HoldenEommodore. HoldenEalais. VK SERIES SERVICEMANUAL SUPPLEMENT FOREWORD SECTIONINDEX The information in this Supplement, when used in conjunctionwith HoldenCommodore 'VB' series Service OA GENERALINFORMATION Manual M38145, 'VB' Station Wagon Supplement B LUBRICATION M38265, VC Service Manual Supplement(Number 1) M38366 and Number2 M38401, lmprovedPerformance A- BoDY Manual M38338and VH Series I L6 & VB EnginesService _ RADIATORGRILLE M38731,provides new spec- C ServiceManual Supplement _ ifications and new service procedures lor Holden Com- D BUMPERBARS modore and Holden Calais VK Series vehicles. assemblies are 2 A - vENTTLATToN&HEATING Transmission,front brake and rear axle _ similarto those used in other GMH vehicles.No major B AIRCONDITIONING service repair and overhaul procedures are given for these assemblies,and reference should be made to 3 FRoNTSUSPENSToN existingService Manuals. The Section lndex on this page enables the user to 4 A- REARSUSPENSToN quickly locate the numeric identifiers for each group of B _ REARAXLE Sections.Bend the Manual back to expose the black C _ PROPSHAFT & UNIVERSALJOINTS tabs on the pages and locate the tab indicating the you find. An identifier for the group of Sections wish to BRAKES index is included at the beginningof each Section. In 5 addition. numeric identifiers are also used to signify the individualoperations within the Sections.Specifications 6 A- ENGTNEMEcHANIcAL for vehicle componentsare providedat the end of each B _ ENGINECOOLING Section where apProPriate. C _ ENGINEFUEL Summarieso1 Special Service Tools, where required, are D - ENGINEELECTRICAL also includedat the end of Sections. E _ ENGINEEMISSION CONTROL Service Tools, unless otherwise specified, are available F - ENGINETUNE from: I Kent-MooreAustralia PtY' Ltd. 7 A - cLUrcH Unit 3, 9 PioneerAvenue, B _ MANUALTRANSMISSION Thornleigh.N.S.W. Australia' 2120. C _ AUTOMATICTRANSMISSION Telephonel02l 848'9777 Telex 22355 General Motors-Holden'sdoes not endorse, prefer, or 8 A_ FUELTANK assume responsibilityfor the products of this firm nor for B - EXHAUSTSYSTEM any such items which may be available from other makers. 9 sTEERTNG All information,illustrations and specificationscontained in this Supplementare based on the latest product 10 wHEEts& rYRES informationavailable at the time ol publicationapProval. The right is reserved to make changes at any time A _ BATTERY&CABLES without notice. B _ LIGHTINGSYSTEM C - INSTRUMENTS,GAUGES, WINDSHIELD EFFECTIVE:MARCH, 1984. WIPERS/WASHERS& HORN SERVICEMANUAL NO. M39101 D _ RADIO& TAPEPI-AYER 0 l.s.B.N.0.86836 009 E _ WIRINGHARNESSES&FUSES PRINTEDIN AUSTRALIA F - WIRINGDIAGRAMS
GENERAL MOTORS_HOLDEN'SSALES PTY. LIMITED SERVICE DEPARTMENT
COPYRIGHT _ GENERAL MOTORS-HOLDEN'S SALES PTY, LTD Reprocjuctionin whole or in oart prohibitedwithout wrrtten approval 2 GENERALINFORMATION OA-1
SECTIONOA GENERALINFORMATION INDEX Ref. Subject Page Ref. Subject Page 1. GENERALDESCR|PT|ON...... --...... 0A-1 6.4 VEHICLEIDENTIFICATIONNUMBERING 2. MODEL AVAILABILITY & BASE SYSTEM 0A-5 EOUIPMENT oA-2 6.5 VEHICLESERIAL NUMBER...... 0A-6 3. POWERTRAIN COilBlNAT|OlilS.....-...... 0A-2 6.6 ENGII{ESERIAL NUMBEB...... 0A-6 4. ENGINE DAT4...... 0A-3 7. ADDITIONALGENERAL INFORMATION.... nA-A I 5. EXTERIORDIUENSIONS 0A'3 ElectrlcalTransients and Radio .:E 6. SERtAL NUMBERS...... i. 0A-4 Frequency Interference 9t'9 r 6.1 LOCATIONOF IDENTIFICATIONPLATES oA-4 Radio Frequency lnterference ...... NA-A I 6.2 SAFEW CO]IIPLIANCEPLATE ...... 0A-4 Electrlcal Transients 0A-7 6.3 BODY & OPTIONIDENTIFICATION 0A-4
1. GENERALDESCRIPTION The VK Series is a minor facelift of the VH Series The 3.3 litre L6 engine, equipped with ElectronicSpark incorporatingexterior, interior and mechanicalchanges. Timing (EST), is the base engine tor SL and Berlina The model line-up differs from the VH Series, with the models, and the 3.3 litre LO engine equipped with deletionof the 69 body style (4 door, 4 window sedan) Electronic Fuel Injection (EFl) is the base engine on and the introductionof the '19 body style (4 door, 6 Calaismodels. windowsedan). The three speed Trimatic Automatic Transmissionis standardequipment on Calais and Berlinamodels and is MODELLINE UP availableas an ootion on CommodoreSL models.The Torquemasterfour speed manualtransmission is standard 8VK19 CommodoreSL Sedan4 door.6 window on CommodoreSL models. 8VK35 Commodore SL Station Wagon The 5.0 litre V8 engine is availableon all modelsas an 8VL19 Commodore Berlina Sedan4 door,6 window option.A five speed manualtransmission is also available litre L6 EST engines 8VL35 Commodore Berlina Station Wagon as an optionon all 3.3 charts contain model availability,power 8VX19 Calais Sedan4 door,6 window The following train combinations,engine data and exteriordimensions for VK Seriesmodels.
3 OA.2GENERAL INFORMATION
2. MODELAVAILABILITY & BASE EQUIPMENT
TRANSMISSION REAR BODY MODEL No. OF AXLE STYLE NO. MODEL NAME DOORS ENGINE SHIFT RATIO TYRES WHEELS TYPE LOC. :l
Sedan 8VK19 Commodore SL 4 3.3EST 4 SpeedManual F loor ?na BR78S14 5.50 JJX14 Steel S/Wagon 8VK35 Commodore SL 5 3.3EST 4 SpeedManual Floor 3.08 cR78S14 6.0 JJX14 Steel Sedan 8VL19 Commodore Berlina 4 3.3EST 3 SpeedAuto Floor 3.08 cR78S14 6.OJJX I4 Steel S/Wagon t'V LJ5 Commodore Berlina 5 3.3EST 3 SpeedAuto F loor 3.08 cR78S14 6.0 JJX14 Steel Sedan 8VX19 Calais 4 J.J EFI 3 SpeedAuto Floor 3.08 P20s/ 6.0 JJXl5 Alloy 60HR1 5
3. POWERTRAIN COMBINATIONS
REARAXLE RATIO: 1 ENGINE TRANSMISSION MODEL FIRSTGEAR TYPE AVAILABILITY RATIO: 1 BASE PERFORMANCE
SL Sedan SL Station Wagon 4 SpeedManual 3.50 3.08 BerlinaSedan BerlinaStation Wagon
3.3 Litre SL Sedan SL Station Wagon Six Cylinder 5 SpeedManual 3.24 3.36 EST BerlinaSedan BerlinaStation Wagon
SL Sedan SL Station Wagon SpeedAutomatic 2.31 3.08 BerlinaSedan BerlinaStation Wagon
3.3 Litre SL Sedan SixCylinder SpeedAutomatic BerlinaSedan 2.31 3.08 EFI Cala is 5.0 Litre 3 SpeedAu tomatic Eight Cylinder All Models z.J I 2.60 3.08
4 GENERALINFORMATION OA.3
4. ENGINEDATA
ENGINE DESIGNATION 3.3 L]TREEST 3.3 LITREEFI 5.0 LITRE
PISTONDISPLACEMENT NOM.- cc 3298 3298 5044 COMPRESSIONRATIO: 1 8.8 8.8 9.2 NUMBEROF CYLINDERS 6 6 R BORExSTROKE-mm 92.O75x 82.550 92.075x 82.550 101.60x 77.775 TAXABLEH.P. RAC or SAE 31.5 31.5 51.2 POWERK.W. DIN 86 kw @4200 106kw @4400 117kw @4000 @ R.P.M. TOROUENm DIN 232 Nm @2400 266 Nm @3200 336 Nm @2400 @ R.P.M.
5. EXTERIORDIMENSIONS
SEDANMODELS STATIONWAGON MODELS BODY DIMENSIONS 8VK19 8VL19 8VX19 8VK35 I 8V135
OVEBALLLENGTH 4713.5 4713.5 4713.5 I 4716.5 4716.5 OVERALLWIDTH 1722 1722 1722 1722 1722 OVERALLHEIGHT I 378 1374 1360 1401 1465 WHEELBASE 2668 | 2668 2668 2668 2668 OVERHANG_ FRONT 922.5 922.5 922.5 922.5 922.5 OVERHANG_ REAR 1123 1 123 1123 1 126 ttlo TREAD- FRONT 1451.3 1451.3 t45 I .J t45 | .J 1451.3 rREAD - REAR t4 lo.3 1416.5 1416.5 1440 1440
Dimensionsin mm
5 OA-4GENERAL INFORMATION
6. SERIALNUMBERS The complete vehicle and various components of the vehicle are identified by number plates or numbers stampedinto the part. lt is essentialthat when compiling warranty claims or product and field reports that the vehicle identificationnumber 'VlN' is quoted in conjunc- tion with the identificationnumber of the component affected.
6.1 LOCATIONOF IDENTTFICATION PLATES Plates are attached to the left side wheelhousereinforce- ment and the front panel upper (reler Fig. 0A-l).
SAFEW COMPLIANCEPLATE - Refer Fig. 0A-2. BODY AND OPTION IDENT|F|CAT|ONPLATE - Refer Fig. 0A-3. VEHICLEIDENTIFICATION PLATE - Refer Fig. 0A-4.
Flgure 0A-1
6.2 SAFETYCOMPLIANCE PLATE (Not applicableto Export). THIS VEHICLE Plate WAS MANUFACTURED BY stamped with the following information: Flefer GENERAL MOTORS-HOLDEN'SLI MITED Fig. 0A-2. TO COMPLY WITH AUSTBALIAN DESIGN RULES NOS. AUSTRALTANDEStcN RULENOS. (A.D.R.) 1,2, 3A. 40,58. 6, 7, 8, 108, 11. 12, 14, 15, 15, 1aA,20 21, 22A, 23A, 24, 25A, 27C, 28A, n, 31, 34 VEHICLEMAKE - HOLDEN. VEHICLEMODEL NAME AND STYLE. MONTHAND YEAR OF MANUFACTURE. 3-84 VEHICLE AVKOOOOOTA SERIALNUMBER. GVw Ks sEATING cAp. s SEATINGCAPACITY OF VEHICLE. THIS PLATE IS AFFIXED WITH THE APPROVAL OF THE GROSSVEHICLE MASS IN KILOGRAMS. AUSTRALIAN MOTOF VEHICLE CERTTFICATIONBOARD
Flgure 0A-2 6.3 BODY& OPTIONIDENTIFICATION PLATE GENEFAL MOTORS_HOLDEN'SLIMITED Plate stampedwith the followinginformation - Refer Fig.0A-3. CORRESPONDENCEMUST BEAR THESENUMBERS MODEL: VK8VL19 MODEL: BODY NO.: 621423A Combinationof lettersand numbersidentitying the TRIM: 1442-63X Body, Modeland Style. PAINT: 567-30518 BODYNO.: BUILT: MAR84 Referencenumber followed by Assemblyplant Suffix. ENG.44 TRANS.M4O AXLE GU4 A - Adelaide M - Melbourne MADE IN AUSTRALIA NZ - New Zealand
TRIM: Figure 0A-3 ExteriorPaint Colour and Trim combination. PAINT: ExteriorPaint Material and Colour identificatron. BUILT: Thedate of manufactureby calendarmonth ano vear in which the body shell and power train are conjoined and the vehicle is driven or moved from the production line-
6 GENERALINFORMATION OA-5
VEHICLEIDENTIFICATION The significance of these characters or blocks of 6.4 characters is explained below, using as an example NUMBERINGSYSTEM identificationnumber:- The Vehicle ldentificationNumbering System (V.l.N.) is 8L19LDL60oO25K based on the uniform Car Model Designation System' This is to identify the vehicle in one coded series of characters.
r GENERALMOTORS-HO LOEN'S LIMITEO o
MODELDESIGNATION Division Degreeof Luxury Body Style Code ENGINECODE MODELYEAR CODE ASSEMBLYPLANT CODE SERIAL(Sequence) NUMBER SERIESCODE
MODELDESIGNATION Division - 1st Character- 8 - StandardNumeral allocated to GMH Limited Degree of Luxury - 2nd Character- L :- K - COMMODORE'SL' L. COMMODORE"BERLINA" X. "CALAIS' Body style code - 3rd & 4th character - 19 Body Style ldentification 19 - Sedan (4 door, 6 window) 35 - StationWagon
ENGINECODE Sth Character- L - Engine ldentificationCode. L - 3.3 litreEST K - 3.3 litreEFI T - 5.0 litre"
MODELYEAR CODE 6th Character- D - ldentifiesModel Year. This letter changes 1st September each year & relates to GM Internal OPerationsOnlY:- D-1984 E-1985 F-1986
ASSEMBLYPLANT CODE 7th & 8th Characters- J6 - AustralianAssembly Plant ldentificationCode:' Jl thru J9 - Melbourne L1 thru J9 - Adelaide
SERIAL(Sequence) NUMBER 9th to 13th character- 00025 - sequentialProduction serial Number. NOTE: This designatesthe SeriatUnit Numberat each Vehicle Plant, starting at (00001) and continues in Numerical Sequence regardless of vehicle type-
SERIESCODE 14th Character- K GMH LimitedModel Code Designationfor each Model Programme. e.o.'VK'.
Flgure 0A-4
7 0A-6 GENERALINFORMATION
6.5 VEHICLESERIAL NUMBER The vehicle serial number is stampedon the top of the left hand side strut tower - Refer Fig. 0A-5. 1. DESIGNRULE COMPLIANCE LETTER. 2. VEHICLESERIES'VK'. 3. ASSEMBLYPLANT SERIAL NUMBER. 4. ASSEMBLYPLANT IDENTIFICATION 'A' ADELAIDE. 'M'MELBOURNE. 5. REQUIREMENT IN EVENT OF SERIAL NO. DUPLICATION. 6. REQUIREMENTIN EVENT OF SECOND OR FURTHERSERIAL NO. DUPLICATION. nEr FllolE TT R2T II I AVK OOOOO1A 6.6 ENGINESERIAL NUMBER Figure 0A-5 The engine number for 3.3 litre engine is stamped on a pad above the right hand engine mountingboss, and at top front left side of cylinder and case for 5_0litre engines.
J ENGINENUMBER PREFIX ENGINETYPE
VL J.J ilIre trS I VK 3.3 litre EFI VT 5.0 lltre Automatic
7. ADDITIONALGENERAL INFORMATION ELECTRICAL TRANSIENTS AND RADIO FREQUENCY INTERFERENCE Electronic circuits are used in VK Series rnodels to performa number of functionsassociated with electronic instruments,electronic fuel injectionand electronicspark timing.These circuitscan be damagedor cause mallunc- tion by electricaltransients or excessiveradio frequency (RF)radiation.
RADIO FREQUENCY INTERFERENCE One of the chief sources of RF interlerence is the ignitionsystem; other sourcesinclude CB radio and radio telephones-The followingare normallyused to suppress RF interference. Resistors e.g. high tension cables and connectors. Capacitorsand chokecoils. Metal braid lor screening leads or suppression covers made from conductivematerial for scree- ningequipment. To preventdamage to equipment: Do not replace interference- suppressedhigh tension ignitioncables or conneclorswith un_ suppressedtypes. Do not remove or reposition interferencesup_ pressionfilters or cagacitors.
8 GENERALINFORMATION OA.7
ELECTRICAL TRANSIENTS Electricaltransients are high voltage spikes producedby the sudden switchingor interruptionof electric currents. Older styletiming lights and batterychargers can produce serioustransients, hence it is importantto use only good quality equipment suitable for use with electronic systems. It is also good practice to ensure that the battery is disconnectedbefore using a battery charger. Indiscriminatefitting of solenoids,indicators or relayscan also causetransients.
SOURCESOF INTERFERENCE IN A MOTOR VEHICLE (EXAMPLE)
1. ALTERNATOR
2. ELECTRIC FUEL PUMP
3, ELECTRICWINDSCREEN ld1a!*\ WASHER T;- 4. BLOWER MOTOR q 5. ELECTRICWINDSCREEN =\ Lja WIPER 6. SPARK PLUGS )wllrrn 7. IGNITION DISTRIBUTOR
8. rGNlrloN colL I iltl rfrh 9. HORN ,dH' '1iitT -# l:: :..1 10. INDICATOR WITH VOLTAGE Vlr - STABILIZER T*fl'-ffi#m^ E:T (e.9.FUEL GAUGE) l:l H ffifffin4-"Fu --:-=-.. \ rdlfu \ ADDITIONAL SOURCEOF INTERFERENCe;I [ :\': ::::l 'o ) POOR ELECTRICAL CONNECTIONS I ___,--l BETWEENTHE VABIOUS METAL PARTS i (e.9. I OF THE VEHICLE BETWEEN THE i //i/1 ENGTNEAND FTREWALL). - I ------\, l/ 1
Figure 0A{
9 LUBRICATIONOB.1
SECTIONOB LUBRICATION INDEX Ref. Subiect Page Ref. Subject Page 1. GENERALINFORMATION 0B-1 1.3 AIR CLEANEB...... 0B-2 1.1 RECOMMENDEDLUBRICANTS ...... 0B-2 1.4 FUEL FILTER 0B-3 1.2 BRAKE FLUID REPLACEMENT...... 0B-2 1.5 COOLINGSYSTEM 0B-3
1. GENERALINFORMATION This section provides details of the lubricants specific to services should be canied out are contained in the VK seriesvehicles. Service and Maintenance Section of the VK Series lnstructions on the time or distance intervals at which Owner Handbook.
CAPACITIES
ENGINESIZE CAPACITY
Engine- ServiceRefill 3.3 Litre 3.7 Litres 5.0 Litre 4.33 Litres Add for Oil Filter ALL 3 Litres ManualTransmission (ProductionOption MC6) 3.3 Litre EST 1.6 Litres ManualTransmission (ProductionOption M76) 3.3 LitreEST 2.75 Litres AutomaticTransmission (Dry) (lnc. Converter) 3.3 Litre 6.1 Litres 5.0 Litre 8.7 Litres ServiceRefill . 3.3 Litre 2.3 Litres 5.0 Litre 2.3 Litres CoolingSystem 3.3 Litre 8.5 Litresapprox 5.0 Litre 12.0 Litresapprox BrakeHydraulic System ALL .62 Litres
10 OB.2LUBRICATION
1.1 RECOMMENDEDLUBRICANTS
GMH COMPONENTS SPECIFICATION LUBRICANTS
Engine 3.3 Litre EST SE Oils For gradesand application,refer Fig. 0B-i 3.3 Litre EFI I Se Oits For gradesand application,refer Fig. 0B-1 SF Oilsfor severeservice. Refer OwnersHandbook. 5.0 Litre SE Oils For gradesand application,refer Fig. 0B-1 ManualTransmission ProductionOption MC6 HN1046 SAE 8OW9O ProductionOption M76 HN1855 CastrolGear Oil 80W Automatic Transmission GM9985286 DEXRON I[ Automatic TransmissionFluid RearAxle HNi 181 if unavailable EPSAE 90 RearAxle L.S.D. HN1561 PowerSteering GN49985286 DEXRON If Automatic TransmissionFluid BrakeSystem HN1796 PolyglycolBrake Fluid to GM SpecificationHN1796
-1oo oo 1oo 2oo 3oo 4oo 5oo DEGREES_ CENTIGRADE
Fagure0B-1
1.2 BRAKE FLUIDREPLACEMENT The polyglycolbrake lluid used in VK Series models is hydroscopicand absorbs moisture from the air throuoh the brake hoses etc. The boiling resistanceof the flu'id decreasesas the moisturecontent increasesand so the possibilityof a vapour lock under heavy brakingcondit- ions increaseswith the age of the fluid. Therefore,for maximum brake effectiveness,a two yearly change of brake fluid is mandatory.Service Instructions for changing brake fluid are covered in Section 5, Service Ooeralioi 2.1 in this Supplement.
1.3AIR CLEANER The air cleaner element may be partiallycleaned of dust by lightlytapping the element.lt shouldnot be washedor oiled.The time or distanceintervals at whichthe element requrres servicing depends on the vehicle operating conditions.Under dusty conditions, the elementshould be checked for restrictionmore often that for normal citv operation.
11 LUBRICATIONOB.3
The air cleaner elementshould be replacedat the time or distance interval specified in the VK Series Owner Handbook. ServiceInstructions tor the removaland installationol the AIR FLOW FLOW element (Fig. 0B-2), on vehicles with f,\ ;AlR air cleaner METER DUCT electronic fuel injection are covered in Section 6C, / ServiceOperation 3.6 in this Supplement. AIR CLEANER HOUSIN G
Figure 0B-2
1.4FUEL FILTER INLINE On 3.3 litre engineswilh electronicspark timing,a fuel {ilter is located in the suction side of the fuel line and TO FUEL PUMP-\. / to the right handfender panel. Refer Fig. 0B-3' >-}^iq c; attached ---l-')w-t fuel iniected vehicles, the fuel filter On electronic -\ I (Fig. OB-4) is located on the pressure side of the tuel ll---- pump and attached to the floor pan of the vehicle, in -*i-rl front of the differential. Fuel lilters should be replacedat the time or distance specifiedin the VK SeriesOwner Handbook. MOUNTING intervals BRACKET ServiceInstructions for the removala;rd installationof the fuel filter on electronictuel iniectedvehicles are coverecl in Section6C, ServiceOperation 3.15 in this Supplement. R+ FRONT OF CAR
Figure 0B-3
1.5 COOLINGSYSTEM RUBBER_lNSULATOR The cooling systemis filled initiallywith a coolantmixture ; comprising 1.5/o to 3.0% (by volume) of corrosion inhibitorto GMH specilicationHN1109. /t..\\ '\\ --\ It is recommendedthat the coolant be drained, the hl systemflushed and refilledwith clean water and inhibitor rnixtureat the time and distanceintervals sel out in the \ VK SeriesOwner Handbook. _\))\ Reier to Service Operation 2.2, Section68 'Cooling lriA System'of this Supplementfor details. 1r| 6/:( iq6* (-ryy-^,R a MOUNTING ,f.1'.t*./','ffi\->(l ' ruuriii'')i'-\ll , , \1'l\, 'Y;r/ /
CLAMP BOLT
Figure 0B-4
12 BODY 1A-1
SECTION1A BODY CONTENTSOF THIS SECTION Ref. Subjecl Rel. Subject Page 1. GENERALINFORMA 6. SEATS& SEAT BELT ASSEMBLIES.....-....1A.31 2. UNDERBODY 1A-3 7. EXTERTORORNAMENTATION ...... 1A-39 3. 8. ROOF RACK ...... 1A-s1 4. REAR QUARTER 1A-19 9. BODY ELECTR|CAL...... 1A-53 5. STATTONARYGLASS ...... 1A-21 10. SPEC|ALTOOLS ...,.... 1A-67 1. GENERALINFORMATION INDEX Ref. Subiect Page I Ref. Subject Page 1.1 GENERALDESCR|PT|ON...... 1A-1 | 1.2 SERVICENOTES 1A-1
1.1 GENERALDESCRIPTION This Section contains descriptions and procedures lor interior and exterior body service operationson VK Series Commodoreand Calais models.When used in conjunc- tion with previously released Commodore Service Publications, it will provide information necessary for etficient servicing of VK body styles and their related assemblies. The VK Series includes two different body styles: the '19 Style, which is a six window sedan and the 35 style StationWagon. sEcrroruA-A The stationary fifth and sixth windows on the new 19 in their upper rear quarter apertures Styles are retained SEAT BELT with urethane adhesive, which creates a bond between the glass and the metal flange to which it is applied.On 35 Styles, the tailgate window is retained with urethane adhesive; the same material which is used in production FlgurelA-'l to retainthe JB CamiraWindshields and back windows' involving high heat application, appropiate precautions Also featured on VK Series are revised transmission against fume inhalation such as the wearing ol re- consoles, new instrumentpanel facia and instruments, spirators,forced ventilation,etc., are mandatory.Whene- seat and door trim designs and 'see through' head ver possible, such repairs should be canied out without restraintson front seats. the use of high temperature producing equiPment. On the Calais model, see through head restraints are fitted to the rear seats. Electricallycontrolled exterior rear IMPORTANT: Whenever items such as body side vision mirrors are also standard on this model. An mouldings,Dealer name plates,mud/9lash guards,etc., adjustablelumbar support built into the drivers seat back which requirepiercing of sheet metal panels,are added is includedon Berlinaand Calaismodels. to a vehicle after it has been manufactured,a possibility VK external features include new exterior ornamentation, exists for sheet metal corrosionto occur in areaswhere decals, tailgate handle on 35 body style, radiator grille the metal has been pierced, as well as other areas and colour co-ordinated front and rear bumper bar affected by water entry at the point of piercing.Abrasion 'added-on' assemblies. of the painted or treated surfaces by the material may contribute to corrosion and unsightly Front turn signal lamps and rear lamp assembliesare appearances. also new. The reliabilityand performanceof 'add-on' equipment 1.2 SERVICENOTES installationsmust become the responsibilityof the maker and the installer (Dealer or vehicle owner). For this small CAIITiON: As a sound deadening medium, a reason,you shouldevaluate the proceduresused in your upper volume of polyurethane foam is installed into the Dealership (and outside sublet shops) to assure that section ot the rear body pillars of VK Commodore propersteps are being taken to provideappropriate sheet Fig. 1A'1. sedans, as illustrated in shaded areas in metal corrosion protection to offset the etfects of with its During norma! seruice, there is no risk associated 'add-on'equipment. use. However, when polyurethane is subiected to high temperatures such as during welding or naked flame CAIJTION: To avoid damage when servicing instrument to cutting, this material can release black pungent fumes. panels, trames, instrumentc/usters, etc., it ls essentia/ During repair of these pafts of the body structure handle these componentswith the utmost care.
13 1A-2 BODY
clvT I
-lT n^l I:=-- ., \.<--rye*-J--96y--- :;; I i1 5 /l z o o >; F tr7 I r o (, o ) z I z> 07t< d lcc o ! +LUa-n o AH O c <= F ,^- I F] IV]S 9NIUdS a z> N o z z o AH - >E r1 F F= <: C) zz o -ft J <3 F FJ 6 L o o J I u.r I JF *< od a-o +l a =Y z
+ t90t E F U I @r E ^ - .,E 3$l CCJL 3 l- < oal z 20 U <; 2 r2 ^uU' JU-: !> 14 BODY 1A.3 2. UNDERBODY INDEX Ref. Subject Page Rel. Subject Page 2.1 UNDERBODYDIUENSIONS & HOIST 2.4 SHROUDLOWER TRIM . RIGHT& LEFT LOCATIONS. 1A-2 HAND ...... --..- 1A-6 2.2 TRANSMISSIONCONSOLE.MANUAL...... 1A-3 Remove....--.. 1A-6 llodel - 'SL' 1A-3 Reinstall 1A-6 Remove 1A-3 ROCKERPANEL COVER - RIGHT& Relnstall 1A-3 LEFTHAND. 1A-6 Models - Calais & Berllna fltted Remove...... 1A6 with Power Operated Slde Reinstall 1A-6 Wlndows...... 1A-3 FLOORCOVERING 1A-7 Remove...... 1A-3 Remove....,...... 1A-7 Reinstall 1A-3 Reinstall 1A-7 TRANSMISSIONCONSOLE. AUTOMATIC 1A-5 Remove.,,..-.. 1A-5 Relnstall 'tA-5 2.1 UNDERBODYDIMENSIONS AND HOISTLOCATIONS ReferFig. 1A-1A. 2.2 TRANSMISSIONCONSOLE . MANUAL MODEL.'SL' Remove 1. Disconnectbattery ground cable. 2. Unscrew knob from gearshift control lever, then screw cover buttons and screws securing front and reat of console to transmission tunnel (refer Fig. 1A-2). 3. Partially raise console then disconnect electrical connectorsprior to removalof transmissionconsole. Reinstall Reverseremoval operations, ensuring that non hardening sealer is appliedto the threadsof the console attaching screwsprior to their installation(refer Fig. 1A-2). MODELS. CALAIS & BERLINA FITTED WITH POWER OPERATED SIDE WINDOWS Remove 1. Disconnectbattery ground cable. 2. Unscrew knob from gearshift control lever then removecover from handbrakelever. 3. With console compartmentlid raised, remove rear end of carpet in base of console which covers screwssecuring rear end of console to transmission tunnelbracket (refer Fig. 1A-3)then removescrews. 4. Partiallyraise rear end of console,disconnect electr- ical connectors,then easing console reanvards to disengage front end of console from attaching bracket (refer Section B-B, Fig. 1A-3) remove con- sole assembly. Reinstall Reverseremoval operations. 15 1A.4 BODY a WIPER cll---->c, ,/- IWASHER SWtTCH ASM. {4 PLACES) # W z- HEATED REAR WTNDOW Ascnew.-----..---..-->s swlrcHAssEMBLY (4 PLACES) i € GEABSHIFT LEVER CONTROL BOOT OUU I RETAINER (9 PLACES} VIEW TRANSMISSION CONSOLEASM. SECTIONA_A ...-..--. EOOT STRAP TO BE PLACED _ TOWARDS FRONT OF CAR SEAL SCREWWITH NON.PORITE >:\ OR EOUIVALENT NON-HARDENING A VIEWrFrl SEALER. 11",2.4 - 3.4Nm (4 PLACES) Flgure 1A-2 TRANSMTSSTONCONTROL COVER _ FOR AUTO TRANS ,.- g:3I:lf r coNrR o L --r 3?I:3 LEVERBOOT ""?:'j BEFORE INSTALLATION APPLY ,^ NEOPRENECEMENT TO INSIDE ": OF BOOT OVER AREA SHOWN / THUS, /////// FOR 533|,13'^G /- CONNECTTON -r' ' REFER SECTION 12E _=_==3*{ acARPET /-**-f.* / SECTIONB_B REFER SECTION 12E r_ -_ / vrEWa A TRANSMISSION CONSOLEASM. ELECTRIC DOOR WINDOW REGULATORS APPLY TRIM ADHESIVE SWITCH ASSEMBLY OVER AREA SHOWN THUS \\\\\\\ ( B POINT'A' - r.'/ lu /i- 961=) -->-rr- Y ,6, s.t-SPEED NUT _---- :4 - ; - -- =, "-4:1 SECTIONA_A /t \ I .5 - 2.0 Nm Figure 1A-3 16 BODY 1A-5 2.3 TRANSMISSIONCONSOLE . AUTOMATIC Remove 1. Disconnectbattery ground cable. 2. Using a wide bladed screwdriver,carefully prise cap from console (refer SectionC-C, Fig. 1A-4)turn cap through 90C, then remove cap of 'T' bar gear control lever. 3. Remove gear lever location indicator scale from console (referSections A-A and B-B, Fig. 1A4). 4. On 'SL' models, remove screw cover buttons and scrervs securing lront and rear end of console to transmissiontunnel (refer Fig. 1A-2). 5. On Berlina and Calais models. raise console compartment lid and remove rear end of carpet in base of console which covers screws securing rear end of console to transmissiontunnel bracket (refer SectionB-8, Fig. 1A-3)then removescrews. 6. Partially raise rear end of console, disconnect electrical connectors then, easing console rearwards to disengagefront end of console from attaching bracket (reler Section B-8, Fig. 1A-3),then remove screwsand consoleassembly. Reinstall Reverse removal operations ensuring that the note relerringto automaticconsole scale installationin Fig.1A- 4. is observed. CONSOLECAP _ +---___> € <.,/ ' sEcrroruA-A CONTROL LEVER OPENING COVER RETAIN SCALE AS SHOWN WITH GEAR SHIFT LEVER \ IN NEUTRAL, ALIGN'N'ON SCALE WITH INDICATOR ARROW ON COVER BEF RETAINING SCALE. srcrroruB--B CONSOLECAP i././r2,./ sEcrroruC-C (4 PLACES) TRANSMISSIONSELECTOR INDICATOR_ TRIMATICAUTOMATICTRANSMISSION Figure 1A-4 17 1A-6BODY 2.4 SHROUDLOWER TRIM - RIGHT& LEFT HAND REMOVE 1. Prise front end of front rocker panel cover from rockerpanel (referSection A-A, Fig. 1A-5)then ease lower front end of linishing lace and weatherstrip assemblyfrom door opening pinchweldflange (refer SectionA-A, Fig. 14-6). 2. Using a fabricated trim clip removal tool (refer Special Tool Section) located between shroud lower trim and shroud panel and direcily under fastener head (referSiections B-B and F-F, Fig. 14-6) careful- ly prisefasteners from shroud panel,removing trim. REINSTALL Reverseremoval operations. 2.5 ROCKERPANEL COVER - RIGHT& LEFT HAND REMOVE 1. Using a wide bladed prisingtool positionedbetween outer edge of cover and rocker panel,carefully prise cover from door opening lower pinchweld flange (referFig. 1A-5). REINSTALL Locate front cover over door opening lower pinchweld flange,ensuring that ends of cover overlapends of door openingfinishing lace, then using the hand or a rubber mallet, tap top of cover until it completely engages retainingflange. NOTE:On rear covers,locate front end of rear cover so that it butts against the rear end of the front seat belt retractorcover priorto tappingcover into position. fREAR ROCKER PANEL COVER \ ; FRONT ROCKER / PANEL COVER ._- A - secrroHA-A secrroruB_B secrrorvC-C ROCKERPANEL COVER INSTALLATION Figure 1A-5 18 BODY 1A-7 CARPET PROTECTOR FLUTED FACE DOWN. 8VL, X EVK SECTION A_A TRIM -J FASTENE R /r" ,-o*.* t*) ONE PIECE FLOOR CARPET SECTION B_B (RIGHT SHROUD NOTE: SERVICE REPLACEMENT SIDE ONLY) _ TWO PIECE TRANSMISSION -m t CONSOLE 'a -. \ LOWER TRIM-\ t/ TRIM secrrorrrF -F 8vK SHROUD \ - rAJ ttrt\trH (LEFT SIDE ONLY} CARPET ATTACHING PLUG 12 PLACES \ SECTIONC-C SECTIOND_D SECTIONF_F 8VL, X (LEFTSIDE ONLY) Figure 1A€ 2.6 FLOORCOVERING REMOVE 1. Disconnectbattery ground cable. 2. Bemove front end rear rocker panel covers and shroudlower trims (reler2.5 and 2.4 in this Section). 3. Removetransmission console (reler 2.2 or 2.3 in this Section). 4. Remove panel cover assembly from heater case (referFig- 1A-7). 5. Removefront seat and rear seat cushionassemblies. Remove front seat belt retractor covers and seat belt inner and outer, lower attachingbolts (refer 6.3 in this Section). Using a fabricated trim clip removal tool (refer Special Tool Section) located between edge ol carpet and rocker panel and directly under head ol carpet attachingplug, prise plugs from rocker panels (refer Section C-C, Fig. 14-6) then remove floor covering. REINSTALL Reverseremoval operations. . LOWEB INSTRU\4E\T NOTE: Separate front and rear floor coverings are PANEL EXTENSION availablefrom GM P & A as ServiceReplacements- - HEATER CASE TO PANIt. COVER ASM. Figure 1A-7 19 BODY 1A-9 3. FRONTEND INDEX Ref. Subject Page Ref. Subject Page . 3.1 SEHVICENOTE 1A-9 3.4 INSTRUUENTPANEL LOWER RIGHT 3.2 INSTRUMENTPANEL LOWER TRIM. HAND ...... 1A-16 RIGHT & LEFT HAND 1A-9 Remove .. 1A-16 Reinstall ...... -...1A-16 3.5 INSTRUMENTPANEL LOWER. LEFT 3.3 HAND INCLUDINGRADIO AND RADIO/CASSETTEPLAYER RECEIVER.... 1A.16 Relnstall ...... 1A-10 Remove...... 1A-16 Relnstall ... 1A-17 3.1 SERVICENOTE REINSTALL Reverseremoval operations ensuring that leadingedge of CAIITION: To avoid damage when seruicing instrument left hand trim is correctlylocated beneath the dash panel panels, frames, instrumentclusters, etc., it is essent€t/to bracket and into wiring harness grommet (refer Section handle these components with the utmost care. C-C, Fig. 1A-8) and that the leading edge of the right hand trim is locatedin the acceleratorpedal supportcap' as illustratedin SectionB-B, Fig. 1A-8. 3.2 INSTRUMENTPANEL LOWERTRIM . RIGHT& LEFT HAND REMOVE 1. From under instrumentpanel and using a labricated trim clip removal tool (refer Special Tool Section) located directly under head of trim clip, carefully prise clips from attachingholes in instrument.panel lower (referSection A-A' Fig. 1A-8)removtng trtm' NOTE: Removal of right hand lower trim necessitates disengagementof adlustablestrap which partiallysecures trim t; Jteeringcolumn (refer Section D'D' Fig' 1A-8)' 5 TRIM CLIP \ _5PLACESR/SIDE \ - a PLAcES L/slDE EXc. c6o \-2PLAcEs LislDE&c6o "r LOWER PART - INSTRUMENT secrtoruA-A PANEL LH INSTRUMENT ACCELERAToR--7 PANEL LOWER TRIM PEDAL |, cr lopnFIT r-AP - 8VX & C6O -<\ - \ .>t-, erusunETRtM BoARD ls RH INSTRUMENT-/ -- ASSEMBLEDIN ACCELERATOR PANEL LOWEB TRIM PEDAL SUPPORTCAP AS SHOWN ADJUSTABLE-_\ secrroruB-B STFAP RETAIN FRONT EDGE OF INSTRUMENT- PANEL LOWER TRIM RIGHT SIDE TO STEERINGCOLUMN DASH PANEL SEAL TRIM BOARD TO BE WITH ADJUSTABLE STRAP, ASSEMBLED INTO WIRING HARNESS tr LtrSJ5IhAT IUbtr GROI\4MET TUCKED AWAY OR TRIMMED. secrroruC-C Figure 1A-8 20 1A.10BODY 3.3 INSTRUMENTPANEL PAD REMOVE UPPERSTEERING 1. Disconnectbattery ground cable. COLUMN COVER 2. Remove screw attached lower cover from upper sectionof steeringcolumn (refer Fig. 1A-9). 3. Remove screws securinginstrument frame, centre air outlet nozzle and touch panel lrom instrumentcover, disengage electrical connectors from main wiring harness (refer Fig. 14-10) then remove fram6 assembly. 4. Remove screws securing top of instrument panel lower extension to base of instrument location cover A ..u - 4.6Nm (referFig. 1A-10). 5. Remove screws securing combined instrument Flgure 1A-9 assemblyto instrumentlocation cover (refer Fio.1A_ 1 1) ease assembly.rearward then disengage eiectr- ical connectorsand on all models,excepi those with electronic instruments, the speedo cable from speedohead (referView A, Fig. 1A-1j) then remove instrumentassembly. 6. Remove instrumentlocation cover (refer Fig. 14_11) front radio speaker grille and speaker assem-blylrefei ViewB, Figs.14-12 and 14-13). 7. Using a fine bladed screwdriver,carefully prise right hand and left hand upper and lower inserts from within side vent upper ouflet assemblies prior to removingscrews securingupper air outlet assemblies to instrumentpanel pad assembly(refer Fig. 14-14) then removeoutlet assemblies. 8. With instrument panel compartmentopen, remove screws securing rearward edge o{ instrument Danel pad to instrumentpanel brace (referFig. 14-14). 9. Usinga 10 mm socketattached to a ratchet handle, loosen right and centre nuts securingpad assembly to instrumentpanel brackets(refer Fig. 1A_11).Usin! the same tool with a 630 mm entensioninstalled oi the left hand attachingnut (use left hand upper air outlet apertureto gain access) loosen off left hand nut. 10. Ease pad reanaards,disengaging pad studs from anstrumentpanel slotted brackets. With left hand of rnstrumentpanel pad raised, remove pad assembly fromvehicle. REINSTALL Reverseremoval operations, including try-out of electrical ctrcurts, air ducting, vacuum hoses and temperarure controlcable disturbedduring removal operations- 21 BODY1A-11 J Tu ;z F r< z :o tIJ z B __: ao l a tu Itr tr z I OF F ul @ z )z F Ul X z = U (J- if -J F z< u! U IU (J >: 3 z U ul-|: a N. -( J u 32> r 2uo I f c_ :E< r I tr F FF> ul z=< c il P< J ?o t r^ F U. I z= z fr A(- = > cc \! ft 5r = cn z ilu U It == \ (-1 z- z i-) \ \\ ao F T Z; U \H z = Lu ,(,\ i z 3 O /\J U -z_ E r N >y I 6 U cz o FP o/ 3? 6t (3a. t!l t^ zx_U 9n (! o I uJ,,1--.1 \i-:co v r'. i => -9 ...\- ) o< l! !_\_\ / (\r€\l- \.\ \\/ .:z} \I\\ 6 uJ 29 j -a 3 ucc-4 U OU = .,^\ Gv UJ Fr! ' v(Ju 22 14.12 BODY nu U d< (/) Q J I I B U z Or u) ft J ---J z- tsl i OUJ U ur> Z) fi d ; rY tn zv >|; uz UJ -c) U IJ >o =< 8Z J li tlJ tfa N F FK O6 N u 6J l z o (n z2 U U) J CC U7 F uJ F T z L F UJ = z ---\ I I z A14fr LU -zu) \ '---b--- u=rN9AEU zS'- I J {\ L 7z3z /l o Y--uO v\>- /i cc>Eh 3r ul L-LA99SE trl U) o 5 ot lr F tu J r of \\ -, r-1 ,,,\\\,-,'.i 6 :N U >N r!O =< oz llr\\ O- ,^ a U O _uJ i< \L =: z:: -*co :_: l o U \\ L l,A\ \\ LJ ili \ '.\ F zS z rrQ) \ U -tr- l U) tr cc il< F zo l = LL 23 BODY 1A.13 E 3 uJ ; : F o z U l 3 o U J F ) UJ IF o ? -t! U GI -<:CO t- z'. o a> I IL -t -66< z a F i 2 o n - f -E cc a T t -, U F >Y *i< S n; 24 1A-14BODY a = ,> t tr q z o J\ i:, LLU 9o r= L\z zE (I llrY- R:tff U -(9 UJ - =vUt U FJ :FJ; UF LgD ;F u'loO- : z u UIF o< -ul^(f q). OT=U o >c) ut F tr (r-!{v U zyu UU UV U xF\< .tt Z U-< )lJ @--- z UU v; 5 o Y a z (r l u (, F v j z L Hr F S ;.^ U z z f :=cc ) ul o F.^( o dl ?22 a U 5=i € o z Y 'xo il th li tr 1vu N q>O it\ ul i\ ul *uf ? I \ I ) U z F< ZO U< 3 >L u U )t E t +uJ z o h= zE F I z z9 N = 25 BODY 1A-15 F z z ,u ooJ F ZE -;> P.:YA 3; IIJ (r !t FF 3-*gq ( U FJ v< Jp- rU t 26 1A-16BODY 3.4 INSTRUMENTPANEL LOWER. RIGHTHAND REMOVE 1. Disconnectbattery ground cable. 2. Remove screws securing instrument frame, centre air outlet nozzleand touch panel from instrumentcover (refer Fig. 14-10), disengage electrical connectors from main wiring harness then remove frame assembly. 3. Usjng a fine bladed screwdriver, carefully-within prise out right hand upper and lower inserts from side vent upper outlet assembly. Remove screws securing upper air ouflet assembly to instrumentpanel pad (referFig. 14-14)then remove ouflet assembly. 4. Remove screw attached lower cover from upper sectionof steeringcolumn (refer Fig. 1A-9). 5. F_romunder right hand side of instrument panel, disengage electrical connectors from rear of light switch and dimmer control, vacuum hoses and temperature control cable, remove panel cover, then screws securing right hand instrument panel lower to base of instrumentlocation cover (refer View 'B' and Section A-A, Fig. 1A-14) then remove instrument panel lower. 6. Using a wide bladed screwdriver, carefully prise headlampswitch and dimmer control housing,ihen dimmer control from right hand instrumeni panel lower. REINSTALL Reverseremoval operations, including try-out of electrical circuits, air ducting, vacuum hoses and temperature controlcable disturbedduring removal operations. 3.5 INSTRUMENTPANEL LOWER. LEFT HAND,INCLUDING RADIO AND RADIO/CASSETTEPLAYER RECEIVER REMOVE 1. Disconnect battery earth cable. BUMPER \N 2. Removetransmission console (reler 2.2 or 2.3 in this (2 PLACES) Section). 3. Remove heater case to panel cover assembly (refer Fig. 1A-10). 4. Remove left hand instrument panel lower trim (refer SectionA-A, Fig. 1A-8). 5. With instrument panel compartment open and with the blade of a screwdriver located between head of hinge pin and right hand compartmentside, prise out hinge pin compartment(refer Fig. 1A-t5) ihen re_ move comDartment. 6. Removeleft hand shroudlower trim (refer2.4 in this Section). 7. Removelett hand upperside vent ouilet (refer3.4 in this Section). 8. Remove touch switch control panel and electrical connector(refer Fig. 1A-10). INSTRUMENT PANEL COMPARTMENT 9. Remove screws securing the centre nozzle and instrumentlocation frame assembly(refer Fig. lA_10) disengage electricalconnectors from front e-nOwiring Figure 1A-15 harness,then removeframe assemblv. 27 BODY 1A-19 4. REARQUARTER INDEX Ref. Subiect Page 4.1 OUARTERWINDOW INNER UPPER TRIM 1A.19 ilodels - 19 Body Styles ...... 1A-19 INNERUPPER 4.1 QUARTERWINDOW CUSHION ASM.- REAR FLOOR TRIM RETAIN ER BRACKET MODELS. 19 BODY STYLES Remove 1. Depress front edge of rear seat cushion assembly then ease assembly rearwardsto disengageassemb- ly retainer from brackets attached to the floor (refer SectionA-A, Fig. 1A-16)remove and place assembly secrroruA-A onto a clean protected surface. NOTE: On rear seats fitted with head restraints, it is necessary to remove the head restraints and guide sleeves(refer 6.4 in this Section)prior to removalof rear seat back assembly. REAR COMPARTMENT 2. Unclinch tabs securing seat back frame to rear FRONT PANEL wheel-houses(refer View A, Fig. 1A-16). 3. Lift seat back frame from retaining brackets attached to the rear compartment front panel (refer Section B-8, Fig. 14-16) then place rear seat back assembly onto a clean protected surface. SEAT BACK RETAINER secrroruB-B k=- , Flgure 'lA-16 Remove rear seat belt upper attachment (refer SectionB-B, Fig. 1A-17). Figure 1A-17 28 1A.20BODY 5. From inside rear compartment,tap out fasteners securingtrim to rear parcel shelf (refer Section A-A, Fig. 14-18) quarter REAR PARCEL on side from which window trim SHELF is to be removed. TRIM FA5 III\EH (3 PLACES) SECTIONA_A Figure 1A-18 6. Ease rear door openingfinishing lace from leading edge ol quarterwindow inner upper trim, then usini a broad bladedscrewdriver located between trim and quarterinner panel,adjacent to trim fasteners (refer Sections A-A and B-B, Fig. 14-19) carefully prise fasteners and trim lrom rear quarter inner upper panet. IaUARTER WINDOW Reinstall INNERUPPER Fleverseremoval operations. NOTE: Damaged barbs on trim panel fasteners requtre fastenerreplacement. FASTENERS_\ secrroruA-A secrloruB-B {4 PLACES R/L) (1 PLACE Ri L) Figure 1A-19 29 BODY 14.21 5. STATIONARYGLASS INDEX Re{- Subject Page Ref. Subject Page 5.1 DESCRIPTION ..... 1A-21 5.4 5.2 SERV|CENOTES ...... -...... 1A-21 5.3 REAR OUARTERWINDOW ASSEMBLY.... 1A-22 Models - 19 Body Sty|es...... -.1A-22 Remove...... 1A'22 Reinstall ... 'tA-28 Quarter Window Aperture Check .--. 14'23 Long Method..... 1A-29 Reinstall 1A-23 Reinstall ... 1A-29 5.1 DESCRIPTION The repair kit developedto servicethis Short Methodor Minor Water Leak correction is part number9201861 1 glass is fitted to rear quarterapertures on 19 Toughened and contains: body stylesand to tailgateson 35 body styles. 300 ml UrethaneAdhesive. These glasses are bonded to the rear quarter upper panel and tailgate qperture flanges with a self curing 25 ml ClearGlass Primer. metalto glass urethaneadhesive. 25 ml Glass Black Out Primer. ln situations necessitating complete removal of the NecessaryApplicators. original urethane,such as damage to window apertures Instructions. where paint finish or base metal is exposed,a urethane These replacementkits are availablefrom:- adhesivekit has been developedand must be used to maintainthe originalstructural specifications. Dimet, 53 Showers Street. Part No. 92018612 'Long Method'.The repair kit for this Preston, Vic. 3072. operationcontains: An additionalshort methodreplacement kit which is only 300 ml UrethaneAdhesive. recommendedfor rear quarter windows on sedans, is from GM P & A under Part No. M38977 and 25 ml Glass Primer- Clear. available contains300 ml of silicone. 25 ml GlassPrimer - Black. This materialis also recommendedfor minor water leak 25 ml BodYPrimer. 435-56 correctionon all urethaneinstalled stationary glass. NecessaryaPPlicators. lnstructions. 5.2 SERVICENOTES window replacement- Long Method, NOTE: For tailgate WARNING:WORK GLOVESMUST BE WORNAT ALL kit, Part No. M39097, which an additional auxiliary TIUES WHEN OPERATINGWITH GLASS. contains300 ml of urethaneadhesive, is required. NOTE: Skinning (partial curing) ol the urethane com- ADDITIONALCOMPONENTS REOUIRED (Not part of mencesafter exposureto the atmosphere.At 23oC and package) 50 % relative humidity, skinning commences after window Appropriatemouldings as required. 30 minutes. Therefore, installation of tailgate mouldingsmust be completedwithin that time limit on methodlor window replacementreferred to as A second station wagons. the 'Short Method' is used when original urethane this temperatureand adhesiveleft intact on the windowaperture flanges after Complete curing of urethane at glass removal can serve as a satisfactory base Jor the humiditytakes 72 hours. reinstallalionof the original or new glass. This would The recommendedtool for cutting through the urethane occur when the glass is being removedto overcome a is the glass sealant removalTool No. J24402,which can severewater leak, or when a glass is broken- be obtainedfrom Kent-MooreAustralia Pty. Ltd. 30 1A-22 BODY 5.3 REAR QUARTERWTNDOW ASSEMBLY MODELS. 19 BODY STYLES Remove The quarterwindow glass removalprocedure is similarfor both the 'Short' and 'Long' InstallationMethods with one exception.lf the Short Method installationis to be used, more care must be taken during glass removalto ensure that an even bead of urethane adhesive rematns on quarter window aperture flanges to serve as a base for the replacementglass. 1. To prevent damage to paint finish and trim and to minimiseclean up, mask and place protectivecovers over parts adjacent to glass. 2. Using fingers or a wide bladed screwdriver,carefully prise ..otf _leading edge of roof drip guner teal mouldingfrom garnish moulding(retei S6ctron nU- AM, Fig. 14-20). 3. Remove screw securing rear end of quarter reveal moulding lower (refer Section AN_AN; Fig. 1A-20) and removemoulding. \ *ao" RooF DRrp GUTTERMOULDING QUARTER WINDOW GARNISH MOULDING ASSEMBLY SECTION AM_AM OUARTER WINDOW GARNISH MOULDING LOWER OUARTER WINDOW REVEAL MOULDING sEcrtoNAN-AN Figure 1A-20 4. Femove remainingscrews securinggarnish moulding to rear quart€r aperture (refer Fig. 14_21) thei remove garnish moulding,which is ittached to the outer surfaceof the glass with four (4) short strips of buVl, spaced at top, Oottdm and sides garnish.centrally of moulding (refer View H, Fig. 14_22) then removegarnish moulding. Fagure1A-21 31 BODY 1A-23 S BUTYL STRIPS (4 PLACES) VIEW Flgure 1A-22 glass 5. Locate blade of Tool No. J24402, sealant J24402 remover, beveen inside of glass and urethaneas GLASS SEALANT illustratedin Fig. 14-23, then cut through urethane, REMOVAL TOOL aroundcomplete periphery of glass. 6. Carefully lift glass out of aperture. lf there is evidence of glass adhesion to urethane, re-apply APPROXIMATE cuttingtool to problemarea. AREA EOUALS 7. lf glass is to be reinstalled,place glass on a ONE SOUARE original cENTIMETRE ---7 protectedbench or holdingfixture and using a sharp I scraper, carefully remove original urethane lrom I glass. Clean glass with a suitable oil-free cleaning agent such as Prepsolor equivalent. NOTE: Do not use petroleum base solvents to clean 170 glass or aperture flange as the presence of oil will \ HN 1749 prevenlthe adhesionof new urethane/silicone. 7\ URETHANE ADH ESIVE VIEW Flgure 1A-23 OUARTER WINDOW APERTURE CHECK Thoroughly check rear quarter window aperture flange to ensure that no surface irregularities exist' Correct any that do. lf 'Short Method'glass installationis being used' check originalurethane on flange for loosenessor voids' Where these exist, cut away any loose urelhaneand fill in any voids or uneveness in bead' using urethane/silicone. Reinstall Short Method 1. Short Method installationof rear quarter glass is used where the maximum amount of original urethaneadhesive is left intact on the body opening to form a base for the replacementglass- This method should be used when replacinga cracked glass or leak conditionthat cannot be overcomeby using minor water leak repair procedures. Any previous service installation using other adhesive materialsrequires complete replacementof material to achievean effectiveglass to metal bond. 32 1A-24 BODY 2. Thoroughly clean surface of glass to which new urethane/siliconeis to contact (includingedge of glass). Use clean cloths with a suitaSle oil_free cleaningsolvent, such as prepsolor equivalenl- URETHANEONLY ') Usingan applicatorin Kit,.applyHN1747 (clear glass ?lr"r) around entire perimeterof glass'edge and 12 mm in.from edge of glass.This is-a wipe o"n/wipe off operation,using clean lint free cloths'(referView E, Fig. 14-24). - URETHANEONLY 4. U.singa.second applicator,apply HN1748 (black-out glass primer) around entire perimeterof glasJ edge and on,.glassbonding surface (refer View-G, Fig.1"A_ 24). Allow primer to dry for lS minutes. Avoid touchingprimed area of glass. Install glass with its inner surface facing upwardsinto garnishmoulding as illustratedin View H, Fig. 1A_24, then firmly press glass onto butyl strips loEateo on garnishmoulding recess. Apply a smooth continuous bead of urethaner (BLACK OUT) PRIMER silicone between centre and outer edge on top of originalurethane and aroundentire periireterof body opening. Silicone bead should be a minimum of 6 mm in diameter. 7. Installglass.and garnish moulding assembly into rear quarter window aperture,applying sufficieni pressure on assembly to evenly distribute silicone between glass and aperture flange to effect a watertightseal. BUTYL STRIPS (4 PLACES) VIEW Figure 'lA-24 8. Install screws securinggarnish mouldingto the top and sides of the windowaperture (refer Fig. 1A-25). r5rSCREEW 9. 'lPtr Water leak test quarter window using a moderate AUtrJ spray of water. NOTE: Do not direct a heavy stream of water onto i freshly applied silicone.lf watei leak is evident,remove garnish ,9 moulding and apply additionalsilicone to teak v area, using a flat bladed tool to work fresh siliconernro the sourceof the leak,then installgarnish moulding. Figure 1A-25 33 BODY 14.25 10. Installscrew attachedquarter reveal mouldinglower to lower section of garnish moulding(refer Section AN-AN,Fig. 1A-26). 11. Locatehooked edge of roof drip gutterrear moulding over reanrard outer edge of garnishmoulding, then with the hand, lightlytap oppositeside of moulding over garnish moulding (refer Section AM-AM' Fig. 1A-26). '12. Removepaint and trim protectivemasking tape and REAR ROOF DRIP covers. GUTTER MOULDING NOTE: White spirit is recommended for removal of siliconefrom paintfinish and trim' OUARTER WINDOW GARNISH MOULDING ASSEMBLY sEcrroNAM-AM Long Method The long method of glass replacementis used when original urethane adhesive material cannot serve as a OUARTER WINDOW base lor replacementglass. GARNISH MOULDING This method should be used on vehiclesrequiring metal or paint repair to the quarter window aperture flange when original adhesive is completely removed and replacedwith new urethanefor glass installation. This method is also used when the quarterwindow has been previouslyreplaced, using the Short Method. In such instances,the build-up of urethane/siliconecould LOWER OUARTER WINDOW positionthe glasstoo far out of the opening. REVEAL MOULDING glass removal tool andlor sharp 1. Using the sealant sEcrroNAN-AN scraper,remove original urethane from aroundentire perimeterof quarterwindow apertureflange. 2. Using an applicator supplied in 'Long Method' ReplacementKit No.92023123, apply HN1752 Figure 1A-26 (Flangeprimer) to any section of the quarterwindow aperture flange that is back to bare metal or has been cleaned back to original paint surface (refer Views A, B, C & D, Fig. 1A-27).Allow primerto dry for 30 minutes.Avoid touchingprimed area. FLANGE PRIMER E u,.*lfl u,.*lEl Figure 1A-27 34 1A-26 BODY 3. Thoroughly clean inner surface of glass to which urethaneis to be appliedas well as aroundcomplete edge of aperture flange. Use clean cloths with \-- suitableoil-free cleaning solvent such as prepsol or equivalent- 4. llging an applicator in Long Method Kit, appty HN1747 (clear glass primer) around entire perimeier v 12.O gf glass edge and 12 mm in from edge of glass. This is a wipe on/wipe off operation,ushg - clean lint free cloths (referView E, Fig. 14-28). 5. To maintain appearance and minimise clean up, install a foam sealingdam, part Number920181i9 VI EW to glass.Commencing at either lower cornerof glass, locate dam around entire perimeterof glass, 7 mm from edge on inner surface (refei View F. Fig. 1A-28). NOTE: A suitablegauge to maintainthe dam 7 mm from edge of glass can be readily fabricated by cutting a 7 mm notch in a piece of wood. Locate the 7 mm dimension of the gauge onto the inner surface of the glass, locatingthe outside edge of the dam on the end of the 7 mm dimension. 6. U.singa second applicalor,apply HN174g (black_out glass primer)around entire perimeterof glass edge qnd on glass bondingsurface (refer View-G, Fig.1;A- 291. Allow primer to dry for 15 minutes. Avoid touchingprimed area of glass. 7. Tidy up strips of butyl centrally located on top, bottom and on both sides ol garnish moulding(refer View H, Fig. 14-29) [F 8. Install glass with its inner side facing upwards into 'fE [-cTJl garnishmoulding as illustratedin VievrrH, Fig. 14-29. Firmly press glass onto butyl strips locateJ at four Figure 1A-28 places on garnishmoulding recess- o Using a hand operatedapplicator with specialnozzle supplied in kit, apply a smooth continuousbead of HN1749urethane adhesive, 17 mm high and 7 mm at base, around entire perimeterof inner surface of glass (referView J, Fig. 1A-29). 7.O -\-'/ APPROX AREA EOUALS ONE SOUARE CENTIMETRE oo**,r*l MOULDING URETHANE ADHESIVE BUTYL STRIPS (4 PLACES) Figure 1A-29 35 BODY 'IA-27 placement cartridges NOTE: In cold weather, the of GLASS PAINT-OUT adlacent to a source of warmth, will assist the flow of urethanewhen using a hand applicator. 10. Installglass and garnishmoulding assembly into rear quarter window aperture (refer Views K and L' Fig. 1A-30) applyingsufficient pressure on assembly to evenly distribute urethane between glass and aperture flange to effect a watertight seal' 11. Install screws securinggarnish mouldingto top and sides of the quarter window aperture (refer Fig. 1A-30). GARNISH 12. Water test quarterwindow using a moderatespray of water. NOTE: Do not direct a heavy stream of water onto VIEW VIEW freshly applied urethane. ll a water leak is evident, removegarnish moulding and apply additionalurethane to the leak area, using a flat bladed tool to work urethane into sourceof leak, then installgarnish moulding. x\ '\\ \ '\w \\ Figure 'lA-30 IJ Install screw attached quarter reveal mouldinglower to bottom horizontalpart of garnish moulding(refer SectionAN-AN, Fig. 1A-31). 14. Locate hooked edge of roof drip gutter rear moulding over rearwardouter edge of garnish moulding,then with the hand, lightly tap opposite side of moulding over garnish moulding (refer Section AM-AM, Fig. 1A-31). BEAR ROOF DRIP GUTTER MOULDING OUARTER WINDOW GARNISH MOULDING ASSEMBLY sEcrroNAM-AM OUARTER WINDOW GARNISH MOULDING \ . ! SCREW LowER OuARTEBwrNDow --- REVEALMOULDING sEcrroNAN-AN Figure 1A-31 36 1A-28BODY 5.4 TAILGATEWINDOW MINOR WATER LEAK CORRECTION Locate area of leak. Workingon inside surfaceof glass, apply paint scraper or similar wide blade tool between glass and lacing. Gently flex lacing away from glass in area concerned. Clean any foreign material from this area. Apply HN1770silicone to area concernedro correct leak. SHORT METHOD PROTECTIVETAPE Remove 1. Disconnect battery ground cable and on Berlina model, remove tailgatewindow wiper arm and blade assemblyand electricaldemist connector. 2. Apply protective tape to paintwork adjacent to mouldings as shown in View A, Fig. tA_32, and place protective covering adjacent to gliss. 3. Removemoulding system:- a. Side mouldings- Inserta paint scraperor similar wide blade tool between moulding and body. Apply a rolling action towards the glass as shown in View A, Fig. 14-33, over fult iength of moulding to loosen, carefully remove moulding intact for reuse. b. Upper and lower mouldings- Methodas for side VIEW mouldings. 4. Remove glass all fragments from original glass Figure 14-32 adhesiveleaving adhesive intact on tailgate. 5. Using clean, lint free cloths, dampenedwith an oil free solvenl such as Prepsolor equivalent,thorough_ PROTECTIVETAPE ly clean surfaceof glass which siliconeis to contact. includingglass edges. CAUTION: Do not use petroleum based solvents,as the presence of oil will prevent adhesion of the fresh urethane/silicone. Reinstall URETHANEONLY VIEW 1. Prime the edge of glass and on the glass bonding surface '12 mm lrom the edge with glass primeri clear (HN1747).This is a wipe on wipe otf operation Figure 1A-33 (referView B, Fig. 14-35). URETHANEONLY 2. Prime the edge of glass and on the glass bonding surface 7 mm from the edge with gl-assprimer : black (HN1748) and ailow to dry for 15 minutes (relerView C, Fig. 14-35). 3. Apply 6.0 mm bead of urethane/siliconeto original adhesiveand also to the groove left in the adhelive by the mouldings. 4. With tailgatein near horizontalposition fit new qtass. 5. Refit upper and lower mouldings. 6. Refitside mouldings. 7. Apply tape to hold mouldings in position where reguired. This tape to be left on' for 24 hours mtntmum. 37 BODY 1A-29 8. Leavetailgate in horizontalposition for a minimumof which time vehicle may be driven 5 hours, after KNIFE providing tailgate is not slammed excessively for ,/-COLD 24 hours. 9. On Berlina model, install tailgatewindow wiper arm r TAILGATE WINDOW UPPERMOULDING and blade assemblyand demist electricalconnector and on both models,battery ground cable- KNI FE 10. Remove maskingtape from tailgate,clean adiacent BLADE paint finish and glass, then remove protectivecove- ring from interior. URETHANE' TAILGATE TO BE IN NEAR HORIZONTAL POSITION Figure 1A-34 LONG METHOD Remove 1. Disconnect battery ground cable and on Berlina model, removetailgate window wiper arm and blade assemblyand electricaldemist connector. 2. Apply protective tape to paintwork adiacent to mouldings as shown in View A' Fig. 1A-32, and place protectivecovering adiacent to glass- 3. Removemoulding system:- a. Side mouldings- Inserta paint scraperor similar wide blade tool between moulding and body' Apply a rolling action towards the. glass as shown in View A, Fig. 14-33, over tull length of mouldingto loosen, carefully remove moulding intact for reuse. b. Upper and lower mouldings- Method as for side mouldings. 4. Remove all glass fragments and urethane, using blade of glass sealant removal Tool No' J24402 illustratedin Fig. 1A-34. NOTE:lt is not necessaryto removeall traces of original urethane. However, any remaining urethane must be smoothand firm. Reinstall 1. Prime body aperturewith body primer (HN1752)and allow to dry for 30 minutes (refer View A' Fig. 1A-35). 2. Prime the edge of glass and on the glass bonding surface 12 mm from the edge with glass primer - clear (HN1747).This is a wipe on wipe off operations (referView B, Fig. 1A-35). 3. Prime the edge of glass and on the glass bonding surface 7 mm from the edge with glass primer - black (HN1748)and allow to dry for 15 minutes (referView C, Fig. 1A-35). Figure 1A-35 38 1A.30 BODY 4. Apply an even bead of urethaneadhesive (HN1749) 9.0 mm x 7.0 mm to blading flange as shown In View B, Fig. 1A-36, using nozzle cut as shown in ViewC, Fig. 14-36). 5, Fit the glass immediatelythe urethane bead is appliedto the body. o. lmmediatelythe glass is installed,fit mouldingsystem after. ensuring that enough urethane is pr6sent to bond the mouldings.(Apply additional adhesive to bond mouldingsif required.) 7. Apply tape to hold mouldings in position where reguired. This tape to be left on for 24 hours mrntmum. Leavetailgate in horizontalposition for a minimumof 5 hours, after which the vehicle may be driven providing tailgate is not slammed extessively for 24 hours. 9. On Berlina model, install tailgate window wiper arm h"' and blade assemblyand demist electricalconnector vrewlel and on both models,battery ground cable. 10. Remove. masking tape from tailgate,clean adjacent Figure tA-36 paint finish and glass, then remove protectivecove- ring from the interior. 39 BODY 1A-31 6. SEATS& SEAT BELT ASSEMBLIES INDEX Re{. Subject Page Ref. Sublect Page 6.1 DESCRIPTION 1A-31 6.4 REAR SEAT BELT RETRACTOR 6.2 LUMBARSUPPORT. DRIVERSSEAT ...... 1A-31 ASSEMBLY ...... -...... 1A-34 Models - Berlina and Calais 1A-31 Remove...-...- 1A-31 Reinstall 1A-33 FRONTSEAT BELT RETRACTORAND BUCKLEASSEMBLIES 1A-33 Remove...... 1A-33 Reinstall 1A-34 6.1 DESCRIPTION New seat trim materialsand patterns are released for VK models. New features on front seats include 'see through' head restraints on all models and on the drivers seat on Berlina& Calaismodels, a knob operatedlumbar support is built into the seat back assembly(refer Fig- 14-37). On the Calais model, see through head restraints are fitted to the rear seat backs. Figure 1A-37 6.2 LUMBARSUPPORT . DRIVERSSEAT MODELS. BERLINA AND CALAIS Remove 1. Slide seat fully fonrvardand remove bolts securing rear end of seat adiusterto floor (reler Fig. 1A-38). -S 2. Slide seat rearward and remove bolts securing lront end of seat adiuster. 3. Removeseat from vehicle and place face down on a clean protected surface. SCREW (20.0 - 25.0 Nm) OUTBOARD COVER I vtout'lrtruc L APPLY 5.0 DIA BEAD OF SEALEF AROUND TOP EDGE OF HOLES sEcrroruA-A IN FLOOF PAN BEFORE INSTALLATION OF SEAT ASM. Figure 1A-38 40 1A-32BODY 4. From under driver's seat cushion, remove elastic straps which are looped under tension over sear cushion spring convolutions SEAT BACK COVER and which retain lower CARPET RETAINER edge of seat back carpet assembly(refer Fig. 1A-39) ancl tape carpet up out of the way. Figure 1A-39 5. Remove hog rings securing seat back cover retainerto front retainer(refer Fig. 1A-40). SEAT BACK COVEB RETAINER .,W'' CLIP Figure 1A-40 Locate the forked end of a door interiorhandle clip removal tool (refer Fig. 14-41) inside of lumbar support handle, then press INTEFIOR DOOR tool downwards ro HANDLE disengage'horse shoe' CLIP type retainingclip from slot REMOVAL TOOL in splinedspindle, then removehandle. LUMAAR SUPPORT CONTROL KNOB NOTE: i wlrH LUMBAB suppoRr, IN'SOFT'POSITION, INSTALL HANDLE I UPFIIGHT & PARALLEL ] TO FRAME. R ECLIN FR CONTROL KNOB Figure 1A-41 41 BODY 1A.33 7. Carefullyease sides of seat back cover upwards, exposingheads of screws securing lumbar support bracketsto sidesof seat frame (referFig. 14-42). Figure 1A-42 Remove attaching screws, then lumbar support assemblyout throughbottom oi seat back assembly (referFig. 1A-43). SEAT CUSHION ASM Reinstall Reverseremoval operations, ensuring to adequatelyseal seat assembly attaching screw threads (refer Section A-A, Fig. 14-38) and to observe lumbar support control knob note in Fig. 1A-4'l. Figure 1A-43 6.3 FRONTSEAT BELT RETRACTOR AND BUCKLEASSEMBLIES REMOVE 1. With front seat located fully forward,remove cover from bolt securing upper seat belt attachment lo centre pillar (refer Section A-A, Fig. 14-44) then removebolt and upperattachment. 2. Using a pointed tool, carefully prise out the pins securingthe seat belt retractorcover to the centre pillar(refer Section C-C, Fig. 1A-44). 3. Remove cover from bolt securing seat belt lower attachmentto floor pan, then removebolt and lower seat belt attachment. 4. Ease front end of rear rocker oanel cover and rear end of front rocker oanel cover uowardsto release lower part of retractor cover, ease upper tastener from centre pillar, releasing cover and seat belt retractor (refer Fig. 1A-44). 42 1A-34BODY . /. LOCATE SEAT BELT 7 TONGUE WITHIN _t 76.0 mm OF THE SPACER ^ SASH GUIDE. -bULI UPPER ATTACHMENT COVER WAVE WASHER WITH aBUCKLE SEAL ,/ ASM. NON HARDENING SEALER SECTIONA_A SECTIONB_B / ZWITH SEAT IN FULL FORWARD POSITION THE INBOARD PART OF BELT IS TO BE INSTALLED AT AN ANGLE WHICH PASSESTHROUGH INTERSECTION OF SEAT CUSHION & SEAT BACK CONTOURS. LOWER ATTACHMENT BOLT SEAL WITH sEcrtoNc-c r.. NON HARDENING JtrALtsH SEAT BELT RETRACTOR COVER Fagure1A-44 5. Remove cover and bolt securing seat belt buckle assemblyto transmissiontunnel (refer Section B-B. Fig. 1A-44)then removebuckle assemblv. REINSTALL Reverseremoval operations, ensuring that both lower bolt threadsare sealedwith non hardeningsealer and that all seat belt attachingbolts are torquedto 53 - 71 Nm. 6.4 REAR SEAT BELT RETRACTOR ASSEMBLY Remove '1 . Depresstop of seat back adjacentto head restraint sleeve to gain access to clip, retainingsleeve (refer Section A-A, Fig. 14-45). Using i ttat btaded screwdriver,carefully disengage sleeve clips then lift out head restraints. 2. Twist head restraint sleeves in an anti_clockwise directionthen lift sleeves out of bracketswelded to the rearparcel shelf (refer Section A-A. Fiq. 1A-45). 43 BODY 14.35 SLEEVE RESTRAINT INSERT SLEEVE INTO MOUNTING 7 ,-\ / BRACKET, ROTATE AND PUSH SLEEVE DOWN. ENSURING THAT LUGS A, B & C PASSTHRU NOTCHES IN TOP OF MOUNTING BRACKET & ENGAGE AS SHOWN IN SECTIONS AA. BB. LUG A MOUNTING BRACKET SECTION A_A LUG B SECTIONB_B Figure 'lA-45 e Depress front edge of seat cushion assembly re- from cusHloN ASM.-1 ; REAR FLOOR arwards to disengage assembly retainer I brackets attached to the floor (refer Section A-A, RETAINER \ eRncret Fig. 1A-46)remove, then place assemblyon a clean protected surface. Unclinch tabs securing seat back frame to rear wheelhouses(refer View A, Fig- 1A-46) lift trame from retaining brackets attached lo the rear compart- ment front panel (refer Section B-8, Fig. 1A-46) remove, then place frame assembly on a clean protected surface. SECTION A_A COMPARTMENT FRONT PANEL SEAT BACK RETAINER r CLINCH ...OVER TAB SECTIONB_B Figure 1A-46 44 1A-36BODY From inside rear compartment,tap out fasteners securingtrim panelto rear parcelshelf (referSection REAR PARCEL A-A, Fig. 1A-47)disconnect retractor seat belt guides SHELF TRIM from outer edges of rear parcel (refer shelf Section \' A-A, Fig. 14-48) parfly raise rear parcel shelf trim, disconnect speaker connectors from rear harness, then removerear parcelshelf trim. Remove bolts securing tear seat belt lower attachments,including lap type seat belts, to floor pan and rear wheelhousepanels (refer Section C_C and D-D,Fig. 14-48). Remove cover, then bolt securing rear seat belt upper attachmentto quarter inner upper panel (refer SectionB-B, Fig. 1A-48). From inside of tear compartment, remove bolt '/...-'_,.-',(3 PLACES) securingrear seat belt retractorassembly quaner / to tYfrn lnnrn inner panel (refer Section A-A, Fig. 14-49) luur-ZtU.l1.l1 remove :-irlli=i: retractor assembly,feeding seat belt, buckles, etc. 1r out throughslot on outer edge of rear parcelshelf. SECTIONA_A Figure 1A-47 Reinstall R.everse.removal operations,ensuring that the threads o{ all seat beft lower attachingbotts aie aJequitery seateO harde.ningseatei (refer Sectionsb_C anO O-O, :,,1hFrg. ?^"-ol. tA-4E)and that all rear seat belt attachingbolts are torquedto 50-70 Nm duringinstallation. NOTE: On 35 body styles, the retractorassemblies are mountedonto the rear quarterinner panels (referSection A-A, Fig. 1A-49). SASH GUI DE SEAT BELT BOLT RETRACTOF A ASSEMBLY /S\ N\/ i\/ ti ASSEIVIBLY_-+- r} sEcloN B-B -2pLACES -t, t A JtrAL C ANCHoRTo 8E WITH NON VERTICALLY - eOLr I sEcrtoN A-A -2pLAcES HARDEN ING UPWARDSWHEN ,/ SEALER FITTED .{ u.-J . /-SEAL WITH NON :-+y-. f HARDENTNGSEALER S AXIS OF SYMMETRY ENSUREw,"i'r,c HARNESsrs cLEAR OF ANCHOR TO BE t-ro.t OF ANCHORWHEN ANCHOR IS FITTED, PARALLEL TO VEHICLE A IN FRONT VIEW sEcrtoN _2pLACES C-C secrroruD-D .,'l . so - ro i.r- Figure 14-48 45 BODY1A-37 #i3fitl?"fal'^ri;. n t--' oF sASHGUIDE if.gl----=--h curDE l i''' ,. LN< 4 (f",- i'''\ SEAT BELT | -\:1-'.,',, TONGUE=- '' .-'.' ..".1 .' A eo.t u,a* R AXIS OF SYMMETRY OF ANCHOR TO BE PARALLEL ro vEHrcLE0 rrurRorur VIEW. NOTCH TOWARDS FRONT OF CAR srcrroruA-A SEAL WITH NON HARDENING SEALER BELT RETAINER eoLrA SLEEVE .,/ qtv 'rBOLT,/1\ , 'p, secrroruC_C (, VERTICALLY WHEN ANCHOR TO BE UPWARDS SEAL WITH NON FITTED. ENSUREWIRING HARNESSIS CLEAR OF HARDENING SEALER sEcrroruB-B ANCHOR WHEN ANCHOR IS FITTED. secrroruD-D A,uo-7oNm Figure 1A-49 46 BODY 1A.39 7. EXTERIORORNAMENTATION INDEX Ref. Subject Page Ref. Subject Page 7.1 DESCR|PTION...... 1A-39 7.7 TAIL LAMP REVEALMOULDING 7.2 FRONTPILLAR DRIP MOULDING...... 1A-46 ASSEMBLY ... 1A-48 Remove 1A-45 Models - SL and Berlina, 19 Body Reinstall 1A-46 Styles ...... -.1A-48 7.3 DRIP MOULDINGASSEMBLY REAR...... 1A.46 Remove ...... 1A-48 Models - 19 Body Sty|es...... '...... 1A'46 Remove 1A-46 Reinstall ...... 1A-46 7.4 ROOF DRIP I'OULDING 1A-47 7.8 Reinstall 1A-47 7.5 FRONT& REAR DOORSIDE MOULDING 1A-47 Model - Ca1ais...... - 1A-47 Remove...... 1A-47 7.9 Reinstall ...... -...... 