SECTION 2B - HVAC CLIMATE CONTROL

(MANUAL A/C) – REMOVAL AND INSTALLATION

IMPORTANT

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

CAUTIONS AND NOTES for correct workshop practices with regard to safety and/or property damage.

CONTENTS

1. GENERAL INFORMATION

2. MANUAL HVAC CONTROLLER

REMOVE

REINSTALL

2.1 WATER VALVE VACUUM SWITCH

REMOVE

REINSTALL

2.2 AIR MIX DOOR ROD RETAINER

REMOVE

REINSTALL

2.3 FRONT HOUSING/SWITCH ASSEMBLY

AND PRINTED CIRCUIT BOARD

REMOVE

REINSTALL

2.4 MODE SWITCH VACUUM VALVE

REMOVE

REINSTALL

3. HEATING, VENTILATION AND AIR

CONDITIONING (HVAC) UNIT

REMOVE

REINSTALL

4. EVAPORATOR CORE

REMOVE – LHD

REINSTALL – LHD

REMOVE – RHD

REINSTALL – RHD

5. HEATER CORE

REMOVE – LHD

REINSTALL – LHD

REMOVE – RHD

REINSTALL – RHD

6. BLOWER MOTOR AND

FAN ASSEMBLY

REMOVE – LHD

REINSTALL – LHD

REMOVE – RHD

REINSTALL – RHD

7. BLOWER MOTOR RESISTOR

REMOVE – LHD

REINSTALL – LHD

REMOVE – RHD

REINSTALL – RHD

8. VACUUM TANK AND VACUUM

ACTUATORS

8.1 VACUUM TANK

REMOVE – LHD

REINSTALL – LHD

REMOVE – RHD

REINSTALL – RHD

8.2 FRESH/RECIRCULATION (INTAKE)

ACTUATOR

REMOVE – LHD

REINSTALL – LHD

REMOVE – RHD

REINSTALL – RHD

8.3 FACE ACTUATOR

REMOVE – LHD

REINSTALL – LHD

REMOVE – RHD

REINSTALL – RHD

8.4 FOOT ACTUATOR

REMOVE – LHD

REINSTALL – LHD

REMOVE – RHD

REINSTALL – RHD

8.5 DEMIST ACTUATOR – LHD ONLY

REMOVE

REINSTALL

9. A/C HOSE AND PIPE CONNECTIONS

AND RETAINERS

REMOVE AND REINSTALL

10. THERMAL EXPANSION VALVE (TXV)

REMOVE

REINSTALL

11. A/C PRESSURE TRANSDUCER

REMOVE AND REINSTALL

12. CONDENSER

12.1 V6 AND V6 SUPERCHARGED ENGINE

REMOVE

REINSTALL

12.2 GEN III V8 ENGINE

REMOVE

REINSTALL

13. FILTER DRIER RECEIVER

REMOVE

REINSTALL

14. A/C DRIVE BELT AND PULLEYS

14.1 V6 ENGINE

REMOVE

REINSTALL

14.2 V6 SUPERCHARGED ENGINE

REMOVE

REINSTALL

14.3 GEN III V8 ENGINE

REMOVE

REINSTALL

14.4 A/C DRIVE BELT IDLER PULLEY

ASSEMBLY – V6 AND V6 S/C ENGINE

REMOVE

REINSTALL

14.5 A/C DRIVE BELT IDLER PULLEY

ASSEMBLY – GEN III V8 ENGINE

REMOVE

REINSTALL

14.6 A/C DRIVE BELT TENSIONER PULLEY

ASSEMBLY – GEN III V8 ENGINE

REMOVE

REINSTALL

Techline

15. A/C COMPRESSOR

15.1 V6 AND V6 SUPERCHARGHED ENGINE

REMOVE

REINSTALL

15.2 GEN III V8 ENGINE

REMOVE

REINSTALL

16. MINOR A/C COMPRESSOR REPAIR

PROCEDURES

16.1 A/C COM PRESSOR CONTROL VALVE

REMOVE

REINSTALL

16.2 A/C CLUTCH DRIVE PLATE AND HUB

ASSEMBLY

REMOVE

REINSTALL

16.3 A/C CLUTCH PULLEY AND BEARING

ASSEMBLY

REMOVE

REINSTALL

17. UNDER HOOD HEATER COMPONENTS

17.1 WATER VALVE

REMOVE

REINSTALL

17.2 HEATER HOSES AND VACUUM LINES

REMOVE AND REINSTALL

18. HVAC INLET, DUCTS AND

VENTILATION OUTLETS

18.1 HVAC INLET SCREEN

REMOVE

REINSTALL

18.2 HVAC SYSTEM DUCTS

REMOVE – DRIVER’S SIDE OUTER DUCT

REINSTALL – DRIVER’S SIDE OUTER DUCT

REMOVE – DRIVER’S SIDE INNER DUCT

REINSTALL – DRIVER’S SIDE INNER DUCT

REMOVE – PASSENGER SIDE DUCT

REINSTALL – PASSENGER SIDE DUCT

REMOVE – FLOOR CONSOLE REAR DUCT

REINSTALL – FLOOR CONSOLE REAR DUCT

REMOVE – FLOOR CONSOLE FRONT DUCT

REINSTALL – FLOOR CONSOLE FRONT

DUCT

REMOVE – FOOT DUCT, LHD

REINSTALL – FOOT DUCT, LHD

REMOVE – FOOT DUCT, RHD

REINSTALL – FOOT DUCT, RHD

18.3 CABIN VENTILATION OUTLETS

REMOVE AND REINSTALL

18.4 BODY VENTILATION OUTLETS

REMOVE – SEDAN AND COUPE

REINSTALL – SEDAN AND COUPE

REMOVE – WAGON

REINSTALL – WAGON

REMOVE – UTILITY

REINSTALL – UTILITY

19. TORQUE WRENCH SPECIFICATIONS

20. SPECIAL TOOLS

1. GENERAL I NFORMATI O N

The inf or mation that is provided in this Sec tion is to be us ed f or both lef t and r ight-hand dr ive vehicles . Although the

information shown is primarily right-hand drive, it also applies to left-hand drive vehicles unless otherwise specified.

The instrument panel for left-hand drive vehicles is a mirror of the right-hand drive instrument panel, with a few

exceptions. The body control module r emains on the r ight-hand s ide of the vehic le, mounted vertically for right-hand

drive or horizontally for left-hand drive. A fuel filler door release switch is m ounted in the left-hand drive instrument

cluster trim.

While similar in function and performance, the HVAC units fitted to left and right-hand drive vehicles differ

significantly in terms of their case construction as well as their internal and external components. Accordingly,

certain Remove and Reinstall procedures in this area are specific to left and right-hand drive application and are

detailed in this Section.

The Remove and Reinstall procedures in this Section relating to the HVAC unit removal can be used for both the

HVAC Climate Control (Manual A/C) type system and the HVAC Occupant Climate Control (Auto A/C) type system.

The m anual HVAC controller Remove and Reins tall procedures in this Section relate only to HVAC Climate Control

(Manual A/C) type system. For Remove and Reinstall procedures of the OCC control module used to control the

HVAC Occupant Climate Control (Auto A/C) type system refer to Section 2E, 2. OCC CONTROL MODULE.

2. MANUAL HVAC CONTROLLER

LT Section – 08-155A

REMOVE

1. If fitted, remove the navigation remote control cradle. Refer to Section 12L, 3.2 NAVIGATION REMOTE

CONTROL ASSEMBLY.

2. If fitted, remove the navigation monitor escutcheon. Refer to Section 12L, 3.3 NAVIGATION DISPLAY

ASSEMBLY.

3. Remove the floor console front compartment liner

(1) by lifting upwards to disengage it from the

console cover.

Figure 2B-1

4. Remove the screw (1) slightly to the right of centre,

attaching the floor console cover assembly (2).

NOTE: Vehicles fitted with Navigation System do not

have this screw.

5. Prise the cover assembly from the floor console,

six places (3).

6. Lift the cover assembly up from the rear,

disconnect the wiring connector (4) from the side

window switch assembly and any auxiliary

switches if fitted, and remove the cover assembly.

Figure 2B-2

7. Insert Spec ial T ool KM6067 ( 1) into the holes eac h

side of the radio assembly.

8. While holding outward pressure on the tools

(toward each outer side of the vehicle), pull the

radio assembly from the radio housing.

NOTE: The wiring connectors remain attached to the

radio housing and will disconnect on removal of the

radio assembly.

Figure 2B-3

Referring to Figure 2B-4:

9. Carefully prise the front edge of the instrument panel upper centre trim panel (1), and pull upward to

disengage the retaining clips at each corner from the centre trim assembly (2).

NOTE: A fine flat blade screwdriver may be used; however take steps to ensure the trims are not marked or

damaged.

10. Remove the lower screw (3), two places, attaching the centre trim assembly to the instrument panel.

11. Remove the upper s crews (4 and 5), two places eac h, attaching the centre trim assem bly to the instrum ent

panel.

12. Remove the centre trim assembly, noting the four clips (6), far enough to disconnect the wiring connectors

from the rear of the hazard warning switch.

13. Remove the centre trim assembly.

Figure 2B-4

Referring to Figure 2B-5:

14. From the rear of the HVAC controller, open the air mix door rod retainer (1) and disconnect the rod (2).

15. Remove the screw (3), two places each side, attaching the HVAC controller (4) to the instrument panel.

16. Partially remove the HVAC c ontro ller as s embly outwards f rom the ins trument panel to ac ce ss the r ear of the

controller.

17. Disconnect the two vacuum hose connections (5 and 6) and two wiring connectors (7).

18. Remove the HVAC controller assembly.

NOTE: For service and diagnosis of the manual HVAC controller, refer to Section 2C, 7. ELECTRICAL

COMPONENT TESTS and Section 2C, 8. VACUUM RETENTION TESTS.

Figure 2B-5

REINSTALL

1. Install the two wiring connectors and the lower then upper vacuum hose connections.

2. Push the control rod toward the HVAC unit (front of vehicle) fully.

3. Seat the control assembly in position.

4. Install the four screws and tighten to the specified torque.

MANUAL HVAC CONTROLLER

ATTACHING SCREW TORQUE

TORQUE SPECIFICATION 1.0 – 3.0 Nm

5. Rotate the temperature switch to the full cold position.

6. Position the air mix door rod retainer so that it will close upward.

7. Connect the rod to the air mix door rod retainer.

8. Close and lock the rod retainer over the rod.

9. Check for correct operation of the temperature switch.

10. Install the instrument panel centre trim assembly. Tighten all screws to the specified torque.

INSTRUMENT PANEL CENTRE TRIM

ASSEMBLY ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

11. Insert the radio assembly into the housing.

12. Push the unit home to engage the retaining clips and wiring connectors.

NOTE: The Special Tool is not required.

10. Install the floor console cover assembly. Installation is the reverse of removal. Tighten the screw to the

specified torque.

FLOOR CONSOLE COVER ASSEMBLY

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

2.1 WATER VALVE VACUUM SWITCH

LT Section – 08-155A

REMOVE

1. Remove the manual HVAC controller. Refer to 2. MANUAL HVAC CONTROLLER in this Section.

2. Turn the temper ature s witch to the f ull hot pos ition.

Using needle nose pliers (1), carefully compress

the locking legs (2) of the vacuum switch (3)

together and withdraw the switch from the rear

housing (4) of the controller.

Figure 2B-6

REINSTALL

1. Insert the vacuum switch locking legs (1) through

the rear housing ensuring that the locating

dowels (2) are installed into the two dowel

locators (3) of the rear housing (4).

2. Push the vacuum switch into position ensuring the

lock ing legs lock into position and retain the switch

in the rear housing.

3. Install the controller to the instrument panel. Refer

to 2. MANUAL HVAC CONTROLLER in this

Section.

Figure 2B-7

2.2 AIR MIX DOOR ROD RETAINER

LT Section – 08-155A

REMOVE

1. Remove the manual HVAC controller. Refer to 2. MANUA L HVAC CONTROLLER in this Section.

2. Using needle nose pliers (1), carefully compress

the rod retainer ( 2) together and withdraw the rod

retainer from the crescent gear (3) of the

controller.

Figure 2B-8

REINSTALL

1. Insert the rod retainer (1) into the pivot hole ( 2) of

the crescent gear (3) ensuring it locks into

position.

2. Install the controller to the instrument panel.

Refer to 2. MANUAL HVAC CONTROLLER in

this Section.

Figure 2B-9

2.3 FRONT HOUSING/SWITCH ASSEMBLY

AND PRINTED CIRCUIT BOARD

LT Section – 08-155A

REMOVE

1. Remove the manual HVAC controller. Refer to 2. MANUA L HVAC CONTROLLER in this Section.

2. Rotate the switches (1) so that all switch position indicators (2) are at the 12 o’clock position.

Figure 2B-10

3. Holding the controller (1) as shown in Figure 2B-

11, disengage the middle retaining tangs of the

front housing/switch assembly from the rear

housing by caref ully m oving the retaining tangs (2)

of the front housing outwards with thumb pressure.

Figure 2B-11

4. Holding the controller (1) as shown in Figure 2B-

12, continue to disengage the front housing/switch

assem bly from the rear housing by m oving the end

retaining tangs (2) of the front housing outwards

with thumb pressure while simultaneously

separating the rear housing from the front

housing/switch assembly using index finger

pressure at the mounting flange (3) of the

controller.

Figure 2B-12

5. Rotate the controller (1) through 180° and

disengage retaining tangs (2) at the other end of

the controller by using the same technique as

described in Step 4.

Figure 2B-13

6. Remove the front housing/switch assembly (1) from the rear housing (2).

7. Remove the printed circuit board (3) from the rear housing.

Figure 2B-14

REINSTALL

1. Ensure that the switch shaft pins (1) are located at the 9 o’clock position.

2. Install the printed circuit board (2) to the rear housing (3). Ensure that the circuit board locating pins (4) are

aligned with the corresponding holes of the circuit board prior to installation.

Figure 2B-15

3. Rotate the switches so that all switch position indicators (1) are at the 12 o’clock position. Ensure that all

three of the shaft pins (2) are still located at exactly the 9 o’clock position.

4. Install the front housing/switch assembly (3) to the rear housing (4) ensuring that its six retaining tangs are

fully engaged over the rear housing tang protrusions.

5. Ensure that all the s witches rotate f reely and that the s witc h position indicators align cor rectly with all switch

positions. Ensure that all switches do not rotate past intended rotation limits.

6. Install the controller to the instrument panel. Refer to 2. MA NUAL HVAC CONTROLLER in this Section.

Figure 2B-16

2.4 MODE SWITCH VACUUM VALVE

LT Section – 08-155A

REMOVE

1. Remove the manual HVAC controller. Refer to 2. MANUAL HVAC CONTROLLER in this Section.

2. Remove the front housing/switch assembly and printed circuit from the rear housing. Refer to

2.3 FRONT HOUSING/SWITCH ASSEMBLY AND PRINTED CIRCUIT BOARD in this Section.

3. Using needle nose pliers (1), carefully compress

both pairs of locking tangs (2) on the mounting

dowels on the mode switch vacuum valve and

withdraw the switch assembly from the rear

housing (3) of the controller.

Figure 2B-17

REINSTALL

1. Ensure that the mode shaft pin (1) is located at

the 9 o’clock position. On the mode switch valve

assembly (2) ensure that the larger drive pin (3)

is positioned at the 12 o’clock position.

2. Align the mounting dowels (4) to the

corresponding holes (5) in the rear housing and

install the switch assembly ensuring that the

locking tangs of the mounting dowels engage

fully into the rear housing

3. Install the front housing/switch assembly and

printed circuit to the rear housing. Refer to

2.3 FRONT HOUSING/SWITCH ASSEMBLY

AND PRINTED CIRCUIT BOARD in this Section.

4. Ensure that all switches rotate freely and that all

the switch position indicators align correctly with

all switch positions. Ensure that all switches do

not rotate past intended rotation limits.

5. Install the controller to the instrument panel.

Refer to 2. MANUAL HVAC CONTROLLER in

this Section.

Figure 2B-18

3. HEATI NG, VENTILATION AND AIR CONDITIONING (HVAC) UNIT

LT Section – 08-150

REMOVE

NOTE: Disconnection of the battery affects certain vehicle electronic systems. Refer to Section 00, 5. BATTERY

DISCONNECTION PROCEDURES prior to disconnecting the battery.

1. Disconnect the battery ground lead. Refer to Section 00, 5. BATTERY DISCONNECTION PROCEDURES.

2. Disable the OPS, SRS system. Refer to Section 12M, 2.2 SYSTEM DISABLING AND ENABLING

PROCEDURE.

