Holden Commodore Full Workshop Manual

Eommodore.
Holden
Ealais.
Holden VK SERIES
MANUALSUPPLEMENT
SERVICE
FOREWORD SECTIONINDEX
The information in this Supplement, when used in
conjunctionwith Holden Commodore'VB' series Service OA GE N E R A LIN FOR MA TION
Manual M38145, 'VB' Station Wagon Supplement B LU B R IC A TION
M38265, VC Service Manual Supplement (Number 1)
M38366 and Number 2 M38401, lmprovedPerformance I A- B o DY
L6 & VB EnginesServiceManual M38338and VH Series C _ R A D IA TORGR ILLE
ServiceManualSupplementM38731,providesnew spec-
ifications and new service procedures lor Holden Com- D _ B U MP E RB A R S
modore and Holden Calais VK Series vehicles.
2 A - vENTTLATToN&HEATING
Transmission,front brake and rear axle assemblies are
similar to those used in other GMH vehicles.No major B _ AIRCONDITIONING
service repair and overhaul procedures are given for
these assemblies,and reference should be made to 3 FRoNTSUSPENSToN
existingService Manuals.
The Section lndex on this page enables the user to 4 A- REARSUSPENSToN
quickly locate the numeric identifiers for each group of B _ REARAXLE
Sections. Bend the Manual back to expose the black C _ PROP JOINTS
SHAFT& UNIVERSAL
tabs on the pages and locate the tab indicating the
identifier for the group of Sections you wish to find. An BRAKES
index is included at the beginningof each Section. In 5
addition. numeric identifiers are also used to signify the
individualoperationswithin the Sections.Specifications 6 A- E N GTN E ME cH A N IcA L
for vehicle componentsare providedat the end of each B _ E N GIN EC OOLIN G
Section where apProPriate. C _ E N GIN EFU E L
Summarieso1 Special Service Tools, where required, are D - E N GIN EE LE C TR IC A L
also includedat the end of Sections. E _ E N GIN EE MIS S IONC ON TRO L
Service Tools, unless otherwise specified, are available F - E N GIN ETU N E
from:
I Kent-MooreAustraliaPtY' Ltd. 7 A - cLUrcH
Unit 3, 9 PioneerAvenue, B _ MA N U A LTR A N S MIS S IO N
Thornleigh.N.S.W.Australia'2120. C _ A U TOMA TICTR A N S MIS SI O N
Telephonel02l 848'9777 Telex 22355
General Motors-Holden'sdoes not endorse, prefer, or 8 A_ FUELTANK
assume responsibilityfor the products of this firm nor for SYSTEM
B - EXHAUST
any such items which may be available from other
makers. 9 sTEERTNG
All information,illustrationsand specificationscontained
in this Supplement are based on the latest product 10 s rY RE S
wHE E t &
informationavailableat the time ol publicationapProval.
The right is reserved to make changes at any time A _ B A TTE R Y & C A B LE S
without notice. B _ LIGH TIN GS Y S TE M
C - IN S TR U ME N TS GA, U GE S,WI NDSHI ELD
E F F E C T IVE :MA R C H ,1 9 8 4 . & SH ORN
W IP E R S /W A S H E R
S E RV IC EMA N U ALN O.M3 9 1 0 1 D _ R A D IO& TA P EP I-A Y E R
l.s.B.N.0.86836009 0 E _ W IR IN GH A R N E S S E SFUSES
&
P RI NTEDIN A U S T R A L IA
F - W IR IN GD IA GR A MS
GENERAL MOTORS_HOLDEN'SSALES PTY. LIMITED

SERVICE DEPARTMENT
COPYRIGHT _ GE N E R A L MOTOR S -H OLD E N 'S S A LE S P TY , LTD

Re p r o cju cti oni n w hol e or i n oart prohi bi tedw i thout w rrtten approval
2
GENERALINFORMATION
OA-1
SECTIONOA
GENERALINFORMATION
INDEX
Ref. Subject Page Ref. Subject Page
1. 0A-1
GENERALDESCR|PT|ON.........--................... 6.4 VEHICLEIDENTIFICATIONNUMBERING
2. MODEL AVAILABILITY & BASE SYSTEM 0A-5
EOUIPMENT oA-2 6.5 VEHICLESERIALNUMBER...... 0A-6
3. POWERTRAIN COilBlNAT|OlilS.....-..........0A-2 6.6 ENGII{ESERIAL NUMBEB...... 0A-6
4. ENGINE DAT4............ 0A-3 7. ADDITIONALGENERALINFORMATION....nA-A I
5.
6.
EXTERIORDIUENSIONS
SERtAL NUMBERS.........................i.
0A'3
0A-4
ElectrlcalTransients and Radio
Frequency Interference
.:E
9t'9 r
6.1 LOCATIONOF IDENTIFICATIONPLATES oA-4 Radio Frequency lnterference .......... NA-A I
6.2 SAFEW CO]IIPLIANCEPLATE ...... 0A-4 Electrlcal Transients 0A-7

6.3 BODY & OPTIONIDENTIFICATION
0A-4
1 . GENERALDESCRIPTION
The VK Series is a minor facelift of the VH Series The 3.3 litre L6 engine, equipped with ElectronicSpark
incorporatingexterior,interiorand mechanicalchanges. Timing (EST), is the base engine tor SL and Berlina
The model line-up differs from the VH Series, with the models, and the 3.3 litre LO engine equipped with
deletion of the 69 body style (4 door, 4 window sedan) Electronic Fuel Injection (EFl) is the base engine on
and the introductionof the '19 body style (4 door, 6 Calaismodels.
windowsedan). The three speed Trimatic Automatic Transmissionis
standardequipmenton Calais and Berlinamodels and is
MOD ELL IN E U P availableas an ootion on CommodoreSL models.The
Torquemasterfour speed manualtransmissionis standard
8V K 19 C o m m o d o re
SL Se d a n4 door.6 w i ndow on CommodoreSL models.
8VK35 Commodore SL Station Wagon The 5.0 litre V8 engine is availableon all models as an
8VL 19 Com m odor e Ber lina Sedan4 d o o r , 6 w i n d o w option.A five speed manualtransmissionis also available
8VL35 Commodore Berlina Station Wagon as an option on all 3.3 litre L6 EST engines
8VX1 9 Calais Sedan4 d o o r , 6 w i n d o w The following charts contain model availability,power
train combinations,engine data and exterior dimensions
for VK Seriesmodels.
3
OA.2GENERALINFORMATION
2. MODELAVAILABILITY& BASE EQUIPMENT

TR A N S MIS S ION REAR
B O DY MODEL No . OF A X LE
S T Y LE NO. M O D EL NAM E DOORS ENGINE S H I FT R A TIO TY R E S WH E E LS
TY P E LOC . :l
Sedan 8VK19 C o m mo d o r eSL 4 3.3 EST 4 S peedManual F l oor ?na BR78S 1 4 5.50 JJX 14 S teel
S/Wagon 8VK35 C o m mo d o r eSL 5 3.3 EST 4 S peedManual Fl oor 3.08 c R 7 8 S 1 4 6.0 JJX 14 S teel
Se d a n 8VL19 C o m m o d o r e Be r lin a 4 3.3 EST 3 Speed Auto Fl oor 3.08 c R 7 8 S 1 4 6.O JJX I4 S teel
S/ Wa g o n t'V LJ5 C o m m o d o r e Be r lin a 5 3. 3 EST 3 Speed Auto F l oor 3.08 c R 7 8 S 1 4 6.0 JJX 14 S teel
Sedan 8VX19 Calais 4 J.J EFI 3 Speed Auto Fl oor 3.08 P20s/ 6.0 JJX l 5 A l l oy
6 0 H R15
3. POWERTRAIN COMBINATIONS
R E A RA X LE R A TIO: 1
E NGINE TRANSM I SSI O N M O D EL FIR S TGE A R
TYPE A VA IL AB I LITY R A TIO: 1 BASE PERFORMANCE
SL Sedan
SL Station Wagon
4 SpeedManual 3.50 3.08
BerlinaSedan
BerlinaStation Wagon
3. 3 Litre SL Sedan
S ix C ylin de r SL Station Wagon
5 SpeedManual 3.24 3.36
EST Ber linaSe d a n
SL Seda n
SL Station Wagon
SpeedAutomatic 2.31 3.08
Ber linaSe d a n
3 .3 L i tr e SL Seda n
Si x C yl inder Sp eedAut om at ic Ber linaSe d a n 2.31 3.08
EFI Calais
5. 0 Litre
3 SpeedAu tomatic All M ode l s z .J I 2.60 3.08
E ight C ylind er
4
GENERALINFORMATIONOA.3
4. ENGINEDATA
ENG I NE DESI G NATI O N 3.3 L]TR EE S T 3.3 LITR E E FI 5.0 LITR E
P IST OND ISP L AC EME N T

N OM.- c c 3298 3298 5044
C O MP R E SS IORNAT IO: 1 8.8 8.8 9.2
N U MB EROF C YL IN D E R S 6 6 R
B O R Ex ST R O K E-mm 92.O75x 82.550 92.075x 82.550 101.60x 77.775
T AX AB L EH .P.R ACo r SA E 31.5 31.5 51.2
P O W E RK .W.D IN 117kw @ 4000

86 kw @4200 106kw @4400
@ R .P.M.
T OR O U EN m D IN 266 Nm @3200 336 Nm @2400
232 Nm @2400
@ R .P.M.
5. EXTERIORDIMENSIONS
S E D A NMOD E LS S TA TIONW A GONMO DELS
BODY
D IME N S IO N S 8 VK 19 8V L19 8V X 19 8V K 35 I 8V 135
O V EB AL LL E N GT H 4713.5 4713.5 4713.5 I 4716.5 4716. 5

O V ER AL LWID T H 1 722 1722 1722 1722 1722
O V ER AL LH EIGH T I 378 1374 1360 1401 1465
W H E EL B AS E 2668 | 2668 2668 2668 2668
O V ER H A N G_ F R O N T 922.5 922.5 922.5 922.5 92 2. 5
O V ER H A N G_ R EA R 1 1 23 1123 1123 1126 ttl o
T R E AD- F R ON T 1 451.3 1451.3 t45 I .J t45 | .J 1451. 3

r R E AD - R E AR t4 l o.3 1416.5 1416.5 1440 1440
D i m e n s i o n si n m m
5
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 identificationnumber 'VlN' is quoted in conjunc-
tion with the identificationnumber of the component
affected.
6.1 LOCATIONOF IDENTTFICATION

PLATES
Plates are attached to the left side wheelhousereinforce-
ment and the front panel upper (reler Fig. 0A-l).
SAFEW COMPLIANCEPLATE- Refer Fig. 0A-2.

BODY AND OPTION IDENT|F|CAT|ONPLATE - Refer
Fig. 0A-3.
VEHICLEIDENTIFICATION
PLATE- Refer Fig. 0A-4.
Flgure 0A-1
6.2 SAFETYCOMPLIANCEPLATE
(Not applicableto Export).
T H IS VEH IC LE W AS M AN U F AC T U R ED BY
Plate stamped with the following information: Flefer GEN ER AL M OT OR S- H OLD EN 'SLI M IT ED
Fig. 0A-2. T O C OM PLY W IT H AU ST BALIAN D ESIG N R U LES N O S.
AUSTRALTAN 1,2, 3A. 40,58. 6, 7, 8, 108, 11. 12, 14, 15, 15, 1aA,20
DEStcN RULENOS.(A.D.R.)
21, 22A, 23A, 24, 25A, 27C , 28A, n, 31, 34
VEHICLEMAKE- HOLDEN.
VEHICLEMODELNAME AND STYLE.
MONTHAND YEAR OF MANUFACTURE.
3-84 AVKOOOOOTA
VEHICLESERIALNUMBER. GVw Ks s EAT IN G c Ap. s
SEATINGCAPACITYOF VEHICLE. T H IS PLAT E IS AF F IXED W IT H T H E APPR OVAL O F T H E
GROSSVEHICLEMASS IN KILOGRAMS. 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 GE N E FA L MOTOR S _H OLD E N 'SLIMITE D
Plate stampedwith the followinginformation- Refer
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
Fig.0A-3.
MOD E L: V K 8V L19
MODEL: B OD Y N O.: 621423A
Combination
of lettersand numbersidentitying
the TRIM: 1442-63X
Body,Modeland Style. P A IN T: 567-30518
BODY NO.: B U ILT: MA R 84
Reference
numberfollowedby AssemblyplantSuffix. E N G.44 TR A N S . M4O A X LE GU 4
A - Adelaide MA D E IN A U S TR A LIA
M - Melbourne
NZ - New Zealand
TRIM: Figure 0A-3

ExteriorPaintColourand Trimcombination.
PAINT:
ExteriorPaintMaterialand Colouridentificatron.
BUILT:
Thedateof manufacture by calendarmonthanovear
in which the body shell and power train are
conjoined and the vehicle is driven or moved from
the production line-
6
OA-5
GENERALINFORMATION
The significance of these characters or blocks of

6.4 VEHICLEIDENTIFICATION characters is explained below, using as an example
NUMBERINGSYSTEM identificationnumber:-
The Vehicle ldentificationNumberingSystem (V.l.N.) is
8L19LD L60oO25K
based on the uniform Car Model Designation System'
This is to identify the vehicle in one coded series of
characters.
r G E N E R A LM O T O R S - HLOO E N 'SL I M I T E O
o
MODELDESIGNATION
Division
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 :-
K - COMMODORE 'SL' L. COMMODORE "BERLINA" X. "CALAIS'
Body style code - 3rd & 4th character - 19 Body Style ldentification
19 - Sedan (4 door, 6 window)
35 - StationWagon
ENGINECODE
Sth Character- L - Engine ldentificationCode.
L - 3.3 litre EST K - 3.3 litre EFI T - 5.0 litre "
MODELYEAR CODE
6th Character- D - ldentifiesModel Year.
This letter changes 1st September each year & relates to GM Internal
OPerationsOnlY:-
D-1984 E-1985 F-1986
ASSEMBLYPLANT CODE
7th & 8th Characters- J6 - AustralianAssemblyPlant ldentificationCode:'
Jl thru J9 - Melbourne L1 thru J9 - Adelaide
SERIAL(Sequence)NUMBER
9th to 13th character - 00025 - sequentialProductionserial Number.
NOTE: This designatesthe SeriatUnit Numberat each Vehicle Plant, starting at
(00001) and continues in Numerical Sequence regardless of vehicle type-
SERIESCODE
14th Character- K GMH LimitedModel Code Designationfor each Model Programme.
e.o.'VK'.
Flgure 0A-4
7
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 ICLES E RI E S ' V K ' .
3. ASSEMBLYPLANTSERIALNUMBER.
4. ASSEMBLYPLANTIDENTIFICATION 'A' ADELAIDE.
'M'ME LB O URNE .
5. REQUIREMENT IN EVENT OF SERIAL NO.
DUPLICATION.
6. REQUIREMENTIN EVENT OF SECOND OR
FURTHERSERIALNO. DUPLICATION.
nEr E
Fllol
II
AVK OOOOO1
A
TT
R2 T
I
6.6 ENGINESERIALNUMBER Figure 0A-5
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.
J ENGINENUM B E RP RE F IX E N GIN ET YP E
VL J.J ilIr e tr S I
VK 3. 3 lit r e EFI
VT 5. 0 llt r e Aut om at ic
7. ADDITIONALGENERALINFORMATION
ELECTRICAL TRANSIENTS AND RADIO
FREQUENCY INTERFERENCE
Electronic circuits are used in VK Series rnodels to
performa number of functionsassociatedwith electronic
instruments,electronicfuel injectionand electronicspark
timing.These circuitscan be damagedor cause mallunc-
tion 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
telephones-The followingare normallyused to suppress
RF interference.
Resistors e.g. high tension cables and
connectors.
Capacitorsand choke coils.
Metal braid lor screening leads or suppression
covers made from conductivematerialfor scree-
ning equipment.
To preventdamageto equipment:
Do not replace interference- suppressedhigh
tension ignitioncables or conneclorswith un_
suppressedtypes.
Do not remove or reposition interferencesup_
pressionfiltersor cagacitors.
8
GENERALINFORMATIONOA.7
ELECTRICAL TRANSIENTS
Electricaltransientsare high voltage spikes producedby
the sudden switchingor interruptionof electric currents.
Older style timinglightsand batterychargerscan produce
serioustransients,hence it is importantto use only good
quality equipment suitable for use with electronic
systems.
It is also good practice to ensure that the battery is
disconnectedbefore using a battery charger.
Indiscriminate fitting of solenoids,indicatorsor relayscan
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 ld1a
!* \
T;-
4 . B L OWER M OT OR q
= \ Lja
)w
5 . E L ECT RIC WINDSCREEN
W I P ER
6 . S P ARK PL UGS
l l rrn
7 . I G NIT ION DIST RIBUT OR
8 . r G N lr lo N co lL
I iltl
9. HORN rfrh ,dH
1 0 . I N DICAT OR WIT H VOL T AGE
S T A BIL IZ ER
( e . 9 .F UEL GAUGE)
T*fl'-ffi#m^
-# ' '1iitT
l :: :..1
Vlr
E:T
l :l
-
ffifffin4-"Fu --:-=-..
H
\
A D D I T I ONAL SOURCEOF INT ERF ERENCe; I
rdlfu'o
[ :\': ::::l
\
P O O R EL ECT RICAL CONNECT IONS
B E T W E EN T HE VABIOUS M ET AL PART S
I
i
___,--l )
I
O F T H E VEHICL E ( e .9 .BET WEEN T HE
E N G T NEAND F T REWAL L ) .
i i /1
//
I
-
------\, l/ 1
Figure 0A{
9
LUBRICATIONOB.1
SECTIONOB
LUBRICATION
INDEX
Ref. Subiect Page Ref. Subject Page
1. GENERALINFORMATION 0B-1 1.3 AIR CLEANEB.......... 0B-2
1. 1 RECOMMENDED LUBRICANTS..................0B-2 1.4 FUEL FILTER 0B-3
1. 2 BRAKE FLUID REPLACEMENT....... 0B-2 1.5 COOLINGSYSTEM 0B-3
1. GENERALINFORMATION
This section provides details of the lubricants specific to services should be canied out are contained in the
VK seriesvehicles. Service and Maintenance Section of the VK Series
lnstructions on the time or distance intervals at which Owner Handbook.
CAPACITIES
E N GIN ES IZE CAPACITY
En gin e- Ser v ic eRef ill 3.3 Litre 3.7 Litres

5.0 Litre 4.33 Litres
Add for Oil Filter A LL 3 Litres
Ma nu alTr ans m is s ion
(ProductionOption MC6) 3.3 Litre EST 1.6 Li tres
Ma nu alTr ans m is s ion
(ProductionOption M76) 3.3 Li treE S T 2.75 Litres
Au tom at ic Tr ans m is s ion( Dr y ) ( lnc . Co n v e r t e r ) 3.3 Li tre 6.1 Li tres
5.0 Litre 8.7 Li tres
Se rvi c eRef ill . 3.3 Li tre 2.3 Li tres
5.0 Li tre 2.3 Li tres
CoolingSystem 3.3 Litre 8.5 L i t r e sa p p r o x
5.0 Litre 12.0 Litresapprox
BrakeHydraulic System A LL .62 Litres
10
OB.2LUBRICATION
1.1 RECOMMENDED
LUBRICANTS
GMH
COM P O NE NT S S PE C IF IC AT ION LU B R IC A N TS
E ngin e
3.3 Litre EST SE O ils F o r g r a d e sa n d a p p l i c a t i o n ,r e f e r F i g . 0 B - i
3.3 Litre EFI I Se O it s F o r g r a d e sa n d a p p l i c a t i o n ,r e f e r F i g . 0 B - 1
SF O ils f or s ev er es er v ic e .
Refer Owners Handbook.
5.0 Litre SE O ils F o r g r a d e sa n d a p p l i c a t i o n ,r e f e r F i g . 0 B - 1
Manua l Tran smissio n
P ro du ctio n Optio n M C6 H N 10 4 6 SAE 8OW9O
P rod uction Optio n M 76 H N 18 5 5 CastrolGearOil 80W
A ut omatic Tran smiss ion GM9985286 D E X R O N I [ A u t o m a t i c T r a n s m i s s i o nF l u i d
R earAxle HNi 181 if unav ailabl e EPSAE90
Rear Axle L .S.D. HN1561
Power Steering GN49985286 D E X R O N I f A u t o m a t i c T r a n s m i s s i o nF l u i d
Brake System H N 17 9 6 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 nH N 1 7 9 6
-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 brakingcondit-
ions increaseswith the age of the fluid. Therefore,for
maximum brake effectiveness,a two yearly change of
brake fluid is mandatory.ServiceInstructionsfor 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 lightlytappingthe element.lt shouldnot be washedor
oiled.The time or distanceintervalsat whichthe element
requrres servicing depends on the vehicle operating
conditions. Underdustyconditions, the elementshouldbe
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.
ServiceInstructionstor the removaland installationol the
f,\ A IR FLOW ;A l R FLOW
air cleaner element (Fig. 0B-2), on vehicles with ME TE R DUCT
electronic fuel injection are covered in Section 6C, /
ServiceOperation3.6 in this Supplement. A IR C LE A N E R
H OU S IN G
Figure 0B-2
1.4 FUELFILTER IN LIN E

On 3.3 litre engineswilh electronicspark timing, a fuel
{ilter is located in the suction side of the fuel line and TO FU E L P U MP -\. /
attachedto the right hand fender panel. Refer Fig. 0B-3' >-}îq c;
---l-')w-t
On electronic fuel iniected vehicles, the fuel filter -\ I
(Fig. OB-4) is located on the pressure side of the tuel ll----
pump and attached to the floor pan of the vehicle, in -*i-rl
front of the differential.

Fuel lilters should be replaced at the time or distance
MOU N TIN G
intervalsspecifiedin the VK SeriesOwner Handbook. BRACKET
ServiceInstructionsfor the removala;rd installationof the
fuel filter on electronictuel iniectedvehiclesare coverecl
in Section6C, ServiceOperation3.15 in this Supplement.
R+
FR ON T OF C A R
Figure 0B-3
1.5 COOLINGSYSTEM
R U B B E R _lN S U LA T OR
The cooling systemis filled initiallywith a coolantmixture ;
comprising 1.5/o to 3.0% (by volume) of corrosion
inhibitorto GMH specilication HN1109.
It is recommended that the coolant be drained, the
/t..\\
hl '\\ --\
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 lr
iA
System'of this Supplementfor details.
| 6/:
1r (
ryy-^,R
i6*q (- ,f.1'.t*./','ffi\->(l a'
iii'')i'-\
MOU N TIN G
ruurll ,
, \1'l
\, 'Y ;r/
/
C LA MP B OLT
Figure 0B-4
12
BODY 1A-1
SECTION1A
BODY
CONTENTSOF THIS SECTION
Ref. Subjecl Rel. Subject Page
1. GENERALINFORMA 6. SEATS& SEAT BELT ASSEMBLIES.....-.... 1A.31
2. UNDERBODY 1A-3 7. EXTERTORORNAMENTATION 1A-39
....................
3. 8. ROOF RACK ...... 1A-s1
4. REAR QUARTER 1A-19 9. BODY ELECTR|CAL............ ..... 1A-53
5. STATTONARYGLASS .............1A-21 10. SPEC|ALTOOLS ...,.... 1A-67
INDEX
Ref. Subiect Page I Ref. Subject Page
1.1 1A-1
GENERALDESCR|PT|ON.............................. | 1.2 SERVICENOTES 1A-1
1.1 GENERALDESCRIPTION
This Section contains descriptions and procedures lor
interior and exterior body service operationson VK Series
Commodoreand Calais models.When used in conjunc-
tion 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. A-A
sEcrroru
The stationary fifth and sixth windows on the new 19
Styles are retained in their upper rear quarter apertures S E A T B ELT
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 FlgurelA-'l
to retainthe JB CamiraWindshieldsand back windows'
involving high heat application, appropiate precautions
Also featured on VK Series are revised transmission
against fume inhalation such as the wearing ol re-
consoles, new instrumentpanel facia and instruments,
spirators,forced ventilation,etc., are mandatory.Whene-
seat and door trim designs and 'see through' head
ver possible, such repairs should be canied out without
restraintson front seats.
the use of high temperature producing equiPment.
On the Calais model, see through head restraints are
fitted to the rear seats. Electricallycontrolled exterior rear IMPORTANT: Whenever items such as body side
vision mirrors are also standard on this model. An mouldings,Dealer name plates,mud/9lash guards,etc.,
adjustablelumbarsupportbuilt into the drivers seat back which require piercingof sheet metal panels,are added
is includedon Berlinaand Calaismodels. to a vehicle after it has been manufactured,a possibility
VK external features include new exterior ornamentation, exists for sheet metal corrosionto occur in areas where
decals, tailgate handle on 35 body style, radiator grille the metal has been pierced, as well as other areas
and colour co-ordinated front and rear bumper bar affected by water entry at the point of piercing.Abrasion
assemblies. of the painted or treated surfaces by the 'added-on'
material may contribute to corrosion and unsightly
Front turn signal lamps and rear lamp assembliesare
appearances.
also new.
The reliabilityand performanceof 'add-on' equipment
1.2 SERVICENOTES installationsmust become the responsibilityof the maker
and the installer (Dealer or vehicle owner). For this
CAIITiON: As a sound deadening medium, a small reason,you should evaluatethe proceduresused in your
volume of polyurethane foam is installed into the upper Dealership (and outside sublet shops) to assure that
section ot the rear body pillars of VK Commodore proper steps are being taken to provideappropriatesheet
sedans, as illustrated in shaded areas in Fig. 1A'1. metal corrosion protection to offset the etfects of
During norma! seruice, there is no risk associated with its 'add-on'equipment.
use. However, when polyurethane is subiected to high
temperatures such as during welding or naked flame CAIJTION: To avoid damage when servicing instrument
cutting, this material can release black pungent fumes. panels, trames, instrumentc/usters, etc., it ls essentia/to
During repair of these pafts of the body structure handle these componentswith the utmost care.
13
1A-2 BODY
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BODY 1A.3
2. UNDERBODY
INDEX
Ref. Subject Page Rel. Subject Page
2.1 UNDERBODYDIUENSIONS& HOIST 2.4 SHROUDLOWERTRIM . RIGHT& LEFT
LOCATIONS. 1A-2 HAND ......--..- 1A-6
2.2 TRANSMISSIONCONSOLE.MANUAL...... 1A-3 Remove....--.. 1A-6
llodel - 'SL' 1A-3 Reinstall 1A-6
Remove 1A-3 ROCKERPANELCOVER- RIGHT&
Relnstall 1A-3 LEFT HAND. 1A-6
Models - Calais & Berllna fltted Remove........ 1A6
with Power Operated Slde Reinstall 1A-6
Wlndows...... 1A-3 FLOORCOVERING 1A-7
Remove........ 1A-3 Remove....,........... 1A-7
Reinstall 1A-3 Reinstall 1A-7
TRANSMISSION CONSOLE.
AUTOMATIC 1A-5
Remove.,,..-.. 1A-5
Relnstall 'tA-5
2.1 UNDERBODY AND

DIMENSIONS
HOISTLOCATIONS
Refer Fig. 1A-1A.
CONSOLE.
2.2 TRANSMISSION
MANUAL
M O DE L. ' S L '
Remove
1. Disconnectbatterygroundcable.
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
connectorsprior to removalof transmissionconsole.
Reinstall
Reverseremovaloperations,ensuringthat non hardening
sealer is appliedto the threads of the console attaching
screwspriorto their installation(refer Fig. 1A-2).
MODELS. CALAIS & BERLINA FITTED WITH

POWER OPERATED SIDE WINDOWS
Remove
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.
4. Partiallyraise rear end of console,disconnectelectr-
ical connectors,then easing console reanvards to
disengage front end of console from attaching
bracket (refer Section B-B, Fig. 1A-3) remove con-
sole assembly.
Reinstall
Reverseremovaloperations.
15
1A.4 BODY
cll---->c, a WIPER IWASHER SWtTCH ASM.

,/-
{ 4 P L A C E S)
#
W H E A TE D R E A R WTN D OW
z-
Ascnew.-----..---..-->s sw l rcHA ssE MB LY
(4 PLACES) i €
GE A B S H IFT LE V E R
C ON TR OL B OOT
OUU I
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.
SECTIONA_A
EOOT ST RAP T O B E P LA C E D
...-..--. T OWARDS F RON T OF C A R
_ 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
A VIEW rF r l S E A LE R .
1 1", 2.4- 3 .4 Nm (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
,.- g:3I: r coN

rRoL--r 3?I:3
L E V E Rlf
BOOT
B E FOR E IN S TA LLA TION A P P LY
""?:'j
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
533|,13'^G
-r'
'/- R E FE R S E C TION 12E _=_==3*{
acARPET
REFE R S E C T I O N 1 2 E /-**-f.* / S E C T I O NB _ B
r_ -_
/
vrEW
a A
TR A N S MIS S ION
C ON S OLE A S M.
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
A P P LY TR IM A D H E S IV E
SW I T C H A S S E M B L Y
OV E R A R E A S H OWN
THUS \\\\\\\
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/t \ I
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Figure 1A-3
16
BODY 1A-5
CONSOLE.
2.3 TRANSMISSION
AUTOMATIC
Remove
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
transmissiontunnel (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
relerringto automaticconsolescale installationin Fig.1A-
4. is observed.
CONSOL E CAP _ +---___>

€
<.,/
' sEcrroruA-A
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
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.
srcrroruB--B
C ON S OLEC A P
i././r2,./
C-C
sEcrroru
(4 P LA C E S )
SELECTORINDICATOR_ TRIMATICAUTOMATICTRANSMISSION
TRANSMISSION
Figure 1A-4
17
1A-6 BODY
2.4 SHROUDLOWERTRIM - 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 (referSiectionsB-B and F-F, Fig. 14-6) careful-
ly prisefastenersfrom shroud panel,removingtrim.
REINSTALL
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
retainingflange.
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
A
._-
-
s ec r r oHA - A secrroru
B_B secrrorv
C-C
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 EVK
S E C TION A _A TR IM -J
FA STE NE R
/r" ,-o*.* t*) ON E P IE C E FLOOR C A R P E T S E C TION B _B

SHROUD (R IGH T S ID E ON LY )
N OTE : S E R V IC E R E P LA C E ME N T
_ TWO P IE C E
T R AN SM ISSION
-m t
C ON SO LE 'a
\
-.
L OWER TR IM-\
SHR OU D t/ T R IM F -F
\ - secrrorrr 8 vK
rAJ ttrt\trH (LE FT S IDE ON L Y}
CARPET
AT T ACHING
PL UG
1 2 PL ACES \
SECTI O NC- C SEC T I O ND _ D S E C T I O NF _F 8 VL , X
( L E F TS I D EON L Y)
Figure 1A€
2.6 FLOORCOVERING
REMOVE
2. Bemove front end rear rocker panel covers and
shroudlower trims (reler 2.5 and 2.4 in this Section).
3. Removetransmissionconsole(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
. LOWE B IN S T R U \4E \T
NOTE: Separate front and rear floor coverings are P A N E L E X TEN S ION
availablefrom GM P & A as ServiceReplacements-
- 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
3.1 SEHVICENOTE 1A-9 3.4 INSTRUUENTPANEL LOWER. RIGHT
3.2 INSTRUMENT PANELLOWERTRIM. HAND ....... 1A-16
RIGHT & LEFT HAND 1A-9 Remove .. 1A-16
Reinstall ......-...1A-16
3.5 INSTRUMENTPANEL LOWER. LEFT
3.3 HAND INCLUDINGRADIO AND
RADIO/CASSETTEPLAYERRECEIVER....1A.16
Relnstall ............1A-10 Remove........ 1A-16
.....................
Relnstall ... 1A-17
3.1 SERVICENOTE REINSTALL

Reverse removaloperationsensuringthat leadingedge of
CAIITION: To avoid damage when seruicing instrument left hand trim is correctlylocatedbeneaththe dash panel
panels, frames, instrumentclusters,etc., it is essent€t/to bracket and into wiring harness grommet (refer Section
handle these components with the utmost care. C-C, Fig. 1A-8) and that the leading edge of the right
hand trim is locatedin the acceleratorpedal supportcap'
as illustratedin SectionB-B, Fig. 1A-8.
3.2 INSTRUMENTPANEL LOWERTRIM .
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
prise clips from attachingholes in instrument.panel
lower (refer SectionA-A' Fig. 1A-8)removtngtrtm'
NOTE: Removal of right hand lower trim necessitates
disengagementof adlustablestrap which partiallysecures
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
\- 2 PL AcEs L islDE&c6 o
"r
L O W E R P ART -
I N S T R U M ENT secrtoruA-A
PANEL
L H INSTR U ME N T
A C C E L ERAT o R- - 7 PANEL LOWE R TR IM
PEDAL |,
c r l o p n F IT r - AP - 8V X & C 6O
-\< -
\
-,
.>t
er us unETRt M BoARD ls
-- R H IN S TR U ME N T-/
ASSEM BL ED IN ACCEL ERAT OR
P A N E L LOWE B TR IM
PEDAL SUPPORTCAP AS SHOWN
A D JU S TA B LE-_\
secrroru
B-B S TFA P
R E TA IN FR ON T E D GE OF IN S TR U M E N T-
P 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
T R I M BOARD T O BE WITH A D JU S TA B LE S TR A P ,
A S S EM BL ED INT O
W I R I N G HARNESS tr LtrSJ5IhAT IUbtr
G R O I\4 M ET TU C K E D A WA Y OR TR IMME D .
secrroru
C-C
Figure 1A-8
20
1A.10BODY
3.3 INSTRUMENT
PANELPAD
REMOVE U P P E RS TE E R IN G
1. Disconnectbatterygroundcable. C OLU MN C OV E R
2. Remove screw attached lower cover from upper

sectionof steeringcolumn(refer Fig. 1A-9).
3. 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.
4. Remove screws securing top of instrument panel
lower extension to base of instrument location cover A ..u - 4.6N m
(referFig. 1A-10).
5. Remove screws securing combined instrument
assemblyto instrumentlocation cover (refer Fio.1A_ Flgure 1A-9
1 1) ease assembly.rearward then disengage eiectr-
ical connectorsand on all models,excepi those with
electronic instruments, the speedo cable from
speedohead (referView A, Fig. 1A-1j) then remove
instrumentassembly.
6. Remove instrumentlocationcover (refer Fig. 14_11)
front radio speaker grille and speaker assem-blylrefei
View B, Figs. 14-12and 14-13).
7. 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 securingupper air outlet assemblies
to instrumentpanel pad assembly(refer Fig. 14-14)
then removeoutlet assemblies.
8. With instrument panel compartment open, remove
screws securing rearward edge o{ instrument Danel
pad to instrumentpanelbrace (referFig. 14-14).
9. Usinga 10 mm socketattachedto a ratchet handle,
loosen right and centre nuts securingpad assembly
to instrumentpanel 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.
10. Ease pad reanaards,disengagingpad studs from
anstrumentpanel slotted brackets. With left hand of
rnstrumentpanel pad raised, remove pad assembly
fromvehicle.
REINSTALL
Reverseremovaloperations,includingtry-outof electrical
ctrcurts, air ducting, vacuum hoses and temperarure
controlcable disturbedduringremovaloperations-
21
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--. [ --'f ::\'-"=-i-'/ utr l u H
!
1F ^z I
z?t ;
26
1A-16BODY
3.4 INSTRUMENTPANEL LOWER.

RIGHTHAND
REMOVE
1. Disconnectbatteryground 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 disturbedduring removaloperations.
3.5 INSTRUMENT PANEL LOWER. LEFT

HAND, INCLUDINGRADIO AND
RADIO/CASSETTE PLAYER RECEIVER
REMOVE
1. Disconnectbattery earth cable.
2. Removetransmissionconsole (reler 2.2 or 2.3 in this
B U MP E R
(2 P LA C E S )
\N
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 compartmentside, 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). IN S TR U ME N T P A N E L
9. Remove screws securing the centre nozzle and C OMP A R TME N T
instrumentlocationframe assembly(refer Fig. lA_10)
disengageelectricalconnectors from front e-nOwiring Figure 1A-15
harness,then removeframe assemblv.
27
BODY 1A-19
4. REARQUARTER
INDEX
Ref. Subiect Page
4.1 OUARTERWINDOWINNERUPPERTRIM 1A.19
1A-19
ilodels - 19 Body Styles ....................
4.1 QUARTERWINDOWINNERUPPER C U S H ION A S M.- R E A R FLOOR

T R IM R E TA IN E R BRACKET
MODELS. 19 BODY STYLES

Remove
1. Depress front edge of rear seat cushion assembly
then ease assembly rearwardsto disengageassemb-
ly retainer from brackets attached to the floor (refer
SectionA-A, Fig. 1A-16)removeand place assembly secrroruA-A
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
REAR
seat back assembly. C OMP A R TME N T
2. Unclinch tabs securing seat back frame to rear FR ON T P A N E L
wheel-houses(referView A, Fig. 1A-16).
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. SEAT BACK
R E TA IN E R
B-B k=- ,
secrroru
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,
REAR PARCEL
Fig. 14-18) on side from which quarterwindow trim
S H E LF TR IM
is to be removed.
FA5 III\EH
(3 P LA C E S )
SECTIONA_A
Figure 1A-18
6. Ease rear door opening finishing lace from leading

edge ol quarter windowinner upper trim, then usini
a broad bladed screwdriverlocatedbetweentrim 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. IaUARTER
WI N D O W
I N N E RU P P E R
Reinstall
Fleverseremovaloperations.
NOTE: Damaged barbs on trim panel fasteners requtre

fastenerreplacement.
FA S TE N E R S _\
secrroru
A-A secrloruB-B
{4 P LA C E S R /L) (1 P LA C E R i L)
Figure 1A-19
29
BODY 14.21
5. STATIONARYGLASS
INDEX
Re{- Subject Page Ref. Subject Page
5. 1 DESCRIPTION ..... 1A-21 5.4
5.2 SERV|CENOTES 1A-21
........-...........
5.3 REAR OUARTERWINDOWASSEMBLY....1A-22
1A-22
Models - 19 Body Sty|es..................-.
Remove........ ...........1A'22 Reinstall ... 'tA-28
Quarter Window Aperture Check .--. 14'23 Long Method..... 1A-29
Reinstall 1A-23
Reinstall ... 1A-29
5.1 DESCRIPTION The repair kit developedto servicethis Short Methodor

Minor Water Leak correction is part number92018611
Toughenedglass is fitted to rear quarterapertureson 19 and contains:
body styles and to tailgateson 35 body styles.
300 ml UrethaneAdhesive.
These glasses are bonded to the rear quarter upper
panel and tailgate qperture flanges with a self curing 25 ml ClearGlass Primer.
metal to glass urethaneadhesive. 25 ml Glass Black Out Primer.
ln situations necessitating complete removal of the NecessaryApplicators.
original urethane,such as damage to window apertures Instructions.
where paint finish or base metal is exposed,a urethane These replacementkits are availablefrom:-
adhesivekit has been developedand must be used to
maintainthe originalstructuralspecifications. Dimet,
53 ShowersStreet.
Part No. 92018612 'Long Method'.The repair kit for this Preston, Vic. 3072.
operationcontains: An additionalshort method replacementkit which is only
300 ml UrethaneAdhesive. recommendedfor rear quarter windows on sedans, is
25 ml Glass Primer- Clear. availablefrom GM P & A under Part No. M38977 and
contains300 ml of silicone.
25 ml GlassPrimer- Black.
This materialis also recommendedfor minor water leak
25 ml BodYPrimer.435-56 correctionon all urethaneinstalledstationaryglass.
NecessaryaPPlicators.
lnstructions.
5.2 SERVICENOTES
NOTE: For tailgatewindow replacement- Long Method, WARNING:WORK GLOVESMUST BE WORN AT ALL
an additional auxiliary kit, Part No. M39097, which TIUES WHEN OPERATINGWITH GLASS.
contains300 ml of urethaneadhesive,is required.
NOTE: Skinning (partial curing) ol the urethane com-
ADDITIONALCOMPONENTSREOUIRED (Not part of mences after exposureto the atmosphere.At 23oC and
package) 50 % relative humidity, skinning commences after
Appropriatemouldingsas required. 30 minutes. Therefore, installation of tailgate window
mouldingsmust be completedwithin that time limit on
A second method lor window replacementreferredto as station wagons.
the 'Short Method' is used when original urethane
adhesiveleft intact on the window apertureflanges after Complete curing of urethane at this temperatureand
glass removal can serve as a satisfactory base Jor the humiditytakes 72 hours.
reinstallalionof the original or new glass. This would The recommendedtool for cutting through the urethane
occur when the glass is being removedto overcome a is the glass sealant removalTool No. J24402,which can
severewater leak, or when a glass is broken- be obtainedfrom Kent-MooreAustraliaPty. Ltd.
30
1A-22 BODY
5.3 REAR QUARTERWTNDOW

ASSEMBLY
Remove
The quarterwindowglass removalprocedureis similarfor
both the 'Short' and 'Long' InstallationMethods with one
exception.lf the Short Method installationis 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 replacementglass.
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 nU-
AM, 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
G U T T E RM O U L D I N G
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 remainingscrews securinggarnish moulding

to rear quart€r 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. Locate blade of Tool No. J24402, glass sealant J24402

remover, beveen inside of glass and urethaneas GLA S S S E A LA N T
illustratedin Fig. 14-23, then cut through urethane, R E MOV A L TOOL
aroundcompleteperipheryof glass.
6. Carefully lift glass out of aperture. lf there is
evidence of glass adhesion to urethane, re-apply A P P R OX IMA TE
cuttingtool to problemarea. A R E A E OU A LS
ON E S OU A R E
7. lf originalglass is to be reinstalled,place glass on a cE N TIME TR E ---7
protectedbench or holdingfixture and using a sharp I
scraper, carefully remove original urethane lrom I
glass. Clean glass with a suitable oil-free cleaning
agent such as Prepsolor equivalent.
NOTE: Do not use petroleum base solvents to clean
glass or aperture flange as the presence of oil will 170
\ H N 1749
prevenlthe adhesionof new urethane/silicone. 7\ 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
that do. lf 'Short Method'glass installationis being used'
check originalurethaneon flange for loosenessor voids'
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 equivalenl-
URETHANEONLY
') Usingan applicatorin 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). -
URETHANEONLY
4. U.singa.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 illustratedin View H, Fig. 1A_24,
then firmly press glass onto butyl strips loEateo on
garnishmouldingrecess.
Apply a smooth continuous bead of urethaner (B LA C K OU T) P R IME R
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.
B U TY L S TR IP S
(4 P LA C E S )
V IE W
Figure 'lA-24
8. Install screws securinggarnish mouldingto the top

and sides of the windowaperture(referFig. 1A-25).
9. Water leak test quarter window using a moderate r5rS'l PCtrRE W
AUtrJ
spray of water.
NOTE: Do not direct a heavy stream of water onto
freshly applied silicone.lf watei leak is evident,remove
i
garnish moulding and apply additional silicone
to teak
,9
v
area, using a flat bladed tool to work fresh siliconernro
the sourceof the leak, then installgarnishmoulding.
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 R E A R R OOF D R IP
covers. GU TTE R M OU LD IN G
NOTE: White spirit is recommended for removal of
siliconefrom paint finishand trim' OU A R TE R WIN D OW GA R N IS H
sE crroNA M-A M
Long Method
The long method of glass replacementis used when
original urethane adhesive material cannot serve as a OU A R TE R WIN D OW
base lor replacementglass. GA R N IS H MOU LD IN G
This method should be used on vehiclesrequiringmetal
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
such instances,the build-up of urethane/siliconecould LOWE R OU A R TE R W IN D OW
positionthe glass too far out of the opening. R E V E A L MOU LDIN G
1. Using the glass sealant removal tool andlor sharp
sEcrroNAN-AN
scraper,removeoriginalurethanefrom around entire
perimeterof quarterwindow apertureflange.
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 Figure 1A-26
(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
for 30 minutes.Avoid touchingprimedarea.
F L ANGE PRIM ER
u,.*lfl u,.*lEl
Figure 1A-27
34
1A-26 BODY
3. 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
equivalent-
4.
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.
v
12.O
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 VI EW
to glass.Commencingat 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;A-
291. 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 'fE[F[-cTJl
garnishmouldingas illustratedin VievrrH, Fig. 14-29.
Firmly press glass onto butyl strips locateJ at four Figure 1A-28
places on garnishmouldingrecess-
o Using a hand operatedapplicatorwith specialnozzle
supplied in kit, apply a smooth continuousbead of
HN1749 urethaneadhesive,17 mm high and 7 mm
at base, around entire perimeterof inner surface of
glass (referView J, Fig. 1A-29).
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 GLA S S P A IN T-OU T

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).
GA R N IS H
12. Water test quarterwindow using a moderatespray of
water.
V IE W V IE W
NOTE: Do not direct a heavy stream of water onto
freshly applied urethane. ll a water leak is evident,
removegarnishmouldingand apply additionalurethaneto
the leak area, using a flat bladed tool to work urethane
into source of leak, then installgarnishmoulding.
x\
'\\ \
'\w
\\
Figure 'lA-30
IJ 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
over rearwardouter edge of garnish moulding,then
with the hand, lightly tap opposite side of moulding
over garnish moulding (refer Section AM-AM,
F ig. 1 A -3 1 ). 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
sEcrroNAM-AM
OU A R TE R WIN D OW
GA R N IS H MOU LD IN G
\ !
. SC R EW
L o w E R O u A R T E Bw r N D o w
---
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 concernedro correct
leak.
SHORT METHOD
P R OTE C TIV E TA P E
Remove
1. Disconnect battery ground cable and on Berlina
model, remove tailgatewindow wiper arm and blade
assemblyand electricaldemistconnector.
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 V IE W
mouldings.
4. Remove all glass fragments from original glass
Figure 14-32
adhesiveleavingadhesiveintact on tailgate.
5. Using clean, lint free cloths, dampenedwith an oil
free solvenl such as Prepsolor equivalent,thorough_ P R OTE C TIV E TA P E
ly clean surfaceof glass which siliconeis to contact.
includingglass edges.
CAUTION: Do not use petroleum based solvents,as the
presence of oil will prevent adhesion of the fresh
urethane/silicone.
Reinstall
URETHANEONLY
V IE W
1. 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 Figure 1A-33
(referView B, Fig. 14-35).
URETHANEONLY
surface 7 mm from the edge with gl-assprimer :
black (HN1748) and ailow to dry for 15 minutes
(reler View C, Fig. 14-35).
3. Apply 6.0 mm bead of urethane/siliconeto original
adhesiveand also to the groove left in the adhelive
by the mouldings.
4. With tailgatein near horizontalpositionfit new qtass.
5. Refit upper and lower mouldings.
6. Refitside mouldings.
7. Apply tape to hold mouldings in position where
reguired. This tape to be left on' for 24 hours
mtntmum.
37
BODY 1A-29
8. Leavetailgatein horizontalpositionfor a minimumof

5 hours, after which time vehicle may be driven K N IFE
providing tailgate is not slammed excessively for ,/-C OLD
24 hours.
r TA ILGATE W IN D OW
9. On Berlina model, install tailgatewindow wiper arm U P P E RMOU LD IN G
and blade assemblyand demist electricalconnector
and on both models,battery ground cable- KN I F E
10. Remove maskingtape from tailgate, clean adiacent BLAD E
paint finish and glass, then remove protectivecove-
ring from interior.
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
assemblyand electricaldemistconnector.
2. Apply protective tape to paintwork adiacent to
mouldings as shown in View A' Fig. 1A-32, and
place protectivecoveringadiacentto glass-
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 tull length of
moulding to loosen, carefully remove moulding
intact for reuse.
b. Upper and lower mouldings- Method as for side
mouldings.
4. Remove all glass fragments and urethane, using
blade of glass sealant removal Tool No' J24402
illustratedin Fig. 1A-34.
NOTE: lt is not necessaryto removeall traces of original
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).
surface 12 mm from the edge with glass primer -
clear (HN1747).This is a wipe on wipe off operations
(referView B, Fig. 1A-35).
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. 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).
5, Fit the glass immediatelythe urethane bead is
appliedto the body.
o. lmmediatelythe glass is installed,fit mouldingsystem
after. ensuring that enough urethane is pr6sent to
bond the mouldings.(Apply additional adhesive to
bond mouldingsif required.)
7. Apply tape to hold mouldings in position where
reguired. This tape to be left on for 24 hours
h"'
mrntmum.
Leavetailgatein horizontalpositionfor a minimumof
5 hours, after which the vehicle may be driven
providing tailgate is not slammed extessively for
24 hours.
9. On Berlina model, install tailgate window wiper arm
and blade assemblyand demist electricalconnector vrew
lel
and on both models,batterygroundcable.
10. Remove.masking tape from tailgate,clean adjacent Figure tA-36
paint finish and glass, then remove protectivecove-
ring from the interior.
39
BODY 1A-31
6. SEATS& SEAT BELT ASSEMBLIES

INDEX
Re{. Subject Page Ref. Sublect Page
6.1 DESCRIPTION 1A-31 6.4 REAR SEAT BELT RETRACTOR
6.2 LUMBARSUPPORT. DRIVERSSEAT ...... 1A-31 ASSEMBLY 1A-34
.........-.........
Models - Berlina and Calais 1A-31
Remove...-...- 1A-31
Reinstall 1A-33
FRONTSEAT BELT RETRACTORAND
BUCKLEASSEMBLIES 1A-33
Remove........ 1A-33
Reinstall 1A-34
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
6.2 LUMBARSUPPORT. DRIVERSSEAT

MODELS. BERLINA AND CALAIS
-S
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.
SCREW
(20.0 - 25.0 N m)
OU TB OA R D C OV E R
I c
vtout'lrtru
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
A-A
sEcrroru 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 S E A T B A C K C OV E R
C A R P E T R E TA IN E R
edge of seat back carpet assembly(refer Fig. 1A-39)
ancl tape carpet up out of the way.
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 IN TE FIOR D OOR
H A N D LE C LIP
disengage'horse shoe' type retainingclip from slot
R E MOV A L TOOL
in splinedspindle,then removehandle.
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
I
U PF IIG H T & PAR ALLEL ]
T O F R AM E.
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
Reverseremoval operations,ensuringto adequatelyseal
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
attachmentto floor pan, then remove bolt and lower
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
_t 7 6 .0 m m OF T HE SPACER
^ SASH GUIDE.
-bULI
UPPER
A TTA C H ME N T
C OV E R WA V E WA S H E R
a BUCKL E S E A L WITH
,/ ASM. N ON H A R D E N IN G S E A LE R
SECT I O NA _ A
S E C T I O NB _ 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
sEcrtoNc-c r.. NON HARDENING
JtrALtsH
S E A T B E LT R E TR A C TOR C OV E R
Fagure1A-44
5. Remove cover and bolt securing seat belt buckle

assemblyto transmissiontunnel (refer Section B-B.
Fig. 1A-44)then removebuckleassemblv.
REINSTALL
Reverseremovaloperations,ensuringthat both lower bolt
threadsare sealedwith non hardeningsealerand 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(referSectionA-A. Fiq. 1A-45).
43
BODY 14.35
S LE E V E
RESTRAI NT
IN S E R T S LE E V E IN TO MOU N TIN G
7 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
S E C T I O NB _ B
Figure 'lA-45
e Depress front edge of seat cushion assembly re-

arwards to disengage assembly retainer from cusHloN ASM.-1 ; R EAR F LO O R
RETAINER \ I eR ncret
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 compart-
ment front panel (refer Section B-8, Fig. 1A-46)
remove, then place frame assembly on a clean
protected surface. 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 r C LIN C H
...OV E R TA B
S E C T I O NB _ B
Figure 1A-46
44
1A-36BODY
From inside rear compartment,tap out fasteners

securingtrim panel to rear parcel shelf (refer Section REAR PARCEL
A-A, Fig. 1A-47)disconnectretractorseat belt guides S H E LF TR IM
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 / (3PLACES)
inner panel (refer Section A-A, Fig. 14-49) remove tYfrn lnnrn
luur-ZtU.l1.l1
retractor assembly,feeding seat belt, buckles, etc. :-irlli=i:
1r
out throughslot on outer edge of rear parcel shelf. S E C T I O NA _ A
Figure 1A-47
Reinstall
R.everse.removal operations,ensuringthat the threads o{
all seat beft lower attachingbotts aie aJequitery seateO
harde.ningseatei (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 B OLTA

RETRACTOF
ASSEMBLY
/S\
N\/
i\/
ti
_-+-
ASSEIVIBLY r} sEcloN B-B -2pLACES
-t,
t A
JtrAL
C A NC HoRTo 8 E WITH N ON
VERT I CA L L Y - e OL r I sEcrtoN A-A -2pLAcES H A R D E N IN G
UPW A RD SW H E N ,/ S E A LE R
FITTED .{
u.-J WIT H NON
. / - S EAL
:-+y-. HARDENT NGSEAL ER
f
S A X IS OF S Y MME TR Y
ENSUREw,"i'r,c HARNESsr s c LEAR OF A N C H OR TO B E
P A R A LLE L TO V E H IC LE
t-ro.t
OF ANCHORWHENANCHO RI S FI TTED, A
IN FR ON T V IE W
sE cr to N C-C _ 2p LACES
secrroru
D-D
.,'l . so - ro i.r-
Figure 14-48
45
BODY 1A-37
#i3fitl?"fal'^ri;. n
t--'
cif.gl----=--h
ur DE
LN< 4
oF sASHGUIDE
l
i''' ,.
(f",- i '''\
SEAT BELT | -\:1-'.,',,
TONGUE=-
'' .-'.' ..".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 rcLE0 r r ur Ror ur
V IE W. N OTC H TOW A R D S
FR ON T OF C A R
srcrroruA-A
S E A L WITH N ON
HARDE N IN G S E A LE R
B E LT R E TA IN E R
eoLrA S LE E V E
.,/
qtv 'rB OLT,/ 1\
'p, secrroruC_C
( , ANCHOR T O B E V E R TIC A LLY U P WA R D SWH E N
,
S E A L W ITH N ON
F IT T ED. ENSUR E WIR IN G H A R N E S SIS C LE A R OF H A R D EN IN G S E A LE R
sEcrroruB-B ANCHOR WHEN A N C H OR IS FITTE D .
secrroru
D-D
A , uo- 7oN m
Figure 1A-49
46
BODY 1A.39
7. EXTERIORORNAMENTATION
INDEX
7.1 DESCR|PTION.................... ....... 1A-39 7.7 TAIL LAMP REVEALMOULDING
7.2 FRONTPILLAR DRIP MOULDING..............1A-46 ASSEMBLY ... 1A-48
Remove 1A-45 Models - SL and Berlina, 19 Body
Reinstall 1A-46 Styles ..........-.1A-48
7.3 DRIP MOULDINGASSEMBLYREAR..........1A.46 Remove ............1A-48
1A'46
Models - 19 Body Sty|es.............'......
Remove 1A-46
Reinstall ...... 1A-46
7.4 ROOF DRIP I'OULDING 1A-47
7.8
Reinstall 1A-47
7.5 FRONT& REAR DOOR SIDE MOULDING
1A-47
Model - Ca1ais............ ....- 1A-47
Remove........ ...........1A-47 7.9
Reinstall 1A-47
.......-.........
7.6 FRONTFENDERSIDE & SIDE PANEL
FRONTMOULDINGASSEMBLIES..............1A.48
Model - Calais 1A-48
7.1 DESCRIPTION
Exteriorornamentationon the VK seriesconsistsof deep with the base engine (E-S.T.) automatic transmission
section body side mouldingson Calais and wide section together with power steering,an 'Executive'applique is
body side mouldingson SL and Berlina19 and 35 body appliedto the quarterwindowson sedansand rear door
styles. The Commodore/Berlinaname appears on the stationary windows on station wagons. Belt line
rear of 19 and 35 body styles except on Calais, which mouldingsare fitted to all models (reler Figs. 14-50,
featuresa Calaisbadge on the rear compartmentlid and 1A -51,1A -52,1A -53,1A -54,1A -55).
front fenders.Calaisemblemsare also fitted to the front Clips,fastener studs, bushes,screws and contact adhes-
fender and engine hood. Holden and Lion badges are ive secure the various exterior mouldings,badges, em-
fitted to the lront and rear of all modelsexcept the front blems,etc. to the VK body styles.
of the Calais, which features a Holden badge on its The tailgatewindow exteriormouldingsare embeddedin
radiator grille. Badges for option engines and for the urethanesecuringthe windowin the tailgateaperture.
electronic iniection are fitted to the front fenders of Replacementproceduresfor these mouldingsare inclu-
sedans excepl on the Calais, which leatures these ded in the StationaryGlass Sectionof this Supplement.
badges on the rear compartmentlid. On models fitted
47
1A-40BODY
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50
BODY 1A.43
BUSH r TFRONT FE N D E R
1 P LA C E R /LH nsr,tt
I
7A
SCREW- 2 PL ACESR/L H
CL IP_ 2 PL ACESR/L H carrJ
1 P LA C E R /LH
secrtoruJ-J
secrroruS-S
7- S C R E W
/ 1 P LA C E R /LH
S E C TION R _R
R OOF D R IP MOU LD IN G _-
secrtoruU-U
secrroruT-T
C LIP
5 P LA C E S R /LH 69 & 19 S TY .
8 P LA C E S R i LH 35 S TY
V-V
secrroru
V \\
OUT ER DOOR H A N D LE
I NSERT
1O P LA C E S R /LH FR T. D OOR
8 P LA C E S R /LH R R . D OOR
srcrroruZ-Z
SECTIONAZ_AZ
D
S n e e r - v N o N H A R D E N TNsEAL
G ER
O V E RH O L E ST O E F FEC TA
A , . t - 2 .4N m WA T E R T I G H STEAL.
Figure 1A-53
51
14.44 BODY
O U A R T ER WINDOW
G A R N I S H M OUL DING
MOU LD IN G A S M. QTR WIN D OW

SECTION AN_AN GA R N IS H FOR IN S TA LLA TION
SECTI O NAP _ A P R E FE R S TA TION A R Y GLA S S -
NO TE : TH IS S U P P LE ME N T
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 S E C TION A M_A M
O T R WI N D O W G A R N I S H M OUL DING. 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
S E C T I O NA T _ A T
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 WA S H E R
5 PL ACES R/L H F RONT D OOR I P LA C E R /LH
3 PL ACES R/L H REAR D OOR
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
S E C T I O NA U - A U
6 PLACE S R / L H F R O N T D O OR L.
4 p L AcE sR/ LHRE A RDo6 ;" D R rL L2 s s I
![! o ,a H or_e
ON
OF WEL D ST UD AS CL OS E A S
POSSIBL ET O WEL D ST UD LOC A TION .
S E C T I O NA S _ A S
F O R E M E R G E N CU Y S EO N L Y
S E C T I O NA X _ A X
S E C T I O NAV_AV C LIP - 2 P LA C E S
SECTI O NAW _AW S E C T I O NA Y _ A Y
A r.r - 2 .4 Nm Q e e e r - v N o N H A R D E N T NsGE A L E Ro v E R
H O L E ST O E F F E C TA 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
S E C T I O NA E _ A E
SECTI O NAD_AD
DRrLL
2.3sI !l! o,o HoLEoN A"
/'I
OF WEL D ST UDS AS CLOS E A S SCREW

;
POSSIBL ET O WEL D STU D 1 P LA C E R /LH
L OCAT ION, 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 sEcrroNAF-AF GA S K E T
F O R E M E RGENCY USE ONL Y
S E C T I O NA K _ A K
r BUSH
2 P LA C E S R /LH
REAR L AM P
sEcrroNAJ-AJ
REAR BUM PER BAR * R OOF D R IP MOU LD IN G

)
REAR sM.\
SECTIO NAH_AH
SECT I O NA L _ A L
-A G
,A
2 . 4 - 3 .4 Nm
' I. 8 - 2 .4 Nm
S n e e l v N o N H A R D E N T NsGE AL EBo vER
A H O L E ST O E F F E C TA WA T E RTIGH SEAL
T
Figure 14-55
53
14.46 BODY
7.2 FRONTPILLARDRIP MOULDING

Remove BUSH
1 P LA C E R /LH
With.front door open, removethe screw and clip securing
moulding to front body pillar and front fender (refei 3 P LA C E S R /LH
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 C LIP
1 P LA C E R /LH
drip moulding as illustratedin Section U-U, Fig. 1,4-56
and that the screw securingthe centre of the mouldinoto SECTIONT_T
the front body pillar is adequately sealed with ion
secrrorvS-S
hardeningsealer.
R OOF D R |P MOU LD TN G
--
N \
\
\\ /
\bZzeY
z
( secrtoru
u-u
\.,-,,
Y 5 pLecEs
R / L H6 9 & 1 9 s r y .
8 P LA C E S R /LH 35 S TY ,
secrloruV-V
Q a e e r - v N o N H A R D E N T N sGE A L E Ro v E R
H O L E ST O E F F E C TA WA T E R T I G H S TEAL.
Figure 1A-56
7.3 DRIP MOULDINGASSEMBLYREAR

R OOF D R IP MOU LD IN G
Remove
Grasp.theleadingedge of the moulding,carefullypulling K\\\
it off the rear quarter window garnish moulding,aliowin! \\ IA\\
the trailing end of the drip moulding rear to oecome \ \N.

