Holden Commodore Full Workshop Manual

Holden

Eommodore.

Holden

SERVICE

FOREWORD

The information
conjunction

Manual
M38265,
M38366
L6 &
Service
ifications and
modore and

Transmission,

similar
service
these assemblies,
existing

The Section
quickly

Sections.
tabs on

identifier
index is
addition.
individual operations
for
Section

Summaries
also

Service
from:

General
assume
any

makers.
All

in
information
The right
without

EFFECTIVE:

SERVICE

l.s.B.N. 0.86836
PRINTED IN

M38145,

VC

and

VB

Engines

Manual Supplement

those

to

repair and

Service

locate

Bend

the

for the

included at
numeric

vehicle components

where apProPriate.

included

Tools,

Motors-Holden's

responsibility

such

information,

this Supplement

notice.

in this

Holden

with

Holden

o1

items

available

is reserved

MANUAL

'VB'

Service

Number

Service

new service

Calais

brake

front

used

overhaul

and

Manuals.

lndex on

numeric

the

the Manual

pages

group

identifiers are

Special

the end

at

unless
Kent-Moore

I

Unit 3, 9
Thornleigh.
Telephone

which may

illustrations and

MARCH,

009

AUSTRALIA

Manual

2 M38401

in other

this

and

of

the beginning
within

are

Service

otherwise

for the

are

at

1984.

NO.

0

MANUAL

Supplement,

Commodore

Station

Manual

M38731,

procedures

VK Series

and

reference should

identifiers

locate
Sections

of Sections.

Australia

Pioneer Avenue,

N.S.W.

l02l
does

based on
the time ol
to make

M39101

Wagon

Supplement

lmproved

,

M38338

vehicles.

rear axle

GMH

procedures

page

enables
to expose

back

the tab

you

of

also

the Sections.

provided

Tools,

specified, are available

PtY'

Australia'

848'9777

not

products

be available

specifications

publication

changes

VK SERIES

used

when

'VB'

provides

lor

assemblies

vehicles.

for each

wish

each

used

the end

at

where

Ltd.

endorse,

this

of

the

Service

series

Supplement

(Number

Performance

VH

and

are

indicating

latest

Series

new spec-

Holden Com-

are
No major
given

made to

be

the user

group

the black

the

find. An

to
Section.

to signify

Specifications

required, are

2120.

Telex

firm nor for

from other

at any

the

of each

22355

prefer,

contained

product

apProval.

time

Ealais.

SUPPLEMENT

SECTION

in

1)

for

to
of

In

or

OA

I

2

GENERAL

LUBRICATION

B

A- BoDY

_

RADIATOR

C

D _ BUMPER

vENTTLATToN&HEATING

A

-

B _ AIR CONDITIONING

3
4

5

6

7

8

9

10

FRoNTSUSPENSToN
REARSUSPENSToN

A-

_

REAR

B

_

PROP SHAFT

C

BRAKES

A- ENGTNEMEcHANIcAL

_

ENGINE COOLING

B

_

ENGINE

C

D - ENGINE
E _ ENGINE
F -

ENGINE

A - cLUrcH

_

MANUAL

B

_

AUTOMATIC

C

FUELTANK

A_
B - EXHAUST

sTEERTNG

wHEEts &

A _ BATTERY&CABLES
B _ LIGHTING

- INSTRUMENTS,

C

WIPERS/WASHERS

D _ RADIO &

_

WIRINGHARNESSES&

E

WIRING

F -

INFORMATION

BARS

AXLE

FUEL
ELECTRICAL
EMISSION CONTROL
TUNE

TRANSMISSION

TAPE

DIAGRAMS

INDEX

GRILLE

& UNIVERSAL

TRANSMISSION

SYSTEM

rYRES

SYSTEM

GAUGES,

HORN

&

PI-AYER

FUSES

JOINTS

WINDSHIELD

GENERAL

COPYRIGHT

Reprocjuction

MOTORS_HOLDEN'S

SERVICE

_

GENERAL

in whole or

DEPARTMENT

MOTORS-HOLDEN'S

prohibited

in

oart

SALES

2

without

PTY. LIMITED

PTY, LTD

SALES

wrrtten

approval

GENERAL

INFORMATION OA-1

Ref. Subject

1. GENERAL

2. MODEL
EOUIPMENT
POWER

3.
ENGINE

4.
EXTERIOR

5.
SERtAL

6.

LOCATION

6.1
SAFEW

6.2

BODY

6.3

The VK Series
incorporating exterior,

The model
deletion
and
window sedan).

8VK19

8VK35
8VL19 Commodore
8VL35
8VX19 Calais

of

introduction of

the

DESCR|PT|ON.........--...................

AVAILABILITY

TRAIN COilBlNAT|OlilS

DAT4............

DIUENSIONS

NUMBERS.........................i.

OF

CO]IIPLIANCE

& OPTION

is a

line-up differs

the 69 body

Commodore SL

Commodore SL Station

Commodore

GENERAL

BASE

&

IDENTIFICATION

minor

interior and

MODEL

Berlina
Berlina

PLATE

IDENTIFICATION

facelift of

mechanical

the VH Series,

from

(4

style

the

door,

'19

body

LINE

Sedan

Sedan
Station
Sedan

UP

SECTION

INFORMATION

INDEX

Page
0A-1

oA-2

.....-..........

PLATES

......

1. GENERAL

the

4 window sedan)

style

4 door. 6 window

Wagon

4

door,6 window

Wagon

4

door,6

0A-2
0A-3
0A'3
0A-4
oA-4

0A-4
0A-4

VH

Series

changes.

with

(4

door,

window

the

6

OA

Ref.

Subject
VEHICLE

6.4
SYSTEM

6.5

VEHICLE
ENGII{E SERIAL

6.6

7.

ADDITIONAL GENERAL

DESCRIPTION

The
Timing
models, and
Electronic
Calais models.

The three speed
standard
available as an ootion on
Torquemaster four speed
on Commodore

The

option.
as an option

The following
train combinations, engine
for VK Series

litre L6

3.3
(EST),

litre

5.0

A five speed

IDENTIFICATION

SERIAL NUMBER......

Electrlcal
Frequency
Radio Frequency
Electrlcal Transients

engine, equipped

is the base engine

the 3.3 litre LO engine equipped

Fuel Injection

Trimatic

equipment

on

models.

SL

V8

engine

on all 3.3

manual transmission

charts contain

models.

NUMBERING

NUMBEB......

Transients and Radio

Interference

Calais and

litre L6 EST engines

INFORMATION....

lnterference ..........

with Electronic

tor SL and

(EFl)

is the base engine on

Automatic Transmission

Berlina models and

Commodore

manual transmission

is

available

model

data and exterior

SL

on all

is

availability,

Page

0A-5
0A-6
0A-6

nA-A I

.:E

9t'9 r

NA-A I

0A-7

Spark

Berlina

with

is
is

models.

models as an

also available

The

is standard

power

dimensions

3

OA.2

GENERAL

2.

INFORMATION

MODEL

AVAILABILITY

& BASE

EQUIPMENT

BODY

STYLE

Sedan

S/Wagon

Sedan

S/Wagon

Sedan

ENGINE

MODEL

NO.

8VK19
8VK35
8VL19

t'V LJ5

8VX19

MODEL

NAME

Commodore
Commodore
Commodore Berlina
Commodore
Calais

SL
SL

Berlina

3. POWER

TRANSMISSION

TYPE

4

Speed

Manual

No.

OF

DOORS

4
5
4
5
4

ENGINE

3.3 EST

3.3

3.3

3.3

J.J EFI

TRAIN

AVAILABILITY

SL Sedan

SL

Station Wagon

Berlina

Berlina

4

Speed Manual

EST
EST
EST

4

Speed Manual
3
3

Speed Auto

3

Speed

COMBINATIONS

MODEL

Sedan

Station Wagon

TRANSMISSION

TYPE

Speed Auto

Auto

FIRST

RATIO:

3.50

SHI FT

LOC.

F loor
Floor

Floor
F loor
Floor

GEAR

1

REAR

AXLE

RATIO

:l

?na

3.08

3.08

3.08

3.08

REAR

BASE

3.08

TYRES

14

BR78S
cR78S14
cR78S14
cR78S14

P20s/

60HR 1 5

AXLE

5.50 JJX14

6.O JJX

6.0 JJX14

6.0 JJXl5

RATIO:

PERFORMANCE

WHEELS

6.0 JJX14
I4

1

Steel
Steel
Steel
Steel

Alloy

3.3

Litre

Six Cylinder

EST

3.3

Litre

Six Cylinder

EFI

5.0 Litre

Eight

Cylinder

5

Speed Manual

Speed

Automatic

Speed Automatic

3 Speed

Au tomatic

SL

SL Station

Berlina

Berlina

SL

SL

Station Wagon

Berlina

Berlina

Station

SL

Berlina

All Models

Sedan

Wagon

Sedan

Station Wagon

Sedan

Sedan

Wagon

Sedan

Sedan

la

Ca

is

3.24

2.31

2.31

z.J I

3.36

3.08

3.08

2.60

3.08

4

GENERAL

INFORMATION

OA.3

ENGINE

PISTON
NOM.

COMPRESSION
NUMBER

BORExSTROKE-mm
TAXABLE
POWER K.W.

@

TOROUE

@

DIMENSIONS

DESIGNATION

DISPLACEMENT

- cc

OF

CYLINDERS

H.P. RAC or SAE

DIN

R.P.M.

Nm DIN

R.P.M.

BODY

RATIO:

4. ENGINE

3.3 L]TRE

3298

1

EXTERIOR

5.

8VK19

8.8
6

92.O75 x 82.550

31.5

kw @ 4200

86

Nm @ 2400

232

SEDAN

DATA

EST

3.3 LITRE

92.075 x 82.550

106 kw @ 4400

266 Nm @ 3200

DIMENSIONS

MODELS

8VL19

8VX19

3298

8.8
6

31.5

EFI

STATION

5.0

LITRE

5044

9.2

R

101.60 x 77

51.2

kw

117

336 Nm @ 2400

WAGON

8VK35 I

.775

@4000

MODELS

8V135

OVEBALL
OVERALL
OVERALL
WHEELBASE
OVERHANG
OVERHANG
TREAD
rREAD -

LENGTH

WIDTH

HEIGHT

_
_

FRONT

­REAR

FRONT

REAR

4713.5
1722

I 378 1374

2668

922.5 922.5

1123

1451 .3

t4 lo.3

4713.5 4713.5
1722 1722

| 2668 2668

1

123

1451 .3

1416.5

1 360

922.5

1123

t45 I .J

1416.5

4716.5

I

1722

401

1

2668

922.5

1 126

t45 | .J

1440

Dimensions

4716.5
1722

465

1
2668

922.5

ttlo

.3

1451

1440

mm

in

5

OA-4 GENERAL

The

complete vehicle
vehicle
stamped

warranty
vehicle
tion with

are identified

into

claims

identification

the

affected.

the

identification

part.

product

or

number

and

by number

lt is

INFORMATION

6.

SERIAL

various

essential that

and field reports
'VlN'

number

components
plates

or numbers

when

quoted

is

of the

of the

compiling

that

in

conjunc-

component

NUMBERS

the

6.1 LOCATION

Plates

are

ment

SAFEW
BODY

Fig. 0A-3.

VEHICLE

(Not

Plate
Fig.

AUSTRALTAN
VEHICLE

VEHICLE

MONTH
VEHICLE
SEATING
GROSS

attached

and the front

COMPLIANCE

AND

OPTION IDENT|F|CAT|ON

IDENTIFICATION

6.2

SAFETY

applicable

to Export).

stamped

0A-2.

DEStcN

MAKE

-

MODEL

AND

YEAR

SERIAL

CAPACITY

VEHICLE

OF IDENTTFICATION

PLATES

to the left

panel

side wheelhouse

(reler

upper

PLATE

-

PLATE

COMPLIANCE

with

the

following

RULE

NOS.
HOLDEN.
NAME

AND

STYLE.

OF

MANUFACTURE.

NUMBER.

OF

VEHICLE.

MASS

IN

KILOGRAMS.

Fig. 0A-l).

Refer Fig.

PLATE

Refer

-

information:

(A.D.R.)

reinforce-

0A-2.

-

Fig.

0A-4.

PLATE

Refer

Flefer

TO

COMPLY

1,2,

3A. 40,58.

21, 22A,

3-84
GVw

THIS PLATE

AUSTRALIAN

THIS

VEHICLE

GENERAL

WITH

23A,

IS

MOTOF

Flgure

0A-1

WAS

MANUFACTURED

MOTORS-HOLDEN'S

AUSTBALIAN

7,

6,

108,

8,

25A,

27 C,

Ks

WITH THE

VEHICLE

Flgure

11.

0A-2

24,

AFFIXED

BY

MITED

LI

DESIGN RULES

12,

14, 15, 15,

28A,

n, 31,

APPROVAL

CERTTFICATION

1aA,20

34

AVKOOOOOTA

sEATING

NOS.

cAp.

OF THE

BOARD

s

6.3 BODY

Plate

stamped

Fig.

0A-3.

MODEL:

Combination
Body,

Model

BODY

BUILT:

Reference

A

-

NZ - New

TRIM:

Exterior

PAINT:

Exterior

The
in

conjoined
the

NO.:

Adelaide

date

which

production

&

OPTION

PLATE

with

the following

letters

of

and

Style.

number

Zealand

Paint

Paint

of manufacture

the

and the

followed

Colour

and Trim

Material

and

body

vehicle

line-

shell

IDENTIFICATION

information

and numbers

Assembly

by

M - Melbourne

combination.

Colour identificatron.

by calendar

and

is

driven

month

power

or

-

identitying

plant

ano

train

moved

Refer

the

Suffix.

vear

are

from

GENEFAL

CORRESPONDENCE

MODEL:
BODY NO.:
TRIM:
PAINT:
BUILT:

ENG.44

MOTORS_HOLDEN'S

TRANS.

MADE

6

MUST

BEAR THESE

VK8VL19

621423A

1442-63X
567-30518
MAR84

M4O

AXLE

IN AUSTRALIA

Figure

0A-3

LIMITED

NUMBERS

GU4

GENERAL

INFORMATION

OA-5

6.4

The Vehicle

based
This
characters.

the uniform

on

identify

is to

MODEL

ENGINE
MODEL
ASSEMBLY
SERIAL
SERIES

MODEL

VEHICLE

IDENTIFICATION

NUMBERING

ldentification

DESIGNATION
Division ­Degree

Body style

Numbering

Model

Car

vehicle

the

DESIGNATION

Division

Degree of

Style Code

Body

CODE

YEAR CODE

PLANT

(Sequence)

CODE

1st

Character

of Luxury -

K - COMMODORE

code -

19 - Sedan

Station

35 -

SYSTEM

System

Designation

in one

Luxury

coded

CODE

NUMBER

8 - Standard

-

2nd Character

'SL'

4th character -

&

3rd

(4

door,

Wagon

(V.l.N.)

series

6 window)

is

System'

of

Numeral

:-

L

-

L. COMMODORE

The significance
characters is
identification

GENERAL

r

o

allocated

"BERLINA"

19 Body Style

of these characters or blocks of

explained below, using as an example

number:-

8L19LDL60oO25K

MOTORS-HO LOEN'S LIMITEO

to GMH

ldentification

Limited

"CALAIS'

X.

ENGINE

MODEL

ASSEMBLY

SERIAL

SERIES

CODE

Sth Character

YEAR

6th Character

7th & 8th

(Sequence)

to

9th

CODE

14th Character

L - Engine

-

L - 3.3

CODE

This

OPerations
D-1984

PLANT CODE

Jl thru

13th character -

NOTE:

e.o.'VK'.

litre

D

-

letter

Characters

J9

NUMBER

This designates

(00001)

-

EST

ldentifies

­changes

OnlY:-

E-1985

J6

-

Melbourne

-

00025 -

and

K

GMH

ldentification

litre EFI

3.3

K

-

Year.

Model

1st September

F-1986

Australian

­thru J9

L1

sequential

the Seriat

continues

Limited

Model

Code.

T - 5.0

each

Assembly

Adelaide

-

Production

Number

Unit

Numerical

in

Designation

Code

litre

year

ldentification

Plant

serial

at each

Sequence

"

&

Number.

for

relates

Code:'

Vehicle

regardless

each

Internal

GM

to

Plant, starting

vehicle

of

Model

Programme.

at

type-

Flgure 0A-4

7

0A-6

GENERAL

INFORMATION

6.5 VEHICLE

The

vehicle

left

hand

1.

DESIGN

2.

VEHICLE

3.

ASSEMBLY

4.

ASSEMBLY
'M'MELBOURNE.

5. REQUIREMENT
DUPLICATION.

6. REQUIREMENT
FURTHER

serial

side

strut

RULE

SERIES'VK'.

PLANT

PLANT

SERIAL

number

tower

COMPLIANCE

nEr

II

AVK

The

engine number

pad

above

top

front

engines.

OOOOO1

6.6 ENGINE

the right

left

for 3.3 litre

side

SERIAL

is

stamped

Refer

-

SERIAL

IDENTIFICATION

IN

IN

NO.

Fig.

LETTER.

NUMBER.

EVENT

EVENT

DUPLICATION.

Fllol

TT

R2

SERIAL

hand
of cylinder

engine is

engine mounting

and

NUMBER

on the

0A-5.

OF

OF

top

'A'

ADELAIDE.

SERIAL

SECOND

E

T

I

A

NUMBER

stamped

boss,

case for

of the

NO.

OR

on a

and

at

5_0 litre

Figure

0A-5

ENGINE

J

ELECTRICAL
FREQUENCY

Electronic
perform

instruments,
timing.
tion

by

(RF)

radiation.

RADIO
One

ignition
telephones­RF

interference.

prevent

To

NUMBER

circuits

a number

electronic fuel

These

electrical

FREQUENCY

of the

system;

The

Resistors
connectors.

Capacitors

Metal
covers
ning

equipment.

damage

Do

not
tension
suppressed

Do

not
pression

PREFIX

VL
VK
VT

7.

TRANSIENTS

INTERFERENCE

are used in

functions

of

circuits

transients

chief

other

following

and choke

braid

made

to

replace
ignition

types.

remove
filters

injection

can be

sources

sources

e.g. high

lor

damaged

or excessive

INTERFERENCE

of RF interlerence

are normally

screening

from

conductive

equipment:

interference

cables

or reposition

or cagacitors.

ENGINE

J.J

3.3 litre EFI

5.0 lltre

ADDITIONAL

AND RADIO

VK

Series rnodels

associated with

and

or

include

CB radio

used

tension

coils.

leads

material

-

suppressed

or conneclors

interference

TYPE

ilIre

trS I

Automatic

GENERAL

electronic

electronic spark

cause mallunc-

radio

frequency

is the

radio

and

to suppress

cables

or suppression

for

scree-

high

with

sup_

INFORMATION

to

and

un_

8

GENERAL

INFORMATION

OA.7

ELECTRICAL

Electrical
the sudden
Older

serious

quality

systems.

It

disconnected

Indiscriminate

also

transients are

switching or

timing

style

transients,

equipment

is

SOURCES

IN A
(EXAMPLE)

good

also

cause

1. ALTERNATOR

2. ELECTRIC
3,

4.

5.

6. SPARK

7. IGNITION

8.

9. HORN

10.

ADDITIONAL
POOR
BETWEEN

OF
ENGTNE AND

before

transients.

OF INTERFERENCE

MOTOR

ELECTRIC WINDSCREEN
WASHER

BLOWER

ELECTRIC

WIPER

rGNlrloN

INDICATOR WITH VOLTAGE
STABILIZER

(e.9.

FUEL

ELECTRICAL

VEHICLE

THE

TRANSIENTS

high voltage spikes

lights and battery

practice

fitting of

VEHICLE

FUEL

MOTOR

WINDSCREEN

PLUGS

DISTRIBUTOR
colL

GAUGE)

SOURCE

THE VABIOUS

FTREWALL).

interruption of electric
it is important

hence

suitable

to ensure

using a battery

solenoids,

PUMP

OF

CONNECTIONS

(e.9.

BETWEEN

chargers

to use

for use

INTERFERENCe;

METAL

with electronic

that the

charger.

indicators or

PARTS

THE

produced

can

only

battery

relays can

by

currents.

produce

good

is

rfrh

-#

T*fl'-ffi

ffifffin4-"Fu

I
I

i
i

I

,dH

#m^

--:-=-..

rdlfu

:\': ::::l

[

___,--l

-

------\,

ld1a
T;-

q

Lja

=\

)w

llrrn

I iltl

'1iitT

'

:..1

l::

Vlr

E:T

l:l

H

!*\

-

'o

\

i/1

//

l/

\

)

I

1

9

Figure

0A{

LUBRICATION

OB.1

Ref.

Subiect

1.

GENERAL

1.1

RECOMMENDED

1.2

BRAKE

This section

VK

lnstructions

vehicles.

series

on

Engine -

for

Add
Manual Transmission

(Production

Manual Transmission

(Production

Automatic

Service

Cooling System

Brake Hydraulic

INFORMATION

FLUID REPLACEMENT.......

LUBRICANTS

1. GENERAL

provides

time

the

Service

Filter

Oil

Transmission

Refill .

System

details of

Refill

Option MC6) 3.3 Litre

Option

the lubricants specific

distance

or

(Dry)

M76)

intervals

(lnc.