3. Discharge the A/C system. Refer to Section 2C, 2. DISCHARGING SYSTEM – REFRIGERANT

RECOVERY.

4. Drain engine coolant into a suitable, clean container. For GEN III V8 engines, refer to Section 6B-3, 2.3

DRAINING AND FILLING COOLING SYSTEM.

5. Remove the three screws (1) attaching the

right-hand side (shown) and left-hand side

instrument panel outer cover (2) to the

instrument panel.

6. Remove the cover by rotating outward to

disengage the ventilation duct.

Figure 2B-19

Referring to Figure 2B-20:

7. Remove the screw (1) attaching each windshield defroster grille (2) to the instrument panel.

8. Carefully remove the grille by unclipping (3), four places, at an angle equal to the windshield.

NOTE: As the grille is retained securely, removal may prove difficult. If required, a hook (such as an Allen key

held with vice- grips) can be used to assist in removal of the grille. Insert the hook at the inner then outer end of

the vent opening. Ensure it is hooked under the grille and not the sheetmetal below. Do not attempt to remove

the grilles by placing any removal tools between the grilles and the sun load sensor (4).

Figure 2B-20

9. Carefully unclip the sun load sensor (1) from the

instrument panel.

10. Disconnect the wiring connector (2), unclip the

wiring harness from the sensor assembly and

remove.

NOTE 1: The sun load sensor also functions as the

remote key receiver and provides data for headlamp

auto control.

NOTE 2: For diagnosis of the remote key receiver

and headlamp auto control functions, refer to

Section 12J, BODY CONTROL MODULE.

NOTE 3: For diagnosis of the sun load sensor

function, refer to Section 2F, HVAC OCCUPANT

CLIMATE CONTROL (AUTO A/C) – DIAGNOSTICS.

Figure 2B-21

11. Referr ing to information in 2. M ANUAL HVAC CONT ROLLER in this Section, rem ove in order, the f ollowing

items:

• Navigation remote control assembly (if fitted)

• Navigation display assembly (if fitted)

• Floor console front compartment liner

• Floor console cover assembly

• Radio assembly

• Instrument panel upper trim assembly

• Instrument panel centre trim assembly

• Manual HVAC controller (for manual A/C systems)

NOTE 1: If the HVAC unit to be removed is an Occupant Climate Control (Auto A/C) type, the OCC

control module will have been removed with the instrument panel centre trim assembly. If required, refer to

Section 2E, 2.1 OCC CONTROL MODULE for additional removal information.

NOTE 2: T he O CC c ontrol m odule does not have to be removed f r om the instr ument panel centr e trim ass embly

for HVAC unit removal purposes.

12. Referring to Figure 2B-22 for the left-hand side of the floor console:

a. Remove the screw (1) attaching the instrument panel lower extension side trim (2) to the floor console.

b. Open the instrum ent panel compartm ent (RHD) or instrument panel lower trim panel (LHD) and remove

the two screws (3) attaching the side trim to the instrument panel.

c. Remove the side trim.

Figure 2B-22

13. Referring to Figure 2B-23 for the right-hand side of the floor console:

a. Open the instrum ent panel lower trim panel (RHD) or instrum ent panel compartm ent (LHD) and remove

the two screws (1) attaching the instrument panel lower extension side trim (2) to the instrument panel.

b. Prise the rear of the trim panel downward to disengage it from the floor console retaining clip (3).

c. Remove the side trim.

Figure 2B-23

14. Remove the f loor c onsole c ompartment liner (1) by

carefully grasping the liner and disengaging the

two lugs (2).

Figure 2B-24

15. For automatic transmission models, remove the

screw (1), four places , attaching the console to the

automatic transmission selector assembly.

Figure 2B-25

16. For manual transmission models, use a fine flat-

blade screwdriver to disengage the lug (1),

attaching the manual transmission gear lever boot

assembly (2) to the console, two places front and

rear.

17. Remove the boot assembly from the console and

raise it over the gear knob. Remove the console

over the boot assembly when the remaining

fasteners are removed.

IMPORTANT: Do not attem pt to r emove the gear knob

from the gear lever shaft as it is glued in place. The

gear knob, boot assembly and lever shaft can be

removed from the transmission if required, refer to

Section 7B, MANUAL TRANSMISSION.

Figure 2B-26

18. Disconnect the console wiring connector (1) from

the front of the console storage bin.

Figure 2B-27

19. Remove the two nuts (1) attaching the floor

console (2) to the vehicle floor.

20. Remove the two screws (3) attaching the front of

the console to the instrument panel assembly.

21. As required disconnect any console wiring

connectors.

22. Lift the rear of the console upward and remove.

NOTE: The console rear air duct will disconnect from

the console front air duct during removal. The rear air

duct will remain with the console.

Figure 2B-28

NOTE: Where fitted, an instrument panel ashtray

assembly replaces the instrument panel lower

compartment. Removal of both components is the

same.

23. Remove the screw (1), three places, attaching the

instrument panel lower compartment assembly or

ashtray assembly (2) to the instrument panel.

24. Slide the compartment or ashtray assembly

outward to remove.

NOTE: If an ashtray assembly is fitted, disconnect the

wiring connector (3).

Figure 2B-29

Referring to Figure 2B-30:

25. Remove the two screws (1) attaching the instrument panel lower extension (2) to the instrument panel.

26. For the left-hand side, remove the screw (3) attaching the floor console front duct.

27. Grasp the top of the extension and pull rearwards to release the clip (4).

28. Rem ove the floor console front duct from the HVAC unit. Refer to item 6 in Figure 2B-55 for left-hand drive

models or Figure 2B-56 for right-hand models.

29. If f itted, disconnect the wiring connec tor (5) f rom the r ear com par tm ent lid release switch (6) and rem ove the

panel.

Figure 2B-30

Referring to Figure 2B-31:

30. Remove the screw (1) from the rear face of the radio housing (2) attaching the housing to the instrument

panel.

31. Remove the screw (3), two places, attaching the front edge of the radio housing.

32. Lift the retaining tab (4), two places in the top of the housing and one place at the bottom.

33. Withdr aw the hous ing from the br ack et ass em bly far enough to allow access to the r adio and antenna wiring

connectors.

NOTE: If ther e is not s uff icient length in the radio harness , either unclip the c onnector f rom within the housing or

remove the passenger side instrument panel lower extension side trim and unclip the harness from the vehicle

floor.

34. From the rear of the housing, unclip the radio wiring connector (5), if not previously done, the antenna

connector (6) and if fitted, the diversity antenna connector (7) from the housing.

35. Disconnect the antenna lead(s) and remove the housing.

Figure 2B-31

Referring to Figure 2B-32:

36. Remove the screws (1, 2, 3 and 4), two places each side, attaching the radio bracket assembly (5) to the

instrument panel.

37. Remove the bracket assembly from its locating tabs.

Figure 2B-32

38. For automatic transmission models, remove the retainer (1) attaching the driver’s side instrument panel

lower trim plate assembly (2) to the HVAC unit, refer to Figure 2B-33.

NOTE: The area shown A is removed for manual transmission models.

39. Prise the insert and remove the retainer (3), two places, attaching the plate assembly to the instrument

panel.

40. Lower the plate assembly slightly and withdraw the lug (4) from the pedal bracket.

41. If fitted, remove the stepwell lamp (5) by rotating the socket and removing from the plate assembly.

42. Remove the driver’s side plate assembly.

Figure 2B-33

Left-Hand Drive Vehic les

43. Grasp the inner end of the passenger side instrum ent panel lower trim plate assembly (1) and carefully pull

downwards to disengage the retaining clip (2), two places, refer to Figure 2B-34.

44. Withdraw the plate assembly from the hinge pillar trim panel, disengaging the lug (3), two places.

NOTE: The rear lug has a hook that engages the hinge pillar trim panel.

45. Lower the passenger side plate assem bly slightly and, if f itted remove the stepwell lamp (4), by rotating the

socket and removing from the plate assembly.

46. Remove the passenger side plate assembly.

Figure 2B-34

Right-Hand Drive Vehicles

47. Grasp the passenger side instrument panel lower trim plate assembly (1).

48. Carefully pull downw ard to disengage the retaining clip (2), three places, refer to Figure 2B-35.

49. Lower the plate assembly slightly and, if fitted remove the stepwell lamp (3), by rotating the socket and

removing from the plate assembly.

50. Remove the passenger side plate assembly.

Figure 2B-35

All Vehicles

51. O pen the instrument panel c om partm ent assem bly

(1).

52. Using a fine flat-blade screwdriver, flatten the

instrument panel compartment bumper stop (2)

each side, and carefully open the compartment

assembly fully.

53. From the inside of the compartment assembly,

push outwards on the bumper stop (2), and slide

the bumper from the lug (3). Repeat for the

opposite side.

54. Close the compartment assembly a third of the

way and grasping each side pull rearward to

disengage the compartment assembly from each

instrument panel compartment hinge (4).

IMPORTANT: T ake c are when disengaging the hinges

as removing the com partment assem bly on the wrong

angle may cause damage.

Figure 2B-36

55. From either side of the instrument panel

compartment lamp switch (1), carefully insert a

fine flat blade screwdriver and prise the switch

from the instrument panel.

56. Disconnect the wiring harness connectors and

remove the switch.

57. From the right-hand side of the instrument panel

compartment lamp (2), carefully insert a fine flat

blade screwdriver.

58. Pr ise the lam p fr om the instrum ent panel and s lide

it out of its cavity.

59. Disconnect the wiring harness connectors.

60. Remove the lamp ensuring that the globe (3) is not

dislodged or damaged during the removal

procedure.

Figure 2B-37

61. Grasp the upper edge of the instrument panel

lower trim panel assem bly ( 1) and pull outward s to

disengage the three retaining clips (2).

62. Swing the panel assembly open.

63. Holding each side of the panel assembly, pull

rearwards to disengage it from the instrument

panel lower trim panel retainer (3), two places.

Figure 2B-38

64. Remove the screw (1), two places, attaching the data link connector (2) to the instrument panel lower trim

panel retainer (3), refer to Figure 2B-39, A – left-hand drive or B – right-hand drive.

65. For left-hand drive vehicles, remove the screw (4) attaching the retainer to the driver’s side inner air duct.

66. For r ight-hand drive vehicles, r emove the sc rew (4) attaching the retainer to the driver’s s ide inner and outer

air duct joint.

67. Remove the screw (5), attaching the driver’s side inner duct to the retainer.

68. Remove the screw (6), three places, attaching the retainer to the instrument panel.

69. Slide the retainer downward to disengage the two lugs from the instrument panel assembly as shown at

Section A-A and remove the retainer.

Figure 2B-39

70. Remove the screw (1) attaching the driver’s side outer duct (2) to the instrument panel.

NOTE: The lower retaining screw (3) and (4) are removed during removal of the instrument panel lower trim

panel retainer at Step 65 or Step 66. On left-hand drive models this screw retains only the inner duct (4) to the

instrum ent panel. On right-hand drive models, this screw retains both the inner and outer duct to the instrum ent

panel. For left-hand drive models refer to item 5 in Figure 2B-55. For right-hand drive m odels refer to item 5 in

Figure 2B-56.

71. Raise the steering column to its highest adjustment position.

72. Separate the dr iver’s side outer duc t and the driver’s side inner duct by partially withdrawing the driver’s side

outer duct through the end cavity of the instrument panel.

73. Remove the driver’s side inner duct through the instrument panel lower trim plate assembly cavity.

74. Remove the driver’s side outer duct through the instrument panel lower trim plate assembly cavity.

75. Remove the screw (6) attaching the passenger side duct (7) to the instrument panel.

NOTE 1: The floor console front duct retaining screw (8) is removed at Step 25 and duct (9), at Step 28.

NOTE 2: The floor console rear duct (10), is removed with the floor console at Step 22.

Figure 2B-40

76. Release the steering column adjustment lever (1)

and move the column to its lowest position.

77. From below the steering column, remove the

screw (2) attaching the lower cover (3).

NOTE: The covers can be removed with the steering

wheel installed; however, it is not shown for clarity.

78. Depress the face of the lower cover inwards to

disengage the tabs (4) and lift the steering column

upper cover (5).

79. Raise the upper cover as high as possible to

disengage the lugs (6) and remove the cover.

80. Slide the lower cover rearward to disengage it from

the lugs (7) and remove the cover.

81. Remove the steering wheel inflatable restraint

module, refer to Section 12M, OCCUPANT

PROTECTION SYSTEM.

NOTE: Special Tool required.

Figure 2B-41

82. Place the road wheels in the straight-ahead

position and lock the steering column.

83. Remove the screw (1).

84. Remove the steering wheel, disconnecting and

feeding the wires through the aperture as required.

NOTE: A puller should not be required, however if the

wheel assembly cannot be removed fairly easily, use

puller J1859-A and legs E1408.

85. Check that the green indicator (2) on the inflatable

restraint module coil assembly has engaged the

inner clock spring to lock it in the central position.

Figure 2B-42

86. Remove the two screws (1) attaching the

instrument cluster trim assembly (2) to the

instrument panel.

87. Depress the top of the trim assembly slightly and

tilt the top of the trim assembly out of the

instrument panel pad, disengaging the retaining

clips (3) each side.

88. Unhook each lug (4) from the instrument panel

pad.

89. For left-hand drive models, disconnect the fuel

tank filler door lock release switch wiring

connector.

90. Remove the trim assembly.

Figure 2B-43

91. Disconnect the wiring connectors from the rear of

the turn signal switch assembly (1) and windshield

wiper and washer switch assembly.

92. Depress the two tabs (2) securing the switch and

slide from the steering column assembly. Repeat

for the other switch.

Figure 2B-44

93. Remove the four screws (1) attaching the

instrument cluster (2) to the instrument panel.

94. Roll the top of the cluster from its cavity.

95. Using a f ine flat blade scr ewdriver, open the wiring

connector locking tab (3) on the back of the

cluster.

96. Remove the cluster assembly.

Figure 2B-45

IMPORTANT: Care m ust be exercis ed when removing

the headlamp switch as the retaining clip and locating

guide will catch and damage the instrument panel

outer material.

NOTE: Complete switch assembly removal is not

necessar y for HVAC unit rem oval. Figure 2B-46 shows

the switch assembly removed only for clarity of detail.

97. From behind the instrument panel pad, depress

the retaining clips (1). Use a fine, flat blade

screwdriver if required.

98. Carefully push the headlamp switch assembly (2)

part way from its cavity.

99. Insert a fine, flat-blade screwdriver (3) as shown

and hold the retaining clip depres sed, while slowly

manipulating the s witch from its cavity. Repeat for

the opposite side and for the locating guide

underneath as required.

100. Disconnect the wiring connector but do not

remove the switch assembly, as complete

removal is not necessary.

Figure 2B-46

IMPORTANT: Care m ust be exercis ed when removing

the trip computer switch as the retaining clip and

locating guide will catch and damage the instrument

panel outer material.

NOTE: Complete switch assembly removal is not

necessar y for HVAC unit rem oval. Figure 2B-47 shows

the switch assembly removed only for clarity of detail.

101. From behind the instrument panel pad, depress

the retaining clips (1). Use a fine, flat blade

screwdriver if required.

102. Carefully push the trip computer switch

assembly (2) part way from its cavity.

103. Insert a fine, flat-blade screwdriver (3) as shown

and hold the retaining clip depressed, while

manipulating the s witch from its cavity. Repeat for

the opposite side and for the locating guide

underneath as required.

104. Disconnect the wiring connector but do not

remove the switch assembly, as complete

removal is not necessary.

Figure 2B-47

105. Remove the screw (1) attaching the instrument

panel speaker (2) to the instrument panel (3).

106. Disconnect the wiring connector and remove the

speaker by withdrawing it from the slot in the

instrument panel.

Figure 2B-48

Left-Hand Drive Vehic les

107. Remove the screw (1) attaching the BCM (2) to

the HVAC BCM bracket.

108. Release the rear retaining tang and gently

manoeuvre the BCM from the mounting bracket.

Figure 2B-49

Right-hand Drive Vehicles

109. Remove the screw (1) attaching the BCM (3) to

the instrument panel bracket outer brace.

110. Release the two rear retaining tangs (2) and

gently manoeuvre the BCM f r om the top mounting

bracket.

Figure 2B-50

111. If fitted, remove the telematics module (1). Refer

to Section 12K, TELEMATICS.

Figure 2B-51

112. If the vehicle is fitted with a satellite navigation

system, remove the passenger side hinge pillar

trim assembly. Refer to Section 1A8, 2.8 HINGE

PILLAR TRIM ASSEMBLY.

