Go Torque. Trade News Direct. Winter 2012 RRP $8.90 Charging Future.into the

Inside this issue:

> Introducing the All New Holden Volt > Fabietti's new look Top Doorslammer > Torana Tough > LPG Commodore > Remanufactured Steering Racks SectionIntroduction Title

Go Torque isis published published by by HoldenHolden Service Service Parts Parts Operations Operations for for the automotive trade.the Newsworthy automotive articlestrade. or comments are Newsworthywelcomed and articles may or be comments are welcomed submittedand may be to: Contents. submitted to The Editor, Go Torque, The Editor, Go Torque, 5/35 Dunlop Road, Mulgrave VIC 5/35 Dunlop3170, Road, or > 4-7 All New Holden Volt [email protected] VIC 3170, Holdenor [email protected] is not responsible for GM Holdenthe Ltd accuracy is not responsibleof any information for the > 8-9 Motorsport Update accuracycontained of any ininformation materials submitted contained in materialsby third submitted parties and by published third parties in thisand magazine, published and in acceptsthis magazine, no liability and > 11 Holden Genuine Panel Test accepts no liability inin relationrelation to to such such materials oror their their content. content. > 12-13 Holden Manufacturing Secured Welcome...Welcome. > 14-15 Holden Trade Club - Everyday Prices 16-17 Remanufactured Steering Racks Welcome to the Winter 2012 edition of Go Torque – Trade News Direct. > Insert David’s message here. In this issue we take a first look at the future of motoring with the > 18-19 Torana Tough Holden Volt. The Volt is a game changing vehicle with the benefit of all electric drive, coupled with the ability of an extended range with built-in > 21-23 Holden Trade Club Doorslammer onboard charging. > 24 Holden Restoration Parts Feature We speak to Holden expert and author Norm Darwin about his latest book ‘Torana Tough’. This is a great read and covers many aspects of the > 26 Holden Rental design process and the history of this now legendary model previously known only by a select few. We have a signed copy to give away, see > 27 Holden News page 19 for more details. > 28-29 All New LPG Commodore Most of you I am sure will have heard, seen or read about the commitment to co-invest in Holden’s future made by State and Federal > 30-31 New ACDelco Catalogues Governments. We cover the details on page 12 and 13. > 33 Model in Focus - Mazda3 We look back at the 2012 V8 Supercar season so far. Our friends in Blue have made an early charge but, with Holden engraved on 11 of the > 34 Holden Tech - VE/WM Charging Systems past 16 championship trophies we are confident we’ll have another for the ‘pool room’ come December. > 35 Accessories - New Colorado

The difference between Genuine Parts and Aftermarket equivalents is not always easy to see. On page 10 we look at what goes into a Genuine VE Commodore fender compared to an aftermarket equivalent. We debut the new look Holden Trade Club Monaro after it got out of the Stay Connected. wrong side of the bed at a recent race meet in Tasmania and rolled over If you like keeping up to date with all the latest news from Holden, be Whether you’re fitting to a car, truck, boat or anything in between, ACDelco has a range after been caught by a wayward parachute. of high quality Sealed Maintenance Free Batteries to suit your needs. sure to 'Like' or follow us on our social media pages. On page 16 we take you through the process of how we remanufacture a Steering rack and also cover off the three new ACDelco catalogues They require no ongoing maintenance and utilise lead calcium expanded which have been recently released. grids, which are less susceptible to corrosion and water loss, meaning they hold charge longer than conventional Lead Acid batteries. Plus, you’ll find information on some of the great offers currently available to you as a Holden Trade Club member and much more. holdenhq.com.au With features such as heavy-duty factory sealed polypropylene rib cases, low resistance Thanks Holden's All new Blog envelope separators and backed by a long warranty^ they have earned ACDelco a solid Go Better, facebook.com/HoldenAustralia reputation for reliability and longevity. Holden's Facebook twitter.com/HoldenNews For more information regarding the ACDelco range or to locate your nearest stockist visit Holden's twitter acdelco.com.au or call 1800 ACDelco (1800 223 352) today. David Metzke youtube.com/HoldenAustralia Aftersales Marketing Manager ^ Warranty conditions vary depending on the product and application. For full details refer to www.acdelco.com.au/warranty. Holden's YouTube Channel P.S. Got a subject you would like us to cover in 2012 or any feedback on the magazine? Drop us a line via email [email protected] facebook.com/HoldenMotorsport Holden Motorsport's Facebook facebook.com/Fabietti.Racing acdelco.com.au 1800 ACDelco Holden Trade Club Top Doorslammer Team's Facebook

Go Torque. Trade News Direct. - Winter 2012 03 Holden Volt Introducing Holden's Game Changer.

The cutting-edge Holden Volt electric vehicle with extended range mode Charging Volt’s battery is simple and intuitive, and can be done through conventional will establish an entirely new segment in the Australian market when it household electrical outlets. The Holden Volt is completely rechargeable in six to launches late in 2012. The five-door, four-passenger Volt is designed to ten hours using the standard 1.2kW portable charge chord. Using a dedicated 3kW provide the benefits of an electric vehicle without the range limitations charging station, the time is reduced to between four and six hours. Once the vehicle usually associated with electric vehicles. is plugged in, owners can schedule either immediate or delayed charges, even coordinating charging according to departure time or when electricity rates are lower. Volt is in a class by itself The Holden Volt is not a hybrid. It is a one-of-a-kind, all-electrically driven vehicle Volt is designed and refined to impress designed and engineered to operate in all climates, with a total range of more than Volt’s bold, sleek, performance-oriented stance conveys its electrically driven 500 kilometres (depending on conditions). Powered by GM’s revolutionary Voltec capabilities, and looks like an upscale, midsize sport sedan. This is made possible propulsion system, it consists of a 16-kWh lithium-ion battery pack and electric drive by its wide front and rear tracks (1556 / 1578 mm), 2685 mm wheelbase, unit that provide a pure electric range of between 60 to 80 kilometres, depending wheels-out stance, sculpted belt line and premium execution. Working closely with on conditions. A 1.4 litre petrol-powered engine extends the range by operating the aerodynamicists in GM’s own wind tunnel to shape the Volt, design and engineering vehicle’s electric drive system until the car can be recharged or refuelled. teams developed one of the most aerodynamic vehicles in GM’s history. By reducing the energy needed to overcome air resistance, Volt aerodynamicists contributed an This distinguishes Volt from other electric-only vehicles, which cannot be estimated 12.5-km of electric range, and approximately 80-km of extended range. operated when recharging is not immediately available — such as during a power interruption or on a long-distance trip. Every major element of Volt was designed Volt features excellent driving dynamics and analysed for efficiency, including its highly aerodynamic exterior, lightweight Holden Engineers in early testing Great driving dynamics begin with a solid body-frame-integral structure that wheels, specially designed tyres and more. This attention to detail makes Volt one of a left hand drive Chevrolet Volt. enables optimal tuning and provides drivers with an enhanced sense of stability of the most aerodynamic and energy-efficient vehicles in the market. and confident road manners. Volt’s MacPherson strut-type suspension, sophisticated compound crank rear axle and quick-reacting, rack-mounted electric Volt redefines electric drive power steering system with ZF steering gear — a feature commonly found on The heart of the Holden Volt is its Voltec propulsion system, which combines pure premium sport sedans — have been tuned to deliver a smooth, refined ride with electric drive and an efficient, range-extending engine, giving Volt a total range of responsive handling and solid, on-centre feel. more than 500 kilometres, depending on conditions. A low centre of gravity combines with the wider track and long wheelbase for Volt’s long-life battery consists of a 198.1 kilogram T-shaped, 16-kWh lithium-ion balanced performance, and front and rear hydraulic ride bushings, another premium battery pack manufactured in Brownstown Township, Michigan. It supplies energy addition, help eliminate road harshness. The electro-hydraulic regenerative brake to an advanced, 111-kW electric drive unit to propel the vehicle. Using only the system captures energy up to 0.2g for transfer back to the battery. The friction energy stored in the battery, Volt delivers between 60 and 80 kilometres of fuel braking system features large rotors with a special finishing process that protects and tailpipe emissions-free electric driving, depending on conditions. against corrosion and promotes longer life. The Volt battery is designed to deliver value, safety, quality, performance, durability Volt continues Holden’s ongoing commitment to safety and reliability. Since 2007, GM engineers have completed more than 1.5 million Occupant protection continues with a strong structure, and the Holden Volt’s kilometres and four million hours of validation testing of Volt battery packs, as well body-frame-integral structure strategically blends advanced steels to help as each pack’s nine modules and 288 prismatic cells. The development, validation optimise crashworthiness and stiffness. Nearly 80 percent of Volt’s overall and test teams have met thousands of specifications and validated each of the structure consists either of high-strength, advanced high-strength or ultra high- Volt battery’s 161 components, 95 percent of which GM designed and engineered. strength steel. Active occupant protection features include eight standard air When the battery energy is depleted, Volt seamlessly transitions to extended- bags and safety belts with dual pretensioners. range mode. Power is inverted from a technically advanced, 1.4 litre 63-kW Due to Volt’s quietness when in all-electric mode, it takes pedestrian safety into petrol-powered onboard engine to the electric drive unit to provide additional account, with a driver-activated feature that makes a chirping sound to warn range. Volt proves electric driving can be spirited. The electric drive unit’s excellent nearby pedestrians. low speed torque of 368 Nm ensures Volt never lacks for performance.

Go Torque. Trade News Direct. - Winter 2012 Go Torque. Trade News Direct. - Winter 2012 04 05 Volt Tech Looking inside the Volt.

Lithium-ion Battery Electric Drive Developed by GM in conjunction with LG Chem, the Volt battery pack A 111kW electric drive unit powers the Volt’s wheels at all times. is one of the first lithium-ion battery packs offered on high-volume Positioned under the bonnet next to the petrol engine, it packages a production vehicles. The battery pack is positioned in the centre tunnel pair of electric motors and a multi-mode transaxle with continuously of the Volt and is protected by ultra high-strength steel. It comprises variable capability. One, or both, of the motors drives the Volt based on nine linked battery modules that contain 288 prismatic lithium-ion performance and speed. The main traction motor is the primary source cells, with integrated thermal management and on-board diagnostics. of propulsion, but the secondary motor will activate as necessary for The total weight of the battery pack is 198kg and produces 16 kW efficiency and either assist the traction motor or act as a generator to hours. This is enough to provide up to 80km of pure electric driving keep the battery pack at its minimum charge buffer. before the petrol generator kicks in to recharge the battery.

Petrol Engine On the Charge What sets Volt apart from other electric vehicles is the ability to drive after Volt can be recharged seamlessly and easily at any standard household the battery’s energy is depleted. With a range of more than 500km, the Volt power point — if you can charge a mobile phone you can charge the Holden is the end of range anxiety and the no-compromise electric car. When the Volt. The Volt comes standard with a 1.2kW portable charge cord (stowed battery reaches minimum charge, this 1.4-litre, 63kW petrol engine kicks in in the boot) which plugs directly into any standard power point and take to act as a generator and provide charge to the battery, which in turn drives approximately six hours for a full charge. An optional 3kW charging station the wheels. To continue driving if a power socket isn’t available the customer can be installed in a customers home, which will reduce the charge time. only needs to refill the Volt with petrol. The 4-cylinder, aluminium cylinder- head engine is designed for easy maintenance and if a customer drives purely on electric power for extended time periods, the Volt automatically starts the engine and cycles the fuel to ensure it doesn’t go stale.

Go Torque. Trade News Direct. - Winter 2012 Go Torque. Trade News Direct. - Winter 2012 06 07 Motorsport News V8 Supercars Update.