SECTION

LUBRICATION

INDEX

Page

..................

Converter)

0B-1
0B-2
0B-2

INFORMATION

to

which

at

CAPACITIES

OB

Ref.

Subject

1.3

AIR CLEANEB..........

1.4

FUEL

1.5

services should be
Service
Owner Handbook.

ENGINE

3.3 Litre

5.0 Litre

3.3 Litre

3.3

5.0

3.3 Litre

5.0 Litre

3.3 Litre

5.0 Litre

FILTER

COOLING SYSTEM

and Maintenance

SIZE

ALL 3 Litres

EST 1.6

EST
Litre
Litre

ALL .62 Litres

canied

Section of the VK

out are

CAPACITY

12.0

contained

Litres

3.7

4.33 Litres

Litres

2.75 Litres

6.1 Litres
Litres

8.7

2.3 Litres
Litres

2.3

8.5 Litres approx
Litres

Page

0B-2
0B-3
0B-3

in the

Series

approx

10

OB.2 LUBRICATION

1.1

RECOMMENDED

LUBRICANTS

COMPONENTS

Engine

3.3

Litre EST

3.3

Litre EFI

5.0

Litre

Manual

Automatic

Rear

Rear
Power
Brake

Transmission
Production
Production

Transmission

Axle
Axle

L.S.D.

Steering

System

Option MC6
Option M76

SPECIFICATION

SE

I

SF Oils

Refer

Se

for

Owners Handbook.

SE Oils

HN1
HN1

GM9985286

HNi

181

HN1561

G N49985286

HN1 796

GMH

Oils
Oits

severe

service.

046
855

if unavailable

grades

For

grades

For

grades

For

SAE

8OW9O

Gear

Castrol

DEXRON

EP

DEXRON
Polyglycol

SAE

90

LUBRICANTS

and application,
and application,

and application,

Oil

80W

I[ Automatic Transmission Fluid

If Automatic

Brake Fluid

refer

Fig.

refer

Fig.

refer Fig.

Transmission

to GM

Specification

0B-i
0B-1

0B-1

Fluid

HN1796

1.2

BRAKE

polyglycol

The
hydroscopic
the

brake
decreases
possibility
ions
maximum
brake
brake fluid

2.1 in

The
by lightly
oiled. The
requrres
conditions.
checked

hoses
as the moisture

of

increases

brake

fluid

is

are

this

Supplement.

air cleaner

tapping

time

servicing

Under

for

operation.

FLUID

brake

and

a vapour

mandatory.

restriction

lluid
absorbs
etc. The

lock

with

the

effectiveness,

Service Instructions

covered

1.3

in

AIR

element may

the

element.

or distance

depends

dusty conditions,

more

REPLACEMENT

used in

moisture

boiling

content

under

age

Section

resistance

of the

a two

VK

Series

from

the

increases

heavy

fluid.

yearly

5,

Service

CLEANER

partially

be

lt should

intervals

on the vehicle

often that for

cleaned

not

at which

the

element

models

throuoh

air

of the flu'id

and so

braking

condit-

Therefore,

change

for

changing

Ooeralioi

of dust

be washed

the

element

operating

should be

normal

the

for

of

or

citv

-1oo

oo

DEGREES

1oo

2oo

_

CENTIGRADE

Fagure 0B-1

3oo 4oo 5oo

is

11

LUBRICATION OB.3

The air cleaner

distance

or
Handbook.

Service

cleaner

air
electronic
Service

On 3.3

{ilter is

attached
On

(Fig.
pump
front of

Fuel
intervals

Service

filter

fuel
in Section

interval specified

Instructions

element

fuel injection are covered

Operation

litre

engines

located in

to the right

electronic

is located on

OB-4)

attached

and

the differential.

lilters should

specified

Instructions

on electronic

6C, Service

tor the

in this

3.6

should be

removal and installation ol

(Fig.

element

1.4 FUEL

wilh electronic

the suction side

fender

hand

iniected

fuel

in the

the

to the

replaced at

be

VK

for the

tuel

Operation

removal

iniected

replaced at

in the VK Series Owner

0B-2),

Supplement.

on

in

the time

vehicles with

Section

FILTER

timing, a

panel.

vehicles,

pressure

floor

Series

3.15

spark

the fuel

of

Refer

side

pan

of

the time or

Owner

installation

a;rd

vehicles are

in this Supplement.

line and

Fig. 0B-3'

fuel filter

the

the

of

vehicle,

the

distance

Handbook.

coverecl

of

the
6C,

fuel

tuel

in

the

AIR CLEANER

N

G

HOUSI

FUEL

TO

MOUNTING

BRACKET

AIR FLOW

f

,\

METER

PUMP-\.

---l-')w-t

Figure

0B-2

INLINE

>-}^iq

c;

ll----

-*i-rl

R+

FRONT OF CAR

-\

/

I

;AlR

DUCT

/

FLOW

1.5

COOLING

The cooling
comprising
inhibitor to GMH specilication

It is recommended
system
rnixture
VK Series Owner

Reier to Service

System'

system is

1.5/o to 3.0 %

flushed and

the time and

at

this

of

filled initially with a coolant mixture

that the coolant be drained,

refilled

Handbook.

Operation

Supplement

(by

HN1109.

with

distance

for details.

SYSTEM

volume)

clean

intervals sel

2.2, Section 68

of corrosion

water

and

inhibitor

in the

out

'Cooling

12

the

_\)

)\

iA

lr

|

1r

6*

iq

MOUNTING

iii'')i'-\

ruur

ll ,

\,

\1'l

,

'Y;r/

/

CLAMP BOLT

Figure 0B-3

RUBBER_l

;

/t..\\

hl

NSULATOR

'\\

\

(

6/:

ryy-^,R

(-

,f.1'.t*

./','ffi\->(l

Figure 0B-4

--\

a

'

BODY

1A-1

Subjecl

Ref.

GENERAL

1.
UNDERBODY

2.

3.

4.

REAR QUARTER
STATTONARY

5.

Ref. Subiect

1.1 GENERAL

1.1 GENERAL

This Section
interior
Commodore

with

tion
Publications,
etficient
assemblies.

The VK Series
Style,
Station

The stationary

Styles are

with urethane

glass

the
35 Styles,
adhesive;

retain the JB

to

featured

Also
consoles,

and

seat

restraints

the Calais

On

to the

fitted
vision
adjustable

included on

is

VK

external

decals,

colour co-ordinated

and
assemblies.

Front

new.

also

contains

exterior

and

and

previously

it will

servicing

which is a

Wagon.

mirrors are

turn signal

includes

fifth and sixth

retained

adhesive,

the

and

the tailgate

same

the

on

new

door

front seats.

on

rear seats.

lumbar support

Berlina and

features

tailgate

1.2 SERVICE

CAIITiON:

volume

section
sedans,
During

use.
temperatures
cutting,

During

As a

polyurethane

of

the

ot

as

norma!

However,

material

this

repair

illustrated

seruice,

such

SECTION

CONTENTS

INFORMA

GLASS

.............

1. GENERAL

DESCR|PT|ON..............................

DESCRIPTION

descriptions and

service operations

body

models. When

Calais

released Commodore

provide

VK body

of

two different

window sedan and

six

in their upper

which creates

flange to which

metal

window is

material

Camira
instrument

model,

Windshields

VK Series are

trim designs

see

Electrically

standard

also

built
Calais

include new

handle

when

of

on

lamps and

sound

foam

rear body

in shaded

there

polyurethane

during

as

can

these

information

styles and

windows on

which

panel

facia

and

through

into the

models.

35 body

front

and

rear

NOTES

deadening

is installed

pillars

is no

welding or
release black
pafts

of

procedures

on

used

necessary

body styles:

the 35

quarter

rear

retained with urethane

controlled

exterior

bond between

a

it is applied.

is

used

and back

revised transmission

and

'see

through'

restraints are

head

this

on

drivers seat

ornamentation,

style,

rear bumper

lamp assemblies are

medium, a

into the

VK

of
areas

risk associated

is subiected

pungent

the body

1A-3

1A-19
1A-21

Page I Ref. Subject

VK

Series

in

conjunc-

Service

related

their

the

the new

apertures

production

in

windows'

instruments,

exterior

model. An

radiator

Commodore

Fig.

in

with

to

naked

fumes.

structure

1A

BODY

THIS SECTION

OF

Rel.

Subject

6.

SEATS & SEAT
EXTERTOR ORNAMENTATION

7.
ROOF RACK

8.

BODY ELECTR|CAL............

9.

10.

SPEC|AL

INFORMATION

INDEX

its

1.2

SERVICE

involving high

against
spirators,

ver

the use of
IMPORTANT:

mouldings,

which require

to a vehicle after
exists for sheet
the metal
affected
of the
material
appearances.

The reliability

installations must become the

and

reason,
Dealership
proper
metal corrosion
'add-on'

CAIJTION:

panels,

handle

fume

forced

possible,

high temperature

Dealer name

has been

by

painted

may contribute

installer

the

you

steps are

equipment.

trames,

these components

1A-1 |

lor

for

'19

style

19

On

head

rear

back

grille

bar

small

upper

1A'1.

high

flame

ASSEMBLIES.....-....

BELT

TOOLS ...,....

NOTES

Flgure lA-'l

heat

application,

inhalation

ventilation, etc.,

such

Whenever

piercing

it has

metal corrosion

water entry at the

or

and

should evaluate

(and

outside

being

protection

To avoid

instrument

such

repairs

should

producing

items

plates,

of sheet

been

pierced,

treated surfaces by

to corrosion

performance

(Dealer

or

the

sublet

taken to

damage

c/usters, etc.,

with the

....................

sEcrroru

BELT

SEAT

appropiate

as

are

mud/9lash
metal

manufactured,

to occur

as

point

responsibility of

vehicle owner).

procedures

provide

to offset

when servicing

wearing ol

the

mandatory.

be canied out

equiPment.

such as

panels,

in

well as other

piercing.

of

the

and

'add-on'

of

appropriate

it

utmost

to assure

the

ls

care.

shops)

Page
1A.31
1A-39
1A-s1

......

..... 1A-53

1A-67

Page

1A-1

A-A

precautions

Whene-

without

body side

guards,

areas

used

etc.,

added

are

possibility

a

where

areas

Abrasion

'added-on'

unsightly

equipment

maker

the

For

your

in

that

sheet

etfects

instrument

essentia/

re-

this

of

to

13

1A-2

BODY

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Ref. Subject

2.1 UNDERBODY
LOCATIONS.

TRANSMISSIONCONSOLE.MANUAL......

2.2

llodel

Models
with

Wlndows......

TRANSMISSION
AUTOMATIC

DIUENSIONS

'SL'

-

Remove
Relnstall

Calais &

-

Power Operated

Remove........

Reinstall

CONSOLE.

Remove.,,..-..
Relnstall

&

Berllna fltted

Slde

HOIST

2.

UNDERBODY

INDEX

Page

1A-2
1A-3
1A-3
1A-3
1A-3

1A-3
1A-3
1A-3

1A-5
1A-5

'tA-5

Rel.

2.4 SHROUD

Subject

HAND ......--..-

ROCKER

LEFT HAND.

FLOOR COVERING

LOWER TRIM

Remove....--..

Reinstall

PANEL COVER

Remove........

Reinstall

Remove....,...........

Reinstall

BODY

.

RIGHT & LEFT

RIGHT &

-

1A.3

Page

1A-6
1A-6
1A-6

1A-6
1A6
1A-6
1A-7
1A-7
1A-7

2.1 UNDERBODY DIMENSIONS
HOIST LOCATIONS

Fig. 1A-1A.

Refer

2.2 TRANSMISSION CONSOLE
MANUAL

MODEL.'SL'
Remove

ground

1. Disconnect

2. Unscrew
screw cover
reat of
Fig. 1A-2).

3. Partially
connectors

Reinstall
Reverse removal operations, ensuring

is

sealer
screws

prior

MODELS. CALAIS
POWER

Remove

Disconnect battery

1.

2. Unscrew
remove

With console

3.

end of

screws

tunnel bracket

4. Partially
ical connectors,
disengage
bracket
sole assembly.

battery

from

knob

buttons and

console

raise console then disconnect

prior

to removal of

the threads

applied

OPERATED

to

to their

cover

securing

installation

&

from

knob

from handbrake

compartment

(refer

front

(refer

in base of

rear

then easing

Section B-B,

carpet

raise rear end of console,

cable.

gearshift

to transmission

BERLINA FITTED

SIDE

ground

gearshift

end

Fig.

end of

control

screws securing

transmission console.

that

the console attaching

of

(refer

Fig.

WINDOWS

cable.

control

lever.

lid raised,

console

of console

1A-3) then

disconnect electr-

console

console

Fig.

1A-3)

AND

.

lever, then

front

and

tunnel

non hardening

1A-2).

which covers

to transmission

remove

from

(refer

electrical

WITH

lever then

remove rear

screws.

reanvards

attaching

remove con-

to

Reinstall
Reverse

removal

operations.

15

1A.4

BODY

cll---->c,

PLACES)

{4

Ascnew.-----..---..-->s

(4

PLACES)

...-..--.

A

11",

2.4 - 3.4 Nm

VIEW

_

>:\

rFrl

a

#

W

i

EOOT
TOWARDS

€

STRAP

FRONT

TO

,/-

z-

BE

WIPER

HEATED

swlrcH

PLACED

OF

CAR

IWASH

ER

SWt TCH

REAR

WTNDOW

AssEMBLY

ASM.

VIEW

TRANSMISSI

SECTION

SEAL

SCREW

OR

EOUIVALENT

SEALER.

(4

PLACES)

GEABSHIFT
CONTROL

ON CONSOLE

A_A

WITH

NON.PORITE

NON-HARDENING

LEVER

BOOT

ASM.

OUU I

RETAINER
(9

PLACES}

REFER

SECTION 12E

ELECTRIC
WINDOW
SWITCH ASSEMBLY

/t \ I

.5 -

2.0

vrEW

a

DOOR

REGULATORS

Nm

Flgure

1A-2

TRANSMTSSTON

,.-

BEFORE
NEOPRENE
OF BOOT
THUS,

FOR

/-

'

REFER

CONTROL

g:3I:

LEVER

INSTALLATION

CEMENT

OVER

///////

CONNECTTON

SECTION 12E

acARPET

/-**-f.* /

r_

-_

r coN

lf

BOOT

AREA

COVER _

rR

TO INSIDE

SHOWN

/

o L --r

APPLY

FOR

AUTO

TRANS

3? I:3

""?:'j

":

533|,13'^G

,^

/

-r'

_=_==3*{

SECTION

B_B

A

TRANSMISSION
CONSOLE

APPLY TRIM

AREA

OVER
THUS

B

r.'/

-

PO

INT'A'

,6, s.t-SPEED

_----

-

:4

;

--

"-4:1

-

NUT

\\\\\\\

=,

SECTION

ADHESIVE

SHOWN

(

u

l

/i-

961=)

-->-rr-

ASM.

Y

A_A

Figure 1A-3

16

BODY 1A-5

TRANSMISSION

2.3

CONSOLE

AUTOMATIC

Remove

1. Disconnect

2.

Using a

wide bladed screwdriver, carefully
from console
through 90C, then

lever.

3.

4.

Remove
console

On

gear

(refer

'SL'

models, remove screw cover buttons and
scrervs securing
transmission tunnel

5.

On

Berlina
compartment
base of console
end of console
Section

Partially raise rear end of console,

6.
electrical

B-8, Fig.

connectors
to disengage
bracket

(reler

screws and console

Reinstall
Reverse

relerring to

4.

removal operations ensuring

automatic

is observed.

ground

battery

(refer

remove

cable.

Section C-C,

cap of

lever location indicator scale

Sections

and

lid and

A-A

lront

and

(refer

Calais

remove rear

and

rear

Fig. 1A-2).

models. raise console

which covers screws securing

to transmission tunnel bracket

1A-3)

front

end of

Section

remove

then

then,

easing

console

B-8, Fig. 1A-3), then

assembly.

console scale

.

prise

Fig. 1A-4) turn cap

gear

'T'

bar

Fig. 1A4).

B-B,

end

end

screws.

console

from attaching

installation

control

from

of console

of carpet

(refer

disconnect

rearwards

remove

the note

that

in Fig.1A-

cap

to

in

rear

_

CONSOLE

WITH GEAR SHIFT LEVER

IN NEUTRAL, ALIGN'N'ON

WITH INDICATOR

SCALE
ARROW

RETAINING

ON COVER

CAP

BEF

SCALE.

i././r2,./

CONTROL
OPENING

LEVER

COVER

<.,/

€

'

+---___>

sEcrroru

\

srcrroru

(4

PLACES)

C-C

sEcrroru

A-A

RETAIN
AS

SCALE

SHOWN

B--B

CONSOLE

CAP

TRANSMISSION

SELECTOR

INDICATOR _ TRIMATIC

1A-4

Figure

17

AUTOMATIC

TRANSMISSION

1A-6

REMOVE

1.

2.

REINSTALL

REMOVE

1.

BODY

2.4

SHROUD

Prise

front

panel

rocker
lower

front
assembly from
Section

Using

a fabricated

Special Tool

trim

and

(refer

head

prise

ly

Reverse

2.5

ROCKER

Using

a

outer

edge

cover

from

(refer

Fig.

LOWER

LEFT

end

(refer

end

A-A,

fasteners

door

Fig.

Section)

shroud

Siections

removal

PANEL

LEFT

wide

bladed

cover

of

door

1A-5).

TRIM

HAND

of front

Section

of linishing
14-6).

panel

from

operations.

rocker

A-A, Fig.

opening

trim

clip removal

located

and direcily

B-B

and F-F, Fig.

shroud

COVER

HAND

prising

and rocker

opening lower

tool

RIGHT

-

panel

1A-5)

lace

and weatherstrip

pinchweld

between

panel,

panel,

shroud lower

under

14-6)

removing

RIGHT

-

positioned

carefully

pinchweld

&

cover from

then

ease

(refer

flange

(refer

tool

fastener

careful-

trim.

between

prise

flange

&

REINSTALL

Locate
flange,
opening finishing
mallet,
retaining

NOTE:

that
retractor

front

ensuring

tap

flange.

On rear

it

butts

cover

cover

top

covers,

against

prior

over

that

ends

lace,

then

of cover

the rear

to tapping

fREAR

door

of

using

until it

locate

PANEL

\

opening lower

cover

overlap

the

hand

completely

front

end

end

cover into

ROCKER

COVER

of

of the front

position.

pinchweld

ends

of door

or a rubber

engages

rear

cover

seat

so

belt

;

/

FRONT

PANEL

ROCKER

COVER

secrroH

A-A

ROCKER

secrroru

PANEL

Figure

._-

B_B

COVER

1A-5

INSTALLATION

18

­secrrorv

A

C-C

BODY 1A-7

/r"

,-o*.*

SHROUD

SECTION

t*)

C-C

CARPET

ATTACHING

PLUG

PLACES

12

LOWER TRIM-\

SHROUD

SECTION D_D

CARPET

FLUTED

PIECE FLOOR

ONE

NOTE:

TRANSMISSION
CONSOLE

1A€

Figure

PROTECTOR

FACE

DOWN.

SECTION

TWO

\

t/

PIECE

-m

'a

REPLACEMENT

SERVICE

_

-.

CARPET

t

rAJ

A_A

TRIM

ttrt\trH

8VL,

SECTION

(RIGHT

secrrorrr

\

-

(LEFT

\

SECTION
(LEFT

SIDE ONLY)

X

-J

TRIM
FASTEN

B_B

SIDE ONLY)

-F

F

SIDE

ONLY}

F_F

EVK

E

R

8VL,

8vK

X

FLOOR COVERING

2.6

REMOVE

1. Disconnect

2.

Bemove

shroud

front

lower trims

battery

end

ground

cable.

rear rocker

(reler

2.5

and

3. Remove transmission console
Section).

4. Remove

(refer

5. Remove

Remove
inner

panel

Fig- 1A-7).

front

seat and

front

seat belt

and outer,

cover assembly

rear

seat cushion assemblies.

retractor

lower

attaching

this Section).
Using a

Special
carpet
carpet attaching
(refer

fabricated trim clip

Tool Section)

panel

rocker

and

plug, prise plugs

Section

C-C, Fig. 14-6) then

located between

and directly under

covering.

REINSTALL
Reverse

NOTE:
available from

removal

Separate

GM P & A as

operations.

front

and

rear floor

Service

panel

covers and

2.4 in this

(reler

2.2

2.3

or

from heater case

covers and

(refer

bolts

removal

tool

from rocker

remove floor

coverings are

Replacements-

Section).

in

this

seat belt

in

6.3
(refer

edge ol

head ol

panels

-

HEATER

COVER

.

LOWEB INSTRU\4E\T

PANEL

EXTENSION

PANIt.

TO

CASE

ASM.

19

Figure

1A-7

BODY

1A-9

Ref. Subject

SEHVICE

3.1
INSTRUMENT

3.2
RIGHT

3.3

Relnstall

CAIITION:
panels,

handle

3.2

To

frames,

components

these

INSTRUMENT

RIGHT

REMOVE

1. From

NOTE:
disengagement
trim t;

under

clip

trim

located
prise

clips

(refer

lower

Removal

Jteering

directly

NOTE

PANEL LOWER

& LEFT

HAND

3.1 SERVICE

damage

avoid

instrument

when

clusters,

with the utmost

PANEL

LEFT

&

instrument

removal

from

Section

of

adlustable

of

column

panel

(refer

tool

head of

under

attaching

Fig.

