked. carburettor, This test is necessarybecause a weak pump can still producean adequatevolume of fuel when it is not under pressure. 1. Install a suitable adaptor and tee fitting to the fuel line at the carburettor fuel inlet line. Fit a short rubber hose to the tee piece and attach the other end to a pressuregauge havinga scale readingto at least 60 kPa. 2. Start the engine and run at idle, note readingon gauge. pressure 3. lf the pump is operating conectly, the pressure 30-40 kPa after 30 seconds shouldbe approximately of running.
2.5 CONTROLRELAY OPERATION

BATTERY SUPPLY VOLTAGE controlrelaYas Per 2-2. 1. Remove 2. Check for voltage supply to the terminal corresponding to terminal 30 of control relay and earth, refer of wiring to Fig. 6C-156.lf not, check for continuity teiminal.Refer to wiring diagramsin Section 12F of lf O.K. proceedto next testthis Supplement.
87
TE S T LA MP
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87b
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C ON TR OL R E LA Y TE R MIN A L B LOCK
uo
Figure 6C-156
IGNITION SUPPLY VOLTAGE 1. With control relay still removedand vehicleignition s wit c he d ' O N ' , c h e c k fo r v o l ta g e s u ppl y to the to terminal15 o{ controlrelay conesponding terminal and earth,refer Fig. 6C-157Refer of wiringto terminal. 2. lf not, check for continuity to wiring diagrams in Section 12F of this lf O.K. proceedto next test. Supplement.
- EST
LAM P
C ON TR OL R E LA Y T=R MIN A L B LOCK Fi gure 6C -157
CONTROL REI-.AYOUTPUT 1. Refit control relaYto fuse box. checkfor voltagesupplyat 2. Withthe enginecranking, the fuel pump terminalon the fuel gaugetank untt. 58. ReferFig. 6C-1 of winng 3. lf no voltage reading,check lor continuity from tank unit to the terminal in the fuse box to terminal87b of the controlrelay.lf corresponding the wrringis O.K. replacecontrolrelayand retest. 4. lf the wiring and control relays are O.K., and the pump is stif not operating,removefuel gauge lank unit as per serviceoperation2.6 in Section 12C ot this SuPPlement. 5. Check wiring f rom terminalson tank unit to fuel lf O.K. removeand replacefuel pump for cohtinuity. pumpas per operation2-1 and retest.
/- FU :L P U MP TE FTIi IN A LS
Fi gure 6C -158
FUEL 6C.90 ENGINE 3. SPECIFICATIONS

FUEL PUM P: Pr es s ur e Volt age ( at f uel pum p - engineo p e r a t i o nt 30 - 40 kPa 13.5 t .1 volts
NOTES
------------r
ENGINE ELECTRICAL 6D.1
SECTION 6D
ENGINEELECTRICAL
OF THIS SECTION CONTENTS
Subject Page
6D'1 CHARGING SYSTEM ........r.rr.rr....r................-..r..t....... 6D'1 5 STARTING SYSTEM .....r.r..............r.....r............r..r..... 6D'17 IGNITION SYSTEM......r............r...........................r...r.,
CHARGING SYSTEM
INDEX
Ref. 1. 2. 2.1 2.2 Page Subiect GENERAL DESCRIPTION...r...r.'r..........''r.r 6D-1 MINOR SERVICE OPERATIONS .'r....!!,.r,.... 6D-3 6D-3 SAFEW pRECAUTIONS ..........r...r.,.r...!.r.t.,r.. MAINTENANCE AND ADJUSTMENTS........ 6D-3 6D-3 .............r ...........r r r ...r ............r . L UbflCatlOn Testlng the Generator Output 6D-4 and Voltage Regulator..r........r.,..'...,.. Tgstlng Generator Output ........ 6D-4 Testlng the Voltage Regulator 6D-4 Charglng Clrcult Voltage Drop 6D-5 t.rr..!t!.r.rr............r..o.............r..r. TgSt 6D-5 MAJOR SERVICEOPERATIONS.................. 6D-5 .r.r.r.r...r..r.r.r!.r.t.'r...r.r.......rot.!.....!. G E N E RATOR o...... 6D-5 R gmOV.....r..r.....r...1...................o...... 6D-5 ......r.....r.--...........................r.r.... R gl nStall Ref.
Subject Page Disassembly..r..,.r-........r..,......,.........r..... 6D-o C l e a n i n g a n d I n s p e c t i o n o . . . . . . . ............ 6D-B T e s t i n g C o m p o n g n t s . . . . . . . . . . . . . . . ,............ 6D-8 Diodg Assembly ......r.........,.......,. 6D-B StatOf ...........r............'...............r..... 6D-8 lnsulation Test for the Stator.. 6D-9
BfU ShgS........!............r ......r ........ . . . . o R O tOf ..r .......'..,......r .r ..,r ........... . . . . . . . . . 6 D -9 6D'9
InsulationTest for the Rotor

C O i l ...r ..................r ....t'.......r ....r . r. . . . . . 6 D ' 1 0
3. 3.1
4. 5. 6.
Rgassgmbly r...............................r.....-..... 6D'10 ..........,.............,............... FAULT DIAGNOSIS 6D-1 2

S P E C I F I C A TION S ..............o.......r..........r..r..r.r.. 6 D' 13
TOROUEWRENCH SPECIFICATIONS........ 6D.13
1 . G E NERALDESCRIPTION
carriesover from VH to VK The Bosch 45 amp generator Series for the base 3.3 litre Electronic Spark Timing rnodels. or ElectronicFuel On models fitted with air conditioning Injection,VK Series models have fitted a new Hitachi 60 amp generator. and ElectronicFuel On models with both air conditioning Injection, a new Hitachi70 amp generatoris fitted. Service proceduresfor the Bosch 45 amp generator are as publishedin Section 08 GeneratingSystems, lmproved PerforrnanceLO and VB Engine Service Manual No. M38338. The followingSection covers the service proceduresfor (Fig. 6D-1) both 60 amp and 70 amp Hitachigenerators Both models are similar in mechanical construction. in the numberof turnsand the wire gaugeon Differences the respectiverotor and stator windings result in the characteristics. differentelectricalperformance The stator comprises a three phase star connected pack. The output winding on a ring shaped lamination and carriesa slip ring fed rotor is of 12 pole construction field winding.The rotor is supportedby ball bearingsin both drive and slip ring end brackets.
Fi gure 6D -1
ELECTRICAL 6D.2 ENGINE

Rectification of the generatoroutput is achieved by six silicondiodes containedwithin the slip ring end bracket and connectedin a three phase bridge circuit between stator and output terminals.A second rectifier bridge is formedby usingthree auxiliary low currentdiodes used in conjunctionwith three main diodes. This supplies the currentfor the generatorfield coil via the brushes,slip ringsand voltage regulator(referFig. 6D-2). The generator output is controlled by an electronic voltage regulatorunit mounted inside the slip ring end bracket.Design featuresof the voltage regulatorinclude, ternperaturecompensation, radio frequency interference suppression.The regulator requires no adjustment in service. The 'generator has three external connections. The batterypositivelead to the 'BAT' terminal,the 'L' terminal for the generatorwarning light and the 'S' terminalfor sensingthe outputvoltage. The diode and stator windings are cooled by air flow throughthe generator, inducedby two internallymounted ventilating fans, one on each end of the rotor.
STATOF
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ALTERNATOR
Figure 6D-2
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-14
7 . SEAL = D BALL B E A R IN G 8 . DRiVE END B R A C K E T 9 . NUT M 5 , NU T M6 _ D IOD E A S II T O SL IP RING E N D B R A C K E T 1 0 . SL IP RING EN D B R A C K E T 1 1 . ST AT C R
o
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1. 2. 3. 4. 5
T HRO U G H B O L T P ULL E Y N U T P UL L E Y RO T O R S CRE WM 4 _ R E T A I N ING PL AT E T O DRIV E E N D B R A C K E T 6. B E A R I N G R E T A I N I N G PL AT E
12, N U T M4 - FA N G U I D E TO D IOD E 13 FA N GU ID E 14 R IV E T 15. B A TTE R Y TE R MIN A L 16. D IOD E A S S E MB LY 17. B R U S H _ FE GU LA TOR A S M.
Figure 6D-3
ENGINE ELECTRICAL 6D-3 OPERATIONS 2. MINORSERVICE

2.1 SAFEW PRECAUTIONS
Since the generator and voltage regulator are designed for use only on a negative earth system, the following precautions must be observed. Failure to observe these precautions will result in serious damage to the generator. 1. When installing a battery, first fit the positive (+) connector to the battery positive (+) terminal and fit the negative (-) connector to the negative (-) battery terminal. 2. When a slave battery is utilised for starting purposs, ensure the two batteries are connected in parallel' i.e. positive terminals together and negative terminals together. 3. When charging the battery, disconnect the battery negative C) cable, thus isolating the generator from the battery and external chargingequipment. 4. lt is recommended that the generator not be operated on open circuit (this is without battery in clrcuit), and the battery not be disconnected while the generatoris running. ll the battery is disconnected when the engine is running,do not operate above idle speed, and for only a limited Period. NOTE: This will enable exchangeof batteries,if a slave battery has been used for starting, when jumper leads are not available. 5. The cable connecting the generator and battery is 'live' even when the engineis not running. 6. Do not aftempt to polarisethe generator. 7. Always ensure that the generator lamp glows when the ignitionswitch is turnedto the 'ON' position. NOTE: As this circuit is related to and assists in the excitation of the rotor lield windings,do not proceed until any faults in the generator light circuit have been rectified. Refer to 4.0 Fault Diagnosisof this Section.
AND ADJUSTMENTS 2.2 MAINTENANCE

of the generator inspectthe terminals At regularintervals, and the wiringfor frayed for corrosion,loose connections check Check the mountingbolts for tightness, insulation. and wear and the drive pulley the drive belt for alignment for damage.Check the drive belt for correct tension as outlined under heading 'Fan Belt Adiustment' in the 'Cooling System' Section6 of the VH Series Service No M38731. Supplement Manual Becauseof the high inertiaand speedsof IMPORTANT: the rotcr used in generators,correct belt tensioningis critical.
LUBRICATION The balt bearings in both end brackets are sealed, cannotbe lubricated. therefore lf the bearings are removed during overhaul, it is that they be replaced. recommended
6D-4 ENGINE ELECTRICAL

TESTING THE GENERATOR OUTPUT AND VOLTAGE REGULATOR Beforetestingthe output,make certainthat the generator circuitis thoroughly checkedfor loose or dirty connections and the fan belt is correctly tensioned. The generator must alwaysbe connectedto the batteryduring testingothenryise damageto the diodes could result.The batteryshould be fully charged.The generatorwaming light, in addition to indicatingthat the generator is charging, also carries the currentnecessary for initialfield excitation. The globeused shouldbe 2.2 watt. Testing Generator Output 1. Disconnect the batterynegativeterminal. 2. Remove the wire from the 'BAT' terminal on the generator. 3. Usingan accurateammeterhaving at least an 0-80 scale, connect the positive lead to the generator 'BAT' terminal and the other lead to the disconnected positivewire. Refer Fig. 6D-4 4. Connectbatterylead, fit a loadingdeviceacross the i.e, an adjustable carbonpile. Refer batteryterminals, Fig. 6D-4. NOTE: Loadingdevice must have a power consurnption of 1000watts mrnimum. lead of a voltmeter to the 'BAT' 5. Connectthe positive lead to a terminal on the generator and the negative good groundon the generator body.ReferFig 6D-4. 6. Start the engine and increasethe engrnespeed to approximately 2500 rpm. Adjust the loading device to achieve a reading of 14 volts on the voltmeter. The generatoroutput should be over 55 amps for the generator LR160-706 and over 65 amps for the LR170703 generator, on the ammeter. as indicated CAUTION:On completion of the above check, release the adjustment of the loading device and rduce the engine speed. NOTE: If the generator does not providerated ouput, it shouldbe disassembled and checkedfurtheras outlined in this Section.
A D JU S TA B LE LOA D
i--fJo
A MP S +
o2{U .
GE N E R A TOR
+ V OLTS -
Figure 6D-4
Testing the Voltage Regulator

1. Connect the positive lead of a voltmeter to the positive terminal on the battery and the negative lead to the negative terminal. Place a resistance or test lamp load across the battery and adjust to maintain a current flow of 11 amps or as an alternative, switch on the high beam headlights.
2.
ENGINEELECTRICAL 6D.5
3. 2500 rpm, maintain Run the engine at approximately this enginespeed for 15 secondsand check voltage volts. This shouldbe 14.1-14.5 reading. unit and NOTE:The voltage regulatoris a non-adjustable if provedfaulty rnust be replacedwith a new unit. Charging Circuit Voltage Drop Test With the normal connectionsmade at the generator,the charging circuit can be checked for voltage drop as follows:1. Connecta low range voltmeterbetweenthe generator positiveterminaland the batterypositivepost. 2. Switch on the headlights, start the engine and 2500 rpm increase engine speed to approximately and note voltmeterreading. 3. Reduce engine speed and transfer the voltmeter connections negative to the generator body and positiveto the battery negativepost, increaseengine speed to approximately2500 rpm and again note voltmeterreading. 4. lf the readingsexceed 0.5 volt on the posrtiveside and 0.25 volt on the negativeside there is a high resistance in the charging circuit which must be tracedand corrected.
OPERATIONS 3. MAJORSERVICE
3.1 GENERATOR
REMOVE CAUT,ON: Disconnect the battery ground (negative) short circuits. cable to prevent accidental outputterminal. 1. Removethe wire from the generator 2. Remove the connector from the warning light terminalon the generator. 3. Loosenthe generatorto support bracket bolt. Refer Fig. 6D-s. 4. Remove the generator brace bolt and detach the drivebelt from pulley.ReferFig. 6D-55. Remove generator to support bracket bolt and Refer Fig. 6D-5' from engine. removegenerator REINSTALL the generatoron the mountingbracketand 1. Position installthe bolt and nut; do not fullytightennut. drive pulley2. Installdrive belt to generator 3. Install the generator to brace bolt and washers, finger tight; generatorpulley should be alignedwith and water pump pulleys. crankshaft 4. Adjust dnve belt tension as outlined under the heading 'Drive Belt Adiustment' in the 'Cooling System Section 6 of the VH Series Service Manual Tightenthe bracebolt to 20-25 Nm. supplement. 5. Tightenthe generatorto mountingbracketbolt and nut to a torque of 34-44 Nmto the warninglight (L) terminal. 6. lnstallthe connector 7. Connectthe red wire to output(BAT)terminalof the generator. the batterygroundcable' 8. Reconnect
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B R A C E sOLT
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GE I'i E R A TORTO S U P P OR T B R A C K E T B OLT Figure 6D-5
6D.6 ENGINE ELECTRICAL

DISASSEMBLY 1. Mark the relative positions of the slip ring end bracket,stator and drive end bracket. 2. Removethe four throughbolts ReferFig. 6D-6. 3. Separateand removthe stator and slip end bracket from the rotor and drive end bracket,by insertingtwo screwdriverson opposite sides between the drive end bracketand stator core and prise apart. cAUTloN: care should be exercised so as not to damage the stator coil with the screwdrivers.
D R IV E E N D B R A C K E T
._
tf-
rr r
TH R OU GH S '*F B O uTS
S LIP R IN G E N D BRACKET
Figure 6D-6 4.
Hold the rotor in a vice (using copper iaws) and remove pulley attaching nut with a 22 mrn socket. Take care not to damage or bend the blades of the fan. 5. Remove pulley lock washer, pulley and distance collar.withdraw the rotor from the drive end bracket.
D R IV E E N D B R A C K E T
r- P Ul -LE Y
_ R OTOR
Figure 6D-7 6.
7.
Removethe four screws securingthe front bearing retaining plate to drive end bracket, remove the plate.ReferFig. 6D-8. retaining Press the front bearing out from the dnve end bracket. Discardbearing.
Figure 6D-8
8.
Using a suitablepuller, remove the slip ring end bracketbearingfrom the rotor shaft. Refer Fig. 6D-9.
' \\l n_ R E MOV IN G B E A R TN G
Figure 6D-9
9. Removethe six slip ring end bracketfixing nuts and remove the slip ring end bracketfrom the stator and diode assembly. Refer Fig. 6D-10.
t-
r D IOD E A S S E MB LY
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NUTS {6}-=>r, e
Figure 6D-10
10. Remove the stator coil by unsolderingthe three stator winding connectionsfrom the diode assembly and separating the diode assembly from the stator 1. windingend points.Refer Fig. 6D-1
S TA TOR WIR IN G E N D P OIN T
srAroR
t
/
D IOD E A S S E MB' " J
Fi gure 6D -11
11 . Remove the five nuts holdingthe fan guide to the
Refer Fig. 6D-12. diode assembly.
1 \
Nurs (5) 6/
7-FA N GU ID E
L D IO D E ASS E t . , t B! y
Figure 6D-12
12. To remove the brush and regulatorassemblyfrom the diode assembly,remove the rivet by filing away peened end. Once the rivet is removed,removethe battery terminal and the diode and brush regulator can be seParated. assemblies NOTE: Never remove the rivet except when replacing diodesor the brushassemblY.
B R U S H _ R E GU LA TOR
ASSEM B LY
/eattE R Y TE R MIN A L
L DICDE A S S E MB LY
Fi gure 6D -13
ItF
-v
6D-8 ENGINEELECTRICAL
CLEANING AND INSPECTION with generatorcompletelydismantled, the components shouldbe cleanedand inspected. 1. wash all metal parts except stator and rotor assemblies in cleaning solvent. 2. Blow off any dust or foreign matter from the rotor and stator assemblies with compressed air. CAUTTON:On no account should the rotor or stator windings be cleand in any degreasingcompound, since this might damage the insulationto the ertent that a short circuit or ground could subsequentlydevelop. 3. lnspect the slip rings, clean off foreign matter with solvent. cleaninq
TESTINGCOMPONENTS Diode Assembly Testof diodeconductivity.

The currentflows in one directiononly in each diode. lt shouldflow down from the positiveside diode (at the top of the assembly) in the direction of the arrows refer Fig. 6D-14.
-FIE LD D IOD E P OS ITIV E S ID E D IOD E -, U V W
N E GA TIV E S ID E D IOD E
----< rl>
BAT
Figure 6D-14
Using a 1.5 watt test lamp and a 12 volt battery connect to each diode in turn to check conductivity refer F ig. 6D -1s. Connect one lead to the diode stem and the other lead to the diode base plate. Reverse the leads, the bulb should light in one direction only. Check all positive and negative diodes. lf any diode shows current flow in both directon or not at all, replace the diode assembly. To test the field diodes, located on top of the assembly, place the test lamp and battery lead at end of the diode. Check that the bulb lights in one directron only. Check all three field diodes. lf any diode proves faulty, replace drode assembly.
t<-
1.5 WA TT TE S T LA MP
12 V OLT
Fi gure 6D -15
Stator
Open circuit test for the stator windings. The continuity of the stator windings has to be checked, by first connecting any two of the three stator leads in series with an ohm meter. Refer Fig. 6D-16. Repeat the test by checking at the third lead. lf continuity is found !n all windings the stator can be considered to be normal.
Q n l v 1M ET ER
S TA TO R WIN D IN G TE R MIN A LS
S TA TOR C OR E Fi gure 6D -16
6D-9 ENGINEELECTRICAL
Insulation Test for the Stator Using an ohm rneter,connect the test leads to the stator core and to one of the winding terminals. Refer Fig. 6D-17. lf continuityis found, the stator is consideredfaulty and must be replaced.
:-OH M ME TE R
S 'TA TOR\ry IN D IN G TE R n.l l NA L -
Fi gure 6D -17
Brushes of brushlength: Measurement brushlengthis found to be less than lf the 'free-standing' 2 mm from the brush holder, then replace the brush holderassembly. This rninimumaccePtablelength is marked on the brush Refer Fig. 6D-18. with a shallowindentation.
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Fi gure 6D -18
Rotor Open circuittest for rotor coil: Usingan ohm meter check for continuitybetweenthe slip 9. rings.ReferFig. 6D-1 to the rotor coil can be considered found, is lf continuity be normal. is found,the rotor cotl is if no continuity On the contrary, to be defectiveand should be replaced. considered
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l v lET ER q
Lsl -rP R rN G
Fi gure 6D - 19
q7

Insulation Test for the Rotor Coil using an ohrnmeter,check the insulationbetween the two slip rings and the rotor core or shaft. Refer Fig. 6D-20. lf no continuityis found,the rotor coil can be considered to be normal. lf continuityis found, the rotor coil is consideredto be shortedand it must be replaced. The slip rings should be checked for wear or damage and polished with fine glass paper until smooth, or replacedif badly worn or damaged. lf necessary,the slip rings may be skimmeddown on a latheto a minimum diameter of 21.6 mm. lf the outside diameterof the slip rings is found to be less than 21.6 mm, the rotor must be replaced. NOTE: No attempt shouldbe made to straightena bent rotor shaft.
OH M ME TE R
E
\OO
SLIP R IN G
Figure 6D-20
REASSEMBLY
The reassemblyof the generator is the reversal of the disassemblyprocedure,with considerationgiven to the following: 1. Tighteningtorques(refer Torque Wrench Specifications at the end of this Section). 2. Reassemblyof the slip ring end bracket and the drive end bracket. a. Holding the rotor, note the thin semi circular band located in the groove of the slip ring bearingoutercircumference. ReferFig. 6D-21.
Fi gure 6D -21
b.
By pushing on the pinched portion of the band, rotate the band to a position of least exposure (the deepest section of the bearing groove). Refer Fig. 6D-22.
Figure 6D-22
ENGINE ELECTRICAL 6D-1 1

3. Insert a pin into the small hole near the outside centreof the slip ring end bracket.Refer Fig. 6D-23.
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Figure 6D.23
Use the pin to hold the brushesback into the brush holder.Refer Fig. 6D-24. 4 . Assemblethe generatorby offenngdrive end bracket and rotor assemblyto the stator and slip ring end bracket assembly,aligning the marks made during disassembly. 5. Fit and tighten the four through bolts evenly to the torque specifiedat the end of this Section. Ensure the end bracketsare sitting evenly on the stator. Use bolt, or an equalsize rod through the lower mounting lower mountingholes in the drive end and slip ring to ensurethe holes are aligned. end brackets, the pin used in step 3. 6. Slowlywithdraw
Figure 6D-24
6D-12ENGINEELECTRICAL 4. FAULT DIAGNOSIS

Beforeconductingany generatortest, ensurethat: 1. Batteryis fufly charged. 2. Generator drive belt is correctly tensioned.Ref er Fig. 6D-25. 3. Generatormountingbolts and bracketsare secure. 4. Check battery terminals and check for loose or corrodedconnections to generator.
TENSION
NEW
lbs.
USED
lbs. kg.
ks.
41
A n y b e l t t h a t h a sb e e nr u n f or more than 10 minutes is to be considered used.
90
55
25
Figure 6D-25
S U ITA B LE WIR E
Figure 6D-26
@
lgn it i o n s wit c h " o n " (Chec k I i g h t f or oper a t i o n r I L g h t"o ff"
Dis c on nec t lea df r o m ' L' t er m inalan d e a r t h ' L' t er m inal l e a d . ( Chec klight f or o p e r d i , o h )
I L ig h t " o n"
Li ght ''oft" r-
B u r n t o u t b u l b , d e f e c t i v eb u l c s o c k e to r d e f e c t i v ew i r i n g . R e p a i ra n d r e t u r n t o ( A ) .
Light " o n "
' L' t e r m n a l Rec onnec t leadand gr ounC' F ' t e r m i n a l ( Ref er Fig. 6D - 2 6 )
F a u l t y v o l t a g er e g u a l tor.
Li ght "o n " R epl ace.
Faul ty generator. R emove and test components. Engine i d l i n g (Chec k li g h t f o r operat i o n )
L ' q h t "o n " ( d im lig h t, lig h i f ,,cke r s, bri ght l i ght)
F a ul t y g e n e r a t o r . R e m o v ea n d t e s t c o m p o n e n t s .
Lign t "o f f "
E nginespe ed ; 1500 rpm (Measure BAT terminalvo ltag e)
H ig h e r
15.0V
Faul ty vol tage regul ator R epl ace.
ENGINEELECTRICAL 3 6D.1
1. UNDE R C H AR G EBA D T T ER Y a. Loose drive belt. b. Defective battery. in charging ctrcuit. c. Loose connection in chargingcircuit. d. Corrodedconnections e. Defectivewiring. f. Faultygenerator. g. Faultyvoltageregulator. 2. O V ERC H A R GE D B AT T E R Y a. Shorted batterycell. b. Fauftyvoltageregulator. c. Short circuitin rotor winding 3. N OIS YGE N E R A TOR OP E R A TION a. Normal magnetichum. b. Badly dischargedbattery. c. Generator mountingbracketsand/or bolts loose. d. Worn or frayed drive belt. e. Worn or damageddrive pulley. f. Worn bearings. g. Loose drive belt. h. Loose drive pulleyattachingnut. i. Open or shortedmain diodes. i. Open or shortedstator windings.
5. SPECIFICATIONS
GENERATO R: Type Ea rth Polar it y No minal Volt age r pm No minal O ut put at 6000 gener at or Reg ulat edO ut put Volt age@ 20oC. Sta tor Phas es. Stato r W i nding Connec t ions Nu mber of Poles . . 1R160 - 706 N egative 12 volts 60 amps Approx 14,2 - 14 6 volts 3 Star 12 L R 17 0 - 7 0 3 N e ga itve 1 2 vo l ts 7O amps A p p r o x 1 4 . 2 - 1 4 .6 vo l ts 3 Star 12
SPECIFICATIONS 6. TORQUEWRENCH
Nm
r'o u gh Bolts Tr^ P, ?' v Nut . . Fr c r ' t Bear ingRet ainin gP l a t eS c r e w s Fan G . r de t o Diode As s e m b l yN u t s End Br ac k et M 6 N u t s Siip R "g Slip R ng End Br ac k et M 5 N u t s G ener at orBr ac eBolt . . G ener at or t o Br ac k et B o l t a n d N u t
3.14- 3.92 39.20- 58.80 1.67- 2 35 1.67- 2 35 5.88- 7 84 3.92 3.14 20.00- 25.00 34.00- 44.00
ENGINE ELECTRICAL 5 6D.1
STARTINGSYSTEM
INDEX
Ref. 12. Page Subiect 6D-15 GENERALDESCR|PT|ON.............................. ................................ 6D-15 SERVICEOPERATIONS Ref. 2.1 Subiect Page STARTER MOTOR(EFr)................................ 6D-15 Remove........ ..................... 6D-15 Reinstall .... 6It-15
The starter motors used on 3.3 litre and 5.0 litre VK Seriesmodels carry over from VH Series models,except that the 3.3 litre starter motor now incorporatesa plastic shifterfork (similarto JB Camira).
The service operations for these starter motors are as described in the lmproved Performance LO and V8 Engine Service Manual, Part No. M38338, SectionA7 for 3.3 StarterMotor Rernovaland Installationoperations EST and 5.0 Litre engines, carryover f rom VH Series. However, revised proceduresare required for 3.3 EFI engines.
2.1 STARTERMOTOR(EFl)
REMOVE 1. 2. batteryearth lead. Disconnect Rernovebattery feed wire and starter motor solenoid on the solenoid. wire from the terminals 3. Removetop starter motor mountingbolt. 4. Loosen bottorn starter motor rnountingbolt. With left hand supporting the rear of the starter motor, removethe bottom rnountingbolt with the right hand. 5. Remove the starter motor from its positionand rnove it along between the exhaust extractors and the strut tower. bottom of the passengerside suspension Nos. 2 and 3 between motor out up starter Pull the 6. inlet manifoldbranches(refer Fig. 6D-271.
Figure 6D-27
REINSTALL
Installationis the reversal of removal procedures. Tighten starter rnotor mounting bolts to 20 - 28 Nm torque.
IGNITION SYSTEMS
INDEX
Ref. 1. 1.1
1.2
1.3
1.4
2. 2.1 2.2, 2.3
2.4
Page Subiect 6D -17 ......................-..... GENERALINFORMATION 6D-18 SPARKT1M1NG....,...........r..... ELECTRONIC 6D-18 Gengral Description......r..'.........rr......-. 6D -18 SYSTEM I-AYOUT ..................r..!......r....r.r,..... SPARKTIMINGSYSTEM ELECTRONIC 6D-19 COM PONENTS .................r!......!t................r.r.. 6D-19 COntrOl MOdul ........r....r......r....r..r......... 6D-19 Englne Speed Sensol'.......................... 6D-20 Manifold Vacuum Sensor..........!r.r.....r Englne Goolant TemPerature 6D-20 Sen SOr ..... r.....rr....r...o. r.....tt. r.. ..... r.........r..t 6D-20 Throttlg Posltion Sw|tch...................... 6D-20 Staftgr MOIOr........r.rrr............................. Alr Gondltlonlng ComPressor 6D-20 ClUtCh ..t...........tr............r......................... 6D-21 lgnltlOn COll ............r...................t......r.... 6D-21 HODES OF OPERATION r....r...............r........ 6D-21 r....r...r....rr..rrrr............r..........t.... Cranklr|$ 6D-21 6D-22 iiOdg.r........r........!.....i.t.............. NOfmal ...........r..rrtr............ 6D-23 Control Overspggd .r.t..t.r........r....tt......r.r.......'. 6D-23 DgCglgfatlng 6D-23 HOmg MOde...r......t!.!!...r........r...... Llmp 6D-24 SERVICE OPERATIONS ........'.t........r....r...... !..rr...............r..........r.t.r.t...... 6D-24 NOTES SERVICE 6D-24 SETTINGlGNlrloN T1M1NG...............,.'.!..... D IS TR I BUTOR ...............r t.r .............r ...r t..!......... 6D'24 Rgm OV..........................................a..1.....r 6D-24 R glnStal | ...........................................t.r .... 6D-25 DlSaSSem b 1y.r ........r F.' ................ ............. 6t>26 o............................. .....r ..'r .!. 6D-26 RgaSSem bly 6D-26 MANIFOLD VACUUM SENSOR ...........r.r...... R gmOV ...........- r........ . ...r .. .r .. . .. . . .. .. . r.a....... 6D-26 ..........r ......................r ...........r r ..r 6D-26 ReinStall ...r......r.rr.rr.!r.r.................o......r...!. 6D-27 Tgstinl$
l dl g .at.r t..r r r ...a..!.r .r 1.r ...!r ...r .r .........r 1........ rr. . .
Ref. 2.5 2.6
Subject Page ELECTRONIC CONTROLMODULE ............ 6D.27