1^ @9)) srcrroru
U-U
disengaged(refer SectionAM-AM, Fig. tA-57).
// v>
(( R OOF D R tP
tleinstall \ MOU LD IN G
Locate the rear hooked edge of the mouldingover the sEcrtoNAL-AL

rear.-quanerwindow 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.
MOU LD IN G A S M. OTR 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
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.14-
58, under top of front pillar drip moulding,carefully
ease top of pillar mouldingoff front end of roof drip
moulding(referSectionU-U,Fig. 14-56).
3. Using a similarprocedurewith Tool No. 1A7, remove
the roof drip moulding,carefullydisengagingrear end
of roof drip moulding from top of drip moulding
assemblyrear (referSectionU-U, Fig. 14-56).
Reinstall Figure 1A-58

Reverseremovaloperationsensuringthat the ends of the
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
adequatelysealedwith a non hardeningsealer.
7.5 FRONT& REARDOORSIDE

MOULDINGASSEMBLIES
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
screwdriver,carefullyprise upper section of moulding
assembly out of retaining bushes (refer Section FA S TE NE F
AR-AR, Fig. 1A-59)then raise mouldingassemblyoff S TU D
the clips securingthe lower section of the moulding
assembly to the door (refer Section AS-AS, sECrroNAS-AS
Fig. 1A-59).
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
Reinstall 3 P LA C E S R /LH R E A R D OOR
Reverseremovaloperations. 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
sEcrroNAU-AU
sEcrroN AT-AT
Q n e e l v N o N H A R D E N T NscE A L ERo vER

H O L E ST O E F F E C TA WA T E R TIGH SEAL
T
Figure 1A-59
55
1A.48 BODY
7.6 FRONTFENDERSIDE& SIDE PANEL

FRONTMOULDINGASSEMBLIES
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
illustratedin SectionAT-AT,Fig. 1A-59.
NpJe: Rear compartmentlid 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 correspondingpanel
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 GA S K E T
using a wide bladedscrewdriver,carefullyprise lower
section of moulding out of retaining-bush (refer S E C TION A K _A K
2 P LA C E S R /LH
SectionAJ-AJ,Fig. 1A-60).
Reinstall
A 1.8 - 2.4 N m
Reverse removaloperationsensuringto adequatelyseal A,
/z\, 2.4 - 3.4 N m
the attaching screw with non hardening sealer as sE crtoN A J-A J
illustratedin SectionAK-AK,Fig. 14-60-
Qneel v N oNH A R D E N TN
sEGA LE R
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
Figure 1A-60
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 mouldingassembly.
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) .
56
BODY 1A.49
A S E C T I O NA X_ AX
NUT
4 P LA C E S
S E C T I O NA W_ A W
Onppl v N oN H A B D E N TN Gs E A LE R
OV E R H OLE S TO E FFE C T A
WA TE R TIGH T S E A L.
A 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
R E A R E N D P A N E L A S M.
sEcrroNAG-AG
A t.t - 2.4N m
Figure 1A-62
57
I
1A-50BODY
7.9 MOULDINGASSEMBLYREAR
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
illustratedin SectionAV-AV,Fig. 14-63.
sEcrtoN AV-AV
Q n n e r - v N o N H A R D E N T N sGE A L E Ro v E R
H O L E ST O E F F E C TA WA T E R T I G H S TEAL
Figure 1A€3
7.10 EMBLEMASSEMBLYHOOD
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 removeemblem-
Reinstall C LIP - 2 P LA C E S
!9ve1s9 removal operations ensuring that the tubular sEcrtoN AY-AY

clipsfullyretainthe embrem.
Q n e e r - v N o N H A R D E N T NsGE A L E Ro v E R
H O L E ST O E F F E C TA WA T E R T I G H ST EAL.
Figure 1A-64
58
BODY 1A.51
8. ROOFRACK
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59
BODY 1A.53
9. BODYELECTRICAL
INDEX
Ref. Subject Page Ref. Subiect Page
9.1 DESCRIPTION .... 1A-53 9.6 LIMIT SWITCHASSEMBLY ... 1A.61
9.2 EXTERIORREAR VIEW MIRROR& Remove........ .....................
1A-61
MOTORASSEMBLY 1A-54 Reinstall .... 1A-61
Remove ........1A-54 9.7 ELECTROIIICTODULEASSEMBLY..........14.62
Reinstall ..-........1A-54 Remove.....-.. 1A-62
.....................
9.3 SWITCHASSEMBLY. EXTERIORREAR Reanstall .... 1A-62
vtEwMrRRoRs................. ......lA-ss CABLE ASSEMBLY 1A-62
Remove........ 1A-55
..................... Remove.-...... 1A€2
Reinstall ... 1A'55 Reinstall 1A-64
9.4 SUNROOFSLIDINGGLASS PANEL ..........1A'55 9.9 SLIDINGSUNROOFMOTORASSEMBLY.. 1A.65
Remove......._ 1A-55
...._................ 1A-65
ilotor Assembly Remova|..................
Reinstall 1A-55
............... Motor Assembly Feinstallation....-..-.. 1A-65
Vertical Adjustment ol Sliding Motor Drive Gear Removal....--..........1A-65
Panel 1A-59
................-..... Motor Drive Gear Reinstallation........1A-65
9.10 SYSTEMTlMlNG...--.... ..--..........
1A-66
Reinstall 1A-60
................
9.1 DESCRIPTION located under the transmissionconsole (refer View A,

Fig. 1A-67).
The electrically operated e!.terior rear view mirror
assemblyfitted to Calaismodels consistsof a mirrorwith Choice of the mirror to be adiustedinvolvespushingthe
its electric drive motor contained in the door mounted raised bar of the switch to the left or right. Depressing
mirror housingassembly(refer Fig. 1A-66). the four way directionalarrows illustratedon the upper
face of the switch will provide the desired mirror
The electric motor, which is activated by a switch adjustment.
mounted onto the transmissionconsole (refer View A,
Fig. 14-67) providescompleteadiustmentof the mirrors. Electricallyoperated venting sun roofs are released as
ProductionOption CF5 for 19 body styles except 'SL'
An 'ln-line' one amp fuse and holder assembly is models.
attached to the mirror switch electrical harness and is
60
1A.54 BODY
7l
' ,'-..,
\\ E X T E R I O RR E A RV I E W
\ M t R R o RA N D M o r o R A s M .
. uMrRnoR coNTRO-
CONDUIT
A o .tg- r 19Nm
Figure 1A{6
9.2 EXTERIORREAR VIEW MIRROR&

MOTORASSEMBLY
REMOVE
1. With the front door window in the lowered position,
disconnectthe 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,disengagemirrorassembly
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
61
BODY 1A.55
9.3 SWITCHASSEMBLY. EXTERIOR E S C U TC H E ON

REARVIEW MIRRORS \
\
E X TE R IOR R E A R V IE W --\
REMOVE MIR R OR S S WITC H N S IT,I.\.
1. Disconneclbatteryground cable.
2. Using a wide bladed screwdriver,carefullyprise cap
and bezel covering top of switch assembly (refer
View A, Fig. 1A-67)'fromtransmissionconsole.
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.
T R AN SM ISSIO N
C O N SO LE
Figure 1A-67
9.4 SUNROOFSLIDINGGLASS PANEL

REMOVE
1. Place sunroofslldingpanel in VENT position.
2. Slide sunshadelull rean'vard'
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
62
1A.56 BODY
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64
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 DEFLECTORFRAME

REMOVE
1. Placeslidingpanelin 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 housingstuds-
REINSTALL
Reverseremovalooerations.
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 installationof 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
MODULEASSEMBLY
REMOVE
1. Removeweltanddropheadliner at frontof housing.
2. Uncouple connectorat moduleassembly.
3. Removescrewsattachingmoduleassemblyto roof
rail(referFig. 1A-75).
REINSTALL
Reverseremovalooerations.
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 headlinerat rear of housing.
2. Remove__cableguide lower retainer cover (reter
Fig. 1,4-76).
3. Disengagecablesfrom 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
5. Move trough rod and cable assembliesreanarardof

notch in track, to slide front guide shoes reanivardto
notch,rotate and remove(refer Fig. 1A_72).
6. Rotate right hand front guide shoe fonivardto remove
trough assembly(refer Fig. 1A-77).
7. Remove sunshadeby adding a slight hano pressure
upwardto disengagefront track.
8. Remove three (3) screws retainingeach track (refer
Fig. 1A-78).
9. Lift front of track up and disengagefrom 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).
Figure 1A-77
71
BODY 1A.65
Figure 1A-78
9.9 SLIDINGSUNROOFMOTOR
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.
MOTOB
4. Removetwo (2) hex head screws attachingmotor to A S S E MB LY
mounting brackets using 7 mm socket (refer
Fig. 1A-79).
MOTOR ASSEMBLY REINSTALLATION

ReverseremovaloPerations.
\b
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).
MOU N TIN G
MOTOB DRIVE GEAR REINSTALLATION
BRACKET
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 SYSTEMTIMING
1. Remove drive gear from motor as describedin g.9
Sliding Sunroof Motor Assembly,Motor Drive Gear
Removaland Reinstallation in this Section.
z. 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 Reinstallationin thts
Section.
73
BODY 1A.67
10. SPECIALTOOLS
F A B R I C A TED T RIM CL IP REM OVAL T OOL
Uf,MM
- E N D C ON S TR U C TION
t_ TO S U IT H A N D LE
R E OU IR E ME N TS
f
mm- <-75.0 mm---
_ ^ 9 .0
1^8 .0 mm- - 10.0 mm D IA
- 8 .5 mm
G L A S S S EAL ANT R OOF S ID E MOU LD IN G R E MOV A L TOOL

R E M O V A L T OOL
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
RADIATORGRILLE1C.1
SECTION1C
RADIATORGRILLE
INDEX
Ref. Sublect Page Ref. Sublect Page
1. DESCRIPTION 1C-1 1.1 SERVICENOTES rc-r
Remove 1G l
Reinstall 1C- 1
1. DESCRIPTION
The new one piece plastic radiator grille fitted to VK models, they are painted cool or warm grey, depending
series is painteil silver on Calais model, whilst on other on the body colour'
1.1 SERVICENOTES
Remove
1. With enginehood raised,removescrewssecurlng
grilleto radiatoruppersuppctrt (referFig. 1C'1).
2. Easetop of grillefonrvard, lift grillepegsout of
then
grommets installedin the bumperfacia.
Relnstall
NUT l
2 PL ACES \
A
g S C R EW
\ 2 P L ACES
& -,/---'- 7/
A/
scREl/-\6tr
-7
A . . u - 4 .6N m
/ |^r o- 3. 4 N m
Figure 1C-l
75
76
1D.1
FRONT& REAR BUMPERBAR ASSEMBLIES
SECTION1D
FRONT& REARBUMPERBAR ASSEMBLIES
INDEX
1. DESCRIPTION 1D -1 1.3 REAR BUMPERBAR ASSEMBLY 1D-4
1. 1 SERVICENOTES tD -1 Models 19 Body Sty1es............ 1D- 4
lntroduction. 1D -1 Remove........ 10-4
Recommended Materials 1D-2 Disassemble 1D- 4
Reassemble 'tD-4
GolourFinishing of Replacement
Parts 1D-3 Reanstall.. 10- 4
1D-2
Repairing Colour Coat .'...................'.. Models 35 Body Sty1es............ 1D-6
Warning - Use of BodY Remove 1D-6
Golour Lacquer........ 1D-2 Disassemble 1D-6
1. 2 FRONTBUMPERBAR ASSEMBLY............ 1D-3 Reassemble 1D-6
Remove........ 1D-3 Reinstall 1D-6
Disassemble 1D-3
Reassemble 1D-3
Reinstall 1D-3
1. DESCRIPTION
Front and rear bumper bar assemblies titted to VK styles,the finishingstripscoverthe completeupperedge
models are of polycarbonateconstruclion.Brightfinishing of the rear bumperbar assemblywhilston the 35 body
strips featuringa rubber upper edge are clippedover lhe styles these finishrngstrips are fitted to the rear bumper
top edge ol the side and part ol the centre front bumper faciasonly (reterFigs. 1D-1,1D-2,1D-3and 1D-4).
facias.-Onthe rear bumper assembliesfitted to 19 body
1.1 SERVICENOTES
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
solvents are applied the polycarbonatewill be damaged
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.
The following service recommendationsare compiledto

guide Dealerships,on the correct materialsand methods
to be employedwhen refinishingVK Series bumperbars
and side mouldings,also when preparingnew parts for
serviceinstallation.
77
1D.2 FRONT& REAR BUMPERBAR ASSEMBLIES
RECOMMENDED MATERIALS Bumper)The paint repair area should be to the nearest

convenientbreakline.Spot repairsare not recommended
Irol.9nq rear bumperbars and side moutdingsinstalled due to possiblecolour match problems.
to VK Series are made from high impaCt strength
polycarbonateplastic.
It is essential that only GMH approvedmaterials,paints 1. 91l9il9 - dependingupon the degree of damage,
and thinners, be employedwhen paint repair operations P320 (or.coarsergrit).wet or Ory sa-ndpapermay be
are performedand when preparingnew parts lor installa_ requiredfor initialsanding.Finishsand wiin eCOtigrit
tion to the vehicle. paper to remove sanding marks and dry scuff
Lll
over the whole of the area to be resprayed.
Use of the wrong materialswill affect finishedqualitvand
will affect the polycarbonatematerial. 2. Cleaning - wipe the area to be paintedat least twice
with a clean cloth soaked in meihylatedspiritswiping
The GMH approvedmaterialsare: dry with a new clean cloth each time.
. MethylatedSpirits- for cleansingbeforepainting.
3. Painting - mix the polycarbonatelacquer with appro_
r Paint - Berger PolycarbonateLacquerin the following ved.thinners(approximately1:1 ratio) and spray'the
cotours: repaired area to build colour followed by one wet
coat all over to achieve colour uniformitv.
S ilver G MH4 J 0 2 2 - Be rg eHr H 9 9 9 1 4. Drying - allow 10 minutesair flash then use a heat
Warm Gre y G MH4 H 0 1 6 - Be rs eH r Hgg89 tamp or similar set up to warm the painted surface
f9r
C ool G r e y G MH4 H 0 1 5 - B e rg eHr H g 9 9 0 99 minutes. (Surface temperature of the part
should not exceed gOoC) Lamp baking will speed
. Thinner- Berger LT2p6. removal of the special slow solvents in-the laiquer
The Berger lacqueris a specialacryliclacquerdeveloped and hardenthe paintfilm.
for polycarbonateand requires NO primer. The pol-
ycarbonateparts are moulded in-colourfor ease of top WARNING. USE OF BODY COLOUR LACQUER
coating. When ordering spare parts quote the GMH
colour number and name,for exampleWarm Grey (GMH Normal lacquersused for refinishpaintingof sheet metal
4H0 1 6 ). are not suitable for repainting the VK polvca;gon"r"
bumpersand side mouldings.
COLOUR FINISHING OF REPLACEMENT PARTS

Spare parts are suppliedunpainted,to be coated before
installationto 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 rectifiedby dry sandingwith-pa0Opaper.
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 polycarbonatelacquer to spraying
viscosity with approved thinners (approximately -1:i
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 minutesair flash then use a heat
tamp or similar set up to warm the paintedsurface
{or 30 minutes (part surfacetemperaiureshould 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 circumstancesshouldpaint be
washed otf with lacquer thinners. (i.e. Sections of the
78
FRONT& REAR BUMPERBAR ASSEMBLIES1D-3
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).
3. With Jront bumperbar assemblyfully supportedand
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
Reverseto disassemblyoperations.
REINSTALL
Reverseto removaloPerations.
F R O N T B UM PER h
B A R A S M.
\
/
-\\
,/ ah,",
FRoNT
reruoea/ +-<'
PANEL t r-/.
; .(
A
/1 \ ,/
t{.. -,,,)1 *,r
S C R E WA S M.
1 P LA C E R /L l:t
I
fl
i: .L
t1
F RONT BUM PER BAR

INNER ERACKET ASM - R & LH
zl.
\Yfl-" secrtoruC-C
BOLT 4L
2 PL ACES Ri L
\J FR ON T FE N D E R l
WASHER
u,r*E PANEL
\
.
2 PL ACES R/L SCR E Wl \

2 PL ACESR/L FA S TE N E R-I \
! 'r P LA C E R /L
__if f_
secrtoruA-A \ 7-,
F RONT F ENDE R J g
PANEL R/L
A 4 0 - 5 4 Nm
S E C TION B _B
A
11\ 8 - 1 1 Nm srcrtoruD-D
Figure 1D-1
79
1D-4FRONT& REAR BUMPERBAR ASSEMBLIES
,,6\scR.*
4 PL ACES
R&L SIDE
NUT
A FTE R A S S E MB LY OF B U MP E R B A R -
FRONT 4 PL ACES
LOC A TE A N D S N A P C LIP FIN IS H E R
B U M P E R BAR N d L JIUE
S TR IP SR /L OV E R B U MP E R B A R A S M,
B R A C K E T ASM .
secrroruB-B
secrroru
A-A
sgcrroru
C-C
R H S I D EF A C I A
5- R H F IN ISH tN G ASSEMBLv
ant 7- CENT RE F ACIA - \ST R IP 7
5ilocer\ ASSEM BL Y \ /
R&L SIDE
L H F IN IS HIN G
\
S T RIP ,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 wa5H5q---.7s
,:. 2(
A 10-' r 5 N m , I'NUTJ
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 BUMPERBAR ASSEMBLY

MODELS 19 BODY STYLES
Remove
1. From under rear quarter panels, remove screws
securinglower section of side facias to rear quarter
panel(referSectionC-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 unscrewlicenceplateholder
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
finishingstrips.
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 removeside facia(s).
Reassemble
Reversedisassemblyoperations.
Reinstall
Reverse removal operationsensuring that the sealing
instructionsfor the rear bumper bar assemblvattachino
screwsand nuts illustratedFig 1D-3are observed
80
FRONT& REAR BUMPERBAR ASSEMBLIES1D.5
R H FIN IS H IN G S TR IP l \
R H S ID E
= FA C IA A S M.
-4t\
7;i l'
*
Z".---
l4.l \.r*r*. ro",o
A S M.
C ENT RAL IZ E AND SNAP_ CL IP
F INISHER ST RIPS OVER \.*
BUM PER BAR ASSEM BL Y r,o.
FA C IA A S M.
A FA STE NE R
l P LAC E R & L
SCREW
, 7 - 2 PL ACESR&L
secrtonC-C
A ,Ar scnewl
NUT _ 2 PL ACES 4P LA C E S R & L/
SECTIONA - A
WAHSER _ 2 PL AC E S J NUT---T\
4PLAC ESR &L
T SCREW
\ 2 PL ACESR&L
S E C T I O NB _ B
S E C TION D_D
V
V E-' -E
SECTI O NE_E
Q n e e l v N oN H A R D E N IN G S E A LE R
AROU N D 8U I.1P E CA TTA C H ME N T H OLE S
A 6- 8 Nm
A , o- 2 7N m u,r *lIl R&L s r D E

A 8- 1 1 N m
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 assembliesfrom top of centre
facia and disconnectelectricalconnectors.
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 bum-
per 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 removefinishingstrip(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
Reversedisassemblyoperations.
Reinstall
Reverse removal operationsensuring that the sealing
instructionsfor the rear bumper bar lssembly attachin!
screwsand nuts illustratedin Fig. 1D-4are observeo.
82
FRONT& REAR BUMPERBAR ASSEMBLIES1D.7
R H F IN ISH I N G
FIH S ID E ST R IP
FA C IA A S M.
LH F IN ISH IN G
_4
---D
I i>!P - C E N TR E FA C IA A S M.
SNAP- CLI PFI NI SHERS T R I PR / 1 . l a .

O VERBUM PERBAR A S S E M B L Y , LH S ID E FA C IA A S M.
g
"h"
WA S H E R
2 P LA C E S
B U MP E R A S M
S E C T I O NC _ C
r NUT
secrromA-A WASHER
I + pr-aces Rlr-
2 PL ACES SCREW .,
4 P LA C E S R /L,/3'
SCREW
2 PL ACES Ri L
S E C T I O NB - B
S ecrl Ot'D
t -D
SECTI O NE- E
/\ 6-8 Nm
O
vrEWlAl R/LsrDE
Q a e e lv No N H A R D E N TN GS E A LE R
A 1 2 - 1 6Nm AROUND B U MP E R A TTA C H ME N T H OLE S
A 8- 1 1 Nm
Flgure 1D-4
83
5 ta t-. k
VENTILATION& HEATING2A.1
SECTION2A
VENTILATION& HEATING
INDEX
1. GENERALDESCRIPTION 2A-3 1.5 BLOWERMOTOR......... 2A-9
1. 1 2A-4 Remove........ 2A'9
2A-4 Reinstall 2A-9
2A-4 1.6 BLOWERMOTORHOUSINGASSEMBLY..2A. 10
2A-4 Remove........ 2A- 10
244 Reinstall 2A- 10
2A-4 1.7 HEATERASSEMBLY-....... 2A-11
1. 2 SERVICENOTES 2A€ Remove........ .........-.....-....
2A-11
1. 3 UPPERSIDEVENT OUTLETS.RIGHT & Reinstall ..- 2A-11
LEFT HAND 2A-6 1.8 HEATERCOREAND PIPEASSEMBLY......2A-13
Remove.,...... 2A-6 Remove........ ....................
2A-13
Reinstall 2A-6 Reinstall ... 2A-13
a
1. 4 MOOESELECTION,TEMPERATURE 1.9 WATERVALVEASSEMBLY.HEATER
CONTBOLAND BLOWER FAN SWITCH.. 2A-7 coRE .-........ --_-.--2A-14
ilodels - A11.........-..-.. 2A-7 Remove..-..... ....................
2A-14
Remove 2A-7 Reinstall ... 2A-14
Reinstall 2A-7
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
The ventilatingand 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 assembliesand to be heated,
mixed or allowed to remain at ambient temperature,as
required.The air then enters the passengercompartment
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
illustratesthe air flow within the heaterassemblywith the
variousmodesactivated.
On sedans, air from the passenger compartmentex-
hausts throughventilatoroutlets located behindthe right
and lelt hand side drip mouldingassemblyrear,illustrated
in Fig. 2A-3. On stationwagons,the air is exhaustedvia
the edges of the rear quarter inner trim panels,into the
roof, then out into the atmospherethroughtailgatehinge
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
tilting and/or swivellingthe ventilatorupper outlet inserts.
To slop the air supply from the upper side vent outlets,
rotate the regulatingwheel to the right,and on the centre
air outlet. rotate the wheel downwards until a stop is
reached. Figure 2A-3
The heatingsystem utilisesan air mix principlewhere the
temperatureof air enteringthe passengercompartmentis
controlledby a temperaturelever illustratedin Fig. 2A-2
which operates the mixture door. This regulates the
volume of air passingthroughthe heatercore.
The temperature, mode and blower motor control
assemblyilfustratedin Fig. 2A-2 consistsof a four speed
fan switch,which regulatesthe 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
right hand lever,the particularmode required.
OUT ER UPPER :Ii

AIR OUT L ET
HOUSING ASM .I
\
./l
OUT ER UPP E R
i{
N'
@
V
v ffi
SCREW
{ 4 PL ACES)
'q R E GU LA TIN G WH E E L
\
OUT EF L OWER AIRI LOWE F LH
OUT T ET INSERT ASM I N S TR U ME N T
PANEL
Figure 2A-4
1.1 MANUALCONTROLS
The mode control leverhas five positions:
DEM
In this positionthe air flows onto the windscreenthrough
the demistvents on top of the instrumentpanel-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
adjustedat 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 ventilationsystem.This setting is only
recommendedto 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 selectinga highernumber.
;C E N TR E A IR
r LH D E MIS T N OZZLE / D IS TR IE U TION D U C T
D U C T A S S E MB LY
-\
\S C R E W
L H A I R O U T L ET DUCT
llrJ' I
nH J
A IR OU TLE T
DUCT
j4 L R s D E tutsr N ozzLE
D U C T A S S E ME LY
. H E A TE R A S S E I\4B LY
E L OWER M OT OR - ' . B LOWE R IV OTOR H OU S IN G

H O U SING ASSET \4 BL Y TO H E A TE R A S S E ME LY D U C T
Figure 2A-5
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2A.6 VENTILATION& HEATING
1.2 SERVICENOTES
The non air conditioned air ducting on VK Series
illustrated in Fig. 2A-5 as polypropolene tubing with
matingindentationsand protrusionswhich retain the ends
of the ductingtogether.Screwsinstalledthroughthe right
and left hand air outlet ducting to the centre air
distributionduct, 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 necessitatesremoval 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
cluctingnecessitatesremoval of the touch control panel
and the instrument panel location cover illustrated in
Fig. 24-6.
1.3 UPPERSIDE VENT OUTLETS,RIGHT

& LEFT HAND
REMOVE
Usinga fine bladed screwdriver,carefullyprise right hand
and left hand upper and lower inserts from within side g O U T E RU p p E RA t R
vent upperassembliesprior to removingscrews,securing ,
ourlErlNSERrAsM.
the upper air outlet assembliesto ths instrumentoanel \
.// ,
pad assembly as illustratedin Fig. 2A-7, then remove
outlet assembly. ,/' ,i \
REINSTALL
Reverseremovalprocedures.
/,(v\
/,/u
-\Yg....f/^@ia
scREw_
rffi \Lg! \ - o u r E R _ L O WE R
A tR OU TLE T
(4PLACES)
i,vsa*t nsrr,r.
LOWE R LH -'
IN S TR U ME N T
PANEL
Figure 2A-7
-
TEMPERATURE
1.4 MODESELECTION,
CONTROL AND BLOWER FAN SWITCH
M O DE LS . AL L
Remove
1. Disconnectthe batteryearth cable.
2. Remove the transmissionconsole assembly (refer
2.2, Body Sectionof this Supplement).
3. From the left hand side of the heater assembly'
disengagethe front end of the control cable from the
temperaturedoor rod, illustratedin View B' Fig. 2A-8.
4. Remove the touch switch control panel and the
centre nozzleand instrumentlocation{rame assemb-
ly illustratedin Fig. 2A-9.
5. Remove the temperature,mode, booster fan and
wiper dwell control knobs.
6. Remove the lower instrumentpanel enension illustr-
ated 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
partly ease out assembly,disconnectingmode con-
trol vacuumhoses and electricalconnector'
8. Remove ihe rear end of the cable from the
temperaturecontrol lever.
Reinstall
E _ FOF C ON TIN U ATION

B E FE R S E C TIO N 12E
\
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vrw@ l:7{
A S S E M B L E NUM BERED HOSES I ' ./
T O C O R R E CT PORT ON VAL VE \- ? - -
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I N S T R U M ENT PANEL
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FU LL FoR WA R D -z sN A p l N
WITH TE MD E R A TU R E Z
LE V E R IN D OWN P OS ITION
H E A T E R VENT IL AT ION
u , a *@
C O N T R OL ASSEM BL Y E E FOR E S N A P P IN GC A B LE IN , P OS ITION MU S T B E
F U LL FOR WA R D (A S S H OWN ) WITH TE MP E R A TU R E
C A UT ION NOT E _ NO KINKS IN HOSE S LE V E R IN D OWN P OS ITION .
Figure 2A-8
2A-8 VENTILATION& HEATING
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1.5 BLOWERMOTOR
REMOVE
1. Disconnectbatteryearth cable.
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 ).
JL ^NS
)\A{1'LIP-4PLACES
1 LOWE R P A R T
I N S TR U ME N T
PANEL
A-A
sEcrroru
Figure 2A-10
3. From under the instrument panel, disengage the

blower motor to main wiringharnessconnector,then
supportingthe blower motor, removethe two screws
securingthe motor to the blower housingillustrated
in Fig. 2A-11,removingthe motor.
REINSTALL
Fleverseremovalprocedures.
a LH A IR IN LE T
\ D E F LE C TOR - SCREW
(2 P LA C ES )
s RH AIR INL ET
DEF L ECT OR
LAI R IN I- E: SEAL R IN G
Figure 2A-11
2A-10VENTILATION
& HEATING
1.6 BLOWERMOTORHOUSING
ASSEMBLY
REMOVE
1. Disconnectbattery earth cable and blower moror to
main wiringharnessconneclor-
E U MP E R-
2. From under left hand of instrumentpanel ano usrng (2 P LA C E S )
a fabricatedtrim clip removal tool (iefer 10 Speciai
Tools at the end of Section 28) remove the instru-
ment 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 compan-
ment side, prise the hinge pin into the compartment
as illustrated in Fig. 2A_12, then remove the
companment.
5. Removethe blowermotor housingto heaterassemb-
ly duct illustratedin Fig. 24_13.
6. From the base of blower motor housing,remove bolt IN S TR U ME N T P A N E L
C OMP A R TME N T
securing lower part of housing to le'ii hano dash
panel lower,illustratedin Fig. 2A_13.
7. Removethe nuts securingthe blower motor housing Flgure 2A-12
to the studs attached to the left hand side of the
plenum chamberillustratedin Fig. 2A-13, removtng
the housingassembly.
REINSTALL
-.:/'
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,1 - tr o ,tT
7. 5 - 1 0 N m \- *-
B L OWER M OT Otr
2
H OUST NGASSEf,r Br y
Figure 2A-13
J
& HEATING2A.11
VENTILATION
1.7 HEATERASSEMBLY
REMOVE
2. Disconnectthe vacuumfeed hose at the check valve
R OU TE H E A TE R H OS ESB E TW E E N
then from inside the engine compartment,remove P OWE R U N IT MOU N TIN G B R A C K E T
the rubber grommetfrom the dash and the coolant A N D R OC K E R C OV E F,
hoses from the inlet and outlet heater core oioes
illustratedin Fig. 24-141
CAUTION:The heater can easily be damaged in the area V IE W
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 OU TLE T H OS E
remaining on the tube should then be split longitudinally.
Once the hoses have been split, they can be removed IN LET H O SE
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
assemblyduct illustratedin Fig. 2A-13.
6. Remove the ends oi the ducting attached to the
heaterassemblyillustratedin Fig. 2A-15.
- cFC r.r..' =- r '
7. Remove the bolt securing the lower part of the
heater assembly to the floor pan bracket, as B E FOR E TN S TA LLA TTON \.-..
illustratedin View A Fig. 24-13. OF GR OMME T, P U S H ( * L
V A C U U M S OU R C ETO C H E C K '-S \.-
8. Removethe two bolts securingthe top of the heater V' - U
ÛNtrU
\ AI I
C ' r \ \ ^L ' -
V A LV E H OS ETH R OU GH
assemblyto the instrumentpanel brace as illustrated cR oMME ruPro rA B N o.4 C\
in Fig. 24-13, then removethe heaterassembly. Frr GR oN l N 4E rovE R H E A TE R \;v
P IP E SA N D I\TO D A S H P A N E L. )
REINSTALL E N S U R E P R OP E RFIT A N D S E A L,
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
proceduresare operatingeffectively. Figure 24-14
,T C EN T R E AI R
z- LH D E MIS T N OZZLE / D r s r R r B L r t o r 'JDU C T
D U C T A S S E MB LY ,
- R H A IR OU TLE T D U C T
L H AIR OUT L ET DUCT
R H D E MIS T N OZZLE
D U C T A S S E MB L Y
H E A TE R A S S E MB LY
BL OWER M OT OR B LOWE R MOTOR H OU S IN (J

HOUSING ASSEM BL Y TO H E A TE R A S S E MB LY D U C T
Figure 2A-15
rl- t---
2A,.12VENTILATION& HEATING
>R >
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ta
& HEATING2A.13
VENTILATION
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 assemb-
ly from the heater case.
REINSTALL
LE V E R - 2 P E R
C OR E & V A LV E AS M
_ B R A C KE T "A "
NtrA ICN LUHtr
r S CR E W
\'.//\
;, ,/
!'J
-
LA IR MIX T.JU
Mrx D OORU HU
C ON N E C TIN G R OD
\ -A rH
L R OD R E TA IN IN G C LIP - 2 P E R
Figure 2A-17
1.9 WATERVALVE ASSEMBLY-

HEATERCORE
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 rubbergrommetserling the heatercore
ptpespassrngthroughthe 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
securingthe water valve assemblyto the heatercore
prpe illustratedin 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.
,-WA S H E R -4P E R
B OLT - 4 P E R
r WA TE R V A LV E A S M.
TEATER CORE-r
.\
GASKET
O' RING
_ ROD RE TA IN .
AND A D J. C LIP
R E TA IN , B K : .J
S EA L
\- H E A TE R C OR E
V IE W
U P P E RS E A L
Figure 2A-18
28-1
AIR CONDITIONING
SECTION28
AIR CONDITIONING
INDEX
1. GENERALTNFOFMATTON 2B-1
............................ 3.4 COMPRESSOR INSPECTION
2. GENERALDESCRrPT1ON.............................. 2B-3 PROCEDU RES...._...._....._.___. 2g-14
2. 1 MANUAL CONTROLS 2B-3 Leak Test 2B-14
'DEiI' 2B-3 CompressorSmoothness Test..........2B-14
'FLOOR' 2B-3 Glutch Test .............. 29.14
'VENT' 2B-3 Nolse....................... 28-14
'BI LEVEL' 2*4 Remove.......,. 28- r 6
'NORM' 2B-.4 Relnstall 28- 16
'MAX' 28.4 Disassembly 28- 16
'OFF' 2H Reassembly 28-18
Retrlgerant Glrcult 2B-5 Air Gap Adiustment.. 28'-20
Gompressor 2B-8 3.5 EVAPORATORASSEMBLY 28'20
Thermostatlc Swltch 2B-9 Remove 28,-20
Evaporator.. 2B-9 Reinstall .............
2B-2s
Thermostatlc Expanslon Va1ve.......... 2B-9 3.6 EVAPORATOBCOREAND PIPE
Recelver Dehydrator.. 2B-9 ASSEMBLY 29-27
Condenser 2B-9 Remove............... 28,-27
3. SERVICEOPERATIONS 2B,-11 Reinstall 2V27
3.1 COilPRESSORDBIVE BELT TENSION i 3.7 CONDENSOR AND AUXILIARYFAN
AND ADJUSTMENT.... 2B -11 ASSEMBLY 29-27
s.2 CHECKINGCOMPRESSOR OIL CHARGE Remove........ 29-27
ON VEHICLE 2B.11 Relnstall 28-27
Addlng Oll Durlng Component AUXILIARYFAN 28-27
Replacement 2B-11 Remove ........-..28-27
Compressor 2B-11
Reln8talllngthe Orlglnal 3.9
Compressor 2B-11
Installlng a New Compressor.. 2B -11
Evaporator.. 2* 11 4.
Condenser 28-11 5.
Revelver Dehydrator.. 2g-11
REFRIGERANTSYSTEMCHARGING........2B.-12
Fllllng Charglng Cyllnder ..........2B-12
Installatlon of Charglng
2B-12
Chargfng System . 28-13
Eyacuatlonand Leak Test........ 28-13
Purglng (lf Necessary) ..-........... 2B-13
Charglng System . 28-13
FunctlonalTestlng ot System.. 28-13
1 . GENERALINFORMATION
The Air Internationalair conditioningsystem used on VK The following information provides basic service
models is a cycling clutch system with thermostatic operationsfor the C.C.T.X.V.air conditioningsystem'
expansionvalve (C.C.T.X.V.) and a Sanden TR 70 Spiral includingthe TR 70 SpiralCompressor.
Compressor-
L
2B..2AIR CONDITIONING
Figure 2B-1
1
I;FL-
E LOWE R MOTOR -.4'l P, o
S WITC H "
f*
VENT
8l
NORM
MAX
TE MP E R A TU R E _
DE M I S T C ON TR OL
H E A T,'V E N T/A IR C ON D . C ON TR OLS
VENT
ci
e\.
'1
VENT BI_ L EVEL MA X A N D N OR M B LOWE R (R E R C IR C )

FOR OFF A N D MA X .
Figure 2B-2
J --^
--
28.3
AIR CONDITIONING
2. GENERALDESCRIPTION
The VK cycling clutch and thermostaticexpansionvalve
(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 levers-
Air entering the air conditioning/heating system via the
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
assemblies,then out throughthe variousoutlets into the
passengercompartment.
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 passengercompartmentex-
hausts through the ventilatoroutlets located behind the
right and left hand side rear drip mouldingassemblies,
illustratedin Fig. 2B-3.
On station wagons, the air is exhaustedvia the edges of
the rear quarterinner trim panels,into the roof, then out
into the atmospherethroughthe tailgatehinge pockets'
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
selectionof the particularmode required.The mode lever
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
the settingrequiredto demistthe windscreen.
'FLOOR'
In this position,the main air flow is directedto the Jloor
outlets with a small amount of air going to the demrst
vents. The air conditioningcompressordoes not operate
in this mode.
'VENT'
This setting directs all air to the centre and side vents.
The air flow and directioncan be adiustedat each vent
by directionalvanes and thumb wheels.The air can also
be shut off individuallyat these vents to achieve the
desired comfort. The air conditioningcompressordoes
not ooeratein this mode.
aa-- ll --
v
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 temperaturelever is positionedat 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
lemperaturedeterminedby the temperaturecontrol lever.
'MAX'
Use fcr maximumcoolingor quick cool down on very hot
days. On this settingthe cabin air is recirculatedthrouoh
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
conditloningcompres$r does not operate.
NOTE: The fan automaticallyswitches on to its lowest
speed vyhenthe mode lever is moved awav from OFF
position.Fan speed can then be increasedbv setectrnoa
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
intenorof the vehicle,excludingdust entry.
3. Undermost conditionsit is recommendedthat 'MAX'
(recirculatedair) setting be avoidedif occupanrsare
smokingas residuesfrom the tobaccosmoke adhere
to the evaporatorand air ducts and will result in
stalesmellingair insidethe 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
increaseyour enginespeed which in turn aids engine
coolingand air conditionerperformance.
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
normallybe 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 recirculatesthe oil within the com-
pressor 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 recommen-
ded that the windowsshould be opened for the first
minuteto allow the hot air to escaoe.
REFRIGERANT CIRCUIT
The refrigerantcircuil illustratedin Fig. 2B-4 incorporates
the followingmajor components:
A eompressor, thermostatic switch, evaporator,
thermostatic expansion valve, receiver dehydrator and a
condenser.
Figs. 2B-5, 28-6 and 2B-7 illustraterefrigeranttube and
hose routingand connections.
RE F RI G E R A N T
C IR C U IT& C O MP O N EN TS
LEGE ND UUI! UtrI\JtrT

vm7)
V'//4 High Pr essur e High Tem per atur e VAPO U R
[:i!!!J Hish Pr essur e High Tem per atur e LIOUI D
ffi Low Pr essur e Low Temper atur e LIOUID +
f--] lo* Pr essur e Low Temper atur e VAPOU R
_ S E R V IC E FITTIN G
R E C . D E H Y D R A TOF
L
H IGH .l
S ID E
\J :f
{D IS C H A R GE )
H IGH S ID E
- C OMP R E S S OR -
i .OW S ID E E X P A N SI
C U T O U T S WIT CH T O COM PB E S S OR V A LV E
CL UT C H
)S oru u rc H PRESSURE LOW
SERVICEFI TTI NGO N C API LLAR Y
SIDE
COMPRESSO R (sucrro\) S E R V IC E FITTIN G
B A LA N C E TU B E
T HERM OST AT IC E V A P OR A TOR

SWIT CH
.<-
Figure 2B-4
lL- rll--
7
28-6 AIR CONDITIONING
/- scREW P OWE RS TE E R IN GA
R E S E R V OIR -\
,.2 -- aa
z'
M A , Nw r R 'N G- / l '-
..D HARNESS
siiew ->*\.- o secrtoruD-D
I '.--
vr e wI Lrrr, ,*o, 'L;.)\
; .- r , ?\ i,
RECEIVER DEHYD R A TOR r- / \
T O T HERM OST ATIC t) .)
EXPANSION VAL VE
Az- c, ! r'
', ,t2
:.$) ti\
Ir
-= - ruB E FR oMR E cE TvER
il
'f-\- )I DEHYDRATORTO
\ SCREW f . coNDENSER
l 1_
lr
, ..t,oJ A- A
2 PTACES I ' o c r ^r c - 3 PLACE S
TGR OMME T
B z,
A 7. 5 - 9 . 5 N m a' ;---
K
A.
1J\
A
15 . 0 - 1 8 . 0 N m
19 . 0 - 2 2 . 0 N m
R E F R IGE R A T ED
\{,",?-
'llil+" r '_,
(f
T U BE R OU T IN G lYi q
A t secrroru
B-B
Figure 2B-5
C LA MP \
_\j4_L
ll
l,
A
I z;]ry
.t
'^--t'-'
secrroru
A-A
E V A P OB A TOR TO
-
C OMP R E S S OR
H OS E
-1
/
: - E V A P OR A TOR
OU TLE T
,O'R IN G
USE EXIST I\G SASK E TS ct,
( 2 PL ACES)
: -1*
J )-! l ' ^ '
))
' : -*/
,4, z o -G-'f-ScREw
1r'' zb t\m tf - /A ;''
oN LY / // \
\
A 24- 3 0 N m .';a
./\ \ \ *o.".*
t. 30- 3 4 N m t"''o
u,.* El
F igure 28-6
/l
AIR CONDITIONING
2B,.7
E V A P OFA TOR H OS E
TO C OMP R E S S OR
L ev ep o R n t o R o u r L E T
secrroru
A-A
U S E E X I S TING
GASKETS 'l :S C R E W
(2 PLACES)
12
L',', _ 7
{ :---
^ r-
C O M P R E S SORHOSE
T O C O N D ENSER ^
/-t
A
1l\ 2 6 - 28 Nm
vrEWEl
,4.
12" 2 4 - 3 0 Nm
A
1r\ 3 0 - 34 Nm
Figure 2B-7
NOTES
28.8 AIR CONDITIONING
COMPRESSOR
The compressor fitted to VK models illustratedin cut
away section in Fig. 2B-8 is the TR 70 manufacturedby
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 componentsare housed
in a cylindricalcasing, with one in a fixed position and
the other interleaved with the former at an angular
relationshipof 1800, The free moving componentsare
driven by a crankshaftin an orbiting motion.The orbiting
motion of the free moving component provides a
continuouscompressionprocessin two pairs of compres-
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 evaporatorcore freezing.
r DI S C H A R G E P O R T
\^,
,TC HI c o l
y'- S P TR A LA S M.
P U LIL E Y
1": A.: \
J;'.,,'
\\,,
r-F R O NT P LA TE
\
i:.$,,{
!/ E.
u'
'R OTOR P U LLE Y B E A R IN G
- SH AF T SEAL
:BONT HOUSING_
L C OU N T-FW:IGH T A S M
Figure 2B-8
AIR CONDITIONING
28.9
THERMOSTATIC SWITCH
The switch,througha capillarytube, 'senses'variationsin
the temperatureof the evaporatorcore and, by makingor
breaking the electricalcircuit to the compressorclutch
coil, causes the clutch to engage and disengage,thus
keepingthe evaporatorcore just above freezing.
EVAPORATOR
The evaporator assembly located under the instrument
panel and adjacentto the instrumentpanel compartment,
cools and dehumidifiesthe air before it enters the
passengercompartmentol the car.
THERMOSTATIC EXPANSION VALVE

The thermostaticexpansionvalve regulatesthe supplyof
liquidrefrigerantto the evaporator.
IMPORTANT:No attempt should be made to adjust this
valve or damageto the compressormay 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 refrigerantcharge
is low, a persistantfrothingconditionwill be visibleat this
sight glass. To overcome this condition, refer to the
DiagnosticChart 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.
The system carries1050 g of R12 relrigerantand 150 cc
ol Suniso No. SGSrefrigerantoil.
rl- /---
rHBoucH Botr /),,

4 P LA C E S
COM PRESSOR --
DRIVE BEL T
.-WA S H E R -4P LA C E S
* c o w p R e sson FOR C ON TIN U A TION R E F. S E C TION 12E
{
ASSEM BLY
j< -.:_
CO MPR E S S O F-
DRI VE B E t T /\'
A
AT T ACHIN G
ADJ , B O L T /\\ BOL T
i\i 2 PL ACE S
/ r,i-
ttv | -
uLArvrrtr\u
"rotr,*o
ENSURE NUT IS
RET IGHT ENED
AF T ER BEL T
ADJUST M ENT
AT T A C H IN G -
BOL T
2 PL A C E S
6 C Y L. E N GIN E
J6 o o lr o r REM o vE sHr p p r NG pLA TE S A N D ,oR pLU Gs

