SECTION 1E - COCKPIT MODULE

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.

1. GENERAL I NFORMATI ON

The cockpit module assembly on WH Series Models essentially carries over from VT Series Models, with the

introduction of the GEN III V8 engine, except for some changes to the procedure for removing the cockpit module

assembly.

The cockpit module panel is clearly visible in the engine bay and is painted gloss black with the glue track apparent

where the panel joins to the floor and A-pillars.

The module consists of a sub-assembly comprising the dashboard, air conditioner, radio, pedals, steering column,

instruments etc. After completion of the-sub assembly, the operation of the electrical components is tested before

fitting to the vehicle.

The sub-assembly is retained in a channel (glue track) filled with a special silicone adhesive in the front floor

extension and inner shroud panels of the body shell. Refer to 1.2 GENERAL PRECAUTIONS, as under repair

conditions the glue track must be free of refinishing paint.

The module locates on self-centering dimples, two bolts, installed through the A-pillar, and two bolts, installed in the

plenum area. These points maintain the location until the adhesive cures. After installation and when the adhesive is

fully cured, the module becomes an integral part of the body structure.

Prior to removal of the module, the vehicle should be mounted in a jigging system to ensure that the body structure

is fully supported and cannot move.

The upper section of the module forms the base for the front windshield, which is bonded to the module using a

urethane adhesive.

The Vehicle Identification Number (VIN) plate is secured to the left side of the module by unique rosette headed

rivets. As a theft deterrent, the VIN number is visible through the front windshield.

The silicone adhesive in the glue track is suited for the high temperature conditions generated in the engine

compartment. The silicone also has excellent bonding, sealing and longevity characteristics.

Techline

1.2 GENERAL PRECAUTIONS

Unless repairing a crack or tear in the glue track, only two-part silicone adhesive should be used when refitting the

cockpit module.

NOTE: Remove as much of the old adhesive as possible from the glue track before installing the cockpit module.

As the cockpit module panel forms part of the vehicle structure, where the module panel has any damage or cracks

in the sheet metal, or if fire damage has occurred, the module must be removed and replaced.

Tears, separation or splitting in the adhesive exceeding 300 mm in length requires removal and complete reglueing

of the module.

The silicone adhesive, Part Number 92140052 used in the glue track must not be replaced with any other type of

adhesive or sealant other than that which is recommended by Holden Ltd.; urethanes, epoxies, acrylic etc. are not

suitable for use in this application. Failure to correctly seal the cockpit module panel to the vehicle may allow

exhaust, fuel or other fumes to enter the passenger compartment.

INSTALLATION PRECAUTIONS

IMPORTANT: To obtain a satisfactory bond between the two parts, the following procedures must be observed.

1. Remove as much of the remaining adhesive as possible from the glue track prior to reinstallation of the panel.

2. After r epairing the s heet metal work , if all the r emaining adhesive has been thor oughly removed, apply a coat of

primer inside the glue track. Do not apply primer over any remaining adhesive.

NOTE: The finish on the front floor extension and shroud panel service parts will not require priming before applying

the adhesive to the glue track.

3. W hen reinstalling a m odule after a repair, ensure that no re-finishing paint or over spray is in the glue track or

on the remaining adhesive.

Apply a layer of masking tape to the track before painting, and install the module after oven baking the paint

(where appropriate).

4. Do not use an adhesive other than that, which is recommended by Holden Ltd.

5. Body shell assemblies are available (at the time of publication) in white enamel finish with the cockpit module

installed.

6. Before commencing installation of the module, thoroughly read 2.1 COCKPIT MODULE - MIXING SILICONE

ADHESIVE.

7. Although the cockpit m odule is installed as an assembly on the production line, this m ethod is not practical for

repairing the vehicle. Service Operation 2.1 COCKPIT MODULE describes the cockpit module disassembly

and reassembly procedure in the vehicle.

SAFETY PRECAUTIONS

The silicone adhesive used in the glue track, once cured requires no special precautions. However, when mixing

the adhesive compound with the catalyst, the precautions listed below should be observed.

1. Do not swallow–the catalyst is a toxic substance, keep away from children.

2. Safety glasses should be worn to avoid contact with eyes. If eye contact occurs, wash the area in clean water

only, and seek immediate medical advice.

3. Wear protective gloves when handing the adhesive and catalyst, as they may cause skin irritation. If irritation

occurs, wipe the adhesive/catalyst off with a clean cloth and wash the affected area thoroughly in clean water.

4. Vapour produced by the adhesive and catalyst may cause breathing difficulties, use only in a well ventilated

area.