113. Disconnect the satellite navigation speaker

connector (1) and the satellite navigation system

connectors (2).

NOTE: Rem oval of the navigation s peaker (3) fr om the

instrument panel lower bracket (4) is not necessary.

The brac ket and s peaker are r emoved as an as s embly

at a latter stage.

Figure 2B-52

All Vehicles

114. Remove the four BCM wiring harness connectors from the module and remove the module.

115. Remove the antenna lead from the retaining clips loc ated on the underside of the RHD HVAC unit or at the

case join on the LHD HVAC unit.

116. Remove the two inner screws (1) attaching the instrument panel inflatable restraint (2) or instrument panel

outer upper bracket (3) and instrument panel lower bracket (4) to the instrument panel inflatable restraint

bracket (5), refer to Figure 2B-53.

NOTE: View A is for models with an instrument panel inflatable restraint. View B is for models without an

instrument panel inflatable restraint.

Figure 2B-53

117. Prior to instrum ent panel pad rem oval, refe r to Figure 2B-54 and ensur e that the following screws attaching

the instrument pad assembly are removed:

a. left-hand end (1) one place,

b. to the passenger side air duct (2) one place, (removed previously at Step 75)

c. passenger side lower (3 and 4) two places each,

d. left of centre (5) one place,

e. driver side lower (6) one place,

f. behind instrument cluster (7) one place,

g. to the driver’s side outer air duct (8) one place, (removed previously at Step 70)

h. right-hand end (9) one place,

i. along the upper edge (10), five places.

With the aid of an assistant, carefully lift the pad assembly out of the vehicle and place on a soft surface.

Figure 2B-54

118. If fitted, remove the instrument panel inflatable restraint module assembly. Refer to Section 12M, 2.4

INSTRUMENT PANEL INFLATABLE RESTRAINT MODULE ASSEMBLY.

119. Remove the passenger side HVAC duct from the HVAC unit. Refer to item 9 in Figure 2B-55 for left-hand

drive models or Figure 2B-56 for right-hand models.

NOTE: At this stage, all ducting required for HVAC unit removal, should have been removed.

Figure 2B-55

Legend

1. HVAC Unit 6. Floor Console Front Duct, removed at Step 28

2. Driver’s Side Outer Duct, removed at Step 74 7. Screw (1 place), removed at Step 25

3. Screw (1 place), removed at Step 70 8. Foot Duct

4. Driver’s Side Inner Duct, removed at Step 73 9. Passenger’s Side Duct, removed at Step 118

5. Screw (1 place), removed at Step 65 10. Screw (1 place), removed at Step 75

NOTE 1: The foot duct remains attached when the HVAC unit is removed.

NOTE 2: The floor console rear duct (not shown) is removed and installed with the floor console assembly.

NOTE 3: The steering column (not shown) does not have to be removed for HVAC unit removal.

NOTE 4: The floor console front duct is not applicable to utility models.

Figure 2B-56

Legend

1. HVAC Unit 7. Screw (1 place), removed at Step 25

2. Driver’s Side Outer Duct, removed at Step 74 8. Floor Console Front Duct, removed at Step 28

3. Screw (1 place), removed at Step 70 9. Passenger’s Side Duct, removed at Step 118

4. Driver’s Side Inner Duct, removed at Step 73 10. Foot Duct

5. Screw (1 place), removed at Step 66 11. Screw (1 place), removed at Step 75

6. Screw (1 place), removed at Step 67

NOTE 1: The foot duct remains attached when the HVAC unit is removed.

NOTE 2: The floor console rear duct (not shown) is removed and installed with the floor console assembly.

NOTE 3: The steering column (not shown) does not have to be removed for HVAC unit removal.

NOTE 4: The floor console front duct is not applicable to utility models.

Figure 2B-57

Legend

1. Instrument Panel Compartment Bracket, refer to Step 117 c, and Step 120 through to Step 121

2. Instrument Panel Lower Bracket, refer to Step 122 through to Step 124

3. Instrument Panel Outer Upper Bracket, refer to Step 124 and Step 125

4. Lower Radio Bracket, refer to Step 122, Step 126, Step 127, Step 130 and Step 131

5. Steering Column Bracket Inner Brace, refer to Step 127 through to Step 129

6. Steering Column Bracket Outer Brace, do not remove

NOTE1: Item 3, the instrument panel outer upper bracket, is fitted only to models not fitted with an instrument panel

inflatable restraint module assembly.

NOTE 2: Item 2 and 3 are removed as an assembly.

NOTE 3: If the vehicle is fitted with a satellite navigation system, the navigation speaker will be attached to, and removed

with Item 2. Refer to Figure 2B-52.

120. Remove the screw (1) attaching the HVAC unit (2)

to the instrument panel compartment bracket (3).

121. Remove the screw (4), two places, attaching the

bracket to the instrument panel lower bracket (5)

and remove the bracket.

Figure 2B-58

Referring to Figure 2B-59:

122. Remove the screws (1 and 2) attaching the instrument panel lower bracket (3) to the lower radio bracket.

123. Remove the screws (4 and 5) attaching the bracket to the vehicle.

IMPORTANT: If the vehicle is fitted with a satellite navigation system, exercise caution when removing the

instrument panel lower bracket to ensure that the attached satellite navigation speaker is not damaged.

124. Remove the outer upper bracket (6) and lower bracket as an assembly.

Figure 2B-59

125. Remove the nut (1), two places, attaching the

outer upper bracket to the dash panel assembly .

Figure 2B-60

126. Unclip the wiring connector (1) from the lower

radio bracket (2).

127. Remove the screw (3) attaching the steering

column bracket inner brace (4) to the lower radio

bracket.

128. Remove the screw (5) attaching the brace to the

steering column bracket (6).

129. Remove the brace.

130. Remove the screw (7), attaching the HVAC

unit (8) to the radio bracket.

131. Remove the screw (9), two places, attaching the

radio bracket to the vehicle and remove the

bracket.

Figure 2B-61

132. Mark the heater hoses (1) in relation to the heater

core pipes (2) to maintain correct coolant flow.

Remove the heater hoses from the heater core

pipes.

133. Disconnect the water valve vacuum hose (3) at

the joiner (4).

134. Disconnect the vacuum supply hose (5) at the

check valve (6).

Figure 2B-62

135. Remove the suc tion and liquid tubes (one bolt) and the ther mal expans ion valve (two cap scr ews). Refer to

10.THERMAL EXPANSION VALVE (TXV) in this Section.

136. On GEN III V8 models, remove the fuel line retaining bracket attached to the HVAC mounting stud. For

location, refer to item 8 in Figure 2B-63 for left-hand drive models and Figure 2B-64 for right-hand drive

models.

137. Remove the screws retaining the HVAC unit to the dash panel. Refer to Figure 2B-63 for left-hand drive

models and Figure 2B-64 for right-hand drive models.

NOTE: Item 7 will have been removed during previous Steps.

HVAC UNIT FASTENER LOCATION – LHD

Figure 2B-63

Legend

1. HVAC Unit 5. Screw – Dash Panel, Cabin on Passenger’s Side

2. Dash Panel 6. Lower Radio Bracket Assembly

3. Screw – Dash Panel, Engine Bay (3 places) 7. Screw – Lower Radio Bracket Assembly, removed at Step 130

4. Screw – Dash Panel, Cabin on Driver’s Side 8. Screw for V6, Stud for GEN III V8 – Dash Panel, Engine Bay

NOTE: The steering column (not shown) does not have to be removed for HVAC unit removal.

HVAC UNIT FASTENER LOCATION – RHD

Figure 2B-64

Legend

1. HVAC Unit 5. Screw – Dash Panel, Cabin Driver’s Side

2. Dash Panel 6. Lower Radio Bracket Assembly

3. Screw – Dash Panel, Engine Bay (3 places) 7. Screw – Lower Radio Bracket Assembly, removed at Step 130

4. Screw – Dash Panel, Cabin Passenger Side 8. Screw for V6, Stud for GEN III V8 – Dash Panel, Engine Bay

NOTE: The steering column (not shown) does not have to be removed for HVAC unit removal.

IMPORTANT: W hen r emoving the HVAC unit from the vehicle take c are not to strain the heater cor e tubes and

evaporator core tubes.

NOTE: Figure 2B-65 shows the right-hand drive HVAC unit and corresponding drain tube / hole location offset

towards the left of the transmission tunnel. The left-hand drive HVAC unit drain tube / hole location is offset

towards the right of the transmission tunnel.

138. Remove the HVAC unit (1) from the vehicle by disengaging the drain tube (2) from the body grommet (3)

installed in the transmission tunnel (4).

139. Carefully lift the HVAC unit away from the dash panel (5).

Figure 2B-65

REINSTALL

Installation of the heating, ventilation and air conditioning (HVAC) unit is in the reverse order of removal noting the

following points and references:

1. Tighten all fasteners to the specified torque. Refer to 19. TORQUE WRENCH SPECIFICATIONS in this

Section.

2. Enable the OPS, SRS in accordance to the correct procedure. Refer to Section 12M, 2.2 SYSTEM

DISABLING AND ENABLING PROCEDURE.

3. Fill the cooling system with the correct specification and quantity of coolant. Pressure test the cooling system.

As applicable refer to:

• Section 6B1, ENGINE COOLING – V6 ENGINE

• Section 6B2, ENGINE COOLING – V6 ENGINE SUPERCHARGED

• Section 6B3, ENGINE COOLING – GEN III V8 ENGINE

4. Evacuate and charge the system with 775 – 825 g of R134a refrigerant, refer to Section 2C, 2.1 SYSTEM

CHARGING AND EVACUATION.

4. EVAPORATOR CORE

REMOVE – LHD

1. Remove the floor console, instrument panel and HVAC assemblies, refer to 3. HEATING, VENTILATION

AND AIR CONDITIONING (HVAC) UNIT in this Section.

2. Remove TXV joint bracket screws (1) and

remove the bracket (2) from the HVAC unit (3).

3. Remove the heater core (4). Refer to

5. HEATER CORE in this Section.

Figure 2B-66

4. On O CC (Auto A/C) HVAC units rem ove the HVAC harness c onnector (1) f rom the evaporative temperatur e

sensor harness connector (2).

5. On both manual A/C and OCC (Auto A/C) type HVAC units, remove the vacuum line (3) to the intake

actuator (4).

Figure 2B-67

6. On manual HVAC units remove the vacuum

line retainers (1) and remove the vacuum lines

(2) from the front case (3). Remove the intake

actuator vacuum line (4) from the front and

upper case.

7. On both types of HVAC units remove

the demist actuator (5). Refer to

8.5 DEMIST ACTUATOR in this Section.

Figure 2B-68

8. On OCC (Auto A/C) HVAC units remove the

harness retainers (1) and remove the

harness (2) from the front case (3).

9. On OCC (Auto A/C) HVAC units remove the

vacuum lines (4) from the water valve VSV (5).

10. On OCC (Auto A/C) HVAC units remove the

aspirator tube and venturi assembly (6). Refer

to Section 2E, ASPIRATOR TUBE AND

VENTURI.

Figure 2B-69

11. Remove the eight s cr ews (1) attaching the f ront

case (2) to the upper and lower case assembly.

Figure 2B-70

12. To access the evaporator (1) separate the

lower case (2) from the upper case (3) by

removing the ten screws (4) installed through

the upper case, one s crew (5) installed thr ough

the lower case, and four clips (6). Do not

remove air doors from either case.

NOTE: Two clips ar e located ins ide the HVAC case

and are accessible after the front case is removed.

Figure 2B-71

13. On OCC (Auto A/C) HVAC units, if the

evaporator is to be replaced, remove the

evaporative temperature sensor clip (1) from

the evaporator (2) and remove the sensor (3).

14. Carefully remove the evaporator core from the

upper case. Pull tubes away from the upper

case to facilitate removal.

Figure 2B-72

15. Rotate the evaporator core (1) and remove

evaporator pipes (2) after removing the

retaining scr ew (3). Remove and discar d the O-

rings (4) from the evaporator pipes.

Figure 2B-73

REINSTALL – LHD

Installation of the evaporator core is in the reverse order of removal procedures noting the following points:

IMPORTANT: 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.

NOTE 1: Install new O-rings at the evaporator to evaporator pipe joint.

NOTE 2: On OCC (Auto A/C) evaporator assemblies, install the evaporative temperature sensor in the correct

location on the evaporator core. Refer to Section 2E, 2.4 EVAPORATIVE TEMPERATURE SENSOR.

1. Tighten evaporator to evaporator pipe screw to the correct torque specification.

EVAPORATOR PIPE SCREW

TORQUE SPECIFICATION 5.0 Nm

2. Tighten the HVAC case screws to the correct torque specification.

HVAC CASE SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

3. Install the heating, ventilation and air conditioning (HVAC) unit, refer to 3. HEATING, VENTILATION AND AIR

CONDITIONING (HVAC) UNIT in this Section.

4. Evacuate and charge the system with 775 – 825 g of R134a refrigerant, refer to Section 2C, 2.1 SYSTEM

CHARGING AND EVACUATION.

LT Section – 08-150

REMOVE – RHD

1. Remove the floor console, instrument panel and HVAC assemblies, refer to 3. HEATING, VENTILATION

AND AIR CONDITIONING (HVAC) UNIT in this Section.

2. On OCC (Auto A/C) HVAC units, remove the

HVAC harness connector (1) from the

evaporative temperature sensor harness

connector (2). Remove the venturi (3) from the

evaporator cover (4).

Figure 2B-74

3. Remove the vacuum hose (1) from the fresh/

recirculation actuator (2).

4. Remove the five screws (3) from the

fresh/recirculation housing (4) and remove the

fresh/recirculation housing.

5. Disconnect the vacuum tube harness retaining

clips (5) above the evaporator core cover (6).

Figure 2B-75

6. On OCC (Auto A/C) HVAC units remove the

aspirator tube and venturi. Refer to

Section 2E, 2.5 ASPIRATOR TUBE AND

VENTURI.

7. On manual HVAC units disconnect the air mix

door actuator rod (1) and quadrant screw (2)

and remove the quadrant (3)

8. Remove the four screws from the evaporator

core cover (4) and remove the evaporator

cover (5).

Figure 2B-76

9. Remove the upper insulator (1) and carefully

rem ove the evapor ator c ore (2) f rom the m iddle

cavity of the HVAC case (3).

Figure 2B-77

10. On OCC (Auto A/C) HVAC units, disconnect

the evaporative tem perature sensor harness. If

the evaporator is to be replaced, remove the

evaporative temperature sensor clip (1) from

the evaporator (2) and remove the sensor (3).

Figure 2B-78

REINSTALL – RHD

Installation of the evaporator core is in the reverse order of removal procedures noting the following points:

IMPORTANT: 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.

NOTE: On OCC (Auto A/C) evaporator assemblies install the evaporative temperature sensor in the correct location

on the evaporator core. Refer to Section 2E, 2.4 EVAPORATIVE TEMPERATURE SENSOR.

1. Tighten the HVAC case screws to the correct torque specification.

HVAC CASE SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

2. Install the heating, ventilation and air conditioning (HVAC) unit, refer to 3. HEATING, VENTILATION AND AIR

CONDITIONING (HVAC) UNIT in this Section.

3. Evacuate and charge the system with 775 - 825 g of R134a refrigerant, refer to Section 2C, 2.1 SYSTEM

CHARGING AND EVACUATION.

5. HEATER CORE

REMOVE – LHD

1. Remove the floor console, instrument panel and HVAC assemblies, refer to 3. HEATING, VENTILATION

AND AIR CONDITIONING (HVAC) UNIT in this Section.

2. Remove heater the two heater core pipe

clamps (1) and screws (2).

3. Remove heater core retaining strap mounting

screw (3) and retaining strap (4).

Figure 2B-79

4. Remove heater pipe bracket mounting

screws (1) and the bracket (2).

5. Position the air mix door mechanism (3) clear

of the top of the heater core (4).

Figure 2B-80

6. Remove the heater core (1) from the HVAC

case without damaging the foam seal (2)

located on top and on both sides of the heater

core.

7. Remove the screw (3) and retainer clip (4)

retaining each heater pipe (5) to the heater

core and remove the pipes from the heater

core. Discard the O-rings (6).

Figure 2B-81

REINSTALL – LHD

Installation of the heater core is in the reverse order of removal procedures noting the following points:

NOTE 1: Install new O-rings at the heater core pipe joints.

NOTE 2: Ensure the foam seals are not damaged when installing heater core to the HVAC case.

