These were lifted straight from the old Phoenix Mechanicals website.  Just parking it here in case I need it.

The categories were:

• Engine
• Gearbox
• Differential
• Brakes
• Electrical
• Suspension
• Air Conditioning
• Body
• Interior

Engine

V6 Engine Pulley noise – Some V6 engine pulleys develope a ringing type noise at idle, which may be caused by the drive belt slapping against the A/C idler pulley. A revised A/C idler pulley was introduced late 2000.

Idler pulley Assembly – Part number 92094003

Idler pulley support – Part number 92065824

Drive belt  – Part number 92100691

Belt Squeal (SC V6) – The supercharger belt may squeal or chirp during cold start conditions, if the belt is old or if the pulleys are misaligned.

Supercharger Drive Belt – Part number 92067829

Rough Idle or Hissing Noise (Gen III) – Some Gen III’s may experience rough idle, a high pitched hissing noise and the engine chack lamp illuminates on the dash. The PCV (positive cranckcase ventilation) pipe may deteriorate, perish and fail causing these problems. A revised PCV pipe made of more durable material was released.

PCV Pipe – Part number 12590632

Gen III Oil leaks – On the front left edge of the engine sump, there is a oil pan transfer cover (just above the oil filter). Some Gen III’s may leak oil from this area. A possible caused can be porosity in the oil pan transfer cover stud holes. A revised sump was introduced early in 2000. O-Rings were added to the oil pan transfer cover studs (with a gasket as well), to help reduce leaks from this area. In some situations, the sump itself can be porous and may need to be replaced.

Unfortunately, early production sumps can not have O rings fitted to them, as they have not been counter bored around the transfer cover mounting studs.

Gen III’s engine covers – Engine cover rattle at idle, or just above idle speed is common. This is caused by the engine cover contacting the coil/bracket assembly. GMH have revised the support brackets and the mounting nuts. Split covers are readily available which reduce inlet manifold temperature for better performance. In mid 2002, the brackets were again revised with bumpers, and no longer require spacer nuts.

RH Engine Cover Support Bracket(includes new bumper 92138641) – Part number 92087580

LH Engine Cover support Bracket (includes new bumper 92138641) – Part number 92087581

Bumper (15mm high, slotted) – Part number 92138641

Nut  – Part number 09440004

Engine cover Insulator (front) – Part number 92086029

The engine cover may also rattle against the hydraulic clutch hose on manuals built before vin # L867194. The clutch hoses may become twisted or distorted and interfer with the engine cover. A revised clutch hose with quick-connect fittings was introduced mid 2002.

Gen III Belt Squeal – In some cases, Gen III engine serpentine belts will squeal at around 1500 to 1900 rpms. The squeal can occur if the power steering pump pulley is misaligned with the crank pulley and the alternator pulley. The pump pulley may be too close to the pump body or too far forward. This can cause the belt to not track straight and will rub on the front or rear flange of the pulley. An adjustment of the power steering pump pulley (between 1 – 3mm) may be required, to re-align the pulleys.

Some Gen III Automatics may develop a belt chirp/squeal under hard acceleration, during the 1-2 shift.

Decreased damping of the belt tensioner increases this condition, so a revised belt tensioner with increased damping was introduced early 2002.

Belt Tensioner – Part No 92111701

Gearbox

Harsh Transmission Shift Gen III – Some VX transmissions may have a harsh 1-2 shift and a harsh 2-3 shift. Revised PCM calibrations with improved transmission shifts were introduced August 2001, along with a revised 1-2 shift accumulator.

Shift 1-2 Accumulator – Part number 24220143

GEN III Vibration -Some owners have reported a mild vibration when the vehicle is in gear with the a/c on, or with the vehicle in gear and a steering load is applied, or at low engine driving speeds between 650 and 1000 rpm. One cause of this can be a stressed driveline.

One sign of a stressed driveline is a bent catalytic converter bracket. Extra gearbox mounting bolts can be added, along with different spacers on the converter bracket, which in most cases will overcome excessive driveline stresses.

Vehicles built before vin # L647630 (14/10/2000), require 2 additional nuts and bolts to be fitted to the gearbox crossmember.

Bolt – Part Number 92138301

Nut – Part Number 11086962

Vehicles built after vin # L647630 (14/10/2000), already have studs inserted in the crossmember, and only require 2 additional nuts, as above.

Torque nuts to 45-55Nm

Spigot Bearing Noise – A squeal may be heard from the spigot bearing, at the first use of the clutch pedal after a cold start. The noise may repeat several times when the clutch is disengaged, during engine warm- up. Possible causes can be the incorrect fitment or damage to the spigot bush, or the lubricant used on the spigot bush dries out. Revised tooling was introduced to minimize possible damage, and the spigot bushes are now impregnated with synthetic oil (10% molybdenum disulphide).