,5: ,o - 27 Nm
F ROI\4REF RIGERANT SYSTE \4,U N TI L II\'l ME D IA TE LY
BEF ORE ASSEM BL Y OF HOS E STOP R E V E N T E N TR Y OF
Lj oo- 54 Nm I\4 OIST UREOR F OREIGN MA TTE R IN TO TH E S Y S TE M.
Figure 2B-9
Figure 28-10
AIR CONDIT IONIN2B
G .11
3. SERVICEOPERATIONS
3.1 COMPRESSORDRIVEBELT NOTE: A new compressorwill contain 150 cc ol factory

installedrelrigerantoil.
TENSIONAND ADJUSTMENT
lf there are no signs of excessiverefrigerantoil loss, add
Adjust the compressr drive belt using belt tension dial
gauge 982350or equivalent. the followingamount of oil dependingon the component
being replaced.
On 6 CylinderEngines:
Before adjusting the compressordrive belt bolt (refer COMPRESSOR
Fig. 2B-9), slacken off the idler pulley clampingnut. On Beinstalling the Original Compressor
completionof belt adjustment,torque clampingnut to 40
1. Drain and measure the refrigerantoil contained in
- 50 Nm.
the compressor.
On 8 CylinderEngines: 2. Replace the oil in the compressorwith the same
Slackenoff the idler pulleyarmlclampingnut assembly amountof new refrigerantoil.
(refer Fig. 2B-10),adjustcompressordrive belt tension,
then torqueclampingnut assemblyto 40 - 50 Nm. Installing a New Gompressor
At the time of initial installationof a new belt only, the 1. Drain and measure refrigerant oil from original
strand tension should be 64 kg (140 lbs) plus or minus compressor.
2.25 kg (5 lbs) but after ten minutes'run-in'or with used 2. Drain factory installed refrigerant oil from new
belts, a value of 43 kg (95 lbs) plus or minus 2.25 kg comoressor.
(5 lbs) applies.
3- Measurethe same amountol new refrigerant orl that
was drainedfrom the originalcompressoranc install
this amountof oil into the new comDressor.
3.2 CHECKINGCOMPRESSOR OIL
C H A R GEON V E H IC L E
The compressoris chargedat the factory with 150 cc of EVAPORATOR
Suniso No. 5GS refrigerantoil. Only this Vpe of oil Drain as much of the originaloii as possibletrom the
shouldbe used when addingor changingoil. evaporator,then add the same amountof new refrigerant
It is not necessaryto regularlycheck the oil level in the oil, either to the originalor new evaporator.
compressor.In general,the compressoroil level should
only be checked in cases where a maior loss of system
oil has occurred,such as:- CONDENSER
a. A broken hose or severe leak. Drain as much of the onginal o l as possiblefrom the
relrigerant system condenser,then add the same amountof new refrigerant
b. Collision damage to
oil, eitherto the originalor new condenser.
components.
c. lf excess oil is suspectedto be in the system.
1 . Dischargerefrigerantfrom system,then remove the RECEIVER DEHYDRATOR
compressor. Drain as much of the originaloil as possiblefrom the
2. Removedischargeport cap of the compressorthen receiver dehydrator,then add the same amount of new
carelullydrain and measurethe refrigerantoil. reirigerant. oil, either to the original or new receiver
3. Flushoil from rest of system using R12 gas. dehydrator.
4. Add 150 cc of new refrigerantoil to the compressor. NOTE: lf the condenser, evaporator or the receiver
dehydratorcontainsmore than 25 cc of refrigerantoil, or
5. Installthe dischargeport cap after first ensuringthat the compressormore than 150 cc of refrigerantoil, then
the seal 'O' ring is not twisted and that the seat and it must be assumedthat the system containsexcess oil.
'O' ring are clean. Tighten the cap to 8-12 Nm
This condition necessitatescomplete f lushing of the
torque. whole system with R12 gas and 150 cc of new
6. Evacuatethen rechargesystem. refrigerantoil added to the compressor.
NOTE: Never over tighten the discharge port cap to
overcomea refrigerantleak.Removethe cap and replace
the 'O' ring.
ADDING OIL DURING COMPONENT

REPLACEMENT
Some oil is lost whenever air conditioning syslem
componentsare replaced.
Where the system has been ruptured, a leak has
occurred or a compressor has to be removed and
reinstalledor replaced,the entire systemmust be flushed
with R12 gas.
IMPORTANT:The completeair conditioningsystem must
conlain 150 cc of refrigerantoil to functioncorrectly.
ra- l--
28'-12AIR CONDITIONING
3.3 REFRIGERANT
SYSTEMCHARGING
The followingproceduresare accomplishedby using the
manifoldgauge set illustratedin Fig. 2B-11, which allows
the rate of refrigerantdischarge to be controlled,thus
minimizingloss of compressoroil 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
refrigerantto enter cylinder.
2. Bleed cylindervia valve on top (behindcontrol panel)
as required to allow refrigerantto enter. lt will be
necessaryto close bleed valve periodicallyto 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.
S CHRADER VAL VES

_- coMP R E S S OR
/ (roPvrE W )
A DAPT ORS
L OW
rntrJ5uhtr
GAUG E I\4A NI FOLD A N D
GA U GE S E T
GA U GE TIN E S
V A C U U I\I C ON TR OL V A LV E
R EF R I G=F i \T C!'L IND ER

=l il|--.t-uo.uuM puMp
=1
r - ll
r li
cHARGtNG - - /
CVL I\D:E
Figure 2B-11
AIR CONDIT ION IN28-13
G
Charging System refrigerant is trapped in the suction side of the

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

range requtrementis 3.0 to 3.5 at 12 volts. Note the
A mbient A i r
oc
Ce n tr e Ou tle t followingsymptomsand remedies.
Temp. Air T e m p . o A very high amperage reading - A short within
A ux . Fan oc
Air B last
the field coil.
. No amperage reading - An open circuit in the
winding.
o An intermittentor 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.
lf operatingpressuresand temperaturesare within the
3. Air Gap - An incorrect air gap could cause erratic
specificatronslisted in this f unctional test table, the
engagementor disengagementand/or clutch ratile.
refrigerant section of the air conditioningsystem is
Check the air gap with a feeler gauge 0.35
functionrngconectly. 0.65 mm. Adjustas outlinedlater in this Section.
4. SuspectedBearingNoise - Carry out the following:
Removebelt. Disengageclutch.
Rotaterotor pulleyby hand.
3.4 COMPRESSOR
INSPECTION Listen for bearing noise. Feel for hard spots. lf
PROCEDURES excessive,repairor replacecompressor.
LEAK TEST
Seeping oil does not necessarily indicate leaking NOISE
refrigerant.Look for the followingproblems: Checkfor:
. Shaft seal area seeping oil. Feet under seal area 1. Loose belt, torque to 43 kg (used),64 kg (new) plus
betweenclutch and compressor. or minus2.25 kg.
. Dislocationof front boss 'O' nng (protrudingsection). 2. Broken bracket and/or compressorbody mounting-
o Oil aroundserviceport. fittings. replacebrokencomponent.
. Oil aroundfillerhole.'O' ring,strippedthreads. 3 Missing,broken or loose bolts at compressorand
o Oil aroundcrackrn compressor housing. engrnefixingpoints.
IMPORTANT:Alwaysclean away all oil, grease,etc., and 4. Torqueboltsto specifications.
blow away residual refrigerantbefore starting detection 5. Looseor wobblingenginecrankshaftpulley.
procedures.Reter to Systemor SupplierManualsfor the 6. Alternalorbearing.
proper techniquesto be used for Halide or 'Electronic'
7. Air pump (wherefitted).
Leak Detectors.
B. Water pump bearing.
HalideFlame Detectors- Any portionof the compressor, 9. Enginevalves.
rncludingthe seals,which showsa leak indicationon the 10. Timinggears.
f lamewill requireleak repar. 11, Looseenginemountingbolts.
12. Low refrigerantcharge can be determinedby persis-
'Electronic' Shop Type Detectors+ In
- - the seal area. tant foaming in the receiver dehydratorsight glass
Se: the instrument1/4 to 1/3 range above maximum and low suction pressure together with low head
selsrtivity.All other portionsof the compressor- set the pressure.
detector at maximum sensitivity.("Detectors with a 13. Oil Level- Insufficientoil can cause unusualnoise.
mlnlmumleak rate of 14-28cc per year).
Remove
'Soap 3ubble' - Any bubbtes,on any portion of the
1. Dischargesystem as previouslyouilined in 'Refriger-
compressor
indicatea leak requiring
repair. ant SystemProcessing.'
2. Removehoses from compressorand tape or plug all
COMPRESSORSMOOTHNESSTEST connectionsto prevent absorptionof moisturefrom
(Compressorinstalled) the atmosphere into the system.
1. Disconnect refrigerant hoses, discharging system. 3. SlackenofJidlerpulleyclampingnut and/or bolt then
2. Disengage disconnectthe drivebelt.
clutch.
3. Rotatearmatureplate by hand. NOTE: On 6 cylinder engines,it will be necessary to
release the tensron from the compressor drive belt
4. While rotating,if severe rough spots or 'catches' are adjustingbolt.illustratedin Fig. 2B-9.
felt, repairor replacethe compressor.
4. Disconnect electrical connector then remove the
attaching bolts and compressorfrom the mounting
bracket.
CLUTCH TEST
5. lf the original or a new compressor is being
1. lf fieldcoil lead is broken,repairlead or replacefield reinstalled,or replaced, refer to 'Add Oil Durino
coil. ComponentReplacement'2.3 in this Section.
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 removalproceduresnotingthe 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
moisturetrom the atmosphereinto the system.
3. Installnew 'O' ring seals after lubricatingthem 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 illustratedin 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
J 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 compressorshaft.
NOTE: lf difficultyis experiencedin removingthe clutch
bearing,locate the ends of two bladed screwdriversinto
grooves inside of clutch rotor, then using a lever action,
lever clutch rotor up and off the compressorshaft.
Figure 2B-15
4. Loosenthe clutch lead wire clamp releasingthe 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 compressorshaft.
--IEry--E-z c-
Figure 28-16
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. 28-
17. 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 protectingtool AU261 over the

end of the compressorshafi then install the seal
head removaland installationtool 41267 over the
protectrngtool and compressorshafl, as illustratedin
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 installa-

ricr tool AU260and installthe tool into the insideol
the seal seat as illustratedin 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 installa-

tion 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
assemby rnstalling tool AU262,then installthe seal
assembryfirmlyinto 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

AU260,apply refrigerantoil to the seat 'O' ring, then
insiall the seal seat into the bore o{ the front nose
with the 'O' ring uppermost- Using the felt seal
assemblyinstallingtool AU262 locatedon top of the
seal seat, exert sufficient downward pressure to
correcllyinstallseal seat.
NOTE: Refer to cautionaryparagraph at start of Dis-
assemblyprocedures.
3. With 'O' ring protectingtool AU261 installedon end
of compressorshaft and with seal head installedin
end of tool 41267, thoroughlyair blow seal head,
then apply refrigerantoil to 'O' ring.
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
head with those on the compressorshaft.
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

retainingbolt illustratedin Fig. 28-24 and install the
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
diagonalsequenceto 14.711.98Nm.
Figure 28-24
lnstall the clutch core assemblyto the f ront end

nose, aligningthe locatingproiectiondimple in tne
base of the clutchcirclipcore assemblywith cut cut
in end plate. Usingwing circlip pliersJ6083, install
clutchcore assemblyas illustratedin Fig. 28-25
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 subsequentserviceoperations).
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 torguearmatureanchorbolt 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 thicknessto achievethe recommended
air gap.
Figure 2&28
3.5 EVAPORATOR
ASSEMBLY
REMOVE
2. Evacuate the system (refer 'Refrigerant System
Processing' in this Section).
3. Disconnect the inlet and outlet refrigerant pipe
connectionsillustratedin 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 illustratedin Fiq. 2ts-29.
AIR CONDITIONING
28-21
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AIR CONDITIONING
28-23
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Figure 2B-3'l
6. Remove combined instrumenlassemblyillustratedin

Fig. 28-30.
7. Disconnect temperature cable at heater assembly
and partially remove vent/heat control assembly- Do
not disconnectvacuumhoses or electri€l connector.
Remove screws securing left hand and centre of
instrumentlocation cover to instrumentpanel pad
and frame illustratedin Fig. 28-30.
9. Remove centre nozle hose assembly and screws
securingright and left hand air ductingto centre air
duct illustratedin Figs. 28-30 and 28-31.
10. Remove instrument panel compartment and rear
comDartmentreleasebutton.
11. Remove left hand upper air outlet assembly and
screw securingleft hand ol instrumentpanel pad to
frame iflustratedin Figs. 2B-30 and 28-32.
12. Firmly support left hand instrumentpanel lower and
remove all of the screws securingthis panel to the
instrumentpanel frame illustratedin Fig. 28-32.
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
base oJ the evaporatorassemblY.
'15. Positiona wooden wedge betweenthe left hand side
of the instrumentpanel pad and the instrumentpanel
frame to gain access to the two bolts illustratedin
Fig. 28-33, which secure the top ol the evaporator
assemblyto the instrumentpanel frame,then using a
socket enension and a ratchet handle, remove the
bolts securing the evaporator assembly to the
instrumentpanel frame.
2B.-24AIR CONDITIONING
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AIR CONDITIONING
28.25
'rv' \" .- o ' 1-P LA C E S

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HOUSINGASM. - OU L
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FR OM E N G. C OMP T.
B
Figure 28.33
16. From inside the engine compartment,remove the

two bolts illustratedin Fig. 28-33, securingthe front
of the evaporatorassemblyto the lowerdash panel.
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.
17. Removethe clamps illustratedin Fig. 28-33, which

retain and seal the ends of the evaporatorhousing
to the heater and blower motor housing assembly,
disconnect the electrical connectors and vacuum
hoses,then carefullyremove the evaporatorass
REINSTALL
Reverseremovaloperationsnoting the following:
1. l{ the originalor a new evaporatoris to be installed,
referto 'AddingOil DuringComponentReplacement'
in this Section.
2. Leave protective plugs or caps until just before
connectingtubes or hoses to preventabsorptionof
moisturefrom the atmosphereinto the system.
3. Install new 'O' ring seals, lubricatingthem with
refrigerant oil then torque A/C hose connectionsas
illustratedin Figs.2B-5,28-6 and 2B-7.
4. Charge the system as outlined under 'Refrigerant
SystemProcessing' in this Section.
5. Checkout the electricsand air ductsdisturbeddurinq
the removaiand installationooerations.
a T N S E R TI N T O SL OT
INSIDE CASE
.BOL T _ 2 PER
_ U P P E RC A S E
T H E R M O S T A T-
ASM ,
! rEy/
E
UPPER CAS: _
<c n
E1
COVER ASl,' . ,O'R IN G
.L
TU E E A S M.
i!\ R. EVAP.
COI L SEAL *oo6 o
6eo o o
o!
oO-.=
]RAIN COVEB
o-Z ,T
LOWE R C A S E
- ' . / A P.
S I L A ST C T HIS EDGE
:.AP G R OM M ET -
Figure 28-34
28.27
AIR CONDITIONING
3.6 EVAPORATORCORE AND PIPE attached to condenser assembly, illustrated in

Fig. 28-36.
ASSEMBLY 5. Removethe screws illustratedin Fig. 28-36 securing
REMOVE the right hand bracket to the condenser and the
1. Remove evaporatorassembly as described in the radiatorside supportpanel.
precedingprocedures. 6. Disconnect the inlet and outlet refrigerant pipe
2. Remove the spring clips illuslratedin Fig. 28-34 connectorslocated on the right hand side of the
which secure the upper and lower sections of the condenserassembly.
evaporatorcase together.
CAUTION: Cap or plug disconnected connectors on
3. Remove the heavy mastic insulationmaterialadia- pipes and on condenser immediatelyto prevent moisture
cent to the expansion valve and inlet and outlet being absorbedfrom the atmosphereinto the syslem.
pipes.
4. Whilst removingthe upper section of the evaporator 7. Disconnectthe horn bracket lead, then remove the
case, carefullyease the TXV sensor tube illustrated horn and bracket assembly from the lett hand
in View 'A' Fig. 28-34, from the slot in the inside radiatorside supportpanel.
case.
8. From under the Jront lower valance panel, remove
5. Removethe rubbersealinggasketand the inlet pipe the two screwsillustratedin Fig. 28-36, securingthe
illustratedin Fig. 28-34 from the evaporatorcore and right and lett hand bracketsattachedto the base ol
pipe assembly. the condenserassembly.
6. Carefullywithdrawthe core from the lower sectionof 9. Remove the screw illustratedin Fig. 28-36 securing
the evaporatorcase taking care not to contact the the left hand upger support bracket to the radiator
aluminiummesh waler collector screen attached to side supportpanel,then removethe condenserand
the rear section of the pipe and core assemblyby auxiliaryfan motor assembly.
hand.
NOTE:Duringmanufacture,this water collectoris chemic- REINSTALL
ally treated to create a slippery surface to accelerate Reverseremovalprocedures.When installingthe new
moisturemovement.Acid depositswhich can result from note the following:
asser"rbly.
touchingthis surfaceby hand can neutralizethis chemic-
ally treated surface. 1. Drainas muchof the originaloil as possiblefrom the
orginal condenser,then add the same amount ol
new refngerantoil, either to the original or new
REINSTALL condenser.
When installingthe new assemblynote the following: lf the condenser contains more than 25 cc ol
1. Drain as much of the original refrigerant oil as refrigerantoil, assume system contains excess oil
possible from the originalevaporatorcore, then add and flush system.Add 150 cc of new refrigerantoil
the same amountof new refrigerantoil, eitherto the to the compressor.
originalor new evaporatorcore. 2. Leave protective plugs or caps until just before
lf the evaporatorassemblycontainsmore than 25 cc connectingtubes to prevent absorptionof moisture
of refrigerantoil, assume syslem containsexcell oil from the atmosphereinto the system.
and flush system,then add 150 cc of new refrigerant 3. Use new 'O' ring seals coated wtth clean refrigerant
oil to compressor. oil when makinginletand outlettube connections.
2. Leave protective plugs or caps until just before 4. Leave final tighteningof the tube connectionsuntil
connectingtubes or hoses to prevent absorptionof the condenseris finallyinstalled.
moisturefrom the atmosphereinto the system. 5. Evacuate,leak test, charge and performancetest the
3. Use new 'O' ring seals coated with clean refrigerant svstem.
oil when makinginlet and outlet tube connections'
4. Leave final tighteningof the tube connectronsuntil
the evaporatoris securelyinstalled.
5. Evacuate,leak test, charge and performancetest the
3.8 AUXILIARYFAN
system. REMOVE
NOTE: Removal and reinstallationof the thermostatic 1. Disconnectthe battery earth cable and the auxiliary
expansionvalve and the thermostaiand switch assembly fan electncalconnectorlocatedon the left hand side
necessitateremoval of the evaporatorassembly. of the condenserassembly.
2. Remove the conneclor body from the end of the
auxiliary1an lead, then attach a length of string to
the end ol the lead.
AND AUXILIARYFAN
3.7 CONDENSOR 3. Removethe radiatorgrilleillustrated in Fig. 2B-35.
ASSEMBLY
4. Remove the nuts securing the auxiliaryfan to the
REMOVE condenser, then removethe fan and lead assembly,
1. Disconnectbatteryearth cable. leaving enough of the string previouslyattached to
2. Evacuate the system (refer 'Refrigerant System the fan lead adjacent to the top of the radratorto
Processing'in this Section). facilitatesubsequentinstallationoJ the fan lead.
3. Removethe radiatorgrille,illustratedin Fig. 28-35.
REINSTALL
4. Disconnect the electrical connectors,then remove
the auxrfraryfan blade from the fan motor assembly Reverseremovalprocedures.
\ JT -
2 PLAC
-S
v --l---/
i
i---t /
l___---'
A ..u - 4. 6Nm _AADIATOR 3F:!E
A t.o - 3. 4Nm
Figure 28-35
F O F CO N T I N U A - 3 \ l = F ER SECT ION 1 2 E - - r .//

\l'
/a'
. -'-1
a:lTEûj
2 P LA C E S
./
-C^
v. .- -
coN D E N S E R & A U X | LTA R Y
FA N A S S E MB LY
4
SCREW
2 P LA C E S
SCREW
\- -- _SCne W 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
Z TLALtr) 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
A 0.8 - 1 .4Nm
Figure 28-36
AIR CONDITIONING
28.29
3.9 RECEIVERDEHYDRATOR
REMOVE
1. Evacuate the system (refer 'Refrigerant System
Processing'in this Section).
2. Disconnectthe inlet and outlet refrigerantpipes from
the inlet and outlet sides of the receiverdehydrator
illustratedin Fig. 28-37.
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 receiverdehydratorout 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
and flush system.Add 150 cc of new refrigerantoil
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
the receiverdehydratorclamp is fully tightened.
5. Evacuate,leak test, charge and performancetest the
syslem.
- POWERST EERING R E C E TV E R
R ESERVOIR ,-
D E H Y D R ATOR
ffi
SIGH T G LA S S
18 N m
MOU N TIi (l
5 --- ERACKE
scne,//--
V IE W
Figure 28-37
4. DIAGNOSIS
CHART C OMP LA IN T _ TN S U FFIC IE N TC OOLIN G
N ORM AL AIR F L OW C H E C K A IR FLOW
C h e ck th a t h e a te r ta p is off wher eve. s on "COLD posr lron

Check d a rr te mper atu' 9 at cutr el lozzle
NOR M A L N O Z Z L E AIR HIGH NOZ Z L E A IR

TEMPERATURE T EM PERAT UF E
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 .
F OAM ING N O FOA MIN G
System is pr obably low on r efr ig er ant. Sy s tem m ay be ei ther ful l y c har ged or em pty .
Check for leaks, r epair and add refr i g- F eel hi gh and l ow pr es s ur e pr pes at c om pr es s or .
er ant. lf foam ing still occur s, che c k H i gh pr es s ur e pi pe s houl d be w ar m ; l ow pr es s ur e
for r estr iction in r efr iger ant system pi pe s houl d be c ol d.
between condenser and sight glas s . 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 H IGH E V A P OR A TOR OR ]

CO M P R E S S O RS U C T I ON PRESSURE C OMP R E S S ORS U C TION P R E S S U R E
Ch e ck e va p o ra to r o utlet line TH E R MOS TA TTC

Ou tl e t l i n e wa rm. S WITC H
C h e ck fo r l i q u i d l i n e resr : cr on C hec k for c l utc h c y c l e.

( 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.
C Y C LE
l f n ot,
C h e ck fo r ce fe cti ve T .X. valve by
o.K
r e m ovrn g va i ve a n d b l o wing thr ough C LU T C H ON I
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 D i s c onnec t c l utc h
l w i r e.
] CL UT CH C LU TC H R E MA IN S
DISENGAGES E N GA GE D
C l utc h i s defec ti v e.
L O W D I S C H A R GE HIGH D IS C H A R GE P R E S S U R E
rhts55uHE
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
C h e c k fo r sl i p p i n g cl u rch or slipping belt.
tnr u COn dens er .
C r g c k fo r su cti o n l rn e re str iction-
R e m o v e co mp re sso r, te a rdown, inspect for Check T.X. v atv e bul b c ontac t and r ns ul ati on.
d e t ? c t s a n d re p a i r. 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 N OZZLE A IF TE MP E R A TU R E

DROPSAS COM PRESSOR I N C R E A S E SA S C OMP R E S S OR
DISCHARGE PRESSUREDROPS D IS C H A R GEP B E S S U R ED R OP S
t--
Lea^ test r ur r "- , r "p"ir - T .X. v al v e s uper heat

as necessar \, dischar ge, s ettr ng i s l ow . R epl ac e
]
evacuate and r ecnar ge. I T .X. v al v e
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 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

Ch e ck for blown fuse, defective blower switch,
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
b ro ke n wir e, loose connection, defective
outl et v al v e or c l os ed ev apor ator c or e.
b l o we r m otor .
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 C hec k i o'c l u:c n

COM PRESSORSUCT ION PB ES S U R E
Nra a !a ;
Check dischar ge Pr essur e C Y C LE
o.K. 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
T her m os tati c s w r ::r C l utc h i s d e f e c t i v e
i s defec ti v e.
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
N OR MA L D IS C H A R GE P RE S S U R E
L O W D I S CHARGE PRESSURE
C h e ck fo r restr iction in liquid line, Refri ge'at on s v s i .m l s O .K.

p a rti a l l Y P lugg€d T.X. valve, or ' I . Chec k i o' nc : !\ai e' v al v e s hut- ot1
d e fe cti ve T.X. valve Replace T' X' 2. Chec k i o- P'3Pg' func ti on of ai r SeleCiOr doOr.
va l ve i f d e fective. 3. Chec k fo'c r c Pe'oPer ati on and sea a.oLnc :emperature door
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
200 g R '12 anc obs er y e per for m anc e D l s c har ge or r ec har ge s /s l em as sp e c i f i e d
5. Chec k tor c 'c ae- s eal ar ouno ev apo ) or ai o- c a,e.
6. C hec k for ex c es s or l r n s y s tem 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
or br ok en 3er : at s peeds i n e xcessof 1OOkmi h. To
removeexcessoi l rn s y s tem
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
and maxrm um c o o
dr ai n and m eas u'e oi l fr om c om pr es s or i f the c om p re s s o
b ) D i s c har ge s y s tem ,
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.
I r em ov e the ex c es s otl
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
5. SPECIALTOOLS
T he Comp resso rTo 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 ei t e m s u n d e r t h e i r
individual
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 ef r o m .
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
t_- 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
^- o
9 .0 m m - -<_75.0 m_--__>
1 8 .0 m m -
-6.0 mm ;- 10.0 mm D IA
v vv 25.-
l
GAUGE | ^-
- aJ .5m m 3.0 mm
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
'. I(
\-o 4U262
FE LT S E A L A S S E ME LY
A U2 5 8 N S TA LLIN G TOOL
C O M PRESSORHOL 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
S E A L S E A T R E MOV A L
W I N G C I RC L IP P L IE R S A N D IN S TA LLA TION TOOL
FRONTSUSPENSION
3.1
SECTION3
FRONTSUSPENSION
INDEX
Ref. Subject Page I Ref. Subject Page
1. GEI{ERAL DESCR|PT|ON..............................3-1 | 2. FRONT STRUT USAGE 3-1
The front suspension on VK Series models remains the interchangeablewith previous Commodoremodels.
same as on VH Series models, with the exception.ol the Service operationsare as described in Section 03 of the
front strut shock absorbers.These have been revised to VB ComniodoreService Manual p/N M3g14S.
suit the differenl variation in vehicle load and to maintain
satisfactory damping control. VK strut inserts are not
2. FRONTSTRUTUSAGE
All VK Series models have the front strut assemblies
painted black, there is no colour identificationas per
previousCommodoremodels.
For non-standardstrut identification,refer to the 'Body
and ldentification Plate'. The plate includes vehicle
optional information if it is fitted with XWs - Outback
Pack or FE-ZSportsSuspensionPack,refer Fig. 3-1.
Figure 3-1
4A.1
REAR SUSPENSION
SECTION4A
REAR SUSPENSION
INDEx
1. GENERALDESCRIPTION 4A'1
...................r.......... 3. SPECIFICATIONS 4A-2
...............-...................r........
2. 4A-1
SERVICEOPERATIONS........'..............!........ 3.1 REAR SHOCKABSORBERUSAGE...........I4A-2
1 , GENERALDESCRIPTION
The rear Suspensionon VK Series models remains the differentvariationin vehicle load over VH Series models.
same aS on VH Series models,with the exceptionof the Serviceoperationsare as describedin Section 04 of the
shock absorbers.These have been revised to suit the VB CommodoreServiceManual.
Service operations arc as described in the VB Com-
modoreServiceManualPart 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 SHOCKABSORBERUSAGE
ID EN TIFIC A TI E X TE N D E D
M O DE LS
ON
LEN GTH C OLOU R
LA B EL
(mm)
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 522.5/528,5 Black
19 St y les ( Sedans )
vG ffi1/635 Yellow
wit h x w5 , FE2
35 S t y les ( St at ionW agons

r )
I LG 523.51527.5 Yellow
W it h XW SiFE2 |
19 St y les ( Sedans )
With FEz 582/588 j B l ack
XWs - O ut bac k Pac k

FEz - Sus pens r onSy s t em Pac k
NOTES
REAR AXLE 48.1
SECTION48
REAR AXLE
INDEX
Ref. Subiect Page I Ref. Subiect Page
1. GENERALDESCR|PT|ON..............................
4B-1 | 2. SERVTCEOPEBAT|ONS................... 4B-1
There are two different size Salisbury Rear Axle 2. A Salisbury type axle with 1gO mm diameter ring
Assembliesused with VK Series models. gear is used on models with s.O litre engine.
1. A Salisbury type axle with 178 mm diameter ring Limited slip differentialis avaitabteon all models.
gear is used as standard eguipment on all models
except those with the 5.0 litre engine.
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
CommodoreServiceManualPart No. M38145.
PROPELLER
SHAFT& UNIVERSALJOINTS4C-1
sEcTtoN4c
PROPELLER
SHAFT& UNIVERSALJOINTS
INDEX
Ref. Subject Pqge page
I Ref. Subject
1. PROPELLERSHAFT IDENTIFICATION......4G1 I 2. UNIVERSALJOINTS IC]T
1. PROPELLERSHAFT 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 TRANSM ISSION PART NO. C OLOU R
3.3 litre MC6 ll s2o24162 | BLACK

EST 1l with gr ey band
r
M4o il gzoz4163 | a LAcK
i 1 41i th
vi ol et band
M76 | 92024160 I eLA C K w i th
ll I o p al i ne greenband
3.3 litre B LAC K w i th

sk y bl ue band
D A R K GR E E N
wi th w hi te band
2. UNIVERSALJOINTS
On VK Series models, with the EFI engine, the propeller The phasing of the front and rea( yokes on propeller
shaft is fitted with universalioints the same as used on shafts fitted to 3.3 litre models, has changed from
5.0 litre models. parallelto 90o apart.
For service operations refer to Section 04 of the VB
CommodoreServiceManualPart No. M38'145.
BRAKES5.1
SECTION5
BRAKES
I NDEX
1. GENERALINFORMATION .........r.........r..-..... 5-1 2.2 BRAKE BOOSTER...........,................., 5-2
1 .1 S E R V ICE NOTES ...' ...........r .o....r r ........!.r .r ....... 5-1 R gm O V€.......- ..r .....- .............r o....r ....... . . . . . . . r 5 -2
1.2 BRAKE BOOSTER - 6 CYLINDER ........,..D't 5-1 ReinStall .-......-...r...........................'.........
5-g
2. SERVICE OPERATIONS .................r...r..r.-.....5-2 3. SPEC1F1CAT|ONS..................r...r..................... 5-4
2.1 BRAKE FLUID CHANGE................................*2 4. TORQUE WRENCH SPECIFICATIONS........ 5.4
1 . GENERALNFORMATION
With the exceptlon o fa non-serviceablebrake booster on all 6 cylinderVK models,the brake system for VK is
and modifiedbrake pipes to suit mastercylinderposition similarto VH models.
1.1 SERVICENOTES
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 condit-
ions 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 Spec-
ification 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.
1.2 BRAKEBOOSTER. 6 CYLINDER

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
2.1 BRAKEFLUIDCHANGE
1. Thoroughly clean master cylinder especially around
wheel brake line connections.
2. Disconnect wheel brake lines from master cylinder
and remove reservoir cap.
3. Allow master cylinder to drair, until empty. (Refer
F ig. 5 -1)
4. 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.
5. 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). Figure 5-1
8. Loosen left hand caliper bleed screw.

D IS C
9. Remove left hand caliper anchor plate retaining bolts. R OTOR <
(See Fig. 5-2) ./\
10. Hold caliper upside down and remove bleed screw to
C A LIP E R
drain contents of caliper into suitable receptacle. 4 A N C H OR P LA TE
1 1. Hand tighten bleed screw and reinstall caliper ') R E TA IN IN G
assembly. 2t B OLTS
12. Tighten anchor plate retaining bolts to torque specifi-
ed at end of section.
13, Repeat step 8 to 12 tor right hand caliper assembly.
14, Bleed front calipers. E R A K E C A LIP E R
Figure *2
2.2 BRAKE BOOSTER

REMOVE
1. Disconnect electrical lead and three brake pipes from
master cylinder.(Refer Fig. 5-3). BRAKE
2. |.Jnscrew nuts securing master cylinder support E OOS TE R
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 BR A C K E T
power booster push rod.
NOTE: Do not depress brake pedal with master cytinder
removed or reaction disc may become dislodged In
booster.
Figure 5-3
BRAKES5-3
6. Remove vacuum hose from brake booster body'

7. Remove two brake booster assembly retaining nuts
at brake pedal support, from inside the vehicle.
(Refer Fig. 5-4)-
Figure 5-4
8. Remove brake push rod retainingclip and washer

from brake pedal and lift push rod off brake pedal
stud. (ReferFig. 5-5)
9. withdraw booster assembly from engine
gasket from WA S H E R
compartment. Remove bracket and
boosterstuds.
telPr-@
v +_ \J/ .-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 Section-
4. Refit vacuumhose to boosterbody'
5. carefullypositionmastercylinderover power booster
push roo' and retainingstuds and torque retaining
nuts to torque specified at end of this Section.
Resecuresupportbracketto springtower and master
cylinder.
this
6. Tightenall bolts to torquesspecifiedat end of
Bleed brake system. lf pressurebleeding is
Section.
lines must be reconnected to
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)
B ra ke Boo ste rfu se m bly
Type S i n g l eV a c u u m S u s p e n d e d
Vacuu m Piston Diam et er 230 mm
4. TORQUEWRENCHSPECIFICATIONS
Nm
Brak e Boos t er Ret ainingNut s 20-25
Ma s t erCy linder t o Br ac k etBolt 15-18
Mas t erCy linder Br ac k ett o PanelNu t s 20-25
Mas t erCy linder t o Br ak e Boos t er 19-28
Pres s ur eDif f er ent ialW ar ningSwit c h
1.4- 1.8
Ca liperAnc hor Plat eRet ainingBoft s 70-85
Brak e Pipest o M as t erCy linder Nut s . .
8-11
ENGINEMECHANICAL
6A.1
SECTION6A
ENGINEMECHANICAL
INDEX
1. GENERALDESCRIPTION .............................. 6A-1 2.3 CYLINDERHEAD (EFl)..................................
6A-5
1. 1 3.3 LITREENGINEWITH ELECTRONIC RgmOV€.............r.....r.r..r............r.......r......6A-5
SPARK TlitlNG (EST) ......r.................!.'..t.t... 6A-2 RginStall ......r......r...r,........................-......6A-7
1.2 3.3 LITRE ENGINEWITH ELECTRONIC 2.4 ENGINEASSEMBLY(EST)....................-.......
6A-7
FUEL INJECTION (EFI) ....,..r!.......r..r....r......... 6A-3 RgmOV9..............r..r.................'..........r..... 6A-7
Inlet ManifOld ........r.r.rr....-...........r....r.... 6A-4 2.5 ENGINEASSEMBLY(EFl) ............................
6A-8
EXhaUSt SySteJfl ......-............rrirrrrrrrrrrrroo 6A-4 RemOV€.t.........r...........r........................!..r 6A-8
2. SERVICEOPERATIONS................................ 6A-4 ReinStall .............r...,....r...........................
6A-1 3
2.1 coilPRESSIoN TEST....r.......-....................... 6A-4 3. TORQUE WRENCH SPECIFICATIONS........6A-13
2.2 GYLINDERHEAD (EST)....'.....r....r..........!.... 6A-5
Rem OV€ ......... r..........! rr.1....... ................... t 6A-5
Three different engines are released for use with VK The 5.0 litre VB engine with automatic transrnission.
Series models. which carriesover from the VH Series,is availableas an
A 3.3 litre engineequippedwith ElectronicSpark Timing optionon all models.
(EST) is standardequipmenton SL and Berlinamodels. The changesto the 3.3 litreenginehave been rntroduced
A 3.3 litre engine with ElectronicFuel Iniection(EFl) is to reduce emissions and improve fuel economy. A
standard on Calais and available as an option on all surnmar/ of the modificationsused for each 3.3 litre
sedan modelswith automatictransmission. enginefollows.
6A-2 ENGINEMECHANICAL
1 . 1 3 . 3 L I T REE N GIN EWIT H

ELECTRONIC SPARKTIMING(EST)
This engine uses the Bosch Electronic Spark riming
system, refer Section 6D, lgnition System, of this Supple-
ment 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
S P E E DS E N S OR
to accurately locate the flyr,vheelor automatic drive plate.
Pistons have been revised to suit the engine operatrng
characteristics.
S E N S ORMOU N T
Figure 6A-3
ff
ENGINEMECHANICAL
6A.3
1.2 3.3 LITREENGINEWITH

ELECTRONIC (EFl)
FUELINJECTION
This engine uses the Bosch LE-2 JetronicFuel Iniection
system.ReferSection6C of this Supplementfor details.
Detailed revisions have been made to the following
engine components,to suit the requirementsof the EFI
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
- _,!/K'3.3 LIT R E
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
Figure 6A-6
lnle t Va lv e OpensBTC
ClosesABC
Duration
Exh au stValv e O pensBTC
ClosesATC
Dur at ion
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-
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 K"
minimiseunder hood ternperatures.
For further details of the exhaust syst€ffi, reter to
Section88 of this Supplement.
Figure 6A-9
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
ENGINEMECHANICAL
2.2 CYLINDERHEAD (EST) - 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 )
REMOVE
TH R OTTLE P OS ITION
Removalproceduresfor the cylinder head on an engine
S WITC H C ON N E C TOR-r \
equippedwith EST are the same as for a VH LO rnodel
with the air pump Vpe Air InjectionReactorsystem. C OOLA N T
The only additions are the disconnectionand removalof TE MP E R A TU R E S E N S OR
wiring at the throttle positionswitch, coolant temperature r C ON N E C TOR
sensorand enginespeedsensor,refer Fig. 6A-11.
Fi gure 6A -11
2.3 CYLINDERHEAD (EFl)

REMOVE
1. Disconnect battery earth lead. Carry out removal
operationsoutlinedin 3.9 'Air Flow Duct' and 3.11
'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 radiatorhose-
CAUT/rOIT; tf the cooling system ts hot, the radiator cap
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.
4. Removetop radiatorand heaterhoses.
5. Depressurizefuel system aS per 3.2 '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.
R E TU R N LIN E -
MOU N TI N G G
8. Disconnect electrical connector from auxiliary air
valve.
B O LT
#
FLE X IB LE _
FU E L H OS E
I
I
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
BRACKET
V A C U U M_
H OS E
'- E LE C TR IC A L C ON N E C TOR
A U X ILIA R Y TO A U X I LIA R Y A I R
A IR V A LV E
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

suitableplugs.Refer Fig. 6A-14.
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 attachingbolt and coil.
13 . lf fitted with air conditioning,loosen drive belt idler
pulleyand disconnectdrivebelt.
Fi gure 6A -14
14. Remove compressor mounting and bracket bolts and

position compressor and bracket away from the C OMP RE S S OR
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 C OM P F ESSO R
arms is retained on assembly. For this purpose, parts M OU N T I N G
should be placed rn a special rack, Tool No. 6A35.
17. Remove the cylinder head bolts, cylinder head and PU LLEY J
gasket. Place cylinder head on two blocks of wood AD J U ST IN G
to prevent damage. 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
ENGINEMECHANICAL
6A.7
REINSTALL
Installationis reversal of removal instructions.However,
additional'Service Operations','Cleaning and Inspection'
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
control power unit cable, ServiceOperations3.3 and 3.4,
Section 6C, 'Fuel Injection',of this Supplernent.
Check for fuel leaks hs described in Service Operation
3.2 'Leak Testing', Section 6C, 'Fuel Iniection' of this
Supplernent.
2.4 ENGINEASSEMBLY(EST) -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
REMOVE
TH R OTTLE P OS ITION
1. Removalproceduresfor a 3.3 litre engine equipped S WITC H C ON N E C TOR-
with EST are the same as for VH LG modelswith the
air pump type Air InjectionReactorsystem. C OOLA N T
2. The only additions are, the removal of wiring
r C ON N EC T OR o- ''
connectionsat the throttle position switch, coolant
temperaturesensor and engine speed sensor.Refer \ ,,
--1i'');,
Fig. 6A-16. \_
- - [./ - - t-
Fi gure 5A -16
NOTE:The speed sensor must be removedfrom the rear

of the cylinderblock before separatingthe cylinderblock
and the transmission.Refer Fig. 6A-17.
S P E E DS E N S OR
S E N S ORMOU N T
Figure 6A-17
ry
FAN SHROUD -
,- 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 batteryearthlead.
2. Remove bottom radiator hose and drain cooling
system. Rernove top rediator hose. Disconnect
automatictransmissioncooler linesfrom radiator.
3. Disconnectradiatorfan shroud from radiator. Re-
move upper radiatorsupport clips, lifi up radiator.
From the front of the radiator,disconnectthe low
coolant sensor wire, if so equipped. Refer
F ig. 6 A-18
4. Remove radiator, taking care not to damage low
coolant sensor, remove shroud.
5. Drain o il pa n.
6. Remove air flow duct as per Service Instruction 3.9,
Section 6C 'Fuel Injection'of this Supplement.
7. Remove engine hood.
8. Loosen generator, and if fitted, power steering pump,
air conditioningcompressor and remove driv-e belts.
Ref er Fig OA-19 . WA TE R P U MP
9. Disconnect brake booster vacuum hose f rom inlet ,.

manifold. r GE N E R A TOR
C ON D ITION IN G P OWE R
C OMP RE S S OR S TE E R IN G
P U MP
C R A N K S H A FT
Figure 6A-19
tr
v
-
ENGINEMECHANICAL
6A.9
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. C OOLIN G FA N
Fig. 6A-21. MOU N TI N G BO LTS
(4 P LA C E S }-l
I
F AN
nt I tTa !- l
I
- Vl-\J | \Jr I
l
,.r-w A TE R
r P U MP
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 '-gggLt\G
(4 P LA C E S)
FA N
Flgure 6A-21
12. On models with air conditioning,remove the com-

pres$r and mounting bracket from its position(refer C OMP RE S S OR
Fig. 6A-22) and support it out of the way without
disconnectingthe hoses.
C OMP RE S S OR
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-10ENGINEMECHANICAL
1 3 . Remove power steering pump mountingand adjus-

ting bolts (refer Fig. 64-23) and supportpump out of
the way withoutdisconnectingthe hoses.
1 4. Disconnectheaterhoses from engine.
P OWER
P U LLE Y A D JU S TIN G
S TE E R IN G
B OLT
P U MP
Figure 6A-23
1 5 Drsconnectwiring harness connectionsf rom starter

motor, generatorand engine earth frorn generator
bracket.Refer Fig. 6A-24.
R IN G H A RIN
I ESS
floN -]
-=l
I
I
IFUJSIB LE
/ N5l
Ltf
\
t
a \- I-
1," V IOLE T LE A D
(S TA R TE R S OLE N OID )
(S TA R TER S OLE N OI D )
B LA C K LE E O )
fi IE D LE AD
(GE N E R A TOR )
(C ONN E C T TO E N G. B LOC K }
Figure 6A-24
1 6. Disconnectwinngconnectionsat oil pressuresender

unit, coolant temperaturesender, ignition coil and rM A IN WIR IN G H A R N . C ON N .
auxiliaryair valve Refer Fig. 64-25.
, 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
(cootillrEyP)
T4//
I*_,.! _ _. ,, ,
.---v
: ^€:: 9.R5f q BLACKLEADSIN
tr S LE E V E
\t -- (A U X ILIA R Y A IR V A LV E )
-:
D K . 3 LU E ,-eoo ] ;" /ss. .R E E N LE A D

(OI L P RE S S U RE ) (A /C C OMP R E S S OR )
E X C . C 6OTA P E B A C K
B R C WN LE A D IN S LE E V E - TOH A R N E S S WITH
(IGN ITION C OIL) GM658M
Figure 6A-25
5
ENGINEMECHANICAL
6A.11
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 c R U t s E c o N T R O- ^ g_
throttle body and vacuum hose from vacuum adaptor UNlT =.r ,!i/-,
as rear of inlet manifold. Refer Fig 6A-26. 'OWER
,,.-THR OTTLE
1 8. Depressure fuel system as per 3.2 'Depressurize', CA BLE
Section 6C, of this Supplement.
19. Remove fuel lines from fuel damper and plug with
\- l - - \
suitable plugs. VACUUM
H OS E
\J
-- t,'F,r.
,-
----:t
rl-1i E LE C TR IC A L C ON N E C TOR
AuXILIAR Y
TO A U X ILIA RY A IR
AIF 'r Ar - r .'F
r V A LV E
)
\ .-
MOU N TIN G B OLT
(2 P LA C E S }
Fi gure 6A -26
20 Removebracketmountingto cylinderhead bolts and

removebracketassembly.Refer Fig. 6A-27.
Figure 6A-27
21. Removewinngconnectorsfrom fuel injectors,throttle

position switch, coolant temperaturesensor. Refer -- Y E _LOW LE A D IN SLE E V E
(l D r-= B OOS TS OLE N OID )
Fig. 6A-28.To avoiddamage,do not pull on wiresat FFi
bl
-?
?-tin
I F r\ftH _
the connectors, SENSCB _ TH R OTTLE V A LV E

Remove f lexiblef uel hose from fuel return line at ITC H
S \,V
enginesideplate,
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
RETURTTT
ilrr r
\ -- MOU N TIN G B O LT
{L---
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. Disconnectthe gear shift from the transmission,refer
to VB Commodore Service Manual, Clutch and
TransmissionSection.
27. Remove the speedornetercable frorn the extension
housing,or if fitted. disconnectspeed sensorwires at
the extenslon housing. Disconnectdetent solenoid
wire and TCS swtch from the transmission.
VACUUM
28. Removetailshaftand inserta protectorin the end of A D A P TOR
the transmissionextensionhousingto preventloss of
fl u i d
Flgure 6A-30
29. Install rool No. oAgT engine lifting hook or equ-

ivalent, raise engine slightly and remove the f ront
engine mountrng to crossmember bracket through
bolt s. Refe r Fig. 6 A-31 .
'm ^F
k' --'id
G:-)A.b ^gojt
wX
)'R,M$ f)\( -'(Sl
-#di,)o-
{{\.^
r
cRossMEMEER
B R A C K E TT H R . U G H B 'L T
tt' r \
::,
V1
Flgure 6A-31
ENGINEMECHANICAL
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. Installationis 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
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.
5. Start engine, check and adjust ignition timing, and for
full throttle opening, check for air leaks.
6. Check for oil and coolant leaks.
3. TORQUEWRENCHS 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 30-40
Cy linder Headt o Cy linder Bi o c k 54 tl rrst torque )
102 ri q3i torque )
Roc k er Ar m Piv ot t o Cy l r n d e rH e a d 30-38
Roc k erCov ert o Cy linde r H e a d 3-6
Fuel Ret ur n Line M ount i n g B o l t s 8 - 10
Fuel Ret ur n Line t o Pr es s u r eR e g u l a t o rN u t . 25-30
Air Flow Duc t M ount ing B o l t 8-11
Air Flow Duc t M ount ing B r a c k e tt o C 'T l i n d e Hr eadBolt 20-27
Air Condit ioningCom pr e s s o M r ounting Bolts 20-27
Com pr es s orBr ac k etBolt s 40-54
Alt er nat c r M ount ing Nut 20-25
Alt er nat or Adjus t ing Bolt . 12-16
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 40-51
Cooling Fan Reiar ningBo l t s 27 -36
EngineM ount ing Nut s 34-46
Rear Tr ans m is s ic nM oun t i n g B o l t s 34-46
Rear Cr os s m em ber M oun t i n g B o l t s 40-50
Ex haus tClam p Nut s 24 -32
ENGINECOOLIN G68-1
SECTION68
E NG I NECO O LI NG
INDEX
Ref. Subject Page Ref. Subject Pa g e
1. 68-1
GENERAL DESCR|PTION.................!r........... 2.1 RADIATOROVERFLOW/WINDSHIELD
2. SERVICE OPERATIONS ..,.....................or......
68-1 WASHERBOTTLE.................................,........
6B-1
RgmOV€...............o...........,........................
6B- 1
ReinStall .....r....r.........o...........-....-............
6B-1
2.2 COOLINGSYSTEM. FLUSHSYSTEM...-.. 68-2
The cooling system employed on VK Series models is All VK 3.3 litre engines have the thermostat housing, fan
canied over from VH, with only a few minor changes. pulleysand fan belt from the L6 2.8 litre VH engine.
The radiator overflow/windscreenwasher bottle has been
redesignedand repositioned(Fig. 68-1).
Service operations are as described in the VB and VH
Series Service Manuals, except where noted in this
Section.
2.1 RADIATOR
OVERFLOW/WINDSHIELD WASHER
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
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.
68-2 ENGINECOOLING
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
A
MO U N T I N G
WA S H E R H OS E
v
EW
\ SCR
)<
-/\
'-t/
lp' c -
I(--_-/.
AD
VE
A 3.0 - 4.0 Nm
Flgure 68-1
2.2 COOLING SYSTEM I FLUSH SYSTEM

1. Placedraintray undervehicle.
2. Removetop radiatorhose from thermostathousing.
3. Removethermostathousingand thermostat.
4. Place water hose into the top radiatorhose, tum on
water pressure,and flush untrl water coming from
rylinder head is clear.
5. Flush heater core by removingtop heater hose from
thermostathousingaM flush untrlclear.
6. Flushradiatorby rernovingbottomradiatorhose from
waterpump and flush until clear.
7. Removeoverflowbottle,as per serviceoperation2.1,
and flush.
8. with the system f lushed clean, replace thermostat
housing gasket and refit all cooling system
components. Mix a coolant concentration of
approximately21 mls of corrosion inhibitor, GMH
SpecificationHN1109, with every litre of clean water.
Add to the coolingsystem and check for leaks.
ENGINEF UE L6C .1
SECTION6C
ENG I NEFUEL
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. Subject Page Ref . Sublect Page
1. GENERAL DESCRIPTION....,r.............r,.....o... 6C-2 3.11 INLET MANfFOLD .....,....................................
6C-35
1. 1 MAIN COITPONENT SYSTEMS ...................r6C-2 Rgm OV€...............................................r....
6C-35
6C-2
Alr FIOW SyStgm ...r.....r.......r.........r.......r RginstalI .........,,.,...........r.........................
6C-37
6C-3
FUgl SyStem.........D.......r'..................r...... 3.12 AUXILIARY AIR VALVE ...............,................ 6C-37
6C-5
Elgctrical System .t...........r....'.!............. RgmOv€.............. r....r.r.....r....o....rr...... ........ 6C'37
1. 2 FUNCTION OF MAIN COMPONENT R gi nstal l .............
r.............r....,...........r,....
6C -37
SYSTEMS ............................r........t.r............r.....6C€ TgS t...................-.........r...... .......... 6C ' 37
Air FlOw SyStem r........................r......r.t. 6C-8 3.13 FU E L P U MP .r...............r..........o...r..r,.... 6C -38
FUgl SyStem 6C€
................rrrr.r..r...!......r.t!.r... Rgmov€.............r.........r...,...... 6C-38
6C-g
ElgCtrlcal System ..r........r.'..!.r.......!rr.r... Reinstall .....................-..--..... -r.3... 6C-38
2. PRINCIPLES OF OPERATION.........r...r,.,...,r 6C-12 TeStin$ ..............-...-............................o....
6C-38
2.1 FUEL INJECTION TIMING ............................ 6C-12 3.14 FUEL DAMPER- REAR ........,.......................
6C-40
2.2 FUEL INJECTION QUANTIW ...r...r.............r 6C-12 R gm OV€.......'..................-.'..........'r".........6C*f0
2.3 6C-12
ENRlCHMENTS........r.........-.......................r..... RginStall ....".....r........!r............................6C'40
Enrlchmgnt Sensors r.r...................-..r.. 6C-12 3.15 FUEL FILTER ........r...,..,...........r...-.................. 6C-40
Accelgratlon Enrichment ...............t....6C-12 R gmov g................r...................!.......!.t.-.,.
6C-40
Full Throttle (Hlgh Load) Reinstall ......... ..r..r..........r............
6C-40
6C -14
EnflChmgnt................-............r-..r............ 3.16 FUEL DAMPER ' FRONT .............r.......,..rr.... 6C-40
2.4 FUEL SHUT OFF ' COASTING r.....,..!.......... 6C -14 Rgmov€....-.......r r..........r.......................!...6C'40
2.5 VOLTAGE CORRECTION FUNCTION ........ 6C-14 RginSt?ll ..-....,....... .Fr..r...r......r.....r...
6C-40
2.6 coilPoNENT OPERATION .......-.................. 6C-14 3.17 FU E L R 4IL....................,..o...........r...............,....
6C ' 4 1
6C-14
Air FlOw SyStem ..,.'.....................r!'......r RgmOv€......t.........r.r..r.........r.. r..... 6C'4 1
FUgl SyStem .......r .r ...............r .r .- .........r .... 6C-17 R gi n stal | .........-....r..............,...............r....
6C-42
6C-20
Elgctrical Systgm ...r....................-......... 3.18 1N JE C TOR S .......r..r............................,........r.....
6C ' 42
3. sERVlcE oPERATIONS ................................ 6C-24 3.19 P R E S S U R E R E GU LA TOR .............r.,..r.,..,......6C ' 42
3. I 6C-24
SERVICE NOTES .....r......r............................... R gmOV€........'......r............D.......................6C'42
3.2 6C-24
FUEL SYSTEM .....o.......................................... Rei nstal | .........r..J.....rr.!D.....................,-....
6C-42
6C-24
Lgak TgStin$ ...'........-............................. 3.20 CONTROL UNIT r.,..r...,........r..t.......!................ 6C'42
o......6C-24
Depressurlzin$ ............................... R gmOv€..........r.................r-..-...,r......rr,-...-6C-42
Fugl Hosgs and G|amps...................r.. 6C-25 6C -43
R gi OS tal l ...........'............r....-.........r..........
3.3 THROTTLE CABLE ADJUSTMENT.............. 6C-26 3.21 THROTTLEPOSITIONSWITCH..................
6C-43
3.4 CRUISE CONThOL POWER UNIT CABLE 6C-43
RgmOV€..'........,.........r..............................
6C-26
ADJUSTM E NT .......-..........r........r.-.................... Rginst?ll .....,.......,.................................r..
6C-43
3.5 ADJUSTING IDLE SPEED AND ]TIIXTURE 6C-26 Ad justmeJ|t...............................,.......,......
6C'4 3
ldlg Speed Adjustment...............r.r......6C-27 3.22 COOLANT TEMPERATURE SENSOR ........ 6C-44
ldlg llixture Ad1ustment...........,..........6C-27 Re plaC€....................... 6C-44
'......r................-....
3.6 AIR cLEANER ELEMENT.............r.........r....-. 6C-28 6C-44
On Engine TgSt...............o...'.......-.........r
6C-28
ReplaCgmgnt o...............'.....i..............-.... 6C-45
Off Engine Tgst ...............................r....
3.7 AIR CLEANER HOUS1NG.....................r........ 6C-29 3.23 6C'46
CONTROL RELAY ...................................,......
6C-29
R g mOV€........ .............. . ..............4.....1........ R gmOV€......'........r...r..."'.....r-............-......
6C-46
RginStall ............r................-.-.........tr....... 6C-30 6C'46
RginStall ...................r.............................r
3.9 AIR FLOW METER.........,........-......,.......,........ 6C-30 4. 6C-47
DIAGNOSIS..'.....r.....-..'........'.....?....r................
RgmOV€.....-......r..........r.rt......-.........t........ 6C-30 4.1 CIRCUIT TESTING PROCEDURE................ 6C-47
R ginStall ................r.......................-......... 6C -31 Electronic Fuel Injection
TeSt .............-.-.r.rr....................t..'............. 6C-32 6C-47
Test Equipmgnt .........-.-.,..r......r...........,
3.9 AIR FLOW DUCT ....r.r..r.......,'..r..........-........... 6C-32 4.2 TROUBLE DIAGNOSISr............,.......... 6C-61
RemOV€..................t...r............................. 6C-32 5. 6C-64
SPECIFICATIONS-...i......,....o.......i..'....---.-.-.....
R ei nStall ...........r......................-......-........ 6C-33 6. TORQUE WRENCH SPECIFICATIONS........ 6C€5
3.10 THROTTLE BODY ......-...,.......rr..r......r.-...r.-.... 6C-33 7. 6C-66
SPECIAL TOOLS ..-.........................................
R e m OV€ ..' -.................... ". 6C-33
... . .....................
RginStall ..-..............................r....'......r."' 6C-34
lrr
6C.2 ENGINEFUEL
1 . G E N E R A LDESCRIPTION
The Electronic Fuel Injection (EFI) used on VK series velocity.when power is required,it is desirableto have
vehicles is the Bosch LE-2 Jetronic system. as largea manifoldpassageas possible.
The LE-z Jetronic is an electronically controlled fuel To supplyboth these requirementsthe manifoldmust be
injectionsystem which injects fuel at regular intervals into a comprornisewhich resultsin passagesof such a size
the inlet ports adjacent to the inlet valves. lt provides a which limitsboth low and high speed performance.
method of more precisely metering f uel to satisfy the With EFI systerns, the elimination of the carburettor
various engine operatingconditrons. enables the induction passages to be designed to
In a carburettor type fuel system, the intake manifold optimizeair flow and an increased engine performance
design must strike a medium between low and high can be expected with the resultant improvementin
speed requirementsfor air flow. At idle, air flow is very volumetric efficiency. Air is induced into the engine
low and in order to keep the fuel mixed with air, it is through the inlet manifold,and fuel is injected under
necessary to have small passages to keep up the air pressureinto the inlet valve port.
A tn F L OW
''.r= | trH
I r F- FA
r 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 SYSTEM
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.
A
ENGINEF UE L6C .3
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 Re-
circulation, 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
in the fuel tank, is a fuel swirl pot, to minimiseaerationat
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
Fuel Damper- Designedto removefuel pulsationsfrcm