1A-47 7.6 FRONTFENDER SIDE & SIDE PANEL FRONTMOULDING ASSEMBLIES ...... 1A.48 Model - Calais 1A-48 7.1 DESCRIPTION Exteriorornamentation on the VK seriesconsists of deep with the base engine (E-S.T.) automatic transmission section body side mouldingson Calais and wide section together with power steering,an 'Executive'applique is body side mouldingson SL and Berlina19 and 35 body appliedto the quarterwindows on sedansand rear door styles. The Commodore/Berlinaname appears on the stationary windows on station wagons. Belt line rear of 19 and 35 body styles except on Calais, which mouldingsare fitted to all models (reler Figs. 14-50, featuresa Calaisbadge on the rear compartmentlid and 1A-51,1A-52, 1A-53, 1A-54, 1A-55). front fenders.Calais emblems are also fitted to the front Clips,fastener studs,bushes, screws and contact adhes- fender and engine hood. Holden and Lion badges are ive secure the various exterior mouldings,badges, em- fitted to the lront and rear of all modelsexcept the front blems,etc. to the VK body styles. on its of the Calais, which features a Holden badge The tailgatewindow exteriormouldings are embeddedin for radiator grille. Badges for option engines and the urethanesecuring the windowin the tailgateaperture. of electronic iniection are fitted to the front fenders Replacementprocedures for these mouldingsare inclu- leatures these sedans excepl on the Calais, which ded in the StationaryGlass Sectionof this Supplement. badges on the rear compartmentlid. On models fitted 47 1A-40BODY pO )Z ur^ q> UU crf o> l< SZ UO J(, F< fz ;z Zu o> JJ za ccu P> OL UNxx i tT U J z s>-Jm ,,, cc> >6 l-2 (r 48 ;1.*__ BODY 1A.41 F J ^J U q> co UU ( o (9 o o 1< t= -l; F =^ u'i z 4 z iz o J --z-_ E. id 59 f L U - o: oa f E: I ; tr u.J uJ o LL UJ ;2 t I tro F z 9z l <; ul z X tlj z0 ;i /, wz u.r 6< c6 ) Js ; t- I 3= d; -- F >; -,4 U (/J a o4 tfl Hl cnZ J U J (/J U U) > r< t'=-V >= F. z T LZ FO J o I n-t tJ OUJ _:: (9 ii a; _<2 U d5 ;< x HH ;z z = X= H> z r) ao z o = >j\ -- x< (I tr cc> u 6= F CN tn -:z= { z t= U o F E cD -J c [! tr ul o d .;\ z t!(r (t) i-- I :-- &z n I ulu a o ) *> tr au <(, co tl J7 o z* r!O >J 49 14.42 BODY tr U :> F 1? OL !(, J(, )z =Z z :JU UJ; ci 3s J -- OZ r- l (JU oo Iv o> ,-z uE oJ J- g F< u- Zw o o> u R> o r r (rUJ cg U (h UU = U o z (t J< 'Z t..' !tr> tr z <-l o H< 5 (9 J z l *Z r! o J J] - U C {: \ = z> o> ul (I d; 6 :gj u LIJ ) ) co oz6 J r- | c U io< 6 Fu- o o ) z>z-No o - Or!< I {,"--'' ;-FA U (,= ets z u u; F z 50 BODY 1A.43 BUSH r TFRONT FENDER 1 PLACE R/LH nsr,tt I 7A SCREW-2PLACESR/LH CLIP_2PLACESR/LH carrJ 1 PLACE R/LH secrtoruJ-J secrroruS-S 7- SCREW / 1 PLACE R/LH SECTION R_R ROOF DRIP MOULDING _- secrtoruU-U secrroruT-T C LIP 5 PLACES R/LH 69 & 19 STY. 8 PLACES Ri LH 35 STY secrroruV-V \ 1OPLACES R/LH FRT. DOOR 8 PLACES R/LH RR. DOOR OUTER DOOR HANDLE V INSERT \\ D srcrroruZ-Z SECTIONAZ_AZ Sneer-v NoN HARDENTNGsEALER OVERHOLES TO EFFECTA A ,.t - 2.4Nm WATERTIGHTSEAL. Figure 1A-53 51 14.44 BODY OUARTER WINDOW GARNISH MOULDING MOULDING ASM. QTR WINDOW GARNISH SECTION AN_AN FOR INSTALLATION SECTIONAP_AP REFER STATIONARY GLASS - NOTE: THIS SUPPLEMENT MOULDING ASM. OTR REVEAL TO BE SECTION ASSEMBLEDIN CONJUNCTIONWITH AM_AM OTR WINDOW GARNISH MOULDING. NOTE: MOULDING DRIP GUTTER REAR To BE INSTALLED AFTER MOULDING ASM. OTR REVEAL AND GARNISH TVIOULDING. SCREW 3 PLACES R/LH SECTIONAT_AT FASTENER STUD SECTION AS -AS 1 PLACE Ri LH FRONT FENDER WASHER 5 PLACESR/LH FRONT DOOR I PLACE R/LH 3 PLACESR/LH REAR DOOR SCREW 1 PLACE Ri LH SECTION AR_AR 1 PLACE R/LH FRONT FENDER SECTIONAU -AU 6 PLACESR/LH FRONT DOOR L. pLAcEs DRrLL2 4 R/LHREAR Do6;" ssI ![! o,a Hor_eON OF WELD STUD AS CLOSEAS POSSIBLETO WELD STUD LOCATION. SECTIONAS_AS FOREMERGENCY USE ONLY SECTIONAX_AX SECTIONAV_AV CLIP - 2 PLACES SECTIONAW_AW SECTIONAY_AY A r.r - 2.4Nm Qeeer-v NoN HARDENTNGsEALER ovER HOLESTO EFFECTA WATERTIGHTSEAL. Figure 1A-54 52 BODY 1A.45 GROMMET 1 PLACE R/LH STUD 1 PLACE R/LH 1 PLACE R/LH SECTIONAE_AE SECTIONAD_AD A" DRrLL2.3s I !l! o,o HoLEoN /'I SCREW OF WELD STUDS AS CLOSE AS ; POSSIBLETO WELD STUD 1 PLACE R/LH LOCATION, TWASHER 1 PLACE R/LH REAR PILLAR IVIOULDING 3 PLACES R/LH sEcroNAF-AF GASKET FOR EMERGENCY USE ONLY sEcrroNAF-AF SECTIONAK_AK r BUSH 2 PLACES R/LH REAR LAMP sEcrroNAJ-AJ REAR BUMPER BAR * ROOF DRIP MOULDING ) REAR sM.\ SECTIONAH_AH SECTIONAL_AL -AG ,A 2.4 - 3.4 Nm Sneelv NoN HARDENTNGsEALEB ovER A 'I.8 - 2.4 Nm HOLESTO EFFECTA WATERTIGHTSEAL Figure 14-55 53 14.46 BODY 7.2 FRONTPILLAR DRIP MOULDING Remove BUSH 1 PLACE R/LH With.front door open, removethe screw and clip securing moulding to front body pillar and front fender (refei 3 PLACES R/LH Sections S-S, T-T, and V-V, Fig. 1A-56) removing moulding. Reinstall Reverseremoval operationsensuring that the front pillar mouldingis correcily CLIP installedover ihe front of the roof 1 PLACE R/LH drip moulding as illustratedin Section U-U, Fig. 1,4-56 and that SECTIONT_T the screw securingthe centre of the mouldinoto secrrorvS-S the front body pillar is adequately sealed with ion hardeningsealer. N ROOF DR|P MOULDTNG -- \ \ \\ / \bzZzeY secrtoruu-u ( \.,-,, Y 5 pLecEs R/LH69 & 19sry. 8 PLACES R/LH 35 STY, secrloruV-V Qaeer-v NoN HARDENTNGsEALER ovER HOLESTO EFFECTA WATERTIGHTSEAL. Figure 1A-56 7.3 DRIP MOULDINGASSEMBLY REAR MODELS. 19 BODY STYLES ROOF DRIP MOULDING Remove Grasp.the leadingedge of the moulding,carefully pulling K\\\ it off the rear quarter window garnish moulding,aliowin! \\ IA\\ the \ \N. trailing end of the drip moulding rear to oecome 1^ @9)) srcrroruU-U disengaged(refer SectionAM-AM, Fig. tA-57). // v> (( ROOF DRtP tleinstall \ MOULDING Locate the rear hooked edge of the mouldingover the sEcrtoNAL-AL rear.-quanerwindow garnishmoulding, then lighilytap the moulding into position, ensuring that th6 rear drip mouldingis correctly installedover the rear of the roof drip mouldingas i[ustratedin SectionU-U, Fig. 14-56. MOULDING ASM. OTR WINDOW GARNISH FOR INSTALLATION REFER STATIONARY GLASS _ THIS SUPPLEMENT sEcrtoNAM-AM NOTE: MOULDING DRIP GUTTER REAR To BE INSTALLED AFTER MOULDING ASM. OTR REVEAL AND GARNISH MOULDING. Figure 1A-57 54 BODY 1A-47 7.4 ROOFDRIP MOULDING Remove 1. With the front door open, removethe screw securing the top of the drip mouldingto the front body pillar (referSection T-T, Fig. 1A-56). 2. Using Tool No. 1A7 located as illustratedin Fig.14- 58, under top of front pillar drip moulding,carefully ease top of pillar mouldingoff front end of roof drip moulding(refer Section U-U, Fig. 14-56). 3. Using a similarprocedure with Tool No. 1A7, remove the roof drip moulding,carefully disengaging rear end of roof drip moulding from top of drip moulding assemblyrear (referSection U-U, Fig. 14-56). Reinstall Figure 1A-58 Reverseremoval operations ensuring that the ends of the roof drip mouldingare correctlyinstalled under the front pillar and rear assemblydrip mouldingsas illustratedin Sections T-T and AL-AL in Figs. 14-56 and 14-57 and that the screw securingthe tront pillar drip mouldingis adequatelysealed with a non hardeningsealer. 7.5 FRONT& REARDOOR SIDE MOULDINGASSEMBLIES MODEL - CALAIS Remove 1. With front ot (ear door open, removescrew securing rear lower sectionof mouldingto door (referSection AU-AU,Fig. 1A-59). 2. Apply maskingtape adlacentto top of mouldingto protect paint finish, then using a wide bladed screwdriver,carefully prise upper sectionof moulding assembly out of retaining bushes (refer Section FASTENEF AR-AR, Fig. 1A-59)then raise mouldingassembly off STUD the clips securingthe lower section of the moulding assembly to the door (refer Section AS-AS, sECrroNAS-AS Fig. 1A-59). 1 PLACE R/LH FRONT FENDER 5 PLACESR/LH FRONT DOOR Reinstall 3 PLACESR/LH REAR DOOR Reverseremoval operations. sEcrtoNAR-AR 1 PLACE R/LH FRONT FENDER 6 PLACES R/LH FRONT DOOR 4 PLACESR/LH REAR DOOR WASHER 1 PLACE R/LH SCREW I PLACE R/LH sEcrroNAU-AU sEcrroN AT-AT Qneelv NoN HARDENTNcsEALER ovER HOLESTO EFFECTA WATERTIGHTSEAL Figure 1A-59 55 1A.48 BODY 7.6 FRONTFENDER SIDE & SIDE PANEL FRONTMOULDING ASSEMBLIES MODEL. CALAIS Remove From inside the wheelhouse,remove screw securing moulding to rear quarter or front fender panel (refei SectionAT-AT, Fig. 1A-59)then removemoutding. Reinstall Reverseremoval operationsensuring to adequately'sealerseal the attaching screw with non hardening as illustratedin SectionAT-AT, Fig. 1A-59. NpJe: Rear compartmentlid mouldingon SL and Berlina 19 body styles and body side and tallgate mouldingson SL.and Berlina35 body styles as well is nameplateiand emblems on all models are secured in position with contact adhesive.lt is necessaryto apply heat to these mouldingsprior to removing them from' the panets to avoid bendingthe outersurface of these mouldinos. CAUTION: Ensure that source of heat is not too close or temperaturetoo high to damage paint finish. When replacingthese mouldings,the correspondingpanel surface must be clean and smooth and be subjeited to warmth prior to installationof the mouldingto effect a sound bondingof the mouldingto the panel. 7.7 TAIL LAMPREVEAL MOULDING ASSEMBLY MODELS. SL AND BERLINA 19 BODY STYLES Remove 1. With rear compartmentlid open, remove the screw securing the upper section of the moulding to the reat quaner outer panel (refer Section AK-AK. Fig. 14-60). 2. Apply masking tape adjacent to the semi vertical GASKET section of the mouldingto protect paint finish, then usinga wide bladedscrewdriver, carefully prise -bush lower 2 PLACESR/LH section of moulding out of retaining (refer SECTION AK_AK SectionAJ-AJ, Fig. 1A-60). Reinstall A 1.8 - 2.4 Nm Reverse A, removaloperations ensuring to adequatelyseal /z\, 2.4 - 3.4 Nm the attaching screw with non hardening sealer as sEcrtoNAJ-AJ illustratedin SectionAK-AK, Fig. 14-60- Qneelv NoNHARDENTNG sEALER ovER HOLES TO EFFECT A WATERTIGHT SEAL. MODEL. CALAIS Figure 1A-60 Remove With rear compartment lid open, remove the nuts securingthe mouldingassembly to the rear quarterouter panel (refer Sections AW-AW and AX-AX, Fig. iA-61) removingthe mouldingassembly. Reinstall Reverseremoval operations ensuring that adequarenon hardening..sealeris applied betweenthe back panel and nut, as illustrated in Sections AW_AW and AX-AX, Fig.14-61). 56 BODY1A.49 A SECTIONAX_AX NUT 4 PLACES SECTIONAW_AW Onpplv NoN HABDENTNGsEALER OVER HOLES TO EFFECT A WATERTIGHT SEAL. A tt-2.4Nm Figure 1A-61 7.8 REARLAMP EXTENSIONMOULDING ASSEMBLY MODELS. 19 BODY STYLES Remove With rear compartment lid raised remove the nuts securing the assembly to the back panel upper (refer SectionAG-AG, Fig. 14-62)and removeassembly. NOTE: To disassemblethe mouldingassembly, remove the screws securing the outer to inner panels of the assembly(refer SectionAG-AG, Fig. 14-62). Reinstall Reverseremoval operations. REAR END PANEL ASM. sEcrroNAG-AG A t.t - 2.4Nm Figure 1A-62 57 I 1A-50BODY 7.9 MOULDINGASSEMBLY REAR COMPARTMENTLID MODEL. CALAIS Remove With rcat compartment lid open, remove the nuts securingthe mouldingto the rear compartmentlid (refer SectionAV-AV, Fig. 14-63)then removethe moulding. Reinstall Reverse . removal operations ensuring that adequate sealingwith non hardeningsealer is appliedbetween the inside o{ the attachingnuts and rear compartmentlid as illustratedin SectionAV-AV, Fig. 14-63. sEcrtoN AV-AV Qnner-v NoN HARDENTNGsEALER ovER HOLESTO EFFECTA WATERTIGHTSEAL Figure 1A€3 7.10EMBLEM ASSEMBLY HOOD MODEL. CALAIS Remove With enginehood raisedand usinga plasticmallet, lightly tap ends of emblem studs protruding through tubular retainingclips in the engine hood (refer Section Ay_Ay, Fig. 14-64)until it is possibleto removeemblem- Reinstall CLIP - 2 PLACES removal operations !9ve1s9 ensuring that the tubular sEcrtoN AY-AY clipsfully retain the embrem. Qneer-v NoN HARDENTNGsEALER ovER HOLESTO EFFECTA WATERTIGHTSEAL. Figure 1A-64 58 BODY1A.51 8. ROOFRACK I 46 U ZO o<_J FL O^ o @- I € cao ' U )uJl z<) oz4 o1 ro< u rI oz2 a z=li z O:) z t!> U o in bt" lr 6(o F i Fr! = = U z U o ,,€ t ,T t! o =H? I o Z vu' )z _Lv 27 E, 3-E ) =il9 ON(O tr 59 BODY 1A.53 9. BODYELECTRICAL INDEX Ref. Subject Page Ref. Subiect Page 9.1 DESCRIPTION .... 1A-53 9.6 LIMIT SWITCHASSEMBLY ... 1A.61 9.2 EXTERIORREAR VIEW MIRROR& Remove...... 1A-61 MOTORASSEMBLY 1A-54 Reinstall .... 1A-61 Remove ...... 1A-54 9.7 ELECTROIIICTODULE ASSEMBLY ...... 14.62 Reinstall ..-...... 1A-54 Remove.....-...... 1A-62 9.3 SWITCHASSEMBLY. EXTERIORREAR Reanstall .... 1A-62 vtEwMrRRoRs...... lA-ss CABLE ASSEMBLY 1A-62 Remove...... 1A-55 Remove.-...... 1A€2 Reinstall ... 1A'55 Reinstall 1A-64 9.4 SUNROOFSLIDING GLASS PANEL ...... 1A'55 9.9 SLIDINGSUNROOF MOTOR ASSEMBLY.. 1A.65 Remove...... _ ...._...... 1A-55 ilotor Assembly Remova|...... 1A-65 Reinstall ...... 1A-55 Motor Assembly Feinstallation....-..-..1A-65 Vertical Adjustment ol Sliding Motor Drive Gear Removal....--...... 1A-65 Panel ...... -.....1A-59 Motor Drive Gear Reinstallation...... 1A-65 9.10 SYSTEMTlMlNG...--...... --...... 1A-66 Reinstall ...... 1A-60 9.1 DESCRIPTION located under the transmissionconsole (refer View A, Fig. 1A-67). The electrically operated e!.terior rear view mirror pushingthe assemblyfitted to Calaismodels consistsof a mirrorwith Choice of the mirror to be adiustedinvolves its electric drive motor contained in the door mounted raised bar of the switch to the left or right. Depressing mirror housingassembly (refer Fig. 1A-66). the four way directionalarrows illustratedon the upper face of the switch will provide the desired mirror switch The electric motor, which is activated by a adjustment. mounted onto the transmissionconsole (refer View A, Fig. 14-67) providescomplete adiustment of the mirrors. Electricallyoperated venting sun roofs are released as ProductionOption CF5 for 19 body styles except 'SL' 'ln-line' An one amp fuse and holder assemblyis models. attached to the mirror switch electrical harness and is 60 1A.54BODY 7l ' ,'-.., \\ EXTERIORREAR VIEW \ MtRRoRAND MoroR AsM. . uMrRnoR coNTRO- CONDUIT A o.tg-r19Nm Figure 1A{6 9.2 EXTERIORREAR VIEW MIRROR& MOTORASSEMBLY REMOVE 1. With the front door window in the lowered position, disconnectthe batteryground cable. 2. Remove door armrest,interior trim and upper front corneroJ water deflector. 3. Using a wide bladed screwdriver,caretully prise off cover from front door window frame inner. then removeseal (referFig. 14-66). 4. Prise out fronl lower section of glass run channel from rear edge of mirrorhousing assembly. 5. Fromwithin door panels,disengage mirror assembly connectorfrom door electricalharness. 6. Remove screws securing mirror assembly to door upper frame (refer Fig. 1A-66) then ease assembly rearuardsand out of upper door frame. REINSTALL Reverseremoval operations. 61 BODY1A.55 9.3 SWITCHASSEMBLY . EXTERIOR ESCUTCHEON REARVIEW MIRRORS \ --\ \ REMOVE EXTERIOR REAR VIEW MIRRORS SWITCHNSIT,I. \. 1. Disconneclbattery ground cable. 2. Using a wide bladed screwdriver,carefully prise cap and bezel covering top of switch assembly (refer View A, Fig. 1A-67)'fromtransmission console. 3. Using a similar procedure, carefully prise switch assembly from lransmission console. Disengage switch connector from front end electrical wiring harness,then removethe switchassembly. REINSTALL Reverseremoval oPerations. TRANSMISSION CONSOLE Figure 1A-67 9.4 SUNROOFSLIDING GLASS PANEL REMOVE 1. Placesunroof sllding panel in VENT position. 2. Slidesunshade lull rean'vard' 3. Remove side finishing covers attaching screws (Fig.1A-70). 4. Loosen rear guides shaft screws until rear of sliding panel drops down using 3 mm allen wrench (Fig.1A-71). 5. Remove front guide shoulder bolts using 7 mm socket (referFig. 14-71). 6. Remove slidingpanel upwardthrough roof opening' REINSTALL Reverseremoval operations. 62 1A.56 BODY ruJz vd- 5l JA Jlzco= iid F =: 6o z A= ozl9< =e E-:: 3d ^.-':>av u) Ei-?6;F:g cF tq r-rir-[*r-{ye:ly;e= vF VV< q> ?AF?EIQ-'9- CCIfF(rUJUTCC z U !O> H r <(rE tA r< tr\> I - (, Flo zJf= z 9u> tuJ-,FCC z ccq i: u< ;- nJ i,,rlJU - !.--^ T = =;a <'l* " o <- iE=o639FO= = i(ooll U ru g r-3+ X ?g F u.Jru -ojsisddrcci oi o- 63 BODY 1A.57 J I > o(,' rO u >< ;f, o u^ zY <= (^ ? *T- .^-.Jt "a' 1z <>50 (t) ;*?F (0 o)o-N o ll-9 J @ U a 5 a 0 v< \ (l :f FnO t i aZ s(orco {1 F , ,, (Y) z ):F U U 3i ) o 3 5 z .i U E o 6) U uo z2 ; : l^ --@- 2, 1a2 -, JJE i!!r =aay. AAr o<<: O)J'2 -NOS 64 1A.58BODY SIDE FINISHING COVER Figure 14-70 b< - REAR GUIDE SHAFT SCREW FRONT GUIDE -- /. SHOULDER EOLT Figure 14-71 65 BODY 1A.59 VERTICAL ADJUSTMENT OF SLIDING PANEL ',|. Activate sun roof switch assemblyuntil rear end of glass panelis fullYlowered. 2. Fully engage rear guide shaft screw illustratedin Fig. 1A-72 into cam block, then back off screw a half turn. 3. Torqueshaft screw lock nut to 2.03 - 2.71 Nm. REAR CAM ASSEMBLY - '-Ro-- \ REAR CAM BOLTS \ ,TFRONT GUIDE SHOULDER EOLT Figure 1A-72 66 1A.60BODY 9.5 WIND DEFLECTORFRAME REMOVE 1. Placesliding panel in full rear position. 2. Remove 'C' clip retainerand flat washer from both sides(refer Fig. 1A-73). 3. Press both wind deflector frame arms inboard to removearms from housingstuds- REINSTALL Reverseremoval ooerations. Figure 1A-73 67 BODY1A.61 9.6 LIMIT SWITCHASSEMBLY REMOVE 1. Removewell and drop headlinerfrom the front right side of the housing. 2. Scribe line on tube at tube entrance to switch assembly(refer Fig. 1A-74). Remove two (2) switch assembly mountingscrews (referFig. 1A-74). 4. Removeswitch assemblyby slidingoff of tube. REINSTALL Prior to installationof new switch, removecotter pin from switch assembly(refer Fig. 'lA-74). Position switch assembly to scribe line of tube. Attach with two (2) screws removed above. Figure 1A-74 68 1A-62BODY 9.7 ELECTRONICMODULE ASSEMBLY REMOVE 1. Removewelt and drop headliner at frontof housing. 2. Uncoupleconnector at moduleassembly. 3. Removescrews attaching module assembly to roof rail(refer Fig. 1A-75). REINSTALL Reverseremoval ooerations. ATTACHING SCREWS t-- ------) -'--, MODULE ASSEMBLY Figure 1A.75 9.8 CABLEASSEMBLY REMOVE ''l. Drop headlinerat rear of housing. 2. Remove__cableguide lower retainer cover (reter Fig. 1,4-76). 3. Disengagecables from drive gear (referFig. tA_76). 4. Remove sliding panel as describedin g.4 Sunroof Sliding Glass Panel, Remove and Reinstall (refer Fig. 14-69). 69 BODY 1A.63 Figure 1A-76 70 1A.64BODY 5. Move trough rod and cable assembliesreanarard of notch in track, to slide front guide shoes reanivardto notch,rotate and remove(refer Fig. 1A_72). 6. Rotateright handfront guide shoe fonivardto remove troughassembly (refer Fig. 1A-77). 7. Remove sunshadeby adding a slight hano pressure upwardto disengagefront track. 8. Remove three (3) screws retainingeach track (refer Fig. 1A-78). 9. Lift front of track up and disengagefrom housing. 10. Removecable assemblyfrom track at rear. REINSTALL Reverse operations using care to install .removal ,system sunshadein lowestslot in track. Refei to Timing, (referFig. 1A-80). Figure 1A-77 71 BODY 1A.65 Figure 1A-78 9.9 SLIDINGSUNROOF MOTOR ASSEMBLY MOTOR ASSEMBLY REMOVAL 'l. Drop headlineral rear of housing. 2. Uncoupleconnector from motor assembly. 3. Remove rear housing support brackets and lower rear of housing. MOTOB 4. Removetwo (2) hex head screws attachingmotor to ASSEMB LY mounting brackets using 7 mm socket (refer Fig. 1A-79). MOTOR ASSEMBLY REINSTALLATION Reverseremoval oPerations. MOTOR DRIVE GEAR REMOVAL 1. Drop headlinerat rear ol housing. 2. Remove two (2) screws from cable guide lower retainercover (referFig. 14-76). 3. Use small screwdriver or other suitable tool to remove 'C' clip attachingdrive gear to motor shaft (referFig. 14-76). \b MOTOB DRIVE GEAR REINSTALLATION MOUNTING BRACKET Reverseremoval operations. CABTE RETAINER Figure 1A-79 72 1A.66 BODY CABLE HOUSING /.'sLoI Figure 1A-8O 9.10SYSTEM TIMING 1. Remove drive gear from motor as describedin g.9 Sliding Sunroof Motor Assembly,Motor Drive Gear Removaland Reinstallationin this Section. z. Position both cable housingsto slots in tracks as shownin Fig. 14-80. Reinstall..drivegear and reverse removal operations as describedin 9.9 SlidingSunroof Motor Assembly, Motor Drive Gear, Removaland Reinstallationin thts Section. 73 BODY 1A.67 10.SPECIAL TOOLS FABRICATED TRIM CLIP REMOVAL TOOL Uf,MM - END CONSTRUCTION t_ TO SUIT HANDLE f R EOUIR EMENTS mm- <-75.0 mm--- _^ ^9.0 18.0 mm- - 10.0 mm DIA - 8.5 mm GLASS SEALANT ROOF SIDE MOULDING REMOVAL TOOL REMOVAL TOOL 147 RADIO _ RADIO/CASSETTEPLAYER REMOVAL TOOLS -rl.{tl -T1l cMT113 74 RADIATORGRILLE 1C.1 SECTION1C RADIATORGRILLE INDEX Ref. Sublect Page Ref. Sublect Page 1. DESCRIPTION 1C-1 1.1 SERVICENOTES rc-r Remove 1Gl Reinstall 1C-1 1. DESCRIPTION grey, The new one piece plastic radiator grille fitted to VK models,they are painted cool or warm depending series is painteil silver on Calais model,whilst on other on the body colour' 1.1SERVICE NOTES Remove 1. With enginehood raised,remove screws securlng grilleto radiatorupper suppctrt (refer Fig. 1C'1). 2. Easetop of grillefonrvard, then lift grillepegs out of grommetsinstalled in the bumperfacia. Relnstall Reverseremoval operations. NUTl 2 PLACES \ A g SCREW \ 2 PLACES & -,/---'- A/ 7/ scREl/-\6tr -7 A ..u - 4.6Nm /|^ro-3.4Nm Figure 1C-l 75 76 FRONT& REARBUMPER BAR ASSEMBLIES1D.1 SECTION1D FRONT& REARBUMPER BAR ASSEMBLIES INDEX Ref. Subject Page Ref. Subject Page 1. DESCRIPTION 1D-1 1.3 REAR BUMPERBAR ASSEMBLY 1D-4 1.1 SERVICENOTES tD-1 Models 19 Body Sty1es...... 1D-4 lntroduction. 1D-1 Remove...... 10-4 Materials 1D-2 Disassemble 1D-4 Recommended 'tD-4 GolourFinishing of Replacement Reassemble Parts 1D-3 Reanstall.. 10-4 Repairing Colour Coat .'...... '..1D-2 Models 35 Body Sty1es...... 1D-6 Warning - Use of BodY Remove 1D-6 Golour Lacquer...... 1D-2 Disassemble 1D-6 1.2 FRONTBUMPER BAR ASSEMBLY...... 1D-3 Reassemble 1D-6 Remove...... 1D-3 Reinstall 1D-6 Disassemble 1D-3 Reassemble 1D-3 Reinstall 1D-3 1. DESCRIPTION Front and rear bumper bar assemblies titted to VK styles,the finishingstrips cover the completeupper edge models are of polycarbonateconstruclion. Bright finishing of the rear bumperbar assemblywhilst on the 35 body strips featuringa rubber upper edge are clippedover lhe styles these finishrngstrips are fitted to the rear bumper top edge ol the side and part ol the centre front bumper faciasonly (reterFigs. 1D-1, 1D-2, 1D-3 and 1D-4). facias.-Onthe rear bumperassemblies fitted to 19 body 1.1 SERVICENOTES INTRODUCTION The paint systemfor the VK bumpersand side mouldings is relatively straight fonrrrardas long as the correct materials are used. lf normal refinish lacquers and solventsare applied the polycarbonatewill be damaged by solvent attack- Therefore, a warning label will be attached to the exterior surface of all unpaintedspare parts suppliedto the field. CAUTION: Painting - Cleansingof this patt for painting must be by methylated spirits wipe only. Do not use lacquer thtnners or other cleaning thinners, as these may damage the plastic- Top Coat with GMH approved paint and thinners as specified in this Section. The followingservice recommendationsare compiledto guide Dealerships,on the correct materialsand methods to be employedwhen refinishingVK Seriesbumper bars and side mouldings,also when preparingnew parts for serviceinstallation. 77 1D.2 FRONT& REAR BUMPERBAR ASSEMBLIES RECOMMENDED MATERIALS Bumper)The paint repair area should be to the nearest convenient rear bumperbars and side moutdingsinstalled breakline.Spot repairsare not recommended Irol.9nq due to possible to VK Series are made from high impaCt strength colourmatch problems. polycarbonateplastic. 1. depending It is essential that only GMH approved 91l9il9 - upon the degree of damage, materials,paints P320 (or.coarsergrit).wet and thinners,be employedwhen paint repair operations or Ory sa-ndpapermay be are performed requiredfor initialsanding. Finish sand wiin eCOtigrit and when preparingnew partslor installa_ paper tion to the vehicle. to remove sanding marks and dry scuff Lll over the whole of the area to be resprayed. Use of the wrong materialswill affect finishedqualitv and 2. Cleaning - wipe will affect the polycarbonatematerial. the area to be paintedat least twice with a clean cloth soaked in meihylated The GMH approvedmaterials are: spiritswiping dry with a new clean cloth each time. . MethylatedSpirits - for cleansingbefore painting. 3. Painting - mix the polycarbonatelacquer with r Paint Berger appro_ - PolycarbonateLacquer in the following ved.thinners(approximately 1:1 ratio) and cotours: spray'the repaired area to build colour followed by one wet coat all over to achieve colour uniformitv. Silver GMH4J022 - BergerHH9991 4. Drying - allow 10 minutesair flash then use a heat Warm Grey GMH4H016 - BerserHHgg89 tamp or similar set up to warm the painted surface f9r Cool Grey GMH4H015 - BergerHHg990 99 minutes. (Surface temperature of the part should not exceed gOoC) Lamp baking will speed . Thinner- BergerLT2p6. removalof the special slow solvents in-the laiquer and hardenthe paint The Bergerlacquer is a specialacrylic lacquer developed film. for polycarbonateand requires NO primer. The pol- ycarbonateparts are mouldedin-colour for ease of top WARNING. USE OF BODY COLOUR LACQUER coating. When ordering spare parts quote the GMH Normal lacquers colour number and name,for exampleWarm Grey (GMH used for refinishpainting of sheet metal 4H016). are not suitable for repainting the VK polvca;gon"r" bumpersand side mouldings. COLOUR FINISHING OF REPLACEMENT PARTS Spare parts are suppliedunpainted, to be coated before installationto the vehicle. Observethe followingprocedures:- 1. Order part with the plastic self colouredto match the requiredtop coat colour. 2. Inspect surface, if slight transit damageis present this can be rectifiedby dry sandingwith-pa0O paper. 3. Cleaning - wipe the surface at least twice using a clean cloth soaked in methylatedspirits, wiping -dry with a new clean cloth each time. 4. Paint - mix. the polycarbonatelacquer to spraying-1:i viscosity with approvedthinners (approximately ratio), and apply one full wet coat. Allow aboul two minutesflash time and apply a secondfull coat. lt is important that only sufficient paint to achieve coverageis applied,too high a paint thicknessmay reduce adhesion.(Correct film thichnessis 30 - 35 microns.) 5. Drying - allow 10 minutesair flashthen use a heat tamp or similar set up to warm the paintedsurface {or 30 minutes (part surfacetemperaiure should not exceed 90oC). Lamp bakingwill speed removatof the special slow solvenlsin the lacquerand harden the paint film to enableassembly of the part to the vehicle. REPAIRING COLOUR COAT Superficial damage to the paint film and/or plastrc surface may be rectifiedby sandingand repainting.parts havingdeep gouges etc. in the plaltic surfaceshould be replaced as repair methods using filling materialsand thinningdown of the plasticsection mai reduce overall rmpactstrength. Under no circumstancesshould paint be washed otf with lacquer thinners. (i.e. Sections of the 78 FRONT& REAR BUMPERBAR ASSEMBLIES1D-3 1.2 FRONTBUMPER BAR ASSEMBLY REMOVE 1. Raise and support tront end of vehicle on jack stands. 2. From within front end section of front wheel openings, remove screws securing sides of front Oirmpeibar assemblyto front {enders(refer Sections B-B and C-C,Fig. 1D-1). 3. With Jront bumperbar assemblyfully supportedand from under front of vehicle, remove bolts securing inner bracket assembliesfrom side frames (refer Section A-A, Fig. 1D-1) removinglront bumper bar assemblY. Disassemble 1. Disengagelower edge of finishing strip. assembly trom ioi'cn in bumper bar side facia(s) (refer Section GC, Fig. 1D-2)then raiseand removefinishing strip' 2. Remove screws securing bumper bar facias to front bumper bar inner bracket assemblies (refer Section A-A, Fig. 1D-2). 3. Remove screws and nuts securing side tacia(s) to centre lacia (refer Section B-8, Fig' 1D'2) then remove side facia(s). Reassemble Reverseto disassemblyoperations. REINSTALL Reverseto removaloPerations. FRONT BUMPER h BAR ASM. \ / ,/ ah,",-\\ FRoNTreruoea/ +-<' PANEL tr;-/. .( A t{.. -,,,)*,r /1\ ,/ 1 SCREWASM. 1 PLACE R/L l:t I fl i: .L t1 FRONT BUMPERBAR secrtoruC-C INNER ERACKET ASM- R & LH \Yfl-" zl. BOLT 4L 2 PLACESRi L \J FRONT FENDERl u,r*E PANEL . WASHER \ 2 PLACES R/L SCREWl \ 2PLACESR/L FASTENER-I \ ! 'r PLACE R/L __if f_ secrtoruA-A \ 7-, FRONT FENDERJ g PANEL R/L 40-54Nm A SECTION B_B A D-D 11\ 8-11Nm srcrtoru Figure 1D-1 79 1D-4FRONT & REARBUMPER BAR ASSEMBLIES ,,6\scR.* 4 PLACES R&LSIDE NUT AFTER ASSEMBLY FRONT 4 PLACES OF BUMPER BAR- LOCATE AND SNAP CLIP FINISHER BUMPERBAR N d L JIUE STRIPSR/L OVER BUMPER BRACKET ASM. BAR ASM, secrroruB-B secrroruA-A sgcrroruC-C RH SIDEFACIA 5- RH FINISHtNG ASSEMBLv ant 7- CENTRE FACIA- \STRIP 7 5ilocer\ ASSEMBLY \ / R&LSIDE LH FINISHING \ STRIP ,RH i FRONT BUMPER BAR INNER BRACKET ^sM7 A, /z\ 6-8Nm wa5H5q---.7s ,:. I' 2( LH FRONT A 10-'r5Nm , NUTJ BUMPERBAR 3PLACES R&LSIDE INNER BRACKET ASM. Figure 1D-2 1.3REAR BUMPERBAR ASSEMBLY MODELS 19 BODY STYLES Remove 1. From under rear quarter panels, remove screws securinglower sectionof side facias to rear quarter panel(refer Section C-C, Fig. 1D-3). 2. With rear bumper bar assembly fully supported, remove nuts and screws securing rear bumper bar assemblyto rear end of vehicle (refer SectionsA-A and B-8, Fig. 1D-3)and unscrewlicence plate holder from centre faciathen removeassemblv. Disassemble 1. Disengage lower edge of finishing strip assembly from notches in right and left hand sides of bumper bar assembly(refer Fig. 1D-3)then raise and remove finishingstrips. 2. Remove screws and nuts securing bumper Dar assemblymounting brackets to centre facia and side facia(s)to centre facia (refer SectionsB-B and D-D, Fig. 1D-3)then removeside facia(s). Reassemble Reversedisassembly operations. Reinstall Reverse removal operationsensuring that the sealing instructionsfor the rear bumper bar assemblvattachino screwsand nuts illustratedFig 1D-3are observed 80 FRONT& REAR BUMPERBAR ASSEMBLIES1D.5 RH FINISHING STRIPl\ RH SIDE = FACIA ASM. 7;i-4t\ l' * Z".--- l4.l \.r*r*. ro",o ASM. CENTRALIZE AND SNAP_CLIP FINISHER STRIPS OVER \.* BUMPER BAR ASSEMBLY r,o. FACIA ASM. FASTENER A lPLACER&L 7- SCREW , 2PLACESR&L secrtonC-C A ,Ar scnewl NUT _ 2 PLACES 4PLACESR&L/ SECTIONA-A WAHSER _ 2 PLACESJ NUT---T\ 4PLACESR&L T SCREW \ 2PLACESR&L SECTIONB_B SECTION D_D V V E-' -E SECTIONE_E Q neelv NoN HARDENING SEALER AROUND 8UI.1PECATTACHMENT HOLES A 6-8 Nm A ,o- 27Nm u,r*lIl R&LsrDE A 8- 11Nm Figure 1D-3 81 5 ra - 1D-6FRONT & REAR BUMPERBAR ASSEMBLIES MODELS 35 BODY STYLES Remove 1. Disc.onnectbattery ground cable then carefully prise out licence plate lamp assembliesfrom top of centre facia and disconnectelectrical connectors. 2. From under rear quarter panels, remove screws securinglower sectionof side facias to rear euarter panel (refer SectionGC, Fig. lD-a). 3. With tailgate raisedand rear quarterinner trim oanel covers removed, remove screws securing rear bum- per bar assembly to rear quarter panel (refer Section A-A, Fig. 1Da). 4. From within spare wheel compartmenl and with rear bumper bar assemblylully supported,remove nuts secunng assemblyto back panel lower (refer Section B-8, Fig. 1D-4)and removeassembly. Disassemble 1. Disengage lower edge of finishing strip assembly from notches on side facia(s) (refer Section A_A, Fig. 1D- ) then raiseand removefinishing strip(s). 2. Remove nuts and screws securing bumper bar assembly mounting brackets to centre facia and centre facia to side facia(s) (refer SectionsB_B and D-D, Fig. tD-4) then removeside facia(s). Reassemble Reversedisassembly operations. Reinstall Reverse removal operationsensuring that the sealing instructionsfor the rear bumper bar lssembly attachin! screwsand nuts illustratedin Fig. 1D-4are observeo. 82 - - FRONT& REARBUMPER BAR ASSEMBLIES1D.7 RH FINISHING FIH SIDE STRIP FACIA ASM. LH FINISHING _4 ---D I i>!P - CENTRE FACIA ASM. SNAP-CLIPFINISHER STRIP R/1. la. OVERBUMPER BAR ASSEMBLY, LH SIDE FACIA ASM. g"h" WASHER 2 PLACES BUMPER ASM SECTIONC_C r NUT I + pr-aces Rlr- secrromA-A WASHER 2 PLACES SCREW ., 4 PLACES R/L,/3' SCREW 2 PLACES Ri L SECTIONB-B SecrlOt'tD-D SECTIONE-E /\ 6-8 Nm O vrEWlAl R/LsrDE Q aeelv NoN HARDENTNGSEALER A 12-16Nm AROUND BUMPER ATTACHMENT HOLES A 8- 11Nm Flgure 1D-4 83 5 ta t-. k - - - VENTILATION& HEATING2A.1 SECTION2A VENTILATION& HEATING INDEX Ref. Subject Page Ref. Subject Page 1. GENERALDESCRIPTION 2A-3 1.5 BLOWERMOTOR...... 2A-9 1.1 2A-4 Remove...... 2A'9 2A-4 Reinstall 2A-9 2A-4 1.6 BLOWERMOTOR HOUSING ASSEMBLY.. 2A.10 2A-4 Remove...... 2A-10 244 Reinstall 2A-10 2A-4 1.7 HEATERASSEMBLY -...... 2A-11 1.2 SERVICENOTES 2A€ Remove...... -.....-....2A-11 1.3 UPPERSIDE VENT OUTLETS.RIGHT & Reinstall ..- 2A-11 LEFT HAND 2A-6 1.8 HEATERCORE AND PIPEASSEMBLY...... 2A-13 Remove.,...... 2A-6 Remove...... 2A-13 Reinstall 2A-6 Reinstall ... 2A-13 1.4 MOOESELECTION, TEMPERATURE 1.9 WATERVALVE ASSEMBLY. HEATER CONTBOLAND BLOWERFAN SWITCH.. 2A-7 coRE .-...... --_-.--2A-14 ilodels - A11...... -..-.. 2A-7 Remove..-...... 2A-14 Remove 2A-7 Reinstall ... 2A-14 Reinstall 2A-7 a 24.2 VENTILATION& HEATING --J Flgure 2A-1 ELOWER MOTOB SWITCH TEMPERATURE CONTROL HEAT'VENT CONTROLS OFF NO AIR FLOW Figure 2A-2 VENTILATION& HEATING2A-3 1. GENERALDESCRIPTION The ventilatingand heatingsystem featured on VK Series models allows air enteringthe syslem via the grilles at the rear of the engine hood to pass throughthe blower motor housingand heater assembliesand to be heated, mixed or allowed to remain at ambient temperature,as required.The air then enters the passengercompartment throughthe centre and or side upperventilator outlets, or through the demist or footwell outlets (refer Fig. 2A-1) dependingon the positionof the mode or temperature control levers illustrated in Fig. 2A-2. Fig. 2A-2 also illustratesthe air flow withinthe heaterassembly with the variousmodes activated. On sedans, air from the passenger compartmentex- hausts throughventilator outlets located behindthe right and lelt hand side drip mouldingassembly rear, illustrated in Fig. 2A-3.On stationwagons, the air is exhaustedvia the edges of the rear quarter inner trim panels,into the roof, then out into the atmospherethrough tailgate hinge pockets. The volumeof air trom the centreor side upperventilator outlets (refer View A, Fig.2A-1) is controlledby a regulatingwheel below the outlet inserts illustratedin Fig. 2A-4. The air llow can be directed as required by tilting and/or swivellingthe ventilatorupper outlet inserts. To slop the air supplyfrom the upper side vent outlets, rotate the regulatingwheel to the right,and on the centre air outlet. rotate the wheel downwards until a stop is reached. Figure 2A-3 The heatingsystem utilises an air mix principlewhere the temperatureof air enteringthe passengercompartment is controlledby a temperaturelever illustratedin Fig. 2A-2 which operates the mixture door. This regulates the volumeof air passingthrough the heatercore. The temperature, mode and blower motor control assemblyilfustrated in Fig. 2A-2 consistsof a four speed fan switch,which regulatesthe rate at which forced air is deliveredinto the vehiclethrough the variousoutlets, and two sliding levers. The left hand lever controls the air temperatureentering the vehicle in all modes and the right hand lever,the particularmode required. OUTER UPPER :Ii AIR OUTLET HOUSING ASM.I \ ./l OUTER UPPER i{ N' V @ vffi SCREW 'q {4 PLACES) REGULATING WHEEL \ OUTEF LOWER AIRI LOWEF LH OUTTET INSERT ASM INSTRUMENT PANEL Figure 2A-4 24.4 VENTILATION& HEATING 1.1 MANUALCONTROLS The mode controllever has five positions: DEM In this positionthe air flows onto the windscreenthrough the demistvents on top of the instrumentpanel- A small amountof air also goes to the floor ouilets FLOOR in this positionthe main air flow is directedto the floor outletswith a smallamount going to the demistvenrs. VENT This settingdirects all the ambient or heated air to the centre and side vents.The air flow and directioncan oe individuallyadjusted at eachvent. BI LEVEL This positiondirects air to the centre and side venls as well as to the floor vents. OFF ln this positionthe fan is switchedoff and no outsideair is admittedvia the ventilationsystem. This setting is only recommendedto be used for short periodswhen driving in very dusty or smokeyconditions with all the wrnoows closed. Return the mode lever to one of the other settingsas soon as conditionspermit, NOTE:The blowermotor fan automaticallyswi166ss .r 1. its lowestspeed when the mode control lever is moved away from OFF position. Fan speed can then be rncreasedby selectinga highernumber. ;CENTRE AIR r LH DEMIST NOZZLE / DISTRIEUTION DUCT DUCT ASSEMBLY -\ \SCREW LH AI R OUTLET DUCT llrJ' I nHJ AIR OUTLET DUCT j4 L Rs DEtutsr NozzLE DUCT ASSEMELY . HEATER ASSEI\4BLY ELOWER MOTOR -' . BLOWER IVOTORHOUSING HOUSING ASSET\4BLY TO HEATER ASSEMELY DUCT Figure 2A-5 - VENTILATION& HEATING2A.5 J TU ^zr< :t z 3 oO--.r d) a o U Tf z I OF u co z )z F UJ X z tIc o- U o ?< J F -O u UA z U a N, L N- oz> \ 2uln =F. t\ ;>< L *)U J- FF> Jq zl;< : F : I z= z L\ ,a =a 2E Oo FU 5= z= l9 crJ FU a^ Z= UV 6 z= uJ Zr F UJ (!a i,z 9n >U -3 (t )@ 2Ez @ €\^/ =v ;H 3: zx N lr r o =2 ctt ' o< L I 3i L_ 1 'Jr )". ci--T - Yr\- z\-::\..-..-l \ \ i-\l \ii \ - \," -'-V| __-\,;i-iF-^ E F< {; } = uff 1.2SERVICE NOTES The non air conditioned air ducting on VK Series illustrated in Fig. 2A-5 as polypropolenetubing with matingindentations and protrusionswhich retainthe ends of the ductingtogether. Screws installed through the right and left hand air outlet ducting to the centre air distributionduct, ensurecorrect retention of the ductino in its designedlocation. Should any of this air ducting be disturbedduring under instrumentpanel operations,it is essential to ensure that such ducting be correctly reinstalledso as to prevent possibleair leaks at these joinsand connections. Removalof any of the ducting necessitatesremoval of the instrumentpanel lower trim on the side from which the ducting is to be removed. Other than the blower housing to heater assembly duct, removal of other cluctingnecessitates removal of the touch control panel and the instrument panel location cover illustrated in Fig. 24-6. 1.3UPPER SIDE VENT OUTLETS, RIGHT & LEFTHAND REMOVE Usinga fine bladed screwdriver,carefully prise right hand and left hand upper and lower inserts from within side , gOUTERUppER AtR vent upperassemblies prior to removingscrews, securing ourlErlNSERrAsM. \ the upper air outlet assembliesto ths instrumentoanel .// , pad assembly as illustratedin Fig. 2A-7, then remove outletassembly. ,/' ,i \ REINSTALL Reverseremoval procedures. /,//,(v\u -\Yg....f/^@ia \Lg!rffi \-ourER_LOWER scREw_ (4PLACES) AtR OUTLET i,vsa*t nsrr,r. LOWER LH -' INSTRUMENT PANEL Figure 2A-7 - VENTILATION& HEATING2A.7 1.4 MODESELECTION, TEMPERATURE CONTROLAND BLOWERFAN SWITCH MODELS. ALL Remove 1. Disconnectthe batteryearth cable. 2. Remove the transmissionconsole assembly (refer 2.2, Body Sectionof this Supplement). 3. From the left hand side of the heater assembly' disengagethe front end of the controlcable from the temperaturedoor rod, illustratedin View B' Fig. 2A-8. 4. Remove the touch switch control panel and the centre nozzleand instrumentlocation {rame assemb- ly illustratedin Fig. 2A-9. 5. Remove the temperature,mode, booster fan and wiper dwell control knobs. 6. Remove the lower instrumentpanel enension illustr- ated in Fig. 2A-9. NOTE:Do not removethe wiper dwell controlswitch. 7. Remove the screw securing the top o1 the temperature and mode control assembly to the instrumentpanel frame illustratedin Fig. 2A-8' then partly ease out assembly,disconnecting mode con- trol vacuumhoses and electricalconnector' 8. Remove ihe rear end of the cable from the temperaturecontrol lever. Reinstall Reverseremoval procedures. E _ FOF CONTINUATION BEFER SECTION 12E \ ,,,1 -s, vrw@ l:7{ ASSEMBLE NUMBERED HOSES I ' ./ TO CORRECT PORT ON VALVE \-?-- E FOR INSTALLATION ,r VACUUM l{OSE HtrrEh rlu. zA- It , CHECK VALVE INSTRUMENT PANEL vrrwp] vrew SCREW- __--t2 @ t-'.- J \ a.=t=4^"<- ( FULL FoRWAR D -z -=. l---- sNAp lN WITH TEMDERATUREZ LEVER IN DOWN POSITION u,a* HEATER VENTILATION @ CONTROL ASSEMBLY EEFORESNAPPING CABLE IN, POSITION MUST BE F ULL FORWARD (AS SHOWN)WITH TEMPERATURE CAUTION NOTE _ NO KINKS IN HOSES LEVER IN DOWN POSITION. Figure 2A-8 2A-8 VENTILATION& HEATING J TU ;< F :L z -z U z (/)O3: o l a I(r r z I )z F U oo o F o = X z z U r J 9 U U 3 z U- o a \ q \ J z a I t F I z U U U J O F r F il, J T z z= a U a ft z ir. ^i; ;uJ FU I ;= z? =n :< EJ rI O,^ UV z4 a =; Ztr 3 u ,.) a -3 a Ea )@ u^ Ez q\^.s frY b" o) n: zx o| {O t-+.,- _io q- o -rJ : )=> I .J-' tt \E I -\ U I -< \\ .--j:\.- l a/) UJ UJ=< F< OA UI FU \o ',r \\\Z OU 1.5 BLOWERMOTOR REMOVE 1. Disconnectbattery earth cable. 2. From under the left hand side of instrumentpanel and using a fabricatedtrim clip removaltool (refer 10 SpecialTools,at the end o{ Section28) remove the lefi hand instrument panel lower trim (refer Fig.2A-10). JL ^NS )\A{1'LIP-4PLACES 1 LOWER PART INSTRUMENT PANEL sEcrroruA-A Figure 2A-10 3. From under the instrument panel, disengage the blower motor to main wiringharness connector, then supportingthe blowermotor, removethe two screws securingthe motor to the blower housingillustrated in Fig. 2A-11,removing the motor. REINSTALL Fleverseremoval procedures. a LH AIR INLET \ DEF LECTOR - SCREW (2 PLACES) s RH AIR INLET DEF LECTOR LAI R INI-E: SEAL RING Figure2A-11 2A-10VENTILATION & HEATING 1.6 BLOWERMOTOR HOUSING ASSEMBLY REMOVE 1. Disconnectbattery earth cable and blower moror to main wiringharness conneclor- 2. From EUMPER- under left hand of instrumentpanel ano usrng (2 PLACES) a fabricatedtrim clip removal tool (iefer 10 Speciai Tools at the end of Section 28) remove the instru- ment panel lowertrim (refer Fig. 2A_10). 3. From insidethe enginecompartment, remove the left hand air inlet deflector and the screw attached air inlet seal ring secured to the left hand side of the plenum chamber,as illustratedin Fig.2A_11. Re_ move the ring assembly 4. With the instrumentpanel compartmentopen and with the blade ol a scredriverlocated between the head of the hinge pin and the right hand compan- ment side, prise the hinge pin into the compartment as illustrated in Fig. 2A_12, then remove the companment. 5. Removethe blowermotor housingto heaterassemb- ly duct illustratedin Fig. 24_13. 6. From the base of blower INSTRUMENT PANEL motor housing,remove bolt COMPARTMENT securing lower part of housing to le'ii hano dash panel lower,illustrated in Fig. 2A_13. Flgure 2A-12 7. Removethe nuts securingthe blower motor housing to the studs attached to the left hand side of the plenumchamber illustrated in Fig.2A-13, removtng the housingassembly. REINSTALL Reverseremoval procedures. -.:/' \,- 7 -.-,''': \i \ -/,---'- WASHERT. \ \\ \ A---! ::-- ;; (YO-.) NUT-\ .') BoLr-y'- l^, l{.) -zt -/ t' \3 / HtrATFR T'] RINIAItrO - !!/)ntrH- Moroa ASM.DUCT ) \ \; tr A. \. lt' L /-\o SCREW 2 PLACES /va /\{, .HEATER ASSEMBLY r.jur-' iu I 2 PLACFS \ _- i \" E '\-=;1^,--WASHEF r u t1 ^ -tro,tT ,1 7.5 - 10 Nm \-*- BLOWER MOTOtr 2 HOUSTNGASSEf,rBry Figure 2A-13 J - - --.- --.at VENTILATION& HEATING2A.11 1.7 HEATERASSEMBLY REMOVE 1. Disconnectthe batteryearth cable. 2. Disconnectthe vacuumfeed hose at the check valve ROUTE then from inside the engine compartment,remove HEATER HOSESBETWEEN POWERUNIT MOUNTING BRACKET the rubber grommetfrom the dash and the coolant AND ROCKER COVEF, hoses from the inlet and outlet heater core oioes illustratedin Fig. 24-141 CAUTION:The heater can easily be damaged in the area VIEW of the core tube attachment seams whenever undue force is exerted on them. When the heater hoses do not readily come otf the tubes, the hoses should be cut just fotward of the core tubes. The portion ol the hose OUTLET HOSE remaining on the tube should then be split longitudinally. Once the hoses have been split, they can be removed INLET HOSE from the tubes without causing damage to the core. 3. Remove the instrument panel lower (refer 3.4 in Section1A, Body Section). 4. Removeheat/vent control assemblyfrom instrument panel (referFig. 2A-8). 5. Remove the blower motor housing to heater assemblyduct illustratedin Fig. 2A-13. 6. Remove the ends oi the ducting attached to the heaterassembly illustrated in Fig. 2A-15. - cFCr.r..'=-r' 7. Remove the bolt securing the lower part of the heater assembly to the floor pan bracket, as BEFORE TNSTALLATTON \.-.. illustratedin View A Fig. 24-13. OF GROMMET, PUSH ( * L the top of the heater VACUUM SOURCETO CHECK '-S\.- \ AI I 8. Removethe two bolts securing V' - ^UC'rUNtrU\ \ ' - to the instrumentpanel brace as illustrated VALVE HOSETHROUGH ^L assembly cRoMMEruP ro rAB No.4 C\ in Fig. 24-13, then removethe heaterassembly. Frr GRoNlN4ErovER HEATER \;v PIPESAND I\TO DASH PANEL. ) REINSTALL ENSURE PROPERFIT AND SEAL, Reverse removal procedures,ensuring that the heater core pipe grommetis correctlyinstalled to fully seal the hole in the lower dash panel. Also check that the electricals and ducting disturbed during the removal proceduresare operatingeffectively. Figure24-14 ,T CENTRE AI R z- LH DEMIST NOZZLE / DrsrRrBLrtor'JDUCT DUCT ASSEMBLY , - RH AIR OUTLET DUCT LH AIR OUTLET DUCT RH DEMIST NOZZLE DUCT ASSEMBLY HEATER ASSEMBLY BLOWER MOTOR BLOWER MOTOR HOUSIN(J HOUSING ASSEMBLY TO HEATER ASSEMBLY DUCT Figure 2A-15 rl- t--- -rL-- 2A,.12VENTILATION & HEATING F >R >P l< UJ F tf t r r> o r!< c UJ F U G r F .' :E lry U U U a I 3 ) U t (o N , o 3 g \J tt U (h F u., J /> F l QnL =e; o 3E: o \cl \ U o cc I U F :,/,.{ ! '/,-1 --( t u.: U C Y f, (-) -N : F : -F -+-- J -N :O -cc l F E z ^Cl\' U E \',tv' @ 8 {r o Oil ----J z> '/ "t\ )L -u | // Y V/, | // ; ',---- J O - ta ------VENTILATION& HEATING2A.13 1.8 HEATERCORE AND PIPI ASSEMBLY REMOVE 1. Remove the heater assembly as previously described. 2. With the right hand side of the heater assembly uppermost,disconnect door rod adjusting retainer clip 'A', then remove screw 'B', both illustratedin Fig. 2A-16. 3. With the heater assembly in the upright position, remove the screw attachedbracket 'A' illustratedin Fig.2A-17,then slideout the coreand pipeassemb- ly from the heatercase. REINSTALL Reverseremoval procedures. LEVER - 2 PER CORE & VALVE ASM _ BRACKET "A" NtrA ICN LUHtr r SCREW !'J \'.//\;, ,/ - LAIR MrxMIX T.JUUHDOOR UCONNECTING ROD \ -ArH L ROD RETAINING CLIP - 2 PER Figure 2A-17 24.14 VENTILATION& HEATING 1.9 WATERVALVE ASSEMBLY - HEATERCORE REMOVE 1. From inside the engine compartment,remove the heatercore hosesillustrated in Fig. 2A-.14. CAUTION: The heatercan eastly be damagedin the area of the core tube attachment seams wienever unctue force is exerted on them. When the heater hoses do not readily come off the fubes, the hoses shou/d be cut just fonarardof the core tubes. The portion of he hose remainingon the tuDeshould then be split longitudinaily. Once the hoses haye been split, they'can be removed from the tubes wfthout causingdamage to the core. 2. Remove:he rubbergrommet serling the heatercore ptpespassrng through the lowerdash panel. 3. Usrnc a cross recess headed screwdrrverlocated ns de of the dash inner panel hole adjacentto the realer core outlet pipe, remove the four screws securingthe watervalve assemblyto the heatercore prpe illustratedin Fig. 24-19, then removethe valve assembly, taking care not to loose the ,O, rino located between the valve and heater core outlei ptpe. REINSTALL Reverseremoval Drocedures. ,-WASHER-4PER BOLT - 4 PER r WATER VALVE ASM. TEATER CORE-r.\ GASKET O'RING _ ROD RETAIN. AND ADJ. CLIP RETAIN, BK: .J SEAL \- HEATER CORE VIEW UPPERSEAL Figure 2A-18 ------AIR CONDITIONING28-1 SECTION28 AIR CONDITIONING INDEX Ref. Subiect Page Ref. Subject Page 1. GENERALTNFOFMATTON ...... 2B-1 3.4 COMPRESSORINSPECTION 2. GENERALDESCRrPT1ON...... 2B-3 PROCEDURES...._...._....._.___. 2g-14 2.1 MANUAL CONTROLS 2B-3 Leak Test 2B-14 'DEiI' 2B-3 CompressorSmoothness Test...... 2B-14 'FLOOR' 2B-3 Glutch Test ...... 29.14 'VENT' 2B-3 Nolse...... 28-14 'BI LEVEL' 2*4 Remove...... ,. 28-r6 'NORM' 2B-.4 Relnstall 28-16 'MAX' 28.4 Disassembly 28-16 'OFF' 2H Reassembly 28-18 Retrlgerant Glrcult 2B-5 Air Gap Adiustment.. 28'-20 Gompressor 2B-8 3.5 EVAPORATORASSEMBLY 28'20 Thermostatlc Swltch 2B-9 Remove 28,-20 Evaporator.. 2B-9 Reinstall ...... 2B-2s Thermostatlc Expanslon Va1ve...... 2B-9 3.6 EVAPORATOBCOREAND PIPE Recelver Dehydrator.. 2B-9 ASSEMBLY 29-27 Condenser 2B-9 Remove...... 28,-27 3. SERVICEOPERATIONS 2B,-11 Reinstall 2V27 3.1 COilPRESSORDBIVE BELT TENSION i 3.7 CONDENSORAND AUXILIARYFAN AND ADJUSTMENT.... 2B-11 ASSEMBLY 29-27 s.2 CHECKINGCOMPRESSOR OIL CHARGE Remove...... 29-27 ON VEHICLE 2B.11 Relnstall 28-27 Addlng Oll Durlng Component AUXILIARYFAN 28-27 Replacement 2B-11 Remove ...... -..28-27 Compressor 2B-11 Reln8talllngthe Orlglnal 3.9 Compressor 2B-11 Installlng a New Compressor.. 2B-11 Evaporator.. 2*11 4. Condenser 28-11 5. Revelver Dehydrator.. 2g-11 REFRIGERANTSYSTEM CHARGING ...... 2B.-12 Fllllng Charglng Cyllnder ...... 2B-12 Installatlon of Charglng 2B-12 Chargfng System . 28-13 Eyacuatlonand Leak Test...... 28-13 Purglng (lf Necessary) ..-...... 2B-13 Charglng System . 28-13 FunctlonalTestlng ot System.. 28-13 1. GENERALINFORMATION The Air Internationalair conditioningsystem used on VK The following information provides basic service models is a cycling clutch system with thermostatic operationsfor the C.C.T.X.V.air conditioningsystem' expansionvalve (C.C.T.X.V.)and a Sanden TR 70 Spiral includingthe TR 70 SpiralCompressor. Compressor- L ------2B..2AIR CONDITIONING Figure 2B-1 I;FL- 1 ELOWER MOTOR -.4'l P, o SWITCH f*" VENT 8l NORM MAX TEMPERATURE _ DEMIST CONTROL HEAT,'VENT/AIR COND. CONTROLS VENT ci e\. '1 VENT BI_LEVEL MAX AND NORM BLOWER (RERCIRC) FOR OFF AND MAX. Figure 2B-2 J --^ - - -^ -- AIR CONDITIONING28.3 2. GENERALDESCRIPTION The VK cycling clutch and thermostaticexpansion valve (C.C.T.X.V.)air conditioning system permits cooled' heated,mixed or ambientair to flow throughthe vehicle, dependingon the positionol the mode and temperature control levers- Air entering the air conditioning/heatingsystem via the grille at the rear of the engine hood, passesthrough the blower motor housing and evaporator and heater assemblies,to be cooled or heated as required,then enters the passengercompartment through the centre and/or side upper ventilator outlets, or through the demist or footwelloutlets (refer Fig. 2B-1) dependingon the position of the mode or temperature control levers illustratedin Fig. 2B-2. Fig. 2B-2 also illustratesthe air flow within the system with the various modes activaled. A four speed high capacity blower lan forces air trom the plenum chamber, through the evaporator and heater assemblies,then out throughthe variousoutlets into the passengercompartment. NOTE: The blower motor is automaticallyswitched on to low speed wheneverthe mode control lever is moved from'OFF' oosition. On Sedans, air lrom the passengercompartment ex- hausts through the ventilatoroutlets located behind the right and left hand side rear drip mouldingassemblies, illustratedin Fig. 2B-3. On station wagons, the air is exhaustedvia the edges of the rear quarterinner trim panels,into the roof, then out into the atmospherethrough the tailgatehinge pockets' The controls illustratedin Fig. 2B-2, consist of a four speed fan switch and two sliding levers.The left hand lever regulatesthe temperatureot the air entering the vehicle in all modes and the right hand lever enables selectionof the particularmode required.The mode lever has seven oositions. Figure 2B-3 2.1 MANUALCONTROLS 'DEM' In this position,the air flows mainlyonto the windscreen through demist vents on top o{ the instrumentpanel. A small amount of air goes to the floor outlets.The air is cooled to reduce humidityand then can be reheatedto the settingrequired to demistthe windscreen. 'FLOOR' In this position,the main air flow is directedto the Jloor outlets with a small amount of air going to the demrst vents. The air conditioningcompressor does not operate in this mode. 'VENT' This setting directs all air to the centre and side vents. The air flow and directioncan be adiustedat each vent by directionalvanes and thumb wheels.The air can also be shut off individuallyat these vents to achieve the desired comfort. The air conditioningcompressor does not ooeratein this mode. ll aa------v 2B-4AIR CONDITIONING 'BI LEVEL' This positiondirects the air both to the centre and side vents as well as to the floor ouilets. When using Bl LEVEL with the temperaturelever in an intermediate position,warm air will be directedto the feet and cooled air to the face (centreand side vents). Cooledair is availableto both loot and tace levelswhen the temperaturelever is positionedat cold. 'NORM' This setting directs outside air through the centre and side vents,used for most coolingneeds on hot days.The air is cooled to reduce humidityand remove dust and pollen etc. lt can then be reheated if required to a lemperaturedetermined by the temperaturecontrol lever. 'MAX' Use fcr maximumcooling or quick cool down on very hot days. On this settingthe cabin air is recirculatedthrouoh the air conditioningsystem. No outside air is admit6d through the inlet grille and therelore the driver should returnto NORMALsetting once interiortemperature has reachedan acceptablelevel. This mode is also used to exclude unwanteo oust or fumesfrom enteringthe system. 'OFF' On this setting the fan is switched off and the door is closed so that no outisde air is admitted and the air conditloningcompres$r does not operate. NOTE: The fan automaticallyswitches on to its lowest speed vyhenthe mode lever is moved awav from OFF position.Fan speed can then be increasedbv setectrnoa highernumbet. 1. Outsideair is used in all modes except MAX and OFF. Do not operatein MAX or OFF for long periods as no outsideair is admittedto the vehicle. 2. When driving in very dusty conditions,i.e. follownq ,OFF' anothervehicle, use 'MAX' or mode deoendin6 on whetheryou requirethe air conditioneron or oi respectively.Through door and window seals either setting wll prevent outside air from entenng until drivingconditions permit return to one of the other settings.Selection oJ 'NORM' A/C with high blower speeds and all wrndowsclosed, will presiunze the intenorof the vehicle,excluding dust entry. 3. Undermost conditionsit is recommendedthat 'MAX' (recirculatedair) settingbe avoidedif occupanrsare smokingas residuesfrom the tobaccosmoke adhere to the evaporatorand air ducts and will result in stalesmelling air insidethe vehicle. 4. Automatic Transmission lf your vehicle is stopped for long periods in hot weatherwith the engine runningand air conditroner operating,setect 'NEUTRAL'or 'pARK'. This will increaseyour enginespeed which in turn aids engine coolingand air conditionerperformance. 5. 'OFF' you should only use this setting with the windowsopen. 6 The following procedure should be carried oul regularly during those periods of the year (e.g. winter) when the air. conditioningmodes may nor normallybe used. _t) --.L - - - AIR CONDITIONING28.5 Once every two weeks, with the engine running, switch the air conditioner on by selecting either 'DEM','Bl LEVEL','NORM' or'MAX' mode.The unit shouldbe run for at least 5-10 minutes. This procedure recirculatesthe oil within the com- pressorand lubricatescompressor shaft seals. This will help to prevent the dryingout of the seals with subsequentoperating failure of the system. 7. The air conditioner operates most etficiently with all windows closed. However, to speed up the cooling of the car interior on very hot days, it is recommen- ded that the windowsshould be opened for the first minuteto allow the hot air to escaoe. REFRIGERANT CIRCUIT The refrigerantcircuil illustratedin Fig. 2B-4 incorporates the followingmajor components: A eompressor, thermostatic switch, evaporator, thermostatic expansion valve, receiver dehydrator and a condenser. Figs. 2B-5, 28-6 and 2B-7 illustraterefrigerant tube and hose routingand connections. REFRIGERANTCIRCUIT & COMPONENTS LEGEND UUI! UtrI\JtrT vm7) V'//4 High Pressure High Temperature VAPOUR [:i!!!J Hish Pressure High Temperature LIOUID + ffi Low Pressure Low Temperature LIOUID f--] lo* Pressure Low Temperature VAPOUR _ SERVICE FITTING L REC. DEHYDRATOF HIGH .l SIDE {DISCHARGE) \J:f HIGH SIDE - COMPRESSOR- i.OWSIDE EXPANSI CUT OUT SWITCH TO COMPBESSOR VALVE CLUTCH )S oruurcH PRESSURE LOW CAPI LLARY SERVICEFITTING ON SIDE COMPRESSOR (sucrro\) SERVICE FITTING BALANCE TUBE THERMOSTATIC EVAPORATOR SWITCH .<- Figure 2B-4 lL- rll-- -- 7 28-6 AIR CONDITIONING scREW /- POWERSTEERINGA RESERVOIR ,.2 -\ z' -- aa l'- MA,NwrR'NG -/ ..D HARNESS siiew ->*\.- o secrtoruD-D I '.-- vrewI Lrrr, ,*o, 'L;.)\; .-r, ?\ i, RECEIVER DEHYDRATOR r- / \ TO THERMOSTATIC t) .) EXPANSION VALVE Az- c, !r' ,t2 ', ti\ :.$) -=- Ir il ruBE FRoMREcETvER 'f-\- )I DEHYDRATORTO \ SCREW f . coNDENSER l1_ ,..t,oJ A-A lr 'o 2 PTACES I cr^rc - 3 PLACES TGROMMET B z, A 7.5 - 9.5 Nm a' K A. ;--- 1J\ 15.0 - 18.0 Nm \{,",?- '_, REFRIGERATED 'llil+" r (fA 19.0 - 22.0 Nm TUBEROUTING lYi q A t secrroruB-B Figure 2B-5 CLAMP\ A _\j4_L ll z;]ry l, I .t '^--t'-' secrroruA-A EVAPOBATOR - TO COMPRESSOR HOSE -1 / : - EVAPORATOR OUTLET ,O'RING USE EXISTI\G SASKETS ct, (2 PLACES) )) : -1*J)-!l'^' ' : -*/ ,4, -G-'f-ScREw 1r'' zo zb t\m tf - /A ;'' oNLY/ // \ \ 24-30Nm A .';a./\ \ \ *o.".* t"''o t. 30-34Nm u,.* El Figure 28-6 /l --.al AIR CONDITIONING2B,.7 EVAPOFATOR HOSE TO COMPRESSOR L evepoRntoR ourLET secrroruA-A USE EXISTING GASKETS 'l :SCREW (2 PLACES) 12 L',', _ 7 { :--- COMPRESSORHOSE ^ r- TO CONDENSER ^ /-t A 1l\ 26-28Nm vrEWEl ,4. 12" 24-30Nm A 1r\ 30-34Nm Figure 2B-7 NOTES 28.8 AIR CONDITIONING COMPRESSOR The compressor fitted to VK models illustratedin cut away section in Fig. 2B-8 is the TR 70 manufacturedby Sanden. lt is a new design based on a gyratingspiral withina spiralprinciple. Two spiralcomponents have 2.8 turn involutespiral walls projectedfrom discs. Both spiral componentsare housed in a cylindricalcasing, with one in a fixed positionand the other interleaved with the former at an angular relationshipof 1800, The free moving componentsare drivenby a crankshaftin an orbiting motion.The orbiting motion of the free moving component provides a continuouscompression process in two pairs of compres- sion pockets. The compressoris belt drivenfrom the enginecrankshaft throughan electro magneticclutch. In the cycling clutch system,the compressoris run intermittently,automatically turning on and off in response to an electric signal controlled by the thermostaticswitch. The compressor will cycle as necessaryto maintainminimum temperature withoutthe evaporatorcore freezing. r DISCHARGE PORT ,TCHI col y'- SPTRALASM. PULI LEY \^,r-F RONT PLATE 1":\ A.: J;'.,,' \ \\,, i:.$,,{ !/ E. u' 'ROTOR PULLEY BEARING - SHAFT SEAL :BONT HOUSING_ L COUNT-FW:IGHT ASM Figure 2B-8 --^--- -^-- AIR CONDITIONING28.9 THERMOSTATIC SWITCH The switch,through a capillarytube, 'senses'variations in the temperatureof the evaporatorcore and, by makingor breaking the electricalcircuit to the compressorclutch coil, causes the clutch to engage and disengage,thus keepingthe evaporatorcore just above freezing. EVAPORATOR The evaporatorassembly located under the instrument panel and adjacentto the instrumentpanel compartment, cools and dehumidifiesthe air before it enters the passengercompartment ol the car. THERMOSTATIC EXPANSION VALVE The thermostaticexpansion valve regulatesthe supplyof liquidrefrigerant to the evaporator. IMPORTANT:No attempt should be made to adjust this valve or damageto the compressormay occur. RECEIVER DEHYDRATOR The receiver dehydratorserves as a reservoirfor storage of high pressure liquid producedin the condenserand incorporatesa screen sack filled with dessicantto absorb traces of moisture. A sight glass built into the top of the receiverdehydrator (reter Fig. 2B-5) enablesa quick check of the amountof relrigerantcharge in the system.lf the refrigerantcharge is low, a persistantfrothing condition will be visibleat this sight glass. To overcome this condition, refer to the DiagnosticChart at the end of this Section. CONDENSER The condenseris mountedforward of the engineradiator and is therefore exposed to a flow of ram air from the movementof the vehicle and from the engine fan. The purposeof the condenseris to convertthe high pressure, high temperature refrigerant gas discharged by the compressor into high pressure liquid refrigerant. An auxiliaryelectric coolingfan is centrallymounted directly in front ol the condenser. The system carries1050 g of R12 relrigerantand 150 cc ol SunisoNo. SGSrefrigerant oil. rl- /--- 28.10 AIR CONDITIONING rHBoucH Botr /),, 4 PLACES COMPRESSOR -- DRIVE BELT .-WASHER-4PLACES *cowpResson FOR CONTINUATION REF. SECTION 12E { ASSEMBLY j< -.:_ COMPRESSOF- A DRIVE BE tT /\' ATTACHING ADJ, BOLT /\\ BOLT i\i 2 PLACES / uLArvrrtr\u r,i-ttv | - "rotr,*oENSURE NUT IS RETIGHTENED AFTER BELT ADJUSTMENT ATTACH ING - BOLT 2 PLACES MOUNTING BRACKET 6 CYL. ENGINE J6oo lror REMovE sHrpprNG pLATES AND,oR pLUGs ,5: ,o - 27 Nm FROI\4REFRIGERANT SYSTE\4,UNTI L II\'lMEDIATELY HOSES oo-54Nm BEFORE ASSEMBLYOF TOPREVENT ENTRY OF Lj I\4OISTUREOR FOREIGN MATTER INTO THE SYSTEM. Figure 2B-9 Figure28-10 AIR CONDITIONING2B.11 3. SERVICEOPERATIONS 3.1 COMPRESSORDRIVE BELT NOTE: A new compressorwill contain 150 cc ol factory TENSIONAND ADJUSTMENT installedrelrigerant oil. lf there refrigerant Adjust the compressr drive belt using belt tension dial are no signsof excessive oil loss, add following gauge982350 or equivalent. the amountof oil dependingon the component being replaced. On 6 CylinderEngines: Before adjusting the compressordrive belt bolt (refer COMPRESSOR Fig. 2B-9),slacken off the idler pulley clampingnut. On Beinstalling the Original Compressor completionof belt adjustment,torque clampingnut to 40 1. Drain and measurethe refrigerant in - 50 Nm. oil contained the compressor. On 8 CylinderEngines: 2. Replace the oil in the compressorwith the same Slackenoff the idler pulleyarmlclamping nut assembly amountof new refrigerantoil. (refer Fig.2B-10), adjust compressor drive belt tension, then torqueclamping nut assemblyto 40 - 50 Nm. Installing a New Gompressor At the time of initial installationof a new belt only, the 1. Drain and measure refrigerant oil from original strand tension should be 64 kg (140 lbs) plus or minus compressor. 2.25 kg (5 lbs) but after ten minutes'run-in' or with used 2. Drain factory installed refrigerant oil from new belts, a value of 43 kg (95 lbs) plus or minus 2.25 kg comoressor. (5 lbs) applies. 3- Measurethe sameamount ol new refrigerantorl that was drainedfrom the originalcompressor anc install this amountof oil into the new comDressor. 3.2 CHECKINGCOMPRESSOR OIL CHARGEON VEHICLE The compressoris chargedat the factory with 150 cc of EVAPORATOR Suniso No. 5GS refrigerantoil. Only this Vpe of oil Drain as much of the originaloii as possibletrom the shouldbe usedwhen addingor changingoil. evaporator,then add the same amountof new refrigerant It is not necessaryto regularlycheck the oil level in the oil, eitherto the originalor new evaporator. compressor.In general,the compressoroil level should only be checked in cases where a maior loss of system oil has occurred,such as:- CONDENSER a. A broken hose or severeleak. Drain as much of the onginal o l as possiblefrom the condenser,then add the same amountof new refrigerant b. Collision damage to relrigerant system oil, eitherto the originalor new condenser. components. c. lf excess oil is suspectedto be in the system. 1. Dischargerefrigerant from system,then remove the RECEIVER DEHYDRATOR compressor. Drain as much of the originaloil as possiblefrom the 2. Removedischarge port cap of the compressorthen receiverdehydrator, then add the same amount of new carelullydrain and measurethe refrigerantoil. reirigerant. oil, either to the original or new receiver 3. Flushoil from rest of systemusing R12 gas. dehydrator. 4. Add 150 cc of new refrigerantoil to the compressor. NOTE: lf the condenser, evaporator or the receiver dehydratorcontains more than 25 cc of refrigerantoil, or Installthe dischargeport cap after first ensuringthat 5. the compressormore than 150 cc of refrigerantoil, then 'O' ring is not twistedand that the seat and the seal it must be assumedthat the system containsexcess oil. 'O' ring are clean. Tighten the cap to 8-12 Nm This condition necessitatescomplete flushing of the torque. whole system with R12 gas and 150 cc of new 6. Evacuatethen rechargesystem. refrigerantoil addedto the compressor. NOTE: Never over tighten the discharge port cap to overcomea refrigerantleak. Remove the cap and replace the 'O' ring. ADDING OIL DURING COMPONENT REPLACEMENT Some oil is lost whenever air conditioning syslem componentsare replaced. Where the system has been ruptured, a leak has occurred or a compressor has to be removed and reinstalledor replaced,the entire systemmust be flushed with R12 gas. IMPORTANT:The completeair conditioningsystem must conlain150 cc of refrigerantoil to functioncorrectly. ra- l-- ---tL-- 28'-12AIR CONDITIONING 3.3 REFRIGERANTSYSTEM CHARGING The followingprocedures are accomplishedby using the manifoldgauge set illustratedin Fig. 2B-11, which allows the rate of refrigerantdischarge to be controlled,thus minimizingloss of compressoroil from the system. CAUTION: The wearing of safety goggles is mandatory duing system charging. Filling Charging Cylinder 1. Open valve on bottom ol chargingcylinder allowing refrigerantto enter cylinder. 