5. The catalyst is combustible, keep away from sparks and flame.

2. SERVICE OPERATIONS

2.1 COCKPIT MODULE

REMOVE

CAUTION: Disable the SRS (Air Bag). Refer to

DISABLING THE SRS, Section 00 CAUTIONS

AND NOTES.

NOTE: This procedure describes the minimum

disassembly required to remove the components

attached to the cockpit module. Where

replacement of individual parts is necessary, refer

to appropriate Section in this Supplement.

IMPORTANT: As a theft deterrent, WH series

vehicles are fitted with a security coded audio

system. After the power supply is interrupted, the

radio will rem ain inoperative af ter reinstallation until

the pin number is entered into the system. The

procedure is described in the glove box literature

accompanying the Owner’s Handbook.

1. If the battery cables have not already been

disconnected, disconnect the battery negative

and positive cables.

2. Drain engine cooling system, refer to Section

6B1-1 ENGINE COOLING - V6 ENGINE,

Section 6B1-2 ENGINE COOLING - V6

SUPERCHARGED or Section 6B3 ENGINE

COOLING - GEN III V8 ENGINE.

3. Where fitted discharge the air conditioning

system, refer to Section 2C AIR

CONDITIONING - SERVICING AND

DIAGNOSIS.

4. Depressurise the fuel system, refer to Section

6C1 POWERTRAIN MANAGEMENT - V6

ENGINE or Section 6C3 POWERTRAIN

MANAGEMENT - GEN III V8 ENGINE.

5. Unclip duct cover flap on right hand side of foot

well upper closing panel left side. Dis engage the

locating lugs to passenger side shroud lower.

Grasp c losing panel firm ly and detach by pulling

left side down first, then disengage right side

clip and remove panel.

6. Remove passenger side shroud lower trim

assembly, refer to Section 1A1 BODY.

T21E063

Figure 1E-1

Techline

7. On a vehicle with V6 or V6 supercharged

engine, disconnect the powertrain control

module harness connection (2) from the

powertrain control module (1), refer to Section

6C1 POWERTRAIN MANAGEMENT - V6

ENGINE. The module should be removed from

the vehicle to prevent damage occurring.

Compress lugs on powertrain harness grom met

(3) and push powertrain harness and

connectors out into the engine compartment.

Figure 1E-2

8. On a vehicle with a GEN III V8 engine,

disconnect the powertrain harness connector

from the throttle relaxer control module as per

the following:

1. Lift the locking lever upwards.

2. Pull the top of the connector out away from

the control module.

3. Lift the wiring harness connector up to

disengage it from the control module.

9. On a vehicle with a GEN III V8 engine,

disconnect the powertrain harness connector (4)

from the Powertrain Interface Module (PIM).

Compress lugs on powertrain harness grom met

and push powertrain harness and connectors

out into the engine compartment.

Figure 1E-3

10. Adjust steering wheel to upper most position.

Grasp the right hand side of the instrument

panel lower cover panel (1) firmly and pull

towards rear of vehicle releasing locating clip

(3). Repeat the procedure for the left hand side

of the cover.

Using a flat bladed screwdriver, prise the left

hand instrument panel lower cover panel hinge

pin (1) out.

Tilt the instrument panel lower cover down on

the left side and dis engage the right hand hinge

pin. Remove panel.

Figure 1E-4

11. Release the steering column height adjuster,

completely lower steering column and leave

lever in the released position.

12. Insert f inger between the steer ing wheel and the

lower cover as shown in Fig. 1E-5 and apply a

small amount of pressure (pushing towards the

instrument cluster) while lifting the upper cover

upwards.

Figure 1E-5

13. Rem ove screw (2) securing the lower cover (1)

to the steering column.

14. Slide lower cover toward the steering wheel to

release cover from the two retaining tangs (3)

on the steering column.

15. While feeding the key reader outer surround

from lower cover, remove co ver.

Figure 1E-6

16. Remove the two scrivets (2) securing the

footwell upper closing panel (1).

Prise off the retaining button (3) and detach the

footwell upper closing panel.

W her e fitted disconnect front f ootwell lamp f rom

footwell upper closing panel.

Figure 1E-7

17. Remove two screws (2) securing the diagnostic

link connector (1) to the instrument panel lower

trim right side assembly.

Figure 1E-8

18. Slide the passenger compartment relay and

fuse block (1) to the left, push through support

panel and withdraw towards front of vehicle.

Figure 1E-9

19. Remove the three screws (2) securing the right

hand instrument panel end cap (1) to the

instrument panel and remove end cap.

Figure 1E-10

20. Open the instrument panel compartment (1),

and lever the hinge pin (2) f rom the right side of

the compartment. Lower compartment and

withdraw the pin. Disengage right hand travel

limiting peg f rom slot in ins trum ent panel roof by

deforming plastic tang.