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 FU E L R A IL-.
pressure and carryingout diagnostic procedures.
fIN JE C TOR
\ R E TA tN tN G
\crre
I\l OU N TIN G B OLT

{3 PLA C E S )
Figure 6C€
I n ject ors Ele ctricallycon t r ofled 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
ELECTRICALSYSTEM
COMPRISING:
Control Unit - Processessignalsfrom 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
unit calculatesenginespeed.Refer Fig. 6C-10.
Figure 6C-10
Air Flow Meter - The control unit receives information

about the engine'sload conditionfrom the air flow signal
sent from the air flow meter.Refer Fig. 6C-11.
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 ENGINEFUEL
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 de-
creases 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, I
and it applies a correction factor to the air flow meter ,
output signal to compensate lor changes in inlet air I
t e m perature .Re fer Fig . 6C - 14.
--
J
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 cornponentsare shown in

Figs.6C-16, 6C-17.
- - I
ENGINEFUEL6C.7
LOCATION OF COMPONENTS
A t R F L OW- r
METER
\
\
A I R C L E A NER A IR FLOW D U C T
HOUSING
,- TH R OTTLE P OS ITION
S l VI TC H
TH R OTT LE
B OD Y FU E L TA N K
llil
r-4
\:t
,11,^-
/,,, J
,--->
S='-
_FU E L R A IL FU E L D A MP E R _
t\-,4
,/
FU E L P uMPl - -
I- IN LET .
FU E L TA N 11-
M AN IF OLD GA U GE U N
P R ESSURE
R E GU L AT OR
C ON TR OL R E LA Y - S IT-A T=] I\ FU S E B OX
FU E L FILTE R - U N D E R I',E A -- .'=H IC LE
C ON TR OL U N IT 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
6C.8 ENGINEFUEL
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.
Pulsationscaused 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
maintainedat 303 kPa (3 bar). Excess fuel is returnedto
the fuel tank by the pressureregulatorvia 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{ormatongatheredincludes,inlet air flow from the air
flow rneter, engine coolant and inlet air temperatures
from their respectivesensorsand engine speed from the
ignitroncoil pulses.ReferFig. 6C-20.
ENGINEFUEL6C-9
Figure 6C- 1I
Fi gure 6C -19
'I
6C.10 ENGIN E FU E L
o
(\I
()
(0
I
o
L
-9
tt
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'i
t-?
IGNITION COI L
IGN I TI O N
SW I TC H
C ON TR OL U N IT
AIR F L OW M ET ER
I N J EC T O R S
a
s,
A I R T EN1 PERAT URE

S ENSOR
Fi gure 6C -21
6C-12ENGINEFUEL
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 electricallyconnec-
ted 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 Figure 6C-22
one 4-stroke cycle, i.e. once every engine revolution.
Refer Fig. 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 ENRICHMENTTABLE
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 F A FTE F S TA R T E N R IC H ME N T
z I
quantity.
l
o
WA R M U P E N R IC H ME N T
LIJ
l
TL
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.
ENGINEF U E L6C .13
Throttle Position Switch

The switch contains two contact point sets, one monito-
ring 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 p€r rev and
extra fuel is injected into the inlet ports.
Cold start enrichment can last for a period up to FU E L
10 seconds depending on the temperature of the engine. I
\ r\ rt a l Y ^
^
N t Tt ' 1 -V
| | | I
Refer Fig. 6C-24.
TIME
Figure 6C-24
After Start
When the ignition switch is released to the 'ON' position
I
I
from 'START', the cold start enrichment drops off. The I
'after start' enrichment is provided to compensate for the 17t

sudden decrease in fuel quantity from 'START' to 'ON'.
The control unit multipliesthe basic fuel inlectionquantity r./LLTIP LIC A TION
pulse by a factor of 1.7 at OoC, this factor decreases F A C TO R
until the engine speed becomes greater than 600 rpm.
Refer Fig. 6C-25 1.0
Fi gure 6C -25
Warm Up
The warm up enrichment provides smooth engine opera-
tion 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
: Or- I
zdoc TE MP rooc
Figure 6C-26
^l
6C.14 ENGIN EFU E L
ACC E LE RATION ENRIC HM ENT

The control unit receives a signal from the air flow meter
1.3
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
r',,l U LTIP LIC A TION
injection quantity by a factor to increase the fuel quantity
F A C TOR
delivered. The enrichment signal lasts approximately
2 seconds. Refer Fio. 6C-27.
FULLTHROTTLE(HtcH LOAD)ENRTCHMENT
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 Figure 6C-27
8 percent to give the au fuel ratio required for maximum
p o wer
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 FU E L S H U T
coasting, the closed throttle contact points wrthrn the OFF
throttle position switch close. With the points closed. the
control unit receives an electrrcalsignal and fuel rnlection o
is stopped until the engrne speed drops to approxirnately LU
uJ
1 800 rpm. With en grn e s peed below 1800 r pm , f uel (n
injection commences again to prevent the engine from LU
cutting out. Refer Fig 6C-28.
=
L!
,C ON S TA N T IN JE C TION
S TA R TS
:TH R OTTLE A GA IN
2.5 VOLTAGECORRECTION
FUNCTION TIME
N O FU E L
Ljnder conditions of low system voltage, such as would U S ED
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 Figure 6C-28
ensure the full quantrtyof fuel is inlected
2.6 COMPONENT
OPERATION
C Ot\4P E N S A TION
r D A MP IN G C H A MB ER
AIR FLOW SYSTEM F LAP
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.
I
r
fn the inlet passage of the air flow meter there is a t
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).
ID LE - _ B Y -P A S S
MIX TU R E
A D JU S TIN G S E N S OR F LA P
S C RE W
Figure 6C-29
ENGINEF 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 r ID LE MIX TU R E
\, A D JU S TING S C RE W
on the variable resistor, causing the output voltage to the
control unit to change. BY.PASS
FLAP
Connected to the air flow flap is a compensation flap - SEN SC R
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.
C O M PEN SAT I O N
F LAP
D A[/PIN G
C H A\,188R
Fi gure 6C -30
Throttle Body
A D JU S TE R (D O N OT R E MOV 'E
The throttle body is located on the inlet manifold and it CAP
contains a throttle butterfly valve. This valve controls the
inlet air flow corresponding to movement from the
TH ROTT L E
accelerator pedal. The butterfly valve shaft is connected A D JU S TER
to the throttle position switch.
/ - T i-. l FC TTL E
B ODY
Figure 6C-31
ID LE S P =ED
_ T H R O T T LE PO SIT ION A D JU S -E 3
S U /ITCH
--TFFOTTLE
LE \/E R
ID LE LOA D
C OMP E N S A TOR
Fi gure 6C -32
6 C-1 6ENG I NEF U E L
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 ID LE S P E E D
butterfly valve. This variance in air flow is measured by ADJUST|NG
S c R =y
the air flow meter, and so the control unit changes the \ __f
injector pulse width accordingly. Refer Fig. 6C-93.
A IR FLOW ID LE MIX TU R E
M E TE R F LA P 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 TH R OTTLE -.\
body. When the air conditioning compressor rs operating, VA LVE \..
ID LE LOA D
I '\coMP
the solenoid is energized. This allows an extra quantity of E N S A TOR
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.
L- AIR F LO W ID LE MIX TU R E
M ET ER F LAP A D JU S TIN G S C R E W
Figure 6C-34
AuxiliaryAir Valve
TH R OTTLE A IR F LOW
when ine en gin e is cold . it m us t pr oduc e higher t or que \./A LV E ME TE R
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 I\
the induction system causes the flap within the arr flow \
meter to deflect and the potentiometersignals the control L , o LE MI X TU R E
unit that more fuel is requrredthereby maintainingthe air A D JU S TIN G S C RE W
f uel rat io con sta nt. Refe r Fig 63- 35 Au) . l r - IAEY- -
/\f-A \t-
Alf'1 , n -' , i
Fi gure 6C -35
-------
- -
ENGINEF U E L6C .17
The auxiliary air valve contains a slotted disc that rotates

to open, close or partially close an air passage in the S LOTTE D D IS C
valve. Current f lows through the heater coil which
controls the operation of a bimetal spring which rotates AIR O U T LET
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. -- ! E A TE R
With a cold engine, the bimetal strip keeps the disc
positioned to open the air passage, permitting air from A IR IN LE T
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.
Figure 6C-36
FUELSYSTEM
Fuel Pump
The electricfuel pump is a roller-cellVpe. Currentto
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 - AR \''IAT tR =
around its circumference which are pressed against the

thrust ring of the pump housing by centrifugal force and
act aS seals. The f uel is carried in the cavtties which S ID E
fr OU TLE T
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 ,i
t
rnaximum requirement of the engine So that the pressure

in the fuel system can be maintainedunder all operatrng
'1t
conditions.
t I Notj F= TU R N
\ \_
R OLLE R VA L =
C E LL
P R E S S U R E- P U MP
R E LIE F
V A LV E
Fi gure 6C -38
6C.1 8ENG I NEF U E L
The pump incorporatesa check valve to maintainsystem

pressureafter the pump is shut off. Also incorporated,is RESSURE
an internal relief valve which provides protection from
excessivepressure.
The fuel pump capacityis 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.
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
:._----_:
i:
t:
FU E L S U P P LY
ffi
D-r):i+t:t:\-.aiat
lri;::::Si.;.:.:t ]:
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 FUEL DAMPER
flow pulsations from the fuel pump and the injectors. Two A IR C H A MB E R
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.
D IA P H R A GM
Changes in the f uel pressure drscharged f rom the fuel
pump and the opening and closrng of the injectors, are FU E L
monitored by the diaphragm and spring, which varies the C H A MB E R
volume of the f uel chamber thereby suppressing fuel
pressure pulsations.Refer Fig. 6C-40.
The fuel dampers are sealed units and are non adjust- FU E L IN LE T F U E L OU TLE T
able in service and are not repairable.
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 FI LTE R
armature attached to a pintle vafve which, when act- E LE C TRIC A L
ivated, opens inwardly. A spring holds the pinile valve C ON NE C TION
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 pro-
portional to the pulse width and thei'efore,the time the
i n j ectoris ope n. S OLE N OID
Typical inlection time for most engine cperating condrt- WIN D IN G
i_onsrange from 2.5 to 10 milliseconds.Refer Fig. 6C-41
S OLE N C ID
for internal view of a typical injector. AR M AT t- .,r IR
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 s S E A LIN G
removed. Refer Fig. 6C-42. R IN G
\,O'
\s
..,,r.*t\
The cap on the injector tip is to protect the injector pintel
\
f rom damage during handling and f itting and also, to T IP l ) ,J SU LA TO R 1

provide heat insulation to prevent vapour formation. lt I
I
SHOUL D N O T BE REM O VED. Ref er Fig. 6C - 4 2 . I
S E A LIN G 'O' R IN G /
I
Fi gure 6C -42
Fuel Pressure Regulator

FU E L R E TU R \ _ gR ESSU R E RE G U L A TO R
The fuel pressureregulator(Fig. 6C-43) is a diaphragm
C ON N E C TION
operated relief valve used to maintain f uel system
pressureto 303 kPa above the inlet manifolddepression.
The diaphragmsenses fuel pressureon one side while
the other side is exposed to inlet manifold vacuum. A f FU E L
spring, rnounted in the engine vacuum side of the \ coN N E C TION
diaphragm,establishesa nominal pre-load of pressure.
With the f uel pump constantly supplying fuel to the
regulator,a situationof too much fuel at the regulatoris V ALV E P LA TE
created.When pressuregreaterthan 303 kPa above the ---J
i ;:;:;i;i;i;i;l
inlet manifold depression is sensed, the diaphragm 1 .\ --i "' ,'i,

:
V A LV E
--?
rnovesto allow excess fuel to be routed back to the fuel i
H O LD E R
-i
tank.
:.-
The continuousflow of excess fuel to the petrol tank ,-J+
helps ensure that the injectedfuel is cool and vapour
f ree. The regulator is a sealed unit and cannot be SPR IN G
- DIAPHRAGM
repaired.
TY P I C A L
Fi gure 6C -43
Fuel Filter
Due to the extremely close tolerances of various com-
ponents 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.20ENGINEFUEL
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.
IN JE C TOR
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.
Figure 6C-46
ELECTRICALSYSTEM
,,- P A S S E N GE R
rAJ5trl\btrF{
Control Unit a' ,/ s r D Ec o w L P A NEL
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 C ON TR OL
pulses to the injectors. lt is connected with the electrical U N IT
components in the system by means of a multiple pin
plug and wiring harness.
/.
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
ENGINEF UE L6C -21
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 C OO LA N T C ON TR OL
coolant temperature rises, the output of the temperature TE MP E R A TU R E U N IT
sensor is changed. With this change, the control unit S EN S OR
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 . IN J EC T OR S
Fi gure 6C -49
Inlet Air Temperature Sensor

The inlet air temperaturesensor 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
temperatureby applyinga 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
other set monitorshighload position.ReferFig. 6C-51.
The closed throttlecontactsare closed when the throttle
butterflyvalve is positionedat 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 TH R OTTLE
slowingdown from highwayspeeds,injectionis stopped V A LV E S H A FT -
to save fuel.As the engineslowsto 1800 rpm the fuel is
reintroduced in preparation
for idle. I D LE C ON TA C T _
Fi gure 6C -51
6C-22ENGINEFUEL
Enrichment is also provided at higfr load as srgnalledby

the closing contacts in the throttle position switch, when TH R OTTLE B OD Y
-
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.
/l
/l
. T HR O T T L E
PO S IT I ON
SW IT C H
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 ] B A TTE R Y
I
r---J 3 rGN tTtoN

I
S WITC H
i S TA R TE R
TC FU E L S OLE N OID
P'- :"4P
EN G IN E C R AN K IN G
Fi gure 6C -54
ENGINEFUEL6C-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.
TO
E LECTR I CA L
coMPoNrrry: '_+
I
i
I
= B A TTE FY
I EA R TH I G N I TI O N
r - - - 'J
I S W I TC H
i I G N I TI O N
TO FU E L COIL
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. _l
I
lf the ignition coil pulses stop because the engine has
stopped, for instance in the case of an accident, the
control relay switches off. PO IN T S
O PEN
This safety circuit prevents the fuel purnp from pumping
fuel when the ignition is switched 'CN' but the engine is B A TTE R Y
not running.Refer Fig. 6C-56. S U P P LY
TO
E LE C TR IC A I
C C IvIP ON E tf fS
S TOP P ED
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
3.1 SERVICENOTES 10. Depressurizef uel system as per service operation

IMPORTANT:The following must be observed when 3.2 in this Section before disconnectingany high
working on vehicles with the electronic fuel injection pressurefuel line, to reducethe residualpressurein
system. the fuel lines.
1. Never start the engine wrthout the battery being NOTE:with very hot engine up to a litre of fuel may be
solidlyconnected. expelfedunder high pressure.
2. Do not use a quickchargeunit to start the engine. 11- Before
?.terpting any electric welding on the
3. Never separate the battery from the 'on board' vehicle,disconnectthe battery leads and Ine control
electricalsystemwhilethe engineis running. unit connector.
4. when charging the battery, disconnect it from the 12. when steam creaningengines, do not direct the
vehicle'selectricalsystem. steam cleaningnozzleat any EFI components.lf this
5. Before makrngany test on the fuel injectionsystem, happens,corrosionof the terminals€n take place.
ensure that the ignition coil and distributorare in 13. Never attempt to bench test the fuel purnp as it is
order, as the control unit operationis triggeredfrom designedto run with the internalsimmersedin fuel.
tr,e ignition coil. checks should also be made of Runningon a bench withoutany fuel can cause the
rgnrtron tirningand spark plug condition. pumpto explode.
6. Never subject the control unit to temperaturesabove 14. The throtile body must be removed every
80oc (1760F) i.e. paint oven, alwaysremovecontrol 40,000 kTr o]' 2 years whichever occurs first, ani
unit first if this temperatureis to be exceeded. ExhaustGas Recirculationdepositscleanedfrom the
7. Ensure that all cable harness prugs are connected throttle blade and throtile bore. Reset idle speed
solidly and that battery terminals are thoroughly after reinstallation.Failure to observe this require-
clean. ment will result in the engine idle speed decreasing
and stalling.
8. Never connect or disconnectcable harnessplug at
15. Disconnectthe batterybefore workingon either the
controlunit when the ignitionis switchedon.
fuel or electricalsystemsof the EFl.
9. when making a compressrontest, remove control
16. Handle all EFr components carefully to avoid
relay from the fuseboxto deactivatethe fuel pump
and prevent fuel being inlected during engine damage,particularly the air flow meter.
cra nking.
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 ionof 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
ENGINEF U E L6C .25
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

depressurizingthe system:-
1. Detachhose from fuel pressuregauge,SD28018.
2. Removecap from schradervalve fittingin fuel rail.
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
reinstallcap. Reinstallhose to gauge.
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
ensure positiveretention.Use only the correct,genuine
EFI system fuel hose. Carburettorfuel hose, emission
hose or non genuinehose, even though it may have a
high pressurerating,ls not suitable.
Hose clampson the EFI systemare speciallydesignedto
exert an even clampingforce around the circumference
of the hose and have roundededgesto avoidcuttinginto
the fuel hose.
Tighten to the correct torque (refer Torque Wrench
Specifications)and never use non genuine substitute
hose clamps.
6C-26ENGINEFUEL
3.3 THROTTLECABLEADJUSTMENT
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
1. Depress accelerator pedal to floor.
2. 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)
v.-\J-
3. Allow accelerator pedal to assume free position. /
iI _ TH R OTTLE V A LV E
4. 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).
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 CRUISECONTROLPOWERUNIT
CABLEADJUSTMENT
1. Ensure ignition is switched 'off ' and the throttle
butterfly valve is completely closed. E N S U R E P OWE R U N IT
2. Check slack in cable. Refer Fig 6C-60. LIN K IS IN S TA LLE D
TH IS WA Y
3. 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.
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 DA N D
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 ransmissionin 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
5. Connect an ACCURATE CO-meter and tachometer.

6. 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.
IDLE SPEEDADJUSTMENT T - J R OT T LE
LOC K N U T -
adiustthe
ln the case of deviationfrom specifications, -=V E R S TOP ;
idlespeedas follows:
1. Loosenoff lock nut (Fig.6C-61).
2. Install an accuratetachometer.Turn the idle speed
adjusting screw to achieve the correct idle speed .,/
ID LE S P E E D ,/'
Fig. 6C-61. A D JU S TIN G S C R E W_
Screwingthe adjusterout, increasesthe idle speed,
screwingin, decrea*s the idle speed.The specifica'
tion for a 'run in' engineis:- 850 t 50 rpm.
DO NOT UNDERANY CIRCUMSTANCES ADJUST
THE THROTTLELEVERSTOP (ReferFig. 6C-61).
3. Check CO-readingafter speed adjustment.The spec-
ificationfor a 'run in' engineis .5 to 1.So/oCO.
Figure 6C€ 1
IDLE MIXTUREADJUSTMENT
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-28ENGINEFUEL
2. Pierce and remove the plastic cap on the air flow

meter to expose the mixture adjustingscrew. Refer
Fig. 6C-62.
3, Turningthe screw in, nchensthe mixture,screwingit
out leans the mixture. ldle CO-specification
is .5 to
1.5%.
4. Recheck idle speed after mixture adjustment.
5. 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 RE L E ME N T
REPL AC E M E NT
1. Drsconnectbatteryearth lead.
2. Loosenhose clamp around arr flow duct at air flow
meter.Refer Fig. 6C-63
3. Disconnectwiring 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 6C€3
I Remove air flow duct mounting bolt. Refer

Fig. 6C-63A. H OS E A IR FLOW D U C T
C LA MP - H OS E
C LA *'/
\/
.----\ //
--\\
---v:\
/
Figure 6C€3A
ENGINEFUEL6C-29
5. 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 removingthe upper air cleanerhousing,be
particularlycareful not to damage or knock the air flow R - - - - - Al R
meter. C:EA\ER
H OU S I N G
7. Rernoveair cleanerelementfrom upperhousing.
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
3.7 AIR CLEANERHOUSING F L3,'y ' * '.tET =R -

REMOVE
1. Disconnect battery earth lead.
2. Disconnect wiring harness connector at the air flow C ONN E C TOR
meter, remove harness from retainer. Refer
Fig. 6C-66.
3. Loosen the hose clamp around air flow duct at air
flow meter. Refer Fig. 6C-66. 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
6C.30ENGINEFUEL
5. Remove air flow duct mounting bolt. Refer

Fig. 6C-67A. H OS E A I R FLOW D U C T H OS E
6. Remove the three air cleaner housing mounting nuts C LA MP C LA MP ;
/
(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.
REINSTALL
1. Installation
is reversal
of removal.
2. Check for air leaks.
-l/,
))
///
/,/
Figure 6C€7A
3.8 AIR FLOW METER

A IR FLOW ME TE R
REMOVE
1. Disconnectbatteryearth lead. WIR IN G H A R N E S S
2. Loosen hose clamp around air flow duct at air flow C ONN E C TOR
rneter.Refer Fig. 6C-68.
3. Disconnectwiring harnessconnectorat the air flor
meter, rernove harness f rom retainer. Refer
Fig 6C-68.
R E TA IN E R
B O LT
Figure 6C-68
4. Remove air flow duct mounting bolt. Refer

Fig. 6C-68A. t u P P oR r B R A C K E T
I
-c
/---
/
FLOW
r -A tR
DUCT
Figure 6C€8A
_ ________
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.
7 . Removeair cleanerelementfrom upperhousing.
L=ANER
t'l G
S NA P LOCK S
Fi gure 6C -69
8. Remove air flow meter mountingbolts f rom upper

innerair cleanerhousing.Refer Fig. 6C-70.
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. lnstallation is reversal of removal.
Fi gure 6C -71
2. Ensure 'O' ring is in Place.
3. 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 housing-
-q
6C.32ENGINEFUEL
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-----
--
7 A IR FLOW
r DUCT
,/--T A U X ILIA R Y
.{ A IR V A LV E
't H OSE
Figure 6C-74
ENGINEFUEL6C.33
3. Remove the engine ventilation hose bracket bolt

from underneath air flow duct. Refer Fig. 6C-74A. E N GIN E
4. Remove the air flow duct mounting bolt from support V E N TI LA TI ON
bracket. Refer Fig. 6C-74.
Figure 6C-74A
5. Loosen the hose clamps around each end of the air

flow duct (refer Fig. 6C-75) and withdraw duct from H C S= AIR F LO !'J D - ]-
its position. C LA\1P -
REINSTALL
2. Check for air leaks at all connections to air flow duct
(this will effect the air fuel ratio).
Figure 6C-75
3.10THROTTLEBODY TH R OT-|-uI _ A C C I:E R A TOR C A B LE -

REMOVE B oD Y
A C S E ::R A TOR r
1. Disconnect battery earth lead. R E -I-LR NS P R TN G\
:*.'.---.--.{ _C C K
\: -
2. Remove air flow duct as per 3.9. '- -r--------=h-f --:-rlTS
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.
".,]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
4
6C.34ENGINEFUEL
4. lf fitted, remove cruise control power unit cable

retarnerfrom throttle linkage. Refer Fig. 6C-77.
[r ,NKNUr \p
,l
i L'|NKAGE Y---
,rTlRo.rr-LE
,----&{
^tr fr
/v
P OWE RU N IT C A B LE
R E TA IN E R
Figure 6C-77
5 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
-
E N GIN E
TV S S WITC H TO -I V E N TI LA TI ON
TH R OTTLE B OD Y
Fi gure 6C -78
6. Disconnect throttle positron switch wiring harness

connector and, i{ fi:ted. rdle load compensator power TH R OTTLE MOU N TIN G N U TS
f eed wire. Re fer F'E. 6C- 79. B OD Y (4 P r-A C E S )
Remove the /- mcunting nuts securing throttle body

to the inlet nanifold and remove throtile body and
MOU N Tl N G
gasket. Refer Fig 6C-79. S TU D S
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.
6g
ID LE LOA D _
C OMP EN S A TOI
RE IN S T AL L
I n st aliat ionis reversalo f r em ov al not ing t he f ollowr ng: TH R C TTLE _
PO SIT IS\ SW IT C H
Use a new throttle body to intet manifold gasket.
Before fifirng the throttle body wrpe Exhaust Gas Re-
circulationdeposit 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 Figure 6C-79
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
ENGINEFUEL 6C.35
3.11 INLET MANIFOLD

1)
REMOVE
batteryearthlead.
1. Disconnect
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. * tr'

1 To s peeds ens ort r ans duc er .
15 To l M oC t her m os t athous ingTVS .
2 To brake booster.
4 To aux iliar y air v alv e.
5 To aut om at ict r ans m is s ionv ac uum
m odulat or v alv e.
3 r egulat orv alv e,
To f uel Pr es s ur e
I SS EG R v alv et o c y linder head EGR T V S s w i t c h . i
Figure 6C-80
HOSE NOS.
61 T h r ot t le body t o c y linderheadEG R T V S s w i t c h .
38 T hr ot t le body t o t her m os t athousi n gT V S .
60 C anis t er t o t h r ot t le body pu r ge.
6 Enginev ent ilat ionhos e.
38
Fi gure 6C -81
4. Disconnect throttle cable from throttle body linkage - AC C ELE R A TOR

TH R OTT L E - A C C E LE R A TOR-
and air f low duct mounting bracket. Remove the B OD Y CA B LE
A E TU R N S P RIN G
upper accelerator return sPring.Refer Fig. 6G82.
.- : --_- --
__l =l
,_LOC K N U TS
-{ F
R ET U R N SPR lN G
Figure 6C-82
6C.36ENGINEFUEL
5. lf fitted, remove cruise control power unit cable

retainer from throttle linkage. Refer Fig. 6C-83.
LIN K N U T
THROTTLE 1)-\--
LIN K A GE
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 C OOLA N T TE MP E R A TU R E
fitted, coolant temperature sensor, injectors and S E N S OR-
generator. Refer Fig. 6C-84. _ID LE LOA D C OMP E N S A TOR
unclip wiring harness clips around fuel rail and top I N JE C TOR S r6 P LA C E S )
radiator hose and withdraw wiring harness towards
the rear of the engine. PC S IT IO N
Figure 6C€4
7 Disconnect E.G.R. pipe from inlet and extracto'

manifolds.Refer Fig. 6C-85.
8. Depressurizefuel system as per 3.2.
9. 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
ENGINEFUEL6C.37
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
I
I
Clean inlet manifold and cylinderhead mating faces and
E.G.R. exhaust gas pipe and manifold surfaces. Install I 'T
new gaskets
Installationis reverse of removal operations. Tighten I
manifoldbolts, working from the centre outwards.Refer
TorqueWrench Specificationfor details.
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 Figure 6C€6
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
unit cable adjustment,refer 3.4.
Start engineand check for air leaks.
3.12 AUXILIARYAIR VALVE

REMOVE ,tr -
,.ff
1. Disconnect battery earth lead. 33'{

2. Disconnect harness plug at top of valve. Refer
Fig. 6C-87.
3. Loosen hose clamps at each end of the valve and
disconnect hoses. Refer Fig 6C-87. ,.- -A I R FL O W
4. Unscrew both mOunting screws and remove auxiliary f D ri c T
air valve. Refer Fig. 6C-87.
7 H A 3 \ E S SP IU G
REINSTAL L
1. Installation is reversal of removal. Valve is to be
installed with the wiring plug connection upwards. AIR
Ensure that the cylinder head and auxiliary air valve 5**t fi--lt
mating surfaces are clean to provide the required HOSz_--'-i' \ ,:,_[
heat transfer.
__---t, | A U X ILIA R Y
-z-
TEST \l -t
al
A rR vA L v E
Thistestmustbe performed
witha coldengine- H OSE
C LA MP S
;i6
1'ffiirui6M o u N r lN G SC R EW
Start engine and pinch the rubber hose between the S/ f l *- -
\-f{T O (2 PLACES)
throttle body and the air valve. \\!./
When the air valve is cold, the engine speed should

decrease as the hose is Pinched. AIR IN LET H OSE
With the air valve hot, the engine speed remarns
unchanged as the hose is Pinched.
Figure 6C-87
6C.38ENGINEFUEL
3 . 1 3F U E L P U MP
REMOVE FU E L D A MP ER
OU TLE T H OS E
2. Drain tank to below level of fuel outlet.
3. Disconnect wiring harness connections on the pump.
Note which way the wiring connectors are fitted to i v(
4.
the pump. Refer Fig 6C-88.
Place a drain tray underneath pump.
rlt
FU E L P U MP
5. Depressurizefuel system as per 3.2 ,,U P B OLT
6. Remove fuel pump clamp bolt and clamp. Refer
Fig. 6C-88
H OS E C LA MP
7. Loosen hose clamps at either end of the fuel pump
and slide hoses off, withdraw fuel pump. Fig. OG8B, Z F U EL D AM PER
_==-_
rl L"-
R EI NS T A L L
[ *,*,*]
Installationis reversal of removal. When installingthe fuel H AR N ESS
purnp ensure that the fuel line hose clamps are properly T ER M IN ALS
seated and check for fuel leaks as per 3.2.
Figure 6C€8
TESTING
Volume Test
1. Depressurize
fuelsysternas ger3.2.
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.
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.
ENGINEFUEL6C.39
2. Start engine and read fuel pressuregauge'

Pressureshould be approximately25O 20 kPa at
idle.
The moment the acceleratorpedal is moved pre-
ssure should increase to approximately300 kPa
(accelerator must be opened rapidly to give 'C'
manifoldvacuum).
3. lf fuel pressureis not as specified,check for clogged
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
the pressureis still not achieved,replacefuel pump-
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
reading.tt ihe readingdrops,it is an indrcation of an
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'
Figure 6C-89
6. Clampthe fuel returnline from the pressureregulator
and observe the pressure gauge reading' lf the
reading stops dropping, the pressure regulator is
faulty and must be rePlaced-
7. lf the readingcontinuesto drop, removethe fuel rail
mountingbolts from inlet manifold'
g. Carefullyremove fuel rail and iniectorsfrom the inlet
manifoldand rest the fuel rail on the manifold'
9. Carry out steP 5.
10. Observewhich iniector/sis leaking'
11. Replace iniector/s which are faulty. Replace the
sealing'o' rings on all other iniectors,and lubricate
usingPetroleumiellY.
12. Refit fuel rail assemblY-
13. Refit starter motor solenoid wire- Start engine and
check fuel pressure gauge reading. Switch'off'
engineand checkfor pressuredrop'
14. Remove pressure gauge and install scrader valve
cap.
6C .40ENG I NEF U E L
3.1 4 FUEL DA MP E RT RE A R
REMOVE H O SE C LAM P

2. Depressurizefuel system as per 3.2.
1r
3. Raise rear of vehicle and support on jack stands. @ t:
rl
4. Loosen hose clamp on fuel outlet hose frorn damper,
/t l
rernove hose. Refer Fig 6C-90. r"
ti
5, Remove fuel damper mountrng nut from bracket,

-/ J]
lr
ti
---''
loosen hose clamp between damper and fuel pump. ----'-'
Refer Fig. 6C-90.
6. Lift damper f rom mounting bracket and withdraw H OS E
from fu el p ump ho se .
RE I NS T AL L
MOU
MOU N
UT
A CK E T
j =

2. C hec k for fue l le aks a s per 3. 2. Figure 6C-90
3 .1 5 F U E LF IL T E R
FR OM FU E L P U MP
REMOVE
1. Disconnectbatteryearthlead.
2. Depressurize fuel systemas per g.Z.
3. Raiserear of vehicleand supporton jack stands.
4. Placea draintray underneathfilter.
5. Loosenhose clampsand disengagefuel hoses from
filter.ReferFig. 6C-91.
6. Loosenfilter mountingclamp bolt and removefilter.
Re fe rF ig. 6C- 91.
REINSTALL
1. Replacingfilteris reversalof rernoval.
NOTE:Directionof fuel flow arrowon filterbody rnustbe
compliedwith (arrowto pointto front of vehrcie). '/
2" Make sure the fuel line hose clamps ate properly
seatedand checkfor fuel leaks.relerinstructiong.Z.
> C LA MP
C LAM P
BO LT
H OS E C I-A I'I,P-,
T O EN G I N E'
Fi gure 6C -91
3 .16 FUEL D AMP E R I FRONT

R EM O V E
i Drsconnectbattery earth lead.
2. Depre ssurizefu el syst em as per 3. 2.
3. Locsen fu el lin e ho s e c lam ps at eac h s ide of FU E L f-
r-1u\l
r,-
H OS E
dampe r, d lscon ne ctfuel hos es . Ref er Fig. 6C- 92 | !/t-
-
D AM P E R
4. R emo ve mo un ting nu t . Ref er Fig 6c - 92 and wit h-
draw d amp er.
\:3J\TIN G
R E I NS T ALL \-T
1. Inst alla tionis re ve rsa lof r em ov al. FU E L H OS E --.^ ,{,2 A U X I LIA R Y
2 Check fo r fu el lea ks a s per 3. 2. A IR V A LV E
Figure 6C-92
ENGINEFUEL 6C-41
3 .1 7 F U E L R A IL
REMOVE
1. Disconnectbatteryearth lead.
2. Depressurize fuel system as per 3.2.
3. Disconnectthe fuel return line from the fuel pressure
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 harnessretai-
ning 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. Removethe injectorretainingclips.Refer Fig. 6C-95.
F U E LR Ar L
rq f I
4
$s
$
K
/ ' , *J Ec r o R
IP
Figure 6C-95
-rfrt-
6C.42ENGINEFUEL
7. Remove the 3 fuel rail mounting bolts. Refer l.t':llnar,
FU E L R A I L
Fig. 6C-95. Using compressed air, blow off dirt y -}
.op'g { . , . ' rv I rl \ \ l D \ , rL |
around the injectors. i 3 PLA C E S ) *r'i ,,
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. IN JE C TOR
10. Withdraw fue! rail toward front of engine, pushing
down slightlyon top radiator hose.
REINSTALL
Before reinstallatingany injector, replace both sealing 'O' IN JEC TOR
rings. lt will be necessary to cut the old 'O' rings fronn R E TA IN IN-T-
G C LIP
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
Figure 5C-96
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.
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
2. Disconnect vacuum hose at the pressure regulator.
Refer Fig. 6C-97.
3. D epr essu rizefue l syst em as per 3. 2.
4. 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.
5. 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 lnstallationis reversal of removal.
2 Check for fuel leaks as per instruction3.2. Fi gure 6C -97
3 . 2 0C ON T R OLU N IT
REMOVE
'1 Make su re ig nitio n is s wit c hed ' oFF' and dr s c onnec t
battery earth lead.
2 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.
ENGINEFUEL6C-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
fnstallationis reversalof removal.
Figure 6C-98A
3.21 THROTTLEPOSITIONSWITCH
REMOVE _ T H R OTTL E
ii /
1. Disconnect battery earth lead. P o s tr to N
r/
2. Disconnect wiring harness plug from throttle position S WI TC H
switch.
3. Remove vacuum fitting from manifold next to throttle
position switch. TH R OTTLE
B OD Y
4. Remove 2 mounting screws and withdraw switch
from throttle shaft. Refer Fig. 6C-99.
-i rl f J N TI N G
REINSTALL SCREWS
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 Figure 6C-99
vacuum fitting.
Do not tighten mounting screws as switch must be
adjusted.
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 adjust-
able and are automatically set when the closed throttle
adjustment is made.
Figure 6C-99A
3.22 COOI-ANTTEMPERATURE
SENSOR
R EPL ACE
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 radiatorand check for leaks.
O N EN GI NE T E S T
The temperature and resistance
readingshouldbe made Figure 6C-100
beforeand after enginewarm up.
Engine Cold
2. Disconnect wiring harness connector from
temperaturesensor.
3. Remove radiator cap, place a thermometer in the
radiatorcoolant and read coolant temperature.
A
s. Usrng an ohmmeter, measure the resistance across
the terrninals of the temperature sensor. Refer C OOLA N T
F ig 6C-10 1. TE MP E R A TU R E
S E N S OR
5. Connect wiring harness connector and battery earlh
lead.
6. 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.
Fi gure 6C -101
-- ----
ENGINEF UE L6C -45
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
terminalsat varioustemperatures. ReferFig. 6C-102.
Check the resultswith the followingchart.
Fi gure 6C -102
tI
I
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 01
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.
6C.46ENGINEFUEL
3.23 CONTROLRELAY
REMOVE F U S E B OX
1. C OV E R
Remove fuse box cover. Fig 6C-104.
Figure 6C-104
2. Pullout relayfrom its position.Ref er Fig. 6C- 105
REIN STALL
Installation
is reversalof removal.
Figure 6C-105
ENGINEF UE L6C -47
4 . DI A G NO S I S
4.1 CIRCUITTESTINGPROCEDURE
FUEL INJECTIONTEST
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 obtain-
able 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.
25 14
Terminals 14 through 25 are on the shorter terminal strip.
Refer Fig. 6C-105A.
Terminal 14 is next to the cable entrance-
Some tests involve cranking the engine, therefore
appropriate safety precautions must be observed.
13
MU LTI_P LU G TE R M \A LS
Fi gure 6C -105A
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E NG I NEF UEL 6 C - 4 9
Function or Measure
Component to Test With Between Test Status lnd ication l f D ef ecti ve N otes
be Tested Ter m ina l s (correct)
Fue l p ump Tes t lam p | + and- on lgnition in Test lamp lights Look for break i n I'pum p runs but
operatin g I f uel pum p crank l f p u m p r u n s ,i t cabl e harness or ergi ne w i l l not run
p o si t i o n can be heard. bl ow n fuse or creck fuel pres s ure
faul ty rel ay. anc \.c ;urne pumpe
aS P erS g' \' l C e
I op.ra i ro- 3 13
Re layclo si ng
i be Lis t ent o lgnition :n R e l a yc l i c k sw h e n C h e c k c ur r e n t R e f e r Fi g . 6 C 1 0 7
lCan i
lhear d or r elay . activatec. supply wires
lcrank
, t es t lam p 87 and ear t h I Position L a mP i ; g h t s t o r el a y.
Batte ry su pply , Tes t lam P 30 and 31 Relay Lamp l i gnts B reak i n suppl y C h e c kfu si b l e
to rela y rernoved cr earth l eads to link.
tP /
lgn ition swit c h r Tes t lam p 15 & ear th lgnitionon Lamp lights B . e a<
'
'a
sign al , I SV/itCf ,,
a
i
Cra nk sig naI Test lam p 50 & ear t h lgnition in Ij L u m p l i g h t s B r e a k r n c - '- : ^ :
crank supply in sta::::
D O Si ttO r . s o l e n o i dc i r c ui t .
lg nitio n p uls e tamp 1 & earth Engine Lannp f l i ckers B r e a ki n l e a d R efe. F 6C 108
sig na l
lr.t, crankrng aS ?nE ,n3 tU rnS 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
Inje cto rvalv es Oh m m e te r Cy l. 1 t hr u 3 lgnitionoff A p p r o xi m a t el y C h ec k ',: , brea k R e f e r Fi g . 6 C 1C g

an d wiring Ter m . 12 & 9 D i s c o nn e c t 3 to 4 ohms cabl € n3-nass
Cy l. 4 t hr u 6 wrring C heck rnj ec:o-s R e f er Fi g . 6 C ' 10
Ter m. 24 & 9 har:^,eS p lSu g s i ndi vi duatl v
a t ai . f ro r , r w i th ohmmete:
meter& arx, va l ue 16 oh ms.
' a i r v a l v e&
throttle
position
; switch.
I C heck fcr break i n
lTes t lam p Cy1. 1t h r u 3 l g ni t i o n o n L a r n pl i g h t s
I
| ( 2 wat t s ) Ter m 12 & 1 3 & in crank cabte -a-ness.

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I Ter m. 24 & 2 5 defect . = S hort
I
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Inje ctio np uls e Tes t lamp Rem ov ep l u g l g^ r cr' Lampf lickers C h:c< w ri ng for
sign alfro m ( 2 uv at t s ) f r om inje c t o r i crank brightlyinitially supci v si gnal s at
con trol u n it a n d m e a sure pos : cr and dimswithin ccntrol uni t
a cr o ss te rms. 10 s e c o n d s connector. l f
o n p lu g 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 e st la m o 9 & earth l g n i t i o n r '. Lamp lights R el ay def ect i r.'e

t o c o n t r o l u n it and in c-ark C heck i or break n
positicn 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-50ENGINEFUEL
F unction o r Measure
Component to Test With Between Test Status Indication l f D ef esti ve Notes
be Tested Ter m inals (correct)
C ont rol unit Te st la m p 9and5 lgnit ion on Lamp l i ghts Check for break
a nd systeme arth i 9and 13 and in c r an k l e a d s5 , 1 3 & 2 5 .
9and25 pos it ion
I n it iat ion of Test lam p 9and1 Operate Lamp f l i ckers C h e c kf o r b r e a k i n R efer 6C-1 1 1
i n ject ionim pu lse starter wiring - ignition
br ief ly 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,
Sta rt s ignal f r o m Test lamp 4and5 Op e r a te Lamp lights C h e c kf o r b r e a k i n Test lamp will
sta rt er f or co n t r o l star te r wiring between light only in
u nit b r ie fly s t a r t e r& t e r m i n a l crank mode. lf
I
I
5 0 o n r e l a y .B r e a k l a m p l i g h t sw i t h
in wire from ignitionon, check
c o n n e c t o rt e r m . 4 why term. 50 has
to starter. power.
Refer Fig.6C-112
O perat iono f id le ' O h m m ete r 2 ano 9 lgnit ion of f C h e c kf o r b r e a k i n R e fe r F i g . 6 C - 11 3
contactsin Ac c eler ato r 0 ohms c a b l e h a r n e s so r
t h rot t le valve pedaI in id l e approx. r e p l a c et h r o t t l e
switch pos it ion F o s i t r o ns w i t c h .
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 ' O h m m e:3 r 3 anc 9 lg n r t:o r , o f f C h e c kf o r b r e a k i n R ef er F i q. 6C - 114
l o ad c ont act s i n Acce le .a to r' cc ohms c a b l e h a r n e s so, r
th r ot t le v alv e p e d a l ir id l e r e p l a c et h r o t t l e
body Po sr tr o n p o s i t r o ns w i t c h .
Acce le - a to r 0 ohms
p e d a ' fu lly approx.
d e p r e sse d
C oolant O h r n m € te r 1C anC 5 lg n itio n o ff Temoerai ure Breakin cabfe

t e mperature oepentant h a r n e s so r r e p l a c e
s en sor 0'C - 5500 ohms tem perature
zO'C-2450ohms s e n s o r
8O"C-320 ohms
97'C- 200 ohms
A r f low me t e r Ohmmet er 7and5 lgnit ion o; f 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
Pus hair a t a n y v a l u eo t h e ' c , r s s , 1 n c a b l e
f low m : : e- t h a n 0 o r i n f i n i t v h a - n e s sA . rr flow
f ap S l"' , , ' y ' the ai r fl ow rne:3r sensor
- v!
i s OK . oefE ct r ve,
Aux il; ary air T e s t l am p Lamp C neck for breaks i n
va l v e c irc uit
auxi i i ary ai r val ve
ear:h and vol tage
s.rppl y w i ri ng.
Au xil iary O h m m e te r Rem ov eplug o ff 35-40 R epl ace.

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v alv em eas ur el
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6C-58ENGINEFUEL
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ENGINEF UE L6C .61
4.2 TROUBLEDIAGNOSIS 2. Make sure the ignition and starting systems are in
good order
The LE-2 Fuel InjectionSystem can be checkedwith the
following.lf any abnormalityis found in any cornponent, 3. The LE-2 system accurately meters the inlet air flow
refer to the testing procedures in the 'Circuit Testing so any air leak can cause an improper air-fuel ratio,
Procedure'or 'ServiceOperations'in this Supplernent. resulting in taulty engrne operation.
Beforeattemptingany test, check the followingitems. NOTE: when connecting or disconnecting harness con-
1. Check all wiring hamess connections to all com- nections, ensure that the ignition switch is 'OFF' and the
ponents, particularlythe 25 pin connector on the negative battery terminal is drsconnected. Failure to do
control unil, the air flow rneterconnectorand coolant so will damage the control unit.
temperaturesensorconnector.
EngineCondition PossibleCause
En gin e Fault y ig n itio n sYStem, D i s c o n n e c th i g h t e n s i o r i sp a r k

a n d c h e c kf o r s p a r k ,
Fault y f uel pum p ope r a t i o n . 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 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 .
i g r '',
C n e c k f u e l c r 3 s s u r ea n d v o l u m e p u r np e c
lm pr oper ignit ion s ig n a li n p u t . 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 .
Pr obr emin t he f ollow i n g c i r c u i t s : C h e c ke a c h c i r c urt
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, open c oolant t em pe r a t u r es e n s o rc i r c u i t C h e c k c i r c ui t a n d c o n n e c t o n s .

spa rk p lug swet . E'Fl system. R e p l a c ef a ui t y s e n s o ri f p r o v e dd e f ecti ve
G oesf ully r ic h.
Eng inesta rt s ,t hen Fault y ignit ion s igna l: n p u t . C heck i gni ti on s gna l rnput.
sta lls Fuel pum p not f unc t o n i n g c o r r e c t l y . 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.
Fault y c oolant t em p e r a t ur e o r a i r C heck ci rcui ts and ccrnponent opera ti or^.
f low s ens orc ir c uit s .
M alf unc t ioningaux i li a r y a ir i , 'al r e . 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.
6C.62ENGINEFUEL
E ngineC on ditio n Po s s ibleCaus e Checks
Enqine M isfire s Fa ult y ignit ions y s t em . C h e c k i g ni t i o n s y s t e m .