2. Bleed cylindervia valve on top (behindcontrol panel) as required to allow refrigerantto enter. lt will be necessaryto close bleed valve periodicallyto allow boilingto subsideto check level in sight glass.When refrigerant reaches desired level, close valve at bottom of cylinder and be certain bleed valve is closedsecurely. Installation of Charging Station 1. Closeall valves on chargingstation. 2. Remove cut-out swilch from high pressure charging port, disconnectswitch leads from compressorand main wiring harness, then reconnect main winng harnessdirect io compressor. 3. Connecthigh pressureand low pressurelines to the gaugeset fittingson the compressor. 4. Connect vacuum pump line and charging cylinder hose to gauge set. SCHRADER VALVES _- coMPRESSOR / (roPvrEW) ADAPTORS LOW rntrJ5uhtr GAUGE I\4ANI FOLD AN D GAUGE SET GAUGE TINES VACUUI\I CONTROL VALVE REFRIG=Fi\T C!'LINDER =l il|--.t-uo.uuM puMp r-ll=1 rli cHARGtNG - -/ CVLI\D:E Figure2B-11 ------.- -l AIR CONDITIONING28-13 Charging System refrigerant is trapped in the suction side of the compressor and that the internal components are The chargingprocess includes the followingsteps:- coated with lubricant. o Fillingcharging cylinder NOTE: Failure to comply with this proceduremay result . Evacuationand leak test in permanentdamage to the compressor. o Purging(if necessaryfor repairs) 3. Open high pressureside refrigerantvalve and allow o Finalcharging full charge to enter system- 1050 g Do not exceed o FunctionalTest this amount. 4. lf the charge will not transler completelyirom the Evacuation and Leak Test station to the system,close the high pressurevalve at the gauge set, set the air conditioningcontrols for 1. vacuum control valve and gauge set low Open cooling,check that the engine compartmentis clear pressurevalve, turn pump on. After severalminutes, of obstructions,start the engine and run at rdle the low pressuregauge readingshould decreaseto speed. Compressoroperation will decreasethe low 102 kPa vacuum. 98 to side pressurein the system.When low side pressure NOTE: This specificationshould be reduced3.5 kPa for falls below 275 kPa, crack open low side valve to every 300 metres above sea level. Allow pump to draw in the remainingrefrigerant charge. At no time operate for 15 minutes after this gauge reading is should the rate of refrigerantdrawn in be such that recorded, close vacuum control valve and tum otf pump hydraulicnoises are created in the compressorby if system holds vacuum for 5 minutes,commence char- the pumpingol liquid.Adjust low side valve opening ging system. to achievethis 2. lf system does not hold vacuum for at least 5. Remove gauge lines from system and replace 5 minutes, open refrigerant valve and allow approx protective cap over low pressure schrader valve 450 grams of refrigerant to enter system. Close fitting,then tighten cap securely.fit cutout switch to refrigerantvalve and locate source of leak using a high pressure schrader valve and !€nten securely leak detector,and repairleak. and leak check. NOTE: Various types and makes of leak detectorsare 6. Disconnect main wiring harness irom compressor currentlyin use. Whicheverleak detector is used, it is and reconnect cut-out switch leads to marn winng important to follow the manufacturersinstructions in harnessand compressor. the instrumentprior to regard to adjustmentand setting WARNING:NEVER RUN COMPRESSORWITHOUT RE- Inspect for leaks by slowly moving conductingthe test. FRIGERANT IN THE SYSTEM, AS COMPRESSOR probe all hose connections the of the detector around LUBRICATIONRELIES ON REFRIGERANTFLOW. and points of possible leakage. Refrigerant Rl2 is heavierthan air and will be more apparentat the bottom 7. Performfunctronal test. of a fitting. Functional Testing of System 3. Close high and low pressurevalves at gauge set, purge systemas describedbelow. The functionaltesting is a quick measurementof the air system perlormance.The air outlet vent 4. Repeat steps 1 and 2 until systemwill hold vacuum conditioner temperaturesand the compressorhead and inlet pre- for at least 5 minutes. ssures are compared with specified tolerances at the prevailingambient temperature. Purging (lf Necessary) To performthe functionaltest proceedas follows:- Disconnectvacuum line at chargingstation vacuum pump This test must be performedwith the vehicle In the and lay end of line on a clean rag on the floor. Crack shadei.e.'no sun load. open high and low pressure control valves and allow 1. Removethe protectivecaps and cut out swrtchfrom refrigerantto purge from system. Refrigerantis complete- the schrader valves on the compressordischarge ly purgedwhen hissingceases. and inlet fittings.Connect compressor lead to main NOTE: wiring harness. a. Do not open valves too much or compressoroil may 2. Connect the manifoldand gauge set charginglines be dischargedwith the refrigerant.Oil loss can be and adaptors to the air conditroningsystem as easilydetected on rag at dischargeline. shownin Fig.2B-11. b. Refrigerant must not be purged through vacuum 3. Close all doors,windows and the enginehood. pump as this will aerate oil in pump thus reducing 4. Set the temperature control lever to the cold sealingetficiency. position,blower fan to high and mode switchto A/C c. Reconnect vacuum line and close high and low 'MAX' position. pressurecontrol valves on manifoldand gaugeset. 5. Place and operatea high volume industrialtype fan d. Repeatevacuation and leak test. in front of the radiator grille to ensure adequate coolingof radiatorand condenser. Charging System 6. Measureambient temperature of this fan. vents. DO NOT STARTENGINE 7. Openall air conditioningface leveloutlet transmrsslon 1. Partiallycharge system with 170 grams (6 ozs) of 8. Start engine and run at 2000 rpm with refrigerantR12 by slowly openingthe high pressure in neutral. valve at the gauge set; gauges should register a 9. Measure the temperatureat the centre outlet after pressure,if not, check systemfor blockage. runningengine for 5 minutes. 2. Close high pressurevalve, and rotate comPressol 10. Compare actual pressures and temperatureswith at least 12 turns by hand to ensure that no liquid those on functionaltest table. /a------.=- 28.14AIR CONDITIONING FUNCTIONALTEST TABLE 2. Check current draw and voltage. The amperage range requtrementis 3.0 to 3.5 at 12 volts. Note the Ambient Air CentreOutlet oc followingsymptoms and remedies. Temp. Air Temp. o A very high Aux. Fan oc amperage reading - A short within Air Blast the fieldcoil. . No amperage reading - An open circuit in the winding. o An intermittentor poor system ground resultsin lower voltage at the clutch.Check for tight fit of coil retainingcirclip. Check to determrneprooer systemground. o Replace field coil if open or short circuit is found. lf operatingpressures and temperaturesare within the 3. Air Gap - An incorrect air gap specificatronslisted in this functional test table, the could cause erratic engagementor disengagement refrigerant section of the and/or clutch ratile. air conditioningsystem is Check the gap functionrngconectly. air with a feeler gauge 0.35 0.65 mm. Adjustas outlinedlater in this Section. 4. SuspectedBearing Noise - Carryout the following: Removebelt. Disengageclutch. Rotaterotor pulleyby hand. 3.4 COMPRESSORINSPECTION Listen for bearing noise. Feel for hard spots. lf PROCEDURES excessive,repair or replacecompressor. LEAK TEST Seeping oil does not necessarily indicate leaking NOISE refrigerant.Look for the followingproblems: Checkfor: . Shaft seal area seeping oil. Feet under seal area 1. Loose belt, torque to 43 kg (used),64 kg (new) plus betweenclutch and compressor. or minus2.25 kg. . Dislocationof front boss 'O' nng (protrudingsection). 2. Broken bracket and/or compressorbody mounting- o Oil aroundservice port. fittings. replacebroken component. . Oil aroundfiller hole. 'O' ring,stripped threads. 3 Missing,broken or loose bolts at compressorand o Oil aroundcrack rn compressorhousing. engrnefixing points. IMPORTANT:Always clean away all oil, grease,etc., and 4. Torquebolts to specifications. blow away residualrefrigerant before starting detection 5. Looseor wobblingengine crankshaft pulley. procedures.Reter to Systemor SupplierManuals for the 6. Alternalorbearing. proper techniquesto 'Electronic' be used for Halide or 7. Air pump (wherefitted). Leak Detectors. B. Water pump bearing. HalideFlame Detectors- Any portionof the compressor, 9. Enginevalves. rncludingthe seals,which shows a leak indicationon the 10. Timinggears. flame will require leak repa r. 11, Looseengine mounting bolts. 12. Low refrigerantcharge 'Electronic' can be determinedby persis- - Shop Type Detectors+- In the seal area. tant foaming in the receiver dehydratorsight glass Se: the instrument1/4 to 1/3 range above maximum and low suction pressure together with low head selsrtivity.All other portionsof the compressor- set the pressure. detector at maximum sensitivity.("Detectors with a 13. Oil Level- Insufficientoil can cause unusualnoise. mlnlmumleak rate of 14-28cc per year). Remove 'Soap 3ubble' Any bubbtes,on portion - any of the 1. Dischargesystem as previously 'Refriger- compressorindicate leak requiring ouilined in a repair. ant SystemProcessing.' 2. Removehoses from compressorand tape or plug all COMPRESSORSMOOTHNESS TEST connectionsto prevent absorptionof moisturefrom the atmosphere (Compressorinstalled) into the system. 1. Disconnect refrigerant hoses, discharging system. 3. SlackenofJ idler pulley clamping nut and/or bolt then disconnect 2. Disengageclutch. the drivebelt. NOTE: On 6 cylinder 3. Rotatearmature plate by hand. engines,it will be necessary to release the tensron from the compressor 4. While rotating, drive belt if severerough spots or 'catches' are adjustingbolt. illustrated in Fig. 2B-9. felt, repairor replacethe compressor. 4. Disconnect electrical connector then remove the attaching bolts and compressorfrom the mounting bracket. CLUTCH TEST 5. lf the original or a new compressor is being 1. lf field coil lead is broken,repair lead or replacefield reinstalled,or replaced, refer to 'Add Oil Durino coil. ComponentReplacement' 2.3 in this Section. --- -^ AIR CONDITIONING2B-15 \? ,A J g e (r L an t! F 5 4 aa UToa ct! F3 ti tr A- tr F ath CE ,/l z 0 L o /tl< e U /'l) J l9 z. t./ cc F l,/ L I (.) @ C) @ z o E /, = ,/- //> U cc c ;: )I z cc N - (, o N I = ul o u U :O tr J ccJ J f U IJJ l< f (I F-J F1 F lrJ z i^ AF <0 J- vt o IJJ ct ui (-)F U lz = il C) =J cr< J S- 2z U' 'TJ< 2Y UI o< u& tt 3 u ul Reinstall Reverseto removalprocedures noting the lollowing: 1. Torque mountingbolts as shown in Figs.2B-9 or 28-10 2. Leave protective plugs or caps until ,ust before connectingtubes or hoses to prevent absorptionol moisturetrom the atmosphereinto the system. 3. Installnew 'O' ring seals after lubricatingthem with refrigerantoil, then torque hose connectionsas shownin Figs.2B-5, 28-6 or 2B-7 4. Adjust the drive belt as outlined under 'Compressor Drive Belt TensionAdjustment' to 43 kg (used)or 64 kg (new)plus or minus2.25 kg. 5. Charge the system as outlined under 'Refrigerant Syslem Processing.'Parts illustratedin Fig. 2B-12 which are servicedfor the TR70 Spiral compressor include: 1. ArmaturePlate 2. ArmaturePlate BalanceWeight RotorPulley A FieldCoil Core 5. ShaftBearing - Front 6 FrontBoss 7 ShahSeal Assembly Disassembly CAUTION: Tool No. 41267, sea/ seat remover and installermust be used to ensure that no contamtnatpn i.e. dirt, humapperspiratton. etc., /s allowed onto the sea! area. With a new seal, tt ts tmperative that it be unpacked carefultyand fifted onto Tool 41267 for in_ stallation onto the compressor shaft. 1. Mountholding fixture AU2S8 into a vice, then usino the pins suppliedwith the fi).ture,secure the coml pressor assemblymounting holes onto the holding fixturebosses as illustratedin Fig. 2B-13. Figure28-13 insertpins of turningstop tool AU259 into holes o{ armalure,then using an 8 mm socket with ratchet handle attached,remove armatureanchor borr as illustratedin Fig.2B-14, then removearmature. Figure2B-14 J t-- - ^ --- - -\ AIR CONDITIONING28-17 3. Remove shim(s)trom top of compressorshaft then using wing circlip pliers J6083, remove the circlip securing the clutch rotor to the clutch core as illustratedin Fig.28-15, then lift the clutch rotor assemblyoff the compressorshaft. NOTE: lf difficultyis experiencedin removingthe clutch bearing,locate the ends of two bladed screwdriversinto grooves inside of clutch rotor, then using a lever action, leverclutch rotor up and off the compressorshaft. Figure 2B-15 4. Loosenthe clutch lead wire clamp releasingthe lead, then using wing circlip pliers J6083, remove the circlip securing the clutch core assembly in the stepped section of the front nose as illustratedin Fig. 28-16, then removethe clutch core assemblyofl the compressorshaft. --IEry--E-z c- Figure28-16 5. Using a 10 mm socket with a ratchet handle attached, remove the iour bolts securingthe front nose to the front end plate as illustratedin Fig. 28- 17. Lift the front nose off the compressorshaft as illustrated in Fig. 2B-18, then remove the square sectioned'O' ring from the end plate. Figure2B-17 Figure28-18 - ^.- 2B-18AIR CONDITIONING 6. Installthe 'O' ring protectingtool AU261 over the end of the compressorshafi then install the seal head removaland installationtool 41267 over the protectrngtool and compressorshafl, as illustratedin Fig. 2B-19. Depress then rotate the tool in a clcckwise directionto engage cutouts in bottom ol 'lool with seal head retainer,then remove the seal head. Figure 2B-19 Depressarms of the seal seat removaland installa- ricr tool AU260and installthe tool intothe insideol the seal seat as illustratedin Fig.28-20. Allow the ends of the tool to expandand engageinto recesses on the base ot the seal seat. Usinga pullingaction, lift seal seat out of seal head. Figure 28-20 Depressarms of the seal seat removaland installa- tion tool AU260and installthe ends of the tool in betweenthe base of the metal cap retainerto which the felt seal is attachedand the front nose. Carefully work the ends of the tool aroundthe base of the felt seal retainer,then usinga pullingaction, lift felt seal assembly out of the front nose as illustrateo rn Fio-28-21. Figure 2B-2't Reassembly 1. Install rhe felt seal assemblyonto the felt seal assemby rnstallingtool AU262,then installthe seal assembryfirmly into the bore ol the front nose. as illustratedtn Fig.28-22. Figure 28.22 -.). - - -^ AIR CONDITIONING2B-19 2. With the seal seat installed on the end of tool AU260,apply refrigerantoil to the seat 'O' ring, then insiall the seal seat into the bore o{ the front nose with the 'O' ring uppermost- Using the felt seal assemblyinstalling tool AU262 locatedon top of the seal seat, exert sufficient downward pressure to correcllyinstall seal seat. NOTE: Refer to cautionaryparagraph at start of Dis- assemblyprocedures. 3. With 'O' ring protectingtool AU261 installedon end of compressorshaft and with seal head installedin end of tool 41267, thoroughlyair blow seal head, then applyrefrigerant oil to 'O' ring. 4. lnstall seal head onto compressorshaft illustratedin Fig. 28-23, then applyingdownward pressure, rotate tool and head to align flats on the base of the seal head with those on the compressorshaft. 5. Remove 'O' ring protectingtool AU261 from end ol compressorshaft then install square sectioned 'O' ring into grooveon the end Plate. * Figure 28-23 Align notched edge of front nose with front plate retainingbolt illustratedin Fig. 28-24 and install the front nose, ensuringthat the square sectioned 'O' nng on the front plate remains in its groove-Apply downwardpressure on the front nose to overcome spring tension from the seal head, then install and torquefront nose to front end plateattaching bolts in diagonalsequence to 14.711.98Nm. Figure28-24 lnstall the clutch core assemblyto the front end nose, aligningthe locatingproiection dimple in tne base of the clutchcirclip core assemblywith cut cut in end plate.Using wing circlippliers J6083, install clutchcore assemblyas illustratedin Fig. 28-25 Figure 28-25 2B-20AIR CONDITIONING 8. Replace the clutch lead wire and tighten the retainingclamp. then installthe clutch rotor. using wing circlipp|ers J6083to to securethe rotorto the clutchcore as illustratedin Fig. 28-26. 9. Install the shim(s)to the end of the comoressor shaft. NOTE: These shims adjust the air gap (refer air gap adjUS1mentin subsequent service operations). Figure 28-26 10. Instalithe clutch armature,aligning flat on end of compressor shaft with correspondingf lat on armature.Using turning stop tool AU259 and an 8 mm socket with ratchet handle attached, install and torguearmature anchor bolt to 9.81r .98 Nm. as illustratedin Fig.28-27. Figure 29-27 AIR GAP ADJUSTMENT Measureair gap betweenclutch armatureand clutch rotor assemblies,using feeler gauges as illustratedin Fig.28-28. Recommendedair gap is 0.35 - 0.65 mm. lf adjustment of the air gap is indicated, remove anchor bolt and armatureclutch assembly (refer preceding instructions) then adjustshim thicknessto achievethe recommended air gap. Figure2&28 3.5 EVAPORATORASSEMBLY REMOVE 1. Disconnectthe batteryearth cable. 2. Evacuate the system (refer 'Refrigerant System Processing'in thisSection). 3. Disconnect the inlet and outlet refrigerant pipe connectionsillustrated in View 'A', Fig. 28-33, from the evaporatorcore. 4. Removetransmission console (reler 2.p or 2.3 in the BodySection ol this Supplement). 5. Removeheater case to panel cover assembly,lower instrument panel extention, touch switch control panel and centre nozzle and instrumentlocation lrame illustratedin Fiq. 2ts-29. AIR CONDITIONING28-21 _il ;< F :d z_ 3: oe >o dl at I U EZ .tO OF FU dl z =< )z ol- zx z CEL -U O- Ll F ;< U -O I ul^ ( =>'r' U |: o< a N. 'oz2 \ zsu) :>< =P l FF> J F z^< il J U. z= = ft z- oai FU =t z= -v Y< Fr -I(),^ Z; UV ; 72 =tr F Ul z_ U= lfL ua 9n 5o 17 C) ?A - FU N c- -\=: zx (\| YN ! o uil )=> I o< ll Jq a\a F< UG OU U- \ FU t ::5 ia U ^-= F J 9=I 28-22AIR CONDITIONING 6 U J V L I 3 U IT z O Orq J \ F .-. -i z Cs t \: b\ U> U z) )Z uC >; ze ! U uz U 8Z J ?e UJ N F r^ N O6 rr o f z> J z2 r\ t- i z? o F Jv l z -ir a t U 161 T }Y l = U cc o a) @ 6| o -9 L l o - u.1 F 'U .-(, >N , S{ uO \ / az \1 -^;:* .----* -ua .r --u < uY -c >i 1- =N t-t ,/ t/ a\, I-$ I -\X,/ AIR CONDITIONING28-23 -\\ =-\ scREW {2 PLACES) -_,/t, o.\ -\ \ -@ I ; ---1-t4 - \[ I -----" -\ L , SCREw vrewI vrewiBl - AIB DISTRIBUTION r LH DEMIST NOZZLE DUCT ASSEMBLY DUCT ASSEMBLY LH AIR OUTLET DUCT SCREW EVAPORATOR ASSEMBLY \ - Q! ntr\freT c ^22 BLowE R rvroron-=-j :- uvv !)):,:!- HOUSING ASM. --4 Figure 2B-3'l 6. Removecombined instrumenl assembly illustrated in Fig. 28-30. 7. Disconnect temperature cable at heater assembly and partially remove vent/heat control assembly- Do not disconnectvacuum hoses or electri€l connector. Remove screws securing left hand and centre of instrumentlocation cover to instrumentpanel pad and frame illustratedin Fig. 28-30. 9. Remove centre nozle hose assembly and screws securingright and left hand air ductingto centre air duct illustratedin Figs. 28-30 and 28-31. 10. Remove instrument panel compartment and rear comDartmentrelease button. 11. Remove left hand upper air outlet assembly and screw securingleft hand ol instrumentpanel pad to frame iflustratedin Figs. 2B-30 and 28-32. 12. Firmlysupport left hand instrumentpanel lower and remove all of the screws securingthis panel to the instrumentpanel frame illustratedin Fig. 28-32. 13. Flemove left harrd air outlet duct illustrated in Fig. 28-31, from under left hand side of instrument panel, taking care not to place undue pressureon left hand instrumentpanel lower. 14. From under the instrumentpanel, disconnect the drain tube illustratedin View 'A' Fig. 28-33 from the base oJ the evaporatorassemblY. '15. Positiona wooden wedge betweenthe left hand side of the instrumentpanel pad and the instrumentpanel frame to gain access to the two bolts illustratedin Fig. 28-33, which secure the top ol the evaporator assemblyto the instrumentpanel frame, then usinga socket enension and a ratchet handle, remove the bolts securing the evaporator assembly to the instrumentpanel frame. 2B.-24AIR CONDITIONING F z z o ) ,0 F Za -=> r l z r U 3 = @ U a r I U) l J o F> F zz U a F t Ir<< ol z - vv;^F o (- i a>) o ;=F? ol = T-e: o z- I l Pi=: tl. i;lr => Y< |a r.ff \! rlll z - 3i UJ --r> tr CCa O6 u!-u = =-z u) o.>_f ; AIR CONDITIONING28.25 o 'rv' \".- '1-PLACES B:rArNS .' , g/ ' -7L -cLAMp A. =5 "rru^r!\ *or r^-/ . ---,2 :1..'2 + ?5?',)#orto=.., YVASFER. a a \_: C? ELOWER MOTOR LOWER ! DRAIN HOSE ASM, \ HOUSING ASM. TO BE INSTALLED -OUL I FROM ENG. COMPT. B Figure 28.33 16. From inside the engine compartment,remove the two bolts illustratedin Fig. 28-33, securingthe front of the evaporatorassembly to the lowerdash panel. CAUTION: Cap or plug evapontor core pipes and refrigerant tube connections as soon as connectionsarc broken to prevent absorption of moisture from the atmosphere into the system. 17. Removethe clampsillustrated in Fig.28-33, which retain and seal the ends of the evaporatorhousing to the heater and blower motor housingassembly, disconnect the electrical connectors and vacuum hoses,then carefullyremove the evaporatorass REINSTALL Reverseremoval operations noting the following: 1. l{ the originalor a new evaporatoris to be installed, referto 'AddingOil DuringComponent Replacement' in thisSection. 2. Leave protective plugs or caps until just before connectingtubes or hoses to preventabsorption of moisturefrom the atmosphereinto the system. 3. Install new 'O' ring seals, lubricatingthem with refrigerantoil then torque A/C hose connectionsas illustratedin Figs.2B-5,28-6 and2B-7. 4. Chargethe system as outlined under 'Refrigerant SystemProcessing' in this Section. 5. Checkout the electricsand air ductsdisturbed durinq the removaiand installationooerations. 28-26 AIR CONDITIONING a TNSERTINTO SLOT INSIDE CASE .BOLT_2PER _ UPPERCASE TH ERMOSTAT - ASM, ! rEy/ E UPPER CAS: _ COVER ASl,'. ,O'RING .L TUEE ASM. i!\ R. EVAP. COI L SEAL *oo6 o 6eo o o oO-.= o! o-Z LOWER CASE ]RAIN COVEB ,T -'./AP. SILAST C THIS EDGE :.AP GROMMET- Figure 28-34 AIR CONDITIONING28.27 3.6 EVAPORATORCORE AND PIPE attached to condenser assembly, illustrated in ASSEMBLY Fig. 28-36. 5. Removethe screws illustratedin Fig. 28-36 securing REMOVE the right hand bracket to the condenserand the 1. Remove evaporatorassembly as described in the radiatorside supportpanel. precedingprocedures. 6. Disconnect the inlet and outlet refrigerant pipe 2. Remove the spring clips illuslratedin Fig.28-34 connectorslocated on the right hand side of the which secure the upper and lower sectionsof the condenserassembly. evaporatorcase together. CAUTION: Cap or plug disconnected connectors on heavy mastic insulationmaterial adia- 3. Remove the pipes and on condenser immediatelyto prevent moisture valve and inlet and outlet cent to the expansion being absorbedfrom the atmosphereinto the syslem. pipes. the upper section of the evaporator 4. Whilst removing 7. Disconnectthe horn bracket lead, then remove the the TXV sensor tube illustrated case, carefullyease horn and bracket assembly from the lett hand 'A' Fig. 28-34, from the slot in the inside in View radiatorside supportpanel. case. 8. From under the Jront lower valance panel, remove gasketand the inletpipe 5. Removethe rubbersealing the two screwsillustrated in Fig. 28-36, securingthe Fig. 28-34 from the evaporatorcore and illustratedin right and lett hand bracketsattached to the base ol pipe assembly. the condenserassembly. the from the lower sectionof 6. Carefullywithdraw core 9. Removethe screw illustratedin Fig. 28-36 securing care not to contact the the evaporatorcase taking the left hand upger support bracket to the radiator screen attachedto aluminiummesh waler collector side supportpanel, then removethe condenserand pipe core assemblyby the rear section of the and auxiliaryfan motor assembly. hand. NOTE:During manufacture, this water collectoris chemic- REINSTALL surface to accelerate ally treated to create a slippery Reverseremoval procedures. When installingthe new Acid depositswhich can result from moisturemovement. asser"rbly.note the following: touchingthis surfaceby hand can neutralizethis chemic- much possiblefrom the ally treated surface. 1. Drainas of the originaloil as orginal condenser,then add the same amount ol new refngerantoil, either to the original or new REINSTALL condenser. When installingthe new assemblynote the following: lf the condenser contains more than 25 cc ol 1. Drain as much of the original refrigerant oil as refrigerantoil, assume system contains excess oil possiblefrom the originalevaporator core, then add and flush system.Add 150 cc of new refrigerantoil the same amountof new refrigerantoil, eitherto the to the compressor. originalor new evaporatorcore. 2. Leave protective plugs or caps until just before lf the evaporatorassembly contains more than 25 cc connectingtubes to prevent absorptionof moisture of refrigerantoil, assume syslem containsexcell oil from the atmosphereinto the system. and flush system,then add 150 cc of new refrigerant 3. Use new 'O' ring seals coated wtth clean refrigerant oil to compressor. oil whenmaking inlet and outlettube connections. 2. Leave protective plugs or caps until just before 4. Leave final tighteningof the tube connectionsuntil connectingtubes or hoses to prevent absorptionof the condenseris finallyinstalled. moisturefrom the atmosphereinto the system. 5. Evacuate,leak test, chargeand performancetest the 3. Use new 'O' ring seals coated with clean refrigerant svstem. oil when makinginlet and outlet tube connections' 4. Leave final tighteningof the tube connectronsuntil is securelyinstalled. the evaporator FAN 5. Evacuate,leak test, charge and performancetest the 3.8 AUXILIARY system. REMOVE NOTE: Removal and reinstallationof the thermostatic 1. Disconnectthe battery earth cable and the auxiliary expansionvalve and the thermostaiand switchassembly fan electncalconnector located on the left hand side necessitateremoval of the evaporatorassembly. of the condenserassembly. 2. Remove the conneclor body from the end of the auxiliary1an lead, then attach a length of string to 3.7 CONDENSORAND AUXILIARYFAN the end ol the lead. ASSEMBLY 3. Removethe radiatorgrille illustrated in Fig. 2B-35. 4. Remove the nuts securing the auxiliaryfan to the REMOVE condenser,then removethe fan and lead assembly, 1. Disconnectbattery earth cable. leavingenough of the string previouslyattached to the radratorto 2. Evacuate the system (refer 'Refrigerant System the fan lead adjacentto the top of fan lead. Processing'in this Section). facilitatesubsequent installation oJ the 3. Removethe radiatorgrille, illustrated in Fig.28-35. REINSTALL 4. Disconnect the electrical connectors,then remove the auxrfraryfan blade from the fan motor assembly Reverseremoval procedures. 28.28AIR CONDITIONING \ JT- 2 PLAC -S v -l---/-i i---t / l___---' A ..u - 4.6Nm _AADIATOR 3F:!E A t.o - 3.4Nm Figure 28-35 FOF CONTINUA- 3\ l=FER SECTION 12E --r .// \l' /a' . -'-1 a:lTE^uj2 PLACES ./ coNDENSER & AUX| LTARY -C^v. .- - FAN ASSEMBLY A SCREW 4 2 PLACES 6 SCREW \- --_SCne W ASSEMBLESCREW TO CONDENSER& BRACKET Z TLALtr) AFTEB OUTLET TUBE IS CONNECTED TO CONDENSERREFER FIGS.2B-5 AND 28-7 A 0.8- 1.4Nm Figure 28-36 AIR CONDITIONING28.29 3.9 RECEIVERDEHYDRATOR REMOVE 1. Evacuate the system (refer 'Refrigerant System Processing'in this Section). 2. Disconnectthe inlet and outlet refrigerantpipes from the inlet and outlet sides of the receiverdehydrator illustratedin Fig. 28-37. CAUTION: Cap or plug disconnected connectors on pipes and on receiver dehydratorimmediately to prevent absorption of moisture from the atmosphere into the system. 3. Loosen the screw clamp illustrated in View 'A', Fig. 28-37, then slide the receiverdehydrator out ol the clamp. NOTE: lf the receiver dehydrator is left open to the atmosphere for more than 15 minutes, the receiver dehydratorshould be replaced. REINSTALL Reverse removal procedures. When installinga new assemblynote the following: 1. Drainas much ol the originaloil as possiblefrom the original receiver dehydrator, then add the same amount of new refrigerantoil, to the original or new receiver dehydrator. ll the receiver dehydratorcontains more than 25 cc of relrigerantoil, assumesystem containsexcess oil and flush system.Add 150 cc of new refrigerantoil to compressor. 2. Leave protective plugs or caps until just before connecting tubes to prevent absorption of moisture from the atmosphereinto the system. 3. Use new 'O' ring seals coated with clean refrigerant oil when making inlet and outlet tube connections. 4. Leave final tighteningol the tube connectionsuntil the receiverdehydrator clamp is fully tightened. 5. Evacuate,leak test, charge and performancetest the syslem. POWERSTEERING - RECETVER R ESERVOIR ,- DEHYDRATOR SIGHT G LASS 18 Nm MOUNTIi (l ffi 5 --- ERACKE scne,//-- VIEW Figure 28-37 -.. 28.30 AIR CONDITIONING 4. DIAGNOSISCHART COMPLAINT _ TNSUFFICIENTCOOLING NORMAL AIR FLOW CHECK AIR FLOW Check that heater tap is off wher eve. s on "COLD posrlron Check d arr temperatu'9 at cutrel lozzle NORMAL NOZZLE AIR HIGH NOZZLE AIR TEMPERATURE TEMPERATUF E Check for air leaks thrcugh frre wall, doors. windows or from neater. FOAMING NO FOAMING System is probably low on refrigerant. System may be either fully charged or empty. Check for leaks, repair and add refrig- Feel high and low pressure prpes at compressor. erant. lf foaming still occurs, check High pressure pipe should be warm; low pressure for restriction in refrigerant system pipe should be cold. between condenser and sight glass. lf pipes are not indicating proper remperatures_ recharge system as recommended. lf nozzle air temperature is still high, check evaOorator. CHECK EVAPORATOR PRESSURE LOW EVAPORATOF OR HIGH EVAPORATOR OR ] COMPRESSOR SUCTION PRESSURE COMPRESSORSUCTION PRESSURE Check evaporator outlet line THERMOSTATTC Outlet line warm. SWITCH Check for liquid line resr: cr on Check for clutch cycle. (Frost spot on line) lf ror, piugged Check for T.X. valve. CYCLE lf not, Check for cefective T.X. valve by o.K removrng vaive and blowing through CLUTCH ON I valve lf unable to blow through valve bulb is drscharged. Replace T.X. va ve Disconnect clutch lwire. ] CLUTCH CLUTCH REMAINS DISENGAGES ENGAGED Clutch is defective. LOW DISCHARGE HIGH DISCHARGEPRESSURE rhts55uHE Check engine cooling fan and condenser cooling fan, and for restricted air flow Check for slipping clurch or slipping belt. tnru COndenser. Crgck for suction lrne restriction- Check T.X. vatve Remove compressor, teardown, inspect for bulb contact and rnsulation. det?cts and repair. Correct if necessary. Check for refrigerant restriction jn condenser. Aeiurn bends at equat elevation should be acprox imately same temperatu re. If te6pg1s1g1s of bends is appreciably different. the cooler bend ncrcates a restricted circuit. Replace condenser ii restrction is found. lf condenser rs O.K., check tor ai. in system. To check: Observe nozzle air temperature and compressor drscharge pressure whr,e slowly discharging system at receiver inlet connectron NOZZLE AIR TEMPERATURE NOZZLE AIF TEMPERATURE DROPSAS COMPRESSOR INCR EASES AS COMPRESSOR DISCHARGEPR ESSUREDROPS DISCHARGEPBESSURE DROPS t-- Lea^ test rurr"-, r"p"ir- T.X. valve super heat as necessar\, discharge, ] settrng is low. Replace evacuate and recnarge. I I T.X. valve -=--. AIR CONDTTIONING28.31 NO OR LOWAIR FLOW Check blower operatton OPERATION BLOWER NOT OPERATIT{G NORMAL BLOWER Check {or loose or disconnected air d!strtbrt,on roses Check for blown fuse, defective blower switch, Restricted or leaking air ducts, partially closec aLr broken wire, loose connection, defective outlet valve or closed evaporator core. blower motor. l{ above check is O.K., check for ice blockrng eva9o'aio' ICE BLOCKING EVAPORATOR Ailow system to warm up. Festari:n-o ne. Check elaO:.a:or Pressure mrgd a:a 7 afler restart and ou i cc$r ol e,'ap3ralor Pressure. tF:t r uJ l r r L SY;ITC H OR NORMAL EVAPORATOF Check io'clu:cn COMPRESSORSUCTION PBESSURE Nra a!a ; Check discharge Pressure CYCLE o.K. CLUTCH O\ Disconnect clutch wrre ,Ln -L! Ut5tr !Jrrtr) CLUTCH OFF Thermostatic swr::r Clutch is defective is defective. Checkelectrical circu rt throughthermostatic switchand clutch solenord NORMAL DISCHARGE PRESSURE LOW DISCHARGE PRESSURE in liquid line, Check for restriction Refrige'at on svsi.m ls O.K. valve, or partiallY Plugg€d T.X. 'I . Check io' nc: !\aie' valve shut-ot1 valve Replace T'X' defective T.X. 2. Check io- P'3Pg' function of air SeleCiOr doOr. valve if defective. 3. Check fo'crcPe'oPeration and sea a.oLnc :emperature door s\'s:em. Add approx 4. Non-foam rg s grt glass does not alwavs rd cate a fully charged recharge s/slem as specified 200 g R'12 anc obserye performance Dlscharge or 5. Check tor c'cae- seal arouno evapo)oraio- ca,e. oil is a slipping clutch or be 6. Check for excess orl rn system A svmotcm of excess excessoil rn system or broken 3er: at speeds in excessof 1OOkmih. To remove and maxrmum co o a) ldle en-one f or 10 minutes wrlh co.trols set at high blower from if the compresso b) Discharge system, drain and measu'e oil compressor has an orl overcnarg' contains mo'e than 85 cc of ref'gerant oil, the system c) Remove T X. valve. remove the excess otl I d) Fturn the remaining components wrth R-11 to valve' e) Drain the excess oil from the T.X. valve and install I f) lnstall the compressor with 95 cc of new refrigerant oil' j g) Evacuate and recharge sYstem -- 29.32 AIR CONDITIONING 5. SPECIALTOOLS The CompressorTools are ava able either in kit form as Tool No. AU263, or as separateitems under their individual Tool number. A Belt TensionGauge is alsoavailable. These Special Tools are availablefrom. Kent Moore- AustraliaPty. Ltd. Unit 3, 9 PioneerAvenue, THORNLEIGH, N.S W 2120. Teephone. (021 8489717 Terex 22355 FAB RICATED TRIM CLIP REMOVAL TOOL 0.5 mm t_- END CONSTRUCTION TO SUIT HANDLE {-- REOUIREMENTS ^-o 9.0 mm- -<_75.0 m_--__> 18.0 mm- -6.0 mm ;- 10.0mm DIA v vv 25.- l | GAUGE - aJ.5^- mm 3.0 mm AU263_ SANDENCOMPRESSOR TOOL KIT COMPRISINGTHE FOLLOWING TOOLS AU261 ,O' RING PROTECTINGTOOL Z '. (I \-o 4U262 FELT SEAL ASSEMELY AU258 NSTALLING TOOL COMPRESSORHOLDING FIXTURE 41267 SEAL HEAD R'MOVAL INSTALLATICN TOOL AU260 SEAL SEAT REMOVAL WING CIRCLIP PLIERS AND INSTALLATION TOOL FRONTSUSPENSION 3.1 SECTION3 FRONTSUSPENSION INDEX Ref. Subject Page I Ref. Subject Page 1. GEI{ERAL DESCR|PT|ON...... 3-1 | 2. FRONT STRUT USAGE 3-1 1. GENERALDESCRIPTION The front suspension on VK Series models remains the interchangeablewith previous Commodoremodels. same as on VH Series models, with the exception.ol the Service operationsare as described in Section 03 of the front strut shock absorbers.These have been revised to VB ComniodoreService Manual p/N M3g14S. suit the differenl variation in vehicle load and to maintain satisfactory damping control. VK strut inserts are not 2. FRONTSTRUT USAGE All VK Series models have the front strut assemblies painted black, there is no colour identificationas per previousCommodore models. For non-standardstrut identification,refer to the 'Body and ldentification Plate'. The plate includes vehicle optional information if it is fitted with XWs - Outback Packor FE-ZSports Suspension Pack, refer Fig. 3-1. Figure 3-1 REARSUSPENSION 4A.1 SECTION4A REARSUSPENSION INDEx Ref. Subject Page Ref. Subject Page 1. GENERALDESCRIPTION ...... r...... 4A'1 3. SPECIFICATIONS...... -...... r...... 4A-2 2. SERVICEOPERATIONS ...... '...... !...... 4A-1 3.1 REARSHOCK ABSORBER USAGE...... I 4A-2 1, GENERALDESCRIPTION The rear Suspensionon VK Series models remains the differentvariation in vehicle load over VH Series models. same aS on VH Series models,with the exceptionof the Serviceoperations are as describedin Section 04 of the shock absorbers.These have been revised to suit the VB CommodoreService Manual. 2. SERVICEOPERATIONS Service operations arc as described in the VB Com- modoreService Manual Part Number M38145. NOTE: Any service operation that requires the removal and reinstallation of the upper control arm to axle attachingbolts, on installationthey must be inserted in an inwarddirection, Refer Fig. 4A-1. Flgure 4A-l -^ar-.- 44.2 REAR SUSPENSION 3. SPEC|F|CAT|ONS 3.1 REARSHOCK ABSORBER USAGE EXTENDED IDENTIFICATION MODELS LENGTH LABEL COLOUR (mm) All 19 Styles(Sedans) Exc. XWS/FE2 All 35 Styles (StationWagons) Exc. XWS/FE2 522.5/528,5 Black 19 Styles(Sedans) vG with xw5 , FE2 ffi1/635 Yellow 35 Styles (StationWagons) r I LG 523.51527 With XWSiFE2 | .5 Yellow 19 Styles(Sedans) With FEz 582/588 j Black XWs - Outback Pack FEz - SuspensronSystem Pack NOTES REARAXLE 48.1 SECTION48 REAR AXLE INDEX Ref. Subiect Page I Ref. Subiect Page 1. GENERALDESCR|PT|ON...... 4B-1 | 2. SERVTCEOPEBAT|ONS...... 4B-1 1. GENERALDESCRIPTION There are two different size Salisbury Rear Axle 2. A Salisbury type axle with 1gO mm diameter ring Assembliesused with VK Series models. gear is used on models with s.O litre engine. 1. A Salisbury type axle with 178 mm diameter ring Limited slip differentialis avaitabteon all models. gear is used as standard eguipment on all models except those with the 5.0 litre engine. 2. SERVICEOPERATIONS There have been some revisions to the rear axle assemblies for VK compared with those fitted to VH Series models. 1. The hypoidpinion has been shot peened. 2. The ditlerentialpinion shaft has been nickle plated. 3. The hypoid pinion bearing spacer has been surface hardened,by a process of nitro carburizing. NOTE: Components from previous Holden models must not be substituted for the above components when overhauling the rear arde assemblies on VK Series models. The remainder of the axle components are identical to those used on previousHolden models. For servicing and overhaul procedures refer to the VB CommodoreService Manual Part No. M38145. PROPELLERSHAFT & UNIVERSALJOINTS 4C-1 sEcTtoN4c PROPELLERSHAFT & UNIVERSALJOINTS INDEX Ref. Subject Pqge I Ref. Subject page 1. PROPELLERSHAFT IDENTIFICATION...... 4G1 I 2. UNIVERSALJOINTS IC]T 1. PROPELLERSHAFT IDENTIFICATION The following chart sets out the propeller shaft usage for VK Series models. PROPELLER SHAFT ENGINE TRANSMISSION PART NO. COLOUR 3.3 litre MC6 ll s2o24162 | BLACK EST with grey band 1l r M4o il gzoz4163 | a LAcK i 141ithviolet band M76 | 92024160 I eLACKwith ll I opalinegreen band 3.3 litre B LACK with sky blue band DARK GREEN with white band 2. UNIVERSALJOINTS On VK Series models, with the EFI engine, the propeller The phasing of the front and rea( yokes on propeller shaft is fitted with universalioints the same as used on shafts fitted to 3.3 litre models, has changed from 5.0 litre models. parallelto 90o apart. For service operations refer to Section 04 of the VB CommodoreService Manual Part No. M38'145. BRAKES5.1 SECTION5 BRAKES INDEX Ref. Subject Page Ref. Subject Page 1. GENERALINFORMATION ...... r...... r..-..... 5-1 2.2 BRAKE BOOSTER...... ,...... , 5-2 1.1 SERVICE NOTES ...'...... r.o....rr...... !.r.r...... 5-1 RgmOV€...... -..r.....-...... ro....r...... r 5-2 1.2 BRAKE BOOSTER - 6 CYLINDER ...... ,..D't 5-1 ReinStall .-...... -...r...... '...... 5-g 2. SERVICE OPERATIONS ...... r...r..r.-.....5-2 3. SPEC1F1CAT|ONS...... r...r...... 5-4 2.1 BRAKE FLUID CHANGE...... *2 4. TORQUE WRENCH SPECIFICATIONS...... 5.4 1. GENERALNFORMATION With the exceptlonofa non-serviceablebrake booster on all 6 cylinderVK models,the brake systemfor VK is and modifiedbrake pipesto suit mastercylinder position similarto VH models. 1.1SERVICE NOTES The polyglycol brake fluid used in VK Series models is hygroscopic and absorbs moisture f rorn the air through the brake hoses etc. The boiling resistance of the fluid decreases as the moisture content increases and so the possibilityof a vapour lock under heavy braking condit- ions increases with the age of the fluid. Therefore, for maximum brake effectlveness, a two yearly change of brake fluid is rnandatory. To prevent the absorption of moisture from the air, it is recommended that the brake f luid be stored in small (500 ml) containers and that any surplus fluid remaining in a container after use be discarded. NOTE: The approved brake fluid (GMH Spec- ificationHN1796) is available from GM P & A in 500 ml containers under part number 92018952 and 250 rnl containers, part number 92018951. lf pressure bleeding equipment is used, it must be of an approved type with a diaphragm separatrng the brake fluid from the air. CAUTIOAT; Brake fluid ls extremely damaging to paint. lf fluid shoutd accidentally touch a painted surlace, immediately wash from paint and clean painted sur-face. 1.2BRAKE BOOSTER . 6 CYLINDER A single diaphram brake booster is fitted to all 6 cylinder VK models. The brake booster is similar to that used on JB Camira models. The booster cannot be serviced and must be replaced if defective. 5-2 BRAKES 2. SERVICEOPERATIONS 2.1 BRAKEFLUID CHANGE 1. Thoroughly clean master cylinder especially around wheel brake line connections. 2. Disconnect wheel brake lines from master cylinder and remove reservoir cap. 3. Allow master cylinder to drair, until empty. (Refer Fig. 5-1) 4. Fill master cylinder reservoir with f resh, specified brake fluid from a sealed 500 ml container and ensure reservoir is at least half full for remainder of procedure. 5. Allow fluid to flow from open connection ports until fluid is free of air. 6. Reconnect wheel brake pipes to master cylinder and tighten to torque specified at end of section. 7. Bleed at each wheel using diaphragm type pressure bleeding equipment, until fluid removed is free of air. NOTE: lf pressure equipment if not available, proceed to bleed brake system manually (at least 6 pumps per wheel brake). Figure 5-1 8. Loosen left hand caliper bleed screw. D ISC 9. Remove left hand caliper anchor plate retaining bolts. ROTOR< (See Fig. 5-2) ./\ 10. Hold caliper upside down and remove bleed screw to CALIPER drain contents of caliper into suitable receptacle. 4 ANCHOR PLATE 11. Hand tighten bleed screw and reinstall caliper ') R ETAIN ING assembly. 2t BOLTS 12. Tighten anchor plate retaining bolts to torque specifi- ed at end of section. 13, Repeat step 8 to 12 tor right hand caliper assembly. 14, Bleed front calipers. ERAKE CALIPER Figure *2 2.2 BRAKEBOOSTER REMOVE 1. Disconnect electrical lead and three brake pipes from master cylinder.(Refer Fig. 5-3). BRAKE EOOSTER 2. |.Jnscrew nuts securing master cylinder support bracket to adjacent spring tower. (Refer Fig. 5-3) 3. Remove master cylinder to bracket bolt and remove bracket. (Refer Fig. 5-g). 4. Remove nuts securing master cylinder to power booster studs. (Refer Fig. 5-3). BRACK ET 5. Remove master cylinder taking care not to disturb power booster push rod. NOTE: Do not depress brake pedal with master cytinder removed or reaction disc may become dislodged In booster. Figure 5-3 BRAKES5-3 6. Remove vacuum hose from brake booster body' 7. Remove two brake booster assembly retaining nuts at brake pedal support, from inside the vehicle. (Refer Fig. 5-4)- Figure 5-4 8. Remove brake push rod retainingclip and washer from brake pedal and lift push rod off brake pedal stud.(Refer Fig. 5-5) booster assembly from engine 9. withdraw WASHER compartment. Remove bracket and gasket from boosterstuds. telPr-@+_ \J/ v .-PUSHROD PUSHROD BRA KE STUD Figure 5-5 REINSTALL 1. Locatebracket and gasketon boosterstuds. 2. Place boosterassembly in positionand fit push rod over brake pedalstud. Refitwasher and clip to stud' 3. Reinstalltwo booster retainingnuts and tighten to torquespecified in rear of Section- 4. Refit vacuumhose to boosterbody' 5. carefullyposition master cylinder over power booster push roo' and retainingstuds and torque retaining nuts to torque specified at end of this Section. Resecuresupport bracket to springtower and master cylinder. this 6. Tightenall bolts to torquesspecified at end of is Section.Bleed brake system.lf pressurebleeding to employed,the brake lines must be reconnected rnaster cylinder before commencing bleeding procedure. - -, 5.4 BRAKES 3. SPECIFICATIONS BrakeFlu id GM SpecificationHN1 796 (GM P & A Part No. 92018952 - 500 mts) 92018951- 2b0 mts) BrakeBooster fusembly Type SingleVacuum Suspended VacuumPiston Diameter 230 mm 4. TORQUEWRENCH SPECIFICATIONS Nm Brake BoosterRetaining Nuts 20-25 MasterCylinder to BracketBolt 15-18 MasterCylinder Bracketto PanelNuts 20-25 MasterCylinder to BrakeBooster 19-28 PressureDifferential Warning Switch 1.4- 1.8 CaliperAnchor PlateRetaining Bof ts 70-85 BrakePipes to MasterCylinder Nuts . . 8-11 -ta - ENGINEMECHANICAL 6A.1 SECTION6A ENGINEMECHANICAL INDEX Ref. Subject Page Ref. Subject Page 1. GENERALDESCRIPTION ...... 6A-1 2.3 CYLINDERHEAD (EFl)...... 6A-5 1.1 3.3 LITREENGINE WITH ELECTRONIC RgmOV€...... r.....r.r..r...... r...... r...... 6A-5 SPARK TlitlNG (EST) ...... r...... !.'..t.t... 6A-2 RginStall ...... r...... r...r,...... -...... 6A-7 1.2 3.3 LITREENGINE WITH ELECTRONIC 2.4 ENGINEASSEMBLY (EST)...... -...... 6A-7 FUEL INJECTION (EFI) ....,..r!...... r..r....r...... 6A-3 RgmOV9...... r..r...... '...... r..... 6A-7 Inlet ManifOld ...... r.r.rr....-...... r....r....6A-4 2.5 ENGINEASSEMBLY (EFl) ...... 6A-8 EXhaUSt SySteJfl ...... -...... rrirrrrrrrrrrrroo 6A-4 RemOV€.t...... r...... r...... !..r 6A-8 2. SERVICEOPERATIONS ...... 6A-4 ReinStall ...... r...,....r...... 6A-13 2.1 coilPRESSIoN TEST....r...... -...... 6A-4 3. TORQUE WRENCH SPECIFICATIONS...... 6A-13 2.2 GYLINDERHEAD (EST)....'.....r....r...... !.... 6A-5 Rem OV€ ...... r...... ! rr.1...... t 6A-5 1. GENERALDESCRIPTION Three different engines are released for use with VK The 5.0 litre VB engine with automatictransrnission. Series models. which carriesover from the VH Series,is availableas an A 3.3 litre engineequipped with ElectronicSpark Timing optionon all models. (EST) is standardequipment on SL and Berlinamodels. The changesto the 3.3 litreengine have beenrntroduced A 3.3 litre enginewith ElectronicFuel Iniection(EFl) is to reduce emissions and improve fuel economy. A standard on Calais and available as an option on all surnmar/ of the modificationsused for each 3.3 litre sedan modelswith automatictransmission. enginefollows. 6A-2ENGINE MECHANICAL 1.13.3 LITREENGINE WITH ELECTRONICSPARK TIMING (EST) This engine uses the Bosch Electronic Spark riming system, refer Section 6D, lgnition System, of this Supple- ment for details. Detailed revisions have been made to the following engine components, to suit the requirements of the EST engine. The cylinder head and inlet valves incorporate changes to improve gas flow refer Figs. 64-1 and 6A-2. Cylinder head gasket, has a pigmented dark brown colour for identification, and is of a heavy duty construction. Spark plugs, copper cored with thicker electrodes. Figure 6A-1 y 'V K' 3.3LITR E \ 'VH'3.3 LITRE \\\ f \\-< \\ \ \, \-'VH'3.3 LITRE Figure 6A-2 The cylinder head is also revised to accept the air pump type Air Injection Reactor system. The cylinder block has been modified at the rear to accept the mounting of the EST speed sensor, refer Fig GA-3 The flyrrheel and torque converter assemblies have three timing pins added around their circumference. There is also a dowel pin added to the rear face the of crankshaft SPEEDSENSOR to accurately locate the flyr,vheelor automatic drive plate. Pistons have been revised to suit the engine operatrng characteristics. SENSORMOUNT Figure 6A-3 ff ENGINEMECHANICAL 6A.3 1.23.3 LITREENGINE WITH ELECTRONICFUEL INJECTION (EFl) This engineuses the Bosch LE-2 JetronicFuel Iniection system.Refer Section 6C of this Supplementfor details. Detailed revisions have been made to the following engine components,to suit the requirementsof the EFI engine. The cylinderhead and inlet valves incorporatechanges to improvegas flow. Refer Figs. 6A-4 and 6A-5. Figure 6A-4 '.K 33LrrRE /- _.VH' 3.3 LITRE T a- ,1 . :-'.";'-'14 \ \ \-'VH' 3.3 LITR E -_,!/K'3.3 LITRE Figure 6A-5 Spark plugs, copper cored with thicker electrodes. Exhaust valves, with improved material specifications, are identified by a forged 'S' in the valve head recess. Refer Fig. 6A-6. Cylinder head gasket, has a pigmented dark brown colour for identification, and is of a heavryduty construction. Camshaft: Cam profiles have been revised. For valve timing details refer chart below. NOTE: Timing includes ramps. Opening ramp 26o Closing ramp 32o. Includ ing Ra mps Figure 6A-6 lnlet Valve OpensBTC ClosesABC Du rati on ExhaustValve OpensBTC ClosesATC Duration ValveOpen OverlaP Pistons have been revised to suit the engine operating characteristics. Timing Gears: Revised gear tooth design for camshaft drive gear set and improved material for steel crankshaft 9ear. The timing case cover has been modified with the addition of an oil redirection rib (Fig. 6A-7). This allows additional oil flow to the timing gears. - OIL REDIRECTED RIB Figure 6A-7 t- 6A-4ENGINE MECHANICAL INLET MANIFOLD A new ram tuned inlet manifold is used to optimise mid range torque. lt has the diameter and length of the runners tuned so that a positive pressure pulse arrives at the inlet valve just prior to its closing. This forces extra air rnto the cylinder giving a pressure charging effect which can be as high as 15 kPa. Figure 6A-8 EXHAUST SYSTEM A substantial power and torque increase has been achievedby the use of exhaustextractors in conjunction with a singleexhaust systern. The exhaust extractors,which are manufacturedf rom K" stainlesssteel, nave a low heat retention,helping to minimiseunder hood ternperatures. For further details of the exhaust syst€ffi, reter to Section88 of this Supplement. Figure 6A-9 2. SERVICEOPERATIONS For service and overhaul operations not listed in this Supplement,refer to the lmproved performanceL6 and V8 EngineService Manual, Part No. Mgg3g8. 2.1 COMPRESSIONTEST on EFI equipped vehicles, the control relay must be remcved from the fuse box (refer Fig. 6A-10), before commencing a compressiontest, to prevent the injection of fuel which may be blown out the spark plug holes Figure 6A-10 ENGINEMECHANICAL 6A.5 2.2 CYLINDERHEAD (EST) - PINK LEAD IN SLEEVE REMOVE (ANTI DIESELING SOLENOID) TH ROTTLE POSITION Removalprocedures for the cylinderhead on an engine -r equippedwith EST are the same as for a VH LO rnodel SWITCHCONNECTOR \ with the air pump Vpe Air InjectionReactor system. COOLAN T The only additions are the disconnectionand removalof TEMPERATURE SENSOR wiring at the throttle positionswitch, coolant temperature r CONNECTOR sensorand enginespeed sensor, refer Fig. 6A-11. Figure 6A-11 2.3 CYLINDERHEAD (EFl) REMOVE 1. Disconnect battery earth lead. Carry out removal operationsoutlined in 3.9 'Air Flow Duct' and 3.11 'lnlet Manifold'in Section6C 'Fuel Iniection'of this Supplement. 2. Secure exhaust extractors away from the cylinder head. 3. Remove the radiatorpressure cap, drain the radiator by removal of lower radiatorhose- CAUT/rOIT;tf the cooling system ts hot, the radiator cap must not be removed quickly- it should be rotated slowly to the first stop, which permitsthe pressurein fhe system to release stowty through the overtlow pipe. The cap must not be removed completely until all escape of steam has ceased, or there is a danger of water or steam scatding the operator. Do not tilt the cap during rotation to the first stop or some steam may escape through the top of the radiator neck instead of through the overtlow pipe. 4. Removetop radiatorand heaterhoses. 5. Depressurizefuel system aS per 3.2 'Depressurize' Section6C of this suPPlement. 6. Removefuel return line mountingbolts from rocker coverand engineside plate- Refer Fig.6A-12' T. Disconnectfuel return line frorn flexible fuel hose RETURN LINE- and plug open end with a suitableplug. MOUNTING G 8. Disconnect electrical connector from auxiliary air BOLT valve. # FLEXIBLE_ FUEL HOSE T I I L FUEL RETURN LINE Figure 6A-12 6A.6 ENGINEMECHANICAL 9. Disconnect throttle cable from mounting bracket. Refer Fig. 64-13. CRUISE CONTROL POWERUNIT TH ROTTLE CABLE BRACKET VACUUM_ HOSE '- ELECTR ICAL AUXILIARY CONNECTOR TO AUXI AIR VALVE LIARY AI R VALVE OUNTI NG BOLT PLACES) Figure 6A-13 10. Remove fuel hoses from fuel damper, plug with suitableplugs. Refer Fig. 6A-14. 11. Remove cruise control power unit bracket mounting to cylinderhead bolts and removebracket assembly. ReferFig. 64-14. 12.Disconnect high tension wires and remove spark plugs, disconnect coil positive and negative wires and removecoil attachingbolt and coil. 13. lf fitted with air conditioning,loosen drive belt idler pulleyand disconnectdrive belt. Figure 6A-14 14. Remove compressor mounting and bracket bolts and position compressor and bracket away from the COMPRESSOR cylinderhead. Refer Fig. OA-15. NorE: Do not bend metal pipes at compressor. This could lead to fracture of the pipes. 15. Remove the ventilation valve, valve rocker cover attaching bolts, the cover and gasket. 16. Remove rocker arm pivot borts, rocker arm pivot, rocker arms and push rods. NOTE: Remove each set (one set per cylinder) as a unit. It is important that the originar rocation of all pivots and COMP F ESSO R arms is retained on assembly. For this purpose, parts MOUNTI N G should be placed rn a special rack, Tool No. 6A35. 17. Remove the cylinder head bolts, cylinder head and PULLEY J gasket. Place cylinder head on two blocks of wood ADJUSTING to prevent damage. BO LT ENSURE NUT IS RETIGHTENED AFTER BEtT ADJUSTMENT REFER SECTION 28 FOR DETAI Figure 6A-15 ENGINEMECHANICAL 6A.7 REINSTALL Installationis reversal of removal instructions.However, additional'ServiceOperations','Cleaning and Inspection' as describedin the lmproved PerformanceLO and V8 Engine Service Manual, Part No. M38388, must be carried out. Attentionmust also be paid to the followingitems. Correct adjustment of the throttle cable and cruise controlpower unit cable,Service Operations 3.3 and 3.4, Section 6C, 'Fuel Injection',of this Supplernent. Check for fuel leaks hs described in Service Operation 3.2 'Leak Testing', Section6C, 'Fuel Iniection' of this Supplernent. 2.4 ENGINEASSEMBLY (EST) -PINK LEAD IN SLEEVE REMOVE (ANTI DI ESELING SOLENOID litre THROTTLE POSITION 1. Removalprocedures for a 3.3 engineequipped SWITCH CONNECTOR- with EST are the same as for VH LGmodels with the air pumptype Air InjectionReactor system. COOLANT 2. The only additions are, the removal of wiring connectionsat the throttle position switch, coolant r CONNECTOR o-'' \ ,, temperaturesensor and engine speed sensor.Refer --1i'');, Fig.6A-16. \_ --[./ --t- Figure 5A-16 NOTE:The speed sensor must be removedfrom the rear of the cylinderblock before separatingthe cylinderblock and the transmission.Refer Fig. 6A-17. SPEEDSENSOR SENSORMOUNT Figure 6A-17 6A-8 ENGINEMECHANICAL FAN SHROUD - ry ,- UPPER SUPPORT CLIP ^_RADIATOR / LowcootRrvtJ SENSOR VIEW Figure 6A-18 2.5 ENctNEASSEMBLY (EFt) REMOVE 1. Disconnectbattery earth lead. 2. Remove bottom radiator hose and drain cooling system. Rernove top rediator hose. Disconnect automatictransmission cooler lines from radiator. 3. Disconnectradiator fan shroud from radiator. Re- move upper radiatorsupport clips, lifi up radiator. From the front of the radiator,disconnect the low coolant sensor wire, if so equipped. Refer Fig. 6A-1 8 4. Remove radiator, taking care not to damage low coolant sensor, remove shroud. 5. Drainoil pan. 6. Remove air flow duct as per Service Instruction 3.9, Section 6C 'Fuel Injection'of this Supplement. 7. Remove engine hood. 8. Loosen generator,and if fitted, power steering pump, air conditioningcompressor and remove driv-e belts. Refer Fig OA-19. WATER PUMP ,. 9. Disconnect brake booster vacuum hose from inlet manifold. r GEN ERATOR CONDITIONING POWER COMPRESSOR STEERING PUMP CRANKSHAFT Figure 6A-19 tr v - ENGINEMECHANICAL 6A.9 10, Disconnect cannister to throttle body purge hose, from cannister. Refer Fig. 6A-20. {\\r \ \\ CAN THR PUR Flgure 6A-20 11. Rernove four retaining bolts from the cooling fan assembly, remove fan and associated parts. COOLING FAN Fig. 6A-21. MOUNTING BOLTS (4 PLACES}-l I FAN nt I tTa!-l I - | \Jr I Vl-\J l ,.r-wATER r PUMP PULLEY F. IF \ - CRANKSHAFT PULLEY - BETAINING BoLT '-gggLt\G (4 PLAC ES) FAN Flgure 6A-21 12. On models with air conditioning,remove the com- pres$r and mountingbracket from its position(refer COMPRESSOR Fig. 6A-22) and support it out of the way without disconnectingthe hoses. COMPRESSO R MOUNTI N G BOLT (4 PLACES) PUL ] ADJUSTING"' BOLT ENSURE NUT IS RETIGHTENED AFTER BELT ADJUSTMENT REFER SECTION 28 FOR DETAI LS Figure 6A-22 6A-10ENGINE MECHANICAL 13. Removepower steeringpump mountingand adjus- ting bolts (refer Fig. 64-23) and supportpump out of the way withoutdisconnecting the hoses. 14. Disconnectheater hoses from engine. POWER PULLEY ADJUSTING STEERING BOLT PUMP Figure 6A-23 15 Drsconnectwiring harness connectionsf rom starter motor, generatorand engine earth frorn generator bracket.Refer Fig. 6A-24. RING HARIIN ESS floN -] -=l I I IFUJSIB LE / LtfN5l \ t a \-I- (STARTER fiIE D LE AD SOLENOID) (GENERATOR) 1,"VIOLET LEAD BLACK LEEO ) (STARTE R SOLE NOI D) (CONN ECT TO EN G. B LOCK} Figure 6A-24 16. Disconnectwinng connections at oil pressuresender unit, coolant temperaturesender, ignition coil and rMAIN WIRING HARN. CONN. auxiliaryair valve Refer Fig. 64-25. , LT. GREEN, PINK & \ ',, oRANGE LEADS .. (TRANSMISSION HARNESS) i. \ ,,-DK(cootillrEyP) GREENLEAD T4//I*_,.! _ _. ,, , .---v q BLACK : ^€ 9.R5f LEADSIN tr :: SLEEVE \t -- -: (AUXILIARY AIR VALVE) DK. 3 LUE ,-eoo ] ;" /ss. .REEN LEAD (O I L PRESSUR E) (A/C COMPRESSOR) EXC. C6OTAPE BACK BRCWN LEADINSLEEVE- TOHARNESSWITH (IGNITION COIL) GM658M Figure 6A-25 5 ENGINEMECHANICAL 6A. 11 17. Disconnect auxiliary air valve hose frorn inlet manifold. Disconnect throttle cable fronn bracket, and if so equipped, cruise control power unit cable from cRUtsE coNTRO- ^g_ throttle body and vacuum hose from vacuum adaptor UNlT =.r ,!i/-, as rear of inlet manifold. Refer Fig 6A-26. 'OWER ,,.-THROTTLE 18. Depressure fuel system as per 3.2 'Depressurize', CABLE Section 6C, of this Supplement. 19. Remove fuel lines from fuel damper and plug with plugs. \-l--\ suitable VACUUM HOSE \J -- t,'F,r. ,- ----:t rl-1i ELECTRICAL CONNECTOR AuXILIARY 'r TO AUXILIARY AIR AIF Ar-r.'F r VALVE ) \ .- MOUNTING BOLT (2 PLACES} Figure 6A-26 20 Removebracket mounting to cylinderhead bolts and removebracket assembly. Refer Fig. 6A-27. Figure 6A-27 21. Removewinng connectors from fuel injectors,throttle position switch, coolant temperaturesensor. Refer -- YE _LOW LEAD IN SLEEVE (lDr-= ?-tin BOOSTSOLENOID) Fig. 6A-28.To avoiddamage, do not pull on wiresat FFi I Fr\ftH _ -?bl the connectors, SENSCB _ Remove flexible f uel hose from fuel return line at THROTTLE VALVE S\,VITCH engineside plate, Figure 6A-28 6A.12 ENGINEMECHANICAL 23. Plug open end of flexible fuel hose with a suitable plug. Refer Fig. 6A-29. RETURN LINE MOUNTING BOLT F LEX I BLE - FUEL HOSE RETURTTTilrr r \ -- MOUNTING BOLT {--- L FUEL RETURN LINE Flgure 6A-29 24. Removevacuum hoses from vacuumadaptor at the rear of the inlet rnanifold,remove adaptor. Refer Fig.64-30. 25. Raisethe vehicleand placeon jack stands. 26. Disconnectthe gear shift from the transmission,refer to VB Commodore Service Manual, Clutch and TransmissionSection. 27. Removethe speedornetercable frorn the extension housing,or if fitted. disconnectspeed sensorwires at the extenslon housing. Disconnectdetent solenoid wire and TCS swtch from the transmission. VACUUM 28. Removetailshaft and inserta protectorin the end of ADAPTOR the transmissionextension housing to preventloss of fluid Flgure 6A-30 29. Install rool No. oAgT engine lifting hook or equ- ivalent, raise engine slightly and remove the front engine mountrng to crossmember bracket through bolts.Refer Fig. 6A-31. --'id'm ^F G:-)A.bk' ^gojt )'R,M$wX f)\( -'(Sl {{\.^ tt'r\ cRossMEMEER-#di,)o-r ::, BRACKETTHR.UGH B'LT V1 Flgure 6A-31 ENGINEMECHANICAL 6A-13 30. Disconnect exhaust system from exhaust extractors. Refer Fig. 6A-32. 31 . Remove engine rear crossmember. 32. Raise the engine with the front tilted upwards and lift the engine and transmission out of the vehicle. DISCONN ECT H ERE Flgure 6A-32 REINSTALL 1. Installationis reversalof removal. 2. Refer Section 6C, 'Fuel Injection'in this Supplement for conect hose and electrical connections. 3. Add recommended oil and coolant. 4. Check fuel system for leaks as described in service operation 3.2'Leak Testing' Section 6C, 'Fuel In- jection', in this Supplement. 5. Start engine, check and adjust ignition timing, and for full throttle opening, check for air leaks. 6. Check for oil and coolant leaks. 3. TORQUEWRENCH SPECIFICATIONS Nm EngineSpeed Sensor to CylinderBlock Bolt 30-40 CylinderHead to Cylinde r Biock 54 tl rrst torque ) 102 riq3i torque) RockerArm Pivot to CylrnderHead 30-38 RockerCover to CylinderHead 3-6 Fuel Return Line Mounting Bolts 8 - 10 Fuel ReturnLine to PressureRegulator Nut . 25-30 Air Flow Duct Mounting Bolt 8-11 Air Flow Duct Mounting Bracketto C'TlinderHead Bolt 20-27 Air ConditioningCompressor Mounting Bolts 20-27 CompressorBracket Bolts 40-54 Alternatcr Mounting Nut 20-25 AlternatorAdjusting Bolt . 12-16 PowerSteer ng Pump Mounting& AdjustingBolts 40-51 CoolingFan ReiarningBolts 27 -36 EngineMounting Nuts 34-46 RearTransmissicn Mounting Bolts 34-46 RearCrossmem ber MountingBolts 40-50 ExhaustClamp Nuts 24 -32 ENGINECOOLING 68-1 SECTION68 ENGINECOOLING INDEX Ref. Subject Page Ref. Subject Page 1. GENERAL DESCR|PTION...... !r...... 68-1 2.1 RADIATOROVERFLOW/WINDSHIELD 2. SERVICE OPERATIONS ..,...... or...... 68-1 WASHERBOTTLE ...... ,...... 6B-1 RgmOV€...... o...... ,...... 6B- 1 ReinStall .....r....r...... o...... -....-...... 6B-1 2.2 COOLINGSYSTEM . FLUSHSYSTEM ...-.. 68-2 1. GENERALDESCRIPTION The cooling system employed on VK Series models is All VK 3.3 litre engines have the thermostat housing, fan canied over from VH, with only a few minorchanges. pulleysand fan belt from the L6 2.8 litre VH engine. The radiator overflow/windscreenwasher bottle has been redesignedand repositioned(Fig. 68-1). 2. SERVICEOPERATIONS Service operations are as described in the VB and VH Series Service Manuals, except where noted in this Section. 2.1 RADIATOR OVERFLOW/WINDSHIELDWASH ER BOTTLE REMOVE 1. Removeradiator overflow cap from bottle. 2. Disconnectwindshield washer hose and electrical connectorfrom washerpump. 3. Remove two mounting screws (Fig. 68-1) and lift bottle assemblyout from its position. REINSTALL 1. Installationis reversalof removal. 2. Fill the radiator overflow boille up to the required level,as indicatedby the mark on the outsideof the bottle. 3. Fill up windshield washer bottle and test washer operation. 68-2 ENGINECOOLING MOUNTING SCREW RADIATOR OVERFLOW/ WINDSHIELD WASHER BOTTLE .WINDSHIELD A WASHER HOSE v MOUNTING EW \SCR )< -/\ '-t/ lp'c- I(--_-/. AD VE A 3.0- 4.0Nm Flgure 68-1 2.2 COOLING SYSTEM I FLUSH SYSTEM 1. Placedrain tray under vehicle. 2. Removetop radiatorhose from thermostathousing. 3. Removethermostat housing and thermostat. 4. Placewater hose into the top radiatorhose, tum on water pressure,and flush untrl water coming from rylinderhead is clear. 5. Flush heater core by removingtop heater hose from thermostathousing aM flush untrlclear. 6. Flushradiator by rernovingbottom radiator hose from waterpump and flushuntil clear. 7. Removeoverflow bottle, as per serviceoperation 2.1 , and flush. 8. with the system f lushed clean, replace thermostat housing gasket and refit all cooling system components. Mix a coolant concentration of approximately21 mls of corrosion inhibitor, GMH SpecificationHN1 109, with everylitre of clean water. Add to the coolingsystem and check for leaks. ENGINEFUEL 6C. 1 SECTION6C ENGINEFUEL CONTENTSOF THIS SECTION Subject Page ELECTRONIC FUEL lNJECTlON....-.r...... 6C-1 CARBURETTOR (3.3 EST) ...... r...... r...... 6C-67 5.0 LITRE ENGINE FUEL SYSTEM ..rr...... !...... 6C-87 ELECTRONICFUEL INJECTION INDEX Ref. Subject Page Ref. Sublect Page 1. GENERAL DESCRIPTION....,r...... r,.....o... 6C-2 3.11 INLET MANfFOLD .....,...... 6C-35 1.1 MAIN COITPONENT SYSTEMS...... r 6C-2 Rgm OV€...... r....6C-35 Alr FIOWSyStgm ...r.....r...... r...... r...... r6C-2 RginstalI ...... ,,.,...... r...... 6C-37 FUgl SyStem...... D...... r'...... r...... 6C-3 3.12 AUXILIARY AIR VALVE ...... ,...... 6C-37 Elgctrical System .t...... r....'.!...... 6C-5 RgmOv€...... r....r.r.....r....o....rr...... 6C'37 1.2 FUNCTION OF MAIN COMPONENT Rginstall ...... r...... r....,...... r,.... 6C-37 SYSTEMS ...... r...... t.r...... r.....6C€ TgSt...... -...... r...... 6C'37 Air FlOw SyStem r...... r...... r.t. 6C-8 3.13 FUEL PUMP.r...... r...... o...r..r,.... 6C-38 FUgl SyStem ...... rrrr.r..r...!...... r.t!.r... 6C€ Rgmov€...... r...... r...,...... 6C-38 ElgCtrlcal System ..r...... r.'..!.r...... !rr.r...6C-g Reinstall ...... -..--..... -r.3... 6C-38 2. PRINCIPLES OF OPERATION...... r...r,.,...,r6C-12 TeStin$ ...... -...-...... o....6C-38 2.1 FUEL INJECTION TIMING ...... 6C-12 3.14 FUELDAMPER - REAR...... ,...... 6C-40 2.2 FUEL INJECTION QUANTIW ...r...r...... r6C-12 R gm OV€...... '...... -.'...... 'r"...... 6C*f0 2.3 ENRlCHMENTS...... r...... -...... r.....6C-12 RginStall ....".....r...... !r...... 6C'40 Enrlchmgnt Sensors r.r...... -..r..6C-12 3.15 FUEL FILTER ...... r...,..,...... r...-...... 6C-40 Accelgratlon Enrichment ...... t....6C-12 R gmov g...... r...... !...... !.t.-.,.6C-40 Full Throttle (Hlgh Load) Reinstall ...... r..r...... r...... 6C-40 EnflChmgnt...... -...... r-..r...... 6C-14 3.16 FUEL DAMPER ' FRONT ...... r...... ,..rr....6C-40 2.4 FUEL SHUT OFF ' COASTING r.....,..!...... 