A-A'

hand

right

strap

(refer

Section

holes

TRIM.

NOTE

seruicing

it

etc.,

care.

LOWER

HAND

using

and

Special

trim

instrument.

in

removtng

1A-8)

trim

lower

which

D'D'

partially

FRONT

3.

Page

1A-9
1A-9

............

1A-10

instrument

is

essent€t/

TRIM

labricated

a

Section)

Tool

carefully

clip,

trtm'

necessitates

secures

1A-8)'

Fig'

INDEX

to

.

panel

END

Subject

Ref.

INSTRUUENT

3.4
HAND

3.5

INSTRUMENT
HAND
RADIO/CASSETTE

REINSTALL
Reverse

left
bracket
C-C,

removal

hand trim

and

Fig. 1A-8) and

hand trim

illustrated

as

PANEL

Remove
Reinstall

PANEL

INCLUDING

Remove........

Relnstall

operations

is

correctly

wiring

into

that

is located

in the accelerator

in Section

LOWER

LOWER

RADIO

AND

PLAYER

RECEIVER....

.....................

ensuring

that

located beneath

leading

the

Fig. 1A-8.

grommet

harness

B-B,

.

RIGHT

.

LEFT

edge

pedal

....... 1A-16

..

......-...

...

leading

dash

the

(refer

of

support

Page

1A-16
1A-16

1A.16

1A-16
1A-17

edge of

panel

Section

right

the

cap'

TRIM

5

\

\

\-2PLAcEs

"r

PART

LOWER
I NSTRUMENT
PANEL

ACCELERAToR--7

PEDAL
cr lopnFIT r-AP

--

-

erusunE

ASSEMBLED
PEDAL

secrroru B-B

TRIM BOARD
ASSEMBLED
WIRING

GROI\4MET

HARNESS

secrroru C-C

CLIP

_5PLACESR/SIDE

PLAcES

a

-

secrtoru

|,

-<

\

-

\

TRtM BoARD

SUPPORT

TO BE

INTO

L/slDE
LislDE&c6o

A-A

-

.>t

-,

IN ACCELERATOR

CAP

c6o

EXc.

LH INSTRUMENT

PANEL

ls

AS SHOWN

LOWER TRIM

8VX & C6O

RH

INSTRUMENT-/

PANEL LOWEB

RETAIN
PANEL LOWER
STEERING
WITH

tr LtrSJ5IhAT

TUCKED

AWAY OR TRIMMED.

TRIM

ADJUSTABLE

STFAP

FRONT EDGE OF

COLUMN

ADJUSTABLE

IUbtr

-_\

TRIM RIGHT SIDE

INSTRUMENT-

DASH

STRAP,

PANEL SEAL

TO

20

Figure

1A-8

1A.10

REMOVE

1.

2.

3.

4.

5.

6.

7.
within
to instrument

then

8.

With
screws

pad

9.

Using
loosen
to instrument panel
the
the
outlet
nut.

10.

Ease
anstrument panel
rnstrument
from

BODY

3.3

INSTRUMENT

Disconnect

Remove
section

Remove
outlet
disengage
harness (refer
assembly.

Remove
lower
(refer

Remove
assembly
1
ical

electronic
speedo
instrument

Remove
front
View

Using
hand

removing

of steering

screws

nozzle

extension

Fig.

1)

ease

connectors

head

instrument

radio

B,

Figs.

a fine

and left

side vent

screws

remove

instrument panel

securing

to instrument

a 10

right

same

left

hand

aperture
pad

vehicle.

ground

battery

screw

attached

column

securing

and touch

electrical

screws

1A-10).

screws
to instrument
assembly.

instruments,

(refer

assembly.

speaker

14-12

bladed

panel

outlet

mm

and

tool

with

attaching

reanaards,

panel

connectors

Fig.

14-10)

securing

to

base

securing

rearward

and

on

View

location

grille

and

screwdriver,

hand

upper

upper

securing

pad

assemblies.

rearward

panel

socket

centre

brackets

a 630

gain

to

slotted

pad

raised,

disengaging pad

PANEL

cable.

lower

(refer

instrument

panel

of

location

models,

all

the

A, Fig.

and speaker

14-13).

ouflet

upper

assembly

compartment

edge

brace

attached

nuts

mm

nut

access)

brackets.

cover

Fig.

lrom

from

then

top

of instrument

instrument

combined

cover

then

excepi

speedo

1A-1

(refer

cover

carefully

and lower

assemblies

air outlet

(refer

o{

(refer

to a ratchet

securing

(refer

Fig.

entension

(use

left

loosen

With

remove pad

PAD

from

1A-9).

frame,

instrument

disengage

instrument

Fig.

centre

main

remove

location

instrument

(refer

those

cable

j)

then

Fig.

assem-bly

prise

inserts

prior

assemblies

Fig.

open,

14-14).

pad

assembly

1A_11).

installed

hand

upper

off left

studs from

left

hand

assembly

upper

air

cover,

wiring
fram6

panel
cover

Fio.

1A_

eiectr-

with

from

remove

14_11)

lrefei

right

from

to

14-14)

remove

Danel

handle,

Usin!

oi
air

hand

of

A

..u

-

4.6

Nm

Flgure

1A-9

UPPER

STEERING

COLUMN

COVER

REINSTALL

Reverse
ctrcurts,
control

removal
air

cable

operations,
ducting,
disturbed

including

vacuum

during

removal

hoses

try-out

of

and

operations-

electrical

temperarure

21

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26

1A-16

3.4

REMOVE

1.

Disconnect

2.

Remove
outlet
(refer
from
assembly.

3.

Usjng

right
vent
upper
(refer

4.

Remove

section

5.

F_rom
disengage

switch
temperature
screws
base
Section
panel

6.

Using
headlamp
dimmer
lower.

BODY

INSTRUMENT

RIGHT

ground

battery

screws

nozzle

Fig.

main
a fine

hand

upper

air

Fig.

of

under

and

securing

instrument

of

A-A,

lower.

a

control

securing

and touch

14-10),

wiring

bladed
upper
outlet

ouflet

14-14)

screw

steering

right

electrical

dimmer

control

right

Fig.

wide

bladed

switch

panel

disengage

harness

screwdriver,

and lower

assembly.

assembly

then remove

attached

column

hand

connectors

control,

cable, remove

hand

location

1A-14)

screwdriver,

and dimmer

from

right

PANEL

LOWER

HAND

cable.

instrument

inserts

Remove

to instrument

lower

(refer

side

instrument

cover

then remove

hand

frame,

from

instrument

electrical

then

remove

carefully

from

screws

ouflet

assembly.

cover

Fig.

1A-9).

of instrument panel,

from

vacuum

panel

panel

(refer

carefully

control

instrumeni panel

centre

connectors

prise

-within
securing

panel

from

rear

of light

hoses

cover,

lower

'B'

View

instrument

housing,

.

air

cover

frame

out

side

pad

upper

and

then

to

and

prise
ihen

REINSTALL

Reverse
circuits,
control

removal

air

ducting,

cable

disturbed

operations,

vacuum

during

3.5 INSTRUMENT

HAND,

INCLUDING

RADIO/CASSETTE

REMOVE

1.

Disconnect

2. Remove
Section).

3.

Remove
Fig.

4.

Remove
Section

5.

With
the

blade
hinge
hinge
move

6.

Remove

Section).

7.

Remove

this

Section).

8.

Remove
connector (refer

9.

Remove
instrument
disengage
harness,

battery

earth

transmission

heater

1A-10).

A-A,

instrument panel

pin

pin

comDartment.

left
lett

then

case to

left

hand instrument panel

Fig.

1A-8).

of a

screwdriver

and right

compartment (refer

touch

screws

location

electrical

hand

shroud

hand

upper

switch
Fig.

securing

frame

remove

hand

1A-10).

connectors

including

hoses

removal

PANEL

RADIO

PLAYER

cable.

console

frame

(reler

panel

compartment

located

compartment

lower

side

vent

control

the

assembly

assemblv.

try-out

of electrical

and temperature

operations.

LOWER

AND

RECEIVER

2.2

or

cover

assembly

lower

trim

open

between

side,

Fig.

1A-t5)

(refer

trim

ouilet

panel

centre

from

and

(refer

front

2.4 in

(refer

nozzle

Fig.

e-nO wiring

.

LEFT

2.3 in

this
(refer
(refer

and with

head

prise

out

ihen re_

this

3.4 in

electrical

and

lA_10)

BUMPER

(2

PLACES)

of

\N

INSTRUMENT
COMPARTMENT

PANEL

Figure

1A-15

27

Ref.

4.1

Subiect
OUARTER

WINDOW

ilodels - 19 Body Styles

4.

INNER UPPER

....................

REAR

INDEX

Page

TRIM 1A.19

1A-19

QUARTER

BODY

1A-19

4.1

QUARTER

MODELS. 19
Remove

1.

Depress

then

ly
Section
onto

NOTE: On
necessary to
sleeves
seat back assembly.

2.

Unclinch
wheel-houses

3. Lift seat
to the

B-8,

onto a

front

ease

retainer from brackets attached

A-A, Fig.

a clean

rear

(refer

6.4

back frame

rear compartment

Fig. 14-16) then

clean

WINDOW

BODY

edge

assembly

1A-16) remove

protected
seats

remove

in this

tabs securing seat

(refer

protected

INNER UPPER

TRIM

STYLES

rear

of

rearwards to disengage assemb-

surface.

fitted

with

the head

Section)

View A,

from retaining brackets attached

front

place

surface.

cushion assembly

seat

floor

to the

place

and

head restraints, it is
restraints

prior

to removal

back

Fig. 1A-16).

panel

rear seat back

assembly

and

frame to

(refer

assembly

(refer

guide

rear

of

rear

Section

CUSHION ASM.­RETAIN

SEAT

BACK

RETAINER

secrroru B-B

ER

secrroru

REAR

COMPARTMENT

FRONT PANEL

k=-

,

REAR
BRACKET

A-A

FLOOR

Remove
Section

rear seat belt

B-B, Fig. 1A-17).

upper attachment

(refer

28

Flgure

Figure

'lA-16

1A-17

1A.20

BODY

5. From
securing
Fig.

is

to

6.

Ease
edge
a

broad

quarter
Sections
fasteners

panet.

Reinstall

Fleverse

inside

rear

trim

14-18)

to rear

on side

be removed.

rear

door

quarter

ol

bladed

panel,

inner

A-A

and

and

removal

operations.

compartment,

parcel

from

which

opening

window

finishing

inner

screwdriver

adjacent

B-B,

trim lrom

Fig.

rear

shelf

quarter

upper

located

to trim

14-19)

quarter

tap

(refer

fasteners

out

Section

window

lace

from

trim,

between

leading

then

trim

fasteners (refer

carefully

inner

A-A,

trim

usini

and

prise

upper

SECTION

A_A

FA5 III\EH

(3

PLACES)

Figure

REAR

SHELF

1A-18

PARCEL

TRIM

IaUARTER

WINDOW
INNER

UPPER

NOTE:
fastener

Damaged

barbs

replacement.

on trim

panel

fasteners

requtre

secrroru

{4

PLACES

A-A

R/L)

FASTENERS_\

Figure

1A-19

secrloru

(1

PLACE

B-B

Ri

L)

29

BODY

14.21

Subject

Re{-

DESCRIPTION

5.1
SERV|CE

5.2
REAR OUARTER

5.3

NOTES

Models

Remove........

Quarter

Reinstall

5.1

glass

Toughened

body styles and

These

glasses

panel

and

metal to
ln

original
where
adhesive
maintain the original

Part
operation

NOTE:
an additional
contains

ADDITIONAL
package)

Appropriate
A second

the
adhesive
glass

reinstallalion
occur
severe

glass

situations

urethane,

paint

kit

No. 9201861

contains:

For tailgate

300

'Short

removal can

when

water

is

to tailgates on 35 body

are bonded

tailgate

urethane adhesive.

necessitating

such as

finish or

has

been

2

300
25
25
25
Necessary

lnstructions.

auxiliary

ml

of

COMPONENTS

mouldings

method lor

Method'

intact on

left

the original or

of

glass

the

leak,

5. STATIONARY

........-...........

WINDOW

Body Sty|es..................-.

19

­Window

DESCRIPTION

fitted

to

qperture

damage
metal

base

developed

structural

'Long

Method'.

ml Urethane
ml Glass
ml Glass
ml BodY

aPPlicators.

window

kit,

urethane

required.

as

window replacement

is used

the window aperture

serve as a

is being

when

or

ASSEMBLY....

Aperture

quarter

rear

rear

the

to
flanges

complete

specifications.

Primer
Primer - Black.

Primer.

replacement

adhesive,

glass

a

with a self curing

window

to

is

exposed,

and

The repair

Adhesive.

- Clear.

435-56

No. M39097,

Part

is required.

REOUIRED

when original

satisfactory

glass.

new

removed

is broken-

.....

...........

.--. 14'23

Check

apertures

styles.

quarter

removal of

must

apertures

a urethane

used

be

kit for this

Method,

Long

-

(Not

referred

urethane

flanges after

base

This

to

overcome

Page
1A-21
1A-21
1A-22
1A-22
1A'22

1A-23

on

upper

the

which

part

to

Jor

would

INDEX

Ref.

5.4

19

to

of

as

the

a

GLASS

Subject

Reinstall

Long Method.....

Reinstall

The repair

Minor Water
and contains:

These replacement kits are available

An additional short
recommended for rear
available
contains

This material
correction

kit

developed

Leak

300 ml
25 ml
25 ml Glass Black Out
Necessary
Instructions.

from GM P & A under

ml

300

of

is

also recommended

all urethane

on

5.2

WARNING:
TIUES

NOTE: Skinning
mences

%

50

minutes.

30
mouldings must be completed
station

Complete curing of
humidity takes

The recommended
is the
be

obtained

WORK GLOVES MUST

WHEN OPERATING

(partial

exposure

after

relative

wagons.

glass

humidity, skinning commences

Therefore, installation of

72 hours.

sealant
from Kent-Moore

...

...

to service

correction

Urethane

Clear Glass

Dimet,
53 Showers

Preston,
method replacement kit

quarter

silicone.

SERVICE

to the

urethane

tool for cutting

removal

part

is

Adhesive.

Primer.

Applicators.

Street.

Vic. 3072.

windows

Part

installed stationary

NOTES

WITH GLASS.

curing) ol

atmosphere.

within that time

at

Tool No. J24402,

Australia Pty.

Page

'tA-28
1A-29

1A-29

this

number 9201861

Primer.

from:-

for minor

BE WORN

the urethane

this temperature and

through the urethane

Method or

Short

which

sedans,

on

No. M38977 and

water

glass.

At

23oC and

tailgate

which

Ltd.

is

only

leak

ALL

AT

com-

after

window

limit

can

1

is

on

30

1A-22

5.3

MODELS.
Remove

quarter

The
both

the
exception.
more

care

that

an

quarter
the

1.

2.

3.

even

window

replacement

prevent

To
minimise

parts

over
Using

prise
moulding

AM,

Fig.

Remove
moulding
and

remove

BODY

REAR

19

window glass

'Short'

lf

the

must

clean

fingers

..otf _leading

from garnish

14-20).

screw

lower

QUARTER

ASSEMBLY

BODY

'Long'

and

Short

be

taken

bead

of urethane

aperture

glass.
damage

up,

adjacent

or a wide

securing

(refer

moulding.

WTNDOW

STYLES

removal procedure

Installation

Method

mask

to

edge

installation

glass

during

adhesive

flanges
to

to

serve

paint

finish

place protective

and

glass.

bladed

screwdriver,

of roof

moulding (retei

rear

end

Section

AN_AN;

is

Methods

is

to

removal

rematns

as

a base

and

trim

guner

drip

S6ctron

quarter

of

Fig.

similar

with

one

be

used,

to

ensure

and to

covers

carefully

teal

nU-

reveal

1A-20)

for

on

for

\

*ao"

RooF

GUTTER

DRrp

MOULDING

4.

Femove
to

rear quart€r

remove

outer

surface

buVl,

.centrally

garnish
remove

garnish

remaining

garnish

moulding,

of the

spaced

moulding

moulding.

screws

securing

aperture (refer

which

glass

with

four (4)

at

top,

View

Oottdm

H, Fig.

(refer

garnish

Fig.

is

ittached

moulding

14_21)

short

and

14_22)

thei

to

strips

sides

then

the

of
of

SECTION

sEcrtoN

QUARTER
MOULDING

AM_AM

OUARTER
GARNISH

LOWER

REVEAL

AN-AN

Figure

WINDOW

ASSEMBLY

WINDOW

MOULDING

OUARTER

MOULDING

1A-20

GARNISH

WINDOW

31

Fagure

1A-21

5. Locate blade of
remover, beveen
illustrated in
around

6. Carefully
evidence
cutting

7. lf

original

protected
scraper,

glass.
agent

NOTE:
glass
prevenl

Do

or

the adhesion

Fig.

complete

lift

glass

of

tool to

glass
bench or

carefully

glass

Clean

such as

not use

aperture

glass

problem

is to be reinstalled,

Prepsol

flange as

Tool No. J24402,

inside

14-23, then cut

periphery

out of

adhesion

glass

of

glass.

of

aperture.

to urethane,

and

through urethane,

area.

place glass

holding
remove

fixture and

original

with a suitable

equivalent.

or

petroleum

the

new urethane/silicone.

of

base

presence

solvents

glass

urethane as

lf there

using a

urethane

oil-free

to clean

of

sealant

is

re-apply

on a

sharp

lrom

cleaning

will

oil

APPROXIMATE
AREA EOUALS

SOUARE

ONE
cENTIMETRE ---7

I

I

\

7\

Flgure

J24402
GLASS
REMOVAL

170

BODY

S

BUTYL STRIPS

VIEW

1A-22

SEALANT

TOOL

1A-23

(4

PLACES)

HN 1 749
URETHANE
ADH

ESI

VE

OUARTER
Thoroughly

ensure
that do.
check original
Where

in any

WINDOW

check

no surface

that

'Short

lf

urethane

these exist,

voids or

urethane/silicone.

Reinstall

Method

Short

1. Short

Method

where

used
urethane

form a base

to

adhesive

method should
glass
using

previous
materials

to achieve

leak condition

or

minor

service
requires complete

an

APERTURE CHECK

rear

quarter

window aperture

irregularities exist'

Method'

glass

on

flange

cut away any

uneveness

installation of

maximum amount

the

is left

intact

for the

be used

when

that cannot

leak

water

installation using

effective

glass

installation

for

loose

is being used'

looseness or

urelhane

in bead'

quarter

rear

the body opening

on

replacement

replacing a

be overcome

repair

procedures.

other adhesive

replacement

metal bond.

to

flange

Correct

voids'

and

glass

original

of

glass-

cracked

material

of

32

to

any

fill

using

is

This

by

Any

VIEW

Flgure

1A-23

1A-24

2.

BODY

Thoroughly
urethane/silicone

glass).
cleaning

Use

solvent,

URETHANE

')

Using

an

?lr"r)

12
off
E,

around

mm

in.from

operation,

Fig.

14-24).

clean

is

clean

such

ONLY

applicator

entire

edge

using

-

surface

to

contact

cloths

prepsol

as

in

Kit,.apply

perimeter

glass.

of

clean

of

with

lint

glass

(including

a

suitaSle

or

equivalenl-

HN1747

glass'edge

of

This

is-a

free

cloths'(refer

to which

edge

oil_free

(clear

wipe

o"n/wipe

new

of

glass

and

View

URETHANE

4.

U.sing

glass

and

on,.glass

24).

Allow

touching primed
Install glass

garnish

then

firmly

garnish
Apply

silicone
original
opening.
6 mm

7.

Install
quarter

on

assembly

glass

and

ONLY

a.second

primer)

around
bonding

primer

with

moulding

press

moulding

a

smooth

between

urethane

Silicone

in

diameter.

glass.and

window

to

aperture

applicator,

entire

surface

to

of

its

inner

illustrated

as

glass

dry for

glass.

onto

area

recess.

continuous

centre

and

around

bead

garnish

aperture,

evenly

flange

apply

perimeter

(refer

surface

in

View

butyl

bead

and

outer

entire

should

be

moulding

applying
distribute
to

effect

HN1748

lS

facing

strips

periireter

assembly

glasJ

of

View-G,

minutes.

upwards

H,

Fig.

loEateo

of

urethaner

edge

on top

a

minimum

(black-out

edge

Fig.

Avoid

into

1A_24,

of

body

into

rear

sufficieni pressure

silicone

a watertight

between

seal.

1"A_

on

of
of

(BLACK

BUTYL
(4

OUT)

STRIPS

PLACES)

PRIMER

VIEW

8.

Install

and

9.

Water
spray

NOTE:
freshly
garnish
area,

using

the

source

screws

sides

of the

leak

of water.

Do

not

applied

silicone.

moulding

a flat

of the

securing garnish

window

test
direct

and

bladed

leak,

aperture (refer

quarter

a heavy

lf

watei

apply

tool

then

install garnish

window

additional

to

moulding

stream

leak

is

work

Fig.

using

of water
evident,
silicone

fresh

moulding.

to

the

top

1A-25).

a moderate

onto

remove

to

silicone

teak

rnro

33

Figure

Figure

'lA-24

1A-25

r5r

i

,9

v

SCRE
'lPtr

EW

AUtrJ

BODY

14.25

attached

10. Install

1. Locate

1

'12.