Figure 1E-11

21. Remove the six screws (3) securing the left

hand instrument panel end cap cover (1) and

end cap (2) to the instrum ent panel and rem ove

end cap cover and end cap.

Figure 1E-12

22. Remove the 11 retaining screws (2) from

instrument panel compartment roof (1) and

screw securing Instrument facia side extension

to console. Disconnect the instrument panel

compartment lamp (3) and switch (4)

connectors, disconnect the luggage

compartment lock switch connector (5) and

unclip instrument panel compartment wiring

harness (6).

Figure 1E-13

23. Remove drivers side shroud lower trim

assembly.

24. Disconnect body harness to main wiring

harness connectors (arrows) at the right hand

cowl panel.

Figure 1E-14

25. Remove Body Control Module (BCM) from

mounting br ackets by pushing the bottom of the

BCM towards the front of the vehicle until the

BCM disengages from the lower mounting

bracket.

NOTE: The wiring harnesses are still connected.

Grasp the BCM, and gently pull the BCM down

disengaging it from the upper mounting bracket.

26. Remove the transmission console and detach

console wiring harness, refer to Section 1A3

INSTRUMENT PANEL & CONSOLE.

Figure 1E-1

27. Remove the two retaining screws (3) from the

left (1) and right (2) hand demist nozzle grilles

and, taking care not to damage the solar

sensor / remote receiver module, remove both

demist nozz le grilles.

Figure 1E-16

28. Disconnect the left and right front instrument

panel speaker wiring harness connectors (2).

Using a Phillip’s head screwdriver, remove the

two screws (3) (one each side) attaching front

instrum ent panel speakers (1) and rem ove both

speakers.

Figure 1E-17

29. Remove the four retaining screws (2 & 3) from

the instrument panel carrier end panel (1) right

side and remove panel.

Figure 1E-18

30. Remove the four attaching screws (2) securing

instrument panel carrier end panel (1) left side

and three bolts (3) attaching the passenger air

bag support rail, lower lef t side r ail, and rem ove

panel.

Figure 1E-19

31. Remove screws (3) retaining the instrument

facia (2) and instrument facia storage

compartment assembly (4).

32. Remove instrument facia storage compartment

and pull instrument facia escutcheon (1) from

retaining clips.

33. Remove instrument facia (2) by pulling facia

from retaining clips.

NOTE: Care must be taken to disconnect the

headlamp switch, fog lamp switch, trip computer

switch, clock and hazard switch from the main

wiring harness connectors.

Figure 1E-20

34. Remove left hand centre facia side extension

refer to Section 1A3 INSTRUMENT PANEL

AND CONSOL.

35. Unclip antenna leads from inboard end of

glovebox lower rail.

NOTE: This is necessary to provide enough

antenna cable to pull radio forward.

36. Remove service tool hole covers (2) and

remove radio/cassette/CD from instrument

panel using service tool 179 1308 0000 (1).

Figure 1E-21

37. Disconnect radio/cassette harness and CD

connector (1). Disconnect antenna and diversity

antenna (2) and remove Radio/Cassette/CD (3).

Figure 1E-22

38. Disconnect the wiring harness connector (2)

and aspirator tube from the in-car temperature

sensor (3). Remove the screws (1) securing

the in-car tem per ature sens or to the ins trum ent

panel and remove the in-car sensor.

Figure 1E-23

39. Remove the 13 screws secur ing the centr e f ac ia

assembly to the instrument panel and remove

centre facia assembly.

Figure 1E-24

40. Using a number T30H Torx bit (1),

commercially available or Tool No. ETX30H

and a suitable holder suc h as T ool No. J 25359-

8, loosen and remove four screws (2) from the

rear of steering wheel securing the horn bar

and air bag inflator module assembly to the

steering wheel.

Figure 1E-25

41. Lift up horn bar and air bag inflator module

assembly (1) from the steering wheel, remove

the yellow clock spring to inflator assembly

connection (2) and disconnect wiring harness

connectors (3 and 4) from rear of assembly.

NOTE: Take extrem e care when disconnecting the

left hand horn pad connector (3) from the stereo

control wiring connector otherwise, damage to the

stereo control wiring could result.

42. Remove horn bar and air bag inflator module

assembly.

CAUTION: When carrying a live (undeployed)

horn bar and air bag inflator module assembly,

make sure the bag opening in the horn bar is

pointed away from you. Never carry the horn

bar and air bag inflator module assembly by the

horn bar wires or connectors on the underside

of the assembly. In case of an accidental

deployment, the bag will then deploy with

minimal chance of injury.