Spigot Bush – Part number 92116034

Clutch Pedal Squeak – The clutch pedal to clutch master cylinder pushrod pivot pin and bush may become dry and squeak. Applying Molybond GA10 Grease to the pin and bush will help reduce squeaks.

Gearshift Knob Rattles Gen III Manual – The gearshift knob may vibrate to the point where it can generally be heard in 3rd or 4th gear at wide open throttle between 2500 to 4000 rpm. This condition is a result of excessive clearance between the shifter knob and the shifter lever. From March of 2002, gearshift knobs were glued on.

Gearshift Rattles Gen III Manual – Under certain driving conditions some VX’s may develope a rattling gear shift lever. This condition is different to gear knob rattle. The cause of the rattle may be due to excessive

clearances in the remote shifter linkages. A revised remote shifter was introduced late 2003 to eliminate rattles.

Shifter Upgrade Kit VT/VX type – Part number 92147248

Soft or Low Clutch Pedal (Gen III) – In some VX’s, the clutch pedal may feel soft and/or has a low disengagement point, along with some difficulty selecting gears. A cause of this can be the clutch slave cylinder. In certain situations, a corrosive chemical reaction can occur between the clutch fluid and the clutch slave cylinder housing. This chemical reaction can produce a gas in the hydraulic system that can give a soft or spongy feel to the clutch pedal. A revised clutch slave cylinder was released late 2003. The new cylinder was made of a different alloy, and was more resitant to chemical reactions.

Clutch Slave cylinder assembly (revised alloy) – Part number 92067460

Excessive Gear or Road Noise from Shifter Area (6 speed Manual) – Some VT’s may have excessive road or gear noise coming from the transmission shifter area. This can be caused by a split inner boot, or a loose retainer plate. A revised gearshift boot and retainer plate was introduced early in 2002, which is of a more durable material (white in colour), and the retainer plate has 4 studs and nuts (instead of 4 holes and nutserts in the sheet metal).

Gearshift Boot Assembly – Part number 92065868

Gear Engagement (Gen III Manual) – Some VX’s may have trouble selecting reverse gear, or the selector does not go into reverse completely. When the clutch is released, grinding of the gears may be heard if reverse isn’t fully engaged. The gear selector may also need to be physically held in reverse to use the gear. A possible cause can be a circlip missing from the forward pivot of the shifter rail. A missing circlip can allow the gearshift pivot pin to partially disengage and become loose, making gear selection difficult.

If excessive effort is used for gear changes, the Remote Shifter Mechanism front pivot ball may dislodge from the nylon retainer. If the pivot ball dislodges, no gear selection would be possible. A metal reinforcing plate was introduced to prevent the ball from dislodging.

T/Bar Damage – The t/bar shifter base may be damaged by the front tailshaft coupling if the car is subjected to extreme rough road usage. A revised rear transmission mount was introduced mid 2002, that also has a travel limiting bracket to help reduce this occurance.

Transmission Mount – Part number 92117399

Differential

LSD Chatter – LSD chatter may be heard when the car is turning left or right (in motion), and is most noticable when negotiating tight corners at low speeds and parking manoeuvres. Chatter may often be experienced as a grabbing feel during the operation of the LSD. To correct this condition, LSD axle units have been revised by the replacement of the previous cast iron cones with sintered iron cones. These axle units are filled with synthetic oil and a friction modifier additive.

Tyre wear – Excessive inside tyre wear (rear) and excessive outside tyre wear (front) is a common complaint I hear about. Rear camber kits are available to correct wheel angle. Definately a good idea.

Brakes

Brake Line Rattles – During ABS operation, the brake pipes located near the fire wall can vibrate or rattle, which may be heard from inside the vehicle. Extra brake line support clips can be added to reduce brake line movement.

Brake line clip – Part number 92138181

ABS Knock – During ABS operation, the ABS module may knock against the module mounting bracket under the bonnet. In this situation, a spacer would need to be added beneath the module support to increase the clearance between the module and bracket.

Hand Brake Scrape – Intermittent scraping noises may be heard from the rear of the car while driving. The noise may appear to go away after re-applying hand brake lever. The front lining of the hand brake shoe may contact the inner drum of the rear disc without the hand brake being applied. In mid 2004, a spring was added into production to centralise the park brake shoe in the drum, and reduce the chance of contact when the hand brake is not applied.