Queensland-based Tekno is fielding two Commodores, one for Webb, the other for Michael Patrizi, Webb’s fourth best qualifying in Adelaide and topping the practice sheets in Tasmania in his plain white Commodore raising eyebrows. The single car Lucas Dumbrell Motorsport is also punching above its weight having landed new major sponsor iSelect and signing rookie driver Taz Douglas, who achieved the best result for both himself and LDM to date with 12th at Symmons Plains. While defending our V8 title in 2012 is important, Holden is also looking to the introduction of V8’s Car of the Future next season, which will also see the arrival of at least one new manufacturer into the sport. Although the COTF V8s will look identical to the current cars on the outside, the difference lies under the skin with a new common chassis, a transaxle and independent rear and bigger 18 inch wheels and tyres. Holden is more than prepared for the challenge the new car and manufacturers bring, recently announcing extended agreements with the factory Holden Racing Team and TeamVodafone. “Holden has been tested many times as series regulations have evolved throughout the years, and we have met each one with success,” Holden Sponsorship Manager, Simon McNamara said at the announcement held at Holden Vehicle Operations at Elizabeth. “V8 Supercars’ Car of the Future in 2013 is no different and our announcement makes a clear statement that Holden is ready to meet the COTF challenge head on. “With the Holden Racing Team and TeamVodafone, we have the two very best teams, four championship-winning drivers, and the finest race engineering The 2012 V8 Supercar Championship is underway with Holden’s Jamie capabilities – Holden is better prepared than ever before.” Whincup beginning his title defence in the best possible way – winning the opening race of the season at Adelaide’s Clipsal 500. Combined, the HRT/Walkinshaw and TeamVodafone operations have won 11 of the past 16 Australian Touring Car/V8 Supercar Championships, and the last 11 After a Holden whitewash in 2011, Commodores winning 24 of 28 championship straight Bathurst 1000s. races, there are signs that we will not have it all our own way again, with Ford’s factory team also rising to the occasion. With number one proudly displayed on the side of his TeamVodafone Commodore, Whincup continues as Holden’s leading man, March’s Clipsal victory an emotional triumph following the sad passing of his father, David, earlier that week. WTCC Cruze 1.6 Turbo Engine Designer Awarded.

The three-time series champion repeated the performance with yet more success Arnaud Martin, the French engineer who designed and developed the in the Tasmania Challenge in April, his eighth win at Launceston’s Symmons Plains 1.6 turbo engine for the 2011 WTCC World Champion Chevrolet Cruze, Raceway breaking the record for most wins at the circuit that he held with Garth has won the much-coveted Race Engine Designer of the Year award. Tander and the late, great Peter Brock. Arnaud received this well-deserved recognition, awarded by the reputed Holden Racing Team’s Garth Tander too got his 2012 campaign off to a strong publication Race Tech, from the magazine’s Publishing Director Soheila start, scoring two podium finishes from two race starts in Adelaide and the Kimberley during the Race Tech World Motorsport Symposium. ever professional Tander remains in touch with the series leaders after the first Arnaud, Chief Engine Engineer at RML, the team that runs the Chevrolet Cruzes two rounds. in the World Touring Car Championship, produced an entirely new 1.6 litre His team-mate, James Courtney endured a difficult start to the season with engine from scratch. The results obtained by the Cruze with Arnaud’s engine are reliability issues in Adelaide, but as this issue of Go Torque was going to press impressive – a staggering 21 wins in 24 races, every single pole position and HRT was putting the finishing touches on a brand new car for the 2010 champion. the car led for more than twice as many laps as all the other teams combined. This success is magnified when considering that Arnaud and his small team of The biggest change at HRT has been the arrival of new managing director Steve engineers produced it in just eight months on a limited budget. Hallam, who comes to the Holden factory team with an incredible resume. It was this inspiring achievement that edged Arnaud ahead of an ultra competitive Hallam spent 27 years in Formula 1, including 18 years at McLaren where he and highly qualified list of nominees, including Rob White (Renault F1), Ulrich moved from track engineer to the Head of Race Operations. Baretzky (Audi Motorsport) and Francois Coudrain (Peugeot Sport). Over the course of his career, Hallam has worked with some of motor racing’s biggest names including Ayrton Senna, Nigel Mansell and Mika Hakkinen. He has four Formula 1 World Drivers Championships (1991, 98, 99, 2008) and two Constructors World Championships (1991, 98) to his credit after overseeing McLaren’s dominance of Grand Prix racing. There have been a number of major highlights amongst the Holden newcomers in early 2012, Jonathon Webb’s Tekno Autosports operation one standout.

Engine Designer Arnaud Martin and Race Tech Publishing Director Soheila Kimberley

Go Torque. Trade News Direct. - Winter 2012 Go Torque. Trade News Direct. - Winter 2012 08 09 Collision The Genuine Difference.

Lord of LESS TALK the rings MORE TORQUE We've ditched the lead in champher Ever wanted more torque at your for a "step down" ring construction, Ring End? Contact is concentrated so you can locate your nuts in on the flats of the fastener, not the even tighter spots. corners, giving you more torque where you need it. Shanks Knuckle a lot! In this issue, we look at what goes into making a Holden Genuine buster? VE Commodore fender and the key points of difference compared with an aftermarket alternative. Spot The Difference? Like many things there is more to a simple pressed metal panel then There will be far less blood spilled meets the eye. The panel is made from a base of flat galvanised mild steel in Holden’s new vehicle plant in South Australia and formed utilising five on the workshop floor with 440's separate pressings. B B patented Antislip design, featuring a locking groove at the open end of the spanner. A Ever been told to “Get a Grip”? A Now you can. The new I-Beam Shank is easier to hold on to as the tensioning load is spread over a larger surface area. The Sidchrome 440 Pro Series Combination Spanners are available in 4 different sets and “Using the five separate presses ensures the fender retains the correct Holden Genuine. Aftermarket. shape and makes certain the panel is smooth, with no ripples or other also as individuals. unsightly marks.” said Andrew Juriansz, Holden Specialist Engineer. Andrew A Scan here to is the lead engineer responsible for fenders and bonnets at Holden. Note the quality of the pressing between the Holden Genuine and There are 22 metric the Aftermarket Panels. Genuine Panels are formed using 5 separate see the 440 “Using this process we can control the amount of spring back which is presses, allowing for a smooth panel without ripples or imperfections. in action! sizes ranging from practically impossible in a cheaper one or two stage process, particularly on a complex shape as found on the VE.” B The Holden Genuine Panel is made from Galvanised Mild steel, where 6mm to 32mm and as the aftermarket panel uses an untreated mild steel. “Our designers spend a lot of time ensuring each Holden looks right, 19 A/F sizes ranging paying particular attention to the highlights – the way light falls on and is from ¼” to 1-¼”. reflected from a surface. The human eye is very good at picking up even At Holden we have a rigorous program to ensure our panels are built minor variations in the way light reflects off the car.” to specification and will fit right. The picture above (top) shows a WM www.sidchrome.com.au It is Andrew’s job to turn the ‘art’ of the designer into reality. fender on what is called a checking fixture. This accurately simulates the mountings on the vehicle body and we can quickly determine if a “As highlighted in the panel comparison above, you can see the ripples in panel is within our tight tolerances. SID/018 the pressing and although these are hidden when the door is shut, it can lead to imperfections on the outer skin.”

Go Torque. Trade News Direct. - Winter 2012Join us at facebook.com/Sidchrome Go Torque. Trade News Direct. - Winter 2012 10 11 Manufacturing Next Generation Holden Manufacturing Secured.

Holden will build two all-new cars in Australia in the second half of “Holden’s business model has been a great success in this competitive this decade with the support of a $275 million co-investment package and challenging environment. Last year we sold more locally-made cars in from the Australian, South Australian and Victorian Governments. Australia than any other manufacturer and nearly 60 per cent of all Holdens sold in this country were built in Elizabeth,” he said. Making the announcement in Canberra, Prime Minister the Hon Julia Gillard MP was joined by Minister for Industry and Innovation, the Hon Greg Combet “We are making the cars Australians want. Commodore and Cruze are top five AM MP, Premier of South Australia, the Hon Jay Weatherill MP, AMWU selling cars in Australia – so it’s clear we’re making small and large cars that Vehicle Division Federal Secretary, Ian Jones, and Holden Chairman and meet the needs of both ends of the market." Managing Director, Mike Devereux. “Government investment has been instrumental in reshaping Holden’s Mr Devereux said the funding announcement would drive investment of more manufacturing operations and has enabled us to build the Cruze small car in than $1 billion from Holden and help secure the future of the local car industry. Australia, rather than import it."

“Co-investment of this kind is critical for our industry and helps Australia “We are acutely aware that with government investment comes great compete against other car making countries that protect their industries responsibility. We are focused on continuously improving our efficiency and through tariffs and/or financial support,” he said. quality to help us be amongst the best in the GM world."

“Holden will receive government co-investment of $275 million and directly “It’s also important that people understand the economic benefits that flow invest well in excess of a billion dollars in the 10-year vehicle development from this public investment. " and manufacturing program." “Holden is delivering a very attractive return on investment. We estimate the “The investment will help Australia retain its capability to design, engineer and current locally-built Cruze will generate more than a billion dollars* of economic build cars with two all-new vehicles going into production at Elizabeth, South activity from Holden in Australia over the life of the program,” Mr Devereux said. Australia, in the second half of this decade." Holden is part of a sophisticated, highly innovative and fast-paced industry “The two new Australian-made cars will be world-class. They will be that supports a complex network of jobs in and outside of the industry. underpinned by global architectures from within General Motors and bring new fuel-saving, connectivity and safety technologies to Holden’s portfolio." “The announcement is a huge vote of confidence in Holden and the Australian car industry and it highlights how important it is to maintain “The program also delivers a significant return on investment. manufacturing in this country,” Mr Devereux said. We estimate Holden will inject around $4 billion* into the Australian economy over the life of the program.” “On behalf of everyone at Holden and our network of component and service suppliers, I’d like to thank the government and the Australian people Holden is one of the most flexible automotive manufacturers in the world, for their support.” producing 45 vehicle variants in the one plant, including small and large cars from Cruze to Caprice, for Australian and international markets. * Economic activity estimates are based on Holden’s incremental spend in Australia as a result of manufacturing these vehicles locally (versus importing), it includes total Mr Devereux said the local market was one the most fragmented and manufacturing expense of Holden (wages, utilities, contractors, maintenance etc), competitive in the world with 230 models on sale in Australia today compared local supplier material content and Holden incremental non-manufacturing costs. It to 144 in 1998 when large cars enjoyed their strongest sales. excludes a multiplier effect through the broader economy.

Go Torque. Trade News Direct. - Winter 2012 Go Torque. Trade News Direct. - Winter 2012 12 13 Trade Club Everyday prices. Exceptional quality.

Everyday prices held for 12 months. You can check parts, prices and application information Starter motor Your profit for this, and all other Holden models in the Trade Club You know where you stand with Holden Trade Club. Part number 92066306 Book. Log in to holdentradeclub.com.au or, if you prefer, Each year in July we publish our recommended prices in the List $325.00 $128.50 just give your local Holden Trade Club Dealer a call. Holden Trade Club Book. We aim to hold these prices for Trade Club $196.50 a full 12 months. So you can rely on us for long-term price All prices are recommended and exclude GST. More electrical items Part no. List Trade Club Holden Dealers are free to set their own prices. stability – not just ‘here today, gone tomorrow’ promotions. Alternator, Bosch 100A 92094625 $325.00 $196.50 And because we publish List and Trade Club prices you can Ignition coil 10472401 $80.00 $58.00 see at a glance the profit you can make on each part.

And of course, all our parts are genuine Holden or ACDelco with a full Australia-wide warranty. Your local Holden Dealer is the expert in all things Holden, just give them a call next time you’ve got a Holden on the hoist.