When placing a live horn bar and air bag

inflator module assembly on a bench or other

surface, always face the bag and horn bar up,

away from the surface. Never rest the horn bar

and air bag inflator module assembly with the

horn bar f ace down . This is necessary so th at a

free space is provided to allow the air bag to

expand in the unlikely event of accidental

deployment. Otherwise, personal injury may

result.

Figure 1E-26

43. Remove the steering wheel, refer to Section

9A STEERING.

44. Remove the screws (2) securing the ECC

module (1) to the instrument panel.

45. Pull module from instrument panel, disconnect

the wiring harness connections (3), and remove

module.

T21E029

Figure 1E-27

46. Remove the two screws (3) securing the

instrument cluster assembly (1).Lift instrument

cluster assembly from instrument panel and

disconnect wiring harness connector (2) from

rear of cluster, remove cluster.

Figure 1E-28

47. Remove the five retaining screws (2) along top

edge of instrument panel pad (1).

Figure 1E-29

48. Remove the five screws attaching the fuse and

BCM panel to the instrument panel, remove

panel.

49. Remove HVAC unit to door outer right hand

side and HVAC unit to door vent inner right

hand side. Refer to Section 2B AIR

CONDITIONING - ECC REMOVAL AND

INSTALLATION.

Figure 1E-30

50. Remove four screws (2 & 3) securing the

steering column bracket outer support (1),

remove support.

Figure 1E-31

51. Remove the three screws securing the centre

facia support rail to the instrument panel,

remove support rail.

Figure 1E-32

52. Remove the support steering column bracket

inner attaching screws, remove bracket.

53. Remove the steering column assembly, refer to

Section 9A STEERING.

Figure 1E-33

54. At the left hand cowl panel disconnect diversity

antenna leads (2 and 3), CD changer harness

connector (4) from main wiring harness

connector (1) and power antenna connector (5).

Figure 1E-34

55. Remove the five scr ews sec ur ing the passenger

air bag support rail assembly, remove rail.

Figure 1E-35

56. Remove the four screws retaining the lower left

side ra il, remove rail.

Figure 1E-36

57. Remove the six instrument panel carrier rail

assembly retaining screws and remove carrier

rail.

Figure 1E-37

58. Disconnect passenger air bag connector (2)

located on the right hand side of air bag (1).

Remove two nuts (3) attaching air bag to

instrument panel assembly.

CAUTION: When carrying a live (undeployed)

front passenger's air bag inflator module

assembly, make sure the b ag openin g is poin ted

away from you. In case of an accidental

deployment, the bag will then deploy with

minimal chance of injury. When placing a live

front passenger's air bag inflator module

assembly on a bench or other surface, always

face with the air bag up, away from the surface.

Never rest the air bag inflator module assembly

wit h the air bag f ace down . This is necessary so

that a free space is provided t o allow t he air bag

to expand in the unlikely event of accidental

deployment. Otherwise, personal injury may

result. Figure 1E-38

59. Remove main wiring harness cabin protector

attaching nut and disengage the protector from

the slot in the retaining bracket.

60. Remove the throttle cable from the accelerator

pedal through to the throttle body or if fitted,

through to the throttle relaxer, refer to the

relevant Section in this Service Information;

Section 6C1 POWERTRAIN MANAGEMENT -

V6 ENGINE or Section 6C3 POWERTRAIN

MANAGEMENT - GEN III V8 ENGINE.

61. If fitted, remove the throttle relaxer assembly

from the cockpit module, refer to Section 6C3

POWERTRAIN MANAGEMENT - GEN III V8

ENGINE.

Figure 1E-39

62. Disconnect the blower motor wiring harness

connector (1) and fan speed control wiring

harness connector (2) from the HVAC unit (3).

Detach wiring harness retaining clip (4) from

HVAC unit.

Figure 1E-40

63. Disconnect windshield washer hose from engine

hood and with engine hood adequately

supported, remove clips (2) securing upper end

of struts ( 1) to hood pivots (3). Dis engage struts

from hood pivots and lay strut down on fender

inner panel.

With the aid of an assistant hold hood

assem bly, remove engine hood brac ket to hinge

attaching screws (4), and remove hood.

Figure 1E-41

64. On vehicles with V6 engine; release powertrain

harness to cockpit module retaining clips (2)

and disconnect the following wiring harness

connectors:

1. The three powertrain harness to main

wiring harness connectors.

3. Intake air temperature sensor at air

cleaner.

4. Air conditioning pressure transducer

connector at air conditioning condenser.

5. Mass Air Flow (MAF) sensor.

Theft deterrent horn (if fitted).

Lay wiring harness on top of engine.

Figure 1E-42

65. On vehicles with GEN III V8 engine; release

powertrain harness to cockpit module retaining

clips (2) and disconnect the following wiring

harness connectors:

1. The three powertrain harness to main

wiring harness connectors.