Park brake shoe scrape kit (includes 2 brackets and 2 springs) – Part number 92147813

Electrical

Starting Problems

1. Some VX’s may have starting issues caused by a defective Fuel Pump relay (or have no low beam headlights, as the Low Beam relay is the same as the fuel pump relay). A revised relay was introduced late 2000. In case of starting or headlamp problems, the old relay (92047112) should not be used.

Relay – Part number 92107897

2. Some starting issues can be cause by the BCM (Body Control Module). The BCM may electronically lock up or freeze (caused by voltage spikes), which may restrict starting, locking and unlocking etc. Some BCM’s were returned under warranty because of these issues. In some situations, the key reader circuit ban be a potential source of a voltage spike, and a grounding patch harness was released to reduce this occurance.

VXII Body Control Module Mid Series – Part number 92109212

VXII Body Control Module Low Series – Part number 92109213

VXI Body Control Module Mid Series – Part number 92145251

VXI Body Control Module Low Series – Part number 92145250

Battery Discharge – Some VX’s with Telematics (Holden Assist) may experience a premature flat battery or receive repeated low battery alert calls from Holden Assist when the vehicle is left for several days. Revised Telematics software was introduced late 2002 to reduce current draw of the telematics module.

V6 Engine Missfire – Some VX’s may prematurely develope an engine missfire, which can be caused by arcing of the ignition lead to the cylinder head. Lead failure may be caused by the ignition lead’s insulating grease “breaking down” the ignition lead boot (which may also become distorted). A new grease and

revised heat shields have been introduced mid 2002. The new grease is green in colour, and its composition will not degrade the boot material as the previous grease did.

BCM Failure – Some BCM’s may suffer from water damage. The retaining bolt in the Right side of the Fire wall panel may be insufficiently sealed. If water leaks past this bolt, connector D of the BCM can be affected. The firewall reatining bolt should be checked for tightness, and resealed with a sealer such as silicone RTV 732 (92140051).

Traction Control – The Traction control warning lamp and engine check lamp may illuminate in Some VX V6’s, due to oversensitive PCM calibration. GMH have found there was some software timing issues in the PCM (Powertrain Control Module), and revised PCM software was introduced early 2001.

Remote Key Readers – On the 25th of May 2001 a Full Circle keyless entry system was introduced. The Full Circle key readers may separate or fall apart. A revised reader was introduced on the 25th July 2001.

Remote Key Reader Assembly – Part number 92092099

Some remote key readers have poor range, especially on hot days. The average working range is within 4 metres. To cope with high ambient temperatures, the remote receivers circuit boards have been upgraded with higher tolerance capacitors from 28/08/2001.

All VT, VX Exec and VU Receiver Remote Key – Part Number 92051734

VX Berllna and Calais and WH Receiver/Sunsensor Remote Key – Part number 92050898

GEN III O2 Sensors – Some Gen III Automatics will experience water contamination on the LH O2 sensor plug, which can cause O2 sensor faults. This problem may be a result of the A/C drain tube in the transmission tunnel, as it is in the same proximity as the O2 sensor harness. A bracket was introduced for the O2 sensor connector, that will position it away from the A/C drain tube.

O2 Sensor Connector Mounting Kit – Part number 92145044

O2 sensor LH  – Part number 25326439

Indicator Fuse Blown (Wagon) – The indicator fuse may blow if excess wiring is trapped between the tail lamp mounting studs and the vehicle body. In mid 2001 excess wiring was taped back to the tail lamp globe holders.

Suspension and Steering

Steering Knock – After long drives, or high operating temperatures, some VX’s have an audible clunk in the front end, that may be felt throught the steering wheel on turns. A possible cause can be excessive movement of the inner tierod end of the steering rack. A revised tierod was introduced into new steering racks early in 2001.

Power Steering Rack – Part number 92092815

Variable Effort Power Steering Rack (Option NV7) – Part number 92092816

Variatronic Steering Intermittent – Variatronic steering is a speed sensitive power steering system, that provides reduced steering effort at low vehicle speeds, and is usually only fitted to higher end models. This system is controlled by the the BCM (Body Control module) in conjunction with a pressure solenoid located on the steering rack. Some Variatronic Steering Systems may operate erratically, causing heavy steering at low vehicle speeds.

A possible cause for variatronic steering issues can be the BCM. A revised BCM (recalibrated) was introduced to help rectify erratic variatronic functions in VX’s.

Steering Leaks – Some VX’s have developed minor leaks from the low pressure power steering return line. An improved hose clamp and revised flexible hoses have been introduced early in 2001.

Steering Rack Boots (Gen III) – Some VX steering rack boots may be damaged by excessive heat from the exhaust system. VX’s with extractors are more susceptible to heat damage. Revised silicone steering rack boots were released and are more durable.