Here are some examples of our everyday prices on parts you’re likely to need for a VX Commodore V6 (’01-’02).

Crankshaft sensor Your profit Part number 10456161 List $87.00 $40.00 Trade Club $47.00 Don't forget ACDelco Essentials!

More sensors Part no. List Trade Club Here is a small selection of what’s on offer from your Air temperature sensor, inlet air 12160245 $40.00 $22.05 local Holden Trade Club Dealer: Oil pressure sensor 19244517 $20.00 $12.30 Part No. List Trade Club dexos2TM 5W30 engine oil 5 litre 19104984 $52.50 $36.80 dexos2TM 5W30 engine oil 20 litre 19104985 $200.00 $140.00 Dexron III ATF 20 litre 12378330 $131.00 $91.50 Dex-Cool red coolant 5 litre 92145527 $45.00 $31.50 Wheel bearing Your profit Brake pads, front Your profit Service kit Your profit Dex-Cool red coolant 20 litre 95710438 $175.00 $122.50 front, with hub, with ABS, RH/LH Air filter, oil filter, fuel filter Part number ACD1331 Combustion chamber cleaner 454ml 88900161 $7.25 $5.08 and spark plugs (6-pack) Part number 92115771/2 $81.00 List $55.00 $16.50 $26.46 Brake parts cleaner 565ml 88900163 $7.25 $5.08 List $205.00 Trade Club $38.50 List $57.60 Sealing compound 250ml 3835215 $55.00 $37.10 Trade Club $124.00 Trade Club $31.14 Spray grease 300g M39760 $10.00 $5.50 Other brake parts Part no. List Trade Club Optikleen screenwash 5 litre 92140006 $35.00 $19.25 More wheel bearings Part no. List Trade Club Brake rotor, front (single)* ACDR040 $58.00 $39.50 More service items Part no. List Trade Club Front hub and bearing, Brake pads, rear ACD1332 $55.00 $38.50 Spark plug lead set 92142484 $95.00 $55.00 $100.00 without ABS 92115770 $165.00 Brake rotor, rear (single)* ACDR041 $55.00 $38.00 Fuel pump, Series I 92158011 $179.00 $116.85 Rear wheel bearing 92077119 $62.50 $38.75 *Holden recommends brake rotors are replaced in pairs. Thermostat 10207377 $14.80 $8.35

If you’re fitting parts to a Holden, you’re better off fittingHolden parts.

Go Torque. Trade News Direct. - Winter 2012 Go Torque. Trade News Direct. - Winter 2012 14 15 Remanufactured Steering You can't beat the feel of a good Rack. ACDelco Remanufactured Steering Racks.

Recently the Go Torque team took a tour of the ACDelco Steering What are the benefits of a Rack remanufacturing centre in Melbourne to learn more about the processes involved in building ACDelco's Remanufactured Remanufactured Steering Rack? Steering Racks.  Gears are completely dismantled. When it comes time to replace a worn or damaged steering rack, you  All tie rods, boots and seals are discarded. normally have a few options. One option is to source a secondhand unit. The All teflon seals are removed and discarded. used unit will probably be a cheaper option initially, but it is worth considering  the longer term complications with a secondhand rack. Second-hand units  The pinion and valve assembly is dismantled and rebalanced. come with limited warranties and the possibility of lost time and reputation The housing, rack and piston are checked for cracks and with your customer when a subsequence failure occurs. discarded if cracks are detected. The better long-term option is an ACDelco Remanufactured Steering  All bent and damaged components are discarded. Rack. ACDelco's racks have been remanufactured to ACDelco's  All teflon seals, tie rods and boots are replaced with new stringent procedures to ensure the supply of the highest quality product. high-quality components. At our facility, all steering racks are first completely stripped down, with all If the pinion shows excessive wear, pitting or is cracked it is All racks are completely stripped down and thoroughly cleaned with all Each rack housing is then put through a pressurised hotwash process damaged and high risk parts thrown away regardless of their condition. replaced. damaged and high risk parts thrown away regardless of their condition. and sandblasted to completely free it from old contaminants such as oil, The rack housings are then put through a pressurised hotwash process, The housing is then closely inspected for faults or blemishes. grease and grime. thoroughly cleaned and inspected to ensure no contaminants or faults remain with the rack. Possible Symptoms of a Worn Steering Rack. All designated high risk parts are replaced with new parts whether worn Feeling through the Steering Wheel. Your steering wheel may have a loose feel to it. The car may also wander on the or not. All electronic controlled steering racks come fitted with new road while driving. Steering may also seem harder than it should, with the car not solenoids/switches and only high-quality components are used in the responding well to the movements of the steering wheel. It may also be harder to remanufacturing process. turn the car in one direction than the other. You may also find that the steering wheel does not return properly to its normal neutral position after you have made a turn. Each steering gear must pass a minimum of five separate tests to attain the ACDelco Remanufacturing Standard. Noises when driving. Sounds such as thudding, clunking, or a persistent knocking can be warnings So the next time you need to replace a steering rack, make the wise of a loose steering system. If you hear these types of sounds, you need to get choice and choose to fit an ACDelco Remanufactured Steering Rack. the system checked out. Front Tyre Wear Unusual tyre wear is another symptom of a steering rack problem, though there are other conditions that can cause uneven tyre wear. If your tyres show uneven wear, you may have a steering rack problem. Leaks If you find that your car seems to be leaking fluid from the front end, it could be a leak from the rack and pinion steering system. If the fluid drips from the boots, you will know that your steering All parts are now replaced and tested with new high-quality parts and the Once the internals of the rack have been installed and tested, the external system is compromised. mechanical operation of the rack is tested by the technician. components such as the power steering fluid lines, tie-rods and rack boots are installed. The steering rack then receives a coat of durable paint.

To view ACDelco's full teering S red) range of Remanufactured (Remanufactu e 1.2 Catalogue: Issu Steering Components, view the latest catalogue Every Rack, thoroughly Tested. online at acdelco.com.au Every steering gear must pass a minimum of five separate tests or speak with your local to attain the ACDelco Remanufacturing Standard. Each gear ACDelco distributor. is tested for leaking, attainment of correct pressure between chambers, returnability and elimination of light/heavy sensation.

s akes Most Model 1800 ACDelco uits Most M au S acdelco.com.

Go Torque. Trade News Direct. - Winter 2012 Go Torque. Trade News Direct. - Winter 2012 16 17 ToranaSection Tough Title Introducing the Torana Bible.

Dealer Principal of Mollison Motors in Kyneton had saved all the old Dealer Trim and Paint books and following the closure of the dealership sold the lot to a Holden enthusiast rather than throw it all out. This collection formed the bases of Norm’s trim and paint research and through other collectors was able to find examples of all Torana Trims. "The UC Torana proved difficult as no one was really interested in this model," Norm said. "Once the V8 was dropped the UC was forgotten so no one really collected anything about it. A chance conversation at the 2011 Toranafest in Newcastle with an LX owner led me to the UC Dealer Trim book lying discarded in his workshop." Norm also turned up old photographs from many sources. For example he found an unpublished photo of the LJ Torana V8 prototype, a car known as the 'Lockwood Special' on account of the two padlocks on the bonnet, taken inside the Holden Dealer Workshop at Bathurst in 1973. The photo was actually of the HDT racecar but tucked in the corner was the Orange V8 Prototype. The LJ V8 Torana program had been killed off the previous year following the well-publicised 'Super Car' scare. Holden 'Show Cars' were also an area ignored by researchers in the past, "I located a number of Monaro Show Cars for the Monaro book," said Norm. "But very few Torana Show Cars were built by Holden Design. Usually they were 350 GTS Monaro Coupes or Statesmans and after running the motor show circuit they ended up as the Sales Director, John Bagshaw’s transport. I did locate good colour images of the ‘Snow White’ Torana, a small 4-cylinder painted White with a ‘Glo-mesh’ roof covering. Previously Torana Tough is the latest book to be released by Norm Darwin. "Who can forget the dominance of the Torana in motor racing, it’s success it has been tagged the Carla Zampatti Torana but Carla had nothing to do The book covers all Torana models from 1967 to 1980. against the V8 GT Falcon and springboard for one of Australia’s favourite with it other than being photographed sitting in it at a motor show." Torana Tough follows the release of Monaro Magic, a history of sons, Peter Brock." Other Torana Show cars in the book are 'The Mod Torana' and a car called the Monaro spanning 1968 to 2006. Both books are full colour 'Fruit Loops', an LX Hatchback with multi-coloured stripes and trim. of around 300 pages and contain hundreds of photographs One of the aims Norm set out to achieve was to photograph original previously unseen. examples of the Torana, cars that were as close to Factory build as Overall the book helps showcase a real history of the Torana, with new possible. Surprisingly all-but-two Toranas featured in the book were stories involving with the design of the Torana that many have never Norm, the former Holden Engineering and Finance employee, first original. One, a 1970 LC GTR XU-1, had just 12,393ks on the clock, it also heard before. Norm has done a fantastic job in compiling this into what became interested in Holden’s history when he was put in charge of had the original factory Dunlop Sovereign tyres fitted. Norm found this car only can be described as a ‘Bible for Torana lovers’. the Technical Library. Norm had also been writing freelance in his spare in Brisbane and only because he sold a Monaro Book to the owner. time for a number of Hot Rod magazines back in the ‘70’s supplying If you want to get your hands on a copy of this great book, you both feature articles and technical items on modified cars while working A second low kilometre car was located in Katoomba. It turned out to be can buy it direct from Norm’s website www.handpub.com.au or it full-time in the Engineering Drawing office at Holden. By 1974 Norm originally owned by Jack Joyce, the former Proving Ground Manager. Jack can be found in select bookshops. headed up the Engineering Budget and Cost Section. Later that year was one of the original Holden 48-215 test drivers; he purchased the Bronze when Noelle Byrne, Holden’s Public Affairs archivist retired, Norm was LC GTR new, keeping it till he passed away. The car has just 34,153km's on asked to take care of the companies archives. The historic material that the clock and it too retains the original Dunlop Sovereign Tyres. had lain hidden for many years helped formed the basis of Norm’s first Perhaps one of the biggest difficulties was locating examples of the trim book, The History of Holden Since 1917. materials used on Torana between 1967 and 1980. Fortunately John Lee, Torana Tough, in addition to covering each Torana model's paint and trim tells the story of their development and design. Stylists like Leo Pruneau, Phil Zmood, Peter Nankervis and Ken Foletta provided stories on the Win a signed Limited Edition sometimes-painful birth of a new model. Norm Darwin (Left) with "The decision to write Torana Tough was easy," said Norm. Having completed former Holden Designer Leo Pruneau (Right) at the recent hard cover copy of Norm Monaro Magic in late 2009 Norm found many of his Holden contacts, both book launch of Torana Tough. former employees and current personnel, were asking about Toranas. Darwin's 'Torana Tough' "A good deal of info crosses over, drivelines are basically the same as is paint and trim. The more I discovered about the Monaro meant the more I Almost everyone has a great story about the Torana from learned about the Torana," explained Norm. years gone by. The Torana story was also given a lift by two chance events. The first was listening to Leo Pruneau, former Director of Design, talking to Holden We want to see your favourite Torana photos and hear Retirees about his roll in the Vauxhall HB Viva design, a car that formed the the story behind them! basis for the HB Torana. The second was having former Interior Designer, Ken Foletta call in at home to purchase a Monaro book. Ken was excited about the Torana book as he had been in the thick of the LC-LX design and Norm will choose his favourite who will receive a signed had kept his design sketches plus being a keen photographer had many copy of his brilliant new book. original Torana images. From Leo and Ken’s recollections came a list of the other designers, this led Norm to more hidden Torana material. Send in your entry to: [email protected] "I found that Engineers and Designers love to talk about their work and Entries Close 31/05/2012 the Torana from the 1970s was a very exciting period," said Norm.