1. Tighten all fasteners to the correct torque specification.

HEATER CORE PIPE

RETAINING SCREWS

TORQUE SPECIFICATION 3.0 – 5.0 Nm

HVAC CASE SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

2. Install the heating, ventilation and air conditioning (HVAC) unit, refer to 3. HEATING, VENTILATION AND AIR

CONDITIONING (HVAC) UNIT in this Section.

3. Evacuate and charge the system with 775 - 825 g of R134a refrigerant, refer to Section 2C, 2.1 SYSTEM

CHARGING AND EVACUATION.

LT Section – 08-150

REMOVE – RHD

1. Remove the floor console, instrument panel and HVAC assemblies, refer to 3. HEATING, VENTILATION

AND AIR CONDITIONING (HVAC) UNIT in this Section.

2. Unclip and remove plastic retainer (1) from the

heater pipes (2) at the rear of the HVAC unit

(3).

Figure 2B-82

3. Remove the heater core (1) from the HVAC

case (2) without damaging the foam seal (3)

located on top and on both sides of the heater

core.

Figure 2B-83

REINSTALL – RHD

Installation of the heater core is in the reverse order of removal procedures noting the following points:

NOTE: Ensure the foam seals are not damaged when installing heater core to the HVAC case.

1. Install the heating, ventilation and air conditioning (HVAC) unit, refer to 3. HEATING, VENTILATION AND AIR

CONDITIONING (HVAC) UNIT in this Section.

2. Evacuate and charge the system with 775 – 825 g of R134a refrigerant, refer to Section 2C, 2.1 SYSTEM

CHARGING AND EVACUATION.

6. BLOWER MOTOR AND FAN ASSEMBLY

REMOVE – LHD

1. Remove the right-hand side instrument panel lower trim plate assembly, refer to Section 1A3,

3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

2. Disconnect the body harness connector to the

blower motor and fan assembly sub harness

connector (1).

3. Remove the three screws (2) and remove the

blower motor and fan assembly (3) from the

lower case housing (4)

4. Remove the blower motor and fan assembly

sub harness and bracket (5) from the blower

motor.

REINSTALL – LHD

Installation of the blower m otor and f an ass em bly is

the reverse order of removal procedures. Tighten

all screws to the specified torque.

BLOWER MOTOR AND FAN

ASSEMBLY ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

Figure 2B-84

LT Section – 08-150

REMOVE – RHD

1. Remove the left-hand side instrument panel lower trim plate assembly, refer to Section 1A3, 3.1

INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

2. Disconnect the body harness connector to the

blower motor and fan assembly connector (1).

3. Remove the blower motor and fan assembly

cover screws (2) from the HVAC unit (3) and

move the cover (4) sufficiently to allow access

to the blower motor and fan assembly (5).

4. Remove the three blower motor and fan

assembly screws (6) and remove the blower

motor and fan assembly from the HVAC unit.

REINSTALL – RHD

Installation of the blower m otor and fan assem bly is

the reverse order of removal procedures. Tighten

all screws to the specified torque.

BLOWER MOTOR AND FAN ASSEMBLY

COVER ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

BLOWER MOTOR AND FAN ASSEMBLY

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

Figure 2B-85

7. BLOWER MOTOR RESISTOR

REMOVE – LHD

1. Remove the right-hand side instrument panel lower trim plate assembly. Refer to

Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

2. Remove the harness connector (1) from the

blower motor resistor (2).

3. Remove the two screws (3) retaining the

blower motor resistor to the HVAC unit (4).

4. Remove the blower motor resistor from below

the HVAC unit.

REINSTALL – LHD

Installation of the blower motor resistor is the

reverse order of removal procedures. Tighten all

screws to the specified torque.

BLOWER MOTOR RESISTOR

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

Figure 2B-86

LT Section – 08-150

REMOVE – RHD

1. Remove the left-hand side instrument panel lower trim plate assembly. Refer to

Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

2. Remove the instrument panel compartment assembly. Refer to Section 1A3, 3.2 INSTRUMENT PANEL

COMPARTMENT ASSEMBLY.

3. Remove the harness connector (1) from the

blower motor resistor (2).

4. Remove the two screws (3) attaching the

blower motor resistor to the side of the HVAC

unit (4).

5. Remove the blower motor resistor from the

HVAC unit.

REINSTALL – RHD

Installation of the blower motor resistor is the

reverse order of removal procedures noting the

following points:

1. Install the resistor with the arrow (5) pointing

towards the rear of the vehicle.

2. Tighten all screws to the specified torque.

BLOWER MOTOR RESISTOR

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

Figure 2B-87

8. VACUUM TANK AND VACUUM ACTUATORS

8.1 VACUUM TANK

REMOVE – LHD

1. Remove the left-hand side instrument panel lower trim plate assembly. Refer to

Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

2. Remove the two vacuum lines (1) from the

vacuum tank (2).

3. Remove the screw (3) located under the

vacuum tank.

4. Move the lower section of the vacuum tank

outwards and move the tank downwards to

disengage the retaining tangs (4) from the

locating slots (5) on the side of the HVAC

case (6).

5. Remove the vacuum tank.

REINSTALL – LHD

Installation of the vacuum tank is the reverse order

of removal procedures noting the following points:

NOTE: Ensure that the vacuum lines are installed

correctly. The black vacuum line (vacuum source)

is connected to tank port closer to the engine bay.

The white vacuum line is c onnected to the tank port

closer to the cabin.

1. Tighten all screws to the specified torque.

VACUUM TANK ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

Figure 2B-88

LT Section – 08-125

REMOVE – RHD

1. Remove the left-hand side instrument panel lower trim plate assembly. Refer to

Section 1A3, 3.1. INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY

2. Remove the two vacuum lines (1) from the

vacuum tank (2).

3. Remove the screw (3) located under the

vacuum tank.

4. Move the lower section of the vacuum tank

outwards and move the tank downwards to

disengage the retaining tangs (4) from the

locating slots (5) on the side of the HVAC

case (6).

5. Remove the vacuum tank.

REINSTALL – RHD

Installation of the vacuum tank is the reverse order

of removal procedures noting the following points:

NOTE: Ensure that the vacuum lines are installed

correctly. The vacuum line with larger connecting

elbow (vacuum source) is connected to tank port

closer to the engine bay. The vacuum line with the

smaller connecting elbow is connected to the tank

port closer to the cabin.

1. Tighten all screws to the specified torque.

VACUUM TANK ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

Figure 2B-89

8.2 FRESH/RECIRCULATION (INTAKE) ACTUATOR

REMOVE – LHD

1. Remove the left-hand side instrument panel lower trim plate assembly. Refer to

Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

2. Remove the BCM. Refer to Section 12J, 2.1 BODY CONTROL MODULE.

3. Remove the vacuum line (1) from the vacuum actuator (2).

4. Remove the e-clip (3), bushes (4) and actuator rod (5) from the lever (6).

5. Remove the vacuum actuator attaching screws (7).

6. Remove the vacuum actuator.

Figure 2B-90

REINSTALL – LHD

Installation of the fresh/recirculation (intake) vacuum actuator is in the reverse order of removal procedures noting

the following points:

1. Tighten all screws to the specified torque.

FRESH/RECIRCULATION

ACTUATOR ATTACHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

REMOVE – RHD

LT Section – 08-150

1. Remove the left-hand side instrument panel lower trim plate assembly. Refer to

Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

2. Rem ove the left-hand s ide instrum ent panel outer cover. Ref er to Section 1A3, 3.17 INSTRUMENT PANEL

OUTER COVER.

3. Remove the vacuum tank. Refer to 8.1 VACUUM TANK in this Section.

4. Remove the vacuum line (1) at the vacuum

actuator (2).

5. Remove the vacuum actuator rod (3) from the

vacuum actuator lever (4).

6. Remove the two screws (5).

7. Remove the vacuum actuator.

REINSTALL – RHD

Installation of the fresh/recirculation vacuum

actuator is the r ever se or der of re moval procedur es

noting the following:

1. Tighten all screws to the specified torque.

FRESH/RECIRCULATION

ACTUATOR ATTACHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

Figure 2B-91

8.3 FACE ACTUATOR

REMOVE – LHD

1. Remove the floor console, instrument panel and HVAC assemblies, refer to 3. HEATING, VENTILATION

AND AIR CONDITIONING (HVAC) UNIT in this Section.

2. From the underside of the HVAC unit (1),

locate the face actuator (2).

3. Remove the vac uum lines (3) from the vacuum

actuator.

4. Remove the e-clip (4), rod bushes (5) and the

actuator rod (6) from the lever (7).

5. Remove the two vacuum actuator nuts (8).

6. Remove the vacuum actuator.

REINSTALL – LHD

Installation of the face vacuum actuator is the

reverse order of removal procedures noting the

following points:

NOTE: Ensure that the vacuum lines are installed

correc tly. The blue vac uum line is c onnected to the

side of the face actuator. The white vacuum line is

connected to the back of the face actuator.

1. Tighten the nuts to the specified torque.

FACE ACTUATOR

ATTACHING NUT

TORQUE SPECIFICATION 3.0 – 5.0 Nm

Figure 2B-92

LT Section – 08-150

REMOVE – RHD

1. Remove the floor console, instrument panel and HVAC assemblies, refer to 3. HEATING, VENTILATION

AND AIR CONDITIONING (HVAC) UNIT in this Section.

2. From the underside of the HVAC unit (1),

locate the face actuator (2).

3. Remove the vacuum actuator rod (3) from the

door lever.

4. Remove the vac uum lines (4) from the vacuum

actuator.

5. Remove the two vacuum actuator attaching

screws (5).

REINSTALL – RHD

Installation of the face vacuum actuator is the

reverse order of removal procedures noting the

following points:

NOTE: Ensure that the vacuum lines are installed

correctly. The green vacuum line is connected to

the side of the face actuator. The white vacuum line

is connected to the back of the face actuator.

1. Tighten the screws to the specified torque.

FACE ACTUATOR

ATTACHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

Figure 2B-93

8.4 FOOT ACTUATOR

REMOVE – LHD

1. Remove the floor console, instrument panel and HVAC assemblies, refer to 3. HEATING, VENTILATION

AND AIR CONDITIONING (HVAC) UNIT in this Section.

2. From the underside of the HVAC unit (1),

locate the foot actuator (2).

3. Remove the vacuum line (3) from the vacuum

actuator.

4. Remove the e-clip (4), rod bushes (5) and the

actuator rod (6) from the lever (7).

5. Remove the vacuum actuator two screws (8).

5. Remove the vacuum actuator.

REINSTALL – LHD

Installation of the foot vacuum actuator is the

reverse order of removal procedures noting the

following:

1. Tighten the screws to the specified torque.

FOOT ACTUATOR

ATTACHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

Figure 2B-94

LT Section – 08-150

REMOVE – RHD

1. Remove the floor console, instrument panel and HVAC assemblies, refer to 3. HEATING, VENTILATION

AND AIR CONDITIONING (HVAC) UNIT in this Section.

2. From the underside of the HVAC unit (1),

locate the foot actuator (2).

3. Remove the vacuum actuator rod (3) from the

door lever.

4. Remove the vac uum lines (4) from the vacuum

actuator.

5. Remove the two vacuum actuator attaching

screws (5).

REINSTALL – RHD

Installation of the foot vacuum actuator is the

reverse order of removal procedures noting the

following points:

NOTE: Ensure that the vacuum lines are installed

correctly. The orange vacuum line is connected to

side of the foot actuator. The pink vacuum line is

connected to the back of the foot actuator.

1. Tighten all screws to the specified torque.

FOOT ACTUATOR

ATTACHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

Figure 2B-95

8.5 DEMIST ACTUATOR – LHD ONLY

REMOVE

1. Remove instrument cluster. Refer to Section 1A3, 3.14 INSTRUMENT CLUSTER.

2. Lower the instrument panel lower trim panel assembly.

3. Through the aperture in the instrument panel,

locate the vacuum actuator (1) and remove the

e-clip (2) and the actuator rod (3), rod

bushes (4) from the lever (5).

4. Remove the vacuum line (6) from the vacuum

actuator.

5. Remove the two vacuum actuator attaching

screws (7).

6. Remove the vacuum actuator.

REINSTALL

Installation of the demist vacuum actuator is the

reverse order of removal procedures noting the

following:

1. Tighten all screws to the specified torque.

DEMIST ACTUATOR

ATTACHING SCREW

TORQUE SPECIFICATION 3.0 – 5.0 Nm

Figure 2B-96

9. AI R CONDI TIONING HOSE AND PI PE CONNECTI O NS AND RETAI NERS

LT Section – 08-200

REMOVE AND REINSTALL

The following four Figures provide under hood views of the air conditioning hose and pipe connections, and

retainers. Refer to these Figures when removing and installing these components.

• For V6 left-hand drive models, refer to Figure 2B-62

• For V6 and V6 Supercharged right-hand drive models, refer to Figure 2B-63

• For GEN III V8 left-hand drive models, refer to Figure 2B-64

• For GEN III V8 right-hand drive models, refer to Figure 2B-6 5

IMPORTANT: 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.

Techline

A/C HOSE AND PIPE CONNECTIONS, AND RETAINERS – V6 ENGINE LHD

Figure 2B-97

Legend

1. Thermal Expansion Valve

(TXV) 6. O-ring – TXV

Discharge 11. Discharge Hose/

Tube 16. O-ring – Condenser

2. O-ring – TXV Suction 7. Compressor 12. Liquid Tube Clip 17. Condenser

3. Suction Tube 8. O-ring – Compressor 13. Discharge Tube Clip 18. O-ring – FDR

4. Screw 9. Nut 14. Discharge Tube 19. Filter Drier Receiver

5. Liquid Tube 10. Suction Hose/Tube 15. Nut (FDR)

A/C HOSE AND PIPE CONNECTIONS, AND RETAINERS – V6 AND V6 SUPERCHARGED ENGINES RHD

Figure 2B-98

Legend

1. Thermal Expansion Valve

(TXV) 6. O-ring – TXV

Discharge 11. Discharge Hose/

Tube 16. O-ring – Condenser

2. O-ring – TXV Suction 7. Compressor 12. Liquid Tube Clip 17. Condenser

3. Suction Tube 8. O-ring – Compressor 13. Discharge Tube Clip 18. O-ring – FDR

4. Screw 9. Nut 14. Discharge Tube 19. Filter Drier Receiver

5. Liquid Tube 10. Suction Hose/Tube 15. Nut (FDR)

A/C HOSE AND PIPE CONNECTIONS, AND RETAINERS – GEN III V8 ENGINE LHD

Figure 2B-99

Legend

1. Thermal Expansion Valve (TXV) 6. Discharge Tube Retaining Clip 11. Retaining Clamp

2. O-Ring 7. Discharge Tube 12. Discharge Hose/Tube

3. Suction Hose/Tube 8. Discharge Tube Retaining Nut 13. Retaining Nut

4. Liquid Tube 9. Condenser 14. Compressor

5. Retaining Screw 10. Filter Drier Receiver (FDR)

A/C HOSE AND PIPE CONNECTIONS, AND RETAINERS – GEN III V8 ENGINE RHD

Figure 2B-100

Legend

1. Thermal Expansion Valve (TXV) 6. Suction Tube Retaining Clip 11. Filter Drier Receiver (FDR)

2. O-Ring 7. Discharge Tube 12. Retaining Clamp

3. Discharge Hose/Tube 8. Discharge Tube Retaining Clip 13. Suction Hose/Tube

4. Liquid Tube 9. Discharge Tube Retaining Nut 14. Retaining Nut

5. Retaining Screw 10. Condenser 15. Compressor

10. THERMAL EXPANSION VALVE (TXV)

LT Section – 08-200

REMOVE

1. Recover the refrigerant from the A/C system, refer to Section 2C, 2.1 SYSTEM CHARGING AND

EVACUATION.

2. Remove the washer f ac ed sc r ew (1) retaining the

tube plate (2) to the Thermal Expansion

Valve (TXV) (3).

3. Remove the plate/suction tube (4) and the liquid

tube (5).

4. Remove and discard the liquid and suction line

O-rings (6).

5. Unscrew the two cap screws (7) and remove the

TXV.

6. Remove and discard the evaporator tube

O-rings (8).

REINSTALL

NOTE: The total quantity of lubricating oil in the air

conditioning system must be maintained. If

lubricating oil loss has occurred during TXV

replacement, oil must be added to the system to

compensate.

1. Lubricate and fit two new O-rings to the

evaporator tubes.

2. Install the TXV with the diaphragm (9) facing

upwards, onto the evaporator tubes (10).

3. Secure the TXV to the evaporator tube plate

using the two cap screws.