6C-14 Rgmov€....-...... rr...... r...... !... 6C'40 2.5 VOLTAGE CORRECTION FUNCTION ...... 6C-14 RginSt?ll ..-....,...... Fr..r...r...... r.....r...6C-40 2.6 coilPoNENT OPERATION ...... -...... 6C-14 3.17 FUEL R4IL...... ,..o...... r...... ,....6C'4 1 Air FlOw SyStem ..,.'...... r!'...... r6C-14 RgmOv€...... t...... r.r..r...... r.. r..... 6C'4 1 FUgl SyStem ...... r.r...... r.r.-...... r.... 6C-17 R gi n stal | ...... -....r...... ,...... r....6C-42 Elgctrical Systgm ...r...... -...... 6C-20 3.18 1NJECTORS...... r..r...... ,...... r.....6C'42 3. sERVlcE oPERATIONS ...... 6C-24 3.19 PRESSURE REGULATOR...... r.,..r.,..,...... 6C'42 3. I SERVICE NOTES .....r...... r...... 6C-24 R gmOV€...... '...... r...... D...... 6C'42 3.2 FUEL SYSTEM .....o...... 6C-24 Rei nstal | ...... r.. J.....rr.!D...... ,-.... 6C-42 Lgak TgStin$ ...'...... -...... 6C-24 3.20 CONTROL UNIT r.,..r...,...... r..t...... !...... 6C'42 Depressurlzin$ ...... o...... 6C-24 R gmOv€...... r...... r-..-...,r...... rr,-...- 6C-42 Fugl Hosgs and G|amps...... r..6C-25 RgiOStall ...... '...... r....-...... r...... 6C-43 3.3 THROTTLE CABLE ADJUSTMENT...... 6C-26 3.21 THROTTLEPOSITION SWITCH ...... 6C-43 3.4 CRUISE CONThOL POWER UNIT CABLE RgmOV€..'...... ,...... r...... 6C-43 ADJUSTME NT ...... -...... r...... r.-...... 6C-26 Rginst?ll .....,...... ,...... r..6C-43 3.5 ADJUSTING IDLE SPEED AND ]TIIXTURE 6C-26 Ad justmeJ|t...... ,...... ,...... 6C'43 ldlg Speed Adjustment...... r.r...... 6C-27 3.22 COOLANT TEMPERATURE SENSOR ...... 6C-44 ldlg llixture Ad1ustment...... ,...... 6C-27 Re plaC€...... '...... r...... -.... 6C-4 4 3.6 AIR cLEANER ELEMENT...... r...... r....-.6C-28 On Engine TgSt...... o...'...... -...... r6C-44 ReplaCgmgnt o...... '.....i...... -....6C-28 Off Engine Tgst ...... r....6C-45 3.7 AIR CLEANER HOUS1NG...... r...... 6C-29 3.23 CONTROL RELAY ...... ,...... 6C'46 R g mOV€...... 4.....1...... 6C-29 R gmOV€...... '...... r...r..."'.....r-...... -...... 6C-46 RginStall ...... r...... -.-...... tr...... 6C-30 RginStall ...... r...... r6C'46 3.9 AIR FLOW METER...... ,...... -...... ,...... ,...... 6C-30 4. DIAGNOSIS..'.....r.....-..'...... '.....?....r...... 6C-47 RgmOV€.....-...... r...... r.rt...... -...... t...... 6C-30 4.1 CIRCUIT TESTING PROCEDURE...... 6C-47 R ginStall ...... r...... -...... 6C-31 Electronic Fuel Injection TeSt ...... -.-.r.rr...... t..'...... 6C-32 Test Equipmgnt ...... -.-.,..r...... r...... ,6C-47 3.9 AIR FLOW DUCT ....r.r..r...... ,'..r...... -...... 6C-32 4.2 TROUBLE DIAGNOSISr...... ,...... 6C-61 RemOV€...... t...r...... 6C-32 5. SPECIFICATIONS-...i...... ,....o...... i..'....---.-.-..... 6C-64 R ei nStall ...... r...... -...... -...... 6C-33 6. TORQUE WRENCH SPECIFICATIONS...... 6C€5 3.10 THROTTLE BODY ...... -...,...... rr..r...... r.-...r.-....6C-33 7. SPECIAL TOOLS ..-...... 6C-66 R e m OV€ ..' -...... ". 6C-33 RginStall ..-...... r....'...... r."'6C-34 lrr 6C.2ENGINE FUEL 1. GENERALDESCRIPTION The Electronic Fuel Injection (EFI) used on VK series velocity.when power is required,it is desirableto have vehicles is the Bosch LE-2 Jetronic system. as largea manifoldpassage as possible. The LE-z Jetronic is an electronically controlled fuel To supplyboth these requirementsthe manifoldmust be injectionsystem which injects fuel at regular intervalsinto a comprornisewhich resultsin passagesof such a size the inlet ports adjacent to the inlet valves. lt provides a whichlimits both low and high speed performance. method of more precisely metering fuel to satisfy the With EFI systerns, the elimination of the carburettor various engine operatingconditrons. enables the induction passages to be designed to In a carburettor type fuel system, the intake manifold optimizeair flow and an increased engine performance design must strike a medium between low and high can be expected with the resultant improvementin speed requirementsfor air flow. At idle, air flow is very volumetricefficiency. Air is induced into the engine low and in order to keep the fuel mixed with air, it is throughthe inlet manifold,and fuel is injectedunder necessary to have small passages to keep up the air pressureinto the inlet valve port. Atn FLOW I rF-FA ''.r= | trH r AIR F LOW ' DUcr ,- THROTTLE BODY INLET MAN IFOLD /(^ / / ArR.LEANER HOUSING AIR FLOW SYSTEM Figure 6C-1 1.1 MAII'ICOMPONENT SYSTEMS The Bosch LE-z Jetronic Fuel Injection system can oe divided into three main component systems,they are: AIR FLOW SYSTEM COMPRISING: Air Cleaner - Filters inccmrng air flow for the englne. Refer Fig. 6C-1. Air Flow Meter - Measures the air inlet flow and sends an electricalsignal to the control unit where the required au/tuel ratio is computed.Refer Fig 6C-1. Arr Flow Duct - Transfers air flow from air cleaner to throttlebody. Refer Fig. 6C-1. A ENGINEFUEL 6C.3 Throttle Body - Located between the air flow duct and the inlet manifold, the throttle body incorporates the throttle valve with provision f or Exhaust Gas Re- circulation, spark advance, canister purge signals and Positive Crankcase Ventilation connection. The throttle valve is connected to the accelerator linkage and controls the flow of air into the inlet manifold. Refer Fig. 6C-1. Inlet Manifold - Distributes air to the inlet ports of the cylinder head. Refer Fig. 6C-1. Auxiliary Air Valve - Allows an additional amount ol air to bypass the throttle valve, to maintain idle stability with a cofd engine. Refer Fig. 6C-2. Figure 6C-2 FUEL SYSTEM COMPRISING: Fuel Tank - Containsa very fine strainerattached to the fuel pick up on the fuel gauge senderunit. Also included in the fuel tank, is a fuel swirl pot, to minimiseaeration at fuel pick up point.Refer Section8A of this Supplement for furtherdetails. Fuel Pump - An electric, rotary roller pump. Refer Fig.6C-3. Figure 6C-3 Fuel Damper- Designedto removefuel pulsationsfrcm the fuel system. Two dampers are fitted in the fuel system.Refer Fig. 6C-4. \, Figure 6C-4 6C.4 ENGINEFUEL Fuel Filter The filter contains a fine paper efement. Refer Fig 6C-5. Figure 6C-5 Fuel larl Drstributespressurized fuel to the injectors. Refer Fg. 6C-6. lt incorporatesa schrader valve (wrth a specra fuel resistant valve core) for bleeding down fuel FUEL RAIL-. pressure and carryingout diagnostic procedures. fINJECTOR \ RETAtNtNG \crre I\lOUNTING BOLT {3 PLAC ES) Figure 6C€ Injectors Electricallycontrof led fron the :ontrol unit. The a-ount of fuel sprayed rntc the rnlet ports is controled by the length of time tne :on:rct unit signals the 'nlectorsto remainoper^ Refe' F,g OC-7. Figure 6C-7 PressureFegulator - Maintainsthe requiredfuel pressure under all load conditions.Refer Fig. 6C-8. *HA&';€rdr'' s{l'' Figure 6C-8 ENGINEFUEL 6C-5 ELECTRICALSYSTEM COMPRISING: Control Unit - Processessignals from the enginesensors to calculate the amount of time the injectors rernain open. Refer Fig. 6C-9. ControlUnit Inputs- Include:ignition coil, air flow meter, throttle position switch, engine coolant temperature sensor, inlet air temperaturesensor and ignition switch position. Figure 6C-9 lgnition Coil - The control unit receives ignition pulses from the ignition coil. From this informationthe control unit calculatesengine speed. ReferFig. 6C-10. Figure 6C-10 Air Flow Meter - The control unit receives information about the engine'sload conditionfrom the air flow signal sent from the air flow meter.Refer Fig. 6C-11. Throttle Position Switch The control unit recerves information f rom the throttle position switch when the engine is idling or under high load. ReferFig. 6C-1 2 Figure 6C-1 2 6C.6 ENGINEFUEL Coolant Temperature Sensor - The control unit receives information about the engine coolant temperature from this sensor. The sensor is of a Negative Temperature Coefficient design. The resistance of the sensor de- creases as the engine temperature increases, thereby allowing the control unit to shorten the injection pulse width signal.Refer Fig. 6C-13 Figure 6C-13 Air Temperature Sensor - The air temperature sensor is located in the inlet passage of the air flow meter housing. It is also of the Negative Temperature Coefficient design, I and it applies a correction factor to the air flow meter , output signal to compensate lor changes in inlet air I - temperature.Refer Fig. 6C-14. J I I I AIR TEMPERATURE I Figure 6C- 14 lgnition Switch - The control unit receives a signal from the ignition switch when the vehicle is starting,and this allows a richer mixturefor starting.Refer Fig. 6C-1s. Figure 6C-15 The locationof the variouscornponents are shown in Figs.6C- 1 6, 6C-17. - - I ENGINEFUEL 6C.7 LOCATION OF COMPONENTS AtR F LOW-r METER \ \ AIR CLEANER AIR FLOW DUCT HOUSING ,- TH ROTTLE POSITION SlVI TCH THROTT LE BODY FUEL TANK llil r-4 11,^- \:t , /,,, J ,---> S='- _ _FUEL RAIL FUE L DAMPER t\-,4 ,/ FUEL PuMPl- - . I- INLET FUEL TAN 11- MANIFOLD GAUGE UN PRESSURE R EGULATOR CONTROL RELAY- SIT-AT=] I\ FUSE BOX FUEL FILTER - UNDERI',EA-- .'=HICLE CONTROL UNIT EHIND L 33w'L PANEL -': Figure 6C-16 li'\J=C-CRS _ 6 PLACES I -) DAI.TPER - PUMP DAMPER Figure 6C-17 f,.r 6C.8ENGINE FUEL 1.2 FUNCTIONOF MAIN COMPONENT SYSTEMS AIR FLOWSYSTEM Inlet air flows through the air cleaner housing and is rneasured by the air flow meter. Air continues along the air flow duct into the throttle body. Air flow to the engine is controlled by the throttle butterfly opening inside the throttle body. During engine warm up, additional air flow is bypassed behind the throttle butterfly to increase engine speed, by the action of the auxiliaryair valve. Refer Fig 6C-18. FUEL SYSTEM Fuelis drawnfrom the fuel tank by the electricfuel pump and it is fed under pressure through the fuel damper. Pulsationscaused by the fuel pump are deadenedby the fuel damper.From the damper the fuel flows through a fuel filter, and through a second fuel damper to reduce the fuel pulsationsgenerated by the openingand closing of the injectors.The fuel continueson into the fuel rail and then is injected into the inlet ports through the injectors. Fuel pressurein the system is governed by the pressure regulator,in such a mannerthat the pressuredifference between fuel pressure and inlet manifold vacuum is maintainedat 303 kPa (3 bar). Excessfuel is returnedto the fuel tank by the pressureregulator via the fuel return line.Refer Fig. 6C-19. ELECTRICAL SYSTEM The control unit receives informationfrom the various sensorsand, based on this information,it sends out an electncalpulse to the injectors,the duration of which controlsthe amount of time the injector nozle remains open In{ormatongathered includes, inlet air flow from the air flow rneter, engine coolant and inlet air temperatures from their respectivesensors and engine speed from the ignitroncoil pulses.Refer Fig. 6C-20. ENGINEFUEL 6C-9 Figure 6C-1 I Figure 6C-19 'I 6C.10 ENGINEFUEL o (\I ()I (0 o L tt-9 ENGINEFUEL 6C-11 Control Unit Signals The main f unction of the control unit is to generate injection pulses, Upon receiving electrical signals from the engine sensors, the control unit generates a pulse whose duration (injector opening time) is controlled to provide an optimum quantity of fuel according to the engine requirements. Because the opening and closing reaction time of the injectors is dependant on battery voltage, the control unit also varies the injection pulse width to compensate for fluctuations in the system voltage. TI-.'iRCTTLE PCSITION S\VITCH 3CC LANT TEMPERATURE SE NSOR t'i t-? IGNITION COI L T IGNITION SWITC H CONTROL UNIT AIR FLOW METER I NJECTORS a s, AIR TEN1PERATURE SENSOR Figure 6C-21 6C-12ENGINE FUEL 2. PRINCIPLESOF OPERATION 2.1 FUELINJECTION TIMING With many early fuel injection systems, fuel was injected into the inlet port just prior to the beginning of the intake stroke. This is not the case with the LE-z Fuel Injection System. The signal for injection begins with the control unit receivingignition pulse signalsfrom the ignitioncoil. With a six cylinder engine, there are six ignition pulses for every two engine revolutions (three pulses every revolution). Upon receiving the third ignition pulse from the coil, the control unit sends the signal for injection to commence. All the fuel injectors are electricallyconnec- ted in parallel to the control unit so they all inject sirnu ltaneously. Cnc injection of fuel provides only half the required quantity necessary for the operation of the 4-stroke cycle of the engine, therefore injection is made twice during Figure 6C-22 one 4-stroke cycle, i.e. once every engine revolution. Refer Fig. 6C-22. 2.2 FUELINJECTION QUANTITY Vehicle engine speed and load are the two requirements needed to calculate the basic fuel requirements for any engine operatingcondition. With LE-z, the speed of the engine is signalled from the ignition coil and engine load is monitored by the air flow meter. The signals from these two sensors provide the control unit with data to select the basic fuel rnjection quantity. 2.3 ENRICHMENTS The basic fuel injection quantity is not enough for all ENRICHMENT TABLE engine operating conditions. Extra fuel quantity is required for cold starting, engine warm up and acceleration.Refer Fig. 6C-23. Various sensors produce electrical signals which are AFTEF directed to the control unit provide F START ENRICHMENT so as to the extra fuel z I quantity. l o WARM UP ENRICHMENT LIJ l TL COLD START ENRICHITlE\T BASIC FUEL REOUIREMENT CRANKI\G TIME/TEMP Figure 6C-23 ENRICHMENTSENSORS Air and Coolant TemperatureSensors Enrichment signals are generated from both sensors. The lower the air or coolant temperature, the longer the injection signal, the longer the inlectors remain open and the larger the quantity of fuel injected, until the engine reaches operating temperature when enrichment conpensationis no longer required. ENGINEFUEL 6C.13 Throttle Position Switch The switch contains two contact point sets, one monito- ring the closed throttle position and the other for high load. An enrichment signal is sent to the control unit when either of the contact point sets are closed. At closed throttle, the idle contacts are closed and high load points are open. At part throttle, both contact point sets are open. At high load, the closed throttle contacts are ooen and high load contacts closed. lgnition Switch The start enrichment signal is generated in the 'START' position of the ignition switch. Various fuel enrichment corrections are computed as a result of these signals in order to provide optimum fuel injectionunder all engine operating conditions. Cold Start When the ignition switch is turned to the 'START' position and the engine is ln the'crankrng'mode, the control unit delivers 3 injection pulses p€r rev and extra fuel is injected into the inlet ports. Cold start enrichment can last for a period up to FUEL I NtTt'1-V \r\rtalY ^ | | | I 10 seconds depending on the temperature of the engine. ^ Refer Fig. 6C-24. TIME Figure 6C-24 After Start I When the ignition switch is released to the 'ON' position I from 'START', the cold start enrichment drops off. The I 17t 'after start' enrichment is provided to compensate for the sudden decrease in fuel quantity from 'START' to 'ON'. The control unit multipliesthe basic fuel inlectionquantity r./LLTIPLICATION pulse by a factor of 1.7 at OoC, this factor decreases FACTO R until the engine speed becomes greater than 600 rpm. Refer Fig. 6C-25 1.0 Figure 6C-25 Warm Up The warm up enrichment provides smooth engine opera- tion once the engine is started. The control unit agatn multiplies the basic fuel lnjection quantity by a factor which is controlled by the engine's coolant temperature. Refer Fig. 6C-26. MULTIPLICATIC\ FACTOR I : Or- I zdoc TEMP rooc Figure 6C-26 ^l 6C.14 ENGINEFUEL ACCELERATION ENRICHMENT The control unit receives a signal from the air flow meter about an increase in airflow and if the coolant 1.3 temperature is less than 70 o C, acceleration enrichment takes place. The control unit multiplies the basic fuel injection quantity by a factor to increase the fuel quantity r',,lULTIPLICATION FACTO R delivered. The enrichment signal lasts approximately 2 seconds. Refer Fio. 6C-27. FULLTHROTTLE (HtcH LOAD)ENRTCHMENT The high load contacts within the throttle position switch close when the throttle is opened greater than 40o. With closed contacts, the controf unit receives an electrical signal and the basic fuel injectionquantity is increased by Figure 6C-27 8 percent to give the au fuel ratio required for maximum power 2.4 FUELSHUT OFF - COASTING When the accelerator pedal is lifted so the vehicle is FUEL SHUT coasting, the closed throttle contact points wrthrn the OFF throttle position switch close. With the points closed. the control unit receives an electrrcalsignal and fuel rnlection o LU is stopped until the engrne speed drops to approxirnately uJ 1800 rpm. With engrne speed below 1800 rpm, fuel (n injection commences again to prevent the engine from LU cutting out. Refer Fig 6C-28. = L! ,CONSTANT INJECTION STARTS :THROTTLE AGAIN 2.5 VOLTAGE TIME CORRECTIONFUNCTION NO FUEL Ljnder conditions of low system voltage, such as would USED occur with a battery in a low state of charge, the inlectors are slightly slower to open. Under these conditions, the pulse wrdth is automatically extended to Figure 6C-28 ensure the full quantrtyof fuel is inlected 2.6 COMPONENTOPERATION COt\4PENSATIONr DAMPING CHAMBER AIR FLOWSYSTEM FLAP Air Flow meter The function of the air f low meter is to generate an electrical srgnal to the control unit proportional to the amount of air flow into the engine. This signal is the base engine load signal to determine the correct amount of fuel to be injected. I fn the inlet passage of the air flow meter there is a t moveable flap and as the air flows through the passage rt exerts a force on this flap. Depending on the air flow and the opposing force cf the flap return spring, the f lap is r held open in a certainangular position which is converted to an electrical signal by a potentiometer (variable resistor). IDLE- _ BY-PASS MIXTURE ADJUSTING SENSORF LAP SCREW Figure 6C-29 ENGINEFUEL 6C.15 when the air flow flap is moved with a change in air flow, a terminal connected to the air flow flap shaft slides r IDLE MIXTURE \, ADJUSTIN on the variable resistor, causing the output voltage to the G SCREW control unit to change. BY.PASS Connected to the air flow flap is a compensation flap FLAP -SENSCR working in a damping chamber. The need for the extra flap and chamber is to provide the air flow flap with a damper so that it cannot be disturbed by pulsations from inlet manifold vacuum during engine operation. In order to set the air fuel ratio at idle, an adjustable air bypass passage is provided. By varying the quantity of air which is allowed to bypass the flap, the air flow meter signal can be changed sufficiently to alter the air fuel ratio at idle. COM PENSATI ON F LAP DA[/PING CHA\,188R Figure 6C-30 Throttle Body ADJUSTER (DO NOT REMOV'E The throttle body is located on the inlet manifold and it CAP contains a throttle butterfly valve. This valve controls the inlet air flow corresponding to movement from the TH ROTT L E accelerator pedal. The butterfly valve shaft is connected A DJUSTER to the throttle position switch. / -Ti-.lFCTTLE B ODY Figure 6C-31 IDLE SP=ED _ THROTTLE POSITION ADJUS-E3 SU/ITCH --TFFOTTLE LE\/ER IDLE LOAD COMPENSATOR Figure 6C-32 6C-16ENGINE FUEL ldle speed adjustment is carried out by loosening off the idle speed adjuster lock nut and screwing the adjuster in or out to set the desired idle speed. This allows a variance in the amount of air to bypass the throttle IDLE SPEED butterfly valve. This variance in air flow is measured by ADJUST|NGScR=y the air flow meter, and so the control unit changes the \ __f injector pulse width accordingly.Refer Fig. 6C-93. - AIR FLOW IDLE MIXTURE M ETER F LAP ADJUSTING SCREW Figure 6C-33 When the vehicle is fitted with air conditioning, an idle load compensator solenoid is installed in the throttle THROTTLE -.\ body. When the air conditioning compressor rs operating, VA LVE \.. IDLE LOAD the solenoid is energized.This allows an extra quantity of I '\coMPENSATOR air to bypass the throttle butterfly valve. The control unit increases the pulse width signal to the injectors because \ of the greater arr flow past the air flow meter and the engine idle speed is increased.Refer Fig. 6C-34. - L-AIR FLOW IDLE MIXTURE METER FLAP ADJUSTING SCREW Figure 6C-34 AuxiliaryAir Valve THROTTLE AIR F LOW when ine engine is cold. it must produce higher torque \./ALVE METER durtng tdie to overcome rncreasedfrictional resistances, - Therefo.e.in additionto a richer arr,'fuelratio during cold startrng ard warm up period, addrtronal rnixture is required tc rncrease the engine's rCle speed rne additional nixture is obtained by the acticn of the auxiliary ar vaive The auxiliary air valve cperatior. rs conrolled by an electric heater coil whrch. w''ren the engine is cold. permits air to bypass the thrortie valve and enter the inlet manifold.The additionalair entenng I\ the induction system causes the flap within the arr flow \ meter to deflect and the potentiometersignals the control L , o LE MI XTURE unit that more fuel is requrredthereby maintainingthe air A DJUSTI N G SCREW fuel ratio constant. Refer Fig 63-35 Au). lr-IAEY-- /\f-A\t- Alf'1 , n-', i Figure 6C-35 ------ ENGINEFUEL 6C. 17 The auxiliary air valve contains a slotted disc that rotates to open, close or partially close an air passage in the SLOTTED DISC valve. Current f lows through the heater coil which controls the operation of a bimetal spring which rotates AIR OUTLET the slotted disc. The current flow to the valve begins when the ignition is switched to 'STAFT' and continues whenever the engine is running. -- !EATER With a cold engine, the bimetal strip keeps the disc positioned to open the air passage, permitting air from AIR IN LET the air flow duct to enter the throttle body, bypassingthe throttle valve. As the heater coil warms up. the bimetal strip deflects, gradually closing the air passage in the valve until at a predeterminedtemperature, the dtsc has completelyclosed the passage and idle compensationvia the auxiliaryair valve ceases. Refer Fig. 6C-36. Figure 6C-36 FUELSYSTEM FuelPump The electricfuel pump is a roller-cellVpe. Currentto operate the fuel pump is fed through a control relay, located in the fuse box. Refer Fig. 6C-37. The pump is driven by a permanent magnet electric motor which is permanentlyimmersed in fuel. Figure 6C-37 The rotor disc, which is eccentrically mounted in the pump housing, is fitted with metal rollers in notches -AR\''IATtR= around its circumference which are pressed against the thrust ring of the pump housing by centrifugal force and act aS seals. The fuel is carried in the cavtties which fr SIDE OUTLET form between the rollers. The fuel flows directly around the electric motor. There is no danger of explosicn, however, because there rs never an ignitable mixture rn ,( t the pump housing.The pump deliversmore fuel than :he ,i rnaximum requirement of the engine So that the pressure in the fuel system can be maintainedunder all operatrng '1t conditions. t \ I Notj F=TURN \_ ROLLER VA L = CELL PRESSURE- PUMP RELIEF VALV E Figure 6C-38 6C.18ENGINE FUEL The pump incorporatesa check valve to maintainsystem pressureafter the pump is shut off. Also incorporated,is RESSURE an internal relief valve which provides protection from excessivepressure. The fuel pump capacityis 130 l/hr. NorE: This type of pump can be noisy when pumping aeratedfuel, as can occur with a low fuel level in the tank under very hot conditions.lt is not harmfulto the pump. The fuel pump is a sealedunit and is not repairable. PUMP HOUSING ROL LER ROTOR D ISC i FUEL NOT UNDER PRESSURE :._----_: i: FUEL t: SUPPLY ffi D-r):i+t:t:\-.aiat lri;::::Si.;.:.:t ]: FUEL UNDER PRESSURE Figure 6C-39 Fuel Damper The purpose of the fuel damper is to suppress the fuel FUEL DAMPER flow pulsations from the fuel pump and the injectors. Two AIR CHAMBER dampers are used in the system. The first is situated at the pressure outlet of the fuel pump and the other is placed prior to the fuel entry into the fuel rail. DIAPHRAGM Changes in the fuel pressure drscharged from the fuel pump and the opening and closrng of the injectors, are FUEL monitored by the diaphragm and spring, which varies the CHAMBER volume of the fuel chamber thereby suppressing fuel pressurepulsations. Refer Fig. 6C-40. The fuel dampers are sealed units and are non adjust- FUEL INLET FUE L OUTLET able in service and are not repairable. TYPICA L Figure 6C-40 Fuel Injectors Each fuel injector incorporates a solenoid, controlled by electric pulses from the control unit together with an FI LTER armature attached to a pintle vafve which, when act- ELECTR ICAL ivated, opens inwardly. A spring holds the pinile valve CONNECTION closed as long as the solenoid is not activated. When the solenoid is energized,the pintle valve opens and the fuel is metered and atomised as it enters the inlet port. Since the fuel pressure drop across the injector is always constant, the amount of fuel delrvered is direcily pro- portional to the pulse width and thei'efore,the time the injectoris open. SOLENOID WIND ING Typical inlection time for most engine cperating condrt- i_onsrange from 2.5 to 10 milliseconds.Refer Fig. 6C-41 SOLENCID for internal view of a typical injector. ARM AT t-.,rRI NEEDLE TYPI CA L Figure 6C-41 ENGINEFUEL 6C.19 The injector has around each end, a sealing 'O' ring, which should be replaced every time the injector is s SEALING RING removed. Refer Fig. 6C-42. \,O' The cap on the injector tip is to protect the injector pintel \ ..,,r.*t\ from damage during handling and f itting and also, to \s TIP l),JSULATOR1 provide heat insulation to prevent vapour formation. lt I I SHOULD NOT BE REMOVED. Refer Fig. 6C-42. I I SEALING 'O' RING / Figure 6C-42 Fuel Pressure Regulator _ gRESSURE The fuel pressureregulator (Fig. 6C-43) is a diaphragm FUEL RETUR\ REGULATOR operated relief valve used to maintain fuel system CONNECTION pressureto 303 kPa above the inlet manifolddepression. The diaphragmsenses fuel pressureon one side while the other side is exposed to inlet manifold vacuum. A f FUEL spring, rnounted in the engine vacuum side of the \ coN NECTION diaphragm,establishes a nominal pre-loadof pressure. With the fuel pump constantly supplying fuel to the regulator,a situationof too much fuel at the regulatoris VALVE PLATE pressuregreater kPa above the i ;:;:;i;i;i;i;l created.When than 303 ---J ,'i, is sensed, the diaphragm 1.\ --i "' VA inlet manifold depression : LVE --? HOLDER rnovesto allow excess fuel to be routed back to the fuel i -i tank. :.- The continuousflow of excess fuel to the petrol tank ,-J+ helps ensure that the injectedfuel is cool and vapour free. The regulator is a sealed unit and cannot be SPR ING - DIAPHRAGM repaired. TYPICAL Figure 6C-43 Fuel Filter Due to the extremely close tolerances of various com- ponents in the fuel system, it is necessary to fit a special, fine filter for the fuel. The filter retains impurities which maybe present in the fuel and which could affect the function of the fuel injection system. The fuel filter contarns a paper element. Refer Fig. 6C-44. Figure 6C-44 6C.20ENGINE FUEL when replacing the filter it is of the utmost importance that the arrow on the housing indicating the flow is complied with. Refer Fig. 6C-4S. The filter must be replaced every 40,000 kms or 2 years, whichever comes first. Figure 6C-45 Fuel Rail The fuel rail guarantees the same fuel pressure at each injector. INJECTOR The fuel rail has a storage function. lts volume compared with the amount of fuel injected during each workrng cycle of the engine is large enough to prevent varrationi in pressure, The injectors,connected to the fuel rail, are therefore subjected to the same fuel pressure. The fuel rail also facilitates fitting of the inlectors, and also lncorporates a schader valve for breeding down fuel pressure and carrying out diagnostic procedures. Refer Fig. 6C-46. Figure 6C-46 ELECTRICALSYSTEM ,,- PASSENGERrAJ5trl\btrF{ Control Unit a' ,/ srDEcowL PANE L The electronic control unit is a pre-programmed analog computer consisting of custom electronic circuits housed in a metal case. The control unit is rnounted behind the passenger side front cowl panel trim. Refer Fig. 6C-47. The control unit recerves information on the quantity of air drawn into the engrne,coolant temperature,position of the throttle valve, the starting process, as well as engine speed. lt processs this information and transmits electnc CONTROL UN IT pulses to the injectors. lt is connected with the electrical components in the system by means of a multiple pin plug and wiring harness. /. Figure 6C-47 Coolant TemperatureSensor The coolant temperature sensor is located towards the front of the cylinder head. on the manifold side. Refer Fig. 6C-48. Figure 6C-48 ENGINEFUEL 6C-2 1 The control unit receives a signal from the coolant temperature sensor and uses it as one of the factors in determining the amount of fuel enrichment required. As COOLANT CONTROL coolant temperature rises, the output of the temperature TEMPERATURE UN IT sensor is changed. With this change, the control unit SENSOR varies the amount of f uel enrichrnent by changing the duration of the fuel injector opening. Refer Fig 6C-49. lf the sensor is diagnosed as defective, it rnust be replaced. NOTE: The coolant temperature sensor for EFI is common with the sensor used for Electronic Spark Timing. INJECTORS Figure 6C-49 Inlet Air Temperature Sensor The inlet air temperaturesensor is built into the air flow meter housing. Refer Fig. 6C-50. The function of this sensor is to compensate for changes in inlet air temperatureby applyinga correctionto the air flow meter outputvoltage. AIR TEMPERATURE SENSOR TH ERMISTOR Figure 6C-50 Throttle Position Switch The throttle position switch is attached to the throttle body and is operatedby the movementof the throttle butterfly valve shaft. The switch contains two sets of points,one set monitorsclosed throttle positionand the other set monitorshigh load position.Refer Fig. 6C-51. The closed throttlecontacts are closedwhen the throttle butterflyvalve is positionedat idle, and are open at any otherthrottle position. The closed throttle contacts when closed, provide the control unit with an electricalsignal for the deceleration fuel shut off function. Deceleraticn condition is detected from the closed throttle contacts and engine rpm above 1800. Under these conditions,which occur while decendinghills or THROTTLE slowingdown from highwayspeeds, injection is stopped VALVE SHAFT - to savefuel. As the engineslows to 1800rpm the fuel is reintroducedin preparationfor idle. I DLE CONTACT _ Figure 6C-51 6C-22ENGINE FUEL Enrichment is also provided at higfr load as srgnalledby the closing contacts in the throttle position THROTTLE switch, when - BODY the throftle blade angle exceeds 40c Ar electricalsignal from the throttle position switch rS sent to the control unit tc increasethe injectorpulse wrdth Refer Fig. 6C-52. /l /l . THROTTLE POS ITI ON SWITCH Figure 6C-52 Control Relay The electrical supply to the f uel pump. control unit, injectors, auxiliary air valve, throtile Dosrton switch and air flow meter is controlled by the control relay. The control refay itself is actuated by the ignition switch and also with either: a. The engine cranking. b. The ignition coil pulses being over the equivalent of 150 engrnerpm. Figure 6C-53 ,unng engtne crankrng,voltage from the ignition swrtch a-d from the starter ^notcr solenoid croses the control reiay points. This allows current to flow from the banery, Supolyrngpower to the ccmpcnents mentioned above. Fefer Fig. 6C-54. TC ELECTq,CAI_ COMPC ir. ! ri -S I ] BATTERY I I r---J 3 rGNtTtoN I SWITCH i STARTER TC FUEL SOLENOID P'- :"4P ENGINE CRAN K ING Figure 6C-54 ENGINEFUEL 6C-23 Voltage frorn the ignition switch is still present at the control relay after the vehicle has started. The rotational speed reached as the engine starts, is high enough to generate the engine running signal, which is taken from the ignition coil pulses being above 150 engine rpm. Refer Fig. 6C-55. TO coMPoNrrry:E LECTR I CA L '_+ I BATTEFY i = I I EARTH IGN ITION r---'J I SWITCH i IGN ITION TO FUEL COIL PUMP ENGINE RUNNING Figure 5C-55 The control relay remains switched on as long as the ignition is switched on and the engine is running. _l I lf the ignition coil pulses stop because the engine has stopped, for instance in the case of an accident, the control relay switches off. POINTS This safety circuit prevents the fuel purnp from pumping OPEN fuel when the ignition is switched 'CN' but the engine is BATTERY not running.Refer Fig. 6C-56. SUPPLY TO ELECTRICAI CCIvIPONEtf fS STOPPED BATTER Y IGNITION SWITCH IGNITION COIL PULSES BELOW 150 RPM (ENGINE SPEED) ENGINE STALLED Figure 6C-56 6C-24ENGINE FUEL 3. SERVICEOPERATIONS 3.1 SERVICENOTES 10. Depressurizefuel system as per service operation IMPORTANT:The following must be observed when 3.2 in this Section before disconnectingany high working on vehicles with the electronicf uel injection pressurefuel line, to reducethe residualpressure in system. the fuel lines. 1. Never start the engine wrthout the battery being NOTE:with very hot engine up to a litre of fuel may be solidlyconnected. expelfedunder high pressure. 2. quick 11- Before Do not use a chargeunit to startthe engine. ?.terpting any electric welding on the 3. Never separate the battery from the 'on board' vehicle,disconnect the batteryleads and Ine control electricalsystem while the engineis running. unitconnector. 4. when charging the battery, disconnectit from the 12. when steam creaningengines, do not direct the vehicle'selectrical system. steamcleaning nozzle at any EFI components.lf this happens,corrosion 5. Beforemakrng any test on the fuel injectionsystem, of the terminals€n take place. 13. ensure that the ignition coil and distributorare in Neverattempt to bench test the fuel purnp as it is order, as the control unit operationis triggeredfrom designedto run with the internalsimmersed in fuel. tr,e ignition coil. checks should also be made of Runningon a bench withoutany fuel can causethe rgnrtrontirning and sparkplug condition. pumpto explode. 6. Neversubject the control unit to temperaturesabove 14. The throtile body must be removed every 80oc (1760 F) i.e. paint oven, alwaysremove control 40,000 kTr o]' 2 years whichever occurs first, ani unit first if this temperatureis to be exceeded. ExhaustGas Recirculationdeposits cleaned from the throttle 7. Ensurethat all cable harness prugs blade and throtile bore. Reset idle speed are connected after reinstallation. solidly and that battery terminals are thoroughly Failure to observe this require- clean. ment will result in the engineidle speed decreasing and stalling. 8. Never connect or disconnectcable harnessplug at 15. Disconnectthe battery controlunit whenthe ignitionis switchedon. before workingon either the fuel or electricalsystems 9. when making of the EFl. a compressrontest, remove control 16. Handle relay from the fusebox all EFr components carefully to avoid to deactivatethe fuel pump damage,particularly and prevent fuel being inlected during engine the air flow meter. cranking. 3.2 FUELSYSTEM LEAKTESTING Priorto starting the engine. follcwrrg the installationof a fuel system component. checx the fuel system for leaks. 1 check to ensure tha::here rs a sufficientlevel of fuel rn the fuel tank. 2 Activatefuel purnp tc pressurisesystem by: a Disconnect purcle lead from starter motor solenoid. 'cranK' c lold ignitionswitch in positionto run fue Dump. 3 let-.n ignitionto'off'position. j 3re:k fuel system for leaks partrcuiarlvar Dcrnts -larked O in Fig. 6C-57. 5 ?ect f., aay fuel leaks. 6 Reccnrec: ead to starter motOrsolenorc DEPRESSURIZING The fuel lines of ihe EFl system retain a residual pressure,even when tne encine is switched 'oFF'. For reasons of safety, rt rs necessary to depressurizethe fuel system before any sectro- c. ine pressure side of the fuel pump is disconnected The system is depressurized,.rsin?:re nose from fuel pressure gauge part no. SD28018 o^ the Sc^radervalve fttting at the front of the fuel rarl. The end c3nnector of t're hose has a built in valve core depressor ENGINEFUEL 6C.25 INJECTORS - 6 PLACES-r I FUE TAN DAM PE R Figure 6C-57 The following procedure should be used when depressurizingthe system:- 1. Detachhose from fuel pressuregauge, SD28018. 2. Removecap from schradervalve fittingin fuel rail. 3. Insert 'Gauge' end of hose into a containerwith a capacityof at leastone litre. 4. Slowly install the other end of the hose to the schradervalve fittingand allow fuel to escapeinto the container(Fig. 6C-57A). 5. When fuel flow ceases,remove hose from fittingand reinstallcap. Reinstallhose to gauge. Flgure 6C-57A FUEL HOSES AND CLAMPS Periodicallyinspect all fuel hosesfor cracksand swelling, replaceany hose that showssigns ol deterioration. NOTE:The EFI systernuses a specialgrade of fuel hose that is necessaryto withstandthe high fuel pressures and temperaturesof the system. The diameterof the hose is also matchedto the fuel pipes and clamps to ensurepositive retention. Use only the correct,genuine EFI system fuel hose. Carburettorfuel hose, emission hose or non genuinehose, even though it may have a high pressurerating, ls not suitable. Hose clampson the EFI systemare speciallydesigned to exert an even clampingforce aroundthe circumference of the hoseand have roundededges to avoidcutting into the fuel hose. Tighten to the correct torque (refer Torque Wrench Specifications)and never use non genuine substitute hoseclamps. 6C-26ENGINE FUEL 3.3 THROTTLECABLE ADJUSTMENT ACCELERATOR PEDAL 7 ADJUSTING SCREW 1. Depress accelerator pedal to floor. i 2. Adjust throttle cable outer lock nuts so that the throttle valve is fully open. Tighten lock nuts to 3.0 to 4.0 Nm (Fig. 6C-58) 3. Allow accelerator pedal to assume free position. / v.-\J- i_I 4. Adjust screw on pedal lever so that the pedal has no THROTTLE VALVE free play, but the cable is taut and idling speed is not affected (Fig. 6C-58). THROTTLE CABLE - OUTER LOCK NUTS AccE LERAToR pEDA L-----7 Figure 6C-58 3.4 CRUISECONTROL POWER UNIT CABLEADJUSTMENT 1. Ensure ignition is switched 'off' and the throttle butterfly valve is completely closed. ENSURE POWER UNIT 2. Check slack in cable. Refer Fig 6C-60. LINK IS INSTALLED THIS WAY 3. To adjust the cable to obtain the correct amount of slack, loosen off lock nut Refer Fig. 6C-59. Turn the adjusting link to get the desired slack of 5.0 to 10.0 mm as shown in Fig. 6C-60. ADJUSTING L IN K Figure 6C-59 Figure 6C-60 3.5ADJUSTING IDLE SPEED AND MIXTURE Before making any adjustnnentsto the idte senrngs, ensure that:- 1. The engine oil and water are at normal oceratrng ternperatures,preferably achreved by drivinc 2. Transmissionin Park or Neutral. 3 Air conditioning(if fitted) turned off 4. Disconnectcanister purge hose but do not plug (refit after test). ENGINEFUEL 6C-27 5. Connect an ACCURATE CO-meter and tachometer. 6. Record values and compare to those specified on the Vehicle Emission Control Information Label in the engine compartment and listed in Specifications in this Section. NOTE: Nominal values are for 'run in' engines. New engines should not be readjusted unless outside the range of 700 to 900 rpm during the first 1500 kms. The following checks must be performed and any defects corrected before any idle adiustrnents are made to the EFI system. 1. lgnitiontiming. 2. Manifold vacuum is present at fuel pressure regulator. (Disconnect vacuum hose at regulator and install vacuum gauge to hose.) 3. Throttle lever closing on to stop - if not check a. Throttle position switch adjustment. b. Throttle linkage and springs. 4. No leaks at hoses and duct between atr flow meter and manifold. 5. Runningon all cylinders- if not check for a. Defective spark plugs and leads. b. Open circuit to injector. 6. Auxiliary air valve fully shut - check by pinching off air hose and observing engine speed - if speed drops, check for a. Engine not sufficientlywarmed up. b. Open circuit in electrical supply to auxiliary au valve. c. Auxiliaryair valve installedupside down. IDLE SPEEDADJUSTMENT LOCK N UT - T-JROTTLE ln the case of deviationfrom specifications,adiust the -=VER STOP; idlespeed as follows: 1. Loosenoff lock nut (Fig.6C-61). 2. Install an accuratetachometer. Turn the idle speed adjustingscrew to achieve the correct idle speed .,/ Fig. 6C-61. IDLE SPEED ,/' ADJUSTING SCREW_ Screwingthe adjusterout, increasesthe idle speed, screwingin, decrea*s the idle speed.The specifica' tion for a 'run in' engineis:- 850 t 50 rpm. DO NOT UNDERANY CIRCUMSTANCESADJUST THE THROTTLELEVER STOP (ReferFig. 6C-61). 3. Check CO-readingafter speed adjustment.The spec- ificationfor a 'run in' engineis .5 to 1.So/oCO. Figure 6C€ 1 IDLE MIXTUREADJUSTMENT This is preset and should not normally be adiusted. In the case of deviation from specification and all previous checks have been carried out and abnormalitres corrected, adjust the idle mixture as follows:- 1. Use only an ACCURATE Co-meter. 6C-28ENGINE FUEL 2. Pierceand remove the plastic cap on the air flow meter to expose the mixture adjustingscrew. Refer Fig.6C-62. 3, Turningthe screw in, nchensthe mixture,screwing it out leans the mixture.ldle CO-specificationis .5 to 1.5%. 4. Recheck idle speed after mixture adjustment. 5. Reseal mixture adjusting screw with a new servtce, plastic cap. The service cap is coloured red, and is available from GM P & A, Part Number VS16400. Figure 6C-62 3.6AIR CLEANERELEMENT REPLACEMENT 1. Drsconnectbattery earth lead. 2. Loosenhose clamp around arr flow duct at air flow meter.Refer Fig. 6C-63 3. Disconnectwiring harnessconnector at the air flow meter, remove harness from retainer. Refer Fig.6C-63. - HOSECLAMP AIR FLOW DUCT FLOW METER Figure 6C€3 I Remove air flow duct mounting bolt. Refer Fig. 6C-63A. HOSE AIR FLOW DUCT CLAMP - HOSE CLA*'/ .----\\/ --\\ // ---v:\/ Figure 6C€3A ENGINEFUEL 6C-29 5. iJnclipsnap locks around upper air cleanerhousing. Refer Fig. 6C-64. 6. Lift upper air cleaner housing from its position and removefrom air flow duct. NOTE:When removingthe upper air cleanerhousing, be particularlycareful not to damage or knock the air flow R -----AlR meter. C:EA\ER 7. Rernoveair cleanerelement from upperhousing. HOUSING SIJAP LOC K Figure 6C-64 8. Fit new air cleaner element into upper housing and check that it is seated correctly. Refer Fig. 6C-65. Refit upper housing, wiring connector battery lead and air flow duct hose clamp. Figure 6C-65 HOUSING 3.7 AIR CLEANER F L3,'y' *'.tET=R - REMOVE 1. Disconnect battery earth lead. 2. Disconnect wiring harness connector at the air flow CONN ECTOR meter, remove harness from retainer. Refer Fig. 6C-66. 3. Loosen the hose clamp around air flow duct at air flow meter. Refer Fig. 6C-66. t, rl Figure 6C-56 4. Remove engine ventilation hose from the lower inner panel of the air cleaner housing.Refer Fig. 6C-67. Figure 6C-67 6C.30ENGINE FUEL 5. Remove air flow duct mounting bolt. Refer Fig. 6C-67A. HOSE A I R FLOW DUCT HOSE 6. Remove the three air cleaner housing mounting nuts CLAMP CLAMP; / (refer Fig. 6C-66) and withdraw air cleaner housing by first sliding the air flow meter from the air flow duct and then removing the housing assembly. REINSTALL 1. Installationis reversalof removal. 2. Check for air leaks. -l/, )) /,//// Figure 6C€7A 3.8 AIR FLOW METER AIR FLOW METER REMOVE 1. Disconnectbattery earth lead. WIRING HARNESS 2. Loosen hose clamp around air flow duct at air flow CONN ECTOR rneter.Refer Fig. 6C-68. 3. Disconnectwiring harness connector at the air flor meter, rernove harness from retainer. Refer Fig 6C-68. RETAIN ER BOLT Figure 6C-68 4. Remove air flow duct mounting bolt. Refer Fig. 6C-68A. tu PPoRr BRACKET I -c /--- / FLOW r -AtRDUCT Figure 6C€8A ______r ENGINEFUEL 6C-31 5. Open snap locks and remove air flow meter with upper section of air cleaner housing. Refer Fig. 6C-69. Remove air flow meter harness retainerbolt. Refer Fig. 6C-68. 7. Removeair cleanerelement from upperhousing. L=ANER t'l G SNAP LOCKS Figure 6C-69 8. Remove air flow meter mountingbolts from upper innerair cleanerhousing. ReferFig. 6C-70. Figure 6C-70 NOTE: A Square 'O' ring is used to seal between the air flow meter and air cleanerhousing. Refer Fig. 6C-71. REINSTALL 1. lnstallationis reversal of removal. Figure 6C-71 2. Ensure 'O' ring is in Place. 3. Check air flow meter flap for correct functioning by moving it all the way to the stop. The movement must not be ierkY. 4. Use a clean lint free cloth to remove any dirt in the area of the flap. DO NOT use any solvent or compressed air to clean the passage of the air flow meter. 5. Tighten air flow meter moulting bolts, and the wiring harness retainer bolt. 6. Refit air cleaner element to upper housing- 7. Check for air leaks. -q 6C.32ENGINE FUEL TEST lf the following test is to be conducted on the vehicle, disconnect the battery earth lead and the wiring harness connector at the air flow meter. 1. Measure the resistance between terminals 7 and 5 while sliding the air flow flap. lf the resistance is at any value other than 0 and infinity, air flow meter is normal. Refer Fig. 6C-72. Figure 6C-72 2. Check insulation resistance between the air f low meter body and any of the terminals. lf continuity exists, the air flow meter is defective and must be replaced. Refer Fig. OC-73. Figure 6C-73 3.9 AIR FLOW DUCT REMOVE 2 Loosen hose clamp and remove hose to the auxilrary air valve from the air flow duct. Refer Fig. 6c-74 SUPPORTBRAC K ET -- i----- 7 AIR FLOW r DUCT ,/--T AUXILIARY .{ AIR VALVE 't HOSE Figure 6C-74 ENGINEFUEL 6C.33 3. Remove the engine ventilation hose bracket bolt from underneath air flow duct. Refer Fig. 6C-74A. ENGINE 4. Remove the air flow duct mounting bolt from support VENTI LATI ON bracket. Refer Fig. 6C-74. Figure 6C-74A 5. Loosen the hose clampsaround each end of the air from flow duct (refer Fig. 6C-75) and withdraw duct HCS= AIR F LO!'J D - ]- its position. CLA\1P - REINSTALL 1. Installationis reversalof removal. 2. Check for air leaks at all connections to air flow duct (this will effect the air fuel ratio). Figure 6C-75 3.10THROTTLE BODY THROT-|-uI _ ACCI:ERATOR CABLE - BoDY REMOVE ACSE::RATORr 1. Disconnect battery earth lead. :*.'.---.--.{RE-I-LRNSPRTNG\ _CCK \: - 2. Remove air flow duct as per 3.9. '- -r------=h-f --:-rlTS 3. Disconnect throttle cable from throttle body linkage and air f low duct mounting bracket. Remove the upper accelerator return spring. Refer Fig. 6C-76. ".,]OUNTING ERACKET \ ACCELE RATO R LINKAGE BFACKET Figure 5C-76 4 6C.34ENGINE FUEL 4. lf fitted, remove cruise control power unit cable retarnerfrom throttle linkage.Refer Fig. 6C-77. [r,NKNUr \p ,l i ,rTlRo.rr-LEL'|NKAGE Y--- ,----&{^tr /vfr POWERUNIT CABLE RETAINER Figure 6C-77 5 Disconnect vacuum hoses to throttle body.noting positions for correct reinstallationRefer Fic. 6C-78. CANISTER TO THROTTLE BODY PURGE - ENGINE TVS SWITCH TO -I VENTI LATI ON THROTTLE BODY Figure 6C-78 6. Disconnect throttle positron switch wiring harness connector and, i{ fi:ted. rdle load compensator power TH ROTTLE MOUNTING NUTS BODY (4 feed wire. Refer F'E. 6C-79. Pr-ACES) Remove the /- mcunting nuts securing throttle body to the inlet nanifold and remove throtile body and gasket. MOUNTlNG Refer Fig 6C-79. STUDS Remove the two bolts securing the throtile linkage bracket to the throttle body and disconnect the throttle rod from the throttle lever ball. Refer 6g Fig. 6C-76. IDLE LOA D _ COMPENSATO I REINSTALL THRCTTLE _ Instaliationis reversalof removal noting the followrng: POSITIS\ SWITCH Use a new throttle body to intet manifold gasket. Before fifirng the throttle body wrpe Exhaust Gas Re- circulationdeposit from the throtile blade and bore. 3low out the smail drillingsfor the spark, EGR and canrster Figure 6C-79 signals with compressedair. NOTE: Reset the idle speed on reinstaltatron afler cleaning,refer 3.5 Check for full throttle and adjust throttle cable as required,refer 3.3. lf fitted with cruise control, check cruise control power unit cable adjustment.refer 3.t. Start engine and check for air leaks ENGINEFUEL 6C.35 3.11 INLET MANIFOLD REMOVE 1) 1. Disconnectbattery earth lead. 2. Remove air flow duct as per 3.9. 3. Disconnect all vacuum hoses frorn inlet manifold and @ throttle body and remove inlet manifold vacuum adaptor from rear of manifold. NOTE: Observe hose positions for correct reinstallation refer Figs. 6C-80, 6C-81. HOSE NOS. *tr' 1 To speedsensor transducer. 15 To l MoC thermostathousing TVS. 2 To brake booster. 4 To auxiliaryair valve. 5 To automatictransmission vacuum modulatorvalve. 3 To fuel Pressureregulator valve, I SS EGR valveto cylinderhead EGR TVS switch. i Figure 6C-80 HOSE NOS. 6 1 Throttle body to cylinderhead E G R TVS switch. 38 Throttle body to thermostathousing TVS. 60 Canister to th rottle body purge. 6 Engineventilation hose. 38 Figure 6C-81 4. Disconnect throttle cable from throttle body linkage THROTT L E- ACCELERATOR- - ACCELERATOR and air f low duct mounting bracket. Remove the BODY A ETURN SPRING CAB LE upper accelerator return sPring.Refer Fig. 6G82. .- : --_- -- ,_LOCK N UTS __l =l -{F RETURN SPRlNG Figure 6C-82 6C.36ENGINE FUEL 5. lf fitted, remove cruise control power unit cable retainer from throttle linkage. Refer Fig. 6C-83. LINK NUT THROTTLE 1)-\-- LINKAGE CRU ISE CONTROL POWERUN IT CABLE RETAINER------> Figure 6C-83 6. Disconnect wiring harness connectors from the throttle position switch, idle load cornpensator if COOLANT TEMPERATURE fitted, coolant temperature sensor, injectors and SENSOR- generator. Refer Fig. 6C-84. _IDLE LOAD COMPENSATOR unclip wiring harness clips around fuel rail and top INJECTORS r6 PLACES) radiator hose and withdraw wiring harness towards the rear of the engine. PCS ITION Figure 6C€4 7 Disconnect E.G.R. pipe from inlet and extracto' manifolds.Refer Fig. 6C-85. 8. Depressurizefuel system as per 3.2. 9. Disconnectfuel rail hose and fuel return hose from fuei regulator. Figure 6C-85 ENGINEFUEL 6C.37 10. Remove inlet manifold brace bar. Refer Fig. 6C-86. 11. Remove manifold to cylinder head attaching nuts and bolts. 12. Release inlet manifold from cylinder head. Once clear of manifold mounting studs, remove manifold and feed the automatic transmission modulator pipe from the manifold. REINSTALL I Clean inlet manifoldand cylinderhead mating faces and I E.G.R. exhaust gas pipe and manifold surfaces. Install I 'T new gaskets Installationis reverse of removal operations. Tighten I manifoldbolts, working from the centre outwards.Refer TorqueWrench Specificationfor details. Installinlet manifoldbrace after torquingup the manifold to head nuts and bolts.Tighten the top end of the brace first to ensure the slotted end is correctlypositioned on Figure 6C€6 the extendedhead bolt. Test fuel system for leaks as per instruction3.2 and check full throttle and adjust throttle cable as required, refer 3.3. lf fitted with cruise control, check cruise control power unit cable adjustment,refer 3.4. Start engineand check for air leaks. 3.12AUXILIARY AIR VALVE REMOVE ,tr ,.ff - 1. Disconnect battery earth lead. 33'{ 2. Disconnect harness plug at top of valve. Refer Fig. 6C-87. 3. Loosen hose clamps at each end of the valve and Refer Fig 6C-87. disconnect hoses. ,.--AI R FLOW 4. Unscrew both mOuntingscrews and remove auxiliary f D ricT air valve. Refer Fig. 6C-87. PIUG REINSTALL 7 HA3 \ ESS 1. Installation is reversal of removal. Valve is to be plug upwards. installed with the wiring connection AIR Ensure that the cylinder head and auxiliary air valve 5**t fi--lt mating surfaces are clean to provide the required HOSz_--'-i' \ ,:,_[ heat transfer. 2. Check for air leaks. __---t, AUXILIARY | -z- TEST \l-t ArR vALvE al Thistest must be performedwith a coldengine- HOSE 1'ffiirui6;i6 Start engine and pinch the rubber hose between the CLAMPS S/ fl*-- MouNrlNGSCREW \-f{T O (2 PLACES) throttle body and the air valve. \\!./ When the air valve is cold, the engine speed should decrease as the hose is Pinched. AIR INLET HOSE With the air valve hot, the engine speed remarns unchanged as the hose is Pinched. Figure 6C-87 6C.38ENGINE FUEL 3.13FUEL PUMP REMOVE FUEL DAMPER OUTLET HOSE 1. Disconnect battery earth lead. 2. Drain tank to below level of fuel outlet. 3. Disconnectwiring harness connections on the pump. Note which way the wiring connectors are fitted to i v( the pump. Refer Fig 6C-88. rlt 4. Place a drain tray underneath pump. FUEL PUMP 5. Depressurizefuel system as per 3.2 ,,UPBOLT 6. Remove fuel pump clamp bolt and clamp. Refer Fig. 6C-88 HOSE CLAMP 7. Loosen hose clamps at either end of the fuel pump and slide hoses off, withdraw fuel pump. Fig. OG8B, _==-_ ZFUEL DAMPER L"- REINSTALL rl [ *,*,*] Installationis reversalof removal. When installing the fuel HAR N ESS purnp ensure that the fuel line hose clamps are properly TERMINALS seated and check for fuel leaks as per 3.2. Figure 6C€8 TESTING Volume Test 1. Depressurizefuel systern as ger3.2. 2. Remove gauge hose f rom fuel rail, and using a schrader valve remover, remove valve core. Refit gauge hose to schrader valve fitting. 3. Place free end of gauge hose in a container with a volume measurementscale. NOTE: Ensure the container has a volume greater than 1 litre and that fuel tank has a sufficient level of fuel. 4. Remove purple lead from starter motor solenoid. 5. Activate fuel purnp by switching ignition to the 'START' position. 6. The volume pumped should be at least one litre in 30 seconds. lf the volume pumped is not sufficient: a. Jack up rear of vehicle and place on safety stands. b. Disconnect f uel hose between fuel pump and fuel filter at the fuel purnp end. Install one end of a suitable length of fuel hose to the fuel pump outlet pipe and insert the end in a container with a volume measurement scafe of at least 1 litre capacity. 7 . Retest as per steps 5 and 6. lf volume pumped is sufficient, fuel filter is blocked. 8. lf volume pumped is not sufficient: a. Remove fuel pump inlet pipe, install a test hose to the fuel pump inlet. lmmerse hose in a container having more than a litre of clean fuel. b. Place the fuel pump outlet test hose In the empty test container. 9. Retest as per steps 5 and 6. lf volume pumped is sufficient,the fuel tank sender unit stainer is blocked. Remove tank unit as per instruction2.6 in section 8A of this supplement. lf volume pumped is not sufficient, replace fuel pump. PressureTest 1. Install fuel pressure gauge and hose (par1 no. SD28018) to schrader vafve fitting at front of fuel rail (Fig. 6c-89). Hose has built in valve core depressor. ENGINEFUEL 6C.39 2. Start engineand read fuel pressuregauge' Pressureshould be approximately25O 20 kPa at idle. The moment the acceleratorpedal is moved pre- ssure should increase to approximately300 kPa (accelerator must be opened rapidly to give 'C' manifoldvacuum). 3. lf fuel pressureis not as specified,check for clogged or deformedfuel lines,blocked fuel filter or pick up strainer. 4. lf above the specified value, check condition and connectionof vacuum hose to pressureregulator, if hose is satisfactory,replace regulator and retest. lf the pressureis still not achieved,replace fuel pump- Fuel Pressure Test r For Internal Leakage 1. Installfuel pressuregauge part no. SD28018as per previoustest. 2. Start engine and allow to idle, note fuel pressure gaugereading. 3. Switch engine 'off' and observe pressure gauge reading.tt ihe readingdrops, it is an indrcationof an internalfuel leakage. 4. Under the vehicle,clamp the fuel pump outlet hose' Observe the fuel pressure gauge reading. lf the reading stops dropping, the fuel pump has an internaituet leakageand must be replaced. 5. lf the reading continuesto drop, while the hose is clamped, rernove the purple lead from the starter motor solenoid. Turn the ignition to the 'START' positionand allow the fuel pump to run. Once the iuel pressure reading has reached the same as recordedin step 2, switch'off ignition' Figure 6C-89 6. Clampthe fuel returnline from the pressureregulator and observe the pressure gauge reading' lf the reading stops dropping, the pressure regulator is faultyand must be rePlaced- 7. lf the readingcontinues to drop, removethe fuel rail mountingbolts from inlet manifold' g. Carefullyremove fuel rail and iniectorsfrom the inlet manifoldand rest the fuel rail on the manifold' 9. Carry out steP 5. 10. Observewhich iniector/sis leaking' 11. Replace iniector/s which are faulty. Replace the sealing'o' rings on all other iniectors,and lubricate usingPetroleum iellY. 12. Refit fuel rail assemblY- 13. Refit starter motor solenoid wire- Start engine and check fuel pressure gauge reading. Switch'off' engineand checkfor pressuredrop' 14. Remove pressuregauge and install scrader valve cap. 6C.40ENGINE FUEL 3.14 FUEL DAMPERT REAR REMOVE HOSE CLAMP 1. Disconnectbattery earth lead. 2. Depressurizefuel system as per 3.2. 1r 3. Raise rear of vehicle and support on jack stands. @ t: rl 4. Loosen hose clamp on fuel outlet hose frorn damper, l r" rernove hose. Refer Fig 6C-90. ti -/ lrJ] 5, Remove fuel damper mountrng nut from bracket, ---'' ti loosen hose clamp between damper and fuel pump. ----'-' /t Refer Fig. 6C-90. 6. Lift damper from mounting bracket and withdraw HOSE from fuel pump hose. MOU UT j = REINSTALL MOUN ACKET 1. Installationis reversalof removal. 2. Check for fuel leaks as per 3.2. Figure 6C-90 3.15 FUELFILTER REMOVE FROM FUEL PUMP 1. Disconnectbattery earth lead. 2. Depressurizefuel systemas per g.Z. 3. Raiserear of vehicleand supporton jack stands. 4. Placea draintray underneathfilter. 5. Loosenhose clampsand disengagefuel hosesfrom filter.Refer Fig. 6C-91. 6. Loosenfilter mountingclamp bolt and removefilter. ReferFig. 6C-91. REINSTALL 1. Replacingfilter is reversalof rernoval. NOTE:Direction of fuel flow arrowon filterbody rnust be compliedwith (arrowto pointto frontof vehrcie). '/ 2" Make sure the fuel line hose clamps ate properly seatedand checkfor fuel leaks.reler instruction g.Z. > CLAMP C LAMP BO LT H OS E C I-A I'I,P-, TO ENGI N E' Figure 6C-91 3.16 FUEL DAMPERI FRONT REMOVE i Drsconnectbattery earth lead. 2. Depressurizefuel system as per 3.2. FUEL f- r,- 3. Locsen fuel line hose clamps at r-1u\l each side of HOSE | !/t- damper,dlsconnect fuel hoses. Refer Fig. 6C-92 - DAMP E R 4. Remove mounting nut. Refer Fig 6c-92 and with- draw damper. \:3J\TING REINSTALL \-T 1. Installationis reversalof removal. FUEL HOSE--.^ ,{,2 AUX I LIAR Y 2 Check for fuel leaks as per 3.2. AIR VALVE Figure 6C-92 ENGINEFUEL 6C-4 1 3.17FUEL RAIL REMOVE 1. Disconnectbattery earth lead. 2. Depressurizefuel system as per 3.2. 3. Disconnectthe fuel return line from the fuel pressure regulator,disconnect vacuum hose to the regulator. 4. Disconnectwiring harness connectorsat the throttle position switch, idle load compensator if fitted, coolant temperaturesensor, injectorsand generator wiring.Refer Fig. 6C-93. Unclipwiring harnessretai- ning clips aroundfuel rail and top radiatorhose, and withdraw wiring harness to the rear of the inlet manifold. Flgure 6C-93 5. Remove the bolt securing the inlet manifoldbrace bar at the manifold and the nut on top of the cylinder head stud. Remove brace bar. Refer Fig.6C-94. Figure 6C-94 6. Removethe injectorretaining clips. Refer Fig. 6C-95. FUELRArL rqf I $ $s4 K /' ,*J EcroR IP Figure 6C-95 -rfrt- 6C.42ENGINE FUEL 7. Remove the 3 fuel rail mounting bolts. Refer l.t':llnar, FUEL Fig. 6C-95. Using compressed air, blow off dirt RAI L y -} the injectors. .op'g {.,.'rv I rl\\l D\,rL | around i3 PLACES) *r'i,, 8. Pull fuel rail towards the inlet manifold and CAREFULLY loosen injectors from the inlet manifold or fuel rail. 9. Remove all injectorsand place in a clean location. INJECTOR 10. Withdraw fue! rail toward front of engine, pushing down slightlyon top radiatorhose. REINSTALL Before reinstallatingany injector,replace both sealing 'O' INJECTO R rings. lt will be necessary to cut the old 'O' rings fronn RETAINING CLIP -T- the injectors.Take care not to damage the tip insulator. - Smear the sealing 'O' rings with petroleum jelly. lnsert Figure 5C-96 each injector into the fuel rail, then install retainingclips. With all inlectorsin fuel rail, carefully position numbers 5 and 6 cylinder injectors into the manifold ports. Next, posrtron the centre two injectors, then the remaining two injectors. With all injectors correctly positioned in the manifold, push fuel rail squarely in to fully engage injectors. Installationis reversalof removal, Check for fuel leaks as per 3.2. 3.18INJECTORS For removal and reinstalling instructions, reter to Fuel Rail Remove and Reinstall,3.17. 3.19PRESSURE REGULATOR REMOVE 1. Disconnect battery earth lead. 2. Disconnect vacuum hose at the pressure regulator. Refer Fig. 6C-97. 3. Depressurizefuel system as per 3.2. 4. Disconnect the fuel ccnnections tc anC from the pressureregulator. Refer Fig. 6C-97. 5. Remove regulator mounting nut on fuel rail bracket and remove regulator.Refer Fig. 6C-97. REINSTALL 1 lnstallationis reversalof removal. 2 Check for fuel leaks as per instruction3.2. Figure 6C-97 3.20CONTROL UNIT REMOVE '1 Make sure ignitionis switched 'oFF' and drsconnect battery earth lead. 2 Remove the left hand ccw canel trim from the front passengercompartment" as described in Section 1A of this Supplement. ENGINEFUEL 6C-43 3. Removethe two controlunit mounting screws. Refer Fig.6C-98. LE FT H AN D ----r. HARNESS PLUG /B- MOUNTING BC-TS (2 PLACEST Figure 6C-98 4. Disconnectthe wiring hamess plug from the control unit by pullingup tang and swing hamess out from controlunit. Refer Fig. 6C-98A. REINSTALL fnstallationis reversalof removal. Figure 6C-98A 3.21 THROTTLEPOSITION SWITCH REMOVE _THROTTLE ii / PostrtoN 1. Disconnect battery earth lead. r/ 2. Disconnect wiring harness plug from throttle position SWITCH switch. 3. Remove vacuum fitting from manifold next to throttle position switch. THROTTLE BODY 4. Remove 2 mounting screws and withdraw switch from throttle shaft. Refer Fig. 6C-99. -irl fJNTING REINSTALL SCREWS Installation is reverse of removal, however the following should be noted. Ensure that the f lat section of throttle shaft slides into the correct position inside the throttle switch. Refit vacuum fitting into manifold and check that the automatic transmission modulator pipe rs fitted securely into the Figure 6C-99 vacuum fitting. Do not tighten mounting screws as switch must be adjusted. ADJUSTMENT 1. The throttle position switch is to be positioned so that the closed throttle contacts open with the slightest throttle opening. lf the position of the switch is correct, a 'click' from within the switch is heard on opening the throttle. 6C.44ENGINE FUEL 2. lf there is no'click', rotate the switch slightly and then operate the throttle, continue adiusting the switch until the correct position is found. Reler Fig 6C-99A. 3. Check that the switch is not preventing the throttle butterfly from returning to its stop and tighten mounting screws. NoTE: The high load switching contacts are non adjust- able and are automatically set when the closed throttle adjustment is made. Figure 6C-99A 3.22COOI-ANT TEMPERATURE SENSOR REPLACE 1. Disconnectbattery earth lead. 2. Remove wiring harness connector from coolant temperaturesensor. Refer Fig 6G100. 3. Draincoolant from engine to belowsensor level. 4. Removesensor from cylinderhead. 5. ApplyGMH sealantP/N 3835214,to sensorthreads, refit into cylinderhead. 6. Refitharness connector. 7. Add coolantto radiatorand check for leaks. ON ENGINETEST The temperatureand resistancereading should be made Figure6C-100 beforeand afterengine warm up. Engine Cold 1. Disconnectbattery earth lead. 2. Disconnect wiring harness connector from temperaturesensor. 3. Remove radiator cap, place a thermometer in the radiatorcoolant and read coolant temperature. s.A Usrng an ohmmeter, measure the resistance across the terrninals of the temperature sensor. Refer COOLANT Fig 6C-101. TEMPERATURE SENSOR 5. Connect wiring harness connector and battery earlh lead. 6. warm up engine sufficientlyand then follow steps 1 thru 4. Check results with the following chart. lf results indicate suspect temperature sensor, perform the more accurate test below. Figure 6C-101 ------ ENGINEFUEL 6C-45 OFF ENGINE TEST RemoveSensor as per steps 1 thru 4 tor replacement. With the temperaturesensor suspendedin a beaker of 50/50 glycol/water, record resistance across the terminalsat varioustemperatures. Refer Fig. 6C-102. Checkthe resultswith the followingchart. Figure 6C-102 tI 8000 I 6000 RNTC 4000 3000 2000 1000 800 600 RESISTANCE 400 300 200 100 80 60 40 30 20 40 60 TEI\1'ERATURE 01 Figure6C-103 lf, in either test, the resistanceof the Sensorwith respect to coolant temperature is not as specified in the above graph the sensor is faultY. 