FueI bl oc k age. C h e c k f u e l l i n e f o r b l o c k a g e si n :
Tank filter
Fuelfilter
Fuel pipes
F u e l i nj e c t o r s
Wat er in f uel. Drain tank and lines.
Lo w f uel pr es s rue. Perform fuel pressuretest.
Lo os eHar nes sc onnec t or s . c h e c k a l l c o n n e c t o r sf o r l o o s e n e sosr 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 .
lmpr oper c ont r o r eiay o per at ion. C h e c kc o n t r o l r e l a yo p e r a t i o n .
Fa ult y EFlc ir c u : P e r fo r m c i r c ui t t e s t .
De fec t iv e injec t o' v ar v es . C h e c k i nj e c t o r so p e r a t i o n .
Malfunc t ioninoc ont r ol unit . T r y a n o t h e rc o n t r o l u n i t .
Eng ne lacks p owe r Fault y ignr t o^ s , / s t em . Check ignitionsystem.
Malf unc t ion ng r n t hr ot t le v alv e bod y . M a k e s u r et h r o t t l e b u t t e r f l y o p e n i n gf u l l y a n d
not,amming.
fu laifunc t ion in air f low m et er 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 .
Fuet bloc k age. C h e c k f u e l l i n e f o r b l o c k a g e si n :
Tank filter
Fuelfilter
F u e l p ip e s
F u e l i nj e c t o r s
Blo c k edo, r t t er . C h e c k e l e m e n tc o n d i t i o n .
Poor enginec ondit ion. C h e c k e n g i n ec o m p r e s s i o n s .
Chec k c i' c u it s in t hr ot t le pos it ion s w i t c h . 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
LOw f ue, pr es s ur e. P e r fo r m f u e l p r e s s u r et e s t .
Pr oblem r n t he f ollowing c ir c uit s : 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
Air and c oolantt em per at ur es e n s o r s . wh ere necessary.
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 .
Enginesur g e M a ffu n ctio n r ' g a ir flo w m e te r . 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.
I n t a ke a ir lsa ka g e a t th e fo llo win g cc r)tsl 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 '
M a n ' c d g a ske ts. 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 .
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 . P e r t o . '^ nr u e t p . e s s u r et e s t .
N c ' a cu u m a d va n ce . 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 .
F o -' i' r , EG R syste m . Check EGR operation.
P r ob le r n n th e fo llo win g cir cu is: 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
T h r o tiie p o sitio n switch , d le contact checks.
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.
ENGINEFUEL6C-63
E ngine Condition PossibleCause Checks
F lat spo t o n lm pr oper r gnit ion s y st e m . 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

acce lera tion signal.
M alfunc t ioningair f low m e t e r . 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 l o v em e 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 - :
I nt ak e air leak ageat f o l l o w i n g p o i n t s . C h e c kf o r i n t a k ea i r l e a k 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 . P eri orm fuel pressure test.
lm pr oper EFf c ir c uit . P er+crrn compl ete ci rcui t test, then p e r fo r m
ccmpcnerl ts cteck.
EG R s y s t em . l nccrrec:,tac -rrn hose connecti ons. C h e ck
E GR ooe'a: o-
Excessive pe t r ol lm p r o p e r ig n itio n tim ing or i gni ti on system. C heck i gn rtrcr : - - i a- d 'vacuum advanc e s i gnal .
con su mptio nCO C heck i gni ti on syS i 3- ':- .ct spark.
rea din g h ig h lm pr oper air c leanerf i i t e . C heck ai r cl eaner f rte' a-c'?: 3Je :f n ec es s ary .
lm pr oper f uel pr es s u
r e, P erform fuel pressure tes'.
Pr oblemin t he f ollow i n g c i r c u : t s: C h e c ke a c hc i r c u i t , t h e n p r o c e : c ::-3 f , ^ e n t
Coolant t em per a t u r es e n s o r . I check.
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 operati on of uni t, w i th a k now n
good u n i t.
Difficult to s t ar t FueI s y s t emn o t h o ld ing pressu'e a i ow ,nc F u e i p r e s s u r es t a y sa t 2 5 0 - 2 0 k P af o r t h o u r a fte r

a fter sta ndin g h ot f uel t o boil in in je cto r s w hen engi ne 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 er e g u i a to r
s iopped. 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,
Eng inestallswhen ld le sp e e d to o L o w.
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 Aer at edf uel due t o lo v vf u e l l e v e li n t a n k N u scti on requi rec f qui et
-nder norm al
co nd ition s c om bined wit h v er y n c t f u el . ccncj i ti ons. Wi l i nc: damag: pump.
2. Un de r n or m aI Filt er on f uel pic k up i r : i a n K r e s t r r c t e d . R ernove sender uni t i .or-r ta ^ k and cl ean f i l ter
co nd itron s Rearf uel dam per inop e r a t i v e . R ep ace damper.
j-,,e
Rubber m ount ing c us h i o n so n c-mp R eca - pump mounti ng system.
br ac k etdef ec t iv e.
Pum p wor n out . R ep ace fuel pump.
6C.64 ENGINEFUEL
5. SPECIFICATIONS
Air Flow System Components:
Air Flow Meter:
No mina l air flo w 500 m3/hr
A ux iliary Air Va lve :
Air flo w 17 ! 2 m3/hr
Ave rag etime to s hut at
+20 oC a nd 1 4 v olt s 4 minutes
Nomin al resis t anc e 30 - 40 ohms
Leakage 1.0 m3 /hr (maximum with slotted disc closed)
Fuel S ection :
F uei Pu mp:
Flo w ca pa city minimum 130 l/hr at 12 voltsand 303 kPa pressure
F uel Pre ssure :
At idle 250 kPa
The moment the acceleratorpedal
is depressed(zero enginevacuum) 300 kPa
F uel Filter:
Flow rate 1.5 l/hr
Pressu redro p . . 10 kpa maximum at 120 llhr
Filter are a 3000 cm2
Ave rag epo re s iz e 8 - 10 micro metre
Injector:
Static f low 185 cm3 /min = 3orcat 303 kpa
Dynamic flow . 4.38 cm3 /1000 strokest 3% at aboveatmosphencpressure
Permissable leakage 0.015 cm3 /min at 303 kPa aboveatmosphencpressure
(1 drop/min)
P ressureRe 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.
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. . . . . . . 3.4milliseconds
Warm-upenrichmentfactor I .2 at ZOoC
After start enrichmentfactor 1.7 at OoC
Cold start injection pulse 16 millisecondsar OoC
Acceleratorenrichment{actor . 1.3 below 50oC
Full loa d e nric hm enrf ac t or . 8 Y oi n c r e a s e
Fue l cut off on dec ee: ar ion U n t i l 18 0 0 r o m
Coolant TemperatureSensor:
Temp era rure oc . . . -l0ll - 2 0 =j -gor1
Re sistan ce
k oh m s 8.26 - 10.56 2.28 - 2.72 0.290 - 0.364
F uel Pu mp Co ntro ' R e ay "
Hold in vo ltag eat t e' r ninal No. 15 . . . 5.5 volts minrrnur,.
Ho ld in ign ition pu s esai t er m inalNo. l . 150 rpm min mum
Throttle PositionSwitch:
ld le co nta ct o peningangr e l.0o from dle end oosition
ld le co nta ct clos ingangle 0.2o from dle end position
Fu ll lo ad co nta c t c los ingangle 4 0 "! 2 f r o m : d e e n d o o s i t i o n
ldle sp ee dat n orma l o per at ingt em per ar ur e-
run-in en gin e g50 t 50 rom
ldle mixture a t n orm al aper at ingt em per at ur e-
run-in en gin e .5 - 1.b%CO
ENGINEFUEL 6C.65
Nm
I nlet M anif old M oun t i n g N u t s 41-48
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 41-48
EG R M ount ing Bolt s 20-25
E G R Feed Pipet o I n l e t M a ni f o l d B oIt s 20-25
EG R Feed Pipet o M a n i f o l d N u t s , 27 -36
I nlet M anif old Br ac eB o l t 20 -25
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 . 20-25
Fuel Rail M ount ing B o l t s 2A -27
Pr es s ur eRegulat or M o u n t i n g N u t 25-30
Pr es s ur eRegulaio. F u e l L i n e G l a n d N u t s 25-30
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 8 - 10.6
Fuel Ret ur n Line Br a c k e tt o S i d e P l a t eB o l t 4 - 10
A; r CleanerHous ingM o u n t i n g N u t s 8 - 10.6
A r Duc t t o Suppor t B r a c k e t B o l t 20-27
Thr ot t le Body M oun t n g N u t s 8 - 10.6
a4
Thr ot t le CableLoc k N u t s , z-.+
F uel Pum p Suppor t B r a c k e t N u t s 15-25
Fuel Pum p I ns ulat o r s 15 - 25
Rear Fuel Clam perM o u n t i n g N u t 15-25
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 15-25
Fuel Filt er Suppor t B r a c k e t N u t s . 3-4
Thr ot t le Valv eSwit ch M o u n t i n g S c r e w s 1 - 1.5
F - . r elPipe Hos eClam p s 1
Air Flow M et er M ou n t i n g B o l t s 8-11
Ai r F low M et er Har n e s sR e t a i n e rB o l t 20-27
6 C-66 EN GIN E FU E L
7. SPECIAL TOOLS
E NG I NEF UEL 6 C .6 7
CARBURETTOR(3.3 EST)
INDEX
1. GENERALDESCRIPTION .......r...................-..
6C€7 3.1 CARBURETTOR ...........................................o..
6C-70
1.1 CARBURETTOR..................-...........................
6C-67 Rem OV€......................................o.............
6C'70
2. MINORSERVICEOPERATIONS.................. 6C€8 Disassemb1y..............................r......6C-70
2.1 CARBURETTORADJUSTMENTS'ON ChgCkS .........................................'....o.....
6C-72
6C€8
VE H I C LEt ...............................................r.....r.... ReaSSgmbly............................................
6C-73
ChOkg OperatiOn ..'...t......................-.... 6C€8 AdjustmgJlt.......o......................................
6C-75
ldlg Speed Adjustment........................ 6C€8 RginStall ...-.............. ...!.r..............6C'79
Fast ldlg Adjustment..r.........................6C€8 4. DIAGNOSIS .............r.,.........r.......r.....r............r.
6C€0
2.2 THROTTLE POSITION SWITCH 5. SPECIFICATIONS ..........................,............o...r
6C-85
6C-68
ADJ USTM ENT ....................................t.......t....r 6. TOROUE WRENCH SPECIFICATIONS........6C.86
MAJOR SERVICEOPERAT1ONS.................. 6C-70 7. SPECIAL TOOLS .........................-..........-.......
6C'86
The fuel system emPloyedon carburettored3.3 litre VK for revisions tc the Varajet ll carburettor as noted rn tftis
Series enginesis similarto VH 3.3 litre models,except 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
Fig. 6C- 117. The accelerator pump lever has
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 '\ P OS TTTON
S W ITC H
THAN 8O,OOO KM IS SET OUT IN THE 'MINOR SER.
VICE OPERATIONS.' IF THIS IS INSUFFICIENT, THE
CARBURETTOR MUST BE REPLACED. Fl gure 6C -117
6 C . 68 ENGIN E FU E L
2. MINORSERVICEOPERATIONS
2.1 CARBURETTOR
ADJUSTMENTS'ON
VEHICLE'
CHOKEOPERATION
NOTE:
a. 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.
Flgure 6C-118
IDLE SPEED ADJUSTMENT

1. Ensuresparkplugsare correctlygapped.
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. Ensureair conditioning is OFF.
7. Adjust mixture by-pass adjusting'screw (shown in
Fig. 6C-119) to set idle to specification.
WARNING: To MAINTAIN DESIGNED EMtsstoN
LEVELS, DO NOT ADJUST IDLE STOP SCREW OR Fl gure 6G119
IDLE MIXTURESCREW.
FAST IDLE ADJUSTMENT

1. Engineat operatingtemperature. FA S T ID LE
r LOWEST STEP
2- Removeair cleaner"plug vacuumhoseto air preheat CAM
sensor.
3. Start engine.
4. Throttlepositionswitchmust be closed.
NOTE: The throttle positionswitch may be simulatedin
the closed positron by removing both electrical con- I D LE A D JU S T -
ne'ctorsfrom the switch and connectingthem together SCREW
with a bridgewire.
5- with fast idle screw on lowest step of fast rdle cam
as shownin Fig. 6c-120,enginespeedshouldbe to
specification.
Adgustfast idrescrewif necessary. Flgure 6C-120
ADJUSTMENJ'
Fol adjustrnent instructions,refer to service operation
2.7
in section 6D, lgnition system of this Supplement.
ENGINEFUEL 6C-69
F-to
66
-ufrI
pl
471 |
v
*
Vj
/14 -t-\
d-':li
w
43 -'/
6
-,>;)
35
tfu
l
,t-
t. .t
36
yv
enA
ff_r, R E F E RN E X TP A G EF O RL EGEN D
Fi gure 6C -121
6C.70ENGINEFUEL
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 24. Dischar ge pur np r etai ner 46. F l oat bow l

2 . Ba f f l e f la p sh a ft 25. Car bur ettor f uel i nl et f i l ter 47 . M eter i ng pr i m ar y j et
3 . N e e d l e r e ta i n e r 2 n d sta g e 26. Car bur ettor f uel f i l te. f l ar e nut 48 . Pow er pi s ton s p r i ng
4. A i r h o r n ve n t scre e n a n d retainer 27. Dischar ge pum p s pr i ng 49. Pow er pi s ton as s em bl y
5 . B a f f l e f la p 28. Dischar ge pum p batl 50. M eter i ng pr i m ar y r od and s pr i ng as m .
6. B a f f l e f la p scre w 29. M ixtur e bypass s c r ew and s eal as m . 51 . C hok e l i nk c am end c l i p
7. C h o k e va l ve 30. M ixtur e bypass s eal 52. C hok e l i nk c am end bus h
8. C h o k e va l ve scre w 53. F as t i dl e c am to c hok e l i nk
9 . Ai r h o r n to fl o a t b o wl screw 32. Float bcwl to thr ottl e body gas k et 54. C hok e s haft
1 0 . A i r h o r n to fl o a t b o wt screw 33. Ant r d ieseling sol enoi d 55, C hok e l ev er
1 1 . Ai r h o r n a sse mb l y 34. Pum p iink 56. C hok e l i nk c l i p
1 2 . Pu m p l e ve r a n d scre w a sse rnbly 35. ldr e needle scr e w and s eal as s em bl y 57. C hok e l i nk bus h
1 3 . Ai r h o r n to f i o a : b o w i g a sket 36. ld,s ne€dle seal 58. C oi i c ontac t s l eev e
1 4 . F l o a t p r vo t i n se rl 37 . Thr ottle body to f l oat bow t s c r ew 59. C hok e l ev er bus h
1 5 . Pu m p p i srcn a sse mb l y 38. Secondar y dr ive s pr i ng 60. Sec ondar y s haft s pr i ng
16. F l o a t r eta ,7 '1 gpr ro 39. Pr imar y thr ottle l ev er 61. Vac uur n br eak hos e
1 7 . F l o a t a n c re ve r a sse mb l y 40. Fast idle scr ew a nd s pr ng as s em bl y 62. C hok e c ov er and ther m os tat r etai ner
18. F l o a : i e ve - to n e e d l e cl i p 41 . Thr ottle body 63. Vac uum br eak hous i ng and s tem as m .
19. F l o a r n e e d ,e va i ve a n d se a t assem bly 42. Basic idle scr ew and s pnng as s em bl y 64. C ov er and ther m os tat as s em br y
2 0 . F i o a t n e e d re va l ve se a t se a l 43. Fast idle cam r e tai ner 65. Vac uum br eak del ay v al v e
21 . Pu m p i nl e t b a l l 44. Fast idle cam as s em bi v 66. T h r ottl e pos r r i on s w i tc h
22. P i s t o n c u p 45. Fast idle cam oiv ot 67. Br ac k et
2 3 . P i s t o n r etu rn sp ri n g
3. MAJORSERVICEOPERATIONS
3.1 CARBURETTOR
REMOVE
1. Disconnectbatteryearth 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. Remove fuel line flare nut and filter. Remove
anti-dieselingsolenoid.
2. 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
v ----
ENGINEF UEL 6C .71
3. 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
assembly.Gasketremainson float bowl.
NOTE: The acceleratorpump is spring loaded.
NOTE: Do not rest air horn on protudingtubes.
Figure 6C-123
6. Remove acceleratorpump assembly(Fig. 6C-124).

7. Remove gasket.
Figure 6C-124
8. Remove power piston assemblyusing a patr of side

cutters and screwdriveras a fulcrum(Fig. 6C-125\
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.
CAUTIOAT:DO NOr LEVER UF CN HORTZONTALIANG

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)
10. Using a suitablescrewdriver,remove seat and seal.
ai|r
Fi g u re 6C - 126
6C.72ENGINEFUEL
1 1. Using a suitable screwdriver, remove main iet

(F.g. 6G1 27).
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
ENGINEF UEL6C -73
REASSEMBLY
1. Placegasket on invertedfloat bowl assembly.Ensure
gasket is correctly located. Place throttle body
assemblyover gasket and retain with four screws.
Re-checklinkageoperation(Fig. 6C-130).
Figure 6C-130
2. Using a suitable screwdriver,reinstall needle valve

seat and sealingring.
3. 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

and needlevalve assembly(Fig. 6G133).
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
specification(Fig. 6C-134).
Figure 6C- 134
Adjustif necessaryby bendingarm (Fig. 6G13S).
7. Reinstallfloat pivot insert. Reinstallgasket in correct

orientation.
Figure 6C- 135
8. pumpassembly(Fig.6C-136).
Reinstallaccelerator
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. Reinstallacceleratorpump actuatinglinkageon lever
and reinstall pivot screw. Reinstallthrottle position
switchto air horn.
Figure 6C- 137

ENGINEF UE L6C .75
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 actua-
ting lever. Screw retainingring in place, ensuring
arow on choke cover pointsto specifiedindex mark
(Fig.6C-13e).
Reinstallvacuumhose.
13. Reinstallfilter, fuel inlet flare nut and antidieseling
solenoid.
Figure 6C-139
ADJUSTMENT
Wide Open Throttle
1. Hold fast idle cam down and open throttlecomplete-
ly - 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 ^-C
YJ 900
sectionfor measurement. SEC OIJ D AR Y PR IM A R Y
I
\
L -_-L
tr
PR IM AR Y C VER D R IVE
Fi gure 6C - 140
6C.76ENGINEFUEL
Secondary Throttle Opening

1. Open prirnary valve, ensuring secondary valve re-
mainsclosed (lock engaged).
2. Measure clearance between tang on secondary
throttle lever and intermediatelever. Bend tang on
secondarythrottle lever to adjust (Fig. 6C-141).See
specificationsfor measurement.
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 intermediatelever 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. ChokeSetting.
a. Set the automatic choke to closed.
b. Remove vacuum hose to vacuum break unil
(Fig. 6C-143). Use hand vacuum pump J23937-
01 or equivalant to apply vacuum to vacuum
break unit to fullv retract stem.
Figure 6C- 143

ENGINEFUEL 6C.77
Distance between choke valve and carburettor wall

should be to specification(Fig. 6C-144).
Adjustby turningscrew 'B' (Fig. 6C-144).
NOTE: This adjustmentshould be perforrnedin conjunc-
tion 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.
.\,
F
Fi gure 6C -144
2. Air Valve Setting

a. Use J23987-01or equivalentto apply vacuumto
break unit. V A C U U T\4B R E A K S TE M FU LL IN _
WITH V A C U U M A P P LIE D
b. Clearancebetween air valve lever and vacuum
break stem should be to specification
(Fig.6C-145).
c. Bend tang to adjust.
A IR V ALV E
FU LL C LOS E D
Figu;'e 6C- 145

6 C-7 8ENG I NEF U E L
Second Step Setting

With choke coil cold (ambienttemperature),ensure fast
idle screw is seated on second highest or 2nd step of
C H OK E V A LV E
cam (Fag.6C-146).
With light pressure applied on choke valve, clearance
between valve and carburettor throat should be to
specification. OPENINGF O R C Eo N - - 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 (bendingincreasesclearance,

reducesclearance).See Fig. 6C-.,147.
straightening
Figure 6C-147
Wide Open Kick Setting

1. Choke valve held closed.
2. Primary throttle lever held fully open. ,s3--.,_J
3. 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.
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
ENGINEFUEL6C.79
Secondary Lockout Lever Rotation C H OK E FU LL H OTT

1. Choke controlleverheld fully open (use elasticband
to overcomeautomaticchoke closingforce.)
Clearancebetweensecondarylockout lever and tang on
intermediate lever should be to specification
(Fig.6C-14e).
lf dimension is inconect, check 'Secondary Lockout
Setting'below.
Figure 6C- 149
Secondary Lockout Setting r v- r

J1 n
,r h .
PL -
1. Chokecontrolleverclosed.
/v 4
-
2. Primarythrottleleverwide open'
3. secondary lockout lever fully engaged. secondary
throttle valve should have clearance as specified
(Fig.6C-1s0).
Bend tang on secondaryvalve leverto adiust. I
S E C OND A R Y TH R OTTLE V A LV E S E C. LOC K OU T

E N G A GE D
FU LL
C LOS E D
P OS ITION
,A '
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. Throttle closed, carburettor set 10r idle, choke held
off
2. slowly depress accelerator pump plunger until sec-
ondary spring resistance is felt. The distance travel-
led from reit position should be to specifications
(Fig. 6 G 151)
3. Bend pump arm to adiust (at B).
4. Readjust throttle position switch if pump-arm is bent'
Refei to Section 6D of this Supplement for details'
REINSTALL
1. Clean all mating surfaces. Take care that material
does not fall into manifold.
2. Using new gasket, install carburettor.Torque nuts to
specification.
3. Reinstallfuel line, electricalleads and vacuum hoses'
4. Reinstallair cleaner.Torque nut to specification' Fi gure 6C '1 51
5. Install air pre-heat, engine ventilation and vacuum
hoses on air cleaner.
6C-80ENGINEFUEL
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 U S E P R OP E R C OR R E C T S TA R TI N G

EROCEDUREUSED i S TA R TIN G P R OC E D U R E I P R OC E D U R EU S E D
LI
ST I L L NO ST ART S TILL N O S TA R T
CHECK VACUU[1 C H E C K A LL V A C U U M
HOSESAND EL EC;RICAL H OS E SA N D E LE C TR IC A L
L EADS LE A D S
C H E C K ITE MS
ENGrf\E C H OKE VAL VE 'l N o FU E L 1 & 2 UNDER
?
i-/ FLOODE D NOT CL OSING : IN C A R B U R E TTOR N O S TA R T C OLD
CHOK E V A L V E CHECK AUT OM AT IC

NO T U N T O A D I N G N O FU E L IN TA N K
CHOKE COI L
ADJUST MET \T
CHE CK T H R O T T L E FU E L LIN E S OR
LI NK A G E F O R F ILTE R S P LU GGED
CH ECK F OF BI NDI NG
F U LL T B A V E L OR ST UCK CHOKE
(W . C.T H R O T T L E )
VAL VE OR L i\KAGE
D E FE C TIV E FU E L
P U MP .
P R E S S U R ETE S T
CHE C K F L C A T
NEEDL E A N D S E A T CHECK A\D ADJUST
VACUUM BREAK,
FOR LEAKAGE = AST I DL E,
C H E C K FLOA T N E E D LE
AND UNL OADER FOR S TIC K IN G IN
CHE C K F L O A T * S E A T OR tsIN D IN G
L E V EL . F LOA T
F LO A T F O R D A M A G E i
* 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.Jt-
r-r.t'
ENGINEFUEL6C.81
ENGI N E S T A L L S
S T AL L S COL D S TA LLS H OT
U SE PROPER U S E P R OP E R
S T A R TING PROCEDURE S TA R TIN G P R OC E D U R E
C H E C K AL L VACUUM C H E C K A LL V A C U U M
H O S E S& EL ECT RICAL L EADS 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 I
C HOKE COIL CHOK E C OI L FU E L LE V E L FUEL LEVEL

I NCORRECT L Y ADJU S TED H IGH IN * CK
ADJUST ED CORR E C TLY F LOA T B OWL
ST A L LIN G
CON TIN U E S
S EC ON D A R Y
FU E L P U MP
THR OTTLE
P R E S S U R EH I GH
CHECK C H OK E STIC K IN G
TE S T FU E L P U N 1P
VALV E A N D OP EN
L IN K A GE FOR
BIND IN G OR
STIC K IN G
F LOA T N E E D LE GA SK E TS N OT
S E A T LE A K IN G S E A LIN G
IF UNA B LE TO CA U S IN G
ADJI.JS T,C H E C K A IR OR FU E L
IDL E S Y S TE M FOR LE A K S
DIRT , A IR LE A K S , F LC AT LEAKIN G
PL UGGED P A S S A GE S C R BIN D IN G
I D LE P A S S A GE S
CARBURETTOR FLOOD I N G
P LU G GE D ,ID LE
OR HIGH FLOA T LE V E L
A IR B LE E D S
P LU GGE D
I
T EST F UE L i C H E C K FOR D IR TY
PUMP I on LE A K TN G FLoA T
I 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 C H E C K A LL V A C U U M H OS E S
O P E N I N G A T C A R BURET T OR A N D E LE C TR IC A L LE A D S
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 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
P R IMA R Y ME TE R IN G R OD
O R J E T S B L OCKED
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
P OWE RP IS TON S TIC K !N G
D IR TY , S P R IN G MIS S IN G,
F L O A T L E VEL * F L OAT ST ICKING, OR IN C OR R E C T P A R T
I N C O R R E CT M ISAL IGNED
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 OND 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 OORFU 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 C H E C K P OWE R P IS TON FOR S TIC K IN G C H E C K P OWER P IS TON

S P R I NG F OR DIST ORT ION OR B E IN G B E N T OR LOOS E 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 C H E C K MA IN ME TE R IN G JE T
F OR BEING FOR B E IN G P LU GGE D , LOOS E , tvl A K E S U R E GA S K E TS
B E N T OR WRONG PART OR IN C OR R E C T P A R T 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
FLOA T B E N T, S TIC K I N G
LE A K IN G FR OM D IR T, WE A R ,
MI S A LI GN E D , MI S A D J U S TED
D A MA GE , LOOS E NE S S
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 R E FE R S E C TION 2 FOR C OR R E C T

A F T E R M AJOR OVERHAU L A D JU S TME N T P R OC E D U R E .
6C-84ENGINEFUEL
ENG I NE HESI TATE S O N A C C E L E R A T I O N
A IR VALVE EINDING A C C E LE R A TOR P U MP C IR C U IT D IR TY ,

OA STICKING 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 SECONDARY
T : r q C TT L E VA L VE L OCKOUT LOW FU E L LE V E L IN
I,JOTOPERAT ING F LOA T B OWL
SE CONDARY T HROT T L E C H E C K FU E L P U MP
V A L VE ST ICKING OPEN P RE S S U RE
S L I GHT L Y - CHECK FO R
DAM AG 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 E N GIN E S LU GGIS H ON A C C E LE R A TION

ACCELE R A T I O N D U R I N G WA R M OR C OLD
CO LD D R I V E A W A Y
ADJ US T A U T O M A T I C AIR VAL VE BIN D IN G i

CH O K E C O I L FU E L FILTE R IN C A R B U R E TTOF
OR ST ICKIN G
D IR TY OR P LU GGE D .
FLOA T S TIC K IN G OR
N OT P R OP E RLY A D JU S TE D *
A DJ US T V A C U U M B R E A K 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 LIGNE D , P OIV E RP IS TON S TU C K ,
CHE CK A I R V A L V E O R ST ICKING, DIRT Y OR B E N T, B IN D IN G, LOOS E
SECO ND A R Y T H R O T - I - L E SECONDARY M ETE R IN G
VALV E L O C K O U T JET PL UGGE D
\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 RLY 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
ENGINEFUEL6C.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 mi s s i o n)
P.O.E. Bl eed 1. 4 2 m m ldle Tube 0 .6 5 m m
P.O.E. Noz z le 1.85 mm M.B.P. Restriction 1 .6 0 m m
P.O.E.Tu be . 0.65 mm Top M.B.P.Inlet . . 5 .5 0 m m
Se co nd ar yM et er ingJ et 3.20 mm M . B . P . D o w n C h a n n e li n F l o a t B o w i 7 .0 0 m m
Se co nd ar yM et er ing Rod Full dia. 2 . 9 75 r nm P r i m a r y M e t e r i n gR o d 1 18 mm
Se co nd ar yM et er ing Rod Tip dia. . 1.970mm P r i m a r y M e t e r i n gJ e t . . 1 .8 3 m m
Se co nd ar y Ai r Bleed i .00 mm l d i e N e e dl e O r i f i c e 2 .2 0 m m
Primary Noz z le Relat ion 3.50 mm l d l e P o r t Wi d t h 0 .7 0 m m
Main Well Boos t Bleed . . 1,00mm ldte Por: Length 3 .0 0 m m
Auxiliary W ell Bleed 1.00 mm
N OTE: P .O .E. Pull O v er Enr ic hr nent M.B .P . l / xi ure B '7-P ass
FUEL PUM P:
Pressu
re Test 22 - 26 kP a @ 1000 'crn
A DJ USTM ENTSPECIFI 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 IO N S )
F IG .
I
REF. ITE M sPEc.

I
N. A. 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 ) 1 7.Om m
6 C-134 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 ) 8 .0 m m
6 C_1 40 i W I DE O PEN TH RO TTLE - P RI M A R Y 90 Deg.
6C_ 140 I W I DE O PEN THRO TTLE - S E C O N D A R Y 90 Deg.
6 C-140 W I DE O PEN THRO TTLE - P R I M A R Y O V E R D R I V E 'tA "- 0. 5mm

'
6C_ 141 SECO NDARY TH RO TTLE O P E NI N G I N I T I A L tt
Att
_
0.45 mm
6C-1 42 SECO NDARY CLO SI NG S E T T I N G tt _

0.60mm
^t,
6C_ 144 CHO KE SETTI NG tt _

4.2 m m
^tt
6 C-145 AI R VALVE SETTI NG A"= 0.3 m m

D ST E PSE T T IN G
6C- 1 4 6 I SE C ON Att = 3.70 mm
6C_1 4 8 I W ID EOP ENK IC KSE T T I N G A"= 10. 0m m

L O C KOU TLE V E RR OTA TION
6C- 1 4 9 I SE C ON D A R Y A"= 2 .0 m r n
6C_1 5 0 I S EC O N D A R Y
L O C KOU TS E TTIN G A"= 0 .4 m m
6C_ 151 I RCCELERATO R PUM PSE T T I N G At'= 8.0 m rn
N A. PUM P CAPACI TY FO R 1O S L O W S T R O K E S 14.5 cc
N A. CHO KE CO VER I NDEXI N G 1 N.L
N A. AI R VALVE O PENI NG 84 Deg.
N A. I c H o K E o P EN T N G
T rMEAT 22oc 2 - 3 mins
I
ENG I NE I DLE SPEED

( fn Neut r al - M anualTr ans m is s i o,nP a r k - A u t o T r a n s m i s s i o n
Air Condit ioning" O FF" , Engin eWa r m) 850 t 25 rpm
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
I
6C.86ENGINEFUEL
Nm
Carburettorto Manifold Stud Nuts 14 - 16
* Air C leanerSt ud. .
10
Throttle Position Switch to Mounting Screws 0.5 - 0.7
Throttle Position Switch Mounting to Air Horn Screws 3.b - 4.s
Throttle Linkage Bracketto Manifold Bolts . . 12 - 16
Accelerator Cable Lock Nuts . 3 - 4
* Usethread locking sealantsuch as Loctite 675.
7. SPECIALTOOLS
HAND VACUUM PUM P
J23987-01
( or egui v al ent)
ENGINEFUEL6C-87
5.0 LITREENGINEFUELSYSTEM
INDEX
Ref. Subiect Page I Ref. Subject Page
1. GENERAL DESCRlPTlON.........!.................'.. 6C-87 1 2.3 6C€8
FUEL FLOW TEST....r...r....................o.....,......
2. SERVICE OPERATIONS .......-.r...................." 6C€8 2.4 6C-89
PUMPPRESSURETEST.........'......o..........-.'..
2.1 FUEL PUi|P......................t..t................."""'i"' 6C€8 2.5 coNTRoL RELAY OPERATION..............o-.. 6C-89
R e m O V € . . . . . . . . - . . . . . . . '! " t " t " " " " - t t " 't t " " " t " " ' 6C-88 6C€9
Battery Supply Voltage ............,.o...o...
R glnSta ll ..................r........................ ts.o.- 6C€8
6C-89
lgnltlon Supply Voltage .........r.....o..o...
2 .2 C ONT ROL RELAY r r ...r .....- .....- ..........o..d..ts .....6C€8 6C-89
Control Relay Output .............r-..........
R gmOV€...............r.....r..........-................... 6C€8 r3. 6C'90
SP EC I Fl CATIONS ....r.r...r.......!..........r..6..........
R glnStall .......r .!r r ..r .....- ................... .......... 6C€8
I
All 5.0 litre VK Series models are equipped with a
revised fuel pump system to improvedriveabilityin high
ambienttemPeratureconditions.
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
incorporatinga gauze filter screen,refer Fig. 6C-152.
The revised fuel pump system includes,an electric fuel FU E L
pump mounted on the fuel gauge tank unit, inside the R E TU R N
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
the EFI System control relay, refer to 'ElectrOnicFuel
Injection'in Section6C of this Supplement. The fuel lines
hive also been revisedwith the deletionof the mechan-
ical 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
No. M38338,for adiustmentprocedures. TO C A R B U R E TTOR
F(l ure 6C -152

6C-88ENGINEFUEL
2 . 1 F U E LP U MP
FU E L GA U GE
REMOVE TA N K U N tT_i
LOWEB
1. Remove fuel gauge tank unit, reter to service E R A C K E T -\
I
operation2.6, Section12C of this Supplement. I
2. Disconnectwiringfrom tank unit to fuel pump. -\

., l
3. Remove filter from pump. Slide upper rubber con-

\\
--. I
nectorfrom fuel pump outlet,then removepump by --

r''rr
slidingout from lower bracket.
i - gP P E R R U B B E R
REINSTALL
, MOU N T
Instalfation is reversal of removal procedure. \
L
NOTE: The electric fuel pump is a sealed unit and non \

\- W Ai N G
repairable. C ON N EC T IO N
Figure 6C-153
2.2 CONTROLRELAY
REIIOVE FU S E 8C X C OV E R
1. Remove fuse box cover.

2. Pull out relay from its position in the fuse box, reter
F ig. 6C-15 5.
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. Disconnect the carburettor fuel line at the carburettor
- prior to the vapour seperator.
2. 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.
ENGINEFUEL6C.89
TEST
2.4 PUMPPRESSURE
lf fuel flows in good volume from the pipe at the
carburettor,fuel deliverypressuremay then be checked.
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
pressuregauge.
3. lf the pump is operating conectly, the pressure
shouldbe approximately30-40 kPa after 30 seconds
of running.
2.5 CONTROLRELAY OPERATION

BATTERY SUPPLY VOLTAGE 87
TE S T LA MP n i'-1
1. RemovecontrolrelaYas Per 2-2. 15 | i -
ll
2. Check for voltage supply to the terminal correspon- :[n ||
tJ r-]
87b
[1
ding to terminal 30 of control relay and earth, refer
Fig. 6C-156.lf not, check for continuityof wiring to \
teiminal.Refer to wiring diagramsin Section 12F of t't uo
this Supplement.lf O.K. proceedto next test- : I []
C ON TR OL R E LA Y
TE R MIN A L B LOCK
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
terminalconespondingto terminal15 o{ controlrelay
and earth,refer Fig. 6C-157-
2. lf not, check for continuityof wiringto terminal.Refer
to wiring diagrams in Section 12F of this - EST LAM P
Supplement.lf O.K. proceedto next test.
C ON TR OL R E LA Y
T=R MIN A L B LOCK
Fi gure 6C -157
CONTROL REI-.AYOUTPUT
/- FU :L P U MP
1. Refit control relaYto fuse box. TE FTIi IN A LS
2. Withthe enginecranking,checkfor voltagesupplyat
the fuel pump terminalon the fuel gaugetank untt.
ReferFig. 6C-158.
3. lf no voltage reading,check lor continuityof winng
from tank unit to the terminal in the fuse box
corresponding to terminal87b of the controlrelay.lf
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
pump for cohtinuity.lf O.K. removeand replacefuel
pumpas per operation2-1 and retest. Fi gure 6C -158
6C.90 ENGINEFUEL
3. SPECIFICATIONS
FUEL PUM P:
Pr es s ur e 30 - 40 kPa
Volt age ( at f uel pum p - engineo p e r a t i o nt 13.5 t .1 volts
NOTES
------------r
ENGINEELECTRICAL
6D.1
SECTION6D
ENGINEELECTRICAL
Subject Page
CHARGING SYSTEM ........r.rr.rr....r................-..r..t.......6D'1
STARTING SYSTEM .....r.r..............r.....r............r..r..... 6D'1 5
IGNITION SYSTEM......r............r...........................r...r.,6D'17
CHARGINGSYSTEM
INDEX
1. GENERAL DESCRIPTION...r...r.'r..........''r.r 6D-1 Disassembly..r..,.r-........r..,......,.........r..... 6D-o
2. MINOR SERVICE OPERATIONS .'r....!!,.r,.... 6D-3 C l e a n i n g a n d I n s p e c t i o n o . . . . . . . ............ 6D-B
2.1 SAFEW pRECAUTIONS ..........r...r.,.r...!.r.t.,r..
6D-3 T e s t i n g C o m p o n g n t s . . . . . . . . . . . . . . . ,............
6D-8
2.2 MAINTENANCE AND ADJUSTMENTS........ 6D-3 Diodg Assembly ......r.........,.......,. 6D-B
L UbflCatlOn .............r ...........r r r ...r ............r . 6D-3 StatOf ...........r............'...............r..... 6D-8
Testlng the Generator Output lnsulation Test for the Stator.. 6D-9
and Voltage Regulator..r........r.,..'...,.. 6D-4 BfU ShgS........!............r ......r ........ . . . . o 6 D -9
Tgstlng Generator Output ........ 6D-4 R O tOf ..r .......'..,......r .r ..,r ........... . . . . . . . . . 6D'9
Testlng the Voltage Regulator 6D-4 InsulationTest for the Rotor
Charglng Clrcult Voltage Drop C O i l ...r ..................r ....t'.......r ....r . r. . . . . . 6 D ' 1 0
TgSt t.rr..!t!.r.rr............r..o.............r..r. 6D-5 Rgassgmblyr...............................r.....-.....
6D'10
3. MAJOR SERVICEOPERATIONS.................. 6D-5 4. FAULT DIAGNOSIS ..........,.............,...............
6D-12
3.1 G E N E RATOR .r.r.r.r...r..r.r.r!.r.t.'r...r.r.......rot.!.....!. 6D-5 5. S P E C I F I C A TION S ..............o.......r..........r..r..r.r..
6 D' 13
R gmOV€.....r..r.....r...1...................o...... o...... 6D-5 6. TOROUEWRENCHSPECIFICATIONS........
6D.13
R gl nStall ......r.....r.--...........................r.r.... 6D-5
1 . G E NERALDESCRIPTION
The Bosch 45 amp generatorcarriesover from VH to VK
Series for the base 3.3 litre Electronic Spark Timing
rnodels.
On models fitted with air conditioningor ElectronicFuel
Injection,VK Series models have fitted a new Hitachi
60 amp generator.
On models with both air conditioningand ElectronicFuel
Injection,a new Hitachi70 amp generatoris fitted.
Service proceduresfor the Bosch 45 amp generator are
as publishedin Section 08 GeneratingSystems, lmpro-
ved PerforrnanceLO and VB Engine Service Manual
No. M38338.
The followingSection covers the service proceduresfor
both 60 amp and 70 amp Hitachigenerators(Fig. 6D-1)
Both models are similar in mechanical construction.
Differencesin the numberof turnsand the wire gaugeon
the respectiverotor and stator windings result in the
differentelectricalperformancecharacteristics. Fi gure 6D -1
The stator comprises a three phase star connected
output winding on a ring shaped laminationpack. The
rotor is of 12 pole constructionand carriesa slip ring fed
field winding.The rotor is supportedby ball bearingsin
both drive and slip ring end brackets.
6D.2 ENGINEELECTRICAL
Rectificationof the generatoroutput is achieved by six

silicondiodes containedwithin the slip ring end bracket
and connectedin a three phase bridge circuit between STATOF
stator and output terminals.A second rectifier bridge is rTror SWITCH
---t
formedby usingthree auxiliarylow currentdiodes used in I
conjunctionwith three main diodes. This supplies the ,-d^-b_ s I 'sffi 6E I
I
currentfor the generatorfield coil via the brushes,slip L
F
,^
r \- |
L AM P
J.
: BATTERY
ringsand voltage regulator(referFig. 6D-2). |
^t
H
A-
lli
-
ix I | |
e REFULATOF
I
The generator output is controlled by an electronic
-,tl
t
* CONDENSER i
voltage regulatorunit mounted inside the slip ring end ALTERNATOR
bracket.Design featuresof the voltage regulatorinclude,
ternperaturecompensation,radio frequency interference
suppression.The regulator requires no adjustment in
service. Figure 6D-2
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.
/,-8
//
-2 rl
r
-3 f-.1
r-7 [5 /-4
f .-l
t -rl .l rG
lrrl'l
I
f- l
ll- - I I I /
0
JED I €-a
A\
s0 a .,- - l
III.I
fII
--F
I
t'Itf I
w =o-o
-a
fl
A-rf rFl
I'trlAI)
t
'r-t
!
U -r'U
r10 .- 1
15 -17 \ I
[12 -13 '-

\ i
I
\ 7 \
T
o ,^. I 7
IL -
E
I\
o , {\
/o - t \ I
I
SL: EFI
E
o I.I--
o
t
v
t\
cu)
oo @ c E
-
aTF--''-- O 1$
-14
1. T HRO U G H B O L T 7 . SEAL = D BALL B E A R IN G 12, N U T M4 - FA N G U I D E TO D IOD E

2. P ULL E Y N U T 8 . DRiVE END B R A C K E T 13 FA N GU ID E
3. P UL L E Y 9 . NUT M 5 , NU T M6 _ D IOD E A S II 14 R IV E T
4. RO T O R T O SL IP RING E N D B R A C K E T 15. B A TTE R Y TE R MIN A L
5 S CRE WM 4 _ R E T A I N ING PL AT E T O 1 0 . SL IP RING EN D B R A C K E T 16. D IOD E A S S E MB LY
DRIV E E N D B R A C K E T 1 1 . ST AT C R 17. B R U S H _ FE GU LA TOR A S M.
6. B E A R I N G R E T A I N I N G PL AT E
Figure 6D-3
ENGINEELECTRICAL
6D-3
2. MINORSERVICEOPERATIONS
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 purpos€s,
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
At regularintervals,inspectthe terminalsof the generator
for corrosion,loose connectionsand the wiringfor frayed
insulation.Check the mountingbolts for tightness,check
the drive belt for alignmentand wear and the drive pulley
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
ManualSupplement No M38731.
IMPORTANT:Becauseof the high inertiaand speedsof
the rotcr used in generators,correct belt tensioningis
critical.
LUBRICATION
The balt bearings in both end brackets are sealed,
thereforecannotbe lubricated.
lf the bearings are removed during overhaul, it is
recommended that they be replaced.
6D-4 ENGINEELECTRICAL
TESTING THE GENERATOR OUTPUT AND

VOLTAGE REGULATOR
Beforetestingthe output,make certainthat the generator
circuitis thoroughlycheckedfor loose or dirty connect-
ions and the fan belt is correctly tensioned. The
generatormust alwaysbe connectedto the batteryduring
testingothenryisedamageto the diodes could result.The
batteryshould be fully charged.The generatorwaming
light, in addition to indicatingthat the generator is
charging,also carriesthe currentnecessaryfor initialfield
excitation.The globeused shouldbe 2.2 watt.
Testing Generator Output

1. Disconnectthe 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' terminaland the other lead to the disconnec-
ted positivewire. Refer Fig. 6D-4
4. Connectbatterylead, fit a loadingdeviceacross the
batteryterminals,i.e, an adjustablecarbonpile. Refer
Fig. 6D-4.
NOTE: Loadingdevice must have a power consurnption
of 1000watts mrnimum.
5. Connectthe positivelead of a voltmeterto the 'BAT' A D JU S TA B LE LOA D
terminalon the generatorand the negativelead to a
good groundon the generatorbody.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
LR160-706generatorand over 65 amps for the LR170-
703 generator,as indicatedon the ammeter.
CAUTION:On completion of the above check, release
the adjustment of the loading device and rduce the i--fJo
engine speed.
NOTE: If the generatordoes not providerated ouput, it
shouldbe disassembled and checkedfurtheras outlined - A MP S +
in this Section.
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.
2. 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.
ENGINEELECTRICAL6D.5
3. Run the engine at approximately2500 rpm, maintain

this enginespeed for 15 secondsand check voltage
reading.This shouldbe 14.1-14.5 volts.
NOTE:The voltage regulatoris a non-adjustable unit and
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 gener-
ator positiveterminaland the batterypositivepost.
2. Switch on the headlights, start the engine and
increase engine speed to approximately2500 rpm
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.
3. MAJORSERVICEOPERATIONS
3.1 GENERATOR
B R A C E sOLT
REMOVE f
CAUT,ON: Disconnect the battery ground (negative)

cable to prevent accidentalshort circuits.
1. Removethe wire from the generatoroutputterminal.
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-5-
5. Remove generator to support bracket bolt and
removegeneratorfrom engine.Refer Fig. 6D-5'
--r-
REINSTALL \)
1. Positionthe generatoron the mountingbracketand GE I'i E R A TORTO S U P P OR T
installthe bolt and nut; do not fullytightennut. B R A C K E T B OLT
2. Installdrive belt to generatordrive pulley-
3. Install the generator to brace bolt and washers, Figure 6D-5
finger tight; generatorpulley should be alignedwith
crankshaftand water pump pulleys.
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
supplement.Tightenthe bracebolt to 20-25 Nm.
5. Tightenthe generatorto mountingbracketbolt and
nut to a torque of 34-44 Nm-
6. lnstallthe connectorto the warninglight (L) terminal.
7. Connectthe red wire to output(BAT)terminalof the
generator.
8. Reconnectthe batterygroundcable'
DISASSEMBLY
1. Mark the relative positions of the slip ring end
bracket,stator and drive end bracket.
._
2. Removethe four throughbolts ReferFig. 6D-6. tf-
rr
3. Separateand remov€the stator and slip end bracket r
from the rotor and drive end bracket,by insertingtwo
screwdriverson opposite sides between the drive
end bracketand stator core and prise apart.
D R IV E E N D B R A C K E T
cAUTloN: care should be exercised so as not to
damage the stator coil with the screwdrivers.
S LIP R IN G E N D
TH R OU GH S '*F BRACKET
B O uTS
Figure 6D-6
4. Hold the rotor in a vice (using copper iaws) and

remove pulley attaching nut with a 22 mrn socket. D R IV E E N D B R A C K E T
Take care not to damage or bend the blades of the
fan.
5. Remove pulley lock washer, pulley and distance r- P Ul -LE Y
collar.withdraw the rotor from the drive end bracket.
_ R OTOR
Figure 6D-7
6. Removethe four screws securingthe front bearing

retaining plate to drive end bracket, remove the
retainingplate.ReferFig. 6D-8.
7. 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
ENGINEELECTRICAL
6D.7
9. Removethe six slip ring end bracketfixing nuts and

remove the slip ring end bracketfrom the stator and r D IOD E A S S E MB LY
diode assembly.Refer Fig. 6D-10.
i de
t''O
rr
t-
\
SI.- IP R IN G EN D -
EqA]KET
NUTS{6}-=>r,
e
Figure 6D-10
10. Remove the stator coil by unsolderingthe three

S TA TOR WIR IN G E N D P OIN T
stator winding connectionsfrom the diode assembly
and separating the diode assembly from the stator
windingend points.Refer Fig. 6D-11. 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

diode assembly.Refer Fig. 6D-12. Nurs (5) 7-FA N GU ID E
1
\
6/
L D IO D E ASS E t . , t B! y
Figure 6D-12
12. To remove the brush and regulatorassemblyfrom B R U S H _ R E GU LA TOR

the diode assembly,remove the rivet by filing away ASSEM B LY
peened end. Once the rivet is removed,removethe
battery terminal and the diode and brush regulator
assembliescan be seParated.
NOTE: Never remove the rivet except when replacing /eattE R Y
diodesor the brushassemblY. 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
assembliesin cleaningsolvent.
2. Blow off any dust or foreign matter from the rotor
and stator assemblieswith compressedair.
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
cleaninqsolvent.
TESTINGCOMPONENTS
-FIE LD D IOD E
Diode Assembly P OS ITIV E
Testof diodeconductivity. S ID E D IOD E -, U V W
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
N E GA TIV E ----< BAT
Fig. 6D-14. rl>
S ID E D IOD E
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 t<- 1.5 WA TT TE S T LA MP
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. 12 V OLT
Check that the bulb lights in one directron only. Check all
three field diodes.
lf any diode proves faulty, replace drode assembly.
Fi gure 6D -15
Stator
Open circuit test for the stator windings. Q n l v 1M ET ER
The continuity of the stator windings has to be checked,

S TA TO R
by first connecting any two of the three stator leads in WIN D IN G
series with an ohm meter. Refer Fig. 6D-16. TE R MIN A LS
Repeat the test by checking at the third lead.
lf continuity is found !n all windings the stator can be
considered to be normal.
S TA TOR C OR E
Fi gure 6D -16
ENGINEELECTRICAL6D-9
Insulation Test for the Stator

S 'TA TOR\ry IN D IN G
Using an ohm rneter,connect the test leads to the stator TE R n.l l NA L -
core and to one of the winding terminals. Refer :-OH M ME TE R /
Fig. 6D-17.
t
lf continuityis found, the stator is consideredfaulty and
must be replaced.
Fi gure 6D -17
Brushes
of brushlength:
Gq
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
with a shallowindentation.Refer Fig. 6D-18.
n
WE A R LIT\4IT
r tt
[\\..- / /l
\-L-'1
_lv-A
g
=
t:,
Va
-
-t !-tl -
Fi gure 6D -18
Rotor
O l v lET ER q
-lNl
Open circuittest for rotor coil:
Usingan ohm meter check for continuitybetweenthe slip
rings.ReferFig. 6D-19.
lf continuityis found, the rotor coil can be consideredto
be normal.
On the contrary,if no continuityis found,the rotor cotl is
consideredto be defectiveand should be replaced.
Lsl -rP R rN G
Fi gure 6D - 19
q7
Insulation Test for the Rotor Coil
E
using an ohrnmeter,check the insulationbetween the OH M ME TE R
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
\OO
replacedif badly worn or damaged.
lf necessary,the slip rings may be skimmeddown on a
latheto a minimumdiameterof 21.6 mm.
lf the outside diameterof the slip rings is found to be
less than 21.6 mm, the rotor must be replaced. SLIP R IN G
NOTE: No attempt shouldbe made to straightena bent
rotor shaft.
Figure 6D-20
REASSEMBLY
The reassemblyof the generator is the reversal of the
disassemblyprocedure,with considerationgiven to the
following:
1. Tighteningtorques(refer Torque Wrench Specificat-
ions 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
ENGINEELECTRICAL
6D-11
3. Insert a pin into the small hole near the outside

centreof the slip ring end bracket.Refer Fig. 6D-23.
Qr
$,
c
-/,t h
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
the lower mountingbolt, or an equalsize rod through
lower mountingholes in the drive end and slip ring
end brackets,to ensurethe holes are aligned.
6. Slowlywithdrawthe pin used in step 3.
Figure 6D-24
6D-12ENGINEELECTRICAL
4. FAULT DIAGNOSIS
Beforeconductingany generatortest, ensurethat:
1. Batteryis fufly charged.
2. Generator drive belt is correctly tensioned.Refer
Fig. 6D-25.
TENSION
3. Generatormountingbolts and bracketsare secure.
4. Check battery terminals and check for loose or NEW USED A n y b e l t t h a t h a sb e e nr u n
corrodedconnectionsto generator. lbs. ks. lbs. kg. f or more than 10 minutes
i s t o b e c o n s i d e r e du s e d .
90 41 55 25
Figure 6D-25
S U ITA B LE WIR E
Figure 6D-26
@
I
lgn it i o n Dis c onnec t lea df r o m 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 wit c h " o n " ' L' t er m inalan d e a r t h s o c k e to r d e f e c t i v ew i r i n g .
- L g h t"o ff" - Li ght ''oft" r-
(Chec k I i g h t ' L' t er m inal l e a d . R e p a i ra n d r e t u r n t o ( A ) .
f or oper a t i o n r ( Chec klight f or o p e r d i , o h)
I
L ig h t " o n"
Rec onnec t' L' t e r m n a l F a u l t y v o l t a g er e g u al t o r .