Go Torque. Trade News Direct. - Winter 2012 Go Torque. Trade News Direct. - Winter 2012 18 19 LS Trade Club Doorslammer Want More Rolling Repair Work. HORSEPOWER? think...

317kW 430 Horsepower Horsepower: 430hp @ 5900rpm Torque: 424 ft/lbs @ 4600rpm

OR 353kW 480 Horsepower with Hot Cam Kit

Horsepower: 480hp @ 5900rpm Images courtesy of Aussie Slamfest Torque: 475 ft/lbs @ 4600rpm OR Maurice Fabietti sure knows how to get his share of media attention, if 386kW he is not powering his Monaro down the track to victory, he is doing the 525 Horsepower spectacular to ensure he still gets his 'air time'. Recently, down at the Tasmanian leg of the Aussie Slamfest Series, Fabietti had an incident with ASA Cam Kit that can only be described as sheer bad luck. Horsepower: 525hp @ 5900rpm In round one, lining up against Tony Defelice in his Camaro, at about half track Torque: 489 ft/lbs @ 4600rpm Fabietti's car got loose and crossed into Tony Defelice’s lane, Fabietti appeared to stab the throttle in a bid to get out of Tony’s way and back into his own lane, but this then sent the car darting back across the track to strike the wall in his lane. As Fabietti wrestled to regain control he closed in on the back of Defelice's LS3 6.2 Litre V8 Call us for car who's parachutes had been deployed. The left 'chute entangled itself around The LS3 is an awesome package in it's own the Monaro's rear wing and as Fabietti slowed, Defelice’s momentum pulled him right but now there are two new variants Great Prices! around backwards and as the rear slicks dug in, the Monaro did two complete barrel rolls before coming to rest back on it's wheels. available from GM Performance Parts that will Excellent Value per kW help feed your appetite for extra horsepower. Luckily both drivers walked away without any injuries, but the damaged sustained to Fabietti's car was enough to rule him out of the Westernationals in Perth that were held less that 2 weeks after the crash. "It was an unfortunate set of circumstances, but that's drag racing sometimes" Maurice said. Australia's only Authorised Distributor for: “The damage was largely cosmetic but we took the car straight off the boat from NEW Tasmania to (chassis builder) Murray Anderson’s to put it on the jig and make sure N We e’v got ALL YOUR GM Performance everything was right,” he said. BRAD Parts needs covered! Commodore LS1 • LS Controller Kits • Valve Covers Murray Anderson is regarded as one of Australia's best drag car chassis builders 5.7L Long Block and has been the man entrusted with all the chassis work on the Monaro since Limited Stock • Crate Engines • Dress Up Accessories it was first built. Now Available! • Engine Covers • Internal Engine Parts As soon as the Monaro rolled into Anderson's workshop, the fibreglass body was pulled off and the car was put on a jig to check that everything was still square. Luckily for Maurice, his initial suspicions were correct and the car was still structurally OK, with only very slightly bent wing struts and of course the cosmetic damage to the fibreglass body shell of the car. Check out our website or call 1300CHEV2 4 3 8 V88 8 Anderson also picked up a few other minor things, unrelated to the roll-over that mel bourne 92 South Gippsland Hwy, Dandenong VIC 3175 03 8710 3000 may have been effecting the Monaro getting down the track as fast as possible. The team at Anderson Race Cars quickly repaired the chassis damage and the car S ydney Cnr Fairford & Watson Rds, Padstow NSW 2211 02 9781 1000 was rolled back onto the transporter to head home to Sydney. The aim being to have the car back racing in time for Round Four of the ANDRA Pro Series Top Bris bane 1/100 Park Rd, Slacks Creek QLD 4127 07 3442 8000 Doorslammer in Sydney.

eagleautoparts.com.au Go Torque. Trade News Direct. - Winter 2012 21 Trade Club Doorslammer 'Fabulous' new Livery hits the Track.

Photos: Cackling Pipes Photography

After a month of hard work behind the scenes, it was time for the Once back in Sydney, the body was sent to Narrabean Smash Repairs, where good Holden Trade Club Monaro to finally hit the track with it’s new livery mate and fellow team owner Lucky Belleri was given the task of getting the Monaro and do what it does best. Sixteen of the nation's Top Doorslammers looking great again. A brand new rear end clip was required, as the damaged ascended on Sydney Dragway for the 4th round of the Top sustained was too substantial to repair. Where as the front end panels were able to Doorslammer ANDRA Pro Series. be fixed, as well as the doors. The big field meant for some very competitive racing and with perfect weather Being a full fibreglass body, many hours were spent prepping and rubbing back the conditions, there was talk that a few records may be in danger of falling. panels in preparation for paint, it might just be a race car, but that doesn't mean it can't can have an immaculate body and perfect paint! Lucky and Mark Kamminga at “It’s exciting to be back at the track again after missing out on the Narrabean Smash Repairs are perfectionists, which means that every car that leaves Westernationals, we can’t take anything for granted though as this field their workshop is faultless. looks to be one of the most competitive fields ever.” Said Fabietti. Seeing as though the whole car needed a respray, Maurice and his team saw this as The big name field did not disappoint either, at the beginning of round three the perfect opportunity to update the livery, the previous paint-scheme had graced the of qualifying, the bump was already an astonishing 6.0 seconds, making it panels of the Monaro for a few years now, seeing a great deal of success on and off the fastest ever qualifying field in ANDRA Top Doorslammer history. the track, but the idea of an updated livery seemed to be just the tonic to begin a bold new chapter in the Fabietti Doorslammer story. It didn’t stop there either, the third qualifying session saw 6 cars run into the 5’s including an amazing final pass for the Holden Trade Club Monaro Maurice and the guys from Holden Trade Club decided to draw on some inspiration from running a 5.987 @ 242.32MPH to pip Gary Phillips and Gary Cannuli who the 2012 Holden Racing Team V8 Supercar, by introducing the Gold and Black Lion over both ran 5.99’s to grab the final qualifying spot for eliminations on Sunday. the big rear bags of the Monaro, as well as introducing more black to the rear of the car. in what was a thrilling final that lived up to what was a fantastic race meet. The all 5 second field was the first ever in Australian Top Doorslammer Over the weekend, there was an astonishing nineteen 5-second passes as Once the livery had been decided on, it was time to lay down the paint. The guys history and just shows how competitive this series is becoming, it's also well as a new National Record of 5.801 by Zappia in his HQ Monaro. at Narrabean Smash Repairs use the Glasurit 90 LINE waterborne paint system, worth noting that 12 of the 16 cars ran 6.1 seconds or under. which is the most technologically advanced paint system in the world. Water-based Be sure to get along to the next Top Doorslammer event to cheer on “It was great to run that 5.98 in the third round and to make history with paint releases less VOCs (volatile organic compounds) than solvent-based paint Fabietti and the Holden Trade Club Monaro. You can either follow the seven other ‘slammers as the first ever, all five-second field” said Fabietti when evaporating which helps make it more efficient, economical, easy to use, safe, team on Facebook at facebook.com/Fabietti.Racing or via the team's environmentally friendly yet still produces the highest quality finish. Unfortunately though, for the Holden Trade Club Monaro Team, things didn’t website at fabiettiracing.com.au With the main colour of the new scheme being red, the whole shell was firstly painted go to plan on the Sunday. Lining up against Robin Judd in the first round with a coat of Glasurit red, before being masked up to do the black, then white parts of of eliminations the Monaro decided not to fire on the start line, letting Judd the scheme. There is also a subtle gold pinstripe around the car that helps break up the stroll straight into the semi-finals with a solo pass. colours and hold it all together. “That’s the unpredictability of drag racing sometimes” Fabietti said Finally it was hit with a coat of Glasurit 923-255 HS Clear to really give the paint it's “Frustratingly though, having towed the car back from the start-line, the car deep, glossy shine. With the deadline of the Pro Series meet at Sydney Dragway fast then fired straight up first attempt back in the pits” approaching, the body was sent home to Maurice's workshop to be reunited with it's chassis and new engine. The engine needed to be rebuilt after the roll over, as the crash “Although a bit frustrating, we are still happy with how the Monaro ran and had smashed the injector hat and sent foreign particles such as rocks and debris through we are really looking forward to the Nitro Champs coming up in May as well the still-running engine. as getting to some more rounds of the Aussie Slamfest series.” Thanks to some fantastic support, Maurice and his crew managed to have the car completely The event was won in the end by John Zappia in his HQ Holden Monaro repaired, resprayed with a new livery and racing again in just 32 days from the accident. with a 5.83, defeating Ben Bray in his CV8 Holden Monaro who ran a 5.91

Go Torque. Trade News Direct. - Winter 2012 Go Torque. Trade News Direct. - Winter 2012 22 23 Holden Restoration Parts Holden Senior Technical Officer has a Passion for Classic Cars.

You can’t restore yourour HoldenHolden To bring your old Holden back without Holden Restorationestoration to original, use official Holden Parts by Rare Spares.res. Restoration Parts. Cameron McConvilleonville These parts are labelled to ensure authenticity and are built to Holden specifications by the most recognised name in the Australian restoration market, Rare Spares. They are designed to bring your classic Holden back to A1 condition.