6C.46ENGINE FUEL 3.23CONTROL RELAY REMOVE FUSE BOX COVER 1. Remove fuse box cover. Fig 6C-104. Figure 6C-104 2. Pullout relayfrom its position.Refer Fig. 6C-105 REINSTALL Installationis reversalof removal. Figure 6C-105 ENGINEFUEL 6C-47 4. DIAGNOSIS 4.1 CIRCUITTESTING PROCEDURE ELECTRONICFUEL INJECTION TEST EQUIPMENT A set of special equipment has been developed for diagnosing and testing the EFI system of VK Series vehicles. The set consists of an ignition diagnostic system (part no. SD28013) and a companion electronic fuel injection accessory kit (part no. SD28014). Part Nos. SD28013 and SD28014 are marketed only as a set and are not available separately. The EFI accessory kit includes a fuel pressure gauge. The ignition diagnostic system on its own, serves aS an effective ignition tester. The ignition diagnostic system and the EFI accessory kit must be used together when testing the EFI system. Operating instructions for the ignition system tests and the EFI system tests are included as part of the test equiprnent package. Details on availability of the test equipment are obtain- able from: General Motors-Holden's Sales Pty. Ltd. Service Division, Box 548D, GPO, Melbourne3001. Australia. Should the recommended EFI test equipment not be available,the following material may be used for checking the Fuel Iniection System. 1. 12-volt, 2 watt test lamp with standard test probes. 2. Ohmmeter, measurement range 0 to 5000 ohms. 3. Tachometer. The cable harness plug must be separated from the control unit in order to test the cable harness and the engine sensors. Since the contact terminals on the plug strip are not marked, the contacts must be counted for the various tests. Terminals 1 through 13 are located on the long terminal strip; terminal 1 is next to the cable entrance. Refer Fig. 6C-105A. 25 14 Terminals 14 through 25 are on the shorter terminal strip. Refer Fig. 6C-105A. Terminal 14 is next to the cable entrance- Some tests involve cranking the engine, therefore appropriate safety precautions must be observed. 13 MULTI_PLUG TERM \ALS Figure 6C-105A I 6C.48ENGINE FUEL o o z LU J o CN T Ll-^t- O-- F JE @ c\| =(n cP (Jz (o I z z cE c? (v) t c ogr r4J - F F Fir '- 5 = z za_ ; 9 9E N sf N sf C\I c2 N OCSfLOco !F F \\NN \. c\t c.l F,F N = cc (9 @ o rF ()I 6 (c' C, o =L cc = CD O) cc lr O)O!-N = !-!-F - @ IL [f c? (\l O) AD ; Lo(.or\o 1 F \t F 3 !COA (t) (l) :* l- t- co= co : '= l- Lr- (l)o:l=EEg., l- () u- tr- c! tr)' (c r\ are c.j -eri + :st tO (0 t'\ @ ol O c! l- - F ENGINEFUEL 6C-49 Function or Measure Component to Test With Between Test Status lnd ication lf Def ective N otes be Tested Terminals (correct) +and-on lgnition in Test lamp lights Look for break in I'pump runs but Fuel pump Testlamp | operatin g I fuel pump crank lf pump runs,it cable harness or ergine will not run positi on can be heard. blown fuse or creck fuel pressure faulty relay. anc \.c;urne pumpe aSPerSg'\'lCe I op.rairo- 3 13 i be Listento lgnition :n Relayclicks when Checkcu rrent Refer Fig. 6C 107 Relayclosing lCan i lheard activatec. supply wires or relay. lcrank ,test lamp 87 andearth I Position L amP i ;ghts to relay . Batterysupply ,Test lamP 30 and 31 Relay Lamp lignts Break in supply Checkfusible to relay rernoved cr earth leads to link. tP/ lgnition switch rTest lamp 15 & earth lgnition on Lamp lights B.ea< ' 'a a signal , i I SV/itCf ,, I Test lam p 50 & earth lgnition in Lump lights Breakrn c-'-:^: Crank signa Ij crank supply in sta:::: DOSittOr. solenoidcircu it. pulse tamp 1 & earth Engine Lannp f lickers Breakin lead Refe. F 6C 108 lgnition lr.t, signal crankrng aS?nE,n3 tUrnS f rom - coil terminalor faulty ign it ion system Injectorvalves Oh m mete r Cyl.1 thru 3 lgnition off Approximate ly Ch eck ',: , break ReferFig. 6C 1Cg and wiring Term.12& 9 Discon nect 3 to 4 ohms cabl€ n3-nass ' Cyl.4 thru 6 wrring Check rnjec:o-s ReferFig. 6C 10 Term.24 & 9 har:^,eSSplugs individuatlv at ai. fror,r with ohmmete: meter & arx, value 16 oh ms. ' air valve& throttle position ; switch. I lTest lamp Cy1.1 th ru 3 lgnition on Larnplights Check fcr break in I cabte | (2 watts) Term 12 & 13 & in crank -a-ness. I position lnjecto: , alve I Cyl.4 thru 6 I Term.24 & 25 defect . = Short I ^ I to ea:'.1 '.vires {na^ I lta.c;J. Injectionpulse Test lamp Removeplug lg^ r cr' Lampf lickers Ch:c< w ring for signalfrom (2 uvatts) f rom injector i crank brightly initially supciv signalsat control unit and measure pos : cr and dims within ccntrol unit across terms. 10 seconds connector. lf on plug control unit is considered fau ty test its operat,or' on another veh'c e. r.'e Supply voltage Test lam o 9 & earth lgnition r'. Lamp lights R elay def ect i to control unit and in c-ark Check ior break n positicn wiring f'orn No.9 term na Chec< for break n wiring f rom batte-y supply, fusible iink blowrr. t, - 6C-50ENGINE FUEL Functionor Measure Component to TestWith Between Test Status Indication lf Def estive Notes be Tested Terminals (correct) Controlunit Testlamp 9and5 lgnition on Lamp lights Check for break and systemearth i 9and 13 and in crank leads5, 13 & 25. 9and25 position Initiationof Testlamp 9and1 Operate Lamp f lickers Checkfor break in Refer 6C-1 1 1 injectionimpulse starter wiring - ignition briefly coil terminalto No. 1 connectorterm. Faulty ingjtion system, Start signal from Test lamp 4and5 Operate Lamp lights Checkfor break in Test lamp will starter for control starte r wiring between light only in unit briefly starter& terminal crank mode. lf I 50 on relay.Break I lamp lightswith in wire from ignitionon, check connectorterm. 4 why term. 50 has to starter. power. Refer Fig.6C-112 Operationof idle ' Ohm meter 2 ano 9 lgnition off Checkfor break in Refer Fig.6C-1 13 contactsin Accelerator 0 ohms cableharness or throttle valve pedaI in idle approx. replacethrottle swi tch position Fositronswitch. Accelerator pedalsl ightly ccoh ms depressed Operation ful' of Ohmme:3r 3 anc 9 lgn rt:or, of f Checkf or breakin Ref er F iq. 6C- 114 load contacts in Accele.ator' cc ohms cableharness, or th rottle valve pedal ir idle replacethrottle body Posrtron positronswitch. Acce le-a tor 0 ohms peda' fully approx. depressed Coola nt Ohrnm€ter 1CanC 5 lgnition off Temoeraiure Breakin cabfe peratu tem re oepentant harnessor replace sensor 0'C- 5500 ohms temperatu re zO'C-2450 ohms sensor 8O"C-320 ohms 97'C-200 ohms A r flow meter mmeter Oh 7and5 lgnition o;f lf the resistanceis B-ea -v! is OK. oefEct rve, Auxil;ary air p Test lam Lamp Cneck for breaks in valve circuit auxiiiary air valve ear:h and voltage s.rpply wiring. xil Au iary Oh mmeter Removeplug off 35-40 Replace. valve from aux. air valvemeasure l acrosst.rtr. I of valve I I - ^fr. ENGINEFUEL 6C.5 1 o .\J z u, J o(n Itr 9 .o F -) F A =- U> c1 E o oltr LU -F F F l-6 z! a1 ,2\r(n.tnF *yt \./ V ta U-WJ s N N s c\ s c! F -E (v) UJ r) C\ t; o z \\NN \- arN r\ F (,co o) ZJ a\--( NJ o= vtr,;t F o I O @ ;'l o = \- -l I C? Jul - lt o) i- OE, F(DCFC'j Fe- Ez:-LU @ =uJ H=YF UJ c0 :- t- l- \- ocoo UJ ==-ilstlrF' *I{'PP OOO(J E, c)qj(l)0) c2 r- (- .- (- .- (- .- (- -l -)U) o,l O) LlJ rn1j1F-CCt = N (v) (n K) F tn (c c\ 1- NCO$ O N N N, : F Crt c'l c:i i: : 6C-52ENGINE FUEL o o z UJ J L./(n IF O- | . v 0? F @ 59 c\I a (-)= (o z z cc cf) tr. O- O1.u c2 UJ . EE zz '^ rn J- Y Ya H@ (o cc tr) - cc tl- N F- :E-l-F E ES UJ NC\ rF- iF o 2 J \F etzl - cnz € o a= I JE o(o ful o o-F L zz CD l' our lr I F :-uJ I == ZF 9H UJ E l- t- l- !- oooo J N rP+r,{-rr) cn F c)OQQ (l)(l)0)q.) .- (- r- (- .- (- .- UJ ;r oa LO(or\€ ! ll- sf F : D LO F' N (o tFNO?Sf F ENGINEFUEL 6C,53 o /-\ v z I.IJ J o(n -rr9o F JF @ 09 N =(f) ()z tr e eP -) ;-F F F(r ;t o z z 3 F. -- .^ ra co Y Yo N sr C\l g (r $ F N CJ) r\ J c? 1i z N = t! LJ.J NN \-\ l- NN r z ^v O) N ('c zz E o) o =N (JI E, A, (0 o o= b 1- \( q !- c) I CJ= lr O) g= F o)OFN 2tr. F!-|t- rUJ co F c'j t- l- t- !- N oooo F OC)(JO - .q.q .q .sr a iY N ttJ- O) J c/) O F' .-li €r-cd (o z N ! = ct co sf (J t- LO F /R'rer\ qo /l'a (0 ;A e\ 6-; \'/ w e 6= =F |el'.c. -r l- I-- F it rO qg n- € $l O F N c, r- 6C.54ENGINE FUEL o o z lri J o a Itr sro F J 6r) F @ o9 N = (Jz cn (o z z cr (D cc rrl .r, v':.; t- e9B3 L -(- \v \v A\ rvw L(l)tr= l_LL coLt- L- E A hErr sf v F N v) --rbL - rEdd J z c'j + rri ccj IF = 'F E UJ F (- z c) .;P o -a I g) .- U' c(9 o r_.9 z z (l)P- o x'av E. F t-- sf 7. c3- I N r-r-ac) = o g o q) € p{J:- 5= cc O {J-F J o (l)q):- O =L- =.= = = F cc l- l- ,-- CD _si_C)-< z IL UJ F = F oj o--c.j = cc !-!- UJ @ F G' I N I F' sf cn E, ul _.,-l 0a rri co r- cc, o 'j F z J- $ C) H F A q LJ- ^\ (a :,LF L - D rv ro =l-s F : c 6 o) a)o:lf FOU-TL (o ,F-NCC$ F ENGINEFUEL 6C-55 o o z |'ll J o CN Io -rrF J F = o9 AO (o c? (Y = =n cc :\-i\_J- J LLJ-F FFf-tv lJ- ;-b =z z t! \r l4 rn F cc Y Y'a cc c0 E, c\I UJ s F c\l E F CN sf N UJ '(o lr, F !l! c? vJ aF lE t; c! =uJ -)n r-/AE v z -\ \\N(\l N(\ 9s FrF FE -(J OF .;P UJ V) N arl (. =e-l ,- .9 (l)+t ltz LJ :.. .t', o= xo (F l- b4 I -\ zE O !-!-aq) (0 o o = OUJ ,) +) v p -l- (J(J+'O o ^ FI L .-Q)c)\r- .- a (r) l-: I ll. O) tro F -O) Fci)c)-C.i =o !- @ 6^FZ lI.F r4O vl !- t- t- !- oooo =a *b-l N ,) t-, ,t u YZ P- llF (.)()(J(J A\ A\ AT c r-) wvww .-'\ .- H= N rcr (Jl]J F 15€f\@ c\ z l-lJ UJ sf = F' .g F ts€ LtJ v',o= 6 t_ \v UJ (-a\J !, ro '= r- cc F F+)a\:- l-I-t/, f A\A WVJJ CN F O tJ- lJ- ai l.tj (0 NClS = tr =-r I 6C.56ENGINE FUEL o z LU)- v -1a IF t! 9c 0/) F @ = cQ ol (t(J @ cf) z z cc (Y) - ! t_ N e933 LR sf coorXX- N )-q)trtr l_bL (\J-1l-l- H@ -.g(l)c.) = E : 6 hrsE -b+,Pv F acoovJ-) -\-L FU) CD L- r- -1 -l JZ=a C? \f, LO (O !f !F' !- :=v rr rr NN \i\ Nc! ;ur !- !- 2F oz v e CJO N ELO (-al) oo A ,\J - trz Q)P- N +. J F 6 \ lt', v (- tt'/ I l- r- r C) !-r-aq) (D AA- \,,, \,, a] ,)u:+-r G3 o ()()!Fr-\ b n\ Ar vw.L 6 3 .- .- ctt cr) c c'; F= o) \l- lr - (r:; !F- F oio-N SE F F !- @ 6H Xz Eil e= N ZF F (? =H N fiH O) ?lr _r-l 00 -) F 6e tr| sf H c- ct T lc) F roi rel\ ;.o e ,e .,o R tA ,A 6 F la 16,; -l '- - r- iS l-d ro -ri- - ---I -- ENGINEFUEL 6C-57 o o z TU J o v, -(r90 F J F co = og (\l v) C)z (o cr) v, v', (? lt', tt1 h e eH Fcc F F FI:. -tuo)R :- j(o(o , z z S o-c-c a ct, ct) d 9 9.-- (JCC Y.=.; E 9'='3 N =-EFF \r N .^\- LWFF t-bb 3-rt-L g E, (v) c1 z <.i i rri ''.t rF !- F = ?cc N(\l iuJ \\r N(\ L./ l- F (F. ()- Sz .;u) zC Oo) oJ an c)C L .o uJz (t) (n *t ol2 F t- \J * IF CO- =N oI r-r-eq) ? cf) (o A- -l o ()C).,r ga b L-7 = c? 3 3;\F i e= ]t-9 o) 6E F rL F 61i--nj [! l-li-F r LIJ a-l @ FF Lz t\ L., IIJ E, uJ IB l- L- l- l- oooo FF +Jtsr+)P UJ C)(J(JO (l)0)q)q) o .q .- .- .q |-|-(-L IIJ E f rri co -- co cn (o N ITJ (|)(9 = $ l- .g trjr^ ttE =: E 21J \J l-l LO '=I-- ,t 6r F : c 6 o) orO:l= FOIJ-LL oi (o tF- Gl C') sf F r--ll 6C-58ENGINE FUEL c-l z LU -J \J a rrr O11 v tlt (\.ooo = - r- U) (JZ (o z zE ct v) 1t', O O$' I.J.J -F ?33 F E EE ;cc F z zn tvG'(u o-c-c c0 e e.E or cl) -q -'r'=L/CC b;'; ", E6FF- r-otrtr l_bL G,tbt- F KEE E v F 5. ;E 8E33-)bt- o -). 0) r- t- O ?i to t; (Jz co$tf)(o t-FIFF- .<-}.<' =fi UF .;C) 56 Fo) FF\ It 92 (F IF i I F c/) o(o Cl) r o - l-J L = = CD cc tLl-- tr o) F oCE F- o)OtF-N -= lFr Fur @ >F-l -cn z ulil F= N vvV\J FF !--)- F- -A ,\ vvvv ,\ ar vvg gH fuJ FE -l-l cr) Lolcr\€ :) 1 F cn IIJ \t = LE F = .h; w O- l-F ct Gr= = o : D ro '= l- \4 l- = E s6 oOf,= il I- FOt.t-LL 'O rrTrl CO' 'O)t (0 'F- N CD sf F = lr l':J F G-N NN ii _qi ENGINEFUEL 6C-59 c c z uJ J o a IE 90 F J F = og c\ (t) C)z ca E6 6E (Y) F F Ftr , z z! ; g g-- g .G-.-, r € E -r sf F (\l CN 5 iE J c? O z Lo t; c\I c"is.lit = !-FF f7 b \\\c\ (\ truJ C\S oF FF 9,2 a 4. r- uJv ; cno (\l N F UJA IY tJ =z lt rF l- F I O (o UJJ o L g t ct) I lt O) I i= ct F= F O)OFN FE IFFT- @ ZFJ JZ OUJ (') l.tJ | --l-^- --- l- t- !- l- o= I | \i,, \J \r' \.' >^.-v ! P+JPP F .J OOO(J LU cJq)oro cc .q .q a !LL |- (\l I.JJ o) E ,-a l.cj F- cct -\J (o CN N (v) UJ = .g +)j U', t LJ- ^Y/ LF rv (-J- -!- \-, D 1l]) l- #, at\ -) F . c 6 q) 6ofr FOIJ-LL NcDsf, 'N' s) -q' '!o' a'a\' qr ,6.'<>- ji ft 6 6 6 c or)' : : l$l':i lq ro cr>'r\ co A 9. a q-.1 q? S rn: 6C.60ENGINE FUEL o o z LU J c U) TF *lI I .c l- Jl- o 00 = c9 (\l 5:: (/) O (o (Y) c) .J1 V) li: o cP A?n t4J F F F'rr -)vw a-L o \v \v \v tr F (- !=\r =3 I \./ - - cc Y'ch ,Q ct cr) \JCC V t-! L tr CD E 9 3 3 I ,F- F l- -C) v z .; o (n € cff^ L.9 (l){-t Z ,. '-rt, H (0 Y o ilJ I C)(o 56;5Eb:i = A o .gl .q), rb =L 5c -9 .l lL F- o'3=: r- = E F z UJ IIJ N !:ii F F ?:.)oouIg.g = i ELuJ|- o E ; Lridr.-d f, (o cn C\ -l (Y) UJ c9 sf = H F 3 :J A an a\ tf v lb t- (l'L cO : \D ro '= r- L4 F E E V, E (l,O=l FOLLLL o- tF-NC?S F F (\l l- 'F- C\ C\l $r 3J N; ENGINEFUEL 6C.6 1 4.2 TROUBLEDIAGNOSIS 2. Make sure the ignition and starting systems are in The LE-2 Fuel InjectionSystem can be checkedwith the good order following.lf any abnormalityis found in any cornponent, 3. The LE-2 system accurately meters the inlet air flow refer to the testing proceduresin the 'Circuit Testing so any air leak can cause an improper air-fuel ratio, Procedure'or 'ServiceOperations' in this Supplernent. resulting in taulty engrne operation. Beforeattempting any test, check the followingitems. NOTE: when connecting or disconnecting harness con- 1. Check all wiring hamess connections to all com- nections, ensure that the ignition switch is 'OFF' and the ponents, particularlythe 25 pin connector on the negative battery terminal is drsconnected. Failure to do control unil, the air flow rneterconnector and coolant so will damage the control unit. temperaturesensor connector. EngineCondition PossibleCause Engine Faulty ignition sYStem, Disconnecth igh tensiori spark and checkfor spark, Faulty fuel pump operation. Checkelectrical connections. Renicvestarter motor solenoidw'it? zi- I :*'n igr'',itrol to "START," pump actionshou c oeneard. Cneckfuel cr3ssureand volume purnpec lmproper ignition signalinput. Checkignit o1rsignal input. Checkthe ope:at,onof relay. Probremin the following circuits: Checkeach c ircu r t cooiant tem peraturesensor. Air flow sensor. Fuel injecto rs. Control un it. No fuel - tank empty. Enginef looded, open coolant temperaturesensor circuit Checkcircu it and connectons. sparkplugs wet. E'Fl system. Replacef auity sensorif proveddefectiv e Goesfully rich. Enginestarts, then Faulty ignition signal:nput. Check ignition s gna l rnput. stalls Fuel pump not funct oningcorrectly. Check electrica, connections at fuel purnp Check operation cf cor-trol relay. Check fuel pump p'essure and volume purnped. Faulty coolant temperature or air Check circuits and ccrnponent operatior^. flow sensorcircuits. Malfunctioningauxil iary air i,'alr e. Start engine (cold), pinch the hose wh ch leads 'rom the air valve to behind the throttie body. Results: It idle speed drops, perf orm c .cu it test. -') lf idle speed remains high or unstable, perf orrn th e f ollowing checks : Check for manifold vacuum ,eaks, if no problem is found, perform the following c ircu it tests : Throttle position srvitch (idle contact and full load contact). Control unit ground circuit. Air f low meter potentiometer. Air regulator and fuel pump circult. Air regulator circuit. Control u n it power in put c ircu it. In jector circu it. 6C.62ENGINE FUEL EngineCondition PossibleCause Checks Enq ine Misf ires Faulty ignitionsystem. Check ignition system. FueI blockage. Checkfuel line for blockagesin: Tank filter Fuelfilter Fuel pipes Fuel injectors Waterin f uel. Drain tank and lines. Low f uel pressure. Performfuel pressuretest. LooseHarness connectors. check all connectorsfor loosenessor corrosion, includi ng earthcircuits. lmpropercontro reia y operation. Checkcontrol relayoperation. Faulty EFlcircu : Perform circu it test. Defective injecto' varves. Check injectors operation. Malfunctionino control unit. Try anothercontrol unit. Engne lackspower Faulty ignrt o^ s,/stem. Check ignitionsystem. Malfunctionng rn throttle valvebody. Makesure throttle butterfly openingfully and not,amming. fulaifunction in air flow meter Checkair flow flap movement. Checkthat openssmoothly and fully. Fuetblockage. Checkfuel line for blockagesin: Tank filter Fuelfilter Fuel pipes Fuel injectors t Blockedo,r ter. Checkelement condition. Poor enginecondition. Checkengine compressions. Checkci'cu its in throttle positionswitch. Checkswitch operation and w ir,ng LOwf ue, pressure. Perform fuel pressuretest. Problemrn the following circuits: Checkeach circuit. Performcomponent checks Air and coolanttemperature sensors. whe re necessary. Fuel pump. Air f low meter. Throttle positionswitch contacts. lgnition coi I to control relay. Control ur' : power input circuit. Injectorc -cu t. Enginesurge Maffunction r'g air flow meter. Checkair flou; merermechanical movement. Intake air lsakage at the following cc r)tsl Usinga f inger,cneck f lap movementfor smootf' Man 'c d gaskets. operation. Cneckfor intakeair leaks. A . t crl rrreterhoses. lmp'o3e' f uel pressure. Perto.'^nruet p.essuretest. Nc 'acuum advance. Check'cr ccrect vacuumhose connections ig" lt ion C,str';butor operation. Fo-'i'r, EG R system. Check EGR operation. Problern n the following circu is: Cneckeacn circuit. Then proceedlc component Th rotiie position switch, dle contact checks. and fuil load contact. Air f lou.,meter. Control unit circuit. Air temperature sensor. Coolant temperatu'e se^s3r. Auxiliary air valve circu i lgnition coil to control re ay. Control unit power input orcuit. I n jector c ircu it. ENGINEFUEL 6C-63 Engine Cond ition PossibleCause Checks Flat spot on lmproper rgnition system. Checkignition system and vacuurrai',,ance acceleration signal. Malfunctioning air f low meter. Checkair f low metermechanical novem en: Usinga f inger,check for smooth f rapmo! e-e-: Intakeair leakageat following points. Checkfor intakeair leaks. Manifold gaskets. Air f low meter hoses. lmproper fuel pressure. Periorm fuel pressure test. lmproper EFf circuit. Per+crrn complete circuit test, then perform ccmpcnerlts cteck. E R G system. lnccrrec:,tac -rrn hose connections. Check EGR ooe'a: o- Excessivepetrol lmproper ignition timing or ignition system. Check ign rtrcr : - - i a- d 'vacuum advance signal. consumptionCO Check ignition sySi3- ':- .ct spark. reading high lmproperair cleanerf iite. Check air cleaner f rte' a-c'?: 3Je :f necessary. lmproper f uel pressure , Perform fuel pressure tes'. Problemin the f ollowing circu:ts: Checkeach circuit, then proce:c ::-3f,^ent Coolanttemperature sensor. I check. Ai r temperatu re sensor, Throttle positionswitch, idle contac: and full loadcontact. Air f low meter. Auxiliary air valve. Fuel pump circurt. In jector circu its. Control unit defective, Check operation of unit, with a known good u n it. Difficult to start Fue I systemnot holding pressu'e a iow,nc Fuei pressurestays at 250 - 20 kPafor t hour after after standing hot fuel to boil in injectors when engine e^g ^e stopped.Leaking v3rr€s in pressurereguiator siopped. r or;ue cu'lrp. Loosefuel p ce connections, Enginestalls when ldle speed too Low. returningto idle from t smallthrottle opening Fuel pump noisy fuel lovvfuel levelin Nu sction requirec f quiet 1. Under very hot Aerated due to tank -nder normal conditions combinedwith very nct f uel. ccncjitions. Wili nc: damag: pump. 2. Under norma I Filter on fuel pickup ir: ianK restrrcted. Rernove sender unit i.or-r ta ^ k and clean f ilter conditrons Rearfuel damperinoperative. Rep ace damper. j-,,e Rubbermounting cushionson c-mp Reca - pump mounting system. bracketdefective. Pump worn out. Rep ace fuel pump. 6C.64ENGINE FUEL 5. SPECIFICATIONS Air Flow SystemComponents: Air Flow Meter: Nominal air flow 500 m3 /hr Auxiliary Air Valve: Air flow 17 ! 2 m3 /hr Averagetime to shut at +20oC and 14 volts 4 minutes Nominal resistance 30 - 40 ohms Leakage 1.0 m3 /hr (maximum with slotted disc closed) Fuel Section: Fuei Pump: Flow capacity minimum 130 l/hr at 12 voltsand 303 kPa pressure Fuel Pressure: At idle 250 kPa The moment the acceleratorpedal is depressed(zero engine vacuum) 300 kPa Fuel Filter: Flow rate 1.5 l/hr Pressuredrop . . 10 kpa maximum at 120 llhr Filter area 3000 cm2 Averagepore size 8 - 10 micro metre Injector: Static f low 185 cm3/min = 3orcat 303 kpa Dynamic flow . 4.38 cm3 /1000 strokest 3% at aboveatmosphenc pressure Permissableleakage 0.015 cm3 /min at 303 kPaabove atmosphenc pressure (1 drop/min) PressureRegulator: Fuel pressure 303 kPa = 6 kPa at4}l/hr with regularorvacuum connecilon open to atmosphere. Electrical Section: Control Unil CalibrationSummary: Basecablibration...... 3.4milliseconds Warm-upenrichment factor I .2 at ZOoC After start enrichmentfactor 1.7 at OoC Cold start injection pulse 16 millisecondsar OoC Acceleratorenrichment {actor . 1.3 below 50oC Full load enrichmenrfactor . 8Yoincrease Fuel cut off on decee:arion Until 1800 rom Coolant TemperatureSensor : Temperarureoc... -l0ll -20=j -gor1 Resistancek ohms 8.26 - 10.56 2.28 - 2.72 0.290 - 0.364 Fuel Pump Contro' Re ay" Hold in voltageat te'rninalNo. 15 . . . 5.5 volts minrrnur,. Hold in ignition pu sesai terminalNo.l . 150 rpm min mum Throttle PositionSwitch : ldle contactopening angre l.0o from dle end oosition ldle contactclosing angle 0.2o from dle end position Full loadcontact closing angle 40"!2 f rom :d e end oosition ldle speedat normal operatingtemperarure - run-inengine g50 t 50 rom ldle mixture at normalaperating temperature - run-inengine .5 - 1.b% CO ENGINEFUEL 6C.65 6. TORQUEWRENCH SPECIFICATIONS Nm Inlet ManifoldMounting Nuts 41-48 ExhaustExtractor Mounting Boltsand Nuts 41-48 EGR MountingBolts 20-25 EG R FeedPipe to In let Manifo ld BoI ts 20-25 EGR FeedPipe to Manifold Nuts , 27 -36 Inlet Manifold BraceBolt 20 -25 Inlet Manifold BraceNut to CylinderHead Stud . 20-25 Fuel Rail MountingBolts 2A-27 PressureRegu lator Mounting Nut 25-30 PressureRegu laio. Fuel Line Gland Nuts 25-30 Fuel Return Line Bracketto RockerCover Bolt 8 - 10.6 Fuel Return Line Bracketto SidePlate Bolt 4 - 10 A;r CleanerHousing Mounting Nuts 8 - 10.6 A r Duct to Support BracketBolt 20-27 Throttle Body Mount ng Nuts 8 - 10.6 a4 Throttle CableLock Nuts , z-.+ Fuel Pump Support Bracket Nuts 15-25 Fuel Pump Insulators 15 - 25 Rear Fuel ClamperMounting Nut 15-25 Mounting Platef or Support BracketBolts 15-25 Fuel Filter Support Bracket Nuts . 3-4 Throttle ValveSwitch Mounting Screws 1 - 1.5 F-.rel Pipe Hose Clamps 1 Air Flow MeterMounting Bolts 8-11 Ai r Flow MeterHarness Retainer Bolt 20-27 6C-66ENGINE FUEL 7. SPECIAL TOOLS ENGINEFUEL 6C.67 CARBURETTOR(3.3 EST) INDEX Ref. Subject Page Ref. Subject Page 1. GENERALDESCRIPTION ...... r...... -.. 6C€7 3.1 CARBURETTOR ...... o..6C-70 1.1 CARBURETTOR...... -...... 6C-67 RemOV€...... o...... 6C'70 2. MINORSERVICE OPERATIONS...... 6C€8 Disassemb1y...... r...... 6C-70 2.1 CARBURETTORADJUSTMENTS 'ON ChgCkS ...... '....o.....6C-72 VEH I C LEt ...... r.....r....6C€8 ReaSSgmbly...... 6C-73 ChOkg OperatiOn ..'...t...... -....6C€8 AdjustmgJlt...... o...... 6C-75 ldlg Speed Adjustment...... 6C€8 RginStall ...-...... !.r...... 6C'79 Fast ldlg Adjustment..r...... 6C€8 4. DIAGNOSIS ...... r.,...... r...... r.....r...... r.6C€0 2.2 THROTTLE POSITION SWITCH 5. SPECIFICATIONS ...... ,...... o...r6C-85 ADJ USTM ENT ...... t...... t....r6C-68 6. TOROUE WRENCH SPECIFICATIONS...... 6C.86 MAJOR SERVICEOPERAT1ONS...... 6C-70 7. SPECIAL TOOLS ...... -...... -...... 6C'86 1. GENERALDESCRIPTION The fuel system emPloyedon carburettored3.3 litre VK for revisions tc the Varajet ll carburettor as noted rn tftis Seriesengines is similarto VH 3.3 litre models,except Section. 1.1 CARBURETTOR The carburettor used on VK is a Varalet ll. Differences betyveen VH and VK models include, new float bowl design, deletion of the spark advance signal port and a high mass choke coil which holds the choke valve open foi longer periods after the vehicle is switched off. There is also the addition of a delay valve in the choke vacuum break hose, to aid in quicker starting and a revised secondary air valve restraint mechanism (Refer No. 60, Fig. 6C-121). A throttle position switch has been added to the carburettor and is mounted on the air horn, refer Fig. 6C-117 . The accelerator pump lever has inCorporated a lever which actuates the throttle position switch. For throttle position switch operation refer to Section 6D, lgnition System, of this Supplement. The internal calibration has been changed to suit the characteristics o{ the 3.3 litre EST engine. Calibration details are listed in the Specifications at the end of this Section. WARNING: TO AVOID THE POSSIBILITY OF ALTE' RING THE CERTIFIED EMISSION CONTROL SETTING OF THE CARBURETTOR, NO MAJOR SERVICE OPER. ATIONS MAY BE CARRIED OUT ON IT DURING THE EARLY LIFE OF THE VEHICLE EXCEPT FOR RE. MOVAL AND INSTALLATION. THE EXTENT OF THE WORK WHICH MAY BE CARRI. WHICH HAVE COVERED LESS ED OUT ON VEHICLES '\ POSTTTONSWITCH THAN 8O,OOOKM IS SET OUT IN THE 'MINOR SER. VICE OPERATIONS.' IF THIS IS INSUFFICIENT,THE CARBURETTOR MUST BE REPLACED. Flgure 6C-117 6C.68 ENGINEFUEL 2. MINORSERVICE OPERATIONS 2.1 CARBURETTORADJUSTMENTS'ON VEHICLE' CHOKEOPERATION NOTE: a. Ensure cover index is set to specification, refer Fig. 6C-118 and specificationsat the end of this Section. b. Engine temperature must be within 5 oC of arnbient temperature. 1. Remove air cleaner and open and close throttle to set choke. 2. Switch ignition on. Do not start engine. 3. Depress and release the choke butterfly to enable the position of the control spring to be determined. The choke should be fully open withrn two to five minutes. lf the choke does not perform to specification,check for binding or stuck choke valve or linkage. lf necessary, replace choke cover and bi-metallic coil assembly. Flgure 6C-118 IDLE SPEED ADJUSTMENT 1. Ensurespark plugs are correctlygapped. 2. Ensure engine is at normal operatingtemperature. (Drive 10 kms or idle engine for 15 minutes or more.) 3. Ensurechoke is fullyopen. NoTE: The throttleposition switch must be closed. 4. Ensurethrottle cable is adjustedcorrectly. 5. Ensuretransmission is in Neutralor Park. 6. Ensureair conditioningis OFF. 7. Adjust mixture by-pass adjusting'screw (shown in Fig. 6C-119) to set idleto specification. WARNING: To MAINTAIN DESIGNED EMtsstoN LEVELS, DO NOT ADJUST IDLE STOP SCREW OR Flgure 6G119 IDLEMIXTURE SCREW. FAST IDLE ADJUSTMENT 1. r LOWEST STEP Engineat operatingtemperature. FAST IDLE 2- Removeair cleaner"plug vacuumhose to air preheat CAM sensor. 3. Startengine. 4. Throttleposition switch must be closed. NOTE: The throttleposition switch may be simulatedin the closed positronby removing both electrical con- I DLE ADJUST- ne'ctorsfrom the switch and connectingthem together SCREW with a bridgewire. 5- with fast idle screw on lowest step of fast rdle cam as shownin Fig.6c-120, engine speed should be to specification.Adgust fast idrescrew if necessary. Flgure 6C-120 2.2 THROTTLEPOSITION SWITCH ADJUSTMENJ' Fol adjustrnent instructions,refer to service operation 2.7 in section 6D, lgnitionsystem of this Supplement. ENGINEFUEL 6C-69 a F-to 66 -ufr I pl 471 | v * Vj /14 -t-\ d-':li w6 43 -'/ tfu,t- 35 l -,>;) t. .t 36 yvenA ff_r, REFERNEXT PAGE FOR LEGEND Figure 6C-121 6C.70ENGINE FUEL L EG EN D FOR FIGU R E 6C-121 1. Retainer to vacuum brake screw 24. Discharge purnp retainer 46. Float bowl 2. Baf f le flap shaft 25. Carburettor f uel inlet f ilter 47 . Metering primary jet 3. Needle retainer 2nd stage 26. Carburettor f uel f ilte. f lare nut 48 . Power piston sp ring 4. Air horn vent retainer screen and 27. Discharge pump spring 49. Power piston assembly 5. Baffle flap 28. pump Discharge batl 50. Metering primary rod and spring asm. 6. Baffle flap screw 29. Mixture by-pass screw and seal asm. 51 . Choke link cam end clip 7. Choke valve 30. Mixture by-pass seal 52. Choke link cam end bush 8. Choke valve screw 53. Fast idle cam to choke link 9. Air horn float to bowl screw 32. Float bcwl to throttle body gasket 54. Choke shaft 10. ieseling Air horn to float bowt screw 33. Ant r d solenoid 55, Choke lever 1 1. Air horn assembly 34. Pump iink 56. Choke link clip 12. Pump lever and screw assernbly 35. ldre needle screw and seal assembly 57. Choke link bush 13. Air horn to f ioa: gasket bowi 36. ld,s ne€dle seal 58. Coii contact sleeve 14. Float prvot inserl 37 . Throttle body to f loat bowt screw 59. Choke lever bush 15. Pump pisrcn assembly 38. Secondary drive spring 60. Secondary shaft spring 16. Float reta,7'1grpro 39. Primary throttle lever 61. Vacuurn break hose 17. Float anc rever assembly 40. Fast idle screw and sprng assembly 62. Choke cover and thermostat retainer 18. Floa: ieve- to needle clip 41 Throttle . body 63. Vacuum break housing and stem asm. 19. Floar need,e vaive and seat assembly 42. Basic idle screw and spnng assembly 64. Cover and thermostat assembry 20. Fioat needre valve seat seal 43. Fast idle cam retainer 65. Vacuum break delay valve 21 . Pump inlet ball 44. Fast idle cam assembiv 66. Th rottle pos rrion switch 22. Piston p cu 45. Fast idle cam oivot 67. Bracket 23. Piston return spring 3. MAJORSERVICE OPERATIONS 3.1 CARBURETTOR REMOVE 1. Disconnectbattery earth cable. 2. Removewing nut holdingair cleanerand removeair cleaner. 3. Disconnectelectrical leads, fuel line and vacuum hosesfrom carburettor. 4. Remove throttle linkage and cable assembly from bracket. 5. Remove carburetlor to mount nuts and remove carburettor. DISASSEMBLY 1. Remove fuel line flare nut and filter. Remove anti-dieselingsolenoid. 2. Remove vacuum hose from throttle body and rernove the three screws from choke retaining ring. Remove choke cover and vacuum break dssembly (Fig. 6C-1zz). Figure 6C-122 v ---- ENGINEFUEL 6C.71 3. Press off securingclip and withdrawchoke valve link from fast idle cam slot (Fig. 6C-123). 4. Rernovepivot screw from acceleratorpump actuatrng lever. 5. Unscrew two short and four long retaining screws and remove air horn and throttle position switch assembly.Gasket remains on float bowl. NOTE: The acceleratorpump is spring loaded. NOTE: Do not rest air horn on protudingtubes. Figure 6C-1 23 6. Remove acceleratorpump assembly(Fig. 6C-124). 7. Removegasket. Figure 6C-124 8. Remove power piston assemblyusing a patr of side cuttersand screwdriveras a fulcrum(Fig. 6C-125\ NOTE: Prefcrredmethod is to 'flick' the piston down and allow the springto hammer againstthe plastic retaining sleeve. This is repeated untit the assembly can be removed. CAUTIOAT:DO NOr LEVER UF CN HORTZONTALIANG ABOVE POWER P'SION ASSEMBLY. GRIP POWER P/S7'ON ACHOSS INDENIAT/ONS /N BODY, ABOVE PLAST/C/NSEFI. Figure 6C-125 9. Remove float pivot insert and float assembly tFig. 6C-126) 10. Using a suitablescrewdriver, remove seat and seal. ai|r Figu re 6C-1 26 6C.72ENGINE FUEL 11. Using a suitable screwdriver, remove main iet (F.g. 6G1 27). Figure 6C-127 12. Remove four screws accessiblefrom undersideof carburettorand separatethrottfe body assemblyfrom float bowl assembly(Fig. 6C-128). Figure 5C- 128 CHECKS Clean all parts in suitable cleaning fluid. Blow dry with compressed au. Jets and ports should be blown dry in normaldirection of flow. All mating surfaces should be cleaned and checked to ensurethere are no imperfections. With float bowl upright, fill pump area with fuel. Check that fuel level does not drop. lf fuel is escaping, blow check ball passages out with compressedair. Check main meteringrod. Ensure rod is conect unit, see specifications.Replace if necessary. Check throttle body finkage for freedom of movement. Ensure there is no binding of throttle valves (Fig.6C-12s). Figure 6C-129 ENGINEFUEL 6C-73 REASSEMBLY 1. Placegasket on invertedfloat bowl assembly.Ensure gasket is correctly located. Place throttle body assemblyover gasket and retain with four screws. Re-checklinkage operation (Fig. 6C-130). Figure 6C-130 2. Using a suitable screwdriver,reinstall needle valve seat and sealingring. 3. Using suitable screwdriver, reinstall main iet (Fig.6C-131). Figure 6C-1 31 4. Reinstall power piston and primary metenng rod assembly. Remember spring under power Piston (Fig.6C-132). Figure 6C-132 5. Hook float needle valve on float arm, Reinstallfloat and needlevalve assembly (Fig. 6G133). Figure 6C-133 6C.74ENGINE FUEL 6. Hold needlevalve actuatingarm as shown and push down until valve rests on seat. Distancefrom top of float to top face of float bowl should be to specification(Fig. 6C-134). Figure 6C- 134 Adjustif necessaryby bendingarm (Fig. 6G13S). 7. Reinstallfloat pivot insert.Reinstall gasket in correct orientation. Figure 6C- 135 8. Reinstallaccelerator pump assembly (Fig. 6C-136). FiEure6C- 136 9. Reinstall air horn assembly ensuring accelerator pump push rod passes throughcorrect hole in air horn and gasketis correcilyseated (Fig. 6C-197). 10. Reinstallaccelerator pump actuatinglinkage on lever and reinstall pivot screw. Reinstallthrottle position switchto air horn. Figure 6C- 137 ENGINEFUEL 6C.75 11. Reinstallchoke valve link into fast idle cam slot. Ensure plastic sleeve is in place. Replace securing clip (Fig.6C-138). Figure 6C-138 12. Reinstallvacuum break assemblyand choke cover. Ensurechoke spring correctlyengages choke actua- ting lever. Screw retainingring in place, ensuring arow on choke cover pointsto specifiedindex mark (Fig.6C-13e). Reinstallvacuum hose. 13. Reinstallfilter, fuel inlet flare nut and antidieseling solenoid. Figure 6C-139 ADJUSTMENT Wide Open Throttle 1. Hold fast idle cam down and open throttlecomplete- ly - ensure2nd stage valve is open as well. 2. Measure clearance between tang on intermediate lever and spring end. Bend tang on intermediate (Fig. 6C-140).Check Specifications lever to adjust YJ^-C 900 sectionfor measurement. SECOIJDARY PRIMARY \ I L tr-_-L PRIMARY CVERDRIVE Figure 6C-140 6C.76ENGINE FUEL Secondary Throttle Opening 1. Open prirnary valve, ensuring secondary valve re- mainsclosed (lock engaged). 2. Measure clearance between tang on secondary throttle lever and intermediatelever. Bend tang on secondarythrottle lever to adjust (Fig. 6C-141).See specificationsfor measurement. CLOSING FORCE BEND TANG TO ADJUST SECOND THROTTLE CLOSED Figure6C-141 Secondary Closing Setting 1. ldle stop lever against slow idle stop screw (Fig.6C-142). Movement of secondary throttle valve should be to specification.Bend tang on intermediatelever to adjust. IDLE STOP LEVER AGAINST BASIC IDLE SCREW FULL CLOSED POSITIONr OPENIN G FORCE BEND TANG TC ADJUST_ Figure 6C-142 VacuumBreak Settings 1. ChokeSetting. a. Set the automatic choke to closed. b. Remove vacuum hose to vacuum break unil (Fig. 6C-143). Use hand vacuum pump J23937- 01 or equivalant to apply vacuum to vacuum break unit to fullv retract stem. Figure 6C- 143 -\ ENGINEFUEL 6C.77 Distance between choke valve and carburettor wall should be to specification(Fig. 6C-144). Adjustby turningscrew 'B' (Fig. 6C-144). NOTE: This adjustmentshould be perforrnedin conjunc- tion with 'Air Valve Setting' below. (Remember that interferencebetween air vafve lever and vacuum break stem will affect travel of vacuum break stem.) Lock stop screw with paint after adjustment. .\,F Figure 6C-144 2. Air Valve Setting a. Use J23987-01or equivalentto applyvacuum to breakunit. VACUUT\4BREAK STEM FULL IN _ b. Clearancebetween air valve lever and vacuum WITH VACUUM APPLIED break stem should be to specification (Fig.6C-145). c. Bend tang to adjust. AIR VALVE FULL CLOSED Figu;'e 6C-1 45 6C-78ENGINE FUEL Second Step Setting With choke coil cold (ambienttemperature), ensure fast idle screw is seated on second highestor 2nd step of cam (Fag.6C-146). CHOKE VALVE With light pressure applied on choke valve, clearance between valve and carburettor throat should be to specification. OPENINGFORCE oN--1 cHoKE VALVE \ r- cLostNG FoRcE oN \ cHOKEcoIL LEVER -- TOP OR FIRSTJ Figure 6C-146 Bend choke link to adjust (bendingincreases clearance, straighteningreduces clearance). See Fig. 6C-.,147. Figure 6C-1 47 Wide Open Kick Setting 1. Choke valve held closed. 2. Primarythrottle lever held fully open. ,s3--.,_J 3. Push choke valve against kick lever to remove backlash. Dimension A, choke valve to carburettor throat clearance, should be to specification(Frg. 6C-148). Bend lever on fast idle cam to adjust. NOTE: Secondary throttle lockout lever must be fully engaged in tang on interrnediate lever. CLOSING FORCE ON CHOKE COIL LEVER. OPENING FORCE ON CHOKE LEVER. PRIMARY THROTTLE WIDE OPEN. Figure 6C-148 -\ ENGINEFUEL 6C.79 Lockout Lever Rotation Secondary CHOKE FULL HOTT 1. Chokecontrol lever held fully open (use elasticband to overcomeautomatic choke closingforce.) Clearancebetween secondary lockout lever and tang on intermediate lever should be to specification (Fig.6C-14e). lf dimension is inconect, check 'Secondary Lockout Setting'below. Figure 6C-1 49 Setting Secondary Lockout rv-r ,rh. J1n PL- leverclosed. /v4 1. Chokecontrol - 2. Primarythrottle lever wide open' 3. secondary lockout lever fully engaged. secondary throttle valve should have clearance as specified (Fig.6C-1s0). Bend tang on secondaryvalve leverto adiust. I SECONDARY THROTTLE VALVE SEC. LOCK OUT ENGAGED FULL CLOSED POSITION ,A' PRIMARY THROTTLE ROTATED TO WIDE OPEN Figure 6C-150 Accelerator PumP 1. Throttle closed, carburettor set 10r idle, choke held off 2. slowly depress accelerator pump plunger until sec- ondary spring resistance is felt. The distance travel- led from reit position should be to specifications (Fig. 6G151) 3. Bend pump arm to adiust (at B). 4. Readjust throttle position switch if pump-arm is bent' Refei to Section 6D of this Supplement for details' REINSTALL 1. Clean all mating surfaces. Take care that material does not fall into manifold. 2. Using new gasket, install carburettor.Torque nuts to specification. 3. Reinstallfuel line, electricalleads and vacuum hoses' 4. Reinstallair cleaner.Torque nut to specification' Figure 6C'151 5. Install air pre-heat, engine ventilation and vacuum hoses on air cleaner. 6C-80ENGINE FUEL 4. DIAGNOSIS The following DiagnosisCharts rnust not be taken as approval to carry out major operationson vehicles with lessthan 80,000kms. ENGINE CRANKS _ NO START NO START COLD NO START HOT CORRECT STARTING USE PROPER CORRECT STARTI NG EROCEDUREUSED i STARTING PROCEDURE I PROCEDUREUSED LI STILL NO START STILL NO START CHECK VACUU[1 CHECK ALL VACUUM HOSESAND ELEC;RICAL HOSESAND ELECTRICAL LEADS LEADS CHECK ITEMS 1 UNDER ? ENGrf\ E CH OKE VALVE 'l No FUEL & 2 i-/ FLOODE D NOT CLOSING : IN CARBURETTOR NO START COLD CHOKE VALVE CHECK AUTOMATIC NO FUEL IN TANK NOT UN TOADING CHOKE COIL ADJUSTME T\ T CHECK THROTTLE FUEL LINES OR F ILTERS PLUGGED LINKAGE FOR CHECK FOF BINDI NG FU LL TBAVE L OR STUCK CHOKE (W.C. THROTTLE) VALVE OR Li\KAGE DEFECTIVE FUEL PUMP. PRESSURETEST CHECK F LCAT CHECK A\D ADJUST NEEDLE AND SEAT VACUUM BREAK, FOR LEAKAGE = AST I DLE, CHECK FLOAT NEEDLE AND UNLOADER FOR STICKING IN CHECK F LOAT * SEAT OR tsINDING LEV EL. F LOAT FLOAT FOR DAMAGE i * DO NOT ADJUST FLOAT L='",EL =XCEPT AFTER MAJOR OV ERHAi.Jt- r-r.t' ENGINEFUEL 6C.8 1 ENGINE STALLS STALLS COLD STALLS HOT USE PROPER USE PROPER STARTING PROCEDURE STARTING PROCEDURE CHECK ALL VACUUM CHECK ALL VACUUM HOSES& ELECTRICAL LEADS HOSES& ELECTRICAL LEADS CHECK I DLE SPEEDT CHECK IDLE I CHOKE COIL CHOKE COIL FUEL LEVEL FUEL LEVEL INCORRECTLY ADJUSTED HIGH IN * CK ADJUSTED CORR ECTLY F LOAT BOWL STA L LING CONTINU ES SECONDARY FUEL PUMP THROTTLE PRESSUREH IGH CHECK CHOKE STICKING TEST FUEL PUN1P VALVE AND OPEN LIN KAGE FOR BINDING OR STICKING F LOAT NEEDLE GASKETSNOT SEAT LEAKING SEALING IF UNABLE TO CAUSING ADJI.JST,CH ECK AIR OR FUEL IDLE SYSTEM FOR LEAKS DIRT, AIR LEAKS, FLCAT LEAKING PLUGGED PASSAGES CR BINDING IDLE PASSAGES CARBURETTOR FLOODING PLUGGED,ID LE OR HIGH FLOAT LEVEL AIR BLEEDS PLUGGE D I TEST FUE L i CHECK FOR DIRTY PUMP I on LEAKTNG FLoAT I rvEEDLE DO NOT ADJUST FLOAT LEVEL EXCEPT AFTER MAJOR OVERHAUL REFER SECTION 2 FOR CORRECT ADJUSTMENT PROCEDURE. .fr, --'..''"-ll' 6C-82ENGINE FUEL POOR HIGH SPEEDPERFORMANCE ENGINE RUNS ROUGH, SURGES CHECK FOR FULL THROTTLE CHECK ALL VACUUM HOSES OPENING AT CARBURETTOR AND ELECTRICAL LEADS ADJUST THROTTLE LI NKAGE AS N ECESSARY CHECK FUEL PUMP PRESSURE AIR VALVE BINDING, STICK I NG FUEL FILTERS OR SCREENS PLUGGED OR DIRTY AIR VALVE OR SECONDAR Y VALVE NOT UN LOCKING MAIN METERING JET PLUGGED, LOOSE OR WRONG PART PRIMARY OR SECONDARY METERING ROD BENT PRIMARY METERING OR JETS BLOCKED ROD BENT, ALTERED OR INCORRECT PART POWERPISTON STUCK OR BINDING CHECK FOR DISTORTED SPRING POWERPISTON STICK!NG DIRTY, SPRING MISSING, OR INCORRECT PART F LOAT LEVEL * F LOAT STICKING, INCORRECT MISALIGNED FLOAT ADJUSTMENT INCORRECT * GASKETS NOT SEALI NG MAY BE HARD OR BRITTLE CHECK FOR LOOSESCREWS F LOAT BENT OR MISALIGNED ADJUST IDLE SPEE D I TO SPECIF ICATIONS CHECK IDLE SYSTEM FOR DIRTY OR PLUGGED PASSAGES GASKETS NOT SEALI NG. MAY BE HARD OR BRITTLE, CHECK FOR LOOSE SCREWS SECONDARY THROTTLE VALVE STICKING OPEN OR MISALIGNED DO NOT ADJUST FLOAT LEVEL EXCEPT AFTER MAJOR OVERHAUL REFER SECTION 2 FOR CORRECT ADJUSTMENT PROCEDURE -.. ENGINEFUEL 6C.83 POORFUEL ECONOMY RUN CONSUMPTIONTEST CHECK DRIVER HABITS IF CONSUMPTIONIS POOR, CHECK THE FOLLOWING CHECK CHOKE VALVE AND LINKAGE FOR BINDING OR STICKING CHECK POWERPISTON CHECK POWERPISTON FOR STICKING CHECK POWER PISTON SPRING FOR DISTORTION OR BEING BENT OR LOOSE VACUUM PASSAGESFOR LEAKS OR BEING PLUGGED CHECK METERING RODS CHECK MAIN METERING JET FOR BEING FOR BEING PLUGGED, LOOSE, tvlAKE SURE GASKETS PART BENT OR WRONG OR INCORRECTPART SEAL PRCPERLY ON ALL VACUUM PASSAGES CARBURETTOR FLOODING. SEE BELOW CHECK FLOAT NEEDLE SEAT FOR FLOAT LEAKING FROM DIRT, WEAR, BENT, STICKING MISALI DAMAGE, LOOSENESS GN ED, MISADJUSTED CHECK AND ADJUST . IDLE SPEED GASKETS NOT SEALING OR CASTINGSLEAKING PUMP DISCHARGE BALL NOT SEATING, CHECK FOR DIRT, DEFECTIVE SEAT OR DISCHARGESPRING CARBURETTORFLOODING R UN F UEL PUMPTEST CHECK PRESSURE CHECK FLOAT NEEDLE AND SEAT FOR DIRT, WEAR, DAMAG: OR LOOSEPARTS. CLEAN FUEL SCqEENSAND FILTERS CHECK F LOAT I-E V EL, CHECK FOR D ISTORTED FLOAT ARN|SOR IMPROPERALIGNMENT CHECK FOR FLOAT BOWL LEAKS (FILL BOWL WITH FUEL ON BENCHAND OBSERVE FOR LEAKS) CHECK SEAL ON ALL BOWL GASKETS DO NOT'ADJUST FLOAT LEVEL EXCEPT REFER SECTION 2 FOR CORRECT AFTER MAJOR OVERHAU L ADJUSTMENT PROCEDURE. 6C-84ENGINE FUEL ENGINE HESITATESON ACCELERATION AIR VALVE EINDING ACCELERATOR PUMPCIRCUIT DIRTY, OA STICKING PLUGGED OR INOPERATIVE _ BALL NOT SEATING _ PLUNGER NOT SEALING A I A '/ A LV E OR SECONDARY q T:r CTT L E VA LVE LOCKOUT LOW FUEL LEVEL IN I,JOTOPERATING F LOAT BOWL SECON DARY THROTTL E CHECK FUE L PUMP VALVE STICKING OPEN PRESSUR E SLIGHTLY - CHECK FO R DAMAG E ENGINE SLUGGISH ON ACCELERATION ENGINE SLUGGISH ON ENGINE SLUGGISH ON ACCELERATION ACCELERATION DURING WARM OR COLD COLD DRIVE AWAY ADJUST AUTOMATIC AIR VALVE BINDING i FUEL FILTER IN CHOKE COIL OR STICKING CARBURETTOF DIRTY OR PLUGGED. FLOAT STICKING OR NOT PROPERLY ADJUSTED * ADJUST VACU UM BREA K SECON DARY NOZZ LE PLUGGED OR DIRTY: SECONDARY METERING ROD MTSALIGNED, POIVERPISTON STUCK, STICKING, DIRTY BENT, CHECK AIR VALVE OR OR BINDING, LOOSE SECONDARY THROT-I-LE SECONDARY METERIN G VALVE LOCKOUT JET PLUGGED \lAIN METERING JET DIRTY, PLUGGEDOR INCORRECT PART. MAIN METERING ROD DIRTY, BENT, STICKING OR INCORRECT PART THROTTLE VALVE STICKING IDLE SPEED T NOT PROPERLY ADJUSTE D * DO NOT ADJUST FLOAT LEVEL EXCEPT AFTER MAJOR OVERHAUL. REFER SECTION 2 FOR CORRECT ADJUSTMENT PROCEDURE ENGINEFUEL 6C.85 5. SPECIFICATIONS CARBURETTOR - 2 BarrelVara jet ll Calibrationltem (Automaticand ManualTransmission ) P.O.E. Bleed 1.42 mm ldle Tube 0.65 mm P.O. E. Nozzle 1.85 mm M.B.P. Restriction 1.60 mm P.O.E.Tube . 0.65 mm Top M.B.P.Inlet . . 5.50 mm SecondaryMetering Jet 3.20 mm M.B.P.Down Channelin Float Bowi 7.00 mm SecondaryMetering Rod Full dia. 2.975 rnm Primary MeteringRod 1 18 mm SecondaryMetering Rod Tip dia. . 1.970mm Primary MeteringJet . . 1.83 mm Secondary Ai r Bleed i .00 mm ldie Needle Orifice 2.20 mm Primary Nozzle Relation 3.50 mm ldle Port Width 0.70 mm Main Well Boost Bleed. . 1,00 mm ldte Por: Length 3.00 mm Auxiliary Well Bleed 1.00 mm NOTE: P.O. E. Pull Over Enrichrnent M.B.P. l/ xiure B'7-Pass FUEL PUMP: Pressure Test 22 - 26 kPa @ 1000 'crn A DJUSTMENTSPECI FICATI ONS (AUTOMATI C & MANUAL TRANSMISSIONS) FIG. I REF. ITEM sPEc. I N.A. LIQUID FUEL LEVE L (Fuel levelto f loat bowl top - no gasket) 17.O mm 6C-134 DRY FLOAT LEVEL SETTING (Float top to fuel bowl top - no gasket) 8.0 mm 6C_140 i WIDE OPEN TH ROTTLE - PRIMARY 90 Deg. 6C_140 I WIDE OPEN THROTTLE - SECONDARY 90 Deg. 6C-140 WIDE OPEN THROTTLE - PRIMARY OVERDRIVE 'tA"- 0.5mm ' tt _ 6C_ 141 SECONDARY TH ROTTLE OPENING IN ITIAL Att 0.45 mm 6C-142 SECONDARY CLOSING SETTING tt _ 0.60mm ^t, 6C_144 CHOKE SETTING tt _ 4.2mm ^tt 6C-145 AIR VALVE SETTING A"= 0.3mm 6C-146 I SECOND STEPSETTING Att = 3.70 mm 6C_148 I WIDEOPEN KICK SETTING A"= 10.0mm 6C-149 I SECONDARYLOCKOUT LEVER ROTATION A"= 2.0 mrn 6C_150 I SECONDARYLOCKOUTSETTING A"= 0.4 mm I 6C_151 RCCELERATOR PUMPSETTING At'= 8.0 mrn N A. PUMPCAPACITY FOR 1OSLOW STROKES 14.5 cc N A. CHOKE COVER INDEXING 1 N.L N A. AIR VALVE OPENING 84 Deg. N A. I cHoK E oPENTNGTrME AT 22oc 2 - 3 mins I ENGINE IDLE SPEED (fn Neutral- ManualTransmission , Park - Auto Transmission Air Conditioning" OFF" , EngineWarm ) 850 t 25 rpm ENGINE FAST IDLE SPEED L;west stepof fast idie cam 1,150 ! 25 rpm I 6C.86ENGINE FUEL 6. TORQUEWRENCH SPECIFICATIONS Nm Carburettorto Manifold Stud Nuts 14 - 16 * Air CleanerStud. . 10 Throttle PositionSwitch to Mounting Screws 0.5 - 0.7 Throttle PositionSwitch Mountingto Air Horn Screws 3.b - 4.s Throttle LinkageBracket to Manifold Bolts . . 12 - 16 Accelerator Cable Lock Nuts . 3 - 4 * Usethread locking sealantsuch as Loctite 675. 7. SPECIALTOOLS HAND VACUUM PUMP J23987-01 (or eguivalent) ENGINEFUEL 6C-87 5.0 LITREENGINE FUEL SYSTEM INDEX Ref. Subiect Page I Ref. Subject Page 1. GENERAL DESCRlPTlON...... !...... '..6C-87 1 2.3 FUELFLOW TEST....r...r...... o.....,...... 6C€8 2. SERVICE OPERATIONS ...... -.r...... "6C€8 2.4 PUMPPRESSURE TEST...... '...... o...... -.'.. 6C-89 2.1 FUEL PUi|P...... t..t...... """'i"'6C€8 2.5 coNTRoL RELAY OPERATION...... o-.. 6C-89 RemOV€...... -...... '!"t"t""""-tt"'tt"""t""' 6C-88 Battery Supply Voltage ...... ,.o...o...6C€9 R glnSta ll ...... r...... ts.o.- 6C€8 lgnltlon Supply Voltage ...... r.....o..o...6C-89 6C-89 2.2 CONTROL RELAY rr...r.....-.....-...... o..d..ts.....6C€8 Control Relay Output ...... r-...... R gmOV€...... r.....r...... -...... 6C€8 r3. SP EC I Fl CATIONS ....r.r...r...... !...... r..6...... 6C'90 I R glnStall ...... r.!rr..r.....-...... 6C€8 1. GENERALDESCRIPTION All 5.0 litre VK Series models are equipped with a revised fuel pump system to improvedriveability in high ambienttemPerature conditions. The mechanicalfuel pump has been deleted, a cover plate is added to the fuel pump access hole on the ilming case cover. The inline plasticfuel filter has been deleted and replaced by a revised fuel vapour separator incorporatinga gauze filter screen,refer Fig. 6C-152. fuel The revised fuel pump system includes,an electric FUEL pump mounted on the fuel gauge tank unit, inside the RETURN iuel tank, refer Fig. 6C-153. The operationof the fuel pump is controlledby a control relay insidethe fuse box. The principleof operationis the same as describedfor the EFI Systemcontrol relay, refer to 'ElectrOnicFuel Injection'in Section6C of this Supplement.The fuel lines hive also been revisedwith the deletionof the mechan- ical fuel pumPand inlinefilter. The float level height has also been revisedto 11.5 mm (.460 ins.).Refer to the Section10 'Enginef.un" Up' of ine lmproved PerformanceEngine Service Manual Part No. M38338,for adiustmentprocedures. TO CARBURETTOR F(lure 6C-152 6C-88ENGINE FUEL 2. SERVICEOPERATIONS 2.1 FUELPUMP REMOVE FUEL GAUGE LOWEB TANK UNtT_i 1. Remove fuel gauge tank unit, reter to service ERACKET -\ I operation2.6, Section12C of this Supplement. I -\., l 2. Disconnectwiring from tank unit to fuel pump. \\ 3. Remove filter from pump. Slide upper rubber con- --. I -- nectorfrom fuel pump outlet,then removepump by r''rr slidingout from lowerbracket. i- REINSTALL gPPER RUBBER , MOUNT Instalfationis reversal of removal procedure. L\ NOTE: The electric fuel pump is a sealed unit and non \ \-W AiNG repairable. CON N ECTION Figure 6C-153 2.2 CONTROLRELAY REIIOVE FUSE 8CX COVER 1. Remove fuse box cover. 2. Pull out relay from its position in the fuse box, reter Fig. 6C-155. REINSTALL lnstallation is reversal of removal procedures. lf the engine fails to start and the normal diagnosis procedure indicates to a fault in the fuel supply to the carburettor, check fuel pump pressure and fuel flow. Figure 6C-154 _ CONTROL RE E BOX Figure 6C-155 2.3 FUELFLOW TEST 1. Disconnect the carburettorfuel line at the carburettor - prior to the vapour seperator. 2. Disconnect '+' wire at rgnitioncoil terminal,place a suitable container at the end of the fuel line and crank the engine a few revolutions. lf litile or no fuel flows from the open end of the pipe, then the fuel pipe is blocked or fuel purnp is inoperative. ENGINEFUEL 6C.89 2.4 PUMPPRESSURE TEST lf fuel flows in good volume from the pipe at the carburettor,fuel deliverypressure may then be checked. This test is necessarybecause a weak pump can still producean adequatevolume of fuel when it is not under pressure. 1. Installa suitable adaptor and tee fitting to the fuel line at the carburettorfuel inlet line. Fit a short rubber hose to the tee piece and attach the other end to a pressuregauge having a scale readingto at least 60 kPa. 2. Start the engine and run at idle, note readingon pressuregauge. 3. lf the pump is operating conectly, the pressure shouldbe approximately30-40 kPa after 30 seconds of running. 2.5 CONTROLRELAY OPERATION BATTERY SUPPLY VOLTAGE 87 TEST LAMP n i'-1 15 | i - 1. Removecontrol relaY as Per 2-2. ll 2. Check for voltage supply to the terminalcorrespon- | | 87b :[n tJ [1 ding to terminal 30 of control relay and earth, refer r-] Fig. 6C-156.lf not, check for continuityof wiringto \ teiminal.Refer to wiring diagramsin Section 12F of t't uo this Supplement.lf O.K. proceedto next test- : I [] CONTROL RELAY TERMINAL BLOCK Figure 6C-156 IGNITION SUPPLY VOLTAGE 1. With control relay still removedand vehicleignition switched'ON', check for voltage supply to the terminalconesponding to terminal15 o{ controlrelay and earth,refer Fig. 6C-157- 2. lf not,check for continuityof wiringto terminal.Refer to wiring diagrams in Section 12F of this -EST LAMP Supplement.lf O.K. proceedto next test. CONTROL RELAY T=RMINAL BLOCK Figure 6C-157 CONTROL REI-.AYOUTPUT /- FU:L PUMP 1. Refitcontrol relaY to fuse box. TEFTIiINALS 2. Withthe enginecranking, check for voltagesupply at the fuel pump terminalon the fuel gaugetank untt. ReferFig. 6C-158. 3. lf no voltage reading,check lor continuityof winng from tank unit to the terminal in the fuse box correspondingto terminal87b of the controlrelay. lf the wrringis O.K.replace control relay and retest. 4. lf the wiring and control relays are O.K., and the pump is stif not operating,remove fuel gaugelank unit as per serviceoperation 2.6 in Section12C ot thisSuPPlement. 5. Check wiring from terminalson tank unit to fuel pumpfor cohtinuity.lf O.K. removeand replacefuel pumpas per operation2-1 and retest. Figure 6C-1 58 6C.90ENGINE FUEL 3. SPECIFICATIONS FUEL PUMP: Pressure 30 - 40 kPa Voltage(at fuel pump - engineoperation t 13.5 t .1 volts NOTES ------r ENGINEELECTRICAL 6D.1 SECTION6D ENGINEELECTRICAL CONTENTSOF THIS SECTION Subject Page CHARGING SYSTEM ...... r.rr.rr....r...... -..r..t...... 6D'1 STARTING SYSTEM .....r.r...... r.....r...... r..r.....6D'1 5 IGNITION SYSTEM...... r...... r...... r...r.,6D'17 CHARGINGSYSTEM INDEX Ref. Subiect Page Ref. Subject Page 1. GENERAL DESCRIPTION...r...r.'r...... ''r.r 6D-1 Disassembly..r..,.r-...... r..,...... ,...... r.....6D-o 2. MINOR SERVICE OPERATIONS .'r....!!,.r,.... 6D-3 Cleaning and Inspection o...... 6D-B 2.1 SAFEW pRECAUTIONS ...... r...r.,.r...!.r.t.,r..6D-3 Testing Compongnts...... ,...... 6D-8 2.2 MAINTENANCE AND ADJUSTMENTS...... 6D-3 Diodg Assembly ...... r...... ,...... ,.6D-B LUbflCatlOn ...... r...... rrr...r...... r. 6D-3 StatOf...... r...... '...... r..... 6D-8 Testlng the Generator Output lnsulation Test for the Stator.. 6D-9 and Voltage Regulator..r...... r.,..'...,.. 6D-4 BfUShgS...... !...... r...... r...... o 6D-9 Tgstlng Generator Output ...... 6D-4 ROtOf ..r...... '..,...... r.r..,r...... 6D'9 Testlng the Voltage Regulator 6D-4 InsulationTest for the Rotor Charglng Clrcult Voltage Drop COil ...r...... r....t'...... r....r.r...... 6D' 1 0 TgSt t.rr..!t!.r.rr...... r..o...... r..r. 6D-5 Rgassgmblyr...... r.....-..... 6D'1 0 3. MAJOR SERVICEOPERATIONS...... 6D-5 4. FAULT DIAGNOSIS...... ,...... ,...... 6D-12 3.1 G E N E RATOR .r.r.r.r...r..r.r.r!.r.t.'r...r.r...... rot.!.....!. 6D-5 5. SPEC IF ICATIONS ...... o...... r...... r..r..r.r..6 D' 1 3 R gmOV€.....r..r.....r...1...... o...... o...... 6D-5 6. TOROUEWRENCH SPECIFICATIONS...... 6D.13 R gl nStall ...... r.....r.--...... r.r.... 6D-5 1. GENERALDESCRIPTION The Bosch45 amp generatorcarries over from VH to VK Series for the base 3.3 litre ElectronicSpark Timing rnodels. On models fitted with air conditioningor ElectronicFuel Injection,VK Series models have fitted a new Hitachi 60 amp generator. On modelswith both air conditioningand ElectronicFuel Injection,a new Hitachi70 amp generatoris fitted. Service proceduresfor the Bosch 45 amp generator are as publishedin Section08 GeneratingSystems, lmpro- ved PerforrnanceLO and VB Engine Service Manual No. M38338. The followingSection covers the serviceprocedures for both 60 amp and 70 amp Hitachigenerators (Fig. 6D-1) Both models are similar in mechanical construction. Differencesin the numberof turnsand the wire gaugeon the respectiverotor and stator windings result in the differentelectrical performance characteristics. Figure 6D-1 The stator comprises a three phase star connected output windingon a ring shaped laminationpack. The rotor is of 12 pole constructionand carriesa slip ring fed field winding.The rotor is supportedby ball bearingsin both drive and slip ring end brackets. 6D.2 ENGINEELECTRICAL Rectificationof the generatoroutput is achieved by six silicondiodes containedwithin the slip ring end bracket and connectedin a three phase bridge circuit between STATOF stator and output terminals.A second rectifier bridge is rTror SWITCH ---t formedby usingthree auxiliarylow currentdiodes used in I conjunctionwith three main diodes. This suppliesthe ,-d^-b_ s I 'sffi6E I L LAMP I currentfor the generatorfield coil via the brushes,slip ,^r\- | J. F BATTERY A- : ^ ringsand voltageregulator (refer Fig. 6D-2). Ht lli ix I | | e REFULATOF | -,tl - I The generator t output is controlled by an electronic * CONDENSER i voltage regulatorunit mountedinside the slip ring end ALTERNATOR bracket.Design features of the voltage regulatorinclude, ternperaturecompensation, radio frequency interference suppression.The regulator requires no adjustment in service. Figure 6D-2 The 'generator has three external connections. The batterypositive lead to the 'BAT' terminal,the 'L' terminal for the generatorwarning light and the 'S' terminalfor sensingthe outputvoltage. The diode and stator windings are cooled by air flow throughthe generator,induced by two internallymounted ventilatingfans, one on each end of the rotor. ,-8 // r/ -2 rl [5 f-.1 r-7 /-4 -3 f .-l t -rl .l rG lrrl'l f-l ll-- I I I / I JED I €-a a.,--l A\ t'Itf I s0 III.I fII =o-o I w --F 0 -a fl A-rf rFl I'trlAI)'r-t t ! U -r'U r10 .-1 -17 I [12 15 \ -13 '- \ I 7 i \ \ 7 I T ,^. \ o I IL E , {\ I -E o /o-t \ I SL: EFI o I.I-- o t\ t cu) oo @ c - E v aTF--''-- O 1$ -14 1. THROUGH BOLT 7. SEAL=D BALL BEARING 12, N UT M4 - FAN G U I DE TO DIODE 2. PULLEY NUT 8. DRiVE END BRACKET 13 FAN GUIDE 3. PUL LEY 9. NUT M5, NUT M6 _ DIODE ASII 14 RIVET 4. ROTOR TO SLIP RING END BRACKET 15. BATTERY TERMINAL 5 SCREWM4 _ RETAINING PLATE TO 10. SLIP RING END BRACKET 16. DIODE ASSEMBLY DRIVE END BRACKET 11. STATC R 17. BRUSH_ FEGULATOR ASM. 6. BEARING RETAINING PLATE Figure 6D-3 ENGINEELECTRICAL 6D-3 2. MINORSERVICE OPERATIONS 2.1 SAFEW PRECAUTIONS Since the generator and voltage regulator are designed for use only on a negative earth system, the following precautions must be observed. Failure to observe these precautions will result in serious damage to the generator. 1. When installing a battery, first fit the positive (+) connector to the battery positive (+) terminal and fit the negative (-) connector to the negative (-) battery terminal. 2. When a slave battery is utilised for starting purpos€s, ensure the two batteries are connected in parallel' i.e. positive terminals together and negative terminals together. 3. When charging the battery, disconnect the battery negative C) cable, thus isolating the generator from the battery and external chargingequipment. 4. lt is recommended that the generator not be operated on open circuit (this is without battery in clrcuit), and the battery not be disconnected while the generatoris running. ll the battery is disconnected when the engine is running,do not operate above idle speed, and for only a limited Period. NOTE: This will enable exchangeof batteries,if a slave battery has been used for starting, when jumper leads are not available. 5. The cable connecting the generator and battery is 'live' even when the engineis not running. 6. Do not aftempt to polarisethe generator. 7. Always ensure that the generator lamp glows when the ignitionswitch is turnedto the 'ON' position. NOTE: As this circuit is related to and assists in the excitation of the rotor lield windings,do not proceed until any faults in the generator light circuit have been rectified. Refer to 4.0 Fault Diagnosisof this Section. 2.2 MAINTENANCEAND ADJUSTMENTS At regularintervals, inspect the terminalsof the generator for corrosion,loose connectionsand the wiringfor frayed insulation.Check the mountingbolts for tightness,check the drive belt for alignmentand wear and the drivepulley for damage.Check the drive belt for correct tension as outlined under heading 'Fan Belt Adiustment'in the 'Cooling System' Section6 of the VH Series Service ManualSupplement No M38731. IMPORTANT:Because of the high inertiaand speedsof the rotcr used in generators,correct belt tensioningis critical. LUBRICATION The balt bearings in both end brackets are sealed, thereforecannot be lubricated. lf the bearings are removed during overhaul, it is recommendedthat they be replaced. 6D-4ENGINE ELECTRICAL TESTING THE GENERATOR OUTPUT AND VOLTAGE REGULATOR Beforetesting the output,make certainthat the generator circuitis thoroughlychecked for loose or dirty connect- ions and the fan belt is correctly tensioned. The generatormust alwaysbe connectedto the batteryduring testingothenryise damage to the diodescould result.The batteryshould be fully charged.The generatorwaming light, in addition to indicatingthat the generator is charging,also carriesthe currentnecessary for initialfield excitation.The globeused should be 2.2 watt. Testing Generator Output 1. Disconnectthe batterynegative terminal. 2. Remove the wire from the 'BAT' terminal on the generator. 3. Usingan accurateammeter having at least an 0-80 scale, connect the positive lead to the generator 'BAT' terminaland the other lead to the disconnec- ted positivewire. Refer Fig. 6D-4 4. Connectbattery lead, fit a loadingdevice across the batteryterminals, i.e, an adjustablecarbon pile. Refer Fig. 6D-4. NOTE: Loadingdevice must have a power consurnption of 1000watts mrnimum. 5. Connectthe positivelead of a voltmeterto the 'BAT' ADJUSTABLE terminalon the generatorand the negativelead to a LOAD good groundon the generatorbody. Refer Fig 6D-4. 6. Start the engineand increasethe engrnespeed to approximately2500 rpm. Adjust the loading device to achieve a reading of 14 voltson the voltmeter. The generatoroutput should be over 55 amps for the LR160-706generator and over 65 amps for the LR170- 703 generator,as indicatedon the ammeter. CAUTION:On completion of the above check, release the adjustment of the loading device and rduce the i--fJo engine speed. NOTE:If the generatordoes not providerated ouput, it shouldbe disassembledand checkedfurther as outlined - AMPS + in this Section. o2{U. GENERATOR - + VOLTS - Figure 6D-4 Testing the Voltage Regulator 1. Connect the positive lead of a voltmeter to the positive terminal on the battery and the negative lead to the negative terminal. 2. Place a resistance or test lamp load across the battery and adjust to maintain a current flow of 11 amps or as an alternative, switch on the high beam headlights. ENGINEELECTRICAL 6D.5 3. Run the engine at approximately2500 rpm, maintain this enginespeed for 15 secondsand checkvoltage reading.This shouldbe 14.1-14.5volts. NOTE:The voltageregulator is a non-adjustableunit and if provedfaulty rnust be replacedwith a new unit. Charging Circuit Voltage Drop Test With the normal connectionsmade at the generator,the charging circuit can be checked for voltage drop as follows:- 1. Connecta low range voltmeterbetween the gener- ator positiveterminal and the batterypositive post. 2. Switch on the headlights, start the engine and increase engine speed to approximately2500 rpm and note voltmeterreading. 3. Reduce engine speed and transfer the voltmeter connections negative to the generator body and positiveto the battery negativepost, increaseengine speed to approximately2500 rpm and again note voltmeterreading. 4. lf the readingsexceed 0.5 volt on the posrtiveside and 0.25 volt on the negativeside there is a high resistance in the charging circuit which must be tracedand corrected. 3. MAJORSERVICE OPERATIONS 3.1 GENERATOR BRACE sOLT REMOVE f CAUT,ON: Disconnect the battery ground (negative) cable to prevent accidentalshort circuits. 1. Removethe wire from the generatoroutput terminal. 2. Remove the connector from the warning light terminalon the generator. 3. Loosenthe generatorto supportbracket bolt. Refer Fig. 6D-s. 4. Remove the generator brace bolt and detach the drivebelt from pulley.Refer Fig. 6D-5- 5. Remove generator to support bracket bolt and removegenerator from engine.Refer Fig. 6D-5' --r- REINSTALL \) bracketand 1. Positionthe generatoron the mounting GEI'iERATORTO SUPPORT installthe bolt and nut;do not fullytighten nut. BRACKET BOLT 2. Installdrive belt to generatordrive pulley- 3. Install the generator to brace bolt and washers, Figure 6D-5 fingertight; generatorpulley should be alignedwith crankshaftand water pump pulleys. 4. Adjust dnve belt tension as outlined under the heading 'Drive Belt Adiustment' in the 'Cooling System Section 6 of the VH Series ServiceManual supplement.Tighten the bracebolt to 20-25 Nm. 5. Tightenthe generatorto mountingbracket bolt and nut to a torque of 34-44 Nm- 6. lnstallthe connectorto the warninglight (L) terminal. 7. Connectthe red wire to output(BAT) terminal of the generator. 8. Reconnectthe batteryground cable' 6D.6 ENGINEELECTRICAL DISASSEMBLY 1. Mark the relative positions of the slip ring end ._ bracket,stator and drive end bracket. 2. Remove through tf- the four bolts ReferFig. 6D-6. rr 3. Separateand remov€the stator and slip end bracket r from the rotor and drive end bracket,by insertingtwo screwdriverson opposite sides between the drive end bracketand statorcore and prise apart. DRIVE END BRACKET cAUTloN: care should be exercised so as not to damage the stator coil with the screwdrivers. SLIP RING END THROUGHS'*F BRACKET BOuTS Figure 6D-6 4. Hold the rotor in a vice (using copper iaws) and remove pulley attaching nut with a 22 mrn socket. DRIVE END BRACKET Take care not to damage or bend the blades of the fan. 5. Remove pulley lock washer, pulley and distance r- PUl-LEY collar.withdraw the rotor from the drive end bracket. _ ROTOR Figure 6D-7 6. Removethe four screws securingthe front bearing retaining plate to drive end bracket, remove the retainingplate. Refer Fig. 6D-8. 7. Press the front bearing out from the dnve end bracket.Discard bearing. Figure 6D-8 8. Using a suitablepuller, remove the slip ring end bracketbearing from the rotor shaft. Refer Fig. 6D-9. ' \\ln_ REMOVING BEARTNG Figure 6D-9 ENGINEELECTRICAL 6D.7 9. Removethe six slip ring end bracketfixing nuts and remove the slip ring end bracketfrom the stator and r DIODE ASSEMBLY diodeassembly. Refer Fig. 6D-10. i de t''O rr t- \ SI.-IP RING END- EqA]KET NUTS{6} -=>r, e Figure 6D-10 10. Remove the stator coil by unsolderingthe three stator winding connectionsfrom the diode assembly STATOR WIRING END POINT and separatingthe diode assembly from the stator windingend points.Refer Fig. 6D-11. srAroR { t / DIODE ASSEMB'" J Figure 6D-11 11. Remove the five nuts holdingthe fan guide to the Nurs (5) GUIDE diodeassembly. Refer Fig.6D-12. 1 7-FAN \ 6/ L DIODE ASSEt.,tB!y Figure 6D-12 from 12. To remove the brush and regulatorassembly BRUSH _ REGULATOR the diode assembly,remove the rivet by filing away ASSEMB LY peened end. Once the rivet is removed,remove the battery terminal and the diode and brush regulator assembliescan be seParated. NOTE: Never remove the rivet except when replacing /eattERY diodesor the brushassemblY. TE RMINAL L DI CDE ASSEMBLY Figure 6D-13 ItF -v 6D-8 ENGINEELECTRICAL CLEANING AND INSPECTION with generatorcompletely dismantled, the components shouldbe cleanedand inspected. 1. wash all metal parts except stator and rotor assembliesin cleaningsolvent. 2. Blow off any dust or foreign matter from the rotor and stator assemblieswith compressedair. CAUTTON:On no account should the rotor or stator windings be cleand in any degreasingcompound, since this might damage the insulationto the ertent that a short circuit or ground could subsequentlydevelop. 3. lnspect the slip rings,clean off foreign matter with cleaninqsolvent. TESTINGCOMPONENTS -FIELD DIODE Diode Assembly POSITIVE Testof diodeconductivity. SIDE DIODE -, U V W The currentflows in one directiononly in each diode. lt shouldflow down from the positiveside diode (at the top of the assembly) in the direction of the arrows refer Fig.6D-14. N EGATIVE ----< BAT SIDE DIODE rl> Figure 6D-14 Using a 1.5 watt test lamp and a 12 volt battery connect to each diode in turn to check conductivity refer t<- 1.5 WATT TEST LAMP Fig. 6D-1s. Connect one lead to the diode stem and the other lead to the diode base plate. Reverse the leads, the bulb should light in one direction only. Check all positive and negative diodes. lf any diode shows current flow in both directon or not at all, replace the diode assembly. To test the field diodes, located on top of the assembly, place the test lamp and battery lead at end of the diode. 