Steering Rack Boot – Part number 92146712

Strut Noises – On certain road conditions such as gravel or loose surfaces, small stones and dirt can enter into the front strut upper support bearing. This may lead to noises or grinding while steering. GMH have introduced a foam dust seal to help reduce this problem.

Front Strut Bearing Dust Shield – Part number 92144452

Rear Suspension Drone – Some VX’s V8 Automatics may develope a moan or drone noise at 105-110km/h, which can often be similar to an exhaust resonance. This noise may be caused by vibrations from the rear suspension cross member. A revised cross member with vibration dampers was introduced during VX production (August 2002).

Cross Member Assembly – Part number 92145688

Damper – Part number 92115982

Damper Bolt – Part number 11098391

Damper Nut – Part number 11095804

Damper Washer – Part number 92001572

Front Sway bar links – VX front sway bar links are rubber mounted to the strut housing. These rubbers are a common failure, as they can over squash and split. New rubbers were introduced early 2003, made of revised rubber with increased hardness, reduced compression set and improved high temperature performance.

Sway Bar link bush – Part number 92159373

Air conditioning

Climate Control Temperature Memory – Some Climate Control control units may not retain the previous temperature setting due to revised software that was introduced from August 2001. New control units were programmed with pre August 2001 software to remove this issue.

Control module (single zone) – Part number 92111235

Control module (dual zone) – Part number 92111236

Climate Control Thud – VX’s with Climate Control may have a light thud noise when the ignition is turned off, or intermittently, during mode changes. The cause of this noise can be the rapid closing of the previously open mode door. The rate of closure is controlled by air entry into the vacuum solenoid module. Fitting a specifically designed, additional foam pad over the existing foam pads in the vacuum solenoid module will correct the condition. Revised six pack solenoids (with foam) were introduced mid 2001.

Climate Control Solenoid Foam Pad – Part number 92144689

Insufficient Heating with Electronic Climate Control – Some Climate Control Systems may not warm the cabin effectively, even though a high temperature is selected. A possible cause can be water entering the ambient temperature sensor connector (located on the front of the Air Conditioning Condensor, just behind the front bumper). Water in the connector may short circuit the sensor, and in doing so, the Climate Control Unit believes that the outside temperature is higher than it actually is. This can cause relatively low or cool heater performance. In this situation, the connector should be dried and cleaned. Insulating grease can be applied to the connector to limit the chances of water re-entering. A revised ambient temperature sensor connector was introduced late 2000, which had improved water retention.

Ambient Temperature Sensor Repair Kit – Part number 92144967

Ambient Temperature Sensor – Part number 09152245

Gen III Air Conditioning rumble – Some VX’s may have a rumble type noise coming from the dash area when the Air Conditioning is on. A possible cause can be the TX valve of the Air Conditioning Unit. A revised Eaton Brand TX valve (92116220) was introduced January 2002, and a further revision was introduced in April 2002, with the use of a TGK Brand TX valve (92117402) as used in V6’s from April 2002 onwards.

Poor Illumination Climate Control Display – Some Climate Control units have poor illumination, which can be caused by faulty globes (6 in total).

Globe and holder clear – Part number 92140515

Globe and holder green – Part number 92140514

Air Conditioning Vibration (Gen III) – In some VX’s, a vibration may be felt inside the vehicle while idling

in Drive, with air conditioning on. A possible cause could be the plastic end tanks of the radiator contacting the mounting brackets on the radiator support panel. It may also be the radiator retaining clips contacting the plastic end tanks, instead of just the locating rubber. Carefull bending of the support brackets will increase clearances (3mm suggested minimum clearance between mounting bracket and tank. 1mm suggested minimum clearance between retaining clips and tank).

Body

Body Noises – Some VX’s may have a creak noise from behind the instrument panel, especially when travelling over bumps. This may be caused by a metal tab located on the fire wall, which can rub against the under side of the plenum chamber (aka windscreen wiper area). A revised fire wall panel with an insulating pad added between the fire wall panel and plenum chamber panel, has been fitted to vehicles from Feb 2001 onwards.

VX Headlamp Fog – VX’s use a pressure tested and vented, clear lense headlamp (no optics). This style of headlamp is more prone to atmospheric conditions becoming evident on the inside of the headlamp lense. In most cases, there is no cause for alarm, as the moisture will disipate within 3 to 4 minutes of driving with the headlamps on. Under no circumstances should high pressure water be sprayed at the rear of the headlamp, as water will enter in through the venting system.