TXV TO EVAPORATOR TUBES

SECURING SCREWS

TORQUE SPECIFICATION 4.0 – 4.5 Nm

Figure 2B-101

4. Fit two new lubricated O-rings to the suction tube and liquid tube.

5. Install the liquid and suction tubes and retaining plate onto the TXV.

6. Secure using original washer faced screw.

LIQUID AND SUCTION TUBE

RETAINING PLATE TO TXV SCREW

TORQUE SPECIFICATION 7.5 – 12.5 Nm

7. Evacuate and charge the A/C system with 775 – 825 g of R134a refrigerant, refer to

Section 2C, 2.1 SYSTEM CHARGING AND EVACUATION.

11. A/ C PRESSURE TRANSDUCER

LT Section – 08-200

REMOVE AND REINSTALL

To remove and install the A/C pressure transducer, refer to the following:

• For V6 engines: Section 6C1-3, 6.4 A/C REFRIGERANT SENSOR.

• For V6 Supercharged engines: Section 6C2-3, 6.6 A/C REFRIGERANT SENSOR

• For GEN III V8 engines: Section 6C3-3, 5.3 A/C REFRIGERANT SENSOR

Figure 2B-102 shows the location of the A/C

pressur e transducer (1) f or V6 and V6 Superchar ged

engines.

Figure 2B-102

Figure 2B-103 shows the location of the A/C

pressure transducer (1) for GEN III V8 engines.

Figure 2B-103

12. CONDENSER

12.1 V6 AND V6 SUPERCHARGED ENGINE

LT Section – 08-200

REMOVE

1. Recover the refrigerant from the A/C system, refer to Section 2C, 2.1 SYSTEM CHARGING AND

EVACUATION.

2. Remove the cold air intake duct and radiator

upper shroud retainers (1 and 2). Remove the

cold air intake duct (2), then disengage the

shroud locating tabs (5) by pulling the

shroud (4) towards front of vehicle, prior to

removal.

Figure 2B-104

3. On models with removable grille, remove the

three screws (1) securing the radiator grille

assembly (2) and raise that grille so that

locating tabs (3) disengage from the bumper

fascia and remove.

NOTE: To access air conditioning components in

front of the condenser on V2 Coupe models, it will

be necessary to raise the vehicle and remove the

under vehicle air baffles. Refer to

Section 0A, GENERAL INFORMATION for the

location of jacking and support points. Refer to

Section 6B-3, 2.13 AIR BAFFLES.

Figure 2B-105

4. If fitted, release each of the automatic

transm ission cooling pipes (1) from the integral

clips (2) on the fan shroud.

Figure 2B-106

5. Depress tang on main wiring harness to cooling

fan motor wiring harness connector (1) and

separate the connector.

Figure 2B-107

6. Release the discharge tube retaining clip (1).

7. Remove the nut (2) retaining the discharge

hose pad fitting (3) to the condenser (4).

8. Cap all open tubes/hoses to avoid moisture

from entering the system.

9. Discard the O-ring (5).

Figure 2B-108

10. Remove the liquid tube union (1) from the

FDR (2) and discard the O-ring (3).

Figure 2B-109

11. On OCC (Auto A/C) equipped models

disconnect the harness connector (1) from the

ambient temperature sensor (2). Do not

attempt to remove the bracket (3) from the

condenser (4).

Figure 2B-110

12. Using a screwdriver, compress and lever out

radiator retaining clips (1) from radiator upper

mounting brackets.

IMPORTANT: Do not lift the radiator assembly by

lifting on the fan rings as this will bend the fan

motor shaft and create an unnecessary vibration.

13. Lift radiator assembly upwards out of lower

insulators. Slant the upper section of the

assembly behind the radiator support sheet

metal work and allow it to remain there.

Figure 2B-111

14. Release one of the clips securing the

condenser to the radiator Do this by pressing

down as indicated by the arrow, on the locking

retainer (1) with the fingers of one hand, while

lifting the condenser assembly (2) with the

other hand. Repeat for the other side.

Figure 2B-112

15. Lift the condenser assembly (1) upwards

suff ic iently to clear the mounts moulded to f r ont

of the radiator (2). Rem ove the condenser from

engine bay with the FDR attached.

NOTE: If the FDR is to be removed from the

condenser mark the mounting position of the FDR

in relation to the mounting bracket for correct

positioning when installing, and note the IN mar king

on the filter head for the correct flow direction. For

FDR installation information, refer to 13. FILTER

DRIER RECEIVER in this Section.

Figure 2B-113

REINSTALL

IMPORTANT: 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.

Installation of the condenser is the reverse of removal procedures, noting the following points:

1. Before installing radiator, inspect cor e to ensure that there is no for eign matter in cor e fins. Clean out between

core fins with compressed air, blowing from rear to front.

2. Ensure that radiator lower mounting insulators are correctly located in the radiator support panel.

3. Ensure that upper insulators are installed on each of the upper mounting pins and radiator retainers are

correctly installed on each side of the radiator by checking that the clips engage on both sides of the channel

support bracket.

4. If removed ins tall the FDR, ensuring that the union thread with the word IN is connected to the c ondenser side

of the FDR. Tighten the FDR unions and the FDR mounting bracket screw.

5. Ins tall the liquid tube and the dis charge hos e using new lubricated O -rings to the c ondenser. T orque the unions

to specification.

FDR TUBE UNION

TORQUE SPECIFICATION 7.5 – 12.5 Nm

6. Evacuate and charge the A/C system with 775 – 825 g of R134a refrigerant, refer to

Section 2C, 2.1 SYSTEM CHARGING AND EVACUATION.

7. Ensure that fan and shroud assembly to radiator attaching clips are all fully engaged and that the two locking

tangs on the upper clips are securing the shroud correctly.

8. Check cooling fan operation, refer to Section 6C1 POWERTRAIN MANAGEMENT – V6 ENGINE.

12.2 GEN III V8 ENGINE

LT Section – 08-200

REMOVE

1. Allow engine to cool to am bient temperature (less than 50° C) , slowly loos en the screw-on pressur e cap at the

coolant surge tank to relieve any residual coolant pressure, and then remove the cap.

CAUTION: Do not remo ve the screw-o n pressure cap while t he engine coolant temperature is above 50°

°°

° C,

as personal injury will most likely occur.

NOTE: Disconnection of the battery affects certain vehicle electronic systems. Refer to

Section 00, 5. BATTERY DISCONNECTION PROCEDURES before disconnecting the battery.

2. Disconnect the battery ground lead.

3. Remove engine dress cover decorative

nuts (1), then remove the cover (2).

4. Lift the locking lever on the Intake Air

Temperature (IAT) sensor wiring harness

connector (3), then remove the connector.

5. Lift the locking lever on the Mass Air Flow

(MAF) sensor and remove the connector.

6. Loosen the two intake duct clamps, one at the

throttle body and the other at the MAF to air

cleaner connection. Remove the duct (4) and

MAF as an assembly and carefully set to one

side.

7. Drain engine coolant into a suitable, clean

container. Refer to Section 6B-3, 2.3

DRAINING AND FILLING COOLING

SYSTEM.

8. Release the vapour hose from the radiator fan

shroud clips, remove the clamp securing the

hose to the radiator, remove the hose and

route to one side.

9. Remove the clamp sec uring the vapour hos e to

surge tank at the radiator end. Remove the

hose and route to one side.

Figure 2B-114

10. Remove the upper shroud (1) by removing the

4 radiator upper shroud retainers (2). Do not

rem ove the screw sec tions com pletely fr om the

retainers. Lift the upper shroud on the

right-hand side first, to allow release of the

locating tab on the left-hand side end.

11. Recover the refrigerant from the A/C system,

refer to Section 2C, 2.1 SYSTEM CHARGING

AND EVACUATION.

Figure 2B-115

12. Remove the upper radiator hose clamps, then

remove the hose (1) and set to one side.

CAUTION: Wear eye protection when working

with spring type hose clamps.

Figure 2B-116

13. On models with removable grille, remove the

three screws (1) securing the radiator grille

assembly (2) and raise that grille so that

locating tabs (3) disengage from the bumper

fascia and remove.

NOTE: To access air conditioning components in

front of the condenser on V2 Coupe models, it will

be necessary to raise the vehicle and remove the

under vehicle air baffles. Refer to

Section 0A, GENERAL INFORMATION for the

location of jacking and support points. Refer to

Section 6B-3, 2.13 AIR BAFFLES.

Figure 2B-117

14. Press the retaining tang on wiring harness to

cooling fan m otor wiring harness connector (1),

then separate the connector halves.

Figure 2B-118

15. While holding the shroud locking tang in the

release position, lift the shroud and fan

assembly upwards. Repeat for the second side.

NOTE: While the automatic transmission fluid

cooling pipe is shown removed, this is not a

mandatory requirement for shroud removal. Pipe

has been shown rem oved to m ore clearly show the

shroud release method.

Figure 2B-119

IMPORTANT: When rem oving, transpor ting or installing the f an ass em bly, do not grasp the assem bly by the fan

rings (1) as this may bend the fan motor shafts and cause fan vibrations.

Figure 2B-120

When handling the fan assembly, always hold the assembly at the fan shroud (1) or fan motor mounting

struts (2).

Figure 2B-121

16. Lif t the shroud and f an assembly clear from the

engine bay, grasping the motor mounting

brackets.

Figure 2B-122

17. Release the discharge tube retaining clip (1).

18. Remove the nut (2) retaining the discharge

hose pad fitting (3) to the condenser (4).

19. Cap all open tubes/hoses to avoid moisture

from entering the system.

20. Discard the O-ring (5).

Figure 2B-123

21. Remove the liquid tube union (1) from the

FDR (2) and discard the O-ring (3).

Figure 2B-124

22. On OCC (Auto A/C) equipped models

disconnect the harness connector (1) from the

ambient temperature sensor (2).

NOTE: Do not attempt to remove the bracket (3)

from the condenser (4). If the ambient temperature

sensor is to be removed from the condenser, refer

to Section 2E, 2.6 AMBIENT TEMPERATURE

SENSOR.

Figure 2B-125

23. Using a screwdriver, compress and lever out

radiator retaining clips (1) from radiator upper

mounting brackets.

IMPORTANT: Do not lift the radiator assembly by

lifting on the fan rings as this will bend the fan

motor shaft and create an unnecessary vibration.

24. Lift radiator assembly upwards out of lower

insulators. Slant the upper section of the

assembly behind the radiator support sheet

metal work and allow it to remain there.

Figure 2B-126

25. Release one of the clips securing the

condenser to the radiator Do this by pressing

down as indicated by the arrow, on the locking

retainer (1) with the fingers of one hand, while

lifting the condenser assembly (2) with the

other hand. Repeat for the other side.

Figure 2B-127

26. Lift the condenser assembly (1) upwards

suff ic iently to clear the mounts moulded to f r ont

of the radiator (2).

27. Remove the condenser from engine bay with

the FDR attached.

NOTE: If the FDR is to be removed from

the condenser mark the mounting position of the

FDR in relation to the mounting bracket for correct

positioning when installing, and note the IN mar king

on the filter head for the correct flow direction.

For FDR installation information, refer to

13. FILTER DRIER RECEIVER in this Section.

Figure 2B-128

REINSTALL

IMPORTANT: 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.

Installation of the condenser is the reverse of removal procedures, noting the following points:

1. Bef ore installing radiator , inspect c ore to ensur e that there is no for eign matter in cor e fins. Clean out between

core fins with compressed air, blowing from rear to front.

2. Ensure that radiator lower mounting insulators are correctly located in the radiator support panel.

3. Ensure that upper insulators are installed on each of the upper mounting pins and radiator retainers are

correctly installed on each side of the radiator by checking that the clips engage on both sides of the channel

support bracket.

4. If removed, ins tall the FDR, ensuring that the union thread with the word IN is directed to the condenser side of

the FDR. Install the FDR mounting bracket screw. Torque the screw to specification.

FDR MOUNTING BRACKET SCREW

TORQUE SPECIFICATION 7.5 – 12.5 Nm

5. Ins tall the liquid tube and the dis charge hos e using new lubricated O -rings to the c ondenser. T orque the unions

to specification.

FDR TUBE UNION

TORQUE SPECIFICATION 7.5 – 12.5 Nm

6. Evacuate and charge the A/C system with 775 – 825 g of R134a refrigerant, refer to

Section 2C, 2.1 SYSTEM CHARGING AND EVACUATION.

7. Ensure that fan and shroud assembly to radiator attaching clips are all fully engaged and that the two locking

tangs on the upper clips are securing the shroud correctly.

8. Fill the cooling system and test concentration levels. Refer to Section 6B-3, 2.3 DRAINING AND FILLING

COOLING SYSTEM and Testing Coolant Concentration, in Section 6B-3, 2.2 COOLANT MAINTENANCE.

9. Check cooling fan operation, refer to Section 6C3, POWERTRAIN MANAGEMENT – GEN III V8 ENGINE.

13. FILTER DRI ER RECEIVER

LT Section – 08-200

REMOVE

1. Recover the refrigerant from the A/C system, refer to Section 2C, 2.1 SYSTEM CHARGING AND

EVACUATION.

2. On models with removable grille, remove the

three screws (1) securing the radiator grille

assembly (2) and raise that grille so that

locating tabs (3) disengage from the bumper

fascia and remove.

NOTE: To access air conditioning components in

front of the condenser on V2 Coupe models, it will

be necessary to raise the vehicle and remove the

under vehicle air baffles. Refer to

Section 0A, GENERAL INFORMATION for the

location of jacking and support points. Refer to

Section 6B-3, 2.13 AIR BAFFLES.

Figure 2B-129

3. Remove the liquid tube union (1) from the

FDR (2) and discard the O-ring (3).

4. Remove the discharge pipe union (4) from the

FDR and caref ully flex the disc harge pipe (5) to

the left clear of the FDR. Discard the O-ring (6).

Figure 2B-130

5. Remove the screw (1) on the FDR mounting

bracket (2).

6. Cap all open tubes/hoses to avoid moisture

from entering the system.

7. Expand the bracket and remove the FDR (3) by

lifting it upwards clear of the bracket.

Figure 2B-131

8. On models with removable grille, remove the

FDR (1) through the grille aperture (2). On

V2 Coupe models, remove the FDR (3) from

below the bumper bar fascia.

Figure 2B-132

REINSTALL

IMPORTANT: 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.

Installation of the filter drier receiver is the reverse of removal procedures, noting the following points:

1. Install the FDR (1), ensuring that the condenser

union is connected to the thread (2) adjacent to

the word IN (3) stamped on the head of the

FDR.

Figure 2B-133

2. Install the liquid tube and the discharge hose using new lubricated O-rings to the condenser. Torque the

mounting screw and unions to specification.

FDR MOUNTING BRACKET SCREW

TORQUE SPECIFICATION 7.5 – 12.5 Nm

FDR TUBE UNION

TORQUE SPECIFICATION 7.5 – 12.5 Nm

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

Section 2C, 2.1 SYSTEM CHARGING AND EVACUATION.

14. A/C DRIVE BELT AND PULLEYS

14.1 A/C DRIVE BELT – V6 ENGINE

LT Section – 01-003

REMOVE

1. Disconnect the battery ground lead. Refer to Section 00, 5. BATTERY DISCONNECTION PROCEDURES.

2. Remove four nuts (1) securing engine dress

cover (2).

Figure 2B-134

3. Using a 15 mm socket on the drive belt

tensioner pulley pivot bolt, release the belt

tension by turning the tensioner in an anti-

clockwise direction.

4. Starting at the water pump pulley remove the

drive belt.

Figure 2B-135

REINSTALL

1. Clean the engine accessory and air conditioning drive belt running surfaces.

2. Using Figure 2B-136 as a guide, fit the drive belt starting at the water pump pulley.

3. Inspect the installation to ensure that the belt is correctly aligned on all pulleys.

4. Start the engine to ensure correct operation.

5. Install the engine dress cover.

Figure 2B-136

Legend

1. Power Steering Pump 5. Idler

2. Generator 6. Idler

3. Tensioner 7. Air Conditioner Compressor

4. Water Pump 8. Crankshaft Pulley

14.2 A/C DRIVE BELT – V6 SUPERCHARGED ENGINE

LT Section – 01-003

REMOVE

1. Disconnect the battery ground lead. Refer to Section 00, 5. BATTERY DISCONNECTION PROCEDURES.

2. Remove the four nuts securing engine dress cover.

3. Using a 15 m m sock et on the supercharger drive belt tensioner, release the supercharger drive belt tension

by turning the tensioner in an anti-clockwise direction.

4. Remove the supercharger drive belt starting at the double idler pulley.

5. Using a 15 mm socket on the main drive belt tensioner pulley retaining bolt, release the belt tension by

turning the tensioner in an anti-clockwise direction.