12 VOLT Check that the bulb lights in one directrononly. Check all three field diodes. lf any diode proves faulty, replace drode assembly. Figure 6D-15 Stator Open circuit test for the stator windings. Q n lv1METER The continuity of the stator windings has to be checked, STATOR by first connecting any two of the three stator leads in WINDING series with an ohm meter. Refer Fig. 6D-16. TERMINALS Repeat the test by checking at the third lead. lf continuity is found !n all windings the stator can be considered to be normal. STATOR CORE Figure 6D-16 ENGINEELECTRICAL 6D-9 Insulation Test for the Stator S'TATOR\ryINDING Using an ohm rneter,connect the test leads to the stator TERn.llNAL- core and to one of the winding terminals. Refer :-OHM METER / Fig. 6D-17. t lf continuityis found, the stator is consideredfaulty and must be replaced. Figure 6D-17 Brushes Measurementof brushlength: lf the 'free-standing'brush length is found to be less than 2 mm from the brush holder, then replace the brush holderassembly. This rninimumaccePtable length is marked on the brush with a shallowindentation. Refer Fig. 6D-18. Gq n WEAR LIT\4IT r tt [\\..-/ /l \-L-'1_lv-A g= t:, Va - -t !-tl - V Figure 6D-18 Rotor O lvlETER q Open circuittest for rotor coil: -lNl Usingan ohm meter check for continuitybetween the slip rings.Refer Fig. 6D-19. lf continuityis found, the rotor coil can be consideredto be normal. On the contrary,if no continuityis found,the rotor cotl is consideredto be defectiveand should be replaced. Lsl-rP RrNG Figure 6D-19 q7 6D.10ENGINE ELECTRICAL Insulation Test for the Rotor Coil using an ohrnmeter,check the insulationbetween the OHM METER two slip rings and the rotor core or shaft. Refer Fig.6D-20. lf no continuityis found,the rotor coil can be considered to be normal. E lf continuityis found,the rotor coil is consideredto be shortedand it must be replaced. The slip rings should be checked for wear or damage \OO and polished with fine glass paper until smooth, or replacedif badly worn or damaged. lf necessary,the slip rings may be skimmeddown on a latheto a minimumdiameter of 21.6 mm. lf the outside diameterof the slip rings is found to be lessthan 21.6 mm, the rotor must be replaced. SLIP RING NOTE: No attempt shouldbe made to straightena bent rotor shaft. Figure 6D-20 REASSEMBLY The reassemblyof the generatoris the reversal of the disassemblyprocedure, with considerationgiven to the following: 1. Tighteningtorques (refer Torque Wrench Specificat- ions at the end of this Section). 2. Reassemblyof the slip ring end bracket and the drive end bracket. a. Holding the rotor, note the thin semi circular band located in the groove of the slip ring bearingouter circumference. Refer Fig. 6D-21. Figure 6D-21 b. By pushing on the pinched portion of the band, rotate the band to a position of least exposure (the deepest section of the bearing groove). Refer Fig. 6D-22. Figure 6D-22 ENGINEELECTRICAL 6D-1 1 3. Insert a pin into the small hole near the outside centreof the slip ring end bracket.Refer Fig. 6D-23. Qr $, c -/,t h Figure 6D.23 Use the pin to hold the brushesback into the brush holder.Refer Fig. 6D-24. 4. Assemblethe generatorby offenngdrive end bracket and rotor assemblyto the stator and slip ring end bracket assembly,aligning the marks made during disassembly. 5. Fit and tighten the four through bolts evenly to the torque specifiedat the end of this Section. Ensure the end bracketsare sitting evenly on the stator. Use the lower mountingbolt, or an equalsize rod through lower mountingholes in the drive end and slip ring end brackets,to ensurethe holesare aligned. 6. Slowlywithdraw the pin used in step 3. Figure 6D-24 6D-12ENGINE ELECTRICAL 4. FAULTDIAGNOSIS Beforeconducting any generatortest, ensurethat: 1. Batteryis fuflycharged. 2. Generator drive belt is correctlytensioned. Ref er Fig. 6D-25. TENSION 3. Generatormounting bolts and bracketsare secure. 4. Check battery terminals and check for loose or NEW USED Any belt that hasbeen run corrodedconnections to generator. lbs. ks. lbs. kg. f or more than 10 minutes is to be consideredused. 90 41 55 25 Figure6D-25 SUITABLE WIRE Figure 6D-26 @ I lgn it io n Disconnect leadf rom Burnt out bulb, defectivebulc switch " on" 'L' terminaland earth socketor defectivewiring. - L ght"off" - Light ''oft" r- (Check Iigh t 'L' terminallead. Repairand return to (A). for operation r (Checklight for operdi,oh) I Light " on" Reconnect'L' term nal Faulty voltageregul ator. Light " on" leadand grounC'F' terminal Light "o n " Replace. (ReferFig.6D-26) Faulty generator. Remove and test components. Engine idling Faulty generator. (Check light f or L'qh t "on " Removeand test components. operatio n ) (dim light, lighi f ,,ckers, bright light) I Lignt "off " Enginespeed ; H igher 15.0V Faulty voltage regulator 1500 rpm Replace. (MeasureBAT terminalvoltage) ENGINEELECTRICAL 6D.1 3 1. UNDERCHARGEDBATTERY 3. NOISYGENERATOR OPERATION a. Loose drive belt. a. Normalmagnetic hum. b. Defective battery. b. Badlydischarged battery. c. Loose connectionin chargingctrcuit. c. Generatormounting brackets and/or boltsloose. d. Corrodedconnections in chargingcircuit. d. Worn or frayed drive belt. e. Defectivewiring. e. Worn or damageddrive pulley. f. Faultygenerator. f. Worn bearings. g. Faultyvoltage regulator. g. Loose drive belt. h. Loose drive pulleyattaching nut. i. Open or shortedmain diodes. 2. OVERCHARGED BATTERY i. Open or shortedstator windings. a. Shortedbattery cell. b. Fauftyvoltage regulator. c. Short circuitin rotor winding 5. SPECIFICATIONS GENERATOR: Type 1R160 - 706 LR170 - 703 Earth Polarity Ne gat ive Negative Nominal Voltage 12 volts 12 volts Nominal Output at 6000 generatorrpm 60 amps 7O amps RegulatedOutput Voltage@ 20oC. Approx 14,2 - 14 6 volts Approx 14.2 - 14.6 volts Stator Phases. 3 3 Stator Winding Connections Star Star Number of Poles. . 12 12 6. TORQUEWRENCH SPECIFICATIONS Nm Tr^r' o u gh Bolts 3.14- 3.92 P, ?'vNut . . 39.20- 58.80 Frcr't BearingRetaining Plate Screws 1.67- 2 35 Fan G.r de to Diode AssemblyNuts 1.67- 2 35 Siip R End BracketM6 Nuts 5.88- 7 84 "g Slip R ng End BracketM5 Nuts 3.14 3.92 GeneratorBrace Bolt. . 20.00- 25.00 Generatorto BracketBolt and Nut 34.00- 44.00 ENGINEELECTRICAL 6D.1 5 STARTINGSYSTEM INDEX Ref. Subiect Page Ref. Subiect Page 1- GENERALDESCR|PT|ON...... 6D-15 2.1 STARTERMOTOR (EFr)...... 6D-15 2. SERVICEOPERATIONS ...... 6D-15 Remove...... 6D-15 Reinstall .... 6It-15 1. GENERALDESCRIPTION The starter motors used on 3.3 litre and 5.0 litre VK that the 3.3 litre starter motor now incorporatesa plastic Seriesmodels carry over from VH Series models,except shifterfork (similarto JB Camira). 2. SERVICEOPERATIONS The service operations for these starter motors are as EST and 5.0 Litre engines, carryover f rom VH Series. described in the lmproved Performance LO and V8 However,revised proceduresare required for 3.3 EFI Engine Service Manual, Part No. M38338, SectionA7 engines. StarterMotor Rernovaland Installationoperations for 3.3 2.1 STARTERMOTOR (EFl) REMOVE 1. Disconnectbattery earth lead. 2. Rernovebattery feed wire and starter motor solenoid wire from the terminalson the solenoid. 3. Removetop startermotor mountingbolt. 4. Loosen bottorn starter motor rnountingbolt. With left hand supporting the rear of the starter motor, removethe bottom rnountingbolt with the right hand. 5. Removethe starter motor from its positionand rnove it along between the exhaust extractors and the bottom of the passengerside suspensionstrut tower. 6. Pull the starter motor up out between Nos. 2 and 3 inlet manifoldbranches (refer Fig. 6D-271. Figure 6D-27 REINSTALL Installationis the reversal of removal procedures. Tighten starter rnotor mounting bolts to 20 - 28 Nm torque. ENGINEELECTRICAL 6D. 17 IGNITIONSYSTEMS INDEX Ref. Subiect Page Ref. Subject Page 1. GENERALINFORMATION ...... -..... 6D-17 2.5 ELECTRONICCONTROL MODULE ...... 6D.27 1.1 ELECTRONICSPARK T1M1NG....,...... r..... 6D-18 R gm OV€'...... 6Ot27 Gengral Description...... r..'...... rr...... -.6D-18 RginStal | .....t...... r...... ,..6D'27 1.2 SYSTEM I-AYOUT ...... r..!...... r....r.r,.....6D-18 2.6 COOI-.ANT TEMPERATURE SENSOR ....r... 6D,28 1.3 ELECTRONICSPARK TIMING SYSTEM Rem OV€...... r...... oo...... 6 Dt28 COM PONENTS ...... r!...... !t...... r.r..6D-19 TgSt ...... -...... r.'...... o.o...... 6 D28 COntrOl MOdul€ ...... r....r...... r....r..r...... 6D-19 RginStal | .-...... ts.'...,r..,...... r.....6D28 Englne Speed Sensol'...... 6D-19 2.7 THROTTLEPOSITION SWITCH ...... _... 6D,29 Manifold Vacuum Sensor...... !r.r.....r6D-20 RemOV€...... r...... r...... 6D28 Englne Goolant TemPerature RginStall ...... r...... 6D'28 Sen SOr ..... r.....rr....r...o. r.....tt. r...... r...... r..t 6D-20 AdiuStment...... o...o...... -...rr...!...... 6D29 Throttlg Posltion Sw|tch...... 6D-20 2.8 ENGINE SPEED SENSOR ..,...... rr.....,..6D.30 Staftgr MOIOr...... r.rrr...... 6D-20 TeSt...r...... r .rr...... r. 6I)-30 Alr Gondltlonlng ComPressor RemOV€...... r...... '...... 6D-30 ClUtCh ..t...... tr...... r...... 6D-20 ReinStall ...... -...!...... -...ro..r...... 6D'30 lgnltlOn COll ...... r...... t...... r....6D-21 3. DI AG NOSI S ...... r...... r...'.€..-...or.,'...... r. 6D'3 1 1.4 HODES OF OPERATION r....r...... r...... 6D-21 3.1 DIAGNOSIS LIMP LAMPT.!...-...... ,,...... ,...... 6D-31 Cranklr|$ r....r...r....rr..rrrr...... r...... t.... 6D-21 3.2 DIAGUOSTIC ELECTRICAL ldlg .at.rt..rrr...a..!.r.r1.r...!r...r.r...... r1...... rr... 6D-21 CONNECTIONFOR EST...... -...... -..r,.,..,..6D-31 NOfmal iiOdg.r...... r...... !.....i.t...... 6D-22 3.3 DIAGNOSIS OF LIMP LAMP OPERATION 6D.32 Overspggd Control ...... r..rrtr...... 6D-23 Ump Homg Mode,...... ,..,h.,....6D-32 DgCglgfatlng .r.t..t.r...... r....tt...... r.r...... '. 6D-23 Poggible Temperature Sensor Llmp HOmg MOde...r...... t!.!!...r...... r...... 6D-23 FaUlt.r..r.....!..r...... r...... o...... o...... 6D-32 2. SERVICE OPERATIONS ...... '.t...... r....r...... 6D-24 PossibleVacuum Sensor or 2.1 SERVICE NOTES !..rr...... r...... r.t.r.t...... 6D-24 Throttle Position Switch Fault (1) .... 6D-32 2.2, SETTINGlGNlrloN T1M1NG...... ,.'.!.....6D-24 PossibleVacuum Sensor or 2.3 DISTR I BUTOR ...... rt.r...... r...rt..!...... 6D'24 Throttle Position Switch Fault (2) .... 6D-33 RgmOV€...... a..1.....r 6D-24 i 3.4 WIRINGHARNESS CHECKING R glnStal | ...... t.r.... 6D-25 PROCE DU R E .r.....'...r...D.r...... r...rr..r.t...... r...o.. 6D'38 DlSaSSem b 1y.r...... r F.'...... 6t>26 4. SPECI F I CATI ONS -.r...... '...... r...... '...... 6D-40 RgaSSembly o...... r..'r.!. 6D-26 5. TORQUE WRENCH SPECIFICATIONS.O"""6D-41 2.4 MANIFOLD VACUUM SENSOR ...... r.r...... 6D-26 6. SPECIAL TOOLS ...... r.r.....r...'...r...... r...6D-41 R gmOV€ ...... - r...... r .. .r...... r.a...... 6D-26 ReinStall ...... r...... r...... rr..r 6D-26 Tgstinl$ ...r...... r.rr.rr.!r.r...... o...... r...!. 6D-27 1. GENERALNFORMATION The ignition system employed on 3.3 litre ElectronicFuel The igniticn system for 5.0 litre VK Series rroceis carrles Injected VK Series models is similar to the system used over from VH. on 3.3 litre VH. Revisions have been made to the On SL anc Berlinamcdels with the lase 3.3 lrtreengine, distributor advance mechanism and spark plugs have a a Bosch Electrcric Spark Timing StSte'n tS used instead revised heat range. Refer to Specifications at the end of of the conventrcna rgnitionadvance svstem. this Section for details. 4-r 6D.18 ENGINEELECTRICAL 1.1ELECTRONIC SPARK TIMING GENERALDESCRIPTION The ElectronicSpark Timing (EST) system replaces the tirning function of the distributor (conventional vacuum and centrifugal advance mechanisms are not used). The EST system accurately matches the ignition timing to the engine requirementsat all speeds and loads. The EST system processes the input from six sources. These are crankshafl position, coolant temperature, inlet manifold vacuum, throttle position, starter rnotor and, if fitted, air conditioning load is sensed from the cycling of the compressor clutch. An electronic micro processor control module controls coil primary current and therefore the generation of the secondary voltage to fire the spark plugs. Distributors used in the EST system are a simplified version of those used in past High Energy lgnition systems. Having no mechanical or vacuum advance mechanism, the EST distributor simply switches high tension voltage to the appropriate spark plug. 1.2SYSTEM LAYOUT Figure6D-28 shows sensorsused by the ControlModule to monitor engine operation.The only output from the module,controls coil primarycunent. ENGINE SPEED IGNITION SE NSOR COIL ELECTRONIC CONTROL ENGINE MODULE WATER TEMPERATU R E l- l- I STARTER TH ROTTLE MOTOR POSITION AIR SWITCH MANIFOLD CONDITION IN VACUUM CL UTCH SENSOR Figure 6D-28 .-r---.. - ENGINEELECTRICAL 6D.19 1.3 ELECTRONIGSPARK TIMING SYSTEMCOMPONENTS ELECTRON IC CONTROL -- MODULE ),r CONTROLMODULE g (--\ The micro processorbased controlmodule is located }--/ behind the left hand side cowl panel trim. Refer r''--1 Fig. 6D-29. sl The controlmodule performs the followingfunctions: ti' :.a 1. A mernory is used to store the micro processor :.1 -:t i ' programmeand data tables for spark advance as a ii , function of speed and load, temperature, throttle 6,e'a,(Z switch positionand tjme after start. 1* I 2. The micro processorexecutes the programmecontai- L-WIRING ned in the memory. HARNESS processor CON N ECTOR 3. The spark timing signals from the micro al are converted into signals to control coil primary -/- \o<- MouNTTNGscREWS current. (3 PLACES) For every combinationof engine speed and engine load there is a unique spark advance value specified and Figure 6D.29 storedin the controlmodule. The spark advance information is stored in a memory table. Each entry of this table may be specified ind- ependentlyof any other point. The electronic control module memory contains two tables. 1. Optimumadvance table - for highwayuse. 2. Modrfied advance table - for low emission requirements. The memorytables are used by the micro processorfor everyignition pulse calculation. ENGINE SPEED SENSOR An electronicspeed sensor, inductivemagnetic pick up ..- TNGINE BLOCK type, is mountedon the rear of the cylinderblock. Refer Fig.6D-30. Three mild steel timing pins spaced 120o apart, ate MOUNTIN G located around the circumferenceof the flyrheel or BOLT torqueconverter assembly, and the pick-upof the speed sensorextends through a hole in the clutch or converter ..T------housing. spEED As each pin passesthe sensor,a signal is generated SENSOR which is sent to the controlmodule. The pins pass the sensorat six degreesbefore top dead centre. The time intervai Detweenany two pins passing the sensor pick-up,allows the control module to calculate enginespeed. Figure 6D-30 6D.20ENGINE ELECTRICAL MANIFOLD VACUUM SENSOR UNDERS|DE VtEW OF -r \ Mounted on the outside of the fuse box, the engine FUSE BOX vacuumsensor relaysinformation to the control module regardingthe engine'sload condition. Refer Fig. 6D-31. The manifoldvacuum sensor senses engine vacuum and from an inputvoltage of 5 volts from the controlmodule, a variableoutput voltage is sent from the sensor to the control module to inform it of the engine's load conditions. NOTE: Never apply battery voltage to the sensor terminals,as permanentdamage can occur. The sensoris non repairable,if provedfaulty, it must be replaced. Figure6D-31 ENGINE COOLANT TEMPERATURE SENSOR The coolanttemperature sensor is mountedon top of the engine thermostat housing. The coolant temperature sensor determinesthe use of the appropriateadvance table during cold starts, normal operation and high temperatureoperation. The temperaturesensor (Fig,6D-32) is of the negative temperaturecoefficient design (NTC).The resistanceof the sensor decreases as the engine temperaturein- creases,this causes a decreasein the signal voltage beingfed into the controlmodule. NorE: The coolant temperaturesensor for EST is the samesensor as usedfor ElectronicFuel Injection. Figure6D-32 THROTTLE POSITION SWITCH The throttle position switch is mounted on the carburettor float bowl. Refer Fig 6D-33. The function of the throttle position switch is to inform the electronic control module when the throttle is closed (idle position). TH ROTTLE POStTtONSWTTCH t Figure 6E)-33 STARTERMOTOR A signal from the starter motor solenoid informs the electronrc control module when the engine is being cranked. AIR CONDITIONING COMPRESSOR CLUTCH A signal from the compressor clutch, indicates to the electroniccontrol module when the air conditioner com- pressor is operating. This results in an increased ignition advance at idle, thereby increasing the idle speed to preventthe engine from stallingor overheating. _--_____- ENGINEELECTRICAL 6D.21 IGNITION COIL The ignition coil used with the EST system is the standardHigh Energylgnition coil. Coil triggeringis fully controlledfrom the electroniccontrol module, including dwell time. The electronic control module takes into account battery voltage to adjust the dwell to com- pensatefor the time requiredfor the coil to reach full currentlevel at varioussupply voltages. 1.4MODES OF OPERATION With the many varied conditions under which the engine is required to operate, the ignition system must cater for a nurnber of different operational modes. In addition, compensation factors in'ignition performance are required to allow for changes in engine temperature and load conditions, to ensure optimum engine performance with minimum emissions. For convenience, engine operation can be considered to have six operation modes. CRANKING The timing pins situated around the flytruheelor torque converter circumference are positioned at 60 BTDC. As the flyrruheelor torque converter assembly is rotated by the starter motor, the engine speed Sensor signals the electronic control module to trigger the ignition coil and firing occurs at 6 o BTDC. With a cranking speed less than 4OO rpm, the timing will remain at 60 BTDC. IDLE With electronicspark timing, idle is defined as follows: 1. Engine speed between 400 and 900 rpm. 2. Throttle position switch closed. There are a number of functions which operate at idle to maintain idle quality, compensate for loads and maintain idle speed and quality after a cold start. ldle advance without compensation f unctions is six degrees BTDC. This is retarded from the optimum advance for emission control. Compensatton functions operate to increase advance and maintain idle speed and q uality. ldle - Low TemperatureCompensation ADDITICN,JAL To maintain idle speed and quality after a cold start, AD\./AIiCE spark advance is increased. The amount the advance is increased is a functiOn of engine coolant ternperature at 'Engine Start' and time after start. This function is shown in Fig. 6D-34 Fig. 6D-34 shows additional advance as a functron cf coOlant temperature at 'Engine Start' and time Srnce 'Engine Start'. lf 'Engine Start' coolant temperature is A. then additional acivance B is available for 12 mrnutes. 17oc provided engine is idling. lf engine speed exceeds COOLANT 900 rpm due to additional advance, advance slowly TEMPERATUAE decreases to effectively govern engine to 900 rpm. AT EI{GINE START 12 MIN UTES TIME SINCE START Figure 6D-34 6D.22ENGINE ELECTRICAL ldle - High Temperature Compensation ADDITIONAL lf the engine coolant temperature exceeds 95oC, while ADVANCE the engine is at idle, the spark advance is increased to improve idle quality and increase rdle speed for improved t 8oc cooling. See Fig. 6D-35 lf coolant temperature exceeds 95oC, spark advance is increased up to a maxrmurl of 24o BTDC at 105oC, ldle advance will not exceed 24o BTDC under any circumstances. gsoc t osoc ENGIN E COOLANT TEMPERATURE Figure 6D-35 ldle - Load Compensation The:gnition system has the capability to control idle speec ':o compensate for loads impcsed by engine driven accessories. Air Conditioning Clutch Load When the engine is at idle aro the air conditioningclutch is engaged,the advance rS Inc''easedby 12o to maintain an idle speed of approxmately 85C rpm. EngineLoad lf the engine slows due to hrgh loads such generator as MANUAL AUTOMATIC charging and power Steering, advance is increased as shown in Fig. 6D-36. 760 RPM As engine speed falls below speed A, advance increases to a rnaximum at soeed B. AD f ITIONAL A DVANCE 7.so BTDC 60 gtoc 4OO RPM A ENGINE SPEED Figure 6D-36 NORMALMODE Under normal vehicle operations, the contro ^nodule optimizes spark advance for improved fuel econcm/ and driveability.The control module also takes into acccunt the necessity for meeting legislated emission levels. Normal mode is defined as engine speed above 900 rprn and throttleposrtron switch OPEN. I I t------ENGINEELECTRICAL 6D.23 Normal Mode - Low Temperature Compensation ADDITIONAL After a cold start, advance is increased during normal ADVANCE mode operationto improve cold driveability.The amount of advance selected is based on engrne coolant temperatureat 'lgnition ON', and is graduallyreduced with elapsedtime after 'Start'.Refer Fig. 6D-37. ooc'\ c ,t'to COOLANT TEMPERATURE AT KEY "ON" E ^.1IN UTES TI\1E SINCE START Figure 6D-37 OVERSPEEDCONTROL When the engine speed exceeds 5800 rpm the control rnodule reduces the spark advance to 20o BTDC to avoid engine over speeding. DECELERATING When the throttleis released,the enginespeed is greater than 900 rpm and the throttle positionswitch is closed, the operationis definedas deceleratingmode. The controlmodule receives information that the vehicle is in the deceleratingmode, and advanceis selectedby the controlmodule to reduceemissions under decelera- ting conditions. LIMP HOME MODE During normal operation above 400 rpm, the micro processor in the control module calculatesthe required spark advance for each timing impulse. lf the micro processoris unableto operatenormally (due to mechan- .WARNING ical damage for example)the system revertsto the Limp LAMP Home Mode. In this conditionall firing impulsesare at PANEL 6CBTDC. lf the limp mode is initiated,the diagnostic DIAG\OSTIC lamp on the warning lamp panel (Fig.6D-38) is lit LA\1P. continuouslyin the normaldriving mode. Figure 6D-38 6D.24ENGINE ELECTRICAL 2. SERVICEOPERATIONS 2.1 SERVICENOTES The following requirements must be observed when working on vehicles with the Electronic Spark Timing (EST)system. 1. Before removing any EST system component,dis- connect the battery earth lead. Failure to do so could result in the service operator receiving an electricalshock. 2. Never start the engine without the battery being solidlyconnected. 3. Do not use a quick charge unit to start the engine. 4. Neve. separate the battery from the on board electricalsvstem while the engineis runnrng. 5. When charging the battery, disconnect it from the vehicle'selectrical system. 6. Never subject the Electronic Control Module to temperaturesabove 80oC (176oF) i.e. paint oven. Always remove control module first if this temperatureis to be exceeded. 7. Ensurethat all cable harness plugs are connected solidly and that battery terminals are thoroughly clean. 8. Never connect or disconnect cable harness plug at the control module when the ignition is switchedon. 9. Before attempting any electric arc welding on the vehicle, disconnect the battery leads and the control module connector. 10. When steam cleaning engrnes, do not direct the stearn cleaning nozzle at any EST component. lf this happens,corrosion of the terminalscan take place. 11. Do not rotate distributor from standard setting as crossfiringwill occur. 2.2SETTING IGNITION TIMING Since the ignitiontiming in the EST system rs electronic- ally controlled,the distributor position has no effect on the engrneignition timing setting. The onlv requirement for distributor setting is that the rotor button must be aligned wrth the appropriate segments in the distributorcap to frre the spark plugs. To set distributor,loosen distributorclamp bolt and carry out steps 4 and 5, as descrrbed in 2.2 Distributor Reinstall. 2.3 DISTRIBUTOR REMOVE 1. Unfasten spring clips holding distributor cap and remove distributorcap. 2. Crank the engine until the distributor rotor rs in positionto fire No. 1 cylinderand the timing mark on the torsionaldamper is in alignmentwith the longest mark (TDC) on the front cover trming scale Fig.fu- 39 shows the No. 1 firing positronfor EST engines with the mark on the rotor lined up witn the notched mark in the distributorhousrng. NOTE: The longest mark on the timing scale on the front cover is top dead centre number 1 cylinder. Figure 6D-39 ENGINEELECTRICAL 6D.25 3. Clean all foreign matter from around the distributor and clamp, then remove the distributor clamp bolt and clamp. 4. Withdrawthe distributorfrom the engine. REINSTALL 1. Align the centre line of the protruding gear retaining pin with the raised mark on the distributor body. Refer Fig. 6D-40. The rotation of the distributor rotor during meshing of RAISED MARK OI,J the distributor and camshaft gears will align the firing DISTRIBUTOR position for No. 1 spark plug. When a replacement HOUSING pin is fitted, the pin does not protrude. PROTBUDING RETAINING PIN Figure 6D-40 2. Installthe distributorinto its position.Rotate the body so as the distributorcap clampsare at approximately 45o to the crankshaftcentreline. Refer Fig. 6D-41. 3. Installdistributor clamp and bolt,do not tightenbolt. CRANKSHAFT CENTRE LINE Figure 6D-41 4. Place a right angled set square across the top face of the distributor body. Align the centre mark on the rotor button and the No. 1 cylinder mark on the distributor body by rotating the body. Refer Fig. 6D-42. 5. Tighten distributor clamp bolt and install distributor cap. lf the engine is accidentally cranked after the distrrbutor was rernoved, the following procedure can be used, for installing: 1. Remove No. 1 spark plug. 2. Place finger over No. 1 spark plug hole and crank engine slowly until compression is felt. 3. Align timing mark on torsional damper with the longest mark C[DC) on the front timing cover scale. 4. Install the distributor as previouslyoutlined. Figure 6D-42 .*--L - 6D-26ENGINE ELECTRICAL DISASSEMBLY 1. Remove distributorand rotor. 2. Remove circlip and upper distributor shaft thrust washers. 3, Press out the pin securing the drive gear and remove gear and thrust washers. Refer Fig. 6D-43. 4. Push shaft from housing by applying light force at the drive end. REASSEMBLY Reassemblyis reverse of disassembly. 1. DISTRIBUTOR CAP SHI\4 WASHER 2. ROTOR 1 DRIVE GEAR ? SHAFT 8 DRIVE GEAR PIN 4 UPPER& LOWER BUSHES 9 DISTRIBUTOR HOUSING 5 FIBRE WASHER Figure 6D-43 2.4 MANIFOLDVACUUM SENSOR ,- MOUNT| NG REMOVE /' SCREW / (2 PLAC ES) 1. Remove the two screws securing the sensor to the bottom of the fuse box. Refer Fig. 6D-44. UNDERNEATH VIEWOFT 2. Disconnect wiring and vacuurn connectors. Refer FUSE 8OX Fig. 6D-44. , REINSTALL Installationis reversalcf removal. WIRING _/ CON N ECTO R Figure 6D-44 .-r..-f. - ENGINEELECTRICAL 6D.27 TESTING Testing the vacuum sensor can be done on the vehicle. 1. Disconnect sensor vacuum hose from inlet manifold adopter. 2. Use a hand vacuum pump, such as Tool No.J23987- 01 or equivalent, insert end into open hose end. Refer Fig 6D-45. Figure 6D-45 3. Connecta voltmeteracross the CB and CA terminals of the sensor.Refer Fig. 6D-46.Switch on ignition. 4. With a varyingamount of vacuum,the outputvoltage variesaccording to the followingtable: OUTPUTVOLTAG E 4.4to 5.3 3.2to 3.8 2.0to 2.5 0.7to 1.1 VO LT}I ET E R Any deviation in the output voltage figure with the nominated applied vacuum, indicates a faulty sensor, which mustbe replaced. Figure 6D-46 2.5 ELECTRONICCONTROL MODULE WIRING ELECTRONIC CONTROL REMOVE HARNESS MO DU LE 1. Make sure ignitionis switched'off' and disconnect batteryearth lead. 2. Removethe lefi hand cowl panel trim from the front passengercompartment. 3. Removemodule mounting screws. Refer Fig 6D-47. 4. Disconnect wiring harness and withdraw control modulefrom its position.Refer Fig. 6D-47 REINSTALL Installationis the reverseof removalprocedure. / MOUNTING ,//,i' *}. scRSCREIVS.E\vs. ,rr %,'W (3 PiACES) r/ Figure 6D-47 6D.28ENGINE ELECTRICAL 2.6 COOLANTTEMPERATURE SENSOR REMOVE 1. Disconnectbattery earth lead. 2. Disconnect wiring harness connector from temperaturesensor. Fig. 6D-48. 3. Draincoolant from engine,below sensor level. 4. Removesensor from thermostathousing. Figure 6D-48 TEST 1. Suspendsensor in a containerof 50/50 glycol/water. Ensurethat sensordoes not touch the container. 2. Place thermometer,having a scale reading of at least 100oC, into containerand heat. 3. Record resistanceacross sensor terminalsat various temperatures.Refer Fig. 6D-49. Checkthe resultswith the followingchart. R ESISTANCE ohms 54to6.3ka 23to2.7kn 300to 350 n 170to 210 n Figure 6D-49 Any deviation in the resistance values recorded at the norninated ternperaturereadings indicates a faulty sensor BRACKET SCREWS which must be replaced. -- r (2 PLAcES) REINSTALL 1. Apply GMH sealant P/N g}3szi4 to sensor threads, MOUNTING BRACKET refit in thermostat housing and tighten. MOUNTI NG 2. Refit wiring harnessconnector. PLATE 3. Fill up radiatorand check for coolant leaks. CARBURETTOR 2.7 THROTTLEPOSITION SWITCH REMOVE ACCELERATOR - 1. Femove carburettorair cleaner. LINKAGE 2. Disconnectthe two wiring connectors at switch. 3. Remove the 2 switch mounting screws, washers and SCREWS mounting plate. Refer Fig. 6D-50. \ REINSTALL \ SWITCH ACTUAToR Installationis reverse of removal procedure. The swrtch rnust be readjustedafter installation. Figure 6D-50 ENGINEELECTRICAL 6D.29 ADJUSTMENT 1. Disconnect wiring connectors from switch. 2. Connect an ohmmeter across the switch terminals (Do not use a test light). Refer Fig- 6D-51- THROTTLE POSITIONSWITCH Figure 6D-51 3. Positionthe fast idle screw onto the second highest step of the fast idle cam. Refer Fig. 6D-52. Check that the switchis open, the ohmmeterreads infinity ohms. 4. Rotate the fast idle cam so that the fast idle screw sits on the third higheststep. Check that the throttle positionswitch is closed,the needle of the ohmme- FAST IDLE CAM\ ter reads 0 ohms. Loosen mounting Screws and \ adjust switch as required to achieve correct I adiustment. SECOND STEP 5. When switch is correctlyadiusted, tighten mounting screws and recheckadiustment- 6. Reconnect wiring connectors to switch. Reinstall carburettorair cleaner. On vehicleswith manualtransmissions, for the engineto return to idle, it is essentialthat whenever the throttle throttle nudger shaft, the closes onto the extended Figure 6D-52 throttleposition switch must be closed- lf the throttle closes onto the extended nudger without closingthe throttleposition switch, the enginewill run at approximatelY1400 rpm. To Check Operation 1. Disconnectthrottle positionswitch wiring connectors and connect together (this simulates a closed switch),connect an ohmeteracross switch terminals. 2. Start the engine. 3. Open the throttle until the switch opens, (ohmeter reads 'infinitY'). 4. Depress the spring loaded button on the throttle nudger and close the throttle.Wath the throttle lever resting on the extended nudger shaft, the ohmeter shouldshow zeroohms. 5. Readjustidle speed,fast idle speed,throttle position switch or throttle nudger setting to ensure correct oPeration. 6D.30ENGINE ELECTRICAL 2.8 ENGINE SPEED SENSOR MEASURE ACROSS TEST TH ESETERMINALS 1. Disconnect sensor wiring harness connection, at the fuse box side of the rocker cover. Refer Fig. 6D-53A. 2. Connect an ohmeter across sensor terrninals shown in Fig. 6D-53. Resistance should be in the range of 1 to 1.2 k Q. Any deviation in the resistance value than specified the sensor is considered faulty and must be replaced. FRONT VIEW OF CONNECTOR LEAD TO ENGINE SPEEDSENSOR Figure 6D-53 REMOVE 1. Disconnect battery earth lead 2. Disconnect engine speed sensor wiring harness ENGINE HARNESS rocker cover. connection, at the fuse box side of the STRAP Refer Fig. 6D-53A MOUNTIN G 3. Remove harness strap at rear of rocker engine BOLT cover. 4. Remove bolt securing engine speed sensor supporl to the rear of the cylinder block. SPEED 5. Remove sensor assembly from its location. SENSOR NOTE: Do not damage support locating lug. SPEED 6. lf necessary, mount speed sensor support carefully in SENSOR jaws, a vice with soft remove mounting bolt and SUPPORT separate sensor from support. SECURING BOLT REINSTALL Installationis reverse of removal operations. SUPPORT LOCATIN G LUG Flgure 6D53A ENGINEELECTRICAL 6D.3 1 3. DIAGNOSIS 3.1 DIAGNOSTICLIMP LIGHT When the system is operatingnormally, the lamp is on during engine cranking and while the engine is not running with the ignition 'ON'. lt will go out a few secondsafter the engine starts if everythingis operating normally.lf the light does not come on at all, the bulb, the wiringor the modulemay be faulty. The lamp will come on whilst driving for one of two reasons. 1. lf the control module detects an operatingfault with one of the EST systemsensors. The control module assumes a normal operating value for that sensor, and continuesto supply the engine with a spark advancevalue, althoughtnot necessarilythe optimumvalue. 2. lt means that there is a malfunctionin the control moduleitself. In this case the EST systemwrll revert to a spark advancevalue of 6C BTDC (Limp Home Mode),this enablesthe vehicleto remainoperational at a reducedperformance level. 3.2 DIAGNOSTICELECTRICAL CONNECTIONFOR EST Situatedwithin the EST engine wiring harnessassembly is a single cavity connector body and terminal, taped back to the wiring harnessas shown in Fig. 6D-54. With the aid of a jumper lead fitted with aligatorclips, this allows the connectionof the connectorbody terrninalto a suitable earth point on the engine. With this con- nection,the diagnosticlimp light is activated. The diagnostrclimp light is located within the dash warning light panel. By means of a coded flashing warning,the limp light definesthe source of the EST systerncomponent failure. TAN&PINK-=iDS MAIN E.S.T.DIAGNOSTIC WIRING (lGNlTlON COt:-' HARNESS CONN. CONNECTCR \) )c'l .-/| TRANSMISSIC\ tx -'\ H ARN ESS q_ DK SLUE LEAD (OIL PRESSURESW i Figure 6D-54 6D.32ENGINE ELECTRICAL ln the event of the limp light coming on to indicate a After the 8 minute period is complete, the module system component failure, make the earth connection to detectsthe fault, turns the warning light on (or ftashes the connector body without turning off the engine, and let the diagnosticcode in diagnosticmode) and assumesa the engine idle. normal temperature(90o C). The light remainson con- Description of the diagnostic limp light operation is tinuously in normal mode (or continues to flash in covered in 3.3 of this Section. diagnosticmode) until the ignitionis switchedoff. To reset the diagnostic lamp for normal mode condition, when the light comes on, the idle speed will return to turn off the ignition and remove jumper lead. Restart normalas the very high temperatureis no longerseen. vehicle and if the fault has not been corrected the diagnostic lamp will come on again when the appropriate Open Circuit test conditions are re-established. lf an open circuit fault is present, the temperature appears very low (-14oC) to the module. lf the temperatureat ignition key on is low, the idle low temperature compensationis enabled. For the first 12 minutes of engine operation,idle spark advance is 3.3 DIAGNOSISOF LIMPLAMP increasedfor improvedidle quality. Note that this will causethe idle speed of a warm engineto fluctuateabout OPERATION 900 rpm. This is because additional advance is only (Refer to chart at the end of this Section.) present at idle, which is defined as engine speed less than 900 rpm and idle switchclosed. LIMP HOME MODE lf the speed is above 900, the advance is slowly go0 lf the microprocessor (or computer) fails, a limp home removedand the engine slows. lf it is below rpm, mode is activated and the warning light is turned on. the advance increases and the speed increases.This provides Limp home mode is provided to minirnisethe likelihood of engineidle speedgoverning at 900 rpm. the owner being stranded. Spark timing is very retarded After 8 minutesof operationwith the open circuitfault, in this mode (60 BTDC always) and this will €use the module turns the light on (or flashes the code in increased fuel consumption, poor engine response and diagnostic mode), assumes a normal operating higher engine operating temperatures, Prolonged opera- temperatureand continuesto provide additionalspark tion in this mode should be avoided. Monitor engine advanceat idle until 12 minutesafter ignitionkey on. temperature regularly if limp mode operations is necess- ary at high ambient temperatures or while towing. Stop if POSSIBLE VACUUM SENSOR OR THROTTLE necessary. POSTTTONSWTTCH FAULT (1) lf the microprocessor starts operating normally, the light whenever the engine is operating,the module is will be turned off in normal and diagnostic modes, chec- king for a vacuumsensor fault. provided no other faults have been detected. lf the diagnostic light is on continuously in norrnal mode and lf the throttle position switch is closed and the engine does not flash a recognisable code in diagnostic mode, speed exceeds 1500 rpm, the rnoduleexpects to see a the EST module should be replaced. manifold vacuum greater than 30 kPa. lf the module detects a vacuum of less than 30 kPa under these conditions,it will turn the diagnosticlight on (or give z POSSIBLE TEMPERATURE SENSOR FAULT flashesevery 8 secondsin diagnosticmode) and assume lf a fault is detected in the temperature sensor circuit, the the manifoldvacuum is zero at all times. light is on in normal mode. In diagnosticmode, the light lf the engine is switchedotf and re-started,the light will flashes on for 1 second in every 8 seconds. go out until the engine speed exceeds 1500 rpm while The control module does not check the temperature the throttle position switch is closed. lf the vacuum is sensor circuit until the ignition has been on for again seen by the moduleas less that 30 kPa,the light 8 minutes. From I minutes onwards the module con- will be turnedon again. trnuously checks for a temperature between 50oC and This fault will be indicatedif the hose comes off the 125oC. ff the ignition is switched on without starting the vacuumsensor, if the signalwires rn the vacuumsensor engine the temperature may be outside the specified harnessare shortedtogether or if the vacuumsensor is limits without a fault being present, I minutes after faulty. This fault may also be indicated if the throtile ignition'ON'. positionswitch wires are shortedtogether or to groundor To check for this false indication,switch ignition off, start the switch itself is badly adjustedor short circuited.For the engine and check the light in 8 minutes. example,the enginemay be operatingat 1600 rpm wide open throttle and with zero vacuum, lf lf the light comes on again, it may be due to either an the throtile positionswitch is operatingnormally, open circuit, a short circuit or a faulty temperature it will be open and no fault will be recorded.lf the posrtion sensor. A faulty sensor may give the same symptoms as throttle switch wires are shorted together, an open or short circuit. the module sees the same inputas a closedswitch and recordsa fault condition. Short Circuit It is necessaryto assumethe engineis operatingat zero vacuum all the time this fault is present.This is to lf a shortcircuit is present,the temperatureappears very prevent the module frorn giving the engine excessive high (130oC ) to the module. In the I minutes between advance at wide open throttle and causingdetonation the ignition being turned on and the detection of the damage. fault, the module will increase idle spark advance as if the temperature really were high. This is done to increase idle speed for improvedengine cooling. ------r ENGINEELECTRICAL 6D-33 POSSIBLE VACUUM SENSOR OR THROTTLE POSTTTONSWITCH FAULT (21 This section describes a second test for a possible vacuum sensor fault. lf the throttle position switch is closed and the engine speed is between 825 and 900 rpm, the module expects to see a manifoldvacuum of between10 kPa and 75 kPa. lf the moduledetects a vacuumoutside these limitsit will turn the diagnostic light on (or give 3 flashes every 8 secondsin diagnosticmode) and assumethe manifold vacuumis zero at al times. If the engine is switchedoff and re-started,the light will go out until the check conditionsare met and the fault re-detected.This fault will be indicatedif the electrical connector comes otf the vacuum sensor, a vacuum sensor wire is broken or the vacuum sensor is faulty. lt may also be indicatedif the throttleposition switch wires are shortedtogether or to ground or the switch itself is short circuited. EST DIAGNOSTICLAMP CHART i LIMP LIGHT OPERATION CORRECT SYSTEM FAULT DESCRIPTION FAULT CONDITION Diagnostic Normal oPERATTON Mode Mode PossibleEST Control Control moduleselects * Lamp Lamp or module fault limp mode uncontrolled until resetis control moc - . the f usually of successful - c light is no: c re red Possibleengine coolant Assumes engine coolant One pulseof Lamp on ,A'ier the engine n:s been temperature sensorfault temperature = 95oC lamp every until reset rLtnrng for 8 mi-ru:=s, the 8 seconds successful er^Cne temperatu'= .',rll be beivveen 50oC t: ',25oC Possiblevacuum sensor Assumesvacuum is 0 kPa Two pulses of Lam p on W:n throttle posi::on switch or throttle positron with the throttle position lamp every Jrtil reset cicsed, engine vacLUrn must switch fault (1) switchopen or closed 8 seconds successful be greater than 30 kPa provided the engire speed s greater than 1500 rpm Possible vacuum sensor Assumes vacuumis 0 kPa 3 pulsesof Lamp on t h th rott le pos r: ;on switch or th rottle position witn theth rottle position lamp every until reset ciosed and engirrE rdling switch fault (2) switchooen or closed 8 seconds successfu I bei'veen850 anci900 rpm th: enginevacuu m must be be:'veen10 and 75 kPa * Becauseof the natureof this failureit isnot possibleto statewhether the lamp will be on or o'r or f lashing. However if the lamp cioesflash it is very unlikelythat it will correspondto any of th e vaI id diagnost ic codes. Despite this it should be obviousthat the EST is in the i mp home mode. due to the veh c;es performance. 6D.34ENGINE ELECTRICAL INITIAL CHECKS t--- i START 1. Checkthat DiagrosticLead is NOT earthed. 2. Startengine ard allow to idle. 3. Notetime v.,henstarting engine. lsDiagnostie I yES ( tttO LamPon? i->- I Con nect D iagnostic Connect DiagnosticLead Lead to earth. to earth. Allow engineto idle until 10 minutes after start. ls Diag-osticLamp ls light flashing once f las'ring1 ,2 or 3 every 8 seconds? times every8 seconds? NO NO See Chart correspond rng SeeCha rt 2 f or possible to number of f lashes. CoolantTemperature Sensorfault. 1. Connect timing light SeeCharts 3 & 4 for possible 2. Open throttle while END Vacuum Sensoror throttle engine is idling. PositionSwitch faults. 3. Look for timing mark on harmonic balancer. Does timing mark move as engine speed changesT Work throucn Charts Nos.2,3 & 4 n that order. ls light still on? +YES- -l Replace EST Control Modu le CheckWiring Harness, NO detailsat the end of this Section. CHART1. ENGINEELECTRICAL 6D.35 E.S.T.DIAGNOSTIC LIGHT F LASHES THREE TIMES IN DIAGNOSTIC MODE. POSSIBLEENGINE VACUUM SENSOR OR TH ROTTLE POSITIONSWITCH FAU LT. START I t. F't Tachometer. 2 Fit Manifold Vacuum Gauge. I ldle Enginebetween 850 - 870 rpm with 20 to 70 kPa \{a^''old Vacuum. A 9. Automatic Transmission - |n Drive, open throttle fully f i'or- dle. 5. ManualTransmission - In top gearat 830 rpm, open throttre f rl y for 1 second. Light YES is Vacuum Hose connected RECTIFY - to Vacuum Sensor? I YES ls Wiring HarnessConnectoron RECTIFY NO - Vacuum Sensorand rr:akng COntact? YES Does Th rsli ls PositionSwitch op:'a:e RECTIFY - NO as sPec;fieCon Emission La be ) YES I I I Test and Check EngineVacrum Sensorano RECTIFy _ FAULT!---* Throttle PositionSwitch \\' - irQ Harnesses, detailsat the end of th rsSection, o.iK. Test EngineVacuum Sensoras per REPLACE -FAULTY ( serviceoperation 2.5 in th rsSection. o.t K. I Reolace ESTControl Module END CHART2. I 6D.36ENGINE ELECTRICAL E.S.T.DIAGNOSTIC LIGHT FLASHES TWICE IN DIAGNOSTIC MODE. POSSIBLEENGINE VACUUM SENSOROR THROTTLE POSITION SWITCH FA U LT. ; START 1 Fi: Tacrometer. 2 F : l't/an rfold Vacuum Gauge D.ive vehiclewith an enainespeed of 2000 rpm or more. Open Throttle until Vacuurndrops below 20 kPaand then closeThrottle until enginespeed reaches approx mately 1600 rpm. DoesLight f lashtwice 8 seconds? YES ls Vacuum Hoseconnected to RECTIFY __, VacuumSensor and is Vacuum FAULTS I availableat Sensor? YES RECTIFY FAU LTS YES REPLACE i Test EngineVacuum per FAULTY-<. Sensoras SENSOR serviceoperation 2 5 in this Section. t OK I a^d Chec RepiaceE ST ControlModu le END CHART3. ENGINEELECTRICAL 6D-37 E.S.T.DIAGNOSTIC LAMP FLASHESONCE IN DIAGNOSTICMODE. POSSIBLECOOLANT TEMPERATURE SENSOR FAULT. START Start Engine and allow to idle for ten minutes. Light may come on if Engineis not started NC - seconds? assoon as ignition s :u rned 'ON' ls Wiring HarnessConnector REFIT fitted to Coolant TemperatureSensor? YES Test CoolantTern cerature Sensor 1 REPLACE per ce oPeration - FAULTY as serv SENSO R in th is Seci'cn. Testand CheckCoolant Terr'pe'ature R REPAI FAULTY-+ SensorWiring Harness, HARNESS cetails at the end of this Seci cn ' Repl3ceEST Control Module END CHART4. .--^ 6D-38ENGINE ELECTRICAL 3.4WIRING HARNESS CHECKING PROCEDURE 1. Remove electronic control module as per service 25 14 operation2.6. 2, Separate the EST wiring harness from the control module. 3. Sincethe contactterminals on the plug stripare not marked, the contacts must be counted for the 13 varioustests. Terminals 1 through 13 are located on the long terminal strip, terminal 1 is next to the cable entrance. Refer Fig. 6D-55. MULTI_PLUG TERMINALS Terminals 14 through 25 are located on the short terminal strrp, terminal 14 is next to the cable entrance. Refer Fig. 6D-55. 4. Remove the wiring harness connector from the EST Figure6D'55 sensor to which the test is directed. 5. Using an ohmmeter, connected to the appropriate terminal on the plug strip and the terminal on the disconnected sensor harness plug, check the wiring for: a. Short circuit, b. Open circuit. c. Short circuit to earth Refer to followrng chart and Fig. 6D-56 for details. TERMINAL HARNESS CONNECTOR SENSOR NO TE RMINA L Black Blackiwh Coolant Temperatu re Black .', te Sensor Black \r/n,te wire Thrott le Position B ac< White wire rac Switch B k wire ccil terminal c c n nector Engine 21 A Vacuu m 24 B Sensor v C * Remove wiring c: - i:c:l-s from throttle pcs : :- switch before check r: ,A, r- .a3.- - - - ENGINEELECTRICAL 6D.39 EST WIRING DIAGRAM SPEED SE NSOR (STARTER SOLENOI D) IGNITION STARTER SWITCH ENGIi\: COOLAi',lT TEMPERATJRE I SENSOF _ I -_. GND TH ROTT L E c o POSITION ()F- SWITCH UJ z 15 z o C) ul f-- f o TO o IGN. SW. DIAGNOSTIC LA\IP 3 WATTS MAX. o 17 G F z - o 18 '.--.------B--l O i coNNEcroR rl SERVICE DIAGNOSTIC -, cf) I I lu I SWITCH TO GROUND I ---J 24 19 EARTH FOR EST 20 ON CENTRAU EAaTH lN G POINT 14 EARTH FOR IGNITIC\ ON CENTRAL EARTHING POINT + IGN. SWITCH A GND 16 B TO E^r iNE B SIGNAL '. ':r,JM a-r C + VE v s tVVl- - I Figure 6D-56 6D.40ENGINE ELECTRICAL 4. SPECIFICATIONS ;flh ENGINE DESIGNATION . . 3.3litre EST, EFI 5.91;,,. D'stributor Make..... Bosch SparkAdvance Refer"lgnition DistributorAdvance Details" Charton following paSe.(3.3 titre EFI and 5.0 litre only.) Pick up Cc R:sistance 1.0 - 1.2 Kil OHM @ 25oC Firing O'ce' 1,5,3,6,2,4 1,2,7,8,4, 5,6,3 Coil Mak: Bosch Cu'.eni EngineStopped.... 0 Engineldling 7 amos P:imaryCoil Resistance 0.5 - 0.7 OHMS @ 25oC SecondaryCoil Resistance 5- 7 Kilo OHM@2SoC SparkPlugs Make . AC Model . A2CLTSX 44TX Tread . 14 mm GaP . . 1.5 mm (.060in. ) TightenTorque 17 - 18 Nm High TensionLead Resistance 2000 to 8000 OHMS oer 300 mm IGNITI ON DISTRIBUTOR ADVANCE DETAI LS IN ITIAL IDENTI FICATI ON ON DIST. DIST. CENTR IFUGAL ADVANCE VACUUM ADVANCE WHITE LABEL ON APP ICATION L PART i AOVANCE ENG. DEGREES AT ENG. R.p.M. ENG. DEGREES @ kPa VACUUM ADVANCE NUMBER i{DEGREES) UN IT I teroct srART TNTERMEDTATEI rulr_ START tl FULL 12 -3.0 to 1.0 3 : :3 :3.5 16.0to 20.0 tl 11 - 15 3.3 litre 92Ct 7t9O BELOW @ + @ \: @ BLACK 120 EFI 1 100 RPM 1-l 1200 2410 5000 tt 34 6 | -ZtoZ E:c'2 20 to 24 0 14 - 1g 5.0 litre 92023157 BELOW O I 3 @ Y @ ELACK 60 E5CRPM i 1000 20c0 4400 22-29 42-47 l r ------r ENGINEELECTRICAL 6D- 41 5. TORQUEWRENCH SPECIFICATIONS Nm Throttle PosrticnSwitch fulcuntingScrew to Plate 5 - .7 fv'lountingBracket to Carbu'e:icr , 3.5 - 4.5 EngineSpeed Sensor SensorSupport to CylinderB cck Bolt 30 - 40 Sensorto SuPPortBolt B - 11 EngineVacuum Transducer MountingScrews to FuseBox 1.5 - 2-A 6. SPECIALTOOLS HAND VACUUM PUMP J23987-01 EOU IVALENT EMISSIONCONTROL 6E.1 SECTION6E EMISSIONCONTROL INDEX Ref. Subject Page Ref. Subject Page 1. GENERALDESCR1PT|ON...... 6E-1 1.8 THROTTLENUDGER...... 6E-16 1.1 EARLY FUEL EVAPORATION 6E-5 2. SERV|CEOpERAT|ONS...... _...... 6E-17 1.2 EVAPORATIVEEMISSION CONTROL...... 6E-5 2.1 GENERALTNFORMATTON ...... 6E-17 1.3 POSITIVECRANKCASE VENTILATION .... 6E-6 2.2 EGR MODULATORVALVE ...... 6E-17 1.4 VACUUMADVANCE CONTROL 6E-9 6E-17 VAG System (NSw) 6E-9 3. SPECIALTOOLS 6E-18 1.5 AIR PREHEAT...... 6E-14 1.6 ArR tNJECTTONREACTOR ...... 6E-14 1.7 EXHAUSTGAS RECIRCULATION 6E-14 3.3 Litre EFI Engines 6E-14 3.3 Litre EST Engines 6E-14 1. GENERALDESCRIPTION The EmissionControl Systems employedon VK Series The chart below sets cut the EmissionControt Systems vehicles catry over in general from VH. However, apprrcableto the variousenqines used in VK Serres. significantrevisions to some systemshave been made to suit specificengine requirements. EMISSIONCONTROL SYSTEM L6 3.3 EST _6 3.3 EFt 5.0 L Early Fuel Evapo :: r' X EvaporativeEmiss o'' Contro, X X PositiveCrankcase Vent iat on X Vacuum AdvanceCo"iro N/A X X Arr Preheat X N,A X Air lnjection Reacto'. X N,,A NiA Exhaust Gas Recircua: r:n X X X Throttle Nudger Manualonly N/A N/A Ni A = Not APP c:DIe The followingparagraphs summarise the changesto the svstemsfor VK Series. 6E.2 EMISSIONCONTROL 2 ; !, E o a E tsd 3 q7 RF 7rI R b< ^P'; i - 6 z o ; < = F E J tr a z F I F : F z z .9 F (, z F l 9^ uJ 2 r !:> z : gi 2i,! 6 :EJ6 R6 E F L I Filt;srr!: i = o ; [9 a ;o ; ; a Jei F z ; o o I E g z 4 F ,) 9 9 ; : d o tr' F tr 9 I ! E B z : 6 )r z 9r Iz F f XE E o I z ! lrl g E 6 2 u!-1: ?; *o>iig ! i €-?g:;:; E9 3 E3:;:33! E 62=5= z ;-F:EE;o ! E Fiegggd1 d giFFFF: " I isrrEEi 3 aiHbr ttt! I 6E-4 EMISSIONCONTROL z o ti 6 z \ CE /( F tr F it l J z I 5 z!J z F ,a, z tr 9 l = EO 6 E r z *z o;!E ! I j-A 3E = ,! 1:;a ! i;) : 096 q 2iicy 3 !E: t =3 ii''rI"il = qJY 4 i ddE i ll EMISSIONCONTROL 6E-5 1.1EARLY FUEL EVAPORATION The EFE system is carriedover from VH for the L6, 3.3 EST enginesand 5.0 litreengines. Refer Figs. 6E-1, 6E-2 and 6E-3 for hose routing for L6, 3.3 EST enignes. 5.0 litre engine hose routing carries over from VH. The EFE is not used on engineswith electronicfuel injection. 1.2 EVAPORATIVEEMISSION CONTROL On L6 engines,the EEC system has been modifiedto meet emission reeuirements.The cannister has been relocated in the engine compartment and has new mounting brackets (Fig.6E-a). Refer Figs.6E-1, 6E-2 and 6E-3for EEC hose routine. . ief_F RET!tr' - tJ= SlUt l-l-{Al\ L :- Vr:! -5): a - \HCS' 'CANlST=A;]STON CAP WH=\. I\STALLED r DRAIN CAP CI,TOUTS TO BE CORRECTL "/ ' ALIGNED WITH LOCATING BAq ON CANISTER ? - FRONT :ANISTER TO SIT ].'.] CAP WHEN OF CAR ..S-ALLED P fF: liP cuTouTS To BE - FRONT CO;-:l--Y" ALIGNED WITL OF CAR LOC:_ 3AR ".:J ON CANIST=- EEC CANISTER INSTALLATION DETAILS EEC CANISTER INSTALLATION DETAILS _ ENGINES WITH EFI _ ENGINES WITH EST Figure 6E-4 6E.6 EMISSIONCONTROL 1.3 POSITIVECRANKCASE VENTILATIO?.I The PCV systemsfor L6, 3.3 engineswith EST and the 5.0 litre engine,carry over from VH. The system layout has been revisedfor engines with EFl. Refer Fig. 6E-5 for details. CONN ECTOR -.\ GROMMET zu+-€, 6 \ VIEW PCVVALVE\ '.UTPC' GF]O\1'. : - VIEW /7-==- /\ ( )- i/ , fFl \v f'l:. . I THROTT \*==r/f 'a'-zf- - \o \,\\J u,r*l-El VIEW POSITIVECRANKCASE VENTILATION SYSTEM - 3.3ENGINES WITH EFI Figure 6E-5 EMISSIONCONTROL 6E.7 = E E8E ,-',:' ? a3'n E z7 :i95sj '@ E 3 Eq _ Ei:g;i 6 6 Ea1,;63r s I E z 3FaaxEoooE:!HE3E; G E ri -u 2 5f r i:iai.!"!;" 6 5 E ;i g EeiEEeE:i tlc4 ,/Lt _t H:gE5:::gE - z 9 r I DN tt )\z/,2\. I tYl = ; E = 1 z F F o z z - z F l o E o I z () ,' a UJ I I 6 9 6E.8 EMISSIONCONTROL o i- A z ,i------! 6 :={ F ,j. z ; U; n 9 : 5 6 o 6 d z 6 2 2 E' " E € zd z F g F .9! o r! z z uJ d IL E I z F l Fi;?:2i?RE_ 5 .?eEiA zJ 3 2 seEEt;i ; z Fi;i;6 i : :; 6 .c6?!!! i 2 E .. 'yi ".P "'. ^.". I T IT 3 !{ EMISSIONCONTROL 6E-9 1.4VACUUM ADVANCE CONTROL The ignitionadvance on engineswith EST is electronic- ally controlled,therefore no VAC system is used on these engines. Engineswith EFI (except those for registrationin New South Wales) use a VAC system similarto VH with 3.3 engine and automatictransmission. The hose layout has been revisedto suit the EFI installation.Refer Figs. 6E-6 and 6E-7 for hose routinodetails. vAc SYSTEM(NSW) The vacuumadvance control system ior 3.3 engineswith EFI and production option V7Y (New South Wales emission requirements)differs in certain respects from the system meetingthe nationalrequirement: The follow- ing paragraphsrefer to the V7Y Wpesystem. Description ln addition to the high temp#Jife (1O4oC) thermal vacuum switch in the therm6stab: housing, which is common to both VAC systems,thp:componenls specific to the VAC systemfor the V7Y optionconsists of: r A low temperature(150C) thermal vacuum switch locatedin the air flow duct and sensingthe inlet air temoeralUre. r A medium temperature (40oC) ihermal vacuum switch located in the engine brock and sensing engineblock metaltemperature. r The necessary vacuum hoses to connec the components.Refer Fig. 6E-8 for componentlayout. LOW I:'.'': ? (15ocl -. s 1# MEDIL..'- TEMPERATU R: (4ooc) TVS ] STRIEUIOR_ Figure 6E-8 Operation - Refer Fig. 6E-9 104oC Thermal Vacuum Switch .1 The 04oC thermal vacuum switch in the thermostat housing,senses engine coolant temperature.When coo- lant temperatureis below 104 o C, the TVS directs a portedvacuum signal from the throttlebody to the centre port of the 15oC TVS located in the air flow duct. lf coolant temperatureexceeds 104oC, the 104o TVS operates to direct full manifold vacuum (rather than ported vacuum) to the distributor and provides full vacuumadvance at idle to preventengine overheating. 6E.10EMISSION CONTROL 1yg 4606 ---....-.- (IN ENGINE B LOCK) DIST A IBUTOR f=i ASSEMBLY I 1.; AtR FLOW-\k< )---7 DUCI'nl tnt- \ i i{ MANI FOLD V qCUU1/] SOUFCE ..T\,. 10a c TI EP fOUS,l;G,"IOSTAT )Oq--fED VACUUM - THROTTLE BODY j Figure 6E-9 'l5oC Thermal Vacuum Switch The I5oC therma vacuum switch in the arr |ow duct, sensesinlet air temperature.When inlet air :ernperature E\CJNE rs below 15oC, the ported vacuum sigr-a rs routed c.ectly to the distributor,by-passing the :O:C TVS in the engine block. When the inlet air temceratureis above 15.rC,the 15oC TVS redirectsthe po(ed vacuumsignal awavfrom the distributorto the lC, C TVS in the cylinder c ocK 40oC Thermal Vacuum Switch When the lnletair temperatureexceeds 150C. the Dorted .l vacuumsrgnal s directedto the 40oC TVS vra the 50C TVS in the arr flow duct. The 40oC TVS sensesengine blocktempe'ature. When this temperatures celow40oC, the vacuumsrgnal through the .10oCTVS rs blockedand vacuum aovance is dened. When engine metal temperatureexceeds 40iC :he TVS 'openi' and the portedvacuum signal is tirecled lo the distributorvacuun advanceuntt to permitvacuu-n advance. PORTE D * VACUU[4 ADVAN CE Fig. 6E-10 summerizesthe operationof the VAC system A LLOW: D when productionoperation V7Y is excersided.Figs. 6E- 11. 6E-12 and 6E-13 show the emissionhose routinir w9 wrthV7Y. Figure 6E-10 EMISSIONCONTROL 6E-11 3?, E rE...H i 3ii c = o E;ii,;9.. ; ! cPFt=.: ; 6 E"t1,;61i+ s 2 t E z :J EiisE'i3!utr;O:^^^FF Ei c 5 : @ F E ; ,ffi, i ilEi.r.;5EEi" 9 EHeEFPEP"T'r:! 5 Hif;EH::::: HP e ..-..fi.$^ -= z r r r ! E: 6 2 = =3 = = z tr o F 3 z E z (9 z F l I z 9 2 E m:ii 1 \9 [. -$ 6E-12EMISSION CONTROL E F z F P> F 42 E \ z E a' IE 5 z "9I 6 = z , N 2 E z tr E : ; I F ; = UJ z 6 I I ! z 6 ; a ..': ..: k I U9 (9 =z z F l ; iiE E3 ut i.rii,:i z !- EiiHF';3; 6 : FEHs:iiE 2 i sXis{{t H E E EFFEPP9: I = e.Ptcq.1 6^ ? s3E?i:i e t'. eea.eEp r--- EMISSIONCONTROL 6E.13 o L z -FF i '-H: I z ! d= Eu1;o ;xzE aEo* z 6 I d2i,u, E lt-og = z 1Ee; z E F I ? F = I z :i z 6- .. I 9 = z B F P l '),@ E cc ru I tl 6IH1 : z 1\\\ *:oi.;F i 6 ,-' \ i e;565 3 2 = I E E_a'e'e'e; I u^ u1.i 6.qq. yl 6 >9>>> 6 1 6E.14EMISSION CONTROL 1.5AIR PREHEAT The air preheat system for L6, 3.3 EST and 5 O litre engines,carries over in generalfrom the VH. No air oreheatis reouiredwith EFI 1.6AIR INJECTIONREACTOR The air pump type a' ^.ecio- reactorsystem is fitted to 3.3 EST engines S r 3' 9rp€Sare balancedfor air flow by inclusion:' :" scecrficallysized for each pipe and located a: :-: :, ^der head end. The syster. rs essentra, :- = sa-e as used on VH witl 2.a tre engines :=':' Section06, VH Serviceila.L,a. S,.pple- menl '.'i:-3' for principlesof operatic. a'3 service rpera:: - :elarls. Refer Figs. 6E-1 6:-2 a.o 6E-3 for rac,-- ^:se routingdetails. 1.7EXHAUST GAS RECIRCULATION The EGRsystem for th€ : : .treengine carries over rrcm r'H The EGR systens ':' 3 3 litre engineshave ceen substantiallyrevised .,/.' :f'reVH type. 3.3 LITRE EFI ENGINES The exhaust gas s Crrectedto the EGR valve via an :xternalpipe (F; a=-14)to a port in the inlet manifold. -ie EGR val,,: s mounted on the inlet manifold, copositethe p:: rrefer Fig. 6E-14).Ported vacuum is J rectedto the iGR valve via a thermalvacuum switch, 'e'er Figs.6E-6 6E 7, 6E-11and 6E-12for EGR system ^cse lavout. Figure 6E-14 3.3 LITRE EST ENGINES The iGR slsrem for EST engineshas the E3r raive EGR VALVE - mountedcn :he ,nletmanilold (refer Fig. 6E-15) GASKET _.. MANUAL -TRANSMISSIONS ON LY Figure 6E-15 EMISSIONCONTROL 6E-15 Models with EST & Automatic Transmission Portedvacuum is directedvia a thermal vacuum switch to the EGRvalve. Refer Fig. 6E-2tor hoselayout. Models with EST & Manual Transmissions The EGRsystem for EST engineswith manualtransmiss- ions incorooratesan EGR modulatorvalve located in the F=1 rL vacuumline betweenthe thermalvacuum switch and the EGRvalve (refer Fig. 6E-16). - EGR VALVE - The purposeof the EGR modulatorvalve is to control the ooerationof the EGR valve so that the admissionof exhaustgas into the combuslionchamber is highest at times of potential high oxides of nitrogen emission generation. r ?,1'\\ \ \. li Very little Oxides of nitrogen are generated at engine \\ ' ' \\ \ --::/'/ idle, light engine loads or on overrun.Oxides of nitrogen EGF'.IODULATOR emissionincreases during acceleration. VAL'.: As the throttle opens, a ported vacuum signal is routed througha thermal vacuum switch. The switch 'turns on' at 40oC to prevent exhaust gas recirculationwhen the Figure6E-16 engineis cold. EGR valve operationis furtherregulated on EST engines and manual transmissions by the operation of the modulatorvalve. EGR Modulator Valve Description The modulatorvalve is a bleed type vacuum control TO VACUUI\,4C_:"'3ER devrcewhich uses exhaustgas pressureto control an air R ESTR I CTC F OF EGR VAL..: bleed within the valve and modulatesthe vacuumsignal - TO CARBURETiO= from the carburettor to the EGR valve according to I engineload. ,,lA TVS _\r1 // The valve (refer Fig. 6E-17)consists of two chambers has separatedby a diaphragm;the diaphragm a seat at : LLTER its centre.The centre tube of the tee preceis retainedin the upperchamber which is ventedlo atmospherevia a filter. The two exposedbranches of the tee piece each contain a restrictingorifice. One branch is connected to the vacuumline from the carburettorand TVS and the other to the vacuumchamber of the EGRvalve. DIAPHRAGT,' The purposefo the restrictorsis to damp any pulsations in the vacuumsignal from the manifoldand help control EGR valve responseto rapid changesin exhauslgas oressure. Figure 6E-17 The lower chamber of the valve is exposed to exhaust gas pressure via a hose from an adaptor located ECA ', ALVE between the EGR valve and inlet manifold teter TO BACK PRESS!AE Fig.6E-18). TRANSDUCEA - >-9a \" . ADAPTOB _ l!,r\JAL _, TFANSi\IISS O)JS \ 649xg1- O\ LY Figure 6E-18 6E.16EMISSION CONTROL RESTRICTORS ^ +-TO CARBURETTOR EGR VALVE PORTEDVACUUM SIGNAL UPPERCHAMEEF - LOWEF CI]A\1BEq- VACUUM VENT / EGF \iODULATOR..,, VA L\.'E ADAPTOR BACKPRESSURE-/ TAPPING CONTROLLING ORIFICE EXHAUST UAJ JIUtr MANIFOLD SIDE Figure 6E-19 EGR Modulator Valve Operation (Refer Fig. 6E-19) With low exhaust back pressure in the valve lower chamber,the vacuumline is vented to atmospherevia the centrebranch of the tee and filter.The EGF valve remainsclosed and no recirculationtakes place. As exhaustback pressureincreases during acceleration or under load, the pressure on the diaphragmalso increases,the diaphragmmoves the diaphragmseat and restrictsthe ventingof the vacuum line. This results n vacuum being appliedto the vacuum chamber of the EGR valve, the EGR valve opens and recirculatron commences.As engineload, (reflectedin the vaiue of exhaust back pressure)increases, the venting of the vacuumsignal decreases, applying more vacuumto the EGR valvevacuum chamber, permitting the EGR valveto ooen further and admit more exhaust oas rnto the inductionsystem. As engineload decreases,exhaust pressure deCreases, diaphragmforce decreases,vacuum signal venting in- creases and the EGR valve reduces the amount of exhaust gas being recirculated.The valve thereiore modulatesthe vacuumsignal to the EGR valve to make EGR valveoperation sensitive to enqineload. 1.8THROTTLE NUDGER Vehicles with 3.3 EST engine and manual transmissions are fitted with a throttle nudger similar to that used on VH with the 2.8 litre engine and manual transmissron. Refer Section 06, VH Service Manual Supolement M38731 for descriptionand operation. Refer Fig. 6E-1 for throttle nudger hose routing. EMISSIONCONTROL 6E-17 2. SERVICEOPERATIONS 2.1 GENERALINFORMATION Serviceoperations lor emissionsystem componenls carry over in generalfrom VH Seriesvehicles. Service procedures for the following components are covered in Section09 'EmissionControl Systems' of the lmprovedPerformance Engine ServiceManual part num- ber M38338. . EGR Thermal Vacuum Switch Testing and Replacement. . EGRValve Checking, Cleaning and Fleplacement. o EFE Thermal Vacuum Switch and Actuator Testing and Feplacement. o Air PreheatSystem Testing. o VAC SystemTesting. o Positive Crankcase VentilationSystem Testing and Servicing. . EvaporativeEmission Control System Servicing. Serviceprocedures. for the Air Pump and ThrottleNudger are coveredin Section06 'EmissionControl' of the VH SeriesManual Supplement part numberM3873 1 The followingservice operationis new for VK series vehicles. 2.2 EGR MODULATORVALVE TEST 1. Disconnectall hoses from the EGR modulatorvalve and removevalve. 2. Installa vacuumsource such as hand pump J23987- 01 or equivalentto the bottomvalve port. 3. Operatethe vacuumpump, and it shouldbe possible to draw a vacuum on the valve diaphragm.lf a vacuum is not drawn, the valve diaphragm is defectiveand the valve must be replaced. 4. Connect the vacuum pump to one side of the 'T' piece on top of the valve, plug the opposrteend of the 'T' piecewith a suitableplug. 5. Operate the vacuum pump and it should nol be oossible to draw a vacuum.This indicatesthat the valve fitter is operating correctly. lf a vacuum is drawn, the fitter is defectiveand the valve must be reolaced. 6E.18 EMISSIONCONTROL 3. SPECIALTOOLS HA\D VACUUM PUMP J23738 (or equivalent) NOTES ENGINETUNE 6F-1 SECTION6F ENGINETUNE INDEX Ref. Subject Page I Ref. Sublect Page 1. GENERALINFORMATION ...... 6F-1 3.2 3.3 LITREEFr .. 6F-4 2. ENGINETUNE RECOMMENDATIONS...... 6F.2 Tune Conditions 5F-4 3. ENGINETUNE DATA. 6F.3 3.3 5.0 LITRE 6F-4 3.1 3.3 LITREEST ...... 6F-3 Tune Conditions...... 6F-3 Check List ...... 6F-3 1. GENERALINFORMATION To maintaindesigned vehicle performance and emission The EngineTune Recommendations.ha1. sets out the levels, it is recommendedthat regular maintenanceand items recommendedfor attentionduring an enginetune adjustments be carried out in accordance with the and cross referenceis providedto the appropnatesource scheduleoutlined in the VK SeriesOwner Handbook. of informationThe EngineTune Data charts(reler 3.1. Engine tune specificationsnecessary to achieve the 3.2 and 3.3 in this Section), provide abndgeo engine cor-rect emission levels are located on the Vehicle tuningdata for both 3.3 litre and 5.0 litre engines. EmissionControl InformationLabel attachedto the right hand suspenslonstrut tower underthe enginehood. The label should be referred to before making any adjustments. 