R gm OV'................................................... 6Ot27 RginStal | .....t....................r....................,.. 6D'27 COOI-.ANT TEMPERATURE SENSOR ....r... 6D,28 Rem OV.......................r....................oo...... 6 Dt28 TgSt .............. 6 D28 -...........r.'...................o.o...... RginStal | .-........ts.'...,r..,......................r..... 6D28
2.7
THROTTLEPOSITIONSWITCH.............._... 6D,29
RemOV.......................r.................r.......... 6D28 RginStall ...............................r.................. 6D'28 AdiuStment.......o... o...............-...rr...!......... 6D29 ENGINE SPEED SENSOR ..,.................rr.....,.. 6D.30
T eSt...r ...................r .r r ........ . . . . . . . . . r. 6 I )-3 0
2.8
3. 3.1 3.2 3.3
RemOV................r.......'..... ....................... 6D-30 ReinStall ......-...!.............-... ro..r................ 6D'30 D I AG NOSIS .........r........r...'...-... or.,'..............r. 6D'3 1 DIAGNOSIS LIMP LAMPT.!...-......,,.......,........ 6D-31 DIAGUOSTIC ELECTRICAL CONNECTION FOR EST...........-........-..r,.,..,.. 6D-31 DIAGNOSIS OF LIMP LAMP OPERATION 6D.32 Ump Homg Mode,.....................,..,h.,.... 6D-32 Poggible Temperature Sensor
F aU l t.r ..r .....!..r .........r ....................o. . . . . . o . . . . . . .6 D -3 2
i 3.4 4. 5. 6.
PossibleVacuum Sensor or Throttle Position Switch Fault (1) .... 6D-32 PossibleVacuum Sensor or Throttle Position Switch Fault (2) .... 6D-33 CHECKING WIRINGHARNESS
PR O C E o D U R E .r .....'...r ...D .r .......r ...r r ..r .t... . . . . . . r. .. . 6 D ' 3 8
6 D-40 SPECI F ICATIONS -.r.........'.........r..........'......... 6D-41 TORQUE WRENCH SPECIFICATIONS.O""" 6D-41 SPECIAL TOOLS ..........r.r.....r...'...r.............r...
1 . GENERALNFORMATION
The ignition system employed on 3.3 litre Electronic Fuel Injected VK Series models is similar to the system used on 3.3 litre VH. Revisions have been made to the distributor advance mechanism and spark plugs have a revised heat range. Refer to Specifications at the end of this Section for details. The igniticn system for 5.0 litre VK Series rroceis carrles over from VH. O n S L a n c B e r l i n a m c d e l s w i t h t h e l a s e 3 .3 l r tr e e n g i n e , a Bosch Electrcric Spark Timing StSte'n tS used instead of the conventrcna rgnitionadvance svstem.
4-r
6D.1 8 ENGINE ELECTRICAL

1. 1 EL EC T R ON IC S P A R KT IMIN G
GENERAL DESCRIPTION The Electronic SparkTiming(EST)system replaces the
tirning function of the distributor (conventional vacuum and centrifugal advance mechanisms are not used). The EST system accurately matches the ignition timing to the engine requirements at all speeds and loads. The EST system processes the input from six sources. These are crankshafl position, coolant temperature, inlet manifold vacuum, throttle position, starter rnotor and, if fitted, air conditioning load is sensed from the cycling of the compressor clutch. An electronic micro processor control module controls coil primary current and therefore the generation of the secondary voltage to fire the spark plugs. Distributors used in the EST system are a simplified version of those used in past High Energy lgnition systems. Having no mechanical or vacuum advance mechanism, the EST distributor simply switches high tension voltage to the appropriate spark plug.
1.2 SYSTEM LAYOUT

Figure6D-28 shows sensorsused by the ControlModule to monitor engine operation.The only output from the module, controlscoil primary cunent.
E N GIN E S PE ED SENSOR ENG I NE WATER TEMPERATU RE

EL E C T R O N I C CONTROL MODULE
IGNITION COIL
lI
l-
T H ROTTL E P OS ITION S WITCH
MA N IF OL D VA C U UM S EN SOR
Figure 6D-28
AIR C O ND I T I O N I N CL U T C H
STARTER MOTOR
.-r---..

1.3 ELECTRONIG SPARKTIMING COMPONENTS SYSTEM
CONTROLMODULE The micro processor based controlmoduleis located
behind the left hand side cowl panel trim. Refer Fig. 6D-29. The control moduleperformsthe followingfunctions: 1. A mernory is used to store the micro processor programmeand data tables for spark advance as a function of speed and load, temperature, throttle switch positionand tjme after start. contaiexecutesthe programme 2. The micro processor ned in the memory. 3. The spark timing signals from the micro processor are converted into signals to control coil primary current. For every combination of engine speed and engine load there is a unique spark advance value specified and storedin the controlmodule. The spark advance information is stored in a memory table. Each entry of this table may be specified indof any other point. ependently The electronic control module memory contains two tables. table - for highwayuse. 1. Optimumadvance 2. Modrfied advance table - for low emission requirements. The memory tables are used by the micro processorfor everyignitionpulsecalculation.
E LE C TR ONIC C ON TR O L -MOD U LE
g
r''--1
),r
(--\ }--/
sl
ti ' :.a
6,e
ii '
:.1 -:t i
,
'a,(Z
L -W I R I N G HARNESS C O N N E C TO R
al
1* I
- / - \ o <-
M o u NTTN G scR EWS

(3 P LA C E S )
Figure 6D.29
ENGINE SPEED SENSOR An electronicspeed sensor, inductivemagneticpick up type, is mountedon the rear of the cylinderblock.Refer Fig. 6D-30. Three mild steel timing pins spaced 120o apart, ate located around the circumferenceof the flyrheel or and the pick-upof the speed torqueconverterassembly, sensorextendsthrougha hole in the clutch or converter housing. As each pin passesthe sensor, a signal is generated which is sent to the control module.The pins pass the sensorat six degreesbeforetop dead centre. The time intervai Detween any two pins passing the sensor pick-up,allows the control module to calculate enginespeed.
..- TN GIN E B LOC K
MOU N TI N G B O LT
..T-----spEED S E N S OR
Figure 6D-30
6D.20ENGINEELECTRICAL
MANIFOLD VACUUM SENSOR Mounted on the outside of the fuse box, the engine vacuumsensor relays information to the control module regarding the engine'sloadcondition. ReferFig. 6D-31. The manifold vacuum sensorsensesenginevacuumand from an input voltage of 5 volts from the controlmodule, a variableoutput voltage is sent from the sensor to the control module to inform it of the engine's load conditions. NOTE: Never apply battery voltage to the sensor terminals, as permanent damagecan occur. The sensoris non repairable, if provedfaulty,it must be replaced.
U N D E R S |D E V tE W OF -r \ FU S E B OX
Figure 6D-31
ENGINE COOLANT TEMPERATURE SENSOR The coolanttemperature sensoris mountedon top of the engine thermostat housing. The coolant temperature sensor determinesthe use of the appropriateadvance table during cold starts, normal operation and high temperature operation. The temperature sensor (Fig, 6D-32) is of the negative temperature coefficientdesign (NTC).The resistanceof the sensor decreases as the engine temperatureincreases,this causes a decreasein the signal voltage beingfed into the controlmodule. NorE: The coolant temperature sensor for EST is the samesensoras used for Electronic Fuel Injection.
Figure 6D-32 TH ROT T LE POSITION SW I TCH The throttle position switch is mounted on the carburettor float bowl. Refer Fig 6D-33. The function of the throttle position switch is to inform the electronic control module w h en t he th rottle is closed ( idle pos it ion) .
TH R OTTLE P OS tTtONS WTTC H
Figure 6E)-33
STARTER MOTOR
A signal from the starter motor solenoid informs the electronrc control module when the engine is being cranked.
AI R CON DITIONING COM PRESSO R CLUTCH A signal f rom the compressor clutch, indicates to the electronic control module when the air conditioner compressor is operating. This results in an increased ignition advance at idle, thereby increasing the idle speed to prevent the engine from stalling or overheating.
_--____

IGNITION COIL The ignition coil used with the EST system is the is fully standardHigh Energy lgnitioncoil. Coil triggering controlledfrom the electroniccontrol module, including dwell time. The electronic control module takes into account battery voltage to adjust the dwell to compensate for the time requiredfor the coil to reach full currentlevel at varioussupplyvoltages.
1.4 MODESOF OPERATION

With the many varied conditions under which the engine is required to operate, the ignition system must cater for a nurnber of different operational modes. In addition, compensation factors in'ignition performance are required to allow for changes in engine temperature and load conditions, to ensure optimum engine performance with minimum emissions. For convenience, engine operation can be considered to have six operation modes.
CRANKING
The timing pins situated around the flytruheelor torque converter circumference are positioned at 60 BTDC. As the flyrruheelor torque converter assembly is rotated by the starter motor, the engine speed Sensor signals the electronic control module to trigger the ignition coil and firing occurs at 6 o BTDC. With a cranking speed less than 4OO rpm, the timing will remain at 60 BTDC.
IDLE
With electronic spark timing, idle is defined as follows: 1. Engine speed between 400 and 900 rpm. 2. Throttle position switch closed. There are a number of functions which operate at idle to maintain idle quality, compensate for loads and maintain idle speed and quality after a cold start. ldle advance without compensation f unctions is six degrees BTDC. This is retarded from the optimum advance for emission control. Compensatton functions operate to increase advance and maintain idle speed and q uality.
ldle - Low Temperature Compensation

To maintain idle speed and quality after a cold start, spark advance is increased. The amount the advance is increased is a functiOn of engine coolant ternperature at 'Engine Start' and time after start. This function is shown in Fig . 6D- 34 Fig. 6D-34 shows additional advance as a functron cf coOlant temperature at 'Engine Start' and time Srnce 'Engine Start'. lf 'Engine Start' coolant temperature is A. then additional acivance B is available for 12 mrnutes. provided engine is idling. lf engine speed exceeds 900 rpm due to additional advance, advance slowly decreases to effectively govern engine to 900 rpm.
AD D IT IC N ,J AL AD \./AIi C E
17o c COOLA N T T E MP E R A TU A E AT E I{ GIN E STA R T 12 MIN U TE S TIME S IN C E S TA R T
Figure 6D-34
6D.22ENGINEELECTRICAL
l dle - H igh Temp era ture Com pens at ion
A D D ITION A L ADVANCE t 8oc
lf the engine coolant temperature exceeds 95oC, while the engine is at idle, the spark advance is increased to improve idle quality and increase rdle speed for improved cooling. See Fig. 6D-35 lf coolant temperature exceeds 95oC, spark advance is increased up to a maxrmurl of 24o BTDC at 105oC, ldle advance will not exceed 24o BTDC under any circumstances.
gsoc
t osoc
ENGINE COOLANT TEMPERATURE Figure 6D-35 ldle - Load Compensation The:gnit io n system ha s t he c apabilit y t o c ont r ol idle speec ':o compensate for loads impcsed by engine driven accessories.
Air Conditioning
Clutch Load
When t he e ng ine is at idl e ar o t he air c ondit ioningc lut c h i s engaged, th e a dvan ce r S I nc ' ' eas edby 12o t o m aint ain a n idle sp ee d o f a pp roxm at ely 85C r pm .
Engine Load
lf the engine slows due to hrgh loads such as generator charging and power Steering, advance is increased as s hown in Fig . 6 D-36 . As engine speed falls below speed A, advance increases to a rnaximum at soeed B.
MA N U A L 760 R P M A U TOMA TIC
A D f ITION A L A DVANCE
7.so B TD C
60 gtoc
4O O R PM
A
E N GIN E SPEED
Figure 6D-36
NORMALMODE
Under normal vehicle operations, the contro ^nodule optimizes spark advance for improved fuel econcm/ and driveability.The control module also takes into acccunt the necessity f or meeting legislated emission levels. Normal mode is defined as engine speed above 900 rprn a nd throttle p osrtronswitc h O PEN.
I I
t-
6D.23 ENGINEELECTRICAL
Normal Mode - Low Temperature Compensation After a cold start, advance is increased during normal The amount mode operationto improve cold driveability. of advance selected is based on engrne coolant temperatureat 'lgnition ON', and is gradually reduced with elapsedtime after 'Start'.Refer Fig. 6D-37.
A D D ITION A L ADVANCE
ooc'\
c ,t' to C O OLA N T TEMP E R A TU R E A T K E Y "ON "
E ^.1I N U TE S
T I\1E SIN C E ST AR T
Figure 6D-37
CONTROL OVERSPEED
When the engine speed exceeds 5800 rpm the control rnodule reduces the spark advance to 20o BTDC to avoid engine over speeding.
DECELERATING the enginespeed is greater When the throttleis released, than 900 rpm and the throttle positionswitch is closed, mode. the operationis definedas decelerating that the vehicle The control modulereceivesinformation mode, and advanceis selectedby is in the decelerating under decelerathe controlmoduleto reduceemissions ting conditions.
LIMP HOME MODE During normal operation above 400 rpm, the micro processor in the control module calculatesthe required spark advance for each timing impulse. lf the micro processoris unableto operatenormally(due to mechanical damage for example)the system revertsto the Limp Home Mode. In this conditionall firing impulsesare at 6CBTDC. lf the limp mode is initiated,the diagnostic lamp on the warning lamp panel (Fig.6D-38) is lit mode. in the normaldriving continuously
.WA R NIN G LA MP
PAN EL D IAG\OST IC LA\1P.
Figure 6D-38
6D.24ENGINEELECTRICAL 2. SERVICE OPERATIONS

2.1 SERVICE NOTES
The following requirements must be observed when working on vehicles with the Electronic Spark Timing (EST)system. 1. Before removing any EST system component,disconnect the battery earth lead. Failure to do so could result in the service operator receiving an electrical shock. 2. Never start the engine without the battery being solidly connected. 3. Do not use a quick charge unit to start the engine. 4. Neve. separate the battery from the on board electrical svstem whilethe engineis runnrng. 5. When charging the battery, disconnect it from the vehicle's electricalsystem. 6. Never subject the Electronic Control Module to temperatures above 80oC (176oF) i.e. paint oven. Always remove control module first if this temperature is to be exceeded. 7. Ensurethat all cable harness plugs are connected solidly and that battery terminals are thoroughly
clean. Never connect or disconnect cable harness plug at the control module when the ignition is switched on. 9. Before attempting any electric arc welding on the vehicle, disconnect the battery leads and the control module connector. 10. When steam cleaning engrnes, do not direct the stearn cleaning nozzle at any EST component. lf this happens,corrosion of the terminals can take place. 1 1. Do not rotate distributor from standard setting as crossfiringwill occur. 8.
T IMIN G 2 . 2 SE T T I N G IGN IT ION

Since the ignition timing in the EST system rs electronically controlled, the distributor position has no effect on the engrneignitiontiming setting. The onlv requirement for distributor setting is that the rotor button must be aligned wrth the appropriate segments in the distributorcap to frre the spark plugs. To set distributor,loosen distributorclamp bolt and carry out steps 4 and 5, as descrrbed in 2.2 Distributor R e inst all.
2.3 DISTRIBUTOR
REMOVE
1. 2. Unfasten spring clips holding distributor cap and remove distributorcap. Crank the engine until the distributor rotor rs in positionto fire No. 1 cylinder and the timing mark on the t orsion ald amp er is in alignm entwit h t he longes t mark (TDC) o n the fr ont c ov er t r m ing s c ale Fig. f u39 sho ws th e No . 1 f ir ing pos it r on f or EST engines w ith t he ma rk o n th e r ot or lined up wit n t he not c hed mark in the distributorhousrng.
NOTE: The longest mark on the timing scale on the front cover is top dead centre number 1 cylinder.
Figure 6D-39

3. Clean all foreign matter from around the distributor and clamp, then remove the distributor clamp bolt a nd cla m p. Withdraw the distributorfrom the engine.
4.
REINSTALL 1. Align the centre line of the protruding gear retaining pin with the raised mark on the distributor body. Refer Fig. 6D-40. The rotation of the distributor rotor during meshing of the distributor and camshaft gears will align the firing position for No. 1 spark plug. When a replacement pin is fitted, the pin does not protrude.
R A IS E D MA R K OI,J D IS TRIB U TOR H OU S IN G P R OTB U D IN G R E TA IN IN G P IN
Figure 6D-40
2.
into its position.Rotatethe body Installthe distributor cap clamps are at approximately so as the distributor Refer Fig. 6D-41. centreline. 45o to the crankshaft clamp and bolt, do not tightenbolt. 3. Install distributor
C R AN K S H A FT C E NTR E LIN E Fi gure 6D -41
4.
Place a right angled set square across the top face of the distributor body. Align the centre mark on the rotor button and the No. 1 cylinder mark on the distributor body by rotating the body. Refer Fig . 6 D- 42. 5. Tighten distributor clamp bolt and install distributor cap. lf the engine is accidentally cranked after the distrrbutor was rernoved, the following procedure can be used, for installing: 1. Remove No. 1 spark plug. 2. Place finger over No. 1 spark plug hole and crank engine slowly until compression is felt. 3. Align timing mark on torsional damper with the longest mark C[DC) on the front timing cover scale. 4. Install the distributor as previouslyoutlined.
Figure 6D-42
.*--L -
6D-26ENGINEELECTRICAL
DIS A S S EMBLY 1. 2. 3, 4. Remove distributorand rotor. Remove circlip and upper distributor shaft thrust washers. Press out the pin securing the drive gear and remove gear and thrust washers. Refer Fig. 6D-43. Push shaft from housing by applying light force at the drive end.
REASSEMBLY
Reassembly is reverse of disassembly.
1. D IS TR IB U TOR C A P 2. R OTOR ? S H A FT 8 4 U P P E R & LOWE R B U S HE S 9 5 FIB R E WA S H E R

1
S H I\4 WA S H E R D R IV E GE A R D R IV E GE A R P IN D IS TRIB U TOR H OU S IN G
Figure 6D-43
2.4 MANIFOLD VACUUM SENSOR

REMOVE
1. 2. Remove the two screws securing the sensor to the bottom of the fuse box. Refer Fig. 6D-44. Disconnect wiring and vacuurn connectors. Refer Fig. 6D-44. ,
,- MOU N T| N G /' S C RE W (2 P LA C E S ) / U N D E R N E A TH V IE WOFT FU S E 8OX
R EI NS T ALL Installationis reversal cf removal.
WIR IN G _/ CON N ECTO R
Figure 6D-44
.-r..-f. -
TESTING
Testing the vacuum sensor can be done on the vehicle. 1. Disconnect sensor vacuum hose from inlet manifold adopter. 2. Use a hand vacuum pump, such as Tool No.J2398701 or equivalent, insert end into open hose end. Refer Fig 6D-45.
Figure 6D-45
3.
4.
Connecta voltmeter acrossthe CB and CA terminals of the sensor.Refer Fig. 6D-46.Switchon ignition. With a varyingamountof vacuum,the output voltage variesaccording to the following table: E V OLTA G O U T PU T 4 .4 to 5.3 3 .2 to 3.8 2 .0to 2.5 0 .7to 1.1
VO L T} I E T E R
Any deviation in the output voltage figure with the nominated applied vacuum, indicates a faulty sensor, which must be replaced.
Figure 6D-46
MODULE 2.5 ELECTRONIC CONTROL

REMOVE
1. 2. 3. 4. Make sure ignitionis switched'off' and disconnect batteryearth lead. Removethe lefi hand cowl panel trim from the front passenger compartment. Removemodulemounting screws.Refer Fig 6D-47. Disconnect wiring harness and withdraw control Refer Fig. 6D-47 modulefrom its position.
E LE C TR ON IC C ON TR OL MO D U LE
WIR IN G HARNESS
REINSTALL is the reverseof removalprocedure. Installation

/
,//,i' ,rr r/
MOU N TIN G
*}. %,' W
scR S C RE\vs. E IV S .
(3 PiACES)
Figure 6D-47
6D.28 ENGINE ELECTRICAL

2.6 COOLANT TEMPERATURE SENSOR
REMOVE
1. 2. 3. 4. Disconnect batteryearth lead. Disconnect wiring harness connector temperature sensor.Fig. 6D-48. Draincoolantfrom engine,below sensor level. Removesensorfrom thermostathousing.
from
Figure 6D-48
TEST 1. Suspend sensorin a container of 50/50 glycol/water. Ensurethat sensordoes not touch the container. 2. Place thermometer,having a scale reading of at least 100oC, into containerand heat. 3. Record resistanceacross sensor terminalsat various temperatures. Refer Fig. 6D-49. Checkthe resultswith the followingchart.
R ESI STANCE ohm s
5 4 to 6 .3 k a 2 3 to 2 .7 k n 300to 350 n 1 7 0to 2 1 0 n

Any deviation in the resistance values recorded at the norninated ternperature readings indicates a faulty sensor which mu st be re pla ce d. RE I NS T AL L 1. 2. 3. Apply GMH sealant P/N g}3szi4 to sensor threads, refit in thermostat housing and tighten. Refit wiring harnessconnector. Fill up radiator and check for coolant leaks.
Figure 6D-49
r --
B R A C K E T S C RE WS (2 P LA cE S )
MOU N TIN G B R A C K E T MOU N TI N G P LA TE
C A R B U R E TTOR
2.7 THROTTLE POSITION SWITCH

REMOVE
1. 2. 3. Femove carburettorair cleaner. Disconnectthe two wiring connectors at switch. Remove the 2 switch mounting screws, washers and mounting plate. Refer Fig. 6D-50.
A C C ELE R A TOR LIN K A GE
S C RE WS
\
RE I NS T AL L Installationis reverse of removal procedure. The swrtch rnust be readjusted after installation.
\ S WITC H A C TU A ToR
Figure 6D-50
6D.29 ENGINEELECTRICAL
ADJUSTMENT
1. 2. Disconnect wiring connectors from switch. Connect an ohmmeter across the switch terminals (Do not use a test light). Refer Fig- 6D-51-
TH R OTTLE P OS ITIONS W ITC H
Fi gure 6D -51
3.
Positionthe fast idle screw onto the second highest step of the fast idle cam. Refer Fig. 6D-52. Check that the switch is open, the ohmmeterreads infinity ohms. 4. Rotate the fast idle cam so that the fast idle screw sits on the third higheststep. Check that the throttle positionswitch is closed,the needle of the ohmmeter reads 0 ohms. Loosen mounting Screws and adjust switch as required to achieve correct adiustment. 5 . When switch is correctly adiusted,tighten mounting screws and recheckadiustment6. Reconnect wiring connectors to switch. Reinstall air cleaner. carburettor for the engineto On vehicleswith manualtransmissions, return to idle, it is essentialthat whenever the throttle closes onto the extended throttle nudger shaft, the throttlepositionswitchmust be closedlf the throttle closes onto the extended nudger without closingthe throttlepositionswitch,the enginewill run at 1400 rpm. approximatelY To Check Operation 1. Disconnectthrottle positionswitch wiring connectors and connect together (this simulates a closed switch),connectan ohmeteracrossswitch terminals. 2. Start the engine. 3. Open the throttle until the switch opens, (ohmeter reads 'infinitY'). 4. Depress the spring loaded button on the throttle nudger and close the throttle.Waththe throttle lever resting on the extended nudger shaft, the ohmeter shouldshow zero ohms. 5. Readjustidle speed,fast idle speed,throttleposition switch or throttle nudger setting to ensure correct oPeration.
F AST ID LE C AM \
\
I
S E C OND S TE P
Figure 6D-52
6D.30ENGINE ELECTRICAL
2.8 ENGINE SPEED SENSOR TEST
1. 2. Disconnect sensor wiring harness connection, at the fuse box side of the rocker cover. Refer Fig. 6D-53A. Connect an ohmeter across sensor terrninals shown in Fig. 6D-53. Resistance should be in the range of 1 to 1.2 k Q. Any deviation in the resistance value than specified the sensor is considered faulty and must be replaced.
FR ON T V IE W OF C ON N E C TOR LE A D TO E N GIN E S P E E D S E N S OR
ME A S U R E A C R OS S TH E S E TE R MIN A LS
Figure 6D-53
REMOVE
1. 2. Disconnect battery earth lead Disconnect engine speed sensor wiring harness connection, at the fuse box side of the rocker cover. Refer Fig. 6D-53A 3. Remove engine harness strap at rear of rocker cover. 4. Remove bolt securing engine speed sensor supporl to the rear of the cylinder block. 5. Remove sensor assembly from its location. NOTE: Do not damage support locating lug. 6. lf necessary, mount speed sensor support carefully in a vice with soft jaws, remove mounting bolt and separate sensor from support. REINSTALL Installationis reverse of removal operations.
E N GIN E H A R N E S S S TRA P MOU N TI N G B OLT
SPEED S E N S OR SPEE D S E N S OR S U P P OR T S E C U R IN G B O LT
S U P P OR T LOC A TI N G LU G
Flgure 6D53A
ENGINE ELECTRICAL 6D.3 1 3. DIAGNOSIS

3.1 DIAGNOSTICLIMP LIGHT
When the system is operatingnormally,the lamp is on during engine cranking and while the engine is not running with the ignition 'ON'. lt will go out a few is operating secondsafter the engine starts if everything normally.lf the light does not come on at all, the bulb, the wiringor the modulemay be faulty. The lamp will come on whilst driving for one of two reasons. 1. lf the control module detects an operatingfault with one of the EST systemsensors. The control module assumes a normal operating value for that sensor, and continuesto supply the engine with a spark advance value, althoughtnot value. necessarily the optimum 2. lt means that there is a malfunction in the control moduleitself. In this case the EST system wrll revert to a spark advancevalue of 6C BTDC (Limp Home Mode),this enablesthe vehicleto remainoperational at a reducedperformance level.
ELECTRICAL 3.2 DIAGNOSTIC FOR EST CONNECTION

