Page 1782 of 2490
Air Distribution and Filtering - Plenum Chamber
Removal and Installation
Removal
Installation
1.
Remove instrument panel for access; refer to 76.46.01.
2. Remove rear face primary duct.
Remove fasteners.
Remove duct.
3. Remove right and left hand ai r distribution box ducts from
instrument panel.
Remove screws.
Remove ducts.
4. Remove air distribution bo x from instrument panel.
Remove nuts.
Position air distribution box for access to connector.
Disconnect connector.
Remove air distribution box.
5. Remove center vent servo motor; refer to 82.20.83.
6. Remove defog vent servo motor; refer to 82.20.84.
1. Installation is a reversal of the removal procedure.
Page 1785 of 2490

Engine speed (valve closed with the engine not running) Demand (set) temperature In-car temperature sensor Solar sensor
Re-heating of the refrigerated air is contro lled by the time that the water valve is open (i.e. not energised) over a six secon d
interval. The duty cycle of the water valve, the time open / time closed, is controlled by the A/CCM.
Maximum heating demand will cause the water valve to be fu lly open (not energised) to allow maximum coolant flow
through the heater matrix.
At Maximum cooling, the water va lve will be fully closed (energised) to prevent hot (engine temperature) coolant entering
the heater circuit; the pump however will continue to circulate coolant through both the heater matrix and water valve
bypass.
The water valve defaults open when the ignition is OFF.
Under engine stall conditions, when ignition is ON, the water valve will be open.
Water Pump Assembly
Located in the same area as the water valve, the water pump continually circulates coolant through the heater matrix
except when the conditions below apply:
The engine coolant is below 16°C. The ignition is OFF. Under engine stall conditions, when ignition is ON. Control panel OFF
Non return valves
The heater bypass hose has a non-return valve, located between the engine feed and return hoses. The valve prevents the
water pump from recirculating coolant fro m the heater at low engine speeds.
The flow indicator arrow embossed on the valve bo dy MUST point towards the coolant header tank.
CAUTION: Coolant flow will be compromi sed if either valve is fitted incorrectly. Observe the correct direction.
A second non-return valve is located betw een the water pump and water valve. This valve prevents hot coolant from flowing
into the heater with the engine switched off. The flow indicator arrow MUST point towards the water pump.
Heater feed and return hoses
The heater feed and return hoses are connected to the engine feed and return hoses by 'Quick-Fit' connection unions. The
feed hose has a Norma R20 connector and the return hose a Norma push and seal connector. The coolant system bleed
joints have Cobra clamps. All remaining hose connections have spring band hose clamps.
The engine feed hose is connected to the engine bypass hous ing and the engine return hose is connected to the engine
water pump.
Clamp Identification
Page 1787 of 2490
Heating and Ventilation - Heater Core
Removal and Installation
Removal
Installation
1.
Drain radiator coolant only; re fer to 26.10.01 or (SC) 26.10.01.
2. Remove instrument panel for access; refer to 76.46.01.
3. Remove driver footwell duct.
Remove screw.
Remove duct.
4. Disconnect cool air bypass serv o motor connector and heater
matrix pipes.
1. Disconnect connector.
• NOTE: Position suitable clot h to absorb coolant leakage
before disconnecting pipes.
2. Remove screws and retaining brackets.
3. Remove screws and matrix clamps.
• NOTE: Discard O-ring seals from pipes; fit suitable
blanking plugs.
Detach pipes from matrix.
5. Remove heater matrix from heater/cooler assembly.
1. Remove screw.
2. Remove retaining plate.
Reposition instrument panel support bracket to permit
removal of heater matrix (RHD only).
3. Remove heater matrix.
1. NOTE: Lubricate and install new O-ring seals.
Installation is the reverse of removal procedure.
Page 1788 of 2490
Heating and Ventilation - Heater Core and Evaporator Core Housing
Removal and Installation
Removal
1. Disconnect battery ground cable (IMPORTANT, see SRO
86.15.19 for further information).
2. Recover refrigerant from air co nditioning system; refer to
82.30.30.
3. Drain radiator coolant only; refer to 26.10.01 or (SC)
26.10.01.
4. Remove instrument panel for access, refer to 76.46.01.
5. From under the hood: Disconnect air conditioning pipes at the
evaporator.
1. Remove bolts.
2. Discard O-rings.
3. Install suitable blanking plugs.
6. Disconnect heater hoses from heater matrix pipes.
1. Release spring band clips and disconnect heater hoses.
2. Install suitable blanking plugs.
7. From inside the vehicle: re move driver footwell duct.
Remove screw.
Remove duct.
8. Remove upper steering column lower fixings.
1. Remove nut.
2. Remove bolt.
Page 1798 of 2490
Air Conditioning - Air Conditioning
Description and Operation
Introduction
Parts List
The climate control system features fully automatic control of temperature, blower speed (airflow) and air distribution to
maintain optimum comfort under most driving conditions.
Manual controls are provided to allow the operator to over-ride automatic operation.
System Features
ItemPart NumberDescription
1—Fascia panel with integral ducting
2—Heater / cooler assembly
3—A/CCM
4—Blower LH and RH
5—Plenum
6—Control panel
7—Solar sensor
8—Assembly valve - water
9—Assembly pump - water
10—Temperature sensor - external
11—Compressor
12—Pressure switch - 4 level
13—Motorized in-car aspirator (LHD shown)
14—Receiver drier
15—Condenser
Page 1799 of 2490

Twin blower assemblies Center mounted evaporator, heater and air distribution unit Electric solenoid water valve controlled heating Electric water pump assembly Servo motor driven air distribution flaps Dedicated side glass defrost / demist vents External temperature sensor Motorised in-car aspirator Solar sensor
Electronic Control Panel
Liquid Crystal Display (LCD) Digital temperature display Manual fan speed level External temperature display Celsius / Fahrenheit selection Heated windshield switch (where fitted) Heated backlight switch Defrost switch Manual airflow distribution overrides (4) Access to self diagnostic system and error codes
Sensors
External ambient temperature sensor Motorized in-car aspirator Heater matrix temperature sensor Evaporator temperature sensor Solar sensor
These sensors feedback information to the Air Conditioning Control Module (A/CCM) which automatically adjusts air
temperature, airflow volume and distributi on from the air conditioning unit to maintain a stable passenger compartment
average temperature under changing weather conditions.
Major Components
Page 1809 of 2490
10. Disconnect radiator bottom hose.
1. Release hose retaining clip.
2. Disconnect hose.
11. Disconnect radiator top hose.
1. Release hose retaining clip.
2. Disconnect hose.
12. Disconnect connector from pressure switch.
13. Release radiator top retaining panel.
Remove bolts.
Page 1810 of 2490
14. Disconnect compressor to condenser discharge line from
condenser.
1. Remove bolt.
2. Discard O-ring seal.
3. Install suitable blanking plugs.
15. Disconnect condenser to receiver / drier line from receiver /
drier.
1. Remove bolt.
2. Discard O-ring seal.
3. Install suitable blanking plugs.
16. Remove radiator retaining panel.
1. Remove panel.
2. Remove mounting bushes.
17. Disconnect hood switch harness connector.