3. Theft deterrent horn (if fitted).

4. Powertrain control module, refer to

Section 6C3 POWERTRAIN

MANAGEMENT - GEN III V8 ENGINE.

5. Intake air temperature sensor at air

cleaner.

6. Mass Air Flow (MAF) sensor.

7. Air conditioning transducer.

Lay wiring harness on top of engine.

Figure 1E-43

66. Remove the front wiper motor and linkage

assembly, refer to Section 12C

INSTRUMENTS, WIPERS / WASHERS &

HORN.

67. Disconnect the main wiring harness from the

engine compartment electrical equipment.

68. Tag and remove all relays, fusible links, and

fuses from the relay housing in the engine

compartment, refer to Section 12N FUSES,

RELAYS & WIRING HARNESSES for the

location and terminal assignments.

Figure 1E-44

Legend

1. Wiper Motor 11. Body Earth 21. LH Front Headlamp

2. Brake Failure Warning Switch 12. Body Earth 22. LH Front Turn Signal Lamp

3. Diagnostic Interconnect 13. RH Front Turn Signal Lamp 23. LH Horn (2 connections)

4. Powertrain Harness (1) 14. RH Front Headlamp 24. LH Fog Lamp

5. Powertrain Harness (2) 15. Washer Pump 25. LH Front Wheel Speed Sensor

6. Powertrain Harness (3) 16. RH Fog Lamp 26. Battery Harness

7. Cruise Control Actuator 17. RH Horn (2 connections) 27. Battery Harness

8. Relay Box 18. Cooling Fan Motor 28. Power Steering Solenoid

9. ABS ABS/ETC Control Module 19. Ambient Sensor

10. RH Front Wheel Speed Sensor 20. Theft Deterrent Hood Switch (2

connections)

69. Release engine compartment harness tie down

clips, then push the main wiring harness

grommet into the cabin.

Figure 1E-45

70. If the vehicle is fitted with cruise control,

disconnect the cruise control actuator

connector, located under the main wiring

harness protector.

71. Unclip main wiring harness protector retaining

clips from the strut tower. Pass engine

compartment relay block and main wiring

harness assembly through the cockpit module

panel opening.

IMPORTANT: Take extreme care not to damage

the wiring harness while performing this

operation.

72. Disconnect the fuel feed, return and vacuum

hoses at quick connects, refer to Section 6C1

POWERTRAIN MANAGEMENT - V6 ENGINE

OR Section 6C3 POWERTRAIN

MANAGEMENT - GEN III V8 ENGINE. Plug all

openings to prevent foreign matter entry.

NOTE: Do not attempt to remove hoses from fuel

rail connections. Once removed from fuel rail

connection hoses require replacement.

73. Unscrew fuel pipe retaining bracket from the

cockpit module.

Figure 1E-46

74. Tag and disconnect the heater hoses and

vacuum lines at the cockpit module, refer Fig.

1E-47 (V6 application) or Fig. 1E-48 (GEN III V8

application).

Figure 1E-47

Figure 1E-48

75. Remove nuts and bolt securing the master

cylinder to strut tower brace, remove brace.

Figure 1E-49

76. Tag and disconnect the brake lines, vacuum

hose and electrical harness from the brake

booster, ABS modulator and master cylinder

assembly. Seal all apertures with suitable plastic

plugs.

Remove the two nuts securing the brak e m as ter

cylinder to the brake booster and remove the

brake master cylinder.

77. Remove the nuts from the blanking plate

adjacent to the brake booster.

Figure 1E-50

78. Remove the retaining clip (2), washers (1) and

brake booster pushrod (3) from the brake pedal.

Figure 1E-51

79. Remove stop lamp switch harness connector

(3) and if fitted, cruise control cancel switch

harness connector (2) from the brake pedal

assembly (1).

T21E049

Figure 1E-52

80. Remove the four nuts securing the accelerator

pedal assembly to the cockpit module and

remove accelerator pedal assembly.

81. Remove the remaining two nuts securing the

brake pedal, brake booster to the cockpit

module, and remove the brake booster

assembly.

82. Remove the three screws securing the brake

pedal assembly to the cockpit module and

remove the brake pedal assembly.

T21E050

Figure 1E-53

83. Remove the air conditioning compressor to

thermal expansion valve and condenser to

thermal expansion valve line and hose, then

plug all the fittings. Refer to Section 2B AIR

CONDITIONING - ECC REMOVAL AND

INSTALLATION.

84. From within the engine compartment, remove

the four screws securing the heater case

assembly to the cockpit module.

Figure 1E-54

85. Remove the HVAC unit (1) from the vehicle by

disengaging the drain grommet (2) and easing

the assem bly from the vehicle tak ing c are not to

strain the heater core tubes.