6F.2ENGINE TUNE 2. ENGINETUNE RECOMMENDATIONS ENGTNETUNE RECOMMENDATIONS I REFEBENCE EngineCompression Test lS".t'o. 10. "Engine Tune Up" of the lmprovedPerformance Eng ne ServiceManual P/N M38338. For EFI vehicles,also refer Section6C ElectronicFuel Injection,Service Note 9. of tnis Suoolement. EngineD.i,.'e 3ert. Checkand adjustas Section6, "Cooling Systems"of the VH SeriesService Manual necessary. SupplementP/N M38731. Section6, "Cooling Systems"of the VB SeriesService Manual P/N M38145. ldle SoeeC i Checkanc aCjustas 3.3 Litre EST. Section6C, "Carburettors"of this Supplement 3.3 L tre EF l. Section6C, "Electronic Fuel Injection,"of this Supolement. 5.0 Litre. Section5, "Engine FuelSystems," of the lmproved Performance Engine Service Manual. Referto specifications on the emissioncontrol labelon the right handstrut tower. Automatic Choke Checksettings and linkage. 3.3 Litre EST. Section6C, "Carburettors"of this Supplement. 5.0 Litre. Section5, "Engine Fuel gystems"of the lmproved PerformanceEngine Service Manual. Air Frlter Element Section10, "Engine Tune Up" of the lmpr-ovedPerformance EngineService Manual. For EFI engines,also refer Section 6C "ElectronicFuel Injection" instruction3.5 of this Supplement. ValveLash Adjus:^len1 Non adjustablehydraul ic I lashadjusters. in'line Fuel Filter Checkor replace. 3.3 Lirre EST Section10, "Engine Tune Up" of tne Improved Perf ormance Engine Service [\4anual. 3.3 Litre EFI Section6C, "Electronic Fue Injection,,,of this Supplement. CLean,adjust or reDlace Section10, "Engine Tune Up" of the lmprovedperformance EngineService Manual- gnitionTiming Checkand resetas Sectior 6D, "lgnition System" Specifications of thrs necessarY. Suool e me nt. .-- r9nttton Htgn lenston Sectior 10, "Engine Tune Up" of the lmprovedperformance Cables Eng ne ServiceManual. Throttle Nudger Check and resei as Sectio- 6, "EmissionCont-ol" of the VH SeriesService Manual ' ESTmanual only) necessa ry. Suop le me nt. EGR Valve Air PreheatSystem Check for correct 3peration. EngineVentilaiion System Sectro^9, "EmissionCont'ol Systems"of the lmproved EvaporativeEnr rssions .8ep ace carisle- f te. at PerformanceEngine Service Manual. Systems specified interval. Batteryand Cables Check Section12, "ElectricaiSection', of the VB Seres Service Manual I and Secton 12A "Battery and Cablesof th s Supplement. Checkall hosesand connectorsfor air leaks. Checkand rectify as necessary. Throttle Position Switch Check for correct operation. Sectio- 6D, "lgnition System"service operation 2.7 of this EST models only ) Supolement. ENGINETUNE 6F-3 3. ENGINETUNE DATA 3.1 3.3 LITREEST ENGINE SPARKADV. SPARK PLUGS TRANSMISSION IDLE SPEED RPM FASTIDLE BELOW (IN NEUTRAL) SPEED 900 RPM 3'ese:'.,isual 3.3 Litre EST Manualor C^e:k crlv AC 1.51!!m- ,: HC I (114) Automairc 6' : C42CLTSX NOTE:Carburettor is not to be adjustedprior to 1500 km service. Only the idle speed may be adiusted from 1500 kms onwarcls. Prior to making any carburettoridle adjustments,refer to Section6C, Garburettorof this Supplement. TUNE CONDITIONS Before making any checks or adjustments,warm the tn engine by running for 6 minuteswth transmtsston ^,.a>\,J-- neutral and fast idle screw on second step of fast idle / Fig. 6F-1, or running for 10 minutes at ^ refer _l cam, -- 80 km/hr on a chassisdynamometer. / in I Switch ignition off, restart vehicle with transmission l neutral.Check engine tune specifications' i I 1sr.srEP I -t^rn QTtrp -,?+ I,vr J '/A 3FD. STEPJ ' . 2 ' -L_n- | aTH. ST:e Figure 5F- l CHECK LIST (A) Engineidle speed exceeds880 rpm. 1. Checkthat enginehas beenrunning 15 minules. 2. Checkthat throttle closes onto stop. Ensurethat the throttlenudger, choke and throttlecable are ccrrectly adiustedto allow the throttleto close onto stcp. 3. Checkthat throttleposition switch is closed 4. Checkthat advanceat idle is lessthan 1O: 3TDC. (B) Engineidle speedis lessthan 700 rpm 1. Checkengine has been running15 minutes 2. Checkpower to antr-dreselingsolenoid. 3. CheckPCV valve for flow. 4. Checklor vacuumleaKs I 5 Creck for greaterthan 2 BTDCadvarce 6F.4ENGINE TUNE 3.2 3.3 LITREEFI DlsrRlB-u.T-oR ENGINE IDLE SPEEDRPM IDLEco spARKpLUGs ADVANCI SIZE i OPTION RUN IN ENGINE "k^ BTDC* RpM GAP EFI 12"BELOW AC {LLgr 1100 C42CLTSX TUNE CONDITIONS Enginetune settingsare lor an enginewith:- 1. Engine coolant and oil at normal operating temperature,preferably achieved by drrving(both CO and idle speed are dependant on engine temperature). 2. Transmissionin oarkor neutral. 3. Air conditioningswitched ofl. The followingchecks musl be performedand any defects correctedbefore any idle adjustmentsare made to the EFI system. 1. lgnitiontiming. 2. Vacuumto luel pressureregulator. 3. Throttlelever closingon to stop - if not check: a. Throttleposition switch adjustment. b. Linkagesn! 5prrngs. 4. No leaksat hosesand duct betweenair flow meter and engine. 5. Runningon all cylinders- if not checkfor a. Defectivespark plugs and leaks. b. Open circurtto iniector/s. 6 Auxiliaryair valvefully shut - check by pinchingoff air hoseand observingengine speed. lf speeddrops checkfor: a. Enginenot sufficientlywarmed up. b. Open circuitin electricalsupply to auxiliaryair valve. c Auxiliaryair valveon upsidedown. NOTE:Before adjustingthe idle speed,disconnect th€ canisterpurge hose from the canisterand then adJUSt idlespeed. Refer to serviceoperation 3.5, Section 6C of thisSupplement. 3.3 5.0 LTTRE ENGINE IDLE SPEED RPM DISTRIBUTOR SPARK PLUGS INITIAL ADVANCE GAP srzE coMp TRANS. sLow FASr TYPE Jr-r?|, ] ETDC @ BPM mm 1500 NlAN. Fo ptnn 5,0 HC L31 2nciaTGHEST AUTO. ^a-?1 1 5 44Tx ) ttrr a50 F F^.' VACUUM ADVANCE I-,OSEDISCONNECTED AND PLUGGED For 5.0 litre Tune Conditions refer to Section 6 Engine Tune of the VH Series Service Manual Supplement. Engine Tune Specificationsare on the Emission Control label on the rignt hand susper iron strut tower. CLUTCH7A.1 SECTION7 A CLUTCH INDEX Ref. Subject Page Ref- Subiect Page 1. GENERALDESCR1PT1ON...... -...... 7A-',t 2. SERVICEOPERATIONS 7A-1 1. GENERALDESCRIPTION The clutch assemblyused on VK Seriesmodels is carried over from the VH Series. 2. SERVICEOPERATIONS For clutch adiustmentdetails refer Figs. 7A-'l and 7A-2. For all service operations refer Section7 of the VB ,/t'/ CommodoreService Manual, Part No. M38145. -t ).-- .. EI \ --:'t ,ta ds // t//' '\\ ' \(^\ \Y '/z \ .<_BEFC,= ADJUSTMENTS A=: CARRIED OUT, ENSURE CLUTCts FORK IS FULLY S:A-:] IN BALL STUD. ADJUS- SLEEVE ON CABLE :'iD ;ITTING,TO ACHIEVE CLUTCF C:DAL POSITIONAS SHOIVNON FIG.7A-2, Figure7A-1 To adjustclutch cable, lightly load clutchfork in direction ol arrow Z, reter Fig. 7A-1, so that throwout bearlng contactsclutch spring fingers. Then usingcable adjusting sleeve set clutch pedal to correcl heightwith rubbertrim pad removedfrom Pedat. Figure 7A-2 MANUALTRANSMISSION 7B-1 SECTION78 MANUALTRANSMISSION INDEX Ref. Subiect Page i Ref. Subjecl tage 1. GENERALDESCR1PT1ON...... 78-1 | 2.1 TOROT.TOROUEMASTER 78-2 2. SERVICEOPERATIONS 7B-2 I 2.2 BORGBORGWARNEB(5-SPEED)...... 7B-2 1. GENERALDESCRIPTION The Torquemasterfour speed manual transmissionis The followrngchart sets out rnanualtransmission applica- standardequipment on VK Series SL 19 and 35 styles tion lor VK Seriesmodels. with the 3.3 litre EST engine. The Borg Warger five speed manual transmissionis available as a productionoption on vehicles with the lor 3.3 EST engine 3.3 litre EST engine.Transmissions Body Style application,carry the code BE stencilledin yellow paint on the lefi hand side of the transmissioncase- 3.3 llt:e EST Torquemaster 'lst Revisionsintroduced for code BE transmissionsare:- (3.50:l gear) 1. GEARS:stress relieved by shot peening. E:rg lVarner 2. 5TH SPEEDMAINSHAFT GEAR: needle roller bea- ring has been deleted (refer Fig. 7B-1).The gear now rotates on a revised bearing surface on the J Sta':a'c !:, :rent mainshaft. N/A Noi A,: a: = Avairaci::s t-c:-c: on Option 3. GEARRATIOS: I rsr 3.23 1 I 2ND 1.96:1 NOTE: Manual transmrssons are not available if an 3RD LZO I engine is equippedwitn E eclronic Fuel Iniection 4TH 1.00: 1 5TH REVE RSE THIS BEARING IS \OT USED tN CODE,,BE'. TRAf.rSr,ltSStONS - G!J.-,\ G._ .+ ,ai-: --,\ - /:rE=\ u{,- ,J -JgE{e= .*, ' -zi 'L: Figure 7B-1 I 7B..2MANUAL TRANSMISSION 2. SERVICEOPERATIONS NOTE: Before removingany manual transmission,the EST soeed sensor must be removedfrom the rear of the cylinder block. Refer to Service Instruction2.8, Sec- tion 6D, lgnitionSystem. of this Supplement. 2.1 TORQUEMASTER For removal and installationinstructions refer to Sec- tion 07 of the VB Commodore Service Manual Part No. M38145. For overhaul procedures refer to the Torquemaster Service Manual,Part No. 92010388,and Torquemaster ServrceManual Supplement, Part No. M39043. 2.2 BORGWARNER (s-SPEED) For all service operations refer to the Holden Com- modoreFive SpeedManual Transmission Service Manual, PartNo. M39071. AUTOMATICTRANSMISSION 7C-1 SECTION7C AUTOMATICTRANSM ISSION INDEX Ftef. Subject Page Ref. Sublect Page 1. GENERALDESCRIPT1ON...... 7C-1 1.12 BANDAOJUSTMENT...... 7C-5 1.1 TRANSMISSIONCODES. 7C-1 1.13 THIRDCLUTCH ASSEMBLY 7C-5 1.2 1.2 & 2-3 SHIFTCONTROL VALVES AND 1.14 SECONDCLUTCH DUMP BALL 7C-6 SLEEVES 7C-2 1.15 PRESSUREREGULATOR BOOST VALVE 1.3 1-2 & 2-3 SHIFT VALVES...... -..-....- 7C-2 AND SLEEVE 7C€ 1.4 MANUALVALVE 7C-3 2. TRANSMISSIONSHIFT SPEED CHART .... 7C-13 1.5 LOW SPEEDTIMING VALVE...... 7C-3 3. TRIMATICTRANSMISSION SPRING 1.6 1-2 ACCUMULATORCONTROL VALVE.... 7C-3 IDENTIFICATIONCHARTS .... 7C.14 't.7 ACCUMULATORP|STONP1N...... 7C-3 3.1 coDE LP (3.3LITRE EST ENGTNE)...... 7C-14 1-8 TRANSFERPLATE...... 7C-4 3.2 coDE LR (3.3LITRE EFr ENGTNE)...... 7C-14 1.9 SERVOPISTON 7C-4 3.3 coDE LS (5.0LITRE ENGTNE) ...... 7C-15 1.10 VALVE BODYIDENTIFICATION 7C-4 4. LINEPRESSURE SPECIFICATION 1.11 VACUUMMODULATOR VALVE AND CHART ...... 7C-15 SLEEVE... 7C-4 5. SPEC|F|CAT|ONS...... 7C-16 1. GENERALDESCRIPTION The Trimatic Automatic Trasmissionis standard equip- LP Code incorporatesthe earlierdesign olen converter ment for VK Series on Berlina and Calais. Trimatic is housingand IR code uses the carry:ver 'full circle' availableas an optionon all other VK Seriesmodels with converterhousrng design. the 3.3 litreEST, 3.3 litreEFI or 5.0 litreengines. Transmission code tS. 5.0 litre. ca" es over from Carryoverof the Trimaticto the above 3.3 litre engines 5.0 litre VH rrodels and WB Statesman has necessitatedthe release ol new Trimatic transmis- The followingparagraphs set out the calibrationdetails sion codes. for eachof the rew transmissioncooes Transmissioncodes LP, 3.3 litre EST, and LR. 3.3 litre EFl, are the same as transmissioncode FP, 3.3 litreVH, exceptwhere noted in this Section. 1.1 TRANSMISSIONCODES The lransmissionidentification plate carriesthe transmis- sion serial numberand applicationcode. The following codes are used with VK SeriesTrimatic transmission. TRANSMISSION CODE ENGINE LP 3.3 litre equippeC.'. t' EST LR 3.3 litre equippec'.'.ln EFI LS 5.0 litre 7C.2 AUTOMATICTRANSMISSION 1.2 1-2 & 2-3 SHIFTCONTROL VALVES AND SLEEVES All three transmissionsuse the same 1-2 and 2-3 shift controlvalves. ldentilicatronis by a ring aroundthe valve reier Fig. 7C-1 lor 1-2 shifl conlrol valve identification. IDENTIFICATION RING Flgure 7C-1 For 2-3 shift controlvalve identification reter Fig. 7C-2. The three transmissionsalso use the same 1-2 and 2-3 controlvalve sleeves. The 1-2 control valve sleeve is identifiedby a green colourmarking on the open end of the sleeve. The 2-3 control valve sleeve has no colour markinoon the open end of the sleeve. IDENTIFICATION _ RING Figure 7C-2 1.3 1-2 & 2-3 SHTFTVALVES All three transmissionsuse the same 1-2 and 2-3 shift valves. The 1-2 shift valve is identifiedby a hole drilled in the end of the valve. ReferFig. 7C-3). This hole has a 1-2 shift valve spring inserted,which assists governor pressureto reduce the road speed at whichthe lightthrottle 1-2 upshifts occur. This valve is not interchanoeablewith the Series 3 shift valve. DRILLI\G - Figure7C-3 The 2-3 shift valve is identiiiedby a ring around the centreof the valve stem (referFig. 7C- ). This valve is not interchangeablewith the Series 3 shift valve. IDENTIFICATION RI\G- Figure 7C-4 AUTOMATICTRANSMISSION 7C-3 1.4MANUAL VALVE A modified manual valve is used with LS code transmissions. It incorporatesan end drillingwith 2 bleed holes (refer Fig. 7C-5). The modifications to the manual valve improvethe shift qualityfrom drive into neutralrange. Figure 7C-5 1.5 LOW SPEEDTIMING VALVE The low speed timing valve in codes LR and LS transmissionshas been revised.The overall lengthof the valve has been decreasedfrom 48.M-48.90 to 43.5- 43.8 mm (referFig. 7C-6). This is to allow the inclusion of a low speed timing controlvalve and sleeve. For details of the low speed timing valve and control valve operation,refer to page 40 of the ServiceManual 'TrimaticPrinciples of Operation'Part No. M37823. Figure 7C-6 1.6 1.2 ACCUMULATORCONTROL VALVE All three new code transmissionsuse a common 1-2 accumulatorcontrol valve. The diameterof the spool sectionof the valve has been increased from 8.705-8.712 mm to 11 .079- 1 1 .087 mm (referFig. 7C-7). + This valve is not interchangeablewith the Senes 3 controlvalve. _-_I_ 11 n70 :i:^: DtA.! tt.u6/ Figure 7C-7 1.7ACCUMULATOR PISTON PIN The accumulatorpiston pin on all three transrnissionshas been increased in length trom 43.2 mm to 44.2 mm (referFig. 7C-8). The accumulatoroiston sorinq has been deletedfrom the three transmissions. .<_ 43.2 _ 44.2 mm ______> Figure 7G-8 7C.4 AUTOMATICTRANSMISSION 1.8 TRANSFERPLATE Transfer plates are identified by their part PART NUMBER number STAMPED IN THIS AREA stampedin the area shownin Fiq. 7C-9. I 9/' TRANSFER PLATE PART NUMBER APPLICATION ( r-n 92017838 LP lrll f - o 9242',278 -+t J O Figure 7C-9 1.9 SERVOPISTON For identificationdetails of the servo piston used in all threetransmissions, refer Fig. 7G10. The servo piston is the same in all three transmissrons but the servo cushion springs ditfer. Refer to Spring ldentificationCharts in this Section for cushion spnng identification. DfMENSfON'A' = 21.99-2'i.f4nm Figure 7C-10 1.10VALVE BODYIDENTIFICATION The valve body for each transmissioncarries three digits followed by the calibrationalpha letter stamped on the undersideof the body,adjacent to the accumulatorpiston pin (relerFig. 7C-11). ------TRANSMTSSIONr qODE_-- VALVE BODY LP I eZe" IDENTI F ICATI ON LR calib"ation - aiphacharacter Figure 7C-11 1.11VACUUM MODULATOR VALVE AND SLEEVE - IDENTI FICATION RING All three transmissionsuse the same vacuum modulator valve and sleeve. Valve identificationis by a ring aroundthe valve stem as shownin Fig. 7C-12. Figure7C-12 AUTOMATICTRANSMISSION 7C-5 The vacuum modulatorsleeve is identifiedby the length of the sleeve,Fig.7C-1 3, and a blue colourmarking on the closedend. Figure 7C-13 1.12BAND ADJUSTMENT The correctband adjustmentprocedure is as follows: 1. Remove oil pan and servo cover, loosen adjusting screw lock nut. .1 2. Using Tool No. 7AT4 and a torque wrench, tighten .1 I: t- adiustingscrew to 4.5 Nm then back off screw. TURNSBACKED OFF pan. 3. Tightenlock nut and install servo cover and oil OUICK Refill transmission with Dexron ll Automatic R E LEASE TransmissionFluid. VALVE Jtrh. . Figure7C-14 1.13THIRD CLUTCH ASSEMBLY The third clutch assembly for code LS transmissions diflersfrom that used in the six cylindercodes. Revisionshave been made to the clutch piston return springsand spring retainer. Dimensionsfor third clutch returnsprings are as follows: ] rnnrrrsrvrssroN I cooE LP& LR LS Free Length 26.97 mm 29.13mm Total Coils 8.75 Diameter 10.9mm For identification of the LS return spring retainer,refer Fig. 7C-15. Figure 7C-'15 7C.6 AUTOMATICTRANSMISSION 1.14SECOND CLUTCH DUMP BALL Code LS transmissionshave incorporateda dump ball in the secondclutch circuit. When the second clutch is being applied,second clulch oil seats the ball and the leed is directed through an orifice. During the release of the clutch, the ball is unseated and the clutch can exhaust at a faster rate throughthe two onfices.Refer Fig. 7C-16. T F - O o z -oRrFtcE Flgure7C-16 1.15PRESSURE REGULATOR BOOST VALVEAND SLEEVE The transmission pressure regulator boost valve and sleevehave been revisedon LS code transmissions. For details ol the boost valve and sleeve used on the three transmissionsrefer to Figs.7C-17,7C-18 and the chartsbelow. VALVE CHART 15.126- 15.118 mm 11.765- 1'l .758 mm 15.'126- 15.118 mm 11765-11.758mm 16.502- 16.494mm rJ /bo - tJ.//v mm Figure 7C-17 SLEEVE CHART rRANS CODE -lB ----T--A] LP 15.159- il 15.138mm 1'1.796-il 778mm i ii LR 15.159- i5.138 mm 11.796- 11 778mm BA LS 16 535 - 16.515 mm i3.8i9 - i3 779 mm .L Figure7C-18 AUTOMATICTRANSMISSION 7C.7 . '-;i-- ---"--"a-!sa-. ::/ -'l . I ,-=s.r. SENSORHOL: -\ --\. -t. -\--< // ) Ol- ; TUBE ASM. d%\ ,a . --ER q-l\i@)\ ,.,- - ia r--- _-___...-.r,,.,r, (\ , tt .\,, /^J\ w) :^5,i v@+s,t - \ \ -(./' \ --.fr i),X \l/ )s/ \1. /)\,. r --d O A------t\L.- \: CONVEFTEB --l MATCH BLUE PAiNT BALANCE MARK ON CONVEFT=R \!ITH ELUE PAINT 20-28Nr BALANCE i\lAFK ON DRIVE PLATE. VIEW 45-5ONm 7.0 - 19.0 Nm TRANSMISSIONINSTALLATION DETAILS _ 3.3 LITRE E.S.T. 61 -7ONm Figure7C-19 7C.8 AUTOMATICTRANSMISSION \\ I ,/. ,e .. tv . ''i /.t:- ' ,." ),, ,,2, . CONVERTER HOUSING BOLTS 4 PLACES B:, t1 / ?--",' % <-- : 4 --" (R,' ,A /J MATCH BLUE PAINT BALANCE MARK-- 1c r ON CONVERTER WITH 3LUE PAINT - 2 PLACES BALANCE MARK ON DRIVE PLATE. 5 3 - 10.6Nm ; 20-28Nm A VI EW L"_ 45-50Nm &A 61 -70Nm A TRANSMISSIONINSTALLATION DETAILS - ENGINE z t\ 40 51 Nm 3.3 LITRE E.F.I. Figure 7C-20 AUTOMATICTRANSMISSION 7C.9 /^:L-- ^ tv t =F :H Har !r^ --:-/ T. lg rL-!:: % tr . ).\ :-{- \ \ \ € ! (aJifr ,,/'- 4 PLACES .3 MATCH BLUE PAINT EALANCE \1ARK -' ON CONVERTER WITH BLUE PAINT BALANCE MAFK ON DRIVE PLATE VIEW 3 7.0 - 10.0 Nm , 40-54Nm TRANSMISSION I NSTALLATION DETAI LS _ 1 40 48 Nrn 5.0 LITRE ENGINE Figure 7C-21 i---tlrr- 7C.10AUTOMATIC TRANSMISSION q) aJ = U IJJ o t u z il o tr tr .J gJ l z t2 z; O-^ F z 9- => (-)o o> q.1 Ll =F o-; t q@ o 2o) O-g u cc u.i iz YU' zr-I =tr ats u J:- LrJ + cor-- O c't cr9> F He; 3 4 ;.).; o I = z '46--6 r !:< i z UJ o ;:>F = F L IU a:o k F rn = a -1--; A* X uJ 6| -F 6| fv € r--: o () sz t! o i+ Y 2 UO> - g ><- J a-lor^zt- z --Jo<< > ) ) >e 2= :c '. !- >r =u 0- // / 1r ,/ t> -/ / : z --. c r >ia l LC)I A -\l AUTOMATICTRANSMISSION 7C.1 1 z 9 t UJ 3 J U o N o N o t 6 lt-9 F 1,, z6 UL \< :-LA ccEcr ug)u JCC> : t. F vl ,, uiA enHi =vd! Zt!n{ "'A-,, U U =u{>z L d o- YOL!U F loni uJ F a J LIJ) a F l = -L T II ; '-t U J o :o o x 6\, )>{< 7- Gl :l O)\ l\ /<= \.. \ \,,,,: .:\-\ u ( 1' ' rl ' ''\ tl \ Dn -.a rrt 7C-12AUTOMATIC TRANSMISSION z I J l= a -- L:J u) z --) 7 '1Tr it .n IIJ ,1 -U ul CL /,, EuJ ,-x I iv ccE e-J FF \ z ,uJ UJF A-- o \Yi \\/ F \\ / / O \\t/ U Urt -W z cr o I (h A:- 2 Y:!Cco E L-r)O u) z -E"t!uu: zQrz; (r =U5;< IuEu* I+8.. i,^'o c z .^ >, 2 Yli>u- zz=)l N tttt- I a U /C 9s_€c N-N ;l N(oGo NC .€ ...1 <--l -- J-! AUTOMATIGTRANSMISSION 7C'13 2. TRANSMISSIONSHIFTSPEED CHART (3'3litre EST) UPSHIFTS km/h - LP FULL THROTTLE CLOSEDTHROTTLE 110-120 All Tvre Sizes,3.08 axl (3.3 EFI) UPSHIFTS km/h - LR litre FULL THROTTLE CLOSEDTHROTTLE All Tyre Sizes,3'08 axle (5'0 UPSHIFTS km/h - LS litre) FULLTHROTTLE CLOSEDTHROTTLE All Tyre Sizes,2.60 axle (3.3 EST) DOWNSHTFTSkmih - LP litre THROTTLE PARTTHROTTLE CLOSEDTHROTTLE FULL *) 3 - 2 (AvailableUP To .^. 11'z An i;, IUJ-llJlvv - All Tyre Sizes,3.08 axle I (3.3 EFI) DOWNSHIFTS km/h - LR litre THROTTLE PARTTHROTTLE CLOSEDTHROTTLE FULL *) 1 z- l 3 - 2 (AvailableUP To "-, t^^ 65-73 14 -: 114-124 i All Tyre Sizes, 3.08 axle 12 - \ " (5'0 litre) DOWNSHIFTS km/h - LS THROTTLE PART THROTTLE CLOSEDTHROTTLE FULL (AvailableUP To ") 3-2 2 -'l 3 - 2 88 94 112-122 , 60-68 All Tyre Sizes,2.60 axle WITHDETENT SWITCH DISCONNECTED - 7C.14AUTOMATIC TRANSMISSION 3. TRIMATICTRANSMISSION SPRING IDENTIFICATION CHARTS 3.1 CODELP (3.3 L|TREEST ENGTNE) F REE O'D. SPRING COLOUR LENGTH TOTAL SPRING DESCRIPTION mm IDENTIFICATION APPROX. cotLs PART NO. mm NOMINAL 3 - 2 Contro Va ve Yellow 54.7 15.0 , 13.2 9942033 1-2Accumuiato.valve_ P.k I o.J o-u 13.2 92020511 Low Speed Downs.if i Vaiv€ Dark Eiue JC. / ; 10.3 2823165 High Speec Dorvnsh if 1 Trming Valve Purpte Jb.U rJ.c 10.3 2U68A2 Detent P.s55g1s Regulalor Valve Orange 42.E 1J.f, 12 92004309 - 1 _ 2 sn fi va ve orange 4r.o 13.5 ,", . ,"rr 'l - 2 Control Valve " II 2-3Control Valve None 36.5 10.3 14.2 994201 0 2-3ShiftValve Not Used Man. Low & Rev. Contrct Valves Green& Whrle 38.7 11.5 10.3 5258547 Pressure Regulator Valve U/nrte 70.3 12.3 19.6 JZSd I bb DetentValve Green& Red 36.8 13.5 10.3 9929681 I Accurula:o. Piston -l Not Used I Gov. Secondary Green& Orange 39.C 10.3 9944999 4' n-., ,1010646 lr ServoPisron Cushion I n"C 26.g 4 i 319 I s258564 Frls inside Shift Valve 3.2CODELR (3.3 LTTREEFt ENGTNE) FREE SPRING COLOUR LENGTH DESCRIPTION IDENTIFICATION APPROX. mm 3-2Control Valve I -2AccumulatorValve Low Speed Downshift Valve Hrgh Speed Downshift Timinq Valve 13.5 10.3 Detenl Pressu.e Regulator Valve 13.5 12.O 2811015 1-2Con:'ol Valve 10.3 14.2 92007171 i-2ShiilVa,ve 2-3Control Valve 10.3 14.2 I 9942010 2 - 3 Shift Va ve J t.3 N4an.Low & Rev. Conirol Va ves Green& White JO. / 11.5 10.3 Pressure Regu ator Valve 6a.9 12 3 19.6 Detenl Valve Green & Red 36.8 tJ.5 10.3 9929681 AccLmulator Piston Not Used Gov. Secondarv Green & Orange 390 I r.J 10.3 9944999 Servo Piston Release Green of,6 3. /a 47.O 92020646 Servo Piston Cushion I Orange 25.9 3.9 31.9 5258568 F its inside Sh if i Valve AUTOMATICTRANSMISSION 7C-15 3.3 CODELS (5.0 LTTREENGTNE) FREE o.o. SPRING COLOUR LENGTH SPRING mm DESCRIPTION IDENTIFICATION APPROX. PART NO. mm NOMINAL 3 - 2 Control Valve Light Green 13.2 ?945053 1-2AccumulatorValve 9:1205 12 Low Speed Downshift Valve Orange 3 5 aa'-1)A High Speed Downshift Timing Valve P*pb l -zo I a65z Detent Pressure Regu lator Valve 1-2Control Valve 9200717 1 1-2ShiftValve 2 - 3 Control Valve None 2-3ShiftValve fut"n.l-o* a n"u. Co. ., Green& White 5258541 PressureRegulator Va ve None 28 10499 Detent Valve 9929681 Accumulator Piston \ ot Used Gov. Secondary ,r.arw Servo Piston Release ServoPiston Cushion 31.9 9929676 * F ts nside Shift Valve 4. LINE PRESSURESPECIFICATION CHART TRANSMISSIONCC IOES LP LR LS 3.3 litre EST 3.3 litre EFI 5.0 litre kPa kPa kPa CHECK NO. 1 - Line Pressure in D + S Ranges iVacuum Modulato. P pe Connecrecl Veh cte coasting between 55 - 50 km/h 324 - 360 403 - 425 4C3 - 425 CHECK NO. 2 -Line Pressure ln Low Range (\'acuum Modulator P pe Connectecl) Vehicle coasr nq between 40 - 3O km/h 531 - 614 606 - 688 606 5:€ CHECK NO.3' Line Pressu.e In D Range (Vacuum Modulator Prpe Disconnected) 1200 rpm engine speed - foot and parking brake app red 903 - 978 973 - 1041 11-c9 1273 During Check No. 3 with the vacuum modulator pipe disconnected. the manifold connec:or must be plugged to p,event an :^c3ssrve air leak into the manif old. --- 7C.16 AUTOMATICTRANSMISSION 5. SPECIFICATIONS TRANSMISSIONCODE: LP - 3.3 litre EST SELECTORLEVER: Location Floor Floor Floor Sequenceof Sh'ftPositions "P" (Park),"R" (Reverse),"N" (Neutral), "D" (Drive), "S" (lntermediate),"L" (Low Range) TOROUE CONVEFTE R ASSEMBLY: Mernodof Attachmentto DrivePlate . WeldedNut & Bolt Nut & Bolt lder-tlfca:ron Letter (Printed Yellovl on F'orr Faceof Converter) Y Stal Ratio :1 2.4 2.4 2.0 Diameter (Nominal) 254 mm 254 mm 298 mm SPEEDODRIVE GEAR: Numberof Teeth 9 9 10 Colour Blue Blue Yellow GEAR RATIOS: First . . 2.31:l 2.31:1 2.31: 1 Second 1.46:l 1.46:'l 1.46: 1 Third . 1.00:l 1.00:1 1.00: 1 Reverse I .dr :1 t.tJ5 :l 1.85: 1 TORQUEMU LTIPLICATION : MaximumOverall Ratio in i st :1 554 4.62 LU BR ICANT: Tvpe . "DEXRON ll" Automatic TransmissionFluiC Capacity- Dry (includingConverter). . . . . 6.1 litres 6.1 litres 8.7 litres ilt Ref 2.3 litres 2.3 litres 2.3 't.es FLUID LEVEL INDICATOR {DIPSTICKI: Length (From Top of Cap lo End of Indicator) 808 mnr 808mm 680 mm C LUTCHES: Reve rse Tvpe..., Multiple Wet D,sc Dr ve Plates Description Friction Fac ng on SteelPlate Number 445 ReactionPlates Description Steel Steel SteeI Number c5 6 Piston Le1 Eth 35.99-36.09mm 35 99-36.09mm 3l.39-3 1 50 mm Crshion Plateused Yes Yes Yes Second Type . i\lultipleWet Disc Drive Plates Descript ro n Friction Facing on Steei Plate Number 556 AUTOMATICTRANSMISSION 7C.17 SPECrFTCAT|ONS (CONT'D.) TRANSMISSIONCODE: CLUTCHES (Cont'd.) DrivenPlates Descripti on SteeI Steel Stee * Number o 6 7 CushionPlate Used Yes ves Yes * NOTE: SomeTransmlssions have one additionalSteel Pla:g and one or more Sca::- , ":: Soacer Length 35.63-35.74mm 31.04-31 .14 mm SecondClutch Spacerscan alsobe rdent,f,edby the lastdigit of the PartNumber on the Spacer SpacerPart Numberapplication 2820681 282068i ?2019879 Clutch PackEnd Play .38/.76 m- .38i.76mn 33 76 mm Third TYPe... \4ultipleWet Disc Drive Plates Description Fr;ci o^ Facingon SteelP a Number 4 5 DrivenPlates Description Steel Steel S::e Number 5 5 6 Piston Length . . 17 17-17.27 mm \,'t/-ll.l/mm lJ: -13 6'1mm CushionPlate Used Yes yes One Way Clutch So.ag Sprag So'ag Function Co^nectsInput:c GearSet in First Ge:- D.rve, O,,er-runsor b',.oassedin other c:-: : f,ns. - tt- FUELTANK 8A.1 SECTION8A FUELTANK INDEX Ref. Subject Page Ref. Subject Page 1. GENERALINFORM ATION 84.1 1.3 FUELTANK 8A-3 1.1 SWIRLPOT 2. TORQUEWRENCHSPECIFICATIONS...... 8A.12 1.2 FUEL GAUGETANK UNIT. 84.2 1. GENERALINFORMATION The fuel tank for VK Series models with 3.3 litre EST Also incorporatedin the fue tank ior EFI equipped engine canies over from VH, except for the deletion of vehiclesis a fuel return line, whrcr ceirversfuel from the the fuel filler limiter pot from inside the fuel tank and EFI fuel pressureregulator, back :c :he swrdpot. revision to the fuel filler cap pressure relief valve. VK Seriesmodels with 5.0 litre engrnes.r.corporate a hot Pressureis now 12 to'16 kPa. Revisionhas also been fuel handlingpackage, refer to Sect'on6C'Engine Fuel made to the fuel venting system due to the deletion oJ 5.0 litre Eng-ines'oflhis SupptementThe crang-esmade the fuel filler limiterpot. to the 3.3 litre EST fuel tank carry ove. to. use with the Revisionsintroduced for 3.3 litre EFI equippedvehicles, 5.0 litre engines. include the same modificationsto the venting system' fuel filler cap and ihe deletionof the fuel filler limiterpot as for 3.3 EST engines.Additions include a swirl Pot and a new fuel gaugetank unit (Fig.8A-1). =LOAT f FUEr GAUC: / (FUL- P:)StirON) L *>vvthL rul FUEL PICK.UPFI LTER FuEL RETURN LINE FUEL GAUG: (FOB PRESUREREGU LATOR) -ANK UNIT Figure 8A-1 8A.2 FUEL TANK 1.1 SWIRLPOT FUEL PICK.UPPIPE The plastic swirl pot, located inside the fuel tank on ; 3.3 litre EFI models, is mounted on the bottom of the tank (Fig. 8A-2). lt providesa reservoirof fuel to prevent the fuel pick up becominguncovered during cornering or when the fuel level in the tank is low. -1 For practical purposes, the swirl pot is part of the tank and no servicework is possibleon it. \ SWIRL CHAMBER _ Flgure 8A-2 The fuel return line is connectedto a venturiat the base of the swirl pot. This high velocity jet of fuel picks up VENTURI extra fuel and deliversit to the pot througha tangential passage.This keeps the pot full of fuel irrespectiveof the levelin the tank, and the swirlingaction separatesau vapourfrom fuel (referFig. 8A-3). and the :. The continuoussupply of luel to the swirl pot ensures 'l ]- pick not draw into the fuel ---->l that the fuel up does any air FUEL V,,l system. ENTBY F ROM TAN K FUEL RETUFNING FROM PRESS!R= REGULATOR Figure 8A-3 1.2FUEL GAUGE TANK UNIT The fuel gaugetank unit (Fig. 8A-4) for the EFI systemis of a new design and is not interchangeablewith previous Commodore tank units. The fuel pick up filter is immersedin fuel insidethe swirl pot. The gaugeunit is mounted to the tank by 5 screws and sealed against leakage by a cork gasket between the tank and the gauge unit. Sealant Part No. M39040 is appliedto the threadsof the screws and matingsurface of cork seal to fuel tank. For removal,testing and reinstallationinstructions, refer to service operation 2.6, Section '12C in this Supplement. Figure 8A-4 !t- v - ry FUELTANK 8A-3 1.3FUEL TANK Fuel tank removaland installationinstructions remain the same as on previousCommodore models. The only differenceis with EFI models,on removal,the luel return line must be disconnectedand reconnected on installation(refer Fig. 8A-5). Extreme caution musl be exercisedwhen disconnecting either the fuel return hose or the fuel feed hose to the fuel pump, as a great deal of tuel will spill trom the hoses. Beforestarting vehicle, carry our fuel systemleak test as per service operation 3.2' Section6C, ElectronicFuel Injection,of this SuPPlement. FTEL FEED LIN: GhEIU-\/ -" ---, -UtrLhUJtr Figure 8A-5 8A.4 FUEL TANK G cr LJJU t N ua r!< O r. C I == r-n : a F ! --F (i z F a aa 2 u :c f> II'::: u - ( t \ t! tr' 6 u F F 1 = o l --=__ L z F i: X\ -\ tr.J \r a : ,,/ c F z 3 U (r qJ U ct) J U z J F cn q) <.-,4^J \N =uJ _ I 1A ./ <5 T Ats __.)L:+b'., eE I - z-z I F< (o z - lo _--_\,_ Our ru z E ./' F O t't c/, I U -F -u, u o S-) U \JE rl (/> I IIJ \' ;cn \z ZY 3 uJ> -=+: U6 tll a z ) U = r{< F z (-) )-o E a o Lu -1 !t F Jz :- 2 UN o l t -: o u ( I -l rl / t:-, +-f-+ I '-tt - -""/ rt- FUELTANK 8A-5 a F zTz U] >l"d UiCE @ O- I rX o": @ U! z '-=- E,'i ; o uJ cc I \r\-/ U \-': LIJ o : z \ (J it' I F F O E U U tt) z a I I F ul O tr 6 a'. B r L u o a cc P J 2 vZ F -- :== Z.- !oI -- a2r z? 3ni I F nt! z lcu z z= \ vN Fjg FC a :> FT q Zr -F -U 1d -1- l 3> l-col 2@ oa6 6^--=3- r z I c0 I 6 = u = z z J z a d .a F N o u - @ € i I 8A.6 FUELTANK u oi zl L (I 4z u t= CE \ ^L (J -\ o 11 0 I o z 0() =z 2 t" z -t, o L ^ tn- F Il- n* Lv "! U a* r o nZ ilo ) LUF F O o l 7 z .U \ z auJ.. 63 @ Zsr a F UJ =^ t!- f I d) z z a : - z U- .\: s o YI rt- FUELTANK 8A.7 z o 9 z 6 rr F L!u :: OC) :) r!< z _I a- On F (t , G= z z' i-n tr; u1 ;= = +a Zt St ul k; cc of : $ ua o il l. -U .- u o \ gH ut ouJ F ICf \ F ... \ \': t'.. - ," = -t, I o "\i .r'-, o :. ';":/-\, -- .'' 1'. ,/.- ,. : l,r. a: Li \\. i r'l - - ri a :i I I 'j I - ,l | ^l 'z - \ .l leJ -l --- t=l o o \ ('' 3 F )---) u \ ; l 4",/ 6-_ -z ; t! a/t O 5 z) -z U il tr 6o t o= 7z JJ II -z o J uA z< o) o z (-l a F= I <\J U (D t= n ?= o ;Y 3 J I xcc I r U(J I U ctr O :!^ < tt z /l z XF c z 9 Yv) F o 1./ FUJ U u.l z= z O 6 z U = U > t 8A-8 FUELTANK (r l o c cr I UI \: F z F 9 = l u J U z II - u ) ,,4 u U il 7 n vl z o z< -z F tr I,.i O F <; U U) u ztr o t[- E ZJ) 3 oa u u cn II a F I -v) F (9J o z u n =x L r == r:< oz so o Y"z-: sH<5 ?= (o . VF d: >o I z @ o I (-) o -U z a a tr z U a - i.. N \J \-] FUEL TANK 8A-9 : u u- tr- =< U@ >N Zlas >: uu z 9 = z o = F 6 z - ) v) t1 =6 uJ> zq @ J6 ctt P= lt a> ,i:./Z >J ,cY./.. / \ re) ,/ v),/ ) lrl \,/ - E2 lol ,3 t:l : u - ^-- 8A.10FUEL TANK U z = U I cc z co F --'--, C) i#{ L = ,r'-\ z! L !r -= lz ( l-, a t -)) a? cc lu l u(! tr l o a r_T] II?J Z't FUJ fr- Of tr co ul 4 z= t-l f= t? (o H o t I ?o lt t1 (n >! V --- --]:. rr --- \ \\ \\ -. = J u\ tz C f= F ol rF = ! \Z >c! t\ I : 5 -rl 4 FUELTANK 8A.11 (I ,i\;(Jr u v,,, i,',* \*> ( \ 6._, U F J r -,_lo-l J a-41-r U f L ,a; ?rt == 2_dtA = ce U L € az o o 2-a ; ll 41J : 2v = CU) r- ! zu) -.2 : ,u T !uJ =U) //r ItTtl l-Y ( lEl € = ..\ lzl L (I o cc = u cc F ? z z tr O f F o U tr F r l o < u-) c l i I I U z_ l z ) o Z ( E (-)F l ); F U U @ )) E 5 I 8A.12 FUEL TANK 2. TORQUEWRENCH SPECIFICATIONS Nm Fuel Tank Strap, Boltsand Nuts 26 - 32 Fuel P oe HoseClamos 1 Fuei Tank SenderUnit Scrervs( E.F.l. onlv) . 2.8 -3.2 NOTES ^a EXHAUSTSYSTEM 8B.1 SECTION88 EXHAUSTSYSTEM INDEX Ref. Subject Page j Ref. Subject Paqe 1. GENERALDESCRTPTTON ...... 8B-1 r 3. SPECtFtCATIONS...... 8B-i1 2. SERVICEOPERATIONS 8B-1 4- TORQUEWFENCH SPECIFICATIONS...... 8B-12 2.1 EXHAUSTEXTRACTOR 8B-1 Remove...... 8B-l Reinstall 8B-2 1. GENERALDESCRIPTION All 3.3 litre VK Series models equippedwith Electronic but in place of the standardexhaust manifold. a set of Spark Timing (EST) have a single exhaustsystem which stainlesssteel exhaustextractors rs fitled carries over from VH L6 models. Five litre VK Series models have fifted a dual type All 3.3 litre VK Series models equippedwith Electronic exhaust system.which is carried over from VH 5.0 litre Fuel lnjection(EFl) have the singletype exhaustsystem, models. 2. SERVICEOPERATIONS When installingthe exhaustsystem, care must be taken When installing the exhaust system, ensure that the to installeach part or assemblyin correct relationto one correct assembly,installation, tightening sequenceand another. Inconect assemblyof exhaust system compon- clearancefor the systeminvolved is observed. ents can frequentlybe the cause oi rattles or 'booms' due to incorrectalignment or clearancefrom the body or suspensionparts. 2.1 EXHAUSTEXTRACTOR BRACE BOLt REMOVE z- 1. Disconnectbattery earth lead. 2. Remove air flow duct and inlet manifoldas per service operations 3.9 and 3-11 Section6C (ElectronicFuel Injection)of this Supplement. 3. Removegenerator brace bolt (Fig.8B-1), disengage fan belt from generatorpulley. Loosen generatorto support bracket bolt and nut (Fig. 8B-1) and swing generatordown awayfrom the engineblock. 4. Raisefront of vehicleand place on stands. BRACKET EOLT Figure 88-1 8B.2 EXHAUSTSYSTEM 5. Loosen exhaust clamp around exhaust eltractors (Fig. 8B-2). Tie up exhaust pipe with wire, so that the pipe is supported when the extractors are removed. 6. Lowerfront of vehicle. 7. Remove erlractor end flange mounting bolts from cylinder head. Disconnectenractors from the ex- pipe lift extractors from engine haust and out \ ,T EXHAUST compartment. { CLAMP ,, \=\ ----7 1r^rou* EXTRACTORS EXHAUST PIPE - ..--: Flgure 8B-2 REINSTALL 1. Clean mating surfacesol exlraclors,inlet manifold and cylinderhead. 2. Inserla new manifoldgasket in place on the cylinder head. 3. Positionextractors, engaging the exhaust pipe and positioningonto cylinderhead. 4. Reinstall inlet manifold and air flow duct as per service operations 3.9 and 3.11, Section 6C (ElectronicFuel lnjection)of this Supplement. 5. Tightene).tractor mounting bolts to torque specified at end of this Section 6. Refit fan belt and generatorbrace bolt, readlustfan belt and tighten generatorto support bracket bolt and nut. 7. Raisefront of vehicleand place on stands. 8. Removesupporting wire. Tighten exhaust clamps and check exhaustsystem clearance. 9. Connectbattery earth lead. Check for fuel leaks as per service operation 3.2, Section6C (Electronic Fuel Iniection)of this Supplement. 10. Startengine and checkfor exhauslleaks. 11. Lowerfront ol vehicle. EXHAUSTSYSTEM 8B-3 E. ul) LUL L J ;> +L ) O uZl -J cc< J m i I I o ) -Tl.-L ; F U U l@ 1 i! >--L! .a UA aa coY /o <= 5 * z -9 o i Q =; I U ao CO o ul J ;i $O tv^/.;rll '4= ^N ct) P< F ( J :d lt =k L a /'L \-l (J dl !< z rl z z< 22 N3 - 'I 88.4 EXHAUSTSYSTEM I co 4 (i z (, cc^ u ,6 r =u U P< uJ O I cri cc co U a I l c! a z F z U E F; q a- CC +a U 3 6J UJ l z (9 ifi 2 uJ E FUJ ? r.,r >E <- a 5a? @ Ec'' GO v)l c) z !: 4.> U'= g F :> l- ctt tt u7 (tJ cc- gco fLu >S ^- -rt + 3 : O ,ieE I 'V z z = N J o i v F t U \J EXHAUSTSYSTEM 88.5 tr -G, U J m> ia o- fu >: (9o' [-J ut- : r@ - <6 U,N trO 9> ",=Yii"-: .h 4 ': ! :, cf u uJ r'> co > du,. Aaa :- i: uJ[ -n -6 (a t. ,^1 z=- \ l z -= F 22*,2#, F tr _eel:v,j J z o c-Jr(Jr -JJ-Uf r A^- q LlJ FU z z U: qJ F r.! 22 z\ >: -! )[ -\ \..1 )J />l C:=-1i\ '='t\ U X-\l) \a =ul \< o iL'os L aF O'r t p; / F U.1 ,t( \\-< Rfi J a UJ !3 '\. UU - z< U ' / z< U7 zz -L! 88.6 EXHAUSTSYSTEM zz liP L/ a- .=^a) 3- -L -z @Y I I F tt I z ^z q > u.l J_ 6 zu tt z z uJ I x= z ->\o>) X >z J z ^u LLilI uJ a q< zz ;-C).^ FUJ U r)!? f,o: : z N - s N \l EXHAUSTSYSTEM 8B-7 z : UU )-J r- ,1\ \ LlJ FF (h at) \)l o)6 / tt) U- z^ o)o /F = U c) OI I a of _U I zo U - F- ou U cc J U a U l o cr i r!v I f,z z C -1 trL \ o (" o J J li J () u ti r I tr il lll z cc -;N F U c/2 lll z ) U z J IJJ O t\ \Z (o @ @ ul = uJ o tr F U ct) I = lt o J F f C, T I I x (9 ul z z tr o U F F i U U ct) r zF o ct rI UU I ,,tr --(t (t I "/ o i: I ,c ;t o = a z ) E I o qq Ul F I FO ,i ! I .t U- a 3 .z l q-. >- (ouJ -,,>, < - a I C - -\ 88.8 EXHAUSTSYSTEM n U I J c0 \l ,; ul :> z ; ( -) l<=J n J L i\ U o I t^ ct U a I J z (, o o z z F z O F : U z ig 0 l 5 I c U a.<1< o o : @l z z -j F z : tr c O : o F J o O ) tr I @ T ? ! q Lu z (9 z ut 'v FUJ //o fE OF ,'n P >-i U- //\r :l // t; @ 5ro o cc t&- trF o CD nr\ FF iln, o z -) g= H! 9 q, ct) z \J, FJ tr u z sx a Zo l = rE r U Xo uJ qJ z J :l tr : uJ c : cn z : d Y J \,r \V' 'y'' I 'rz// /=.. i5 // '\ I z // ,/ /// -r -F z O //R U \, /tr \ = a di / dx :: u,7 J EXHAUSTSYSTEM 88.9 REAR cRossMEMBE R ---r, FUEL TANKl \ ,\ \, ti ra;-- Ai fl \\ BAr\VI \\ __>120il\ o l<_ SECTION E_E SECTION F_F S:CTION G-G FOR LOCATION OF SECTIONSREFER FIG ub-5 5 O LITRE DUAL lr FLOORPAN ,,-f:AR ^i: :: '.' -;: -ER /TREARMUFFLER -f /---\ I <-- \ ("----'I, FUEL TANK 25.0->i <-- secrroruK-K :cr :.. L-L FOR LOCATTONOF SECTIONSREFER FrGS 3B-3,5 EXHAUSTSYSTEM CLEARANC ES Figure 8B-9 FUEL TA\K -""t.' ' lJ.! \ ;\\ \ \--'------>1 '\ /-^\ {- --7 \ secrror A-A S=CrrCNB-B sEcrroruC-C FOR SECTION LOCATIONSREFER FIG 38 J EXHAUST SYSTEMC LEARANCES Figure8&10 88-10 EXHAUSTSYSTEM a o o tr ?,3 A[@ = Y- .y v UJ F F./) - IL T E X U UJ F F l o f UJ ( X uJ i a (, z *1* U o F L I ,# r EXHAUSTSYSTEM 88.11 r e: CRAi.]KSIAFT + | | /.! -- V '<-2J2 0 mm --> EXHAUSTEXTRACTOR CLEARANCES 3.3LITRE EFI I]IODELS Figure 8B-12 3. SPECIFICATIONS Type: Single. 3.3 'tre EST all rrodels Single. 3 3 t'e EFI (w :h extractors) Dual . . 5.0 'itre mode s ExhaustPipe 5C8mm Material Seam i,n,eldedsteel tube Engine Pipe Diameter: ExhaustExtractor pipe d a 3 s.zes 35 mm x 6 PiPes 4i.5 mm x 3 PiPes 50.8mmx1pp- Intermediatepipe dia. 50 8 mm Muf f ler connecting pipe d a 50.8 mm T^ir^i^^ l;^ I orrPrPr uio. 50.8 rrm 88.12 EXHAUSTSYSTEM 4. TORQUEWRENCH SPECIFICATIONS Nm Exhaus:Extractor to HeadBolts 27 -34 ExhaustExrractor to HeadNuts 41 -48 EnginePrpe Flange to Manifold Nuts L6 & V8 I z - to ExhaustClamp Nuts 24-32 NOTES STEERING9-1 sEcTtoN9 STEERING INDEX Ref. Subject Page I Ref. Subject paae 1. cENERALDEscRtPTtoN...... sr 3. ToRouE wRENcHspEcrFrcATroNs...... ;i 2. SERVTCEOPERAT|ONS...... 9.1 1. GENERALDESCRIPTION The steering system for VK Series mo'delscanies over from VH Seriesmodels. 2. SERVICEOPERATIONS For all service operations not noted in this Section refer to the VB CommodoreService Manual Part No. M38145 and the VH CommodoreService Manual Supplement Part No. M38731. On VK Series models there is fitted two types ol lower steering shaft to intermediate steering shaft couplingclamp. Part No. 92021862is identifiedby a date code stamp, refer to Fig. 9-1, Part No. 7809433 which does not have a date code stamp. The clamp nut tighteningtorque specificationhas been revised,refer to specificationsat end of this Section. LUU tr _l> Flgure 9-1 3. TORQUEWRENCH SPECIFICATIONS CouplingClamp Nui 42-48Nm -L WHEELSAND TYRES10.1 SECTION10 WHEELSAND TYRES INDEX Ref. Subiect Page Ref. Subject page 3. TORQUEWRENCH SPECIFICATIONS...... 'Io.2 1. GENERALDESCRIPTION The tyre and wheel size on SL sedan models has been The Calais has fitted, as slancard eouipment,a newly revised.The SL sedan has fitted a new 5.5 x 14 JJ steel designedallov road wheel. The atov road wheel as used wheelwith a BR78S14(P175/75 SR14) size tyre. on VH SLE modelsnow becomesocrronat eouioment on A new tyre P185/75 HR14 is now used on 5.0 litre Berlinamodels. models, this replaces the CR78 H14 tyre used on VH Service operationsare as described,n the Commodore models. VB and VH seriesservice manuals. All other wheel and tyre sizes remainthe same as used on VH models. 10.2WHEELS AND TYRES 2. SPECIFICATIONS SteelWheel: Rim Width 5.5JJ (OnSL Sedanonly) 6.0JJ Diameter t.{ tncn Maximum permissableradial run-out 0.8 mm Maximum permissablelateral run-out 1.0mm Offset. .... 5.5JJX 14-37mm 6.0JJX14-43mm Alloy Wheels: Rim Width 6.0JJ Drameter.... 15 inch Maximum permissableradial run-out 0.25mm Maximum permissablelateral run-out 0.3 mm Offset 44 mm DynamicBalancing: Maximum permissableWheel/Tyre out of balance 1.5kg mm Maximum permissableTyre radialist harmonic force variation(Tyre only) . 80N Maximum Load Ratinglper Tyre): BR78 S14 525 ks cR 78 S',r4 560 kg cR 70 Hl4 600 ks P205i',60HR15 590 kg P185/75HR14 530 ks P185/755R1 4 585 kg RECOMMENDEDCOLD INFLATION PRESSURE- kPa I t nE uP TO 3 PASSENGERS UPTO MAX.HEAD DESTGNATTON FRONT i RCAN FRONT REAR BR 78 S14 200 200 240 240 P175175SRr4 200 200 240 240 P185/75HRi4 200 200 240 240 cR 78S',r4 193 10? | 221 221 CR 70 H14 193 193 221 221 P205l60HR1 5 200 200 221 221 3. TORQUEWRENCH SPECIFICATIONS RoadViheel Securing Nuts . . 100- 108Nm F! BATTERY& CABLES 12A.1 SECTION12A BATTERY& CABLES INDEX Ref. Subject Page Ref. Subject paqe 1. GENERALTNFORMATTON ...... 124-1 2.3 CHARGINGBATTERTES...... :nEA 1.1 DESCRTPTTON...... 12A.-1 Low MaintenanceTypes ...... 12A-4 1.2 SERVICENOTES 12A.-1 MaintenanceFree Types...... 12A-5 2. SERVICEOPERATIONS 124-2 2.4 VEHICLEWIRING, PERIODICAL CHECKS 12A-5 2.1 BATTERY,SERVICE 124-2 2.5 DRY CHARGEDBATTERY, STORE AND 2.2 BATTERY,TEST...... ,, 124-2 ACTIVATE ...... t2A-s State of Charge - Low 3. DIAGNOSTS ...... 12A-6 llaintenance Type Batteries - 4. SPEC|FICAT|ONS...... 12A-5 Hydrometer Test -...-...... 12A.-2 State of Charge - MaintenanceFree Batteries ...... 12A-3 Load Test - All Batteries ...... 12A.4 1. GENERALINFORMATION 1.1 DESCRIPTION In all VK Series models,the 12 volt batteryis locatedin the engrne compartment behind the passenger side headlamp.The main battery cables are attachedto the battery terminals by spring ring type clamps and the negativeterminal is earthedto the vehicle body and the engineblock. Vehiclesfitted with the 3.3 litre EST or EFI engine are equipped with a low maintenance 80 min/215 amp battery.(Optional equipment such as air conditioningand trip computerdo not requirea larger battery). Vehicles litted with the 5.0 litre engine, a 75 min/ 235 amp, maintenancefree battery is fitted. 1.2 SERVICENOTES NOTE:The spring ring clamp batteryterminals should be removedas shown in Fig. 124-1. Never priseclamps off with a screwdriveror hammer. Push down as far as possibleon the battery post when refitting battery leads. CAUTION: Do not allow liquid from battery to contact eyes, skin, clothing or painted surfaces. Battery fluid containssulphuric acid which causes injury and damage in the event of contact. Flgure 12A-1 12A-2BATTERY & CABLES 2. SERVICEOPERATIONS The followingprocedures should be used to service,test properly followed, good batteries may be replaced and recharge batteries. Unless these procedures are needlessly' 2.1 BATTERY,SERVICE 1. Check batteryterminals and around battery area for corrosion deposits.Remove any deposits and treat with a solution of warm water and baking soda or ammonia, then rinse otf with clean water. Smear battery posts and terminals with petroleumjelly to resistcorrosion. 2. Check battery case and replace battery if case is cracKeo. 3. On all batteriesexcept mainlenancefree batteries, check electrolyte level and carefully top up with distilledwater as necessaryto level of indicator.DO NOTOVERFILL. NOTE: Normal battery water usage is less than 30 ml per 10,000 km, but may be more for long continuous runningor hightemperatures. 4. Check that batteryis firmly secured by its clamping bracket. 5. Check that battery cable terminals are securely attachedto batteryposls and that cable insulationis not damagedor wom anyrnherealong cable. Check that cables do not have broken or frayed strands and that they are securein their terminals. 2.2 AATTERY,TEST STATEOF CHARGE. LOW MAINTENANCETYPE BATTERIES. HYDROMETERTEST NOTE: a. Ensure specificgravity of battery electrolytehas not been previouslyreduced to suit hot climate (explanatorytag specifying specific gravity of new electrolyteshould be attachedto battery in conspicuousposition.) b. lf water has been added to battery,do not use hydrometeruntil electrolytehas been mixed by chargingfor at least30 mins. Hold hydrometervertically and draw in sufficient liquid from batterycell to allow float to float freely with bulb fullyreleased. Compensatereading for temperatureby adding0.004 tor every 5oC that the electrolyte temperature exceeds27oC, or subtracting0.004 lor every 5oC lessthan 27oC. Flgure 12A-2 BATTERY& CABLES 12A.3 3. Determine state of charge of battery using temPerature compensated specilic gravity and followingtable. TemperatureComPensated SpecificGravitY Fully Charged 1.240to 1.260 RechargeWhen Below Fully Discharged 1.110to 1.130 NOTE: a. lf electrolytespecilic gravity has been reduced for service in hot climates, typical temperature adjusted value of specific gravity below which batteryshould be rechargedis 1.150. b. The specific aravity of a charged battery should not vary more than 0.025 between cells. Large variationsindicate defective cells. STATE OF CHARGE. MAINTENANCE FREE BATTERIES NOTE: Maintenance free batteries operate on the same basic principle as other lead-acid batteries.As the battery is charged, lead sulphate in the plates is convertedto lead in- the negative plate, and to lead oxide in the positiveplate. Also, the specific gravity of the sulphuric acid electrolyteincreases. The essential differencebetween low maintenanceand maintenancefree batteries,is in the lead alloy in the grids.When the battery is operatedin the car at 14.0 V to ta.S V, the rate of water loss is so low that topping up is unnecessaryduring the life ol the battery,and the top can be permanently sealed. In the AC Delco MainlenanceFree batteryin the VK Seriesmodels, all of the acid is held within a hightlyporous separator material. Even when tully charged,the gases which are normally evolved from the water in the electrolyte are fully reabsorbed.Acid cannot leak at all. There is much less risk of explosionwith this type of battery' '1. The state of charge of a sealed battery can be checked by measuring the OPEN CIRCUIT VoLTAGE. (O.C.V.) 2. Disconnectbattery from all loads. Measurevoltage across terminalswith a voltmeteraccurate to at least 0.1 volts. A digitalmeter is recommended. 3. Determine state of charge of battery using the following table, which is accurate if the battery has been off chargeor dischargelor severalhours' BATTERY CONDITION OPEN CIRCUIT VOLTAGE Fuilv Charged UVCT I I.Y V I RechargeWhen Below 12.5V Fully Drscharged Lessthan 11 .1 V 12A.4 BATTERY& GABLES CAUTION: lf battery is in a car which has just stopryd, or has just come off charge or discharge,the O.C.V. will be higher or lower. Reliable readings will be obtained if battery is left standing tor several hours, say overnight. For quick checks just off charge, connect a load of about 10 to 15 amps, such as headlights, for five to ten minutes. The O.C.V. will be close to the fully stabilized reading.A little experience,carefully noting if the voltage is varying duing checks, and how quickly, will soon enable reliable measurementsto be obtained. LOAD TEST . ALL BATTERIES 1. Check batterystate of charge as above.lf under half MI:rER lQl rov n N charge,recharge before conducting this test. =-119I- 2. Connecta voltmeteracross batteryterminals. 3. Start engrnewhilst reading voltmeter. During starting at normal temperatures,indicated voltage of a fully charged battery should not fall below 10V. lf voltage lalls away quickly, battery is faulty. lf battery and engine temperaturesare below 5oC, voltage may be 0.5 to 1.0V lower.lf one cell is EATTERY faultyit will show up in this test by excessivegassing or overheating. NOTE: Battery €n be tested under load using a commercial battery tester as per manufacturer's instructions. Flguro 12A-3 2.3 CHARGINGBATTERIES Proceduresfor charging low maintenanceand mainten- ance free batteries are basicallythe same. With both types,fully flat batteriescan safely be boost charged,but care is necessaryto avoid excessivecurrent if the battery is over half charged,and particularlyif it is almost fully charged.Slow chargingis advisableil time permits. CAUTION: During charging, an explosive hydrogen- orygen gas mixture is released by the battery. Ensure there are no naked flames or electrical spark discharges in the vicinity of the battery during charging. NOTE: a. Fast chargingcan substantially'boost' a battery,but the fully chargedcondition can only be achievedby slow charging. b. Fast chargingmust not be used if: i. Specific Aravity readings are not uniform bet- ween battery cells, or are above 1.200 at the start. ii. Electrolyteis discolouredwith brownsediment. iii. Either of the above two conditions develops after commencingfast charge. iv. in the case of maintenancefree batteries,if the O,C.V.is above12.7 volts. c. The followrngtables assume 'constantcurrent' type chargers. lf 'constant voltage' charger is used, charge at 14.5V to 15.0V the battery will automaticallyregulate the currentto a safe level. LOW MAINTENANCE TYPES 1. Removebattery from vehicleand removevent caps. Rest caps loosely in openingsto prevent acid mist escaoino. BATTERY& CABLES 12A.5 2. Connect battery, with correct polarity, to charging CAUTION: Refer note under low maintenance type apparatusand set chargingcurrent accordingto the regarding overcharging- followingtable. 5. Refit battery to vehicle. Operate starter motor for approximately10 seconds,to removesurface charoe from battery. 6. Load test battery as previously described in this Section. 4A approx. 24 hrs.max. Proportional to the charge 2.4 VEHICLEWIRING, PERIODICAL 35A approx. 1 2 hrs.max at the start CHECKS To ensure etficientop€ration of electricalsystem and to safeguardagainst damage, the following checks should 3. Atter a few minutes, check electrolyte specific gravity be carriedout periodically: (as per operation2.2 in this section)and colour (see 1. Check that all wires are held securely by their note iii). respectiveretainer clips. 4. Monitor electrolyte temperature during charging 2. Check wires for chaffing or damagedinsulation and procedure. lf temperature reaches 55oC, switch otf repairor replaceas necessary chargingcunent and allow battery lo cool. Reduce 3. Check that wire terminalsand luses are secure and chargingcurrent to preventsubsequent overheating. that fuses are as specifiedat end of Section. NOTE: A fast charged battery can be brought to the fully charged condition by slow charging for a few hours. Duringthe last few hours on charge the current should 2.5 DRY CHARGEDBATTERY, STORE be 1.0 amp or less. AND ACTIVATE 5. Check voltage and electrolyte specific gravity once Dry chargedbatteries are fully chargedwhen manufactu- per hour. Slow chargingis completedwhen there is red and contain no electrolyteuntil actryatedfor no change in voltage or electrolytespecific gravity servrce. The dry chargedbattery is completely over a three hour period. seaiedand can be stored indefinatelywith no servicing untit actrvated.To CAUTION: Charging at over the recommended times or activate a dry charg€d battery: cuftents can significantlyreduce battery life. 1. Remove vent caps and add electrolyteof 1.265 specific gravit_vto each cell until corect level is reached. MAINTENANCE FREE TYPES 2. Several minutes after activating batrery. check electrolytelevel (not 1. Removebattery lrom vehicle. and add more electrolyte water) as necessary. 2. Connect battery, with polarity conect to charging NOTE: apparatusand set chargingcurrent accordingto the followingtable. a. After dry charge battery is activated,il becomesa 'wet' battery and only water should be added in subseguentservicing. b. Althougha dry chargebattery can be put into service immediatelyafter activation,the following tests are recommended: i. After adding electrolyte, check open circuit 24 hrs.max Proportional terminal'voltageof battery.lf less that 10V, replace battery. :o the charge Check specificgravity of electrolytein each cell. at the start lf any temperaturecorrected reading (see opera- tion 2.2 in this section)shows more than a 0.030 drop from initial specilic gravity of electrolyte, NOTE: lf the O.C.V.was very low, less than 10.0 V, the slow charge batterybeJore use as per operation initial charge current may be quite low. The current 2.3 in this Section. shouldincrease after a short time at the charge voltage. ilt. Check cells for violent gassingand if detected, 3. Monitor battery temperalure. lf the battery feels slow chargebattery before use. noticeablywarm, switch off charging cunent and allow battery to cool. Reduce chargrng cunent to prevenl subsequent overheating.A fast charged bafterycan be broughtto the fully chargedcondition by slow chargingfor a few hours.During the last few hours on charge,the current should be 1.0 amp or less and the voltage 15.0 V maximum. 4. Checkvoltage and currentonce per hour, as charge approachescompletion. Slow charging is completed when both voltage and currentare constantover a three hour period. 12A.6BATTERY & CABLES 3. DTAGNOSTS CAUSE BatteryOverfilled *-e X Battery Underf;lleo l X Battery Cracked o o o BatteryOld Faulty O X o Generato.Faulty o VoltageRegulator Faulty o X lgnition Switch Faulty O Faulty or Worn Wire/Cable O Bad Connectlon(s ) O O Indicatesocssrble cause. X lnd;catesmore orobablecause 4. SPECIF|CAT|ONS BATTER Y: R:-:el \/nlteno 12 r'olts Capecitv... Reserve/ColdCrankino Veh cleswith 3.3 l;:'e EFI or EST 80 min./215 amp Vehicleswith 5.0 I :-: engine 75 min.l235 amp NOTE: Specified ra: ngswhen testedin accordance with Australiar^Standard AS 2149 - 1980 1- LIGHTINGSYSTEM 128-1 SECTION12B. LIGHTINGSYSTEM INDEx Ref. Subject Page Ref. Subtect Page 1. GENERALDESCRtPT1ON...... 12B,-1 2.3 HEADLAMPSWITCH...... 128-4 2. SERVTCEOPERATTONS ...... 12B.2 Remove...... 12B'-4 2.1 REAR TArL LAMP (SEDAN)...... 12B'-2 Reinstall 12B,-4 Rernove...... 12B.2 2.4 DASHLtcHTS DTMMERSWITCH...... 12B-5 Reinstall 128-3 Remove...... 128-5 LICENCEPLATE LAMP SOCKET Reinstall 128-5 (SEDAN) 12B,-4 3. sPECrFtCATtONS...... 12B-5 Remove...... 12B.-4 Reinstall 12B.-4 1. GENERALDESCRIPTION The lighting system for VK Series models carries over TA L .AMP LENS from VH Series models except where noted in this f Section. On all models,the front turn signallamp assemblieshave a clear crystalappearance lens, with an amber inner lilter for amber illumination. On all sedan models,there is a new style rear tail lamp lens and tail lampextension moulding, refer Fig. 128-1. ==--- Sil=== LTAIL LAf..p --\ EXTENSI: ). MOULDIN 3 Figure 128-1 On all sedan models,the rear licence plate is illuminated by a new licence plate lamp socket assembly and is attachedto the bumoer.refer Fio. 128-2. Figure 128-2 -- 128-2 LIGHTINGSYSTEM On stationwagon models,the rear licenceplate illumina- tion is by two Camira sedan style licence plate lamp assemblies, mounted on the rear bumper bar. Refer NUMBER PLATE LIGHT ASSEMBLY Fig. 128-24. (2 PLACES) REAR BUMPER Flgure128-2A 2. SERVICEOPERATIONS Serviceoperations for the VK Serieslighting system carry over from VH Seriesmodels. exceot where noted in this Section. 2.1 REAR TAIL LAMP (SEDAN) REMOVE '1 . From inside boot, remove globe sockets from the rear tail lamp assembly that is to be removed, Fig. 128-3. NOTE: To remove the globe sockets on the passenger side tail lamp, removethe spare wheel. => LrLuuE- SOCKETS (8 PLACES) LICENCEPLATE LAMP CONNECTORS Flgure 128-3 The two outer globe sockets on the passengerside tail lamp are removed by depressingthe lever (arrowedin Fig. 128-4\ and twist the gtobe socket in the directionof the REMOVEarrow. Figure 128-4 -t v LIGHTINGSYSTEM 128-3 2. Remove the four screws around the outside of the tail lamp extensionmoulding, refer Fig. 128-5. I- NUT TAIL LAMP_ EXTENSION SC8:!V MOU LDING 2 9LAC:S REAR LA'tl' SCREW 2 PLACES \*u-, \- -\ -- tr: AR BUMPER BAR -,-/ Flgure 'l2B-5 3. From inside the boot, removethe two nuts securing the tail lamp enension mouldingmounting brackets to the rear end panel, refer Fig. 128-6. Remove e)|tension. TAIL LAMP_ NOTE: On Calais models, it will be necessaryto remove EXTENSION MOULDING the boot caroet to reveal the two nuts. n,, - - ----:5 Flgure 12&6 4. Remove the five tail lamp mounting screws from inside the boot, refer Fig. 128'-7,remove tail lamp assembly. ''.-.: REINSTALL Installationis reversalof removalprocedures. Check lamp ooeration. ,., Flgure 128-7 128.4 LIGHTINGSYSTEM 2.2 LICENCEPLATE LAMP SOCKET (SEDAN) REMOVE 1. Disconnectbattery earth lead. 2. From inside bool, disconnectlicence plate lamp socketwiring connectors, refer Fig. 'l2B-8. 3. Pushgrommet and wrringconnectors out towardsthe rearof the vehicle. 4. Removerear bumper bar as per service instruction 1.3,Section '1 D of tbrssupplement. GLOEE- SOCKETS (8 PLACES) / PtnTE -lCE\CE -/ -AI,'1PCONNECTORS Figure 128-8 5. Removescrew holding lamp socket lo bumper bar, referFig. 128-9 and removesocket. NOTE: Licence plate globe replacementis by pushing globe against spring in the socket and twisting globe, which releasesit lrom the socket. REINSTALL lnstallationis reversal of removal procedures.Ensure licence plate lamp wrring grommet is fitted correctly. Checklamp operation. BUMPER BAR-=-T\ Figure 128-9 2.3 HEADLAMPSWITCH REMOVE 1. Removecover from lower right hand dash panel, referFig. 128-10. 2. Reachup behindswitch throughcavity in lower right handdash panel,and pull wiringharness connector fromswitch. 3. The light switch is a snap fit into the instrument facia.Push out lightswitch from behindJacia. REINSTALL Installationis reversalof removalprocedure. Check light switchoperation. Figure 128-10 r LIGHTINGSYSTEM 128.5 2.4 DASH LIGHTSDIMMER SWITCH RIGHT HAND REMOVE LOYJER DASH PA\EL 1. Remove headlampswitch as per servtce operation (REAq'ilEW) 2.3. 2. Through the hole vacated by the headlampswitch, remove the two switch mounting screws, refer Fig. 128-11. 3. Pull the switch back and disconnectwiring connector, DASH L 3.ITS withdraw switch. / DI MME F MOUNTING _, SWITCH REINSTALL SCREW{2) Installation is reversal ol removal procedures. Check operationof dash lights. Figure 128-11 TURN SIGNAL F LASHER UN IT EDGE CLIP-\ .iSTRUI\1ENT _-rhrtrH ,:\Er-1,_ ITAZAFD WARNING "- FLASFER UNIT Figure 128-12 3. SPECIFICATIONS TURNSIGNAL FLASHER UNIT Make. Hella Operation . . 60l120 flashesoer mrnutewith audibe i3unc LOCatron fnstrument car e- panel. ReferFig. 128-12 Accessis garnedcv removingcover f ron lorver right hand dashpanel, refer Fig. 12B-l0. HAZARDWARN ING FLASHER UNIT: Make Delco Operation 60/120 f lashesper minute. Location fnstrument carne' panel. ReferF ig. 128-12. Accessis gainedcy removingcover f rom lower right handdash panel, refer Frg.1 2B-10. RATING OF GLOBES: Headlamp 60/55 watt Haiogen Instrument Panel I llumination 1.2 watter Push-ln ALL SWITCH& CONTROL ILLUMINATION: GeneratorCharge Indicator 2 c.P. Back Up and Turn SignalLamps 21 watt Bavoret Dome Lamp 10 watt Festcon Eng ^e and RearCompartment 10 wait Fesioon Dome Lamp - Calars 10 watt Festoon Front ReadingLamp - Calais. . 12 watt Bayonet lnterror RearOuarter Lamps- Except SL model . . . 10 watt Festoon Front Park Lamp . 4 watt BaYonet Glove Box Lamp 5 watt Festoon LrcencePlate Lamp - Sedan. 10 watt Bavonet LicencePlate Lamp - StationWagon 3 watt Bayonet (2 off ) Stop/Tail Lamp 21 5 'ta'.t BaYonet w -- INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C-1 SECTION12C INSTRUMENTS,GAUGES, WINDSHIELD WIPERS/WASHERS INDEX Bef. Sublect Page I Ref. Subject Page 1. GENERALDESCRIPTION 12C-1 | 2.2 INSTRUMENTCLUSTEF . MECHANICAL 1.1 MECHANICALINSTRUMENT ASSEMBLY 12C-1 INSTRUMENTS 12C-14 1.2 ELECTRONICINSTRUMENT ASSEMBLY.. 12C-3 Remove...... 12C-14 Warnlng !:mp Panel. 12C-3 Reinstall...... 12C-14 Alpha lVarnlng Display... 12C4 INSTRUMENTCLUSTEB - ELECTRONIC Temperature Gauge...... 12C-5 rNsTRUMENTS...... __.. 12C-14 Fuel Gauge.. 12C-5 Speedometer and Digltal Speed Dlsplays 12C-6 2.4 Tachometer 12C-6 Odometer and Trlp Meter ...... 12C-6 Trlp Gomputer 12C-7 2.5 Automatlc lnstrument Display Dlmming 12C-7 2.6 1.3 TOUCHSWITCHES - MECHANICAL& ELECTRONICINSTRUMENT ASSEUBLIEC 12C-8 1.4 TR|P COMPUTER...... 12C€ Reinstall ...... 12C-19 General Descrlptlon...... 12C-8 Fuel Tank ...... 12C-19 Functlon Descrlption.. ... 12C-9 2.7 SPEEDOMETERGEAR CHART...... 12C-23 1.5 TRtP COMPUTERCOMPONENTS...... 12C-1 1 3. WINDSHIELDWIPER AND WASHER...... 12C.24 Fuel Flow Sensor 12C-11 3.1 GENERALDESCRtpTtON .._...... 12C-24 Fuel Level Sensor ...... 12C-ll 3.2 SERVTCEOPERATTONS ...... 12C-24 Electronlc Control Modu|e...... 12C-11 3.3 wfPER DWELLCONTROL SWTTCH ...... 12C-24 Speed Sender 12C-12 Remove...... 12C-24 2. Reinstall ..12C-24 2.1 1. GENERALDESCRIPTION All VK Series models have a redesigned instrument assembly. 1.1MECHANICAL INSTRUMENT ASSEMBLY SL models have a speedomeler, fuel consumption indicator, voltmeter, temperture, oil pressure and fuel gauges.An analog clock is situatedin the middle of the instrumentcluster. Refer Fig. 12C-1. Below the instrumentcluster is the warning lamp panel incorporatingturn indicator,charge indicator lamp, park brake and brake failure lamps, low oil pressurewarning lamp, high beam indicatorand EST diagnosticlamp. On Berlinamodels the assemblyis the same except tor the additionof a tachometerinstead of the fuel consump- tion indication. A control panel to the left of the instrumentcluster containstouch switchesfor the rear windowdemister and other options for both Berlina and Commodore SL models.Refer Fig. 12C-1. 12C.2INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS { mur 13 > p; +2. rsr 1. OIL PRESSUREGAUGE 6. VOLTMETER 2. FUEL GAUGE 7. TEMPERATURE GAUGE 3. TACHOMETER(EERLINA) 8. REAR WINDOW DEMIST SWITCH (BERLINA) FUEL CONSUMPTIONINDICATOR (SL) 9. ANTENNA RETRACTOR SWITCH (BERLINA) 4. ANALOGUE CLOCK IO. ANTENNA EXTENSIONSWITCH (BERLINA) 5. SPEEDOMETER I 1. REMOVABLE BLANKS: FOR SPECIFIC OPTIONS Flgure 12G1 1. ALPHA WARNING DISPLAY 9. PHOTOTRANSISTOR - AUTOMATIC DTSPLAYDIMMING 2. ENGINE COOLANT TEMPERATUREGAUGE (DAYLIGHT OPERATION) 3. FUEL LEVEL GAUGE 10. FUNCTION CONTROL BUTTONS- TRIP COMPUTER 4. SPEEDOMETER 11. WARNING LAMP PANEL 5- TACHOMETER 12- TOUCHSWITCHES 6. ODOMETER AND TRIPMETER 13. SWITCHSYMBOLS 7. DIGITAL SPEEDINDICATOR 14. BLANKS 8. TRIP COMPUTERAND CLOCK 15. WARNING BUZZER Flgure 12C.2 INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C-3 1.2 ELECTRONICINSTRUMENT ASSEMBLY Calais models have a new Electronic Instrument assembly. The instrumentationis fully electronic and vacuum flourescent,featuring trip computerand automaticdisplay dimming. Electronic instruments feature a combination of bar graphics in green light lor speedometer,tachometer, fuel and temperature gauges, with digital displays for speedometer,odometer and trip meter. The Electronic Instrument Assembly, as shown in Fig. 12C-2,consists ol the {ollowingcomponents: 1. AlphaWarning Display 2. EngineCoolant Temperature Gauge 3. Fuel LevelGauge 4. Speedometer 5. Tachometer 6. Odometerand Trip Meler 7. DigitalSpeed Indicator 8. Trip Computerand Clock 9. Photo Transistor - Automatic Display Dimming (daylightoperation) Manual Rheostat Conrol (night operation). 10. FunctionControl Buttons - Trip Computer 11- WarningLamp Panel 12. Touch Switches '13. SwitchSymbols '14.Blanks 'f5. Warning Buzer WARNING LAMP PANEL The warning lamp panel is located along the bottom edge of the instrumentcluster. The warninglamp panel containswarning lamps for: 1. BatteryCharge 2. BrakeFailure 3. ParkBrake 4. Lett HandTurn Indicator 5. RightHand Turn Indicator 6. Headlightson (withignition off) 7. High Beam Indicator L ReversingIndication Lamp Warningsare displayedand a buzzersounded for various componentfunctions. R:tfor\/ Chrrnp YES NO BrakeFailu'e YES 2 BEEPS ParkBrake YES 2 BEEPS (if carmov;ng above5 k"hr) Right Hand Indicato. YES NO Left Hand lndrcator YES NO ReversingWarning YES NO The 2 beeoswill sound in a half secondtime interval 12C.4INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS ALPHA WARNING DISPLAY The alpha warning display comprisesten, 14 segment alpha numericcharacter displays. lt is situatedin the right hand too cornerof the instrumentcluster. When the ignitionis first switched 'on' and the motor is not running,the waming monitor displays'SEAT BELT' continuously,until the motor is started,after which the message will display for a further 10 seconds. Refer I Fig. 12C-3. f -!- lf another messageis waiting to be displayedafter the L--!: t-1 T t-11- t T motor has started,the 'SEAT BELT' warningwill display _u_rtt t_lt_l_ t only for 5 seconds,allowing the olher messagesto be displayed. Flgure '12G3 In the situationthat more than one warning occurs at once, the messagescycle through,each for 10 seconds and a 1 secondgap betweeneach messageand in order I of priority.The priorityorder being: I -t- 1. OIL ALERT II'| In IItt 2. ENGINEHOT lltt iit /--l-[/ 3. LO COOLANT 4. LO FUEL ReferFig. 