6. Starting at the water pump pulley remove the drive belt.

REINSTALL

1. Clean the engine accessory and air conditioning drive belt running surfaces.

2. Using Figure 2B-137 as a guide, fit the drive belt starting at the water pump pulley.

3. Inspect the installation to ensure that the belt is correctly aligned on all pulleys.

4. Install the supercharger drive belt starting at the double idler pulley.

5. Inspect the installation to ensure that the belt is correctly aligned on all pulleys.

6. Start the engine to ensure correct operation.

7. Install the engine dress cover.

Figure 2B-137

Legend

1. Accessory Drive Belt (Inner) 5. Accessory Drive Belt (Outer) 9 Crankshaft Pulley

2. Generator 6. Tensioner Pulley 10. Water Pump

3. Tensioner Pulley 7. Idler Pulleys 11. Power Steering Pump

4. Supercharger Pulley 8. Air Conditioning Compressor

14.3 A/C DRIVE BELT – GEN III V8 ENGINE

LT Section – 01-003

REMOVE

1. Disconnect the battery ground lead. Refer to Section 00, 5. BATTERY DISCONNECTION PROCEDURES.

2. Remove the four engine dress cover decorative

nuts (1), then remove the dress cover (2) from

the engine.

3. Remove the air intake sensor wiring harness

connector (3), then loosen both hose clamps

securing the intake hose (4) to the MAF sensor

and the throttle body. Remove the hose from the

engine.

Figure 2B-138

4. Using a 15 mm socket attached to the centre

bolt (1) of the engine accessory drive belt

tensioner (2) , rotate the tensioner in a clockwise

direction, to reduce belt tension.

5. Remove the engine drive belt (3) from the

pulleys, taking note of the belt routing.

Figure 2B-139

6. Using a 15 mm socket attached to the centre

bolt (1) of the air conditioning drive belt

tensioner (2) , rotate the tensioner in a clockwise

direction to relieve belt tension.

7. Remove the air conditioning drive belt (3) from

the pulleys.

8. Inspect belts for wear or damage and replace if

necessary.

Figure 2B-140

REINSTALL

1. Clean the engine accessory and air conditioning drive belt running surfaces.

2. Using a 15 mm socket attached to the centre bolt of the tensioner, rotate the air conditioning drive belt

tensioner in a clockwise direction, and install the drive belt over the pulleys, routing the belt correctly as

shown in Figure 2B-141.

3. Inspect the installation to ensure that the belt is correctly aligned on all pulleys.

4. Using a 15 mm socket attached to the centre bolt of the tensioner, rotate the engine accessory drive belt

tensioner in a clockwise direction, install the engine accessory drive belt over the pulleys, routing the belt

correctly, as shown in Figure 2B-141.

5. Inspect the installation to ensure that the belt is correctly aligned on all pulleys.

6. Start the engine to ensure correct operation.

7. Install the air intake sensor wiring harness connector and the intake hose.

8. Install the engine dress cover.

Figure 2B-141

Legend

1. Tensioner 7. Crankshaft

2. Water Pump 8. Drive Belt (Air Conditioning Compressor)

3. Drive Belt 9. Tensioner (Air Conditioning Compressor Drive Belt)

4. Power Steering Pump 10. Air Conditioner Compressor

5. Generator 11. Idler (Air Conditioning Compressor Drive Belt)

6. Idler

14.4 A/C DRIVE BELT IDLER PULLEY ASSEMBLY –

V6 AND V6 SUPERCHARGED ENGINE

LT Section – 01-020

REMOVE

1. Remove the dr ive belt. F or V6 engines , refer to 14.1 A/C DRIVE BELT – V6 ENGINE in this Sec tion. F or V6

Supercharged engines, refer to 14.2 A/C DRIVE BELT – V6 SUPERCHARGED ENGINE in this Section.

2. Remove the idler pulley retaining bolt (1),

washer (2) and idler pulley (3).

3. Remove the three mounting bracket nuts (4).

4. Remove the idler pulley mounting brack et (5), the

together with the harness clip (6) from the

engine.

REINSTALL

1. Fit the idler pulley mounting bracket to the

engine.

2. Install the harness clip as shown.

3. Install the three nuts.

IDLER PULLEY MOUNTING

BRACKET RETAINING NUTS

TORQUE SPECIFICATION 20.0 – 30.0 Nm

4. Replace the pulley, washer and bolt onto the idler

pulley bracket.

5. Tighten the idler pulley retaining bolt.

IDLER PULLEY RETAINING BOLT

TORQUE SPECIFICATION 45.0 – 50.0 Nm

6. Install the drive belt. For V6 engines, refer to

14.1 A/C DRIVE BELT – V6 ENGINE in this

Section. For V6 Supercharged engines, refer to

14.2 A/C DRIVE BELT – V6 SUPERCHARGED

ENGINE in this Section.

Figure 2B-142

14.5 A/C DRIVE BELT IDLER PULLEY ASSEMBLY – GEN III V8 ENGINE

LT Section – 01-020

REMOVE

1. Remove the air conditioning com pr essor drive belt. Refe r to 14.3 A/C DRIVE BELT – GEN III V8 ENGINE in

this Section.

2. Using a 15 mm socket attached to the centre

bolt (1) of the air conditioning drive belt

tensioner (2), rotate the tensioner in the

direction shown to relieve the tension on the

A/C belt (3).

3. Remove the air conditioning drive belt from all

pulleys except the crankshaft pulley (4). Allow

the A/C belt to remain on the crankshaft pulley.

Figure 2B-143

4. Using a commercially available, Torx bit T50,

remove the bolt (1) securing the air

conditioning compressor drive belt idler

pulley (2) to its mounting boss (3) on the water

pump housing, then remove the pulley

assembly.

REINSTALL

1 Install the idler pulley to its mounting boss.

2. Install the idler pulley retaining bolt and tighten

to the correct torque specification.

AIR CONDITIONING COMPRESSOR

DRIVE BELT IDLER PULLEY BOLT

TORQUE SPECIFICATION 50.0 Nm

3. Install the air conditioning compressor drive

belt. Refer to 14.3 A/C DRIVE BELT – GEN III

V8 ENGINE in this Section.

Figure 2B-144

14.6 A/C DRIVE BELT TENSIONER PULLEY ASSEMBLY – GEN III V8 ENGINE

LT Section – 01-020

REMOVE

1. Remove the air conditioning com pr essor drive belt. Refe r to 14.3 A/C DRIVE BELT – GEN III V8 ENGINE in

this Section.

2. Using a 15 mm socket attached to the centre

bolt (1) of the air conditioning drive belt

tensioner (2), rotate the tensioner in the

direction shown to relieve the tension on the

A/C belt (3).

3. Remove the air conditioning drive belt from all

pulleys except the crankshaft pulley (4). Allow

the A/C belt to remain on the crankshaft pulley.

Figure 2B-145

4. Remove the bolt (1) securing the air

conditioning compressor drive belt tensioner (2)

and remove the assembly.

REINSTALL

1 Install the tensioner assembly and the

mounting bolt.

2. Tighten the tensioner mounting bolt to the

correct torque specification.

AIR CONDITIONING DRIVE BELT

TENSIONER BOLT

TORQUE SPECIFICATION 25.0 Nm

3. Install the air conditioning compressor drive

belt. Refer to 14.3 A/C DRIVE BELT – GEN III

V8 ENGINE in this Section.

Figure 2B-146

15. A/C COMPRESSOR

15.1 V6 AND V6 SUP ERCHARGHED ENGINE

LT Section – 08-200

REMOVE

1. Disconnect the battery ground lead. Refer to Section 00, 5. BATTERY DISCONNECTION PROCEDURES.

2. Discharge the A/C system. Refer to Section 2C, 2. DISCHARGING SYSTEM – REFRIGERANT

RECOVERY.

3. Remove the nut (1) securing the

suction/discharge hose pad (2) to the

compressor (3).

4. Remove and discard the port sealing O-

rings (4).

5. Cap or plug the disconnected hoses and ports

immediately to prevent absorption of moisture

from the atmosphere.

6. Remove the A/C drive belt.

7. Disconnect the compressor clutch electrical

connector.

8. Raise the vehic le and place the vehicle on jac k

stands. Refer to Section 0A, GENERAL

INFORMATION for the location of jacking and

support points.

Figure 2B-147

9. Remove the bolt (1) and two nuts (2) retaining

the compressor (3) to the engine block (4).

Figure 2B-148

REINSTALL

IMPORTANT: 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.

1. Install the compressor to the engine using the original two nuts and bolt. Torque to specifications.

COMPRESSOR RETAINING

BOLT AND NUT

TORQUE SPECIFICATION 40.0 – 60.0 Nm

2. Install the A/C drive belt. Inst all the drive belt. For V6 engines, refer to 14.1 A/C DRIVE BELT – V6 ENGINE in

this Section. For V6 Super char ged engines, refer to 14.2 A/C DRIVE BELT – V6 SUPERCHARGED ENGINE in

this Section.

3. Remove the compressor port protection caps.

4. Install two new port sealing washers.

5. Secure the suction/discharge hose assembly to the compressor with original nut.

SUCTION/DISCHARGE HOSE

PAD RETAINING NUT

TORQUE SPECIFICATION 25.0 – 35.0 Nm

6. Evacuate and charge the A/C system with 775 – 825 g of R134a refrigerant, refer to

Section 2C, 2. DISCHARGING SYSTEM – REFRIGERANT RECOVERY.

IMPORTANT: If replacing with a new compressor, refer to Section 2C, HVAC CLIMATE CONTROL (MANUAL

A/C) – SERVICING & DIAGNOSIS for lubrication requirements.

15.2 GEN III V8 ENGINE

LT Section – 08-200

REMOVE

1. Disconnect the battery ground lead. Refer to Section 00, 5. BATTERY DISCONNECTION PROCEDURES.

2. Drain coolant and rem ove the heater hoses and lower radiator coolant hose from the cylinder block, ref er to

Section 6B3, 2.3 DRAINING AND FILLING COOLING SYSTEM.

3. Discharge the A/C system. Refer to Section 2C, 2. DISCHARGING SYSTEM – REFRIGERANT

RECOVERY.

4. Using a 15 mm socket attached to the centre

bolt (1) of the air conditioning drive belt

tensioner (2), rotate the tensioner in the

direction shown to relieve the tension on the

A/C belt (3).

5. Remove the air conditioning drive belt from all

pulleys except the crankshaft pulley (4). Allow

the A/C belt to remain on the crankshaft pulley.

Figure 2B-149

6. Loosen and remove the nut (1) retaining the

suction (2) and discharge (3) hoses to the

compressor (4). Remove the hoses (2 and 3)

from the compressor.

7. Discard O-rings (5).

8. Cap or plug the ports immediately to prevent

entry of moisture from the atmosphere.

9. Disconnect the compressor clutch electrical

connector.

NOTE: Figure 2B-150 shows the hose

configuration applicable to RHD models with the

suction and discharge hoses connected to a

common pad. On LHD models the pad is a two

piece design, i.e. the suction and discharge hoses

are separate. Refer to the compressor installation

view in Figure 2B-99.

Figure 2B-150

10. Remove the four bolts (1) retaining the

compressor (2) to the mounting bracket (3).

NOTE: Figure 2B-151 shows several components

removed for clarity only (i.e. heater hoses and

coolant hoses ). To remove the compres s or , it is not

necessary to remove these components.

11. Remove the compressor.

12. If necessary, remove the four bolts retaining

the compressor mounting bracket to the

cylinder block and remove the mounting

bracket.

Figure 2B-151

REINSTALL

IMPORTANT: 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.

1. If removed, reinstall the compressor mounting bracket and tighten the four retaining bolts to the correct torque

specification.

COMPRESSOR MOUNTING BRACKET

RETAINING BOLT

TORQUE SPECIFICATION 40.0 – 60.0 Nm

IMPORTANT: If replacing with a new compressor refer to Section 2C, AIR CONDITIONING – SERVICING AND

DIAGNOSIS for lubrication requirements/specifications.

2. Fit the com pr es sor to the c ompres sor mounting brac k et, ins tall the f our r etaining bolts and tighten to the c or rec t

torque specification.

COMPRESSOR RETAINING BOLT

TORQUE SPECIFICATION 40.0 – 60.0 Nm

3. Install the air conditioning com pressor drive belt. Refer to 14.3 A/C DRIVE BELT – GEN III V8 ENGINE in this

Section.

4. Remove caps from compressor ports and install new sealing washers.

5. Using new O-rings lubric ated with PAG re f riger ant oil ins tall the air c onditioning s uc tion and dis char ge hos e pad

fitting onto the compressor.

CAUTION: Do not allow PAG refrigerant oil to contact bare skin or vehicle paint work. If contact occurs to either,

wash PAG refrigerant oil off immediately.

6. Install the suction and discharge hose pad retaining nut and tighten to the correct torque specification.

SUCTION AND DISCHARGE HOSE

PAD RETAINING NUT

TORQUE SPECIFICATION 25.0 – 35.0 Nm

7. Install the compressor clutch electrical connector.

8. Install the heater and lower radiator coolant hoses, fill coolant system with correct coolant and pressure test

cooling system, refer to Section 6B3, ENGINE COOLING – GEN III V8 ENGINE.

9. Recharge air conditioner system, refer to Section 2C, AIR CONDITIONING – SERVICING & DIAGNOSIS.

16. M INOR A/C COMPRESSOR REPAI R PROCEDURES

Illustrations used in the following procedures show the compressor removed from the vehicle for easier viewing.

When servicing the compressor, remove only the parts that preliminary diagnosis shows are in need of service.

Removal and installation of external parts of the compressor and disassembly/assembly of internal parts must be

performed on a clean workbench. The work area, tools and parts must be clean at all times.

NOTE: The only components that can be serviced are:

• Control Valve

• Port Sealing Washers

• Clutch Drive Plate and Hub Assembly

IMPORTANT: 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.

16.1 A/C COMPRESSOR CONTROL VALVE

LT Section – 08-200

REMOVE

1. Discharge the A/C system. Refer to Section 2C, 2. DISCHARGING SYSTEM – REFRIGERANT

RECOVERY.

2. Rais e fr ont of vehic le and support on saf ety stands. Refer to Section 0A, GENERAL INFORMAT ION for the

location of jacking and support points.

3. On GEN III V8 models remove the four bolts securing the under-tray to the crossmember and remove tray

from vehicle. Refer to Section 6B-3, 2.12 OIL PAN UNDER-TRAY.

4. From beneath the vehicle remove the lower air baffle / shute as required. Refer to

Section 6B-3, 2.13 AIR BAFFLES.

5. F rom beneath the vehicle r em ove the circ lip (1)

securing the control valve (2) to the

compressor (3).

6. Using a pair of s uitable cir c lip pliers r emove the

control valve from the compressor by pulling

downwards. Quickly insert the replacement

control valve (this will avoid any minor oil loss).

REINSTALL

1. Lubricate the control valve O-rings and

carefully push the control valve into the

compressor.

NOTE: V6 and GEN III V8 control valves have

different control settings. Ensure that the correct

control valve is installed.

2. Inspect the control valve retaining circlip. If it is

undamaged, reuse it to secure the control

valve. If it is not serviceable, replace it with a

new circlip. Ensure that the circlip is fully

seated in the circlip groove.

3. If A/C lubricating oil has been lost during

control valve removal procedure, add new

lubricating oil as required, through the suction

port of the A/C compressor. Refer to

Section 2C, 2.4 LUBRICATING OIL

COMPENSATION.

4. Install the lower air baffle / shute and under-tray

where fitted.

5. Evacuate and charge the A/C system with

775 – 825 g of R134a refrigerant, Refer to

Section 2C, 2. DISCHARGING SYSTEM –

REFRIGERANT RECOVERY.

Figure 2B-152

16.2 A/C CLUTCH DRIVE PLATE AND HUB ASSEMBLY

LT Section – 08-200

REMOVE

1. Discharge the A/C system. Refer to Section 2C, 2. DISCHARGING SYSTEM – REFRIGERANT

RECOVERY.

2. Remove the compressor from the vehicle. Refer to 15.1 V6 AND V6 SUPERCHARGED ENGINE or

15.2 GEN III V8 ENGINE as applicable in this Section.

3. Place the compressor (1) on a clean work

bench (2).

4. Use the clutch hub holding tool 09-74770 to

keep the hub assembly (3) from turning and

remove the compressor shaft nut using suitable

hand tools (4).

Figure 2B-153

5. Assemble the nut (1) and centre screw (2) of

the A/C clutch hub and drive plate rem over tool

09-74768 as shown in Figure 2B-154. Install

the centre screw no more than 2 cm into the

nut.