Situatedwithin the EST engine wiring harnessassembly is a single cavity connector body and terminal, taped back to the wiring harnessas shown in Fig. 6D-54. With the aid of a jumper lead fitted with aligatorclips,this allows the connectionof the connectorbody terrninalto a suitable earth point on the engine. With this connection, limp lightis activated. the diagnostic The diagnostrclimp light is located within the dash warning light panel. By means of a coded flashing warning,the limp light definesthe source of the EST systerncomponentfailure.
TA N & P IN K -=i D S (l GN l Tl ON C Ot :-'
MAIN W IRING HARNESS CONN.
E.S.T.D IA GN OS TIC CON N E C TC R
\)
. -/
T R ANSM ISSIC\ H ARN ESS
)c
'l
tx
DK SL UE L EAD ( OI L PRESSURE SW i
-'\
q_
Figure 6D-54
ELECTRICAL 6D.32ENGINE
ln the event of the limp light coming on to indicate a system component failure, make the earth connection to the connector body without turning off the engine, and let the engine idle. Description of the diagnostic limp light operation is covered in 3.3 of this Section. To reset the diagnostic lamp for normal mode condition, turn off the ignition and remove jumper lead. Restart vehicle and if the fault has not been corrected the diagnostic lamp will come on again when the appropriate test conditions are re-established.
After the 8 minute period is complete, the module detects the fault, turns the warning light on (or ftashes the diagnostic code in diagnostic mode) and assumesa normal temperature(90oC). The light remains on continuously in normal mode (or continues to f lash in diagnostic mode) until the ignitionis switchedoff. when the light comes on, the idle speed will return to normalas the very high temperature is no longerseen. Open Circuit lf an open circuit fault is present, the temperature appears very low (-14oC) to the module. lf the temperatureat ignition key on is low, the idle low temperature compensationis enabled. For the first 12 minutes of engine operation,idle spark advance is increasedfor improved idle quality. Note that this will cause the idle speed of a warm engine to fluctuateabout 900 rpm. This is because additional advance is only present at idle, which is defined as engine speed less than 900 rpm and idle switchclosed. lf the speed is above 900, the advance is slowly removedand the engine slows. lf it is below go0 rpm, the advance increases and the speed increases.This provides engineidle speed governing at 900 rpm. After 8 minutesof operationwith the open circuitfault, the module turns the light on (or flashes the code in diagnostic mode), assumes a normal operating temperatureand continues to provide additionalspark advanceat idle until 12 minutesafter ignitionkey on. POSSIBLE VACUUM SENSOR OR THROTTLE POSTTTON SWTTCHFAULT (1) whenever the engine is operating, the module is checking for a vacuumsensorfault. lf the throttle position switch is closed and the engine speed exceeds 1500 rpm, the rnoduleexpects to see a manifold vacuum greater than 30 kPa. lf the module detects a vacuum of less than 30 kPa under these conditions, it will turn the diagnosticlight on (or give z flashesevery 8 secondsin diagnosticmode) and assume the manifoldvacuumis zero at all times. lf the engine is switchedotf and re-started, the light will go out until the engine speed exceeds 1500 rpm while the throttle position switch is closed. lf the vacuum is again seen by the moduleas less that 30 kPa, the light will be turnedon again. This fault will be indicatedif the hose comes off the vacuumsensor,if the signalwires rn the vacuumsensor harnessare shortedtogetheror if the vacuumsensor is faulty. This fault may also be indicated if the throtile positionswitch wires are shortedtogetheror to groundor the switch itself is badly adjustedor short circuited. For example, the enginemay be operating at 1600 rpm wide open throttle and with zero vacuum, lf the throtile positionswitch is operatingnormally, it will be open and no fault will be recorded.lf the throttle posrtionswitch wires are shorted together,the module sees the same inputas a closedswitchand recordsa fault condition. It is necessary to assumethe engineis operating at zero vacuum all the time this fault is present.This is to prevent the module frorn giving the engine excessive advance at wide open throttle and causing detonation damage.
3.3 DIAGNOSIS OF LIMP LAMP OPERATION

(Refer to chart at the end of this Section.) L IMP HOME MODE lf the microprocessor (or computer) fails, a limp home mode is activated and the warning light is turned on. Limp home mode is provided to minirnisethe likelihood of the owner being stranded. Spark timing is very retarded in this mode (60 BTDC always) and this will use increased fuel consumption, poor engine response and higher engine operating temperatures, Prolonged operation in this mode should be avoided. Monitor engine temperature regularly if limp mode operations is necessary at high ambient temperatures or while towing. Stop if necessary. lf the microprocessor starts operating normally, the light will be turned off in normal and diagnostic modes, provided no other faults have been detected. lf the diagnostic light is on continuously in norrnal mode and does not flash a recognisable code in diagnostic mode, the EST module should be replaced. POSSIBLE TEMPERATURE SENSOR FAULT lf a fault is detected in the temperature sensor circuit, the light is on in normal mode. In diagnostic mode, the light flashes on for 1 second in every 8 seconds. The control module does not check the temperature sensor circuit until the ignition has been on for 8 minutes. From I minutes onwards the module contrnuously checks for a temperature between 50oC and 125oC. ff the ignition is switched on without starting the engine the temperature may be outside the specified limits without a fault being present, I minutes after i gnit ion' ON'. To check for this false indication,switch ignition off, start the engine and check the light in 8 minutes. lf the light comes on again, it may be due to either an open circuit, a short circuit or a faulty temperature sensor. A faulty sensor may give the same symptoms as an open or short circuit.
Short Circuit very is present, lf a shortcircuit the temperature appears

high (130oC ) to the module. In the I minutes between the ignition being turned on and the detection of the fault, the module will increase idle spark advance as if the temperature really were high. This is done to increase idle speed for improvedengine cooling.
-----------r
ENGINEELECTRICAL 6D-33
POSSIBLE VACUUM SENSOR OR THROTTLE POSTTTON SWITCH FAULT (21 This section describes a second test for a possible vacuum sensor fault. lf the throttle position switch is closed and the engine speed is between 825 and 900 rpm, the module expects to see a manifoldvacuum of between10 kPa and 75 kPa. lf the moduledetectsa vacuumoutsidethese limitsit will turn the diagnostic light on (or give 3 f lashes every mode) and assumethe manifold 8 secondsin diagnostic vacuumis zero at al times. the light will If the engine is switchedoff and re-started, go out until the check conditionsare met and the fault re-detected.This fault will be indicatedif the electrical connector comes otf the vacuum sensor, a vacuum sensor wire is broken or the vacuum sensor is faulty. lt may also be indicatedif the throttlepositionswitch wires are shorted together or to ground or the switch itself is short circuited.
EST DIAGNOSTIC LAMP CHART

i FAUL T DESCRI PTI O N Poss ible EST Cont r ol m odule f ault FAULT C O N D I T I O N Cont r ol m o d u l e s e l e c t s lim p m o d e LIMP LIGHT OPERATION Diagnostic Mode * Lamp uncontrolled u s u a l ly o f f O n e p u l s eo f lamp every 8 seconds Normal Mode Lamp or u n t i l r e s e ti s l successfu Lamp on until reset successful C O R R E C T SYSTEM o P E R ATTON
c o n t r o l mo c - . the c re red - c light is no:

,A 'i er the engine n:s been rLtnrng for 8 m i -ru:= s , the er^Cne temperatu' = .' ,rl l be bei vveen 50oC t: ' ,25oC
Po ssible enginec oolant r e s ens orf ault temp er at u
Assu m e s engi ne cool ant te m p e r a ture = 95oC
Possi ble v ac uum s ens or o r thr ot t le pos it r on sw it c h f ault ( 1)
va c u u m i s 0 k P a As s um es wit h t he t h r o t t l e p o s i t i o n s wit c h op e n o r c l o s e d
Two pu lsesof lamp every 8 seconds
Lam p on W:n throttl e po s i ::on s w i tc h Jrtil reset ci csed, engi ne v ac LU rn mus t successful be greater than 30 k P a
provi ded the engi re s peed s greater than 1 500 rpm
Po ssi ble v ac uum s ens or o r th r ot t le pos it ion swit c h f ault ( 2)
m es v a c u u mi s 0 k P a As s u wit n t he t h r o t t l e p o s i t i o n s wit c h o o e n o r c l o s e d
3 p u l s e so f l a mp e v e r y 8 seconds
Lamp on until reset successfu I
t h th rott l e po s r: ;o n s w i tc h ci osed and en gi rrE rdl i ng
b e i 'v e e n8 5 0 a n ci9 0 0 r p m m m u st b e t h : e n g i n ev a cu u b e : 'v e e n1 0 a n d 7 5 kPa
t o s t a t ew h e t h e r the l amp w i l l be on or o'r or f l ashi n g. H ow ev er of t he nat ur e of t his f ailur e it is n o t p o s s i b l e Be ca us e f las h it is v er y unlik ely t h a t i t w i l l c o r r e s p o n d if th e l am p c ioes t o a n y of th e va I i d di agnost i c codes. D espi te thi s i t sh ou ld be obv ioust hat t he EST is in t he i m p h o m e m o d e . d u e t o t h e veh c;es performance.
ELECTRICAL 6D.34ENGINE
INIT IAL CHECKS
t---
i ST A R T
1. Chec kt hat Diagr os t i c L e a d i s N O T e a r t h e d . 2. St ar t enginear d allo w t o i d l e . 3. Not e t im e v . , hen s t ar t i n ge n g i n e .
yES
lsDia g n o stie
LamPon? i->I
tttO
C o n n e c t D i a g n ostic L e a d t o e a r t h.
C o nn e c t D i a g n o s t i cL e a d t o e a r t h . A l l o w e n g i n et o idle until 10 minutes after start.
ls Diag -osticL am p f las'ring 1,2 or 3 t imes every8 seconds ?
l s l i ght fl ashi ng once every 8 seconds?
NO NO
Se e Ch a r t co r r e sp o n d rng to n u m b e r o f f la sh e s.
SeeChart 2 f or possible C o o l a n tT e m p e r a t u r e S e n s o rf a u l t .
1. C o n n e c t t i m i n g l i gh t 2. Op e n t h r o t t l e w h i le engine is idling. 3. L o o k f o r t i m i n g m a r k o n h a r m o n i c b a l an ce r .
END
S e e C h a r t s3 & 4 f o r p o s s i b l e Vacuum Sensor or throttle P o s i t i o nS w i t c h f a u l t s .
D o e s t i m i n g m a r k m o ve as e n g i n e s p e e d c h a n g e sT
W or k t hr ouc n Char ts Nos .2, 3 & 4 n t hat or d e r . ls light still on?

Rep l a c e E S T C o n t r o l M o d u le
+YES-
-l
NO
C h e c k Wi r i n g H a r n e s s , d e t a i l sa t t h e e n d o f this Section.
CHART 1.

E. S. T. DI AG NO STI C L I G H T F L A S H E S T H R E E T I M E S I N D I A G N O S T I C M O D E . PO SSI BLE ENG I NE VAC U U M S E N S O R O R T H R O T T L E P O S I T I O N S WI T C H F A U L T . START
t.
2
I A 9.
5.
F ' t Tac hom et er . Fit M anif old Vac uum G a u g e . ldle Enginebet ween8 5 0 - 8 7 0 r p m w i t h 2 0 t o 7 0 k P a \ {a ^ ''o l d V a c u u m . is s i o n- | n D r i v e , o p e n t h r o t t l e f u l l y f i 'o r - d l e . Aut om at ic Tr ans m - I n t o p g e a ra t 8 3 0 r p m , o p e n t h r o t t r e f r l y f o r 1 s e c o n d . M anual Tr ans m is s io n
Light
YES
RECTI FY
i s V acuum H ose connected to V acuum S ensor?
YES
RECTI FY -
NO
l s Wi r i n g H a r n e s s C o n n e c t o ro n V a c u u m S e n s o ra n d r r : a kn g C O n t a c t ?
YES
RECTI FY -
NO
D oes Th rsl i l s P o s i t i o nS w i t c h o p : 'a : e as sP ec;fi eC o n E mi s s i o n L ab e )
YES
I
RECTI Fy _
FAULT! - - - *
T e s t a n d C h e c k E n g i n eV a c r u m S e n s o r ano T h r o t t l e P o s i t i o nS w i t c h \ \ ' - i rQ H a r n e s s e s , d e t a i l sa t t h e e n d o f t h r s S e c t i o n ,
o.K.
T e s t E n g i n eV a c u u m S e n s o r asper o p e r a t i o n2 . 5 i n t h r s S e c t i o n . service
RE PLACE - FAULTY
o.K.
R eol ace
E S TC ontrol
Modul e
END
2. CHART

E . S. T. DI AG NO STI C LI G HT FLA S H E S T WI C E I N D I A G N O S T I C M O D E . POSSIB LEENG I NE VACUUM SENSO R O R T H R O T T L E P O SI T I O N S WI T C H F A U L T .
; ST A R T
1 2
F i : T a cr o m e te r . F : l' t/a n r f o ld Va cu u m Ga u g e
D.ive v ehic lewit h an enaines peedof 2 0 0 0 r p m o r m o r e . Op en Thr ot t le unt il Vac uur ndr ops b e l o w 2 0 k P a a n d t h e n c l o s eT h r o t t l e u n t i l en gines peedr eac hes appr ox m at ely 1 6 0 0 r p m .
Does Ligh t f l a s ht w i c e
8 seconds?
YES
RECTIFY _ _,
I F A ULT S
ls Vac u u m H o s ec o n n e c t e dt o Vac uum S e n s o r and is Vacuum av a i l a b l e at Sensor?
YES
R ECTIFY FAU LTS
YES
REPL ACE i SENSOR
F A U L T Y -< .
Tes t Eng i n eV a c u u m S e n s o r asper s er v ic e ope r a t i o n2 5 i n t h i s S e c t i o n .
OK
HA;ruissl-I
RE P A I R I
FAULTY
a^d C h e c <E n g i n eV a c u u m Se" s o rV / i r r n gH a r n e s s ,
Repiac e ES T C o n t r o l Modu l e
END
CHART3.
6D-37 ELECTRICAL ENGINE

E. S. T.DI AG NO STI C L A M P F L A S H E S O N C E I N D I A G N O S T I C M O D E . PO SSI BLECO O L A N T T E M P E R A T U R E S E N S O R F A U L T .
START
S tart E ngi ne and al l ow to i dl e for ten mi nutes.
seconds?
NC -
Light may comeon if E n g i n ei s n o t s t ar te d a s s o o n a s i g n i ti o n s : u r n e d 'O N '
REFI T
Connector l s Wi r i n g H a r n e s s fitted to Coolant Sensor? Temperature
YES
REPLACE SENSOR
FAULTY
c e r a t u r eS e n s o r 1 T e s t C o o l a n tT e r n a s p e r s e r vc e o P e r a t i o n i n t h i s S e c i'c n .
R EPAIR HARNESS
FAULTY- +
Te s t a n d C h e c kC o o l a n t T e r r 'p e 'a t u r e Wi r i n g H a r n e s s , Sensor c e t ai l s a t t h e e n d o f t h i s S e c i c n '
ESTControl Module Repl3ce
END
CHART4.
.--^
6D-38ENGINE ELECTRICAL
3.4WIRING H AR N E S S C H E C K IN G PROCEDURE
1.
2,
Remove electronic control module as per service operation 2.6. Separate the EST wiring harness from the control module.
25
14
3. Sincethe contactterminals on the plug strip are not marked, the contacts must be counted for the varioustests. Terminals 1 through 13 are located on the long terminal strip, terminal 1 is next to the cable
entrance. Refer Fig. 6D-55. Terminals 14 through 25 are located on the short terminal strrp, terminal 14 is next to the cable entrance. Refer Fig. 6D-55. Remove the wiring harness connector from the EST sensor to which the test is directed. Using an ohmmeter, connected to the appropriate terminal on the plug strip and the terminal on the disconnected sensor harness plug, check the wiring f or: a. Short circuit, b. Open circuit. c. Short circuit to earth Refer to followrng chart and Fig. 6D-56 for details. TERMINA L HARNESS CO NNECTO R NO TE RM I NA L Blac k Blac k iwh C oola nt T emperatu re S ensor T hrot t le P osition Switch
Bla ck .' , te Bla ck \r /n ,te wir e
13
MU LTI_P LU G TE R MIN A LS
4. 5.
Figure 6D'55
S E NSOR
B ac< W hit e wir e Br ac k wir e

ccil te r m in a l c c n n e cto r
E ngine V acu um S ens or

*
21 24
v
A B C
fr o m th r o ttle p cs : :-
Remo v e w i r i n g c : - i :c:l- s s wit c h b e f o r e c h e c k r:
,A,
r-
.a3.-
EST WIRING DIAGRAM
SPEED SEN S O R
( STARTER SOLENOI D) IGNIT ION ST AR T ER SW IT C H ENGIi\: COOLAi',lT TE MP E R A TJ R E S EN S O F
I
_ I -_.
GN D
c o
()
FUJ
TH R O TT L E P O S I TI O N S W I TC H 15
z z o
f
C) ul
f-TO IG N . SW . DIAGNOSTIC LA\IP 3 W AT T S M AX. 17 18
o o o
z o
O cf) lu
G F
'.--.-----i I I c oNNEc r oR
SERV IC E D IAGN O ST IC SWIT C H T O GR O U N D
B--l
-,rl
---J
I I
24 19 20 14 16 EARTH FOR EST ON CENTRAU EAaTH lN G POIN T EARTH FOR IGNITIC\ ON CENTRAL EARTHING POIN T B + TO IGN. SW ITCH A B C GN D SIGN AL + VE
E^r iNE '. ':r,JM
a -r s v tV V -l - I
Figure 6D-56
6D.40ENGINE ELECTRICAL 4. SPECIFICATIONS

E NGIN E DESIGNATION D ' stribut or Mak e..... S park Advan ce P ick u p Cc F iring O'ce' C oil Mak: C u' .en i En gin eSto pp ed. . . . En gin eldlin g P : imary Co il Resistance Secondary Coil Re sistan ce Spark Plugs Make . Model . Tread . G aP . . T ighte nTo rqu e High Tension Lead Resistance AC A2CLTSX 14 mm 1 . 5 m m ( . 0 6 0i n .) 17 - 18 Nm 2000 to 8000 OHMS oer 300 mm 44TX Bosch 0 7 amos 0.5 - 0.7 OHMS @ 25oC 57 Kilo OHM@2SoC R:sista nc e Bosch R e f e r" l g n i t i o n D i s t r i b u t o r A d v a n c eD e t a i l s " C h a r t o n f o l l o w i n g p a S e .( 3 . 3 t i t r e E F I a n d 5 . 0 l i t r e o n l y . ) 1.0 - 1.2 Kil OHM @25oC 1,5,3,6,2,4 1,2,7,8,4, 5,6,3 . . 3.3litre EST, EFI ;flh 5.91;,,.
I G NI TI O N DI STRI BU T O R A D V A N C E D E T A I L S
IN ITIAL DIST. AOVANCE ID EN T I F IC AT I O N O N W H IT E LABEL ON VAC U U M AD VAN C E U N IT
AP PL I C A T ION
DIS T . P A RT NU MB E R
i i{ DEGREES)
CENTR IFUG AL AD VAN C E ENG. DEGREE S AT EN G. R .p.M .
VAC U U M AD VAN C E EN G. D EG R EES @ k Pa ST AR T

tl
I
tl
t er oc t
12 BELOW 1 100 RPM
s r ART
- 3.0 to 1.0 @ 1200
TNTE R M E D T AIT E r u l r _
3 : :3 :3.5 + 2410
F U LL 11 - 15 @ 34 14 - 1g @ 42- 47
3.3 litre EFI
9 2 Ct 7 t9 O
16.0to 20.0 @ 5000 20 to 24 @ 4400
\:
1-l tt
BLAC K 120
5.0 litre
92023157
6 BEL OW E5 CRPM
| I i
- Z to Z O 1000
E :c'2 3 20c0
0
Y
22-29
ELAC K 60
------r
41 6DELECTRICAL ENGINE
5. TO R Q UE W RE NCHS P E CI F I CA T I O NS
Nm Thr ot t le Pos r t ic nSw i t c h Sc r e wt o P l a t e f ulc unt ing Br a c k e tt o C a r b u 'e : i c r , f v ' lount ing EngineSpeedSens o r Suppo r t t o C y l i n d e r B c c k B o l t Sens or t o SuP P o r tB o l t Sens or EngineVac uum Tr a n s d u c e r t o F u s eB o x M ount ing Sc r e w s 5 - .7 3.5 - 4.5 30 - 40 B - 11 1. 5 - 2 - A
6. SPECIALTOOLS
HAND VAC U U M P U MP
J23987 -01
EO U I V A L E N T
EM ISSION CONT R OL6E .1
SECTION 6E
EMISSION CONTROL
INDEX
Ref. 1. 1. 1 1. 2 1. 3 1. 4 1.5 1.6 1.7 Page Subject 6E -1 GENERALDESCR1PT|ON.............................. 6E-5 EARLY FUEL EVAPORATION CONTROL........ 6E-5 EMISSION EVAPORATIVE POSITIVE CRANKCASEVENTILATION.... 6E-6 6E-9 V A CUUMAD VA N C EC ON T R OL 6E-9 VAG System (NSw) 6E -14 A I R P RE H E AT .................... 6E -14 REACTOR.......................... ArR tNJECTTON 6E -14 EXHAUSTGAS RECIRCULATION 6E -14 3.3 Litre EFI Engines 6E -14 3.3 Litre EST Engines Ref. 1.8 2. 2.1 2.2 3. Subject Page THROTTLENUDGER...... 6E- 16 S E R V | C E OpE R A T| ON S ........_..... . . . . . 6E- 17 GENERALTNFORMATTON ............................ 6E- 17 EGR MODULATOR VALVE .......................... 6E- 17 6E- 17 SPECIALTOOLS 6E- 18
1 . G E NERALDESCRIPT ION
The EmissionControl Systems employed on VK Series vehicles catry over in general f rom VH. However, revisions to some systemshave been made to significant suit specificenginerequirements. EMIS SION C O N T R OLS YS TE M
Ear ly Fuel Ev apo : : r ' Ev apor at iv eEm is so' ' Cont r o , Vent iat o n Pos it iv eCr ank c as e Vac uum Adv anc e Co"ir o Ar r Pr eheat Air ln jec t ion Reac t o' . Ex haus t G as Rec ir c u a: r : n Thr ot t le Nudger Ni A = Not APP c : D I e
The chart below sets cut the EmissionControt Systems apprrcablto e the vari ous enqi nes used i n V K Ser r es.
L6 3.3 E S T
_6 3.3 E Ft
5.0 L X X
X X N /A X X X Manual onl y
X N ,A N ,,A X N /A
X X NiA X N /A
p a ra g ra p h s u mma ri s e th e c h a n gesto the T he f ollowing svstemsfor VK Series.
6E.2 EMISSION CONTROL
!,
o tsd
q7
RF
7rI ^P';
R b
gi
2 i ,! R6 E
F
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1.1EARLYFUELEVAPORATION
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1 . 2 E V A P OR A T IV E E MIS S ION C ONTROL

On L6 engines,the EEC system has been modifiedto meet emission reeuirements. The cannister has been relocated in the engine compartment and has new m ount ing br ac ke ts (F i g .6 E -a ). R e fe r F i g s .6E -1, 6E -2 a nd 6E - 3 f or E EC h o s e ro u ti n e .
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1 . 3 PO S I T IV E CRANKCASE VENTILATIO?.I
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1.4 VACUUM ADVANCE CONTROL
The ignitionadvance on engines with EST is electronically controlled,therefore no VAC system is used on these engines . Engines with EFI (except those for registration in New South Wales) use a VAC system similarto VH with 3.3 engine and automatictransmission. The hose layout has been revisedto suit the EFI installation. Refer Figs. 6E-6 and 6E-7 for hose routinodetails.
(NSW) vAc SYSTEM

The vacuumadvancecontrol system ior 3.3 engineswith EFI and production option V7Y (New South Wales emission requirements) differs in certain respects from the system meetingthe nationalrequirement: The following paragraphs refer to the V7Y Wpe system. Des c r ipt ion ln addition to the high temp#Jife (1O4oC) thermal vacuum switch in the therm6stab : housing, which is common to both VAC systems,thp:componenlsspecific to the VAC systemfor the V7Y option consistsof: (1 5 0 C ) th e rma l v a c uum sw i tch r A low t em p e ra tu re loc at edin t h e a i r fl o w d u c t a n d s e n s i n gthe i nl et ai r temoeralUre. r A m edium te m p e ra tu re (4 0 o C ) i h e rmal vacuum s wit c h loc ate d i n th e e n g i n e b ro c k a n d sensi ng engineblock metal temperature. r The necessary vacuum hoses to connec the Refer Fig. 6E-8 for componentlayout. components.
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6E.10 E MI SSI ON CONTROL
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1.5AIR PREHEAT
The air preheat system for L6, 3.3 EST and 5 O litre engines,carriesover in generalfrom the VH. No air oreheatis reouired with EFI
R E A C T OR 1 . 6 A I R I N J E C T ION
The air pump type a' ^.ecio- reactorsystem is fitted to 3.3 EST engines S r 3' 9 rp Sa re b a l a n c e dfo r a i r fl ow by i n cl us ion :' :" s c e c rfi c a l ls yi z e d fo r e a c h p i p e a nd lo ca te d a: : - : : , ^de r h e a d e n d . T h e s y s te r. rs , : - = s a- e a s u s e d o n VH w i tl 2 .a tre esse n tra en g i n e s : = ' : ' S ec t ion0 6 , V H S e rv i c e i l a .L ,a . S,.p pl eme n l '.'i : - 3' f or pr in c i p l e so f o p e ra ti c . a ' 3 s e rv i ce rp e ra :: - : elar ls . Ref er F i g s . 6 E-1 6 :-2 a .o 6 E -3 for r a c,-- ^ : s e r out ing det a i l s .
1. 7 E XH A U S TGA S R E C IR C U L A T ION
Th e EGR s y s t emf or t h : : .tre e n g i n ec a rri e so v e r rrcm r'H Th e E G R s y s t ens ' :' 3 3 l i tre e n g i n e s h a v e c een substantially revised.,/.' :f'reVH type. 3 .3 L ITR E E F I E NG I N E S The exhaust gas s Crrected to the EGR valve via an : xte rn a l p ipe ( F ; a= - 1 4 )to a p o rt i n th e i n l e t m a n i fol d. -ie EGR val,,: s mounted on the inlet manifold, co p o si tet he p: : r r ef e r F i g . 6 E -1 4 ). Po rte d v a c u u m i s J rected to the iGR valve via a thermal vacuum switch, 'e 'e r Fi gs .6E - 6 6E 7, 6 E-1 1 a n d 6 E -1 2 fo r EGR s y s t em ^cse lavout.
Figure 6E-14
3.3 L ITR E E S T E NG I N E S Th e i GR s ls r em f or E ST e n g i n e sh a s th e E 3 r mo u n te dc n : he , nletm a n i l o l d (re fe rF i g . 6 E -1 5 )
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EM ISSION CONT ROL 6E -15