Light " o n " leadand gr ounC' F ' t e r m i n a l Li ght "o n " R epl ace.
( Ref er Fig. 6D - 2 6 )
Faul ty generator.
R emove and test components.
Engine i d l i n g F a ul t y g e n e r a t o r .
(Chec k li g h t f o r L ' q h t "o n " R e m o v ea n d t e s t c o m p o n e n t s .
operat i o n ) ( d im lig h t, lig h i f ,,cke r s, bri ght l i ght)
I
Lign t "o f f "
E nginespe ed; H ig h e r 15.0V Faul ty vol tage regul ator

1500 rpm R epl ace.
(MeasureBAT
terminalvo ltag e)
1. UNDE R C H AR G EBA
D T T ER Y 3. N OIS YGE N E R A TOROP E R A TION
a. Loose drive belt. a. Normal magnetichum.
b. Defective battery. b. Badly dischargedbattery.
c. Loose connectionin chargingctrcuit. c. Generatormountingbracketsand/or bolts loose.
d. Corrodedconnectionsin chargingcircuit. d. Worn or frayed drive belt.
e. Defectivewiring. e. Worn or damageddrive pulley.
f. Faultygenerator. f. Worn bearings.
g. Faultyvoltageregulator. g. Loose drive belt.
h. Loose drive pulleyattachingnut.
i. Open or shortedmain diodes.
2. O V ERC H A R GE DB AT T E R Y
i. Open or shortedstator windings.
a. Shorted batterycell.
b. Fauftyvoltageregulator.
c. Short circuitin rotor winding
5. SPECIFICATIONS
GENERATO R:
Type 1R160 - 706 L R 17 0 - 7 0 3
Ea rth Polar it y N egative N e ga itve
No minal Volt age 12 volts 1 2 vo l ts
No minal O ut put at 6000 gener at orr pm 60 amps 7O amps
Reg ulat edO ut put Volt age@ 20oC. Approx 14,2 - 14 6 volts A p p r o x 1 4 . 2 - 1 4 .6 vo l ts
Sta tor Phas es. 3 3
Stato r W i nding Connec t ions Star Star
Nu mber of Poles . . 12 12
Nm
Tr^r'o u gh Bolts 3.14- 3.92

P, ?' v Nut . . 39.20- 58.80
Fr c r ' t Bear ingRet ainin gP l a t eS c r e w s 1.67- 2 35
Fan G . r de t o Diode As s e m b l yN u t s 1.67- 2 35
Siip R End Br ac k et M 6 N u t s 5.88- 7 84
"g
Slip R ng End Br ac k et M 5 N u t s 3.14 3.92
G ener at orBr ac eBolt . . 20.00- 25.00
G ener at ort o Br ac k et B o l t a n d N u t 34.00- 44.00
ENGINEELECTRICAL
6D.15
STARTINGSYSTEM
INDEX
Ref. Subiect Page Ref. Subiect Page
1- 6D-15
GENERALDESCR|PT|ON.............................. 2.1 STARTERMOTOR(EFr)................................
6D-15
2. SERVICEOPERATIONS................................
6D-15 Remove........ .....................
6D-15
Reinstall .... 6It-15
The starter motors used on 3.3 litre and 5.0 litre VK that the 3.3 litre starter motor now incorporatesa plastic
Seriesmodels carry over from VH Series models,except shifterfork (similarto JB Camira).
The service operations for these starter motors are as EST and 5.0 Litre engines, carryover f rom VH Series.
described in the lmproved Performance LO and V8 However, revised proceduresare required for 3.3 EFI
Engine Service Manual, Part No. M38338, SectionA7 engines.
StarterMotor Rernovaland Installationoperationsfor 3.3
2.1 STARTERMOTOR(EFl)
REMOVE
2. Rernovebattery feed wire and starter motor solenoid
wire from the terminalson the solenoid.
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
bottom of the passengerside suspensionstrut tower.
6. Pull the starter motor up out between Nos. 2 and 3
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.
ENGINEELECTRICAL
6D.17
IGNITIONSYSTEMS
INDEX
1. GENERALINFORMATION......................-..... 6D -17 2.5 ELECTRONIC
CONTROLMODULE............
6D.27
1.1 ELECTRONICSPARKT1M1NG....,...........r..... 6D-18 R gm OV€'...................................................
6Ot27
Gengral Description......r..'.........rr......-. 6D-18 RginStal | .....t....................r....................,..
6D'27
1.2 SYSTEM I-AYOUT ..................r..!......r....r.r,..... 6D -18 2.6 COOI-.ANT TEMPERATURE SENSOR ....r... 6D,28
1.3 ELECTRONICSPARKTIMINGSYSTEM Rem OV€.......................r....................oo......
6 Dt28
COM PONENTS .................r!......!t................r.r.. 6D-19 TgSt .............. 6 D28
-...........r.'...................o.o......
COntrOl MOdul€ ........r....r......r....r..r......... 6D-19 RginStal | .-........ts.'...,r..,......................r.....
6D28
Englne Speed Sensol'.......................... 6D-19 2.7 THROTTLEPOSITIONSWITCH.............._...
6D,29
Manifold Vacuum Sensor..........!r.r.....r 6D-20 RemOV€.......................r.................r..........
6D28
Englne Goolant TemPerature RginStall ...............................r..................
6D'28
Sen SOr ..... r.....rr....r...o. r.....tt. r.. ..... r.........r..t 6D-20 AdiuStment.......o... o...............-...rr...!.........
6D29
Throttlg Posltion Sw|tch...................... 6D-20 2.8 ENGINE SPEED SENSOR ..,.................rr.....,.. 6D.30
Staftgr MOIOr........r.rrr.............................6D-20 T eSt...r ...................r .r r ........ . . . . . . . . . r. 6 I )-3 0
Alr Gondltlonlng ComPressor RemOV€................r.......'.....
.......................
6D-30
ClUtCh ..t...........tr............r......................... 6D-20 ReinStall ......-...!.............-...
ro..r................
6D'30
lgnltlOn COll ............r...................t......r.... 6D-21 3. D I AG NOSIS .........r........r...'.€..-...
or.,'..............r.
6D'3 1
1.4 HODES OF OPERATION r....r...............r........ 6D-21 3.1 DIAGNOSIS LIMP LAMPT.!...-......,,.......,........ 6D-31
Cranklr|$ r....r...r....rr..rrrr............r..........t.... 6D-21 3.2 DIAGUOSTIC ELECTRICAL
l dl g 6D-21
.at.r t..r r r ...a..!.r .r 1.r ...!r ...r .r .........r 1........ rr. . . CONNECTION FOR EST...........-........-..r,.,..,.. 6D-31
NOfmal iiOdg.r........r........!.....i.t.............. 6D-22 3.3 DIAGNOSIS OF LIMP LAMP OPERATION 6D.32
Overspggd Control ...........r..rrtr............ 6D-23 Ump Homg Mode,.....................,..,h.,.... 6D-32
DgCglgfatlng .r.t..t.r........r....tt......r.r.......'. 6D-23 Poggible Temperature Sensor
Llmp HOmg MOde...r......t!.!!...r........r...... 6D-23 F aU l t.r ..r .....!..r .........r ....................o. . . . . . o . . . . . . .6 D -3 2
2. SERVICE OPERATIONS ........'.t........r....r...... 6D-24 PossibleVacuum Sensor or
2.1 SERVICE NOTES !..rr...............r..........r.t.r.t...... 6D-24 Throttle Position Switch Fault (1) .... 6D-32
2.2, SETTINGlGNlrloN T1M1NG...............,.'.!..... 6D-24 PossibleVacuum Sensor or
2.3 D IS TR I BUTOR ...............r t.r .............r ...r t..!......... 6D'24 Throttle Position Switch Fault (2) .... 6D-33
Rgm OV€..........................................a..1.....r 6D-24 i 3.4 WIRINGHARNESSCHECKING
R glnStal | ...........................................t.r .... 6D-25 PR O C E D U R E .r .....'...r ...D .r .......r ...r r ..r .t... . . . . . . r.o. . . 6 D ' 3 8
DlSaSSem b 1y.r ........r F.' ................ ............. 6t>26 4. 6 D-40
SPECI F ICATIONS -.r.........'.........r..........'.........
RgaSSem bly o............................. .....r ..'r .!. 6D-26 5. TORQUE WRENCH SPECIFICATIONS.O"""6D-41
2.4 MANIFOLD VACUUM SENSOR ...........r.r...... 6D-26 6. 6D-41
SPECIAL TOOLS ..........r.r.....r...'...r.............r...
R gmOV€ ...........- r........ . ...r .. .r .. . .. . . .. .. . r.a....... 6D-26
ReinStall ..........r ......................r ...........r r ..r 6D-26
Tgstinl$ ...r......r.rr.rr.!r.r.................o......r...!. 6D-27
1 . GENERALNFORMATION
The ignition system employed on 3.3 litre Electronic Fuel The igniticn system for 5.0 litre VK Series rroceis carrles
Injected VK Series models is similar to the system used over from VH.
on 3.3 litre VH. Revisions have been made to the 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 ,
distributor advance mechanism and spark plugs have a a Bosch Electrcric Spark Timing StSte'n tS used instead
revised heat range. Refer to Specifications at the end of of the conventrcna rgnitionadvance svstem.
this Section for details.
4-r
1. 1 EL EC T R ON IC
S P A R KT IMIN G
GENERALDESCRIPTION
The Electronic
SparkTiming(EST)systemreplacesthe
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 SYSTEMLAYOUT
Figure6D-28 shows sensorsused by the ControlModule
to monitor engine operation.The only output from the
module,controlscoil primarycunent.
E N GINE
S PE ED IGNITION
SENSOR COIL
EL E C T R O N I C
CONTROL
ENG I NE MODULE
WATER
TEMPERATU RE
l-
I
l-
STARTER
T H ROTTL E
P OSITION AIR MOTOR
S WITCH MA N IF OL D C O ND I T I O N I N
VA C UU M CL U T C H
S EN SOR
Figure 6D-28
.-r---..
ENGINEELECTRICAL
6D.19
SPARKTIMING
1.3 ELECTRONIG
E LE C TR ONIC C ON TR O L --
SYSTEMCOMPONENTS MOD U LE ),r
CONTROLMODULE g
(--\
The micro processorbased controlmoduleis located }--/
r''--1
behind the left hand side cowl panel trim. Refer
Fig. 6D-29.
The control moduleperformsthe followingfunctions:
sl
ti '
1. A mernory is used to store the micro processor :.a
:.1
-:t i
programmeand data tables for spark advance as a
function of speed and load, temperature, throttle
switch positionand tjme after start.
6,e ii
1*
'
'a,(Z
,
I
2. The micro processorexecutesthe programmecontai- L -W I R I N G
ned in the memory. HARNESS

C O N N E C TO R
3. The spark timing signals from the micro processor al
are converted into signals to control coil primary - / - \ o <- M o u NTTN GscR EWS
current. (3 P LA C E S )
For every combinationof engine speed and engine load
there is a unique spark advance value specified and Figure 6D.29
storedin the controlmodule.
The spark advance information is stored in a memory
table. Each entry of this table may be specified ind-
ependentlyof any other point.
The electronic control module memory contains two
tables.
1. Optimumadvancetable - for highwayuse.
2. Modrfied advance table - for low emission
requirements.
The memory tables are used by the micro processorfor
everyignitionpulsecalculation.
ENGINE SPEED SENSOR

An electronicspeed sensor, inductivemagneticpick up ..- TN GIN E B LOC K
type, is mountedon the rear of the cylinderblock.Refer
Fig. 6D-30.
Three mild steel timing pins spaced 120o apart, ate MOU N TI N G
located around the circumferenceof the flyrheel or B O LT
torqueconverterassembly,and the pick-upof the speed
sensorextendsthrougha hole in the clutch or converter ..T------
housing. spEED
As each pin passesthe sensor, a signal is generated S E N S OR
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.
Figure 6D-30
6D.20ENGINEELECTRICAL
MANIFOLD VACUUM SENSOR

U N D E R S |D E V tE W OF -r
Mounted on the outside of the fuse box, the engine FU S E B OX
\
vacuumsensor relays informationto the control module
regardingthe engine'sloadcondition.ReferFig. 6D-31.
The manifoldvacuum 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 permanentdamagecan occur.
The sensoris non repairable,if provedfaulty,it must be
replaced.
Figure 6D-31
ENGINE COOLANT TEMPERATURE SENSOR

The coolanttemperaturesensoris mountedon top of the
engine thermostat housing. The coolant temperature
sensor determinesthe use of the appropriateadvance
table during cold starts, normal operation and high
temperatureoperation.
The temperaturesensor (Fig, 6D-32) is of the negative
temperaturecoefficientdesign (NTC).The resistanceof
the sensor decreases as the engine temperaturein-
creases,this causes a decreasein the signal voltage
beingfed into the controlmodule.
NorE: The coolant temperaturesensor for EST is the
samesensoras used for ElectronicFuel 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
t
Figure 6E)-33
STARTERMOTOR
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 com-
pressor is operating. This results in an increased ignition
advance at idle, thereby increasing the idle speed to
prevent the engine from stalling or overheating.
_--____
ENGINEELECTRICAL
6D.21
IGNITION COIL
The ignition coil used with the EST system is the
standardHigh Energy lgnitioncoil. Coil triggeringis fully
controlledfrom the electroniccontrol module, including
dwell time. The electronic control module takes into
account battery voltage to adjust the dwell to com-
pensate 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 AD D IT IC N ,J AL

To maintain idle speed and quality after a cold start, AD \./AIi C E
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. 17oc
provided engine is idling. lf engine speed exceeds COOLA N T
900 rpm due to additional advance, advance slowly T E MP E R A TU A E
decreases to effectively govern engine to 900 rpm. 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
l dle - H igh Temp era ture Com pens at ion

A D D ITION A L
lf the engine coolant temperature exceeds 95oC, while ADVANCE
the engine is at idle, the spark advance is increased to
improve idle quality and increase rdle speed for improved t 8oc
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
MA N U A L A U TOMA TIC
charging and power Steering, advance is increased as
s hown in Fig . 6 D-36 . 760 R P M
As engine speed falls below speed A, advance increases
to a rnaximum at soeed B.
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.
II
t-
Normal Mode - Low Temperature Compensation

A D D ITION A L
After a cold start, advance is increased during normal ADVANCE
mode operationto improve cold driveability.The amount
of advance selected is based on engrne coolant
temperatureat 'lgnition ON', and is gradually reduced
with elapsedtime after 'Start'.Refer Fig. 6D-37.
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
When the throttleis released,the enginespeed is greater
than 900 rpm and the throttle positionswitch is closed,
the operationis definedas deceleratingmode.
The control modulereceivesinformationthat the vehicle
is in the deceleratingmode, and advanceis selectedby
the controlmoduleto reduceemissionsunder decelera-
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 mechan- .WA R NIN G
ical damage for example)the system revertsto the Limp LA MP
PAN EL
Home Mode. In this conditionall firing impulsesare at
D IAG\OST IC
6CBTDC. lf the limp mode is initiated,the diagnostic
LA\1P.
lamp on the warning lamp panel (Fig.6D-38) is lit
continuouslyin the normaldrivingmode.
Figure 6D-38
2.1 SERVICENOTES
The following requirements must be observed when
working on vehicles with the Electronic Spark Timing
(EST)system.
1. Before removing any EST system component,dis-
connect the battery earth lead. Failure to do so
could result in the service operator receiving an
electricalshock.
2. Never start the engine without the battery being
solidlyconnected.
3. Do not use a quick charge unit to start the engine.
4. Neve. separate the battery from the on board
svstemwhilethe engineis runnrng.
electrical
5. When charging the battery, disconnect it from the
vehicle'selectricalsystem.
6. Never subject the Electronic Control Module to
temperaturesabove 80oC (176oF) i.e. paint oven.
Always remove control module first if this
temperatureis to be exceeded.
7. Ensurethat all cable harness plugs are connected
solidly and that battery terminals are thoroughly
clean.
8. 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.
2 . 2 SE T T I N GIGN IT IONT IMIN G

Since the ignition timing in the EST system rs electronic-
ally 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. Unfasten spring clips holding distributor cap and
remove distributorcap.
2. 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 u-
39 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
ENGINEELECTRICAL
6D.25
3. Clean all foreign matter from around the distributor

and clamp, then remove the distributor clamp bolt
a nd cla m p.
4. Withdraw the distributorfrom the engine.
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 R A IS E D MA R K OI,J
the distributor and camshaft gears will align the firing D IS TRIB U TOR
position for No. 1 spark plug. When a replacement H OU S IN G
pin is fitted, the pin does not protrude.
P R OTB U D IN G
R E TA IN IN G
P IN
Figure 6D-40
2. Installthe distributorinto its position.Rotatethe body

so as the distributorcap clamps are at approximately
45o to the crankshaftcentreline.Refer Fig. 6D-41.
3. Installdistributorclamp and bolt, do not tightenbolt.
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
-
DIS A S S EMBLY
1. Remove distributorand rotor.
2. Remove circlip and upper distributor shaft thrust
washers.
3, Press out the pin securing the drive gear and remove
gear and thrust washers. Refer Fig. 6D-43.
4. 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 S H I\4 WA S H E R
2. R OTOR 1
D R IV E GE A R
? S H A FT 8 D R IV E GE A R P IN
4 U P P E R & LOWE R B U S HE S 9 D IS TRIB U TOR H OU S IN G
5 FIB R E WA S H E R
Figure 6D-43
2.4 MANIFOLDVACUUMSENSOR
,- MOU N T| N G
REMOVE /' S C RE W
/ (2 P LA C E S )
1. Remove the two screws securing the sensor to the
bottom of the fuse box. Refer Fig. 6D-44.
U N D E R N E A TH V IE WOFT
2. Disconnect wiring and vacuurn connectors. Refer FU S E 8OX
Fig. 6D-44.
,
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.J23987-
01 or equivalent, insert end into open hose end.
Refer Fig 6D-45.
Figure 6D-45
3. Connecta voltmeteracrossthe CB and CA terminals

of the sensor.Refer Fig. 6D-46.Switchon ignition.
4. With a varyingamountof vacuum,the output voltage
variesaccordingto the followingtable:
O U T PU TV OLTA GE
4 .4 to 5.3
3 .2 to 3.8
2 .0to 2.5
VO L T} I E T E R
0 .7to 1.1
Any deviation in the output voltage figure with the

nominated applied vacuum, indicates a faulty sensor,
which must be replaced.
Figure 6D-46
CONTROLMODULE
2.5 ELECTRONIC WIR IN G
E LE C TR ON IC C ON TR OL
REMOVE MO D U LE
HARNESS
1. Make sure ignitionis switched'off' and disconnect
batteryearth lead.
2. Removethe lefi hand cowl panel trim from the front
passengercompartment.
3. Removemodulemountingscrews.Refer Fig 6D-47.
4. Disconnect wiring harness and withdraw control
modulefrom its position.Refer Fig. 6D-47
REINSTALL
Installationis the reverseof removalprocedure.
/ MOU N TIN G
,//,i' *}.
%,' C RE\vs.
scR
S E IV S .
,rr W (3 PiACES)
r/
Figure 6D-47
2.6 COOLANTTEMPERATURE
SENSOR
REMOVE
2. Disconnect wiring harness connector from
temperaturesensor.Fig. 6D-48.
3. Draincoolantfrom engine,below sensor level.
4. Removesensorfrom thermostathousing.
Figure 6D-48
TEST
1. Suspendsensorin a containerof 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 Figure 6D-49
Any deviation in the resistance values recorded at the

norninated ternperature readings indicates a faulty sensor
which mu st be re pla ce d. B R A C K E T S C RE WS
r -- (2 P LA cE S )
RE I NS T AL L
1. Apply GMH sealant P/N g}3szi4 to sensor threads,
refit in thermostat housing and tighten.
MOU N TI N G
2. Refit wiring harnessconnector. P LA TE
3. Fill up radiator and check for coolant leaks.
C A R B U R E TTOR
REMOVE
A C C ELE R A TOR -
1. Femove carburettorair cleaner. LIN K A GE
2. Disconnectthe two wiring connectors at switch.
3. Remove the 2 switch mounting screws, washers and
S C RE WS
mounting plate. Refer Fig. 6D-50.
\
RE I NS T AL L \ S WITC H A C TU A ToR
Installationis reverse of removal procedure. The swrtch
rnust be readjusted after installation. Figure 6D-50
6D.29
ENGINEELECTRICAL
ADJUSTMENT
1. Disconnect wiring connectors from switch.
2. 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 ohmme- F AST ID LE C AM \
ter reads 0 ohms. Loosen mounting Screws and \

adjust switch as required to achieve correct I
adiustment. S E C OND S TE P
5 . When switch is correctly adiusted,tighten mounting
screws and recheckadiustment-
6. Reconnect wiring connectors to switch. Reinstall
carburettorair cleaner.
On vehicleswith manualtransmissions, for the engineto
return to idle, it is essentialthat whenever the throttle
closes onto the extended throttle nudger shaft, the Figure 6D-52
throttlepositionswitchmust be closed-
lf the throttle closes onto the extended nudger without
closingthe throttlepositionswitch,the enginewill run at
approximatelY 1400 rpm.
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.
2.8 ENGINE SPEED SENSOR

ME A S U R E A C R OS S
TEST TH E S E TE R MIN A LS
1. Disconnect sensor wiring harness connection, at the
fuse box side of the rocker cover. Refer Fig. 6D-53A.
2. 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
Figure 6D-53
REMOVE
1. Disconnect battery earth lead
2. Disconnect engine speed sensor wiring harness
E N GIN E H A R N E S S
connection, at the fuse box side of the rocker cover. S TRA P
Refer Fig. 6D-53A
MOU N TI N G
3. Remove engine harness strap at rear of rocker B OLT
cover.
4. Remove bolt securing engine speed sensor supporl
to the rear of the cylinder block. SPEED
5. Remove sensor assembly from its location. S E N S OR
NOTE: Do not damage support locating lug.
S P E ED
6. lf necessary, mount speed sensor support carefully in
S E N S OR
a vice with soft jaws, remove mounting bolt and S U P P OR T
separate sensor from support.
S E C U R IN G
B O LT
REINSTALL
Installationis reverse of removal operations.
S U P P OR T
LOC A TI N G LU G
Flgure 6D53A
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
secondsafter the engine starts if everythingis operating
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
necessarily the optimumvalue.
2. lt means that there is a malfunctionin 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 reducedperformancelevel.
3.2 DIAGNOSTIC
ELECTRICAL
CONNECTION FOR EST
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 con-
nection,the diagnosticlimp lightis activated.
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
MAIN W IRING E.S.T.D IA GN OS TIC (l GN l Tl ON C Ot :-'
HARNESS CONN. CON N E C TC R
\)
. -/
)c 'l
|
T R ANSM ISSIC\
H ARN ESS tx -'\
q_
DK SL UE L EAD
( OI L PRESSURESW i
Figure 6D-54
ln the event of the limp light coming on to indicate a After the 8 minute period is complete, the module
system component failure, make the earth connection to detects the fault, turns the warning light on (or ftashes
the connector body without turning off the engine, and let the diagnosticcode in diagnosticmode) and assumesa
the engine idle. normal temperature(90oC). The light remains on con-
Description of the diagnostic limp light operation is tinuously in normal mode (or continues to f lash in
covered in 3.3 of this Section. diagnosticmode) until the ignitionis switchedoff.
To reset the diagnostic lamp for normal mode condition, when the light comes on, the idle speed will return to
turn off the ignition and remove jumper lead. Restart normalas the very high temperatureis no longerseen.
vehicle and if the fault has not been corrected the
diagnostic lamp will come on again when the appropriate Open Circuit
test conditions are re-established.
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
3.3 DIAGNOSIS increasedfor improved idle quality. Note that this will
OF LIMP LAMP cause the idle speed of a warm engine to fluctuateabout
OPERATION 900 rpm. This is because additional advance is only
(Refer to chart at the end of this Section.) present at idle, which is defined as engine speed less
than 900 rpm and idle switchclosed.
L IMP HOME MODE lf the speed is above 900, the advance is slowly
lf the microprocessor (or computer) fails, a limp home removedand the engine slows. lf it is below go0 rpm,
mode is activated and the warning light is turned on. the advance increases and the speed increases.This
Limp home mode is provided to minirnisethe likelihood of providesengineidle speed governingat 900 rpm.
the owner being stranded. Spark timing is very retarded After 8 minutesof operationwith the open circuitfault,
in this mode (60 BTDC always) and this will €use the module turns the light on (or flashes the code in
increased fuel consumption, poor engine response and diagnostic mode), assumes a normal operating
higher engine operating temperatures, Prolonged opera- temperatureand continues to provide additionalspark
tion in this mode should be avoided. Monitor engine advanceat idle until 12 minutesafter ignitionkey on.
temperature regularly if limp mode operations is necess-
ary at high ambient temperatures or while towing. Stop if POSSIBLE VACUUM SENSOR OR THROTTLE
necessary. POSTTTONSWTTCHFAULT (1)
lf the microprocessor starts operating normally, the light
whenever the engine is operating,the module is chec-
will be turned off in normal and diagnostic modes,
provided no other faults have been detected. lf the
king for a vacuumsensorfault.
diagnostic light is on continuously in norrnal mode and lf the throttle position switch is closed and the engine
does not flash a recognisable code in diagnostic mode, speed exceeds 1500 rpm, the rnoduleexpects to see a
the EST module should be replaced. 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
POSSIBLE TEMPERATURE SENSOR FAULT flashesevery 8 secondsin diagnosticmode) and assume
lf a fault is detected in the temperature sensor circuit, the the manifoldvacuumis zero at all times.
light is on in normal mode. In diagnostic mode, the light lf the engine is switchedotf and re-started,the light will
flashes on for 1 second in every 8 seconds. go out until the engine speed exceeds 1500 rpm while
The control module does not check the temperature the throttle position switch is closed. lf the vacuum is
sensor circuit until the ignition has been on for again seen by the moduleas less that 30 kPa, the light
8 minutes. From I minutes onwards the module con- will be turnedon again.
trnuously checks for a temperature between 50oC and This fault will be indicatedif the hose comes off the
125oC. ff the ignition is switched on without starting the vacuumsensor,if the signalwires rn the vacuumsensor
engine the temperature may be outside the specified harnessare shortedtogetheror if the vacuumsensor is
limits without a fault being present, I minutes after faulty. This fault may also be indicated if the throtile
i gnit ion' ON'. positionswitch wires are shortedtogetheror to groundor
To check for this false indication,switch ignition off, start the switch itself is badly adjustedor short circuited.For
the engine and check the light in 8 minutes. example,the enginemay be operatingat 1600 rpm wide
lf the light comes on again, it may be due to either an
open throttle and with zero vacuum, lf the throtile
positionswitch is operatingnormally,it will be open and
open circuit, a short circuit or a faulty temperature
sensor. A faulty sensor may give the same symptoms as
no fault will be recorded.lf the throttle posrtionswitch
wires are shorted together,the module sees the same
an open or short circuit.
inputas a closedswitchand recordsa fault condition.
Short Circuit It is necessaryto assumethe engineis operatingat zero
vacuum all the time this fault is present.This is to
lf a shortcircuitis present, appearsvery
the temperature prevent the module frorn giving the engine excessive
high (130oC ) to the module. In the I minutes between advance at wide open throttle and causing detonation
the ignition being turned on and the detection of the damage.
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
ENGINEELECTRICAL6D-33
POSSIBLE VACUUM SENSOR OR THROTTLE

POSTTTONSWITCH 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
8 secondsin diagnosticmode) and assumethe manifold
vacuumis zero at al times.
If the engine is switchedoff and re-started,the light will
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 LIMP LIGHT OPERATION

C O R R E C T SYSTEM
FAUL T DESCRI PTI O N FAULT C O N D I T I O N Diagnostic Normal
o P E R ATTON
Mode Mode
Poss ibleEST Cont r ol Cont r ol m o d u l e s e l e c t s * Lamp Lamp or
m odule f ault lim p m o d e uncontrolled u n t i l r e s e ti s c o n t r o l mo c - . the
u s u a l ly o f f successfu l - c light is no: c re red
Po ssibleenginec oolant Assu m e s engi ne cool ant O n e p u l s eo f Lamp on ,A 'i er the engine n:s been
temp er at ur e s ens orf ault te m p e r a ture = 95oC lamp every until reset rLtnrng for 8 m i -ru:= s , the
8 seconds successful er^Cne temperatu' = .' ,rl l be
bei vveen 50oC t: ' ,25oC
Possi blev ac uum s ens or As s um esva c u u m i s 0 k P a Two pu lsesof Lam p on W:n throttl e po s i ::on s w i tc h
o r thr ot t le pos it r on wit h t he t h r o t t l e p o s i t i o n lamp every Jrtil reset ci csed, engi ne v ac LU rn mus t
sw it c h f ault ( 1) s wit c h op e n o r c l o s e d 8 seconds 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 As s um es v a c u u mi s 0 k P a 3 p u l s e so f Lamp on t h th rott l e po s r: ;o n s w i tc h
o r th r ot t le pos it ion wit n t he t h r o t t l e p o s i t i o n l a mp e v e r y until reset ci osed and en gi rrE rdl i ng
swit c h f ault ( 2) s wit c h o o e n o r c l o s e d 8 seconds successfuI b e i 'v e e n8 5 0 a n ci9 0 0 r p m
t h : e n g i n ev a cu um m u st b e
b e : 'v e e n1 0 a n d 7 5 kPa
* Be ca us eof t he nat ur e of t his f ailur e it is n o t p o s s i b l et 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

if th e l am p c ioesf 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 dt 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.
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 . , hens t ar t i n ge n g i n e .
lsDia g n o stie I
yES ( tttO
LamPon? i->- I
C o n n e c t D i a g n ostic C o nn e c t D i a g n o s t i cL e a d
L e a d t o e a r t h. 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 l s l i ght fl ashi ng once

f las'ring1,2 or 3 every 8 seconds?
t imes every8 seconds ?
NO
NO
Se e Ch a r t co r r e sp o n d rng SeeChart 2 f or possible
to n u m b e r o f f la sh e s. 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 S e e C h a r t s3 & 4 f o r p o s s i b l e
2. Op e n t h r o t t l e w h i le END V a c u u m S e n s o ro r t h r o t t l e
engine is idling. P o s i t i o nS w i t c h f a u l t s .
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 .
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 .
Rep l a c e E S T C o n t r o l M o d u le
ls light still on? +YES- -l
C h e c k Wi r i n g H a r n e s s ,
NO d e t a i l sa t t h e e n d o f
this Section.
CHART1.
ENGINEELECTRICAL
6D.35
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. F ' t Tac hom et er .

2 Fit M anif old Vac uum G a u g e .
I 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 .
A
9. Aut om at ic Tr ans mis 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 .
5. M anual Tr ans m is s io n- 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 .
Light
YES
i s V acuum H ose connected

- RECTI FY
to V acuum S ensor?
I
YES
l s Wi r i n g H a r n e s sC o n n e c t o ro n
RECTI FY - NO
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
D oes Th rsl i l s P o s i t i o nS w i t c h o p : 'a : e

RECTI FY - NO
as sP ec;fi eC o n E mi s s i o n L ab e )
YES
I
I
I
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 ra n o
RECTI Fy _ FAULT! - - - * 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 ,
i
o.K.
( T e s t E n g i n eV a c u u m S e n s o ra s p e r
RE PLACE - FAULTY
s e r v i c eo p e r a t i o n2 . 5 i n t h r s S e c t i o n .
t
o.K.
I
R eol ace E S TC ontrol Modul e
END
CHART2.
I
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 F i : T a cr o m e te r .
2 F : l' t/an 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 hesappr 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
ls Vac u u m H o s ec o n n e c t e dt o
RECTIFY _ _,
Vac uum S e n s o ra n d i s V a c u u m
I F A ULT S av a i l a b l ea t S e n s o r ?
YES
R ECTIFY
FAU LTS
YES
REPL ACE i Tes t Eng i n eV a c u u m S e n s o ra s p e r

F A U L T Y -< .
SENSOR s er v ic eope r a t i o n2 5 i n t h i s S e c t i o n .
OK
t
I
a^d C h e c <E n g i n eV a c u u m
RE P A I R I
HA;ruissl-- FAULTY Se" s o rV / i r r n gH a r n e s s ,
I
Repiac eES T C o n t r o l Modu l e
END
CHART3.
6D-37
ENGINEELECTRICAL
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.
Light may comeon if

E n g i n ei s n o t s t ar te d
seconds? NC -
a s s o o n a s i g n i ti o n
s : u r n e d 'O N '
l s Wi r i n g H a r n e s sC o n n e c t o r
REFI T fitted to Coolant
T e m p e r a t u r eS e n s o r ?
YES
T e s t C o o l a n t T e r nc e r a t u r eS e n s o r 1
REPLACE FAULTY a s p e r s e r vc e o P e r a t i o n
-
SENSOR i n t h i s S e c i'c n .
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
R EPAIR FAULTY- + S e n s o rWi r i n g H a r n e s s ,
HARNESS 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 '
R e p l 3 c eE S T C o n t r o l M o d u l e
END
CHART4.
.--^
3 . 4 W I R I N GH AR N E S SC H E C K IN G
PROCEDURE
1. Remove electronic control module as per service 25 14
operation 2.6.
2, Separate the EST wiring harness from the control
module.
3. Sincethe contactterminalson the plug strip are not
marked, the contacts must be counted for the
13
varioustests.
Terminals 1 through 13 are located on the long
terminal strip, terminal 1 is next to the cable
entrance. Refer Fig. 6D-55. MU LTI_P LU G TE R MIN A LS
Terminals 14 through 25 are located on the short
terminal strrp, terminal 14 is next to the cable
entrance. Refer Fig. 6D-55.
4. Remove the wiring harness connector from the EST
Figure 6D'55
sensor to which the test is directed.
5. 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

S E NSOR NO TE RM I NA L
Blac k
Blac k iwh
C oola nt
T emperature Bla ck .' , te
Bla ck \r /n ,te wir e
S ensor
T hrot t le
P osition B ac< W hit e wir e
Switch Br ack wir e
ccil te r m in a l
c c n n e cto r
E ngine 21 A
V acuu m 24 B
S ens or v C
* Remo v e w i r i n g c : - i :c:l- s fr o m th r o ttle p cs : :-
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
I S EN S O F
_ I
-_.
GN D
TH R O TT L E
c P O S I TI O N
o
S W I TC H
()
F-
UJ
z 15
z
o
C)
ul
f--
f
o TO
o
IG N . SW .
DIAGNOSTIC LA\IP 3 W AT T S M AX.
o 17
G
F
z -
o 18 '.--.------ B--l
-,rl
O
i c oNNEc r oR
cf) II SERV IC E D IAGN O ST IC I
lu I
SWIT C H T O GR O U N D
---J
24
19
EARTH FOR EST

20
ON CENTRAU EAaTH lN G POIN T
14 EARTH FOR IGNITIC\
ON CENTRAL EARTHING POIN T
16 B + TO IGN. SW ITCH A GN D
E^r iNE
B SIGN AL '. ':r,JM
a -r
C + VE v s tV V- l - I
Figure 6D-56
4. SPECIFICATIONS
E NGIN E DESIGNATION . . ;flh

3.3litre EST, EFI 5.91;,,.
D ' stribut or
Mak e..... Bosch
S park Advan ce 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 . )
P ick u p Cc R:sista nc e 1.0 - 1.2 Kil OHM @25oC
F iring O'ce' 1,5,3,6,2,4 1,2,7,8,4, 5,6,3
C oil
Mak: Bosch
C u' .en i
En gin eSto pp ed. . . . 0
En gin eldlin g 7 amos
P : imary Co il
Resistance 0.5 - 0.7 OHMS @ 25oC
SecondaryCoil
Re sistan ce 5- 7 Kilo OHM@2SoC
Spark Plugs
Make . AC
Model . A2CLTSX 44TX
Tread . 14 mm
G aP . . 1 . 5 m m ( . 0 6 0i n .)
T ighte nTo rqu e 17 - 18 Nm
High Tension Lead Resistance 2000 to 8000 OHMS oer 300 mm
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 ID EN T I F IC AT I O N O N
DIS T . DIST. CENTR IFUG AL AD VAN C E VAC U U M AD VAN C E W H IT E LABEL ON
AP PL I C A T ION P A RT i AOVANCE ENG. DEGREE S AT EN G. R .p.M . EN G. D EG R EES @ k Pa VAC U U M AD VAN C E
NU MB E R i{ DEGREES) U N IT
I
tl
t er oc t s r ART TNTE R M E D T AIT E r u l r _ ST AR T F U LL
12 - 3.0 to 1.0 3 : :3 :3.5 16.0to 20.0 tl

11 - 15
3.3 litre
EFI
9 2 Ct 7 t9 O BELOW @ + @ \: @ BLAC K 120
1 100 RPM 1200 2410 5000 1-l
tt 34
6 | - Z to Z E :c'2 20 to 24 0 14 - 1g
5.0 litre 92023157 BEL OW O 3 @
I Y @ ELAC K 60
E5 CRPM i 1000 20c0 4400 22-29 42- 47 l
r ------r
6D-41
ENGINEELECTRICAL
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
f ulc unt ingSc r e wt o P l a t e 5 - .7
f v ' lount ingBr a c k e tt o C a r b u 'e : i c r , 3.5 - 4.5
EngineSpeedSens o r
Sens orSuppo r t t o C y l i n d e r B c c k B o l t 30 - 40
Sens ort o SuP P o r tB o l t B - 11
EngineVac uum Tr a n s d u c e r
M ount ing Sc r e w st o F u s eB o x 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 ISSIONCONT R OL6E .1
SECTION6E
EMISSION
CONTROL
INDEX
1. GENERALDESCR1PT|ON..............................6E -1 1.8 THROTTLENUDGER...... 6E- 16
1. 1 EARLY FUEL EVAPORATION 6E-5 2. S E R V | C E OpE R A T| ON S ........_..... . . . . . 6E- 17
1. 2 EVAPORATIVEEMISSIONCONTROL........ 6E-5 2.1 GENERALTNFORMATTON ............................
6E- 17
1. 3 POSITIVECRANKCASEVENTILATION.... 6E-6 2.2 EGR MODULATORVALVE .......................... 6E- 17
1. 4 V A CUUMAD VA N C EC ON T R OL 6E-9 6E- 17
VAG System (NSw) 6E-9 3. SPECIALTOOLS 6E- 18
1.5 A I R P RE H E AT .................... 6E -14
1.6 ArR tNJECTTON 6E -14
REACTOR..........................
1.7 EXHAUSTGAS RECIRCULATION 6E -14
3.3 Litre EFI Engines 6E -14
3.3 Litre EST Engines 6E -14
1 . G E NERALDESCRIPT ION
The EmissionControl Systems employed on VK Series The chart below sets cut the EmissionControt Systems
vehicles catry over in general f rom VH. However, apprrcablto
e the vari ousenqi nesused i n V K Ser r es.
significantrevisionsto some systemshave been made to
suit specificenginerequirements.
EMIS SIONC O N T R OLS YS TE M L6 3.3 E S T _6 3.3 E Ft 5.0 L
Ear ly Fuel Ev apo : : r ' X

Ev apor at iv eEm is so' ' Cont r o , X X
Pos it iv eCr ank c as eVent iat o n X
Vac uum Adv anc e Co"ir o N /A X X
Ar r Pr eheat X N ,A X
Air ln jec t ion Reac t o' . X N ,,A NiA
Ex haus t G as Rec ir c u a: r : n X X X
Thr ot t le Nudger Manualonl y N /A N /A
Ni A = Not APP c : D I e
T he f ollowingp a ra g ra p h s u mma ri s eth e c h a n gesto the

svstemsfor VK Series.
6E.2 EMISSIONCONTROL
2 ; !,
E
o
tsd
a E 3
q7
RF 7rI
^P'; R b z
: gi 2 i ,!
6
: EJ 6 R6 E F L I
=
<
Fi l t ; srr!i :
E I 3B; E e a e3 ; 9
: d q s9 ;* Ezr; ( 2
a ;
EiEEEE!E:Fg!F
; 5 : : : E:eEd9;
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z2
!3
-a
H
p
= oa,
Er
3:HH$9fr3E3$
I I
I l l tl t
EMISSIONCONTROL6E-3
o
;
[9 a
;o
;
;
a
Jei F
;
z
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g z
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9 9
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I isrr EEi 3 aiHbr

ttt! I
6E-4 EMISSIONCONTROL
z
o
ti 6
z
\ CE
F
it
/(
tr
F
l
5
!J
z
z
F
,a,
z
9
tr
l
=
EO
6
E r
z
*z
j-A o;!E ! I
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3E =
i;) : 096 q
2 iicy
ii''rI
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3 q!E:
= JY
t
4 =3
i ddE i
ll
EMISSIONCONTROL6E-5
1.1EARLYFUELEVAPORATION
The EFE system is carriedover from VH for the L6, 3.3
E S T enginesan d 5 .0 l i tree n g i n e s .R e fe r F i g s .6E -1,6E -2
and 6E-3 for hose routing for L6, 3.3 EST enignes.
5.0 litre engine hose routing carries over from VH. The
EFE is not used on engineswith electronicfuel injection.
1 . 2 E V A P OR A T IV EE MIS S IONC 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 .
. ief_F R ET !tr '

- tJ=
SlUt l-l-{Al\ L
-5):
:-
a Vr:! -
\H C S'
'C AN l ST =A;]ST O N
C AP W H =\. I \ S TA L L E D
r D R A IN C AP C I,TOU TS
"/ TO B E C O R R E C TL
'
A LIGN E D W ITH
LOC A TIN G B A q ON
C A N IS TER
? - :ANIST ER T O SIT
FRONT
OF CAR ].' .] CAP WHEN
..S- AL L ED
P
fF : liP cu T o u T S T o BE - FR ON T
" -Y
CO;- :l- AL IGNED WIT L OF C A R
L OC:_ 3 AR ON CANIST =-
".:J
EEC CANISTER INSTALLATION DETAILS EEC CANISTER INSTALLATION DETAILS

_ ENGINES WITH EFI _ ENGINES WITH EST
Figure 6E-4
1 . 3 PO S I T IV EC R A N K C A S E
VENTILATIO?.I
The PCV systemsfor L6, 3.3 engineswith EST and the
5.0 litre engine, carry over from VH. The system layout
has been revised for engines with EFl. Refer Fig. 6E-5
for details.
C ON N E C TOR
zu+- -.\
€, 6 \ GR OMME T
VIEW
P C V V A LV E \
'.U
TP C'
GF]O\1' . : -
VIEW
/7-==-
/\ (
)-
i/ ,
fFl
\v
f' l:. . I
TH R OTT
\*==r/f -
'a'-zf-
\o
\,\
\J
u,r*l-El V IE W
POSITIV E
CRA NK CA S V
E E NTILA T I O NS Y S T E M- 3 . 3 E NG I NE S
WI T HE F I
Figure 6E-5
EMISSIONCONTROL6E.7
=
E
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z7
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E :i 95sj '@ E 3
_ q Ei:g;i 6
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I T IT
3
!{
EM ISSIONCONT ROL6E -9
1.4 VACUUMADVANCECONTROL
The ignitionadvance on engines with EST is electronic-
ally controlled,therefore no VAC system is used on these
engines .
Engines with EFI (except those for registrationin 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.
vAc SYSTEM(NSW)
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 follow-
ing paragraphsrefer 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:
r A low t em p e ra tu re(1 5 0 C ) th e rma l v a c uum sw i tch
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
components.Refer Fig. 6E-8 for componentlayout. LOW I:'.'': ?
(15ocl -. s
1#
ME D IL..'-
TE MP E R A TU R :
(4ooc) TV S
] S TR IE U IOR _
Figure 6E-8
O per at ion - Re fe r F i g . 6 E-9

1 04oC T her m a l V a c u u m S w i tc h
.1
The 04oC thermal vacuum switch in the thermostat
housing,senses engine coolant temperature.When coo-
lant temperatureis below 104o C, the TVS directs a
portedvacuum signalfrom the throttlebody to the centre
port of the 15oC TVS located in the air flow duct. lf
coolant temperature exceeds 104oC, the 104o TVS
operates to direct full manifold vacuum (rather than
ported vacuum) to the distributor and provides full
vacuumadvanceat idle to preventengineoverheating.
6E.10 E MI SSI ONC O N T R O L
1yg 4606 ---....-.-

( IN ENGINE
B L OCK) D IS T A IB U TOR
I
f =i 1.;
---7
A S S E MB LY
A tR F LOW-\k< )
nl tnt- '
DUCI \ i
i{
MA N I FOLD V qC U U 1/]
S OU FC E ..T\,.
10a c
TI E P
fOU S ,l"IOS
;G, TA T
) Oq--fE D V A C U U M
- T HROT T L E B OD Y
j
Figure 6E-9
'l 5 o C Ther m al V ac uu m
Sw i tc h
Th e I5 oC t her m a v ac u u m s w i tc h i n th e a rr | o w d uct,
se n se s inlet air t em pera tu reWh . e n i n l e t a i r :e rn p e ra ture E\CJNE
rs b e l o w 15oC, t he p o rte d v a c u u m s i g r-a rs ro u ted
c.e ctl y to t he dis t r ibut o r, th e :O:C T VS i n the
b y -p a s s i n g
en g i n e b loc k . W hen t h e i n l e t a i r te mc e ra tu rei s a b ove
15 .rC,the 15oC T V S r e d i re c tsth e p o (e d v a c u u ms i gnal
awa v fro m t he dis t r ibut oto r th e l C , C T V S i n th e c y l i n der
c o cK
4 0 o C Ther m al V ac uu m S w i tc h
W h e n th e lnlet air t em p e ra tu re e x c e e d s1 5 0 C . th e D o r ted
v a cu u ms r gnals dir ec t e dto th e 4 0 o C T VS v ra th e .l5 0 C
TVS i n th e ar r f low duct. T h e 4 0 o C T VS s e n s e s e n gi ne
bl o ck te mpe' at ur e.W hen th i s te m p e ra tu res c e l o w 4 0 o C ,
t he va cuums r gnalt hr ou g hth e .1 0 o CT V S rs b l o c k e da nd
va cu u m aov anc e is d e n e d . Wh e n e n g i n e m e tal
t e mp e ra t ur eex c eeds 40 i C :h e T V S ' o p e n i ' a n d t he
portedvacuumsignalis tirecled lo the distributorvacuun
a d va n ceunt t t o per m itv a c u u -na d v a n c e .
w9
PORTE D
VACUU[4
*
ADVAN CE
A LLOW: D
Fig. 6E-10 summerizesthe operationof the VAC system
when productionoperation V7Y is excersided.Figs. 6E-
1 1 . 6 E-12 and 6E - 13 s h o w th e e m i s s i o nh o s e ro u t i ni r
wrthV7 Y . Figure 6E-10
EMISSION
CONTROL6E-11
3?, E
rE...H
i 3i i c = o
E;i i ,;9.. ;
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6E-12EMISSIONCONTROL
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EMISSIONCONTROL6E.13
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6E.14 EM I S S I O NC O N T R O L
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 reouiredwith EFI
1 . 6 A I R I N J E C T IONR E A C T OR
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 lsyi 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
esse n tra, : - = s a- e a s u s e d o n VH w i tl 2 .a tre
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 e-
me 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 ingdet 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
substantiallyrevised.,/.' :f'reVH type.
3 .3 L ITR E E F I E NG I N E S
The exhaust gas s Crrectedto 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 rai ve E GR V A LV E -
mo u n te dc n : he , nletm a n i l o l d(re fe rF i g . 6 E -1 5 )
GA S K E T _..
MA N U A L
-TR A N S MIS S ION S
ON LY
Figure 6E-15
EM ISSION
CONT ROL6E -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

The EGRsystemfor EST engineswith manualtransmiss-
ions incorooratesan EGR modulatorvalve located in the F= 1 rL
vacuumline betweenthe thermalvacuum switch and the

EGR valve(referFig. 6E-16). - E GR V A LV E -
The purpose of the EGR modulatorvalve is to control
the ooerationof the EGR valve so that the admissionof
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 ?,1'\\ r \ \. li
\\ \\ \ '
idle, light engine loads or on overrun.Oxides of nitrogen E GF'.IOD U LA TOR
' --::/'/
emissionincreasesduringacceleration. V A L'.:
As the throttle opens, a ported vacuum signal is routed
through a thermal vacuum switch. The switch 'turns on'
Figure 6E-16
at 40oC to prevent exhaust gas recirculationwhen the
engineis cold.
EGR valve operationis further regulatedon EST engines
and manual transmissions by the operation of the
modulatorvalve.
EGR Modulator Valve Description

The modulator valve is a bleed type vacuum control
devrcewhich uses exhaustgas pressureto control an air TO V A C U U I\,4
C_:"' 3E R
R ESTR I CTC F
OF E GR V A L..:
bleed within the valve and modulatesthe vacuum signal -
from the carburettor to the EGR valve according to TO C A R B U R E Ti O=
I
engineload. ,,l A TV S _\r1
//
The valve (refer Fig. 6E-17) consistsof two chambers
separatedby a diaphragm;the diaphragmhas a seat at : LL TE R
its centre.The centre tube of the tee prece is retainedin
the upperchamberwhich is ventedlo atmospherevia a
filter.
The two exposedbranchesof the tee piece each contain
a restrictingorifice. One branch is connected to the
vacuumline from the carburettorand TVS and the other
to the vacuumchamberof the EGR valve. D IA P H R A GT,'
The purposefo the restrictorsis to damp any pulsations
in the vacuumsignalfrom the manifoldand help control
EGR valve responseto rapid changes in exhauslgas
oressure.
Figure 6E-17
The lower chamber of the valve is exposed to exhaust

gas pressure via a hose from an adaptor located E C A ', A LV E
between the EGR valve and inlet manifold teter TO B A C K P R E S S !A E
F ig.6E - 18 ). TR A N S D U C E A -
a
>-9
\"
. A D A P TOB _ l ! , r\ J A L
_, T F AN Si \ I I S S O )J S
\ 649xg1- O\ LY
Fi gure 6E -18
6E.16EMISSIONCONTROL
RESTRICTORS
^
+-T O CAR B U R E T T O R
E GR V A LV E
PO RT E D V A C U U M
SIG NAL
UPPERC H A M E E F -
LO W E F CI ]A \ 1 B E q - VACUUM VENT
/
EG F \ i O D U L A T OR ..,,
VA L \ . ' E
A D A P TOR
B A C K P R E S S U R E -/
TA P P IN G
C ON TR OLLIN G
OR IFIC E
EXHAUST
UAJ JIUtr 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,the vacuum line is vented to atmospherevia
the centrebranch of the tee and filter.The EGF valve
takesplace.
remainsclosedand no recirculation
As exhaustback pressureincreasesduringacceleration
or under load, the pressure on the diaphragm also
increases, the diaphragmmoves the diaphragmseat and
restrictsthe 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, (reflectedin the vaiue of
exhaust back pressure)increases,the venting of the
vacuumsignaldecreases,applyingmore vacuum to the
EGR valvevacuumchamber,permittingthe EGR valve to
ooen f urther and admit more exhaust oas rnto the
inductionsystem.
As engineload decreases,exhaustpressuredeCreases,
diaphragmforce decreases,vacuum signal venting in-
creases and the EGR valve reduces the amount of
exhaust gas being recirculated.The valve thereiore
modulatesthe vacuumsignalto the EGR valve to make
EGR valveoperationsensitiveto enqineload.
1 . 8T H R O TT L EN 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 ROL6E -17
2.1 GENERALINFORMATION
Serviceoperationslor emissionsystemcomponenlscarry
over in generalfrom VH Seriesvehicles.
Service procedures for the following components are
covered in Section 09 'EmissionControlSystems'of the
lmproved PerformanceEngine ServiceManual part num-
ber M38338.
. EGR Thermal Vacuum Switch Testing and
Replacement.
. EGR ValveChecking,Cleaningand Fleplacement.
o EFE Thermal Vacuum Switch and Actuator Testing
and Feplacement.
o Air PreheatSystemTesting.
o VAC SystemTesting.
o Positive Crankcase VentilationSystem Testing and
Servicing.
. EvaporativeEmissionControlSystemServicing.
Serviceprocedures. for the Air Pump and ThrottleNudger
are coveredin Section06 'EmissionControl'of the VH
SeriesManualSupplementpart numberM38731
The following service operationis new for VK series
vehicles.
2.2 EGR MODULATORVALVE

TEST
1. Disconnectall hoses from the EGR modulatorvalve
and removevalve.
2. Installa vacuumsource such as hand pump J23987-
01 or equivalentto the bottomvalve port.
3. Operatethe vacuumpump, and it shouldbe possible
to draw a vacuum on the valve diaphragm.lf a
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
ENGINET UN E6F-1
SECTION6F
ENG I NETUNE
INDEX
Ref. Subject Page I Ref. Sublect Page
1. GENERALINFORMATION 6F-1
............................ 3.2 3.3 LITREEFr .. 6F-4
2. ENGINETUNERECOMMENDATIONS........ 6F.2 Tune Conditions 5F-4
3. ENGINETUNE DATA. 6F.3 3.3 5.0 LITRE 6F-4
3.1 3.3 LITREEST .............. 6F-3
Tune Conditions............... 6F-3
Check List ..... .. 6F-3
1 . GENERALINF ORM AT ION

To maintaindesignedvehicleperformanceand emission The EngineTune Recommendations .ha1. sets out the
levels, it is recommendedthat regular maintenanceand items recommendedfor attention during an engine tune
adjustments be carried out in accordance with the and cross referenceis providedto the appropnatesource
scheduleoutlinedin the VK SeriesOwnerHandbook. of informationThe EngineTune Data charts (reler 3.1.
Engine tune specificationsnecessary to achieve the 3.2 and 3.3 in this Section), provide abndgeo engine
cor-rect emission levels are located on the Vehicle tuningdata for both 3.3 litre and 5.0 litre engines.
EmissionControl InformationLabel attachedto the right
hand suspenslon struttower underthe enginehood.The
label should be referred to before making any
adjustments.
6F.2 E NG I NETU N E
2 . E N G I N ET U N E RECOM M ENDAT IONS
ENGTNETUNE RECO M M ENDATI O NS I REFEBENCE
E ngineComp ressio n Tes t 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

E n g n e S e r v i c eM 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, l s o
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 eN o t e 9 . o f
tnis Suoolement.
EngineD.i,.'e3e rt. Chec k and adjus tas 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 sS e r v i c eM a n u a l
necessary. 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 sS e r v i c eM a n u a l
P/N M38145.
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
P e r fo r m a n c eE n g i n eS e r v i c eM 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 .
A utomatic Ch oke Chec ks et t ingsand link age. 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
P e r f o r m a n c eE n g i n eS e r v i c eM a n u a l .
A ir F rlter Ele men 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 .
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 .
V alve LashAd jus:^ le n1 Non adjus t ablehy dr aulic
I las hadjus t er s .
i n'line Fue l F i l t e r 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
I m p r o v e d P e r fo 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 .
CL e a n ,a d ju st o r r e Dla ce 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 -
gnit ion T imin g Chec k and r es etas 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
necessarY. S uo o lem en t .
.--
r9 nt t t on Ht g n l e n s t o n 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
C ables E n g n e S e r v i c eM a n u a l .
Throt t le Nud ge r Ch e ck a n d r e se i a s S e c t i o - 6 , " E m i s s i o n C o n t - o l " o f t h e V H S e r i e sS e r v i c eM a n u a l
' ES T manu al on ly) n e ce ssar y. S uo pl em en t .
E GR V alv e
Air P rehea tSyste 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 iveEnrrssio ns .8 e p a ce ca r isle - f te . a t P e r f o r m a n c eE n g i n eS e r v i c eM a n u a l .
S y st ems sp e cifie d in te r va l.
Bat t eryand Ca ble s Chec k 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 eM a n u a l

I 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 so f t h s S u p p l e m e n t .
Chec k all hos esand

c onnec t or sf 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 Ch e ck fo r co r r e ct o p e r a tio n . 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 eo p e r a t i o n2 . 7 o f t h i s
E ST mode l s o n l y ) S up o l e m e n t .
ENGINET UNE6F-3
3. ENGINETUNE DATA
3.1 3.3 LITREEST
ENGIN E S P A R KA D V . S P A RK P L U GS
TRANSM I SSI O N I DL E S P E E D R P M FA S TID LE B E LOW
(IN NEUTRAL) SPEED 900 R P M
3 'e s e : '. , i s u a l
3 .3 L itre EST M anualor Cê:k crlv AC 1 . 51! ! m -
HC I ( 114) Aut om air c 6' : ,: C42CLTSX
NOTE:Carburettoris not to be adjustedpriorto 1500 km

service. Only the idle speed may be adiusted from
1500 kms onwarcls.
Prior to making any carburettoridle adjustments,refer to
Section 6C, Garburettorof this Supplement.
TUNE CONDITIONS
Before making any checks or adjustments,warm the
engine by running for 6 minutes wth transmtsstontn ^,.a>\
,J--
neutral and fast idle screw on second step of fast idle / ^
cam, refer Fig. 6F-1, or running for 10 minutes at -- _l
80 km/hr on a chassisdynamometer.
/
Switch ignition off, restart vehicle with transmissionin

Il
neutral.Check engine tune specifications' i
I 1sr.srE P
I
-t^rn QTtrp
-,?+ I,vr
J
'/A
3FD. STEPJ ' .
2 '
-L_
n- | aTH . S T:e
Fi gure 5F- l
CHECK LIST
(A) Engineidle speed exceeds880 rpm.
1. Checkthat enginehas been running15 minules.