12C-4. I lf 'ENGINEHOT' is displayedand 'LO COOLANT'is I -a- queued for display and then suddenlyan 'OlL ALERT' L_l\il_ t t\lt__ tn l t fault occurs,then the 'OlL ALERT' warningwill lump the t_ t tltJ t t \tl t1t_t t queueand take precedenceover the other warnings. When an alpha warning is displayed,it is accompanied by an audible(5 beep)warning. This audiblewarning will only occur once for the initial displayo.f each individual messageand every time the ignitionis switchedon until I the sourceof the lault is remedied. -t- I l-t t- t-t T Everytime an alphawarning is first displayed,the audible t-tt t-il\ | warningwill sound5 beeps in two seconds. l_ t_t t_ t_u_tL f lt \t t I I -a- I l-t I - t tt t l_ l_l | r_t 1_ r_ Flgure 12C-4 When there is no warning messageevident, the word 'MONITOR'is disolaved.Reier Fio. 12C-5. Figure 12C-5 INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C.5 TEMPERATURE GAUGE The temperature gauge, rclet Fig. 12C-6, is located betweenthe alpha warningdisplay and fuel gaugeon the Dt]OC right hand side of the instrumentcluster. The engine coolant temperature display consists ol 13 segmentbars, the last three bars from the right are red and the remainingare green. With an increase in coolant temperature,the bars light up, one at a time, from left to right. When the red zone is reached,these bars light up progressivelyand remain alight so that at maximumtemperature, all the red bars are alight. When the coolant temperatureis sufJicientto cause the first of the red bars light up, the alpha warningdisplays 'ENGINEHOT' and the audiblewarning sounds 5 beeps. TEMP lllililillill -E---- Figure 12C€ FUEL GAUGE The fuef gauge, refer Fig. 12C-7,is located in the lower instrument right hand cornerof the cluster. lll! llr U The fuel gauge is a progressivebar displayin which the - bars lightup to indicalethe level of fuel in the tank. The first three bars from the left of the gauge are red, whilst the remainingbars are green. As the fuel level drops below '10.5litres (approximately)and the last left hand green bar goes out, a 'LO FUEL' warning is displayed on the alpha warning display. An audible warning is also sounded,consisting of 5 beeps. When the last red bar goes out, there is less than 1.5 litres of fuel left in the tank. There is approximately3 litresof fuel in the tank for each lightedred or green bar. FUEL llllilillililililil Figure 12C-7 12C.6INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS SPEEDOMETERAND DIGITAL SPEED DISPLAYS The speedometer,refer Fig. 12C-8, is situated in the ooocoD=q:= t-- centre section ol the instrument cluster. lt has a green light bar graph commencing at 0 and finishing at -.;= 180 km/hr. When the ignition is switchedon, all the digits light up. When the vehicle is moving,the bar graph lights up to indicatevehicle speed. To the lefl ol the speedometer is a digital speed display showingvehicle speed.The last digit of the digitalspeed display does not change more than once every half second, so as to guaranlee good legibility.When the vehicle is stationary and the ignition is on, the digital displaywill indicate'0'. km/h Flgure 12C-8 TACHOiIETER The tachometer, reler Fig. 12GBA, is situated below the E- speedometerin the centre of the instrumentcluster. : The digits 0 to 7 light up whenever the ignition is switched on. The green bar graph lights up as an indicationof enginespeed. The colour of the bar graph above 5500 rpm is red, indicatingengine speed above this level should not be maintained. Flgure 12C-8A ODOMETER AND TRIP METER The odometer, reler Fig. 12G9, is a seven segment 6 digit displayand togetherwith the seven segment4 digit trip meterdisplay, is situatedbelow the tachometer. The odometerindicates distance travelled in one kilome- ter unitsfrom 1 to 999,999kilometers. The trip meter indicatesdistance travelled in tenths of a kilometerup to 999.9 kilometers.Below the trip meter is a resetbutton. flflA.E F_IEEHEE TRIP ODOMETER Flgure 12C-9 -- INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C-7 TRIP COMPUTER The trip computer is situated to the left of the speedometer. It comprises three seperate displays for time, distance TIME and fuel functions.Refer Fig. 12C-10. E, i_t.i:t i_t For additionalinformation refer to 1 4 in this Section. ELAPSED {-, {_,' !_, l_, DISTANCE AV SPEED nflnfi TRVLD !l t-l.t-t lJ TO Elv'lPTt' FUEL AV t/100 USED EEI.EI.EI Flgure 'l2C-10 AUTOMATIC INSTRUMENT DISPLAY DIMMING The intensity ot the instrumentdisplay is automatically variedto accountfor surroundingdaylight conditions, by a photo transistor situated in the right hand side of the warninglamp panel (Fig. 12C-1 1). The photo transistor,upon sensrnga change in surroun- ding daylightconditions, will change the displayintensity i -!!!!t! , at one secondtime intervals. PHOTO- TRANS ISTOq Flgure 12C-11 When the headlightsare turned on, the displayintensity will,if the ambientlight is belowa daylightthreshold level (equivalentto dusk), immediatelydrop to the intensity level set by the rheostat(Fig. 12C-12).The intensitycan then be manually controlled by the rheostat during darkness. The rheostat is located next to the headlightswitch. lt ambient light is above this daylightthreshold, display intensity will be varied automaticallyvia the photo transistor.This permits full display intensity in daylight even with headlightson. To preventflickering. a time delayis rncorporated.For example,if enteringa tunnelor a very shaded area with headlightson and tf display intensityis on a daylightsetting. the displaywill not dim to rheostat control till 5 seconds after the ambient light has fallen below the daylightthreshold. Display intensity control will not revertto automaticuntil the ambientlight level is significantlyhigher than the daylightthreshold or the headlightsare turnedoff- Figure 12C-'t2 12C-8INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS 1.3TOUCH SWITCHES - MECHANICAL& ELECTRONICINSTRUMENT ASSEMBLIES The touch switch control panel is located to the left of the instrument cluster, above the centre dash vents. Refer Fig. 12C-13. Theseswitches are activatedby pressingthe small raised finger pad in line with the symbol representingthe functionto be operated. Switches are provided tor rear window defrost, power antennaup and down.and on stationwagon modelsrear windowwipe and wash. Flgure 12C-13 1.4TRIP COMPUTER GENERAL DESCRIPTION The trip computerfitted to Calais models(Fig. 12C-14)is part of the electronicinstrument assembly, and has three separatedisplays to displaytrip intormation. The trip computer is located to the left of the TIME sDeedometer. Fuel flow measurementis suppliedby the injectorsignal from the electroniccontrol unit for vehiclesequipped with ELAPSEDE Ei:E E the 3.3 litre EFI engine,or from a Fuel Flow Sensorlor vehiclesequipped with a 5.0 litre engine. An electronicspeed sensor is mounted on the cruise controltransducer. The eight different pieces of inlormationavailable from DISTANCE the trip computerare shownbelow: AV SPEED TRVLD EIEI.E.EI TIME (1) Time TO EMPTY (2) Elapsed DISTANCE (1) Averagespeed (km/hr) (2) Travelied (kilometres) FUEL (3) To en pty (kilometres) FUEL A,'e:sgg (litres/100km ) |NSTt 100 Usec (litres) lnsiantaneous(litres,rl 00 kr-:rI The trip computerdisplays three tunctionssimultaneously, one from each display of 'TIME', 'D|STANCE'and Flgure 12C-14 'FUEL',and are calledup in sequenceby depressingthe selectbutton. Each time the select button is pressed,the function in each displaywill incrementby one. 'TIME' and 'ELAPSED TIME' alternate with other functions,giving a variablecombination ol time with other functions. The trip computercontrol buttons are located below the displays(Fig. 12C-15) and are: 1. DISPLAY- (Displaystime with ignitionoff) 2. SELECT- (lncrementsfunctions displayed) 3. HOURS- (Adjustshours when pressedwith display button) 4. MINUTES- (Adjustsminutes when pressed with displaybutton) 5. RESET- (Resetscomputer when pressedwith select button) To avoid accidentalreset, time adjustmentor calibration, a combination of two buttons must be oresseo simultaneouslyto performthe!; operations. Flgure 12C-15 INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C.9 FUNCTION DESCRIPTION 3. Press reset and hours buttons simultaneouslyand displaywill go to zero. Drive off and the Time displaywill increasein whole numbersup to a numberbetween The clock is a 12 hourclock with flashingdecimal point. 615 and 650, whilsttravelling a distanceof 10 km. When the batteryis first connected,the clock will show This is the cablibrationnumber. Stop vehicle exactly 12.00 and if this is not the correcl time, the appropriate 10 km from startingpoint, e.g. centre pillar againsta setting is achievedby pressingthe 'DISPLAY'and 'MlN' major highwayshield 10 km from onginal shield. buttons together for minute adjustment and the Press reset and minutes buttons simultaneously. 'DISPLAY'and 'HOURS'buttons for hour adiustment. When these buttons are released the calibration It is recommendedthat the minutesbe adjustedprior to number will enter the computer memory and the the hours becauseas the minutespass 60, the hourswill displaywill return to travelledmode, and shows the automaticallyincrement by one. total distance travelledsince reset. This calibration cloesnot reset other functionsback to zero. The clock can be accuratelyset as the next minutewill not display until 60 seconds after releasingthe adiust- The calibrationnumber should be between615 and 650 ment button. lor standard vehrcles, however, special tyres, transmission,axle, tyre oressures,vehicle loading, etc. will have a bearingon this number. Elapsed Time Depressingthe reset and minutebuttons simultaneously Indicatesaccumulated 'lGNlTlON ON' time since resef any time the distancetravelledrcaiibrate lunction is called ting in hours and minutesup to 99 hoursand 59 minules. up, will displaythe calibrationnumber, For those who do not wish to have this degree of accuracy(1 metre in 10 km) or who do not have access DistanceTo Empty(DTE) to an accurately measured 10 km. an approximate The distance to empty function is an estimate on how numberof 625 is used for distancecalculations. much turther the vehicle can be driven on the luel When the batteryis first connected,oalibration numbers remainingin the tank, basedon the rate of fuel usagefor will automatrcallybe 625. lf requiredcalibration number is the previous15 minutes. know, select travelled/calibratedmode, press reset and The DTE readoutadjusts in 5 km incrementsfor values hours buttonssimultaneously, drive vehrcleapproximately in excess of 50 km and single kilometre increments 10 km until requiredcalibration number is reachedthen below this value.No computercan predict the future,so press reset and minutesbuttons simultaneously. Alternati- the DTE function can only be an estimate based on vely recalibrateas describedearlier. previously obtained information. For this reason, as Whilst in the calibrate mode, i.e. after the reset and conditions become more suited for economicaldriving, hours buttonsare pressedand prior to depressionof the the distanceto empty can actuallyincrease, for example, reset and minute buttons, the 'SELECT' button is from City to Highwaydriving. inactivatedto preventselection of other functionsduring After initialbattery connection DTE will start at 500. The the calibrationprocedure because this would affect the computerwill then performan initial update trom a short calibration number and compuler distance lunctions average prior to commencingthe normal long averaging would be inaccurate. process. A built-insafety teature allows up to approximately30 km Average Speed of driving under highway conditions after DTE shows The averagespeed readingdisplays average speed since zeto. However, due to tolerance variations on the the computerwas reset.The averagespeed is calculated components from which the computer derives its in- by dividingdistance travelled by the time that the ignition formation,this figurewill vary from vehicleto vehicle. has been cn. The computer has electronic damping to flatten out To enable the computer to collect enough data to fluctuationsof fuel level in the tank and rate ol fuel calculatea sensiblespeed, the displaywill show zero lor usage and will update the readout after consumptionof the first minuteafter reset. 0.32 litres of fuel approximately. Readingis updatedat one minuteintervals. Oue to the large fuel level fluctuationswhilst mobile,the readingsare heavilydamped and averagedover a long time - up to half an hour. This does not matter during Instantaneous Consumption normal operations,but after fuel {ill a long delay to The instantaneousfuel consumptionfunction reads in displaya sensibleDTE is not acceptable.So with a fill of litres/'lOOkm in whole numbersonly and updatesat halJ 10 litres or more the computerwill calculatea higher second intervals. DTE from a short averageat the next normal updateand When the vehicle is stationary,the display shows zero, the long averagingwill proceedfrom the new figure. however,when slowingdown to a stop, due to fuel being used and a small distancebeing travelled,some large Distance Travelled/Calibrate numbers may be displayed.Also, when the function is This functionreads distancetravelled in krlorneterssince first called up, some large numbersmay appear,due to the computerwas resel, showingtwo decimal points up the small time frame over which the comouter is to 100 and whole numbersthereafter. Dre0areo. The calibrate function is designed to allow a very accuratedistance calculation and is enteredas follows: Average Consumption 1. Selectdistance travelled mode. The averagefuel consumptionreads in litres/100km and 2. Line up the vehicleagainst a known marker,e.g. calculates fuel usage since last reset and updates at cenlre pillaragainst a major highwayshield. approximatelyone minuteintervals. -- 12C.10INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS F z (, zii zl FO z< F; a.- Q* :< '\- > SY /^ | --->VC, >co ) '|(t). I &..' F @ / o ca c 8.. z F z cc :) U cn F U = UJ \ 3 U o \>m- t o = J. L I UI u f E, I f q r * {<. EE; zz- I $€- N-V t-- t1 <\JA INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C'11 Fuel Used Total fuel used since reset is measuredin litres to a maximumof 999 litres. The 'Fuel Left in Tank' is not normallydisplayed' but a mode if the RESET nrtO"t--ffnS can be displayed'M|-['IUTEin the DTE or buttons are depressed "nOiimultaneously. This numberis equivalentto the amount of fuel, in litres, remainingin the fuel tank that the cornprt'etis using to obtain its calculationsfor the DTE display. 1.5TRIP COMPUTERCOMPONENTS FUEL FLOW SENSOR With the 5.0 litre engine,the fuel llow sensor.isthe same ;;- on VH Series models' Refer Figs 12G16' 12C-17,"sedfor installationdetails. is On fuel iniectionequipped models, the fuel flow signal orouiOeObv the EFi control unit. The control unit controls is [n"-pJ""-*iOth signal to the iniectors'and.this signal and aiso-transminedto- the trip comPuter control module used as a measureof fuel usage' FUEL LEVEL SENSOR unit The 'fuel to empty' is sensedby the fuel gaugetank in the i"titt"n"" reaOing.The tank unit may be checked *"ner (r-eterFuel Gauge SenderDiagnosis - 2'6 to readout "-o-ttJilfii; suppremdnUshould any query rrise as on displaymodule and actualfuel gaugereaolng' ELECTRONIC CONTROL TTIODULE with the The electronic control module is integrated instrument Oi.pf"V and function module on electronic assemblies' - - ,// Y. t,,r7'lC. )-'r^> j-\-i-\- - -\-- \! GM658M(3 PLAc=s f tto- TAPEwtrH FUELFLoWSENSoRW|R|NGHARNESS_5'0L|TREMoDELS Flgure 12C-17 fa- 12C.12INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS SPEED SENDER (For Electronic lnstruments) A Hall Etfect Speed Sender is used to produce an \ electricalsignal which is proportionalto the vehicle'sroad .l^ instrument ,,\ speed. This signal is used for the electronic SPEEDSENDER- I readoutsof speed and odometer. This signal is also used by the trip computer and is required for readings of distance to empty, average speed,distance travelled and instantaneousand average fuelconsumption. The sender consists of a metal body which houses a 7 6) ! / rotating16 pole magnet.Fitted into the metal body is a i 't/+)l plasticcap which containsthe electricalterminals and the / F!r- Hall effect integratedcircuit. 1."r,r.'"i*t*o,- The soeed sender is mounted on the cruise control _ 12Q-'18. TFANSDUCER I CONNECTIONTO transducer.Refer Fig. I ENGINE HARNESS I SPEEDO CABLE -' Flgure 12G'18 Theory Of Operation NO MAGNET The Hall effect principleis shown in Fig. 12C-19 EFFECT PRINCIPLE A constantcontrol currentis passedthrough a thin strip of semi-conductormaterial. When a magnet is brought near, such that its magnetic field is directed at right anglesto the lace of lhe semi-conductor,a small voltage NO HALL appears .at the contacts placed across the narrow VOLTAGE dimensionof the slrip. The hall effecl voltageis dependenton the presenceof the magnetic field and on the current flowing in the semi-conductor.lf eilher inout is zero. Hall voltaoe is 70fd INCREASES HALL VOLTAGE DECREASING rolr.t,tt f, | t --t^:-5 ----=-rx--/ HALL VoLTAGE Flgure 12C-19 -- INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C.13 2. SERVICEOPERATIONS For serviceoperations not covered in this Section, refer and VH CommodoreService Manual Suoolementpart to the VB CommodoreService Manual Part No. M38145 No. M38731. 2.1 TOUCHSWITCH CONTROL PANEL REMOVE 1. Carefullylift up front edge ol touch switch control panel so as to disengageit from the centre dash vent housing.Refer Fig. 12C-20. Flgure 'l2C-20 2. Raise the rear of the touch switch control panel and pull panel out slightlyto gain access to the wiring harness connector underneath the panel. Refer Fig. 12G21. Disconnect wiring harness connector and withdraw switch. Figure 12C-21 TEST Using an ohmeter, test for continuityacross terminals when the touch button is pressed.Fig. 12G22. Refer to Section 12F 'Wiring Diagrams'of this Supple- ment for touch switch controlpanel winng. REINSTALL Installationis reverse of removal proceduresensuring wiringharness connector is securelyconnected. Figure 12C-22 12C-14INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS 2.2 INSTRUMENTCLUSTER . MECHANICALINSTRUMENTS WARN ING LAI\4P INSTRUMENT PANEL WIRING REMOVE SURROUND _ CONNECTORS 1. Disconnectbattery earth lead. 2. Remove touch switch control panel as per service operation2.1. INSTRUMENT 3. Removethe screws securingthe instrumentframe to FRAME the instrumentsunound. Refer Fig. 12C-23. 4. Pull the instrumentframe out, far enough to gain accessto the warninglamp panel wiring connectors. ReferFig. 12C-23. 5. Disconnectwiring connectors and withdraw instru- menttrame. 6. Removethe right hand instrumentpanel lowertrim. 7. Reach uo behind the instrument cluster and dis- connectthe vacuumhose from the fuel consumption meter (SL models),and the speedometercable by depressingthe springretainer. LtrI\ I H: UA5 N - VENT TOUCH SWITCH- CONTROL PANET Flgure 12C-23 8. Remove the five screws securing the instrument clusterto the instrumentsurround. Refer Fig. 12C-24. INSTRUMENT 9. Pull the cluster from its location and rotate the CLUSTER bottom of the cluster upwards to gain access to the wiringconnectors. 10. Disconnectwiring connectors and withdraw instru- mentcluster. REINSTALL - INSTRUMENT SURROUND r:i N Installationis reversalof removalprocedures. Ensure that )) \3) all electricalconnectors are securelvconnected. NIOUNTINGSCREWS $\J Flgure 12C-24 2.3 INSTRUMENTCLUSTER . WARNING LAMP ELECTRONIC ,f INSTRUMENTS I\STRUMENT PANEL WIRING REMOVE SLFBOUND-J CONNECTORS 1- Disconnectbattery earth lead. 2. Remove touch switch control panel as per service operation2.1. I 3. Removethe screwssecuring the instrumentframe to the instrumentsunound. Refer Fig. 12C-25. 4. Pull the instrumentframe out, far enough to gain accessto the warninglamp panel wiring connectors. ReferFig. 12G25. 5. Disconnectwiring connectors and withdraw instru- mentframe. CENTRE DASH _ VENT TOUCH SWITCH- CONTROL PANEL Figure 12C-25 - INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C.15 6. Remove the five screws securing the instrument clusterto the instrumentsurround. Refer Fig. 12C-26. INSTRUMENT 7. Pull the cluster from its location and rotate the LLUJ I Eh bottom of the cluster upwardsto gain access to the wiringconnectors. 8. Disconnectwiring connectors,and withdraw instru- ment cluster. -/. / REINSTALL I- INSTRJ^JENT lnstallationis reversalof removalprocedures. Ensure thal SURRO!N ] all electricalconnectors are securelyconnected ...c NTt (5)-/ - NG SCREWS Figure 12C-26 2.4 MECHANICALINSTRUMENTS DISASSEMBLY Pall adiustingknob from clock. Remove the six screws ( 1) retaining the clear lacia panel to the instrumelt hYusing, rerioue facia. Remove the three screws @ retainingthe black instrumentsunound to the instrume-it housing,remove surround. (Refer Fig. 12C-27). o l o + ir i t ;- 2' c e-\ J_. Flgwe 12C-27 Speedometer, Fuel Consu4ption Indicator and Tachometer Remove retaining screws and withdraw unit (Refer Fig. 12C-28).When removingtachometer, carefully with- draw contactsfrom printedcircuit. Flgure 12C-28 12C-16INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS Fuel and Temperature Gauges Removegauge retainingscrew (Fig.12C-29). Compress plastic retainingtang and withdraw gauge contacts from printedcircuit. (Fig. 12C-29). Flgure 12G29 Voltmeter and Oil Pressure Gauge 1. Remove overlappingfuei or temperaturegauge as RETAINING previouslydescribed SCREWS 2. Remove remainingscrew and withdrawgauge con- tacts from printedcrrcurt (Fig. 12C-30). Figure 12C-30 Clock From behindthe instrumenthousing, remove connector from printedcircuit. Bemove rhe two screwsretaining the clock assembly to the instrumenthousing and remove clock.(Fig. 12C-31). Figure 12C-3't INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C.17 Printed Circuit Board 1. Compressand withdrawretaining clip/heat sink and voltage stabilizer assembly from housing. (Fig.12C-32). 2. Slide printed circuit board to the right as viewed in Fig. 12C-32 and lift out. REASSEMBLY a Reverse removal operations. z- Install retaining clip/heat sink ensuring voltage stabilizercontacts locate properly. Install upper gauges first, ensuring gauge contacts VOLTAGE STABI LI:ER are properly seated. rr:JJ ruutrtntrn A\) PULL UP Fagure1rc-32 2.5 INSTRUMENTTESTING For mechanicalinstrument testing refer to Section 12 of the VB CommodoreService Manual Part No. M38145. Should a fault develop in the electronic instrument assembly, it must be returned to an authorizedVDO serviceagent for repair. In the event that the electronic instrumentassembly provesfaulty, the odometerreading must be noted before lhe unit is removedto allow the VDO agent to transfer the odometer reading to the replacementinstrument assembly.The VDO agent also has equipmentto read the odometerfrom the instrumentscomputer memory if a displayblackout occurs. SPEED SENDER Remove 1. Disconnectbattery earth lead. 2. Disconnect sender wirino connector. Refer Fig. 12C-33. 3. Unscrew sender from cruise control transducerre- move senoer. Test 1. Connect4.7 ohm 1/4 watl resistoracross terminais markedr and A. 2. Connect 12 volt DC battery supply to terminals marked= and - (observepolarity). TRANSDUCE F -CONNECTION TO 3. Connect pointer type multimeters€t on DC volts ENGINE HARNESS scale to terminals+ and A (observepolarity, positive )rtrtri! tqbLtr- termanal of multimeter to terminal - , negative terminalof multimeterto terminalA). 4. Rotate sender square drive slowly by hand and Figure 12C-33 observe multimeterreading which should pulse bet- ween 12 voltsand O volts. 5. No pulse readrngon multimeterrndicates faulty sender. NOTE:Sender is non repairable. Reinstall Installationis reversalof removat. 12C.18INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS 2.6 FUELGAUGE SENDER UNIT r. ') REMOVE \ !-,/ \ The removaland installationinstructions for vehicleswith .-:,,,, ,/,>-^ 5.0 litre engine with the revisedfuel pump system and :i I 3.3 litre EST engine,are coveredin Section 8 of the VB CommodoreService Manual. The followingremoval and installationprocedures are for 3.3 litreEFI equipped vehicles. 'l. Disconnectbattery earth lead. -.-1_''\ ; -\\ 2. Placethe vehicleon jack standsand drainthe tank - through fuel filler opening using a commercially :< availablefuel syphoningdevice. @-i --(/<.: 3. Disconnectthe fuelline lrom gaugeunit. 4. Disconnectthe electricalfeed and earth cablesfrom unit.Refer Fig. 12C-34. FUE L PUMP- CONNECTORS 5. Remove5 mountingscrews around gauge unit. :-...2 6. Removegauge unit, liftinggauge unit filter from swirl pot \ FUEL GAUGEI CAUTION: Care should be exercised during removal of CONNECTORS gauge unit from the tank not to damage the filter. Before installingthe assemblyinto luel tank, clean the screen by Flguro 12C-34 blowing oft carefully with low pressuredried compressed air; replace screw if damagedor unable to clean. FUEL GAUGE SENDERUNIT DIAGNOSIS 1. turn ignitionto 'ON' and obsevethe fuel gaugefor one minute.The gauge readingwill do one ot three things. a. Gauge reads below empty - Fuel tank empty of gaugesender is opencircuited. b. Gauge reads between empty and full, but is suspectedto be inaccurate.Proceed to step 2. c. Gauge reads above full - Fuel tank is full or gaugesender is shortcircuited. 2. Usinga voltmeter,check for a voltage readingat the fuel gauge sender unit flange to earth (ignition switched'ON'). lf recordinga voltagereading. correct faultyearth at fuel tank or add an earth wire. 3. Removethe wire terminalconnector (fuel gauge to sender unit) irom sender unit and check voltage at the terminalconnector to earth with an accuratehigh resistancevoltmeter (ignition switched'ON'), lf the voltagerecorded at the terminalconnector ts 10 0.1 volts, then the voltage regulatoron the instrument printedcircuit board is OK. lf the reading is outside the specification of 10 0.1 volts, check for poor connections at the printed circuitboard and voltageregulator. lf the connectorsare OK, replacevoltage regulator,refer to service ooeration2.4 Mechanicallnstrument Dis- assembly,in this Section. lf the readingis withinthe specificationof 10 0.1 volts, remove the fuel gauge sender unit, refer to service operation2.6 Fuel GaugeSender Unit - Remove,in this Section. Checkthe senderunit for bindingor sticking. Connectan ohmmeterto fuel gaugeterminal on sender unitand to the senderunit flange. Set the float to the variousheight dimensions, as shown in the followingchart, and recordthe resistanceat each dimension. INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C.10 i nnoa.t Height tmml 3.3 litre EST - Sedan Empty 283!7 @ O % 91=14 @ l5 FulI 35-40 @ 3.3 litre EST - Wagon Empty 283!7 @ o Yz 1001 14 @ 66.5 FulI 35-40 @ top 3.3 litre EFI - Sedan Empty 283!7 @ 0 5.0 litre - Sedan '/a 145.5i4 @ 35.25 '/, 97.3i3 @ 69.5 % [email protected] FulI 40!2 @ 140.8 Upper Stop Under35 @ 147 - Wagon Empty 283!7 @ 0 % 145.5t 4 @ ?A Tz 97.313 @ 67 66.51 2.5@ 100 Full 40!2 @ ttz Upper Stop 189.4 REINSTALL Reverseto removaloperations noting the following: 't. Installseal betweenthe gaugeunit flange and tank. 2. Apply sealing compoundpart no. M39040 to mating surfaces of cork seal and fuel tank, also to screw threads. 3. Fill fuel tank with tuel and check for leaks around gaugeunit. FUEL TANK Fuel tank removaland installationinstructions remain the same as on previous models. The only differencewith EFI models is on removal,the fuel return line must be disconnected and reconnected on installation. Refer Section8A in this Supplementfor details. 12C-2OINSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS Ut (,U q (! o UI ll (I l yr u = tr slo (rlul" U U i- I rm I u) @ J U @ a F 2 u = v) n -a = uJco o in1 F (J<( *-' t-z G= =? ro E,= cit I th= N =e o g cnz :<6-o -l ir <( llJ ()? =o?2, io C)F uJ qJ >v Q t l/ - l' [': { INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C-21 Zu r cJ) ;- I U7 l z\> J x? F -, z U J;^ U _ zZ l z> cc \J F LO = uosNSso.LoHd = II F U J g : -lro Mo] = z (n = f)VH8 )UVd f -a z : ) ISU3A:lU F uJ z LU NUNI ]H9IU z HJI IAS dN-)JV8 z j uos\rs oloHd F z LIJ z O c) 'l tsv ! s\ | 3lN t81lo3 o = U) N NHN-LTJSI J 't^sv tsr.l 33Nt8lAoc t-lJ o z CD rsNr 33Nr€t 03 ISNr33Nr8r 03 (^e os 3) 1 'wsv lsN | 3: \ rSt^loS (n A-r8WfSSV rN=WnUtSNI z O3NlSl OOVrlHIUV3 I'ooll^ F 2 Yt^l oo iti' (dtrJe-l urM Un Ileuratx3) oo U ll lr 2 'WSV I-SN| Ct\rdNO3 3 -looi@1/ z r-c- t- = (J H3].rMS3UnSS3Ud r rOMO-r 3 -l3NVd:Snr = vtn NoltrN9rnzt E 0 HC.LIMS3>V88 )UVd F {HU) H3l-lMS IVNCIS NUnl. r r l'€^ uor-vI I Nl9 6 [- i-]I^ ,: ![T (due-l urill unil l leuratxf i i lll^ ) : .-Jt tv a :r :l l- H3l.rMS 1HC|l =w= SlnOOW r_S'3 (;otef,rpul uJeag q6rH) H3t-rMSUIHSV-IIIt tAlC s s HJIIMS ''IIVJ 3>VU8 (Hl) H3l-lMS -1VN9iS NUfl.L N N l- HI!Yf - v 12C.22INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS U J o o F = f, F L 3 F I F l F z F F = J F l l U J L = U tr o \ = U o I = U I tu F; ;4 U J t 1N z F l o F Z: u o uJ U lN ]R U o U T = Y U J Y :l z lco UJ 6 : U J I IL (, q ) U) uJ F o lo z t! 6 f th z ul z a L a :) 2 = H L- + t = ut r F z ]B 4 - li ol< o o l cr c/, ll F I u) F = z F = ;- l F o r- iF G F F F l U) JL ll-r rJ F l aF U CC z_ ) z = l tr F- F = O F zz =z = J z = !z F =, UJ F dl I r u T F >z I. z uJ trJ uJ F-j F F F : v; z z F F z U u U =1" F - ; o z z) I = -l = Y uu) Y BI u) C) I O o ;= z @l A^ z 76 F U) U' LU U n F F o l uJ I tll t, 113 (n z UJ U U I.U ;F E n r.u l >i> lu = i T Y luJ t +1+ z Y [,L t T () (ft 2= = | i 5 a,l) l I o (no cc IIJ I -.r Q o f c, gF F r o F N f : f Ztd- () d -L,O lz o = = zo-, U -f F z r z UJfr; IJJ I . \z f,i l+ F l z = uJ f Y U #ls,g t E I- 3l-'ii th E"z J 3 = o = <=\ J " ft? = I = o z --UU g o \)Y E, (DA tn (J UJ l LrJ i- B INSTRUMENTS,GAUGES, W'SHIELD WIPERS/WASHERS 12C-23 2.7 SPEEDOMETERGEAR CHART REAR AXLE TRANSMISSION SPEEDODRIVEN GEAR TYRE OPTION NUMBERS SpeedoDrive I Number P/O I Ratio pl' Colour OBC OCJ OCH OCR OBD OST ooY OFL OEU OBY OON Gear Colour of Te€th G70 2.60 : 1 M40 10 Teeth Dark Brue 22 X X XX i yeilow Green 21 L GU4 3.08:1 lvlc6 7 Teeth Red 18XXlX X X XI X X Brown , M4O 9 Teeth Red 23 X X X XXXX Biue r-_f_- M76 8 Teeth White 20 X X X X L6 Pink Green 21 X ut M40 10 Teeth Light Blue X X X I Yellow GV4 3.36:1J M76 8 Teeth Dark Blue X XXX X \ XX Pink KEY TO TYRE OPTION NUMEERS OBC BR6OHl5 ocR cR78S14 00Y 175SF13 OEU EP;O H 14 ocJ cR70 H14 oBD BR78Sl3 UFL rzJf, bu nn r f OBY BF;E S14 ocH cR78 H14 OST 165SR14 ooN Pr75/75 SR14 12C-24INSTRUMENTS, GAUGES, W'SHIELD WIPERS/WASHERS 3. WINDSHIELDWIPER AND WASHER 3.1 GENERALDESCRIPTION The windshieldwiper and washer system carries over from VH to VK Seriesmodels, except for the locationof the dwell controlswitch. On modelswith dwell wiper control,the control switch is now locatedon the left hand lower dash sunound. The windshieldwashers 'in line',one way valvehas been deleted. 3.2 SERVICEOPERATIONS Service operations arc as described in Section 12, Holden Commodore VB Series Service Manual Part No. M38145.exceot where noted in this Section. 3.3 WIPERDWELL CONTROL SWITCH REMOVE UPPERSCREW 1. Removeinstrument assembly surround as per service PLACES) instruction2.3, steps 1 - 5, in this Section. 112 2. Pull knobfrom switch. 3. Remove the left hand lower dash surround uooer and lowerscrews. Refer Fig. 12C-38. NOTE: lt may be necessary to remove the centre consoleto gain accessto the lower screws. 4. Removethe righthand instrument panel lower cover. \- /' -{9 /oor* suRRouND \ LOWER SCREW LOCATING HOLE _ (2 PLACES) \- LEFT HAN D LOWEB DASH SURROUND Flgure 12C-38 5. Disconnectthe wiper dwell control switch wiring connector from the main wiring harness. Reler Fig. 12C-39. .,.l'^sl:y11.'rranr\trJJ / 6. Removelower dash surroundand switch. \V. TSCREW 7. Remove switch mounting nut and separate switch x.} , (2 PLAcES from panel. \e ,& *\eB^ 5:< ry REINSTALL '- ./_ A -/ - Installationis reversalof removalprocedures. Ensurethe . locatinglug on the left hand lower dash surroundfits into iVAIN WIRING the locatrngsquare. Check operation of switch. HARNESS CONNECTION WIPER DWELL ] CONTROL SWITCH ! SWITCH RETAINING NUT Flgure 12C-39 RADIOAND TAPE PLAYER12D-1 SECTION12D RADIOAND TAPE PLAYER INDEx Ref. Subject Page Ref. Sublect page 1. GENERALDESCRIPTION 12D-1 3. DIAGNOSIS...... 12D-8 2. SERVICEOPERATIONS..... 12D-2 4. sPECrFlCATrONS...... 12D-9 2.1 RADIO OR RADIO CASSETTEPLAYER 5. TORQUEWRENCH SPECIFICATIONS...... 12D-9 ASSEMBLY 12D-2 6. SPECTALTOOLS ...... 12D-9 Remove t2D-2 Beinstall 12D-3 2.2 SPEAKERS.. 12D-3 Remove...... 12D-3 Reinstall 12D-5 1. GENERALDESCRIPTION All VK Series models are fitted with a radio. SL models The four speakers are located,two in the rear parcel are suppliedwith a high performanceAM/FM radio with shelf and one at each upper corner of the instrument digital display for channels and frequencies,a 2 way dashpanel. speakersystem and a manual,key lock anlenna. The operatinginstructions for each unit is includedin the Berlina models have an AM/FM stereo radio cassette OwnersHandbook. unit,in lieu of the AM/FM radio.The radio is an AM/FM A power operated antenna is standard on Berlina and stereo signal radio seeking with digital display for Calaismodels. The antennais automaticallyraised to a channels and frequencies.The speaker syslem is a 2 medium height wnen the radio is turned on and can be way speal(er system. turther raised or lowered by means of the antenna Calaismodels are fitted with a similarradio/cassette unit controlswitches on the instrumenttouch controloanel. to the Berlinamodels. Features of this radio/cassetteunit include a single joystick balance control lor a 4 way speaker system and automatic programme search for cassenes. 12D-2RADIO AND TAPE PLAYER 2. SERVICEOPERATIONS 2.1 RADIO OR RADIO CASSETTE PLAYERASSEMBLY REMOVE 1. Disconnectbattery earth lead. 2. Removetouch controlpanel as per serviceoperation 2.1,Sectron 12C of this Supplement. 3. Removeinstrument surround and instrumentassemb- ly as per serviceoperation 2.2 or 2.3, Section12C of this Suooliment. 4. Remove centre console, centre lower instrument panel, glove box, steering column lower surround, heater cover panel and lefl hand lower dash panel as per serviceoperations described in Section14 of thissupplement. _ REAR BRACKET 5. Removecentre air vent duct. SCREW/S Remove radio/cassetteplayer rear a TNSTRUMENTCARRTER 6. radio - bracket / PANEL ASSEMELY screw/s from instrument canier panel assemblv. ReferFig. 12D-1. FRONT MOUNTING 7. Removeheal/vent control assemblywith temperature control cable attached,removing vacuum hose and electricalconnectors. 8. Removelower lett side instrumentDanel and radio - radio/cassetteplayer as an assembly. L Disconnectelectncal connector and antenna from radio- radio/cassetteplayer. ----=: _ REAR BRACKET ATTACHING SCREW INSTRLI\45NTPANEL-, LOWER ;ACIA Flgure 12I)"1 10. Removethe front mountingbracket, screwed into the top FRONT MOUNTING BRACKET of the unit. ReferFig. 12D-2. - 11. Removerear bracketattaching screw. ,,- MOUNTING SCREW-2 o'5 I w_i Flgure 12D-2 RADIOAND TAPE PLAYER12D.3 12. Insert removal tools CMT113 simultaneouslyinto slots in right and left hand sides of radio radio/cassette player facia, reler Fig. 12D-3, to disengagethe spring mechanismsecuring the inner part of the radio facia to the left hand lower dash panel. 13. Removeradio - radio/cassettefrom dash panel. 14. From behind sides of radio facia, depress spring mechanism,which will release removal tools from radio - radio/cassetteplayer. No. CMT113, which are released SERVICE TOOL 15. Removaltools, Part NO. CMT 113 in pairs,are availabledirect lrom - EurovoxAustralia, 6 UniversityPlace, ClaytonNorth. Vic. 3168. Flgure 12D3 REINSTALL Insert radio - radio/cassetteplayer in dash apertureuntil the lockingsprings click. The remainder of the installation is the reversal ol removal procedures. 2.2 SPEAKERS REMOVE /.SPEAKERGRILLE Single Speaker - Front 1. Removespeaker grille. 2. Removespeaker securing screws, reter Fig. 12D-4. 3. Litt up speaker to disconnectwiring harness connector.Remove speaker, refer Fig. 12D-4. SECURINGSCREWS PLACES) x CONNECTOR Flgure 12D-4 12D.4RADIO AND TAPE PLAYER Dual Speakers - Front 1. Using a wide blade screwdriver,insert betweengrille FRONT SPEAKER and instrumentpad. AND GRILLE 2. Carefullylever speaker grille upwards. Lift speaker ASSEMBLY from its position, disconnect wiring harness con- nectorand removespeaker, refer Fig. 12D-5. - INSTRUMENT PAD r- wtRtNG HARNESScoNNEcroR Flgure 12D5 Rear Speakers - Sedan KER GRI LLE 1. Removepush-on speaker grille. . rrSPEA 2. Removespeaker securing screws, refer Fig. 12D-6. ' @.w /-SECURING SCREWS , (3 PLACES) zz SPEAKER -r-: s WIRING HARNESS htrAh TAhLtrL SHELF Figure 12D-6 Disconnectwiring harness connector,refer Fig. 12D- 7, removesoeaker. HARNESS Figure 12D-7 -!t RADIOAND TAPE PLAYER12D.5 Rear Speaker - Station Wagon 1. Bemove the interiorside panel trim as per instructions in Section 01 of the Holden Commodore VB Series StationWagon SupplementPart No. M38265. 2. Disconnectwiring harness connector. 3. Remove speaker securing screws and remove speaker,refer Fig. 12D-8. INNER SIDE PAN:I- -- SPEAKE R REINSTALL Reinstallation in each case is the reversal of removal orocedures. SECURINGSCREV^J _ (4 PLACES) WITH CONNECTIONS FACING REAR OF CAR Flgure 12D8 12D.6RADIO AND TAPE PLAYER o ul J Iv F- uco U J l o 2 o rI tr F B uJ U t ; j o : I u r U I U r O) g 6 N lm] o = E -9 t q ---- | 'i.r' \ l\. cc F 'l ) U U z I z z z< L -z z J (t <:^z = F 2 z^ CE U )zOF oc I z 7.6 z- U Zu,-E a pJ=r! - f, I ?3d3 JU 9< =- -tt RADIO AND TAPE PLAYER 12D.7 U J ?T za= cPv E-q 4 4VU+:< z 7 3 IJ ; o o I N U J c, l I =z g I L1 z F J I.IJ f Z) uJ oF (J z 4 J) F cu z l F o z {r 2a ZY UO N 7n 12D.8RADIO AND TAPE PLAYER 3. DIAGNOSIS :.. !:: ;'l :,.- a i - RADIOAND TAPE PLAYER12D.9 4. SPECIFICATIONS AM/FM Radio . Stereo,5W at 10%THD per channel RadioCassette Stereo,5W at 10%THD per channe Speakers 4 ohms, 10W capacity PowerAntenna Maximum continuouscurrent 3 amos Lock up current 9 amps 5. TORQUEWRENCH SPECIFICATIONS Radio - Radio/CassetteMounting BracketScrews 0.9 - 1.2 Nm AntennaMounting Nut . . Frngertight then one comple:eiur. PowerAntenna Mountino Bolts 'l2-16Nm 6. SPECIALTOOLS RADIO _ RADIO/CASSETTEPLAYER REMOVAL TOOLS Availablefrom: -l {ll EurovoxAustraiia, 6 UniversityPlace, Clayton - --il North. 3168. cMTl 13 WIRINGHARNESS & FUSES12E-1 SECTION12E WIRINGHARNESS AND FUSES INDEX Ref Subject Page t Ref. 1. FUSE BOX ...... 12E-1 2.1 1.1 GENERALINFORMATION 12E-1 Remove...... 12E-3 3. Relnstall 12E-3 3.1 FUSIBLELINK 12E-4 4. 1. FUSEBOX 1.1 GENERALINFORMATION The fuse box used with VK CommodoreSeries is located in the engine compartment,behind the passengerside struttower, refer Fig. 12E-1. cr taa J --/ €? BOX LEFT HAND - STRUT TOWER f-rvrArr\MAIN WIRINGvvrnrr!u HAFNE / coNNEcrtoN Flgure 12E-1 The main wiring harness connectionsto the fuse box UNDERNEATH VIEW assembly are made via connectors located on the OF FUSE BOX undersideof the fuse box, refer Fig. 12E-2. --1i || flge, I r-,' t------'r uiLJ i _- lr-i ,T----l € ui.,-a lr I r_l r__lI F-alfJa l,- ./G ,/a:V / .\\.,'- or^l '\ !/ b\ ':tb tr.F.1. - CONN ECTlON ON LY E.S.T.VACUUN4- -. TRANSDUCER L_WIRING HARNESS (3.3 LITRE EST ON LY) CONNECTOR Figure 12E-2 12E-2WIRING HARNESS & FUSES Fuses are blade type mini fuses, as used on Camira models,refer Fig. 12E-3. Flgure 12E-3 The following chart sets out fuse identificationand function. FUSE RATING NO. FUNCTION (AMPS} [-_--lr ,l [----l z Headlamps- low beam 2 Headlamps- high bearn [---ls 3 Parkinglamps and ll uminatronof [----l c Instruments 15A Fuel Pump (E.F.l.) 7.54 l-----ls Fuel Pump (5.0 itre) 5.0A [---l o Air conditioningblower 254 [-.l z o Horn and stop lights 15A 7 Heatedrear window 15A [----] e Hazard warning iamps and air [----.l s conditioning auxi liary fan t5A q Clock trip computer, interior illumination, [----lro rear compartment and lock l5A l---ltt lgnition system 15A Rear window wiper/washer 15A f---l tz 'l Instruments and trip computer 5A [-l rs Wiper/washer, turn signal, cigar lighter IJA Radio and power antenna [----l tr Tape and power antenna 7.5A [--_-l r Heater btower 15A Spare fuse Flgure 12E-{ The fuse box also housesa numberof relaysand control modules, depending on the vehicle's equipment level, referFig. 12E-5. Figure 12E-5 WIRINGHARNESS & FUSES12E.3 A Heatedrear window - module B Bearwindow washer/wiper- module a Door lock - relay D Door lock - relay E Horn - relay F Powerwindow - relay G Air conditioningauxiliary fan - relay H Air conditioningblower - relay I Air conditioningcompressor clutch delay- module J Fuel pump control - relay REMOVE 1. Disconnectbattery earth lead. 2. Removefuse box cover. 3. Removeretaining bolt, referFig. 12E-6. 4. Slide tuse box towards the engine to release fuse FETAINING---\\ box from bottom retainingbracket. 80LT ---\ 5. Lift fuse box up slightlyand rotate to gain access underneathbox. t /A Figure 12E-6 6. Disconnect all wiring harness connectors, reter UNDEq\EATH VIEW Fig. 12E-7. OF FI-SE BOX lf vehicle is equippedwith ElectronicSpark Timing, removethe two enginevacuum transducermounting screws. 7. Lifl out fuse box. , -\' REINSTALL >.. 1. Connectall wiring harnessconnectors. Ensure all are =-t+ securelyinstalled. CONNECTOR 2. Refit EST engine vacuum transducer (if equipped ON LY with EST). the bottom of the fuse box 3. Engagethe tongueson TRANSDUCER !WIRING HARNESS into the retainingbracket. (3,3 LITRE EST ONLY) CONNECTOR 4. Fit retainingbolt, fuse box cover and battery earth lead. Figure 12E-7 12E.4WIRING HARNESS & FUSES 2. FUSIBLELINK 2.1 GENERALINFORMATION *- The chassis wiring is protected against short circuit - -. .==.- FUSEBox ,' € damageby a fusible link placed within the battery wiring harness. '!-..'\/ rvtAil\ WIRINGYYtHil\tr HARNESSHAHI It is taped back to the battery wiring harness,near the -r,z , ,--MAIN n CONNECTION battery,refer Fig. 12E-8. I \.\ An additionalfusible link is incorporatedfor 3.3 litre EFI \-,r.^._*Y-il---., F US|BLE modelsfor EFI wiringharness protection. lt is taped back .. t L,NK to the battery wiring harness,between the battery and {l:-,'.S.. BATTERY startermotor, refer Fig. 12E-8. F / FUSTBLELINK - 7 {EFr) REPLACE 1. Disconnectbattery earth lead. Figure 12E-8 2. Untapefusible link wire from batterywiring harness. 3. Disconnectfusible link connectorand installnew link, referFig. 12E-9. 4. Tape back to harness. 5. Reconnectbattery earth terminal. Flgure 12E-9 WIRINGHARNESS & FUSES12E.5 3. WIRINGHARNESSES 3.1 GENERALINFORMATION All VK series models are served by two main wiring harnesses, plus associated ancillary wiring harnesses, dependingupon the equipmentlevel of the vehicle. 1. MainWiring Harness There are two levels of main wiring harness. The lower level carries only the base options and accommodatesEST only. The upper level accommodatesall availableoptions includingany EFI circuits. 2. EngineHarness Different engine harness assemblies are used for 3.3 litre EST, EFI and 5.0 litre. 3. Battery Harness A different battery harness is used for each engine application. 4- InstrumentPanel Harness There are two ditferent levels of instrument panel harness. a. Mechanicalinstruments and touch switches. b. Electronicinstruments and touch switches. Ancillaryharnesses are requiredwhen various equip- ment level optionsare exercised. a. Air conditioning. b. Power antenna c. Powerwindows and door locks. d. Power operatedexternal mirrors. e. Readinglamps. f. Heated rear window. S. Rear speakers. h. Rear lamps. k 12E.6WIRING HARNESS & FUSES 4. HARNESSDIAGRAMS z r o z I F U O F N z z U U z z F aa I z z ^:- t! O z )r z z VU z cc o >ii z F F r o n- O o frz tr z za o = cr l U cr z J = rl U I !li I = c-zi U 3 U z CAFi o z z J ; I aYl L z F UV J - (J zEl U ; z 8 *. P; i z UII o Zt\ +\ )\. <\ I I\. F uJ ': Z.\ ; (, ta =- = z cr (n 3 U) IJ z E U z I o e t lrl ; co Q 6. J j = o E ) CD = lr = z z C? l!z z 2g; = F o z .(4t!=zz U ) U -u : J -i = !! t F E >( ?A*-z -::vEz= Icr; - ) U U J F o Zt a il o loa u -u l: -L,Z ^=J F z^a .l-r. 56* o F o(/)= I.TJ 'l \ t- ul t\ zh z ,\, ir cc z L z -@o J 8(,2 rtsZ z c; =xo t t;) F o LUO ( ze L?-uJ 2... z= I,.i lz 4U z6 Oz -U OU ul rF z oul =X r I U *z =a ul z t7 r[ . aoE z6 t oz ArlE / OU f o uul>^(J <>: uluY F i =o1 t ts \--\ \. I <6 F u(h JU = ZF o ti.l o i( ,r li= F< a_ lJ. -\ uJ E IJ,J 3 E U ; €o J o zL z Ud a a? (r| U a U e) -) cr- z a --- ul Y aaa g WIRINGHARNESS & FUSES12E.9 <6"F :'<*-,- ) 1 ,). ua ' JU '.- \ z* -1 ,^ l.ll= U \ / v --.. \ / -^t U a\ U v\ J ': -- o: = o : < --i U= JY 57o / ts zz /',9P , Z= '// o U dv dE ul l J o zz U <(, .-"/t l U 2=----t\* J c \ ,) ,ll, =*il-'l / o //1t/ =-':ll -i) lol = U Zw ; .^ZN YO- // r U) ut a Tiin z ul =2fi ! < r [!F F = ulr \. 1Y o rt t ^__-:_,,q z z9 ^'\ u.rF f JE >6 1\o U- ) z ud - -a-^:J.. Zl \,.'H(/)F 3 ,/-\ rfj - I !, '9 \T r\\-----\\ ; \ ! 'iF 12E-10WIRING HARNESS & FUSES dd <-" (, Zl U = -U:N o l (/:F* J YnO LU = UUV z zzi -J o v 1o= trz* o U o 6=6 - J uZ z- ; t> >L! U -[ J U- v z: 2 d z< z o 3 /l z U {< o uo4 cc J F_.r-l I --U tiJ 11 < u ==,f' (, - o t F ,JZ Yl =9 1) &ca U> XCC lA UJO '' t,''.,/ c- ' .a' Y. Kll 'ra 3 -'' .- \\ U a_ :- :./)_. ...'z ; z= a= / .-' Nz ' u(, \o? ,r .;;:-y'" .'-,, t z/' /' r- iinJ -A, $ / "'( ./ ">o )auH -4"-\ .N- = il, > m-F UAP *O- F rF alZ f,?r *La59- J:l <'* zi,<- >l-- F-= iii L>- -o I 2- < SY u-':a NM r-15 c .{< 12E.12WIRING HARNESS & FUSES ./../' .a/. U t (J U UJ I = 6 ttt o aZ F \ z< J \luI\ w,' I z- k za,; o f- o UJ(r 3Etr U U rd J -z zzu Y uJ ^J 5 g5H <; q uf to co -u lr FF v) t9 v) -.t> lrJ <- vF:a t! sa z& t9) z =r o ccu -"^ t 6U CD \, a- ./ 4 lt tuu ,/. -.- a/^. \ (/' J€ . \:- // 'V 9z E ut -U 3I >J^< J< tU rrr U, l'-co> z m <,,i : F rsu-r> :ol U ! @t' z /l f?* z \-l >Y= iiP'< Oc = F =>z l )>= Al z z;, - UU rl zN >-< -U ( e<:i ^ rr ldc 2c!2 < -[ u u- ...1 _ v FOU 4zt r zl, (! o z u U 7 :N u C a/) u CD Fi " -v=N Z'L owJ 12 r.2 oz i, ;oo" -U tr1 JZ X=E ;# -oO UY -Z n 2\ + ;i^- L 9"uts=< f -L:Fv L EK=gF tr a_vr=v =z j F F ft-zi )z IF ?VT-E cco OO FU o €P -7 EU o F => [< 1J,l o z NO U =c! to FI z z q T =2 f \l{ U dp9= tr \J r U = = z ,\ {- uj 3=:E F z .t> vt-=zrEi d ltS= I CN F \ -Pz F v, tr -\ P=5 2 IIJ U _/P = v \?-' E z F u- c J t Y F (, f, U z U z z d T I O F E € nl) F =2 U lrJ = E (\a s1h ) wUJF J z fr o t a ED HaI! z E lt -q-U z o)o ZZ N ^o=c{ lt tr{ r UJ IIJ JO I u <^ > ru> F urJJ = --u- f o() o JF U (9J ccu p l-Z z> zz = U ; UJI B: JCC z^ Z cc= *OfP t- z7-Z UU YZ { >a u l= tr 3 u J [! z (, z = \ z J'\ E I J\ U (t) ) U t o = u o {\- (,@ \ jff 2 tr o F (/)c ,F ; U (; z = o lrJ I .l u oa F O rc \.. o z o zo I T tt E- -< ts UJ -3 ; K. = = z 2t. a 1z E 51e --<:=9 z- l il t,/ J I I F ( in ; B F .-*(-] ;3 t! tr atl cEc t = OlAl O5 U o \611f ; = [s.Ju z- t cr N\/ /-1 l TI F wnr \\ ll 12E.16WIRING HARNESS & FUSES I I lco() zo- F oz-<= = =Y6 v:- 8= '----d...... =\,,^ -Flz :_f ______-"\-, r= ip (")1-,r .:(I FL \ t.-,'Q)-' =2 -\..-1tt" '\ d >5 r E iX iii:.i,4q\av="3 = -. n-'m-- a9 = = =i 'r\J tr=ulU\\\.(---. i)ni c.: >r! I i cca- lR\ -\\)) ) o> _ F Hr {}\\l J '--- ) z \ !-a ; n \t-'-- LIJ: uZ = ".d G>)\--./ =i "Ul ' ^,= ! = - gt ;- H Jl t//t l -Z L! 1rI ---/ -arw f't${ ; \ -'t- I (sJ\ f \ --r..r | :- ) r /- A / a/') IJJ -\ ') ( / o z -'^rtr W = o- €t'/v Yr 'z cn "cE e .I gz o an GI ,1 zo (n IJJ \N Etr LlJ N lh >u=s? 1 z 1-'- E o \" =2 \ g ,-jl\ S U lt > l- : a s = -'1 = :.zr_(,,' 'r ; U- <)ze r.. ) \- C = != =6= tr z u]! F a a L== = 3zr Y- >=; E -'v ir r z,,t, =-JN F U J: zL 7* o I O_ r as o U- cr F z^ ccY F U 2 O cc a 6 F U I <-_ [ \ F 'l z F LIJ 5 a U) = J z Uq tr o E z 2@ i c U F r ^ )z a CN z- - >aE (r uJ z O -z 2F \L I. \,- z \v,v O UU7z l u aa o v- J ac F> F F 1r : il F uU uca z= 7l- ztt J- a= 12E.18WIRING HARNESS & FUSES r z^iT -F U= zL Zn (Ju_oil uar! !L 6 2= F I N o m O EI z z --\ T T U I s6 F NU iI o UN U fi -L ..L r F :; o :a L s-: o uJ CE l.ttl 2 - . lvl : L[lr-l- { O6 = IJ t ltri = UU z uJr = io "16I A 2 (nu ; z<) ttot q aa u o< LU FlL ; c (n -lol:g; 2 I nJ \J FS- J v) -ui v) i>(/) uJ \> 5o z ccd L{n g z T ) rlj _E = o o| z UJ N R o I zQ* = F U otl i\ o N F ) J z ri <=x z g -<.^. t! lr F tr =5s z r E; = U =3H F E F ooY Iuu J I t-lJ -:) .; z z r F I U l N I = F z G o lf =l a) E U CE U Ptr ]-.rt 12E.2OWIRING HARNESS & FUSES a 6 U z tr I I (9 = z r 9 =;. :J U F a l F n UA *-i z6 3z =U ?= ;< -'L co UU <:i )o (, o z 3 IIJ U = t F c o-o o '--,.-=-j:/ 2 @ oB >> > I]J LIJ 4JL- fu UV > f-: 4 WIRINGHARNESS & FUSES12E-21 @ry t U r IJJ N : I 7 Z':. {-* uJ i! ;_, '-, : :> l: B: .l .\ = K, tt^ IA z <[i 9 =Z J .A u >I t 12E.22WIRING HARNESS & FUSES -l cc v)F -= za I U- JU- ,a F t U z rO ul u- ta ul F F 4 l o Ch o UJ LIJ z (rz I F Y (9 Z= -= co tr!l o = r'' (o U s< N UJ N F FE Al zz 3 o lrJ O o I = F= lt z f\ o -zEL o r 4 c/, U U ir6t g UA ui cr ) c F ;= u (n fr* o F g J U U * rrJ J d {E F Y B U E I I d O J co E 3 U ; ':E 3 ! o o ; :7 : ?: z c r= c< za UU A <-- | 4 WIRINGHARNESS & FUSES12E.23 Hd E -H *::6 4 fft8 ff coF< tr >=: r o )Y: \ rr\ ct) Z J:l \ \\\ lu g . \, \\\\ z 3 \ \l\t UJ \- llil ; ,ul + F +1, U 3 F o U Z= o /,,_t'-. ; ccH = ! r o / t:*'=.' 6| O z =x \ /e=, UJ c \F/ N z F F= U t zz o uJo 3 F= I ES tt fr,' E (J E uJ E F ITI-o U U:- ;- o O (,u JF U- []-7 12E.24WIRING HARNESS & FUSES O N o ,U z z--N U = >9 U Fu z o :c z >; I t Zo U- sl tr ll< LIJ U o UU cc: U ZJ U^ F F(, 3= oI U (t I LJ z;i I E = Ful u O(E t z- H IEI rE z o tr IJ,J g o I v) tr o = u,l U z t 0c tr I (9 ao (, o z t! U N z L U; L @4 o ff= = = = 0. a F I ;1 \ tt r 9:1 z .z= Iu uZ-uL E 3s1 .^F \ //-"\ \ x t- zl )r !tr-l ,- t z- uL tr !.t c z> U: "" Oil -Jr? 7^- F c O /"1 |r N c I E ,/ UJ @v 2a ul (,)= q N -7 C^ JUJ r'" 0 (\|gt (N,r ! 6 = UJ = il t\ J s 6a U u ;9 tr U ; \#:^r-li . tZ = o -)*/' rZ > rfq.: - g =- z E UJ 3 \- u E E \rv. 1-< i.-r - ' F r-(:\ l_-{ E = "'r,E uJ O a == arU /r/ F:z- z2 \rt, ll!^ trtr li / 'a' cn UJo o = CN (J I CL o = !l uJ oa F o 5 z I \, I uJ tt \',' = \il E A, U = l''', ! ti,i @ o :,t ' (J i = LU //, ,, U z "'/ uJv z .Jlz_ UJ us l-u t1 o= a; F; UI?- --u / E = .0' z rl ni . . I oi \, ( -);.\ ( .,. \ \6..u.l . \ WIRING HARNESS& FUSES12E.27 U 'T U o a= au0 Za J zE si E ^s=o FI te = f z z/ g F zi o il< LIJ ct ! ul -u, c{ o UJ t lt-9 t t! tr 3 U ul t = o- z-n f ei o F J - E 3 U ; 12E.28WIRING HARNESS & FUSES I J \ E, l-+t n\ l:j \ Eqri Il @ z1 e U xN I f/ F; : J a l z U) =- = F u /1 _-_._:=jL U \./ tn Xe ;E ,1 CE tr E 3 = J z fr t! a) F X LIJ uJ o 2_= U ,_\ ul -9 T F L-l = (.)-j \ tr ; ! O' )l q a /->\ (l [, WIRINGHARNESS & FUSES12E-29 \ a o C. U I U U N f, -O U =< IL (, z? o^, tr Fq U @ I lcr Fr U z- : T1 = cc -=l/' = -=3 \ co mI = xo -_----..._l \ \ Yl (jd rI ? ,5. I CN -: aa o = t ; = iil, ltr = )4ND'/ n i ,,='---- F ------llr -\ z = LU r a ! I z - x a L UJ c = U) o O 2 r :-i trl F F c Zu -c v= a a 6 t-\t o a2 ._<= UJ \) N s: o -Y@ts == tr o uJ o r[- o IrJ F \ (\-. - E = uJ ,<,yir._ U _ > I cc: L u ir-; I 3 an gJ FU zv I < (,) tr U 2 r il U F z u X o u@ UJ VJU Oo F- UA <; az FU r^i $Jtr <= 2>; t< !\ il< cc LU\ -.'2u --v o 2 otr d9 F -N n at) TIJ Uf fir 2 uJ 3E LL ao z z i> UX = LU t -J o o cn U L o t G LU J U o o il E = a t cc U z o = F F tr- > 1t -! _L cc cEo ul o> = o o. {p UT n E = u WIRINGHARNESS & FUSES12E.31 (r U ; il tr ccu s 3 zo- 6 u Qa o 9 FI r ; <= t U tr O6 ) U Ftu ?2 Y a/) 3 ta LIJ z N = o uJ I o IL a (/) U I o tr uJ F 3 F U U) L ; LlJ Zu IJJ = CL t Ou !3 J"' rT =i E 3 u ; 12E.32WIRING HARNESS & FUSES z ^6:O FI z-N FO tr zi = -U = cu ct) v z (J U ^o=o FI FF U' r 3 (o o a) z l! o c{ = o Z,l, t ooil g zF-. ?H x- F*o -H -v= =o ^ii*-trul == o CC \ O I \^ ar U E:/-PE\-g N F- I v tl :' yN I _ e)_ | r o r = i f\,on-#> U E : ;G: frt*--.'i = v@ U t z :m cc 5 F] o c! F r (,) . z ul\ = =(, z: - J zi zL <@ lz z@ 'z rU frz r* oul Jq X< ftX urO t o,l lv LU -o uz U_ >F :)u 'ao o z z -o< z U) ^r:- v FI (J G UJ o-o U ,F tr F G ttA g 3 U t WIRINGHARNESS & FUSES12E.35 UJ uJ .JJ tu oan o TT )a<5Y el a-z- U) 7z=i ZZ :9 J E J o = f, <= U /- U o ; @ F;3 z F uO >>c l =-z v) 9zi ou) = o uuJ^ o (U "oz oo o UJ z l[] JA N r f tll z Iftr< o I F(/) ua7 t7= rn z 3 I t o UJ o 6 J cc tr u = U t ; WIRINGDIAGRAMS 12F.1 SECTION12F WIRINGDIAGRAMS INDEX Subject Page ' Subject page WIRINGSCHEMATIC SYMBOLS LEGEND...... 12F.2 CIGARLIGHTER, TURN SIGNALAND HAZARD SYMBOLSUSED IN VK WTRINGCIRCUIT WARNINGLAMPS, WIPER WASHER AND DtAGRAMS...... 12F-4 DWELLCONTFOL 12F.25 WTRTNGSCHEMATTC(PART"A)...... 12F-s HEATEDBEAR WINDOW AND REAB wTRtNGSCHEMATTC(PART"B)...... 12F-6 wfNDow wtPER AND WASHER...._...... -...... 12F-27 WIRINGSCHEMATIC(PART"C")...... 12F-7 HEATfNGAND AtR CONDtTtONtNG...... -...... 12F-29 wf RTNGSCHEMATTC (PART 'D')...... 12F-8 RADIOAND POWERAI{TENNA.... 12F.31 GENERATOR,BATTERY, STARTER MOTOR CLOCK,TRIP COMPUTER, INTERIOR AND IGN|T|ON...... -.....-._.-.. 12F-9 ILLUMINATION,REAR COMPARTMENT ELECTRONICFUEL INJECTIONSYSTEM ...... 12F-11 LAMP AND LOCK ...... __. 12F_33 5.0 LTTREENGTNE FUEL SYSTEM...... 12F-13 ELECTRICDOOR LOCKS AND POWER ELECTRONICSPARK TIMING SYSTEM 12F-15 oPERATEDS|DE W|NDOWS...... 12F-35 HEADLAMPS.STOPLAMPS AND HORN...... -.....--12F-17 ELECTRICMIRRORS....- 12F.37 PARKINGLAMPS AND INSTRUMENTPANEL FRONTEARTHING CIRCUIT...... 12F-39 tLLUMtNATtON...... 12F-19 FRONTEARTHING CIRCUIT CONTINUED...... 12F-41 INSTRUMENTS- MECHANICAL...... 12F-2',1 REAREARTHING CIRCUIT 12F.43 INSTRUMENTS. ELECTRONIC...... 12F-23 TRfp cottpuTER.-...... _..._ .t2F-45 TRAILERHARNESS..... 12F-47 12F-2WIRING DIAGRAMS WIRINGSCHEMATIC SYMBOLS LEGEND LAMPBULBs swlTcHEs A (MANUALLY OPERATED) \O INSTRUMENTS Max. Code Name Max. Loc. Code Name Loc Code Name Max. Amp Amp i Amp Loc- B2 L.H. Rear Turn S 1 Horn Button TBA 309 Generator ndrcator 0.10 92 Signal Lamp 1.15 23s 2 Auro RetractAnt. 3 Brake Farlure B3 L.H. Front Turn (Touch Sw. Conrrol) 292 Warning Lamp 0.10 SignalLamp I 1.75 92 S 3 CruiseControl Sw 121 t4 Park Brake Warnrng B4 R.H. Front Turn Lamp Sional Lamn S 4 CruiseControl Speed 0.10 94 ; Restr. Sw. 122 7 voltmerer i 0.10 110 B5 h.d. Hear lurn Signal Lamp 238 s5 CruiseControl Brake r8 Temperature Gauge 102 Switch 1.0 High t9 Oil Pressure Gauoe Beam 5.0 s6 107 B7 Low Beam 4.58 I 165 l 10 Fuel Gauqe 105 S9 Turn Srgna Swr | 1l Tachometer 0 20 t'11 s 13 Heated Fear Wrnoow 142t 12 B9 I nstr. Compartmenl Swrtch iMan ual i 20.0 't49 L.H. Turn Signal Box lllum a 4? I ndicator :12e J tl Eleclr c Door Lock I I3 810 Dome Lamp 0.83 I 134 Sw tch (Key) L.H. Fl.H.Turn Signat i Indicator i o tz O.]O 237 s 15 Dwelt Qe611q15*;1ah zta 114 s 17 Hazard Warning Sw 237 I nstrumentCluster I 15 Orl PressureWarning lllum. Lamp O-1 112 s 20 Arr Conditioner 249/ Lamp 0 10 96 MasterSwitch 274 | 20 Coolant Level Swilch lllum. 0.1 172 s 2r Air Conditioner Fan 264/ WarningLamp 117 Switch 15.0 --- I 15 Front Parkin( | 23 Electronicspeedo .--; s22 Dimmer & FlasherSw. rb4 816 Tail Lamps 25 I Trip Computer Windshied WroerSw 223 I DisolavModute 160 817 Rear Licence P ate lllum. 0.83 169 s26 Lighi SwLrch 169 t26 Trrp Computer Function ndicator 421 s29 Power Operated Side I 160 WasherSwitch llum 0.1 172 Windoer Swrrch 344 t28 Electronic Spark Timanq Lamo 0.1O 76 Bear Quarter Lamo o.42i1.O 132 s30 E ec:r c Door Locks (Button) Sw,tch 321 t29 S13 Indicaror Lamp 823 Rear Compt. Lamp 0.83 tJb 32 Rea'Compartment (TouchConrror i 0.10 142 s24 Heat/Air Cond. Lock Switch rJd r36 Back-Up Lamps Contr. lllum. 0.05 172 34 lcn rron Switch 13 Warnrnq 1369 0.10 114 B'5 Radio lllum. 0.'l 172 r37 llum S 35 W ndsheld Wash.Sw. 227 Exte.ror I uzo Light Switch lttum. 0.1 172 Wa rn Ing Lamp 0.10 169 RearWrndow Wiper 828 Cigar Liqhter lilum 0.1 172 Sn. {Touch Control) 204 ELEcrRoNrcMoDULEs 829 Back-Up Lamps 1.75 1't4 38 RearWindow Washer E (Touch 830 Heated Rear Window Sw. Controt) 07 209 N Dwe lControl Unit I Switch lilum. 0l 172 s 40 Power Operated Side N 3 Power Antenna 831 Clock lllum- Lamp 0.1 172 Wrndow Sw. {O/ride) 111 Conrrol Unit 291 Engine Compartmenl S 45 Power Operated Side N 6 Coolant Level Wrndow Sw. (4 way) lllum. Lamp 0.83 169 , 343 L Warning Module 11j UJJ Power Antenna s53 Electric Mjrror N 10 Electronac Contact Adjustment Sw. Switch lllum. o.1 172 0.7 Breaker t 6q 848 Trip Computer Heated Rear Window N 12 Radio Recerver Controls lllum. 0.10 72 Sw. (Touch Control) 20.0 N19 Clock Diaita s36 RearWindow Waper TFAI LER WasherSw. (Manuat) N21 E.S.T. Cont.o Mooule (Manua ) L.H. Rear T/S LP. ?1 t6 33 S 14 Heater Fan Switch 264 N'] B 105 R.H. Rear T/S LP o.6 240 E.S.T Conirol Modute (Autcme: cr 76 81 08 Stop 136p 0.5 SOUND PRODUCINGDEVICES 313 N22 Trrp Comcuter B116 Tail Lamp lr'last?r 2.1 169 H 1 Hor^ 3.0 f/odule r)/ 8117 Rear Ptare Lrc. lilum. o.42 tbY H2 Badio Speaker Frcni N 26 ! J :ag? Srabrlrzer i0 8129 Back-UpLamp I O.gg 114 R.H. or Cenrre 304 N28 :FLConrrolModule 3 Radro Soeake. N 29 Fu:l Pump Module 36 POWER Fronr L H SUPPLY 304 q'Condrtioner N 30 I H4 Badio Soeake. P,I Battery SvstemModule 256 Bea: R H 304 6 Cyl. 1604 I H Fad,o 8 Cyl. 253A 1 5 Speake. N'lodu le I Flear L.H 304 P2 Generator -- - N 32 Rear H Window Wiper/ 45 amp 1 6-T-- ]------WasherModuie 2Oj 55 amp 1 70 amp 1 60 amo 7 - WIRINGDIAGRAMS 12F-3 SENSORS MOTORS €N RELAYS,soLENotDs rrl Max. Max. Code Name Loc. Code Name Amp Loc Code Name Y"t Loc. Amp Amp l Brake Fa I Warn- Sw. M2 Antenna f/oio. 2.Ot9.O 29 R1 Horn Relav 311 ss2 Park Erake Warn Sw. 94 M5 Taoe Plaver 30 R3 Anti-Dieseling ss4 Cold Feed Swrrch 30 M6 Heater I or,,9. l,4tr. r 5.0 262 Solenoid 0 5 2A a 4 ss5 T.C.S. Swrtch 30 M3 WindsheJWpe' DrstributorVacuum i Motor 1De co AdvanceSolenoid | 30 ss7 O I Pressure Swrlch 96 224 ---f--- M9 Washer Pump l"'oio r ransmrssron ss8 Neutral Siarl Sw. 1J De:ent (Windsh ield ) 2.9 2?1 Solenoid t.10 200 ss9 Back-Up Swrtch F Flasher M10 Electric Fuel Pump 6 Relav 235 ss10 Slop Lamos Sw 313 Motor 37 F - A 'Conditioner 255/ 3c-g'essor ss11 Arr Cond- Aux. M11 Air Conditioner 251 I Clutch Fan Temp. Switch 283 Fan Motor 16.6 276 R E A'Coro,:oner o.2/ 21Ol F:. Re:r 30.0 245 Arr Cond. Evap i 255 M 12 lAirConditioner ';;;?qq/ I nler Contr. Sw 281 Aux. Fan Motor 6 a Rl0lA.Ccr::orer o.2l 2581 I AJr :? a/ ss16 Coolant Level ll 1: Power Operated -:- 30.o 284 Warnrng Sensor 117 Srde Window Motor 342 R 11 Pow.3e-::r o.2/ ae SS19 Transmrssi on M 16 E,ecr.Door Lock Windorr ar 30.0 Detenl Switch 200 ' MoIor Front R-H 8.0 23 Starter [':. S: ?no d r3 ss20 Door Jamb Switch 134 M 17 Erecr.Ooor Lock R14 Rear Comparr-en: l\4oro.Front L.H ss23 Engine Flevolut ons 64/ 8.0 Lock Soleno c 14.O 138 Sensor 76 M18 Starier Nrotor R16 Hazard Flasher ie,av 237 ss26 TrapComp- Vehicle R 17 Electric Doof 0.15/ 330/ 8 C,, SpeedSensor tol Locks Relay 30.0 322 ss27 Trip Computer F uel R21 Heated Rear O.2i M20 Rear !!1ndow 3.5' F low Sensor 151 Window Relay 149 Wioer fvlo:or 20.4 205 30.0 SS26 Etect.Speedometer M21 Rear !!rndo4 Washer I Speed Sensor tol Pump Mo:o. 3.E 2C3 SS29 Rear Companment e 2E M22 Elect Doo- Lcck Eng. ldle Sp€d Boosl 256 Lamp Swrtch rJb (6 Motc Rea'R H Solenoid Cyl.) 0.45 2t1 ss30 Insi: Compt- 8ox R30 M25 Elect. Doo- Lsck CruiseControl 0.3i I lur Sw tch 129 TransducerSolenord 2.2 121 Motor Rea. L r'l 8.0 )> JJ Throt: € Valve ;?F Iniedor Valve 43 M26 Elect. Mirro. \'oicr 0.80 . 5wlrca tts.5 I I 82 R.H. Vertrca tc F5: Elect.Mrrrors 0 15 E.F.l. Ar F ow Seisor 55 1E6 M28 Elect. Mrrroi Mc:3 Select.Relay R.H. 30.0 ss36 Throttle Va ve R.H. Horizon:a 186 a 53 i Elect.Mi.rors 0 15 Switch (E.F.l.) 12 181 M29 Elect. Mirror fr4c:c Select.Relay L.H. 3! J ss37 Camshaft Posrtion L.H. Vertrcal 179 R 55 Arrcond. Fan C2 241, Sensor 22 Re M30 Elect Mirror l\'lcic ay Negative 3l.l 212 SS43 | Oisiributor High I L.H. Horizonr. 142 I TensronSw. (6 Cyl.) o CIRCUIT PROTECTIONDEVICES I \,f I WindshieldWrp€ Motor ( Lucas) 224 I E I WindshieldWiper 2 Fuse 5 SS44 W pe: Motor I Motor (Preslrte) 5.O Park,ngSwitch 222 3 Fuse *, 4SE- 5546 Carb Vac Sensor 83 RESISTORS,RHEOSTATS V 4 r Fuse 37 -5 5 Fuse 25- 241 -{ F cApActroRs E I Heated Rear 1451 Wrndow 150 6 Fuse :5 313 c2 Radto lnle'ierence I e 2 lnstr. lllum. Bhecs:.i 45w 7 Fuse :5 145 Supp.(Generaro,r 35\lFl 10 E 3 Arr Conditioner 8 FUSe 237 c a lPrimaryvollage Fan Resistors 276 I Caoacitor ?4 9 Fuse , 15 136 E 4 CAarL'ghter 10 Fuse '5 32 E5 Orl Pressure 108 +,'1- RECTIFIERS Senoer 11 Fuse 201 E6 Coolant Temperature Fuse I5 125 D 5 Air Cond. Clutch Sender (8 & 6 Cv .) 103 Protect- Diode :62 F use ?.26 E7 Fuei Level Sender D 3 Elect Instruments Sedan 3 14 F use Drsplay 5.0 9e Wagon 105 "oo E9 Ballast Resrstor 1.8 22 t5 r use 262 MISCELLANEOUSITEMS E 1l Transistor Load G P, O Side Windows za 346 Bes istor 101 X 1 Js:'buto' .ST 63 P Antenna Molor F o 291 tr 13 Crurse Control R Fusrble Lrnk (E.F.l.) 63 Transd. Resist. 40 121 X3 tr 6 Coolant Temp. 47t TRANSFORMERS Sensor(EST & EFI) 18 o (6 6i G I lqn. Co,l & 8 Cvl.) t.5 62 X4 Conneci a: _:'Tesl E 15 Auxrrrary 49 i 81 1!l"T i . 1 _ l l 12F.4WIRING DIAGRAMS SYMBOLSUSED IN VK WIRINGCIRCUIT DIAGRAMS o FIXED CONTACT a LIGHT BULB a FIXED CONTACT (UNDER POWER) c FIXED CONTACT SPEAKER (UNDER POWERTHRU RESISTANCE) fl d MOVABLE CONTACT r x'r tr I d{ SIMULTANEOUSLY r9,l HORN MOVABLE CONTACTS L?J I tr-r FUSE E€ RELAY q FUSIBLE LINK I b <" RHEOSTAT I SPARK PLUG . T LOCATION OPTIONAL ^ LocATtoN FtxED By REstsrANcE 1 SWITCH o' CONNECTORBODY WITH FEMALE TYPE TERMINALS +! MAGNETIC SENSOR t=l MALETypE TERMTNALS -_1 DIODE {F lc ol StMPLtFtEDVtEW OF ]"ol AcONNEcToRBODY of= io _\_ = RESISTOR RED LOCATTON& COLOUR i OF LEAD SOLENOID SIMPLIFIED VIEW OF AN ELECTRICAL t (WITH I I COMPONENT 2 MALE l-l- +- TERMINALS) MAGNETIC INSTRTJMENT I @ I EARTH FROM COMPONENT TO VEHICLE BODY @ THERMAL INSTRUMENT EARTH THROUGH EARTHING @ ELECTRONICMODULE LEAD TO VEHICLE c ELECTRICMOTOR ALL SWITCHESSHOWN IN "OFF" POSITION F WIRINGDIAGRAMS 12F-5 l + I :. I a GN 3: e3 uJ- ca l ll an tL z IJJ z F z ; = EZ 9l c s- -l I __r r i a I q. l o I I 6 E o @ o 3 lt N o I I ! B .R 12F.6WIRING DIAGRAMS I l! N UJ - E z -r z r z F G o. I () o I E o (, o ct E = l_+-- N -----1:ll tt o ED L 3- z2 ;a t. = ?"= : VV aa rf V WIRINGDIAGRAMS 12F.7 s g (r. tr z UJ z F z O i l-f- :e E I o 6- ,, ,-a 3 :: lr N (, 12F.8WIRING DIAGRAMS -F g c o 6 E o o 6 CD E = !t t! ol o I lt ;::r5 ;V *V ;V VV 9 : WIRINGDIAGRAMS 12F-9 iil[s- L lF+lli,lh'i;g:i :!'- i n+-"""*i l;#-'*' ;-,--.-=+--" l- Ill,ls;=_:i;,, Effi,i,ii: Tii ::i;:ii' i:ic,f, lTl['W; ":1 u;:::;'i:' q;9 ::: i .9 fHfL-e 1J; ;;C'Y',*ii iH\ :: | ' ,ul ntff)nn - ii'i ir=I;iJfll,,,i, !ei, I . littllrulIa ibllol6r ' i' 'oP.i J""il, E.'il I I E o m':I tL- ". [r_'* "' ii i -={[hElii;r",.",1;;: I ! f _tn++ffi:.-- 39 : :,--" i | -- --"'; -o ;a : i ttf,r!-*.%=rulFl' qa9; ; i i:ii!!it!!.iui::l!i i i riii:ii i;:ii;ii;,ii ii UUULtUUItU ', iiiiiiiiiiri"iiiiiii il:::ii*i; ;;,'!3 :' !c3 g - :: i WIRINGDIAGRAMS 12F-11 : .QH : -: : - ,; i j,i!lr':_ tL - E] !s:;a : a .t!L!lrtl F !t :; "=q=li rE i; t ii ;:lu.Ft' Ir.ti: aa : '- I rtl r.g -iL*,,. -; -9 E 11 :: ;l \-}1 ;: i 5 E jl tlt WIRINGDIAGRAMS 12F-13 !6 !* ! ; E €3 t c 3 tl Zi I PE -i z I EiE" I $5!: -, . :: i[F*J iE nt 13 t J | 5; t ?= P* WIRINGDIAGRAMS 12F-15 ["- - 1! tt ;; : :a 1lj .l ! rll-fi-'ir :: I E : i fiiin-' :: ; I i' a i; ; :!E !e! E tl E I ;/!j E _ll: l,r_,,i l _ li i_,i_i. WIRINGDIAGRAMS 12F-17 I -t:tr =]l ;" H i rl 6*E . {A\. r ;_E I t---eY ? :i9 iF it " i i le'{j: I !:i:!! r J-!l 1': ? !:!;i. i 6ta + . t+ '" j 6 \2: lll '== ii i :Eq::E i a) AP J J t ". -/ 1? I i-.^'+ _a f-- lrl! tl Y 3 | 5l i q'@ mF r- . i I :: i ! d t; : I t I ! :Effi[!r ; rL:Si l-t r,t :- i I t -t: : 1rvrtr ! ll L ._r,,ni L 0a ; -, t! I ^+11,.,+ii : | iii I IJ | \€-P!r/- {! i !t !Fl+a+ ;: s "it il !q Z ar 1e -,.--."',.-l -c E t I I WIRINGDIAGRAMS 12F.19 i ;- ;- ; i :; 9<< \ /'- 1FZ A D,;t !^ , loi jrr zr \"\#,,.,.i_/ a -.- i:- .l 5^ {r_ r. t;n 1' L tu .r, E rh an E = G ;: Ot J G 1 o- --a- I lt YL N ; ctl lt 11::: 11,l l: ,li,'; , z I -- Oo ri;ltct6Ft9(ffl z< ,OlO rnt]t r t-r r-. :r Llii'a - : L-riU rrlrr! 5 < -'-ll ttrj tu' lf .5*o..r^0,-, 3: ! rcvre- * a WIRINGDIAGRAMS 12F.21 g gi. a. \a lE is .': 9: ?t ;dI f- -,1 ,,:l _a- I I T 1 i:: : dli ot; :l C e ; = 2 E .E E' :ii ; q; I !i 9rt $r! q:;: !; +. WIRINGDIAGRAMS 12F.23 r {E'.2 ,... ,;i P ;i ; i i'csTi=| !: 1 | f-- i s;q ! - i- ii :- -i- '1- ';i - ;;; ; l:; , :Fi-F E l;i r !'i. ... rE!:; ! F:: :...:) :.; I ; Hi!-: I q :! i- . ; -nfflinh 5 || s; ' : rltDa6 r * it _-j; . :-lF?.6-->*Y--- !E rl trhfitlrn-.-.- IlE +1.i r i= g !3 : -,3: L_i i '1"; s lff I '-????--, --r'-L- .. -tELrioDD..r _ .. jD- : L e:; :a i!: :; .....*, . lll i ! IllILJ:: +t . i: " ' ni' - i; rprali::l I | ..,_' :i -+". -t ! i ! 'tnn ll ti - . : lL t$ - \irt i: t= E= ': : z ):' ;r :J ,t :: _3 t! - ll- ^1 pl -:]-=iJt-_,.i | -,.= rJ i rlli ir E ':-; | 5t: "" F I -..-: itl| ";' |[ ii : :E i'l 3a i : 5 s! i i |.r i: - lll ilu ! I :: I F5s-i -ll I fNrH: t! ,E; {!-1]r,tsF .i: 9Ei E.i c:2 zt 7- !t - -8 |.9a E I; x ;ir WIRINGDIAGRAMS 12F.25 E+ @ ;+ W*sa^"'r! E: h trl*; t",4 !:! ait ! T'= - :3 a i:' it aii tnd: ji :;-.^,".".5c.;"-.-"- . : 1I : ?s! : :ErIi ar= r ;2 :: :' 'i; l .Li t =t 3 = E z - j @;*'Hr-r i :: 3; i i: Ri.d' Jh*L;rE .) f - 713 ]|]::lFlh ;E .9 \ja:jtesv:3 fl il E I arl frr+1l1rr;{I{n+lii :; ;Bi i5 | ' !!I!-,1- -,1l.. .rt: Tii i ! g: i 5 Ei 1a i-t ;r "r-rr i: ff: - WIRINGDIAGRAMS 12F.27 ; f;_o :b c! J :;tr :P .------fL--11--_ : o 2rIJ'''l[| ]|]: o; E .!co!oioD'!s:::l-- : :;i 3! ;i i: 11 l ri+ i3 tl ;:t !!c I .!Lirl l,LLt_ ;t 6: r;3 :; " ;r rlfi-* 6 !! lf''111 . 3 ::.lil-l.l:' i i6,]|[ffi1;;.._::_ nla 'a : a-Yl--rllr{; ] -ijllU![.-=*, a, ;i .r. !i' 5l mo t :1 F-""- i:9 3 o i: $:=! ' ,.1 ; ii | r Fldl1+ {-f lll - -- H -E*! |l\. I L]; -\ n i!' ; +- Ef E lil e r '-! lH! n5l T Ej'El;: r--t !+r/ I i Kfr : !r + ":r WIRINGDIAGRAMS 12F-29 : t E I I rFE ! il r;so/+, i 1 i- i a" :i *x :-6 !3! 6 t : t,-l__-_rl ,? : 1l n 3g I irl iJ.{r iuF *l a ii q5! :-3 .*"",.J WIRINGDIAGRAMS 12F-31 ia^ E; ,i:rcn!,--? td €rrir!o= 1 :ffii s i - c I!- iir{-f riu = 5t- :ti 6 ! 3 -6t a 645 L nE{ tf \ -r}to=)t_ is; N- - ra' ql tl l i :9 )+e r#t-,.*-'s! 11 ter:|!-*- i: \a WIRINGDIAGRAMS 12F-33 sg:. i3*iE :H::c -i: e 16@r . , ,1..! ?r i ? lr FE: Niu E !$ il1.,--,"-.'e llt-1::: E i! ;; jg E t 3! it j era /ane< i ;i - E tlE "-Fld( )il i-- a .L?fi li E' 5 91 - i ,+. ll + F'ual + -1/\-2.2 f 9 9; ! N i: i I i, il-{' ;-* :i IA 3P 0 !t ff flFVE =t",H i-* +6 EE- :! WIRINGDIAGRAMS 12F.35 i; c-d _ --l iT l- J.1. lt:R Irt lrl !q *:i' a xi ;:I :,l-[[irll]lllf,,, ' ? !=jffiEF -i59. =i-r s .....-"=!.9\,:i; e : ? I o r"+ '-Hm"E''u',I a !: !!::; r :i I u'lJii;ilLL,,"*" ':'{il)),,";! i= E6'i Ei ll|!; i-; n a 33 :. J-'ttE t 3 Le] 6 :! .r---;; E9 WIRINGDIAGRAMS 12F.37 3' ;a: t. :: 1-11-1-r, s:!i XEE: I a-L --L ' =9 :e ! I : tr€'-.-E; EZ - WIRINGDIAGRAMS 12F.39 3 n) I A",qcX :+ t;/\o\ /ol);l )< \060/ )z v :J F: z; =d z I I l z le :< z= , z o : z :" o :l I r =Li at \ ; E< I \ lY o l- flr ]E -rr ]+,"' ii LIJ lt ot F: \.-. o| i. tLl. !-l , t-l -- . o crl lt I I Ulti . : "ih Xy2a ' 'l"rtr- ;si z;tz o *ro [])fl:-al{z l':' -: J F1 '- I E,i fi -',.,".o i WIRINGDIAGRAMS 12F.41 ?t. <# a, c E 3 drtir,l1H]lt{-trl o 5 F o (J a .:o o ED E (! 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