NOTE:
silicone

Long

The

original
base

This method should
or
when original
replaced

This method
been
such
position

1.

2. Using

screw

section

lower

to
AN-AN,

over

the

with
over

1A-26).

Fig.
Remove

covers.

White spirit

from

Method

long method

urethane

lor replacement

paint

previously

instances,

the

Using
scraper,
perimeter

Replacement
(Flange

aperture
been
Views
for 30

1A-26).

Fig.

hooked

reanrard

hand,

garnish

paint

paint

to the

repair

adhesive

with new

is

also

replaced,

the

glass

glass

the

remove original

quarter

of

applicator

an

primer)

flange that

cleaned

A, B, C &

minutes.

quarter

garnish

of

of

edge

edge of

outer

finish and

adhesive

too far out of

tap opposite

lightly

moulding

trim

and

recommended

is

glass

of

glass.

be used

quarter

urethane

is completely

used

build-up of

sealant

window aperture

Kit No.92023123,

to any section

is back

to original

back

D, Fig.

Avoid touching

reveal

moulding

roof drip

protective

trim'

material

for

when the

using

supplied

gutter

garnish

(refer

replacement

vehicles

on

window aperture

glass

the

urethane/silicone

the opening.

removal

urethane

of

to bare

1A-27).

primed

moulding

(refer

rear

moulding,

side of

Section

masking

for

is used

cannot

requiring

removed and

installation.

quarter

Short

tool andlor

from around entire

flange.

'Long

in

apply

quarter

the

paint

Allow

area.

lower

Section

moulding

then

moulding

AM-AM'

tape and

removal of

when

as a

serve

metal

flange

window has

Method.

could
sharp

Method'
HN1752

window

metal or

surface

primer

(refer

to dry

In

has

sEcrroN

sEcrroN

OUARTER
MOULDING ASSEMBLY

AM-AM

OUARTER
GARNISH

WINDOW GARNISH

WINDOW

MOULDING

LOWER OUARTER
REVEAL MOULDING

AN-AN

1A-26

Figure

ROOF DRIP

REAR
GUTTER

MOULDING

WINDOW

FLANGE

lfl

u,.*

PRIMER

lEl

u,.*

Figure

E

1A-27

34

1A-26

3.

Thoroughly

urethane
edge
suitable
equivalent-

4.

llging
HN1747 (clear

gf

glass

This

is

free

cloths

5. To

NOTE:
edge
7
dimension
glass,
of the 7

6.

7.

8.

o

maintain

install

glass.

to
locate
from
Fig.

1A-28).

A

suitable gauge
glass

of

mm

notch

locating

mm

U.sing
glass

primer)

on

qnd

291.

Allow primer

touching primed
Tidy

up
bottom
View

H,

Install glass
garnish
Firmly
places

Using

a hand
supplied
HN1749

at

base,

glass

(refer

BODY

clean

is

to be

of

aperture

oil-free

an

a wipe

a foam

dam

edge

of the

dimension.

a second

glass

and

Fig.

moulding

press
on

in
urethane
around

cleaning

applicator

glass

edge

and 12

on/wipe

(refer

appearance

sealing

Commencing

around

on

can

in a piece

gauge

the

outside

applicalor,
around
bonding

area

strips

of butyl

on

both

14-29)
with its

glass

garnish

operated

kit,

apply a

entire

View

J, Fig.

inner

flange.

in

primer)

mm

off

E,

dam,

at

entire

inner

to

maintain

of wood.

onto

edge

entire

surface

to

dry for

glass.

of

sides

inner

onto

applicator

smooth

perimeter

1A-29).

surface

well

as

Use

solvent

Long

in

operation,

Fig.

and

part

either lower

perimeter

surface

fabricated

the

of the

apply

perimeter

centrally

garnish

ol

side

butyl strips

recess-

17

applied

View

be readily

as illustrated

moulding

adhesive,

glass

of

as

around

clean

cloths

such
Method

around

from

14-28).

minimise

Number

the

Locate

inner

HN174g (black_out

(refer

15

facing

in

Vievrr

with

continuous

mm

of

prepsol

as

Kit,

entire

edge
ushg

­clean

920181i9

corner

glass,

of

(refei

dam

located

inner

View

dam 7

by

cutting

the 7

surface

on the

glass

of

View-G,

minutes.

moulding (refer

upwards

H, Fig.

locateJ

special

high

and 7

surface

to

which

complete

with

or

appty

perimeier

glass.

of

clean

lint

up,

glass,

of

7 mm

F.

mm

from

a

mm

the

of

end

edge

Fig.

1;A-

Avoid

on

top,

into

14-29.

at four

nozzle

bead

of

mm

of

\--

v

12.O

VI

EW

Figure

'fE

1A-28

[F

[-cTJl

7.O

-'/

-\

APPROX AREA
ONE

SOUARE

CENTIMETRE

EOUALS

URETHANE

ADHESIVE

Figure

1A-29

35

BUTYL
(4

PLACES)

STRIPS

oo**,r*

MOULDING

l

BODY

'IA-27

NOTE:
adlacent
urethane

10.

In cold

to a source
when using

Install

quarter

1A-30)

Fig.

glass

window

to evenly

aperture
Install screws

11.
sides
Fig.

Water

12.

flange

of

1A-30).

test

water.

not direct

NOTE:

Do
freshly applied
remove
the
into source

garnish

leak area,

of

weather,

of

hand

a

garnish

and

aperture

applying

distribute

to

effect

securing

quarter

the

quarter

window using

a

urethane.

moulding and

flat bladed

a

using

leak,

then

install

placement

the

warmth,

will assist

applicator.

moulding

(refer

sufficient

urethane

pressure

watertight

a

garnish

between

moulding

window

heavy stream

water

ll a

apply

additional

tool to

garnish

of

assembly
Views

seal'

aperture

moderate

a

of

leak

work

moulding.

cartridges

flow of

the

into

K and

assembly

on

glass

to top and

(refer

spray of

water onto

is evident,

urethane

urethane

rear

L'

and

to

GLASS

VIEW

PAINT-OUT

GARNISH

x\

\

'\\

'\w

\\

VIEW

Install screw

IJ

to bottom

Section
Locate

14.

over
with
over
Fig.

attached

horizontal

AN-AN,

Fig. 1A-31).

hooked edge

rearward

the hand,

outer

lightly tap opposite

garnish moulding

1A-31).

quarter

part

roof drip

of
edge

garnish

of

moulding

moulding

reveal

gutter rear moulding

garnish moulding, then

of

side of

(refer

Section

lower
(refer

moulding

AM-AM,

sEcrroN

AM-AM

\

.

Figure

OUARTER
MOULDING

OUARTER
GARNISH

!

SCREW

---

'lA-30

BEAR
GUTTER

WINDOW GARNISH

ASSEMBLY

WINDOW

MOULDING

OuARTEB

LowER

REVEAL

MOULDING

DRIP

ROOF

MOULDING

wrNDow

36

sEcrroN

AN-AN

Figure

1A-31

1A-28

BODY

5.4 TAILGATE

MINOR

Locate
apply
glass
area
area.
leak.

SHORT

Remove

1.

2.

3.

4.

5.

CAUTION:

presence
urethane/silicone.

WATER

area

of leak.

paint

scraper

and

lacing.

concerned.

Apply

HN1770

METHOD

Disconnect
model,

assembly
Apply

mouldings

place
Remove

a.

b.

Remove

adhesive
Using

free
ly
including

remove

protective

protective

moulding

Side

mouldings
wide
Apply
shown
moulding
intact

Upper
mouldings.

leaving

clean,

solvenl

clean

surface

glass

Do

of

and

as shown

blade

a rolling

in

for reuse.

and lower

all

not

oil will

LEAK

CORRECTION

Working

or

Gently

Clean

silicone

battery ground

tailgate

electrical

tape

covering

system:-

tool

View

to loosen,

glass

adhesive

lint

free

such

as Prepsol

glass

of

edges.

petroleum

use

prevent

on

similar wide

flex

lacing

any foreign

to

window

demist

to

in

View

adjacent

- Insert
between

action

A, Fig.

carefully

mouldings

fragments

intact

cloths,

which

WINDOW

inside

surface

blade

tool

away

from

material

area concerned

cable

and

wiper

connector.

paintwork

A, Fig.

to

paint

a

moulding

towards

14-33,

over fult

Method

­from

on tailgate.

dampened

or equivalent,

silicone

based

adhesion

on Berlina

arm

adjacent

tA_32,

gliss.

scraper

and

the

remove

as

original

with

is to

solvents,

of the

glass,

of

between

glass

from

this

ro

correct

and

blade

to

and

or

similar

body.

glass

as

iength

of

moulding

for

side

glass

an

oil

thorough_

contact.

as

the

fresh

in

PROTECTIVE

PROTECTIVE

TAPE

Figure

TAPE

VIEW

14-32

Reinstall

URETHANE

1.

Prime
surface
clear
(refer

URETHANE

2.

Prime
surface
black
(reler

3.

Apply
adhesive
by the

4.

With

5.

Refit

6.

Refit

7.

Apply
reguired.
mtntmum.

ONLY

the

edge

'12

mm

(HN1747).

View

B, Fig.

ONLY

the

edge

7

mm

(HN1748)

View

6.0

tailgate

upper
side

Fig.

C,

mm

and also

mouldings.

in

and lower

mouldings.

tape

to

This

glass

of

lrom

the

This is

14-35).

glass

of

from

the

and ailow

14-35).

bead

of

to the

near

horizontal

mouldings.

hold

mouldings

tape

to

and

on

edge

a wipe

and

on

edge with gl-ass

to

urethane/silicone

groove

position

be left

the

glass

with

on wipe

the

dry for

left in

position

in

on' for

glass

otf

glass

the

fit

bonding

primer

operation

bonding

primer

15

minutes

to

original

adhelive

qtass.

new

where

24

hours

VIEW

i

:

Figure

1A-33

37

BODY

1A-29

tailgate

Leave

8.
hours, after

5
providing

24
On

9.
and
and

Remove

10.
paint

ring

LONG

tailgate

hours.

Berlina

blade

both

on

masking

finish and

interior.

from

METHOD

model,

assembly

models,

Remove

1. Disconnect
model,
assembly

Apply

2.
mouldings

battery

remove

and

protective tape

as

place protective covering

3.

Remove
a.

moulding

mouldings -

Side
wide
Apply
shown

blade

a

in

moulding

for

intact

and

Upper

b.

mouldings.

of

not

lt is

However,

firm.

and

all

glass

in Fig.

necessary

Remove

4.
blade
illustrated

NOTE:
urethane.
smooth

in horizontal

which

time

position

vehicle

is not slammed

tailgate

install

demist

and

ground

battery

from tailgate,

tape

glass,

then

remove

ground

tailgate

electrical

window
demist

to

shown

in View

adiacent

system:-

a

Insert

between

tool
rolling
View
to

action

Fig.

A,

loosen,

14-33, over

carefully

reuse.

mouldings

lower

glass fragments

sealant

removal

1A-34.

remove

to

remaining

any

for a minimum of

may be

excessively

window

electrical

cable-

clean adiacent

protective

and

cable

wiper

arm and

connector.

paintwork

Fig.

A'

glass-

to

paint

scraper

moulding

towards

the.

remove

Method

­urethane,

and

Tool

traces

all

urethane

driven

wiper arm

connector

cove-

Berlina

on

adiacent

1A-32,

similar

or

and

glass

length

tull

moulding

for side

as

J24402

No'

original

of

must

for

blade

to

and

body'

as

of

using

be

FE

KNI
BLADE

URETHANE'

TAILGATE

TO BE

NEAR

IN

Figure

,/-COLD

r TAILGATE

UPPER

HORIZONTAL

1A-34

KNIFE

WINDOW

MOULDING

POSITION

Reinstall

1. Prime
allow

1A-35).

Fig.
Prime

2.

surface
clear
(refer

Prime

3.

surface

black
(refer

body aperture

for 30

dry

to

the edge

12

(HN1747).

View

the edge

7 mm

(HN1748)

View

of
from the edge

mm

This

Fig.

B,

of

from

and

Fig. 1A-35).

C,

with body

glass

wipe on

is

a

1A-35).

glass

the edge

allow

primer

minutes

on

and

with

on

and

with

to dry

(HN1752)

(refer

glass

the

glass

wipe off

glass

the

glass

for

and

A'

View

bonding

primer

operations

bonding

primer

minutes

15

38

-

-

1A-35

Figure

1A.30

4.

Apply

9.0
View
View

5,

Fit
applied

o.

lmmediately

after.
bond
bond

7.

Apply
reguired.
mrntmum.

Leave
5 hours,
providing
24

hours.

9.

On

Berlina

and

blade

and

on

10.

Remove.
paint

ring

from

BODY

an

even

mm

x 7.0

B, Fig.

C,

the

ensuring

the

mouldings

tape

tailgate

both

finish

mm

1A-36,

Fig.

14-36).

glass

to

the

body.

the

that

mouldings. (Apply

to

This

in

after

tailgate

model,

assembly

models,

masking

and

the

interior.

bead

of urethane

to

blading

using

nozzle
immediately
glass

enough

if required.)

hold

tape

to

horizontal position

which

is

not

install

and
battery ground

tape

glass,

the

is installed,

urethane

additional

mouldings

be left

the

vehicle

slammed

tailgate

demist

from

tailgate,

then

remove protective

adhesive

flange

as

cut

urethane

fit

moulding

is

position

in

on for

for

a minimum

may

extessively

window

electrical

cable.

clean

(HN1749)

shown

as

shown

bead

system

pr6sent

adhesive

where

24

hours

be

driven

wiper

connector

adjacent

cove-

of

for

arm

to
to

In

in
is

h"'

vrew

lel

Figure

tA-36

39

BODY

1A-31

Re{.

Subject

6.1

DESCRIPTION

LUMBAR

6.2

FRONT SEAT
BUCKLE

SUPPORT.

Models

Remove...-...­Reinstall

ASSEMBLIES

Remove........

Reinstall

6.1

New seat
models.

New features on
restraints on

Berlina

is built into the seat
On the Calais

fitted to the

trim materials and

front seats

all

& Calais

models, a

model, see

rear

seat

SEATS

6.

DRIVERS SEAT

Berlina

-

BELT

and Calais

RETRACTOR

DESCRIPTION

patterns

include

models and on

knob

back assembly

backs.

the drivers

operated

(refer

through

&

SEAT

......

AND

released

are

'see through'

head

seat on

lumbar support

14-37).

Fig-

restraints

INDEX

Page
1A-31
1A-31
1A-31
1A-31
1A-33

1A-33
1A-33

1A-34

for VK

head

are

BELT ASSEMBLIES

Sublect

Ref.

6.4

REAR SEAT
ASSEMBLY

RETRACTOR

BELT

Page

.........-.........

1A-34

LUMBAR

6.2

MODELS.

Remove

rear

end
end of
clean

seat

seat

seat adiuster.

protected

1. Slide

2. Slide

3. Remove

SUPPORT

BERLINA

fonrvard and

fully

seat adiuster

of

rearward and

from

seat

surface.

.

DRIVERS

AND CALAIS

remove bolts

to floor
remove bolts

vehicle and

place

(reler

Fig. 1A-38).
securing

face down on a

SEAT

securing

lront

sEcrroru

A-A

Figure

-S

L

APPLY
AROUND

IN
INSTALLATION

1A-37

I

5.0

FLOOF

SCREW

(20.0

25.0

-

OUTBOARD

vtout'lrtru

DIA BEAD

EDGE OF

TOP

PAN

BEFORE

OF

Nm)

COVER

c

OF SEALEF

HOLES

ASM.

SEAT

40

Figure

1A-38

1A-32

4.

From

straps
cushion
edge
ancl

5.

Remove

retainer

BODY

under

which

spring

of seat

tape

carpet

hog

to

front

driver's

seat

are looped

convolutions

back

carpet

up out

of the

rings

securing

retainer

cushion,

under

and which

assembly

way.

seat

(refer

Fig.

remove

tension

retain

(refer

back

1A-40).

over

Fig.

cover

elastic

sear

lower

1A-39)

SEAT

BACK

RETAINER

COVEB

Figure

1A-39

SEAT

BACK

CARPET

COVER

RETAINER

Locate
removal
support

the forked

(refer

tool

handle,
disengage 'horse
in

splined

spindle,

end

of a door interior

Fig. 14-41)

press

then
shoe'

type

then

retaining

remove

inside

tool

downwards

handle.

handle

of

clip

lumbar

from

clip

ro

slot

INTEFIOR
HANDLE
REMOVAL

DOOR

CLIP

TOOL

.,W''

Figure

CLIP

1A-40

LUMAAR

CONTROL

NOTE:
wlrH

LUMBAB

IN'SOFT'POSITION,
INSTALL
UPFIIGHT

FRAME.

TO

suppoRr,

HANDLE

PARALLEL

&

SUPPORT

KNOB

i

I
]

41

Figure

1A-41

R

ECLI

N FR

CONTROL

KNOB

7.

Carefully
exposing heads
brackets to sides

ease sides

of screws

of seat frame

of seat back cover upwards,

securing lumbar

(refer

Fig. 14-42).

support

Figure 1A-42

BODY

1A.33

Remove attaching screws,

assembly out

(refer

Fig. 1A-43).

Reinstall
Reverse

seat assembly
A-A,
knob note

removal operations, ensuring

Fig. 14-38) and

FRONT

6.3
AND

REMOVE

1. With front
from

bolt securing upper seat belt attachment lo
centre
remove bolt

2. Using a
securing

pillar (refer
Remove

3.

attachment
seat belt

4. Ease

of

end
lower
from centre
retractor

through

attaching

to observe

1A-4'l .

in Fig.

SEAT BELT RETRACTOR

BUCKLE ASSEMBLIES

located fully forward, remove

seat

pillar

(refer

upper

and

pointed

the seat belt retractor cover to the centre

cover

attachment.

front

front rocker

part

(refer

tool,

Section C-C, Fig. 1A-44).

from

to floor

end of

of

rear rocker

retractor

pillar,

Fig. 1A-44).

bottom oi seat back assembly

Section A-A, Fig. 14-44) then

pan,

oanel
releasing

then lumbar

to adequately

threads

screw

lumbar support control

attachment.

carefully

bolt securing seat belt

then

cover, ease upper

prise

remove

oanel

cover uowards

cover and

support

(refer

Section

the

out

bolt and

cover and

to release

tastener

seat belt

seal

cover

pins

lower
lower

rear

CUSHION ASM

SEAT

Figure 1A-43

42

1A-34

FULL

FORWARD
INBOARD
INSTALLED
PASSES
OF
CONTOURS.

THROUGH

SEAT

ATTACHMENT

BODY

ZWITH

POSITION

PART

OF BELT

AT AN

CUSHION

LOWER

BOLT

.

LOCATE

/.

7

TONGUE

76.0

_t

SASH

^

/

SEAT

IN

THE

IS TO
ANGLE WHICH
INTERSECTION

& SEAT

BE

BACK

mm

GUIDE.

aBUCKLE

ASM.

,/

SEAT

WITHIN

OF

THE

BELT

SECTION

A_A

SPACER

-bULI

UPPER

ATTACHMENT

COVER

NON

HARDENING

SECTION

B_B

WAVE

SEAL

SEALER

WASHER

WITH

5.

Remove
assembly
Fig.

1A-44)

REINSTALL

Reverse
threads
seat

belt

6.4

removal

are

attaching

REAR

Remove
'1

.

Depress
sleeve
Section
screwdriver,
out head

2.

Twist

head
direction
the

rear parcel

sEcrtoN

cover

to

transmission

then

operations,

sealed

with

bolts

SEAT

top

of seat

gain

to

access to

A-A,

carefully

restraints.

restraint

then lift

shelf

SEAL WITH

NON

r..

c-c

and

bolt

JtrALtsH

securing

tunnel

remove

buckle

ensuring

non hardening

are torqued

BELT

ASSEMBLY

back

adjacent

Fig.

sleeves

clip, retaining

14-45).

disengage

sleeves

out

(refer

Section

Using

of

HARDENING

seat

belt

(refer

buckle

Section

B-B.

assemblv.

that

both

and that

71 Nm.

-

lower

sealer

to

53

RETRACTOR

to head

i ttat

sleeve

in

an anti_clockwise

brackets

A-A.

restraint

(refer

sleeve

btaded

clips

then

welded

Fiq. 1A-45).

Fagure 1A-44

bolt

all

lift

to

SEAT

BELT

RETRACTOR COVER

43

RESTRAINT

,-\ /

7

INSERT
BRACKET, ROTATE

SLEEVE

LUGS A, B
IN
ENGAGE

AA. BB.