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
4. Checkthat advanceat idle is less than 1O: 3TDC.
(B) Engineidle speedis less than 700 rpm
1. Checkenginehas been running15 minutes

solenoid.
2. Checkpowerto antr-dreseling
3. CheckPCVvalve for flow.
4. Checklor vacuumleaKs
I
5 Creck for greaterthan 2 BTDCadvarce
6F.4 ENG I NET U N E
3.2 3.3 LITRE EFI
D l srR l B -u.
T-oR
E NGINE I DLE SPEED RPM ID L E co spA R KpLU Gs
^ ADVANCI
S IZ E i OPTION RUN I N ENG I NE "k
BTDC* RpM GAP
EFI 12"B E LOW AC

{L Lg r 1100 C 42C LTS X
T UN E CO NDI T I O NS
Enginetune settingsare lor an enginewith:-
1. Engine coolant and oil at normal operating
temperature,preferablyachievedby drrving(both CO
and idle speed are dependant on engine
temperature).
2. Transmission in oarkor neutral.
3. Air conditioning switchedofl.
The followingchecks musl be performedand any defects

correctedbefore any idle adjustmentsare made to the
EFI system.
1. l g n i ti o nt im ing.
2. Vacuumto luel pressureregulator.
3. Throttlelever closingon to stop - if not check:
a. Throttlepositionswitch adjustment.
b. Linkagesn! 5prrngs.
4. No leaks at hoses and duct betweenair flow meter
and engine.
5. Runningon all cylinders- if not checkfor
a. Defectivesparkplugsand leaks.
b. Open circurtto iniector/s.
6 Auxiliaryair valve fully shut - check by pinchingoff
air hose and observingenginespeed.lf speed drops
checkfor:
a. Enginenot sufficientlywarmedup.
b. Open circuit in electricalsupplyto auxiliaryair
valve.
c Auxiliaryair valve on upsidedown.
NOTE: Before adjustingthe idle speed, disconnectth€
canisterpurge hose from the canisterand then adJUSt
idle speed.Referto serviceoperation3.5, Section6C of
this Supplement.
3.3 5.0 LTTRE
E NGIN E IDLE SPEED R PM D IS TR IB U TOR S P A R K P LU GS

srzE IN IT IAL AD VAN C E
coMp TRANS. Jr-r?|, ] sLow FASr G AP
TY P E
ET D C @ BPM mm
15 0 0
5, 0 HC N lAN. Fo ptnn
L31
â- ?1 2 n c ia T G H E S T 15 44Tx
A UT O. a50 F F^.'
) ttrr
V A C U U M A D V A N C E I-,OS ED IS C ON N E C TE DA 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
SECTION7A
CLUTCH
INDEX
Ref. Subject Page Ref- Subiect Page
1. 7A-',t
GENERALDESCR1PT1ON......................-....... 2. SERVICEOPERATIONS 7A-1
1 . G ENERALDESCRIPT ION
The clutch assemblyused on VK Seriesmodels is carried
over from the VH Series.
For clutch adiustmentdetailsrefer Figs. 7A-'l and 7A-2.
For all service operations refer Section 7 of the VB ,/t'/
CommodoreServiceManual,Part No. M38145.
-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
C LU TC ts FOR K IS FU LLY S :A -:] IN B A LL S TU D .
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
SECTION78
MANUALTRANSMISSION
INDEX
Page i Ref. Subjecl ta g e
Ref. Subiect
1. 78-1 | 2.1
GENERALDESCR1PT1ON.............................. TOROUEMASTER
TOROT. 78-2
2. SERVICEOPERATIONS 7B-2 I 2.2 BORG 7B-2
BORGWARNEB(5-SPEED)..........................
1 . G ENERALDESCRIPT ION
The Torquemasterfour speed manual transmissionis The followrngchart sets out rnanualtransmission
applica-
standardequipmenton VK Series SL 19 and 35 styles tion lor VK Seriesmodels.
with the 3.3 litre EST engine.
The Borg Warger five speed manual transmissionis
available as a productionoption on vehicles with the
3.3 litre EST engine.Transmissionslor 3.3 EST engine B ody S tyl e
application,carry the code BE stencilledin yellow paint
on the lefi hand side of the transmissioncase- 3.3 l l t:e E S T Torquemaster
are:- (3.50:l 'l st gear)
Revisionsintroducedfor code BE transmissions
1. GEARS: stress relievedby shot peening. E:r g l Var ner
2. 5TH SPEEDMAINSHAFTGEAR: needleroller bea-

ring has been deleted (refer Fig. 7B-1). The gear
Sta':a'c !:, :r ent
now rotates on a revised bearing surface on the
J
N /A N oi A,: a: =
mainshaft.
Av ai r ac i ::s t- c :- c : on O pti on
3. GEARRATIOS: rsr 3.23 1
II 2 N D 1.96:1 NOTE: Manual transmrssons are not available if an
3RD LZO I engine is equipped witn E eclronic Fuel Iniection
4TH 1.00: 1
5TH
RE VER S E
THIS BEARING IS \OT

USED tN CODE,,BE' . TRAf.r Sr ,ltSSt O N S -
-,\
G!J.
G._
,a
-: i .+
- - ,\ - /:rE=\
u{,-
{ e = .*,
,J -JgE '
-zi 'L:
Figure 7B-1
I
7B..2MANUALTRANSMISSION
NOTE: Before removingany manual transmission,the
EST soeed sensor must be removedfrom the rear of the
cylinder block. Refer to Service Instruction2.8, Sec-
tion 6D, lgnitionSystem.of this Supplement.
2.1 TORQUEMASTER
For removal and installationinstructionsrefer to Sec-
tion 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
ServrceManualSupplement, Part No. M39043.
2.2 BORGWARNER(s-SPEED)
For all service operations refer to the Holden Com-
modoreFive Speed ManualTransmissionServiceManual,
Part No. M39071.
AUTOMATICTRANSMISSION
7C-1
SECTION7C
INDEX
Ftef. Subject Page Ref. Sublect Page
1. 7C-1
GENERALDESCRIPT1ON.............................. 1.12 BANDAOJUSTMENT......... 7C-5
1.1 TRANSMISSION CODES. 7C-1 1.13 THIRDCLUTCHASSEMBLY 7C-5
1.2 1.2 & 2-3 SHIFT CONTROLVALVESAND 1.14 S E C ON DC LU TC HD U MPB A LL 7C-6
SLEEVES 7C-2 1.15 PRESSURE REGULATORBOOSTVALVE
1.3 1-2 & 2-3 SHIFT VALVES.......-..-....- 7C-2 AND SLEEVE 7C€
1.4 MANUALVALVE 7C-3 2. TRANSMISSION SHIFT SPEEDCHART.... 7C-13
1.5 LOW SPEEDTIMINGVALVE.......... 7C-3 3. TRIMATICTRANSMISSION SPRING
1.6 1-2 ACCUMULATOR CONTROLVALVE.... 7C-3 IDENTIFICATION CHARTS .... 7C.14
't.7 ACCUMULATOR 7C-3
P|STONP1N...................... 3.1 coDE LP (3.3 LITRE EST ENGTNE)............ 7C-14
1-8 TRANSFERPLATE........... 7C-4 3.2 coDE LR (3.3 LITRE EFr ENGTNE) ............ 7C-14
1.9 SERVOPISTON 7C-4 3.3 coDE LS (5.0 LITRE ENGTNE) .................... 7C-15
1.10 VALVE BODY IDENTIFICATION 7C-4 4. LINE PRESSURE SPECIFICATION
1.11 VACUUMMODULATORVALVEAND CHART ... . . . . . . . . .7C-
. . . 15
SLEEVE... 7C-4 5. SPEC|F|CAT|ONS.............. ......7C-16
The Trimatic Automatic Trasmissionis standard equip- LP Code incorporates the earlierdesign olen converter
ment for VK Series on Berlina and Calais. Trimatic is housing and IR code uses the carry:ver 'full circle'
availableas an option on all other VK Seriesmodelswith converterhousrngdesign.
the 3.3 litre EST, 3.3 litreEFI or 5.0 litreengines. Transmission code tS. 5.0 litre. ca" es over from
Carryoverof the Trimaticto the above 3.3 litre engines 5.0 litre VH rrodels and WB Statesman
has necessitatedthe release ol new Trimatic transmis- The followingparagraphsset out the calibration details
sion codes. for eachof the rew transmission cooes
Transmissioncodes LP, 3.3 litre EST, and LR. 3.3 litre
EFl, are the same as transmission code FP, 3.3 litreVH,
exceptwhere noted in this Section.
CODES
1.1 TRANSMISSION
The lransmissionidentificationplate carriesthe transmis-
sion serial numberand applicationcode. The following
codes are used with VK SeriesTrimatictransmission.
TRANSM I SSI O N
CO DE ENGI N E
LP 3. 3 lit r e equippe C. '. t ' E S T

LR 3. 3 lit r e equippe c '. '.l n E F I
LS 5. 0 lit r e
7C.2 AUTOMATICTRANSMISSION
1.2 1-2 & 2-3 SHIFTCONTROLVALVES

AND SLEEVES
All three transmissionsuse the same 1-2 and 2-3 shift
controlvalves. ldentilicatronis 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 identificationreter Fig. 7C-2.

The three transmissionsalso 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 SHTFTVALVES

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 upshiftsoccur.
This valve is not interchanoeable with the Series 3 shift
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
7C-3
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 SPEEDTIMINGVALVE

The low speed timing valve in codes LR and LS
transmissionshas been revised.The overall lengthof the
valve has been decreased from 48.M-48.90 to 43.5-
43.8 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
'TrimaticPrinciplesof Operation'Part No. M37823.
Figure 7C-6
CONTROL
1.6 1.2 ACCUMULATOR
VALVE
All three new code transmissions use a common 1-2
accumulatorcontrolvalve.
The diameterof the spool section of the valve has been
increased from 8.705-8.71
(referFig. 7C-7).
2 mm to 11.079-11.087 mm
This valve is not interchangeablewith the Senes 3

+
controlvalve.
_-_I_
11 n70
:i :^: DtA.!
tt.u6/
Figure 7C-7
PISTONPIN
1.7 ACCUMULATOR
The accumulatorpistonpin on all three transrnissions
has
been increased in length trom 43.2 mm to 44.2 mm
(referFig. 7C-8).
The accumulatoroistonsorinqhas been deletedfrom the
three transmissions.
.<_ 43.2 _ 44.2 mm _ ________>
Figure 7G-8
1.8 TRANSFERPLATE
P A R T N U MB E R
Transfer plates are identified by their part number
S TA MP E D IN TH IS A R E A
stampedin the area shownin Fiq. 7C-9. I
9/'
T R ANSFER PLATE
P ART NUMBER APPLI CATI O N
(
r-n
92017838 LP l rl l
f
- o
9242' , 278 -+t J O

Figure 7C-9
1.9 SERVOPISTON
For identificationdetails 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 transmissioncarriesthree digits
followed by the calibrationalpha letter stamped on the
undersideof the body,adjacentto the accumulatorpiston
pin (relerFig. 7C-11).
---- --
T RA NS M T SS IOrN
qODE_-- V A LV E
B OD Y
LP I eZe" I D E N TI F I C A TI ON
LR
c alib"at ion
- aipha c har ac t er
Figure 7C-11
1.11VACUUMMODULATOR
VALVE AND
SLEEVE - ID EN T I F IC AT IO N R IN G
All three transmissionsuse the same vacuum modulator
valve and sleeve.
Valve identificationis by a ring aroundthe valve stem as
shownin Fig. 7C-12.
Figure7C-12
7C-5
The vacuum modulatorsleeve is identifiedby the length

of the sleeve,Fig.7C-13, and a blue colour markingon
the closedend.
Figure 7C-13
1.12 BAND ADJUSTMENT

The correctband adjustmentprocedureis as follows:
1. Remove oil pan and servo cover, loosen adjusting
screw lock nut. .1
.1
2. Using Tool No. 7AT4 and a torque wrench, tighten I:
t-
adiustingscrew to 4.5 Nm then back off screw.
T U R N SBA C K E DOFF
3. Tightenlock nut and install servo cover and oil pan. OU IC K

Refill transmission with Dexron ll Automatic R E LE A S E
TransmissionFluid. 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.
Dimensionsfor third clutch returnspringsare as follows:
] rnnrrrsrvrssroN
I cooE LP& LR LS
Free Lengt h 26. 97 m m 29.13mm
To t al Coils 8 .7 5
Diam et er 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 DC L U T C HD U MPB A L L
Code LS transmissionshave incorporateda 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
T
throughthe two onfices.Refer Fig. 7C-16.
F
-O
o
z
-oRrFtcE
Flgure 7C-16
1.15PRESSUREREGULATORBOOST
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. 11 8 mm 1 1 .7 6 5- 1' l.7 5 8mm

15. ' 126
- 15.11 8 mm 1 1 7 6 5 -1 1 .7 5 8 m m
16. 502- 16.4 9 4mm r J /b o - tJ.//v mm
Figure 7C-17
SLEEV E CHART
r RAN S
COD E B
-l
----T--
A]
LP 15. 159- 15. 1 3 8m m 1 ' 1 .7 9 6 -i l 7 7 8m m i il
ii
LR 15 .15 9- i5.1 38 m m 11. 796- 11 778m m BA
LS 1 6 5 35 - 16 .515 m m i3. 8i9 - i3 779 m m
.L
Figure 7C-18
7C.7
.
'-;i--
!sa-.
---"--"a-
::/ -'l
-\ --\. . I , - =s . r . S E N S O RH O L :
-t.
-\--<
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\i @) \
q-l ,.,-
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r--- _-___...-.r,,.,r,
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w) /^J\
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:
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\ -(./'
i),X
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r
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-t\
L. -
\:
CONVEFTE B --l
MA TC H B LU E P A i N T B A LA N C E MA R K
ON C ON V E FT=R \!ITH E LU E P A IN T
2 0 - 2 8 Nr B A LA N C E i \l A FK ON D R IV E P L A TE .
V IE W
4 5 - 5 ONm
7 . 0 - 1 9 .0 Nm
INSTALLATIONDETAILS _ 3.3 LITRE E.S.T.
TRANSMISSION
6 1 -7 ONm
Figure 7C-19
\\
I
,/.
..
,e
tv . ''i
/.t:-
'
,." ),,
,,2,
. C ON V E R TE R H OU S IN G B OLTS
4 P LA C E S
B:,
t1
% / ?--",'
<-- : 4
--"
(R,'
,A
/J M A T C H B L U E P A INT BAL ANCE M ARK- - 1c r
O N C O N V E R T E R WIT H 3 L UE PAINT - 2 P LA C E S
B A L A N C E M A R K ON DRIVE PL AT E.
5 3 - 10.6Nm
; 20- 2 8 N m
VI EW
A
L"_
45- 5 0 N m
A
& 61 - 7 0 N m
A
z t\ 40 51 Nm TRANSMISSION
INSTALLATIONDETAILS- 3.3 LITRE E.F.I.ENGINE
Figure 7C-20
7C.9
/^:L-- ^
tv t =F :H
Har !r^ --:-/ T.

lg rL-!::
tr
. ).\
:-{-
\
\ \
€
!
fr
(aJi
,,/'-
4 PLACES
.3
MA TC H B LU E P A IN T E A LA N C E \1A R K -'
ON C ON V E R TE R WITH B LU E P A IN T
B A LA N C E MA FK ON D R IV E P LA TE V IE W
3 7 . 0 - 1 0 .0 Nm
, 4 0 - 5 4 Nm
TRANSMISSIONI NSTALLATIONDETAILS
1 40 4 8 Nr n
_ 5.0 LITRE ENGINE
Figure 7C-21
i---tlrr-
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7C-12AUTOMATICTRANSMISSION
z
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7C'13
AUTOMATIGTRANSMISSION
SHIFTSPEEDCHART
2. TRANSMISSION
UPSHI F T S k m / h - L P ( 3 '3 l i t r e E S T )
FU LL TH R OTTLE
C L OS EDTH 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
C L OS EDTH R OTTLE
, 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 )
FU LL TH R OTTLE
C L O S EDTH R OTTLE
, 60 ax le
All Tyre Sizes 2.
DO W N S H T F T Sk m i h - LP (3.3 litre EST)
FULL THROTTLE P A R TTH R O TTLE

C L OS EDT H R OTTLE
*)
3 - 2 ( A v a i l a b l eUP To
.^. 11'z An - i ;,
IU J- l l Jl vv
, 08 ax le
All Tyre Siz es 3. I
DO W N S H I F T S k m / h - LR (3.3 litre EFI)
FULL THROTTLE P A R TTH R OTTLE

C L O S EDT H ROTTLE
*)
1 z- l 3 - 2 ( A v a i l a b l eU P To
"-,
t^ ^
-: 114-124 i 65-73
A l l T y r e S i ze s, 3 .0 8 a xle 12 - 14
\ "
DO WN S H I F T S k m / h - L S ( 5 '0 l i t r e )
P A R T T H R OTTL E
CLO SED TH R O T T L E
FU LL TH R OTTLE
3-2 2 -' l 3 - 2 ( A v a i l a b l eU P To ")
60-68 88 94
112-122 ,
All Tyre S iz es ,2. 60 ax le
W I T HD E T EN TS WIT C HD ISC O N N E CTE D

-
3. TRIMATICTRANSMISSION
SPRINGIDENTIFICATION
CHARTS
3.1 CODELP (3.3 L|TRE EST ENGTNE)
FREE
S P R ING COL OUR LE N GTH TOTAL O'D.
S P R IN G
D E S CR IP T ION IDENT IF ICAT ION A P P R OX . cotLs mm
P A R T N O.
mm N OM IN AL
3 - 2 C on tro V a ve Yellow 54.7 15.0 , 13.2 9942033

1 - 2 Ac c u mu i a to .va l ve _ P.k o- u
I o .J 13.2 92020511
L o w S p ee d Do w n s.i f i V a i v€ Dar k Eiue ;
JC . / 10.3 2823165
H i g h Sp ee c D o rvn sh i f 1 T rmi ng Valve Pur pte Jb.U rJ.c 10.3 2U68A2
D e t e n t P.s5 5 g 1 s R e g u l a l o r Valve Or ange 42.E 1J.f, 12 92004309
- 1 _ 2 sn fi va ve orange 4r.o 13.5 ,", . ,"rr
' l - 2 Co n t r o l V a l v e
" II
2-3Contr o l Valve None 36.5 10.3 14.2 9942010

2 - 3 S h i f t Va l ve
N ot U s ed
M a n . L o w & R e v. C o n trct Valves Gr e e n& Wh r le 38.7 1 1.5 10.3 5258547
P r e s s u r e Re g u l a to r V a l ve U/nr te 70.3 12.3 19.6 JZSd I bb
Det ent V a l v e Gr e e n& Re d 36.8 13.5 10.3 9929681

I
Ac c urula : o . P i s t o n
-l I
N ot U sed
G o v . Se c o n d a ry Gr e e n& Or a n g e 39.C 10.3 9944999
4' n-., ,1010646

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

FR E E
SPRING COL OUR LE N GTH
DESCRIPTION IDENT IF ICAT ION A P P R OX .
mm
3-2Control V a l ve
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
13.5 10.3
D e t e n l Pre ssu .e R e g u l a to r V alve
13.5 12.O 2811015
1 - 2 C o n : ' ol V a l ve 10.3 14.2 92007171
i - 2 Sh i i l Va ,ve
2-3Control V a l ve 10.3 14.2 I 9942010

2 - 3 Sh ift V a ve J t.3
N 4 a n . L o w & Re v. Co n i ro l V a ves Gr e e n& Wh ite JO. / 11.5 10.3

Pr e s s u r e R e g u a to r V a l ve
6a.9 12 3 19.6
D e t e n l V a l ve Gr een & Red 36.8 tJ.5 10.3 9929681
Ac c L m u l a to r P i sto n
N ot U s ed
G o v . S e c o n d a rv Gr een & Or ange 390 I r.J 10.3 9944999
S e r v o P i sto n R e l e a se Gr een of,6 3. /a 47.O 92020646
S e r v o P i sto n C u sh i o n Or ange
I 25.9 3.9 31.9 5258568
F i t s i n s i d e S h i f i V a l ve
7C-15
3.3 CODE LS (5.0 LTTREENGTNE)

FR E E
SPRING C OLOU R LE N GTH o.o. S P R IN G
DESCRIPT ION ID E N TIFIC A TION A P P R OX . mm
P A R T N O.
mm N OMIN A L
3 - 2 C ontr ol Valve Li ght G r een 13.2 ?945053

1 - 2 A c c u m u la to r Va lve 9:1205 12
L o w S p eed Downshift Valve O r ange 35 aa'-1)A
Hi g h S p eed Downshift Tim ing Valve P* pb l

-
zo I a65z
De te n t Pr essur e Regu lator Valve
1 -2 Co n tr ol Valve 9200717 1
1 -2 S h i ftValve
2 - 3 Co n tr o l Va lve N one
2 -3 S h i ftValve
fut"n.l-o* a n"u. Co. ., Green& Whi te 5258541

P r e s s u r eRe g u la to rVa ve N one 28 10499
De te n t Valve 9929681
A ccu mu l ator Piston \ ot U s ed
G o v . S eco n d a r y ,r.arw
S e rvo P iston Release
S e r v o P isto nCu sh io n 31 .9 9929676

* F ts n si de Shift Valve
4. LINE PRESSURE
SPECIFICATION
CHART
TR A N S MIS S IONC CI O E S
LP LR LS
3.3 l i tre E S T 3.3 l i tre E FI 5 . 0 l i t re
kP a k Pa kPa
C HE C K NO. 1 - Line Pr essur e in D + S Range s i Vac uum M odul ato. P pe C onnec r ec l

V e h cte c oasting between 55 - 50 km /h 324 - 360 403 - 425 4C3 - 425
CH E CK NO. 2 - Line Pr essur e ln Low Range ( \'ac uum M odul ator P pe C onnec tec l )
V e h i cl e coasr nq between 40 - 3O km /h 531 - 614 606 - 688 606 5:€
C HE C K NO.3' Line Pr essu.e In D Range (Vac uum M odul ator Pr pe D i s c onnec ted)
1 2 0 0 rp m engine speed - foot and par king br ak e app r ed 903 - 978 973 - 1041 1 1-c 9 1273
Du ri n g Check No. 3 with the vacuum modulator 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
a i r l e ak into the manif old.
5. SPECIFICATIONS
T RAN SMI S S I OCO

N DE : LP - 3.3 litre EST
S EL EC TO RLE V E R:
L o ca ton
i Floor Floor Floor
Se q uencofe S h' f t P o s i ti o n s " P " ( P a r k ) ," R " ( R e v e r s e )", N " ( N e u t r a l ) ,
" D " ( D r i v e ) , " S " ( l n t e r m e d i a t e ) ," L " ( L o w R a n g e )
T OROUE CO NV EF T ER A S SE M BL Y :
Me rn odof A t t ac hm e nto t D ri v ePl a te. We l d e d N u t & B o l t Nut & Bolt
l d e r- t lfc a: r onLet t er( Pri n te dY e l l o v ol n
F ' or r Faceof Con v er t er ) Y
S t al Ratio :1 2.4 2.4 2.0
D iam ete r (No mina l) 254 mm 254 mm 298 mm
S PEEDODRI V E G E A R:
Nu m berof T eet h 9 9 10
C olou r B lue Bl ue Y el l ow
G E A R RA TIOS:
F irst . . 2.31 :l 2.31 : 1 2.31 : 1
Second 1.46:l 1.46: 'l 1.46 : 1
T hird . 1.00:l 1.00: 1 1.00 : 1
Reverse I .dr :1 t.tJ 5 :l 1.85: 1
T ORQUEM ULT I P LI CA T ION :

Ma x im umO v er allRa ti oi n i s t :1 554 4.62
L U B R IC A NT:
Tvpe . " D E X R O N l l " A u t o m a t i c T r a n s m i s s i o nF l u i C
C apacity- Dry (includingConv er t er ) . . . . . 6.1 litres 6.1 litres 8.7 litres
Re fi lt 2.3 litres 2.3 litres 2 . 3 't . e s
F LU I D LEVEL INDICATO R { DI PSTI CKI :

Length (Fro m Top o f Cap lo End of I ndic at or ) 808 mnr 808 mm 680 mm
C L UT C H ES:
Reverse
Tvpe ..., M u l t i p l e We t D , s c
Dr ve Pla tes
De scriptio n F r i c t i o n F a c n g o n S t e e lP l a t e
Nu mbe r 445
R eac tionPlate s
Descrip tion Steel Steel SteeI
Numb er c5 6
P ist on
L e1 Eth 35.99-36.09mm 35 99-36.09mm 3l .39-3 1 50 mm
Crsh ion Pla te u se d Yes Yes Yes
S econ d
Type . i \ l u l t i p l eWe t D i s c
Driv e Pla tes
De scr ip t ron Fri cti on Faci ng on S teei P l ate
Nu mbe r 556
7C.17
(CONT'D.)
FTCAT|ONS
SPECr
TRANSMISSI O NCO DE:
CL UTCHES ( Cont ' d. )
Driven Plat es
Descri pti on SteeI Steel S tee
*
Num ber o 6 7
Cushi onPlat eUs ed Yes ves Yes
* NOTE: 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 35.63-35.74mm 31.04- 31. 14m m
Secon dClut c h Spac er sc an als obe r den t , f , e db y t h e
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 2820681 282068i ?2019879
Clutch Pac k End Play .38/.76m- .38i .76mn 33 76 m m
Third
TYPe. . . \4ul ti pl eW etD i sc
Drive P lat es
Des c r ipt ion F r ; c i o ^ F a c i n go n S t e e lP a
Num ber 4 5
Driven Plat es
Des c ipt
r ion Steel Steel S::e
Num ber 5 5 6
Piston
Length . . 1 7 17-17.27 mm \,'t/-ll.l/mm lJ: - 1 3 6 '1m m
Cu sh ionPlat eUs ed Y es yes
On e W ay Clut c h
So.ag Sprag So 'a g
F unc t ion 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.
- tt-
FUELTANK 8A.1
SECTION8A
FUELTANK
INDEX
1. GENERALINFORMATION 84.1 1.3 FU E LTA N K 8A- 3
1.1 SWIRLPOT 2. TOR QU E W R E N C H S P E C IFIC A TI O NS.8A.
. . . .12
...
1.2 FUEL GAUGETANK UNIT. 84.2
The fuel tank for VK Series models with 3.3 litre EST Also incorporatedin the fue tank ior EFI equipped
engine canies over from VH, except for the deletion of vehiclesis a fuel return line, whrcr ceirversfuel from the
the fuel filler limiter pot from inside the fuel tank and EFI fuel pressureregulator,back :c :he swrdpot.
revision to the fuel filler cap pressure relief valve. VK Seriesmodelswith 5.0 litre engrnes.r.corporatea hot
Pressureis now 12 to'16 kPa. Revisionhas also been fuel handlingpackage,refer to Sect'on6C'Engine Fuel
made to the fuel venting system due to the deletion oJ oflhis SupptementThe crang-esmade
5.0 litre Eng-ines'
the fuel filler limiterpot. to the 3.3 litre EST fuel tank carry ove. to. use with the
Revisionsintroducedfor 3.3 litre EFI equippedvehicles, 5.0 litre engines.
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).
=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 FU E L GA U G:

(FOB P R E S U R ER E GU LA TOR ) -A N K U N IT
Figure 8A-1
8A.2 FUEL TANK
-1
1.1 SWIRLPOT
The plastic swirl pot, located inside the fuel tank on FU E L P IC K .U PP IP E
;
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 possibleon it.
S WIR L C H A MB E R _
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 V E N TU R I
extra fuel and delivers it to the pot through a tangential
passage.This keeps the pot full of fuel irrespectiveof
the level in the tank, and the swirlingaction separatesau
and vapourfrom the fuel (referFig. 8A-3).
:.
The continuoussupply of luel to the swirl pot ensures 'l ]-
---->l
that the fuel pick up does not draw any air into the fuel FU E L
V,,l
system. E N TB Y
F R OM
TA N K
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 GET 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
immersedin 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 reinstallationinstructions,refer
to service operation 2.6, Section '12C in this
Supplement.
Figure 8A-4
!t- v ry
-
FUELTANK 8A-3
1.3 FUELTANK
Fuel tank removaland installationinstructionsremainthe
same as on previousCommodoremodels.
The only differenceis with EFI models,on removal,the
luel return line must be disconnectedand reconnected
on installation(refer Fig. 8A-5).
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
Injection,of this SuPPlement.
FTE L FE E D LIN :
/ ---, -"
Gh EIU - \
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8A.12 FUEL TANK
Nm
Fu el Tank St r ap, Bolt s and Nut s 26 - 32
Fu el P oe Hos eClam os 1
Fu ei Tank SenderUnit Sc r er v s( E. F . l . o n l v ) . 2.8 -3.2
NOTES
EXHAUSTSYSTEM8B.1
SECTION88
EXHAUSTSYSTEM
INDEX
Ref. Subject Page j Ref. Subject Paqe
1. GENERALDESCRTPTTON ..............................
8B-1 r 3. SPECtFtCATIONS.............. .......8B-i1
2. SERVICEOPERATIONS 8B-1 4- TORQUEWFENCHSPECIFICATIONS........ 8B-12
2. 1 EXHAUSTEXTRACTOR 8B-1
Remove........ 8B-l
Reinstall 8B-2
All 3.3 litre VK Series models equippedwith Electronic but in place of the standardexhaustmanifold.a set of
Spark Timing (EST) have a single exhaust systemwhich stainlesssteel exhaustextractorsrs fitled
carries over from VH L6 models. Five litre VK Series models have fifted a dual type
All 3.3 litre VK Series models equippedwith Electronic exhaust system.which is carried over from VH 5.0 litre
Fuel lnjection(EFl) have the singletype exhaustsystem, models.
When installingthe exhaustsystem,care must be taken When installing the exhaust system, ensure that the
to install each part or assemblyin correct relationto one correct assembly, installation,tightening sequence and
another. Inconect assemblyof exhaust system compon- clearancefor the systeminvolvedis observed.
ents can frequently be the cause oi rattles or 'booms'
due to incorrectalignmentor clearancefrom the body or
suspensionparts.
2.1 EXHAUSTEXTRACTOR
B R A C E B O Lt
REMOVE z-
2. Remove air flow duct and inlet manifoldas per
service operations 3.9 and 3-11 Section6C
(ElectronicFuel Injection)
of this Supplement.
3. Removegeneratorbrace 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.
B R A C K E T E OLT
Figure 88-1
8B.2 EXHAUSTSYSTEM
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 ex-
haust pipe and lift out extractors from engine \ ,T E X H A U S T
compartment. { C LA MP
\=\
1r ^r ou*
,, ----7
E X TR A C TOR S
E X H A U S T P IP E-
..--:
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
positioningonto cylinderhead.
4. Reinstall inlet manifold and air flow duct as per

service operations 3.9 and 3.11, Section 6C
(ElectronicFuel 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. Removesupportingwire.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.
EXHAUSTSYSTEM8B-3
E.
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3. SPECIFICATIONS
Ty pe:
Single. 3 . 3 't r e E S T a l l r r o d e l s
Single . 3 3 t 'e E F I ( w : h e x t r a c t o r s )
Dual . . 5.0 'i tre mode s
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Ex haus tClam p Nut s 24-32
NOTES
STEERING9-1
sEcTtoN9
STEERING
INDEX
Ref. Subject Page I Ref. Subject paae
1. cENERALDEscRtPTtoN..............................
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 CommodoreServiceManualSupplementPart
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 specificationhas been
revised,refer to specificationsat end of this Section.
LUU tr _l>
Flgure 9-1
CouplingClam p Nu i 42-48Nm
WHEELSAND TYRES 10.1
SECTION10
WHEELSAND TYRES
INDEX
Ref. Subiect Page Ref. Subject page
3. TORQUEWRENCHSPECIFICATIONS........
'Io.2
The tyre and wheel size on SL sedan models has been The Calais has fitted, as slancard eouipment,a newly
revised.The SL sedan has fitted a new 5.5 x 14 JJ steel designedallov road wheel. The atov road wheel as used
wheelwith a BR78S14(P175/75SR14)sizetyre. on VH SLE modelsnow becomesocrronateouiomenton
A new tyre P185/75 HR14 is now used on 5.0 litre Berlinamodels.
models, this replaces the CR78 H14 tyre used on VH Service operationsare as described,n the Commodore
models. VB and VH seriesservicemanuals.
All other wheel and tyre sizes remain the same as used
on VH models.
10.2 WHEELSAND TYRES
2. SPECIFICATIONS
Ste elWheel:
Rim W idt h 5.5 JJ (OnS L S edanonl y)
6.0 JJ
Di am et er t.{ tncn
Ma x im um per mis s abler adialr un- ou t 0.8 mm
Ma x im um per mis s ablelat er alr un- ou t 1.0 mm
Off s et . . . . . 5.5JJX 14-37mm
6.0JJX 14-43mm
Alloy Wheels :
Rim W idt h 6.0 JJ
Dr am et er . . . . 15 i nch
Ma x im um per m is s able
r adialr un- ou t 0.25mm
Ma x im um per m is s able
lat er alr un- ou t 0.3 mm
Off set 44 mm
Dyna mic Balanc ing:
Ma x im um per m is s able W heel/ Ty r e
out of balanc e 1.5 kg mm
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 ) . 80N
Maximum Load Rat ing lper Ty r e) :
B R 7 8 S1 4 525 ks
c R 7 8 S' ,r4 560 kg
cR 70 Hl4 600 ks
P205i',60H R15 590 kg
P 1 8 5 /7 5 H R 1 4 530 ks
P 18 5 /7 5 5 R41 585 kg
RECO M M END E D C O L D I N F L A T I O N P R E S S U R E- k P a
I t nE
u P T O 3 PA SS E N GE R S U P TO MA X . H E A D
DE S T G N AT T ON
FRONT i RCAN FR ON T REAR
BR 78 S14 200 200 240 240

P 1751 7S5R r4 200 200 240 240
P18 5/7 5 HRi4 200 200 240 240
cR 78S',r4 193 10? | 221 221
CR 70 H 1 4 193 193 221 221
P 205l6 0H R 15 200 200 221 221
Ro adViheelSec ur ingNut s . . 100- 108N m
F!
BATTERY& CABLES 12A.1
SECTION12A
BATTERY& CABLES
I NDEX
Ref. Subject Page Ref. Subject paqe
1. GENERALTNFORMATTON ............................
124-1 2.3 CHARGINGBATTERTES. ....... :nEA
1. 1 DESCRTPTTON .................... 12A.-1 Low MaintenanceTypes ....................
12A-4
1. 2 SERVICENOTES 12A.-1 MaintenanceFree Types....................
12A-5
2. SERVICEOPERATIONS 124-2 2.4 VEHICLEWIRING,PERIODICAL CHECKS 12A-5
2. 1 BATTERY,SERVICE 124-2 2.5 DRY CHARGEDBATTERY,STOREAND
2.2 BATTERY,TEST...........,, 124-2 ACTIVATE .........t2A-s
State of Charge - Low 3. DIAGNOSTS ...... 12A-6
llaintenance Type Batteries - 4. SPEC|FICAT|ONS............. .......12A-5
Hydrometer Test -...-........ 12A.-2
State of Charge -
MaintenanceFree Batteries .............. 12A-3
Load Test - All Batteries .................... 12A.4
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/215 amp
battery.(Optionalequipmentsuch as air conditioningand
trip computerdo not requirea larger battery).
Vehicles litted with the 5.0 litre engine, a 75 min/
235 amp, maintenancefree battery is fitted.
1.2 SERVICENOTES
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
The followingproceduresshould be used to service,test properly followed, good batteries may be replaced
and recharge batteries. Unless these procedures are needlessly'
2.1 BATTERY,SERVICE
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
runningor 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 anyrnherealong cable. Check
that cables do not have broken or frayed strands
and that they are securein their terminals.
2.2 AATTERY,TEST
STATEOF CHARGE. LOW MAINTENANCE
TYPE
BATTERIES. HYDROMETERTEST
NOTE:
a. Ensure specificgravity of battery electrolytehas
not been previouslyreduced to suit hot climate
(explanatorytag specifying specific gravity of
new electrolyteshould be attachedto battery in
conspicuousposition.)
b. lf water has been added to battery,do not use
hydrometeruntil electrolytehas been mixed by
chargingfor at least30 mins.
Hold hydrometervertically and draw in sufficient
liquid from battery cell to allow float to float freely
with bulb fullyreleased.
Compensatereadingfor temperatureby adding0.004
tor every 5oC that the electrolyte temperature
exceeds 27oC, or subtracting0.004 lor every 5oC
l e ssthan 27oC.
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 1 .2 4 0to 1.260
Recha rgeW hen Below
Fu lly Dis c har ged 1. 110t o 1 . 1 3 0
NOTE:
a. lf electrolytespecilic gravity has been reduced
for service in hot climates, typical temperature
adjusted value of specific gravity below which
battery should be rechargedis 1.150.
b. 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.
The essential difference between low maintenanceand
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
up is unnecessaryduring the life ol the battery,and the
top can be permanently sealed. In the AC Delco
MainlenanceFree battery in the VK Seriesmodels,all of
the acid is held within a hightlyporous separatormaterial.
Even when tully charged,the gases which are normally
evolved from the water in the electrolyte are fully
reabsorbed.Acid cannot leak at all. There is much less
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
been off chargeor dischargelor severalhours'
BATTER Y CO NDI TI O N O PEN CI RCU I T V O L T A G E
Fuil v Char ged UVCT I I.Y V
I Re ch ar geW hen Below 1 2 . 5V
Fully Dr s c har ged 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 measurementsto be obtained.
LOAD TEST . ALL BATTERIES

1. Check batterystate of charge as above. lf under half M I :rE R
charge,rechargebeforeconductingthis test. =-119I-
l Ql rov n N
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 temperaturesare below
5oC, voltage may be 0.5 to 1.0V lower.lf one cell is E A TTE R Y
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. Flguro 12A-3
2.3 CHARGINGBATTERIES
Proceduresfor charging low maintenanceand mainten-
ance free batteries are basically the same. With both
types,fully flat batteriescan safely be boost charged,but
care is necessaryto avoid excessivecurrent if the battery
is over half charged,and particularlyif it is almost fully
charged.Slow chargingis advisableil time permits.
CAUTION: During charging, an explosive hydrogen-
orygen 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 bet-
ween battery cells, or are above 1.200 at the
start.
ii. Electrolyteis discolouredwith brownsediment.
iii. Either of the above two conditions develops
after commencingfast charge.
iv. in the case of maintenancefree 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
automaticallyregulatethe 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 CAUTION: Refer note under low maintenance type
apparatusand set chargingcurrent accordingto the regarding overcharging-
followingtable.
5. Refit battery to vehicle. Operate starter motor for
approximately10 seconds,to remove surfacecharoe
from battery.
6. Load test battery as previously described in this
Section.
4 A appr ox . 24 hr s . m ax . Proportional
to the charge 2.4 VEHICLEWIRING,PERIODICAL
3 5A appr ox . 1 2 hr s . m ax at the start CHECKS
To ensure etficientop€rationof electricalsystem and to
safeguardagainst damage, the following checks should
3. Atter a few minutes, check electrolyte specific gravity be carriedout periodically:
(as per operation2.2 in this section)and colour (see 1. Check that all wires are held securely by their
note iii). respectiveretainerclips.
4. Monitor electrolyte temperature during charging 2. Check wires for chaffing or damagedinsulationand
procedure. lf temperature reaches 55oC, switch otf repairor replaceas necessary
chargingcunent and allow battery lo cool. Reduce 3. Check that wire terminalsand luses are secure and
chargingcurrentto preventsubsequentoverheating. that fuses are as specifiedat end of Section.
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 2.5 DRY CHARGEDBATTERY,STORE
be 1.0 amp or less.
AND ACTIVATE
5. Check voltage and electrolyte specific gravity once Dry chargedbatteriesare fully chargedwhen manufactu-
per hour. Slow chargingis completedwhen there is
red and contain no electrolyteuntil actryatedfor servrce.
no change in voltage or electrolytespecific gravity The dry chargedbatteryis completelyseaied and can be
over a three hour period. stored indefinatelywith no servicing untit actrvated.To
CAUTION: Charging at over the recommended times or activate a dry charg€d battery:
cuftents can significantlyreduce battery life. 1. Remove vent caps and add electrolyteof 1.265
specific gravit_vto each cell until corect level is
reached.
MAINTENANCE FREE TYPES 2. Several minutes after activating batrery. check
1. Removebatterylrom vehicle. electrolytelevel and add more electrolyte(not water)
as necessary.
2. Connect battery, with conect polarity to charging
NOTE:
apparatusand set chargingcurrent accordingto the
followingtable. a. After dry charge battery is activated,il becomesa
'wet' battery and only water should be added in
subseguentservicing.
b. Althougha dry chargebatterycan be put into service
immediatelyafter activation,the following tests are
recommended:
i. After adding electrolyte, check open circuit
2 4 h rs .ma x Proportional terminal'voltageof battery. lf less that 10V,
replace battery.
:o the charge
Check specificgravityof electrolytein each cell.
at the start
lf any temperaturecorrectedreading(see opera-
tion 2.2 in this section)shows more than a 0.030
drop from initial specilic gravity of electrolyte,
NOTE: lf the O.C.V.was very low, less than 10.0 V, the
slow charge batterybeJoreuse as per operation
initial charge current may be quite low. The current
2.3 in this Section.
shouldincreaseafter a short time at the charge voltage.
i l t. Check cells for violent gassingand if detected,
3. Monitor battery temperalure. lf the battery feels
slow chargebatterybeforeuse.
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
approachescompletion.Slow charging is completed
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
*-e
l X
X
Battery Cracked o o o
Bat t er y O ld Fault y O X o
Gener at o.Fault y o
Volt age Regulat orFault y o X
lg nit ion Swit c h Fault y O
Fa ult y or W or n W ir e/ Cable O
Bad Connec t lon( s) O
O I ndic at esoc s s r blec aus e.

X lnd; c at esm or e or obablec aus e
4. SPECIF|CAT|ONS
B A T T ERY:
R:-:el \/nlteno 1 2 r 'o l t s
Ca pec it v . . . Reserve/ColC d rankino
Ve h c leswit h 3. 3 l; : ' e EFI or EST 80 min./215 amp
Ve hic leswit h 5. 0 I : - : engine 75 min.l235 amp
NOTE: Spec ified r a: ngswhen t es t ed i n a c c o r d a n c e

wit h Aus t r aliar St
^ andar dAS 2 1 4 9 - 1 9 8 0
1-
LIGHTINGSYSTEM128-1
SECTION12B.
LIGHTINGSYSTEM
INDEx
Ref. Subject Page Ref. Subtect Page
1. GENERALDESCRtPT1ON..............................
12B,-1 2.3 HEADLAMPSWITCH........ 128-4
2. SERVTCEOPERATTONS ................... 12B.2 Remove........ 12B'-4
2.1 REAR TArL LAMP (SEDAN)..........................
12B'-2 Reinstall 12B,-4
Rernove.......... 12B.2 2.4 DASH LtcHTS DTMMER SWITCH................
12B-5
Reinstall 128-3 Remove............... 128-5
LICENCEPLATE LAMP SOCKET Reinstall 128- 5
(SEDAN) 12B,-4 3. sPECrFtCATtONS........... 12B-5
Remove........ 12B.-4
Reinstall 12B.-4
The lighting system for VK Series models carries over
from VH Series models except where noted in this TA L .A MP LE N S
f
Section.
On all models,the front turn signallamp assemblieshave
a clear crystalappearancelens, with an amber inner lilter
for amber illumination.
On all sedan models,there is a new style rear tail lamp
lens and tail lamp extensionmoulding,refer Fig. 128-1.
==--- 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 illumina-

tion is by two Camira sedan style licence plate lamp
N U MB E R P LA TE
assemblies, mounted on the rear bumper bar. Refer
LIGH T A S S E MB LY
Fig. 128-24. (2 P LA C E S )
R E A R B U MP E R
Flgure 128-2A
Serviceoperationsfor 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.
=> LrLuuE -
S OC K E TS
(8 P LA C E S )
LIC E N C E P LA TE
LA MP C ON N E C TOR 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
v
LIGHTINGSYSTEM128-3
2. Remove the four screws around the outside of the

tail lamp extensionmoulding,refer Fig. 128-5. NUT
I-
TA IL LA MP _
E X TE N S ION SC 8:! V
MOU LD I N G 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. TA IL LA MP _
E X TE N S ION
NOTE: On Calais models, it will be necessaryto remove MOU LD IN G
the boot caroet to reveal the two nuts.
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
Installationis reversalof removalprocedures.Check lamp
ooeration.
,.,
Flgure 128-7
128.4 LIGHTINGSYSTEM
2.2 LICENCEPLATE LAMP SOCKET

(SEDAN)
R EMOVE
2. From inside bool, disconnect licence plate lamp
socketwiringconnectors, refer Fig. 'l2B-8.
3. Pushgrommetand wrringconnectorsout towardsthe
rearof the vehicle.
4. Remove rear bumper bar as per service instruction
1.3,Section'1D of tbrssupplement.
GLOE E -
S OC K E TS
(8 P LA C E S )
/
P tnTE -/
-l C E \C E
-A I,'1PC ON N E C TOR S
Figure 128-8
5. 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 releasesit 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 \
Figure 128-9
2.3 HEADLAMPSWITCH
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 behindJacia.
REINSTALL
Installation
is reversalof removalprocedure.Check light
switchoperation.
Figure 128-10
r
LIGHTINGSYSTEM128.5
2.4 DASH LIGHTSDIMMERSWITCH R IGH T H AN D

LOYJ ER D ASH
REMOVE PA\EL
1. Remove headlamp switch as per servtce operation ( R EAq'i l EW )
2. 3.
2. Through the hole vacated by the headlamp switch,
remove the two switch mounting screws, refer
F ig. 128 -11 .
3. Pull the switch back and disconnectwiringconnector, D A S H L 3.ITS
withdraw switch. / D I MME F
MOU N TIN G _, SW ITC H
REINSTALL S C R E W {2)
Installation is reversal ol removal procedures. Check
operationof dash lights. 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
_-rhrtrH
, : \ Er - 1 ,_
IT AZ AF D W AR N IN G "-
F LASF ER U N IT
Figure 128-12
3. SPECIFICATIONS
T URNS IG N ALF L A SH ERU N IT
M ak e. Hella
O per at ion . . 6 0 l 1 2 0 f l a s h e so e r m r n u t ew i t h a u d i b e i3 u n c
L OCa tr o n 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
A c c e s si s g a r n e dc v r e m o v i n gc 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 .
HA Z A R DWA R NI NG FLASHER UNI T :
M ak e Delco
O per at ion 6 0 / 1 2 0 f l a s h e sp e r m i n u t e .
Location 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 .
A c c e s si 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.
RATI NG O F G LO BES:
Headlam p 60/55 watt Haiogen
I ns t r um entPanelI llum inat ion 1. 2 w a t t e r P u s h - l n
AL L S W I TCH & CO NTRO L I LLUM I N A T I O N :

G ener at orChar geI ndic at or 2 c.P.
Bac k Up and Tur n SignalLam ps 21 watt Bavoret
Dom e Lam p 10 watt Festcon
Eng ê and RearCom par t m ent 10 wait Fesioon
Dom e Lam p - Calar s 10 watt Festoon
Fr ont ReadingLam p - Calais . . 12 watt Bayonet
lnt er r or RearO uar t er Lam ps- E x c e p t S L m o d e l . . . 10 watt Festoon
Fr ont Par k Lam p . 4 watt BaYonet
G lov e Box Lam p 5 watt Festoon
Lr c enc ePlat e Lam p - Sedan. 10 watt Bavonet
Lic enc ePlat e Lam p - St at ion W a g o n 3 watt Bayonet (2 off )
St op/ Tail Lam p 2 1 5 't a '. t B a Y o n e t
w
--
GAUGES,W'SHIELDWIPERS/WASHERS
INSTRUMENTS, 12C-1
SECTION12C
INSTRUMENTS,
GAUGES,WINDSHIELD
WIPERS/WASHERS
INDEX
Bef. Sublect Page I Ref. Subject Page
1. GENERALDESCRIPTION 12C-1 | 2.2 INSTRUMENT CLUSTEF. MECHANICAL
1. 1 MECHANICALINSTRUMENTASSEMBLY 12C -1 INSTRUMENTS 12C-14
1. 2 ELECTRONICINSTRUMENTASSEMBLY.. 12C-3 Remove............ 12C-14
Warnlng !:mp Panel. 12C-3 Reinstall.......... 12C-14
Alpha lVarnlng Display... 12C4 INSTRUMENT CLUSTEB- ELECTRONIC
Temperature Gauge........... 12C-5 rNsTRUMENTS ..............__.. 12C-14
Fuel Gauge.. 12C-5
Speedometer and Digltal Speed
Dlsplays 12C-6 2.4
Tachometer 12C-6
Odometer and Trlp Meter ..................
12C-6
Trlp Gomputer 12C-7 2.5
Automatlc lnstrument Display
Dlmming 12C-7 2.6
1. 3 TOUCHSWITCHES- MECHANICAL&
ELECTRONICINSTRUMENT
ASSEUBLIEC 12C -8
1. 4 TR|P COMPUTER............... ...... 12C€ Reinstall .... . . . . . . .1.2C-
. . . . 19
General Descrlptlon.. ..... 12C-8 Fuel Tank .. . . . . . . . . . . 12C- 19
Functlon Descrlption.. ... 12C-9 2.7 SPEEDOMETER GEARCHART....................12C-23
1. 5 TRtP COMPUTERCOMPONENTS................12C-1 1 3. WINDSHIELD WIPERAND WASHER........12C.24
Fuel Flow Sensor 12C-11 3.1 GENERALDESCRtpTtON .._.................
.......... 12C-24
Fuel Level Sensor .........12C-ll 3.2 SERVTCE OPERATTONS ........12C-24
Electronlc Control Modu|e..................12C-1
1 3.3 wfPER DWELLCONTROLSWTTCH..........12C-24
Speed Sender 12C-12 Remove... ................ 12C-24
2. Reinstall ..12C-24
2. 1
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
instrumentcluster.Refer Fig. 12C-1.
Below the instrumentcluster is the warning lamp panel
incorporatingturn indicator,charge indicator lamp, park
brake and brake failure lamps, low oil pressurewarning
lamp, high beam indicatorand EST diagnosticlamp.
On Berlina models the assemblyis the same except tor
the additionof a tachometerinsteadof the fuel consump-
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.
12C.2INSTRUMENTS,
{ mur 13 > p; +2. rsr
1. O I L P R E S S U R EGAUGE 6. V OLTME TE R
2. FUEL GAUGE 7. TE MP E R A TU R E GA U GE
3. T A C H O M E T E R ( E ERL INA) 8. R E A R WIN D OW D E MIS T S WITC H (B E R LIN A )
F U E L C O N S U M P T IONINDICAT OR ( SL ) 9. A N TE N N A R E TR A C TOR S WITC H (B E R LIN A )
4. A N A L O G U E C L OCK IO. A N TE N N A E X TE N S ION S WITC H (B E R LIN A )
5. SPEEDOMETER I 1. R E MOV A B LE B LA N K S : FOR S P E C IFIC OP TION S
Flgure 12G1
1. A L P H A W A R N I NG DISPL AY 9. P H OTOTR A N S IS TOR - A U TOMA TIC D TS P LA YD IMMIN G

2. E N G I N E C O O L A NT T EM PERAT URE GAUGE (D A Y LIGH T OP E R A TION )
3. F U E L L E V E L G AUGE 10. FU N C TION C ON TR OL B U TTON S- TR IP C OMP U TE R
4. SPEEDOMETER 11. WA R N IN G LA MP P A N E L
5- TACHOMETER 12- TOU C H S WITC H E S
6. O D O M E T E R A N D T RIPM ET ER 13. S WITC HS Y MB OLS
7. D I G I T A L S P E E D INDICAT OR 14. B LA N K S
8. T R I P C O M P U T E R AND CL OCK 15. WA R N IN G B U ZZE R
Flgure 12C.2
INSTRUMENTS, 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. AlphaWarningDisplay
2. EngineCoolantTemperatureGauge
3. Fuel Level Gauge
4. Speedometer
5. Tachometer
6. Odometerand Trip Meler
7. DigitalSpeed Indicator
8. Trip Computerand Clock
9. Photo Transistor - Automatic Display Dimming
(daylightoperation)Manual Rheostat Conrol (night
operation).
10. FunctionControlButtons- Trip Computer
11- WarningLampPanel
12. Touch Switches
'13. SwitchSymbols
'14. Blanks
'f5. Warning Buzer
WARNING LAMP PANEL

The warning lamp panel is located along the bottom
edge of the instrumentcluster.
The warninglamp panel containswarninglampsfor:
1. BatteryCharge
2. BrakeFailure
3. ParkBrake
4. Lett Hand Turn Indicator
5. Right Hand Turn Indicator
6. Headlightson (with ignitionoff)
7. High Beam Indicator
L ReversingIndicationLamp
Warningsare displayedand a buzzersoundedfor various
componentfunctions.
R:tfor\/ Chrrnp YE S NO
Bra ke Fa ilu' e YE S 2 B EE P S
Pa rk Bra k e YE S 2 B EE P S
(i f c a rmov;ng
a b o v e5 k" hr)
Rig ht Ha nd I ndic at o. YE S NO
L eft Ha nd lndr c at or Y ES NO
Reversing W ar ning Y ES NO
Th e 2 be eoswill s ound in a half s ec ondt im e i n t e r v a l
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 instrumentcluster.
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 I
Fig. 12C-3. f
-!-
lf another messageis waiting to be displayedafter the L--!: t-1 T t-11- t T
motor has started,the 'SEAT BELT' warningwill display _ u _ rt t t _ lt _ l_ t
only for 5 seconds,allowing the olher messagesto be
displayed.
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: I
I
- t-
1. O I L A L ER T II' | In IItt
2. ENGINEHOT l l tt iit /--l -[/
3. LO COOLANT
4. LO FUEL
ReferFig. 12C-4.
II
lf 'ENGINEHOT' is displayedand 'LO COOLANT'is
-a-
queued for display and then suddenlyan 'OlL ALERT' L_l \i l _ t t\l t__ tn l t
fault occurs,then the 'OlL ALERT' warningwill lump the t _ t t lt J t t \ t l t1t_t t
queueand take precedenceover 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 I
the sourceof the lault is remedied. - t-
Everytime an alpha warningis first displayed,the audible I l-t t- t-t t-tt t-il\ | T
warningwill sound5 beeps in two seconds. l_ t_t t_ t_u_tL f lt \t t
II
-a-
I l -t I t tt t
l_ l_l | - 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,
12C.5
TEMPERATURE GAUGE
The temperature gauge, rclet Fig. 12C-6, is located
betweenthe alpha warningdisplayand fuel gauge on the Dt]OC
right hand side of the instrumentcluster.
The engine coolant temperature display consists ol
13 segment bars, the last three bars from the right are
red and the remainingare green.
With an increase in coolant temperature,the bars light
up, one at a time, from left to right. When the red zone
is reached,these bars light up progressivelyand remain
alight so that at maximumtemperature,all the red bars
are alight.
When the coolant temperatureis sufJicientto cause the
first of the red bars light up, the alpha warningdisplays
'ENGINEHOT' and the audiblewarningsounds5 beeps.
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. lll! llr U
The fuel gauge is a progressivebar 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
drops below '10.5litres (approximately)and the last left
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
fuel left in the tank. There is approximately3 litres of fuel
in the tank for each lightedred or green bar.
FUEL
llllilillililililil
Figure 12C-7
12C.6INSTRUMENTS,
SPEEDOMETERAND DIGITAL SPEED DISPLAYS