Models with EST & Automatic Transmission Ported vacuum is directed via a thermal vacuum switch to the EGRvalve.ReferFig. 6E-2tor hose layout. Models with EST & Manual Transmissions with manualtransmissThe EGRsystemfor EST engines ions incoroorates an EGR modulatorvalve located in the vacuumline betweenthe thermalvacuum switch and the EGR valve(referFig. 6E-16). The purpose of the EGR modulatorvalve is to control the ooerationof the EGR valve so that the admission of exhaust gas into the combuslionchamber is highest at times of potential high oxides of nitrogen emission generation. Very little Oxides of nitrogen are generated at engine idle, light engine loads or on overrun.Oxides of nitrogen emissionincreases duringacceleration. As the throttle opens, a ported vacuum signal is routed through a thermal vacuum switch. The switch 'turns on' when the at 40oC to prevent exhaust gas recirculation engineis cold. EGR valve operationis further regulatedon EST engines and manual transmissions by the operation of the modulator valve. EGR Modulator Valve Description The modulator valve is a bleed type vacuum control devrcewhich uses exhaustgas pressureto control an air bleed within the valve and modulatesthe vacuum signal from the carburettor to the EGR valve according to engineload. The valve (refer Fig. 6E-17) consistsof two chambers the diaphragmhas a seat at separatedby a diaphragm; its centre.The centre tube of the tee prece is retainedin via a the upperchamberwhich is ventedlo atmosphere filter. The two exposedbranchesof the tee piece each contain a restrictingorifice. One branch is connected to the vacuumline from the carburettor and TVS and the other to the vacuumchamber of the EGR valve. is to damp any pulsations The purposefo the restrictors and help control in the vacuumsignalfrom the manifold EGR valve responseto rapid changes in exhauslgas oressure.
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The lower chamber of the valve is exposed to exhaust gas pressure via a hose from an adaptor located between the EGR valve and inlet manifold teter F ig.6E - 18 ).
E C A ', A LV E TO B A C K P R E S S !A E TR A N S D U C E A -
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6E.16EMISSION CONTROL
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A D A P TOR B A C K P R E S S U R E -/ TA P P IN G
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MA N IFOLD S ID E
F ig ure 6E -19
EGR Modulator Valve Operation (Refer F ig. 6 E-19) With low exhaust back pressure in the valve lower chamber, via the vacuum line is vented to atmosphere the centrebranch of the tee and filter.The EGF valve remains closedand no recirculation takesplace. As exhaustback pressure increasesduringacceleration or under load, the pressure on the diaphragm also increases, the diaphragm moves the diaphragm seat and restricts the ventingof the vacuum line. This results n vacuum being appliedto the vacuum chamber of the EGR valve, the EGR valve opens and recirculatron commences. As engine load, (reflected in the vaiue of exhaust back pressure)increases,the venting of the vacuumsignaldecreases, applyingmore vacuum to the permitting EGR valvevacuumchamber, the EGR valve to ooen f urther and admit more exhaust oas rnto the induction system. As engineload decreases, exhaustpressuredeCreases, diaphragm force decreases, vacuum signal venting increases and the EGR valve reduces the amount of exhaust gas being recirculated. The valve thereiore modulates the vacuumsignalto the EGR valve to make EGR valveoperation to enqineload. sensitive
1 . 8T H R O TT L E N U D GE R
Vehicles with 3.3 EST engine and manual transmissions are fitted with a throttle nudger similar to that used on VH with the 2.8 litre engine and manual transmissron. Refer Section 06, VH Service Manual Supolement M38731 for descriptionand operation. Refer Fig. 6E-1 for throttle nudger hose routing.
EM ISSION CONT ROL 6E -17 2. SERVICE OPERATIONS

2.1 GENERALINFORMATION
carry lor emissionsystemcomponenls Serviceoperations over in generalfrom VH Seriesvehicles. Service procedures for the following components are covered in Section 09 'EmissionControlSystems'of the Engine ServiceManual part numlmproved Performance ber M38338. . EGR Thermal Vacuum Switch Testing and Replacement. . EGR ValveChecking, Cleaning and Fleplacement. o EFE Thermal Vacuum Switch and Actuator Testing and Feplacement. o Air PreheatSystemTesting. o VAC SystemTesting. o Positive Crankcase VentilationSystem Testing and Servicing. . Evaporative EmissionControlSystemServicing. for the Air Pump and ThrottleNudger Serviceprocedures. Control'of the VH are coveredin Section06 'Emission part numberM3873 1 SeriesManualSupplement The following service operationis new for VK series vehicles.
VALVE 2.2 EGR MODULATOR

TEST 1. Disconnectall hoses from the EGR modulatorvalve and removevalve. 2. Installa vacuumsource such as hand pump J23987to the bottomvalve port. 01 or equivalent pump, and it shouldbe possible vacuum 3. Operatethe lf a to draw a vacuum on the valve diaphragm. vacuum is not drawn, the valve diaphragm is defectiveand the valve must be replaced. 4. Connect the vacuum pump to one side of the 'T' piece on top of the valve, plug the opposrteend of the 'T' piece with a suitableplug. 5. Operate the vacuum pump and it should nol be oossible to draw a vacuum.This indicatesthat the valve fitter is operating correctly. lf a vacuum is drawn, the fitter is defectiveand the valve must be reolaced.
6E .18 EM ISSIONC ON TR OL
3. SPECIALTOOLS
HA\D VACUUM PUMP
J23738
(or equi val ent)
NOTES
ENGINE T UN E6F-1
SECTION 6F
ENG I NE TUNE
INDEX
Ref. 1. 2. 3. 3.1 Page Subject 6F-1 ............................ INFORMATION GENERAL 6F.2 TUNERECOMMENDATIONS........ ENGINE 6F.3 TUNE DATA. ENGINE 6F-3 3.3 LITREEST .............. 6F-3 Tune Conditions............... .. 6F-3 Check List ..... I Ref. 3.2 3.3 Sublect 3.3 LITREEFr .. Tune Conditions 5.0 LITRE
Page 6F-4
5F-4 6F-4
INF ORM AT ION 1 . GENERAL

and emission vehicleperformance To maintain designed and that regular maintenance levels, it is recommended adjustments be carried out in accordance with the in the VK SeriesOwnerHandbook. outlined schedule Engine tune specificationsnecessary to achieve the cor-rect emission levels are located on the Vehicle Label attachedto the right EmissionControl Information struttower underthe enginehood.The hand suspenslon label should be referred to before making any adjustments. The EngineTune Recommendations .ha1. sets out the items recommended for attention during an engine tune and cross referenceis providedto the appropnate source of informationThe EngineTune Data charts (reler 3.1. 3.2 and 3.3 in this Section), provide abndgeo engine tuningdata for both 3.3 litre and 5.0 litre engines.
TU N E 6F.2 E NG I NE 2. ENGINE T U N E RECOM M ENDAT IONS

ENGTNETUNE RECO M M ENDATI O NS E ngineComp ressio n Tes t I REFEBENCE
lS " . t 'o . 1 0 . " E n g i n e T u n e U p " o f t h e l m p r o v e dP e r f o r m a n c e Eng ne Service M a n u a l P / N M 3 8 3 3 8 . F o r E F I v e h i c l e sa , lso r e fe r S e c t i o n6 C E l e c t r o n i cF u e l I n j e c t i o n ,S e r v i c e Note 9. of tnis Suoolement. S e c t i o n6 , " C o o l i n g S y s t e m s "o f t h e V H S e r i e s Service Manual S u p p l e m e n tP / N M 3 8 7 3 1 . S e c t i o n6 , " C o o l i n g S y s t e m s "o f t h e V B S e r i e s Manual Service P/N M38145.
EngineD.i,.'e3e rt.
Chec k and adjus tas necessary.
l dle S oee C
i Chec k anc aCjus tas
3 . 3 L i t r e E S T . S e c t i o n6 C , " C a r b u r e t t o r s "o f t h i s S u p p l e m e n t 3 . 3 L t r e E F l . S e c t i o n6 C , " E l e c t r o n i c F u e l I n j e c t i o n , "o f t h i s Supolement. 5 . 0 L i t r e . S e c t i o n 5 , " E n g i n e F u e l S y s t e m s , "o f t h e l m p r o v e d Perf o r m a n c eE n g i n eS e r v i c e M a n u a l . R e f e rt o s p e c iifc a t i o n s o n t h e e m i s s i o nc o n t r o l l a b e lo n t h e r i g h t h a n d s t r u t t o w e r . 3 . 3 L i t r e E S T . S e c t i o n6 C , " C a r b u r e t t o r s "o f t h i s S u p p l e m e n t . 5 . 0 L i t r e . S e c t i o n 5 , " E n g i n e F u e l g y s t e m s "o f t h e l m p r o v e d Performance E n g i n eS e r v i c e Manual. S e c t i o n1 0 , " E n g i n e T u n e U p " o f t h e l m p r - o v e d Performance E n g i n eS e r v i c eM a n u a l . F o r E F I e n g i n e sa , l s or e f e r S e c t i o n6 C " E l e c t r o n i c F u e l In j e c t i o n " i n s t r u c t i o n3 . 5 o f t h i s S u p p l e m e n t .
A utomatic Ch oke
Chec ks et t ings and link age.
A ir F rlter Ele men t
V alve LashAd jus:^ le n1

i n'line Fue l F i l t e r
Non adjus t able hy dr aulic I las hadjus t er s . Chec k or r eplac e. 3 . 3 L i r r e E S T S e c t i o n1 0 , " E n g i n e T u n e U p " o f t n e Im p r o v e d P e r f o r m a n c eE n g i n eS e r v i c e[ \ 4 a n u a l . 3 . 3 L i t r e E F I S e c t i o n6 C , " E l e c t r o n i c F u e I n j e c t i o n , , o ,f th i s S u p p l e m e n t . S e c t i o n1 0 , " E n g i n e T u n e U p " o f t h e l m p r o v e dp e r f o r m a n c e E n g i n eS e r v i c eM a n u a l S e c t i o r 6 D , " l g n i t i o n S y s t e m " S p e c i ifc a t i o n so f t h r s S uo o lem en t . S e c t i o r 1 0 , " E n g i n e T u n e U p " o f t h e l m p r o v e dp e r f o r m a n c e Engne Service Manual.
Ch e ck a n d r e se i a s n e ce ssa r y.
CL e a n ,a d ju st o r r e Dla ce
gnit ion T imin g

r9 nt t t on Ht g n l e n s t o n C ables
Chec k and r es etas necessa rY.
.--
Throt t le Nud ge r ' ES T manu al on ly)
S e c t i o - 6 , " E m i s s i o nC o n t - o l " o f t h e V H S e r i e s Manual Service S uo pl em en t .
E GR V alv e Air P rehea t Syste m Ch e ck fo r co r r e ct 3 p e r a tio n . E ngineV en tilaiio n Syste m S e c t r o ^9 , " E m i s s i o n C o n t 'o l S y s t e m s "o f t h e l m p r o v e d E v aporat ive Enrrssio ns Performance E n g i n eS e r v i c e .8 e p a ce ca r isle - f te . a t Manual. S y st ems sp e cifie d in te r va l. Bat t eryand Ca ble s Chec k
I
Chec k all hos es and c onnec t or s f or air leak s . Chec k and r ec t if y as nec es s ar y .
Throt t le P o s i t i o n S w i t c h E ST mode l s o n l y ) Ch e ck fo r co r r e ct o p e r a tio n .
S e c t i o n 1 2 , " E l e c t r i c a i S e c t i o n ',o f t h e V B S e re s S e r v i c e Manual a n d S e c t o n 12 A " B a t t e r y a n d C a b l e s of th s Supplement.
S e c t i o - 6 D , " l g n i t i o n S y s t e m "s e r v i c e o p e r a t i o n2 . 7 o f t h i s S up o l e m e n t .
T UNE6F-3 ENGINE TUNE DATA 3. ENGINE

3.1 3.3 LITREEST
ENGIN E TRANSM I SSI O N I DL E S P E E D R P M (IN NEUTRAL)
FA S TID LE SPEED
SPARK ADV. B E LOW 900 R P M

3 'e s e : '. , i s u a l Cê:k crlv 6' : ,:
S P A RK P L U GS
3 .3 L itre HC I
EST ( 114)
M anualor Aut om air c
AC C42CLTSX
1 . 51! ! m -
is not to be adjustedpriorto 1500 km NOTE:Carburettor service. Only the idle speed may be adiusted from 1500 kms onwarcls. refer to idle adjustments, Prior to making any carburettor of this Supplement. Section 6C, Garburettor TUNE CONDITIONS warm the Before making any checks or adjustments, tn engine by running for 6 minutes wth transmtsston neutral and fast idle screw on second step of fast idle cam, refer Fig. 6F-1, or running for 10 minutes at 80 km/hr on a chassisdynamometer. Switch ignition off, restart vehicle with transmissionin neutral.Check engine tune specifications'
^,.a>\ ,J-/ ^
-/ _l
I l
i
I 1sr.srE P
I
-t^rn
3FD.
QTtrp STEPJ
-,?+ '/A
-L_
n-
I,vr J ' .
| aTH . S T:e
'
Fi gure 5F- l
CHECK LIST (A) Engineidle speed exceeds880 rpm. 15 minules. 1. Checkthat enginehas been running 2. Check that throttle closes onto stop. Ensurethat the throttlenudger,choke and throttlecable are ccrrectly adiustedto allow the throttleto close onto stcp. 3. Checkthat throttlepositionswitchis closed at idle is less than 1O: 3TDC. 4. Checkthat advance (B) idle speedis less than 700 rpm Engine
15 minutes 1. Checkenginehas been running solenoid. 2. Checkpowerto antr-dreseling 3. CheckPCVvalve for flow. 4. Checklor vacuumleaKs I 5 Creck for greaterthan 2 BTDCadvarce
6F.4 ENG I NE TUNE

3.2 3.3 LITRE EFI
E NGINE S IZ E i OPTION EFI {L Lg r I DLE SPEED RPM RUN I N ENG I NE
ID L E co ^ "k
D l srR l B -u. T-oR ADVANCI BTDC* RpM 12"B E LOW 1100
spA R KpLU Gs GAP AC C 42C LTS X
T UN E CO NDI T I O NS Engine tune settingsare lor an enginewith:1. Engine coolant and oil at normal operating temperature, preferably achievedby drrving(both CO and idle speed are dependant on engine temperature). 2. Transmission in oarkor neutral. 3. Air conditioning switched ofl. The followingchecks musl be performedand any defects correctedbefore any idle adjustmentsare made to the EFI system. 1. l g n i ti o n t im ing. 2. Vacuumto luel pressureregulator. 3. Throttlelever closingon to stop - if not check: a. Throttlepositionswitch adjustment. b. Linkage sn! 5prrngs. 4. No leaks at hoses and duct betweenair flow meter and engine. 5. Running on all cylinders - if not checkfor a. Defective sparkplugsand leaks. b. Open circurt to iniector/s. 6 Auxiliary air valve fully shut - check by pinchingoff air hose and observing enginespeed.lf speed drops checkfor: a. Enginenot sufficiently warmedup. b. Open circuit in electricalsupplyto auxiliaryair valve. c Auxiliary air valve on upsidedown. NOTE: Before adjusting the idle speed, disconnectth canisterpurge hose from the canisterand then adJUSt idle speed.Referto serviceoperation 3.5, Section6C of this Supplement.
3.3 5.0 LTTRE

E NGIN E IDLE SPEED R PM
D IS TR IB U TOR
IN IT IAL AD VAN C E ET D C @ BPM
ptnn
S P A R K P LU GS
G AP mm
srzE
coMp
TRANS.
N lAN. A UT O.
Jr-r?|, ]
L31
sLow
FASr
15 0 0 aTGHEST 2nci
) ttrr
TY P E
5, 0
HC
Fo
â- ?1
a50 F F^.'
15
44Tx
V A C U U M A D V A N C E I-,OS E D IS C ON N E C TE D A N D P LU GGE D
For 5.0 litre Tune Conditions refer to Section 6 Engine Tune of the VH Series Service Manual Supplement. Engine Tune Specificationsare on the Emission Control label on the rignt hand susper iron strut tower.
CLUTCH7A.1
7A SECTION
CLUTCH
INDEX
Ref. 1. RefPage Subject 7A-',t 2. DESCR1PT1ON......................-....... GENERAL Subiect SERVICE OPERATIONS Page 7A-1
DESCRIPT ION 1 . G ENERAL

The clutch assemblyused on VK Seriesmodels is carried over from the VH Series.
detailsrefer Figs. 7A-'l and 7A-2. For clutch adiustment refer Section 7 of the VB operations For all service CommodoreServiceManual,Part No. M38145.
,/t'/
-t
).-- ..
EI
--:'t
,ta
//
ds t / /'
'
'\\ \(^\
\Y '/z \ .<_B E FC ,= A D JU S TME N TS A =: C A R R IE D OU T, E N S U R E IN B A LL S TU D . C LU TC ts FOR K IS FU LLY S :A -:] A D JU S - S LE E V E ON C A B LE :'i D ;ITTIN G,T O A C H IE V E C LU TC F C :D A L P OS ITION A S S H OIV NON F IG.7A -2,
Figure 7A-1
To adjustclutchcable,lightlyload clutchfork in direction ol arrow Z, reter Fig. 7A-1, so that throwout bearlng contactsclutchspringfingers.Then usingcable adjusting sleeve set clutch pedal to correcl heightwith rubbertrim pad removedfrom Pedat.
Figure 7A-2
MANUALTRANSMISSION 7B-1
78 SECTION
MANUALTRANSMISSION
INDEX
Ref. 1. 2. Page i Ref. Subiect 78-1 | 2.1 DESCR1PT1ON.............................. GENERAL 7B-2 I 2.2 OPERATIONS SERVICE
ta g e Subjecl 78-2 TOROUEMASTER TOROT. 7B-2 BORG BORGWARNEB(5-SPEED)..........................
DESCRIPT ION 1 . G ENERAL

The Torquemasterfour speed manual transmissionis standardequipmenton VK Series SL 19 and 35 styles with the 3.3 litre EST engine. The Borg Warger five speed manual transmissionis available as a productionoption on vehicles with the lor 3.3 EST engine 3.3 litre EST engine.Transmissions carry the code BE stencilledin yellow paint application, caseon the lefi hand side of the transmission are:BE transmissions for code introduced Revisions peening. shot by relieved stress 1. GEARS: GEAR: needleroller bea2. 5TH SPEEDMAINSHAFT ring has been deleted (refer Fig. 7B-1). The gear now rotates on a revised bearing surface on the mainshaft. 3. GEARRATIOS: 3.23 1 rsr chart sets out rnanual transmission The followrng application lor VK Seriesmodels.
B ody S tyl e 3.3 l l t:e E S T Torquemaster (3.50:l 'l st gear)

E:r g l Var ner
Sta':a'c N oi A,:
!:,
:r ent on O pti on
N /A
a: = Av ai r ac i ::s t- c :- c :
I I 2ND
1.96:1
LZO I
3RD 4TH 5TH RE VER S E
ons are not available if an NOTE: Manual transmrss engine is equipped witn E eclronic Fuel Iniection
1.00: 1
THIS BEARING IS \OT USED tN CODE,,BE' . TRAf.r Sr ,ltSSt O N S -
G!J.
G._
-,\
.+ /:rE=\ {,-: i ,a - - ,\ u { e = .*, ,J -JgE -zi

'L:
'
Figure 7B-1
7B..2MANUALTRANSMISSION 2. SERVICE OPERATIONS

NOTE: Before removingany manual transmission, the EST soeed sensor must be removedfrom the rear of the cylinder block. Refer to Service Instruction 2.8, Section 6D, lgnition System. of this Supplement.
2.1 TORQUEMASTER
For removal and installationinstructionsrefer to Section 07 of the VB Commodore Service Manual Part No . M3 8 145. For overhaul procedures refer to the Torquemaster Service Manual,Part No. 92010388,and Torquemaster Servrce ManualSupplement, Part No. M39043.
2.2 BORGWARNER(s-SPEED)
For all service operations refer to the Holden CommodoreFive Speed ManualTransmission ServiceManual, Part No. M39071.
AUTOMATIC TRANSMISSION 7C-1
7C SECTION
ISSION TRANSM AUTOMATIC
INDEX
Page Ftef. Subject 7C-1 1. GENERALDESCRIPT1ON.............................. 7C-1 CODES. 1.1 TRANSMISSION 1.2 & 2-3 SHIFT CONTROLVALVESAND 1.2 7C-2 SLEEVES 7C-2 1.3 1-2 & 2-3 SHIFT VALVES.......-..-....7C-3 1.4 MANUALVALVE 7C-3 LOW SPEEDTIMINGVALVE.......... 1.5 VALVE.... 7C-3 CONTROL 1-2 ACCUMULATOR 1.6 7C-3 P|STONP1N...................... 't.7 ACCUMULATOR 7C-4 1-8 TRANSFERPLATE........... 7C-4 1.9 SERVOPISTON 7C-4 1.10 VALVE BODY IDENTIFICATION VALVEAND 1.11 VACUUMMODULATOR 7C-4 SLEEVE... Ref. 1.12 1.13 1.14 1.15 2. 3. 3.1 3.2 3.3 4. 5.
Page Sublect 7C-5 BANDAOJUSTMENT......... THIRDCLUTCHASSEMBLY 7C-5 C LU TC H D U MPB A LL 7C-6 S E C ON D REGULATOR PRESSURE BOOSTVALVE 7C AND SLEEVE TRANSMISSION SHIFT SPEED CHART.... 7C-13 TRIMATIC TRANSMISSION SPRING IDENTIFICATION CHARTS .... 7C.14 coDE LP (3.3 LITRE EST ENGTNE)............ 7C-14 ............ coDE LR (3.3 LITRE EFr ENGTNE) 7C-14 .................... 7C-15 coDE LS (5.0 LITRE ENGTNE) LINE PRESSURE SPECIFICATION ... . . . . . . . . .7C. . . 15 CHART ......7C-16 SPEC|F|CAT|ONS..............
The Trimatic Automatic Trasmissionis standard equipment for VK Series on Berlina and Calais. Trimatic is availableas an option on all other VK Seriesmodelswith the 3.3 litre EST, 3.3 litreEFI or 5.0 litreengines. Carryoverof the Trimaticto the above 3.3 litre engines has necessitatedthe release ol new Trimatic transmission codes. Transmission codes LP, 3.3 litre EST, and LR. 3.3 litre code FP, 3.3 litreVH, EFl, are the same as transmission exceptwhere noted in this Section. LP Code incorporates the earlierdesign olen converter housing and IR code uses the carry:ver 'full circle' housrng design. converter Transmission code tS. 5.0 litre. ca" es over from 5.0 litre VH rrodels and WB Statesman paragraphs The following set out the calibration details for eachof the rew transmission cooes
CODES 1.1 TRANSMISSION

plate carriesthe transmisThe lransmissionidentification code. The following sion serial numberand application codes are used with VK SeriesTrimatictransmission.
TRANSM I SSI O N CO DE LP LR
ENGI N E 3. 3 lit r e equippe C. '. t ' E S T ln EFI 3. 3 lit r e equippe c '. '. 5. 0 lit r e
LS
7C.2 AUTOMATIC TRANSMISSION

1.2 1-2 & 2-3 SHIFTCONTROLVALVES AND SLEEVES
All three transmissions use the same 1-2 and 2-3 shift controlvalves. ldentilicatron is by a ring aroundthe valve reier Fig. 7C-1 lor 1-2 shifl conlrol valve identification.
ID E N TIFIC A TION R IN G
Flgure 7C-1
For 2-3 shift controlvalve identification reter Fig. 7C-2. The three transmissions also use the same 1-2 and 2-3 controlvalve sleeves. The 1-2 control valve sleeve is identifiedby a green colourmarkingon the open end of the sleeve. The 2-3 control valve sleeve has no colour markino on the open end of the sleeve.
ID E N TIFIC A TION _ R IN G
Figure 7C-2
1.3 1-2 & 2-3 SHTFT VALVES

All three transmissions use the same 1-2 and 2-3 shift valves. The 1-2 shift valve is identifiedby a hole drilled in the end of the valve. ReferFig. 7C-3). This hole has a 1-2 shift valve spring inserted,which assists governor pressureto reduce the road speed at whichthe lightthrottle1-2 upshifts occur. with the Series 3 shift This valve is not interchanoeable valve.
D R ILLI\G
Figure 7C-3
The 2-3 shift valve is identiiiedby a ring around the centreof the valve stem (referFig. 7C- ). This valve is not interchangeable with the Series 3 shift valve.
ID EN T IF IC AT IO N
R I\G-
Figure 7C-4

1.4 MANUALVALVE
A modified manual valve is used with LS code transmissions. It incorporatesan end drilling with 2 bleed holes (refer Fig. 7C-5). The modifications to the manual valve improvethe shift qualityfrom drive into neutralrange.
Figure 7C-5
1.5 LOW SPEED TIMINGVALVE

The low speed timing valve in codes LR and LS transmissions has been revised.The overall lengthof the valve has been decreased from 48.M-48.90 to 43.543.8 mm (referFig. 7C-6). This is to allow the inclusion of a low speed timing controlvalve and sleeve. For details of the low speed timing valve and control valve operation,refer to page 40 of the ServiceManual 'TrimaticPrinciples of Operation'Part No. M37823.
Figure 7C-6
CONTROL 1.6 1.2 ACCUMULATOR VALVE

use a common 1-2 All three new code transmissions controlvalve. accumulator The diameterof the spool section of the valve has been 11.087 mm 2 mm to 11.079increased from 8.705-8.71 (referFig. 7C-7). This valve is not interchangeablewith the Senes 3 controlvalve.
+
_-_I_
11 n70 :i :^: tt.u6/ DtA.!
Figure 7C-7
PISTONPIN 1.7 ACCUMULATOR

pistonpin on all three transrnissions has The accumulator been increased in length trom 43.2 mm to 44.2 mm (referFig. 7C-8). The accumulator oistonsorinqhas been deletedfrom the three transmissions.
.<_
43.2 _ 44.2 mm _
________>
Figure 7G-8

1.8 TRANSFER PLATE
Transfer plates are identified by their part number stampedin the area shownin Fiq. 7C-9.
T R ANSFER PLATE P ART NUMBER
P A R T N U MB E R S TA MP E D IN TH IS A R E A
9/'
(
APPLI CATI O N
92017838 9242' , 278
LP
f
r-n l rl l
-+t J
O
Figure 7C-9
1.9 SERVOPISTON
For identification details of the servo piston used in all threetransmissions, referFig. 7G10. The servo piston is the same in all three transmissrons but the servo cushion springs ditfer. Refer to Spring ldentificationCharts in this Section for cushion spnng identification.
D fME N S fON 'A ' = 21 .99-2'i .f4nm
Figure 7C-10
1.10VALVE BODYIDENTIFICATION
The valve body for each transmission carriesthree digits followed by the calibration alpha letter stamped on the piston underside of the body,adjacentto the accumulator pin (relerFig. 7C-11). T RA NS M T SS IOr N qODE_----- -V A LV E B OD Y I D E N TI F I C A TI ON
LP
LR
I eZe"
c alib"at ion - aipha c har ac t er Figure 7C-11
1.11VACUUMMODULATOR VALVE AND SLEEVE

All three transmissions use the same vacuum modulator valve and sleeve. Valve identification is by a ring aroundthe valve stem as shownin Fig. 7C-12.
- ID EN T I F IC AT IO N
R IN G
Figure7C-12

The vacuum modulatorsleeve is identifiedby the length 3, and a blue colour markingon of the sleeve,Fig.7C-1 the closedend.
Figure 7C-13
1.12 BAND ADJUSTMENT

procedureis as follows: The correctband adjustment 1. Remove oil pan and servo cover, loosen adjusting screw lock nut. 2. Using Tool No. 7AT4 and a torque wrench, tighten adiusting screw to 4.5 Nm then back off screw.
.1 .1
I: t-
T U R N SBA C K E D OFF
3. Tightenlock nut and install servo cover and oil pan. Refill transmission with Dexron ll Automatic Fluid. Transmission
OU IC K R E LE A S E V A LV E
Jtr h .
Figure7C-14
1.13THIRD CLUTCHASSEMBLY
The third clutch assembly for code LS transmissions diflersfrom that used in the six cylindercodes. Revisionshave been made to the clutch piston return springsand spring retainer. for third clutch returnspringsare as follows: Dimensions
]
I
rnnrrrsrvrssroN
cooE
Free Lengt h To t al Coils Diam et er
LP& LR
26. 97 m m
LS
29.13mm
8 .7 5
10. 9 m m
For identification of the LS return spring retainer,refer Fig . 7C-1 5.
Figure 7C-'15

1. 14SE C O N D CLUTCH D U MPB A L L
Code LS transmissions have incorporated a dump ball in the secondclutch circuit. When the second clutch is being applied,second clulch oil seats the ball and the leed is directed through an orifice. During the release of the clutch, the ball is unseated and the clutch can exhaust at a faster rate through the two onfices. Refer Fig. 7C-16.
T F
O
o z
-oRrFtcE
Flgure 7C-16
1.15PRESSURE REGULATOR BOOST VALVE AND SLEEVE