SLEEVE

DOWN. ENSURING

TOP OF MOUNTING

PASS

& C

AS

SHOWN IN

INTO MOUNTING

SLEEVE

PUSH

AND

THAT

THRU NOTCHES

BRACKET

SECTIONS

LUG

&

A

BODY

14.35

e

Depress
arwards
brackets attached

1A-46)

Fig.
protected

Unclinch
wheelhouses
from retaining

front

ment
remove,

protected

seat cushion

front edge

to

remove,

of

disengage assembly

the

to

then

surface.
tabs securing

(refer

View

brackets attached

(refer

panel

place

then

frame assembly

surface.

floor

place

back

seat

A, Fig-

Section

LUG B

assembly

retainer

(refer

Section

assembly

frame

1A-46)

rear

the

lo

B-8,

on

on a

to rear

lift

compart-

1A-46)

Fig.

a

SECTION

Figure

re-

from

A-A,

clean

trame

clean

MOUNTING

B_B

'lA-45

BRACKET

cusHloN

RETAINER

ASM.-1

\

SECTION

SECTION A_A

FLOOR

REAR

;

I

eRncret

A_A

44

SEAT

RETAINER

SECTION

BACK

B_B

COMPARTMENT

FRONT

Figure

PANEL

1A-46

CLINCH

r

...

OVER

TAB

1A-36

BODY

From

inside

securing
A-A,
from
A-A,
disconnect

then

Remove

trim

Fig.

1A-47)
outer
Fig.

14-48)

remove

edges

speaker

rear

bolts
attachments,
pan

and
Remove

upper

Section
From

securing
inner panel
retractor

out

rear

and

D-D, Fig.

cover,

attachment

B-B,

inside

rear

assembly,

through

Fig.

(refer

slot

Reinstall

R.everse.removal

all

seat

beft

:,,1h ?^"-ol.

Frg.

tA-4E)

torqued

to

operations,

lower

harde.ning

and

that

50-70

Nm

rear

compartment,

panel

to

disconnect

of

parfly

rear

rear

raise

parcel

retractor

parcel

rear

connectors

parcel

shelf

trim.

securing

including

lap

tear

type
wheelhouse panels
14-48).

then

bolt

securing

quarter

to

inner

1A-48).

tear

of

seat

on

compartment,
belt retractor
Section

feeding

outer

A-A,

seat

edge

of

ensuring

attaching

all rear

during

seatei

botts

aie

(refer

Sections

seat

belt

installation.

tap

out

(refer

shelf

seat

(refer

shelf

parcel

from

rear

seat

belts,

(refer

belt

Section

seat

rear

panel

upper

remove

assembly

Fig.

14-49)

belt,

buckles,

parcel

rear

that

the

aJequitery

b_C

attaching

fasteners

Section

guides

belt

Section

shelf

trim,

harness,

lower

to floor

C_C

seat

belt

(refer

bolt

quaner

to

remove

etc.

shelf.

threads

seateO

anO

O-O,

bolts

o{

are

REAR PARCEL

SHELF

TRIM

\'

'/...-'_,.-',

(3

PLACES)

/

tYfrn lnnrn

luur-ZtU.l1.l1
:-irlli=i:

1r

SECTION

A_A

Figure

1A-47

NOTE:
mounted
A-A,

On

onto

Fig.

1A-49).

ASSEIVIBLY

ANCHoR

C

VERTICALLY

UPWARDS
FITTED

sEcrtoN

.,'l

.

so - ro

35

body

the rear

SEAT BELT
RETRACTOF
ASSEMBLY

_-+-

r}

-t,

To

8E

WHEN ,/

.{

u.-J

.

-.

:-+y

ENSURE
OF

i.r-

f

S

w,"i'r,c

ANCHOR

C-C

styles,

the

quarter

t

eOLr

-

/-SEAL

HARDENTNG

HARNESs

WHEN

ANCHOR

_2pLACES

retractor

panels

inner

I

WITH

assemblies

NON

SEALER

rs

cLEAR

IS

FITTED,

(refer

are

Section

A

sEcrtoN

A-A

SASH
GUI

DE

-2pLAcES

AXIS

OF

FRONT

SYMMETRY

VIEW

OF ANCHOR
PARALLEL
IN

sEcloN

TO

BE

TO

VEHICLE

BOLT

/S\

N\/
i\/

ti

B-B -2pLACES

WITH

HARDEN

t-ro.t

secrroru

D-D

A

JtrAL

NON

ING

SEALER

A

Figure

14-48

45

BODY

1A-37

#i3fitl?"fal'^ri;.

if.gl----=--h

curDE

BELT

SEAT

TONGUE=-

t--'

LN< 4

eoLr

.,/

qtv

'p,

sEcrroru

A,uo-7oNm

B-B

oF

sASH GUIDE

eo.t

A

WITH

SEAL

HARDENING

A

(,

ANCHOR TO BE

FITTED. ENSURE WIRING

ANCHOR WHEN ANCHOR IS

VERTICALLY

l

srcrroru A-A

NON

SEALER

secrroru

HARNESS

FITTED.

C_C

UPWARDS

IS CLEAR

WHEN

OF

AXIS
ANCHOR

ro

vEHrcLE

VIEW.
FRONT

secrroru

D-D

n

i''' ,.

(f",- i'''\

-\:1-'.,',,

|

.'

'

".1

.-'.

''

..

u,a*

R

OF SYMMETRY OF

NOTCH TOWARDS

OF CAR

'rBOLT,/1\

,

SEAL
HARDENING

TO BE

0

BELT
SLEEVE

WITH NON

PARALLEL

rRorur

rru

RETAINER

SEALER

Figure 1A-49

46

BODY 1A.39

Ref.

Subject

7.1

DESCR|PTION....................

FRONT

7.2

DRIP

7.3

ROOF

7.4

FRONT

7.5

FRONT

7.6
FRONT

PILLAR DRIP

Remove
Reinstall

MOULDING

Models

DRIP

Model

Model

19 Body Sty|es.............'......

-

Remove
Reinstall

I'OULDING

Reinstall

& REAR

Ca1ais............

-

Remove........

Reinstall
FENDER
MOULDING

Calais

-

7. EXTERIOR

.......

MOULDING

ASSEMBLY

SIDE

DOOR

& SIDE

SIDE

ASSEMBLIES

..............

REAR..........

MOULDING

...........

.......-.........

PANEL

..............

......

....-

ORNAMENTATION

INDEX

Page
1A-39
1A-46
1A-45
1A-46
1A.46
1A'46
1A-46
1A-46
1A-47

1A-47
1A-47

1A-47
1A-47
1A-47

1A.48
1A-48

Ref.

Subject

7.7 TAIL LAMP
ASSEMBLY

Models - SL and

Styles

7.8

7.9

REVEAL MOULDING

Remove

Berlina, 19

... 1A-48

Body

..........-.

............

Page

1A-48

1A-48

Exterior
section
body side
styles.
rear
features a
front
fender and engine
fitted to
of

radiator
electronic
sedans
badges

ornamentation

body

mouldings

The Commodore/Berlina

19 and

of

Calais

fenders.

the

the Calais,

grille.

excepl

on

mouldings

side

35 body

badge

Calais

lront

and

which

Badges

iniection

on

rear compartment

the

VK series

the

on

on

SL and

on

styles

the

on

emblems

Holden and

hood.

rear of all

features a

for

fitted to

are

the Calais,

7.1

consists

wide

and

Calais

Berlina

except

rear compartment

are

option

19

name appears

also

models except

Holden badge

the

which

lid. On

and

Calais,

on

fitted to

badges

Lion

engines

fenders

front

leatures

models

DESCRIPTION

deep

of

section

body

35

on

which

lid and

front

the

front

the

on

and

these

fitted

the

are

its

for

of

with the
together

applied to
stationary
mouldings

1A-51, 1A-52, 1A-53,

fastener

Clips,
ive

secure

blems, etc.
The

tailgate
the urethane securing
Replacement

in the

ded

base engine

power

with

quarter

the

windows on station

fitted to

are

studs,

the various

to the

window

procedures

Stationary

(E-S.T.)

steering, an

windows

all

1A-54,

bushes, screws and

exterior

VK

body styles.

exterior

the window

for these mouldings are

Glass Section of

automatic

'Executive'

on sedans

wagons. Belt

models

1A-55).

mouldings, badges, em-

mouldings

in the tailgate aperture.

transmission

applique

and

(reler

Figs. 14-50,

contact adhes-

embedded

are

this Supplement.

rear door

is

line

in

inclu-

47

1A-40

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14.42

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50

BODY

1A.43

7A

SCREW-2PLACESR/LH

CLIP_2PLACESR/LH

secrtoru

J-J

SECTION

R_R

SCREW

7-

/

1 PLACE

BUSH
1 PLACE R/LH

R/LH

ROOF DRIP

carrJ

PLACE

1

secrroru S-S

MOULDING

secrtoru

r TFRONT

I

R/LH

FENDER

nsr,tt

_-

U-U

A

secrroru

\

V

,.t - 2.4

T-T

\\

D

SECTION

Nm

AZ_AZ

OUTER
I NSERT

DOOR

PLACES R/LH 69

5

PLACES Ri LH 35

8

secrroru

HANDLE

V-V

C LIP

19 STY.

&
STY

PLACES

1O

PLACES

8

FRT. DOOR

R/LH
R/LH

Sneer-v

DOOR

RR.

NoN

HOLES

OVER
WATERTIGHT SEAL.

srcrroru

HARDENTNG

TO EFFECT

Z-Z

sEALER

A

51

Figure

1A-53

14.44

BODY

SECTION

NOTE:
MOULDING
ASSEMBLED
OTR

WINDOW

FASTEN
STUD

ER

OUARTER
GARNISH

AN_AN

ASM.

OTR

IN

CONJUNCTION

GARNISH

WINDOW

MOULDING

REVEAL

MOULDING.

TO

WITH

BE

1 PLACE

PLACES

5

PLACES

3

SECTION

SECTION

Ri LH

R/LH

R/LH

AP_AP

AS

-AS

FRONT

FRONT

REAR

FENDER

DOOR

DOOR

NOTE:

PLACES

3

SECTION

MOULDING
INSTALLED
OTR

REVEAL

SCREW

R/LH

I PLACE

SCREW

1 PLACE

MOULDING
GARNISH
REFER

STATIONARY

THIS

SUPPLEMENT

AM_AM

DRIP

GUTTER

AFTER

AND

SECTION

WASHER

R/LH

Ri

LH

ASM.

QTR

FOR

INSTALLATION

REAR

MOULDING

GARNISH

AT_AT

WINDOW

GLASS

-

To

BE

ASM.

TVIOULDING.

1 PLACE

PLACES

6

pLAcEs

4

SECTION

r.r

A

-

SECTION

R/LH FRONT

R/LH

FRONT

R/LH

REAR

AV_AV

2.4

Nm

AR_AR

FENDER

DOOR

Do6;"

DRrLL

2

ss

OF

WELD

POSSIBLE

SECTION

L.

I

![!

STUD

TO

WELD

o,a

AS

CLOSE

STUD

AW_AW

Hor_e

ON

AS
LOCATION.

SECTION
FOR

EMERGENCY

AS_AS

USE

ONLY

Qeeer-v

HOLES

SECTION

CLIP

-

SECTION

NoN

HARDENTNG

TO

EFFECT

AU

SECTION

2

AX_AX

PLACES

AY_AY

sEALER

A

WATERTIGHT

-AU

ovER

SEAL.

Figure 1A-54

52

BODY 1A.45

GROMMET

1

PILLAR IVIOULDING

REAR

sEcroN

FOR

AF-AF

EMERGENCY USE ONLY

PLACE

DRrLL

OF
POSSIBLE

LOCATION,

R/LH

PLACE

1

SECTION

2.3s

WELD

R/LH

AD_AD

o,o HoLE

I

!l!

STUDS AS CLOSE

TO

WELD

STUD

oN

AS

PLACES

3

sEcrroN

AF-AF

R/LH

STUD

PLACE

1

SECTION

R/LH

AE_AE

GASKET

A"

/'I

SCREW

;

1

SECTION

PLACE R/LH

TWASHER

PLACE R/LH

1

AK_AK

SECTION AH_AH

,A

A

-

2.4
'I

.8 - 2.4

3.4

REAR

Nm
Nm

REAR

BUMPER

LAMP

BAR

SECTION

sEcrroN

*

AL_AL

r

BUSH

PLACES

2

AJ-AJ

ROOF

R/LH

DRIP MOULDING

Sneelv

REAR

NoN HARDENTNG

HOLES TO

EFFECT A WATERTIGHT

sM.\

-AG

sEALEB

)

ovER

SEAL

Figure

53

14-55

14.46

7.2

FRONT

Remove

With.

front

moulding
Sections
moulding.

Reinstall
Reverse

moulding
drip
and that
the
hardening

removal

moulding

the

front

BODY

door

open, remove

to front

S-S,

T-T,

is

correcily

as illustrated

screw

pillar

body

sealer.

PILLAR

pillar

body

and V-V,

operations

installed

securing

the

is

adequately

DRIP

the

screw

and

Fig.

ensuring

over

ihe

in

Section

centre

MOULDING

and clip

front

1A-56)

that

front

U-U, Fig.

of the

sealed

securing

fender

removing

the front

of the

mouldino

with

(refei

pillar

1,4-56

ion

roof

to

PLACES

3

SECTION

T_T

R/LH

BUSH
1 PLACE

CLIP

1 PLACE

R/LH

secrrorv

R/LH

S-S

7.3

DRIP

MODELS.

MOULDING

19

Remove

Grasp.the
it

off the

the

rear

trailing

leading

quarter

end

disengaged (refer

tleinstall
Locate

rear.-quaner

moulding
moulding
drip moulding

the rear

window garnish

position,

into

is

correctly

as i[ustrated

BODY

edge

STYLES

of the

window garnish

of the

Section

hooked

edge

installed

ASSEMBLY

moulding,

drip

moulding

AM-AM,

ensuring

in

Fig.

of the

moulding,

that

over

the

Section

carefully

moulding,

rear

tA-57).

moulding

then

lighily

th6 rear

rear

U-U,

Fig.

REAR

aliowin!

to

oecome

over the

tap the

of the

14-56.

pulling

drip
roof

ROOF

DR|P

\

MOULDTNG

\\ /

\bz

ZzeY

(

Y

pLecEs

5

PLACES

8

secrloru

K\\\

\\ IA\\

\ \N.

1^ @9))

//

((

\

sEcrtoN

AL-AL

\.,-,,

R/LH

R/LH

V-V

Qaeer-v

HOLES

v>

69 & 19

35

STY,

NoN HARDENTNG

TO EFFECT

Figure

ROOF

DRIP MOULDING

ROOF

DRtP

MOULDING

secrtoru u-u

sry.

sEALER

A WATERTIGHT

1A-56

srcrroru U-U

--

N

\

ovER

SEAL.

54

NOTE:

sEcrtoN

MOULDING
INSTALLED
OTR

REVEAL

MOULDING
GARNISH FOR
REFER

THIS

ASM.

STATIONARY

SUPPLEMENT

AM-AM

DRIP

GUTTER

AFTER

MOULDING

AND

GARNISH

Figure

1A-57

OTR

WINDOW

INSTALLATION

GLASS

REAR

To

BE

ASM.

MOULDING.

_

7.4 ROOF DRIP MOULDING

Remove

1. With
the top of the drip moulding to the front body

(refer

2.

Using
58, under top of front

ease

moulding

3. Using a similar
the roof

of
assembly

front

the

Section

Tool No. 1A7 located

top

door

open,

T-T, Fig. 1A-56).

pillar

of

(refer

moulding

Section U-U, Fig.
procedure

remove the

pillar

drip

off

front

moulding,

end of

illustrated in Fig.

as

14-56).

with Tool No. 1A7, remove

drip moulding, carefully disengaging rear

roof

drip moulding from top

(refer

rear

Section U-U,

of drip moulding

Fig.

screw

14-56).

securing

pillar

14-

carefully

roof

drip

end

BODY

1A-47

Reinstall
Reverse

roof
pillar

Sections

that the screw

removal

drip

and

moulding

rear

assembly

T-T

and

securing the tront

adequately sealed

7.5 FRONT &
MOULDING

MODEL
Remove

1. With front ot

2.

Reinstall
Reverse

CALAIS

-

lower

rear

AU-AU,

section

Fig.

Apply masking
protect

screwdriver,
assembly

paint

carefully

out

AR-AR, Fig.

clips securing

the
assembly
Fig.

to the door

1A-59).

removal

operations

are

AL-AL

ensuring that the ends of

mouldings

drip

installed

correctly

in Figs. 14-56

pillar

non hardening

with a

REAR

DOOR

ASSEMBLIES

(ear

door open,

moulding to door

of

1A-59).

tape adlacent to

finish, then using a

prise

of retaining

1A-59) then raise

the

operations.

remove screw

upper

bushes

moulding assembly

lower section of

(refer

under

illustrated

as

14-57

and

moulding is

drip

sealer.

SIDE

(refer

moulding to

top of

wide bladed

section of

(refer

the moulding

Section

the

the front

in

and

securing

Section

moulding

Section

off

AS-AS,

Figure 1A-58

sECrroN

1 PLACE

PLACES

5

PLACES R/LH REAR DOOR

3

AS-AS

R/LH FRONT

FRONT DOOR

R/LH

FENDER

FASTEN
STUD

PLACE

1

PLACES

6
4 PLACES

EF

R/LH

R/LH
R/LH

sEcrtoN

FENDER

FRONT

FRONT

DOOR

REAR

AR-AR

DOOR

55

sEcrroN

Qneelv

HOLES

1

PLACE R/LH

I

AT-AT

NoN

TO EFFECT A

Figure

WASHER

PLACE R/LH

SCREW

sEcrroN

HARDENTNc

1A-59

sEALER

WATERTIGHT

AU-AU

ovER

SEAL

1A.48

7.6

BODY

FRONT

FRONT

MODEL.

Remove

From
moulding
Section AT-AT,

Reinstall
Reverse

the

illustrated
NpJe:

19

body
SL.and
emblems
contact
mouldings prior
avoid

CALAIS

inside

to rear

removal

attaching

in

Section

Rear

compartment

styles

Berlina

on

adhesive.

bending

the

all models

the

FENDER

SIDE

MOULDING

wheelhouse,

quarter

Fig.

operations

screw

and

body

35

body

lt

to

removing

outer

or front

1A-59)

then remove

ensuring

with

AT-AT,

is necessary

non

Fig.

lid

moulding

side

styles

as well

are

them

surface

&

SIDE PANEL

ASSEMBLIES

remove

1A-59.

and

secured

to

of these

screw

fender

moutding.

to

adequately

hardening

on SL

tallgate

nameplatei

is

in

apply

from'

the

mouldinos.

mouldings

position

heat

panel

'sealer

and Berlina

panets

securing

(refei

seal

as

on

and

with

to

these

to

CAUTION:
temperature
When replacing

surface
warmth prior
sound

7.7

MODELS.
Remove

1.

2.

Apply
section
using
section
Section

Reinstall
Reverse

the

illustrated

MODEL.

Remove
With

securing
panel

removing

Ensure

must

bonding

TAIL

With

rear

securing

quaner

reat
Fig.

14-60).

masking

of the

a wide

AJ-AJ,

removal

attaching

in

CALAIS

rear

compartment

the

(refer

the

too

be

to

SL

the

of moulding

Section

moulding

Sections
moulding

that

source

high

to

these

of the moulding

damage

mouldings,

clean

and smooth

installation

LAMP

REVEAL

of the

ASSEMBLY

AND

BERLINA

compartment

upper

outer

tape

moulding

bladed

Fig.

operations

screw

AK-AK,

lid

section

panel

adjacent

to

screwdriver,

out

1A-60).

ensuring

with

non

Fig.

lid

assembly

AW-AW

assembly.

of heat

to the

is

paint

the

not

finish.

corresponding panel

and

be

moulding

subjeited

panel.

MOULDING

19

BODY

open, remove

of the

protect

of

14-60-

open, remove

to the

and

moulding

(refer

Section

to

the

paint

carefully

retaining

to

hardening

rear

AX-AX,

semi vertical

-bush

adequately

quarter

too

close

to

effect

STYLES

the

screw

to

AK-AK.

finish,

then

prise

lower
(refer

seal

sealer

the

nuts

outer

Fig.

iA-61)

the

as

or

to

a

GASKET

PLACES

A

A,

/z\,

SECTION

1.8

-

2.4

2.4 -

3.4

AK_AK

Nm
Nm

Qneelv

HOLES

sEcrtoN

NoN

HARDENTNG

TO

EFFECT

Figure

1A-60

2

AJ-AJ

sEALER

A

WATERTIGHT

R/LH

ovER

SEAL.

Reinstall
Reverse

hardening..sealer
nut,
Fig.

removal

is

as illustrated

14-61).

operations

applied

in

Sections

ensuring

between

AW_AW

that

the

adequare

panel

back

and AX-AX,

non
and

56

BODY

1A.49

7.8 REAR LAMP

EXTENSION

ASSEMBLY

MODELS.

Remove

With rear compartment
securing
Section

NOTE:

the screws

assembly

19 BODY STYLES

the assembly

AG-AG,

Fig.

to the back

14-62)

To disassemble the

securing

(refer

the

Section

AG-AG, Fig.

raised

lid

remove

and

moulding

outer

remove

panel

assembly.

assembly,

to inner

14-62).

MOULDING

the nuts

(refer

upper

remove

panels

of

the

SECTION

tt-2.4Nm

A

A

NUT

PLACES

4

AW_AW

Onpplv

HOLES TO EFFECT A

OVER
WATERTIGHT

1A-61

Figure

SECTION

NoN HABDENTNG

AX_AX

SEAL.

sEALER

Reinstall

Reverse removal operations.

57

A

t.t -

REAR END

sEcrroN

2.4 Nm

PANEL

ASM.