Rear Windscreen Mould End Caps – On some VX’s, the rear windscreen side mould end caps (located at the lower corners of the rear windscreen glass) may dislodged. A revised harder material end cap was introduced mid 2001. Revised side mouldings were also introduced (with a harder material, and do not have a separate end cap).

RH Windscreen Moulding End Cap – Part number 92111721

LH Windscreen Moulding End Cap – Part number 92111720

Windscreen Washer Nozzles – VX’s have twinjet windscreen washer nozzles which are non adjustable. On some vehicles the washer nozzle may direct water too high on the windscreen. Revised washer nozzles with corrected aim were introduced late 2000.

Nozzle twin jet – Part number 92092007

Door seals – VX Commodores use a rubber door seal around each door cavity which is glued to a colour coded pinch strip. The rubber often comes unstuck from the pinch strip and can tear. Re-gluing is sometimes successful, or new items are available from Holdens in a limited range of colours.

Boot Leaks – Water may enter the boot area from an aged or defective boot spoiler mounting gasket.

S Pack Spoiler to decklid Gasket – Part number 92144151

Lumina Spoiler to decklid Gasket – Part number 92144153

SS Pack Spoiler to decklid  Gasket – Part number 92144150

Rear Bumper – Some VX rear bumper facias may become loose at the left hand rear wheel arch area.

This can affect VX’s built from October 2001 which is when the method of attaching the LH liner to wheel arch area was changed from a screw to a scrivet. These scrivets may not effectively retain the liner, and a screw may be needed for sufficient retention.

Liner to wheelarch Screw – Part number 92138310

Side Skirts (S and SS) – Some VX’s may develope a sliding type noise under heavy braking or

acceleration. A possible cause can be stones or road debris inside the side skirts. A suggested fix for this issue is to make 2 rubber flaps/guards and screw them in place in the rear wheel arch area, covering any entry points to the side skirts.

Interior

Steering Wheel Freeplay – Some VX’s may have excessive movement in the upper bearing of the steering column, due to bearing failure. This can allow the steering wheel to have freeplay (or feel loose). A revised bearing design (double sided metal cage instead of a single sided plastic cage) was fitted to new steering columns during 2001.

Steering Column Asm (RHD) – Part number 92145394

Steering Column Rattle – A buzzing noise may be heard fron the steering column area, when driving at highway speeds and/or on coarse bitumen roads. A possible cause may be the steering column adjuster spring rattling/vibrating against the steering column housing. In this situation, cable tying the two sides of the spring together may help.

Dash Panel Noises – Some VX’s may develope a buzz around the headlight switch or the centre

vents when travelling at 60 km/h or faster on slightly rough bitumen surface.This can be caused by movement between the instrument facia and the crash pad. Flocked tape (92145740) added to the upper edge of the instrument facia can help reduce noises.

Console Surround – VX console caps (The one surrounding transmission shift lever) may dislodge from the console on hot days. This conditionis usually caused by reduced retaining clip retention during thermal

expansion. To correct this condition, a stronger retaining clip was introduced during VX production. The new clips are silver, where as the old style were yellow.

Console Clip – Part number 92138618

Front Cup Latch Holder – The front console mounted cup holder cover latch can fail, making the cover hard to open or hard to close.

Cup Holder Latch – Part number 92103515

Rear Seat belt surrounds – The rear seat belts project through the quarter pillar trims, and the plastic finsishing trims around the outlet hole can often become dislodged or broken. Originally, this part was only available with a new seat belt, but can now be purchased individually.

Rear Side Seat Belt surround – Part number 92144275

Seat Map Pockets – The rear panel of the front seats may dislodged due to the locating clips breaking. Revised panel clips were introduced mid 2001. The map pocket can also break away from the rear panel. Revised map pockets with larger diameter (9.5mm) mounting bosses was introduced early 2002.

Rear panel clip – Part number 92140918

Seat Movement (Calais) – While braking, or during a sudden slow speed stop, the drivers seat may move slightly foreward. This can be a result of a loose lead screw nut located on the base of the seat track. The lead screw nut originally had a 2.5mm steel washer which compressed against a rubber washer. A 3.5mm steel washer (92148372) was introduced to provide more compression against the rubber washer, and reduce movement.

Front Seat Hieght Adjuster – The seat height adjuster may become inoperative, which can be caused by the electric motor adjusting shaft separating from the plastic mechanism adjuster nut. A new seat base assembly was introduced early 2003, which featured a metal mechanism adjuster nut.

Related posts:

VX Commodore–that rear window corner moulding 4 is the number of Melbourne Bike Share Bicycles I needed to get home last night. Yamaha TDM 900 assorted parts etc.

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