A lifelong dedication for restoring vintage cars can begin in the unlikeliest places. In the case of 54 year old Mark Cook, an employee of Holden for over 33 years, the passion was born on the dusty paddocks of Broadmeadows, Victoria. CONSOLE COMPLETE HX - WB CONSOLE BODY CONSOLE BODY AUTOMATIC COVER REPAIR KIT As an enthusiastic 16 year old, Mark would race around the paddocks MANUAL WILL SUIT HJ HJ HX HZ WB HJ HX HZ WB CONSOLE HJ-WB LH-LX PART NO. C1001 PART NO: 9939802 PART NO. 9942608 PART NO. GS1001 in his dad’s old Holden FB Wagon, a pastime that would become the catalyst for a lifetime of dedication to the automotive world. Although their passion may not have begun in the vacant paddocks of Broadmeadows, the Rare Spares Directors also share the passion for classic Holden vehicles. This led them to forming a landmark partnership with Holden to create the ‘Holden Restoration Parts by Rare Spares’ program. The partnership with Holden “I can remember using Rare Spares in Brunswick about 30 odd years ago. I was going allows Rare Spares to offer a large number of model specific aftermarket Holden to them to get parts for the 1967 Holden Premier X2 HR Sedan I bought when I was parts that have the GMH stamp of approval. The extensive range of products, 18. Back then they were the only ones who made rubber seals. Rare Spares may not TAIL LAMP REVEAL MOULDING PLATE INDICATOR RETURN LENS TAIL LAMP STOP, BADGE KIT SEAT BELT GM available from participating Holden Dealers and Rare Spares outlets, are helping be an original part, but they work just as well as one. I’ve never had a problem with one KIT VK CALAIS LH & RH HK-HG LC INDICATOR & GASKETS LJ LHR (3) PRESS HK-HZ LC-UC 5 PACKET many enthusiasts live their dreams of owning and restoring a classic Holden. of their parts. I keep going back to Rare Spares because the parts work. They’re the PART NO. MT1001 PART NO. SC1001 PART NO. LRS1039B PART NO. SBD1002 only ones who supply the panels and bits and pieces. The service is also always great; Mark, a Senior Technical Officer at Holden in Powertrain Engineering, has been if they don’t have parts in stock they’ll always ship parts out for me.” passionate about restoring classic cars since he was a teenager. Although his passion was put on hold for a while when family came along, he has picked up Mark’s day job at Holden involves working in Port Melbourne and out at the Lang the spanner again now that his kids have grown up. Mark is currently working Lang testing facility. He is involved in looking at engine and transmission calibration on a 1974 Holden HQ Ute, and is using a number of Rare Spares Holden for future models. This provides Mark with a stark contrast, as he is working on cars Restoration Parts throughout the project build. that have not yet been released to market during the week, and then stepping back in time on the weekends to tinker on the old cars. “I’ve been working on the HQ for about 6 months now,” explained Mark. “I’ve done RADIATOR O/FLOW & WASHER BADGE KIT SEAT BELT GM ENGINE DECAL KIT HOLDEN ENGINE DECAL KIT RESERVOIR VK COMMODORE METAL LION HK-HZ LC-UC 5PKT HQ “308 HOLDEN” HR X2 most of it myself so far; the engine, transmission, diff, and all the mechanical stuff. “The main things that appeal to me about the older cars are the shape, they’re easy PART NO. 92017354 PART NO. SBD1001 PART NO. ED1019 PART NO. ED1009 My brother owns a panel shop, so I’m able to go and work on it there and he can to work on, and I prefer the carbies. The modern cars are fine, but I like to tinker help me out. I’ve put a small block 350 Chev With Mild Cam in it, it’s got turbo 400 and there’s not much you can do with them because they’re all electronic, I prefer transmission, a 9 inch diff, a 600 Holley carburettor, bigger brakes, and it’s been the classics! You can do so much more on old cars with less cost. They’re simple, lowered. I’ve kept the interior original." they’ve got the classic lines and chrome, not plastic. That said, I’ve never restored a car that isn’t a Holden or a Ford." “I probably spent about 6-8 months hunting around for a decent condition HQ, and finally found the one I’ve got now owned by an old guy in Ballarat. The body While Mark has restored a total of five cars over his life, he doesn’t hang onto them was perfect, just a little bit of rust, but I could see potential because it had all the for long. “I’ve sold all the cars I’ve restored so far except for the HQ,” explained right running gear to start with. I like my Utes, especially now that I don’t have to fit Mark. “The fun’s in doing the restoration. It keeps me busy and gives me a hobby. HANDLE T BAR AUTO HJ-WB TAIL LAMP EXTENSION TAIL LAMP LENS (SILVER WHEEL TRIM (RED CENTRE) LH-UC NOT HATCH (KIT) VL CALAIS SURROUND) TORANA LH-LX HK-HT MONARO GTS SET OF 4 any kids in there anymore; just me and my partner!" You drive it, appreciate it and then move on. The enjoyment is starting with PART NO. GK1004 PART NO. 92024358 PART NO. LRS1040 PART NO. WT1002 something that’s run down and then restoring it to its former glory.” “It’s been showing signs of rust so I’ve been collecting panels from Rare Spares, so I’m waiting for the winter to come on and then I’ll put them on. I’ve used Rare Despite this, working on the HQ seems to be changing Mark’s attitude; “I think I’ll Spares parts on every restoration I have done in my life. It’s just far easier to hang onto this one for a while instead of selling it after the restoration like past cars source reliable parts. With eBay now there’s a lot of stuff out there, but it can be of I’ve worked on. I’ve spent a lot of time on the mechanical side of it, and it’s got the For the full Holden Restoration Parts range, go to questionable quality, and I’m one of those people who likes to see what I’m buying." right note and sounds good.” HoldenRestorationParts.com.au

Go Torque. Trade News Direct. - Winter 2012 24 Need a rental car Holden News in a hurry? New Barina Sedan and Hatch.

If you’ve got a customer off the road and need to supply a replacement vehicle there’s a growing list of Holden Dealers you can call for vehicle rentals.

• Highly competitive rates • Flexible – 1 day or 6 months • Latest model Holden vehicles Holden’s Barina has been boosted by the introduction of an all-new hatch, Barina sedan features a level of standard equipment that is rare in the sedan variant to sit alongside the existing hatch model, expanding the light car segment, including Bluetooth phone and audio streaming, USB input • Low KM vehicles appeal of the popular small car. The Barina sedan mirrors its hatch and iPod connectivity, steering wheel controls, cruise control and ‘follow me sibling in boasting strong, sporty Holden design language, must-have home’ headlights, as well as clever interior storage options. technology and five-star safety, all wrapped in a city-friendly light car package. Boasting the same lively 85 kW, 1.6-litre DOHC 16-valve 4-cylinder engine Call your local Holden Dealer and ask for your quote today. as the hatch, the Barina sedan has one of the largest engines in the segment Both the Barina 4-door sedan and the 5-door hatch deliver excellent ride and and blends spirited performance with competitive fuel economy. Barina sedan handling characteristics, sporty and sophisticated design, as well as roominess is equipped with a standard 5-speed manual or optional 6-speed automatic and an impressive list of standard features. With sporty and contemporary styling, transmission with Active Select. the Barina sedan is not merely a stretched version of the hatch. The painstaking Barina sedan shares impressive safety credentials with its Barina hatch, design process has delivered a number of characteristics that contribute to a Commodore and Cruze siblings, receiving the maximum five-star safety rating more upscale and sleek presence than many 4-door vehicles in this category. Victoria Western Australia from the Australasian New Car Assessment Program (ANCAP). Ballarat Ballarat Holden 03 5339 9333 Clarkson Clarkson Holden 08 9407 1777 Its short, compact deck lid is matched to the car's overall proportions, while the Safety features on the all-new Barina sedan include driver, front passenger, Bendigo Poyser Holden 03 5442 3999 Fremantle Shacks Holden 08 9432 9432 taillamps on the Barina sedan carry a dual-element lens, with white and red front side and curtain airbags, dual front seatbelt pretensioners, front seatbelt Braybrook Kevin Dennis Holden 03 9292 9233 Osborne Park North City Holden 08 6365 5476 highlights. The result is a more upscale aesthetic expected of a sedan. The reminders, Electronic Stability Control, a collapsible pedal release system and Cobram Mustica Holden 03 5872 1666 Wanneroo Phoenix Holden 08 9409 9200 extra practicality of the sedan is highlighted by the spacious boot, offering a Echuca 03 5482 1522 Melville 08 9333 5333 head restraints for all seats. D’Alberto Holden Melville Holden storage capacity of 502 litres which is among the best in the segment. Like the Fawkner Mantello Holden 0418 568 506 Frankston Bay City Holden 03 9784 4444 South Australia MansfieldMartins Garage Holden 03 5775 2610 Seymour Neil Beer Holden 03 5792 2777 Elizabeth Peter Page Holden 08 8255 1288 Shepparton Thompson Holden 03 5822 2666 Malvern Claridge Holden 08 8272 1600 General Motors Still No. 1 For Patents. Traralgon 03 5175 7027 Reynella Southgate Holden 08 8381 9555 Colin Watson Holden In the US General Motors remains the No. 1 innovator for the fourth- Warrnambool Callaghan Motors 03 5561 8700 Thebarton Metro Holden 08 8354 9555 Victor Harbour Southgate Holden 08 8552 4399 consecutive quarter among 183 companies ranked by The Patent Board in its quarterly automotive and transportation industry scorecard. GM was New South Wales granted 1,123 U.S. patents in 2011 applied to global product engineering, Rosebery Suttons City Holden 02 9931 3000 Queensland global powertrain engineering, global research and development and OnStar Ryde Hunter Holden 02 8878 7878 Caboolture Beecham Holden 07 5495 1477 organizations. The Patent Board is the leading independent provider of best Wollongong Gateway Holden 02 4222 8888 practices research tools and metrics for patent analysis and intellectual property investment. It tracks and analyzes innovation and patents across 17 industries on a global basis. Some recent technology patents: Quiet Brakes – A friction-damped disc brake design that uses a thin metal ring embedded in the brake rotor to absorb vibrations and mute the squeal. The quieter brake is expected to be available on some cars and trucks within two to three years. OnStar Voice Recognition – OnStar’s speech recognition method can identify the Holden location of the speaker within the vehicle and adjusts its microphone pick-up pattern or magnitude to respond to location-specific commands.

eAssist Thermal Management – Vehicles with engine shut-off capability, such as Above: A GM researcher in the U.S prepares to look at lithium ion battery Rental. Buick LaCrosse with eAssist, use an innovative thermal management system that components through a microscope that is housed in an argon gas filled 'glove box'. maintains occupant comfort during engine-shut off, and prevents engine shut-off if The lithium ion battery components are sensitive to oxygen and humidity. keeps you on the road comfort will be lost, such as during extremely cold or hot weather conditions.

Go Torque. Trade News Direct. - Winter 2012 27 New LPG Range Freedom to Live Large - LPG Commodore.