The transmission pressure regulator boost valve and sleevehave been revisedon LS code transmissions. For details ol the boost valve and sleeve used on the three transmissions refer to Figs.7C-17,7C-18and the charts below.
VALVE CHART
15. 126 - 15. 1 1 8 mm 1 1 .7 6 5 - 1' l.7 5 8mm 15. ' 126 - 15.1 1 8 mm 1 1 7 6 5 -1 1 .7 5 8 m m 16. 502 - 16.4 9 4 mm
r J /b o tJ.//v mm
Figure 7C-17 SLEEV E CHART
r RAN S COD E
LP LR LS
-l
15. 159- 15. 1 3 8 m m 1 ' 1 .7 9 6 -i l 7 7 8m m i

15 .15 9- i5.1 38 m m 1 6 5 35 - 16 .515 m m 11. 796- 11 778m m i3. 8i9 - i3 779 m m
----T-A]
ii BA
il
.L
Figure 7C-18
AUTOMATIC TRANSMISSION 7C.7
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2 0 - 2 8 Nr 4 5 - 5 ONm 7 . 0 - 1 9 .0 Nm 6 1 -7 ONm
V IE W
INSTALLATIONDETAILS _ 3.3 LITRE E.S.T. TRANSMISSION
Figure 7C-19
TRANSMISSION 7C.8 AUTOMATIC
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TRANSMISSION INSTALLATIONDETAILS- 3.3 LITRE E.F.I.ENGINE
Figure 7C-20
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V IE W
,
1
ISSIONI NSTALLATION TRANSM DETAILS _ 5.0 LITRE ENGINE
Figure 7C-21
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TRANSMISSION 7C.10 AUTOMATIC
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7C'13 TRANSMISSION AUTOMATIG SHIFTSPEEDCHART 2. TRANSMISSION

UPSHI F T S k m / h L P ( 3 '3 l i t r e E S T )
TH R OTTLE C L OS ED
FU LL TH R OTTLE
110-12 0
, 08 ax l All Tvre Size s 3. UPSH I F T S k m / h LR (3.3 litre EFI) FULL THROTTLE
TH R OTTLE C L OS ED
, 08 ax le All Tyre Size s 3' UP S H I F T S k m / h L S ( 5 '0 l i t r e )
TH R OTTLE C L O S ED
FU LL TH R OTTLE
, 60 ax le All Tyre Sizes 2. LP (3.3 litre EST) FULL THROTTLE
DO W N S H T F T Sk m i h -
T H R OTTLE C L OS ED
P A R TTH R O TTLE
*) 3 - 2 ( A v a i l a b l eUP To
.^.
, 08 ax le All Tyre Siz es 3.
IU J- l l Jl vv
11'z I
An -
i ;,
DO W N S H I F T S k m / h -
LR (3.3 litre EFI) FULL THROTTLE
T H ROTTLE C L O S ED
P A R TTH R OTTLE
U P To 3 - 2 (Available *)
"-,
t^ ^ A l l T y r e S i ze s, 3 .0 8 a xle 12 - 14 \ " -:
1
i
z- l
65-73
114-124
DO WN S H I F T S k m / h CLO SED TH R O T T L E
L S ( 5 '0 l i t r e )
LE FU LL TH R OTT 3-2 2 -' l , 60-68
P A R T T H R OTTL E U P To ") 3 - 2 (Available 88 94
2. 60 ax le All Tyre S iz es ,
112-122
D ISC O N N E CTE D S WIT C H W I T HD E T EN T
7C.14 AUTOMATIC TRANSMISSION 3. TRIMATIC TRANSMISSION SPRINGIDENTIFICATION CHARTS

3.1 CODELP (3.3 L|TRE EST ENGTNE)
S P R ING D E S CR IP T ION
COL OUR IDENT IF ICAT ION
FREE LE N GTH A P P R OX . mm 54.7

I o .J
TOTAL cotLs
15.0
o- u
O'D. mm
N OM IN AL
S P R IN G P A R T N O. 9942033 92020511 2823165 2U68A2 92004309 . ,"rr
3 - 2 C on tro
V a ve
Yellow P.k Dar k Eiue Pur pte Or ange
13.2 13.2 10.3 10.3 12 ,",
1 - 2 Ac c u mu i a to .va l ve _ L o w S p ee d Do w n s.i f i V a i v H i g h Sp ee c D o rvn sh i f 1 T rmi ng Valve D e t e n t P.s5 5 g 1 s R e g u l a l o r Valve
JC .
;
rJ.c 1J.f,
Jb.U
42.E
4r.o
II
- 1 _ 2 sn fi va ve ' l - 2 Co n t r o l V a l v e 2-3Contr o l
2 - 3 S h i f t Va l ve M a n . L o w & R e v. C o n trct P r e s s u r e Re g u l a to r V a l ve Valves
orange "
None
13.5
Valve
36.5
10.3
14.2
9942010
N ot U s ed
Gr e e n& Wh r le U/nr te Gr e e n& Re d
38.7 70.3 36.8 I
1 1.5 12.3 13.5
10.3 19.6 10.3
5258547
JZSd I bb
Det ent V a l v e Ac c urula : o . P i s t o n

G o v . Se c o n d a ry
9929681
I
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Gr e e n& Or a n g e 39.C 10.3
N ot U sed 9944999 ,1010646
Pisron Servo Cushion

F r l s i n s i d e S h i ft V a l ve
lr I
4' n-.,
n"C 26.g 4 i
319
s258564
3.2 CODELR (3.3 LTTRE EFt ENGTNE)

SPRING DESCRIPTION
3-2Control V a l ve
COL OUR IDENT IF ICAT ION
FR E E LE N GTH A P P R OX . mm
I - 2 A c c u mu l a to rV a l ve L o w S p e e d Do w n sh i ft V a l ve
H r g h Sp e e d D o wn sh i ft T i mi nq Valve D e t e n l Pre ssu .e R e g u l a to r V alve 1 - 2 C o n : ' ol i - 2 Sh i i l Va ,ve 2-3Control V a l ve

J t.3
13.5 13.5 10.3
10.3 12.O 14.2 2811015 92007171
V a l ve
10.3
14.2
9942010
2 - 3 Sh ift V a ve N 4 a n . L o w & Re v. Co n i ro l V a ves Pr e s s u r e R e g u a to r V a l ve D e t e n l V a l ve Ac c L m u l a to r P i sto n G o v . S e c o n d a rv S e r v o P i sto n R e l e a se S e r v o P i sto n C u sh i o n F i t s i n s i d e S h i f i V a l ve I Gr een & Or ange Gr een Or ange Gr een & Red
Gr e e n& Wh ite
JO.
11.5 12 3
tJ.5
10.3 19.6
6a.9 36.8
10.3
9929681
N ot U s ed
390
of,6
I r.J 3. /a
10.3 47.O 31.9
9944999 92020646 5258568
25.9
3.9

3.3 CODE LS (5.0 LTTRE ENGTNE)
SPRING DESCRIPT ION C OLOU R ID E N TIFIC A TION FR E E LE N GTH A P P R OX . mm
o.o.
mm N OMIN A L 13.2
S P R IN G P A R T N O.
3 - 2 C ontr ol Valve
Li ght G r een
?945053 9:1205 12
1 - 2 A c c u m u la to r Va lve
L o w S p eed Downshift Hi g h S p eed Downshift Valve Tim ing Valve O r ange P* pb
l
35
aa'-1)A
zo
I a65z
De te n t Pr essur e Regu lator Valve 1 -2 Co n tr ol 1 -2 S h i ftValve Valve
9200717 1
2 - 3 Co n tr o l Va lve
2 -3 S h i ftValve
N one
fut"n. l-o* a n"u. Co.

Pressure Re g u la to rVa ve
De te n t Valve A ccu mu l ator Piston
.,
Green& Whi te N one
5258541 28 10499 9929681 \ ot U s ed
G o v . S eco n d a r y
S e rvo P iston Release
,r.arw
31 .9 9929676
S e r v o P isto nCu sh io n
* F ts n si de Shift Valve
4. LINE PRESSURE SPECIFICATION CHART

TR A N S MIS S IONC CI O E S LP 3.3 l i tre E S T kP a
C HE C K NO. 1 Line Pr essur e in D + S Range s i Vac uum M odul ato. 55 50 km /h M odul ator P pe C onnec tec l ) P pe C onnec r ec l
LR 3.3 l i tre E FI
k Pa
LS 5 . 0 l i t re
kPa
V e h cte c oasting between CH E CK NO. 2 - Line
324 - 360
403 - 425
4C3 - 425
Pr essur e ln Low Range ( \'ac uum
V e h i cl e coasr nq between 40 - 3O km /h C HE C K NO.3' Line Pr essu.e In D Range (Vac uum M odul ator 1 2 0 0 rp m engine speed - foot and par king br ak e app r ed Du ri n g Check No. 3 with the vacuum modulator a i r l e ak into the manif old. Pr pe D i s c onnec ted)
531 - 614
606 - 688
606
5:
903 - 978
973 - 1041
1 1-c 9 1273
pi pe di s c onnec ted. the m ani fol d c onnec :or m us t be pl ugged to p,ev ent a n : ^ c 3 s s rv e
7C.16 AUTOMATICTRANSMISSION 5. SPECIFICATIONS

T RAN SMI S S I OCO N DE : LE V E R: S EL EC TO R L o ca ton i Se q uencof e S h' f t P o s i ti o n s LP - 3.3 litre EST
Floor Floor Floor ,N " ( N e u t r a l ) , " P " ( P a r k ) ," R " ( R e v e r s e )" "D" (Drive), "S" (lntermediate), "L" (Low Range)
T OROU F T ER A S SE M BL Y : E CO NV E Me rn od of A t t ac hm e nto t D ri v ePl a te. Y e l l o vo ln l d e r- t lf c a: r onLet t er( Pri n te d

F ' or r Faceof Con v er t er ) S t al Ratio :1 D iam ete r (No mina l)
We l d e d N u t & B o l t
Nut & Bolt Y
2.4 254 mm
2.4
254 mm
2.0 298 mm
DRI V E G E A R: S PEEDO Nu m ber of T eet h

C olou r G E A R RA TIOS: F irst . . Second T hird . Reverse
9 B lue
9 Bl ue
10 Y el l ow
2.31 :l 1.46:l 1.00:l

I .dr
2.31 : 1 1.46: 'l 1.00: 1

t.tJ 5
:1
:l
2.31 : 1.46 : 1.00 : 1.85:
1 1 1 1
T ORQUE : M ULT I P LI CA T ION Ma x im um O v er all Ra ti oi n i s t :1

L U B R IC A NT: Tvpe . C apacity- Dry (includingConv er t er ) . . . . . Re fi lt F LU I D LEVEL INDICATO R { DI PSTI CKI : Length (Fro m Top o f Cap lo End of I ndic at or ) C L UT C H ES: Reve rse Tvpe ..., Dr ve Pla tes De scriptio n Nu mbe r R eac tionPlate s Descrip tion Numb er P ist on L e1 Eth Crsh ion Pla te u se d S econ d Type . Driv e Pla tes De sc r ip t ron Nu mbe r
554
4.62
"DEXRON ll" Automatic Transmission FluiC 6.1 litres 6.1 litres 8.7 litres 2.3 litres 2.3 litres 2 . 3 't . e s
808 mnr
808 mm
680 mm
M u l t i p l e We t D , s c F r i c t i o n F a c n g o n S t e e lP l a t e 445 Steel c5
Steel
SteeI 6
35.99-36.09 mm
Yes
35 99-36.09mm 3l .39-3 1 50 mm
Yes Yes
i \ l u l t i p l eWe t D i s c
Fri cti on Faci ng on S teei P l ate
556
AUTOMATIC TRANSMISSION 7C.17 (CONT'D.) FTCAT|ONS SPECr

TRANSMISSI O NCO DE: CL UTCHES ( Cont ' d. ) Driven Plat es Descr i pti on * Num ber Cushi onPlat eUs ed * NOTE:
I Stee o Yes
Steel 6 ves "::
S tee
7 Yes
hav eo n e a d d i t i o n a lS t e e lP l a : ga n d o n e o r m o r e S c a : : - , Som e Tr ans m ls s ions
Soacer Lengt h c an als obe r den t , f , e db y t h e Secon dClut c h Spac er s last di git of t he Par t Num ber on t he Spa c e r Sp acerPar t Num ber applic at ion Clutch Pac k End Play Third TYPe. . . Drive P lat es Des c r ipt ion Num ber Driven Plat es Des c ipt r ion Num ber Piston Length . . Cu sh ionPlat eUs ed On e W ay Clut c h F unc t ion So.ag So 'a g Sprag C o ^ n e c t sI n p u t : c G e a rS e t i n F i r s t G e : - D .r ve , O , , e r - r u no s r b ', . o a s s e d i n o t h e r c : - : : f,n s. 1 7 17-17.27 mm
\,'t/-ll.l/mm lJ:
35.63-35.74 mm
31.04- 31. 14m m
2820681
.38/.76m-
282068i mn .38i .76 \4ul ti pl e W etD i sc
?2019879 33 76 m m
F r ; c i o ^ F a c i n go n S t e e lP a
4
Steel 5
Steel 5
S::e 6 - 1 3 6 '1m m
Y es
yes
tt-
FUELTANK 8A.1
SECTION 8A
FUELTANK
INDEX
Ref. 1. 1.1 1.2 Subject INFORM ATION GENERAL SWIRLPOT FUEL GAUGETANK UNIT. Page 84.1 84.2 Ref. 1.3 2. Subject Page FU E LTA N K 8A- 3 TOR QU E W R E N C H S P E C IFIC A TI O NS. . . . .12 ... 8A.
INFORMATION 1. GENERAL
The fuel tank for VK Series models with 3.3 litre EST engine canies over from VH, except for the deletion of the fuel filler limiter pot from inside the fuel tank and revision to the fuel filler cap pressure relief valve. is now 12 to'16 kPa. Revisionhas also been Pressure made to the fuel venting system due to the deletion oJ the fuel filler limiterpot. Revisionsintroducedfor 3.3 litre EFI equippedvehicles, include the same modificationsto the venting system' fuel filler cap and ihe deletionof the fuel filler limiterpot as for 3.3 EST engines.Additionsincludea swirl Pot and a new fuel gaugetank unit (Fig. 8A-1). Also incorporatedin the fue tank ior EFI equipped vehiclesis a fuel return line, whrcr ceirvers fuel from the regulator, back :c :he swrdpot. EFI fuel pressure r.corporatea hot VK Seriesmodelswith 5.0 litre engrnes. package, fuel handling refer to Sect'on6C'Engine Fuel 5.0 litre Eng-ines' oflhis SupptementThe crang-esmade to the 3.3 litre EST fuel tank carry ove. to. use with the 5.0 litre engines.
=LOA T f FU E r GA U C : / (FU L- P :)S ti rON )
*>vvthL
rul
F UEL PIC K .U P FI LTE R
L FuE L R E TU R N LIN E (FOB P R E S U R ER E GU LA TOR )
FU E L GA U G: -A N K U N IT
Figure 8A-1
8A.2 FUEL TANK

1.1 SWIRLPOT
The plastic swirl pot, located inside the fuel tank on 3.3 litre EFI models, is mounted on the bottom of the tank (Fig. 8A-2). lt providesa reservoirof fuel to prevent the fuel pick up becominguncoveredduring corneringor when the fuel level in the tank is low. For practical purposes, the swirl pot is part of the tank and no servicework is possible on it.
-1
\
S WIR L C H A MB E R _
FU E L P IC K .U PP IP E
Flgure 8A-2
The fuel return line is connectedto a venturiat the base of the swirl pot. This high velocity jet of fuel picks up extra fuel and delivers it to the pot through a tangential passage.This keeps the pot full of fuel irrespective of the level in the tank, and the swirlingaction separates au and vapourfrom the fuel (referFig. 8A-3). The continuoussupply of luel to the swirl pot ensures that the fuel pick up does not draw any air into the fuel system.
V E N TU R I
:.
---->l FU E L E N TB Y F R OM TA N K
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FU E L R E TU FN IN G FR OM P R E S S !R = R E GU LA TOR
Figure 8A-3
1.2 F U ELG AU GE T A N K U N IT
The fuel gauge tank unit (Fig. 8A-4) for the EFI systemis of a new design and is not interchangeable with previous Commodore tank units. The fuel pick up filter is immersed in fuel insidethe swirl pot. The gaugeunit is mounted to the tank by 5 screws and sealed against leakage by a cork gasket between the tank and the gauge unit. Sealant Part No. M39040 is appliedto the threadsof the screws and mating surfaceof cork seal to fuel tank. For removal,testing and reinstallation instructions, refer to service operation 2.6, Section '12C in this Supplement.
Figure 8A-4
!t-
ry
FUELTANK 8A-3
1.3 FUELTANK
remainthe instructions Fuel tank removaland installation models. same as on previousCommodore The only differenceis with EFI models,on removal,the and reconnected luel return line must be disconnected (refer Fig. 8A-5). on installation Extreme caution musl be exercisedwhen disconnecting either the fuel return hose or the fuel feed hose to the fuel pump, as a great deal of tuel will spill trom the hoses. Before startingvehicle,carry our fuel systemleak test as per service operation 3.2' Section6C, Electronic Fuel of this SuPPlement. Injection,
FTE L FE E D LIN :
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8A.12 FUEL TANK WRENCH 2. TORQUE SPECIFICATIONS

Nm Fu el Tank St r ap, Bolt s and Nut s Fu el P oe Hos eClam os ( E. F . l . o n l v ) . Fu ei Tank SenderUnit Sc r er v s 26 - 32 1 2.8 -3.2
NOTES
EXHAUST SYSTEM8B.1
SECTION 88
EXHAUST SYSTEM
INDEX
Ref. 1. 2. 2. 1 Subject Page GENERALDESCRTPTTON .............................. 8B-1 SERVICE OPERATIONS 8B-1 EXHAUSTEXTRACTOR 8B-1 Remove........ 8B-l Reinstall 8B-2 j Ref. r 3. 4Subject Paqe SPECtFtCATIONS.............. .......8B-i1 TORQUE WFENCHSPECIFICATIONS........ 8B-12
1 . GENERAL DESCRIPTION
All 3.3 litre VK Series models equippedwith Electronic Spark Timing (EST) have a single exhaust systemwhich carries over from VH L6 models. All 3.3 litre VK Series models equippedwith Electronic Fuel lnjection(EFl) have the singletype exhaustsystem, but in place of the standard exhaustmanifold. a set of stainlesssteel exhaustextractors rs fitled Five litre VK Series models have fifted a dual type exhaust system.which is carried over from VH 5.0 litre models.
When installingthe exhaustsystem,care must be taken to install each part or assemblyin correct relationto one another. Inconect assemblyof exhaust system components can frequently be the cause oi rattles or 'booms' due to incorrectalignment or clearancefrom the body or parts. suspension When installing the exhaust system, ensure that the correct assembly, installation, tightening sequence and clearancefor the systeminvolvedis observed.
2.1 EXHAUST EXTRACTOR

REMOVE 1. Disconnect batteryearth lead. 2. Remove air flow duct and inlet manifoldas per service operations 3.9 and 3-11 Section6C (Electronic Fuel Injection) of this Supplement. 3. Removegenerator brace bolt (Fig.8B-1),disengage fan belt from generatorpulley. Loosen generatorto support bracket bolt and nut (Fig. 8B-1) and swing generatordown away from the engineblock. 4. Raise front of vehicleand place on stands.
zB R A C E B O Lt
B R A C K E T E OLT
Figure 88-1
SYSTEM 8B.2 EXHAUST

5. Loosen exhaust clamp around exhaust eltractors (Fig. 8B-2). Tie up exhaust pipe with wire, so that the pipe is supported when the extractors are removed. 6. Lowerfront of vehicle. 7. Remove erlractor end flange mounting bolts from cylinder head. Disconnectenractors from the exhaust pipe and lift out extractors from engine compartment.
,,
,T E X H A U S T C LA MP
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E X TR A C TOR S E X H A U S T P IP E-
----7
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Flgure 8B-2
REINSTALL 1. Clean mating surfaces ol exlraclors, inlet manifold and cylinderhead. 2. Inserla new manifoldgasket in place on the cylinder head. 3. Positionextractors,engaging the exhaust pipe and positioning onto cylinderhead. 4. Reinstall inlet manifold and air flow duct as per service operations 3.9 and 3.11, Section 6C (Electronic Fuel lnjection) of this Supplement. 5. Tighten e).tractormountingbolts to torque specified at end of this Section 6. Refit fan belt and generatorbrace bolt, readlustfan belt and tighten generatorto support bracket bolt and nut. 7. Raisefront of vehicleand place on stands. 8. Removesupporting wire.Tightenexhaustclampsand check exhaustsystemclearance. 9. Connectbattery earth lead. Check for fuel leaks as per service operation 3.2, Section6C (Electronic Fuel Iniection) of this Supplement. 10. Startengine and checkfor exhauslleaks. 11. Lowerfront ol vehicle.
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3. SPECIFICATIONS
Ty pe: Single. Single . Dual . . Ex haus tPipe
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88.12 EXHAUSTSYSTEM 4. TORQUEWRENCHSPECIFICATIONS

Ex haus : Ex t r ac t or t o Head Bolt s Ex haus t Ex r r ac t or t o Head Nut s EnginePr peFlanget o M anif old Nu t s L 6 & V 8 Ex haus tClam p Nut s
Nm 27 -34 41 -48
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STEERING 9-1
sEcTtoN9
STEERING
INDEX
Ref. Subject Page I Ref. Subject paae 1. cENERAL DEscRtPTtoN.............................. sr 3. ToRouE wRENcHspEcrFrcATroNs........;i 2. SERVTCE OPERAT|ONS.................... 9.1
The steering system for VK Series mo'delscanies over from VH Seriesmodels.
For all service operations not noted in this Section refer to the VB CommodoreService ManualPart No. M38145 and the VH Commodore ServiceManualSupplement Part No. M38731. On VK Series models there is fitted two types ol lower steering shaft to intermediate steering shaft couplingclamp. Part No. 92021862is identifiedby a date code stamp, refer to Fig. 9-1, Part No. 7809433 which does not have a date code stamp. The clamp nut tighteningtorque specification has been revised,refer to specificationsat end of this Section.
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WRENCH 3. TORQUE SPECIFICATIONS

CouplingClam p Nu i 42-48Nm
WHEELSAND TYRES 10.1
10 SECTION
WHEELS AND TYRES
INDEX
Ref. Subiect Page Ref. 3. page Subject TORQUEWRENCHSPECIFICATIONS........ 'Io.2
The tyre and wheel size on SL sedan models has been revised.The SL sedan has fitted a new 5.5 x 14 JJ steel (P175/75SR14)sizetyre. wheelwith a BR78S14 A new tyre P185/75 HR14 is now used on 5.0 litre models, this replaces the CR78 H14 tyre used on VH models. All other wheel and tyre sizes remain the same as used on VH models. The Calais has fitted, as slancard eouipment,a newly designedallov road wheel. The atov road wheel as used on VH SLE modelsnow becomesocrronat eouioment on Berlina models. Service operationsare as described,n the Commodore VB and VH seriesservicemanuals.
AND TYRES 10.2 WHEELS 2. SPECIFICATIONS

Ste elWheel: Rim W idt h Di am et er r adialr un- ou t Ma x im um per mis s able lat er alr un- ou t Ma x im um per mis s able Off s et . . . . . Alloy Wheels : Rim W idt h Dr am et er . . . . Ma x im um per m is s able r adialr un- ou t lat er alr un- ou t Ma x im um per m is s able Off set Dyna mic Balanc ing: W heel/ Ty r e Ma x im um per m is s able out of balanc e Ma x im um per m is s able Ty r e r adial ist h a r m o n i c f or c e v ar iat ion( Ty r e only ) . Maximum Load Rat ing lper Ty r e) :
5.5 JJ (OnS L S edan onl y) 6.0 JJ

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1.5 kg mm 80N 525 ks 560 kg 600 ks 590 kg 530 ks 585 kg
B R 7 8 S1 4 c R 7 8 S' ,r4 cR 70 Hl4 P205i',60H R15 P 1 8 5 /7 5 H R 1 4 P1 8 5 /7 5 5 R4 1
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3. TORQUE WRENCH SPECIFICATIONS

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BATTERY& CABLES 12A.1
SECTION 12A
BATTERY& CABLES
I NDEX
Ref. 1. 1. 1 1. 2 2. 2. 1 2.2 Subject Page GENERALTNFORMATTON ............................ 124-1 DESCRTPTTON .................... 12A.-1 SERVICENOTES 12A.-1 SERVICEOPERATIONS 124-2 BATTERY,SERVICE 124-2 BATTERY,TEST...........,, 124-2 State of Charge - Low llaintenance Type Batteries Hydrometer Test -...-........ 12A.-2 State of Charge MaintenanceFree Batteries .............. 12A-3 Load Test - All Batteries .................... 12A.4 Ref. 2.3 2.4 2.5 3. 4. paqe Subject CHARGING BATTERTES. ....... :nEA Low MaintenanceTypes .................... 12A-4 Maintenance Free Types.................... 12A-5 VEHICLEWIRING,PERIODICAL CHECKS 12A-5 DRY CHARGEDBATTERY,STOREAND ACTIVATE .........t2A-s DIAGNOSTS ...... 12A-6 SPEC|FICAT|ONS............. .......12A-5
1. GENERAL INFORMATION
1.1 DESCRIPTION
In all VK Series models,the 12 volt batteryis locatedin the engrne compartment behind the passenger side headlamp. The main battery cables are attachedto the battery terminals by spring ring type clamps and the negativeterminalis earthedto the vehicle body and the engineblock. Vehiclesfitted with the 3.3 litre EST or EFI engine are equipped with a low maintenance 80 min/21 5 amp battery.(Optionalequipment such as air conditioning and trip computerdo not requirea larger battery). Vehicles litted with the 5.0 litre engine, a 75 min/ free battery is fitted. 235 amp, maintenance
1.2 SERVICE NOTES

NOTE:The spring ring clamp battery terminalsshouldbe removedas shown in Fig. 124-1. Never prise clamps off with a screwdriveror hammer. Push down as far as possibleon the battery post when refitting battery leads. CAUTION: Do not allow liquid from battery to contact eyes, skin, clothing or painted surfaces. Battery fluid containssulphuric acid which causes injury and damage in the event of contact.
Flgure 12A-1
12A-2BATTERY& CABLES 2. SERVICE OPERATIONS

should be used to service,test The followingprocedures and recharge batteries. Unless these procedures are properly followed, good batteries may be replaced needlessly'
SERVICE 2.1 BATTERY,

1. Check battery terminalsand around battery area for corrosion deposits.Remove any deposits and treat with a solution of warm water and baking soda or ammonia, then rinse otf with clean water. Smear battery posts and terminals with petroleumjelly to resistcorrosion. 2. Check battery case and replace battery if case is cracKeo. 3. On all batteriesexcept mainlenancefree batteries, check electrolyte level and carefully top up with distilledwater as necessaryto level of indicator.DO NOT OVERFILL. NOTE: Normal battery water usage is less than 30 ml per 10,000 km, but may be more for long continuous running or high temperatures. 4. Check that batteryis firmly secured by its clamping bracket. 5. Check that battery cable terminals are securely attachedto batteryposls and that cable insulationis not damaged or wom anyrnhere along cable. Check that cables do not have broken or frayed strands and that they are securein their terminals.
2.2 AATTERY,TEST
TYPE STATEOF CHARGE. LOW MAINTENANCE . HYDROMETER BATTERIES TEST NOTE:
Ensure specificgravity of battery electrolytehas reduced to suit hot climate not been previously (explanatorytag specifying specific gravity of new electrolyte should be attachedto battery in position.) conspicuous b. lf water has been added to battery,do not use hydrometeruntil electrolytehas been mixed by charging for at least30 mins. Hold hydrometervertically and draw in sufficient liquid from battery cell to allow float to float freely with bulb fullyreleased. Compensate reading for temperature by adding0.004 tor every 5oC that the electrolyte temperature exceeds 27oC, or subtracting 0.004 lor every 5oC l e ssthan 27oC. a.
Flgure 12A-2
BATTERY& CABLES 12A.3