Figure 2B-154

6. Install the nut (1) of the tool 09-74768 fully into

the clutch hub (2) of the compressor (3).

7. Hold the nut of tool 09-74768 with a suitable

hand tool (4) and turn the centre screw (5) of

the tool using a s ec ond suitable hand tool (6) to

remove the clutch drive plate and hub

assembly as shown in Figure 2B-155.

8. Remove the shaft key.

Figure 2B-155

REINSTALL

1. Assemble the bearing (1), nut (2) and centre

screw (3) of the A/C clutch hub and drive plate

installer tool 09-74767 as shown in Figure 2B-

156. Install the nut up to the hexagonal section

of the centre screw.

Figure 2B-156

2. Ensure that the clutch contact surfaces of the

clutch pulley (1) and clutch plate (2) are clean

before installing the clutch plate and hub

assembly to the A/C compressor. If necessary,

remove any oil or grease from the clutch

surfaces with a clean, lint free cloth dampened

with methylated spirits and allow the surfaces

to dry.

Figure 2B-157

3. Place a small amount of assembly grease on

the key (1) to locate it in the keyway of the

compressor shaft (2). Install the key level with

the top of the tapered section (3) of the

compressor shaft as shown in Figure 2B-158.

Align the clutch hub keyway with the key and

install the clutch plate and hub assembly onto

the compressor shaft. Push as far as possible

by hand, the clutch plate and hub assembly

onto the compressor shaft ensuring that the

key has remained in the position as shown in

Figure 2B-158.

Figure 2B-158

4. Install the c entre screw (1) f ully onto the end of

the com pressor s haft and turn the nut (2) down

the centre screw until the bearing (3) of installer

tool 09-74767 contacts the A/C clutch hub (4).

5. Hold the centre screw with a suitable hand

tool (5) and continue to tur n the nut down using

a second a suitable hand tool (6) to press the

A/C clutch hub and drive plate onto the

compressor shaft.

IMPORTANT: Excessive force is not required to

install the A/C clutch hub and drive plate onto the

compressor shaft. If excessive force is required,

remove the special tool 09-74767 and inspect

com ponents. If the k ey has fallen down the keyway

causing it to protrude ex cessively f rom the k eyway,

continuing the installation procedure will damage

components.

6. Turn the nut several turns and remove the

installer tool 09-74767 from the compressor.

7. Check that the shaft key is located correctly in

the keyway before installing the A/C clutch

plate and hub assembly to its final position.

8. Install tool 09-74767 onto the compressor

again and press the A/C clutch hub and drive

plate fully onto the compressor shaft.

Figure 2B-159

9. Using a non-magnetic feeler strip (1) measure

the air gap between the frictional surfaces of

the clutch plate (2) and the clutch pulley (3).

Figure 2B-160

NOTE: The air gap between the frictional surfaces

of the clutch plate (1) and the clutch pulley (2)

should be 0.38 – 1.0 mm.

10. Remove tool 09-74767 and check for proper

positioning of the shaft key. The key should be

level with, or slightly above the clutch hub.

11. Install the shaft nut, and holding the A/C clutch

plate and hub assembly with the clutch hub

holding tool 09-74770, torque the nut to

specification.

CLUTCH DRIVE PLATE AND HUB

ASSEMBLY RETAINING NUT

TORQUE SPECIFICATION 11.0 – 22.0 Nm

12. Re-check the air gap and spin the pulley by

hand, checking that the pulley is not touching

the drive plate.

13. Install the compressor to the vehicle. Refer to

15.1 V6 AND V6 SUPERCHARGED ENGINE

or 15.2 GEN III V8 ENGINE as applicable in

this Section.

14. Evacuate and charge the A/C system with

775 – 825 g of R134a refrigerant. Refer to

Section 2C, 2. DISCHARGING SYSTEM –

REFRIGERANT RECOVERY.

Figure 2B-161

16.3 A/C CLUTCH PULLEY AND BEARING ASSEMBLY

LT Section – 08-200

REMOVE

1. Remove the A/C clutch drive plate and hub assem bly. Refer to 16.2 A/C CLUT CH DRIVE PLATE AND HUB

ASSEMBLY in this Section.

2. Using suitable external c irc lip plier s (1) , remove

the circlip (2) the retaining the clutch pulley and

bearing assembly (3) to the compressor

housing (4).

Figure 2B-162

3. Install the puller pilot tool J-33023-A onto the

end of the shaft (1) of the compressor (2).

Figure 2B-163

4. Attach puller legs J-33025 to the puller bar

J-8433-1. Locate the centre screw (1) of the

puller bar in the countersink hole of the puller

pilot J-33023-A. Engage the puller leg tangs

under the clutch pulley (2) as shown in Figure

2B-164.

5. Turn the centre screw of the J-8433-1 puller

bar us ing a s uitable hand tool (3) to remove the

clutch pulley and bearing assembly from the

compressor (4).

Figure 2B-164

REINSTALL

1. Assemble the bearing (1), nut (2) and centre

screw (3) of the A/C clutch hub and drive plate

installer tool 09-74767 as shown in Figure 2B-

156. Install the nut up to the hexagonal of the

centre screw.

Figure 2B-165

2. Position the clutch pulley and bearing

assembly (1) on the compressor housing (2).

3. Position special tool J-33017 with the larger

diameter facing down, between the pulley

bearing (3) and the bearing (4) of the installer

tool 09-74767 as shown in Figure 2B-166.

Install the centre screw (5) of special tool 09-

74767 fully onto the end of the compressor

shaft. Rotate the nut (6) down the screw until

the assembly is hand tensioned.

Figure 2B-166

4. Hold the centre screw (1) with a suitable hand

tool (2) and turn the nut (3) with a second

suitable hand tool (4) to press the pulley and

bearing assembly (5) onto the compressor

housing (6).

5. Install the circlip retaining the clutch pulley and

bearing assembly to the compressor housing.

6. Install the clutch drive plate and hub assembly,

refer to 16.2 A/C CLUTCH DRIVE PLATE AND

HUB ASSEMBLY in this Section.

Figure 2B-167

NOTE: The air gap between the frictional surfaces

of the clutch plate (1) and the clutch pulley (2)

should be 0.38 – 1.0 m m . This clearance should be

checked using a non-magnetic feeler strip.

7. Remove tool 09-74767 and check for proper

positioning of the shaft key. The key should be

level with, or slightly above the clutch hub.

8. Install the shaft nut, and holding the A/C clutch

plate and hub assembly with the clutch hub

holding tool 09-74770, torque the nut to

specification.

CLUTCH DRIVE PLATE AND HUB

ASSEMBLY RETAINING NUT

TORQUE SPECIFICATION 11.0 – 22.0 Nm

9. Re-check the air gap and spin the pulley by

hand, checking that the pulley is not touching

the drive plate.

10. Install the compressor to the vehicle. Refer to

15.1 V6 AND V6 SUPERCHARGED ENGINE

or 15.2 GEN III V8 ENGINE as applicable in

this Section.

11. Evacuate and charge the A/C system with

775 – 825 g of R134a refrigerant, Refer to

Section 2C, 2. DISCHARGING SYSTEM –

REFRIGERANT RECOVERY.

Figure 2B-168

17. UNDER HOOD HEATER COMPONENTS

17.1 WATER VALVE

LT Section – 08-075

REMOVE

1. Drain engine coolant into a suitable, clean container. For GEN III V8 engines, refer to

Section 6B-3, 2.3 DRAINING AND FILLING COOLING SYSTEM.

2. Remove the vacuum hose (1) from the water valve actuator (2).

3. Remove the four hose clips (3) from the water valve (4) ports.

4. Remove the four heater hoses (5) from the water valve.

5. Remove the water valve assembly from the water valve bracket (6).

Figure 2B-169

REINSTALL

Installation of the water valve is the reverse of removal procedures, noting the following points:

1. Install the hoses to the correct ports of the water valve to maintain correct coolant flow. As applicable, refer

to the following Figures:

• For V6 left-hand drive models fitted with an oil cooler, refer to Figure 2B-170.

• For V6 left-hand drive models not fitted with an oil cooler, refer to Figure 2B-171.

• For V6 and V6 Supercharged right-hand drive models, refer to Figure 2B-172.

• For GEN III V8 left-hand drive models, refer to Figure 2B-173.

• For GEN III V8 right-hand drive models, refer to Figure 2B-174.

• For V6 right-hand drive models fitted with LPG, refer to Section 8A2, 3.23 COOLANT HOSES.

2. Fill the cooling system with the correct specification and quantity of coolant. Pressure test the cooling

system. As applicable refer to:

• Section 6B1, ENGINE COOLING – V6 ENGINE

• Section 6B2, ENGINE COOLING – V6 ENGINE SUPERCHARGED

• Section 6B3, ENGINE COOLING – GEN III V8 ENGINE

17.2 HEATER HOSES AND VACUUM LINES

LT Section – 08-075

REMOVE AND REINSTALL

The following five Figures provide under hood views of heater hose and HVAC vacuum line installations. Refer to

these Figures when removing and installing these components.

• For V6 left-hand drive models fitted with an oil cooler, refer to Figure 2B-170.

• For V6 left-hand drive models not fitted with an oil cooler, refer to Figure 2B-171.

• For V6 and V6 Supercharged right-hand drive models, refer to Figure 2B-172.

• For GEN III V8 left-hand drive models, refer to Figure 2B-173.

• For GEN III V8 right-hand drive models, refer to Figure 2B-174.

• For V6 right-hand drive models fitted with LPG, refer to Section 8A2, 3.23 COOLANT HOSES.

NOTE 1: Install all heater hoses to the ports indicated to maintain correct coolant flow.

NOTE 2: After the heater hoses are installed, fill the cooling system with the correct specification and quantity of

coolant. Pressure test the cooling system. As applicable refer to:

• Section 6B1, ENGINE COOLING – V6 ENGINE

• Section 6B2, ENGINE COOLING – V6 ENGINE SUPERCHARGED

• Section 6B3, ENGINE COOLING – GEN III V8 ENGINE

HEATER HOSES AND VACUUM LINES – V6 ENGINE LHD WITH OIL COOLER

Figure 2B-170

Legend

1. Water Valve 12. Vacuum Hose – To Vacuum Switch

2. Water Valve Actuator 13. Hose Clamps – Heater Core (2 places)

3. Heater Hose – To Cabin 14. Vacuum Hose – To Water Valve Actuator

4. Heater Hose – From Cabin 15. Brake Lines

5. Vacuum Hose (2 piece) – HVAC Supply 16. Hose Clamps – Water Valve (4 places)

6. Check Valve 17. Wheel House – RHS

7. Vacuum Hose – To Inlet Manifold 18. Mounting Clip – Water Valve

8. Oil Cooler 19. Hose Clamps – Engine (2 places)

9. Heater Hose – To Engine 20. Oil Filter

10. Heater Hose – To Oil Cooler 21. Hose Clamps – Oil Cooler (2 places)

11. Heater Hose – From Engine NOTE: Heater hoses and vacuum hose to be routed

behind brake lines as shown in View B.

HEATER HOSES AND VACUUM LINES – V6 ENGINE LHD WITHOUT OIL COOLER

Figure 2B-171

Legend

1. Water Valve 10. Vacuum Hose – To Vacuum Switch

2. Water Valve Actuator 11. Hose Clamps – Heater Core (2 places)

3. Heater Hose – To Cabin 12. Vacuum Hose – To Water Valve Actuator

4. Heater Hose – From Cabin 13. Brake Lines

5. Vacuum Hose (2 piece) – HVAC Supply 14. Hose Clamps – Water Valve (4 places)

6. Check Valve 15. Wheel House – RHS

7. Vacuum Hose – To Inlet Manifold 16. Mounting Clip – Water Valve

8. Heater Hose – To Engine 17. Hose Clamps – Engine (2 places)

9. Heater Hose – From Engine NOTE: Heater hoses and vacuum hose to be routed

behind brake lines as shown in View B.

HEATER HOSES AND VACUUM LINES – V6 AND V6 SUPERCHARGED ENGINE RHD

Figure 2B-172

Legend

1. Water Valve 11. Hose Clamps – Heater Core (2 places)

2. Water Valve Actuator 12. Vacuum Hose – To Water Valve Actuator

3. Heater Hose – To Cabin 13. Brake Booster

4. Heater Hose – From Cabin 14. Steering Shaft

5. Vacuum Hose (2 piece) – HVAC Supply 15. Brake Lines

6. Check Valve 16. Hose Clamps – Water Valve (4 places)

7. Vacuum Hose – To Inlet Manifold 17. Wheel House – RHS

8. Heater Hose – To Engine 18. Mounting Clip – Water Valve

9. Heater Hose – From Engine 19. Hose Clamps – Engine (2 places)

10. Vacuum Hose – To Vacuum Switch NOTE: Heater hoses and vacuum hose to be routed

behind brake lines as shown in View B.

HEATER HOSES AND VACUUM LINES – GEN III V8 ENGINE LHD

Figure 2B-173

Legend

1. Water Valve 12. Heater Hose – From Engine

2. Water Valve Actuator 13. Vacuum Hose – To Vacuum Switch

3. Heater Hose – To Cabin 14. Hose Clamps – Heater Core (2 places)

4. Heater Hose – From Cabin 15. Vacuum Hose – To Water Valve Actuator

5. Vacuum Hose (2 piece) – HVAC Supply 16. Brake Lines

6. Check Valve 17. Hose Clamps – Water Valve (4 places)

7. Vacuum Hose – To Inlet Manifold 18. Wheel House – RHS

8. Heater Hose – To Engine 19. Mounting Clip – Water Valve

9. Hose – To Coolant Surge Tank 20. Hose Clamps – Engine (2 places)

10. Heater Hose T-piece 21. Hose Clamps – T-piece (3 places)

11. Heater Hose – To T-piece NOTE: Heater hoses and vacuum hose to be routed

behind brake lines as shown in View B.

HEATER HOSES AND VACUUM LINES – GEN III V8 ENGINE RHD

Figure 2B-174

Legend

1. Water Valve 13. Vacuum Hose – To Vacuum Switch

2. Water Valve Actuator 14. Hose Clamps – Heater Core (2 places)

3. Heater Hose – To Cabin 15. Vacuum Hose – To Water Valve Actuator

4. Heater Hose – From Cabin 16. Brake Booster

5. Vacuum Hose (2 piece) – HVAC Supply 17. Steering Shaft

6. Check Valve 18. Brake Lines

7. Vacuum Hose – To Inlet Manifold 19. Hose Clamps – Water Valve (4 places)

8. Heater Hose – To Engine 20. Wheel House – RHS

9. Hose – To Coolant Surge Tank 21. Mounting Clip – Water Valve

10. Heater Hose T-piece 22. Hose Clamps – Engine (2 places)

11. Heater Hose – To T-piece 23. Hose Clamps – T-piece (3 places)

12. Heater Hose – From Engine NOTE: Heater hoses and vacuum hose to be routed

behind brake lines as shown in View B.

18. HVAC I NLET, DUCTS AND VENTILATION OUTLETS

18.1 HVAC INLET SCREEN

Figure 2B-175

Legend

1. Plenum Cover 4. HVAC Inlet Screen Retaining Clip

2. Plenum Chamber 5. HVAC Inlet

3. HVAC Inlet Screen 6. Foam seal

LT Section – 10-510

REMOVE

1. Remove the plenum cover and water deflector assembly. For all models except V2 Coupe, refer to

Section 12N, 2.5 PLENUM COVER ASSEMBLY, EXCEPT COUPE. For V2 Coupe models refer to

Section 12N, 2.6 PLENUM COVER ASSEMBLY – COUPE.

NOTE 1: Prior to removing the HVAC inlet mesh screen and clip assembly, clear away any foreign matter

such as leaves or twigs that m ay have accum ulated on or near the HVAC inlet m esh scr een. Failure to do so

may allow foreign matter to fall into the HVAC inlet causing noisy blower fan operation.

NOTE 2: Exercise c are when rem oving the m esh scr een and clip assem bly. Im proper rem oval technique will

distort the screen and may cause unsatisfactory screen fitting at HVAC inlet.

2. Remove the mesh screen from the HVAC inlet by grasping the mesh screen retaining clip and lifting the

mesh screen retaining clip and screen assembly upward clear of the HVAC inlet rim.

REINSTALL

Installation of the mesh screen and clip assembly is the reverse of removal procedures, noting the following

points:

1. Install the mesh screen and clip assem bly in the c orrect orientation, i.e. with the retaining clip to the f ront

of the vehicle and the foam seal to the rear of the vehicle, as shown in Figure 2B-175.

