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

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

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

1.3 LHD Vehicles.......................................................................................................................................................... 4

2 Service Operations.................................................................................................................................5

2.1 Evaporator Core – RHD......................................................................................................................................... 5

Remove................................................................................................................................................................... 5

Install ...................................................................................................................................................................... 7

2.2 Blower Motor and Fan – RHD................................................................................................................................ 8

Remove................................................................................................................................................................... 8

Install ...................................................................................................................................................................... 8

3 Torque Wrench Specifications..............................................................................................................9

Techline

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

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1 General Information

With the following exception, MY 2004 VY and V2 Series HVAC Climate Control (Manual A/C) – Removal and

Installation information carries over from MY 2003 VY and V2 Series vehicles.

• From Tag No. L171506 a revised HVAC unit has been fitted to RHD vehicles.

1.1 RHD Vehicle Builds from Tag No.

L171506 Onwards

From Tag No. L171506 a revised HVAC unit has been fitted to RHD vehicles. The information in this Section appli es to

the revised HVAC unit.

For all other information regarding the remov al and installation of the heating and ventilation system, 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–3

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1.2 RHD Vehicle Builds Prior to Tag No.

L171506

For all information regarding the remov al and installation of the heating and ventilation system fitted to RHD 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

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1.3 LHD Vehicles

For all information regarding the removal and installation of the heating and ventilation system fitted to LHD vehicles,

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

Service Information.

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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.

2.1 Evaporator Core – RHD

LT Section – 08-150

Remove

1 Remove the HVAC unit, refer to Section 2B,

3 Heating, Ventilation and Air Conditioning (HVAC)

Unit in the MY 2003 VY and V2 Series Service

Information.

2 On OCC (Auto A/C) units, disconnect the OCC

wiring harness connector (1) from the evaporative

temperature sensor connector (2). Remove the

venturi pipe (3) from the evaporator cover (4).

Figure 2B – 1

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3 Remove the screw (1) and washer holding th e air

mix door quadrant lever (2) to the evaporator

cover (3) and move the quadrant lever asid e.

4 Remove the two screws (4) from the evaporator

cover, swing the cover open and remove it.

5 Carefully remove the evaporat or core from its cavity

in the HVAC case.

Figure 2B – 2

6 On OCC (Auto A/C) units, if the evaporator core (1)

is to be replaced, remove the evaporative

temperature sensor (2) by removing its mounting

clip (3) from the core.

Figure 2B – 3

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Install

Installation of the evaporator core is a reversal of removal procedures, noting the following:

NOTE

On OCC (Auto A/C) units, install the evaporative

temperature sensor in the correct location on the

evaporator core. Refer to Section 2E,

2.4 Evaporative Temperature Sensor in the

MY 2003 VY and V2 Series Service Information.

1 Tighten all screws to the specified torque.

Evaporator cover screw torque

specification................................................1.0 – 3.0 Nm

Air mix quadrant lever attaching

screw torque specification...........................1.0 – 3.0 Nm

2 Install the HVAC unit, refer to Section 2B, 3 Heating, Ventilation and Air Conditioning (HVAC) Unit in the

MY 2003 VY and V2 Series Service Information.

CAUTION

The total quantity of lubricating oil in the air

conditioning system must be maintained. If a

compressor, evaporator, condenser, filter

drier receiver, hose or pipe is to be replaced,

a specified quantity of lubricating oil must be

added to the system to compensate for oil

removed with the original component. Refer

to Section 2C, 2.4 Lubricating Oil Compensation

in the MY 2003 VY and V2 Series Service

Information.

3 Evacuate and charge the system with 775 – 825 g of R134a refrigerant, refer to

Section 2C, 2.1 System Charging and Evacuation in the MY 2003 VY and V2 Series Service Information.

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2.2 Blower Motor and Fan – RHD

LT Section – 08-150

Remove

1 Remove the left-hand side instrument panel lower

trim plate assembly, refer to Section 1A3, 3.1

Instrument Panel Lower Trim Plate Assembly in

the MY 2003 VY and V2 Series Service

Information.

2 On OCC (Auto A/C) units, disconnect the OCC

wiring harness connector from the left-hand end of

the solenoid pack (1).

Figure 2B – 4

3 Disconnect the body wiring harness connector

from the blower motor sub-harness connector (1)

4 Remove the three screws (2) securing the blower

motor and fan assembly (3) to the HVAC unit (4)

and remove the assembly. Note that the screw

closer to the rear of the vehicle also secures the

fuse mounting bracket to the blower motor and fan

assembly mounting flange.

Figure 2B – 5

Install

Installation of the blower motor and fan assembly is a reversal of removal procedures, noting the following:

1 Tighten all screws to the specified torque.

Blower motor and fan assembly

mounting flange attaching scre w

torque specification.....................................1.0 – 3.0 Nm

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3 Torque Wrench Specifications

Evaporator Cover Screw ...............................................................1.0 – 3.0 Nm

Air Mix Quadrant Lever Attaching Screw.......................................1.0 – 3.0 Nm

Blower Motor and Fan Assembly Mounting F lange

Attaching Screw ............................................................................1.0 – 3.0 Nm