3. Determine state of charge of battery using temPerature compensated specilic gravity and followingtable.
TemperatureComPensated SpecificGravitY Fully Char ged W hen Below Recha rge Fu lly Dis c har ged 1. 110t o 1 . 1 3 0
to 1.260 1 .2 4 0
NOTE: a. lf electrolytespecilic gravity has been reduced
b.
for service in hot climates, typical temperature adjusted value of specific gravity below which battery should be rechargedis 1.150. The specific aravity of a charged battery should not vary more than 0.025 between cells. Large variationsindicatedefectivecells.
STATE OF CHARGE. MAINTENANCE FREE BATTERIES NOTE: Maintenance free batteries operate on the same basic principle as other lead-acid batteries.As the battery is charged, lead sulphate in the plates is convertedto lead in- the negative plate, and to lead oxide in the positiveplate. Also, the specific gravity of the sulphuric acid electrolyteincreases. and The essential difference between low maintenance maintenancefree batteries, is in the lead alloy in the grids.When the battery is operated in the car at 14.0 V to ta.S V, the rate of water loss is so low that topping during the life ol the battery,and the up is unnecessary top can be permanently sealed. In the AC Delco Free battery in the VK Seriesmodels,all of Mainlenance material. the acid is held within a hightlyporous separator Even when tully charged,the gases which are normally evolved from the water in the electrolyte are fully Acid cannot leak at all. There is much less reabsorbed. risk of explosionwith this type of battery' '1. The state of charge of a sealed battery can be checked by measuring the OPEN CIRCUIT VoLTAGE. (O.C.V.) 2. Disconnectbattery from all loads. Measurevoltage across terminalswith a voltmeteraccurateto at least 0.1 volts. A digitalmeter is recommended. 3. Determine state of charge of battery using the following table, which is accurate if the battery has lor severalhours' been off chargeor discharge
BATTER Y CO NDI TI O N Fuil v Char ged I W hen Below Re ch ar ge Fully Dr s c har ged O PEN CI RCU I T V O L T A G E
UVCT I I.Y V
1 2 . 5V
Les st ha n 1 1 . 1 V
12A.4 BATTERY& GABLES

CAUTION: lf battery is in a car which has just stopryd, or has just come off charge or discharge,the O.C.V. will be higher or lower. Reliable readings will be obtained if battery is left standing tor several hours, say overnight. For quick checks just off charge, connect a load of about 10 to 15 amps, such as headlights, for five to ten minutes. The O.C.V. will be close to the fully stabilized reading.A little experience,carefully noting if the voltage is varying duing checks, and how quickly, will soon enable reliable measurements to be obtained. LOAD TEST . ALL BATTERIES 1. Check batterystate of charge as above. lf under half charge,rechargebeforeconducting this test. 2. Connecta voltmeteracross batteryterminals. 3. Start engrnewhilst readingvoltmeter. During starting at normal temperatures,indicated voltage of a fully charged battery should not fall below 10V. lf voltage lalls away quickly, battery is faulty. lf battery and engine temperatures are below 5oC, voltage may be 0.5 to 1.0V lower.lf one cell is faulty it will show up in this test by excessivegassing or overheating. NOTE: Battery n be tested under load using a commercial battery tester as per manufacturer's instructions.
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2.3 CHARGING BATTERIES

Procedures for charging low maintenance and maintenance free batteries are basically the same. With both types,fully flat batteries can safely be boost charged,but care is necessaryto avoid excessivecurrent if the battery is over half charged,and particularly if it is almost fully charged. il time permits. Slow chargingis advisable CAUTION: During charging, an explosive hydrogenorygen gas mixture is released by the battery. Ensure there are no naked flames or electrical spark discharges in the vicinity of the battery during charging. NOTE: a. Fast chargingcan substantially 'boost' a battery,but the fully chargedconditioncan only be achievedby slow charging. b. Fast chargingmust not be used if: i. Specific Aravity readings are not uniform between battery cells, or are above 1.200 at the start. ii. Electrolyte is discoloured with brownsediment. iii. Either of the above two conditions develops after commencing fast charge. iv. in the case of maintenance free batteries,if the O,C.V. is above12.7 volts. c. The followrngtables assume 'constantcurrent' type chargers. lf 'constant voltage' charger is used, charge at 14.5V to 15.0 V the battery will automatically regulate the currentto a safe level. LOW MAINTENANCE TYPES 1. Removebatteryfrom vehicle and removevent caps. Rest caps loosely in openingsto prevent acid mist escaoino.
BATTERY & CABLES 12A.5

2. Connect battery, with correct polarity, to charging apparatus and set chargingcurrent accordingto the followingtable. CAUTION: Refer note under low maintenance type regarding overcharging5. 6. Refit battery to vehicle. Operate starter motor for approximately 10 seconds,to remove surfacecharoe from battery. Load test battery as previously described in this Section.
4 A appr ox . 3 5A appr ox . 1
24 hr s . m ax . 2 hr s . m ax
Proportional to the charge at the start
2.4 VEHICLEWIRING, PERIODICAL CHECKS

To ensure etficientoprationof electricalsystem and to safeguardagainst damage, the following checks should be carriedout periodically: 1. Check that all wires are held securely by their respective retainerclips. 2. Check wires for chaffing or damagedinsulation and repairor replaceas necessary 3. Check that wire terminalsand luses are secure and that fuses are as specifiedat end of Section.
Atter a few minutes, check electrolyte specific gravity (as per operation2.2 in this section)and colour (see note iii). 4. Monitor electrolyte temperature during charging procedure. lf temperature reaches 55oC, switch otf chargingcunent and allow battery lo cool. Reduce charging currentto preventsubsequent overheating. NOTE: A fast charged battery can be brought to the fully charged condition by slow charging for a few hours. During the last few hours on charge the current should be 1.0 amp or less. 5. Check voltage and electrolyte specific gravity once per hour. Slow chargingis completedwhen there is no change in voltage or electrolytespecific gravity over a three hour period. 3. CAUTION: Charging at over the recommended times or cuftents can significantlyreduce battery life. MAINTENANCE FREE TYPES 1. Removebatterylrom vehicle. 2. Connect battery, with conect polarity to charging apparatusand set chargingcurrent accordingto the following table.
2.5 DRY CHARGEDBATTERY, STORE AND ACTIVATE

Dry chargedbatteriesare fully chargedwhen manufactured and contain no electrolyteuntil actryatedfor servrce. The dry chargedbatteryis completelyseaied and can be stored indefinatelywith no servicing untit actrvated. To activate a dry chargd battery: 1. Remove vent caps and add electrolyteof 1.265 specific gravit_v to each cell until corect level is reached. 2. Several minutes after activating batrery. check level and add more electrolyte(not water) electrolyte as necessary. NOTE: a. After dry charge battery is activated,il becomesa 'wet' battery and only water should be added in subseguent servicing. b. Althougha dry chargebatterycan be put into service immediatelyafter activation,the following tests are recommended: i. After adding electrolyte, check open circuit terminal'voltageof battery. lf less that 10V, replace battery. Check specificgravityof electrolyte in each cell. lf any temperature correctedreading(see operation 2.2 in this section)shows more than a 0.030 drop from initial specilic gravity of electrolyte, slow charge batterybeJoreuse as per operation 2.3 in this Section. i l t. Check cells for violent gassingand if detected, slow chargebatterybeforeuse.
2 4 h rs .ma x
Proportional :o the charge at the start
NOTE: lf the O.C.V.was very low, less than 10.0 V, the initial charge current may be quite low. The current shouldincrease after a short time at the charge voltage. 3. Monitor battery temperalure. lf the battery feels noticeablywarm, switch off charging cunent and allow battery to cool. Reduce chargrng cunent to prevenl subsequent overheating. A fast charged bafterycan be broughtto the fully charged condition by slow chargingfor a few hours.Duringthe last few hours on charge,the current should be 1.0 amp or less and the voltage 15.0 V maximum. 4. Checkvoltageand currentonce per hour, as charge completion.Slow charging is completed approaches when both voltage and currentare constant over a three hour period.
12A.6 BATTERY& CABLES 3. DTAGNOSTS
CAUSE Bat t er y O v er f illed Bat t er y Under f ; lleo Battery Cracked Bat t er y O ld Fault y Gener at o.Fault y Volt age Regulat orFault y lg nit ion Swit c h Fault y Fa ult y or W or n W ir e/ Cable ( s) Bad Connec t lon O X c aus e. I ndic at es oc s s r ble m or e or obablec aus e lnd; c at es
*-e
l
o
O
o o
o o
O O O
4. SPECIF|CAT|ONS
RY: BATTE
R:-:el \/nlteno
Ca pec it v . . . Ve h c leswit h 3. 3 l; : ' e EFI or EST Ve hic les wit h 5. 0 I : - : engine NOTE: ied r a: ngswhen t es t ed i n a c c o r d a n c e Spec if wit h Aus t r aliar St ^ andar dAS 2 1 4 9 - 1 9 8 0
1 2 r 'o l t s Reserve/ColC d rankino 80 min./215 amp 75 min.l235 amp
1-
LIGHTING SYSTEM128-1
SECTION 12B.
LIGHTING SYSTEM
INDE x
Ref. 1. 2. 2.1 Subject Page GENERALDESCRtPT1ON.............................. 12B,-1 SERVTCE OPERATTONS ................... 12B.2 REAR TArL LAMP (SEDAN).......................... 12B'-2 Rernove.......... 12B.2 Reinstall 128-3 LICENCE PLATE LAMP SOCKET (SEDAN) 12B,-4 Remove........ 12B.-4 Reinstall 12B.-4 Ref. 2.3 2.4 3. Subtect Page HEADLAMP SWITCH........ 128-4 Remove........ 12B'-4 Reinstall 12B,-4 DASH LtcHTS DTMMER SWITCH................ 12B-5 Remove............... 128-5 Reinstall 128- 5 sPECrFtCATtONS ........... 12B-5
The lighting system for VK Series models carries over from VH Series models except where noted in this Section. have the front turn signallamp assemblies On all models, a clear crystalappearancelens, with an amber inner lilter for amber illumination. On all sedan models,there is a new style rear tail lamp refer Fig. 128-1. lens and tail lamp extension moulding,
f TA L .A MP LE N S
==--- Sil===
LTAIL LAf..p --\
E X TE N S I: ). MOU LD IN 3
Figure 128-1
On all sedan models,the rear licence plate is illuminated by a new licence plate lamp socket assembly and is attachedto the bumoer.refer Fio. 128-2.
Figure 128-2
128-2 LIGHTINGSYSTEM
On station wagon models,the rear licenceplate illumination is by two Camira sedan style licence plate lamp assemblies, mounted on the rear bumper bar. Refer Fig. 128-24.
N U MB E R P LA TE LIGH T A S S E MB LY (2 P LA C E S )
R E A R B U MP E R
Flgure 128-2A
Serviceoperations for the VK Serieslightingsystemcarry over from VH Series models.exceot where noted in this Section.
2.1 REAR TAIL LAMP (SEDAN)

REMOVE '1 . From inside boot, remove globe sockets from the rear tail lamp assembly that is to be removed, Fig. 128-3. NOTE: To remove the globe sockets on the passenger side tail lamp, removethe spare wheel.
=>
LIC E N C E P LA TE LA MP C ON N E C TOR S
LrLuuE S OC K E TS (8 P LA C E S )
Flgure 128-3
The two outer globe sockets on the passengerside tail lamp are removed by depressingthe lever (arrowedin Fig. 128-4\ and twist the gtobe socket in the directionof the REMOVEarrow.
Figure 128-4
LIGHTINGSYSTEM128-3
2. Remove the four screws around the outside of the tail lamp extensionmoulding, refer Fig. 128-5.
TA IL LA MP _ E X TE N S ION MOU LD I N G
I-
NUT
SC 8:! V 2 9LA C : S
R EAR
LA'tl'
SCREW 2 P LAC E S
\*u-, \-\
tr : AR BU M P E R B A R
--
- ,- /
Flgure 'l2B-5
3.
From inside the boot, removethe two nuts securing the tail lamp enension mouldingmountingbrackets to the rear end panel, refer Fig. 128-6. Remove e)|tension. NOTE: On Calais models, it will be necessaryto remove the boot caroet to reveal the two nuts.
TA IL LA MP _ E X TE N S ION MOU LD IN G
n,, - - - --: 5
Flgure 12&6
4.
Remove the five tail lamp mounting screws from inside the boot, refer Fig. 128'-7,remove tail lamp assembly.
''.-.:
REINSTALL Installation is reversalof removalprocedures. Check lamp ooeration.
,.,
Flgure 128-7
128.4 LIGHTINGSYSTEM
2.2 LICENCE PLATE LAMP SOCKET (SEDAN)
R EMOVE 1. Disconnect batteryearth lead. 2. From inside bool, disconnect licence plate lamp socketwiringconnectors, refer Fig. 'l2B-8. 3. Pushgrommet and wrringconnectors the out towards rearof the vehicle. 4. Remove rear bumper bar as per service instruction 1.3,Section'1 D of tbrssupplement.
/
P tnTE -/ -l C E \C E C ON N E C TOR S -A I,'1P
GLOE E S OC K E TS (8 P LA C E S )
Figure 128-8
Removescrew holding lamp socket lo bumper bar, referFig. 128-9 and removesocket. NOTE: Licence plate globe replacementis by pushing globe against spring in the socket and twisting globe, which releases it lrom the socket. REINSTALL lnstallationis reversal of removal procedures.Ensure licence plate lamp wrring grommet is fitted correctly. Checklamp operation.
BU M PER BAR - =- T \
5.
Figure 128-9
2.3 HEADLAMP SWITCH

R E MOVE 1. Removecover from lower right hand dash panel, re fe rFig. 128- 10. 2. Reachup behindswitch throughcavity in lower right hand dash panel,and pull wiringharnessconnector fromswitch. 3. The light switch is a snap fit into the instrument facia.Pushout lightswitchfrom behind Jacia. REINSTALL Installation is reversal of removalprocedure. Check light switchoperation.
Figure 128-10
LIGHTING SYSTEM 128.5

2.4 DASH LIGHTSDIMMERSWITCH
REMOVE 1. Remove headlamp switch as per servtce operation 2. 3. 2. Through the hole vacated by the headlamp switch, remove the two switch mounting screws, refer F ig. 128 -1 1. wiringconnector, 3. Pull the switch back and disconnect withdraw switch. REINSTALL Installation is reversal ol removal procedures. Check operationof dash lights.
R IGH T H AN D LOYJ ER D ASH PA\EL ( R EAq'i l EW )
/
MOU N TIN G _, S C R E W {2)
D A S H L 3.ITS D I MME F SW ITC H
Fi gure 128-11
TU R N S IGN A L F LA S HE R U N IT
E D GE C LIP -\
.i S TR U I\1E N T
, : \ Er - 1 ,_
_-rhrtrH
IT AZ AF D W AR N IN G F LASF ER U N IT
"-
Figure 128-12
3. SPECIFICATIONS
U N IT T URNS IG N ALF L A SH ER
M ak e. O per at ion
L OCa tr o n
. .
Hella o e r m r n u t ew i t h a u d i b e i3 u n c 60l120 flashes f n s t r u m e n tc a r e - p a n e l . R e f e r F i g . 1 2 8 - 1 2 Access i s g a r n e dc v r e m o v i n g c o v e rf r o n l o r ve r r i g h t h a n d d a s hp a n e l ,r e f e r F i g . 1 2 B - l 0 . Delco per minute. 60/120 f lashes f n s t r u m e n tc a r n e ' p a n e l . R e f e r F i g . 1 2 8- 1 2 . Access i s g a i n e dc y r e m o v i n gc o v e rf r o m l o w e r r i g h t h a n d d a s hp a n e l ,r e f e r F r g .12 B - 1 0. 60/55 watt Haiogen 1. 2 w a t t e r P u s h - l n
I NG FLASHER UNI T : HA Z A R DWA R N M ak e O per at ion Location
RATI NG O F G LO BES: Headlam p I ns t r um entPanelI llum inat ion AL L S W I TCH & CO NTRO L I LLUM I N A T I O N : G ener at or Char geI ndic at or Bac k Up and Tur n SignalLam ps Dom e Lam p Eng ê and RearCom par t m ent Dom e Lam p - Calar s Fr ont ReadingLam p - Calais . . lnt er r or RearO uar t er Lam ps- E x c e p t S L m o d e l . . . Fr ont Par k Lam p . G lov e Box Lam p Lr c enc ePlat e Lam p - Sedan. Lic enc ePlat e Lam p - St at ion W a g o n St op/ Tail Lam p
2 c.P. 21 watt Bavoret 10 watt Festcon 10 wait Fesioon 10 watt Festoon 12 watt Bayonet 10 watt Festoon 4 watt BaYonet 5 watt Festoon 10 watt Bavonet 3 watt Bayonet (2 off ) 2 1 5 't a '. t B a Y o n e t
--
W'SHIELD INSTRUMENTS, GAUGES, WIPERS/WASHERS 12C-1
SECTION 12C
INSTRUMENTS, WINDSHIELD GAUGES, WIPERS/WASHERS
INDEX
Bef. 1. 1. 1 1. 2 Page I Sublect 12C-1 | GENERALDESCRIPTION MECHANICALINSTRUMENT ASSEMBLY 12C -1 ELECTRONIC INSTRUMENT ASSEMBLY.. 12C-3 12C-3 Warnlng !:mp Panel. 12C4 Alpha lVarnlng Display... Temperature Gauge........... 12C-5 12C-5 Fuel Gauge.. Speedometer and Digltal Speed 12C-6 Dlsplays 12C-6 Tachometer 12C-6 Odometer and Trlp Meter .................. 12C-7 Trlp Gomputer Automatlc lnstrument Display 12C-7 Dlmming & TOUCHSWITCHES - MECHANICAL INSTRUMENT ELECTRONIC EC 12C -8 ASSEUBLI ...... 12C TR|P COMPUTER............... ..... 12C-8 General Descrlptlon.. ... 12C-9 Functlon Descrlption.. 1 TRtP COMPUTER COMPONENTS................12C-1 Fuel Flow Sensor 12C-11 .........12C-ll Fuel Level Sensor 1 Electronlc Control Modu|e..................12C-1 12C-12 Speed Sender Ref. 2.2 Subject Page . MECHANICAL INSTRUMENT CLUSTEF INSTRUMENTS 12C-14 Remove............ 12C-14 Reinstall .......... 12C-14 INSTRUMENT CLUSTEB - ELECTRONIC rNsTRUMENTS ..............__.. 12C-14
2.4 2.5 2.6
1. 3 1. 4 1. 5
2.7 3. 3.1 3.2 3.3
2. 2. 1
Reinstall .... . . . . . . .1 .2C. . . . 19 Fuel Tank .. . . . . . . . . . . 12C- 19 SPEEDOMETER GEARCHART....................12C-23 WINDSHIELD WIPERAND WASHER........12C.24 GENERAL DESCRtpTtON .._................. .......... 12C-24 SERVTCE OPERATTONS ........12C-24 wfPER DWELLCONTROL SWTTCH ..........12C-24 Remove... ................ 12C-24 Reinstall ..12C-24
All VK Series models have a redesigned instrument assembly.
1 . 1 ME C H A N IC A IN L S T R UMENT ASSEMBLY
SL models have a speedomeler, fuel consumption indicator, voltmeter, temperture, oil pressure and fuel gauges.An analog clock is situatedin the middle of the . instrument cluster.Refer Fig. 12C-1 Below the instrumentcluster is the warning lamp panel turn indicator,charge indicator lamp, park incorporating brake and brake failure lamps, low oil pressurewarning lamp. lamp, high beam indicatorand EST diagnostic On Berlina models the assemblyis the same except tor insteadof the fuel consumpthe additionof a tachometer tion indication. A control panel to the left of the instrument cluster containstouch switchesfor the rear windowdemisterand other options for both Berlina and Commodore SL . models. ReferFig. 12C-1
WIPERS/WASHERS GAUGES, W'SHIELD 12C.2INSTRUMENTS,
mur
13
> p;
+2. rsr
1. 2. 3. 4. 5.
O I L P R E S S U R EGAUGE FUEL GAUGE T A C H O M E T E R ( E ERL INA) F U E L C O N S U M P T IONINDICAT OR ( SL ) A N A L O G U E C L OCK SPEEDOMETER
6. 7. 8. 9. IO. I 1.
V OLTME TE R TE MP E R A TU R E GA U GE R E A R WIN D OW D E MIS T S WITC H (B E R LIN A ) A N TE N N A R E TR A C TOR S WITC H (B E R LIN A ) A N TE N N A E X TE N S ION S WITC H (B E R LIN A ) R E MOV A B LE B LA N K S : FOR S P E C I FIC OP TION S
Flgure 12G1
1. 2. 3. 4. 56. 7. 8.
A L P H A W A R N I NG DISPL AY E N G I N E C O O L A NT T EM PERAT URE GAUGE F U E L L E V E L G AUGE SPEEDOMETER TACHOMETER O D O M E T E R A N D T RIPM ET ER D I G I T A L S P E E D INDICAT OR T R I P C O M P U T E R AND CL OCK
9. 10. 11. 1213. 14. 15.
P H OTOTR A N S IS TOR - A U TOMA TIC D TS P LA YD IMMIN G (D A Y LIGH T OP E R A TION ) FU N C TION C ON TR OL B U TTON S- TR IP C OMP U TE R WA R N IN G LA MP P A N E L TOU C H S WITC H E S S WITC HS Y MB OLS B LA N K S WA R N IN G B U ZZE R
Flgure 12C.2
W'SHIELD GAUGES, INSTRUMENTS, WIPERS/WASHERS 12C-3

1.2 ELECTRONIC INSTRUMENT ASSEMBLY
Calais models have a new Electronic Instrument assembly. The instrumentationis fully electronic and vacuum flourescent, featuringtrip computerand automaticdisplay dimming. Electronic instruments feature a combination of bar graphics in green light lor speedometer,tachometer, fuel and temperature gauges, with digital displays for speedometer, odometerand trip meter. The Electronic Instrument Assembly, as shown in Fig. 12C-2,consistsol the {ollowingcomponents: 1. AlphaWarning Display 2. EngineCoolantTemperature Gauge 3. Fuel Level Gauge 4. Speedometer 5. Tachometer 6. Odometer and Trip Meler 7. DigitalSpeed Indicator 8. Trip Computer and Clock 9. Photo Transistor - Automatic Display Dimming (daylightoperation)Manual Rheostat Conrol (night operation). 10. Function ControlButtons- Trip Computer 11- Warning LampPanel 12. Touch Switches '13. SwitchSymbols '14. Blanks 'f5. Warning Buzer
WARNING LAMP PANEL The warning lamp panel is located along the bottom cluster. edge of the instrument The warninglamp panel containswarninglampsfor: 1. BatteryCharge 2. BrakeFailure 3. ParkBrake 4. Lett Hand Turn Indicator 5. Right Hand Turn Indicator 6. Headlights on (with ignitionoff) 7. High Beam Indicator L Reversing Indication Lamp Warningsare displayed and a buzzersoundedfor various component functions.
R:tfor\/
Chrrnp
Bra ke Fa ilu' e Pa rk Bra k e
YE S YE S YE S
Rig ht Ha nd I ndic at o. L eft Ha nd lndr c at or W ar ning Reversing
YE S Y ES Y ES
NO 2 B EE P S 2 B EE P S (i f c a rmov;ng 5 k" hr) above NO NO NO
will s ound in a half s ec ondt im e i n t e r v a l Th e 2 be eos
W'SHIELDWIPERS/WASHERS GAUGES, 12C.4INSTRUMENTS,

ALPHA WARNING DISPLAY The alpha warning display comprises ten, 14 segment alpha numericcharacterdisplays.lt is situatedin the right hand too corner of the instrument cluster. When the ignitionis first switched 'on' and the motor is not running,the waming monitor displays'SEAT BELT' continuously, until the motor is started,after which the message will display for a further 10 seconds. Refer Fig. 12C-3. lf another messageis waiting to be displayedafter the motor has started,the 'SEAT BELT' warningwill display only for 5 seconds,allowing the olher messagesto be displayed.
I f -!-
L-!: t-1 T _ u _ rt t
t-11- t T t _ lt _ l_ t
Flgure '12G3
In the situationthat more than one warning occurs at once, the messagescycle through,each for 10 seconds and a 1 secondgap betweeneach messageand in order of priority. The priorityorder being: 1. O I L A L ER T 2. ENGINEHOT 3. LO COOLANT 4. LO FUEL ReferFig. 12C-4. lf 'ENGINEHOT' is displayedand 'LO COOLANT'is queued for display and then suddenlyan 'OlL ALERT' fault occurs,then the 'OlL ALERT' warningwill lump the queueand take precedence over the other warnings. When an alpha warning is displayed,it is accompanied by an audible(5 beep)warning.This audiblewarningwill only occur once for the initial displayo.f each individual messageand every time the ignitionis switchedon until the sourceof the lault is remedied. Everytime an alpha warningis first displayed, the audible warningwill sound5 beeps in two seconds.
- t-
I
I
II' | l l tt
In iit
IItt /--l -[/
I I
-a-
t _ t t lt J t t \ t l
L_l \i l _
t t\l t__
t1t_t t
tn
l t
I
- t-
l_ t_t
l-t
t_ t_u_tL f lt \t t
t- t-t t-tt
t-il\ | T
I I
-a-
l_ l_l
l -t
I t tt t | - r_t 1_ r_
Flgure 12C-4
When there is no warning message evident, the word 'MONITOR' is disolaved. Reier Fio. 12C-5.
Figure 12C-5
INSTRUMENTS, GAUGES, W'SHIELDWIPERS/WASHERS 12C.5

TEMPERATURE GAUGE The temperature gauge, rclet Fig. 12C-6, is located betweenthe alpha warningdisplayand fuel gauge on the right hand side of the instrument cluster. The engine coolant temperature display consists ol 13 segment bars, the last three bars from the right are red and the remaining are green. the bars light With an increase in coolant temperature, up, one at a time, from left to right. When the red zone is reached,these bars light up progressively and remain all the red bars alight so that at maximumtemperature, are alight. When the coolant temperatureis sufJicient to cause the first of the red bars light up, the alpha warningdisplays 'ENGINEHOT' and the audiblewarningsounds5 beeps.
Dt]OC
TEMP
-E lllililillill
---Figure 12C
FUEL GAUGE The fuef gauge, refer Fig. 12C-7, is located in the lower right hand corner of the instrumentcluster. The fuel gauge is a progressive bar display in which the bars light up to indicalethe level of fuel in the tank. The first three bars from the left of the gauge are red, whilst the remainingbars are green. As the fuel level and the last left drops below '10.5litres (approximately) hand green bar goes out, a 'LO FUEL' warning is displayed on the alpha warning display. An audible warning is also sounded,consisting of 5 beeps. When the last red bar goes out, there is less than 1.5 litres of 3 litres of fuel fuel left in the tank. There is approximately in the tank for each lightedred or green bar.
lll!
llr -
FUEL
llllilillililililil
Figure 12C-7

SPEEDOMETERAND DIGITAL SPEED DISPLAYS The speedometer,refer Fig. 12C-8, is situated in the centre section ol the instrument cluster. lt has a green light bar graph commencing at 0 and finishing at 180 km/hr. When the ignition is switched on, all the digits light up. When the vehicle is moving, the bar graph lights up to indicatevehicle speed. To the lefl ol the speedometer is a digital speed display showingvehicle speed.The last digit of the digitalspeed display does not change more than once every half second, so as to guaranlee good legibility.When the vehicle is stationary and the ignition is on, the digital displaywill indicate'0'.
ooocoD=q:= - .;=
t- -
km/h
Flgure 12C-8
TACHOiIETER The tachometer, reler Fig. 12GBA, is situated below the speedometerin the centre of the instrumentcluster. The digits 0 to 7 light up whenever the ignition is switched on. The green bar graph lights up as an indication of engine speed. The colour of the bar graph above 5500 rpm is red, indicatingengine speed above this level should not be maintained.
E:
Flgure 12C-8A
ODOMETER AND TRIP METER The odometer, reler Fig. 12G9, is a seven segment 6 digit displayand togetherwith the seven segment4 digit trip meter display,is situatedbelow the tachometer. The odometerindicatesdistancetravelledin one kilometer unitsfrom 1 to 999,999kilometers. The trip meter indicatesdistancetravelledin tenths of a kilometerup to 999.9 kilometers. Below the trip meter is a reset button.
flflA.E F_IEEHEE
TRIP ODOMETER
Flgure 12C-9
W'SHIELD WIPERS/WASHERS GAUGES, 12C-7 INSTRUMENTS,