The speedometer,refer Fig. 12C-8, is situated in the ooocoD=q:= t- -
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'.
km/h
Flgure 12C-8
TACHOiIETER
The tachometer, reler Fig. 12GBA, is situated below the E-
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
indicationof engine speed.
The colour of the bar graph above 5500 rpm is red,
indicatingengine speed above this level should not be
maintained.
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 kilome-
ter 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
INSTRUMENTS, 12C-7
TRIP COMPUTER
The trip computer is situated to the left of the
speedometer.
It comprises three seperate displays for time, distance TI M E
and fuel functions.ReferFig. 12C-10. E, i_t.i:t i_t
For additionalinformationrefer to 1 4 in this Section. ELAPSED {-, {_,' !_, l_,
DISTANCE
AV SPEED nflnfi
TRVLD !l t-l.t-t lJ
TO Elv'lPTt'
FUEL
AV t/100
US E D EEI.EI.EI
Flgure 'l2C-10
AUTOMATIC INSTRUMENT DISPLAY DIMMING

The intensity ot the instrumentdisplay is automatically
variedto accountfor surroundingdaylightconditions,by a
photo transistor situated in the right hand side of the
war ningla mpp a n e l(F i g .1 2 C -11 ).
The photo transistor,upon sensrnga change in surroun-
ding daylightconditions,will change the display intensity i -!!!!t! ,
at one secondtime intervals.
P H OTO-
TR A N S I S TOq
Flgure 12C-11
When the headlightsare turned on, the displayintensity

will, if the ambientlightis belowa daylightthresholdlevel
(equivalentto dusk), immediatelydrop to the intensity
level set by the rheostat(Fig. 12C-12).The intensitycan
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
even with headlightson. To preventflickering.a time
delay is rncorporated. For example,if enteringa tunnelor
a very shaded area with headlightson and tf display
intensityis on a daylightsetting.the displaywill not dim
to rheostat control till 5 seconds after the ambient light
has fallen below the daylightthreshold.Displayintensity
control will not revert to automaticuntil the ambientlight
higherthan the daylightthresholdor
level is significantly
the headlightsare turned off- Figure 12C-'t2
12C-8INSTRUMENTS,
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 activatedby 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 electronicinstrumentassembly,and has three
separatedisplaysto displaytrip intormation.
The trip computer is located to the left of the
sDeedometer.
TI M E
Fuel flow measurementis suppliedby the injectorsignal
from the electroniccontrolunit for vehiclesequippedwith ELAPSED
E Ei:EE
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 DISTANCE
AV SPEED
the trip computerare shownbelow:
TIME (1) Tim e

TRVLD
TO EMPTY
EIEI.E.EI
(2) Ela ps ed
DISTA NCE (1) Av er ages peed( k m / hr )

(2) Tra v elied ( k ilom et r es ) FUEL
(3) To en pt y ( k ilom et r es )
FUEL A,'e: s gg ( lit r es / 100k m )

Us ec ( lit r es)
|NSTt 100
lns iant aneous( lit r es , r00
l k r - :Ir
The trip computerdisplaysthree tunctionssimultaneously,

one from each display of 'TIME', 'D|STANCE'and Flgure 12C-14
'FUEL',and are calledup in sequenceby depressing the
selectbutton.
Each time the select button is pressed,the function in
each displaywill incrementby one.
'TIME' and 'ELAPSED TIME' alternate with other
functions,givinga variablecombinationol time with other
functions.
The trip computercontrol buttons are located below the
displays(Fig. 12C-15)and are:
1. DISPLAY- (Displaystime with ignitionoff)
2. SELECT- (lncrementsfunctionsdisplayed)
3. HOURS- (Adjustshours when pressedwith display
button)
4. MINUTES- (Adjustsminutes when pressed with
displaybutton)
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-15
INSTRUMENTS,
12C.9
FUNCTION DESCRIPTION 3. Press reset and hours buttons simultaneouslyand

displaywill go to zero. Drive off and the displaywill
Time increasein whole numbersup to a numberbetween
The clock is a 12 hourclockwith flashingdecimalpoint. 615 and 650, whilst travellinga distanceof 10 km.
When the batteryis first connected,the clock will show This is the cablibrationnumber.Stop vehicle exactly
12.00 and if this is not the correcl time, the appropriate 10 km from startingpoint,e.g. centre pillar againsta
setting is achievedby pressingthe 'DISPLAY'and 'MlN' major highway shield 10 km from onginal shield.
buttons together for minute adjustment and the Press reset and minutes buttons simultaneously.
'DISPLAY'and 'HOURS'buttonsfor hour adiustment. When these buttons are released the calibration
It is recommendedthat the minutesbe adjustedprior to number will enter the computer memory and the
the hours becauseas the minutespass 60, the hourswill displaywill return to travelledmode, and shows the
automaticallyincrementby one. total distance travelledsince reset. This calibration
cloesnot reset other functionsback to zero.
The clock can be accuratelyset as the next minutewill
not display until 60 seconds after releasingthe adiust- The calibrationnumbershouldbe between 615 and 650
ment button. lor standard vehrcles, however, special tyres,
transmission,axle, tyre oressures,vehicle loading, etc.
will have a bearingon this number.
Elapsed Time Depressingthe reset and minute buttons simultaneously
Indicatesaccumulated'lGNlTlONON' time since resef any time the distancetravelledrcaiibrate lunctionis called
ting in hours and minutesup to 99 hours and 59 minules. up, will displaythe calibrationnumber,
For those who do not wish to have this degree of
accuracy(1 metre in 10 km) or who do not have access
DistanceTo Empty(DTE) to an accurately measured 10 km. an approximate
The distance to empty function is an estimate on how numberof 625 is used for distancecalculations.
much turther the vehicle can be driven on the luel When the battery is first connected,oalibrationnumbers
remainingin the tank, basedon the rate of fuel usagefor will automatrcallybe 625. lf requiredcalibrationnumberis
the previous15 minutes. know, select travelled/calibrated mode, press reset and
The DTE readoutadjusts in 5 km incrementsfor values hours buttonssimultaneously, drive vehrcleapproximately
in excess of 50 km and single kilometre increments 10 km until requiredcalibrationnumber is reachedthen
below this value. No computercan predict the future,so press reset and minutesbuttonssimultaneously. Alternati-
the DTE function can only be an estimate based on vely recalibrateas describedearlier.
previously obtained information. For this reason, as Whilst in the calibrate mode, i.e. after the reset and
conditions become more suited for economical driving, hours buttonsare pressedand prior to depressionof the
the distanceto empty can actuallyincrease,for example, reset and minute buttons, the 'SELECT' button is
from City to Highwaydriving. inactivatedto prevent selectionof other functionsduring
After initial batteryconnectionDTE will start at 500. The the calibrationprocedurebecausethis would affect the
computerwill then performan initial update trom a short calibration number and compuler distance lunctions
average prior to commencingthe normal long averaging would be inaccurate.
process.
A built-insafetyteatureallows up to approximately30 km Average Speed
of driving under highway conditions after DTE shows The averagespeed readingdisplaysaveragespeed since
zeto. However, due to tolerance variations on the the computerwas reset.The averagespeed is calculated
components from which the computer derives its in- by dividingdistancetravelledby the time that the ignition
formation,this figurewill vary from vehicleto vehicle. has been cn.
The computer has electronic damping to flatten out To enable the computer to collect enough data to
fluctuationsof fuel level in the tank and rate ol fuel calculatea sensiblespeed,the displaywill show zero lor
usage and will update the readout after consumptionof the first minuteafter reset.
0.32 litres of fuel approximately. Readingis updatedat one minuteintervals.
Oue to the large fuel level fluctuationswhilst mobile,the
readingsare heavilydamped and averagedover a long
time - up to half an hour. This does not matter during Instantaneous Consumption
normal operations,but after fuel {ill a long delay to The instantaneousfuel consumptionfunction reads in
displaya sensibleDTE is not acceptable.So with a fill of litres/'lOOkm in whole numbersonly and updatesat halJ
10 litres or more the computerwill calculatea higher second intervals.
DTE from a short averageat the next normal updateand When the vehicle is stationary,the display shows zero,
the long averagingwill proceedfrom the new figure. however,when slowingdown to a stop, due to fuel being
used and a small distance being travelled,some large
Distance Travelled/Calibrate numbers may be displayed.Also, when the function is
This function reads distancetravelledin krlorneterssince first called up, some large numbersmay appear,due to
the computerwas resel, showing two decimal points up the small time frame over which the comouter is
to 100 and whole numbersthereafter. Dre0areo.
The calibrate function is designed to allow a very
accuratedistancecalculationand is enteredas follows: Average Consumption
1. Selectdistancetravelledmode. The averagefuel consumption readsin litres/100km and
2. Line up the vehicle againsta known marker,e.g. calculates fuel usage since last reset and updates at
cenlre pillaragainsta major highwayshield. approximately one minuteintervals.
12C.10INSTRUMENTS,
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12C'11
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
nrtO"t can be displayed
--ffnS in the DTE mode if the RESET
'M|-['IUTE
or buttons are depressed
iimultaneously.This number is equivalentto the amount
"nO
of fuel, in litres, remaining in the fuel tank that the
cornprt'etis using to obtain its calculationsfor the DTE
display.
1.5 TRIP COMPUTERCOMPONENTS

FUEL FLOW SENSOR
With the 5.0 litre engine,the fuel llow sensor.isthe same
;;- on VH Series models' Refer Figs 12G16'
"sedfor installationdetails.
12C-17,
is
On fuel iniectionequippedmodels,the fuel flow signal
orouiOeObv the EFi control unit. The control unit controls
is
[n"-pJ""-*iOth signal to the iniectors'and.this signal
to- the trip comPuter control module and
aiso-transmined
used as a measureof fuel usage'
FUEL LEVEL SENSOR

unit
The 'fuel to empty' is sensedby the fuel gaugetank
in the
i"titt"n"" reaOing.The tank unit may be checked
*"ner (r-eterFuel Gauge SenderDiagnosis- 2'6
to readout
ilfii; suppremdnUshould any query rrise as
"-o-ttJ
on display moduleand actualfuel gauge reaolng'
ELECTRONIC CONTROL TTIODULE

with the
The electronic control module is integrated
instrument
Oi.pf"V and function module on electronic
assemblies'
- - ,// Y.
t,,r 7'l C .
) - 'r ^>
j-\-i-\-
-
-\--
\!
(3
f t t o - T A P Ew t r H G M 6 5 8 M PL Ac=s
FUELFLoWSENSoRW|R|NGHARNESS_5'0L|TREMoDELS
Flgure 12C-17
fa-
12C.12INSTRUMENTS,
SPEED SENDER (For Electronic lnstruments)

A Hall Etfect Speed Sender is used to produce an \
electricalsignalwhich is proportionalto the vehicle'sroad .l ^
speed. This signal is used for the electronic instrument ,,\

S P E E DS E N D E R - I
readoutsof speed and odometer.
This signal is also used by the trip computer and is
required for readings of distance to empty, average
speed,distancetravelledand instantaneousand average
fuel consumption.
The sender consists of a metal body which houses a 7 6) ! /
rotating16 pole magnet.Fitted into the metal body is a i 't/+)l

plasticcap which containsthe electricalterminalsand the / F!r-
Hall effect integratedcircuit.
1."r,r.'"i*t*o,-
The soeed sender is mounted on the cruise control _ C ON N E C TION TO
TFA N S D U C E R I
transducer.Refer Fig. 12Q-'18. I E N GIN E H A R N E S S
I
SPEED O C ABLE - '
Flgure 12G'18
Theory Of Operation
N O MA GN E T
The Hall effect principleis shown in Fig. 12C-19 EFFECT PRINCIPLE
A constantcontrol currentis passedthrough a thin strip
of semi-conductormaterial.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 N O H A LL
appears .at the contacts placed across the narrow V OLTA GE
dimensionof 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
70f d
INCREASES
H A LL V OLTA GE
D E C R E A S IN G
rolr.t,tt
t --t^:-5f, |
----=-rx--/
HALL VoLTAGE
Flgure 12C-19
INSTRUMENTS,
12C.13
For service operationsnot covered in this Section, refer and VH Commodore Service Manual Suoolementpart
to the VB CommodoreServiceManualPart No. M38145 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 Supple-
ment for touch switch controlpanelwinng.
REINSTALL
Installationis reverse of removal proceduresensuring
wiringharnessconnectoris securelyconnected.
Figure 12C-22
12C-14INSTRUMENTS,
CLUSTER.
2.2 INSTRUMENT
MECHANICALINSTRUMENTS WA R N IN G LA I\4P
P A N E L WIR IN G
IN S TR U ME N T
REMOVE S U R R OU N D _ C ON N E C TOR S
2. Remove touch switch control panel as per service
operation2.1. I N S TR U ME N T
3. Removethe screws securingthe instrumentframe to FR A ME
the instrumentsunound.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 instru-
menttrame.
6. Removethe right hand instrumentpanel lower trim.
7. Reach uo behind the instrument cluster and dis-
connectthe vacuum hose from the fuel consumption
meter (SL models), and the speedometercable by
depressingthe springretainer. LtrI\ I H: UA5 N -
VENT
TOU C H S WITC H-
C ON TR OL P A N E T
Flgure 12C-23
8. Remove the five screws securing the instrument

clusterto the instrumentsurround.Refer Fig. 12C-24. IN S TR U ME N T
9. Pull the cluster from its location and rotate the C LU S TE R
bottom of the cluster upwards to gain access to the
wiringconnectors.
mentcluster.
REINSTALL - IN S TR U ME N T
S U R R OU N D r:i
Installationis reversalof removalprocedures.Ensurethat N
)) \3)
all electricalconnectorsare securelvconnected.
N I O U N T I NS
GC R E WS
$\J
Flgure 12C-24
2.3 INSTRUMENTCLUSTER.
WA R N IN G LA MP
ELECTRONIC INSTRUMENTS I\ S T R U M E N T
,f P A N E L
WIR IN G
REMOVE SLFBOUND-J C ON N E C TOR S
1- Disconnectbatteryearth lead.
2. Remove touch switch control panel as per service
operation2.1.
3. Removethe screwssecuringthe instrumentframe to
I
the instrumentsunound.Refer Fig. 12C-25.
4. Pull the instrumentframe out, far enough to gain
accessto the warninglamp panel wiring connectors.
ReferFig. 12G25.
mentframe.
C EN T R E D ASH _
VEN T TOU C H S WITC H-
C ON TR OL P A N E L
Figure 12C-25
-
INSTRUMENTS, 12C.15
6. Remove the five screws securing the instrument

clusterto the instrumentsurround.Refer Fig. 12C-26. I N STR U ME N T
7. Pull the cluster from its location and rotate the LLUJ I Eh
bottom of the cluster upwardsto gain access to the

wiringconnectors.
8. Disconnectwiring connectors, and withdraw instru-
ment cluster. -/.
/
REINSTALL I- IN ST R J ^J EN T
SU R R O !N ]
lnstallationis reversalof removalprocedures.Ensurethal
all electricalconnectorsare securelyconnected
...c N Tt N G S C R E WS(5) -/
-
Figure 12C-26
2.4 MECHANICALINSTRUMENTS
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).
o
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o
+ ir
t i
2' c e-\ J_.

;-
Flgwe 12C-27
Speedometer, Fuel Consu4ption Indicator and

Tachometer
Remove retaining screws and withdraw unit (Refer
Fig. 12C-28).When removingtachometer,carefullywith-
draw contactsfrom printedcircuit.
Flgure 12C-28
12C-16INSTRUMENTS,
Fuel and Temperature Gauges

Removegauge retainingscrew (Fig. 12C-29).Compress
plastic retainingtang and withdraw gauge contacts from
printedcircuit.(Fig.12C-29).
Flgure 12G29
Voltmeter and Oil Pressure Gauge

R E TA IN IN G
1. Remove overlappingfuei or temperaturegauge as
S C R E WS
previouslydescribed
2. Remove remainingscrew and withdrawgauge con-
tacts from printedcrrcurt(Fig. 12C-30).
Figure 12C-30
Clock
From behind the instrumenthousing,removeconnector
from printedcircuit.Bemoverhe two screwsretainingthe
clock assembly to the instrumenthousing and remove
clock.(Fig. 12C-31).
Figure 12C-3't
INSTRUMENTS,
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.
z- Install retaining clip/heat sink ensuring voltage
stabilizercontactslocate properly.
Install upper gauges first, ensuring gauge contacts V OLTA GE S TA B I LI:E R
are properly seated. rr:JJ ruutrtntrn
A \) P U LL U P
Fagure1rc-32
2.5 INSTRUMENT
TESTING
For mechanicalinstrumenttesting refer to Section 12 of
the VB CommodoreServiceManualPart 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 instrumentscomputermemoryif a
displayblackoutoccurs.
SPEED SENDER
Remove
2. Disconnect sender wirino connector. Refer
Fig. 12C-33.
3. Unscrew sender from cruise control transducerre-
move senoer.
Test
1. Connect4.7 ohm 1/4 watl resistoracrossterminais
markedr and A.
2. Connect 12 volt DC battery supply to terminals
marked= and - (observepolarity). -C ON N E CTION TO
TR A N S D U CE F
3. Connect pointer type multimeter s€t on DC volts E N GIN E H A R N E S S
scale to terminals+ and A (observepolarity,positive )rtrtri! tqbLtr-
termanal of multimeter to terminal - , negative

terminalof multimeterto terminalA).
4. Rotate sender square drive slowly by hand and Figure 12C-33
observe multimeterreadingwhich should pulse bet-
ween 12 volts and O volts.
5. No pulse readrng on multimeterrndicatesfaulty
sender.
NOTE:Senderis non repairable.
Reins t all
Installationis reversalof removat.
12C.18INSTRUMENTS,
2. 6 F U E LG A U GES E N D E RU N IT r. ')
R EMOVE \ ! -, / \
The removaland installationinstructionsfor vehicleswith .-:,,,, ,/,>-^
5.0 litre engine with the revised fuel pump system and :i I
3.3 litre EST engine,are coveredin Section 8 of the VB
CommodoreServiceManual.
The followingremovaland installationproceduresare for
3.3 litreEFI equippedvehicles.
'l . Disconnectbatteryearth lead.
2. Placethe vehicleon jack standsand drain the tank -.-1_''\
; -\\
through fuel filler opening using a commercially
-
:<
availablefuel syphoning device. @- i --(/<.:
3. Disconnect the fuel linelrom gaugeunit.
4. Disconnectthe electricalfeed and earth cables from
unit.ReferFig. 12C-34. FU E L P U MP -
C ON N E C TOR S
5. Remove5 mountingscrewsaroundgaugeunit.
:-...2
6. Removegauge unit, liftinggauge unit filter from swirl \
pot
FU E L GA U GE I
C ON N E C TOR S
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 Flguro 12C-34
blowing oft carefully with low pressuredried compressed
air; replace screw if damagedor unable to clean.
F UEL GA UG E S E NDE R U N IT D IA G N O S IS
1. turn ignitionto '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
suspectedto be inaccurate.Proceedto step 2.
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
switched'ON'). lf recordinga voltagereading.correct
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 terminalconnectorto earth with an accuratehigh
resistance voltmeter(ignition 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.
lf the connectorsare OK, replacevoltage regulator,refer
to service ooeration2.4 MechanicallnstrumentDis-
assembly, in this Section.
lf the readingis withinthe specification of 10 0.1 volts,
remove the f uel gauge sender unit, refer to service
operation2.6 Fuel GaugeSenderUnit - Remove,in this
Section.
Checkthe senderunitfor bindingor sticking.
Connectan ohmmeterto fuel gaugeterminalon sender
unit and to the senderunitflange.
Set the float to the variousheightdimensions, as shown
in the followingchart, and recordthe resistanceat each
dimension.
INSTRUMENTS, 12C.10
i nnoa.t He i g h t
tmml
3.3 litre EST - Sedan Em pt y 2 8 3 !7 @ O
% 91=14 @ l5
FulI 3 5 -4 0 @
3.3 litre EST - W agon Em pt y 2 8 3 !7 @ o
Yz 1001 14 @ 66.5
FulI 3 5 -4 0 @ top
3.3 litre EFI - Sedan Em pt y 2 8 3 !7 @ 0
'/a
5.0 litre - S edan 1 4 5 .5 i 4 @ 35.25
'/, 9 7 .3 i 3 @ 69.5
% 6 6 .5 1 2 .5@ 103.25
FulI 4 0 !2 @ 140.8
Upper Stop U n d e r3 5 @ 147
- Wagon Empty 2 8 3 !7 @ 0
% 1 4 5 .5t 4 @ ?A
Tz 9 7 .3 1 3 @ 67
6 6 .51 2.5 @ 100
Full 4 0 !2 @ ttz
Upper Stop 189.4
REINSTALL
Reverseto removaloperationsnotingthe following:
'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 installationinstructionsremain 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.
12C-2OINSTRUMENTS,
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INSTRUMENTS, 12C-23
GEAR CHART
2.7 SPEEDOMETER
REAR AXLE T RANSM ISSION SPEEDOD R IV E N GE A R TY R E OP TION N U MB E R S
Sp e e d oDr ive I N umber

P/O I Ratio p l' Co lo u r OB C OC J OC H OC R OB D OS T ooY OFL OE U OB Y OON
Gear Colour of Te€th
G70 2.60 : 1 M40 1 0 T e e th Da r k Brue 22 X X XX

i ye ilo w Gr e e n 21
L
GU4 3 . 0 8 :1 lvlc6 7 Teeth Red 18X X l X X X XI X X

Br own
, M4O 9 T e e th Re d 23 X X X XXXX
Biu e r-_f_-
M76 8 T e e th Wh ite 20 X X X X
L6 Pin k Gr e e n 21 X
ut M40 10 T e e th L ig h t Blue X X X
I Ye llo w
GV4 3 .36 : 1J M 76 8 T e e th Da r k Bl ue X XXX X \ XX

Pink
K E Y TO TY R E OP TION N U ME E R S
OBC BR6OHl5 oc R cR78S14 00Y 175SF13 OE U E P ;O H 14

ocJ c R70 H14 oBD B R 7 8S l 3 UFL rzJf, bu nn rf OB Y B F;E S 14
ocH c R78 H14 O ST 165SR14 ooN P r75/75 S R 14
12C-24INSTRUMENTS,
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 SERVICEOPERATIONS
Service operations arc as described in Section 12,
Holden Commodore VB Series Service Manual Part
No. M38145.exceotwhere noted in this Section.
3.3 WIPERDWELLCONTROLSWITCH
REMOVE
U P P E RS C R E W
1. Removeinstrumentassemblysurroundas per service P LA C E S )
112
instruction2.3, 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. Removethe righthand instrument panellowercover.
/' \-
-{9
/oor* suRRouND \ LOWE R S C R E W
LOC A TIN G H OLE _ (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. Disconnectthe wiper dwell control switch wiring

connector from the main wiring harness. Reler
Fig. 12C-39. .,.l'^sl:y11.'r
ranr\trJJ
/
6. Removelower dash surroundand switch. \V. TSCREW
7. Remove switch mounting nut and separate switch x.} , (2 PLAcES
from panel. \ e ,&5:<
*\eB
^
ry
REINSTALL '<a>-
-/ ./_ -
A
Installationis reversalof removalprocedures.Ensurethe
. i V A IN WIR IN G
locatinglug on the left hand lower dash surroundfits into
the locatrng HARNESS
square.Checkoperationof switch.
C ON N E C TION
WIP E R D WE LL ]
C ON TR OL S WITC H ! SW IT C H
R ET AIN IN G NUT
Flgure 12C-39
RADIOAND TAPE PLAYER 12D-1
SECTION12D
RADIOAND TAPE PLAYER
INDEx
Ref. Subject Page Ref. Sublect page
1. GENERALDESCRIPTION 12D-1 3. DIAGNOSIS..... .............
12D-8
2. SERVICEOPERATIONS..... 12D-2 4. sPECrFlCATrONS.............. .......12D-9
2. 1 RADIO OR RADIO CASSETTEPLAYER 5. TORQUEWRENCHSPECIFICATIONS........ 12D-9
ASSEMBLY 12D-2 6. SPECTALTOOLS...... . 12D-9
Remove t2D-2
Beinstall 12D-3
2.2 SPEAKERS.. 12D-3
Remove........ 12D-3
Reinstall 12D-5
All VK Series models are fitted with a radio. SL models The four speakers are located, two in the rear parcel
are suppliedwith a high performanceAM/FM radio with shelf and one at each upper corner of the instrument
digital display for channels and frequencies,a 2 way dash panel .
speakersystemand a manual,key lock anlenna. The operatinginstructionsfor each unit is includedin the
Berlina models have an AM/FM stereo radio cassette OwnersHandbook.
unit,in lieu of the AM/FM radio.The radiois an AM/FM A power operated antenna is standard on Berlina and
stereo signal seeking radio with digital display for Calaismodels.The antennais automatically raisedto a
channels and frequencies.The speaker syslem is a 2 medium height wnen the radio is turned on and can be
way speal(ersystem. turther raised or lowered by means of the antenna
Calais models are fitted with a similarradio/cassetteunit control switcheson the instrumenttouch control oanel.
to the Berlinamodels.Featuresof this radio/cassetteunit
include a single joystick balance control lor a 4 way
speaker system and automatic programme search for
cassenes.
12D-2RADIOAND TAPE PLAYER
2.1 RADIO OR RADIO CASSETTE

PLAYERASSEMBLY
REMOVE
2. Removetouch controlpanel as per serviceoperation
2.1,Sectron12C of this Supplement.
3. Removeinstrumentsurroundand instrumentassemb-
ly 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
as per serviceoperationsdescribedin Section 14 of
this supplement. _ REAR BRACKET
5. Removecentre air vent duct. S C RE W/S
6. Remove radio - radio/cassetteplayer rear bracket a TN S TR U ME N TC A R R TE R

/ P A N E L A S S E ME LY
screw/s from instrument canier panel assemblv.
ReferFig. 12D-1. FR ON T
MOU N TIN G
7. Removeheal/ventcontrol assemblywith temperature
control cable attached,removingvacuum hose and
electricalconnectors.
8. Removelower lett side instrumentDaneland radio -
radio/cassetteplayeras an assembly.
L Disconnect electncal connector and antenna from
radio- radio/cassetteplayer.
----=:
_ 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. -
FR ON T MOU N TIN G B R A C K E T
11 . Removerear bracketattachingscrew.
,,- MOU N TIN G S C R E W-2
o'5
I
w_
i
Flgure 12D-2
RADIOAND TAPE PLAYER12D.3
12. Insert removal tools CMT113 simultaneouslyinto

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.
13. Removeradio - radio/cassettefrom dash panel.
14. From behind sides of radio facia, depress spring
mechanism,which will release removal tools from
radio - radio/cassetteplayer.
S E R V IC E TOOL
15. Removaltools, Part No. CMT113, which are released N O. C M T 1 13
in pairs,are availabledirect lrom -
EurovoxAustralia,
6 UniversityPlace,
ClaytonNorth.Vic. 3168.
Flgure 12D3
REINSTALL
Insert radio - radio/cassetteplayer in dash apertureuntil
the lockingspringsclick.
The remainder of the installation is the reversal ol
removal procedures.
2.2 SPEAKERS
REMOVE
/.S P E A K E R GR ILLE
Single Speaker - Front
1. Removespeakergrille.
2. Removespeakersecuringscrews,reterFig. 12D-4.
3. Litt up speaker to disconnectwiring harness
Removespeaker,referFig. 12D-4.
connector.
S E C U R IN GS C R E WS
PLACES)
x
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 FR ON T S P E A K E R
and instrumentpad. A N D GR ILLE
2. Carefullylever speaker grille upwards. Lift speaker A S S E MB LY
from its position, disconnect wiring harness con-
nectorand removespeaker,refer Fig. 12D-5.
- IN S TR U ME N T
PAD
r- w tR tN G H A R N E S S coN N E croR
Flgure 12D5
Rear Speakers - Sedan

1. Removepush-onspeakergrille. . rrS P E A K E R GR I LLE
2. Removespeakersecuring
screws,referFig. 12D-6. '
@
.w
/-S E C U R IN G S C R E WS
, (3 P LA C E S )
zz SPEAKER
-r-:
s
WIR IN G
H AR N ESS h tr Ah TAh L tr L
SH ELF
Figure 12D-6
Disconnectwiring harness connector,refer Fig. 12D-

7, removesoeaker.
H AR N ESS
Figure 12D-7
-!t
Rear Speaker - Station Wagon

1. Bemove the interiorside panel trim as per instructions
in Section 01 of the Holden Commodore VB Series
StationWagon SupplementPart No. M38265.
2. Disconnectwiringharnessconnector.
3. Remove speaker securing screws and remove
speaker,refer Fig. 12D-8. IN N E R S ID E PA N :I- --
S PE A K E R
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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RADIO AND TAPE PLAYER 12D.7
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12D.8RADIO AND TAPE PLAYER
3. DIAGNOSIS
:..
!::
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:,.-
a
i
-
4. SPECIFICATIONS
AM / FM Radio . 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
Radio Cas s et t e S t e r e o ,5 W a t 1 0 % T H D p e r c h a n n e
Speak er s 4 ohms, 10W capacity
Power Antenna
M ax im um c ont inuousc ur r e n t 3 amos
Loc k up c ur r ent 9 amps
Radio - Radio/Cassette Mounting BracketScrews 0.9 - 1.2 Nm
Ant enna M ount ing Nut . . 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 .
Power Ant enna M ount ino Bolt s '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
A v a i l a b l ef r o m :
-l {ll 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.
--il
cMTl 13
WIRINGHARNESS& FUSES12E-1
SECTION12E
WIRINGHARNESSAND FUSES
INDEX
Ref Subject Page t Ref.
1. FUSE BOX ............. 12E-1 2.1
1. 1 GENERALINFORMATION 12E-1
Remove........ 12E-3 3.
Relnstall 12E-3 3.1
FUSIBLELINK 12E-4 4.
1 . F USEBOX
The fuse box used with VK CommodoreSeriesis located
in the engine compartment,behind the passengerside
struttower,referFig. 12E-1.
cr ta a J --/ €?
B OX
LE FT H A N D
- S TR U T TOW E R
MA IN WIR
f-rvrArr\ IN G
vvrnrr!u H A FN E
/ coNNEcrtoN
Flgure 12E-1
The main wiring harness connectionsto the fuse box U N D E R N E A TH V IE W

assembly are made via connectors located on the OF FU S E B OX
undersideof the fuse box, refer Fig. 12E-2. --1 i
flge, T----l r _ui
r-,' t--------'r
||
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C ONN E C TlON
ON LY
E .S .T.V A C U U N 4-
-.
TR A N S D U C E R L_WIR IN G H A R N E S S
(3.3 LITR E E S T ON LY ) C ON N E C TOR
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 RAT ING
NO. F U N C T ION ( AM PS} [-_--lr
,l [----l z
He a d l a m p s- l o w b e am
2 He a d l a m p s- h i g h b e a r n [---ls
3 Pa r k i n gl a m p sa n d l l um in a tr o no f [----l c
I nst r u m e n t s 15A
Fuel Pump (E.F.l.) 7 .5 4 l-----ls
Fuel Pump (5.0 itre) 5 .0 A [---l o
Air c o n d i t i o n i n gb l o we r 254
[-.l z
o Ho r n a n d s t o p l i g h t s 15A
7 He a t e dr e a rw i n d o w 15A [----] e
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 t5A
[----.l s
q
C l ock tri p co mp u te r, inter ior illumination, [----lro
r e a r co mp a rtme n t a n d lock l5 A
l---ltt
l g n i ti o n syste m 15A
R e a r wi n d o w wi p e r/w asher 15A f---l tz
I n stru me n ts a n d tri p com puter 'l 5A
[-l rs
W i p e r/wa sh e r, tu rn si gnal, cigar lighter IJA
R a d i o a n d p o we r a n te nna [----l tr
T a pe a n d p o w e r a n te n na 7 .5 A [--_-l r
H e a te r b to w e r 15A
Sp are fu se
Flgure 12E-{
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 Hea tedr earwindow - m odule

B Bea rw indow was her / wiper- m odule
a Doo r l oc k - r elay
D Doo r l oc k - r elay
E Horn - r elay
F Powe rwindow - r elay
G Air condit ioningaux iliar yf an - r elay
H Air co ndit ioningblower - r elay
I c lut c h dela y- m o d u l e
Air co ndit ioningc om pr es s or
J Fu el pum p c ont r ol - r elay
REMOVE
2. Removefuse box cover.
3. Removeretainingbolt, refer Fig. 12E-6.
4. Slide tuse box towards the engine to release fuse
FE TA IN IN G---\\
box from bottom retainingbracket. 80LT ---\
5. Lift fuse box up slightly and rotate to gain access
underneathbox.
t
/A
Figure 12E-6
6. Disconnect all wiring harness connectors, reter U N D E q\E A TH V IE W

Fig. 12E-7. OF FI-S E B OX
lf vehicle is equippedwith ElectronicSpark Timing,
remove the two enginevacuum transducermounting
screws.
7. Lifl out fuse box.
,
REINSTALL -\'
>..
1. Connectall wiring harnessconnectors.Ensureall are =-t+
securelyinstalled. C ON NE C TOR
2. Refit EST engine vacuum transducer (if equipped ON L Y
with EST).
3. Engagethe tongues on the bottom of the fuse box TR A N S D U C E R !WIR IN G HARNESS
into the retainingbracket. (3,3 LITR E E S T ON LY ) C ON N E C TOR
4. Fit retainingbolt, fuse box cover and battery earth
lead.
Figure 12E-7
12E.4WIRINGHARNESS& FUSES
2. FUSIBLELINK
2.1 GENERALINFORMATION *- - -. .==.- FUSEBox ,' €

The chassis wiring is protected against short circuit
damageby a fusible link placed within the battery wiring
harness.
'!-..'\/ WIR IN G HAHI
rvtAil\ HARNESS
It is taped back to the battery wiring harness, near the -r,z , -MA
,- INYYtHil\tr
n C ON N E C TION
battery,refer Fig. 12E-8. I
An additionalfusible link is incorporatedfor 3.3 litre EFI \.\

F US|B LE
..\-,r.^._
*Y-il---.,
modelsfor EFI wiringharnessprotection.lt is taped back t L,NK
to the battery wiring harness,between the battery and {l:-,'.S.. B A TTE R Y
startermotor,refer Fig. 12E-8.
F / FU S TB LELIN K -
7 {EFr)
REPLACE
1. Disconnectbatteryearth lead. Figure 12E-8
2. Untapefusiblelink wire from batterywiringharness.
3. Disconnectfusiblelink connectorand install new link,
referFig. 12E-9.
4. Tape back to harness.
5. Reconnectbatteryearth terminal.
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
accommodatesEST only.
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.
a. Mechanicalinstrumentsand touch switches.
b. Electronicinstrumentsand touch switches.
Ancillaryharnessesare requiredwhen various equip-
ment 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.
k
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WIRINGDIAGRAMS12F.1
SECTION12F
WIRINGDIAGRAMS
INDEX
Subject Page ' Subject page
WIRINGSCHEMATICSYMBOLSLEGEND............12F.2 CIGAR LIGHTER,TURN SIGNALAND HAZARD
SYMBOLSUSEDIN VK WTRINGCIRCUIT 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 HEATEDBEAR 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
wf RTNGSCHEMATTC (PART'D')................ 12F-8 RADIOAND POWERAI{TENNA.... 12F.31
GENERATOR,BATTERY,STARTERMOTOR CLOCK,TRIP COMPUTER, INTERIOR
AND IGN|T|ON......-.....-._.-.. 12F-9 ILLUMINATION,REAR COMPARTMENT
ELECTRONICFUEL INJECTIONSYSTEM.......... 12F-11 LAMP AND LOCK ........__. 12F_33
5.0 LTTREENGTNE FUEL SYSTEM........................
12F-13 ELECTRICDOOR LOCKS AND POWER
ELECTRONIC SPARKTIMINGSYSTEM 12F-15 oPERATEDS|DE W|NDOWS................. 12F-35
HEADLAMPS.STOPLAMPSAND HORN......-.....-- 12F-17 ELECTRICMIRRORS....- 12F.37
PARKINGLAMPSAND INSTRUMENT PANEL FRONTEARTHINGCIRCUIT....... 12F-39
tLLUMtNATtON ................... 12F-19 FRONTEARTHINGCIRCUITCONTINUED.......... 12F-41
INSTRUMENTS - MECHANICAL............. 12F-2',1 REAREARTHINGCIRCUIT 12F.43
.
INSTRUMENTS ELECTRONIC............... 12F-23 p
TRf cottpuTER.-........_..._ .t2F-45
TRAILERHARNESS..... 12F-47
12F-2WIRINGDIAGRAMS
WIRINGSCHEMATIC
SYMBOLSLEGEND
LA M P B ULB s s w lTcH E s
A ( M ANUAL L Y OP E R A TE D ) \O IN S TR U ME N TS
Code Max. Max.

Name Loc. Code Name Loc Code Name
Max.
Amp Amp i Loc-
Am p
B2 L .H . R e a r T u rn S 1 Horn Button T BA 309
S i g n a l L a mp 1.15
Generator ndrcator 0.10 92
23s
2 Aur o Retr act Ant. 3 Brake Farlure
B3 L . H. F ro n t T u rn Sw. ( Touch Conr r ol ) 292
S i g n a l L a mp 1.75
Warning Lamp 0.10 92
I
S 3 Cr uiseContr ol Sw 121 t4 Park Brake Warnrng
B4 R.H. Front Turn
Sional Lamn S 4 Cr uiseContr ol Speed Lamp 0.10 94
; Restr. Sw. 122 7 v ol tm er er i 0.10 110
B5 h.d. Hear lurn
Signal Lamp 238 s5 Cr uiseContr o l Br ak e r8 Temperature Gauge 102
Switch 1.0
High Beam 5 .0 t9 Oil Pressure Gauoe 107
s6
B7 Low Beam 4.58 I 165 l 10 Fuel Gauqe 105
S9 Turn Srgna Swr
| 1l Tachometer 0 20 t'11
s 13 Heated Fear Wrnoow 142t
B9 I n str. C o mp a rtme n l Swrtch iMan ual i 20.0 't49 12 L.H . T ur n Si gnal
Box lllum a 4? I ndi c ator
:1 2 e J tl Eleclr c Door Lock
810 Dome Lamp 0 .8 3 I 13 4 Sw tch (Key) L.H.
I I3 F l .H .T ur n Si gnat i
Indi c ator i O.]O 237
o tz s 15 Dwelt Qe611q1 5*;1ah zta
114
s 17 Hazard Warning Sw 237
I n s tru me n t C l u ste r I 15 O r l Pr es s ur e
W ar ni ng
l l l um. L a mp O- 1 112 s 20 Ar r Condition er 249/ Lam p 0 10 96
MasterSwitch 274 | 20 C ool ant Lev el
Swilch lllum. 0 .1 172 s 2r Air Conditioner Fan 264/ W ar ni ng Lam p 117
Switch 15.0 ---
I 15 Front Parkin( | 23 Electronicspeedo .--;
s 22 Dim m er & Fla s herSw . rb4
816 T a i l L a mp s 25 I T r i p C om puter
Windshied Wroer Sw 223 I D i s ol av M odute 160
817 Rear Licence P ate
lllum. 0 .8 3 169 s2 6 Lighi SwLrch 169 t26 T r r p C om puter
s 29 Power Operated Side F unc ti on I ndi c ator 160
421
W a sh e rS wi tch l l u m Windoer Swrrch 344 t28 Electronic Spark
0.1 172
B e ar Qu a rte r L a mo o.4 2 i1.O 132 s 30 E ec:r c Door Locks Timanq Lamo 0.1O 76
Sw,tch (Button) 321 t29 S13 Indicaror Lamp
8 23 Rear Compt. Lamp 0.83 tJb (TouchConrror
32 Rea' Compar tm ent i 0.10 142
s 24 Heat/Air Cond. Lock Switch r Jd r36 Back-Up Lamps
Contr. lllum. 0.05 172 Warnrnq 1369 0.10 114
B '5
34 lcn rron Switch 13
Radio lllum. 0.' l 172
S 35 W ndsh eld W as h.Sw . r37 Exte.ror I llum
227
uzo Light Switch lttum. 0 .1 172 Wa rn Ing Lamp 0.10 169
Rear W r ndow W i per
828 Cigar Liqhter lilum 0 .1 172 Sn. { Touch Contr ol ) 204 E LE crR oN rc
MoD U LE s
829 Ba ck-Up L a mp s 1 .75 1' t4 38 Rear W indow W as her
E
8 30 Heated Rear Window Sw. ( Touch Contr ot) 07 209 N D w e l C ontr ol U ni t I
Switch lilum. 0l 172 s 40 Power Operated Side N 3 Power Antenna
831 C l ock l l l u m- L a mp 0 .1 Wrndow Sw. {O/ride) 111
Conrrol Unit
172 291
Engine Compartmenl S 45 Power Operated Side N 6 Coolant Level
lllum. Lamp 0.83 169 , Wrndow Sw. (4 way) 343 L Warning Module 11j
UJJ Power Antenna s5 3 Electric Mjrror N 10 Electronac Contact
Sw i tch l l l u m. o .1 Adjustment Sw. 0.7
172 Breaker t 6q
848 T r i p Co mp u te r Heated Rear Window N 12 Radio Recerver
C o n tro l s l l l u m. 0.10 72 Sw. (Touch Control) 20.0
N 19 Clock Diaita
s3 6 Rear Window Waper
TFAI LER W asherSw. ( Manuat) N 21 E.S.T. Cont.o Mooule
(Manua ) t6
L . H. Re a r T /S L P . ?1 33 S 14 Heater Fan Switch 264
B 105 R . H. Re a r T /S L P N '] E.S.T Conirol Modute
o.6 240 (Autcme: cr 76
8108 Stop 136p 0.5 313
SOUND PRODUC IN G D E V IC E S
N 22 Trrp Comcuter
B1 1 6 T a i l L a mp 2 .1 169 H 1 Hor ^ lr'last?r f/odule r)/
3.0
8117 Rear Lrc. Ptare lilum. o .4 2 tbY H2 Badio Speaker Frcni N 26 ! J :ag? Srabrlrzer i0
8129 B a ck-Up L a mp I O.gg 114 R.H. or Cenrre 304 N28 :FLConrrolModule
3 Radro Soeake. N 29 F u:l Pum p M odul e 36
P O W E RS U P P L Y Fronr L H 304
N 30 q'C ondr ti oner
H4 Badio Soeake.
I
P, I Battery Sv s temM odul e 256
Bea: R H 304
6 C yl . 1604 I
8 Cyl . H 5 Fad,o Speake.
253A 1 N'lodu le
I Flear L.H 304
P2 Generator -- - N 32 R ear W i ndow W i per /
4 5 a mp 1
H 6-T-- ]------ W as herM odui e 2O j
55 a mp 1
70 a mp 1
60 amo 7
-
WIRINGDIAGRAMS12F-3
SENSORS MOTOR S R E L A Y Ss, o L E N o tD s rrl

€N
Max. Max.
Code Name Loc. Code Name Loc Code Name Y"t Loc.
Amp Amp Amp l
Brake Fa I Warn- Sw. M2 Antenna f/oio. 2.Ot9.O 29 R1 Horn Relav 311

ss2 Park Erake Warn Sw. 94 M5 Taoe Plaver 30 R3 Anti-Dieseling
ss4 Cold Feed Swrrch 30 M6 Heater I or,,9. l,4tr. r 5.0 262 Solenoid 0 5 2A
a 4 D r s tr i butor Vac uum
ss5 T.C.S. Swrtch 30 M3 WindsheJWpe' i
Motor 1De co Adv anc eSol enoi d | 30
ss7 O I Pressure Swrlch 96 224 ---f---
M9 Washer Pump l"'oio r r ans m r s s r on
ss8 Neutral Siarl Sw. 1J (Windsh ield ) D e:ent Sol enoi d t.10 200
2.9 2?1
ss9 Back-Up Swrtch
M10 Electric Fuel Pump F 6 Flasher Relav 235
ss1 0 Slop Lamos Sw 313 Motor 37 F - A 'Conditioner 255/
ss1 1 Arr Cond- Aux. M11 Ai r C ondi ti oner 251 I
3c-g'essor Clutch
Fan Temp. Switch 283 F an M otor 16.6 276 R E A'Coro,:oner o.2/ 21Ol
Arr Cond. Evap i 255 M 12 lAirConditioner ?qq/ F:. Re:r 30.0 245
I nler Contr. Sw
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281 Aux. Fan Motor 6a Rl0lA.Ccr::orer o.2l 2581
ss16 Coolant Level ll 1: Power Operated I AJr -:- :? a/ 30.o 284
Warnrng Sensor 117 Srde Window Motor 342 R 11 Pow .3e- ::r o.2/
S S1 9 T ra nsmr ssion M 16 E,ec r .D oor Loc k W i ndor r ae ar 30.0
De tenl Switch 200 ' M oIor F r ont R - H 8.0 23 Starter [':. S: ?no d r3
ss20 Door Jamb Switch 134 M 17 Er ec r .Ooor Loc k R 14 Rear Comparr-en:
l \4or o. F r ont L.H 8.0 14.O 138
ss23 Engine Flevolut ons 64/ Lock Soleno c
Sensor 76 M18 Starier Nrotor R 16 Hazard Flasher ie,av 237
ss26 T ra p Comp- Vehicle R 17 Electric Doof 0.15/ 330/
SpeedSensor 8 C,,
tol Locks Relay 30.0 322
ss27 Trip Computer F uel
M20 R 21 Heated Rear O.2i
F low Sensor 151
Rear !!1ndow 3.5 '
Wioer fvlo:or 20.4 Window Relay 30.0 149
205
SS26 Etect.Speedometer
I Speed Sensor
M 21 Rear !!rndo4 Washer
tol
Pump Mo:o. 3.E 2C 3
SS29 Rear Companment e 2E Eng. l dl e Sp€d Boos l 256
M22 Elect Doo- Lcck
Lamp Swrtch rJb
Motc Rea'R H Sol enoi d ( 6 C y l .) 0.45 2t1
ss30 Insi: Compt- 8ox
M25 Elect. Doo- Lsck
R 30 C r ui s eC ontr ol 0.3i
I lur Sw tch 129 T r ans duc erSol enor d 2.2 121
Motor Rea. L r'l 8.0
)> JJ Throt: € Valve ;? F Ini edor Val v e 0.80 . 43
M26 Elect. Mirro. \'oicr
5wlrca tts.5 I I 82 R.H. Vertrca tc F 5: El ec t. M r r r or s 0 15
E.F.l. Ar F ow Seisor 55 Sel ec t.R el ay R .H . 30.0 1E6
M 28 Elect. Mrrroi Mc:3
ss36 Throttle Va ve R.H. Horizon:a 186 a 53 i El ec t. M i .r or s 0 15
Switch (E.F.l.) 12 Sel ec t.R el ay L.H . 3! J 181
M29 Elect. Mirror fr4c:c
ss37 Camshaft Posrtion L.H. Vertrcal 179 R 55 Ar r c ond. F an C2 241,
Sens or 22 R e ay N egati v e 3l.l 212
M30 Elect Mirror l\'lcic
S S 4 3 | Oi sir ibutor High I L.H. Horizonr. 142
I T e n sr onSw. ( 6 Cyl.) I o
\,f
C I R C U IT P R OTE C TIONDE V IC E S
I W i nds hi el dW r p€
M otor ( Luc as ) 224
I E I W i nds hi el dW i per
SS44 W p e: Motor I M otor ( Pr es l r te) 2 F us e 5
5.O
P a rk,ngSwitch 222 3 F us e *,
5546 Carb Vac Sensor 83 4 SE - R E S IS TOR S ,R H E OS TA TS 4 r F us e 37
V
5 F us e -
-5
25 241
-{ F c A p Ac tro R s E I Heated Rear
Wrndow
1451
150 6 F us e :5 313
c2 Radto lnle'ierence I e 2 l ns tr . l l l um . Bhec s :.i 45w 7 F us e :5 14 5
Supp.(Generaro,r 35\lFl 10
E 3 Arr Conditioner 8 FU Se 237
c a l P ri mar yvollage Fan Resistors 276
I Ca o acitor ?4 9 F us e , 15 136
E 4 CAarL'ghter
10 F us e '5 32
RECTIFIERS E5 Orl Pressure Senoer 108
+,'1- 11 F us e 201
E6 Coolant Temperature
D Fuse I5 125
5 Air Cond. Clutch Sender (8 & 6 Cv .) 103
Protect- Diode :6 2 E7 Fuei Level Sender
F us e ?.26
D 3 Elect Instruments Sedan 3
14 F use
Drsplay 5 .0 9e Wagon 105 "oo
E9 Ballast Resrstor 1.8 22 t5 r us e 262
M I SCEL L ANEOUSIT EM S E 1l 346
Transistor Load G P, O Side Windows za
X 1
Bes istor 101
Js:'buto'
.ST 63
P Antenna Molor F o 291
tr 13 Crurse Control
R Fusrble Lrnk (E.F.l.)
63 Transd. Resist. 40 121
X3 tr 6 C ool ant T em p. 47t TR A N S FOR ME R S

Sens or( EST & EF I) 18
o
6i G I lqn. Co,l (6 & 8 Cvl.) t.5 62
X4 Conneci a: _:'Tesl i 81 E 15 A uxrrrary 49

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SYMBOLSUSEDIN VK WIRINGCIRCUITDIAGRAMS
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a LIGHT BULB
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c FIXED CONTACT
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c 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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Holden Commodore Full Workshop Manual

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Holden Commodore Full Workshop Manual

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Eommodore.

GENERAL MOTORS_HOLDEN'SSALES PTY. LIMITED

COPYRIGHT _ GE N E R A L MOTOR S -H OLD E N 'S S A LE S P TY , LTD

6.2 SAFEW CO]IIPLIANCEPLATE ...... 0A-4 Electrlcal Transients 0A-7

2. MODELAVAILABILITY& BASE EQUIPMENT

ENG I NE DESI G NATI O N 3.3 L]TR EE S T 3.3 LITR E E FI 5.0 LITR E

P IST OND ISP L AC EME N T

C O MP R E SS IORNAT IO: 1 8.8 8.8 9.2

B O R Ex ST R O K E-mm 92.O75x 82.550 92.075x 82.550 101.60x 77.775

T AX AB L EH .P.R ACo r SA E 31.5 31.5 51.2

P O W E RK .W.D IN 117kw @ 4000

O V EB AL LL E N GT H 4713.5 4713.5 4713.5 I 4716.5 4716. 5

T R E AD- F R ON T 1 451.3 1451.3 t45 I .J t45 | .J 1451. 3

6.1 LOCATIONOF IDENTTFICATION

SAFEW COMPLIANCEPLATE- Refer Fig. 0A-2.

6.3 BODY& OPTIONIDENTIFICATION

TRIM: Figure 0A-3

The significance of these characters or blocks of

RADIO FREQUENCY INTERFERENCE

S O U R C E SOF INT ERF ERENCE

2 . E L E CT RIC F UEL PUM P

E N GIN ES IZE CAPACITY

En gin e- Ser v ic eRef ill 3.3 Litre 3.7 Litres

-1oo oo 1oo 2oo 3oo 4oo 5oo

1.2 BRAKE FLUID REPLACEMENT

The air cleaner elementshould be replacedat the time

1.4 FUELFILTER IN LIN E

pump and attached to the floor pan of the vehicle, in -*i-rl

front of the differential.

2.1 UNDERBODY AND

MODELS. CALAIS & BERLINA FITTED WITH

cll---->c, a WIPER IWASHER SWtTCH ASM.

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

,.- g:3I: r coN

CONSOL E CAP _ +---___>

W I T H G EAR SHIF T L EVER \

2.4 SHROUDLOWERTRIM - RIGHT&

2.5 ROCKERPANELCOVER- RIGHT&

ROCKERPANEL COVER INSTALLATION

/r" ,-o*.* t*) ON E P IE C E FLOOR C A R P E T S E C TION B _B

3.1 SERVICENOTE REINSTALL

2. Remove screw attached lower cover from upper

3. Remove screws securinginstrumentframe, centre air

3.4 INSTRUMENTPANEL LOWER.

3.5 INSTRUMENT PANEL LOWER. LEFT

4.1 QUARTERWINDOWINNERUPPER C U S H ION A S M.- R E A R FLOOR

MODELS. 19 BODY STYLES

Remove rear seat belt upper attachment (refer

5. From inside rear compartment,tap out fasteners

6. Ease rear door opening finishing lace from leading

NOTE: Damaged barbs on trim panel fasteners requtre

5.1 DESCRIPTION The repair kit developedto servicethis Short Methodor

5.3 REAR QUARTERWTNDOW

4. Femove remainingscrews securinggarnish moulding

5. Locate blade of Tool No. J24402, glass sealant J24402

OUARTER WINDOW APERTURE CHECK

2. Thoroughly clean surface of glass to which new

8. Install screws securinggarnish mouldingto the top

10. Installscrew attachedquarter reveal mouldinglower

3. Thoroughly clean inner surface of glass to which

URET HANE ADHE S IV E

NOTE: In cold weather, the placement of cartridges GLA S S P A IN T-OU T

IJ Install screw attached quarter reveal mouldinglower

8. Leavetailgatein horizontalpositionfor a minimumof

/r" ,-o. t*) ON E P IE C E FLOOR C A R P E T S E C TION B _B