Figure 1E-55

86. Remove the grommets and insulation panels

from cockpit module.

87. Remove the front windshield, refer to Section

1A6 STATIONARY GLASS.

88. Remove the front doors, refer to Section 1A5

FRONT AND REAR DOOR ASSEMBLIES.

89. Remove engine, refer to Section 6A1-1

ENGINE MECHANICAL - V6 ENGINE or

Section 6A1-2 ENGINE MECHANICAL - V6

SUPERCHARGED or Section 6A3 ENGINE

MECHANICAL - GEN III V8 ENGINE.

90. Remove the two cockpit module retaining bolts

(one each side) from the A pillar.

Figure 1E-56

91. From within the plenum chamber, remove the

two cockpit module retaining bolts (one each

side).

Figure 1E-57

92. Locate VIN plate (2) and compliance plate (1)

on passenger side of cockpit module panel.

Using a drill and suitable size drill bit, drill out

retaining rivets.

Figure 1E-58

93. Transfer the VIN plate onto the new cockpit

module panel. Using commercially available

hand rivet tool and new rosette headed rivets

(two off each plate) secure the VIN plate to the

new cockpit module panel.

Figure 1E-59

94. Transfer the compliance plate onto new cockpit

module panel. Using commercially available

hand rivet tool and new rosette headed rivets

(two off each plate) secure the safety

compliance plate to the new cockpit module

panel.

Figure 1E-60

95. Remove the two screws retaining cockpit

module to body earth strap and remove from

vehicle.

Figure 1E-61

96. Using a power saw, cut the module panel

approximately 50 mm above the glue track.

CAUTION: Sparks may ignite p etrol in th e fuel or

emission cont rol lines if du e precau tio ns are n ot

taken.

Figure 1E-62

97. Drill a hole in the f lange above the trans mission

tunnel, and attach a chain block and a clevis.

98. Apply and maintain a light tension to the

rem aining part of the module. Heat the adhesive

using a heat gun and pull the panel from the

glue track . Alternatively, cut the adhesive with a

hot knife.

99. Clean the excess adhesive from the glue track

using a hot knife or a heat gun and tool.

CAUTION: To avoid fire, Do Not attempt to burn

the remaining adhesive from the glue track

using an oxygen / acetylene torch.

T21E060

Figure 1E-63

MIXING SILICONE ADHESIVE

Surface Preparation

Clean any remaining adhesive from the glue track using a hot knife or heat gun and tool if necessary .

The vehicle should be painted before installation of the cockpit module. Before painting the vehicle, apply masking

tape to prevent paint entering the glue track.

The adhesive will not properly adhere to paint, over spray, oils, grease etc. The glue track must be free of dirt, dust,

grease, oils and paint or over spray.

Wipe the glue track with a suitable cleaning agent such as “Prepsol”, then clean any residue from the area with a

clean, dry, lint free cloth.

Avoid fitment problems by temporarily installing the cockpit module panel, prior to mixing the adhesive, rectify any

faults found, then remove the panel from the vehicle.

Before mixing the adhesive, it is necessary to have the application gun available. All parts must be clean of any

previous adhesive.

Refer to the latest WH Series Spare Parts Information, for details of where to obtain an applicator gun.

Mixing Adhesive and Catalyst

IMPORTANT: This is a two-part mix, fast cure adhesive, ensure that the panel is ready for installation before mixing

the adhesive. The working time is less than 20 minutes.

Part A : The Adhesive compound, yellow in colour and supplied in a 1.4 kilogram container.

Part B: The Catalyst, used to accelerate the “Cure” time of the adhesive compound and is supplied in a 120 gram

tube.

The contents of the Adhesive Kit, Part Number 92140052 is sufficient to install the module panel in a vehicle.

CAUTION: The vapour from the adhesive may cause breathing difficulties, use only in a well ventilated

area. In case of eye contact, flush immediately with clean water.

COMBUSTIBLE – keep away from spark and flame.

Refer to Safety Precautions in 1.2 GENERAL PRECAUTIONS.

1. Remove the lid from the adhesive compound container.

2. Remove the c ap from the catalyst and pierc e the end of the tube, then squeeze the entire contents of the tube

into the adhesive compound container.

3. Hold the container securely, and mix the catalyst into the adhesive using a paint mixer or a flat clean wooden

utensil.

4. Continue to mix until the adhesive is a consistent grey colour without any streaks.

5. Place the follower plate supplied with the applicator gun into the adhesive container.

6. Remove the front end cap and disposable nozzle from the applicator gun.

7. Cut the tip from the nozzle.

8. Place the applicator gun front end over the hole in the follower plate.

NOTE: The easiest method of drawing the adhesive into the gun is to proceed slowly, allow the downward pressure

on the plate and the suction of the gun to draw the compound.