TRIP COMPUTER The trip computer is situated to the left of the speedometer. It comprises three seperate displays for time, distance ReferFig. 12C-10. and fuel functions. refer to 1 4 in this Section. For additionalinformation
TI M E
E, i_t.i:t i_t ELAPSED {-, {_,' !_, l_,
DISTANCE AV SPEED nflnfi TRVLD !l t-l.t-t lJ

TO Elv'lPTt'
FUE L
AV t/100 US E D
EEI.EI.EI
Flgure 'l2C-10
AUTOMATIC INSTRUMENT DISPLAY DIMMING The intensity ot the instrumentdisplay is automatically by a daylightconditions, variedto accountfor surrounding photo transistor situated in the right hand side of the 1 ). la mpp a n e l(F i g .1 2 C -1 war ning The photo transistor,upon sensrnga change in surrounding daylightconditions,will change the display intensity at one secondtime intervals.
i -!!!!t!
P H OTOTR A N S I S TOq
Flgure 12C-11
When the headlightsare turned on, the displayintensity level threshold will, if the ambientlightis belowa daylight (equivalentto dusk), immediatelydrop to the intensity The intensitycan level set by the rheostat(Fig. 12C-12). then be manually controlled by the rheostat during darkness. The rheostat is located next to the headlightswitch. lt ambient light is above this daylightthreshold,display intensity will be varied automatically via the photo transistor. This permits full display intensity in daylight a time on. To preventflickering. even with headlights if entering a tunnelor For example, delay is rncorporated. a very shaded area with headlightson and tf display setting.the displaywill not dim is on a daylight intensity to rheostat control till 5 seconds after the ambient light Displayintensity has fallen below the daylightthreshold. control will not revert to automaticuntil the ambientlight threshold or higherthan the daylight level is significantly are turned offthe headlights
Figure 12C-'t2
12C-8INSTRUMENTS, W'SHIELDWIPERS/WASHERS GAUGES,

1.3 TOUCHSWITCHES & - MECHANICAL ELECTRONIC INSTRUMENT ASSEMBLIES
The touch switch control panel is located to the left of the instrument cluster, above the centre dash vents. Refer Fig. 12C-13. These switchesare activated by pressingthe small raised finger pad in line with the symbol representingthe functionto be operated. Switches are provided tor rear window defrost, power antennaup and down. and on station wagon modelsrear windowwipeand wash.
Flgure 12C-13
1 . 4 T R I PC OMP U T E R
GENERAL DESCRIPTION The trip computerfitted to Calais models (Fig. 12C-14)is part of the electronicinstrument assembly, and has three separatedisplaysto displaytrip intormation. The trip computer is located to the left of the sDeedometer. Fuel flow measurement is suppliedby the injectorsignal from the electroniccontrolunit for vehiclesequippedwith the 3.3 litre EFI engine,or from a Fuel Flow Sensorlor vehiclesequippedwith a 5.0 litre engine. An electronicspeed sensor is mounted on the cruise controltransducer. The eight different pieces of inlormationavailablefrom the trip computerare shownbelow: TIME
(1) Tim e (2) Ela ps ed (1) Av er age s peed( k m / hr ) (2) Tra v elied ( k ilom et r es ) (3) To en pt y ( k ilom et r es ) A,'e: s gg ( lit r es / 100k m ) Us ec ( lit r es ) ( lit r es , r00 l k r - :Ir lns iant aneous
TI M E
ELAPSED E Ei:EE
AV SPEED TRVLD TO EMPTY
DISTANCE
EI EI.E.EI
DISTA NCE
FUE L
|NSTt 100
FUEL
The trip computerdisplays three tunctionssimultaneously, one from each display of 'TIME', 'D|STANCE'and 'FUEL', and are calledup in sequence by depressing the selectbutton. Each time the select button is pressed,the function in each display will increment by one. 'TIME' and 'ELAPSED TIME' alternate with other functions, givinga variablecombination ol time with other functions. The trip computercontrol buttons are located below the (Fig. 12C-15) displays and are: 1. DISPLAY time with ignitionoff) - (Displays 2. SELECT- (lncrements functionsdisplayed) 3. HOURS- (Adjustshours when pressedwith display button) 4. MINUTES- (Adjustsminutes when pressed with display button) 5. RESET- (Resetscomputerwhen pressedwith select button) To avoid accidentalreset,time adjustmentor calibration, a combination of two buttons must be oresseo simultaneously to performthe!; operations.
Flgure 12C-14
Flgure 12C-15
INSTRUMENTS, W'SHIELDWIPERS/WASHERS GAUGES, 12C.9

FUNCTION DESCRIPTION Time The clock is a 12 hourclockwith flashing decimalpoint. When the batteryis first connected,the clock will show 12.00 and if this is not the correcl time, the appropriate setting is achievedby pressingthe 'DISPLAY'and 'MlN' buttons together for minute adjustment and the 'DISPLAY'and 'HOURS'buttonsfor hour adiustment. It is recommended that the minutesbe adjustedprior to the hours becauseas the minutespass 60, the hourswill increment automatically by one. The clock can be accuratelyset as the next minutewill not display until 60 seconds after releasingthe adiustment button. Elapsed Time 'lGNlTlONON' time since resef Indicatesaccumulated ting in hours and minutesup to 99 hours and 59 minules. Press reset and hours buttons simultaneously and displaywill go to zero. Drive off and the displaywill increasein whole numbersup to a numberbetween 615 and 650, whilst travelling a distanceof 10 km. This is the cablibration number.Stop vehicle exactly 10 km from startingpoint,e.g. centre pillar againsta major highway shield 10 km from onginal shield. Press reset and minutes buttons simultaneously. When these buttons are released the calibration number will enter the computer memory and the displaywill return to travelledmode, and shows the total distance travelledsince reset. This calibration cloesnot reset other functions back to zero. The calibration numbershouldbe between 615 and 650 lor standard vehrcles, however, special tyres, transmission, axle, tyre oressures, vehicle loading, etc. will have a bearingon this number. Depressing the reset and minute buttons simultaneously any time the distancetravelledrcaiibrate lunctionis called up, will displaythe calibration number, For those who do not wish to have this degree of accuracy(1 metre in 10 km) or who do not have access to an accurately measured 10 km. an approximate numberof 625 is used for distance calculations. When the battery is first connected,oalibration numbers will automatrcally be 625. lf required calibration numberis know, select travelled/calibrated mode, press reset and hours buttonssimultaneously, drive vehrcleapproximately 10 km until requiredcalibration number is reachedthen press reset and minutesbuttonssimultaneously. Alternatively recalibrate as described earlier. Whilst in the calibrate mode, i.e. after the reset and hours buttonsare pressedand prior to depression of the reset and minute buttons, the 'SELECT' button is inactivated to prevent selectionof other functionsduring the calibrationprocedurebecausethis would affect the calibration number and compuler distance lunctions would be inaccurate. Average Speed The averagespeed readingdisplaysaveragespeed since the computerwas reset.The averagespeed is calculated by dividingdistancetravelled by the time that the ignition has been cn. To enable the computer to collect enough data to calculatea sensiblespeed,the displaywill show zero lor the first minuteafter reset. Readingis updatedat one minuteintervals. Instantaneous Consumption The instantaneous fuel consumptionfunction reads in litres/'lOO km in whole numbersonly and updatesat halJ second intervals. When the vehicle is stationary, the display shows zero, however,when slowingdown to a stop, due to fuel being used and a small distance being travelled,some large numbers may be displayed. Also, when the function is first called up, some large numbersmay appear,due to the small time frame over which the comouter is Dre0areo. Average Consumption The average fuel consumption readsin litres/100km and calculates fuel usage since last reset and updates at one minuteintervals. approximately 3.
To Empty(DTE) Distance
The distance to empty function is an estimate on how much turther the vehicle can be driven on the luel in the tank, basedon the rate of fuel usagefor remaining 15 minutes. the previous The DTE readoutadjusts in 5 km incrementsfor values in excess of 50 km and single kilometre increments below this value. No computercan predict the future,so the DTE function can only be an estimate based on previously obtained information. For this reason, as conditions become more suited for economical driving, the distanceto empty can actuallyincrease,for example, driving. from City to Highway After initial batteryconnectionDTE will start at 500. The computerwill then performan initial update trom a short average prior to commencingthe normal long averaging process. 30 km A built-insafetyteatureallows up to approximately of driving under highway conditions after DTE shows zeto. However, due to tolerance variations on the components from which the computer derives its information,this figurewill vary from vehicleto vehicle. The computer has electronic damping to flatten out fluctuationsof fuel level in the tank and rate ol fuel of usage and will update the readout after consumption 0.32 litres of fuel approximately. whilst mobile,the Oue to the large fuel level fluctuations readingsare heavilydamped and averagedover a long time - up to half an hour. This does not matter during normal operations,but after fuel {ill a long delay to So with a fill of displaya sensibleDTE is not acceptable. 10 litres or more the computerwill calculatea higher DTE from a short averageat the next normal updateand will proceedfrom the new figure. the long averaging Distance Travelled/Calibrate This function reads distancetravelledin krlorneters since the computerwas resel, showing two decimal points up to 100 and whole numbersthereafter. The calibrate function is designed to allow a very accuratedistancecalculation and is enteredas follows: mode. 1. Selectdistance travelled 2. Line up the vehicle againsta known marker,e.g. cenlre pillaragainsta major highwayshield.
12C.10INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS
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12C'11 W'SHIELDWIPERS/WASHERS GAUGES, INSTRUMENTS,

Fuel Used Total fuel used since reset is measuredin litres to a maximumof 999 litres. The 'Fuel Left in Tank' is not normallydisplayed'but a in the DTE mode if the RESET can be displayed nrtO"t --ffnS 'M|-['IUTE buttons are depressed or to the amount "nO This number is equivalent iimultaneously. tank that the fuel the in remaining litres, in fuel, of for the DTE calculations its obtain to cornprt'etis using display.
COMPONENTS 1.5 TRIP COMPUTER

FUEL FLOW SENSOR With the 5.0 litre engine,the fuel llow sensor.isthe same on VH Series models' Refer Figs 12G16' ;;"sed details. for installation 12C-17, is On fuel iniectionequippedmodels,the fuel flow signal controls unit control The unit. control EFi the bv orouiOeO is [n"-pJ""-*iOth signal to the iniectors'and.this signal and module control trip comPuter the toaiso-transmined used as a measureof fuel usage' FUEL LEVEL SENSOR unit The 'fuel to empty' is sensedby the fuel gaugetank The tank unit may be checked in the i"titt"n"" reaOing. - 2'6 Fuel Gauge SenderDiagnosis *"ner (r-eter "-o-ttJ should any query rrise as to readout ilfii; suppremdnU on displaymoduleand actualfuel gauge reaolng' ELECTRONIC CONTROL TTIODULE with the The electronic control module is integrated instrument Oi.pf"V and function module on electronic assemblies'
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Flgure 12C-17
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W'SHIELDWIPERS/WASHERS 12C.12INSTRUMENTS, GAUGES,

SPEED SENDER (For Electronic lnstruments) A Hall Etfect Speed Sender is used to produce an to the vehicle'sroad electrical signalwhich is proportional speed. This signal is used for the electronic instrument readouts of speed and odometer. This signal is also used by the trip computer and is required for readings of distance to empty, average and average and instantaneous speed,distancetravelled fuel consumption. The sender consists of a metal body which houses a rotating16 pole magnet.Fitted into the metal body is a plasticcap which contains the electrical terminalsand the Hall effect integrated circuit. The soeed sender is mounted on the cruise control transducer. Refer Fig. 12Q-'18.
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Flgure 12G'18
Theory Of Operation The Hall effect principle is shown in Fig. 12C-1 9 A constantcontrol currentis passedthrough a thin strip of semi-conductor material.When a magnet is brought near, such that its magnetic field is directed at right anglesto the lace of lhe semi-conductor, a small voltage appears .at the contacts placed across the narrow dimension of the slrip. The hall effecl voltageis dependenton the presenceof the magnetic field and on the current flowing in the semi-conductor. lf eilher inout is zero. Hall voltaoe is
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Flgure 12C-19
INSTRUMENTS, GAUGES, W'SHIELDWIPERS/WASHERS 12C.13 2. SERVICE OPERATIONS

For service operationsnot covered in this Section, refer to the VB Commodore ServiceManualPart No. M38145 and VH Commodore Service Manual Suoolementpart No. M38731.
2.1 TOUCH SWITCHCONTROLPANEL

REMOVE 1. Carefullylift up front edge ol touch switch control panel so as to disengageit from the centre dash vent housing.Refer Fig. 12C-20.
Flgure 'l2C-20
2.
Raise the rear of the touch switch control panel and pull panel out slightly to gain access to the wiring harness connector underneath the panel. Refer Fig. 12G21. Disconnect wiring harness connector and withdraw switch.
Figure 12C-21
TEST
Using an ohmeter, test for continuityacross terminals when the touch button is pressed.Fig. 12G22. Refer to Section 12F 'Wiring Diagrams'of this Supplement for touch switch controlpanelwinng. REINSTALL Installationis reverse of removal proceduresensuring wiringharnessconnectoris securely connected.
Figure 12C-22
12C-14 INSTRUMENTS, W'SHIELDWIPERS/WASHERS GAUGES,

. 2.2 INSTRUMENT CLUSTER INSTRUMENTS MECHANICAL
REMOVE 1. Disconnect batteryearth lead. 2. Remove touch switch control panel as per service 2.1. operation frame to 3. Removethe screws securingthe instrument the instrument sunound.Refer Fig. 12C-23. 4. Pull the instrumentframe out, far enough to gain accessto the warninglamp panel wiring connectors. ReferFig. 12C-23. 5. Disconnectwiring connectors and withdraw instrumenttrame. 6. Removethe right hand instrumentpanel lower trim. 7. Reach uo behind the instrument cluster and disconnectthe vacuum hose from the fuel consumption meter (SL models), and the speedometercable by depressing the springretainer.
IN S TR U ME N T S U R R OU N D _
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Flgure 12C-23
8.
Remove the five screws securing the instrument clusterto the instrument surround.Refer Fig. 12C-24. 9. Pull the cluster from its location and rotate the bottom of the cluster upwards to gain access to the wiringconnectors. 10. Disconnectwiring connectors and withdraw instrumentcluster. REINSTALL Installation is reversalof removalprocedures. Ensurethat all electrical connectorsare securelvconnected.
- IN S TR U ME N T S U R R OU N D
IN S TR U ME N T C LU S TE R
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. 2.3 INSTRUMENT CLUSTER ELECTRONIC INSTRUMENTS

REMOVE 1- Disconnect batteryearth lead. 2. Remove touch switch control panel as per service operation 2.1. 3. Removethe screwssecuringthe instrument frame to the instrument sunound.Refer Fig. 12C-25. 4. Pull the instrumentframe out, far enough to gain accessto the warninglamp panel wiring connectors. ReferFig. 12G25. 5. Disconnectwiring connectors and withdraw instrumentframe.
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Figure 12C-25
W'SHIELD GAUGES, WIPERS/WASHERS 12C.15 INSTRUMENTS,

6. 7. Remove the five screws securing the instrument clusterto the instrument surround.Refer Fig. 12C-26. Pull the cluster from its location and rotate the bottom of the cluster upwardsto gain access to the wiringconnectors. Disconnectwiring connectors, and withdraw instrument cluster.
I N STR U ME N T
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REINSTALL Ensurethal lnstallation is reversalof removalprocedures. all electricalconnectorsare securelyconnected
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Figure 12C-26
2.4 MECHANICAL INSTRUMENTS

DISASSEMBLY Pall adiustingknob from clock. Remove the six screws ( 1) retaining the clear lacia panel to the instrumelt hYusing, rerioue facia. Remove the three screws @ retainingthe black instrumentsunound to the instrume-it housing,remove surround.(Refer Fig. 12C-27).
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Flgure 12C-28
GAUGES, W'SHIELD WIPERS/WASHERS 12C-16INSTRUMENTS,

Fuel and Temperature Gauges Removegauge retaining screw (Fig. 12C-29). Compress plastic retainingtang and withdraw gauge contacts from printed (Fig.12C-29). circuit.
Flgure 12G29
Voltmeter and Oil Pressure Gauge 1. Remove overlapping fuei or temperaturegauge as previously described 2. Remove remaining screw and withdrawgauge con(Fig. 12C-30). tacts from printed crrcurt
R E TA IN IN G S C R E WS
Figure 12C-30
Clock From behind the instrument housing, removeconnector from printedcircuit.Bemoverhe two screwsretainingthe clock assembly to the instrumenthousing and remove clock.(Fig. 12C-31).
Figure 12C-3't
INSTRUMENTS, GAUGES, W'SHIELDWIPERS/WASHERS 12C.17

Printed Circuit Board 1. Compressand withdrawretainingclip/heat sink and voltage stabilizer assembly from housing. (Fig. 12C-32). 2. Slide printed circuit board to the right as viewed in Fig. 12C-32 and lift out. REASSEMBLY a Reverse removal operations. zInstall retaining clip/heat sink ensuring voltage stabilizer contactslocate properly. Install upper gauges first, ensuring gauge contacts are properly seated.
V OLTA GE S TA B I LI:E R rr:JJ ruutrtntrn A \) P U LL U P
Fagure 1rc-32
2.5 INSTRUMENT TESTING

For mechanicalinstrument testing refer to Section 12 of the VB Commodore ServiceManualPart No. M38145. Should a fault develop in the electronic instrument assembly, it must be returned to an authorizedVDO serviceagent for repair. In the event that the electronic instrument assembly provesfaulty,the odometerreadingmust be noted before lhe unit is removedto allow the VDO agent to transfer the odometer reading to the replacement instrument assembly.The VDO agent also has equipmentto read the odometerfrom the instruments computermemoryif a displayblackoutoccurs.
SPEED SENDER Remove 1. Disconnectbatteryearth lead. 2. Disconnect sender wirino connector. Refer Fig. 12C-33. 3. Unscrew sender from cruise control transducerremove senoer.
Test
1. Connect4.7 ohm 1/4 watl resistor acrossterminais markedr and A. 2. Connect 12 volt DC battery supply to terminals marked= and - (observepolarity). 3. Connect pointer type multimeter st on DC volts positive + and A (observepolarity, scale to terminals termanal of multimeter to terminal - , negative terminalof multimeter to terminalA). 4. Rotate sender square drive slowly by hand and observe multimeterreadingwhich should pulse between 12 volts and O volts. 5. No pulse readrng on multimeterrndicatesfaulty sender. NOTE:Senderis non repairable. Reins t all is reversal Installation of removat.
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Figure 12C-33

U N IT 2. 6 F U E LG A U GE SENDER
R EMOVE The removaland installation instructions for vehicleswith 5.0 litre engine with the revised fuel pump system and 3.3 litre EST engine,are coveredin Section 8 of the VB Commodore ServiceManual. proceduresare for The followingremovaland installation 3.3 litreEFI equipped vehicles. 'l . Disconnect batteryearth lead. 2. Placethe vehicleon jack standsand drain the tank through fuel filler opening using a commercially fuel syphoning available device. 3. Disconnect the fuel linelrom gaugeunit. 4. Disconnect the electrical feed and earth cables from unit.ReferFig. 12C-34. 5. Remove screwsaroundgaugeunit. 5 mounting 6. Removegauge unit, liftinggauge unit filter from swirl pot CAUTION: Care should be exercised during removal of gauge unit from the tank not to damage the filter. Before installingthe assemblyinto luel tank, clean the screen by blowing oft carefully with low pressuredried compressed air; replace screw if damagedor unable to clean.
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F UEL GA UG E S E NDE R U N IT D IA G N O S IS 1. turn ignition to 'ON' and obsevethe fuel gaugefor one minute.The gauge readingwill do one ot three things. a. Gauge reads below empty - Fuel tank empty of gaugesenderis open circuited. b. Gauge reads between empty and full, but is Proceedto step 2. to be inaccurate. suspected c. Gauge reads above full - Fuel tank is full or gaugesenderis shortcircuited. 2. Usinga voltmeter, check for a voltage readingat the fuel gauge sender unit flange to earth (ignition a voltagereading.correct switched'ON'). lf recording faultyearth at fuel tank or add an earth wire. 3. Removethe wire terminalconnector(fuel gauge to sender unit) irom sender unit and check voltage at the terminalconnector to earth with an accuratehigh (ignition resistance voltmeter switched'ON'), lf the voltagerecordedat the terminalconnectorts 10 0.1 volts, then the voltage regulatoron the instrument printedcircuitboardis OK. lf the reading is outside the specification of 10 0.1 volts, check for poor connections at the printed circuitboardand voltageregulator. refer lf the connectorsare OK, replacevoltage regulator, to service ooeration2.4 MechanicallnstrumentDisin this Section. assembly, lf the reading is withinthe specification of 10 0.1 volts, remove the f uel gauge sender unit, refer to service 2.6 Fuel GaugeSenderUnit - Remove,in this operation Section. Checkthe senderunitfor binding or sticking. Connectan ohmmeter to fuel gaugeterminalon sender unit and to the senderunitflange. heightdimensions, Set the float to the various as shown in the followingchart, and recordthe resistanceat each dimension.
W'SHIELD GAUGES, WIPERS/WASHERS INSTRUMENTS, 12C.10

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3.3 litre EST - Sedan Em pt y % FulI 3.3 litre EST - W agon Em pt y Yz FulI 3.3 litre EFI - Sedan Em pt y '/a 5.0 litre - S edan He i g h t tmml
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REINSTALL notingthe following: Reverseto removaloperations 't. Installseal betweenthe gauge unit flange and tank. 2. Apply sealing compoundpart no. M39040 to mating surfaces of cork seal and fuel tank, also to screw threads. 3. Fill fuel tank with tuel and check for leaks around gaugeunit. FUEL TANK Fuel tank removaland installation instructions remain the same as on previous models. The only difference with EFI models is on removal,the fuel return line must be disconnected and reconnected on installation. Refer Section8A in this Supplement for details.
W'SHIELD WIPERS/WASHERS 12C-2O INSTRUMENTS, GAUGES,
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GEAR CHART 2.7 SPEEDOMETER
REAR AXLE P/O I Ratio T RANSM ISSION p l' Sp e e d oDr ive Gear Colour M40 i L GU4 3 . 0 8 :1 lvlc6 1 0 T e e th ye ilo w
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12C-24INSTRUMENTS, W'SHIELDWIPERS/WASHERS GAUGES, 3. WINDSHIELD WIPERAND WASHER

3.1 GENERALDESCRIPTION
The windshieldwiper and washer system carries over from VH to VK Series models,except for the locationof the dwell controlswitch. On modelswith dwell wiper control,the control switch is now locatedon the left hand lower dash sunound. The windshield washers'in line',one way valve has been deleted.
3.2 SERVICE OPERATIONS

Service operations arc as described in Section 12, Holden Commodore VB Series Service Manual Part No. M38145. exceotwhere noted in this Section.
3.3 WIPERDWELLCONTROL SWITCH

REMOVE 1. Removeinstrument assemblysurroundas per service instruction 2.3, steps 1 - 5, in this Section. 2. Pull knob from switch. 3. Remove the left hand lower dash surround uooer and lowerscrews. ReferFig. 12C-38. NOTE: lt may be necessary to remove the centre consoleto gain accessto the lower screws. 4. Remove panellowercover. the righthand instrument
112 U P P E RS C R E W P LA C E S )
\/' /oor* suRRouND

LOC A TIN G H OLE
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LOWE R S C R E W _ (2 P LA C E S )
\- LE FT H A N D LOWE B D A S H S U R R OU N D
Flgure 12C-38
5. 6. 7.
Disconnectthe wiper dwell control switch wiring connector from the main wiring harness. Reler Fig. 12C-39. Removelower dash surround and switch. Remove switch mounting nut and separate switch from panel.
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REINSTALL Installation is reversalof removalprocedures. Ensurethe locatinglug on the left hand lower dash surroundfits into the locatrng square. Checkoperation of switch.
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Flgure 12C-39
RADIOAND TAPE PLAYER 12D-1
SECTION 12D
RADIOAND TAPE PLAYER
INDE x
Ref. 1. 2. 2. 1 Subject GENERALDESCRIPTION SERVICE OPERATIONS..... RADIO OR RADIO CASSETTEPLAYER ASSEMBLY Remove Beinstall SPEAKERS.. Remove........ Reinstall Page 12D-1 12D-2 12D-2 t2D-2 12D-3 12D-3 12D-3 12D-5 Ref. 3. 4. 5. 6. page ............. 12D-8 sPECrFlCATrONS.............. .......12D-9 TORQUEWRENCH SPECIFICATIONS........ 12D-9 SPECTAL TOOLS...... . 12D-9
Sublect DIAGNOSIS.....
2.2
All VK Series models are fitted with a radio. SL models are suppliedwith a high performance AM/FM radio with digital display for channels and frequencies,a 2 way speakersystemand a manual,key lock anlenna. Berlina models have an AM/FM stereo radio cassette unit,in lieu of the AM/FM radio.The radiois an AM/FM stereo signal seeking radio with digital display for channels and frequencies.The speaker syslem is a 2 way speal(ersystem. Calais models are fitted with a similarradio/cassette unit to the Berlinamodels.Featuresof this radio/cassette unit include a single joystick balance control lor a 4 way speaker system and automatic programme search for cassenes. The four speakers are located, two in the rear parcel shelf and one at each upper corner of the instrument dash panel . The operatinginstructions for each unit is includedin the OwnersHandbook. A power operated antenna is standard on Berlina and Calaismodels.The antennais automatically raisedto a medium height wnen the radio is turned on and can be turther raised or lowered by means of the antenna control switcheson the instrument touch control oanel.
12D-2RADIOAND TAPE PLAYER 2. SERVICE OPERATIONS

2.1 RADIO OR RADIO CASSETTE PLAYERASSEMBLY
REMOVE 1. Disconnect batteryearth lead. 2. Removetouch controlpanel as per serviceoperation 2.1,Sectron12C of this Supplement. 3. Removeinstrument surroundand instrument assembly as per service operation2.2 or 2.3, Section12C of this Suooliment. 4. Remove centre console, centre lower instrument panel, glove box, steering column lower surround, heater cover panel and lefl hand lower dash panel in Section 14 of described as per serviceoperations this supplement. 5. Removecentre air vent duct. 6. Remove radio - radio/cassetteplayer rear bracket screw/s from instrument canier panel assemblv. ReferFig. 12D-1. 7. Removeheal/ventcontrol assembly with temperature control cable attached,removingvacuum hose and electrical connectors. 8. Removelower lett side instrument Daneland radio playeras an assembly. radio/cassette L Disconnect electncal connector and antenna from player. radio- radio/cassette
_ REAR BRACKET S C RE W/S a TN S TR U ME N TC A R R TE R / P A N E L A S S E ME LY FR ON T MOU N TIN G
_ REAR BRACKET A TTA C H IN G S C R E W IN S TR LI\45N T P A N E L-, LOWE R ;A C IA
----=:
Flgure 12I)"1
10 . Removethe front mountingbracket,screwedinto the top of the unit. Refer Fig. 12D-2. 11 . Removerear bracketattachingscrew.
FR ON T MOU N TIN G B R A C K E T ,,MOU N TIN G S C R E W-2
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Flgure 12D-2
RADIOAND TAPE PLAYER12D.3

13 simultaneouslyinto 12. Insert removal tools CMT1 slots in right and left hand sides of radio radio/cassette player facia, reler Fig. 12D-3, to disengagethe spring mechanismsecuringthe inner part of the radio facia to the left hand lower dash panel. from dash panel. 13. Removeradio - radio/cassette 14. From behind sides of radio facia, depress spring mechanism,which will release removal tools from radio - radio/cassetteplayer. 15. Removaltools, Part No. CMT113, which are released direct lrom in pairs,are available EurovoxAustralia, Place, 6 University ClaytonNorth.Vic. 3168.
Flgure 12D3
S E R V IC E TOOL N O. C M T 1 13
REINSTALL player in dash apertureuntil Insert radio - radio/cassette the lockingspringsclick. The remainder of the installation is the reversal ol removal procedures.
2.2 SPEAKERS
REMOVE Single Speaker - Front grille. 1. Remove speaker reterFig. 12D-4. securing screws, speaker 2. Remove 3. Litt up speaker to disconnectwiring harness referFig. 12D-4. Remove speaker, connector.
S E C U R IN GS C R E WS /.S P E A K E R GR ILLE
PLACES)
C ON N E C T OR
Flgure 12D-4
12D.4RADIOAND TAPE PLAYER

Dual Speakers - Front 1. Using a wide blade screwdriver, insert betweengrille pad. and instrument 2. Carefullylever speaker grille upwards. Lift speaker from its position, disconnect wiring harness connectorand removespeaker,refer Fig. 12D-5.
FR ON T S P E A K E R A N D GR ILLE A S S E MB LY
- IN S TR U ME N T PAD
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Flgure 12D5
Rear Speakers - Sedan push-on 1. Remove grille. speaker 2. Remove speaker securing screws, referFig. 12D-6.
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Disconnectwiring harness connector,refer Fig. 12D7, removesoeaker.
H AR N ESS
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RADIOAND TAPE PLAYER12D.5

Rear Speaker - Station Wagon 1. Bemove the interiorside panel trim as per instructions in Section 01 of the Holden Commodore VB Series Part No. M38265. StationWagon Supplement 2. Disconnect wiringharnessconnector. 3. Remove speaker securing screws and remove speaker,refer Fig. 12D-8.
S PE A K E R
IN N E R S ID E PA N :I- --
REINSTALL Reinstallation in each case is the reversal of removal orocedures.
_ S E C U R IN G S C R E V ^J (4 P LA C E S )
WITH C ON N E C TION S FA C IN G R E A R OF C A R
Flgure 12D8
12D.6RADIO AND TAPE PLAYER
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RADIOAND TAPE PLAYER12D.9 4. SPECIFICATIONS

AM / FM Radio . Radio Cas s et t e Speak er s Power Antenna M ax im um c ont inuousc ur r e n t Loc k up c ur r ent S t e r e o ,5 W a t 1 0 % T H D p e r c h a n n e l S t e r e o ,5 W a t 1 0 % T H D p e r c h a n n e 4 ohms, 10W capacity 3 amos 9 amps
5. TORQUE WRENCH SPECIFICATIONS

Radio - Radio/Cassette Mounting BracketScrews Ant enna M ount ing Nut . . Power Ant enna M ount ino Bolt s 0.9 - 1.2 Nm F r n g e rt i g h t t h e n o n e c o m p l e : ei u r . 'l 2 - 1 6 N m
6. SPECIALTOOLS
RADIO _ R A D IO/C A S S E TTEP LA Y E R REM OVA L TOOLS
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Available from: E u r o v o x A u s t ra i i a , 6 U n i v e r s i t yP l a ce , ClaytonNorth. 3168.
WIRINGHARNESS & FUSES12E-1
12E SECTION
WIRINGHARNESS AND FUSES
INDEX
Ref 1. 1. 1 Subject FUSE BOX GENERALINFORMATION Remove........ Relnstall FUSIBLELINK
Page ............. 12E-1 t Ref. 2.1
12E-1 12E-3 12E-3 12E-4
3. 3.1 4.
1 . F USEBOX
The fuse box used with VK Commodore Seriesis located in the engine compartment,behind the passengerside struttower,referFig. 12E-1.
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The main wiring harness connectionsto the fuse box assembly are made via connectors located on the underside of the fuse box, refer Fig. 12E-2.
U N D E R N E A TH V IE W OF FU S E B OX
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Figure 12E-2
12E-2WIRINGHARNESS & FUSES

Fuses are blade type mini fuses, as used on Camira models,referFig. 12E-3.
Flgure 12E-3
The following chart sets out fuse identificationand function.