Holden’s dedicated LPG Commodore was the subject of an intensive and exhaustive engineering program that ensures a vehicle tailor- In order to use the vapouriser, Holden engineers had to create and made for Australian conditions, with a raft of local engineering execute new software to operate the vapouriser and integrate it into the solutions that make this the best LPG Commodore ever produced. Fast Facts. powertrain system. This required unique code to be written for both the ECM and VCM management systems. Holden’s Program Engineering Manager for the LPG Commodore program, • 180kW of Power and 320nM of Torque# Spent exhaust gasses are managed through a specifically-designed exhaust Brian McMurray, says the scope and exacting execution of this engineering • Outstanding LPG fuel economy of 11.8L/100km for the program has ensured customers are buying a vehicle that is world-class for system which is differentiated from the rest of the range by a single exhaust driveability, CO2 emissions and fuel running costs. Commodore Omega sedan outlet, which also aids with refueling in hot climate conditions. This newly • Expanded range includes sedan, Sportwagon, ute and designed exhaust uses a twin-muffler system positioned mid-vehicle and is "The engineering team had three crucial targets for this program. To achieve tailored to refinement, power and torque requirements for the LPG engine. less than 200 grams of CO2 per kilometre across the range, to ensure fuel long wheelbase models Refinement has also been paid special attention, with a specifically tailored running costs comparable to a small or medium-sized petrol car and finally, • Exceeds “Beyond Euro 6” exhaust emissions standards to ensure a seamless drive experience for customers familiar with a petrol noise and vibration package to ensure a pleasurable drive. Commodore," said Mr Murray. • Excellent fuel running costs; cheaper to run than many Safety "I’m very proud to say that the team has achieved, or exceeded, those goals. smaller petrol cars As with all Holden products, safety was an overriding priority throughout After more than 1.3 million development kilometres and 78 testing and • Optimised LPG system ideal for Australian conditions the LPG Commodore program. Like all VE Commodores, the LPG model evaluation prototypes, the Holden engineering team has executed a no- goes beyond the mandated Australian regulatory requirements and scores compromise LPG experience." • LPG tank relocated to maximise boot space the maximum five-star ANCAP safety rating while providing outstanding real-world safety. LPG injection system • More than 1.3 million development kilometres completed At the very beginning of the LPG project, Holden engineers evaluated liquid • Five star ANCAP safety rating across the range With its incredibly rigid body structure with multiple load paths for maximum and vapour-injection LPG systems. After preliminary research and building a energy absorption in an impact, ESP standard on all models, as well as six proof of concept liquid injection prototype vehicle, it quickly became apparent standard airbags in every model, the Commodore remains one of the safest cars on the road today. that vapour injection was the only solution to achieving the program’s goals. The fuel control system has also been optimised in the areas of fuelling, – or 13 percent - compared to the dual-fuel LPG Omega sedan. The Omega "Vapour injection provides lower fuel consumption and lower CO2 emissions spark advance and cam positioning to ensure that the advantages of LPG are sedan will also cost less per year in fuel to run than a 1.8-litre Toyota Corolla.* But the LPG program provided its own unique challenges to our safety fully realised for lowest possible CO2 emissions and best performance and engineering team. LPG requires a larger tank than petrol in order to achieve compared to liquid, while vapour also uses fuel more efficiently with fewer Holden’s engineering work has ensured the entire LPG Commodore range driveability under Australian driving conditions. a similar range to it's petrol counterpart, so to keep mass contained, Holden’s pumping and parasitic losses,"said Mr McMurray. has been awarded 4.5 stars by the Green Vehicle Guide, and exceeds 'Beyond safety engineers developed a lightweight, 84-litre aluminium tank – which to Additional highlights include hardened valves and valve seats to ensure long- Euro 6' exhaust emissions standards. "Vapour systems are less mechanically demanding and therefore better our knowledge is the only mass-produced, OEM-equipped, aluminium fuel tank term durability, while the heads and manifold are also designed specifically for suited to the varying grades of LPG fuel found across Australia. anywhere in the world. the LPG Commodore to ensure optimised air flow and combustion. Combine these results with a range of more than 700km, and the LPG Commodore is a no compromise proposition, allowing customers the freedom "Vapour is also best suited to the Australian climate, with more consistent In order to balance mass and weight distribution with our stringent safety As LPG contains a higher octane rating than petrol, new pistons of an and practicality of a large car without the large car fuel bills. start-up in hot climatic conditions." requirements, the safety team relocated the tank rearward of the rear axle optimised design have been used to raise the compression ratio to 12.2:1 to which was an intense engineering exercise in itself and required significant Powertrain take full advantage of LPG fuel. Additional highlights re-routing of the exhaust system among other modifications. The heart of the LPG Commodore is the 3.6-litre, double overhead cam Over the duration of the exhaustive LPG Commodore engineering project, A particular highlight of the dedicated LPG Commodore is the new six- numerous local engineering solutions were implemented by Holden V6 engine, with four valves per cylinder. This engine has been designed The tank itself is constructed from high-strength, multi-celled, aircraft speed automatic transmission. Lighter, smarter and more refined, this new engineers and suppliers. Several of these engineering innovations have to run solely on LPG and therefore has allowed for design optimisation in grade extruded aluminium with strategically-placed additional aluminium transmission boasts sophisticated control software that optimises shift been awarded patents. several key areas. protection plates. patterns to provide outstanding driveability. Additional engineering highlights include the purpose-designed LPG The entire LPG fuel system has seen significant development, with new The aluminium tank was the subject of intense research and development The end result is a world-class engine with excellent performance and vapouriser. This unit regulates the flow of liquid LPG, subsequently heating fuel injectors, fuel rail and LPG fuel filter. Specific fuel injectors have been activity, including numerous simulated and physical tests of both the tank outstanding fuel economy. Producing 180kW of power and 320Nm of torque, the fuel and causing it to vapourise, creating the vapour that is then developed, with these injectors target positioned within the engine to itself and in-situ within the vehicle in the form of nine barrier crash tests the dedicated LPG engine eclipses the outgoing dual-fuel LPG variant by injected into the combustion chamber. The vapouriser is another made-to- optimise fuel delivery – giving better performance, lower CO2 emissions and performed in-house. improved driveability and durability. 5kW and 2Nm. And yet the new LPG Commodore Omega sedan records measure component, and is the only one of its type being used by an OEM 11.8L/100km on the ADR combined cycle, an improvement of 1.6L/100km manufacturer anywhere in the world on an engine of this capacity. * Source: Green Vehicle Guide January 2011, calculated based on 20,000km per year and average ULP and LPG fuel prices for March 2012 # Maximum Figures as per ECE regulations.

Go Torque. Trade News Direct. - Winter 2012 Go Torque. Trade News Direct. - Winter 2012 28 29 New Catalogues New ACDelco Catalogues.

There are three new ACDelco catalogues now available from your ACDelco distributor to keep you up to date with ACDelco's Issue 6 of the ACDelco Brake Pad Catalogue has also just been ever expanding product range. released. The new catalogue has 206 pages full of information as Battery well as many new part numbers. The catalogue has the brake pads Issue 9 of the ACDelco Filters catalogue has 242 pages of information listed in two categories, the first being by application and the second with all the latest listings for Air, Cabin, Fuel and Oil Filters with over 100 Guide being with full-size Disc Brake Pad Profiles to help you clearly identify new Part Numbers. No.4 the correct brake pad for the vehicle. Brake Pad Catalogue: Issue 6 The filters are listed in two categories, the first being by ACDelco Part The catalogue also includes all the latest listings of the ACDelco High Number, then also in a Cross Reference Table with other brand part Performance Brake Pads. To get the latest ACDelco numbers, so now you can be sure you are ordering the correct filter by Brake Pad Catalogue, looking in the ACDelco Filters Catalogue. Features of the Brake Pad Catalogue include: speak with your local • Warranty details ACDelco Distributor or Features of the Filters catalogue include: • Product Information visit acdelco.com.au • Warranty details • Detailed Technical Information • Detailed Product Information • Easy to Read Application Listings • Application Lists • High Performance Brake Pads • Cross Reference Lists • Detailed technical illustrations • Other References

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ACDelco Stockists. Trade Club Prices for select Daewoo Kalos Parts. Air Filter 96536696 $11.50 Oil Filter 96879797 $ 5.70 Did you Know that your Holden Trade Club Dealer ACDelco Products are available Tail Lamp 96540270 $138.00 from your Holden Dealer or local is also your source for Genuine Daewoo parts. All prices are recommended and exclude GST. Holden Dealers ACDelco Stockist. To locate one are free to set their own prices. near you visit us on the web or call our toll free number now. acdelco.com.au 1800 ACDelco

Go Torque. Trade News Direct. - Winter 2012 Go Torque. Trade News Direct. - Winter 2012 30 31 Model in Focus Model in Focus - Mazda3 Wash and wipe

2004 – 2009 BK Mazda3 - LF MZR 2.0L The BK Mazda3 was first introduced to Australia in 2004, replacing the Mazda 323. In 2009 a second generation Mazda3, referred to as the BL was released. Wash Part Number List Trade Club Wipe List Trade Club ACDelco Products available for the 2004 - 2009 BK Mazda3 - LF MZR 2.0L Optikleen all-seasons concentrate Conventional blade assemblies (multi-fit adaptors provided) 5ml 92140004 $0.75 $0.41 350-550mm $11.00 $7.70 500ml 92140005 $5.75 $3.16 600mm $13.50 $9.45 5 litre 92140006 $35.00 $19.25 Retro-fit beam blade assemblies (multi-fit adaptors provided) 350-550mm $23.50 $16.15 600-700mm $31.00 $21.30 Clearly the best value Original-fit beam blade assemblies (low-profile adaptors provided) Wipers - Refill At the recommended ratio of 20ml to 2 litres of water, 375-550mm $29.00 $19.90 AURT6 5 litres of Optikleen concentrate makes 500 litres. 600-700mm $37.50 $25.75 Wiper Assembly M550AU (Drivers) M550AU (Passengers) Helping you look good An upgrade to the latest beam blade technology is great Brake Fluid Coolant Spark Plugs Engine Oil Beam Blade Optikleen 500ml 92147062 92147598 (1L) 41810 88900942 (Mineral) Assembly 92140005 value and superior wiper performance makes the quality 92145527 (5L) or 89063553 (Semi-Syn.) FS550AU (Drivers) service you provide clear for your customers to see. 95710438 (20L) R42LTS 19246958 (dexos1) FS550AU (Passengers) Multi-application Retro-fit beam blades are supplied with adaptors to make fitting to vehicles with traditional wiper assemblies quick and There’s an ACDelco wiper suitable easy – ask your Holden Dealer to demonstrate them. for most makes and models

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ACDelco offers a comprehensive Product Range to suit Most Makes Most Models. For your nearest ACDelco Automotive Parts Stockist call 1800 ACDelco or check online at acdelco.com.au holdentradeclub.com.au

Go Torque. Trade News Direct. - Winter 2012 33 Holden Tech Holden Technical Info.

Now available on the Holden Trade Club website is a detailed look into the charging systems in VE/WM model vehicles. The full 14-page paper covers operating principles and details on the electrical controls. Access to the paper is available to all Holden Trade Club members under the ‘Technical Information’ section of the members website - holdentradeclub.com.au. Charging System Description and Operation. The introduction of Calcium based batteries and the quest for more efficient charging systems has led to the introduction of Electrical Power Management (EPM) systems also referred to as the Regulated Voltage Control (RVC) system. To you, the technician, an understanding of the complete system is essential to accurate diagnosis of charging faults. This article aims to provide all the information you require to diagnose and repair VE/WM charging faults. Calcium batteries have also changed the requirements for off vehicle charging. EPM/RVC Overview. Complete control of the charging system gives improved fuel economy, reliable engine idle and improved battery life. The EPM/RVC system consists of the following components: • Alternator • Body Control Module (BCM) Make sure your • Engine Control Module (ECM) • Instrument Panel Cluster (IPC) • Current Sensor Colorado has what it The EPM system also signals the driver if problems exist in the charging system. The Instrument Panel Cluster (IPC) alerts the driver to these system problems. takes to finish the job. Monitoring of more variables affecting vehicle charge, compared to conventional voltage sensing at the alternator gives greater control over charging conditions. Now if you would like to look at the various sections of the Order any model of the All-new 2012 Colorado electrical charging systems in VE/WM model vehicles in more detail log onto holdentradeclub.com.au and download the full before May 31st and automatically receive a 14-page paper. FREE Genuine Holden Towing Kit.

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The Holden free towbar offer is available on new orders placed prior to May 31st 2012 on the new 2012 model Colorado. The offer includes towbar, tongue, towball & wiring harness installed by the 100 amp alternator 92094625 Holden Dealer. Includes GST & fitment. Private sales and ABN holders only. Colorado LTZ 4x4 model Fits all these popular Holden V6 non-supercharged models: shown with available accessories at extra cost VS/VT/VX/VY Commodore/Calais (’95-’04) www.holden.com.au/accessories VS/WH/WK Statesman/Caprice (’95-’04) ©2012 GM Holden Ltd. All rights reserved. holden.com.au VS/VU/VY Ute (’95-’04) List Price $385.00 Trade Club price $196.50 Prices are recommended and exclude GST. Holden Dealers are free to set their own prices. .

Go Torque. Trade News Direct. - Winter 2012 Genuine Accessories Go Torque. Trade News Direct. - Winter 2012 34 35 Everyday prices held for 12 months. Holden Trade Club aims to hold prices for a full 12 months.* Price stability – not just ‘here today, gone tomorrow’ promotions – means you’ll know exactly where you stand. And, of course, all our parts are genuine Holden or ACDelco with a full Australia-wide warranty.

Everyday prices exceptional quality

*Each year we publish prices in the Holden Trade Club Book during July and aim to hold Holden Trade Club prices for a full 12 months.

holdentradeclub.com.au

INTRODUCTION In this article, we will have a close look at the electrical charging systems in VE/WM model vehicles.

Charging System Description and Operation The introduction of Calcium based batteries and the quest for more efficient charging systems has led to the introduction of Electrical Power Management (EPM) systems also referred to as the Regulated Voltage Control (RVC) system. To you, the Automotive technician, an understanding of the complete system is essential to accurate diagnosis of charging faults. This article aims to provide all the information you require to diagnose and repair VE/WM charging faults.

EPM/RVC Overview Complete control of the charging system gives improved fuel economy, reliable engine idle and improved battery life.

The EPM/RVC system consists of the following components:  Alternator  Instrument Panel Cluster (IPC)

 Body Control Module (BCM)  Current Sensor  Engine Control Module (ECM)

The EPM system also signals the driver if problems exist in the charging system. The Instrument Panel Cluster (IPC) alerts the driver to these system problems.