AG-AG

Figure 1A-62

I

1A-50

7.9

MODEL.
Remove

With

rcat
securing
Section

Reinstall
Reverse

sealing
inside
illustrated

the moulding

AV-AV,

.

with

o{ the

BODY

MOULDING

COMPARTMENT

CALAIS

compartment

Fig.

removal

non

hardening

attaching

in

Section

ASSEMBLY

lid

to

the rear

14-63)

then remove

operations

nuts

AV-AV,

sealer

and rear
Fig. 14-63.

REAR

LID

open, remove

compartment

the moulding.

ensuring

is

that

applied

between

compartment

the nuts

(refer

lid

adequate

the

lid

as

sEcrtoN

Qnner-v

HOLES

AV-AV

NoN

TO

Figure

HARDENTNG

EFFECT

A

WATERTIGHT

1A€3

sEALER

ovER

SEAL

7.10

MODEL.

Remove

With

engine

tap

ends

retaining

Fig.

14-64)

Reinstall

!9ve1s9
clips fully

EMBLEM

CALAIS

hood

raised

of emblem

clips in

removal

retain

until it

the

the

is

operations

ASSEMBLY

and

using

protruding

studs

engine

possible

embrem.

hood

to remove

ensuring

plastic

a
(refer

HOOD

mallet,

through

Section

emblem-

that

the

lightly

tubular

Ay_Ay,

tubular

Qneer-v

HOLES

CLIP - 2

sEcrtoN

NoN

HARDENTNG

TO

EFFECT

Figure

PLACES

AY-AY

sEALER

A WATERTIGHT

1A-64

ovER

SEAL.

58

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cc=

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I

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59

BODY

1A.53

Ref.

Subject
DESCRIPTION

9.1

EXTERIOR

9.2

9.3

9.4

MOTOR

SWITCH

vtEw

SUNROOF

ASSEMBLY
Remove
Reinstall

ASSEMBLY.

MrRRoRs.................

Remove........

Reinstall

Remove......._

Reinstall

Vertical

Panel

Reinstall

9.1

The

electrically

fitted

assembly

its electric

housing

mirror

The electric

mounted onto the
Fig. 14-67)

'ln-line'

An
attached

to

drive motor

assembly

motor,

provides

one

to the mirror switch

VIEW MIRROR

REAR

EXTERIOR

SLIDING

Adjustment

GLASS

PANEL

ol Sliding

DESCRIPTION

operated
Calais

transmission console

complete adiustment

amp

e!.terior

models consists of a
contained in the
(refer

which is activated

fuse

1A-66).

Fig.

holder

and

electrical

BODY

9.

Page

1A-53

....

&

..-........ 1A-54

REAR

1A-54

........ 1A-54

...... lA-ss

.....................

...._................

...............

................-.....

................

rear

door

(refer

of
harness

1A-55

...

1A'55
1A'55

..........

1A-55
1A-55

1A-59

1A-60

view mirror

mirror

mounted

switch

by a

View

mirrors.

the

assembly

and

ELECTRICAL

INDEX

Subiect

Ref.

with

A,

9.6 LIMIT SWITCH

9.7

9.9 SLIDING SUNROOF

9.10 SYSTEM

located
Fig.

Choice of the
raised
the four way directional arrows
face of the switch
adjustment.

Electrically operated
Production

is

models.

is

Remove........

Reinstall

ELECTROIIIC TODULE ASSEMBLY

Remove.....-..

Reanstall

CABLE ASSEMBLY

Remove.-......

Reinstall
ilotor

Motor Assembly Feinstallation....-..-..

Motor Drive Gear Removal
Motor Drive Gear

under

1A-67).

bar of

Option CF5

ASSEMBLY

Assembly Remova|..................

TlMlNG...--....

the transmission console

mirror to be

the switch to the

MOTOR ASSEMBLY..

adiusted

provide

will

venting

for

sun

19

..................... 1A-61

.....................

Reinstallation........

body styles

....--..........

..--.......... 1A-66

involves

left

right. Depressing

or

illustrated

the desired

roofs

are

(refer

Page

... 1A.61

.... 1A-61

.......... 14.62

1A-62
1A-62

....

1A-62
1A€2
1A-64
1A.65
1A-65
1A-65
1A-65

1A-65

View

pushing

on

released as

except

the

the upper

mirror

'SL'

A,

60

1A.54

BODY

7l

,'-..,

'

o.tg-r19Nm

A

9.2 EXTERIOR
MOTOR

REMOVE

1.

With the
disconnect

2.

Remove

corner

3. Using
cover from
remove

4. Prise
from

5. From
connector

6.

Remove
upper
rearuards

front

the

door

oJ water

wide

a

out fronl lower

rear

within

frame (refer

bladed
front
(refer

seal

edge of mirror housing

door

from

screws

and

out

REAR VIEW

ASSEMBLY

door window in

ground

battery

armrest, interior

deflector.

screwdriver,

door window

Fig.

panels,

door

electrical harness.

securing

Fig.

upper

of

cable.

14-66).

section

disengage

mirror

1A-66)

door frame.

MIRROR

the lowered
trim

and

upper

caretully

frame inner.

glass

of

assembly.

then

run

mirror

assembly to

ease

Figure

&

position,

front

prise

off

then

channel

assembly

door

assembly

\\

\

.

uMrRnoR

1A{6

CONDUIT

MtRRoR

coNTRO-

EXTERIOR

AND MoroR

REAR

VIEW

AsM.

REINSTALL
Reverse

removal

operations.

61

SWITCH

9.3

REAR

REMOVE

1. Disconnecl

2. Using a
and
View

3. Using a
assembly
switch
harness,

REINSTALL
Reverse

wide bladed

bezel

A, Fig.

similar

connector

then remove

removal

ASSEMBLY

VIEW

ground

battery

covering

1A-67)'from

procedure,

from lransmission

oPerations.

MIRRORS

cable.

screwdriver,

top of

from

switch

transmission

carefully

front end electrical

the switch assembly.

.

EXTERIOR

carefully

console.

prise

assembly

console.

prise

Disengage

cap

(refer

switch

wiring

EXTERIOR

MIRRORS

ESCUTCHEON

VIEW

REAR

SWITCH

NSIT,I.

TRANSMISSION
CONSOLE

--\

BODY

\

\

\.

1A.55

SUNROOF

9.4

REMOVE

Place sunroof

1.

2. Slide

3.

4. Loosen

5.

6.
REINSTALL

Reverse

sunshade

Remove
(Fig.

1A-70).

panel
(Fig.

1A-71).

Remove
socket

Remove

removal operations.

side

rear

drops

front

(refer

sliding

SLIDING

sllding

rean'vard'

lull

finishing

guides

shaft screws

down

guide

14-71).

Fig.

panel

panel

covers

using

shoulder

upward

GLASS

in VENT

until

mm allen

3

bolts

through

PANEL

position.

attaching

rear of

using

roof

opening'

screws

sliding

wrench

mm

7

Figure

1A-67

62

1A.56

BODY

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1A.57

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64

1A.58

BODY

b<

FINISHING

SIDE

Figure 14-70

COVER

REAR

­SHAFT

GUIDE

SCREW

Figure 14-71

65

--

/.

FRONT

SHOULDER

GUIDE

EOLT

BODY

1A.59

VERTICAL
',|.

Activate

panel

glass

Fully engage

2.

3.

1A-72

Fig.
half turn.

Torque

ADJUSTMENT

switch assembly

roof

sun

into cam

shaft

is fullY

rear

screw

lowered.

guide

block,

lock

OF SLIDING

until

screw

shaft

nut to

then

2.03

REAR

back off

-

CAM

PANEL

rear

illustrated

screw

Nm.

2.71

ASSEMBLY

end

of

-

in

a

'-Ro--

\

REAR

CAM BOLTS

\

Figure

1A-72

,TFRONT

GUIDE

SHOULDER EOLT

66

1A.60

BODY

9.5

REMOVE

1.

Place

sliding

2.

Remove

(refer

sides

3. Press

REINSTALL
Reverse

both

remove

removal

WIND

panel

'C'

clip retainer

Fig.

wind

arms

from

ooerations.

DEFLECTOR

rear

and

frame

studs-

position.

flat

washer

in

full

1A-73).

deflector
housing

FRAME

from

arms

inboard

both

to

Figure

1A-73

67

LIMIT SWITCH ASSEMBLY

9.6

REMOVE

1.

Remove
side

2.

Scribe
assembly

Remove two
(refer

4.

Remove switch assembly

well

and

housing.

the

of

line

on

(refer

Fig. 1A-74).

(2)

REINSTALL

Prior to installation of
from switch assembly

Position switch
Attach with two

drop headliner from the front

tube

Fig. 1A-74).

switch assembly

assembly

(2)

tube entrance

at

mounting screws

by sliding

new switch, remove

(refer

screws

removed above.

Fig.
to

off

'lA-74).

scribe

of

line

tube.

right

to switch

pin

cotter

tube.

of

BODY 1A.61

Figure 1A-74

68

1A-62

BODY

9.7 ELECTRONIC

REMOVE

1.

Remove

2. Uncouple
Remove

3.
rail

REINSTALL
Reverse

welt

and drop headliner

connector at module

screws

(refer

removal

attaching module

Fig.

1A-75).

ooerations.

MODULE

at front

assembly.

ASSEMBLY

of housing.

assembly

to roof

ATTACHING

SCREWS

REMOVE

''l

.

Drop

headliner

2.

Remove__cable
Fig.

1,4-76).

3.

Disengage

4.

Remove

Sliding

Fig.

14-69).

------)

-'--,

9.8

CABLE

rear

at

guide

cables

from

sliding panel

Glass

Panel,

MODULE

ASSEMBLY

ASSEMBLY

of housing.

lower

retainer

gear

drive

as

Remove

(refer

described

and

Figure

cover (reter

Fig.

tA_76).

g.4

in

Sunroof

Reinstall (refer

t--

1A.75

69

BODY

1A.63

70

Figure

1A-76

1A.64

5.

6.

7.

8.

9.

10.

REINSTALL

Reverse
sunshade
(refer

BODY

Move

trough

notch

in

notch,

rotate

Rotate

trough

assembly (refer
Remove
upward
Remove

Fig.

1A-78).

Lift

front

Remove

.removal
in

Fig.

1A-80).

rod

track,

right

sunshade

to

disengage

three

of track

cable

lowest

and cable

to

slide

and remove (refer

hand

front guide

(3)

up

assembly

operations

slot

front

Fig.

by

adding

front

screws

and

disengage

from

in

track.

assemblies

guide

Fig.

shoe

1A-77).

a slight

track.
retaining

track

using

Refei

to

reanarard

shoes

reanivard

1A_72).

fonivard

hano

each

track

from

housing.

at rear.

care

,system

to

remove

pressure

(refer

to

install

Timing,

of
to

Figure

1A-77

71

BODY 1A.65

SLIDING SUNROOF

9.9
ASSEMBLY

MOTOR ASSEMBLY

'l

. Drop

2. Uncouple connector

3. Remove

4. Remove two

MOTOR
Reverse

MOTOR DRIVE GEAR

1. Drop

2. Remove

3. Use small

MOTOB
Reverse removal operations.

headliner

rear
mounting brackets using

Fig. 1A-79).

retainer cover
remove

(refer

rear housing

housing.

of

ASSEMBLY

removal oPerations.

headliner

two

'C'

Fig. 14-76).

DRIVE GEAR

REMOVAL

rear

al

from motor

(2)

hex head

REINSTALLATION

REMOVAL

rear

at

(2)

screws

(refer

Fig. 14-76).

screwdriver or other

clip attaching drive

REINSTALLATION

MOTOR

housing.

of

assembly.

support brackets

screws attaching

7 mm socket

housing.

ol

from

cable

suitable

gear

Figure 1A-78

lower

and

motor to

(refer

guide

lower

to

tool

to motor shaft

\b

MOUNTING
BRACKET

MOTOB
ASSEM B LY

CAB TE
RETAINER

72

Figure

1A-79

1A.66

BODY

/.'sLoI

CABLE

HOUSING

1.

Remove
Sliding
Removal

z.

Position

shown
Reinstall..drive

as described
Motor

Drive

Section.

9.10

drive

Sunroof

and

Reinstallation

both

in Fig.

in

Gear,

SYSTEM

gear

from

Motor

Assembly,

cable

housings

14-80.

gear

and reverse

9.9

Sliding

Removal

TIMING

motor

as described

in this

to

Sunroof

and

Reinstallation

Motor

Section.
slots

in

removal

Motor

Figure

g.9

in

Drive

Gear

tracks

as

operations

Assembly,

in

thts

1A-8O

73

BODY

1A.67

FABRICATED

GLASS

SEALANT

REMOVAL

TOOL

TRIM CLIP

_

18.0 mm-

REMOVAL

t_
f

mm-

^ ^9.0

10. SPECIAL

TOOL

Uf,MM

<-75.0

-

mm

8.5

mm---

TOOLS

ROOF SIDE

-

MOULDING

END

CONSTRUCTION

TO

SUIT

R EOUI

R EMENTS

-

mm

10.0

REMOVAL

HANDLE

DIA

TOOL

RADIO _ RADIO/CASSETTE
REMOVAL

TOOLS

.{tl

-rl

-T1l

147

PLAYER

cMT113

74

RADIATOR

GRILLE

1C.1

Sublect

Ref.

1. DESCRIPTION

piece

The new
series

one

painteil

is

silver

1.1 SERVICE

Remove

1. With

2. Ease

engine

grille

to

top

grommets installed

hood

radiator upper

grille

of

plastic

radiator

Calais

on

raised,

suppctrt

fonrvard,

in the

bumper

grille

model,

NOTES

remove

(refer

lift

then

facia.

SECTION

RADIATOR

INDEX

Page

1C-1

1. DESCRIPTION

VK

to

fitted

on other

whilst

screws
Fig.

grille

securlng

1C'1).
pegs

out

Ref. Sublect

1.1 SERVICE

of

1C

GRILLE

Remove
Reinstall

models,
on

they are

the body

colour'

NOTES

painted

cool

or

warm

grey,

Page

rc-r

1Gl
1C-1

depending

Relnstall
Reverse

removal

A

g

SCREW

PLACES

2

\

&

A/

scREl/-\6tr

..u

A

/|^ro-3.4Nm

operations.

NUTl

PLACES

2

- 4.6 Nm

\

-,/---'-

7/

-7

75

Figure

1C-l

76

FRONT

&

REAR BUMPER

BAR ASSEMBLIES

1D.1

Ref.

Subject
DESCRIPTION

1.
SERVICE

1.1

FRONT

1.2

and

Front
models are

featuring a

strips
top edge
facias.-On

FRONT

NOTES
lntroduction.
Recommended

Golour

Parts
Repairing
Warning
Golour

Remove........

Reinstall

rear bumper

of

ol the

the rear

Finishing

-

Lacquer........

BUMPER

Disassemble
Reassemble

polycarbonate

rubber upper

and

side

bumper

REAR

&

Materials

Replacement

of

.'...................'..

Colour

Coat

BodY

of

Use

BAR ASSEMBLY

bar assemblies

construclion.

part

assemblies

edge

the

ol

are

centre

SECTION

BUMPER

INDEX

Page

1D-1
tD-1
1D-1
1D-2

1D-3
1D-2

1D-2

............

1D-3
1D-3
1D-3
1D-3
1D-3

1. DESCRIPTION

VK

to

titted

finishing

Bright

clipped

fitted

over lhe

bumper

front

to 19 body

Ref.

1.3

1D

BAR

styles,

the

of
styles
facias only

ASSEMBLIES

Subject

BUMPER

REAR

Models 19 Body Sty1es............

Remove........

Disassemble

Reassemble
Reanstall

Models 35

Remove
Disassemble
Reassemble
Reinstall

finishing strips

the

rear bumper bar assembly

finishrng strips

these

(reter

Figs. 1D-1,

BAR ASSEMBLY

..

Body Sty1es............

the complete

cover

fitted to

are

1D-2,

whilst

1D-3

on

the

and

upper

35 body

the

rear

1D-4).

Page

1D-4
1D-4
10-4
1D-4

'tD-4
10-4

1D-6
1D-6
1D-6
1D-6
1D-6

edge

bumper

1.1 SERVICE

INTRODUCTION

paint

The

is relatively
materials are
solvents
by
attached

parts

CAUTION:

Painting
methylated
or other

plastic- Top
as

The
guide
to be employed

and

service

system

straight

used.

applied

are

solvent

specified

attack-

to the exterior

supplied

following service

Dealerships,

side

to

Cleansing

­spirits

cleaning

Coat

this Section.

in

mouldings,

installation.

NOTES

VK

the

for

the

Therefore,

field.

the

wipe only.

thinners,

with GMH approved

on

when

bumpers

fonrrrard as

lf normal

polycarbonate will be damaged

surface

of this

recommendations are

the correct

refinishing

also

refinish

warning

a

of

patt

for

not use

Do

these

as

materials and

VK Series bumper

preparing

when

side

and

long as

lacquers

unpainted

all

painting

lacquer

may damage

paint

new

mouldings

the correct

will be

label

spare

must be by

thtnners
thinners

and

compiled

methods

parts

77

and

the

to

bars

for

1D.2

FRONT

& REAR

BUMPER

BAR

ASSEMBLIES

RECOMMENDED

rear

Irol.9nq

to

VK

polycarbonate
It

is

essential

and thinners,

performed

are
tion

to the

Use

the

of

will

affect

The

GMH

.

Methylated

r

Paint
cotours:

Silver
Warm
Cool Grey

.

Thinner

The

Berger

polycarbonate

for
ycarbonate

coating.
colour

number

4H016).

bumper

Series

Grey

When

are

plastic.

that

be

and

vehicle.

wrong

polycarbonate

the

approved

Spirits

Berger

-

Berger

-

lacquer
parts

ordering

and name,

employed

are moulded

MATERIALS

bars

and

made

from

only

GMH

approved

when

preparing

when

materials

Polycarbonate

is

and requires

will

material.

materials

GMH
GMH 4H016
GMH 4H015

LT2p6.

are:

for

cleansing

-

4J022

a special

spare
for

example

affect finished

acrylic lacquer

in-colour

side moutdings

high

impaCt
materials, paints

paint

repair

operations

parts

new

before

Lacquer

-

-

-

NO

parts

painting.

in

the following

Berger
Berser
Berger

primer.

for

ease

quote

Warm

Grey

lor

qualitv

HH9991
HHgg89
HHg990

developed

The

the

installed
strength

installa_

and

pol-

of top

GMH

(GMH

Bumper)
convenient
due to

1.

2.

3.

4.

WARNING.

Normal
are not
bumpers

The

possible

91l9il9

(or.coarser

P320
required
paper

over

the

Cleaning
with

a

dry

with

Painting

ved.thinners

repaired

coat

all

Drying
tamp

or similar

f9r

99

should
removal
and harden

lacquers

suitable

and

paint

repair

breakline.

colour
depending

-

for

initial

to remove

whole

- wipe

clean

cloth

new

a

- mix
(approximately

area

to

over

to

allow

­minutes. (Surface

not

exceed

of

the

the

USE

used

for

side

mouldings.

area

Spot

repairs

match

upon

grit).wet
sanding.

sanding

of the

area

the

area

soaked

clean

cloth

polycarbonate

the

build

achieve

10

minutes

set

up

to

gOoC

special

paint

OF BODY

slow

film.

for refinish

repainting

should

are

problems.

the

or Ory

Finish

marks

to

be resprayed.

painted

to

be

in

meihylated

each time.

1:1

colour

followed

colour

uniformitv.

air flash

warm

temperature

Lamp

)

solvents

COLOUR

painting
the

be

to

the

not

recommended

degree

sand

lacquer

ratio)

the

of

sa-ndpaper

wiin

and

dry

at least

spirits

with

and

by

then

use

painted

of

baking

in-the

LACQUER

of sheet

polvca;gon"r"

VK

nearest

damage,

may

eCOti grit

scuff

twice

wiping

appro_

spray'the

one

a heat

surface

part

the

will

speed

laiquer

metal

be
Lll

wet

COLOUR

parts

Spare
installation

Observe

1.

2.

3.

4.

5.
{or

exceed
the
the
vehicle.

REPAIRING

Superficial
surface
having
replaced
thinning
rmpact

washed

to

the

Order
the

required

Inspect
this

can

Cleaning
clean

cloth

with

new

a

Paint

­viscosity
ratio),

and
minutes
important

coverage
reduce
microns.)

Drying
tamp

or similar

30

minutes (part

special
paint

may

deep

as repair

down

strength.

otf

FINISHING

are

the vehicle.

following procedures:-

part

surface,

be rectified

wipe

­soaked

clean

mix.

with

apply

flash

that

is

applied,

adhesion.

allow 10

-

90oC).

slow

film

COLOUR

damage

be rectified

gouges

of the

Under

with

OF

supplied

with
top

the

time

to

lacquer

unpainted,

the

coat

colour.

if

slight

by

the

surface

in

cloth

polycarbonate

approved

one full

and

only

too

(Correct

minutes

set

up

surface

Lamp

solvenls
enable

COAT

to

the

by

etc. in

methods

plastic

no

thinners. (i.e.

REPLACEMENT

plastic

transit

dry

sanding

methylated

each

thinners (approximately

wet
apply
sufficient

high

film

to warm

baking

in

assembly

paint
sanding
the

using

section

circumstances

to

be

self coloured

damage

with-pa0O paper.

least

at

spirits,

time.

lacquer

coat.