FU S E NO.
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F U N C T ION He a d l a m p s - l o w b e am He a d l a m p s - highbearn Pa r k i n gl a m p sa n d l l um in a tr o no f I nst r u m e n t s Fuel Pump (E.F.l.) Fuel Pump (5.0 itre) Air c o n d i t i o n i n gb l o we r Ho r n a n d s t o p l i g h t s He a t e dr e a rw i n d o w
H a za rd w a rn i n g i a mp s and air c o nd i ti o n i n g a u xi l i a ry fan
RAT ING ( AM PS}
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The fuse box also housesa numberof relaysand control modules, depending on the vehicle's equipment level, refer Fig. 12E-5.
Figure 12E-5
WIRINGHARNESS & FUSES12E.3
A B
a
D E F G H I J
Hea tedr earwindow - m odule - m odule Bea rw indow was her / wiper Doo r l oc k - r elay Doo r l oc k - r elay Horn - r elay Powe rwindow - r elay Air condit ioningaux iliar yf an - r elay Air co ndit ioningblower - r elay Air co ndit ioning c om pr es s or c lut c h dela y- m o d u l e Fu el pum p c ont r ol - r elay
REMOVE 1. Disconnect batteryearth lead. 2. Removefuse box cover. 3. Removeretaining bolt, refer Fig. 12E-6. 4. Slide tuse box towards the engine to release fuse bracket. box from bottom retaining 5. Lift fuse box up slightly and rotate to gain access underneathbox.
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6.
Disconnect all wiring harness connectors, reter Fig. 12E-7. lf vehicle is equippedwith ElectronicSpark Timing, remove the two enginevacuum transducermounting screws. 7. Lifl out fuse box.
U N D E q\E A TH V IE W OF FI-S E B OX
,
REINSTALL 1. Connectall wiring harnessconnectors.Ensureall are securelyinstalled. 2. Refit EST engine vacuum transducer (if equipped with EST). 3. Engagethe tongues on the bottom of the fuse box bracket. into the retaining 4. Fit retainingbolt, fuse box cover and battery earth lead.
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Figure 12E-7
& FUSES 12E.4WIRINGHARNESS 2. FUSIBLE LINK

INFORMATION 2.1 GENERAL
The chassis wiring is protected against short circuit damageby a fusible link placed within the battery wiring harness. It is taped back to the battery wiring harness, near the battery,refer Fig. 12E-8. for 3.3 litre EFI An additionalfusible link is incorporated lt is taped back modelsfor EFI wiringharnessprotection. to the battery wiring harness,between the battery and startermotor,refer Fig. 12E-8.
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REPLACE 1. Disconnect batteryearth lead. 2. Untapefusiblelink wire from batterywiringharness. 3. Disconnect fusiblelink connectorand install new link, referFig. 12E-9. 4. Tape back to harness. 5. Reconnectbatteryearth terminal.
Figure 12E-8
Flgure 12E-9
WIRING HARNESS & FUSES12E.5 3. WIRINGHARNESSES

All VK series models are served by two main wiring harnesses, plus associated ancillary wiring harnesses, dependingupon the equipmentlevel of the vehicle. 1. Main WiringHarness There are two levels of main wiring harness. The lower level carries only the base options and EST only. accommodates The upper level accommodatesall availableoptions includingany EFI circuits. 2. EngineHarness Different engine harness assemblies are used for 3.3 litre EST, EFI and 5.0 litre. 3. Battery Harness A different battery harness is used for each engine application. 4- InstrumentPanel Harness There are two ditferent levels of instrument panel harness. and touch switches. instruments a. Mechanical and touch switches. b. Electronicinstruments Ancillaryharnessesare requiredwhen various equipment level optionsare exercised. a. Air conditioning. b. Power antenna c. Power windowsand door locks. d. Power operatedexternalmirrors. e. Readinglamps. f. Heated rear window. S. Rear speakers. h. Rear lamps.
12E.6WIRINGHARNESS & FUSES 4. HARNESS DIAGRAMS

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WIRINGDIAGRAMS 12F.1
SECTION 12F
WIRINGDIAGRAMS
INDEX
Subject page Page ' Subject WIRINGSCHEMATIC SYMBOLSLEGEND............ 12F.2 CIGAR LIGHTER, TURN SIGNALAND HAZARD SYMBOLS USEDIN VK WTRING CIRCUIT WARNINGLAMPS,WIPERWASHERAND DtAGRAMS............ 12F-4 DWELLCONTFOL 12F.25 W T RT NG S C H E M AT T C (PA R T " A)................12F-s HEATED BEAR WINDOWAND REAB wT Rt NG S C H E M AT T C (PA R T " B)................ 12F-6 wfNDow wtPER AND WASHER ...._........-............ 12F-27 WIRINGSCHEMATIC(PART"C")................ 12F-7 HEATfNGAND AtR CONDtTtONtNG .............-...... 12F-29 (PART'D')................ wf RTNG SCHEMATTC 12F-8 RADIOAND POWERAI{TENNA.... 12F.31 GENERATOR, BATTERY,STARTERMOTOR CLOCK, TRIP COMPUTER, INTERIOR AND IGN|T|ON......-.....-._.-.. 12F-9 ILLUMINATION, REAR COMPARTMENT ELECTRONIC FUEL INJECTIONSYSTEM.......... 12F-11 LAMP AND LOCK ........__. 12F_33 5.0 LTTRE ENGTNE FUEL SYSTEM........................ 12F-13 ELECTRIC DOOR LOCKS AND POWER ELECTRONIC SPARKTIMINGSYSTEM 12F-15 oPERATEDS|DE W|NDOWS................. 12F-35 HEADLAMPS. STOPLAMPS AND HORN......-.....-12F-17 ELECTRIC MIRRORS....12F.37 PARKINGLAMPSAND INSTRUMENT PANEL FRONTEARTHING CIRCUIT....... 12F-39 tLLUMtNATtON ................... 12F-19 FRONTEARTHING CIRCUITCONTINUED.......... 12F-41 INSTRUMENTS 12F-2',1 REAREARTHING - MECHANICAL............. CIRCUIT 12F.43 . .t2F-45 p INSTRUMENTS ELECTRONIC ............... 12F-23 TRf cottpuTER.-........_..._ TRAILERHARNESS..... 12F-47
12F-2WIRINGDIAGRAMS
WIRINGSCHEMATIC SYMBOLS LEGEND

A
Code
LA M P B ULB s
Name Max. Amp Loc. Code S 1
( M ANUAL L Y OP E R A TE D ) \O
Name Horn Button Max. Amp Loc Code i
s w lTcH E s
IN S TR U ME N TS
Name Generator ndrcator
Max. Am p 0.10
Loc-
B2 B3
B4 B5
L .H . R e a r T u rn S i g n a l L a mp L . H. F ro n t T u rn S i g n a l L a mp
R.H. Front Turn Sional Lamn h.d. Hear lurn Signal Lamp High Beam
1.15 I 1.75
23s
S
S
T BA
309 3
92 92 94
110 102 107 105
2 3 4
Aur o Retr act Ant. Sw. ( Touch Conr r ol ) Cr uiseContr ol Sw Cr uiseContr ol Speed ; Restr. Sw. Cr uiseContr o l Br ak e Switch 1.0
292
121 t4 7
Brake Farlure Warning Lamp Park Brake Warnrng Lamp
0.10 0.10
i 0.10
122
v ol tm er er
Temperature Gauge
238 5 .0
4.58 I 165
s5 s6
S9
r8 t9
l 10 1l 12 I
zta
Oil Pressure Gauoe Fuel Gauqe
B7 B9
810 o tz
Low Beam
Turn Srgna Swr Heated Fear Wrnoow Swrtch iMan ual i Eleclr c Door Lock Sw tch (Key) L.H. Dwelt Qe611q1 5*;1ah Hazard Warning Sw
I n str. C o mp a rtme n l Box lllum Dome Lamp
s 13 a 4? 0 .8 3 :1 2 e I 13 4
114
J tl
20.0
142t 't49
Tachometer L.H . T ur n Si gnal I ndi c ator F l .H .T ur n Si gnat Indi c ator O r l Pr es s ur e W ar ni ng Lam p C ool ant Lev el W ar ni ng Lam p Electronicspeedo
0 20
t'11
I3
s 15
s 17
i i O.]O
237
I n s tru me n t C l u ste r l l l um. L a mp

Swilch lllum.
O- 1
112 172
20
Ar r Condition er MasterSwitch
Air Conditioner Switch Fan
237 249/ 274

264/ 15.0
rb4
I 15 | 20 | 23
0 10
96 117 .--; 160 160
0 .1
s 2r s 22
15
Front Parkin(
---
816 817 421
T a i l L a mp s
Rear Licence P ate lllum.
Dim m er & Fla s herSw . Windshied Wroer Sw

Lighi SwLrch Power Operated Side Windoer Swrrch E ec:r c Door Locks Sw,tch (Button)
223
169 344 321
r Jd
25 I T r i p C om puter I D i s ol av M odute t26 t28 t29 T r r p C om puter F unc ti on I ndi c ator

Electronic Spark Timanq Lamo S13 Indicaror Lamp (TouchConrror Back-Up Lamps Warnrnq 1369 Exte.ror I llum Wa rn Ing Lamp 0.1O 0.10
0 .8 3
0.1 0.83
169
172
s2 6
s 29
W a sh e rS wi tch l l u m B e ar Qu a rte r L a mo
o.4 2 i1 .O 132
tJb
s 30
32
34
76 142
114
8 23 s 24 B '5
uzo
Rear Compt. Lamp

Heat/Air Cond. Contr. lllum. Radio lllum. Light Switch lttum.
0.05
0.' l
Rea' Compar tm ent Lock Switch

lcn rron Switch
172 172 172 172 1' t4 172 172
r36 r37
13
227
0.10 0.10
828
Cigar Liqhter lilum
0 .1 0 .1
1 .75 0l
S 35
W ndsh eld W as h.Sw . Rear W r ndow W i per Sn. { Touch Contr ol )
169
204
07
829 8 30
831
Ba ck-Up L a mp s
Heated Rear Window Switch lilum.
38
Rear W indow W as her Sw. ( Touch Contr ot)

Power Operated Side Wrndow Sw. {O/ride) Power Operated Side , Wrndow Sw. (4 way) Electric Mjrror Adjustment Sw. Heated Rear Window Sw. (Touch Control)
E
N
N 3 6
E LE crR oN rc MoD U LE s
D w e l C ontr ol U ni t
Power Antenna Conrrol Unit Coolant Level L Warning Module Electronac Contact Breaker Radio Recerver Clock Diaita E.S.T. Cont.o (Manua ) E.S.T Conirol (Autcme: cr Trrp Comcuter lr'last?r f/odule ! J :ag? Srabrlrzer :FLConrrolModule Mooule t
209
111
I 291
11j 6q
40
C l ock l l l u m- L a mp
Engine Compartmenl lllum. Lamp
0 .1
0.83
S 45
169
343
N 10
0.7
UJJ
Power Antenna Sw i tch l l l u m. T r i p Co mp u te r C o n tro l s l l l u m. TFAI LER L . H. Re a r T /S L P .
s5 3 o .1
0.10 172
848
N 12
20.0
72 s3 6 33 240
313 169
tbY
Rear Window Waper W asherSw. ( Manuat)

Heater Fan Switch
N 19 N 21 264 N '] N 22
N 26 304 304 304 N28
?1
S 14
t6
Modute
B 105 8108 B1 1 6 8117 8129
R . H. Re a r T /S L P
Stop 136p
o.6
0.5
SOUND PRODUC IN G D E V IC E S
H H2 3 1 Hor ^
Badio Speaker Frcni R.H. or Cenrre Radro Soeake. Fronr L H Badio Soeake. Bea: R H 5 Fad,o Speake. I Flear L.H
76 r)/ i0
T a i l L a mp
Rear Lrc. Ptare lilum.
2 .1 o .4 2
I O.gg
3.0
B a ck-Up L a mp
114
P O W E RS U P P L Y
P, I Battery 6 C yl . 8 Cyl . Generator 4 5 a mp 55 a mp 70 a mp 60 amo H4 1604 253A
I 1 H
N 29 N 30
F u:l Pum p M odul e q'C ondr ti oner Sv s temM odul e

N'lodu le
36 I 256
P2
1 1 1 7
H 6-T--
-- -
304
]------
N 32
R ear W i ndow W i per / W as herM odui e
2O j
WIRINGDIAGRAMS 12F-3
SENSORS
Code Name Brake Fa I Warn- Sw. Max. Amp Loc. Code
MOTOR S
Name Antenna f/oio. Max. Amp Loc
N
Code R1
R E L A Y Ss , o L E N o tD s
Name Horn Relav Anti-Dieseling Solenoid 0 5 Y"t Amp l
rrl
Loc.
M2
94 30 M5 M6 M3 M9 M10 313 M11
2.Ot9.O 29
30
311
2A
ss2 ss4 ss5 ss7 ss8 ss9 ss1 0 ss1 1
Park Erake Warn Sw. Cold Feed Swrrch T.C.S. Swrtch O I Pressure Swrlch Neutral Siarl Sw. Back-Up Swrtch Slop Lamos Sw
Taoe Plaver Heater I or,,9. l,4tr. WindsheJWpe' Motor 1De co Washer Pump l"'oio (Windsh ield ) Electric Fuel Pump Motor
R3
a 4
r 5.0
262
224
30
96 1J
D r s tr i butor Vac uum Adv anc eSol enoi d r r ans m r s s r on D e:ent Sol enoi d
i | ---f--t.10
30 200
2.9
2?1
F 6 -
Flasher Relav A 'Conditioner 3c-g'essor Clutch A'Coro,:oner F:. Re:r :? a/
235
255/
37
16.6 251 I 276
?qq/
F R
Arr Cond- Aux. Fan Temp. Switch Arr Cond. Evap I nler Contr. Sw
283
i 255 281
117
M
Ai r C ondi ti oner F an M otor

lAirConditioner Aux. Fan Motor
12
6a
';;;
o.2/ 30.0
o.2l 30.o
21Ol 245 2581 284
ss16
S S1 9
Coolant Level Warnrng Sensor
ll 1:
Power Operated Srde Window Motor
Rl0lA.Ccr::orer I AJr -:-
342
R 11
T ra nsm r ssi on De tenl Switch

Door Jamb Switch Engine Flevolut ons Sensor
M 16
200
134 64/ 76
tol
E,ec r .D oor Loc k ' M oIor F r ont R - H Er ec r .Ooor Loc k l \4or o. F r ont L.H
Starier Nrotor 8 C,,
Pow .3e- ::r W i ndor r ae ar

Starter [':. S: ?no d
o.2/ 30.0 r3
14.O 0.15/ 30.0
O.2i 30.0
8.0 8.0
23
R 14 R 16 R 17
ss20 ss23 ss26 ss27

SS26 SS29
M 17 M18
Rear Comparr-en: Lock Soleno c Hazard Flasher ie,av Electric Doof Locks Relay Heated Rear Window Relay
138 237
T ra p Comp- Vehicle SpeedSensor

Trip Computer F low Sensor F uel
/ 330 322
149
151
tol
M20
M 21
Rear !!1ndow Wioer fvlo:or Rear !!rndo4 Pump Mo:o. Elect Motc Washer
3.5 ' 20.4
R 21 205
Etect.Speedometer I Speed Sensor Rear Companment Lamp Swrtch Insi: I lur Compt- 8ox Sw tch
3.E
2C 3
e 2E R 30 Eng. l dl e Spd Boos l Sol enoi d ( 6 C y l .) C r ui s eC ontr ol T r ans duc er Sol enor d Ini edor Val v e El ec t. M r r r or s Sel ec t.R el ay R .H . 0.45 0.3i 2.2 0.80 . 0 15 30.0 0 15 3! J C2 3l.l 256 2t1 121 43 1E6 181 241, 212
rJb
M22
M25 M26 M 28 M29 M30
\,f I
ss30
)> JJ
Doo- Lcck Rea'R H
129
Elect. Doo- Lsck Motor Rea. L r'l Elect. Mirro. R.H. Vertrca \'oicr
8.0
;? F tc
Throt: Valve 5wlrca tts.5 I I E.F.l. Ar F ow Seisor
82
55
12 22
F 5:
ss36 ss37
Throttle Va ve Switch (E.F.l.) Camshaft Posrtion Sens or
Elect. Mrrroi Mc:3 R.H. Horizon:a Elect. Mirror fr4c:c L.H. Vertrcal Elect Mirror l\'lcic L.H. Horizonr.
186 179 142
a 53 i El ec t. M i .r or s Sel ec t.R el ay L.H . R 55 Ar r c ond. F an R e ay N egati v e
S S 4 3 | Oi sir ibutor High I T e n sr onSw. ( 6 Cyl.)
I I
W i nds hi el dW r p M otor ( Luc as ) 5.O
C I R C U IT P R OTE C TIONDE V IC E S
224
2 3 F us e F us e F us e F us e F us e
FU Se 5
SS44
5546
W p e: Motor P a rk,ngSwitch
Carb Vac Sensor
E I W i nds hi el dW i per I M otor ( Pr es l r te)
222 83
*,
-5 25 :5 :5
4 SE E I
R E S IS TOR S ,R H E OS TA TS
Heated Rear Wrndow
V
1451 150
4 r F us e 5 6 7 8
-{ F
c2
c
c A p Ac tro R s
Radto lnle'ierence Supp.(Generaro,r I 35\lFl 10
37 241 313 14 5
e E
E
2
3 4
l ns tr . l l l um . Bhec s :.i
Arr Conditioner Fan Resistors CAarL'ghter Orl Pressure Senoer Coolant Temperature Sender (8 & 6 Cv .) Fuei Level Sender Sedan Wagon Ballast Resrstor Transistor Bes istor Load
45w 276 108
237
, 15 '5 136 32 201
I5
a l P ri mar yvollage I Ca o acitor
?4
9 10 11
F us e F us e F us e
Fuse
+,'1D
D 5 3
RECTIFIERS
Air Cond. Clutch Protect- Diode Elect Instruments Drsplay
E5 E6
103
14
t5
125
:6 2 5 .0 9e
E7
F us e 105 1.8
F use
?.26
3 "oo
E9 M I SCEL L ANEOUSIT EM S
X 1 Js:'buto' .ST
22
G 101
P
r us e
P, O Side Windows za
262
346 291
E 1l 63 63
tr tr o 6i
Antenna
Molor
13
6
Crurse Control Transd. Resist.
40
121 47t 18
Fusrble Lrnk (E.F.l.)
X3
C ool ant T em p. Sens or( EST & EF I)
TR A N S FOR ME R S
G
I lqn. Co,l (6 & 8 Cvl.)
t.5
62
X4
Conneci a: _:'Tesl
i i
l
81
E 15
.
l
A uxrrrary 1!l "T
49
12F.4WIRINGDIAGRAMS SYMBOLS USEDIN VK WIRINGCIRCUIT DIAGRAMS

o a c
FIXED CO NTACT FIXED CO NTACT ( UNDER PO W ER) FIXED CONTACT (UNDER PO W ER THRU RESI STANCE) MOVABL E CO NTACT SIMUL TA NEO USLY MOVABL E CO NTACTS FUSE
LIGHT BULB
fl
tr I r9,l
L?J
r x'r
S P E A K ER
d d{
HORN
tr -r
q
b I T
E
FUSIBLE LI NK
I
RELAY
RHEOSTAT
LOCATION OPTIONAL LocATtoN FtxED By REstsrANcE
<"
.
SPARK PLUG
1 o' +! t =l
{F
SWITCH C O N N E C T O RB O D Y WI T H FEMALE TYPE TERMINALS MAGNET I C SENSO R
MA LE TypE TE R MTN A LS -_1

DIODE
i
@ @ @
RESISTO R
S tMP LtFtE D V tE WOF l c ol A cON N E cToR B OD Y ]" ol io of= _\_ R E D= LOC A TTON & C OLOU R OF LE A D
SOLENOID
l -l -
tI I + I
SIMPLIFIED VIEW OF AN ELECTRICAL C O M P O N E N T( WI T H 2 M A L E TERMINALS) EARTH FROM COMPONENT TO VEHICLE BODY
MAGNET I C I NSTRTJ M ENT
THERMAL I NSTRUM ENT EARTH THROUGH EARTHING LEAD TO VEHICLE
EL ECTRONI C M O DULE
ELECTRI C M O TO R
A L L S WI T C H E SS H O WN I N " O F F " P O S I T I O N
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Eommodore. Holden Ealais.

SUPPLEMENT MANUAL SERVICE

GR ILLE C _ R A D IA TOR BARS D _ B U MP E R

A_ FUELTANK SYSTEM B - EXHAUST sTEERTNG

SALES PTY. LIMITED GENERAL MOTORS_HOLDEN'S SERVICE DEPARTMENT

INFORMATION OA-1 GENERAL

OA.2GENERALINFORMATION 2. MODELAVAILABILITY & BASE EQUIPMENT

S H I FT LOC . F l oor Fl oor Fl oor F l oor Fl oor

8VK19 8VK35 8VL19

C o m mo d o r eSL C o m mo d o r eSL C o m m o d o r e Be r lin a C o m m o d o r e Be r lin a Calais

3.3 EST 3.3 EST 3.3 EST 3. 3 EST

4 S peedManual 4 S peedManual 3 Speed Auto 3 Speed Auto 3 Speed Auto

3.08 3.08 3.08 3.08

FIR S TGE A R R A TIO: 1

3. 3 Litre S ix C ylin de r EST

OA.3 GENERALINFORMATION 4. ENGINEDATA

3298 8.8 6 92.075x 82.550 31.5 106kw @4400 266 Nm @3200

101.60 x 77.775 51.2 117kw @ 4000 336 Nm @2400

MO DELS W A GON S TA TION 8V X 19 4713.5 I 1722 1360

8V L19 4713.5 1722 1374 | 2668 922.5 1123 1451 .3 1416.5

8V K 35 4716.5 1722 1401 2668 922.5 1126

8V 135 4716. 5 1722 1465 2668 92 2. 5

6.1 LOCATIONOF IDENTTFICATION PLATES

6.2 SAFETYCOMPLIANCE PLATE

AVKOOOOOTA s EAT IN G c Ap. s

T H IS PLAT E IS AF F IXED W IT H T H E APPR OVAL O F T H E AU ST R ALIAN M O T OF VEH IC LE C ER T T F IC AT IONBO AR D

6.3 BODY& OPTIONIDENTIFICATION PLATE

M O T O R S - HL O O E N 'S LIMITEO GENERAL

for each Model Programme. GMH LimitedModel Code Designation

6.6 ENGINE SERIALNUMBER

3. 3 lit r e EFI 5. 0 llt r e Aut om at ic

7. ADDITIONAL GENERAL INFORMATION

rdlfu 'o ___,--l

SE O ils Se O it s SF O ils f or s ev er e s er v ic e . Refer Owners Handbook. SE O ils

For grades a n d a p p l i c a t i o n ,r e f e r F i g . 0 B - i For grades a n d a p p l i c a t i o n ,r e f e r F i g . 0 B - 1

HN1 046 HN1 855 GM9985286

SAE 8OW9O GearOil 80W Castrol

GN49985286 HN1 796

1.2 BRAKE FLUID REPLACEMENT

MOU N TIN G BRACKET

1.5 COOLING SYSTEM

ruurll , \, 'Y ;r/ , \1'l /

i6* q (- ,f.1'.t*./','ffi\->(l a'

DESCRIPTION 1.1 GENERAL

NOTES 1.2 SERVICE

X* < (J a -5<n 2>

AND 2.1 UNDERBODY DIMENSIONS HOISTLOCATIONS

2.2 TRANSMISSION CONSOLE. MANUAL

WIPER IWASHER SWtTCH ASM. H E A TE D R E A R WTN D OW GE A B S H IFT LE V E R C ON TR OL B OOT

EOOT ST RAP T O B E P LA C E D T OWARDS F RON T OF C A R

r coN rR oL--r 3? I:3 ,.- g:3I: lf LEVER BOOT

533|,13'^G -r' _=_==3*{

TR A N S MIS S ION C ON S OLE A S M.

A P P LY TR IM A D H E S IV E OV E R A R E A S H OWN THUS \\\\\\\

POINT ' A'

+---___> <.,/ '

TRANSMISSION INDICATOR_ TRIMATICAUTOMATICTRANSMISSION SELECTOR

2.5 ROCKERPANELCOVER- RIGHT& LEFT HAND

f R E AR ROCKER P ANEL COVER \

secrroru B_B ROCKERPANEL COVER INSTALLATION

C A R P E T P R OTE C TOR FLU TE D FA C E D OWN .

TR IM -J FA STE NE R S E C TION B _B (R IGH T S ID E ON LY )

ON E P IE C E FLOOR C A R P E T N OTE : S E R V IC E R E P LA C E ME N T _ TWO P IE C E