HVAC Climate Control (Manual A/C) – Removal and Installation Page 2B–1

Page 2B–1

Section 2B

HVAC Climate Control (Manual A/C) –

Removal and Installation

ATTENTION

Before performing any Service Operation or other procedure described in this Section, refer to Section 00

Warnings, Cautions and Notes for correct workshop practices with regard to safety and/or property damage.

1 General Information ...............................................................................................................................2

1.1 Vehicle Builds from Tag No. L171506 Onwards.................................................................................................. 2

1.2 Vehicle Builds Prior to Tag No. L171506 ............................................................................................................. 3

2 Service Operations.................................................................................................................................4

2.1 Body Ventilation Outlets – Crew Cab................................................................................................................... 5

Remove................................................................................................................................................................... 6

Install ...................................................................................................................................................................... 6

Techline

HVAC Climate Control (Manual A/C) – Removal and Installation Page 2B–2

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1 General Information

The information contained within this Section relates specifically to MY 2004 VY Regular Cab and Crew Cab vehicles.

However, most of the service information concerning MY 2004 VY Regular Cab is the same as that previously published

for MY 2003 Regular Cab. Accordingl y, references to MY 2003 VY Regular Cab information are provided where

appropriate.

The optional HVAC Climate Control (Manual A/C) system as fitted to MY 2004 VY Regular Cab and Cre w Cab vehicl es

is carried over from the previously released MY 2003 VY Series vehicles. The removal and installation proce dure of the

body ventilation outlets as fitted to MY 2004 Reg ular Cab vehicles is covered in Section 2B, 2.1 Body Ventil ation Outlets

in the MY 2003 Regular Cab Service Inform ation. The removal and installation procedure of the body ventilation outlets

for MY 2004 Crew Cab vehicles is different and is covered in this Section.

1.1 Vehicle Builds from Tag No. L171506

Onwards

From Tag No. L171506 a revised HVAC unit has been fitted. For information specific to the revised unit, refer to

Section 2B HVAC Climate Control (Manual A/C) – Removal and Installation in the MY 2004 VY and V2 Series Service

Information.

For all other information regarding the removal and installation of heating, ventilation and air conditioning system

components, refer to Section 2B HVAC Climate Control (Manual A/C) – R emova l and Installation in the MY 2003 VY and

V2 Series Service Information.

HVAC Climate Control (Manual A/C) – Removal and Installation Page 2B–3

Page 2B–3

1.2 Vehicle Builds Prior to Tag No. L171506

For all information regarding the removal and installation of heating, ventil ation and air conditioning system

components fitted to vehicles built prior to Tag No. L171506, refer to

Section 2B HVAC Climate Control (Manual A/C) – Removal and Installation in the MY 2003 VY and V2 Series Service

Information.

HVAC Climate Control (Manual A/C) – Removal and Installation Page 2B–4

Page 2B–4

2 Service Operations

ATTENTION

All fasteners are important attaching parts as they affect the performance of vital components and / or could

result in major repair expense. W here specified in this Section, fasteners MUST be replaced w ith parts of the

same part number or a GM approved equivalent. Do not use fasteners of an inferior quality or substitute

design.

Torque values must be used as specified during reassembly to ensure proper retention of all components.

Throughout this Section, fastener torque wrench specifications may be accompanied with the following

identification marks:

 Fasteners must be repl aced after loosening.

 Vehicle must be at kerb height before final tightening.

 Fasteners either ha ve micro encapsu lated sealant ap plied or in corporate a mech anical thread lo ck and

should only be re-used once. If in doubt, replacement is recommended.

If one of these identification marks is present alongside a fastener torque wrench specification, the

recommendation regarding that fastener must be adhered to.

HVAC Climate Control (Manual A/C) – Removal and Installation Page 2B–5

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2.1 Body Ventilation Outlets – Crew Cab

NOTE

The following body ventilation outlet removal and

installation procedur es apply only to MY 2004 VY

Crew Cab vehicles. For removal and installation

procedures on MY 2004 VY Regular Cab

vehicles, refer to Section 2B, 2.1 Body Ventilation

Outlets in the MY 2003 VY Regular Cab Service

Information.

Figure 2B – 1

Legend

1 Outlet Housing 4 Locking Tab (4 places)

2 Rubber Seal 5 Body Panel

3 Foam Seal

NOTE

For body ventilation outlet locations, refer to

Figure 2B – 2.

HVAC Climate Control (Manual A/C) – Removal and Installation Page 2B–6

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LT Section – 08-700

Remove

1 Remove the upper cross beam cover assem bl y. Refer to Section 1A8, 2.5 Upper Cross Beam Cover.

2 Remove the rear outer trim panel. Refer to Section 1A9, 2.10 Rear Outer Trim Pane l and NVH Foam.

3 From inside the passenger compartment, press the locking tabs at each corner of the ventilation outlet housing

while simultaneously moving it partially outwards from the passenger compartment.

4 Remove the body ventilation o utlet from the rear inner p anel.

Install

Installation of the body ventilation outl et is the reverse of removal pr ocedures, noting the following points:

1 Install the body ventilation outlet in the correc t vertical orientation, i.e. as shown in Figure 2B – 1.

2 Ensure all four locking tabs are fully engaged on the inner side of the rear inner pan el.

Figure 2B –2 shows the locations of body ventilation outlets on MY 2004 VY Crew Cab models.

Figure 2B – 2

Legend

1 Body Ventilation Outlet – LHS 2 Body Ventilation Outlets – RHS