9. Simultaneous ly push down on the gun and plate with maxim um pr essure, press the gun’s release plate inward

and slowly pull the T-bar (piston) outward. This procedure will slowly suck the mixed adhesive into the

applicator gun.

10. Wipe any excess adhesive from the applicator gun, screw the end cap onto the applicator gun, and then

reinstall the nozzle.

11. Proceed immediately with installing the panel.

IMPORTANT: After mixing the silicone adhesive, installation of the cockpit module panel should be completed

within 15 - 20 minutes. Under normal conditions, the adhesive will begin to cure in about 25 - 30 minutes. After

installation, the module panel should not be moved or disturbed until the adhesive is fully cured (about 3 hours).

Checklist

Before mixing the adhesive and installing the cockpit module the following items should be checked:

• Familiarise yourself with the precautions in 1.2 GENERAL PRECAUTIONS.

• Ensure the adhesive being used is the material recommended by Holden Ltd.

• The vehicle surface should be finished and the paint fully dry before installation.

• Clean any over spr ay, greas e, oil, dirt, etc. fr om the glue trac k us ing an agent such as ‘Prepsol’ and A CLEAN,

DRY, LINT FREE CLOTH.

• Test fit the module panel in the glue track BEFORE MIXING THE ADHESIVE.

• Is the adhesive applicator gun clean and ready for use?

• Install the main wiring harness plate in position on the module panel.

• Are the cockpit module bolts readily accessible?

COCKPIT MODULE PANEL INSTALLATION

1. Clean any remaining adhesive from the glue

track using a hot knife or heat gun and tool if

necessary.

2. Temporarily install the cockpit module without

adhesive to check fit. Panel should sit in the

centre of the glue track. Rectify any faults

found, then remove from vehicle.

3. Install the harness side plate onto the right

hand side of the module panel.

4. Check each item in CHECKLIST, MIXING

SILICONE ADHESIVE.

5. Mix the silicone adhesive and fill the applicator

gun as described in ‘Mixing Silicone Adhesive’

in this Section.

6. Begin filling the glue track from the lowest

points to prevent air bubbles forming in the

adhesive. Completely fill the channel in a

continuous bead.

7. Apply a patch of adhesive approximately

50 mm diameter to the base or the windshield

pillar.

Figure 1E-64

IMPORTANT: The glue track or any adhesive

remaining within, must be thoroughly clean and free

of grease, dirt, dust, paint over spray or other

foreign material.

NOTE: Do not attempt to install a fully built-up

cockpit module assembly.

8 Have an assistant help install the cockpit

module panel.

9. Push the panel firmly into the glue track

channel until mounting bolt holes align. Check

to ensure that the section above the main

wiring harness hole is correctly installed.

10. Using two new bolts, install the two cockpit

module retaining bolts in the plenum chamber

and tighten to the correct torque specification.

COCKPIT MODULE TO PLE NUM

CHAMBER RETA I NING BOLT 15 - 35 Nm

TORQUE SPECIFICATION

11. Using two new bolts, install the two cockpit

module retaining bolts in the A pillar and tighten

to the correct torque specification.

COCKPIT MODULE TO A PILLAR

RETAINI NG B OLT 35 - 65 Nm

TORQUE SPECIFICATION

12. Wipe any excess adhesive from the plenum

drain holes and shroud panel areas (T he arrow

in Fig. 1E-65 shows the location of the LHS

plenum drain hole).

13. After installing the cockpit module panel,

immediately wipe the exces s adhesive f rom the

applicator gun and follower plate.

Figure 1E-65

REINSTALL

Reinstallation of the cockpit module and

components is the reverse of the removal

procedure, noting the following.

1. Ensure all the rubber grommets and insulation

materials are installed onto the cockpit module

panel.

2. Ensure all fasteners are tightened to the correct

torque specification, refer 3. TORQUE

WRENCH SPECIFICATIONS at the end of this

Section.

3. Ensure the HVAC unit drain tube is correctly

installed.

4. Use new O - rings when installing air

conditioning components.

5. Ensure that all wiring harnesses are correctly

retained and routed correctly, refer to Section

12N FUSES, RELAYS & WIRING

HARNESSES.

6. Re-charge and leak test air conditioning

system, refer to Section 2C AIR

CONDITIONING - SERVICING AND

DIAGNOSIS.

7. Ensure stop lamp switch and cruise control

release switches are adj usted c orrectly, refer to

Section 12B LIGHTING SYSTEM and Section

12E CRUISE CONTROL.