Monitoring of more variables affecting vehicle charge, compared to conventional voltage sensing at the alternator gives greater control over charging conditions.

Block Diagram of major EPM/RVC components:

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EPM Communication Methods:

Alternator with ECM BCM to IPC  Pulse Width Modulation (PWM)  GMLAN Low Speed - Two-way communication, ECM transmits - Single Wire 33.33 kbps on L terminal (X2) and receives on the - Transmit Model, Event and Periodic. F terminal (X1). We will discuss the function of these terminals later.

ECM with BCM Current Sensor Module to BCM  GMLAN High Speed  Pulse Width Modulation (PWM) - Dual wire 500 kbps - Single direction - Transmit Model, Periodic.

Voltage Sense to BCM  Direct voltage reading from battery

GMLAN Definitions: Periodic: Transmission of Data occurs at fixed intervals. An active network means continual data transmission. For example, The EBCM transmits wheel speed information to the ECM every 10ms. The BCM transmits the VIN number on the LS GMLAN every 5 seconds.

Event: Transmission of data occurs in response to events. For example, the “hazards on” message transmits when you switch on the hazard lights. Turning the hazard lights off fires a “hazards off” message.

View the following schematic to understand the EPM communication system:

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The EPM system performs three functions:

1. It monitors the battery voltage and estimates the battery condition.

2. It takes corrective actions by boosting idle speeds and adjusting the regulated voltage.

3. It performs diagnostics and provides driver notification.

Complete monitoring of the charging system gives the following advantages:  Improved engine idle control

 Improved battery life

 Better fuel economy

Calculation of Battery Charge Calculation of battery charge condition occurs during both ignition on and ignition off vehicle states. During ignition off, calculation of the batteries‟ State of Charge (SOC) takes place through monitoring the Battery Open Circuit Voltage. By monitoring Battery Open circuit Voltage over a period of several hours, a more accurate picture of the true battery SOC is given. Longer term voltage monitoring achieves elimination of battery „surface charge‟ readings.

Calculation of Battery Charge:

When the ignition is on, using the calculated SOC as a starting point, estimating the “live” SOC depends on the following parameters:  Current into versus current out of the battery

 Estimated Battery Temperature

 Battery capacity

When the battery is disconnected, the BCM will calculate that the battery is only 20% charged when reconnected, regardless of the actual state of charge of the battery. The BCM does not rely on voltage readings over a short time to evaluate battery charge. The BCM takes 8 hours of ignition connection to relearn the actual battery state of charge.

Consider the following scenario: Jo has to replace a VE battery. Jo hooks the new battery to the multi-stage charger and charges the battery for the specified time. On fitting the battery to the vehicle, Jo discovers that the scan tool is saying that the battery is only 20% charged. What has gone wrong? Well this is OK; as we said the vehicle does not “jump to conclusions” about SOC based on initial voltage alone. If Jo had used the scan tool the next day, even without running the vehicle, Jo would see that the vehicle would be reporting a higher SOC percentage than 20%. When the vehicle is running the most important SOC parameter is the current into and out of the battery called the net current.

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Charging System Operation Modes

There are four main EPM charging modes that are available.  Idle Boost Mode  Regulated Voltage Control (RVC) Mode  Load Shed Mode  Fuel Economy Mode

Idle Boost Mode: At idle, if the battery voltage is lower than a particular threshold and if a high current draw is detected, the EPM will command an increase in idle speed to support the vehicle load and to avoid further discharge of the battery. There are 3 levels of Idle Boost depending on the severity of the situation.

Load Shed Mode: Load Shed Mode is requested when the vehicle loads are still drawing too much current from the battery even when Idle Boost Mode is active. EPM would send out a request message via GMLAN communication to the various controllers that control loads capable of being shed. Similarly, there are 3 levels of Load Shedding depending on the load levels.

Regulated Voltage Control (RVC) Mode: In RVC Mode, the EPM system determines the optimum charging voltage, based on estimates of its SOC and battery electrolyte temperature. On starting the engine, the BCM sets a higher alternator output voltage for a short period of time for the system to recover the charge lost during crank. The BCM will enter Headlamp Mode whenever the headlamps are ON (high or low beams). Voltage regulated to 13.9–14.5 volts. This voltage maximises globe life; conventional globes run best at a slightly lower voltage than required by calcium batteries.

Fuel Economy Mode: The fuel economy mode is an algorithm that allows a fast battery voltage reduction after engine crank and during vehicle driving conditions. The BCM enters Fuel Economy Mode when ALL the following conditions are set:

 The estimated battery temperature is between 0°C (32°F) and 70°C (158°F)

 The calculated battery current is less than +15 amps and greater than −8 amps

 The battery state of charge (SOC) is greater than or equal to 80 percent.

 Vehicle speed is less than 145 kph.

Its targeted alternator output voltage is the open circuit voltage of the battery and can be between 12.5–13.1 volts. The BCM will exit this mode and enter normal RVC Mode when any of the conditions described above are present.

Charging System Components Alternator: This is not a serviceable component. If the alternator fails, and you verify the failure, replace the complete unit with a new Holden Genuine Part. NOTE: Do not fit a VZ alternator to VE/WM; the EPM system now controls alternator voltage output, not the alternator. The major changes are in the charging control and sensing functions. Conventional alternators work as standalone units, that make all the decisions on what current or more accurately what output voltage they run at. The internal voltage regulator sets the output voltage at a constant value; the battery voltage sensing is through the alternator output cable.

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The alternator in the EPM system uses the L terminal, (was used for the charging light) and the F terminal, (a long time ago this was used for external regulator connection) for quite different functions, which will be discussed fully in the Engine Control Module section.

Conventional alternators work as constant voltage generators, the current output is continually changing. Calcium batteries used in VE/WM have different charge requirements to traditional lead acid batteries. Calcium (Ca) batteries require “4 stage charging”; due to their chemical properties, they prefer higher voltages than lead acid units do. Calcium batteries also prefer different current limiting and different charging voltages depending on their state of charge.

The conventional alternator does not have current limiting control; it controls charging by generating a constant voltage, which is always slightly higher than fully charged battery voltage requirements, approximately 14.2 volts. Under heavy electrical load, the conventional alternator supplies a lot of current, up to its maximum rated capacity to retain the preset output voltage. Under light electrical load, the conventional alternator supplies current until it reaches the preset output voltage. When the voltage exceeds the set point, the alternators‟ voltage regulator reduces the field winding current, so reducing the alternator current output.

Fixed output voltage is a compromise between adequately charging the battery under heavy electrical load and not overcharging the battery under light loads.

Battery voltage does not change quickly enough to reflect rapid changes in engine load conditions, caused by increases in electrical load or AC turning on, so the conventional alternator does not limit its output quickly enough to unload the engine. The EPM system reads these changes directly through the associated sensors connected to the BCM and the ECM. The EPM system, on finding a sudden increase in engine load, commands the alternator to stop charging. Rapidly unloading the engine in this way prevents stalling.

The BCM tells the ECM it needs a certain output voltage. The ECM, in turn, directs the alternator to supply this output voltage. The alternator then tells the ECM how hard it is working. This signal from the alternator indicates how much current it is producing to achieve the specified output voltage. Alternator communication signals are Pulse Width Modulated (PWM).

Body Control Module (BCM): The Body Control Module is the major decision making component in the EPM. It communicates data with the following systems:  ECM through GMLAN High Speed (HS) Bus  IPC through GMLAN Low Speed (LS) Bus It reads battery net charge and voltage through the following components:  Net charge current through Battery Current Sensor  Battery Voltage via the Battery Sense Direct line

The BCM receives net charge information from the Battery Current Sensor and monitors the battery Voltage through the Battery Sense Voltage Line. The BCM determines the desired output of the alternator and sends the information to the ECM. The ECM controls the alternator through the PWM signal it sends to the L terminal, connected to the alternator field circuit. The ECM monitors the duty cycle of the alternator field. The ECM reads the duty cycle, via the F terminal, and sends this information to the BCM via the GMLAN bus.

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The BCM also estimates battery temperature based on ambient temperature and net charge to refine its view of the battery‟s state of charge (SOC).

Battery Current Sensor: The net current flow into or out of the battery is measured using the Battery Current Sensor found on the negative battery cable.

This 3 wire Hall Effect device generates a pulse width modulated signal, the duty cycle is proportional to ground current through the earth strap. The BCM reads the signal.

The signal voltage is 0 or 5 volts, a square wave with a base frequency of 125 Hz or 125 cycles per second. The normal duty cycle ranges from 10% to 90% and represents a current draw of -60 to +60 amps. Duty cycle outputs between 0-10% and 90-100% are for diagnostic purposes only.

Engine Control Module (ECM) As illustrated in the EPM communication system diagram above, the ECM receives alternator control information from the BCM through GMLAN HS Bus. The ECM is connected to the alternator by two Pulse Width Modulated signals, the L Terminal and the F Terminal. Both of these PWM signals are 5 volt PWM signals of a frequency of 128 Hz and with a duty cycle of 0–100 percent.

The L Terminal is the command signal from the ECM to the alternator. Normal duty cycle is between 10–90 %. Signals between 0–10 % and 90–100 % are for diagnostic purposes.

The table to the right maps the commanded duty cycle presented to the L terminal against the output voltage of the alternator:

The alternator feeds back information via the F terminal. This information informs the ECM how hard it is working. The ECM in turn relays this information to the BCM. The BCM may make a decision to turn off unnecessary electrical loads if the alternator is not coping. As an example if the headlamps, window wipers, heated rear window and entertainment system are on the BCM orders 70% output to the ECM. The ECM will then send a 70% duty cycle signal to the alternator. The extreme load on the alternator would cause a 95% PWM signal back to the ECM. The BCM on receiving this information from the ECM may switch off the heated rear window. Under lighter current load a 70%, command to the alternator may produce a 30% response. This means the alternator is able to maintain the required voltage while working at one third of its total capacity. Similar to the L Terminal signal, the Normal duty cycle of the F terminal is between 5–95%. Duty cycle outside this range is for diagnostic purposes.

This allows the ECM to adjust the idle speed to compensate for high electrical loads. The ECM monitors the status of the alternator load. When the key is in the RUN position and the engine is OFF, the ECM should detect a duty cycle near 0 percent. When the engine is running, the duty cycle should be between 5–95 percent. Typical values seen in Scan Tool Data for Engine ⇒ Electrical, for L and F signals would be 70-75% for L, commanding about 14.4 volts from the alternator and anywhere between 30-95% signal on the F terminal. The high value (99%) is full electrical load at idle with a battery not fully charged, the low value is low electrical load. Remember if you see 100% duty cycle reported on F terminal the alternator could be faulty. We will cover system diagnosis towards the end of this paper.

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Instrument Panel Cluster (IPC): The IPC provides a means of customer notification in case of EPM failure. This BCM provides EPM information to the IPC via the GMLAN Low speed bus. There are two fault indicators displayed by the IPC:  Charge indicator

 Driver Information Centre (DIC) message “Battery Saver Mode On”

Charge Indicator Operation: The instrument panel cluster (IPC) illuminates the charge indicator and displays a warning message in the driver information centre (DIC) when the one or more of the following occurs:  The engine control module (ECM) detects that the alternator output is less than 11 volts or greater than 16 volts. The IPC receives a GMLAN message from the ECM, via the BCM, requesting illumination.  The IPC determines that the system voltage is less than 11 volts or greater than 16 volts for more than 30 seconds. The IPC receives a GMLAN message from the BCM indicating a system voltage range problem.  The IPC performs the displays test at the start of each ignition cycle. The indicator illuminates or approximately 3 seconds.  The ignition is ON, with the engine OFF. View the charge indicator warning displayed in the DIC and the location of the charge warning lamp, A, in the accompanying diagrams, the actual location depends on vehicle model.