Allow

a second

paint

paint

a

thichness

air flash

plaltic

then

painted

the

temperaiure

will

speed

the

lacquer

of the

film

and/or plastrc

and repainting.

surface

filling

mai

should

Sections

PARTS

coated

twice

thickness

materials

reduce

before

to match

present

is

using

wiping

to

spraying

aboul

full

coat. lt

to

achieve

is

30

use

a heat

surface

should

removat

and harden

part

to

should

overall

paint

of

-dry

-1:i
two

may

35

-

not

of

the

parts

be

and

be

the

a

is

78

FRONT

1.2

REMOVE

Raise

1.
stands.

From

2.

openings,
Oirmpei
B-B and

Jront

With

3.

Disassemble

1.

2.

3.

under

from
inner
Section
assemblY.

Disengage

trom

Fig.

GC,
Remove

bumper

Fig.

A-A,

Remove
centre
remove

support

and

within

remove

assembly

bar

C-C,

bumper

front

bracket

A-A,

lower

in

ioi'cn

1D-2)

screws

bar

1D-2).

screws

lacia

side

BUMPER

tront end

front end

screws

front

to

1D-1).

Fig.

assembly

bar

vehicle,

of

assemblies

Fig.

bumper

then

securing

inner bracket

(refer

facia(s).

1D-1)

edge

bar

raise and

nuts

and

Section

removing

of

FRONT

ASSEMBLY

BAR

vehicle on

of

section

securing

from side

side

bumper

assemblies

securing

of

{enders

fully supported

remove

lront

finishing

facia(s)

remove

bar

B-8,

&

jack

wheel

front

sides

(refer Sections

bolts

frames

strip.

(refer

finishing
facias

(refer

side

Fig'

front

of

securing

(refer

bumper

assembly

Section

strip'

to

Section

tacia(s)

1D'2)

and

bar

front

then

REAR

to

BUMPER

BAR

ASSEMBLIES

1D-3

Reassemble

Reverse

REINSTALL

Reverse

to disassembly

to

FRONT

ASM.

BAR

secrtoru

40-54Nm

A

A

8-11Nm

11\

removal

BUMPER

BOLT
2

WASHER
2

\

A-A

operations.

oPerations.

BUMPER

FRONT

ERACKET

INNER

zl.

4L

PLACES

PLACES

Ri

R/L

L

2PLACESR/L

FRONT
PANE L

BAR

ASM-

SCREWl

FENDERJ

R/L

LH

R &

!

__if

7-,

srcrtoru

D-D

FRoNT reruoea/

PANEL

/1\

SCREW

1

i:

\Yfl-"

\J

u,r* E

A

PLACE R/L

FRONT

PANEL

FASTENER
'r

PLACE R/L

ASM.

,/

tr; .(

t{..

,/ 1

secrtoru

FENDERl

-I
f_

g

SECTION

h

\

/

ah,",

+-<'

-/.

.L

\

\

\

B_B

-\\

-,,,)

*,r

l:t

I

fl

t1

C-C

.

Figure 1D-1

79

1D-4

FRONT

& REAR

,,6\

scR.*

PLACES

4
R&LSIDE

BUMPER

BAR

ASSEMBLIES

secrroru A-A

A,

6-8Nm

/z\

10-'r5Nm

A

1.3

REAR

MODELS
Remove

1.

From
securing
panel

2. With
remove
assembly
and B-8,
from

centre facia

LH FINISHING

STRIP

19

BODY

under

lower

(refer

Section

rear

bumper

nuts

to rear

Fig.

FRONT
BUMPER BAR
BRACKET ASM.

ant 7-

5ilocer

R&LSIDE

\

BUMPER

STYLES

rear

section

and screws

end

1D-3)

then

BAR

quarter

of side facias

C-C, Fig.

bar

assembly

securing

vehicle

of

and unscrew

remove

NUT
4 PLACES

N

d L JIUE

\

ASSEMBLY

panels,

remove

to rear

1D-3).

fully

rear

(refer
licence

assemblv.

secrroru

CENTRE
ASSEMBLY

B-B

FACIA-

wa5H5q---.7s

,:.

I'

,

NUTJ

3PLACES

screws
quarter

supported,

bumper

Sections

plate

bar

A-A

holder

2(

R&LSIDE

Figure

sgcrroru

1D-2

C-C

RH

FINISHtNG

5-

\STRIP

\

LH FRONT
INNER

AFTER

ASSEMBLY

LOCATE

STRIPS

R/L

BUMPER

BRACKET

AND

SNAP

OVER

RH

ASSEMBLv

BAR

ASM.

OF

BUMPER

CLIP

BUMPER

SIDE

FACIA

,RH

FRONT

i

BAR

BRACKET

FINISHER

BAR

7

/

BUMPER

INNER

^sM7

BAR-

ASM,

Disassemble

1.

Disengage

from

notches

bar

assembly

finishing

2. Remove
assembly
facia(s)

Fig.

to

1D-3)

Reassemble
Reverse

disassembly

Reinstall
Reverse

instructions
screws

removal

for

and nuts

lower

in right

(refer

strips.

screws
mounting

centre facia

then

remove

operations.

operations

the rear

illustrated

edge

of

and left hand

Fig.

1D-3)

and nuts

brackets to

(refer
side facia(s).

ensuring

bumper

Fig

1D-3

finishing

then raise

securing

centre

Sections

that

bar

assemblv

are

observed

strip

sides

bumper

facia

B-B

assembly

of bumper

remove

and

and side

and D-D,

the

sealing

attachino

Dar

80

FRONT

REAR

&

BUMPER

BAR

ASSEMBLIES

1D.5

Z".---

l4.l

CENTRALIZE

FINISHER STRIPS
BUMPER BAR

A

SCREW

7-

,

2PLACESR&L

AND SNAP_CLIP

OVER

ASSEMBLY

FINISHING

RH

RH

FACIA

=

\.*

FACIA ASM.

SIDE

r,o.

ASM.

STRIPl\

7;i l'
*

\.r*r*.

-4t\

ASM.

FASTEN
lPLACER&L

ro",o

ER

SECTION

6-8

A

,o-

A

8-

A

A-A

T

\

V

SECTION

Nm

Nm

27

11Nm

WAHSER

SCREW
2PLACESR&L

V

E_E

A

NUT

_

2

_

2

Q

PLACES

PLACESJ

neelv

AROUND

SECTION

HARDENING SEALER

NoN

8UI.1PEC

ATTACHMENT

B_B

HOLES

4PLACESR&L

secrton

,Ar

4PLACESR&L/

NUT---T\

SECTION

E-' -E

u,r*lIl

C-C

scnewl

D_D

R&LsrDE

5 ra

81

Figure

1D-3

1D-6

FRONT

& REAR

BUMPER

BAR

ASSEMBLIES

MODELS
Remove

1.

Disc.onnect

licence

out

facia

and

2.

From
securing
panel

(refer

3.

With

tailgate
covers
per

bar

A-A,

Fig.

4. From

Disassemble

1.

2.

Reassemble
Reverse

within
bumper
secunng
B-8, Fig.

Disengage

from

notches
Fig.

1D-

Remove

assembly
centre

facia

D-D,

Fig.

disassembly

35 BODY

battery

plate

disconnect

under

rear

lower

section

Section

raised

removed,

assembly

1Da).

spare wheel

bar

assembly lully

assembly

1D-4)

and remove

lower

on side

then raise

)

nuts

and

mounting

to

side

tD-4)

then

STYLES

ground

lamp

assemblies

electrical

quarter

of

side facias

GC,

Fig. lD-a).

and rear

remove

to rear

operations.

screws

quarter

compartmenl

to

edge

panel

back

of

facia(s)

and remove

screws

brackets

facia(s)

remove

cable

then

from

connectors.

panels,

quarter

securing

panel

supported,

lower

assembly.

finishing

(refer

finishing

securing

to

centre

(refer

Sections

side

facia(s).

carefully

top

of

remove

to rear

inner

trim
rear

(refer

and with

remove

(refer

strip

assembly

Section

strip(s).

bumper

facia

prise

centre

screws
euarter

oanel

bum-

Section

rear

nuts

Section

A_A,

and

B_B

and

bar

Reinstall

Reverse
instructions
screws

removal

and nuts

for

the rear

operations

bumper

illustrated

ensuring

in

Fig.

bar

lssembly

1D-4

that

are

observeo.

the sealing

attachin!

82

SNAP-CLIP
OVER BUMPER

FINISHER STRIP

FRONT

BAR ASSEMBLY,

&

i>!P

I

R/1.

WASHER

PLACES

2

REAR BUMPER

FIH SIDE
FACIA ASM.

FINISHING

LH

_4

---D

"h"

g

la.

LH

SIDE

BAR

FACIA

ASSEMBLIES 1D.7

FINISHING

RH

STRIP

-

CENTRE

ASM.

FACIA ASM.

secrrom

/\

6-8

O

12-16Nm

A

8-

A

A-A

Nm

11Nm

SCREW

PLACES Ri L

2

SECTION E-E

Q

WASHER

PLACES

2

SECTION

aeelv NoN

AROUND BUMPER

HARDENTNG

B-B

SEALER

ATTACHMENT

HOLES

BUMPER

NUT

r

pr-aces

+

I

SecrlOt't

ASM

D-D

vrEW

SECTION

Rlr-

SCREW

PLACES

4

lAl

R/L srDE

C_C

R/L,/3'

.,

5 ta

Flgure 1D-4

83

t-. k

VENTILATION

& HEATING 2A.1

Ref.

Subject

1.

GENERAL

1.1

1.2

SERVICE

1.3

UPPER SIDE
LEFT HAND

Remove.,......

Reinstall

MOOE SELECTION,

1.4
CONTBOL

ilodels

SECTION

VENTILATION & HEATING

DESCRIPTION

NOTES

VENT

OUTLETS.

AND BLOWER FAN SWITCH..

Remove
Reinstall

TEMPERATURE

A11.........-..-..

-

RIGHT

2A

INDEX

Page

2A-3

2A-4
2A-4
2A-4
2A-4
244
2A-4
2A€

&

2A-6
2A-6
2A-6

2A-7
2A-7
2A-7
2A-7

Ref.

Subject

1.5

BLOWER MOTOR.........

Remove........

1.6

1.7

1.8

1.9

Reinstall

BLOWER MOTOR HOUSING

Remove........

Reinstall

HEATER

HEATER CORE AND PIPE

WATER
coRE

ASSEMBLY

Remove........

Reinstall

Remove........

Reinstall

VALVE ASSEMBLY.

.-........

Remove..-.....

Reinstall ...

ASSEMBLY..

-.......

.........-.....-....

ASSEMBLY...... 2A-13

.................... 2A-13

HEATER

.................... 2A-14

2A.10
2A-10
2A-10
2A-11
2A-11

..- 2A-11

... 2A-13

2A-14

--_-.-­2A-14

Page

2A-9
2A'9
2A-9

a

24.2

VENTILATION

&

HEATING

--J

ELOWER

SWITCH

MOTOB

TEMPERATURE
CONTROL

Flgure

2A-1

HEAT'VENT

CONTROLS

Figure 2A-2

OFF NO

AIR

FLOW

VENTILATION &

HEATING 2A-3

The

ventilating

models

the rear of

motor housing
mixed

required. The
through the centre and or side upper
through
depending on the
control

illustrates the air
various modes

On

hausts

and

in Fig.
the

roof, then

pockets.

The volume

outlets

regulating

Fig.

tilting and/or

To

rotate the

air outlet.

reached.

The heating
temperature
controlled
which
volume

The
assembly
fan
delivered
two sliding
temperature entering

right hand lever, the

allows

the

or allowed

the
levers illustrated in Fig. 2A-2. Fig. 2A-2

sedans, air

through

lelt hand

2A-3. On station

edges of

out

(refer

wheel
The

2A-4.

the

slop

regulating wheel to the right, and

rotate the

by a temperature

operates

of air

temperature,

ilfustrated in Fig. 2A-2 consists of a

which regulates the

switch,

into the vehicle through the

heating system featured

and

air entering

engine

heater

and

to

then enters the

air

demist

position

flow within the heater

activated.

from the

ventilator

side drip
the rear

into the atmosphere

trom the

of air

View

below

llow

air

swivelling

supply

air

system

entering

of air

the mixture door. This regulates

passing

levers. The left hand

the syslem via the

hood to

remain

or footwell

moulding

wagons, the air

quarter

A, Fig.2A-1) is controlled by a

can be directed as
the ventilator
from the

wheel

utilises an air

through the heater core.

mode

the vehicle in

particular

pass

assemblies and

at ambient

passenger

outlets

the mode

of

passenger

outlets

the

located behind the right

assembly

inner trim

through tailgate

centre or side

outlet

upper side

downwards

mix

passenger

the

lever illustrated in

blower

and

rate

lever

mode required.

1.

GENERAL

VK

Series

on

grilles

through the blower

to be heated,

temperature,

compartment

ventilator

assembly

inserts

upper outlet

principle

which forced

at

various
all

outlets, or

(refer

Fig. 2A-1

temperature

or

with the

compartment ex-

rear,

illustrated

is

exhausted

panels,

controls
modes and

into the

hinge

upper ventilator

illustrated

required by

inserts.

vent

outlets,

the centre

on

until a stop

where the

compartment

Fig.

motor control

four speed

air

outlets, and

the

DESCRIPTION

at

as

)

also

via

in

is

Figure 2A-3

is

2A-2

the

is

air

the

UPPER

OUTER

AIR OUTLET

HOUSING ASM.I

./l

SCREW

PLACES)

{4

OUTEF
OUTTET

\

OUTER

V

i{

N'

@

vffi

'q

LOWER AIRI

INSERT ASM

\

UPPER

Figure

REGULATING

LOWEF
I NSTRUMENT
PANEL

2A-4

:Ii

WHEEL

LH

24.4

VENTILATION

1.1

The

mode

control

DEM

position

In

this

the

demist

amount

FLOOR
in

this

outlets with

VENT
This

centre
individually

BI

LEVEL

This
well

OFF
ln

this

is

admitted

recommended

in

very
closed.
settings

NOTE:
its

lowest
away
rncreased

vents

of air

position

setting

and

side

adjusted

position

to

as

the

position

via

dusty

Return

as

soon

The

blower

speed

from

by

also

a small

directs

directs

or smokey

OFF
selecting

MANUAL

lever has

the

flows

air

on top

goes

to

the

main

amount

all the

vents.

The

at each vent.

air to the

floor vents.

the

fan is

the

ventilation

to

be

used for

the mode

as

conditions

motor fan

when

the mode

position.

a higher

& HEATING

CONTROLS

positions:

five

onto the windscreen

of the instrument

the floor

air flow

going

ambient

air

switched

conditions

lever

ouilets

is

directed

to the

demist

or heated

flow

and

direction

centre

and

off

and no

system. This

periods

short

with

all the

to

one

permit,

automatically

control

Fan

lever

speed

number.

through

panel-

A small

to the

venrs.

air to the

can

side venls

outside

setting

when

is
driving

wrnoows

of the

swi166ss

is

moved

other

.r

can then

floor

oe

as

air

only

1.

be

LH AI R

OUTLET DUCT

ELOWER
HOUSING

MOTOR -'

ASSET\4BLY

Figure

r

.

BLOWER

TO HEATER

2A-5

LH

DEMIST

DUCT

NOZZLE

ASSEMBLY

IVOTOR

ASSEMELY

j4

.

HEATER

HOUSING

DUCT

;CENTRE

/

DISTRIEUTION

AIR

-\

L

Rs

DEtutsr NozzLE

DUCT

ASSEMELY

ASSEI\4BLY

DUCT

\SCREW

llrJ'

nHJ

AIR

OUTLET

DUCT

I

-

z

=a
Oo

FU

z=

UV

z=

Zr

-3

z

?<

-O

UA

N,
N-

oz>

2uln

;><

*)U

FF>
zl;<

a

U

UJ
tIc

o-

\

=F.

TU

r<

^z

:t

3

oO

Tf
OF

)z

^/

€\

J

--.r

UJ
(!a

9n

VENTILATION

z

o

z

u
F
X
U

J
u

z

L

t\

L
J-

Jq

& HEATING

d)

I

co

z

o

F
U

a

2A.5

:

F

I

6

uJ

F

i,z

>U

)@

;H

zx
r

=2

o<

'

(t

2Ez

=v

3:
lr

:

z=

L\

,a
2E

5=

l9

crJ
FU

a^
Z=

@

N

o
ctt

L

)".

Yr\-

z\-::\

\

\ i-\l

-

|

-'-V

F<

uff

<t

:R

UJ
Fu

<z

u<

:1

I

3i

L_

'Jr

1

ci--T

..-..-l

-

\ii \

-^

__-\,;i-iF

v

I

o\

: v(JU

(t

's

s

--\/

F

-

{;

\

-

\.-'

}

\,"

-'''

^z:,

-O<

:27

^-t

;=:

:>)

E

=

=

2A.6

VENTILATION

1.2

The

non

air
illustrated
mating

indentations

of the

ducting
and left
distribution
its

designed
disturbed
essential
reinstalled

joins

and connections.

Removal

the

instrument

the

ducting
housing
clucting
and the instrument
Fig.

1.3

necessitates

24-6.

UPPER

conditioned

in

Fig.

together.

hand

air outlet

duct,

ensure correct

location.

during

under instrument

to

ensure that

so

to

as

of any

to heater

of

panel

is to

SIDE VENT

be removed.

&

REMOVE
Using

a fine

and
vent
the

upper

pad
outlet

left

upper

assembly

bladed

hand

upper

assemblies

air

outlet

assembly.

as illustrated

& HEATING

SERVICE

2A-5 as

protrusions

and

Screws installed

Should

prevent possible

the

ducting necessitates

lower

assembly
removal

panel

LEFT

screwdriver,

and lower

prior

assemblies

NOTES

ducting

air

polypropolene

ducting to the

retention

any of this

panel

such

trim

on the side from

Other than the

duct, removal

the

of

location

OUTLETS,

HAND

carefully

inserts

to removing

to ths

in Fig.

on VK

which

ducting

touch

cover illustrated

tubing

retain

through

of the ductino

air

the

the right

centre

air ducting

operations, it is

be correctly

leaks

at

removal

of other

control

RIGHT

prise

right

from within

screws,

instrument

2A-7,

securing

then remove

Series

with

ends

air

in

be

these

of

which

blower

panel

in

hand

side

oanel

,/'

,

.// ,

,i

gOUTER

\

UppER

ourlErlNSERrAsM.

AtR

\

REINSTALL

Reverse

removal

procedures.

/,(v\

/,/ u

/^@ia

-\Yg....f

rffi

\-ourER_LOWER

\Lg!

_

scREw

(4

PLACES)

AtR

OUTLET

i,vsa*t

nsrr,r.

LOWER
INSTRUMENT
PANEL

LH

-'

Figure

2A-7

-

MODE

1.4

CONTROL

MODELS.
Remove

1. Disconnect
Remove

2.

2.2, Body

From the

3.
disengage
temperature

4. Remove
centre
ly

5. Remove
wiper dwell control

6. Remove
ated

NOTE:

7. Remove
temperature

instrument
partly

trol

8. Remove

temperature

ALL

the transmission

Section of

the

nozzle and

illustrated

the

the

Fig. 2A-9.

in

not remove

Do

ease

vacuum hoses

ihe

SELECTION,

AND

the

left hand

the

the screw

panel

BLOWER

battery

front

door

touch switch

in Fig.

temperature,

lower instrument

and

out assembly,

control

earth

this Supplement).

side of

the control

of

end

rod, illustrated

instrument

2A-9.

knobs.

wiper dwell

the

securing

mode control

illustrated

frame

disconnecting

and electrical

rear end

of

lever.

console

mode,

TEMPERATURE

SWITCH

FAN

cable.

assembly

heater assembly'

the

cable

in View

control

location

panel

{rame

booster

panel

enension

control

the

assembly

Fig. 2A-8'

in

connector'

the cable

top o1

(refer

from the

2A-8.

B' Fig.

and

assemb­fan and

illustr-

switch.

to the

mode con-

from the

the

the

then

VENTILATION

&

HEATING

2A.7

Reinstall

Reverse

removal

vrw@

ASSEMBLE
TO CORRECT

INSTRUMENT

NUMBERED

HEATER VENTILATION

CONTROL

CAUTION

procedures.

PORT

ON

INSTALLATION

FOR

HtrrEh

PANEL

ASSEMBLY

NOTE

HOSES

VALVE

rlu.

zA-

SCREW

_

NO KINKS

l:7{

I

\-?--

It

-

IN HOSES

' ./

vrrw

,,,1

p]

FULL

TEMDERATURE

WITH

LEVER

-s,

E

,

FoRWAR

IN

DOWN

EEFORE

F

FORWARD

ULL

LEVER

E

\

VACUUM

,r

CHECK

a.=t=4^"<-

(

D

POSITION

SNAPPING

IN DOWN

l{OSE

VALVE

J

-=.

-z

Z

u,a*

CABLE

(AS

SHOWN)

POSITION.

__--t2

t-'.-

\

l----

sNAp lN

@

POSITION MUST BE

IN,

WITH TEMPERATURE

_

FOF

CONTINUATION

BEFER

SECTION

vrew

12E

@

Figure

2A-8

2A-8

z

a

^i;
FU

z?