8. Top up and bleed brake hydraulic systems,

refer to the Section 5A – STANDARD

BRAKES or Section 5B – ABS AND ABS/ETC

of this Service Information CD.

9. Refill cooling system with the specified coolant

and pressure test cooling system, refer to

Section 6B1-1 ENGINE COOLING - V6

ENGINE, Section 6B1-2 ENGINE COOLING -

V6 SUPERCHARGED or Section 6B3

ENGINE COOLING - GEN III V8 ENGINE.

10. Ensure throttle and cruise control cables are

routed and adjusted correctly, depending on

engine variant, refer to the relevant Sections of

this Service Information CD.

IMPORTANT: Enable the SRS system. Refer to

ENABLING THE SRS Section 00 Cautions and

Notes.

3. TORQUE WRENCH SPECIFI CATIONS

Accelerator pedal bracket securing nut ................................ 20 - 30

Air conditioning compressor suction and discharge hose

pad retaining nut................................................................... 28 - 42

Air conditioning fitting to FDR ............................................... 7.5 - 12.5

Blanking plate securing nut................................................... 20 - 30

Brake line connections.......................................................... 8.0 - 11

Brake master cylinder bracket attaching nut......................... 15 - 20

Brake master cylinder retaining nut ...................................... 15 - 20

Brake pedal assembly securing nut...................................... 20 - 30

Brake pedal assembly securing screw ................................. 20 - 30

Centre console bin retaining nut........................................... 1.0 - 3.0

Centre console securing screw............................................. 1.0 - 3.0

Centre facia assembly securing screw ................................. 1.0 - 3.0

Centre facia support rail attaching screw.............................. 1.0 - 3.0

Cockpit module to A pillar retaining bolt................................ 22*

Cockpit module to plenum chamber retaining bolt................ 25 - 30*

Demist nozzle retaining screw .............................................. 1.0 - 3.0

Diagnostics Link Connector (DLC) attaching screw ............. 1.0 - 2.0

Earth strap retaining screw to cockpit module...................... 2.0 - 4.0

ECC securing screw ............................................................. 1.0 - 3.0

Engine hood bracket retaining screw.................................... 10 - 25

Front wiper arm attaching nut............................................... 20 - 25

Front wiper motor and linkage assembly securing screw..... 4.0 - 6.0

Front wiper motor linkage securing screw............................ 7.0 - 9.0

Heater and air conditioning controls securing screw ............ 1.0 - 3.0

Heater case assembly to cockpit module securing screw.... 6.0 - 14

Horn bar and air bag assembly to steering wheel securing

screw..................................................................................... 10 - 14

In-car temperature sensor retaining screw........................... 8.0 - 11.3

Instrument cluster assembly securing screw........................ 1.0 - 3.0

Instrument facia assembly retaining screw........................... 1.0 - 3.0

Instrument panel carrier end panel attaching bolt................. 3.0 - 5.0

Instrument panel carrier end panel attachment screw.......... 1.0 - 3.0

Instrument panel carrier rail assembly securing screw......... 1.0 - 3.0

Instrument panel compartment attaching screw................... 1.0 - 3.0

Instrument panel compartment lock striker attaching screw 1.0 - 3.0

Instrument panel end cap cover attaching screw ................. 1.0 - 3.0

Instrument panel fuse and BCM panel retaining screw........ 1.0 - 3.0

Instrument panel pad retaining screw................................... 7.0 - 12

Instrument panel speaker .................................................... 1.0 - 3.0

Lower left side rail connecting screw.................................... 1.0 - 3.0

Lower steering column cover screw ..................................... 0.5 - 2.0

Main wiring harness cabin protector securing nut................. 6.0 - 14

Passenger air bag securing nut............................................ 15 - 25

Passenger air bag support rail securing screw..................... 7.0 - 12

Receiver drier to TXV connecting bolt - V6........................... 7.5 - 12.5

Steering column bracket outer support securing screw........ 3.0- 5.0

Steering column clevis cam bolt........................................... 23 - 30

Steering column retaining nut (at base of column) .............. 15 - 30

Steering column upper mounting screw ............................... 15 - 30

Steering wheel securing screw............................................. 40 - 50

Support steering column bracket inner securing screw........ 3.0 - 5.0

Thermal expansion valve plate retaining bolt........................ 7.5 - 12.5

Throttle relaxer to cockpit module retaining nut.................... 2.0 - 3.0

Transmission console retaining screw.................................. 1.0 - 3.0

* Use new bolts

4. SPECIAL TOOLS

TOOL NO. REF IN TEXT TOOL DESCRIPTION COMMENTS

179 1308 0000 RADIO REMOVAL TOOL Previously released for ‘T’ cars.

ETX30H TORX BIT

J25359-8 TORX BIT HOLDER