Battery Voltage Display: On Series I SS and SV6 models there is also a battery voltage/oil pressure gauge

The battery voltage/oil pressure gauge is located in the centre of the dashboard above the air vents. The gauge shows the battery voltage and the engine oil pressure.

The Secondary Information Centre (SIC) displays the system voltage as received from the BCM over the GMLAN serial data circuit. If there is no communication with the BCM, the display will read all dashes.

Note: This feature is not available on Series II models.

Battery Saver Mode: The BCM and the ECM will send a GMLAN message to the DIC informing it to display the Battery Saver Mode On message. When a charging system DTC is current, the IPC displays the message. The IPC stops displaying the message when the conditions for clearing the DTC are satisfied.

7

Charging System Diagnostics The first step to accurate charging diagnosis is the use of the correct testing equipment.

Battery Testing Equipment: Holden recommends the use of a Digital Multimeter with the following specifications:  Input impedance of at least 10MΩ  Accuracy of ±0.05 volts, measuring in DC volts  The maximum voltage range used is 20 volts (Range Hold to 20 volts DC)

Battery Testing Procedure Open Circuit Voltage (OCV) Test: Following the steps outlined will ensure accurate Battery Voltage measurements: 1. Turn off Scan Tool if in use. 2. Remove any surface charge by turning the headlamps to high beam for 10 seconds. 3. Switch of all current drains i.e. headlamps on, doors open etc. 4. Open the boot lid. 5. Remove the key from the ignition then open and close the drivers‟ door. 6. Wait for the last visible vehicle functions to shut down (e.g. headlights, IPC etc) and then wait for at least a minute after activity ceases to allow the battery to settle. NOTE: This ensures that GM-LAN network is asleep, not pulling current and possibly lowering the OCV reading. 7. Switch your DVM to the 20-volt scale and measure the voltage at the battery terminals.

The reading should be a minimum of 12.4 volts for the VE/WM Calcium battery. If the battery requires charging, connect the charger leads to the jump-start posts, not the battery terminals. The charge current then flows through the sensing ground lead and the BCM will have a clearer idea of the state of charge (SOC) of the battery.

Scan Tool Diagnosis: Note: The following Diagnosis has been carried out with a GM „Tech 2‟ scan tool, therefore it may vary to aftermarket equivalent tools.

We will now look at how Tech 2 can help in diagnosing charging faults. Many modules in the vehicle detect low/high voltage problems and set a DTC. We will concentrate on DTC‟s directly related to the charging system only.

Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.

Conditions for Running the DTC:  The vehicle speed is above 8 km/h (5 mph).  The system voltage is between 9.5–18 volts.

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Conditions for Setting the DTC: With the engine running, the ECM detects a PWM signal less than 5 percent for at least 15 seconds (DTC P0625: Generator F Terminal Low Voltage).

With the engine running, the ECM detects a PWM signal of 100 percent for at least 15 seconds (DTC P0626: Generator F Terminal High Voltage).

Circuit/System Verification: With the scan tool installed, ignition ON and the engine running, observe the alternator-F Terminal Signal parameter in the ECM data list. The alternator-F Terminal Signal parameter should read between 5 and 95 percent.

Circuit/System Testing:

1. Verify that a test lamp illuminates between the generator B+ circuit terminal 1 X2 and ground.

⇒ If the test lamp does not illuminate, test the B+ circuit for a short to ground or an open/high resistance.

2. Ignition OFF, disconnect the X1 harness connector at the generator.

3. Ignition ON, verify the scan tool ECM GEN-F Terminal Signal parameter displays less than 5 percent.

⇒ If greater than the specified range, test the signal circuit terminal 2 for a short to voltage. If the circuit tests normal, replace the ECM.

4. Install a 3 A fused jumper wire between B+ and the signal circuit terminal 2.

5. Verify the scan tool ECM GEN-F Terminal Signal parameter displays greater than 95 percent.

⇒ If less than the specified range, test the signal circuit terminal 2 for a short to ground or an open/high resistance. If the circuit tests normal, replace the ECM.

6. If the circuit tests normal replace the Alternator with the correct Holden Genuine replacement Part.

We are producing a crude signal equivalent to 0% with the test light not contacting, to 100% with the test light contacting the F terminal harness side. The Tech 2 should show these two inputs in the data list display, unless there is a problem in the harness to ECM.

⇒ If the test lamp did not affect the alternator-F Terminal Signal parameter, test the alternator-F Terminal Signal circuit for a short to ground or an open/high resistance. If circuit tests normal, replace the ECM.

9

Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, prior to using this diagnostic test.

Circuit/System Description: The engine control module (ECM) uses the alternator turn ON signal circuit to control the load of the alternator on the engine. A high side driver in the ECM applies a PWM signal to the voltage regulator. This signals the output voltage, which the alternator produces. The ECM monitors the state of the alternator F terminal. The ECM should detect low voltage on the alternator turn on signal circuit when the ignition is ON and the engine is OFF or when the charging system malfunctions. With the engine running, the ECM should detect high voltage on the alternator turn on signal circuit. The ECM performs key ON and RUN tests to determine the status of the alternator turn on signal circuit.

Conditions for Running the DTC: The engine is running.

Conditions for Setting the DTC: With the engine running, the ECM detects low/high value compared to a predetermined voltage on the alternator turn on signal circuit for at least 15 seconds.

Action Taken when the DTC Sets : DTCs P0621, P1668, P2500 or P2501 are type C store only DTCs.

Conditions for Clearing the MIL/DTC: DTCs P0621, P1668, P2500 or P2501 are type C store only DTCs. 10

Scan Tool Reference: Engine Control Module Scan Tool Data List

Circuit/System Testing: 1. With ignition ON and the engine OFF disconnect the alternator harness at the alternator and measure the voltage of the alternator turn on signal circuit should read near 0 volts.

⇒ If greater than, 0 volts test the alternator turn on signal circuit for a short to voltage. If circuit test is normal, replace the ECM.

2. With ignition ON and the engine running, the voltage of the alternator turn on signal circuit should read over 3.5 volts.

⇒ If no voltage is measured, test the alternator turn on signal circuit for a short to ground or an open/high resistance. If circuit tests normal replace the ECM.

11

Current Sensor DTC DTCB1516 08: Battery Current Sensor Performance Signal Invalid Diagnostic Fault Information: Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, prior to using this diagnostic procedure.

Circuit/System Description: The battery current sensor supplies a PWM input signal to the body control module (BCM).

Conditions for Running the DTC:  The ignition is ON.  The engine is running.

Conditions for Setting the DTC: The BCM detects a duty cycle of PWM input signal is less than 4 % or more than 96% for more 33 seconds.

Action Taken When the DTC Sets : The setting of this DTC illuminates the SERVICE VEHICLE SOON in the driver information centre (DIC).

Conditions for Clearing the DTC:  The DTC clears as “current status” when the battery sensed current returns to normal range for more than 5 seconds.  Clear the DTC using a scan tool.

Circuit/System Testing: 1. Ignition OFF, disconnect the harness connector at the battery current sensor.

2. Ignition OFF for 90 seconds, test for less than 5 ohms between the low reference circuit terminal B and ground.

⇒ If greater than the specified range, test the low reference circuit for an open/high resistance.

3. Ignition ON, test for 4.8–5.2 volts between the 5-volt reference circuit terminal A and ground.

⇒ If less than the specified range , test the 5-volt reference circuit for a short to ground or an open/high resistance. If the circuit tests normal, then replace the BCM.

⇒ If greater than the specified range, test the 5-volt reference circuit for a short to voltage. If the circuit tests normal, then replace the BCM.

4. Ignition ON, test for 4.8–5.2 volts between the signal circuit terminal C and ground.

⇒ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the BCM.

⇒ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the BCM.

5. If all circuits test normal, replace the battery current sensor.

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BCM Voltage DTC DTCB1517 00: Battery Voltage Below/Above Threshold

Diagnostic Fault Information: Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, prior to using this diagnostic procedure.

Circuit/System Description: The body control module (BCM) has designated circuits for monitoring vehicle system voltage. The BCM monitors the system voltage to keep the voltage within the correct range. Damage to components and incorrect data may occur when the voltage is out of range. The BCM monitors the system voltage over an extended length of time. If the BCM detects the system voltage is outside an expected range for the calibrated length of time or the BCM battery sense circuits differ by 3 volts, DTC B1517 will set. Other modules also monitor system voltage. The system voltage message is sent to the other modules and will default to 12.9 volts.

Conditions for Running the DTC: This DTC will run only if the BCM has power, ground and the ignition is not in START mode. This DTC shall execute regardless of the battery voltage.

Conditions for Setting the DTC: The battery voltage measured is: • Less than 11.8 V for greater than 30 minutes

• Less than 11.6 V for greater than 20 minutes

• Less than 11 V for greater than 90 seconds

Action Taken When the DTC Sets: The DIC displays the SERVICE VEHICLE SOON Message.

Conditions for Clearing the DTC: The condition for setting the DTC is no longer present. A history DTC clears after 50 fault-free ignition cycles. The DTC can be cleared using a scan tool.

Circuit/System Testing 1. Measure and record the battery voltage.

2. Ignition OFF, disconnect the harness connector at the telematics module.

3. Ignition OFF, measure for battery voltage from the telematics module power circuit to a known ground.

⇒ If more than 1 volt difference between battery voltage and the power circuit then test the applicable circuit for a short to ground or an open/high resistance. If the circuits/connections test normal, replace the telematics module.

High Current Drain DTC DTCB1527 00: High Parasitic Load Detected

Diagnostic Fault Information: Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.

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Circuit/System Description: The body control module (BCM) monitors the state of charge (SOC) of the electrical system. If the BCM senses that the SOC at key-on is 30 percent lower than what it was when the engine was running, DTC B1527 will set.

Conditions for Running the DTC: The ignition must be in Accessory or Run mode for this code to set.

Conditions for Setting the DTC: The SOC at key-on is 30 percent lower than when the engine was running and battery drain is more than 2 amps.

Action Taken When the DTC Sets: There is no battery telltale illuminated or driver information centre (DIC) message displayed.

Conditions for Clearing the DTC:  The DTC will clear when run SOC is greater than or equal to 80 percent.  A history DTC clears after 50 fault-free ignition cycles.  The DTC can be cleared using a scan tool.

Circuit/System Testing 1. Ignition ON, with the scan tool compare the Previous State of Charge and Start Up State of Charge parameters. The readings should not differ by more than 30 percent. - If the readings differ by more than 30 percent, refer to Battery Electrical Drain/Parasitic Load Test.

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Charging System Check If these tests check out OK then we need to carry out a charging system check. Note: Remember to wear Safety Glasses when working with batteries.

Connect a DMM set on volts (20 volts range) to the alternator positive terminal and a known good ground.

Connect a current clamp capable of reading 200 amps DC to the alternator charge lead.

Record the voltage reading on the DMM. Connect a suitable loading device to the battery positive and negative posts.

Connect a scan tool and start the engine.

While observing the scan tool, increase the engine speed to 1300 RPM.

Observing the Current Clamp reading, the amperage should be 5.0–10 amps and the DMM voltage should read between 13.8–15.4 volts. 1. While observing the scan tool, increase the engine speed to 1900 RPM. 2. Observe the DMM adjust the loading device to 90 percent of the alternators maximum output. 3. Observe the DMM voltage should read between 13.8–15.4 volts. 4. Adjust the loading device until the DMM reads 13.5 volts. 5. Observe the DMM the amperage should read maximum output of alternator (100 amps or more). 6. Stop the engine. 7. Remove test equipment. If the alternator voltage readings are outside the limits above or the current is below 100 amps then replace the alternator.

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