2. Install the m esh screen and clip assembly by applying light hand pressure to the outer edges only of the

upper face of the screen.

3. Ensure that the front and sides of the screen are installed within the rim of the HVAC inlet.

18.2 HVAC SYSTEM DUCTS

Figure 2B-176

Legend

1. HVAC Unit 6. Foot Duct Outlet – RHS

2. Passenger Side Duct 7. Floor Console Front Duct

3. Demister Cavity 8. Floor Console Rear Duct

4. Driver’s Side Outer Duct 9. Foot Duct Outlet – LHS

5. Driver’s Side Inner Duct

NOTE 1: Figure 2B-176 shows the HVAC ducting configuration as applicable to RHD models. Ducting configuration is

mirrored for LHD models.

NOTE 2: Items 7 and 8 are not fitted to utility models.

LT Section – 08-175

REMOVE – DRIVER’S SIDE OUTER DUCT

1. Remove the driver’s side instrument panel outer cover. Refer to Section 1A3, 3.17 INSTRUMENT PANEL

OUTER COVER.

2. Remove the driver’s side instrument panel lower trim plate assembly. Refer to

Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

3. Remove the driver’s side instrument panel lower trim panel assembly. Refer to

Section 1A3, 3.4 INSTRUMENT PANEL LOWER TRIM PANEL ASSEMBLY.

4. Raise the steering column to its highest adjustment level.

5. Remove the screw (1) attaching the driver’s

side outer duct (2) to the instrument panel.

NOTE: The lower retaining screw (3) is removed

from the duct when the instrum ent panel lower trim

panel assembly is removed. On left-hand drive

models this screw retains only the inner duct to

the instrument panel lower trim panel assembly.

On right-hand dr ive models, this s crew retains both

the inner and outer duct to the instrument panel

lower trim panel assembly. Refer to item 4 in

Figure 2B-39.

6. Separate the inner duct from the outer duct by

partially withdrawing the outer duct through the

instrument panel side cavity.

7. Remove the inner duct from the HVAC unit

outlet.

8. Remove the inner duct through the instrument

panel lower trim panel cavity.

9. Remove the outer duct through the instrument

panel lower trim panel cavity.

Figure 2B-177

REINSTALL – DRIVER’S SIDE OUTER DUCT

Installation of the driver’s side outer duct is the reverse order of removal procedures noting the following:

1. Tighten all screws to the specified torque.

DRIVER SIDE OUTER DUCT

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

LT Section – 08-175

REMOVE – DRIVER’S SIDE INNER DUCT

1. Remove the driver’s side instrument panel outer cover. Refer to Section 1A3, 3.17 INSTRUMENT PANEL

OUTER COVER.

2. Remove the driver’s side instrument panel lower trim plate assembly. Refer to

Section 1A3, 3.1 INSTRUMENT PANEL LOWER TRIM PLATE ASSEMBLY.

3. Remove the driver’s side instrument panel lower trim panel assembly. Refer to

Section 1A3, 3.4 INSTRUMENT PANEL LOWER TRIM PANEL ASSEMBLY.

4. Raise the steering column to its highest adjustment level.

5. Remove the screw attaching the driver’s side outer duct to the instrument panel. Refer to item 1 in Figure

2B-177.

NOTE: T he retaining s c r ew (1) is removed fr om the

duct (2) when the instrument panel lower trim

panel assembly is removed. On left-hand drive

models this s crew retains only the inner duc t to the

instrument panel lower trim panel assembly.

On right-hand dr ive models, this s crew retains both

the inner and outer duct to the instrument panel

lower trim panel assembly. Refer to item 4 in

Figure 2B-39.

6. Separate the inner duct from the outer duct by

partially withdrawing the outer duct through the

instrument panel side cavity.

7. Remove the inner duct from the HVAC unit

outlet.

8. Remove the inner duct through the instrument

panel lower trim panel cavity.

Figure 2B-178

REINSTALL – DRIVER’S SIDE INNER DUCT

Installation of the driver’s side inner duct is the reverse order of removal procedures noting the following:

1. Tighten all screws to the specified torque.

DRIVER SIDE INNER DUCT

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

LT Section – 08-175

REMOVE – PASSENGER SIDE DUCT

1. Remove the instrument panel pad assembly. Refer to Section 1A3, 3.21 INSTRUMENT PANEL PAD

ASSEMBLY.

2. If fitted, remove the instrument panel inflatable restraint module assembly. Refer to

Section 12M, 2.4 INSTRUMENT PANEL INFLATABLE RESTRAINT MODULE ASSEMBLY. For models

not fitted with an instrument panel inflatable restraint module assembly, remove the instrument panel outer

upper bracket. Refer to Figure 2B-60.

NOTE: The s crew (1) attaching the passenger side

duct (2) to the instrum ent panel is removed as part

of the instrument panel pad assembly removal

procedure. Refer to item 2 in Figure 2B-32.

3. Remove the passenger side duct from the

HVAC unit outlet.

4. Remove the passenger side duct.

REINSTALL – PASSENGER SIDE DUCT

Installation of the passenger side duct is the

reverse order of removal procedures noting the

following:

1. Tighten all screws to the specified torque.

PASSENGER SIDE DUCT

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

Figure 2B-179

LT Section – 08-175

REMOVE – FLOOR CONSOLE REAR DUCT

1. Remove the floor console assembly. Refer to the removal procedures in Section 1A3, 2.3 FLOOR

CONSOLE ASSEMBLY.

2. Remove the rear outlet housing from the floor console assembly. Refer to the floor console disassembly

procedures in Section 1A3, 2.3 FLOOR CONSOLE ASSEMBLY.

3. Remove the screw (1) attaching the rear

duct (2) to the floor console.

4. Remove the rear duct from the floor console.

REINSTALL – FLOOR CONSOLE REAR DUCT

Installation of the floor console rear duct is the

reverse order of removal procedures noting the

following:

1. Tighten all screws to the specified torque.

FLOOR CONSOLE REAR DUCT

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

Figure 2B-180

LT Section – 08-175

REMOVE – FLOOR CONSOLE FRONT DUCT

1. Remove the floor console assembly, refer to Section 1A3, 2.3 FLOOR CONSOLE ASSEMBLY.

2. Remove the left-hand side instrument panel lower extension side trim. Refer to Section 1A3,

2.2 INSTRUMENT PANEL LOWER EXTENSION SIDE TRIM.

3. Remove the screw (1) attaching the floor

console front duct (2) to the left-hand side

instrum ent panel lower extension. Refer also to

item 3 in Figure 2B-19.

4. Remove the duct away f rom the HVAC unit and

towards the rear of the vehicle.

5. Rem ove the duc t through the apertur e between

the left-hand side instrument panel lower

extension and the transmission tunnel.

REINSTALL – FLOOR CONSOLE FRONT DUCT

Installation of the floor console front duct is the

reverse order of removal procedures noting the

following:

1. Tighten all screws to the specified torque.

FLOOR CONSOLE FRONT DUCT

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

Figure 2B-181

LT Section – 08-175

REMOVE – FOOT DUCT, LHD

1. Remove the HVAC unit. Refer to 3. HEATING, VENTILATION AND AIR CONDITIONING (HVAC) UNIT in

this Section.

2. Remove the four screws (1) attaching the foot

duct (2) to the underside of the HVAC unit.

3. Remove the foot duct from the HVAC unit.

REINSTALL – FOOT DUCT, LHD

Installation of the foot duct is the reverse order of

removal procedures noting the following:

1. Tighten all screws to the specified torque.

FOOT DUCT

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

Figure 2B-182

LT Section – 08-175

REMOVE – FOOT DUCT, RHD

1. Remove the HVAC unit. Refer to 3. HEATING, VENTILATION AND AIR CONDITIONING (HVAC) UNIT in

this Section.

2. Remove the vac uum lines f or the face and foot

actuators from the retaining clips on the

underside of the foot duct (1).

3. On OCC (Auto A/C) HVAC units, remove the

harness for the air mix motor/s from the foot

duct.

4. Remove the four screws (2) attaching the foot

duct to the underside of the HVAC unit.

5. Remove the foot duct from the HVAC unit.

REINSTALL – FOOT DUCT, RHD

Installation of the foot duct is the reverse order of

removal procedures noting the following:

1. Tighten all screws to the specified torque.

FOOT DUCT

ATTACHING SCREW

TORQUE SPECIFICATION 1.0 – 3.0 Nm

Figure 2B-183

18.3 CABIN VENTILATION OUTLETS

LT Section – 08-175

REMOVE AND REINSTALL

Referring to Figure 2B-184:

• To remove and install the windshield defroster grilles (1), refer to Section 1A3, 3.18 WINDSHIELD

DEFROSTER GRILLE.

• To remove and install the side window defogger duct (2) and side window defogger outlet (3), refer to

Section 1A5, 2.6 FRONT DOOR TRIM PANEL ASSEMBLY.

• To remove and install the front door air duct assembly (4) and front door air outlet assembly (5), refer to

Section 1A5, 2.6 FRONT DOOR TRIM PANEL ASSEMBLY.

• To remove and install the centre air outlet assembly (6), refer to Section 1A3, 3.7 INSTRUMENT PANEL

CENTRE TRIM ASSEMBLY.

• To remove and install the rear outlet housing assembly (7), refer to Section 1A3, 2.3 FLOOR CONSOLE

ASSEMBLY.

Figure 2B-184

18.4 BODY VENTILATION OUTLETS

Figure 2B-185

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-186.

LT Section – 08-700

REMOVE – SEDAN AND COUPE

1. Rem ove the rear bum per fas cia assem bly. Refer to Section 1D, 2.5 REAR BUMPER FASCIA ASSEM BLY,

SEDAN AND COUPE.

2. As required, remove the left-hand side or right-hand side quarter inner rear side carpet. Refer to

Section 1A8, 2.17 QUARTER INNER REAR SIDE CARPET.

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

while simultaneously moving it partially outward of the vehicle.

4. From outside the vehicle, remove the body ventilation outlet from the quarter panel.

REINSTALL – SEDAN AND COUPE

Installation of the body ventilation outlet is the reverse of removal procedures, noting the following points:

1. Install the body ventilation outlet in the correct vertical orientation, i.e. as shown in Figure 2B-185.

2. Ensure all four locking tabs are fully engaged on the inner side of the body panel.

REMOVE – WAGON

1. Rem ove the rear bum per fas cia assem bly. Refer to Section 1D, 2.6 REAR BUMPER FASCIA ASSEM BLY,

WAGON.

2. Carefully insert a flat bladed implement between the body panel and the foam seal at the corners on the

bottom of the ventilation outlet housing.

3. Use the implement to press the two locking tabs at the bottom of the ventilation outlet housing. W hile doing

so, allow the ventilation outlet housing to move upward within the body aperture.

4. Partially remove the ventilation outlet housing by withdrawing the lower section from the body aperture.

5. Move the body ventilation outlet downward within the body aperture and remove it the from the quarter panel.

REINSTALL – WAGON

Installation of the body ventilation outlet is the reverse of removal procedures, noting the following points:

1. Install the body ventilation outlet in the correct vertical orientation, i.e. as shown in Figure 2B-185.

2. Ensure all four locking tabs are fully engaged on the inner side of the body panel.

REMOVE – UTILITY

1. If fitted, remove the LPG tank. Refer to Section 8A2, 3.6 LPG TANK – UTILITY.

2. Remove the load floor front panel assembly. Refer to Section 1B, 2.7 LOAD FLOOR FRONT PANEL

ASSEMBLY, UTILITY.

3. Remove the seat back body panel trim assembly. Refer to Section 1A8, 5.11 SEAT BACK BODY PANEL

TRIM.

4. From inside the passenger compartment, press the locking tabs at each corner of the ventilation outlet

housing while simultaneously moving it partially outward of the passenger compartment.

5. From within the body cavity below the load floor front panel assembly, remove the body ventilation outlet from

the floor panel extension.

REINSTALL – UTILITY

Installation of the body ventilation outlet is the reverse of removal procedures, noting the following points:

1. Install the body ventilation outlet in the correct vertical orientation, i.e. as shown in Figure 2B-185.

2. Ensure all four locking tabs are fully engaged on the inner side of the body panel.

Figure 2B-186 shows the locations of body ventilation outlets across the MY2003 VY and V2 Coupe model range.

Figure 2B-186

Legend

1. Body Ventilation Outlet, Sedan – LHS 5. Body Ventilation Outlets, Coupe – LHS

2. Body Ventilation Outlets, Sedan – RHS 6. Body Ventilation Outlet, Coupe – RHS

3. Body Ventilation Outlet, Wagon – LHS 7. Body Ventilation Outlets, Utility

4. Body Ventilation Outlets, Wagon – RHS

19. TORQUE WRENCH SPECIFICATIONS

Floor console screw.................................................................................................1.0 – 3.0

Instrument panel centre trim assembly screw..........................................................1.0 – 3.0

Blower motor and fan assembly attaching screw.....................................................5.0 – 8.0

HVAC unit case screw .............................................................................................1.0 – 3.0

HVAC Manual controller securing screw..................................................................1.0 – 3.0

Evaporator tube plate securing screws....................................................................4.0 – 4.5

Liquid and suction tube retaining plate to TXV screw............................................7.5 – 12.5

TXV to evaporator tubes securing screw.................................................................4.0 – 4.5

Suction and discharge hose assembly retaining nut............................................25.0 – 35.0

FDR tube unions....................................................................................................7.5 – 12.5

Compressor retaining bolts (GEN III V8) .............................................................40.0 – 60.0

Idler pulley locking bolt.........................................................................................40.0 – 50.0

Idler pulley mounting bracket retaining nut (V6)...................................................20.0 – 30.0

Idler pulley retaining bolt ......................................................................................40.0 – 50.0

Clutch drive plate and hub assembly retaining nut ..............................................11.0 – 22.0

Evaporator pipe screw ......................................................................................................5.0

Heater core pipe retaining screw .............................................................................3.0 – 5.0

Blower motor resistor attaching screw.....................................................................1.0 – 3.0

Vacuum tank attaching screw..................................................................................1.0 – 3.0

Fresh / Recirculation actuator attaching screw........................................................3.0 – 5.0

Face actuator attaching nut (LHD)...........................................................................3.0 – 5.0

Face actuator attaching screw (RHD)......................................................................3.0 – 5.0

Foot actuator attaching screw..................................................................................3.0 – 5.0

Demist actuator attaching screw (LHD)...................................................................3.0 – 5.0

FDR mounting bracket screw.................................................................................7.5 – 12.5

Air conditioning compressor drive belt idler pulley bolt...................................................50.0

Air conditioning compressor drive belt tensioner bolt .....................................................25.0

Air conditioning compressor mounting bracket retaining bolt ..............................40.0 – 60.0

Suction and discharge hose pad retaining nut.....................................................28.0 – 42.0

20. SPECIAL TOOLS

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASIFICATION

KM6067 RADIO REMOVAL TOOL

Used for removing VY audio unit

from its mounting location.

New tool for VY.

Mandatory

J-8433-1

PULLER BAR

Used for removing clutch pulley and

bearing assembly from A/C

compressor shaft.

Desirable

J-33025

CLUTCH COIL PULLER LEGS

Used for removing clutch pulley and

bearing assembly from A/C

compressor shaft.

Desirable

J-33023-A PULLER PILOT

Used for removing clutch pulley and

bearing assembly from A/C

compressor shaft.

Desirable

J-33017

A/C COMPRESSOR PULLEY AND

BEARING ASSEMBLY TOOL

Used in conjunction with installer

tool 09-74767 for installing A/C

clutch pulley and bearing assembly

to A/C compressor housing.

Desirable

09-74770 A/C CLUTCH HUB HOLDER

Used for holding A/C clutch

hub/drive plate during A/C clutch

drive plate and hub assembly

removal and installation.

Available from:

The Aftermarket Department

Air International P/L

80 Turner Street

Port Melbourne

Victoria, 3207

Desirable

TOOL NUMBER ILLUSTRATION DESCRIPTION TOOL

CLASIFICATION

09-74767 A/C CLUTCH HUB AND DRIVE

PLATE INSTALLER

Used for installing A/C clutch drive

plate and hub assembly.

Available from:

The Aftermarket Department

Air International P/L

80 Turner Street

Port Melbourne

Victoria, 3207

Desirable

09-74768 A/C CLUTCH HUB AND DRIVE

PLATE REMOVER

Used for removing A/C clutch drive

plate and hub assembly.

Available from:

The Aftermarket Department

Air International P/L

80 Turner Street

Port Melbourne

Victoria, 3207

Desirable

AU435 COOLANT TESTER Mandatory

AU425 COOLING SYSTEM FILLER TUBE Mandatory