:<

rI
O,^
UV

z4

Ztr

-3

VENTILATION

o
z

\

\

z

a
t

z

U
O

& HEATING

TU

;<

:L

-z
3:

(/)O

I(r
)z

oo

^.s

q\

J

F

z

z

U

o

a

3

u

,.)

a

l

z

r

U

F

F

o

X

=

U

r

J

U

U

3

z

o

q

J

U
F

J
U

z

I

a

.,-

_iot-+

{O

\E

-\ U

.J-'

u^

frY

n:

q-

)=>

r
F

T
a

=;

a

Ea

)@

Ez

b"

zx

-rJ

I

-<

I

I

F
I

U

J

il,
z=

ft

ir.

;uJ

;=

=n
EJ

I

z

9

-

U
a

o)
o|

o

:

I

tt

\\

.--j:\.-

l

a/)
UJ

=<

UJ

F<

OA

UI
FU

t\

<z

U<

fL

\o

',r

\<

I

z

F

+s

a

=f

L

OU
> a_)

5<
oq

>;

\\\Z

'o

d)

cc
U

F
F

)

VENTILATION

& HEATING

2A.9

1.5 BLOWER

REMOVE

1. Disconnect
From under

2.

3.

using

and

10 Special

hand

lefi

the

Fig.2A-10).

From under

motor to

blower
supporting
securing
in

the

Fig. 2A-11,

battery earth

hand side

left

the

fabricated

a

Tools,at

the end

instrument

instrument

the

main wiring

the blower

motor to

removing

MOTOR

cable.

instrument

of

removal

clip

trim

motor, remove

the blower

the

Section

o{

panel

panel,

harness

motor.

lower

housing

panel

(refer

tool

remove

28)
(refer

trim

disengage

connector,

two screws

the

illustrated

the

then

JL

)\A{1'LIP-4PLACES

1

PART

LOWER
I NSTRUMENT
PANEL

sEcrroru

A-A

^NS

Figure

2A-10

REINSTALL
Fleverse

removal

procedures.

AIR

RH

s

LECTOR

DEF

INLET

a

DE

\

AIR INLET

LH

F LECTOR

LAI

R

INI-E:

-

SCREW

(2

SEAL

PLACES)

RING

Figure 2A-11

2A-10

1.6

REMOVE

1.

Disconnect

main

2. From
fabricated

a
Tools
ment

3.

From
hand

inlet
plenum
move

4.

With
with
head

ment
as illustrated
companment.

5.

Remove

ly

duct

6.

From
securing

panel

7.

Remove
to

the

plenum

the

housing

VENTILATION

BLOWER

battery

wiring

harness

under

left

trim

at the

panel

inside
air inlet

seal ring

the

the

the

of the
side,

the
lower,

end

lower

the

chamber,

ring

assembly

instrument

blade

hinge

prise

the

blower

illustrated

base

lower part

illustrated

the

nuts

studs

attached

chamber

assembly.

MOTOR

ASSEMBLY

earth

cable

conneclor-

hand

of instrument

clip

removal

of Section

(refer

trim

engine
deflector
secured

ol a

in

of

compartment,

and

to

the

as illustrated

panel

scredriver

pin

and

the

hinge pin

Fig.

2A_12,

motor

24_13.

of

housing

housing

motor

in Fig.

blower

in Fig.

securing

the

to the

illustrated

in

Fig.

the right

&

HEATING

HOUSING

and

blower
panel

(iefer

tool

28) remove
2A_10).

screw

left

hand

in

Fig.

located

into

the

then

to heater

housing,

to

le'ii

blower

hand

Fig.

2A-13,

remove

attached

side

2A_11.

between

hand

compartment
remove

remove

hano

motor

side

the

compartment

2A_13.

left

moror

ano

usrng

10

Speciai

the

instru-

the

left

air

of

the

Re_

open

and

the

compan-

the

assemb-

bolt

dash

housing

of the

removtng

to

EUMPER

(2

PLACES)

-

INSTRUMENT
COMPARTMENT

Flgure

PANEL

2A-12

REINSTALL
Reverse

removal procedures.

NUT-\

l^,

!!/)ntrH-

,1

7.5

-

10

2

l{.)

-zt -/

t'

/

r.jur-'

PLACFS

2

Nm

HtrATFR T'] RINIAItrO

Moroa

/va

{,

/\

iu

\

\"

'\-=;1^,--WASHEF

ASM.

_-

i

u

BLOWER
HOUSTNG

MOTOtr

ASSEf,rBry

^
\-*-

DUCT

-tro,tT

-.:/'

\\

A---!

A.

\.

lt'

L

SCREW
2

ASSEMBLY

\,-

\i

\

\

PLACES

-.-,

''':

7

\

;;

::--

-/,---'-

.')

-

)

\;

/-\o

I

BoLr

WASHERT.

(YO-.)

-y'-

\3

\

tr

.HEATER

E

r

t1

Figure

J

2A-13

HEATER ASSEMBLY

1.7

REMOVE

1. Disconnect the battery

2. Disconnect the vacuum feed hose
from

then
the

rubber

inside the
grommet

hoses from the inlet

earth cable.

the

at

engine compartment,

from

the dash

and outlet

and

heater

check

the coolant

core

illustrated in Fig. 24-141

CAUTION:

of the core tube

force is

readily

fotward
remaining on the tube
Once the hoses have

from the

3. Remove

4.

5.

6. Remove

7. Remove the

8. Remove

The

exerted

come

the

of

heater

can easily be damaged

attachment seams

them. When the heater

on

the tubes, the hoses

otf

core

tubes. The
should

been split,

then

portion

be split

they

in the

whenever

hoses

be cut

should

ol the
longitudinally.

can be

tubes without causing damage to the core.

instrument

the

Section

1A, Body

Remove heat/vent

(refer

panel

Fig. 2A-8).

panel

Section).

control assembly

(refer

lower

from instrument

Remove the blower motor housing to heater

assembly duct

heater assembly
heater assembly

illustrated
assembly

in Fig. 24-13,

illustrated in Fig.

the ends oi

illustrated

bolt securing the

to the

in View A

Fig.

the two bolts

instrument

to the

then remove the

2A-13.

the ducting attached

in Fig. 2A-15.

part

lower

pan

floor

bracket,

24-13.

securing

panel

the top of

brace

the heater

as

heater assembly.

REINSTALL
Reverse

core

removal

pipe grommet

hole in the

electricals

procedures

procedures,

is

correctly

lower dash

ducting

and
are operating

ensuring

installed to

panel.

disturbed during

effectively.

that the

fully seal the

Also check that

the removal

valve

remove

oioes

area

undue

do not

just

hose

removed

in

3.4

to the

the

of

as

illustrated

heater

the

VENTILATION & HEATING

ROUTE

HEATER HOSES

POWER

UNIT MOUNTING

VIEW

BEFORE

OF GROMMET,

VACUUM
VALVE HOSE

cRoMMEr

Frr
PIPES
ENSURE PROPER FIT

TNSTALLATTON

SOURCE

THROUGH

uP

GRoNlN4Er

I\TO

AND

PUSH

TO

ro

rAB No.4

ovER

DASH

AND ROCKER

CHECK

HEATER

PANEL.

AND

SEAL,

Figure

COVEF,

OUTLET

INLET

-

cFCr.r..'=-r'

\.-..

*

(

L

'-S\.-

V'

C\

24-14

HOSE

HOSE

- UNtrU\

^UC'r

\;v

)

2A.11

BETWEEN

BRACKET

\ A I I

\

^L

'

-

rl-

OUTLET

LH AIR

BLOWER
HOUSING ASSEMBLY

t---

DUCT

MOTOR

LH

DEMIST NOZZLE

z-

DUCT

BLOWER

TO HEATER

Figure 2A-15

ASSEMBLY

MOTOR HOUSIN(J

ASSEMBLY

CENTRE

,T

DrsrRrBLrtor'J

/

,

HEATER ASSEMBLY

DUCT

AI R

-

RH AIR

RH

DEMIST NOZZLE

DUCT ASSEMBLY

DUCT

OUTLET

DUCT

2A,.12

VENTILATION

=

a

r

UJ
F

U

r

r!<
>q

>5

>I
{r

J;

.k
>*

l

(/

&

HEATING

F

>R

F
t

r

c

l
F
O

U

F

rn

N

r>

--f

--

<(J

U<
I>

q

\.

.'

lry

U
a

>P

l<
tf

<O

UJ

o

I
O

U
U

a
co

uJ
F

U

-I

r

E
E

G
F

:E
U

U
I

U

o

I

!

Y

(-)
:

-

F

J

cc

-

F

z

8

----J

cc
U

F

--

u.:

-N

\',tv'

)

3

U

t

,

\J

U
(h

F

u.,

J

\cl

F
l

o
o

\

/>

QnL

=e;

3E:

:,/,.{

'/,-1

(

f,

F

t
U

C

(o

N

o

3

g

tt

:

-+--

-N

^Cl\'

:O

U
@
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Oil
z>

-u

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;

J
O

'/

V/,

"t\

-

l

E
E

o

)L

| //

| //

ta

VENTILATION & HEATING

2A.13

1.8 HEATER CORE
ASSEMBLY

REMOVE

1. Remove the
described.

2. With

the right hand

uppermost,

'A',

clip

then

Fig. 2A-16.

3. With

the heater assembly

remove the screw attached

Fig.2A-17, then slide out
ly from the heater

REINSTALL
Reverse

removal

heater assembly

disconnect

remove screw

case.

procedures.

side of

rod

door

'B',

in the upright
bracket

the core

AND PIPI

previously

as

the heater assembly

adjusting

both

'A'

and

retainer

illustrated

position,

illustrated

pipe

assemb-

in

in

PER

-

2

CORE &

VALVE ASM

LEVER

Figure

;,

\'.//\

\

2A-17

,/

-

LAIR

MIX

Mrx

-ArH

L

ROD RETAINING

_

BRACKET

NtrA

r SCREW

!'J

DOOR CONNECTING ROD

T.JUUH U

CLIP - 2

PER

"A"

ICN LUHtr

24.14

1.9

REMOVE

1. From
heater

CAUTION:
of the

force
readily
fonarard
remaining
Once
from

2.

3.

REINSTALL

Reverse

core

is

exerted

come

of the

on the

the hoses

the

tubes

Remove

ptpes

passrng

Usrnc

ns

de

of the

realer
securing

prpe

illustrated
assembly,
located

ptpe.

removal

VENTILATION

WATER

inside

core
The

tube

off the

wfthout

:he

a

cross recess

VALVE

HEATER

the

engine

hoses illustrated
heater

can

eastly be

attachment

on them.

core

tuDe

haye

rubber grommet

through

When

fubes,

tubes.
should

been

causing

the

& HEATING

ASSEMBLY

CORE

compartment,

in Fig.

seams

the

the

hoses

portion

The
then

be

split,

they'can

damage

serling

lower

headed

dash inner panel

core

the

water

taking

between

outlet

in Fig.

care

the

pipe,

valve

24-19,

valve

remove

assembly

then

not

to

and heater

Drocedures.

remove

2A-.14.

damaged

in

the

wienever

heater

hoses

shou/d

be cut

of he

split longitudinaily.

be removed

to

the

core.

the

heater

panel.

dash

screwdrrver

hole

adjacent

the

to

the

remove

loose

four

heater

the

the

located

,O,

core

-

the

area

unctue

do

not

just

hose

core

to

the

screws

core

valve

rino

outlei

TEATER
GASKET

CORE-r

,-WASHER-4PER

BOLT - 4 PER

r WATER

.\

O'RING

_

ROD

RETAIN.

AND

ADJ.

CLIP

RETAIN,
SE AL

\-

BK:

HEATER

UPPER

CORE

SEAL

VALVE

ASM.

.J

VIEW

Figure

2A-18

AIR CONDITIONING

28-1

Subiect

Ref.

GENERAL

1.
GENERAL

2.
MANUAL CONTROLS

2.1

'DEiI'
'FLOOR'
'VENT'
'BI LEVEL'
'NORM'
'MAX'
'OFF'
Retrlgerant

Gompressor

Thermostatlc

Evaporator..

Thermostatlc

Recelver

Condenser

SERVICE

3.

COilPRESSOR

3.1

AND ADJUSTMENT....

CHECKING

s.2

VEHICLE

ON

Addlng Oll
Replacement

Compressor

Evaporator..
Condenser
Revelver

REFRIGERANT

SECTION

AIR CONDITIONING

Page

........

2B-1
2B-3
2B-3
2B-3

2B-3
2B-3
2*4

2B-.4

28.4
2H
2B-5
2B-8
2B-9
2B-9

2B-9
2B-9
2B-9

2B,-11
2B-11

2B.11
2B-11

2B-11
2B-11

2B-11
2*11
28-11
2g-11
2B.-12

2B-12
2B-12

. 28-13

28-13
2B-13

. 28-13

28-13

TNFOFMATTON

DESCRrPT1ON..............................

Glrcult

Dehydrator..

OPERATIONS

DBIVE

COMPRESSOR

Durlng Component

Reln8talllng

............................

Swltch
Expanslon

BELT

the Orlglnal

Va1ve..........

TENSION

OIL CHARGE

Compressor

Installlng a New Compressor..

Dehydrator..

SYSTEM
Fllllng Charglng
Installatlon of

Chargfng System
Eyacuatlon
Purglng
Charglng

Functlonal

CHARGING

Charglng

and Leak

(lf

Necessary)

System

Testlng ot

Cyllnder

Test........

..-...........

System..

..........

28

INDEX

Ref.

Subject

3.4 COMPRESSOR INSPECTION

PROCEDU RES...._...._....._.___.

Leak Test

Compressor Smoothness Test..........

Glutch Test ..............

Nolse .......................

Remove.......,.

Relnstall
Disassembly
Reassembly

3.5

3.6

i

3.7

Remove
Reinstall

EVAPORATOB

ASSEMBLY

Remove...............

Reinstall
CONDENSOR
ASSEMBLY

Remove........

Relnstall
AUXILIARY FAN

Remove

Air

EVAPORATOR ASSEMBLY

3.9

4.

5.

Adiustment..

Gap

CORE AND PIPE

............. 2B-2s

AND AUXILIARY FAN

........-..

Page

2g-14
2B-14
2B-14

29.14

28-14
28-r6
28-16
28-16

28-18

28'-20

28'20

28,-20

29-27

28,-27
2V27

29-27

29-27

28-27
28-27
28-27

The Air

models
expansion
Compressor-

International

is a cycling

valve

air conditioning

clutch

(C.C.T.X.V.)

and a

1. GENERAL

system

system

Sanden

used on

with thermostatic

TR

VK

70 Spiral

INFORMATION

following

The
operations

including

L

the

information

for the C.C.T.X.V.

TR 70 Spiral

provides

conditioning

air

Compressor.

basic

service

system'

2B..2

AIR

CONDITIONING

DEMIST

Figure

2B-1

1

ELOWER

SWITCH

MOTOR

-.4'l

I;FL-

P,

o

"

f*

VENT

8l

NORM

VENT

MAX

COND.

CONTROLS

TEMPERATURE
CONTROL

ci

e\.

'1

_

HEAT,'VENT/AIR

VENT

BI_LEVEL

Figure 2B-2

J

MAX

AND

NORM

BLOWER
FOR

OFF

--^

(RERCIRC)

AND

MAX.

--

VK

The
(C.C.T.X.V.)

heated,
depending
control

Air
grille

blower
assemblies,
enters

and/or
demist
the

illustrated

flow within

A four speed
plenum

assemblies,
passenger

NOTE:

low

from'OFF'

On

hausts

right and

illustrated

On station

the

into

The controls

speed
lever
vehicle
selection
has seven oositions.

cycling

mixed or ambient

levers-

entering

the

at

motor

the

side

or

position

chamber,

The blower

speed

Sedans,

through

rear

the atmosphere

fan switch

regulates

in

clutch and

conditioning

air

the

on

the air

rear

of

housing

to be

passenger

upper

footwell

the

of

in Fig.

in

quarter

of

2B-2.

the system

high capacity

then out

compartment.

whenever

oosition.

lrom

air

the

left hand

Fig. 2B-3.

wagons,

inner

illustrated

the

modes

all

particular

the

thermostatic

system

to flow

position

air

ol

conditioning/heating

the engine

and evaporator

cooled

outlets

through

motor

and

or

compartment

ventilator outlets,

(refer

mode or

Fig. 2B-2 also

with the

blower

the

through

is

automatically

mode control

the

passenger

the

ventilator

rear drip

side

is

the air

panels,

trim

through

temperature

the

Fig. 2B-2,

in

two sliding

the right

and

mode

through

mode and

the

hood,

heated as

Fig. 2B-1) depending

temperature

various

lan forces air

evaporator

various outlets

the

outlets

moulding assemblies,

exhausted

into

tailgate

levers.

the air

ot

required.

2. GENERAL

expansion

permits

system

passes

required,

through

or

control

illustrates

modes activaled.

switched

lever

compartment

located

via the

the roof,

hinge

consist

The

hand lever enables

The

valve

cooled'

vehicle,

the

temperature

via the

heater

then

levers

the air

trom the

heater

into the

on

is moved

behind

edges

then out

pockets'

of a

left hand

lever

mode

the

the

on

to

ex-

the

of

four

the

through

and

the centre

through

and

entering

AIR

DESCRIPTION

CONDITIONING

28.3

2.1

'DEM'

position,

In this
through
small amount
cooled
the setting

'FLOOR'

In this
outlets
vents.

in this

'VENT'

This setting

The
by
be shut off
desired

demist

reduce

to

required

position,

with a small
The air conditioning
mode.

flow and direction

air

directional

not ooerate

comfort.

MANUAL CONTROLS

flows mainly

air

the

vents on

of air

humidity and

the

directs

vanes

individually at

in this

top

goes

to the

to demist

main air

amount

compressor

to the centre and

all air

can be adiusted

thumb

and

The air conditioning

mode.

onto

instrument

the

o{

floor outlets.

then can

windscreen.

the

is

flow

directed
going

air

of

these

does

wheels.

vents to achieve

windscreen

the

panel.

The

reheated

be

to the

demrst

to the

not operate

vents.

side

at each

The

compressor

can also

air

air

to

Jloor

vent

the

does

2B-3

Figure

A
is

aa--

ll

--

v

2B-4

'BI

This
vents
LEVEL

position,
air to
Cooled
the

'NORM'

This
side vents,
air is

pollen
lemperature

'MAX'
Use fcr

days.
the
through
return
reached

This
fumes

AIR

LEVEL'

position

as well

with

warm

the face

air

temperature

setting

cooled

etc.

maximum

On

this

air

conditioning

the

to

NORMAL

an

mode

from

CONDITIONING

directs

the

is

available

directs

used for

to reduce
lt
determined

setting

inlet

acceptable

is

entering

the

as

to the floor

temperature

will

air

lever

outside

most

cooling

the

system.

grille

setting

used

the

be

and side

is

level.

(centre

can then

also

air

both to

ouilets. When

lever in

directed

vents).

to both loot

positioned

air

through

cooling

humidity

by the temperature

or

cabin

and

system.

needs

be reheated

quick

air is recirculated

No

outside

therelore

once interior

to

exclude

the

centre

an intermediate

to the feet

and tace

at cold.

and remove

cool

levels

the

centre

on hot
if

required

control lever.

down

on very

air is

the

driver

temperature

unwanteo

and

side

using

Bl

and cooled

when

and

days.

The

dust

and

to

a

hot

throuoh

admit6d

should

has

oust

or

'OFF'
On this

closed

conditloning

NOTE:
speed
position.
higher

1.

2.

3.

4.

5.

6 The

setting

so that
The

vyhen

Fan

numbet.

Outside

OFF.

Do not

as no

outside

When

driving
another
on whether you
respectively.
setting
driving

conditions
settings.
speeds
intenor

of the vehicle,

Under

most

(recirculated
smoking
to

the

stale

smelling

Automatic

your

lf

weather
operating,
increase your
cooling
'OFF'

you

windows

following procedure

regularly

winter)

normally

the fan is

no

compres$r

fan

air is

vehicle,

wll

and

as residues

evaporator

vehicle

with

and

open.

when

be

outisde

automatically

the mode

speed

can

used in

operate in

is

air

in very

use

require

Through

prevent

Selection

all wrndows

conditions

air)

setting

inside

air

Transmission

is

the

setect

engine

air

conditioner

should

during

those

the

used.

switched

air is

does not

switches

lever

is

then

admitted to

'MAX'

outside

permit

oJ

from

and

stopped

engine

'NEUTRAL'

speed

only

air.

moved

be increased

all modes

MAX

dusty

conditions,

or

the

air conditioner

door

and window

return

'NORM'

closed,

excluding

it

is recommended

be

avoided

the

air ducts

the vehicle.

for

running

which

performance.

use

should

periods

conditioning

off and the

admitted

operate.

on to its

awav from

except

or OFF for

the

vehicle.

,OFF'

mode

air from

to

one

A/C

with

presiunze

will

dust

entry.

if

long

and

or

in

of the

occupanrs

smoke

and

periods

air

'pARK'.

turn

setting

be

modes

tobacco

this

door

and

the

lowest

bv

long

i.e. follownq

seals

entenng

of the

high

will result

aids

carried

OFF

setectrno

MAX

periods

deoendin6

on

or oi

either

until

other

blower

'MAX'

that

adhere

in

conditroner

This

engine

with

year

(e.g.

may

is

air

a

and

the

are

in

hot

will

the
oul

nor

_t)